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Cisco Carrier Routing System

Field Notice: FN - 63247 - CRS1: 2GB/4GB Flash disk may be incorrectly partitioned for shipment between 2nd March to 12 May 2009 - Workaround available

Field Notice: FN - 63247 - CRS1: 2GB/4GB Flash disk may be incorrectly partitioned for shipment between 2nd March to 12 May 2009 - Workaround available

September 18th, 2009


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
1.1
18-Sep-2009
Updated Failsafe and In-Service Method instructions for 2GB and 4GB Flash Disks.
1.0
06-Aug-2009
Initial Public Release.

Products Affected

Products Affected
Type Tech Group BU Family / SW Type Line / SW Id HW Id / SW Ver
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-16-RP-B
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-8-RP
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-DRP-B
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-DRP-CPU
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-FLASH-DISK-2G
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRS
CRS-FLASH-DISK-4G
Hardware
(SPRTG) Service Provider Routing
CRBU
CRS
CRSMC
CRS-FCC-SC-22GE

Problem Description

The 2GB/ 4GB Flash disks shipped between 2nd March, 2009 to 12th May, 2009 can be incorrectly partitioned due to a flash disk duplicator malfunction in manufacturing. The 2GB Flash Disk can be partitioned and formatted as 1GB, which reduces available disk space. Workaround steps are available.

Background

The Flash Disk storage device on CRS1 is used to store Cisco IOS-XR Operating system (OS), configuration files, system DB, software image or pie files, log files and more. The Flash Disk must be partitioned and formatted before CiscoIOS-XR Operating system (OS) is copied to the Flash Disk.

As part of the manufacturing process, a Flash disk duplicator is used to partition and format multiple flash disks in a single operation. A malfunction in the duplicator script between 2nd March, 2009 and 12th May, 2009 can cause 2GB (CRS-FLASH-DISK-2G) and 4GB (CRS-FLASH-DISK-4G) flash disks to be partitioned and formatted as 1GB Flash Disks. A 1GB Flash disk works for Cisco IOS-XR 3.6.x and earlier, but a 2GB Flash disk is required in order to upgrade to Cisco IOS-XR Release 3.7.0 and later.

The 2GB or 4GB Flash Disk can be shipped as a spare part or part of Cisco CRS1 Product PID ( CRS-16-RP-B, CRS-8-RP, CRS-FCC-SC-22GE, CRS-DRP-B-CPU,CRS-DRP-B). Workaround steps are available. See the Workaround/Solution section.

Problem Symptoms

The 2GB and 4GB Flash Disks shipped between 2nd March, 2009 and 12th May, 2009 on Sales Order Verified can be reported as only 1GB in size on a CRS1 system due to incorrect partitioning by the duplicator in manufacturing. CRS1 Cards with suspect a Flash disk function as expected, but an upgrade to Cisco IOS-XR 3.7.0 and later can fail due to insufficient space of the 1GB partition. Workaround steps are available.

Workaround/Solution

Cisco Flash disks (2GB or few 4GB) shipped under Sales orders between 2th March, 2009 and 12th May, 2009 can be incorrectly partitioned as 1GB. Validate the Sales Order. Complete this workaround procedure depending on the 2GB or 4GB flash received as part of the Sales Order.

Complete these steps:

  1. Verify the 2GB/4GB Flash Disk Type.
  2. Verify Partitions on 2GB/4GB Flash Disk.
  3. Format Partitions.
  4. Fixing the Partition and File System for 2GB/4GB with the Failsafe Method OR In-Service Method.
  5. Verify 2GB/4GB Flash disk.

Insert the Flash disk into the Standby RP's Flash disk slot1 and login with superuser privilege user on CRS1 console.

Important Note: DO THIS PROCEDURE ONLY ON THE STANDBY RP! Backup your configuration, log and other important files to your computer or backup device before you perform these workaround steps.

A) Procedure to fix partition on 2GB Flash Disk

These figures provide information to help you identify your 2GB Flash disk and serial number location.

Figure 1: 2GB Flash Disk Front View

Figure 2: 2GB Flash Disk Back View

Step 1: Verify a 2GB Flash Disk

Run these commands at the command prompt:

show filesystem disk1: firmware location 0/RP0/CPU0
show filesystem disk1: firmware location 0/RP1/CPU0

Verify the Drive Capacity sector count. The expected number is over 4 million sectors, though the exact number can vary slightly. This output shows a good 2GB Flash disk.

Step 2: Verify the flash disk is partitioned as one 2GB partition

Run these commands at the command prompt:

show filesystem location 0/RP0/CPU0
show filesystem location 0/RP1/CPU0

Verify the flash shows disk1 with a partition size of 2101673984 bytes, which is a little less than the calculated 2147483648 bytes. This output shows a good 2GB Flash disk.

