Field Notice: FN - 63461 - Prisma II XD Module / Chassis Alignment Notice
January 19, 2012
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.
Initial Public Release
Net Effect: Misaligned coaxial/55 PIN connectors failed to engage properly for some combinations of specific HD (High Density) modules and chassis. In some cases this results in damage to connectors on either or both.
Cisco Engineers have found two major contributing causes:
Some HD Transmitter modules received from ODM suppliers with mechanical interface dimensions (with respect to connectors) are out of specification due to misalignment of module PCB within the module housing. Those modules affected are noted in the Products Affected section.
Chassis mid-plane PWB is not properly aligned within chassis in some units, resulting in some slots being able to accept modules while others in the same chassis would not.
Cisco has confirmed customer reports of some Prisma II High-Density Transmitter modules exhibiting a misalignment issue with the products listed in the Products Affected section. Cisco has identified this issue and has established a corrective action in manufacturing to address the problem. As of 10/01/11 all new units shipping from Cisco have been corrected. Units exhibiting the misalignment issue in the field will need to be updated via the RMA process, review the Workaround/Solution section to see if you are impacted.
Plan for Containment: HD Modules HD modules being screened via measurement and test fitting in verified dimensionally-correct reference chassis.
Chassis Mid-Plane End-to-end PWB tilt, RF connector height, and lateral clearances of mounted mid-plane being set by gauge during assembly
Cisco has confirmed customer reports of some Prisma II High-Density Transmitter (HD Tx) not installing properly in some Prisma II XD chassis units. In some instances attempts to insert HD Transmitter modules resulted in damage to the Transmitter RF connectors, the chassis's RF connectors, or both.
This problem is currently under investigation.
Users should follow the application installation module procedures outlined in the Prisma XD Platform Guide (Cisco doc no. 4021339, pgs 114-115). Proper alignment of the high density transmitter with the XD chassis should allow for gentle insertion of the transmitter into the chassis until the power and communications connections join onto the midplane. If properly aligned, it should slide in with reasonable force. If insertion is met with significant resistance, the alignment of the module to the chassis is not proper and the module or chassis may need to be replaced.
Caution: Using Excessive insertion force could potentially cause damage to the module, chassis, or both. If customer needs to replace a module or chassis, they should contact Cisco Support to begin the replacement process.
Identifying potentially affected product: Due to it being a tolerance issue with a fairly low instance rate we have been unable to identify a specific date range. The few issues that Cisco has identified occurred in product built during the time frame (January 1st - September 30th 2011). Date code range is from A11 to J11 as identified on the product ID label located on the side of the transmitter or the top of the chassis.
Corrective Actions: HD Modules PCB alignment within module to be set by fixture during installation into housing rather than by verification in a reference host module. This hard tooled alignment will allow for a more precise setting of the module connector locations. This tighter alignment will allow for a bit more chassis tolerance.
Chassis Mid-Plane: Process improvement to incorporate the use of gauges to set mid-plane PWB connector height, tilt, and lateral location during assembly.
If the customer's product does fall in this date range and the cse has verified that there is an insertion issue, the CSE should submit an RMA request. Please inform the customer that there is limited inventory, RMAs are being prioritized as they come and replacement units will be will be made available as necessary and prioritized for shipment.
How To Identify Hardware Levels
Replacement parts will be handled out of normal distribution which is from the San Jose Factory with a 6-8 week turnaround time.
Provide an estimate of inventory levels that will be maintained while this problem is being resolved.
There is a very low failure rate for this product and inventory levels will not be maintained. Replacement of product will be made available as necessary and prioritized for shipment.
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: