Cisco 10005 Hardware Overview and Maintenance
Maintaining the Cisco 10005 ESR
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Maintaining the Cisco 10005 ESR

Table Of Contents

Maintaining the Cisco 10005 ESR

Spare Parts

Redundancy

Required Maintenance Tools

Backing Up the PCMCIA Flash Memory Card

Formatting Flash Memory Cards and Disks

Shutting Down the System

Removing and Replacing Field-Replaceable Units

Replacing the Air Filter

Replacing the Fan Assembly

Installing Power Entry Modules

Installing a Second DC PEM

Replacing a DC PEM

Installing a Second AC Power Supply

Replacing an AC Power Supply

Removing and Replacing Extender Cards

Removing an Extender Card

Installing an Extender Card

Removing and Replacing a Line Card

Replacing the Performance Routing Engine Module

Removing and Installing a PCMCIA Flash Memory Card


Maintaining the Cisco 10005 ESR


The Cisco 10005 ESR is configured to your order and ready for installation when it arrives. After you install the system, you may have to perform specific maintenance procedures to ensure the router operates properly. These routine procedures include replacing the filter, upgrading system components, or replacing field replaceable units (FRUs). This chapter contains the information necessary to perform that maintenance for the Cisco 10005 ESR.


Note Detailed instructions are also shipped with FRUs and upgrade kits.


System components fall into two categories: hot swappable components that do not require you to power off the system before replacing them, and those components that do require you to power off the system before you replace them. For example, all line cards are hot-swappable and can be replaced without powering off the system, but you must power off the system before replacing a single power module or a single Performance Routing Engine (PRE).


Note To prevent alarms from activating, you must administratively shut down a line card before hot swapping it.


Spare Parts

Service providers usually draw on their own experience with similar equipment as they try to determine the number of spare parts of a given item to keep on hand. In developing a strategy for spare parts, the service providers must

Evaluate the criticality of the equipment.

Estimate the mean time between failures, a key component of any spares strategy.

Calculate the number of production routers (and associated components) they need to have on hand. For example, if they have the critical mass to shift capacity to other locations or other devices, they may be able to carry fewer spares.

Service providers may also subscribe to services that supply them with replacement parts, sometimes with turnaround times as short as 4 hours.


Redundancy

Service providers trying to decide on the level of redundancy appropriate for their operations must examine their business models. The service provider invests more heavily in high network reliability if the business model

Calls for protected services

Provides customer service-level agreements

Accommodates customers that require a high degree of reliability

Emphasizes overall reliability as opposed to cost

In addition, the service provider discusses the situation with the supplier to identify those software and hardware features likely to experience the most stress and thus to have the shortest mean time between failures. The point is to determine, not just whether or not redundancy is to be used, but also the quantity to be used (1:1, 2:1, or greater).

Some service providers have redundant chassis, but not redundant routing engines. This approach gives them increased flexibility, so that they can provide reliable service and accommodate a growing number of customers. Customers requiring the highest levels of network reliability and availability often add redundancy by connecting to two different service providers.


Required Maintenance Tools

The tools required to perform the maintenance procedures described in this chapter are:

A Number 2 Phillips screwdriver

A flat-blade screwdriver

An electrostatic discharge (ESD) grounding strap

Backing Up the PCMCIA Flash Memory Card

Cisco recommends that you create a duplicate PCMCIA card that contains the current boot software image and the current software configuration. You can use the backup card to quickly recover from a major system failure. You can also use a backup card to load a new PRE module and avoid the time-consuming reconfiguration process. For instructions to create a backup PCMCIA card, refer to the Cisco 10000 Series ESR Software Configuration Guide.

Formatting Flash Memory Cards and Disks

The Flash memory disk card that shipped with your router contains the default Cisco IOS image for booting your router. This section explains how to format an ATA flash disk.


Caution The formatting procedure erases all information on Flash memory disks or cards.

Flash memory ATA disks and Flash memory cards use similar commands. The primary syntax change is that disk0: or disk1: refers to Flash memory ATA disks while slot0: or slot1: refers to Flash memory cards.

To format a Flash memory disk:


Step 1 Ensure there is a Flash memory disk in PCMCIA slot 0 or slot 1 of the PRE.

Step 2 To format the disk, enter the format diskn: command at the privileged EXEC mode prompt.

