Maintaining the Cisco 6400

This chapter provides maintenance information for the Cisco 6400 carrier-class broadband aggregator. All cards, modules, and components support online insertion and removal (often referred to as hot-swapping). Hot-swapping allows you to remove, replace, and rearrange cards without turning off the system power. When the system detects that a card or module is added or removed, it automatically runs diagnostic and discovery routines, acknowledges the presence or absence of the card or module, and resumes system operation without any operator intervention.

Note If you are a network administrator and need personal technical assistance with a Cisco product that is under warranty or covered by a maintenance contract, refer to the "Obtaining Technical Assistance" section.

Note The illustrations in this guide depict the original Cisco 6400 chassis. Your chassis may appear or look slightly different.

This document includes the following sections:

Tools and Equipment Required

You need the following tools and equipment to remove and replace modules. If you need additional equipment, see the "Obtaining Technical Assistance" section.

One number 2 Phillips screwdriver and one flat-blade screwdriver
Electrostatic discharge (ESD) grounding strap (disposable ESD strap provided with system)

General Safety Precautions and Maintenance Guidelines

General Safety Precautions

ESD, EMI, and Safety Precautions

Caution Static voltages as low as 30 volts can cause latent damage to circuitry. Be sure to observe all standard anti-static procedures (for example, wear a grounding strap) when handling electronic equipment and components.

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 and faceplates are in place. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Laser Safety Precautions

Warning Class 1 laser product. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Because invisible radiation may be emitted from the aperture of the port when no fiber cable is connected, avoid exposure to radiation and do not stare into open apertures. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Invisible laser radiation present. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Statement for Sweden


Varning!	Osynlig laserstrålning när denna del är öppen och förregleringen är urkopplad. Rikta inte blicken in mot strålen.

Warning Statement for Finland


Varoitus	Alleviates ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Äjä katso säteeseen.

Lifting and Reaching Safety Precautions

Warning To prevent personal injury or damage to the chassis, never attempt to lift or tilt the chassis using the handles on modules (such as power supplies, fans, or cards); these types of handles are not designed to support the weight of the unit. Lift the unit only by using handles that are an integral part of the chassis, or by grasping the chassis underneath its lower edge. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Two people are required to lift the chassis. To prevent injury, keep your back straight and lift with your legs, not your back. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Figure 5-1 shows the proper way to lift the Cisco 6400 chassis.

Figure 5-1 Lifting the Cisco 6400 Chassis

Hot-Swapping Modules and Line Cards

The Cisco 6400 system has a hot-swap feature that allows you to install and remove modules andline cards while the system is operating. With hot swapping, you do not need to power down the system.

When unconfigured node line cards (NLCs) are installed for the first time, the system identifies them as present but unconfigured. Read the instructions for initial interface configurations in the Cisco 6400 Software Setup Guide.

If a card or module similar to the one that was removed is reinserted into a slot, the Cisco 6400 automatically configures its ports and brings it online up to the port count of the original card.

Note You must administratively shut down the card or module; otherwise alarms are activated.

Caution To avoid erroneous failure messages, allow at least 15 seconds for the system to reinitialize. Note the current configuration of all interfaces before you remove or insert another card.

Plug-In Module or Card Replacement Suggestions

The following are examples of recommended module and card insertion practices:

Do not force the faceplate into its slot. This action can damage the pins on the backplane if they are not aligned properly with the module or card.
Fully depress the ejector levers to ensure that the card connector mates with the backplane correctly. Ensure that the card or module is firmly seated in the slot.
Use the installation screws (top and bottom of carrier) to secure the module or card firmly in place in the chassis.

Note Any module that is only partially connected to the backplane can disrupt system operation.

Cisco 6400 System Component Identification

Figure 5-2 identifies the major components of the Cisco 6400 system. Card slots 1 through 8 can contain a combination of node route processor (NRP) and node line card (NLC) modules; only node switch processor (NSP) modules can be inserted into card slots 0A and 0B.

Figure 5-2 Cisco 6400 System Components—Front View

Replacing the Front Cover

Note The Cisco 6400 no longer ships with the plastic front cover that was included in shipments made before June 2002. This section covering removal and replacement procedures is included only for reference purposes.

Removing the Front Cover

To remove the front cover, first remove the bezel plugs:

Step 1 Insert the tip of a flat-blade screwdriver into the indentation between the top and bottom of the plug.

Step 2 Rotate the screwdriver blade 90 degrees, pushing out the top of the plug (Figure 5-3).

