Removal and Replacement of the Serrano and Corsica Boards 1. Purpose The purpose of this procedure is to document the removal and replacement of the Serrano and Corsica board of the Deko/Thunder Assemblies. 2. Scope This procedure covers the removal and installation of the Corsica and Serrano Boards into the Deko/Thunder chassis. This procedure is applicable for customer removal and installation by qualified customer technician or customer engineer personnel. 3. Tools and Workstation

Screwdriver Philips #1 Nut Driver 3/16” Application CD for upgrading firmware of Serrano / Corsica after installation

Use a grounding mat, wrist strap or a static safe workstation when handling Electrical Components and Disk Drives. Use caution when handling disk drives, or products that contain disk drives. The disk drive mechanism is very fragile and is sensitive to shock. 4. Removal of Chassis Top / Support Bar

Remove the chassis from the rack or installation and place on a workbench covered with a grounding mat for the steps below. Make sure power cords are not connected and have been removed from the system before proceeding. Remove the top cover plate (7890-03329-01) by removing the 3 Screws 6-32x1/4” SEM (7760-03275-01 x 3) on the rear of the unit. Remove the Cross Support Bracket (7890-03174-01) from the chassis by removing the 4 retaining Screws 6-32x1/4 FHD (7760-03321-01 x 4) – 2 screws are located on each side of the chassis. After removing you must turn the support bracket at an angle to remove safely. Note: The Cross Support Bracket is to be re-installed with the end flanges facing down and the lengthwise flanges facing up. The PEM screw holes in the Cross Support fit over the Corsica board position or the PCI slots of the motherboard.

5. Removal of the Serrano

Remove Vent 1

Remove Serrano

Remove Vent 2

Remove the Vents and Serrano in the following steps by loosening thumb screws at the top and bottom of each assembly:

• Remove Vent 1 • Remove Vent 2 • Remove the Serrano by loosening the thumb screws at the top and bottom

of the Serrano board. Pull straight back on the Serrano until the board disconnects from the connection (digital tether) on the Corsica Board.

• from the rack or installation and place on a Note: Re-installation the Serrano board must be installed in the second slot and guided into position with the guides provided. Make sure the card is successfully mated with the Corsica Digital Tether prior to tightening the thumb screws. Failure to install the board exactly in this manner can damage the Corsica I/O upon power up due to miss-alignment of the digital tether.

6. Removal of the Corsica

Remove Screws

Remove the Fan Cover/Retainer (7890-03173-01) secured with black Screws 4-40x3/16” undercut FHD (7760-03320-01 x 3). Remove the Fan Cover, and save the screws re-installation.

Corsica Board, PCI slot # 5

DVI Cable

Secure Screw

Power Connector

Remove the Corsica Board in the following steps:

• Remove the Power Connector to the top of Corsica Board • Remove the DVI connector and Cable (7070-03328-01) • Remove the secure card screw holding the Corsica in position • See Note Below • Remove the Corsica Board by applying even pulling pressure with your right and

left hand placed at the front and back of the card. The Board once removed from the PCI slot should pull straight up / out of the system assembly.

Note: Please take note of the PCI slot # the Corsica Board is installed in prior to removal – it is necessary to install the replacement board in the same PCI slot for optimal performance of your system.

7. Installation of the Corsica

Replacement Corsica Boards are shipped and pretested in the High Definition (HD) mode. If you have a High Definition (HD) System or High Definition/Standard Definition System the Corsica jumpers must be set to Pins 1 – 2 for the board to operate properly. If your system is Standard Definition Only (SD) you can move the jumper pins to position 2 and 3 as shown. This will prevent board initialization rebooting during power up of the system. To verify which position your Corsica replacement jumpers should be for your system you may compare the new board with the card removed in previous steps and jumper the replacement board accordingly.

PCI SLOT 5

The PCI slots are numbered from the sidewall as PCI Slot 1 to PCI Slot 5 towards the Memory.

