MaxPac X7DAL-E, Single-Screen 8230, Dual-Screen 8230, Triple-Screen 8230 Reference Manual

MaxPac Single/Dual/Triple

Screen 8230 XRA1/2/3 Rev-A

Training and Maintenance Guide

Maintaining and Repairing Your MaxPac

Single/Dual/Triple-Screen 8230 XRA1/2/3 Rev-A

High-Performance Transportable Workstation

MaxVision Corporation

495 Production Avenue

Madison, AL 35758, USA

Part Number: 209-0054-0

ii MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Warranties and Liabilities

MaxVision Corporation warrants that the Product, in the course of its normal use, will conform to MaxVision's
specifications and be free from defects in material and workmanship for a period of twelve (12) months from the date of
the original sale. Such warranty commences on the purchase date appearing on the invoice. The original end user is
entitled to customer support through telecommunication during normal MaxVision business hours and email support to be
responded to as support staff are available. Such support shall be limited to hardware operations and the software
required operating such hardware. Upon written request and subject to the availability of MaxVision personnel, additional
support may be provided by MaxVision in its sole discretion on a time and materials basis.

Limited Warranty for Software. MaxVision warrants to the original end user only that the Software as delivered at the
time of purchase will perform in MaxVision hardware, and that the original diskettes or compact disks are free from
defects in material and workmanship under normal use, for a period of thirty (30) days from the date of original sale,
provided the Software is used with a MaxVision unit. MaxVision makes no warranty that the Software will work in
combination with any hardware or software products provided by third parties, that the operation of the Software will be
uninterrupted or error-free, or that all defects in the Software will be corrected. This limited warranty is void if failure of the
Software has resulted from accident, abuse, or misapplication. MaxVision's entire liability, and your sole and exclusive
remedy shall be, at MaxVision's option, either to (a) correct or help you work around or avoid a reproducible Error or (b)
replace defective diskettes or compact disks. Any replacement Software will be warranted for the remainder of the original
Limited Software Warranty Period.

Limited Warranty for the Product. MaxVision warrants to the original end user only that all Products sold by MaxVision
will be free from defects in material and workmanship and conform substantially to the applicable standards set forth in
the Documentation, under normal use, for a period of 365 days from the date of original sale. This limited warranty is void
if failure of the Product has resulted from accident, abuse, or misapplication. If MaxVision confirms a Product is defective
after you have obtained a Return Materials Allowance Number for such Product and, at your expense, have returned the
Product to MaxVision for inspection, MaxVision will, at its election, repair or replace such Product at no charge to you.

Replacement Product may be either new or remanufactured. In the event that the Product returned is not defective, you
will be responsible for freight costs for return shipment to you. The foregoing warranty shall not apply to Product that has
been (a) damaged by accident, Acts of God, shipment, improper installation, abnormal physical or electrical stress,
misuse or misapplication, as determined by MaxVision in its sole reasonable discretion, or (b) modified without
MaxVision's express written acceptance of such modification for warranty purposes. MaxVision reserves the right to
charge additional fees for repairs or replacements performed outside the Warranty Period. Any replaced or repaired
components, subassemblies or units as well as spare parts are warranted for thirty (30) days or the remainder of the
original warranty period, whichever is longer. MaxVision shall not be responsible for any software, firmware, information or
memory data of yours contained in, stored on, or integrated with any Products returned to MaxVision pursuant to any
warranty under this Agreement.

Disclaimer of Warranties. EXCEPT AS SPECIFICALLY PROVIDED ABOVE, NEITHER MAXVISION NOR ITS
LICENSORS OR SUPPLIERS PROVIDES ANY WARRANTY OF ANY KIND FOR THE SOFTWARE OR THE
PRODUCT, WHETHER EXPRESS, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING BUT NOT LIMITED TO
WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF
THIRD PARTY RIGHTS. EXCEPT AS SET FORTH IN THIS AGREEMENT, THE ENTIRE RISK AS TO THE QUALITY
AND PERFORMANCE OF THE SOFTWARE AND THE PRODUCT IS WITH YOU. If a disclaimer of implied warranties is
not permitted by law, the duration of any such implied warranty is limited to ninety (90) days from the date of purchase by
the original end user. Some jurisdictions do not allow the exclusion of implied warranties or limitations on how long an
implied warranty may last, so such limitations or exclusions may not apply to you. This limited warranty gives you specific
legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.

Liability Exclusions and Limitations. IN NO EVENT SHALL MAXVISION OR ITS LICENSORS OR SUPPLIERS BE
LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL, EXEMPLARY OR CONSEQUENTIAL DAMAGES OF ANY KIND
(INCLUDING LOST PROFITS, LOSS OF USE OR INTERRUPTION OF BUSINESS), OR FOR LEGAL FEES, ARISING
OUT OF THE USE OF THE SOFTWARE OR THE PRODUCT, REGARDLESS OF THE FORM OF ACTION, WHETHER
IN CONTRACT, TORT (INCLUDING NEGLIGENCE), STRICT PRODUCT LIABILITY OR OTHERWISE, EVEN IF
MAXVISION OR ITS LICENSORS OR SUPPLIERS HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES. IN NO EVENT WILL COMPANY'S AGGREGATE LIABILITY HEREUNDER EXCEED THE PURCHASE
PRICE PAID BY YOU. This limitation shall apply notwithstanding any failure or inability to provide the limited remedies set
forth above. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation(s) or exclusion(s) may not apply to you.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide iii

Proprietary Rights-Contracts with Certain U.S. Government Agencies. If the Software is acquired under the terms of
a Department of Defense or civilian agency contract, the Software is "commercial item" as that term is defined at 48
C.F.R. 2.101 (Oct. 1995), consisting of "commercial computer software" and "commercial computer software
documentation" as such terms are used in 48 C.F.R. 12.212 of the Federal Acquisition Regulations and its successors
and 48 C.F.R. 227.7202-1 through 227.7202-4 (June 1995) of the DoD FAR Supplement and its successors. All U.S.
Government end users acquire the Software with only those rights set forth in this Agreement.

Export Restrictions. You acknowledge that the laws and regulations of the United States restrict the export and re-export
of certain commodities and technical data of United States origin, including the Product and the Software, in any medium.
You agree that you will not knowingly, without prior authorization if required, export or re-export the Software or the
Product in any medium without the appropriate United States and foreign government licenses.

Severability. You acknowledge and agree that each provision of this Agreement that provides for a disclaimer of
warranties or an exclusion or limitation of damages represents an express allocation of risk, and is part of the
consideration of this Agreement. Invalidity of any provision of this Agreement shall not affect the validity of the remaining
provisions of this Agreement.

General. This Agreement is the entire agreement between you and MaxVision relative to the Product and the Software,
and supersedes all prior written statements, proposals or agreements relative to its subject matter. It may be modified only
by a writing executed by an authorized representative of MaxVision. No MaxVision reseller or sales representative is
authorized to make any modifications, extensions or additions to this Agreement. This Agreement is governed by the laws
of the State of Alabama without application of the principles of conflicts or choice of laws. The application of the United
Nations Convention on Contracts for the International Sale of Goods to this Agreement is expressly excluded.

Copyright

The materials in this document are the copyrighted works of MaxVision Corporation, copyright © 2005-2006. All rights
reserved. Email [e-mail] for permission to duplicate and otherwise re-use.

Trademarks

MaxVision, and MaxPac are registered trademarks, and MaxPro and TeraPac are trademarks, of MaxVision Corporation.
Microsoft and Windows are registered trademarks of Microsoft Corporation. Intel and Pentium are registered trademarks
and Xeon is a registered trademark of Intel Corporation. Other trademarks and registered trademarks are the property of
their respective owners.

Regulatory Approvals

EN60950, EN55024, EN55022, FCC, Part 15, EN61000-3-2 & EN61000-3-3.

Warnings

Changes or modifications to this device that are not approved by the party responsible for compliance could void the
user’s authority to operate the equipment.

Each type of MaxPac system should be re-shipped only in the Pelican case and/or other packaging materials in
which the system was first delivered to the customer. Damage caused by shipping systems using unapproved
Pelican cases and/or other packaging materials is NOT covered by MaxVision's warranty.

To reduce the risk of electrical shock, do not attempt to open the device unless instructed to do so. Do not use any tool for
purposes other than instructed.

A Lithium Ion battery is included with the system motherboard. This battery is used for the Real Time Clock (RTC) circuit.
The expected lifetime of the battery is approximately 5 years. There is a danger of explosion if this battery is incorrectly
replaced. Replace only with the same or equivalent type recommended by the motherboard manufacturer. Dispose of
used batteries according to the manufacturer’s instructions.

iv MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Contents

Legal and Related Information

Warranties and Liabilities..................................................................................................................................... ii

Copyright............................................................................................................................................................. iii

Trademarks ......................................................................................................................................................... iii

Regulatory Approvals.......................................................................................................................................... iii

Warnings ............................................................................................................................................................. iii

Chapter 1: Troubleshooting Tips for 8230 XRA1/2/3 Systems ........................................................................... 1

Chapter 2: Motherboard Diagrams ........................................................................................................................ 3

Chapter 3: Setting-Up the Software/Devices/Network/RAID Array..................................................................... 5

Setting-Up the Network ....................................................................................................................................... 5

Setting-Up the Graphics...................................................................................................................................... 5

Adjusting the Screens ......................................................................................................................................... 6

Setting Up Video Input for Picture-in-Picture (Dual- and Triple-Screen Configurations Only) ........................... 6

Configuring the RAID Array (with Separate System Drive) ................................................................................ 8

Configuring the RAID Array (with Hot Spare and System Partition on RAID Array)......................................... 22

Chapter 4: Module Replacement and Upgrade Procedures for Single-Screen Systems............................... 33

Introduction ....................................................................................................................................................... 33

Required Tools and Techniques ....................................................................................................................... 33

Names and Types of Screws ............................................................................................................................ 33

Flat Panel Display Module ................................................................................................................................ 34

Opening the Display Assembly into its Service Position................................................................................... 40

Memory ............................................................................................................................................................. 43

PCI Cards (General) ......................................................................................................................................... 44

PCI Express Card (Primary).............................................................................................................................. 45

Power Distribution Assembly ............................................................................................................................ 47

Hard Drive Magazine (also Individual Hard Drives).......................................................................................... 50

Optical Drive (CD/DVD) .................................................................................................................................... 51

Optical Drive (CD/DVD) Backplane .................................................................................................................. 51

External Cooling Fan Assembly........................................................................................................................ 53

CPU Cooling Fans ............................................................................................................................................ 54

Main Power Supply Unit (PSU)......................................................................................................................... 55

Motherboard...................................................................................................................................................... 57

Chapter 5: Module Replacement and Upgrade Procedures for Dual/Triple-Screen Systems....................... 65

Introduction ....................................................................................................................................................... 65

Required Tools and Techniques ....................................................................................................................... 65

Names and Types of Screws ............................................................................................................................ 65

Flat Panel Display Module (Left-Hand Screen)................................................................................................. 66

Flat Panel Display Module (Right-Hand Screen) .............................................................................................. 67

Flat Panel Display Module (Center Screen)...................................................................................................... 68

Opening the Display Assembly into its Service Position................................................................................... 72

Memory ............................................................................................................................................................. 74

PCI Cards (General) ......................................................................................................................................... 75

PCI Express Card (Secondary card for third screen and Projector Port) ........................................................ 76

PCI Express Card (Primary).............................................................................................................................. 77

Power Distribution Assembly ............................................................................................................................ 79

Hard Drive Magazine (also Individual Hard Drives).......................................................................................... 82

Optical Drive (CD/DVD) .................................................................................................................................... 83

Optical Drive (CD/DVD) Backplane .................................................................................................................. 84

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide v

External Cooling Fan Assembly........................................................................................................................ 85

CPU Cooling Fans ............................................................................................................................................ 86

Main Power Supply Unit (PSU)......................................................................................................................... 87

Motherboard...................................................................................................................................................... 89

Chapter 6: Installation of the optional UPS Power Management System........................................................ 98

Installing the UPS Hardware............................................................................................................................. 98

Installing the UPS Software ............................................................................................................................ 102

Using the UPS Software ................................................................................................................................. 104

Chapter 7: Optional TeraPac 3 Connection to the MaxPac8230..................................................................... 107

Using the TeraPac 3 with a MaxPac 8230...................................................................................................... 107

Appendix A: Creating and Using Backup Images (Including Restoring Your OS)....................................... 109

Introduction ..................................................................................................................................................... 109

Appendix B: Regular System Maintenance ...................................................................................................... 118

Cleaning Interior Dust ..................................................................................................................................... 118

Replacing the Lithium Battery ......................................................................................................................... 118

Maintaining (Cleaning) the "Baghdad Filters" ................................................................................................. 118

Resetting the Motherboard BIOS.................................................................................................................... 121

Appendix C: Screws and Required Tools ......................................................................................................... 123

Screws............................................................................................................................................................. 123

Required Tools................................................................................................................................................ 124

Appendix D: Contacting MaxVision Support (RMA and Serial Numbers) ..................................................... 125

Repairing/Replacing Products/Accessories .................................................................................................... 125

Contacting Technical Support and RMA Numbers ......................................................................................... 125

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 1

Chapter 1: Troubleshooting Tips for
8230 XRA1/2/3 Systems

1) The MaxPac8230 has both a hard power switch (at power supply itself ---O; --- for ON) and a soft power
momentary switch (on center monitor behind the display controls). If the optional UPS Power
Management System is installed and the 8230 is ON then removing the AC chord or switching the hard
power to O will not shut down the system. Instead the UPS system will beep and provide power through
the batteries. The system must be shut down via Windows or the soft power switch for a complete
shutdown to occur. Failing to do this step when packing up your system will drain your batteries.