Step 3: If the Flash disk is correctly partitioned and formatted, no action is required.

For a 2GB Flash disk that shows as 1GB, proceed to the next step.

Step 4: Fix the 2GB Flash Disk

All commands in this step are available for Cisco IOS-XR Release 3.6 and later. For Cisco IOS-XR Release 3.4.x and Cisco IOS-XR Release 3.5.x CRS1 Router, only the Failsafe Method is available.

If the partition is wrong, it is assumed the file system is wrong.

Note: These commands are applied under the K-Shell environment. KSH commands do not have many checks or warning messages in place that one normally expects when you work with Cisco IOS-XR CLI commands. Be careful and ensure the commands are correctly entered in order to avoid any problems.

For example, if you mistype a disk0 for disk1 when you use format comands, it formats the primary disk and removes the Cisco IOS-XR Operating system.

Important Note: DO THIS PROCEDURE ONLY ON THE STANDBY RP!

In order to verify Standby RP Card, run the show redundancy command on the router. This output shows 0/RP0/CPU0 is Standby RP:

RP/0/RP1/CPU0:KFP-02#show redundancy
Sun Jun 14 12:50:34.034 PST PDT
Redundancy information for node 0/RP1/CPU0:
==========================================
Node 0/RP1/CPU0 is in ACTIVE role < --Active RP
Partner node (0/RP0/CPU0) is in STANDBY role < --Standby RP
Standby node in 0/RP0/CPU0 is ready
Standby node in 0/RP0/CPU0 is NSR-ready
......

Failsafe Method for 2GB Flash Disk

This Failsafe method section provides steps to partition the disk1 device not currently used by Cisco IOS-XR. These commands are for disk1.

These commands remove and recreate one partition and format in FAT16.

Note: The command must be executed quickly (approximately 5minutes) in sequence.

  1. Type the command at router prompt "unmount disk1:" or "unmount disk1: location "
  2. Type the command at router prompt "run" or "run attach 0/rp1/cpu0" for the Standby RP
  3. At the KSH prompt, enter "fdisk /dev/disk1 delete -a"
  4. At the KSH prompt, enter "fdisk /dev/disk1 add -t6 -p100"
  5. At the KSH prompt, enter "mount -e /dev/disk1"
  6. At the KSH prompt, enter "mkdosfs -F16 -D/pkg/etc/hfr-atamonlib-m /dev/disk1t6"
  7. Type "exit" at the KSH prompt to return to the normal prompt.

Optional: At the router prompt, type "unmount disk1: undo" This command may not be necessary in some case and produces a benign error message.

In-Service Method for 2GB Flash Disk

The In-Service method steps help partitions currently used by Cisco IOS-XR. The commands shown are for disk0.

These commands remove and recreate one partition and format in FAT16

Note: The command must be executed quickly in sequence.

  1. Type the command at router prompt "run attach 0/rp1/cpu0" Example with Standby RP at 0/RP1/CPU0.
  2. At the KSH prompt, enter "fdisk /dev/disk0 delete -a"
  3. At the KSH prompt, enter "fdisk /dev/disk0 add -t6 -p100"
  4. At the KSH prompt, enter "mount -e /dev/disk0"
  5. At the KSH prompt, enter "mkdosfs -F16 -D/pkg/etc/hfr-atamonlib-m /dev/disk0t6"
  6. Type "exit" at the KSH prompt to return to the normal prompt.
  7. Reload Standby RP with "reload location 0/RP1/CPU0" in Admin Mode. Example with Standby RP at 0/RP1/CPU0.
  8. Wait until Standby RP syncs with Active RP and becomes "Standby Ready" using the command "show platform" to check standby status.
    This can take 50 minutes to 100 minutes.

    Caution: Do not proceed to the next step until the card becomes Standby Ready.
  9. Use the show redundancy command in order to verify the Standby RP is Ready, and switch the Active and Standby RP roles in Admin User mode with redundancy switchover.
    Note: This step resets the Active RP.
  10. Repeat all nine steps for the new Standby RP.

You have now successfully partitioned and formatted the 2GB Flash disk.

Procedure to fix partition on 4GB Flash Disk

These pictures provide information to help you identify a 4GB Flash disk and the serial number location.

Figure 3: 4GB Flash Disk Front View

Figure 4: 4GB Flash Disk Back View

Step 1: Verify a 4GB Flash Disk

Insert the 4GB Flash Disk into slot1 of the Standby RP. Log in to the CRS1 Router console port with superuser privileges.

Run these commands at command prompt:

show filesystem disk1: firmware location 0/RP0/CPU0
show filesystem disk1: firmware location 0/RP1/CPU0

Verify the Drive Capacity sector count. The expected number is over 4 million sectors, though the exact number can vary slightly. This output shows a good 4GB Flash disk.

