Guest

Cisco 7500 Series Routers

Field Notice: FN - 62773 - RSP4+, RSP8, RSP16 Unable To Read PCMCIA ATA Flash Disk - Data Loss or System Boot Hang - Replace Flash Card


Revised May 8, 2008
April 26, 2007


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.

Revision History

    
Revision Date Comment
1.4 08-MAY-2008 Removed reference to Upgrade Program from Workaround/Solution section.
1.3 05-MAY-2008 Updated to remove umpire form from fieldnotice and fieldnotice title.
1.2 03-MAY-2007 Updated Upgrade Form to reflect correct Product IDs, updated Product IDs in How to Identify Hardware Levels section
1.1 30-APR-2007 Updated Products Affected list, removed RSP4 from Title
1.0 26-APR-2007 Initial Public Release

Products Affected

Products Affected Top Assembly Printed Circuit Assembly Comments Hardware Revision
Part Number Revision Part Number Revision
MEM-RSP16-FLD128M=
16-2117-01
NA
NA
NA
B0 or earlier HW Rev
B2
MEM-RSP16-FLD64M
16-2733-01
NA
NA
NA
C0 or earlier HW Rev
C0
MEM-RSP4+-FLD128M
16-2117-01
NA
NA
NA
C0 or earlier HW Rev
C0
MEM-RSP4+-FLD64M
16-2733-01
NA
NA
NA
C0 or earlier HW Rev
C0
MEM-RSP8-FLD128M
16-2117-01
NA
NA
NA
A0 or earlier HW Rev
A0
MEM-RSP8-FLD64M
16-2733-01
NA
NA
NA
C0 or earlier HW Rev
C0

 

Problem Description

The PCMCIA ATA Flash disks used in specific Cisco products may contain a Manufacturing defect which reduces reliability of the Flash device. Some Route Switch Processor engines used in Cisco 7500 series platforms that contain a suspect Flash device may not be able to access stored files on the Flash disk. The router may fail to reboot if it relies on an IOS image stored on the Flash
device.

A portion of the Route Switch Processor manufactured between May 2005 and October 2006 may have shipped with an affected PCMCIA ATA Flash disk from the specific component lots. Refer to the How to Identify Hardware Levels section for Flash disk identification information. Refer to the Serial Number Range section for serial number bounding information.

The failure condition would be observed during a power cycle, reload event or during a write event such as a crash file dump. Systems will be unable to pass traffic in the failed state.

The affected Route Switch Processors do not allow ROMMON upgrades via software and therefore the affected Flash devices are recommended for replacement.

NOTE 1 - The Route Switch Processors are not defective; this issue is only related to the removable Flash Disk cards.

NOTE 2 - As customers may remove and re-use Flash Cards, the affected cards shipped with these products may have been re-used in different Cisco products.
Please exercise caution when re-using Flash cards and visually check them against the Identification Section data provided.

Background

This issue affects a specific subset of the PCMCIA ATA Disks and Compact Flash cards that were installed in specific Cisco routers manufactured between May 2005 and October 2006. Cards shipped individually as spares over that same time span may also contain one of the affected units.

This issue has been linked to a component manufacturing problem. The root cause was identified and appropriate steps taken to resolve the problem.

Product impact varies due to different flash memory access methodologies and use patterns. Some products may be able to mitigate the potential effect by re-writing affected memory areas at specific intervals. This feature does not work with all products, so please check work around section for availability and specific instructions.

Problem Symptoms

The problem symptom is typically seen during a system reload or cold start. Under normal circumstances a router's PCMCIA card could contain Cisco IOS software, configurations or other files necessary for system boot or operation. These files are accessed by the router during the boot sequence to reach an operating state.

In the problem state, the router is unable to access the contents of the Flash disk. When the problem occurs, the system is prevented from accessing directory information stored on the Flash disk. This type of error occurs in the controller of the Flash disk. Data stored on the Flash disk should be intact but may not be accessible. The router may indicate the state with a message log below. The router will be unable to read the contents of the Flash disk that were previously read or written to.

The output below shows the system log or terminal monitor message when the router is unable to read the Flash disk contents.


%Error opening slot0:/ (No device available)
The router may stop the boot sequence and remain at a ROM Monitor (ROMmon) prompt as seen below.

Readonly ROMMON initialized
boot: cannot open "flash:"
boot: cannot determine first executable file name on device "flash:"cxxxx processor with xxxxxx Kbytes of main memory Main memory is configured to 64 bit mode with ECC enabled Readonly ROMMON initialized
rommon 1 >

NOTE 3 - The Router will be unaffected and continue to run with a failed Flash disk. Only read/write access such as a logfile write to the flash disk or a router reboot will cause the problem symptom to become evident.