2) When AC power is applied to the 8230 the motherboard goes into standby power mode. Some of the
motherboard circuitry is powered waiting on the soft power or other low level command. When the
motherboard first goes into standby (AC power applied with hard power switch ON) the 3 keyboard led’s
will flash green and then turn back off.

3) When the 8230 is powered on via soft power all of the display power LEDs should turn on with an orange
color. During initial startup the primary display will not light-up until a good portion of the POST (Power On
Self Test) sequence is complete. This time delay depends on the amount of memory present but for most
systems is about 10 seconds. Then all 3 of the keyboard LED’s should flash green. Usually the left
keyboard LED will remain lit. If you need to get into the motherboard BIOS depress the Delete key a few
times now. The BIOS will not be entered until initialization is complete including scanning of drives
attached to the RAID controller.

4) At this stage if any of the display LEDs are RED (instead of Orange or Green) then the display is off.
Depress the display power button (next to the display LED) to power up the display. It’s LED will change
from Red to Orange to Green and back to Orange if the display is not receiving a signal. The LED should
stay green if receiving video signals. Also note that each display must have its input set to DVI and NOT
RGB. To change the input source use the Input button on the display. The RGB input can be used if one
of the display’s PIP VGA inputs is connected from an external source (discussed later) and you wish to
display it’s data rather than the 8230 video data. Initial BIOS initialization data only will appear on the
Primary PCI Express graphics board’s displays. This is normally the Center and Right screens. The Left
screen (if present) will show “No signal DVI” until it has been enabled in Windows. Note that the power
state, input mode, etc of each display is saved for subsequent power-up cycles.

5) At this point depressing the Num Lock key (upper left of the numeric keypad) repeatedly will toggle the
left keyboard LED from green to off. This indicates that the CPU and motherboard is responding to
commands even if you see nothing on the displays. If nothing appears on the display(s) in order to further
debug the problem the 8230 must be put into its service position as documented in chapter 4 (8230XRA1)
or chapter 5 (8230XRA2/3).

6) With the 8230 in its service position refer to Figure 2-2 and find the System Status LED and Post Code
LEDs. Check for proper seating of the PCI Express graphics boards (the 8230XRA3 requires a 2
graphics board for the left screen). Make sure the Poron is attached to the inside of the inner-chassis lid
as shown in Fig 5-33. Assuming the PCI-E boards are seated observe the LEDs in Figure 2-2. With the
motherboard in standby (after proper shutdown with AC applied) the System Status LED should be
yellow. Also both the yellow and green POST Code LEDs should be on.

7) Now depress the soft power button to turn on your 8230. The System Status LED should turn green. The
POST LEDs should sequence as follows: Yellow ON Green OFF during memory checks; Yellow OFF
Green ON during system shadowing checks; Yellow ON Green ON during final CPU checks; then Both
OFF just prior to the keyboard LED’s flashing.

nd

PCI-E

2 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

8) If after system startup the POST LED stick at the Yellow ON Green OFF state then the FBDIMM memory
is not being seen. Refer to the Memory Section of chapter 4 or 5. Note that memory must be installed in
pairs starting with DIMM 1A/1B (Fig 2-2). This means that a bad (or poorly seated) FBDIMM in slot 1A or
1B could cause NONE of the memory to be seen (even in slots 2A and beyond). Note that slots 3A and
4A do not require population in pairs (but must be in order). Memory failures are sometimes just seating
problems so reseating is worth trying. If memory is still failing and you have 4 FBDIMM then try each set
in just slots 1A and 1B (1A/1B bank must be populated in all cases).

9) If you are still not getting video and both POST LEDs are off you could have several video related
problems. Unfortunately the motherboard will allow a boot all the way into Windows with the PCI-E
graphics not present or bad. Assuming neither the middle nor right displays are not getting valid video the
fault is probably with the primary PCI-E graphics card. For 8230XRA3 systems (assuming you do not
have a spare PCI-E board) you could temporarily remove the primary PCI-E graphics board. Now the
secondary PCI-E board (for the left display) should become the primary display for the BIOS and
Windows.

10) Assuming you now have video displaying on your middle and right screen you should see the 3ware
BIOS scan for the RAID array and then boot into Windows. If you are sure a valid image exists on the
RAID array (or individual system disk connected to the motherboard) and you still see “Operating System
not found” a Boot order problem likely exists.

11) Reboot your system and use the delete key to enter the BIOS. Use the arrow keys to go to the Boot
section. Now check your boot order. Make sure that your IDE CD is listed before the 3ware Storage
Controller in the upper part of the screen (listed 1-8). Note that if your system disk is connected directly to
the motherboard it should be listed before the 3ware. If you have connected a USB disk or memory stick
it may be listed ahead of your boot disk. Move it behind your boot disk in this case.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 3

Chapter 2: Motherboard Diagrams

Figure 2-1. Top-down view of the X7DAL-E motherboard.

4 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 2-2. Cable connections and LEDs on the X7DAL-E motherboard.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 5

Chapter 3: Setting-Up the
Software/Devices/Network/RAID Array

Setting-Up the Network

In the majority of environments, it is sufficient to use the Windows XP defaults for the network. Simply
connect the network cable (Figure 3-1) and the system should auto-detect the presence of the
network and the data/communications light next to the network cable connector should start to flash.

Figure 3-1. Connecting the network cable

The easiest way to test your network connection is to invoke your web browser and visit a website
such as www.MaxVision.com. In the event of any problems or special requirements, you should first
consult your on-site IT representative (if the problems persist, contact MaxVision support as
discussed in Appendix D).

Setting-Up the Graphics

When you receive your MacPac dual/triple-screen X-Class system, you will find that the graphics
subsystem has been pre-installed with the following (recommended) characteristics:

• Color Quality: Highest (32-bit)

• Resolution: 1, 2, or 3 x 20.1” displays: 1600 x 1200

Irrespective of the configuration, the graphics on your system will have been custom pre-configured to
suite your particular requirements.

MaxPac systems are available with a variety of different graphics cards depending on your unique
application. The standard configuration for a triple-screen system, for example, is to have the center
and right-hand displays controlled by a PCI Express-based NVIDIA Quadro FX4500 graphics card,
while the left-hand display and projector port are controlled by a second PCI Express-based NVIDIA
Quadro FX-series board.

Note: OpenGL™ acceleration is now available all displays controlled by the PCI Express-based
NVIDIA Quadro FX series controllers. This allows the user to run applications requiring OpenGL
acceleration on all displays as long as all are controlled by the same NVIDIA Graphics driver.

6 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

If you do have a special graphics card, you may consult the manual associated with this card (this
manual will be included in your documentation package as discussed in Chapters 1 and 2) or contact
MaxVision support (as discussed in Appendix D) for more information.

Adjusting the Screens

In the case of a dual-display or triple-display configuration, each screen has a set of controls mounted
on the top of the display (Figure 3-2). (In the case of a single-display system, these controls are
located on the left-hand side of the unit next to the CD/DVD optical drive.)

Figure 3-2. Top-down view of screen controls on dual- and triple-display systems

Observe the power button located to the right of the power light-emitting diode (LED). This is an
independent power button for the display/screen.

Pressing the MENU button will bring up a series of items on the screen. Use the up/down buttons to
move between these items; press and release the SEL button to select that item; and use the
right/left buttons to vary the settings.

Some custom configurations allow the display to be driven from multiple sources. In this case,
pressing the INPUT button selects between digital and analog inputs. These custom configurations
will come equipped with a special documentation addendum that details the actions of the INPUT
button; in the case of standard configurations, the source should always be set to “Digital.”

Setting Up Video Input for Picture-in-Picture
(Dual- and Triple-Screen Configurations Only)

In the case of a MaxPac 8230 XRA2 (dual-screen) system, the right-hand monitor supports multiple
inputs: the default DVI-I input from the system and an external VGA input that can be used for
picture-in-picture monitoring purposes. Similarly, in the case of a MaxPac 8230 XRA3 (triple-screen)
system, both the left- and right-hand monitors support this capability.

1) Observe the VGA connector associated with the left-hand screen (Figure 3-3). The external video
source would be fed into this connector as shown for the right-hand screen (Figure 3-4).

Note: For the purposes of this example, the video signal being used as input to the right-hand
screen originates from another PC. In reality, this input could come from any VGA video source
with a resolution no higher than 1024 x 768.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 7

Figure 3-3

Figure 3-4

2) In order to access the external video source, press the Menu button in the controls mounted on
the top of that display (Figure 3-2), and then use the left/right arrow buttons on this control panel
to access the Picture-in-Picture dialog (Figure 3-5)

Figure 3-5

Figure 3-6

3) Use this dialog to turn the Picture-and-Picture window On/Off and to specify characteristics such
as the size and position of the Picture-and-Picture window (located in the lower right-hand corner
of the screen in Figures 3-5 and 3-6.)

Note: The video source and the Picture-in-Picture window must be set to the same resolution,
which must be less-than or equal-to 1024 x 768.

8 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Configuring the RAID Array (with Separate System Drive)

Note: Your MaxPac8230 may be configured for connection to the optional TeraPac3 8 drive SATA

Expansion. In this case the MaxPac8230 will include a 12 or 16 port SATA RAID 5 controller. This
chapter illustrates and assumes a 4 port SATA RAID 5 controller so the photos may be somewhat
different. Refer to Chapter 7 for a brief section on the MaxPac8230 connection to the TeraPac3 and
to the TeraPac3 User Operation and Maintenance Guide for more details.

Note that these discussions reflect system configurations with a separate system drive as illustrated
in Figures 3-7 and 3-8). Configurations that have the system partition established on the RAID array
itself (leaving a hot-spare drive) are discussed later in this chapter.

When you take possession of your MaxPac 8230 system, the RAID system will already have been
established, initialized, and verified. The instructions in this section are intended to address those rare
situations where you need to replace a degraded/failed drive or you wish to rebuild the RAID system
from the ground up.

Your MaxPac system can contain up to four SATA hot-swappable hard disk drives presented in a
4-drive disk caddy. This caddy is located on the lower left-hand side of the main chassis under the
"Baghdad Filter" assembly as shown in Figure 3-7 (the numbering of the disks is as shown in
Figure 3-8). In the case of a typical RAID 5 system, the upper disk is the system disk, while the
lower three disks are used to implement the RAID data array.

Figure 3-7 Figure 3-8

Installing the Web-Based 3ware Software

If you reload your operating system, then you will also need to reload the appropriate RAID driver
followed by 3ware's 3DM 2 web-based RAID management application as follows:

1) Power-up the system. The operating system will see the RAID controller as a new device and will
therefore prompt you to load the appropriate driver from the 3ware CD, which is provided with
your system.

2) Insert the 3ware CD. The auto-play function will bring up the 3ware Escalade Menu as shown in
Figure 3-9. Initially you should ignore this menu; don’t dismiss it, but instead use the operating
system's Device Manager utility to look for the 3ware driver on the CD and install it.

3) Once the 3ware driver has been loaded, return to the 3ware Escalade Menu and click the Install
3DM 2 button.

4) Approve the license agreement in the ensuing pop-up dialog.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 9

5) Following acceptance of the license agreement, you may be presented with the operating
system's standard Welcome to New Connection Wizard dialog. In this case, use this dialog to
setup your network connection.

6) Following this wizard, 3ware's 3DM 2 software will be installed (when prompted to do so, allow
the installation script to place a 3DM 2 icon on your desktop).

Figure 3-9

Building a New 3ware RAID 5 Array from Scratch

The discussions in this section assume that you have an existing system disk and – for one reason or
another – have installed three new/empty data disks.

1) Start to power-up the system. When you see the BIOS message "<Alt-3> to access 3ware BIOS
Manager" (Figure 2-10) press and hold the <ALT> (alternate) key and – while still holding this key
– press the number "3" key. This will invoke the 3ware BIOS manager; in most cases, you will be
presented with a warning screen as shown in Figure 3-11.

Figure 3-10

Figure 3-11

10 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

2) Press any key to continue, which will take you fully into the 3ware BIOS Manager. Observe that
the Create Unit option is selected by default. Use <Alt-A> to select all of the drives; asterisk "*"
characters appear to the left of each drive's port number to indicate that the drive has indeed
been selected (Figure 3-12)

Figure 3-12

Figure 3-13

3) Ensure that the Create Unit item is still selected (the white box shown to the bottom left of the
screen in Figure 2-12), and then press the <Enter> key to invoke the Create Disk Array screen
(Figure 3-13).

4) Use the up/down arrow keys to highlight the RAID Configuration item, and then press the
<Enter> key to access an associated pop-up dialog (Figure 3-14).

5) Use the up/down arrow keys to highlight the RAID 5 option, and then press the <Enter> key to
select this option.

Figure 3-14

Figure 3-15

6) Use the up/down arrow keys to highlight the Stripe Size item, and then press the <Enter> key to
access an associated pop-up dialog (Figure 3-15).

7) Use the up/down arrow keys to highlight the 256 KB option, and then press the <Enter> key to
select this option.

8) Use the up/down arrow keys to highlight the Write Cache Setting item, and then press the
<Enter> key to access an associated pop-up dialog (Figure 3-16).

9) Use the up/down arrow keys to highlight the Enabled option, and then press the <Enter> key to
select this option.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 11

Figure 3-16

Figure 3-17

10) Use the up/down arrow keys to highlight the StorSave Profile item, and then press the <Enter>
key to access an associated pop-up dialog (Figure 3-17).

11) Use the up/down arrow keys to highlight the Protection option, and then press the <Enter> key
to select this option.

12) Use the up/down/right/left arrow keys to highlight the OK item (Figure 3-18) and then press the
<Enter> key to save your changes.

Figure 3-18

Figure 3-19

13) You will be presented with a warning dialog as shown in Figure 3-19. Press the Y (yes) to allow
the write cache to be enabled (note that this mode significantly improves performance, but it can
result in a loss of data in the event of a power failure, so MaxVision STRONGLY recommends the
use of an uninterruptible power supply (UPS) with your system).

14) At this point, you will be presented with a summary description of the RAID array you have
defined (Figure 3-20).

15) Press the <F8> key to request that your array be established and to exit the 3ware BIOS
setup utility.

12 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-20

Figure 3-21

16) You will be presented with a warning screen as shown in Figure 3-21. Press the Y (yes) key in
order to establish your array and exit the 3ware BIOS setup utility. The system will automatically
reboot itself in order to make your new RAID array available to the operating system. During the
boot process you will see the BIOS report the existence of your new RAID array.

17) Once the system has booted up into Windows®, right-click on the My Computer icon and then
select the Manage option. In the ensuing Computer Management dialog, click on the Disk

Management item. As you have just created a new RAID array, this will automatically launch the
Initialize and Convert Disk Wizard as shown in Figure 3-22.

18) Click the Next button to be presented with the Select Disk to Initialize screen. Click the Disk 1
item as shown in Figure 3-23.

Figure 3-22. The Initialize and Convert Disk Wizard

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 13

Figure 3-23

Figure 3-24

19) Click the Next button to be presented with the Select Disk to Convert screen. Click the Disk 1
item as shown in Figure 3-24.

20) Click the Next button to be presented with the Completing the Wizard screen as shown in
Figure 3-25, and then click the Finish button to perform the operations and exit the wizard.

21) Observe that the Disk Management area of the Computer Management dialog now shows Disk 1
as being a Dynamic disk that is – as yet – unallocated as shown in Figure 3-26.

Figure 3-25. The Completing the Wizard dialog

14 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-26. Disk 1 is – as yet - unallocated

Note: In the case of the system used in this example, the system disk was 120 GB in size, while the

three data disks used to form the RAID array were each 400 GB in size.

Observe in Figure 3-26 that Disk 1 is shown as being approximately 800 GB in size, where 800 GB
equates to 2/3 of the 3 x 400 GB capacity of the data disks (the remaining 400 GB is used to provide
the RAID 5 redundancy).

22) Now, right-click on the Disk 1 item in the lower-right-hand portion of the screen, and then select
the New Volume option from the ensuing pop-up menu as shown in Figure 3-27.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 15

Figure 3-27. Select the New Volume option

23) Observe the New Volume Wizard appear as shown in Figure 3-28.

Figure 3-28. The New Volume Wizard

16 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

24) Click the Next button to be presented with the Select Volume Type screen. Click the Simple

option as shown in Figure 3-29.

Figure 3-29

Figure 3-30

25) Click the Next button to be presented with the Select Disk screen. Ensure that the Disk 1

item is selected and appears in the Selected column on the right-hand side of the dialog as
shown in Figure 3-30.

26) Click the Next button to be presented with the Assign Drive Letter or Path screen. Ensure

that the Assign the Following Drive Letter item is selected and accept the default letter
presented by the system (or enter a different letter if you require) as shown in Figure 3-31.

Figure 3-31

Figure 3-32

27) Click the Next button to be presented with the Format Volume screen. Click the Format this

volume with the following settings item as shown in Figure 3-32. Ensure that the settings

are File system = NTFS, Allocation unit size = Default, and Volume Label = user defined
(the default is "New Volume"). Also ensure that the Perform a quick format item is selected.

28) Click the Next button to be presented with the Completing the New Volume Wizard screen

as shown in Figure 3-33.

29) Click the Finish button to perform all of the operations and exit the wizard.

30) Observe that the Disk Management area of the Computer Management dialog now

shows Disk 1 as being Dynamic, Online, and Healthy as illustrated in Figure 3-34.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 17

Figure 3-33. The Completing the Wizard dialog

Figure 3-34. Disk 1 is now shown as being Dynamic, Online, and Healthy

18 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Rebuilding an Existing (Failed) 3ware RAID 5 Array

The discussions in this section assume that you originally have a good, working RAID 5 array. In this
case, if you double-click the Connect to 3DM 2 icon on your desktop and login to the ensuing
webpage using the default password (which is 3ware), you will see that the status of your array looks
something like that shown in Figure 3-35.

Figure 3-35

Once you have observed this good array, exit out of the 3DM 2 web interface. At some stage, one of
the disks in the array may start to degrade or go completely off-line. For the purposes of these
discussions, we are going to power down the system, physically remove Disk 01 from the array
(thereby simulating a catastrophic failure on this disk) and power up the system back up again.

1) Power down the system and remove the center data disk (Disk 01) as shown in Figure 3-36.

Figure 3-36

Figure 3-37

2) Power the system back up again. The BIOS detects the fact that there is a problem with the RAID
array and displays an appropriate message (Figure 3-37). Press the <Pause Break> key to freeze
the display; from this (and Figure 3-8) you will be able to determine which drive has failed.

3) Press and hold the soft power key in order to power the system down.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 19

4) Remove the failed drive and replace it with a good drive of the same type and capacity
(remember that we only removed the drive above in order to simulate a catastrophic failure
scenario).

5) Power the system up again all the way into windows.

6) Double-click the Connect to 3DM 2 icon on your desktop and login to the ensuing webpage
using your administrator password (note that you may need to contact your IT department in
order to obtain this password).

7) After you have logged in as the administrator, you will see a status of ERROR in the 3DM 2
interface (Figure 3-38).

Figure 3-38.

8) Observe that the system reports the two good drives as being in a DEGRADED unit as shown
in Figure 3-39.

9) Depending on the past history of the disk (whether or not it was previously part of a 3ware RAID
array) the system may report that the new disk is INOPERABLE as illustrated in Figure 3-39.
Alternatively, the system may report the new disk as being AVAILABLE as illustrated in Figure 3-40.

Assuming that the new disk is reported as being INOPERABLE, click the checkbox associated with
that unit (Unit 1 in this example) and then click the Delete Unit button. Observe that the system will
present you with a confirmation dialog as shown in Figure 3-39. Click the OK button, and observe
that the new disk is now reported as being AVAILABLE as illustrated in Figure 3-40.

10) Click the checkbox associated with the two good drives (shown as Unit 0 in this example) and also
click the checkbox associated the new replacement drive (shown as Port 1 in this example) and
then click the Rebuild Unit button associated with the two good drives as illustrated in Figure 3-41.

11) Observe the ensuing pop-up dialog box as shown in Figure 3-42. Click the checkbox associated
with the new drive, and then click the OK button.

20 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-39.

Figure 3-40.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 21

Figure 3-41.

Figure 3-42.

22 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

12) Observe that the replacement drive has now been incorporated into the RAID 5 array as
illustrated in Figure 3-43 (note that this array is still shown as being DEGRADED).

Figure 3-43.

When the new disk has been fully integrated into the array, the interface will reflect the
completion of the rebuild.

Note: This rebuild process can take a significant amount of time (14 hours in the case of our
example using 400 GB disks).

Note: The rebuild process is performed in the background, so you can continue to use your
system while the rebuild is taking place.

Configuring the RAID Array

(with Hot Spare and System Partition on RAID Array)

Note: Your MaxPac8230 may be configured for connection to the optional TeraPac3 8 drive SATA

Expansion. In this case the MaxPac8230 will include a 12 or 16 port SATA RAID 5 controller. This
chapter illustrates and assumes a 4 port SATA RAID 5 controller so the photos may be somewhat
different. Refer to Chapter 7 for a brief section on the MaxPac8230 connection to the TeraPac3 and
to the TeraPac3 User Operation and Maintenance Guide for more details.

Note that these discussions reflect system configurations that have the system partition established
on the RAID array itself (leaving a hot-spare drive) as illustrated in Figure 3-44. Configurations with a
separate system drive are discussed earlier in this chapter.

When you take possession of your MaxPac 8230 system, the RAID system will already have been
established, initialized, and verified. The instructions in this section are intended to address those rare

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 23

situations where you need to replace a degraded/failed drive or you wish to rebuild the RAID system
from the ground up.

Your MaxPac system can contain up to four SATA hot-swappable hard disk drives presented in a
4-drive disk caddy. This caddy is located on the lower left-hand side of the main chassis under the
"Baghdad Filter" assembly as shown to the left of Figure 3-44 (the numbering of the disks is as shown
to the right of Figure 3-44). The main array – including the system partition – occupies disks 00, 01,
and 02, leaving disk 03 as the hot-spare (note that this is the initial/default configuration; once the hot­spare disk has been deployed as discussed below, the failed-and-replaced disk will assume the role
of the new hot-spare).

Figure 3-44

Establishing the Array and Reloading the System Image

These discussions assume that you are reestablishing a system from the ground up, and that you
have four new disks in your disk caddy.

1) Start to power-up the system. When you see the BIOS message "<Alt-3> to access 3ware BIOS
Manager" (Figure 3-45) press and hold the <ALT> (alternate) key and – while still holding this key
– press the number "3" key. This will invoke the 3ware BIOS manager; in most cases, you will be
presented with a warning screen as shown in Figure 3-46.

2) Press any key to continue, which will take you fully into the 3ware BIOS Manager. Observe that
the four disks are shown on the screen, but no drives are initially selected (Figure 3-47).

Figure 3-45

Figure 3-46

24 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-47

Figure 3-48

3) Use the up/down arrow keys to highlight disks 00, 01, and 02 in turn; as each disk is highlighted,
press the <Enter> key to select it (selected disks are indicated with an asterisk '*' character as
shown in Figure 3-48). (Note that the reason disk 03 is not selected is that this is being reserved
as the hot-spare.)

4) Use the <Tab> key to highlight the Create Unit option (Figure 3-48), then press the <Enter> key
to key to invoke the Create Disk Array screen.

5) Use the up/down arrow keys to highlight the RAID Configuration item, and then press the
<Enter> key to access an associated pop-up dialog (Figure 3-49).

6) Now use the up/down keys to highlight the RAID 5 option and then press the <Enter> key to
select this option.

7) Next, use the up/down arrow keys to highlight the Stripe Size item, and then press the <Enter>
key to access an associated pop-up dialog (Figure 3-50).

8) Use the up/down arrow keys to highlight the 256 KB option, and then press the <Enter> key to
select this option.

