SGI Visual Workstation 540 Troubleshooting Guide
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The SGI Visual Workstation 540 reports problems three ways: the green LED behind the sliding front panel, the firmware's power-on diagnostics screen, and Windows NT Diagnostics once the system is up.[1][2] Before opening the case, read SGI Visual Workstation 540 General Maintenance for the cover, interlock and handling notes.
Front LED
[edit | edit source]The LED flashes slowly while the 540 boots and runs its power-on diagnostics and turns solid green once the system is running. It is steady while the machine is on, flashes quickly when the system cannot boot, and is off when the machine is off.[3]
When the memory test finds a failed DIMM in slot group A, the LED repeats a blink count, a pause and the count again:[3]
| Blink code | Failed DIMM |
|---|---|
| 1 blink, pause | Slot group A, DIMM 1 |
| 2 blinks, pause | Slot group A, DIMM 2 |
| 3 blinks, pause | Slot group A, DIMM 3 |
| 4 blinks, pause | Slot group A, DIMM 4 |
| 5 blinks, pause | Slot group A, DIMM 5 |
| 6 blinks, pause | Slot group A, DIMM 6 |
| 7 or 8 blinks, pause | RAM failure, location not known |
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If the LED does not light at all after the power button, LED or reset cables have been unplugged from the system board, check the LED cable: it only works with the label on its connector facing up.[2][4]
No power
[edit | edit source]| Probable cause | Action |
|---|---|
| Mains lead loose or outlet dead | Check the lead at both ends and try another outlet |
| Side cover off or not fully home | The side-cover interlock switches the machine off when the cover is removed.[5] Press the cover home along its top edge until it snaps into place |
| Power supply cables not on the system board | Refit both cables; they are different sizes and go on with the tabs facing up.[6] If the internal fans run and the front LED is lit, the board is receiving power |
| Power button and LED cables off the system board | Refit them with the labels facing up, as shown inside the side cover |
| Primary processor not seated, or failed | Reseat the primary processor; replace it if it still does not start |
| Voltage regulator card dead, missing or in the wrong slot | Check the cards against the table under Processors and voltage regulators and swap in a known-good card |
| Power supply failed | Replace the supply |
| System board failed | SGI's remedy is a replacement board through its support service |
Sources: Owner's Guide Table 8-1, pp. 141–144.[2]
Powers on but no picture
[edit | edit source]| Symptom | Probable cause | Action |
|---|---|---|
| Powers on, LED and monitor dark | Empty processor slot without a terminator card | Fit terminator cards in every unused processor slot |
| Green LED blinks continuously, nothing on screen | Memory error: mixed capacities in slot group A, a badly seated DIMM, a failed DIMM; or a regulator card fitted beside a slot that holds a terminator card | Check that group A holds six DIMMs of the same capacity and that every DIMM is seated. Remove any regulator card that belongs to a slot with a terminator card in it. Replace the failed DIMMs |
| Green LED repeats a blink pattern, nothing on screen | Failed DIMM | Read the blink code above and replace that DIMM |
| Monitor on, no picture, LED lit but not blinking continuously | Brightness turned down, monitor cable off | Turn the brightness up; check the cable at both ends |
Sources: Owner's Guide Table 8-1, pp. 141–143.[2]
The Cobalt chipset drives the VGA port and the optional flat panel adapter itself; there is no separate graphics card to reseat.[7]
Memory
[edit | edit source]Every DIMM in a slot group must be the same type and capacity, group A must be filled, and groups are filled in order with no gaps. Only SGI's own DIMMs work.[8]
After memory is added or removed, the first boot shows the following once. It is not a fault:[9]
[53] Configuration - ** FAILED: Configuration changes: error code 0x0002000
Configuration Changes:
Memory configuration changed 0x00020000
At the prompt "Press ESC to continue booting, or any other key for RAM information", press any key other than Esc to see the size the firmware found in each slot group. A badly seated DIMM, a damaged DIMM or a damaged socket shows up like this:[9]
[06] ECC RAM Bus - ** FAILED : error code 0x00000010 [0a] Test valid RAM Banks - ** FAILED : error code 0x000104b4 ... Slot group B 128 M Bytes - Bad
The RAM information screen marks the whole slot group as bad. One owner's four-processor 540 had 24 DIMMs giving 1,792 MB, but with one bad module only 1,280 MB was usable; the rest of that group would work again once the bad module was fixed or replaced.[10] The LED blink codes only name DIMMs in slot group A; for the other groups use the extensive diagnostics below.
If the machine reaches the firmware but will not start Windows NT and memory is suspected, set Power On Diagnostics to Extensive Tests in the firmware's System Settings and reboot; the extended test checks RAM and names the faulty DIMMs. It adds about a tenth of a second per megabyte to the start-up time, a little over three minutes with 2 GB. The firmware can also switch itself to Extensive Tests after a boot that fails to complete, and it stays there until it is set back to Quick Boot by hand.[2][11]
Processors and voltage regulators
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SGI's rules for the processor cage are strict, and breaking them gives faults that look like a dead board:[12]
- Every processor slot holds a processor or a terminator card. A missing terminator gives a dark screen and LED.