The following example shows the expected output after you enter the format disk0: command:

Router# format disk0: 
All sectors will be erased, proceed? [confirm] 
Enter volume id (up to 30 characters): MyNewdisk 
Formatting sector 1 
Format device slot0 completed 
Router#

The Flash memory disk is now ready for use.


Shutting Down the System

Although most components in the Cisco 10005 ESR are hot-swappable, you might have to shut down the system under certain circumstances—for example, if you are replacing the only power module or the only PRE in a nonredundant system.

To shut down the system:


Step 1 Notify appropriate personnel that you plan to shut down the system and that a shutdown results in loss of service. Appropriate personnel includes the regional alarm or network monitoring center, central office personnel, and customers.

Step 2 Before you shut down the router, use the copy command to save any configuration changes to NVRAM, and also, if you wish, to a PCMCIA Flash card. (See the Cisco 10000 Series ESR Software Configuration Guide for instructions about using the copy command.)

Step 3 Power down the system by setting the switches on all power modules to the 0 (off) or standby position. (Your system can have one or two power modules.)



Warning Before you work on a system that has a standby/off switch, turn off the power by pressing the power switch to standby and unplugging the power cord.


Removing and Replacing Field-Replaceable Units

This section contains procedures to remove and replace all of the field replaceable units (FRUs) for the Cisco 10005 ESR.

Replacing the Air Filter

If the air filter is dirty or clogged, the fan assembly might not be able to provide sufficient cooling air flow through the chassis, causing the system to overheat. To prevent an overheating problem, replace the air filter every 6 months. In dirty or dusty environments, replace the filter more frequently.


Note If you want to reuse the air filter, use a vacuum cleaner to remove the dust.


The air filter is accessible from the rear of the chassis. It occupies a vertical slot on the left side of the chassis.

To replace the air filter:


Step 1 Use a flat blade screwdriver to turn the cam fastener on the air filter cover one half of a rotation (180 degrees) (Figure 3-1).

Figure 3-1 Loosening the Air Filter Cover

Step 2 Using the handle at the top of the cover, pull the cover down, then lift it away from the chassis (Figure 3-2).

Figure 3-2 Removing the Air Filter Cover

Step 3 Grasp the plastic tab on the frame of the air filter and pull the filter out of the chassis (Figure 3-3).

Figure 3-3 Removing and Replacing the Air Filter

Step 4 Insert the new or cleaned air filter into the chassis in such a way that the arrow on the metal filter frame is pointing up and the plastic pull tab is facing outward.

Step 5 To replace the filter cover, insert the tab on the bottom of the cover into the slot at the bottom of the air filter compartment. Pivot the cover up into place.

Step 6 Turn the cam fastener ½ of a rotation (180 degrees) to secure the filter to the chassis.


Replacing the Fan Assembly

The fan assembly supports hot-swapping (for up to 2 minutes) and can be replaced without interruption to system operation.

The fan assembly is accessible from the rear of the chassis. It occupies a vertical slot on the right side of the unit.


Caution To prevent the system from overheating, be sure that the replacement fan assembly is out of its box and packaging, so it is ready to install as soon as the defective module is removed.

To replace the fan assembly:


Step 1 Move any interface cables away from the fan assembly.

Step 2 Loosen the captive screw on the fan assembly and slide the assembly out of the chassis (Figure 3-4).


Warning The fans might still be turning when you remove the fan assembly from the chassis. Keep fingers, screwdrivers, and other objects away from the openings in the fan assembly's housing.


Figure 3-4 Removing or Installing the Fan Assembly

Step 3 Slide the new fan assembly into the chassis, being sure it makes a secure connection to the midplane.

If the fan assembly is operating properly, its LED turns green and the fans start to turn.

If the LED turns red, try reseating the fan assembly.

Step 4 Tighten the captive screw to secure the fan assembly to the chassis.

Step 5 Rerun all interface cables through the cable management bracket.


Installing Power Entry Modules

This section contains the procedures to install or replace AC or DC PEMs.


Note If you are adding a second PEM for redundancy, or if you have redundant PEMs, it is not necessary to shut down the system before replacing a PEM.


Installing a Second DC PEM


Warning Never install an AC power module and a DC power module in the same chassis.