9) Use the up/down arrow keys to highlight the Write Cache Setting item, and then press the
<Enter> key to access an associated pop-up dialog (Figure 3-51).

10) Use the up/down arrow keys to highlight the Enabled option, and then press the <Enter> key to
select this option.

Figure 3-49

Figure 3-50

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 25

Figure 3-51

Figure 3-52

11) Use the up/down arrow keys to highlight the StorSave Profile item, and then press the <Enter>
key to access an associated pop-up dialog (Figure 3-52).

12) Use the up/down arrow keys to highlight the Protection option, and then press the <Enter> key
to select this option.

13) Use the up/down/right/left arrow keys to highlight the OK item (Figure 3-53) and then press the
<Enter> key to save your changes.

Figure 3-53

Figure 3-54

14) You will be presented with a warning dialog as shown in Figure 3-54. Press the Y (yes) key to
allow the write cache to be enabled [note that this mode significantly improves performance, but it
can result in a loss of data in the event of a power failure, so MaxVision STRONGLY
recommends the use of an uninterruptible power supply (UPS) with your system.

15) At this point, you will be presented with a summary description of the RAID array you have
defined (Figure 3-55).

16) Observe that this screen shows the array (3 drives) and the remaining uncommitted drive. Use
the up/down arrow keys to highlight the uncommitted drive and press the <Enter> key to select it
(the fact this has been selected will be indicated with an asterisk '*' character).

17) Now press the 'S' key to designate this selected drive as being the hot-spare (an annotation will
appear next to the drive confirming this status).

26 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-55

Figure 3-56

18) Press the <F8> key to request that your array be committed and to exit the 3ware BIOS
setup utility.

19) You will be presented with a warning screen as shown in Figure 3-56. Before you do anything
else, ensure that the bootable recovery DVD supplied in the accessory pack is in the system's
CD/DVD drive. In the case of a multiple DVD image, ensure Disk #1 is in the drive. Then press
the Y (yes) key in order to establish your array, exit the 3ware BIOS setup utility, and
automatically reboot the machine.

Note: If you are using an image CD/DVD you've created yourself as discussed in Appendix A,
and if that CD/DVD (or the first CD/DVD in a set) has the Acronis Bootable Rescue Media
software on it, then simply insert this disk in the drive and proceed to point 20 below.

Alternatively, if your CD/DVD does not have the Acronis Bootable Rescue Media software on it,
then first insert the bootable recovery DVD supplied by MaxVision in the drive and reboot as
discussed in point 20 below. However, before proceeding to point 21, remove the bootable
recovery DVD supplied by MaxVision from the drive and replace it with the first disk from your
own image.

20) The system will automatically reboot itself from the recovery disk in the DVD drive. Following
the Acronis splash, you will be presented with the Pick a Task page in the Acronis True Image
application (Figure 3-57).

Figure 3-57

Figure 3-58

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 27

21) Click the Recovery item to be presented with the first page from the Restore Data Wizard
(Figure 3-58).

22) Click the Next button to be presented with the Archive Selection screen (Figure 3-59).

Figure 3-59

Figure 3-60

23) Ensure that the CD Drive item in the left-hand selection pane is expanded (if not, click the '+'
icon next to this item) and then use the mouse to click on the image (*.tib) file you will see there
(Figure 3-59).

Note: In the case of a multi-CD/DVD image set, the system will present you with a message
saying that this is not the last created volume in the archive and requesting you to insert the
last created volume. In this case, replace the current CD/DVD with the last disk from the set,
click on the *.tib file on this disk, and proceed to point 24 (at some stage you will be prompted
to return to the first disk).

24) Click the Next button to be presented with the Restoration Type Selection page (Figure 3-60).

25) Select the Restore Disks or Partition item and then click the Next button to be presented with
the Partition or Disk to Restore page (Figure 3-61).

26) Select the NTFS (C) option (a tick-mark indicates that the option has been selected) and then
click the NEXT button to be presented with the Restored Partition Location page (Figure 3-62).

Figure 3-61

Figure 3-62

28 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

27) Select the Unallocated (Disk 1) item and then click the Next button to be presented with the

Restored Partition Type page (Figure 3-63).

Figure 3-63

Figure 3-64

28) Select the Active item and then click the Next button to be presented with the Restored
Partition Size page (Figure 3-64).

29) We have chosen to establish a 200 GB system partition in this example; the remaining "Free
Space" will automatically be allocated to the data portion of the RAID 5 array. Click the Next
button to be presented with the Next Selection window (Figure 3-65)

Figure 3-65

Figure 3-66

30) Select the No, I Do Not option and then click the Next button to be presented with the Restore
Operation options page (Figure 3-66).

31) Simply click the Next button to be presented with the Restore Data Wizard summary screen
(Figure 3-67)

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 29

Figure 3-67

Figure 3-68

32) Click the Proceed button to initiate the restoration, at which time you will be presented with the
Operation Progress dialog (Figure 3-68), which will reflect the status of the restoration. (In the

case of a multi-DVD image, the system will inform you as and when to insert subsequent
DVDs).

33) Once the restoration process has been completed, eject the DVD from the CD/DVD drive,
power-down the system by holding the Soft-Power button on top of the center display for
approximately five seconds, and then power-up the machine using the Soft Power button to
boot-up into Windows.

Note: Once you have re-loaded the original MaxVision-supplied image, you will also have to re­run the initialization procedures – including re-activating/re-registering your OS license – as
described earlier in this manual.

34) After the system has booted up into Windows (and you've re-run the initialization procedures as
noted above), right-click on the My Computer icon and then select the Manage option. In the
ensuing Computer Management dialog, click on the Disk Management item (Figure 3-69).

35) Right-mouse-click in the Unallocated area and select the New Partition item in order to be
presented with the New Partition Wizard as shown in Figure 3-70.

36) Click the Next button, then select the Perform a Quick Format option (ensure the File System
type is set to NTFS), and then click the OK button. The Computer Management window will
reflect your newly formatted partition (Figure 3-71).

30 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-69

Figure 3-70

Figure 3-71

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 31

Rebuilding an Existing (Failed) 3ware RAID 5 Array

The discussions in this section assume that you originally have a good, working RAID 5 array
(consisting of 3 drives for the array and 1 Hot Spare). In this case, if you double-click the Connect to

3DM 2 icon on your desktop and login to the ensuing webpage using the default password (which is
3ware), you will see that the status of your array looks something like that shown in Figure 3-72.

Once you have observed this good array, exit out of the 3DM 2 web interface. At some stage, one of
the disks in the array may start to degrade or go completely off-line. For the purposes of these
discussions, we are going to power down the system, physically remove Disk 01 from the array
(thereby simulating a catastrophic failure on this disk) and power up the system back up again.

1) Power down the system and remove the center data disk (Disk 01) as shown in Figure 3-73.

2) Power the system back up again. The BIOS detects the fact that there is a problem with the RAID
array and displays an appropriate message (Figure 3-74). Press the <Pause Break> key to freeze
the display; from this (and Figure 3-44) you will be able to determine which drive has failed. (In
the case of our example, the RAID array is shown as being "Degraded" and only Ports 0 and 2
are shown as being available.)

3) Press the <Pause Break> key again to un-freeze the display. The system will automatically bring
the hot-spare drive online and integrate it into the array.

4) As soon as possible after the array has been reconstructed as discussed in point 3, power down
the system, remove the failed drive (in this case it was previously removed to simulate the
failure), and replace it with a good drive of the same type and capacity.

Figure 3-72

32 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 3-73

Figure 3-74

5) Start to power-up the system. When you see the BIOS message "<Alt-3> to access 3ware BIOS
Manager", press and hold the <ALT> (alternate) key and – while still holding this key – press the

number "3" key. This will invoke the 3ware BIOS manager; in most cases, you will be presented
with a warning screen; press any key to continue, which will take you fully into the 3ware BIOS
Manager.

6) Observe that this screen shows the array (3 drives) and the remaining uncommitted drive (the
new drive you've just added to the system). Use the up/down arrow keys to highlight the
uncommitted drive and press the <Enter> key to select it (the fact this has been selected will be
indicated with an asterisk '*' character).

Note: If this drive was ever part of a previous 3ware RAID array, it will show up as a "Failed
Array" comprising only a single drive. In this case, use the <Tab> key to select the Delete Unit
option and then press the <Enter> key to select this option and delete the drive as an array.

7) Now press the 'S' key to designate this selected drive as being the new hot-spare (an annotation
will appear next to the drive confirming this status).

8) Press the <F8> key to exit the 3ware BIOS utility and automatically reboot the system.

9) Power the system up all the way into Windows.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 33

Chapter 4: Module Replacement and
Upgrade Procedures for Single-Screen
Systems

Introduction

The instructions in this chapter describe how to replace and upgrade various modules in your
MaxPac unit.

Note: Generally speaking, you should only access the MaxPac internals under the direction of
MaxVision support. In some cases, performing unauthorized procedures or using components that
have not been tested and approved by MaxVision may invalidate your warranty.

Note: Power-down your MaxPac system (shut down Windows® and then turn the hard power switch
to its Off position) and then remove the power cable before performing any of the procedures
discussed in this chapter. Also please be aware of static discharge when working on your MaxPac. In
General, touch the metal part of the chassis to discharge any static prior to handling any delicate
electronic parts.

Note: When accessing the system internals and/or performing module upgrade procedures, you are
quickly going to end up with a lot of screws and other small items. In order to keep track of things and
to prevent misplacing any parts, it is strongly recommended to have a plastic container divided into
small compartments and to label these compartments as you work.

Required Tools and Techniques

Most of the module replacement and upgrade procedures discussed in this chapter can be performed
using only a pair of #1 (small tip) and #2 (regular tip) Phillips screwdrivers. However, some
procedures will require additional tools as discussed in Appendix C.

Note: It is extremely important that you use only high-quality tools so as to avoid any slippage and
stripping of screw heads and threads. Furthermore, in order to avoid any slippage, it is VERY
important to apply adequate force in the form of firm and steady pressure. See Appendix C for
details on the tools required to service the system.

Note: It is highly recommended that you use magnetized screwdrivers so as to prevent screws from
dropping inside the case and/or aiding in retrieving them if they do drop inside the case. (If your
screwdriver isn’t already magnetized, you can make it so by repeatedly “stroking” the blade with a
permanent magnet.

Names and Types of Screws

MaxPac X-Class systems use a variety of different screw types. In order to help you follow the
instructions in this chapter, details on these screws are provided in Appendix C.

34 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Flat Panel Display Module

1) Lay the system flat on the table with the display facing upwards (it is recommended that you lay
the system on bubble wrap in order to protect the finish).

2) Use a Phillips #1 screwdriver to remove the four 4-40 3/16" black countersunk screws – two on
each side – holding the monitor bezel to the main chassis (Figures 4-1 and 4-2).

Figure 4-1

3) Use a Phillips #2 screwdriver to remove the four silver screws – two on the top and two on the
bottom holding the main chassis to the monitor bezel (Figures 4-3 and 4-4).

Figure 4-3

4) Gently lift the monitor bezel away from the main chassis. Observe the soft power cable as
illustrated in Figure 4-5.

Figure 4-2

Figure 4-4

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 35

Figure 4-5

5) Disconnect the soft power cable as illustrated in Figures 4-6 and 4-7.

Figure 4-6

Figure 4-7

6) Gently lift the inner chassis – including the monitor assembly – away from the outer chassis as
illustrated in Figures 4-8 and 4-9.

Figure 4-8

Figure 4-9

36 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

7) Use a Phillips #2 screwdriver to remove the four black countersunk screws holding the screen
assembly to the chassis – two on the top (Figure 4-10) and one on each side (Figure 4-11 and
Figure 4-12).

Figure 4-10

Figure 4-11

8) Observe that the monitor assemble is hinged. Gently lift the display on the side opposite the
hinge (Figure 4-13) until it is in its fully open position).

Figure 4-12

Figure 4-13

Note: The display folds all of the way over until it's horizontal. In fact, it will open further until it

touches the table, but this may strain the hinge. For this reason, it is strongly recommended that
you place some object under the monitor to support it (this object should be covered by some soft
material so as to protect the screen).

9) Use a screwdriver to disengage the latch on the monitor's power cable (Figure 4-14) and then
disconnect this cable (Figure 4-15).

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 37

Figure 4-14

Figure 4-15

10) Use a Philips #1 screwdriver to remove the two screws attaching the over-molded DVI data cable
connector to the graphics board (Figure 4-16) and gently pull the connector a little way from the
system (Figure 4-17).

Figure 4-16

Figure 4-17

11) Use a Phillips #2 screwdriver to remove the two 6-32 screws attaching the access plate – and the
special linking bracket – to the inner chassis (Figure 4-18).

