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Cisco Route Processors and Route Switch Processors

Field Notice: FN - 63390 - GSR PRP-2 may fail while in operation after extended period of time - Upgrade program available

Field Notice: FN - 63390 - GSR PRP-2 may fail while in operation after extended period of time - Upgrade program available

July 12, 2012


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
1.0
12-JUL-2012
Initial Public Release

Products Affected

Product Top Assembly Printed Circuit Assembly Comments
Products Affected
Part #
Rev.
Part #
Rev.
PRP-2(=)
800-27058-01 to -09 
 Rev 09
 73-10242-10
 Rev A0 ver 5
Fixed in 800-27058-11. Legacy PRP-2 with TAN 800-23469-xx not affected

Problem Description

PRP-2 board may fail in GSR Router while in operation for extended period of time. The failure symptom may be several such as PRP-2 failure, switchover to standby PRP-2, router reload, traffic outage, or PRP-2 board in indeterminate state.

Background

PRP-2 in GSR router is the central processor and performs various functions such as routing, traffic management, line card monitoring, and more. The PRP-2 board is made up of CPU, memory, controllers, FPGAs, and other active and discrete components. The FPGA on PRP-2 receives slightly higher voltage on the PLL VCC pins than recommended by the vendor, leading to electrical stress over the long term, reducing reliability of the device and eventually causing failure of PLL circuit and FPGA.

The FPGA converts processor bus to interface the IO devices such as Flash, NVRAM, compact disk, and memory and implements MBUS Mailbox functionality. Failure of FPGA PLL circuit leads to very slow heat up of the FPGA device over time resulting in logic lock-up condition thereby leading to PRP-2 board failure. Since the PLL circuit of FPGA is not used on PRP-2, no hard failure or symptom of the PRP-2 board can be predicted, the failures may manifest different ways due to logic lock-up condition of the FPGA.

Problem Symptoms

PRP-2 board may fail in GSR Router while in operation for extended period of time. There may be several different failure symptoms such as PRP-2 failure, switchover to standby PRP-2, router reload, traffic outage, or PRP-2 board in indeterminate state.

Workaround/Solution

PRP-2s shipped between March 2006 to November 2010 are suspect. PRP-2 boards shipped post November 2010 contain new PCB design to correct VCC_PLL ping voltage. Alternatively refurbished PRP-2 boards shipped by Cisco service under RMA or upgrade program will not have the issue, since the issue is fixed by interposer adaptor.

The table below will help you identify if PRP-2 board is suspect or good board.

TAN or Part number Steps Action
800-27058-09 and lower
If Affected, request replacement by filling Upgrade form at end of FN
800-27058-09 with Deviation D113342, D113851, D115209, D115427
No check required
PRP-2 is good, No replacement required
800-27058-11 and higher
No check required
PRP-2 is good, No replacement required
800-23469-xx(PRP-2 shipped prior March 2006)
No check required
PRP-2 is good, No replacement required

**If TAN information is not available, use Serial Number Tool (SN Tool) to verify if board is affected. SN Tool is updated monthly.

Note: PRP-2 with TAN 800-27058-11 are good boards (not affected) even when the PRP-2 board falls within the serial number listed in tool as affected. PRP-2 boards shipped to customer with TAN 800-27058-09 and deviation D113342, D113851, D115209, D115427 are good boards (not affected). PRP-2 boards with TAN 800-27058-10 were not shipped to customers.

Normal RMA Service Levels and turnaround time do not apply for replacement Program. No Cisco Internal PRP-2 boards will be replaced using this program.

The replacement of PRP-2 is recommended during maintenance window. Customers are requested to retain DIMM (Memory), PCMCIA Flash card as it will be needed for plugin to replacement PRP-2.

How To Identify Hardware Levels

Illustrated below are two methods that can be used to distinguish the different revisions of the PRP-2: A) CLI, and B) Physical inspection.

A) CLI Method

Note: You must log in to GSR router with admin privileges to run the IOS commands.

Information: Your command prompt setting will determine [router-name] shown in example below.