Install the Corsica SD/HD Card into PCI Slot 4 or 5 dependent of your model of Deko / Thunder Systems Secure the card with Screw 4-40x¼” pan head SEM (7760-03271-01)

Product Name Corsica PCI Slot Deko1000 HD / HY PCI Slot 4 Deko3000 HD / HY PCI Slot 4 and 3 DekoCast HD / HY PCI Slot 4 Thunder SD / HD / HY PCI Slot 4 and 3 Deko1000 SD PCI Slot 5 Deko550 SD PCI Slot 5 DekoCast SD PCI Slot 5

Install one of the single Disk Drive power connectors to the Corsica Board. Use Tie Wraps to dress the wiring if they were removed during removal of board.

Connect the DVI Cable (7070-03328-01) to the Corsica Board, the connector is keyed with key locations of the connector located on the bottom of the connector cable.

Replace Screws

Install the Fan Cover/Retainer (7890-03173-01, supplied previously) and secure with black Screws 4-40x3/16” undercut FHD (7760-03320-01 x 3, supplied previously).

8. Serrano Board Installation

Insert the Serrano SD/HD Card into the slot position that aligns with the Corsica Board. The Serrano Card tether will plug into the mating tether in the Corsica Card. Note: Do not use the thumb screws to tighten the board into place until the Serrano card securely seated with the Corsica tether connector.

Serrano Opening Watch for RS 422 cables

Pay special attention to 2 RS 422 Cables coming out of PCA Blastronix to ensure the cables do not get caught when inserting the Serrano SD/HD card. If removal of the tie wraps were required to move the cables and connectors out of you way during removal of the I/O please replace the Tie Wraps to dress the wiring before finishing the re-installation.

Install the Board Mounting Vent (7890-03147-01 X 4) into open positions. Install the Cross Support bracket (7890-03174-01) into the chassis. Secure with Screws 6-32x1/4 FHD (7760-03321-01 x 4). Note the Cross support Bar is to be installed with the end flanges facing down and the lengthwise flanges facing up. Note the PEM holes are to be above the PCI slot locations. Perform a screw check, top to bottom, making sure all fasteners are present and properly tightened. Attach the top cover plate (7890-03329-01) using Screws 6-32x1/4” SEM (7760-03275-01 x 3).

9. Application Software Re-Installation Note: SW installation can take up to 45 minutes due to the updating of the flash parts on the Corsica and Serrano boards. Do not Power off the unit during the updating of the flash parts or damage to the Board may occur.

• Insert the Mfg Application CD into the machine which will auto start. If it does not, browse to the CD and run “setup.exe”. A CD open screen may appear if the CD does not autostart, click cancel to close this window.

• At the “Welcome to the InstallShield Wizard” screen, click “Repair”.

• Press OK to “Please read Readme/Release notes before proceeding” screen.

Note: The installing CODI…screen will appear for several minutes during the installation.

• Press Continue Anyway to proceed to the next screen.

• Press Next> to “Install the software automatically (Recommended).

• Press Continue Anyway to proceed to the next screen.

• Press Finish to proceed to the next screen. Note: A Flash Gordon II Screen will pop up only if the firmware on your Corsica or Serrano Board’s need updated. Each board may have several stages – steps involved in the flashing process. The system MUST NOT be disturbed during this process.

Screen for Corsica Flash Process Screen for Serrano Flash Process

• Once the flashing process has completed a screen showing the success will appear as indicated • Click OK to proceed

• Click “CONTINUE ANYWAY” on the “Hardware Installation” screen for “Mouse and Other Pointing Devices”, and “101\102 Key Keyboard Filters” if they appear.

• At the “Install Shield Wizard Complete” screen, select • “No, I will restart my computer later”, and then click on “Finish”.

• You must now power cycle the system to complete your Flashing Process as well as the removal / replacement procedure for the Corsica or Serrano Boards.