• Topic ID: id_12374007
  • Version: 1.5
  • Date: Jul 5, 2019 10:03:32 PM

eXtreme Gradient Power Supply Replacement

Prerequisites

Table 1 Personnel requirements
Required persons Preliminary requirements Procedure Finalization
1 5 minutes 90 minutes 5 minutes
Table 2 Tools and test equipment
Item Quantity Effectivity Part number Manufacturer
Hoist Service Kit 1 -

5196226

 -
Non-magnetic Tool Kit (or equivalent) 1 -

5113258

 -
Table 3 Consumables
Item Quantity Effectivity Part number Manufacturer
Towels N/A - - -
Nitrile Gloves As needed - - -
Table 4 Replacement parts
Item Quantity Effectivity Part number Manufacturer
XPS Unit 1 systems with XPS units

See FRU manual.

 -
XP2 Unit 1 systems with XP2 units

See FRU manual.

 -
Table 5 Safety
Notice Image
  • danger
  • Electric Shock Hazard!
  • High voltages are present in the PGR cabinet.
  • Perform LOTO on the PGR cabinet. See the “MR Service Safety Manual,” PN 5452735.
Notice Image
  • warning
  • possible personal injury or equipment damage!
  • the module could fall when using the lift tool.
  • before putting weight on the hoist chain, be sure that the links are aligned properly. this help keep the chain from binding or becoming kinked, which is nearly impossible to correct when the chain is under tension.
Notice Image
  • warning
  • Laser Radiation Hazard!
  • Invisible laser radiation can be emitted from disconnected fiber-optic cables or connectors.
  • Do not stare into the beam, point the cable or connector ends at your eyes, or view through optical instruments.
Notice Image
  • notice
  • Electrostatic discharge (ESD) can cause permanent damage to electronic components. Observe the following ESD precautions:
    • Wear a static wrist strap to ensure that any accumulated electrostatic charge is discharged from your body to the ground.
    • Create a common ground for the equipment being worked on by connecting the static-free mat, static wrist strap, and peripheral units to that piece of equipment.
Notice Image
  • notice
    • The SFP optical transceiver is very sensitive to ESD. SFP latent failures can occur, in dry climates or low relative humidity, surpassing their ESD protection.
    • Contaminant failures can occur in SFP optics and exposed glass Rx and Tx cable ends. Do not touch the exposed ends on fiber connectors. Leave the dust caps in place until you are ready to install the SFP module. Use the Fiber Optics Cleaning Kit to clean both the SFP and cable end every time they are replaced or swapped from one port to another, or when using a loopback.
    • For more information on handling and cleaning the SFP transceiver refer to Fiber Optic Cable Devices Installation and Replacement.
note:
  • When working with the SFP optical transceiver or SFP Loopback, also observe the following precautions:
    • Always use ESD protection when handling the SFP optical transceiver to prevent early failure.
    • Always keep a protective cap on unplugged fiber connections.
    • The SFP must be shipped in antistatic packaging. Discard any SFP shipped or stored without proper ESD protection.
Table 6 Required conditions
Condition Reference Effectivity

Perform LOTO on the PGR cabinet before replacing an XPS unit. See the MR Service Safety Manual, PN 5452735.

 - -

Before disconnecting any cables on the front of an XPS unit, shut down the PPMP at the HEC. Press ▲ and F3 simultaneously to stop the pump. Next, switch the PPMP circuit breaker to OFF.

 - -

Overview

This procedure describes how to replace an eXtreme Gradient Power Supply (XPS or XP2) unit in the PGR cabinet. The power supply unit weighs about 160 pounds, so the use of a hoist kit is required. This procedure details the correct way to use a hoist kit to safely remove the power supply unit and replace it with a FRU.

note:

The system contains either XPS or XP2 units. These units have the same form factors, but are not interchangeable. A system will have either all XPS or all XP2 units. Make sure you order the correct FRU for the system.

This procedure refers to both units as XPS.

Procedure

  1. Perform LOTO on the PGR cabinet. See the MR Service Safety Manual, PN 5452735.
  2. Before setting up the hoist kit, detach the XPS J9 connector to properly remove the main lifting beam.

    Figure 1. Lifting Beam and J9 Connector in PGR Cabinet

  3. See Hoist Service Kit and Lifting Accessories to set up and secure the hoist.
    4. Notice Image
    • notice
      • Observe the following:
      • For the next step, wear nitrile gloves. Be prepared to absorb any leakage from the coolant lines with a towel in hand as the line is disconnected.
      • Do NOT bend the fiber-optic cables. They are very delicate and can break easily.
  4. Disconnect the cables and hoses from the front of the XPS unit. This includes the XPS to XGA power cables, coolant lines, and fiber-optic cables.

    Figure 2. Front of XPS and XP2 Units - Cables Disconnected

  5. Unscrew the four screws from the bottom of the module retaining bracket of the XPS unit. (The bottom two screws are captive screws, and will not fully detach from the bracket.) Completely remove the module retaining bracket and set it aside. It is required for the FRU.

    Figure 3. Module Retaining Bracket

    note:

    If replacing the X-axis XPS, you may remove the PGR cabinet door and lean it against the side of the cabinet. Tape the free end of the green/yellow ground wire detached from the upper part of left door to the PGR cabinet frame so the ground does not contact the L1, L2, or L3 AC mains power connections in the terminal strip in the upper left part of the PGR cabinet.

  6. Carefully slide out the XPS unit until the top is completely exposed, but the unit is not fully out of the PGR cabinet.