Good PRP-2 Version:

Below is sample CLI and output: show diagnostic:

i)
SLOT 9 (RP/LC 9): Performance Route Processor
MAIN: type 96, 800-27058-11 rev A0 => Good board TAN
Deviation

HW config: 0x10 SW key: 00-00-00
PCA: 73-10242-13 rev A0 ver 5
Design Release 0.0 S/N SADnnnnnnn ->Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

OR

SLOT 9 (RP/LC 9): Performance Route Processor
MAIN: type 96, 800-27058-09 rev A0
Deviation D115209 => Good PRP-2 board shipped under Deviation D113342, D113851, D115209, D115427.

HW config: 0x10 SW key: 00-00-00
PCA: 73-10242-13 rev A0 ver 5
Design Release 0.0 S/N SADnnnnnnn ->Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

Legacy PRP-2 boards shipped prior to March 2006 are good boards. See below on how to identify.

GSR#sh diag 5

SLOT 5 (RP/LC 5 ): Performance Route Processor
MAIN: type 96, 800-23469-08 rev B0 <- TAN for Good board
Deviation: 0
HW config: 0x10 SW key: 00-00-00
PCA: 73-8812-11 rev B0 ver 4 <-- PCA for good board
Design Release 0.0 S/N SADnnnnnnnn
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0
HW version 0.1 S/N CAT073703QC
Test hist: 0x00 RMA#: 00-00-00 RMA hist: 0x00
DIAG: Test count: 0x00000000 Test results: 0x00000000
FRU: Linecard/Module: PRP-2=
Route Memory: MEM-PRP/LC-2048=
MBUS Agent Software version 2.70 (RAM) (ROM version is 3.68)
ROM Monitor version 1.8(2.83)
Primary clock is CSC 1
Board State is IOS Running ACTIVE (ACTV RP )
Insertion time: 8w4d (24w3d ago)
DRAM size: 2147483648 bytes

Suspect PRP-2 Cards:

Below is CLI of show diags:

SLOT 9 (RP/LC 9 ): Performance Route Processor
MAIN: type 96, 800-27058-09 rev A0 => Affected Board TAN
Deviation

HW config: 0x10??? SW key: 00-00-00
PCA: 73-10242-09 rev B0 ver 5
Design Release 0.0 S/N SAnnnnnnnn --> Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

B) Physical Inspection method

Below are a few images to identify the PRP-2 board PID, version, and serial number location.

a) New PCB respin PRP-2 board (good board) and suspect PRP-2 board.

b) Good PRP-2: New PCB respin PRP-2 board shipped under deviation.

c) Good PRP-2 board with Interposer PCB installed.

Deviation

D113342, D113851, D115209, D115427

Upgrade Program

PRP-2=
You will receive an email within a couple of days with an Order Number.If you need status of your Order, follow these directions:

If you were given a Sales Order Number for the shipment of your replacement parts, please refer to the SO Status Tool (Please note: you must have a CCO User ID and Password to access this site): http://tools.cisco.com/qtc/status/tool/action/LoadOrderQueryScreen

If you were given an RMA Number for the shipment of your replacement parts, please refer to the RMA Status Tool (Please note: you must have a CCO User ID and Password to access this site): http://tools.cisco.com/serviceordertools/svostatus/query.do

If you have not received an email with an Order Number after 3 business days, please send an email with your Request Number, Customer Name and PID in the subject line to:
umpire-escalations@cisco.com

Note: Fields marked with an asterisk (*) are required fields.

Requestor Information
*Name
*E-mail Address
TAC SR Number
Customer Shipping Information
*Company
*Address
Address_line2
*City
*State/Province
*ZIP/Postal Code
*Country
Product
Product *Quantity *Serial# 2
PRP-2=
Customer Contact Information
*First Name
*Last Name
*Phone 1 Ext.
Fax 1 Ext.
*E-Mail
Please use the following format: user@domain.com
*Upgrade Order Reference Number
Please provide a number that you can use when inquiring about order status
Notes
1 For phone and fax, include 011 and the country code outside North America.

2 The serial number input field for each Product ID can hold up to 4,000 characters, including commas and white space. For longer lists of serial numbers, please submit additional requests.

3 For customers in Japan only *** please enter the building and the floor in the address field. Also, enter the contact person's name, the telephone number and the e-mail address in the appropriate fields..

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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