- Processors are fitted in order from the primary (slot 0) upwards with no terminator card between them.
- Regulator cards are fitted only for slots that hold a processor; a regulator left in place for a slot with a terminator card can stop the machine working or make it crash. The graphics regulator is always fitted.
- All processors must be identical, with the same stepping as the primary processor. Windows NT shows the stepping in the System control panel as, for example, "x86 Family 6 Model 3 Stepping 4".
- The four speed jumpers must be changed whenever a processor is added or upgraded.
| Processors | Terminator cards | Regulator cards, including the graphics regulator |
|---|---|---|
| 1 | 3 | 3 |
| 2 | 2 | 4 |
| 3 | 1 | 6 |
| 4 | 0 | 7 |
A four-processor 540 described on IRIXNet in 2025 had seven regulator cards fitted, in line with SGI's figure.[10]
If a second, third or fourth processor is not listed in Windows NT Diagnostics (System panel, Processor 0 to Processor 3), check that it is seated and that its regulator cards are present, in the right brackets and fully home, then check that the right software is installed.[12][2] Two processors run on the original software; three or four need the software on SGI's upgrade CD. If Windows NT does not recognise a newly added processor, SGI's remedy is to reinstall Windows NT.[12][2]
Processor speed jumpers
[edit | edit source]The jumpers sit at the top of the system board above the regulator cards, to the left of the battery. Each jumper goes over the middle pin and either the H or the L pin.[12]
| Processor speed | Bus/core ratio | LINT[1] | LINT[0] | A20M# | IGNNE# |
|---|---|---|---|---|---|
| 150 MHz | 2/3 | H | H | H | L |
| 200 MHz | 1/2 | L | L | L | L |
| 200 MHz (alternative) | 1/2 | H | H | H | H |
| 250 MHz | 2/5 | L | H | L | L |
| 300 MHz | 1/3 | L | L | L | H |
| 350 MHz | 2/7 | L | H | L | H |
| 400 MHz | 1/4 | L | L | H | L |
| 450 MHz | 2/9 | L | H | H | L |
| 500 MHz | 1/5 | L | L | H | H |
| 550 MHz | 2/11 | L | H | H | H |
| 600 MHz | 1/6 | H | L | L | L |
| 650 MHz | 2/13 | H | H | L | L |
| 700 MHz | 1/7 | H | L | L | H |
| 750 MHz | 2/15 | H | H | L | H |
| 800 MHz | 1/8 | H | L | H | L |
SGI notes that either 200 MHz setting can be used.[12]
Firmware and booting
[edit | edit source]| Probable cause | Action |
|---|---|
| Memory error | Check slot group A and DIMM seating, then run the extensive diagnostics (see Memory)[2] |
| Boot drive changed in type or position | Correct the boot entry under Startup Settings. With the standard SCSI system disk the entry reads SCSI 2 Disk 0, partition 1 for the system and partition 2 for the loader[2][13] |
| Loader files missing or moved | arcldr.exe and hal.dll must be on a FAT partition named in the boot entry; the firmware cannot read NTFS[14]
|
Forgotten setup password
[edit | edit source]The password jumper is near the upper regulator cards, immediately left of the processor speed jumpers. Its pins are numbered 3, 2, 1 from left to right; the jumper on the left two pins enforces the password and on the right two pins disables it.[15]
- Shut down, unplug, earth yourself and remove the side cover. Laying the machine on its side makes the jumpers easier to reach.
- Take any PROM image floppy out of the floppy drive. SGI warns that powering on in password-disabled mode with a PROM image disk in the drive installs that PROM.
- Move the jumper to the right two pins, refit the cover, plug in and power on.
- Enter a new password when asked.
- Shut down, unplug, open the case again and move the jumper back to the left two pins. The new password now applies.[15]
Firmware updates
[edit | edit source]The firmware is updated from Windows NT by copying a PROM image from Recovery CD 2 to a floppy disk and flashing the PROM from the firmware's Run System Utilities screen.[16] An image of the 540's Recovery CD v1.1 disc 2 is on archive.org.[17]
Drives
[edit | edit source]| Symptom | Probable cause | Action |
|---|---|---|
| CD-ROM, floppy or option IDE drive not recognised | IDE or floppy cable wrong or off; master and slave settings | Check the cables and the drive's power lead; check the master and slave jumpers[2] |
| Internal SCSI disk not recognised | Duplicate SCSI ID | The system disk must be ID 0 in bay 1. Check the jumpers on the back of the drive: some can be set, in error, to an ID the system already uses[2][18] |
| External SCSI device not recognised | ID clash, termination, cable | Give each device a unique ID from 1 to 15 (7 is the controller), terminate the last device with an LVD/SE terminator, and keep the chain within 3 m, or 12 m if every device is Ultra2. Then check the PCI SCSI card's seating[19] |
See also Hard Drive Maintenance and Repair and Floppy Drive Repair.
