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Contents:

1. Introduction
2. Blade Enclosure and Mechanical Requirements
2.1 Outline Features and Dimensions
2.2 Common Parts and Tooling
2.3 Weight
2.4 Metalwork and Finishes
2.5 Plastics and Finishes
2.6 Painted Finishes
2.7 Design for the Environment
2.8 Labels
2.9 Design for Service Life
2.10 Installation/Removal Cycle Life
2.11 Internal Connector Life
2.12 Fan Life
2.13 Mean Time to Repair or Upgrade
2.14 Unpackaged Handling Drop
2.15 Cooling Inlet and Exhaust Vent Locations
2.16 Component Operating Temperature Limits
2.17 Blade Inlet and Exhaust Air Pressure/Flow Environments
2.18 Air Temperature Rise Through Blade
2.19 Temperature Alarm Thresholds
2.20 Acoustic Noise Emissions
2.21 Shock Fragility
2.22 Blade Enclosure
2.23 Labeling and Indicators
3. References

1. Introduction

This document describes the mechanical requirements of FRUs for use with the Sun Fire B1600 Blade system chassis. This decription is intended as a reference for mechanical design of a Blade FRU, for mechanical engineers responsible for package design, air flow, and finishes. Related drawings, available in the References section, detail the dimensions and sizes for 1P and 2P Blade FRUs.

This document describes common parts, finishes, and labels. The critical area of design is the air flow. Air flow is from front to back of each Blade FRU. Thermal loading and air flow analysis are performed on all Blade FRU designs.

The intention of the Blade FRUs is to provide a solution-based product. Most Blade FRUs are sealed units that require no customer intervention or tampering. The intention is that each Blade FRU is automatically configurable by software switches or environmental conditions, without customer intervention.

This article refers to information in "System Overview of Blade Servers and FRUs" and "Electrical Requirements of Blade Servers and FRUs", also found in the Blade Computing Development Kit (available from the Blade Platform IHV Developer Program). Please send your comments to blade-dk-help@sun.com.

2. Blade Enclosure and Mechanical Requirements

This section defines Blade enclosure form and fit requirements, and Blade-level mechanical function requirements when integrated into the Blade system enclosure.

2.1 Outline Features and Dimensions

Key external feature and dimension requirements are defined in the Blade drawings in the References section. This document also defines external part colors, surface finishes, label locations, and cosmetic surface classifications.

2.2 Common Parts and Tooling

Blade FRUs should adopt a look and feel similar to the FRUs found in the Sun Fire B1600 Blade Platform. Required common parts include:

• Blade base, including PCBA mounting features, EMC spring fingers, and so on
• Blade cover assembly, including fasteners, EMC liner, and so on
• Latch handle assembly, including structural, cosmetic, and latch mechanism parts
• Blade type identification insert (except color; see drawing)

2.3 Weight

Blade assembly weight is limited to 1.50 kg, excluding transit packaging, documents, and so on.

2.4 Metalwork and Finishes

All external and internal Blade metalwork materials must be approved by Sun.

2.5 Plastics and Finishes

All external and internal Blade plastic materials must be approved by Sun. All plastic components must be produced from a PC-ABS blend, for example, GE Cycoloy C6200 or Sun-approved equivalent.

All plastic components used in or on the Blade must have a flammability rating for the applicable thickness to meet Underwriters Laboratories standard UL 94 rating V-0 for solid materials or Underwriters Laboratories standard UL 94 rating HF-1 for foamed materials. Exceptions to the solid material flame rating requirement will be granted for components which meet Underwriters Laboratories standard UL 94 rating V-1 and have an Oxygen Index of 28% or greater, as determined by ASTM D 2863-77; singular non-electrically energized components of less than 6 x 6 x 6mm in dimension or less than 1g mass polymer content may have UL94 V-2 rating.

Unless otherwise specified, all externally visible surfaces must be Mold-Tech MT-11020 texture or equivalent; all other plastic surfaces must be EDM matte finish to SPI/SPE #5.

All colored parts should match with colors used in the Sun Fire B1600 Blade Platform.

All molded plastic parts must be marked with their part number, revision level, date code, material cavity number (if applicable), material recycling mark (if applicable) and UL flammability rating on a surface that is not visible from the exterior of the Blade assembly.

2.6 Painted Finishes

All paint finishes must comply with Sun specification 950-1311-xx, and must be approved by Sun.

2.7 Design for the Environment

No components containing the following substances may be used:

• Beryllium oxide
• Cadmium
• Silicone
• Mercury
• Chlorinated paraffins
• Polychlorinated biphenyl (PCB)
• Polychlorinated naphthalenes (PCN)
• Polychlorinated triphenyl (PCT)
• Polybrominated biphenyl ethers/oxides (PBBE/PBBO)
• Tetrabrominated biphenyl A (TBBA)

No manufacturing processes using the following materials are allowed:

Chloroflourocarbons (CFC)
Class 1 ozone-depleting substances (Annex A and Annex B of the Montreal Protocol)

2.8 Labels

External label locations and orientations are defined in the side-view drawing in the References section. Label content is defined by the vendor, for tracking and FRU identification.

2.9 Design for Service Life

The basic service life shall be five years continuous use, minimum, at 25 degrees C sea-level external (room) ambient.

2.10 Installation/Removal Cycle Life

The Blade assembly, including latch handle and SCA-2 connector, must survive at least 100 installation/removal cycles without degradation to function or cosmetic appearance as specified in this document.

2.11 Internal Connector Life

All connectors inside the Blade assembly (hard disk drive, memory DIMM, and so on) must be specified and tested to survive at least 50 connect/disconnect cycles without mechanical or electrical degradation to contact specifications.