Figure 4-18

12) Lift the linking bracket away from the system (Figure 4-19) then lift the access plate away from
the chassis (Figure 4-20).

Figure 4-19

38 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-20

Figure 4-21

13) Carefully cut the cable ties as illustrated in (Figure 4-21).

14) Gently lift the monitor power and data cables out of the slot as illustrated in (Figure 4-22).

Figure 4-22

15) Place the monitor power and data cables inside the chassis out of the way while you close the
display and remove the four screws – two on each side – holding the LCD panel to the main
monitor display assembly (Figures 4-23 and 4-24).

Figure 4-23

Figure 4-24

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 39

16) Observe that the LCD panel can now be lifted away from the main display assembly (Figures 4-25
and 4-26). However, this step should not be performed just yet, instead proceed to step (18).

Figure 4-25

Figure 4-26

17) While carefully supporting the LCD panel, gently raise the main monitor assembly and "snake"
the cables through the slot as illustrated in Figure 4-27.

Figure 4-27

Figure 4-28

18) Gently lift the LCD away from the inner chassis and lay it face down on a protective surface.
Disconnect the power cable from the LCD (Figure 4-28). Unscrew the jack screws attaching the
data cable to the LCD (Figure 4-29) and detach this cable (Figure 4-30).

Figure 4-29

19) Take the replacement LCD provided by MaxVision support and incorporate it into the system by
performing the steps described above in reverse order.

Figure 4-30

40 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Opening the Display Assembly into its Service Position

In order to replace and/or upgrade modules inside the MaxPac system, it is necessary to open the
display assembly into its service position as discussed below.

1) Lay the system flat on the table with the display facing upwards (it is recommended that you lay
the system on bubble wrap in order to protect the finish).

2) Use a Phillips #1 screwdriver to remove the four 4-40 3/16" black countersunk screws – two on
each side – holding the monitor bezel to the main chassis (Figures 4-31 and 4-32).

Figure 4-31

3) Use a Phillips #2 screwdriver to remove the four silver screws – two on the top and two on the
bottom holding the main chassis to the monitor bezel (Figures 4-33 and 4-34).

Figure 4-33

4) Gently lift the monitor bezel away from the main chassis. Observe the soft power cable as
illustrated in Figure 4-35.

Figure 4-32

Figure 4-34

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 41

Figure 4-35

5) Disconnect the soft power cable as illustrated in Figures 4-36 and 4-37.

Figure 4-36

Figure 4-37

Note: Certain components can be replaced without removing the inner chassis from the outer

chassis. Some of these components include memory, main power supply, PCI and PCI Express
boards. While it is fairly easy to remove the inner chassis for the Single-Display XRA1 it is more
difficult for the Dual/Triple-Display XRA2/3. Some photos will include the outer chassis while
others will not.

6) Gently lift the inner chassis – including the monitor assembly – away from the outer chassis as
illustrated in Figures 4-38 and 4-39.

42 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-38

Figure 4-39

7) Use a Phillips #2 screwdriver to remove the four black countersunk screws holding the screen
assembly to the chassis – two on the top (Figure 4-40) and one on each side (Figure 4-41 and
Figure 4-42).

Figure 4-40

Figure 4-41

8) Observe that the monitor assemble is hinged. Gently lift the display on the side opposite the
hinge (Figure 4-13) until it is in its fully open position.

Figure 4-42

Figure 4-43

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 43

Note: The display folds all of the way over until it's horizontal. In fact, it will open further until it
touches the table, but this may strain the hinge. For this reason, it is strongly recommended that
you place some object under the monitor to support it (this object should be covered by some soft
material so as to protect the screen).

Note: Your MaxPac8230 may contain the optional UPS Power Management System. In this case
the inside of the inner chassis will look similar to the photo above. Please refer to Chapter 6 for
details of the installation and removal of the UPS System. The UPS System must be removed to
gain access to the memory and CPUs.

Memory

Note: Due to the fact that high-end computer systems can experience a host of memory compatibility

issues and problems, you should only use replacement and/or additional memory sticks supplied by
MaxVision.

Note: The MaxPac 8230 uses a Fully Buffered DDR2 memory (FB-DIMM or FBD). Specifically the
MaxPac 8230 uses FBD DDR2 667MHz. What separates FBD from regular DDR2 is a chip on each
module called the AMB (Advanced Memory Buffer), which buffers all data/address/command
requests to the DRAM devices. This buffering allows up to 12GB of memory to be installed in the
MaxPac 8230. FB-DIMMs REQUIRE that memory sticks be used in pairs, with each pair having the
same size/capacity/speed. Population of the first pair of FBD occupies the first and second DIMM
slots (labeled DIMM1A and DIMM1B on the motherboard). Population of the second pair of FBD
occupies the third and fourth DIMM slots (labeled DIMM2A and DIMM2B).

Note: In the event that you begin to experience problems with the memory that is already resident in
your MaxPac, you must first determine which stick has failed under the direction of MaxVision
support.

Note: The BIOS will always report the true amount of physical memory that is present in the system.
This may be as much as 12 GB. However, the actual amount of memory that can be seen by the
system is determined by the main operating system (OS). With regard to the 32-bit Windows® XP
Professional operating system, for example, in the case of a MaxPac 8230 XRA2 (dual-screen)
configuration, the maximum amount of memory reported in the System Information dialog is 3 GB;
by comparison, in the case of a MaxPac 8230 XRA3 (triple-screen) configuration, the maximum
amount of memory reported in the system information dialog is 2 GB. (Further note that even when
the OS reports 3 GB for the dual-screen configuration, the maximum amount of shared user space is
actually only 2 GB.) However, with regard to the 64-bit Windows XP Professional x64 Edition of the
operating system, the System Information dialog will accurately report the true amount of physical

44 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

memory (which can theoretically be up to 128 GB) and all of this memory will be available to the
applications.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) In order to remove and replace a memory stick, gently press down-and-out on the two plastic
“rabbit-ears” at either side of the stick which will cause it to pop out (Figure 4-44), and then
remove the stick from the system (Figure 4-45).

Figure 4-44

3) Observe that the memory sticks are keyed such that they can only be inserted one way. Take the
new (replacement) memory stick sent to you by MaxVision support and gently press it down into
the original slot on the motherboard.

4) Return the system to its initial condition by reversing the order of the operations discussed at the
beginning of this section.

PCI Cards (General)

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) If you are replacing an existing PCI card, use a Phillips #2 screwdriver to remove the 6-32 screw
attaching the card’s retaining bracket to the inner chassis as shown in Figure 4-46. (If you are
adding a new card, remove the corresponding blanking plate screw.)

Figure 4-45

Figure 4-46

Figure 4-47

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 45

3) Gently pull out the old card as shown in Figure 4-47.

4) This particular example features a SATA RAID controller card. In this case, you also need to
disconnect the data cables from the card as shown in Figure 4-48 (see notes below).

Figure 4-48

5) Take the new/replacement PCI card and incorporate it into the system by performing the steps
described above in reverse order.

Note: It is important to ensure that theses cables are attached to the new card in the same
positions as they occupied on the original card.

Note: In the case of these SATA cables, there is no good locking mechanism to ensure that they
remain attached to the card, so MaxVision uses a special adhesive. This adhesive is somewhat
flexible and the connectors can be broken free of the bond by simply pulling the SATA connector
straight out (do not pull on SATA cable itself). Reapply adhesive (provided by MaxVision support)
after reattaching the cables to the new card.

Note: Ensure that the tongue on the new/replacement card’s faceplate lines up with the slot in the
chassis (you may have to bend the tongue slightly in the case of a new card).

PCI Express Card (Primary)

In the case of a single-screen MaxPac system, the graphics will be handled by the PCI Express card
located in the primary PCI Express slot. This topic discusses the replacement of the Primary PCI
Express card.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Use a Phillips #1 screwdriver to remove the screws holding the over-molded video cables to the
PCI Express graphics card (Figure 4-49). Gently disengage the over-molded DVI connector from
the PCI Express graphics board (Figure 4-50).

46 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-49

Figure 4-50

3) Use a Phillips #2 screwdriver to remove the two 6-32 screws attaching the card’s retaining
bracket – and the special linking bracket – to the inner chassis (Figure 4-51) and lift the linking
bracket away from the system (Figure 4-52).

Figure 4-51

Figure 4-52

4) Some PCI Express cards may have an auxiliary power connector. If so, disconnect it as shown
in Figure 4-53.

5) Gently remove the card from the system (Figure 5-54).

Figure 4-53

Figure 4-54

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 47

6) Take the new PCI Express card and incorporate it into the system by performing the steps
described above in reverse order.

Note: Ensure that the tongue on the new/replacement card’s faceplate lines up with the slot in the
chassis (you may have to bend the tongue slightly in the case of a new card).

Note: When removing the video cables keep track of the order of the connections to the PCI
Express card. The right-hand display is connected to the top connector and the center display is
connected to the bottom connector of the PCI Express card. In the case of a triple-display
system, the left display connector (which is a different shape to the other two) is attached to the
bottom DVII connector of the secondary PCI Express graphics board.

Note: In this system there is no plastic latch holding the rear of the PCI Express card. The foam
attached to the hinged inner lid of the MaxPac will hold pressure to the back of the card when
properly secured

Power Distribution Assembly

Note that the following procedure may be facilitated by first removing the PCI and PCI Express cards
as discussed earlier in that chapter; however, removing these cards is not obligatory.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Unplug the top power input connector from the power distribution board (Figure 4-55).

Figure 4-55

3) Unplug the bottom power input connector from the power distribution board (Figure 4-56).

4) Unplug the CD/DVD power output connector from the power distribution board (Figure 4-57).

Figure 4-56

Figure 4-57

Figure 4-58

48 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

5) Use an Allen key/tool to remove the screw attaching the power distribution assembly to the power
supply unit (Figure 4-58).

6) Use a Phillips #1 screwdriver to remove the two 4-40 screws attaching the power distribution
assembly to the side of the inner chassis (Figures 4-59).

Figure 4-59

Figure 4-60

7) Gently remove the input power connector to the power distribution board (note the latch on the
back side of the connector) as shown in Figure 4-60.

8) Gently remove the display power cable from the power distribution board (Figures 4-61 and 4-62)
Cut all cable ties holding the cables to the aluminum cable guide bracket.

Figure 4-61

Figure 4-62

9) Disconnect the right speaker cable from the power distribution board as illustrated in Figures 4-63
and 4-64.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 49

Figure 4-63

Figure 4-64

10) Disconnect the audio input cable from the power distribution board as illustrated in Figure 4-65.
This connector is black and has a latch. Note that the audio amplifier is also on the power
distribution board.

Figure 4-65

11) Disconnect the left speaker cable from the power distribution board as illustrated in Figure 4-66.

12) Gently lift the power distribution assembly up and away from the inner chassis (Figure 4-67).

13) Take the new power distribution assembly supplied by MaxVision support and incorporate it
into the system by performing the steps described above in reverse order.

Figure 4-66

Figure 4-67

50 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Hard Drive Magazine (also Individual Hard Drives)

1) Undo the knurled screw holding the middle binding bar (Figure 4-68) and then remove the binding
bar (Figure 4-69).

Figure 4-68

2) Gently pull on the magazine handle to extract the magazine from the inner chassis (Figure 4-70).

Figure 4-70

3) In order to replace an individual drive, turn each of the four knurled screws attached to the upper
binding bar until they pop out and then remove the upper binding bar (Figure 4-71). Note that the
upper binding bar has tabs that are inserted into slots of the main drive cage.

Figure 4-69

Figure 4-71

Figure 4-72

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 51

4) Gently grasp the drive in question and pull it out of the magazine (Figure 4-72).

Note: These disks are hot-swappable, so you can replace individual drives while the magazine
remains resident in the system. When the upper binding bar is removed the 4 slots in the main drive
cage may slide back. Make sure that when replacing the upper binding bar that the tabs go into
these slots.

Note: In order to easily identify these disks, MaxVision serial numbers are affixed to the bottom
edge (the small white strips shown toward the bottom of the drives in Figure 4-72). Recording the
positions and serial numbers of your disks for each MaxPac is advisable.

Optical Drive (CD/DVD)

1) Note that it is not necessary to open the display assembly into its service position in order to
perform this procedure.

2) Undo the two knurled attaching the CD/DVD drive to the outside of the system's main chassis
(Figure 4-73).

Figure 4-73

3) Gently remove the CD/DVD drive from the system (Figure 4-74).

4) Take the new CD/DVD assembly as supplied by MaxVision support and incorporate it into the
system by performing the steps described above in reverse order.