Step 3 Remove the plug with your fingers.

Step 4 Then firmly grasp the cover with both hands, lift upward as far as possible (about one inch), and pull forward.

Figure 5-3 Removing Bezel Plugs

Note The cover is secured by four posts. Avoid bending or twisting cables and connectors.

Installing the Front Cover

To install the front cover:

Step 1 Line up the hole in each corner of the cover with the four posts on the chassis (Figure 5-4).

Step 2 Gently but firmly push the cover onto the posts and slide downward to secure.

Step 3 Insert one of the bezel plugs into a corner hole, below the post.

Step 4 When the plug is lined up in the hole (Figure 5-5), use your thumb to gently but firmly press on the top of the plug until the top collapses against the bottom.

Step 5 Repeat Steps 3 and 4 for the remaining three corners. Avoid bending or twisting cables and connectors.

Figure 5-4 Installing the Front Cover

Figure 5-5 Installing Bezel Plugs

Powering Down the System

To power down the Cisco 6400 system:

Step 1 Notify appropriate personnel that you plan to shut down the Cisco 6400 system and that this will result in total loss of service. Appropriate personnel includes the regional alarm or network monitoring center, central office personnel, and key customers.

Step 2 Before shutting down the Cisco 6400, use the copy command to save any configuration changes to NVRAM and also to a PCMCIA card. (Refer to the Cisco 6400 Command Reference for instructions on using the copy command.)

Step 3 Complete all copy or write operations involving Flash media (PCMCIA slots or boot Flash) before you power down the Cisco 6400.

Step 4 To power down the Cisco 6400, turn off the switch on all PEMs (your system can be configured with one or two PEMs).

Backing Up the PCMCIA Card

We recommend that you create a duplicate PCMCIA card that contains the current boot software image and the current software configuration. You can use the duplicate to recover from a major system failure with less disruption. If you have a backup PCMCIA card, you can use that card to load a new node switch processor (NSP) module and avoid a time-consuming reconfiguration process. For instructions on creating a backup PCMCIA card, refer to Cisco 6400 Software Setup Guide.

Maintaining the Air Filter

The Cisco 6400 automatically powers down if the system overheats. If the blower module's air filters are too dirty or clogged, the system might have insufficient air flow and might overheat.

You should replace the Cisco 6400 air filters every six months. In certain environments, you might have to replace the air filter more frequently.

Removing the Air Filter

The Cisco 6400 ships with either a screw-type or tab-type air filter.

To remove a tab-type air filter, press the release tabs on each side of the chassis to release the air filter and slide it out of the chassis. (See Figure 5-6.)

Figure 5-6 Tab-type Air Filter Release Tabs

To remove a screw-type air filter, refer to Figure 5-7 and perform the following steps.

Step 1 Locate the filter tray at the bottom front of the chassis, below the plug-in modules. Use a number 2 Phillips screwdriver to unlock the filter tray.

Step 2 Gently pull the filter toward you to remove it from the chassis.

Step 3 If you are replacing the filter, discard the old filter and go to the section "Replacing the Air Filter."

Figure 5-7 Removing a Screw-type Air FIlter from the Chassis

Replacing the Air Filter

The Cisco 6400 ships with either a screw-type or tab-type air filter.

To install a new tab-type air filter, slide the new filter all the way into the chassis and lift it up until it snaps into place. The directional arrows located on the metal frame of the filter should be pointing up. (See Figure 5-8.)

Figure 5-8 Inserting a Tab-Type Air Filter

To install a new screw-type air filter, refer to Figure 5-7 and perform the following steps:

Step 1 Hold the air filter with the arrows (located on the metal frame) facing up.

Step 2 Slide the air filter into the bottom tray of the chassis.

Step 3 Secure the tray by tightening the retaining screws.

Replacing an NSP Module

The Cisco 6400 can contain one or two NSP modules, which are located in slots 0A and 0B (in the middle of the chassis). Figure 5-9 shows the NSP faceplate.

Figure 5-9 NSP Faceplate

Caution Removing an active NSP in a redundant configuration causes a switchover. Removing an active NSP in a nonredundant configuration causes a system shutdown.

Removing the NSP Module

To remove an NSP module:

Step 1 Attach a ground strap to your wrist.

Step 2 Unscrew the upper and lower retaining screws.

Step 3 Disconnect any cables connected to the NSP module that you are about to remove.

