Document fins/I0724-2
FIN #: I0724-2
SYNOPSIS: 18.2GB and 36GB IBM disk drives may be susceptible to early life
failures
DATE: Oct/10/01
KEYWORDS: 18.2GB and 36GB IBM disk drives may be susceptible to early life
failures
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- Sun Proprietary/Confidential: Internal Use Only -
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FIELD INFORMATION NOTICE
(For Authorized Distribution by SunService)
SYNOPSIS: 18.2GB and 36GB IBM disk drives may be susceptible to early
life failures.
Sun Alert: Yes
TOP FIN/FCO REPORT: No
PRODUCT_REFERENCE: 18GB and 36GB IBM Disk Drive
PRODUCT CATEGORY: Storage / Service
PRODUCTS AFFECTED:
Mkt_ID Platform Model Description Serial Number
------ -------- ----- ----------- -------------
Systems Affected
----------------
- A14 ALL Ultra Enterprise 2 -
- A20 ALL Ultra 450 -
- A23 ALL Ultra 60 -
- A27 ALL Ultra 80 -
- N04 ALL Netra t 1120 -
- N03 ALL Netra t 1125 -
- N21 ALL Netra T1 AC200/DC200 -
- N14 ALL Netra t 1400 -
- N15 ALL Netra t 1405 -
- E250 ALL Ultra Enterprise 250 -
- E450 ALL Ultra Enterprise 450 -
- E3000 ALL Ultra Enterprise 3000 -
- E4000 ALL Ultra Enterprise 4000 -
- E4500 ALL Ultra Enterprise 4500 -
- E5000 ALL Ultra Enterprise 5000 -
- E5500 ALL Ultra Enterprise 5500 -
- E6000 ALL Ultra Enterprise 6000 -
- E6500 ALL Ultra Enterprise 6500 -
- E10000 ALL Ultra Enterprise 10000 -
- S8 ALL Sun Fire 3800 -
- S12 ALL Sun Fire 4800 -
- S12i ALL Sun Fire 4810 -
- S24 ALL Sun Fire 6800 -
X-Options Affected
------------------
- A1000 ALL StorEdge A1000 -
- A3500 ALL StorEdge A3500 -
- A3500FC ALL StorEdge A3500FC -
- D1000 ALL StorEdge D1000 -
- T3 ALL StorEdge T3 -
- D240 ALL StorEdge D240 -
- MultiPack ALL StorEdge MultiPack -
- st A1000/D1000 ALL Netra st A1000/D1000 -
- ct 400/800 ALL Netra ct 400/800 -
- st D130 ALL Netra st D130 -
PART NUMBERS AFFECTED:
Part Number Description Model
----------- ----------- -----
540-4177-01 DRV ASSY 18GB10K 1-in SCSI W/SPUD -
540-4178-01 DRV 18GB 10K 1-in SCSI W/SPUD&PLT -
540-4401-01 DRV NEBS 18GB 10K 1-in SCSI W/S&P -
540-4921-01 18GB SCSI 10K 1-in NEBS SD DRIVE -
540-4520-01 DRV ASSY 36GB 1-in SCSI SPUD&PLAT -
540-4689-01 DRV NEBS 36GB 10K 1-in SCSI W/S&P -
540-4440-01 ASSY 18GB 10K 1-in FC LP W/SLED -
540-4367-01 ASSY 36GB 10K 1-in FC LP W/SLED -
(SCSI Devices)
Part Number Description Model Type Vendor
----------- ----------- ----- ---- ------
390-0048-02 DRV IBM 18GB 10K 1-in SCSI DDYST1835 Disk IBM
390-0052-02 DRV IBM 36GB 10K 1-in SCSI DDYST3695 Disk IBM
390-0054-02 DRV IBM 18GB 10K 1-in FCAL PURPLE DDYF-T1835 Disk IBM
390-0057-02 DRV IBM 36GB 10K 1-in FCAL PURPLE DDYF-T3695 Disk IBM
REFERENCES:
BugId: 4490041 - Write Failure occurs on many IBM's DISK.