Optical Drive (CD/DVD) Backplane

Note: The CD/DVD backplane cannot be easily replaced without first removing the main Power

Supply Unit (PSU). In the rare case that support advises that the CD/DVD backplane needs
replacing refer to the section on the PSU later in this chapter and then return to this section.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove the CD/DVD drive as discussed in the previous topic.

3) Remove the ATA cable (observing where the red stripe is for future reference) as illustrated in
Figure 4-75.

Figure 4-74

52 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-75

Figure 4-76

4) Remove the main power connector as illustrated in Figure 4-76 (release the latch with your finger
or thumb nail while pulling ion the cable).

5) Remove the CD/Audio cable as illustrated in Figure 4-77.

Figure 4-77

Figure 4-78

6) Use a Philips #1 screwdriver to remove the two screws attaching the CD/DVD backplane to the
main chassis as illustrated in Figure 5-78.

7) Gently remove the CD/DVD backplane as illustrated in Figure 4-79.

8) Present the replacement CD/DVD backplane supplied by MaxVision support to the inner chassis
and perform the steps described above in reverse order.

Note: If the replacement CD/DVD backplane does not come equipped with a protective (insulating)
Mylar cover, remove this piece from your original backplane and reattach it to the new backplane.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 53

Figure 4-79

External Cooling Fan Assembly

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Disconnect the external cooling fan assembly’s power supply cable from motherboard. Simply
pull it away using your fingers as shown in Figures 4-80 and 4-81.

Figure 4-80

3) All three fans must be treated as a single assembly, so remove the twelve self-tapping Plastite
screws (4 per fan) attaching the fans to the internal chassis (Figure 4-82) and then gently lift the
fan assembly away from the inner chassis (Figure 4-83).

4) Present the replacement fan assembly supplied by MaxVision support to the inner chassis and
perform the steps described above in reverse order.

Note: The fan guards are secured to the outside of the chassis by the Plastite screws. When the
new fan assembly is replaced make sure the fan guards are replaced.

Figure 4-81

54 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-82

Figure 4-83

CPU Cooling Fans

Note: The photos in this section assume the Power Distribution Assembly has been previously

removed. These photos more clearly illustrate the replacement of the CPU Cooling Fans but they can
be replaced with the Power Distribution Assembly installed as well.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) There are two screws on either side of the cooling fan assembly. Use a Phillips #2 screwdriver to
loosen these captured screws (Figures 4-84 and 4-85).

Figure 4-84

3) Gently lift the cooling fan assembly away from the chassis as illustrated in Figure 4-86.

Figure 4-85

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 55

Figure 4-86

4) Each fan has its own power connector that is attached to the main motherboard. Disconnect the
power connector associated with the failed fan (Figure 4-87)

Figure 4-88

5) Figures 4-88 and 4-89 illustrate the removal of the second CPU Fan Assembly.

6) Present the replacement fan assembly supplied by MaxVision support to the CPU and perform
the steps described above in reverse order. Ensure the fan assembly in screwed in with equal
pressure on all side and the fan power connector is replaced prior to powering up the system to
avoid CPU damage.

Figure 4-87

Figure 4-89

Main Power Supply Unit (PSU)

Depending on the problem you are experiencing – and as directed by MaxVision support – you may
need to replace the entire power supply as discussed below.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove the video distribution board as discussed earlier in this chapter.

3) Disconnect the EPS12V 8-pin (4 x 2) power connector from the motherboard. Pull the connector
up while using a flat-blade screwdriver to push the top of the release catch (facing the interior of
the chassis) into the body of the connector (Figures 4-90 and 4-91).

56 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-90

Figure 4-91

4) Disconnect the ATX 24-pin power connector from the motherboard. Pull the connector up while
using a flat-blade screwdriver to push the top of the release catch (facing the bottom of the
chassis) into the body of the connector (Figures 4-92 and 4-93).

Figure 4-92

Figure 4-93

5) Use a Phillips #2 screwdriver to remove the four screws attaching the power supply unit to the
side of the inner chassis (Figures 4-94 through 4-97).

Note: Observe the way in which the inner chassis is lifted in Figures 4-95 and 4-96 so as to
facilitate access to two of these screws.

Figure 4-94

Figure 4-95

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 57

Figure 4-96

6) Gently lift the power supply out of the system as illustrated in Figure 4-98.

Figure 4-98

7) Take the new main power supply unit supplied by MaxVision support and incorporate it into the
system by performing the steps described above in reverse order.

Figure 4-97

Motherboard

Replacing the motherboard is non-trivial. It is easy to damage the motherboard unless one has the
appropriate tools and training. For this reason, you must either return the MaxPac system to
MaxVision or be factory trained by MaxVision personnel (see Appendix D for more details about
contacting MaxVision support and returning your MaxPac to MaxVision).

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove any PCI and PCI Express cards as discussed earlier in this chapter.

3) Remove the Power Distribution Board as detailed earlier in this chapter.

4) In order to replace the motherboard, the display power cables, display data cables and soft power
cable must be disconnected. Cut any cable ties that are holding the display power and data
cables in place as shown in figures 4-99 through 4-101

58 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 4-99

Figure 4-100

Figure 4-101

Figure 4-102

5) Remove the video data cable from the slot leading to the exterior of the left side of the chassis as
illustrated in Figure 4-102.

6) Use a Phillips #1 screwdriver to remove the three 4-40 screws holding the wire harness
protector plate (Figure 4-103), then gently remove the protector plate to expose the right
speaker cables (Figure 4-104).

Figure 4-103

Figure 4-104

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 59

7) The soft power cable must be removed from the motherboard connection posts (the location of
this connector is pointed out in 4-105). Observe that this cable connector is attached to the
motherboard with a flexible adhesive (such as Marine Goop). Simply pull the connector (not the
wire) until the adhesive gives.

Figure 4-105

8) There are two screws on either side of the cooling fan assembly. Use a Phillips #2 screwdriver to
loosen these captured screws (Figures 4-106 and 4-107).

Figure 4-106

9) Gently lift the cooling fan assembly away from the chassis as illustrated in Figure 4-108.

Figure 4-108

Figure 4-107

Figure 4-109

60 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

10) Each fan has its own power connector that is attached to the main motherboard. Disconnect the
power connector associated with the CPU fan (Figure 4-109).

11) Figures 4-110 and 4-111 illustrate the removal of the second CPU Fan Assembly.

Figure 4-110

Figure 4-111

12) Remove the screws from the sides and bottom of the shadow box as shown in Figure 4-112
through 4-115.

Figure 4-112

Figure 4-113

Figure 4-114

13) Disconnect the external cooling fan assembly’s power supply cable from the motherboard. Simply
pull it away using your fingers as shown in Figures 4-116 and 4-117.

Figure 4-115

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 61

Figure 4-116

Figure 4-117

14) Remove the shadow box as shown in Figure 4-118.

Figure 4-118

Figure 4-119

15) Disconnect the EPS12V 4-pin and EPS12V 8-pin (4 x 2) power connectors from the motherboard.
Pull the connector up while using a flat-blade screwdriver to push the top of the release catch
(facing the interior of the chassis) into the body of the connector (Figures 4-119 and 4-120).

Figure 4-120

16) Disconnect the ATX 24-pin power connector from the motherboard. Pull the connector up while
using a flat-blade screwdriver to push the top of the release catch (facing the bottom of the
chassis) into the body of the connector (Figures 4-121).

Figure 4-121

62 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

17) Remove the audio-out cable that normally connects between the motherboard to the power
distribution board (disconnect this cable from the motherboard) as shown in Figure 4-122.
Observe the polarity of this connection.

Figure 4-122

Figure 4-123

18) Remove the CD Audio In cable from the motherboard as illustrated in Figure 4-123.

19) Remove the Internal USB cable connection from the motherboard as illustrated in Figure 4-124.
These internal USB cables are normally used for USB Security Devices common with many
applications.

Figure 4-124

Figure 4-125

20) Remove the DVD ATA cable connecting to the ATA port of the motherboard as shown in
Figure 4-125.

21) Remove the screws securing the motherboard to the inner chassis assembly as shown in Figures
4-126 and 4-127.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 63

Figure 4-126

Figure 4-127

22) Now slide the motherboard out and place it on a protected surface as shown in Figures 4-198
and 4-129.

Figure 4-128

Figure 4-129

23) Under the direction of MaxVision support carefully remove the XEON series 5100 CPU
from its socket as illustrated in Figures 4-130 through 4-131. Observe the keying of the
CPU into its socket.

Figure 4-130

Figure 4-131

64 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

24) Under the direction of MaxVision support carefully remove the XEON series 5100 CPU from
its socket as illustrated in Figures 5-131 through 5-133. Observe the keying of the CPU into
its socket.

Figure 4-132

Figure 4-133

25) Gently assemble the XEON CPUs into the replacement motherboard.

Note: EXTREME CARE must be taken not to damage in any way the delicate pins used in
the CPU sockets. Once bent, these pins cannot be straightened resulting in the total loss of
the motherboard. This type of damage is not covered under the MaxVision Warranty (this
motherboard is valued at almost $500). Always remove the protective CPU pin covers from
the new motherboard and install them onto the suspect or bad motherboard before any
additional handling of the motherboard. The installation of the pin protector is illustrated in
Figure 4-133.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 65

Chapter 5: Module Replacement and
Upgrade Procedures for Dual/Triple­Screen Systems

Introduction

The instructions in this chapter describe how to replace and upgrade various modules in your
MaxPac unit.

Note: Generally speaking, you should only access the MaxPac internals under the direction of
MaxVision support. In some cases, performing unauthorized procedures or using components that
have not been tested and approved by MaxVision may invalidate your warranty.

Note: Power-down your MaxPac system (shut down Windows® and then turn the hard power switch
to its Off position) and then remove the power cable before performing any of the procedures
discussed in this chapter. Also please be aware of static discharge when working on your MaxPac. In
General, touch the metal part of the chassis to discharge any static prior to handling any delicate
electronic parts.

Note: When accessing the system internals and/or performing module upgrade procedures, you are
quickly going to end up with a lot of screws and other small items. In order to keep track of things and
to prevent misplacing any parts, it is strongly recommended to have a plastic container divided into
small compartments and to label these compartments as you work.

Required Tools and Techniques

Most of the module replacement and upgrade procedures discussed in this chapter can be performed
using only a pair of #1 (small tip) and #2 (regular tip) Phillips screwdrivers. However, some
procedures will require additional tools as discussed in Appendix C.

Note: It is extremely important that you use only high-quality tools so as to avoid any slippage and
stripping of screw heads and threads. Furthermore, in order to avoid any slippage, it is VERY
important to apply adequate force in the form of firm and steady pressure. See Appendix C for
details on the tools required to service the system.

Note: It is highly recommended that you use magnetized screwdrivers so as to prevent screws from
dropping inside the case and/or aiding in retrieving them if they do drop inside the case. (If your
screwdriver isn’t already magnetized, you can make it so by repeatedly “stroking” the blade with a
permanent magnet.

Names and Types of Screws

MaxPac X-Class systems use a variety of different screw types. In order to help you follow the
instructions in this chapter, details on these screws are provided in Appendix C.

66 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Flat Panel Display Module (Left-Hand Screen)

1) Lay the system flat on the table with the displays in the closed position and facing upwards (it is
recommended that you lay the system on bubble wrap in order to protect the finish).

2) Use a Phillips #1 screwdriver to remove the six 4-40 3/16" black countersunk screws holding the
left-hand screen's monitor cable access panel (Figure 5-1).

Figure 5-1

3) Gently lift the left-hand screen's monitor cable access panel away from the system (Figure 5-2).

4) Unscrew the jack screws holding the DVI data cable connector (Figure 5-3) and gently pull this
connector away from the display (Figure 5-4).

Figure 5-3

5) Press down on the release catch holding the power cable and gently pull this connector away
from this display (Figure 5-5).

Figure 5-2

Figure 5-4

6) Observe the cable tie attaching the power and data cables to a standoff post mounted to the left
of the screen assembly (this cable-tie is shown just to the left of the hand in Figure 5-5). Cut or
remove this cable tie as needed.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 67

Figure 5-5

7) Open the left-hand screen to a vertical position, use a Phillips #2 screwdriver to remove the eight
6-32 1/4" black countersunk screws – four on each site – holding the screen to its hinge bar
(Figure 5-6), and then lift the screen away.

8) Perform the above steps in reverse order to replace the failed screen with the new unit as
supplied by MaxVision support.

Figure 5-6

Flat Panel Display Module (Right-Hand Screen)

1) Lay the system flat on the table with the displays in the closed position and facing upwards (it is
recommended that you lay the system on bubble wrap in order to protect the finish). If your
MaxPac system has three screens, unfold the left-hand screen as shown in Figure 5-7.