Step 2: Verify the flash disk is partitioned as one 4GB partition

Run these commands at command prompt:

show filesystem location 0/RP0/CPU0
show filesystem location 0/RP1/CPU0

Verify the flash shows disk1: and disk1a: with a partition size of 2101673984 bytes, which is a little less than the calculated 2147483648 bytes. This output shows a good 4GB Flash disk.

Step 3: If the Flash disk is correctly partitioned and formatted, no action is required.

For 4GB Flash disk that shows as 1GB, proceed to the next step.

Step 4: Fix the 4GB Flash Disk

All commands in this step are available for Cisco IOS-XR Release 3.6 and later. 4GB Flash is not recognized for Cisco IOS-XR Release 3.4.x and Cisco IOS-XR Release 3.5.x CRS1 Router.

If the partition is wrong, it is assumed the file system is wrong.

Note: These commands are applied under the K-Shell environment. KSH commands do not have many checks or warning messages in place that one normally expects when you work with Cisco IOS-XR CLI commands. You must ensure that the commands are correctly entered in order to avoid any problems.

For example, if you mistype a disk0 for disk1 when you use format comands, it formats the primary disc and removes the Cisco IOS-XR Operating system.

Important note: DO THIS PROCEDURE ONLY ON THE STANDBY RP!

In order to verify the Standby RP Card, run the show redundancy command on the router. This output shows that 0/RP0/CPU0 is the Standby RP.

RP/0/RP1/CPU0:KFP-02#show redundancy
Sun Jun 14 12:50:34.034 PST PDT
Redundancy information for node 0/RP1/CPU0:
==========================================
Node 0/RP1/CPU0 is in ACTIVE role < ---Active RP
Partner node (0/RP0/CPU0) is in STANDBY role < ----Standby RP
Standby node in 0/RP0/CPU0 is ready
Standby node in 0/RP0/CPU0 is NSR-ready
......

Failsafe Method for 4GB Flash Disk:

The Failsafe method section provides steps to partition the disk1 device not currently used by Cisco IOS-XR. These commands are for disk1.

These commands remove and recreate two partitions and format in FAT16.

Note: The command must be executed quickly in sequence.

  1. Type the command at router prompt "unmount disk1:" or "unmount disk1: location "
  2. Type the command at router prompt "run" or "run attach 0/rp1/cpu0" for the Standby RP
  3. At the KSH prompt, enter "fdisk /dev/disk1 delete -a"
  4. At the KSH prompt, enter "fdisk /dev/disk1 add -t6 -p50"
  5. At the KSH prompt, enter "fdisk /dev/disk1 add -t4 -p100"
  6. At the KSH prompt, enter "mount -e /dev/disk1"
  7. At the KSH prompt, enter "mkdosfs -F16 -D/pkg/etc/hfr-atamonlib-m /dev/disk1t6"
  8. At the KSH prompt, enter "mkdosfs -F16 /dev/disk1t4"
  9. Type "exit" at the KSH prompt to return to the normal prompt.
  10. Optional: At the router prompt, type "unmount disk1: undo" This command may not be necessary in some case and produces a benign error message.

You have now successfully partitioned and formatted the 4GB Flash Disk.

In-Service Method for 4GB Flash Disk:

The In-Service method steps help the partition currently used by Cisco IOS-XR. The commands shown are for disk0.

Note: The command must be executed quickly (approximately 5minutes) in sequence.

  1. Type the command at router prompt "run attach 0/rp1/cpu0" Example with Standby RP at 0/RP1/CPU0.
  2. At the KSH prompt, enter "fdisk /dev/disk0 delete -a"
  3. At the KSH prompt, enter "fdisk /dev/disk0 add -t6 -p50"
  4. At the KSH prompt, enter "fdisk /dev/disk0 add -t4 -p100"
  5. At the KSH prompt, enter "mount -e /dev/disk0"
  6. At the KSH prompt, enter "mkdosfs -F16 -D/pkg/etc/hfr-atamonlib-m /dev/disk0t6"
  7. At the KSH prompt, enter "mkdosfs -F16 /dev/disk0t4"
  8. Type "exit" at the KSH prompt to return to the normal prompt.
  9. Reload Standby RP with "reload location 0/RP1/CPU0" in Admin Mode. Example with Standby RP at 0/RP1/CPU0.
  10. Wait until the Standby RP syncs with Active RP and becomes "Standby Ready" with the "show platform" command in order to check progress. The sync can take 50 minutes to 100 minutes.

    Use the show redundancy command in order to determine if the Standby RP is Ready.
    Caution: Do not proceed to the next step until the standby card is ready.
  11. Once the Standby RP is Ready, switch the Active and Standby RP roles in Admin User mode with the redundancy switchover command.
    Note: This step resets the Active RP.
  12. Repeat all nine steps for the new Standby RP.

You have now successfully partitioned and formatted the 4GB Flash Disk.

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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