To install a second DC PEM for redundancy:


Caution Do not power off the DC PEM in a system that has only one PEM. If you do so, all data traffic halts.


Step 1 Set the power switch on the new DC PEM to 0 (off).

Step 2 Loosen the captive screws and remove the blank cover from the empty power bay.

Step 3 Insert the new PEM all the way into the power bay to ensure a secure connection to the midplane. Tighten the captive screws.

Step 4 For instructions on wiring the new PEM, refer to the installation document that arrived with the PEM, or to the wiring procedure in the Cisco 10005 ESR Hardware Installation Guide.


Replacing a DC PEM


Warning Never install an AC power module and a DC power module in the same chassis.


To replace a DC PEM:


Step 1 Set the power switch to the 0 (off) position. If you have redundant PEMs, set only the power switch of the PEM you are replacing to the 0 (off) position.


Caution Do not power off both of the DC PEMs in a redundant system, or the system shuts and down all data traffic stops. Only power off the DC PEM you are replacing.

Step 2 Turn off power to the branch circuit that feeds power to the PEM that you are replacing.

Step 3 At the terminal block on the PEM that you turned off, use a voltmeter to verify that there is no power present.

Step 4 Use a screwdriver to loosen the screws on the PEM terminal block and remove the wires. Be sure to disconnect the ground (bottom wire) last.

Step 5 Loosen the captive screws on the DC PEM you are removing and pull the PEM from the chassis using the handle on the faceplate (Figure 3-5).

Figure 3-5 Removing and Replacing a DC PEM

Step 6 Insert the new DC PEM all the way into the power bay to ensure a secure connection to the midplane. Tighten the captive screws.

Step 7 If you do not install a new PEM immediately, cover the empty power bay with a blank faceplate.


Warning Blank faceplates (filler panels) serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain electromagnetic interference (EMI) that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, power modules, and faceplates are in place.


Step 8 For instructions on wiring the new PEM, refer to the installation document that arrived with the PEM, or to the wiring procedure in the Cisco 10005 ESR Hardware Installation Guide.


Installing a Second AC Power Supply


Warning Never install an AC power module and a DC power module in the same chassis.


To install a second AC power supply for redundancy:


Step 1 Make sure the power switch on the new AC power supply is set to standby. (Press the left side of the power switch.)

Step 2 Loosen the captive screws and remove the blank cover from the empty power bay.

Step 3 Insert the new AC power supply all the way into the power bay to ensure a secure connection to the midplane. Tighten the captive screws (Figure 3-6).

Figure 3-6 Installing an AC Power Supply

Step 4 Connect the power cord to the new power supply.

Step 5 Snug up the strain relief device the secures the power cord to the power supply. To do this, tighten the screw underneath the power connector (Figure 3-7).

Figure 3-7 Tightening AC Power Cord Strain Relief


Warning Do not over-tighten the strain relief devices that secure the power cords to the power supplies. Because this chassis cannot be switched off completely, you must disconnect the power cords to remove power from the chassis. The power cord serves as the primary disconnect in an emergency.


Step 6 Plug the AC input power cord into a power receptacle.

Step 7 Set the power switch on the new power supply to the | (on) position.

The green LED on the PEM lights up, indicating that the power supply is on.


Replacing an AC Power Supply


Warning Never install an AC power module and a DC power module in the same chassis.


To replace an AC power supply:


Step 1 If your system is configured with redundant power supplies, set only the power switch of the power supply you are replacing to the standby position (Figure 3-8).


Caution Do not power off both AC power supplies in a redundant system, or the system shuts down and all data traffic stops. Only power off the AC power supply you are replacing.

Figure 3-8 Setting AC Power Switch to the Standby Position

Step 2 Disconnect the power cable from the Cisco 10005 power supply.

Step 3 Loosen the captive screws on the power supply you are removing and pull the power supply from the chassis using the handle on the faceplate (Figure 3-9).

Figure 3-9 Removing and Replacing an AC Power Supply

Step 4 Insert the new AC power supply all the way into the power bay to ensure a secure connection to the midplane. Tighten the captive screws on the power supply.

Step 5 If you do not immediately install a new power supply, install a blank faceplate over the empty power bay.


Warning Blank faceplates (filler panels) serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain electromagnetic interference (EMI) that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, power modules, and faceplates are in place.