2) Use a Phillips #1 screwdriver to remove the six 4-40 3/16" black countersunk screws holding the
right-hand screen's monitor cable access panel (Figure 5-8).

3) Gently lift the left-hand screen's monitor cable access panel away from the system.

4) Unscrew the jack screws holding the DVI data cable connector and gently pull this connector
away from the display (Figure 5-9).

Figure 5-7

Figure 5-8

68 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-9

5) Press down on the release catch holding the power cable and gently pull this connector away
from this display (Figure 5-10).

6) Observe the cable tie attaching the power and data cables to a standoff post mounted to the right
of the screen assembly. Cut or remove this cable tie as needed (Figure 5-11).

Figure 5-11

Figure 5-10

Figure 5-12

7) Open the right-hand screen to a vertical position, use a Phillips #2 screwdriver to remove the
eight 6-32 1/4" black countersunk screws – four on each site – holding the screen to its hinge bar
(similar to the procedure for the left-hand screen as shown in Figure 5-6), and then lift the screen
away (Figure 5-12).

8) Perform the above steps in reverse order to replace the failed screen with the new unit as
supplied by MaxVision support.

Flat Panel Display Module (Center Screen)

1) Lay the system flat on the table with the displays in the closed position and facing upwards (it is
recommended that you lay the system on bubble wrap in order to protect the finish). If your
MaxPac system has three screens, unfold the left- and right-hand screens as shown in Figure
5-13 (if your MaxPac system has only two screens, unfold the right-hand screen.)

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 69

Figure 5-13

Figure 5-14

2) Use a Phillips #2 screwdriver to remove the eight 6-32 1/4" black countersunk screws – four on
each site – holding the screen to the wing brackets, which are in turn attached to the main
chassis (Figure 5-14).

3) Lift the center screen into a vertical position standing against the cable-side pair of wing brackets
as illustrated in Figures 5-15 and 5-16 (as these monitors are expensive items, it is recommended
that you keep hold of the screen when it is in this vertical position).

Figure 5-15

Figure 5-16

4) On the other side of the screen (with regard to Figure 5-16), observe the monitor tilt-stand
components lying in/on the main chassis as indicated by the pointing finger in Figure 5-17. It is
very important to ensure that these components remain flat and interleaved.

70 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-17

Figure 5-18

5) Use a Phillips #1 screwdriver to remove the six 4-40 3/16" black countersunk screws holding the
center screen's monitor cable access panel (Figure 5-18).

6) Gently lift the center screen's monitor cable access panel away from the system (Figure 5-19).

Figure 5-19

Figure 5-20

7) Unscrew the jack screws holding the DVI data cable connector (Figure 5-20) and gently pull this
connector away from the display.

Figure 5-21

Figure 5-22

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 71

8) Press down on the release catch holding the power cable and gently pull this connector away
from this display (Figure 5-21).

9) Lift the center screen away from the system (Figure 5-22).

10) Perform the above steps in reverse order to replace the failed screen with the new unit as
supplied by MaxVision support.

Note: When replacing the cable access cover for the center screen, observe that the cables exit
the screen assembly through the larger upper cable guide as shown in Figure 5-23.

When re-installing the center screen, once the cable access panel has been re-attached, any
excess cable must be pushed down into the main chassis.

Figure 5-23

By comparison, in the case of the left- and right-hand screens, the cables exit as shown in
Figures 5-24 and 5-25, respectively (observe that the cable service lengths for the left- and right­hand screens are dictated by the cable ties as discussed in the previous sections).

Figure 5-24

Figure 5-25

72 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Opening the Display Assembly into its Service Position

In order to replace and/or upgrade modules inside the MaxPac system, it is necessary to open the
display assembly into its service position as discussed below.

1) Lay the system flat on the table on top of a piece of firm, non-abrasive foam (or similar material)
capable of supporting the system's weight as shown in Figure 5-26. Observe that the displays
should be in the closed position and facing upwards.

Figure 5-26

2) Use a Phillips #2 screwdriver to remove the two 10-32 1/4" black countersunk screws – one on
each site (on the top-side of the system close to the handles) – holding the screen assembly to
the chassis (Figure 5-27).

3) Use a Phillips #2 screwdriver to remove the two 10-32 silver truss head screws on the top of the
system (Figure 5-28).

Figure 5-28

4) Press the feet down into their fully "tilted" position as shown in Figure 5-29 (this is necessary to
allow the display assembly to fully hinge up).

Figure 5-27

Figure 5-29

5) Walk around to the other side of the system (so you are facing the bottom of the system) and lift
the screen assembly as shown in Figure 5-30.

6) Squeeze the integrated support stands together as illustrated in Figure 5-30.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 73

Figure 5-30

Figure 5-31

7) Pull the support stands down to their maximum extended (service) position as illustrated in Figure
5-31 (ensure that, when you release the supports, their spring mechanism expands them back
into their locked position).

8) Return to facing the top of the system and use a Phillips #2 screwdriver to remove the five 6-32
1/4" black countersunk screws – three on the top and one on each site – holding the inner
chassis cover (Figure 5-32).

Figure 5-32

Figure 5-33

9) Observe that the inner chassis cover is hinged. Gently raise the inner chassis cover to its vertical
position leaning back against the display assembly (Figure 5-33).

74 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Note: Your MaxPac8230 may contain the optional UPS Power Management System. In this case the
inside of the inner chassis will look similar to the above photo. Please refer to Chapter 6 for details of
the installation and removal of the UPS System. The UPS System must be removed to gain access to
the memory and CPUs.

Memory

Note: Due to the fact that high-end computer systems can experience a host of memory compatibility

issues and problems, you should only use replacement and/or additional memory sticks supplied by
MaxVision.

Note: The MaxPac 8230 uses a Fully Buffered DDR2 memory (FB-DIMM or FBD). Specifically the
MaxPac 8230 uses FBD DDR2 667MHz. What separates FBD from regular DDR2 is a chip on each
module called the AMB (Advanced Memory Buffer), which buffers all data/address/command
requests to the DRAM devices. This buffering allows up to 12GB of memory to be installed in the
MaxPac 8230. FB-DIMMs REQUIRE that memory sticks be used in pairs, with each pair having the
same size/capacity/speed. Population of the first pair of FBD occupies the first and second DIMM
slots (labeled DIMM1A and DIMM1B on the motherboard). Population of the second pair of FBD
occupies the third and fourth DIMM slots (labeled DIMM2A and DIMM2B).

Note: In the event that you begin to experience problems with the memory that is already resident in
your MaxPac, you must first determine which stick has failed under the direction of MaxVision
support.

Note: The BIOS will always report the true amount of physical memory that is present in the system.
This may be as much as 12 GB. However, the actual amount of memory that can be seen by the
system is determined by the main operating system (OS). With regard to the 32-bit Windows® XP
Professional operating system, for example, in the case of a MaxPac 8230 XRA2 (dual-screen)
configuration, the maximum amount of memory reported in the System Information dialog is 3 GB;
by comparison, in the case of a MaxPac 8230 XRA3 (triple-screen) configuration, the maximum
amount of memory reported in the system information dialog is 2 GB. (Further note that even when
the OS reports 3 GB for the dual-screen configuration, the maximum amount of shared user space is
actually only 2 GB.) However, with regard to the 64-bit Windows XP Professional x64 Edition of the
operating system, the System Information dialog will accurately report the true amount of physical
memory (which can theoretically be up to 128 GB) and all of this memory will be available to the
applications.

1) Open the display assembly into its service position as discussed earlier in this chapter.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 75

2) In order to remove and replace a memory stick, gently press down-and-out on the two plastic
“rabbit-ears” at either side of the stick which will cause it to pop out, and then remove the stick
from the system (Figure 5-34).

Figure 5-34

3) Observe that the memory sticks are keyed such that they can only be inserted one way. Take the
new (replacement) memory stick sent to you by MaxVision support and gently press it down into
the original slot on the motherboard.

4) Return the system to its initial condition by reversing the order of the operations discussed at the
beginning of this section.

PCI Cards (General)

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) If you are replacing an existing PCI card, use a Phillips #2 screwdriver to remove the 6-32 screw
attaching the card’s retaining bracket to the inner chassis as shown in Figure 5-36. (If you are
adding a new card, remove the corresponding blanking plate screw.)

Figure 5-35

3) Gently pull out the old card as shown in Figure 5-37.

4) This particular example features a SATA RAID controller card. In this case, you also need to
disconnect the data cables from the card as shown in Figure 5-38 (see notes below).

Figure 5-36

Figure 5-37

76 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-38

5) Take the new/replacement PCI card and incorporate it into the system by performing the steps
described above in reverse order.

Note: It is important to ensure that theses cables are attached to the new card in the same
positions as they occupied on the original card.

Note: In the case of these SATA cables, there is no good locking mechanism to ensure that they
remain attached to the card, so MaxVision uses a special adhesive. This adhesive is somewhat
flexible and the connectors can be broken free of the bond by simply pulling the SATA connector
straight out (do not pull on SATA cable itself). Reapply adhesive (provided by MaxVision support)
after reattaching the cables to the new card.

Note: Ensure that the tongue on the new/replacement card’s faceplate lines up with the slot in the
chassis (you may have to bend the tongue slightly in the case of a new card).

PCI Express Card (Secondary card for third screen
and Projector Port)

In the case of a dual-screen MaxPac system, the graphics for both screens will be handled by a
single PCI Express card discussed in the following section. By comparison, in the case of a triple­screen system, the center and right-hand screens will be driven by the Primary PCI Express card,
while the left-hand screen will be driven by a second PCI Express graphics card. The unused port of
this card can also be used as a projector port. This topic discusses the replacement of the secondary
PCI Express graphics card.

1) Open the display assembly into its service position as discussed earlier in this chapter. Use a
Phillips #1 screwdriver to remove the screws holding the over-molded DVI video connector to the
PCI Express graphics card (Figure 5-39).

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 77

Figure 5-39

Figure 5-41

2) Gently disengage the over-molded DVI connector from the PCI Express graphics board
(Figure 5-40).

3) Use a Phillips #2 screwdriver to remove the 6-32 screw attaching the card’s retaining bracket
to the inner chassis (Figure 5-41).

4) Some PCI Express cards may have an auxiliary power connector. If so, disconnect it as
shown in Figure 5-42.

Figure 5-40

Figure 5-42

5) Gently pull the old card out.

6) Take the new/replacement PCI Express card and incorporate it into the system by performing the
steps described above in reverse order.

Note: Ensure that the tongue on the new/replacement card’s faceplate lines up with the slot in the
chassis (you may have to bend the tongue slightly in the case of a new card). In this system there
is no plastic latch holding the rear of the PCI Express card. The foam attached to the hinged inner
lid of the MaxPac will hold pressure to the back of the card when properly secured.

PCI Express Card (Primary)

In the case of a dual-screen MaxPac system, the graphics for both screens will be handled by the
Primary PCI Express card. By comparison, in the case of a triple-screen system, the center and right­hand screens will be driven by the PCI Express card, while the left-hand screen will be driven by a
secondary PCI Express graphics card. This topic discusses the replacement of the Primary PCI
Express card.

78 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Use a Phillips #1 screwdriver to remove the screws holding the over-molded video cables to the
PCI Express graphics card. Gently disengage the over-molded DVI connector from the PCI
Express graphics board (Figures 5-43 and 5-44). Removing the bottom DVI connector will expose
a screw securing the bottom of the DVI cable bracket. Remove this screw with a #1 Phillips
screwdriver.

Figure 5-43

Figure 5-44

Figure 5-45

Figure 5-46

3) Use a Phillips #2 screwdriver to remove the two 6-32 screws attaching the card’s retaining
bracket – and the special linking bracket – to the inner chassis (Figure 5-45 and 5-46).

4) Gently remove the special linking bracket and store it somewhere safe.

Figure 5-47

Figure 5-48

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 79

5) Some PCI Express cards may have an auxiliary power connector. If so, disconnect it as shown in
Figure 5-47.

6) Take the new PCI Express card and incorporate it into the system by performing the steps
described above in reverse order.

Note: Ensure that the tongue on the new/replacement card’s faceplate lines up with the slot in the
chassis (you may have to bend the tongue slightly in the case of a new card).

Note: When removing the video cables keep track of the order of the connections to the PCI
Express card. The right-hand display is connected to the top connector and the center display is
connected to the bottom connector of the PCI Express card. In the case of a triple-display
system, the left display connector (which is a different shape to the other two) is attached to the
bottom DVII connector of the secondary PCI Express graphics board.