Workaround/Solution

Workaround
There is no workaround available for Flash disks used in Route Switch Processors.

Solution
Exchange a failed PCMCIA Flash disk with a known good disk and IOS image. Replacement of the Flash card at the next scheduled maintenance window is recommended to prevent a possible reboot hang on router restart.

Non failed Flash cards matching the replacement criteria should also be replaced to maximize system reliability at the next regular maintenance window.

Installation Instructions
For PCMCIA ATA Flash Disk installation in Route Switch Processors see Flash Memory Card Installation Instructions.

How To Identify Hardware Levels

Identifying affected PCMCIA ATA Flash disks

Please use the following flow chart as a trouble resolution guide for PCMCIA disks.

NOTE #4 - Suspect boards were manufactured between May 2005 and October 2006. Refer to Serial Number Range section for information on serial number range boundaries.
NOTE #5 - See individual card sections [64 MB and 128 MB] for command information and disk information.
NOTE #6 - See individual identification card sections [64 MB and 128 MB] for pictures and code locations.

***64 MB PCMCIA Flash Disks (MEM-RSP4+-FLD64M, MEM-RSP8-FLD64M, MEM-RSP16-FLD64M)****************
Remote Identification of 64 MB PCMCIA Flash disks

For units inserted into operational systems:

Enter the CLI command: show disk[0,1]: filesys

(If the Disk is unable to be read, prioritize this system for card replacement at the next
service window as the disk has failed. The router will continue to run until it reboots and
cannot access the failed disk. Operation should be unaffected until a reboot or logfile write
event to the failed disk.
)

Look for the line: Number of Cylinders 490
If the number is 490, it may be an affected unit. Inspect
visually and confirm card vendor type and date range at the next service window.

Visual Identification of 64 MB PCMCIA Flash disks

An affected unit is shown in the following figure:

Look for
1) Date code is earlier than 060728 (7/28/06)
2) Vendor Part Number starts with "CPC"
3) Cisco Part Number is 16-2733-01

***128MB PCMCIA Flash Disks (MEM-RSP4+-FLD128M, MEM-RSP8-FLD128M, MEM-RSP16-FLD128M)****************
Remote Identification of 64 MB PCMCIA Flash disks

For units inserted into operational systems:

Enter the CLI command: show disk[0,1]: filesys

(If the Disk is unable to be read, prioritize this system for card replacement at the next
service window as the disk has failed. The router will continue to run until it reboots and
cannot access the failed disk. Operation should be unaffected until a reboot or logfile write
event to the failed disk.
)

Look for the line: Number of Cylinders 980
If the number is 980, it may be an affected unit. Inspect
visually and confirm card vendor type and date range at the next service window.

Visual Identification of 128 MB PCMCIA Flash disks

An affected unit is shown in the following figure:

Look for
1) Date code is earlier than 060728 (7/28/06)
2) Vendor Part Number starts with "CPC"
3) Cisco Part Number is 16-2117-01

Frequently Asked Questions

Q1 - Will formatting the Flash disk resolve this issue?
A1 - No, attempts to format the Flash disk will not resolve the problem. When the problem occurs data should be intact and re-formatting after applying the solution should not be necessary.

Q2 - I've applied the solution, but my router does not boot. What do I do?
A2 - There may be a separate issue preventing the router from booting. Further troubleshooting may be necessary.

Q3 - What do I do if my router is currently in ROMMON mode?
A3 - Reference the Cisco Tech Tip for instructions on booting the router using TFTP or use another Flash disk with a known good boot image.

How to Identify Serial Numbers

Product ID and Serial Number Matrix
The following table details the specific Cisco7500 series products that may have shipped with suspect Flash disks between May 2005 and October 2006. The "S/N Location (Quadrant)" heading refers to the physical location of the serial number decal on the specific product as referenced on the "Serial Number Locations Diagram" below.

S/N Location (Quadrant) Product ID Serial Number Range
2
RSP4+ 32814196 Through 34991893
2
RSP8 33656270 Through 35272342
2
RSP16 32152051 Through 35274219

Serial Number Locations Diagram
The below diagram is a generic representation of the affected Route Switch Processor that can be used to aid in the physical identification of suspect units. The top of the card representation is divided into four (4) quadrants. The above "Product ID and Serial Number Matrix" table should be referenced to determine the quadrant location of the serial number decal.

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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