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Cisco 3700 Series Multiservice Access Routers

Field Notice: FN - 62127 - 64K Compact Flash Failure May Cause Service Interruption on 1800, 2691, 2800, 3700 and 3800 Series Routers


Revised September 15, 2006

June 24, 2005


NOTICE:

THIS FIELD NOTICE IS PROVIDED ON AN "AS IS" BASIS AND DOES NOT IMPLY ANY KIND OF GUARANTEE OR WARRANTY, INCLUDING THE WARRANTY OF MERCHANTABILITY. YOUR USE OF THE INFORMATION ON THE FIELD NOTICE OR MATERIALS LINKED FROM THE FIELD NOTICE IS AT YOUR OWN RISK. CISCO RESERVES THE RIGHT TO CHANGE OR UPDATE THIS FIELD NOTICE AT ANY TIME.

Products Affected

  • MEM2691-32U64CF
  • MEM2800-64CF=
  • MEM3725-64CF-EXT
  • MEM3745-64CF-EXT =
  • MEM3800-64CF-INCL
  • MEM3800-64CF-INCL =
  • MEM1800-64CF
  • MEM1800-64CF=

Problem Description

A limited quantity of Cisco 1841, Cisco 2691, Cisco 2800, Cisco 3700 and Cisco 3800 series routers that recently shipped with a specific Vendors 64 Megabyte Compact Flash card, may fail under certain operational conditions. The failure of a Compact Flash card could result in an interruption of the host router's services.

Background

Cisco Systems has identified a design issue in one of our Vendor's 64 Megabyte Compact Flash Card relating to the component height of specific capacitors. This issue could potentially result in a shorting of one of the Compact Flash capacitors which in certain systems can result in a compact flash failure when subsequent system access to the Compact Flash is attempted.

The design issue has been addressed with Cisco's Compact Flash Vendor. However, prior to identifying the quality concern, a limited quantity of Compact Flash cards with this design issue were utilized in the production of the Cisco 1841, 2691, 2800, 3700, and 3800 series routers between the dates of April 21, 2005 and May 13, 2005. The serial numbers of the potentially affected router units have been identified and are listed in Table 1 of this field notice.

Problem Symptoms

  1. The router may fail to auto-boot its flash image:
    Note: This type of failure as shown in 1.a. and 1.b has been seen and documented:
    1. Readonly ROMMON initialized  
      boot: cannot open "flash:"  
      boot: cannot determine first executable file name on device "flash:"  
      cxxxx processor with 524288 Kbytes of main memory Main memory is configured 
      to 64 bit mode with ECC enabled   
      
      Readonly ROMMON initialized rommon 1 >
      The above has been seen on a Cisco 3800 router.
    2. System Bootstrap, Version 12.3(8r)T, RELEASE SOFTWARE (fc1) Technical  
      Support: http://www.cisco.com/techsupport Copyright (c) 2004 by Cisco Systems,Inc. 
      PLD version 0x10 
      
      GIO ASIC version 0x127
      
      At this point, the system cannot execute from boot flash with the affected Compact Flash when the software enables the quick switches.

      The above has been seen on a Cisco 2801 router.


  2. A router reboot may be triggered from a momentary system power resource overload. This reboot may or may not fail due to the symptom described in scenario #1 directly above.


  3. System accesses to compact flash for certain operations like CLI compact flash queries, TFTP download, or IOS VLAN database storage updates may not be complete. Interruption of services requiring compact flash will result as if compact flash were removed from the system.
    Following are two failure messages one can get from console output with a failed compact flash:

    // dir flash: on previously inserted bad CF
    #dir flash:
    %Error opening flash:/ (No device available)
    #
    // dir flash: after booting up bad CF
    #dir flash:
    Directory of flash:/

    No files in directory

    64278528 bytes total (0 bytes free)
    The following console output occurs when inserting a bad compact flash:
    // inserting bad CF
    #
    Flash card inserted in flash. Reading filesystem on the device...
    Wait for the completion message before accessing device
    Error reading flash

Workaround/Solution

How To Identify Hardware Levels

  1. Use the Cisco IOS command: show flash:all
  2. Visually inspect the 64 MB Compact Flash Card (please refer to figure 1 with the flowchart and figure 2).


  3. RMA's of System Level (1800,2691,2800,3700 & 3800) Products utilizing 64MB SMART Modular Flash. If the 64MB flash fits criteria (figure 2), please contact the Cisco Technical Assistance Center for an RMA.

For More Information

If you require further assistance, or if you have any further questions regarding this field notice, please contact the Cisco Systems Technical Assistance Center (TAC) by one of the following methods:

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