Note: In this system there is no plastic latch holding the rear of the PCI Express card. The foam
attached to the hinged inner lid of the MaxPac will hold pressure to the back of the card when
properly secured

Power Distribution Assembly

Note that the following procedure may be facilitated by first removing the PCI and PCI Express cards
as discussed earlier in that chapter; however, removing these cards is not obligatory.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Unplug the top power input connector from the power distribution board (Figure 5-49).

Figure 5-49

3) Unplug the bottom power input connector from the power distribution board (Figure 5-50).

Figure 5-50

Figure 5-51

Figure 5-52

80 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

4) Unplug the CD/DVD power output connector from the power distribution board (Figure 5-51).

5) Use an Allen key/tool to remove the screw attaching the power distribution assembly to the power
supply unit (Figure 5-52).

Figure 5-53

Figure 5-54

6) Use a Phillips #1 screwdriver to remove the two 4-40 screws attaching the power distribution
assembly to the side of the inner chassis (Figures 5-53).

7) Gently remove the input power connector to the power distribution board (note the latch on the
back side of the connector) as shown in Figure 5-54

Figure 5-55

Figure 5-56

8) Gently remove the display power cables from the power distribution board. There will be 1, 2 or 3
of these power cables depending on the number of displays (Figures 5-55, 5-56 and 5-57). Note
that, although the cables may be of different lengths, each of the display power connections are
wired in parallel so the order is not very important. Cut all cable ties holding cables to the
aluminum cable guide bracket.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 81

Figure 5-57

Figure 5-58

9) Disconnect the right speaker cable from the power distribution board as illustrated in Figures 5-58
and 5-59.

Figure 5-59

Figure 5-60

10) Disconnect the audio input cable from the power distribution board as illustrated in Figures 5-60.
This connector is black and has a latch. Note that the audio amplifier is also on the power
distribution board.

11) Disconnect the left speaker cable from the power distribution board as illustrated in Figures 5-61.

12) Gently lift the power distribution assembly up and away from the inner chassis (Figure 5-62).

Figure 5-61

Figure 5-62

82 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

13) Take the new power distribution assembly supplied by MaxVision support and incorporate it into
the system by performing the steps described above in reverse order.

Hard Drive Magazine (also Individual Hard Drives)

1) Undo the knurled screw holding the middle binding bar (Figure 5-63) and then remove the binding
bar (Figure 5-64).

Figure 5-63

2) Gently pull on the magazine handle to extract the magazine from the inner chassis (Figure 5-65).

Figure 5-65

3) In order to replace an individual drive, turn each of the four knurled screws attached to the upper
binding bar until they pop out and then remove the upper binding bar (Figure 5-66). Note that the
upper binding bar has tabs that are inserted into slots of the main drive cage.

Figure 5-64

Figure 5-66

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 83

Figure 5-67

4) Gently grasp the drive in question and pull it out of the magazine (Figure 5-67).

Note: These disks are hot-swappable, so you can replace individual drives while the magazine remains
resident in the system. When the upper binding bar is removed the 4 slots in the main drive cage may
slide back. Make sure that when replacing the upper binding bar that the tabs go into these slots.

Note: In order to easily identify these disks, MaxVision serial numbers are affixed to the bottom edge
(the small white strips shown toward the bottom of the drives in Figure 5-67). Recording the positions
and serial numbers of your disks for each MaxPac is advisable.

Optical Drive (CD/DVD)

1) Note that it is not necessary to open the display assembly into its service position in order to
perform this procedure.

2) Undo the two knurled attaching the CD/DVD drive to the outside of the system's main chassis
(Figure 5-68).

Figure 5-68

Figure 5-69

3) Gently remove the CD/DVD drive from the system (Figure 5-69).

4) Take the new CD/DVD assembly as supplied by MaxVision support and incorporate it into the
system by performing the steps described above in reverse order.

84 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Optical Drive (CD/DVD) Backplane

Note: The CD/DVD backplane cannot be easily replaced without first removing the main Power

Supply Unit (PSU). In the rare case that support advises that the CD/DVD backplane needs
replacing refer to the section on the PSU later in this chapter and then return to this section..

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove the CD/DVD drive as discussed in the previous topic.

3) Remove the ATA cable (observing where the red stripe is for future reference) as illustrated in
Figure 5-70.

Figure 5-70

4) Remove the main power connector as illustrated in Figure 5-71 (release the latch with your finger
or thumb nail while pulling ion the cable).

Figure 5-72

5) Remove the CD/Audio cable as illustrated in Figure 5-72.

6) Use a Philips #1 screwdriver to remove the two screws attaching the CD/DVD backplane to the
main chassis as illustrated in Figure 5-73

Figure 5-71

Figure 5-73

7) Gently remove the CD/DVD backplane as illustrated in Figure 5-74.

8) Present the replacement CD/DVD backplane supplied by MaxVision support to the inner chassis
and perform the steps described above in reverse order.

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 85

Note: If the replacement CD/DVD backplane does not come equipped with a protective (insulating)
Mylar cover, remove this piece from your original backplane and reattach it to the new backplane.

Figure 5-74

External Cooling Fan Assembly

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Disconnect the external cooling fan assembly’s power supply cable from motherboard. Simply
pull it away using your fingers as shown in Figures 5-75 and 5-76.

Figure 5-75

3) All three fans must be treated as a single assembly, so remove the twelve self-tapping Plastite
screws (4 per fan) attaching the fans to the internal chassis (Figure 5-77) and then gently lift the
fan assembly away from the inner chassis (Figure 5-78).

4) Present the replacement fan assembly supplied by MaxVision support to the inner chassis and
perform the steps described above in reverse order.

Figure 5-76

Note that the fan guards are secured to the outside of the chassis by the Plastite screws. When
the new fan assembly is replaced make sure the fan guards are replaced.

86 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-77

Figure 5-78

CPU Cooling Fans

Note: The photos in this section assume the Power Distribution Assembly has been previously

removed. These photos more clearly illustrate the replacement of the CPU Cooling Fans but they can
be replaced with the Power Distribution Assembly installed as well.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) There are two screws on either side of the cooling fan assembly. Use a Phillips #2 screwdriver to
loosen these captured screws (Figures 5-79 and 5-80).

Figure 5-79

3) Gently lift the cooling fan assembly away from the chassis as illustrated in Figure 5-81.

Figure 5-80

Figure 5-81

Figure 5-82

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 87

4) Each fan has its own power connector that is attached to the main motherboard. Disconnect the
power connector associated with the failed fan (Figure 5-82).

5) Figures 5-83 and 5-84 illustrate the removal of the second CPU Fan Assembly.

Figure 5-83

6) Present the replacement fan assembly supplied by MaxVision support to the CPU and perform
the steps described above in reverse order. Ensure the fan assembly in screwed in with equal
pressure on all side and the fan power connector is replaced prior to powering up the system to
avoid CPU damage.

Main Power Supply Unit (PSU)

Depending on the problem you are experiencing – and as directed by MaxVision support – you may
need to replace the entire power supply as discussed below.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove the video distribution board as discussed earlier in this chapter.

3) Disconnect the EPS12V 8-pin (4 x 2) power connector from the motherboard. Pull the connector
up while using a flat-blade screwdriver to push the top of the release catch (facing the interior of
the chassis) into the body of the connector (Figures 5-85 and 5-86).

Figure 5-84

Figure 5-85

Figure 5-86

88 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

4) Disconnect the ATX 24-pin power connector from the motherboard. Pull the connector up while
using a flat-blade screwdriver to push the top of the release catch (facing the bottom of the
chassis) into the body of the connector (Figures 5-87 and 5-88).

Figure 5-87

Figure 5-88

5) Use a Phillips #2 screwdriver to remove the four screws attaching the power supply unit to the
side of the inner chassis (Figures 5-89 through 5-92).

Figure 5-89

Figure 5-90

Note: Observe the way in which the inner chassis is lifted in Figures 5-90 and 5-91 so as to

facilitate access to two of these screws.

Figure 5-91

Figure 5-92

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 89

6) Gently lift the power supply out of the system as illustrated in Figure 5-93.

Figure 5-93

7) Take the new main power supply unit supplied by MaxVision support and incorporate it into the
system by performing the steps described above in reverse order.

Motherboard

Replacing the motherboard is non-trivial. It is easy to damage the motherboard unless one has the
appropriate tools and training. For this reason, you must either return the MaxPac system to
MaxVision or be factory trained by MaxVision personnel (see Appendix D for more details about
contacting MaxVision support and returning your MaxPac to MaxVision).

Note: Certain components can be replaced without removing the inner chassis from the outer
chassis. Some of these components include memory, main power supply, PCI and PCI Express
boards. While it is fairly easy to remove the inner chassis for the Single-Display XRA1 it is more
difficult for the Dual/Triple-Display XRA2/3. Some photos will include the outer chassis while others
will not.

1) Open the display assembly into its service position as discussed earlier in this chapter.

2) Remove any PCI and PCI Express cards as discussed earlier in this chapter.

3) Remove the Power Distribution Board as detailed earlier in this chapter.

4) In order to replace the motherboard, you must first remove the inner chassis. In order to do this,
the display power cables, display data cables and soft power cable must be disconnected.

Figure 5-96

Figure 5-97

90 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-98

Figure 5-99

5) Cut any cable ties that are holding the display power and data cables in place as shown in figures
5-96 through 5-98

6) Remove the 3 video data cables for the slot leading to the exterior of the left side of the chassis.
The triple-screen MaxPac 8230 XRA3 is shown in figure 5-99

Figure 5-100

Figure 5-101

7) Use a Phillips #1 screwdriver to remove the three 4-40 screws holding the wire harness protector
plate (Figure 5-100), then gently remove the protector plate to expose the soft power and right
speaker cables (Figure 5-101).

Figure 5-102

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 91

8) The soft power cable must be removed from the motherboard connection posts (the location of
this connector is pointed out in Figure 5-102). Observe that this cable connector is attached to the
motherboard with a flexible adhesive (such as Marine Goop). Simply pull the connector (not the
wire) until the adhesive gives.

Figure 5-103

Figure 5-104

9) The center and left monitor power and video cables must be removed from the inner chassis
cover cable channel as show in Figure 5-103.

10) The power and video cables for the right monitor (and also and the soft power cable) must be
removed from the inner chassis cover cable channel as shown in Figure 5-104.

Figure 5-105

Figure 5-106

11) You will need a second person to hold the monitor assembly while you lift the inner chassis out of
the outer chassis Figure 5-105.

Note: As the weight of the inner chassis is removed, the display assembly and outer chassis will
topple over if not being held securely

12) Next, the display assembly should be rotated down as illustrated in Figure 5-106.

92 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-107

Figure 5-108

13) Now tilt the alluminum inner chassis lid into a vertical orientation so as to facititate access to the
motherboard. There are two screws on either side of the cooling fan assembly. Use a Phillips #2
screwdriver to loosen these captured screws (Figures 5-107 and 5-108).

Figure 5-109

Figure 5-110

Figure 5-111

14) Gently lift the cooling fan assembly away from the chassis as illustrated in Figure 5-109.

15) Each fan has its own power connector that is attached to the main motherboard. Disconnect the
power connector associated with the CPU fan (Figure 5-110).

16) Figures 5-111 and 5-112 illustrate the removal of the second CPU Fan Assembly.

Figure 5-112

MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide 93

Figure 5-113

Figure 5-114

Figure 5-115

Figure 5-116

17) Remove the screws from the sides and bottom of the shadow box as shown in Figure 5-113
through 5-116.

Figure 5-117

18) Disconnect the external cooling fan assembly’s power supply cable from motherboard. Simply
pull it away using your fingers as shown in Figures 5-117 and 5-118.

Figure 5-118

94 MaxPac Single/Dual/Triple-Screen 8230 Training and Maintenance Guide

Figure 5-119

Figure 5-120

19) Remove the shadow box as shown in Figure 5-119.

20) Disconnect the EPS12V 4-pin and EPS12V 8-pin (4 x 2) power connectors from the motherboard.
Pull the connector up while using a flat-blade screwdriver to push the top of the release catch
(facing the interior of the chassis) into the body of the connector (Figures 5-120 and 5-121).

Figure 5-121

Figure 5-122

21) Disconnect the ATX 24-pin power connector from the motherboard. Pull the connector up while
using a flat-blade screwdriver to push the top of the release catch (facing the bottom of the
chassis) into the body of the connector (Figures 5-122).

22) Remove the audio-out cable that normally connects between the motherboard to the power
distribution board (disconnect this cable from the motherboard) as shown in Figure 5-123.
Observe the polarity of this connection.