Step 6 Connect the power cord to the new power supply.

Step 7 Snug up the strain relief device the secures the power cord to the power supply. To do this, tighten the screw underneath the power connector (Figure 3-10).

Figure 3-10 Tightening AC Power Cord Strain Relief


Warning Do not over-tighten the strain relief devices that secure the power cords to the power supplies. Because this chassis cannot be switched off completely, you must disconnect the power cords to remove power from the chassis. The power cords serve as the primary disconnect in an emergency.


Step 8 Set the power switch on the new power supply to the | (on) position.

The green LED on the power supply lights up, indicating that the power supply is providing power to the chassis.


Removing and Replacing Extender Cards

Follow the procedures in this section to remove and replace the extender cards at the back of the chassis. Extender cards provide connectors for T3/E3 and alarm relay interfaces.

Removing an Extender Card

To remove an extender card from the chassis:


Step 1 Attach an antistatic wrist strap to your wrist and to an ESD socket on the chassis, or to a bare metal surface on the chassis or frame.

Step 2 Ensure that all wires and cables are disconnected from the extender card.

Step 3 Loosen both captive screws on the extender card.

Step 4 Hold the faceplate of the extender card with one hand, and place you other hand under the card carrier (to support the weight of the card).

Step 5 Slide the extender card out of the slot and place it on an antistatic surface, or in an antistatic bag.

Step 6 Install another extender card according to the "Installing an Extender Card" section. Do not leave the slot empty.


Installing an Extender Card

Install the alarm extender card only in the lowest slot in the rear of the Cisco 10005 ESR chassis.

All five top slots at the rear of the chassis should always be populated with DS3 extender cards when the chassis is powered on. The DS3 extender card extends the DS3 signals of the channelized T3 line card that is in the corresponding slot in the front of the chassis. For example, a DS3 extender card installed in the highest slot in the rear of the chassis extends the signals of the channelized T3 line card that is installed in the highest slot in the front of the chassis.

To install an extender card into the rear of the chassis:


Note If you are replacing an extender card, see the "Removing an Extender Card" section before you begin this procedure.



Step 1 Attach an antistatic wrist strap to your wrist and to an ESD socket on the chassis, or to a bare metal surface on the chassis or frame.

Step 2 Hold the faceplate of the extender card with one hand and place your other hand under the card carrier (to support the weight of the card). Position the card in front of the card cage slot.

Step 3 Carefully align the left and right edges of the extender card with the left and right guides in the chassis, and slide the card into the slot until it is firmly seated in the midplane connectors.

Step 4 Securely tighten both captive screws on the extender card.


Removing and Replacing a Line Card

Use the following procedure to remove and replace line cards from the chassis:


Step 1 Attach an antistatic wrist strap to your wrist and to the ESD connection socket on the chassis, or to a bare metal surface on the chassis or frame (Figure 3-11).

Figure 3-11 ESD Chassis Connection

Step 2 Disconnect any interface cables from the line card if necessary.

Step 3 Unscrew the left and right captive screws on the line card (Figure 3-12).

Figure 3-12 Captive Screws

Step 4 Simultaneously pivot both ejector levers away from each other to disengage the line card from the midplane.

Step 5 Slide the line card out of the slot (Figure 3-13) and place it on an antistatic surface or in an antistatic bag.

Figure 3-13 Removing and Replacing the Line Card

Step 6 If you do not plan to immediately install a new line card, install a blank faceplate over the empty line card slot.


Warning Blank faceplates (filler panels) serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain electromagnetic interference (EMI) that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, power modules, and faceplates are in place.


Step 7 Grasp the faceplate of the new line card with one hand and place your other hand under the card carrier (to support the weight of the card). Position the card in front of the card cage slot.

Step 8 Carefully align the left and right edges of the line card with the guides in the chassis and slide the line card into the slot until you can feel it begin to mate with the midplane connectors.

Step 9 Simultaneously pivot both ejector levers toward each other (until they are parallel to the faceplate) to firmly seat the card in the midplane.

The line card cycles through its power-on self-test. The Fail LED stays on briefly (about 5 to 6 seconds) and then shuts off. If the Fail LED remains on or flashes, refer to the Cisco 10000 Series Troubleshooting Guide.

Step 10 Secure the line card in the chassis by tightening the left and right captive screws.