PCI cards, keyboard and mouse
[edit | edit source]- A PCI card that is not recognised may be badly seated, unsupported or missing its driver.[2] Slots 1 to 4 take 5 V and universal cards and slots 5 and 6 take 3.3 V and universal cards.[20]
- The keyboard and mouse are USB. If either stops working, check that it is plugged into a USB port and press the reset button to restart the system; if that fails, try another keyboard or mouse.[2] Under Windows NT 4.0 the keyboard and mouse are the only USB devices supported, and the IEEE 1394 ports are not supported at all.[21]
- If the system hangs and cannot be shut down from the Start menu, press the reset button behind the sliding front panel.[22]
Things that are not faults
[edit | edit source]- The
[53] Configuration - ** FAILEDmessage on the first boot after a memory change.[9] - False POST failures on the first start after the battery has been changed.[23]
- The machine switching off when the side cover is taken off.[5]
- A slow start after the firmware has switched itself to Extensive Tests.[11]
- IEEE 1394 devices and USB devices other than the keyboard and mouse not working under Windows NT 4.0.[21]
Related pages
[edit | edit source]- SGI Visual Workstation 540
- SGI Visual Workstation 540 General Maintenance
- SGI Visual Workstation 540 Capacitor Replacement Guide
- SGI Visual Workstation 540 Documentation
- SGI Visual Workstation 320 Troubleshooting Guide, for the two-processor machine
- Capacitor Failure Symptoms
References
[edit | edit source]- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), Figure 1-10, "Opening the Front Panel", p. 11: LED, drives, reset and power buttons behind the sliding panel.
- ↑ 2.00 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 Silicon Graphics, Inc., Silicon Graphics 540 Visual Workstation Owner's Guide, 007-3882-001, 1999, chapter 8, "Troubleshooting", Table 8-1, pp. 140–144. Hosted as File:SGI Visual Workstation 540 Owner's Guide (007-3882-001).pdf.
- ↑ 3.0 3.1 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Interpreting LED Blink Codes", Figure 8-1 and Table 8-2, pp. 145–146.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Reconnecting the Power Button, LED, and Reset Button Cables", p. 148.
- ↑ 5.0 5.1 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Shutting Down the System", p. 14: the safety interlock powers the system off when the side cover is removed.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Inserting the Power Supply", step 6, p. 127.
- ↑ Silicon Graphics, Inc., Silicon Graphics Visual Workstations for Windows NT: Integrated Visual Computing Architecture (IVC), white paper, 1999, sections 2.3 and 3.0 and Table 4-1. Hosted as File:SGI Visual Workstations Integrated Visual Computing Architecture White Paper (1999).pdf.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "About Memory", pp. 28–29.
- ↑ 9.0 9.1 9.2 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Verifying and Troubleshooting the DIMM Installation", pp. 38–39: the configuration-change message, the RAM information screen and the failure messages.
- ↑ 10.0 10.1 IRIXNet forums, "Visual Workstation 540 for sale", first post, 4 May 2025. Retrieved 2026-10-21. Four 500 MHz processors, seven voltage regulator modules, 24 DIMMs totalling 1,792 MB with one bad module leaving 1,280 MB usable.
- ↑ 11.0 11.1 Silicon Graphics, Inc., Silicon Graphics 320 and Silicon Graphics 540 Visual Workstation Software Installation Guide, 007-3703-002, 1999, "System Settings", Power On Diagnostics Level, p. 45. Hosted as File:SGI Visual Workstation 320 and 540 Software Installation Guide (007-3703-002).pdf.
- ↑ 12.0 12.1 12.2 12.3 12.4 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), chapter 6, "Processors and Voltage Regulators", pp. 102–118: rules (p. 102), Figure 6-1 (p. 103), speed jumpers, Figure 6-8 and Table 6-1 (pp. 110–112), Table 6-2 (p. 116), stepping value (p. 117), verifying the installation (p. 118).
- ↑ Silicon Graphics 320 and Silicon Graphics 540 Visual Workstation Software Installation Guide (007-3703-002), "Startup Settings", pp. 38–42, with the boot entry table on p. 41.
- ↑ Silicon Graphics 320 and Silicon Graphics 540 Visual Workstation Software Installation Guide (007-3703-002), "Partitioning the System Disk", pp. 26–28.
- ↑ 15.0 15.1 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Disabling and Enabling the Setup Password", Figures 8-2 and 8-3, pp. 146–148.
- ↑ Silicon Graphics, Inc., Silicon Graphics Visual Workstations System Firmware User's Guide for Windows NT, 007-4225-001, 1999, "Updating SGI Firmware", pp. 12–14. Hosted as File:SGI Visual Workstations System Firmware User's Guide (007-4225-001).pdf.
- ↑ Internet Archive, "Silicon Graphics 540 Visual Workstation Recovery CD v1.1 Disc 2", dated May 1999. Retrieved 2026-10-21.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "About Internal Hard Drives", p. 61, and Figure 4-14, p. 62.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), Appendix C, "SCSI Information", pp. 173–176.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "About PCI Cards", p. 72.
- ↑ 21.0 21.1 Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), Appendix B, IEEE 1394 and USB notes, pp. 163–164.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Resetting the System", p. 15.
- ↑ Silicon Graphics 540 Visual Workstation Owner's Guide (007-3882-001), "Replacing the Battery", p. 130.