2.12 Fan Life

Blade fan life (L₁₀) shall be 50 khrs minimum at 35 degrees C, 70 kPa Blade external (room) ambient.

2.13 Mean Time to Repair or Upgrade

Basic Blade MTTR, including Blade removal from and installation to the Blade system chassis only, shall be less than 15 minutes and shall require no tools. Mean time to replace or upgrade DIMM(s) inside the Blade enclosure, after the Blade assembly has been removed from the Blade system chassis, shall be less than 15 minutes and shall require only a #2 Phillips screwdriver. Note that captive fasteners are required for this activity, and all fasteners removed to gain access to the DIMMs must be of the same type.

2.14 Unpackaged Handling Drop

The Blade assembly, unpackaged, unpowered, and ready for installation in the Blade system chassis, shall survive:

• Three free-fall drops onto each of the six primary faces of the Blade assembly, from a height of 50mm, per IEC 60068-2-32
• Three corner drops onto each of the eight primary corners of the Blade assembly, from a height of 50mm, with the assembly oriented so that the left and right faces as defined in the Blade drawing are most nearly parallel to the impact surface, per IEC 60068-2-31

The Blade assembly shall meet the acceptance criteria defined in the Blade Environmental Test, EMC and Safety Compliance Specification (Sun 950-3950-xx) during and after the tests.

2.15 Cooling Inlet and Exhaust Vent Locations

Cooling air inlet and exhaust vent locations are defined as being from the front to back of the Blade FRU. For reference, the Blade assembly cooling air inlet vent is the entire front face (latch handle end); the air exhaust vent is the entire rear face (SCA-2 connector end). The four remaining sides provide no ventilation into or out of the Blade assembly.

2.16 Component Operating Temperature Limits

The Blade cooling system must maintain all Blade components within the component manufacturers' normal operating specifications and Sun de-rating guidelines at the extremes of Blade system climatic environments defined in the Blade Environmental Test, EMC and Safety Compliance Specification (Sun 950-3950-xx), when operating in the Blade inlet and exhaust air pressure/flow environments as specified below. Thermal profile verification may be performed in the Blade system; if verification is performed on standalone Blade FRUs, unvented Blade FRU faces must be insulated to prevent heat conduction at these faces. Note that these conditions do not include the Blade system service environment, for example when a power supply or adjacent Blade FRU is removed from the system.

2.17 Blade Inlet and Exhaust Air Pressure/Flow Environments

Blade inlet air environments match the Blade system environments as specified in the Blade Environmental Test, EMC and Safety Compliance Specification (Sun 950-3950-xx).

Normal (full system) operation of the Blade system provides the following exhaust face environment:

• A linear relationship between vacuum pressure and per-Blade air flow of 125 Pa (at zero flow) and 0.003 m³/sec (at zero backpressure), at sea-level, maximum-temperature inlet conditions
• A linear relationship between vacuum pressure and per-Blade air flow of 85 Pa (at zero flow) and 0.003 m³/sec (at zero backpressure), at maximum altitude, maximum-temperature inlet conditions
• A linear relationship between vacuum pressure and per-Blade air flow of 85 Pa (at zero flow) and 0.002 m³/sec (at zero backpressure), at sea-level, 25 degrees C inlet conditions

Note that these conditions do not include the Blade system service environment, for example, when a power supply or adjacent Blade FRU is removed from the system.

2.18 Air Temperature Rise Through Blade

The bulk (average) air temperature rise from inlet to exhaust of the Blade assembly is limited to 20 degrees C maximum, at the maximum altitude, maximum temperature environment described above.

2.19 Temperature Alarm Thresholds

The BSC monitors two actual temperatures measured on the Blade FRU. One is designed to monitor the hottest ASIC point on the Blade FRU. The second is intended to monitor the Blade FRU enclosure at the temperature sense chip, which is located at the hottest point within the Blade FRU.

Review the document "Electrical Requirements for Blade Server BSC" located in the electrical subsection of the Blade Computing Development Kit.

2.20 Acoustic Noise Emissions

The assembly declared sound power emission levels shall not exceed 4.5B per operating and idling, and no prominent discrete tones and no impulsive noise shall be present in the emissions, per ISO 9296. Emissions verification may be performed by substitution in the Blade system.

2.21 Shock Fragility

When rigidly clamped to a suitable test fixture, the unpackaged standalone Blade FRU assembly in any standard shipping configuration must survive three drops on each of its six primary faces at a peak acceleration level of 50G and an equivalent package drop height of 1067mm, per ASTM D3332.

2.22 Blade Enclosure

• Casework and latch handle for the Blade mechanical requirements is in a Pro/E drawing available from Sun Microsystems under a source-level agreement.
• Each vendor should adopt a color scheme for Blade mechanical requirements that is similar to that found in the Sun Fire B1600 Blade Platform.
• ESD grounding contact is on three sides: top face, bottom face, and right-hand side face.
• ESD grounding contacts shall be 1.7+- 0.2 proud of surface.
• Front faceplate inlet for cooling airflow.
• Rear faceplate is exhaust for cooling airflow and should be as open as possible without affecting EMI.
• Blade FRU enclosure requires customer accessibility to memory and jumpers; access into the enclosure must be with minimal effort and without the use of special tools.
• Channel locators should have adequate chamfers for ease of insertion on top and bottom channels of the 3RU rack.

2.23 Labeling and Indicators

Indicators should look and function the same as Blade FRU standard indicators in the Sun Fire B1600 Blade Platform. Additional indicators are allowed, but must not interfere with the air flow cooling.

• Indicators should be located and have the same function as those used by Sun.
• Additional indicators should not replace or interfere with the standard required indicators.
• Additional indicators should not interfere with air flow cooling.
• Additional indicators should be described in vendor documents.

3. References

April 2003