FCO: A0182-1
ESC: 531685
531640
531939
531640
532124
531940
532025
SUN ALERT: 40130
WW StopShip: P200-20006
PROBLEM DESCRIPTION:
-----------------
|FROM FIN I0724-1:|
-----------------
Failure analysis results have highlighted a significant failure rate
for Drive Not Ready (DNR) on returned IBM 18GB & 36GB disk drives.
These failures have been observed to occur as a result of the disk
drives either being stored or operated in extremely hot and humid
environments.
Sample error messages:
/sbus@7,0/QLGC,isp@0,10000/sd@1,0 (sd46):
Error for Command: write Error Level: Fatal
Sense Key: Hardware Error
ASC: 0x2 (no seek complete), ASCQ: 0x0, FRU: 0x0
10098107 c1t8d0 540-4178-01 DDYS-T18350 01061XE682
/sbus@7,0/QLGC,isp@0,10000/sd@1,0 (sd46):
Error for Command: read Error Level: Fatal
Sense Key: Vendor Unique
ASC: 0x80 (<vendor unique code 0x80>), ASCQ: 0x0, FRU: 0xa
10102117 c2t10d0 540-4178-01 DDYS-T18350 01061XE522 108305
/sbus@7,0/QLGC,isp@0,10000/sd@a,0 (sd54):
Error for Command: read Error Level: Fatal
Sense Key: Media Error
ASC: 0x11 (unrecovered read error), ASCQ: 0x0, FRU: 0x0
10102117 c1t5d0 540-4178-01 DDYS-T18350 01061XE630 108305
/sbus@3,0/QLGC,isp@0,10000/sd@0,0 (sd15):
Error for Command: write Error Level: Fatal
Sense Key: Media Error
ASC: 0x3 (peripheral device write fault), ASCQ: 0x0, FRU: 0x0
10088635 c2t13d0 540-4178-01 DDYS-T18350 01061XE750
/sbus@6,0/QLGC,isp@1,10000/sd@d,0 (sd42):
Error for Command: load/start/stop Error Level: Retryable
Sense Key: Not Ready
ASC: 0x4 (LUN not ready), ASCQ: 0x0, FRU: 0x0
10096449 c2t9d0 540-4178-01 DDYS-T18350 01061XE634
The most frequent failures seen are, "Drive not ready" or the drive
may produce excessive read, write or media errors.
Engineering has identified several contributing factors leading to
drive failures. None of the factors stand alone, and all the factors
must occur or be present for the identified DNR failure mode. The
various factors are:
. Microscopic talcum residue,
. Disks packaged in systems in drive trays,
. Exposure to high temperature (30degC or above),
. High humidity (90% or above) for a period greater than 20 days.
These failures have been observed after shipments of disks to countries
in the APAC Geography where the packages are stored in customs for long
periods of time and are subject to extremely hot and humid conditions
resulting in condensation & residue in the disk drives. Subsequently
when these disk drives are installed at customer sites they may
experience early life failures.
The above error messages can also arise due to various other causes.
Therefore failure analysis of disk drive is essential to determine
if the returned drives are failing due to the above mentioned factors.
The magnitude of exposure for this failure mechanism is very small and
customers may not see it at all. The drive's specification for AFR
(Annual Failure Rate) is 1.10% which equals 800K hours MTBF, and the
drive's AFR is currently measured in the field at 1.20%, or 730,000 hours
MTBF. Drives built prior to manufacturing work week 24 (0123 and
before) may exhibit the Drive Not Ready failure mode. As such, it is
unknown which percentage of drives built prior to week 24 are
susceptible to the Drive Not Ready failure mode.
The disk vendor (IBM) has implemented new clean room practices to
eliminate the causes of the "Drive Not Ready" failure mode.
WW Purge P200-20006 has been implemented to purge IBM disk drives
manufactured within the 25th week of 2000 through 23rd week of 2001.
-----------------------
|UPDATE FOR FIN I742-2: |
-----------------------
The following sections in the Corrective Action for FIN I0724-1 has
been updated:
. The affected install base for this problem has been expanded from
specific date code 0025-0123 to all units of the affected 18.2GB
and 36GB IBM disk drives.
. The Corrective Action has been updated to remove the instructions
that relate to date code identification.