    Figure 4. Sliding Out XPS Unit

  7. Place the lifting bracket from the FRU crate on top of the XPS unit. Attachment screws are stored on the bracket. Match the four openings and screw in the lifting bracket.
    note:

    The back two screw holes are slightly offset. Ensure the lifting bracket is placed correctly on top of the XPS unit so the screws are completely intact.

    Figure 5. Lifting Bracket Inside FRU Crate

    Figure 6. Lifting Bracket Attached to XPS Unit

    8. Notice Image
    • warning
    • bodily injury or Equipment damage!
    • the combined weight of the XPS unit and hoist can shift, causing harm to the equipment or the engineer.
    • Make sure the hook is properly seated in the lifting bracket.
  8. Hook the winch from the hoist kit to the lifting bracket, and ratchet the winch to tighten the chain.
  9. With the XPS unit held by the slide rails and the hoist kit, extend the unit until the slide rails lock. Press the release tabs in on each side while pulling the unit out of the PGR cabinet.
    note:

    When the XPS unit is leveled with the hoist, the rails will move freely. If they do not, adjust the hoist.

    Figure 7. XPS Unit - Extended Out of Cabinet

  10. Push the back end of the slide rail to unlatch the cabinet's slide rails from the XPS unit. You may want to use a screwdriver to unlatch the slide rail. After it is unlatched, release the cabinet slide rails, and slide them into the cabinet. (The cabinet rails are a reverse image of each other.)

    Figure 8. Slide Rail Latch Removal

  11. The FRU is packaged in a wooden crate. Remove the top of the wooden crate and turn it on its base. Roll the top under the XPS unit, and lock the wheels so the container does not move.

    Figure 9. FRU Package

  12. Ratchet the winch to lower the XPS unit onto the top of the wooden crate.

    Figure 10. XPS Unit on Crate in Front of PGR Cabinet

  13. After it is lowered, unscrew the side rails from both sides of the XPS unit.

    Figure 11. Slide Rails Removed from XPS Unit

  14. Remove the hook from the lifting bracket.
  15. Unscrew the lifting bracket from the top of the XPS unit and roll the removed XPS unit to the side. Before returning the unit, purge the coolant as described in the Finalization section. Failure to purge coolant before shipping can result in freezing during transit, which can cause severe and permanent damage to the unit.
  16. Remove the center section of the FRU crate and set aside. It is used to package the removed XPS unit.
  17. Bring the FRU package with the new XPS unit to the front of the cabinet. Connect the slide rails to the new unit.
  18. Screw the lifting bracket to the top of the new XPS unit.
    19. Notice Image
    • warning
    • bodily injury or Equipment damage!
    • the combined weight of the XPS unit and hoist can shift, causing harm to the equipment or the engineer.
    • Make sure the hook is properly seated in the lifting bracket.
  19. Hook the lifting bracket on the new XPS unit to the hoist kit.
  20. Ratchet the winch to tighten the chains and begin lifting the unit. Slide the rail out a short distance to see how high to lift the new XPS unit. The slide rails of the XPS unit and PGR cabinet must align for correct insertion.
  21. When the slide rails are aligned, pull them out a short distance to get each side started. After both of the slide rails are attached, pull the XPS unit out until you hear a click, indicating that the XPS unit is docked in the rails.
  22. Ensure the XPS unit is secured on the rails, and slightly loosen the chains with the winch to allow some freedom of movement.
    1. Make sure the cables are clear before inserting the XPS unit.
    2. Press in both release tabs, and begin to slide the XPS unit in until only the top of the unit is exposed.
  23. Unhook the hoist kit from the lifting bracket, and remove the lifting bracket from the top of the new XPS unit.

    Place the lifting bracket onto the XPS FRU crate with the four screws attached to the lifting bracket, as shown in Figure 5.

  24. Slide the XPS unit completely into the PGR cabinet, and reattach the module retaining bracket (removed from the old XPS unit).
  25. Connect the cables to the new unit.
    note:

    If you are installing a new XPS unit (not an XP2), the dual fiber-optic cable may be difficult to reinsert into the new XPS unit. (The connector for the XP2 has been designed to eliminate this issue.)

    Do not remove the SPF module from the XPS unit.

    To connect the fiber-optic cable, insert the dual fiber-optic cable into the SPF module in the XPS by gripping either side of the hard plastic connector housing at the black section and then firmly pushing the connector into the SPF module until the connector clicks into place. Do not grip the molded plastic boot sections where the fiber-optic cables enter the connector.

    If the cable is inserted backwards, it will not go in all the way.

  26. Disassemble the hoist kit (see Hoist Service Kit and Lifting Accessories).
    1. Return the main lifting beam to the PGR cabinet.
    2. After the beam is secure, reconnect the XPS J9 connector, and return the support tube to the HEC.

Finalization

  1. Remove LOTO from the PGR cabinet. See the MR Service Safety Manual, PN 5452735.
  2. Turn on the PPMP circuit breaker at the HEC. Start the pump by pressing ▲ F3 simultaneously.
  3. Run the DQA II tool to verify proper gradient polarities and adjust gradient calibration. (See DQA II Tool and Troubleshooting.)
  4. Recommended: Perform a Save-Info to capture new gradient calibration values.
  5. Remove coolant from the XPS unit being returned using the manual coolant removal kit included with the HEC. (See Coolant Draining.)
  6. Dispose of used towels according to local disposal standards.
  7. Attach the center of the FRU package to the removed FRU unit base. Then attach the top of the FRU crate to prepare the FRU for return.