Caution To ensure that there is adequate space for additional line cards, always tighten the captive screws on each newly installed line card before you insert any additional line cards. These screws prevent accidental removal and provide proper grounding for electromagnetic interference (EMI) shielding.

Step 11 Reconnect any interface cables to the line card if necessary.

Step 12 Configure the line card if necessary. (See the Cisco 10000 Series ESR Software Configuration Guide for information about configuring the line card.)


Note It is not necessary to configure the line card if this is a replacement installation. The system automatically downloads the necessary configuration information from the PRE.



Replacing the Performance Routing Engine Module

To install or to remove and replace a PRE module:


Step 1 Attach an antistatic wrist strap to your wrist and to the ESD socket on the chassis, or to a bare metal surface on the chassis or frame (Figure 3-14).

Figure 3-14 ESD Chassis Connection

Step 2 If you are:

Removing and replacing a PRE, continue with the next step.

Installing a redundant PRE, go to Step 8.

Step 3 Disconnect any interface cables from the PRE if necessary.

Step 4 Remove the PCMCIA card from the PRE (see the "Removing and Installing a PCMCIA Flash Memory Card" section).

Step 5 Unscrew the left and right captive screws on the PRE (Figure 3-15).

Figure 3-15 Loosening the Captive Screws

Step 6 Simultaneously pivot both ejector levers away from each other to disengage the PRE from the midplane.

Step 7 Slide the PRE out of the slot (Figure 3-16) and place it on an antistatic surface or in an antistatic bag.

Figure 3-16 Removing and Replacing the PRE

Step 8 Grasp the faceplate of the new PRE with one hand and place your other hand under the card carrier (to support the weight of the module) and position the card in front of the card cage slot.

Step 9 Carefully align the left and right edges of the PRE with the left and right guides in the chassis, and slide the module into the slot until you can feel it begin to seat in the midplane connectors.

Step 10 Simultaneously pivot both ejector levers toward each other (until they are parallel to the faceplate) to firmly seat the PRE in the midplane.

The PRE cycles through its power-on self-test. The Fail LED stays on briefly (about 5 to 6 seconds) and then shuts off. If the Fail LED remains on or flashes, refer to the Cisco 10000 Series ESR Troubleshooting Guide.

Step 11 Secure the PRE in the chassis by tightening the left and right captive screws.


Caution Always tighten the captive screws on each newly installed PRE. These screws prevent accidental removal and provide proper grounding for electromagnetic interference (EMI) shielding.

Step 12 Reconnect any interface cables to the PRE if necessary.

Step 13 Install the PCMCIA card in the PRE if necessary (see the "Removing and Installing a PCMCIA Flash Memory Card" section). Be sure to secure the PCMCIA slot cover.


Caution If you do not screw down the cover of the PCMCIA slot on the PRE, the open cover exposes the unit to the risk of a harmful ESD event, and might cause electromagnetic interference (EMI) above the prescribed levels.

Step 14 Refer to the Cisco 10000 Series ESR Software Configuration Guide for information about configuring the PRE if necessary.


Note It is not necessary to configure the PRE if this is a second PRE installation for redundancy. The system automatically downloads the necessary configuration information from the primary PRE.



Removing and Installing a PCMCIA Flash Memory Card

To remove and install a PCMCIA flash memory card:


Note For information about formatting flash memory cards and disks, see the "Formatting Flash Memory Cards and Disks" section.



Step 1 Attach an antistatic wrist strap to your wrist and to the ESD socket on the chassis, or to a bare metal surface on the chassis or frame.

Step 2 Loosen the captive screw on the PCMCIA flash card cover on the PRE (Figure 3-17).

Figure 3-17 PCMCIA Flash Card Cover Captive Screws

Step 3 Lift the cover and pull the flash card up and out of its slot (Figure 3-18).

Figure 3-18 Removing the PCMCIA Flash Card

Step 4 Insert the new PCMCIA flash card into one of the card slots on the PRE (Figure 3-19).

Figure 3-19 Inserting the PCMCIA Flash Card

Step 5 Close the cover and tighten the captive screw.


Caution If you do not screw down the cover of the PCMCIA slot on the PRE, the open cover exposes the unit to the risk of a harmful ESD event, and might cause electromagnetic interference (EMI) above the prescribed levels.