IMPLEMENTATION:
---
| | MANDATORY (Fully Proactive)
---
---
| | CONTROLLED PROACTIVE (per Sun Geo Plan)
---
---
| X | REACTIVE (As Required)
---
CORRECTIVE ACTION:
The following recommendation is provided as a guideline for authorized
Enterprise Services Field Representatives who may encounter the above
mentioned problem.
Please adhere to the following guideline:
If the customer site is seeing DNR "drive not ready" failures and
reporting a high failure/replacement rate of the following disk drive
part numbers (IBM vendor only):
. 540-4177-01
. 540-4178-01
. 540-4367-01
. 540-4401-01
. 540-4440-01
. 540-4520-01
. 540-4689-01
. 540-4921-01
A. Route all failed HDD disks meeting the 'Drive Not Ready' + high
failure rate footprint through the Sun Customer Quality CPAS
(Corrective & Preventive Action System) process for failure
analysis. The CPAS request form must be filled out completely
and accompanied by explorer scripts (reference Note below).
B. The Action Plan is to submit a CIC request to CTE if the following
conditions are triggered:
For all products.
. Through the CPAS process, the root cause is identified as the
"talcum residue" failure mode.
NOTE: Open a CPAS request only if the following criteria are met.
Included this information in the CPAS request. CPAS requests
without this failure information will be rejected.
1. High Failure rate of DNR "drive not ready" being
experienced.
2. IBM drives operating in a high temperature environment.
3. IBM drives operating in a high humidity environment.
NOTE: Here's one way to identify high heat/humidity
environment:
. Examine the computer room environment. Non-conditioned
environments may indicate high heat and humidity, or a
room where the HVAC failed for a period of time may
also indicate a high heat environment.
NOTE: Anything else should be handled via standard process.
. IBM Drive model "Discovery".
----------------------------------------------------------
| Part | Product | Vendor| Capacity| Date Codes |
| Number | Name | Name | | Affected |
|==========================================================|
| 540-4177-01 | DDYS-T1835 | IBM | 18.2 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4178-01 | DDYS-T1835 | IBM | 18.2 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4367-01 | DDYF-T3695 | IBM | 36.4 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4401-01 | DDYS-T1835 | IBM | 18.2 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4440-01 | DDYF-T1835 | IBM | 18.2 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4520-01 | DDYS-T3695 | IBM | 36.4 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4689-01 | DDYS-T3695 | IBM | 36.4 GB | ALL |
|-------------+-------------+-------+---------+------------|
| 540-4921-01 | DDYS-T1835 | IBM | 18.2 GB | ALL |
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Note: Information on the CPAS Program can be found at the following
webpage;
http://gsops.central/mcrcca/CPAS/
To identify an affected configuration:
1. Check for the Vendor to be IBM.
2. Check for disk product ID to be either of:
. DDYF-T3695
. DDYF-T1835
. DDYST3695
. DDYST1835
Explorer Output Example:
explorer.80a69595.draco_qfe0-2001.09.10.18.10/disks/sonoma/drivutil-i
where explorer.80a69595.draco_qfe0-2001.09.10.18.10 is explorer o/p dir.
The o/p will look like the following :
-------------------------------------------------
|Location|Capacity|Status |Vendor|Product |
| | (MB) | | | ID |
|========+========+=======+======+================|
|[1,9] |17274 |Optimal| IBM |DDYST1835SUN18G |
|[3,4] |17274 |Optimal| IBM |DDYST1835SUN18G |
|[4,4] |17274 |Optimal| IBM |DDYST1835SUN18G |
|[5,9] |17274 |Optimal| IBM |DDYST1835SUN18G |
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COMMENTS:
None
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Implementation Footnote:
i) In case of MANDATORY FINs, Enterprise Services will attempt to
contact all affected customers to recommend implementation of
the FIN.
ii) For CONTROLLED PROACTIVE FINs, Enterprise Services mission critical
support teams will recommend implementation of the FIN (to their
respective accounts), at the convenience of the customer.
iii) For REACTIVE FINs, Enterprise Services will implement the FIN as the
need arises.
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--------------
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-----------------------
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----------------
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General:
--------
* Send questions or comments to finfco-manager@Sun.COM
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