Step 4 Grasp the upper and lower extraction levers. Pull up on the upper lever while pushing down on the lower lever. This action disengages the module from the connectors on the backplane.

Step 5 Slide the NSP module out of the slot.

Step 6 Place the NSP module on an antistatic surface. If the module will be out of the chassis for several minutes or longer, put it in a static-shielding bag or in a box lined with antistatic material.

Step 7 Install another NSP module or a blank faceplate in the empty slot.

Warning Blank faceplates (filler panels) serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they reduce 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 and faceplates are in place. Translations of this warning can be found in the Regulatory Compliance and Safety Information document that accompanied this device.

Installing the NSP Module

The NSP module can be inserted only in slot 0A or 0B. To install an NSP module in the Cisco 6400 chassis:

Step 1 Remove the blank filler panel from the selected slot, if a blank panel is present.

Step 2 Hold the NSP module vertically, with the NSP faceplate toward you and the backplane connectors away from you. Ensure that the module is right side up by noting the lettering on the faceplate.

Step 3 Carefully align the upper and lower edges of the NSP carrier with the upper and lower guides in the chassis (Figure 5-10).

Figure 5-10 Inserting an NSP into the Chassis

Caution To ensure that the NSP module mates properly with all backplane connector pins, the card length and card slots have been designed with very close tolerances. To slide the module into the slot requires gentle pressure with each hand, at the top and bottom of the faceplate.

Step 4 Gently slide the module into the slot until it makes contact with the backplane.

Step 5 Press the upper lever down and the lower lever up at the same time.

Step 6 Secure the card by tightening the upper and lower retaining screws.

Step 7 Connect the cables.

Step 8 Pull the cables across the wire restraint and bend the restraint upward to trap the cables (Figure 5-11).

Figure 5-11 Wire Restraint on the NSP

Step 9 Route the cables through the cable management bracket, creating a 20-inch (or larger) service loop (Figure 5-12).

Note A minimum 20-inch loop is critical to hot swapping the blower.

Figure 5-12 Routing the NSP Cables Through the Cable Management Bracket

Step 10 Install blank filler panels to cover any unused slots. Like cards and modules, each filler panel is held in place by two retaining screws.

Replacing an NSP Module PCMCIA Card

There are two PCMCIA slots in the NSP module. To replace a PCMCIA card:

Step 1 Unscrew the locking fastener on the bottom of the PCMCIA slot cover.

Step 2 Lift the cover and press the eject button on the PCMCIA slot for the card you are removing. The card ejects.

Step 3 Remove the PCMCIA card and insert the new card. Push firmly to seat the new PCMCIA card.

Step 4 Close the cover and tighten the locking fastener.

Note If you seat a PCMCIA Type II card in Slot 0, you cannot use Slot 1. However, if you seat a Type I card in Slot 0, you can insert either a Type I or Type II card in Slot 1.

Replacing an NSP Module SIMM

General SIMM Information

SIMMs are sensitive components that are susceptible to ESD damage. Handle SIMMs by the edges only; avoid touching the memory modules, pins, or traces (the metal fingers along the connector edge of the SIMM).

Caution To upgrade DRAM, you must install identical SIMMs in both DRAM SIMM connectors.

The default DRAM configuration is 64 MB, contained in two 32-MB SIMMs. The DRAM can be increased to 128 MB by adding two more 32-MB SIMMs. The amount of DRAM required on the NSP module is determined by the number of active physical and logical ports (virtual path tunnels) and the expected number of active switched virtual channels (SVCs) through the switch.

In a 64-MB DRAM configuration, the two accessible SIMM sockets (U51 and U63) are empty. To upgrade to 128-MB DRAM, youmust purchase an upgrade kit from Cisco and insert the SIMMs into the two empty sockets.

Note You must use SIMMs obtained from Cisco Systems.

Removing NSP Module SIMMs

To remove the existing SIMMs:

Step 1 Attach an ESD-preventive wrist strap between you and an unpainted chassis surface.

Step 2 Disconnect the console and auxiliary cables from the NSP module.

Step 3 Loosen the captive installation screws on the NSP module.

Step 4 Place the NSP on an antistatic mat or pad. Position the NSP so that the faceplate is away from you and the edge connector is toward you.

Step 5 Locate the SIMMs. The DRAM SIMMs occupy sockets U51 and U63 (Figure 5-13).

Figure 5-13 Removing an NSP SIMM Module

Step 6 Release the spring clips from the SIMM that you wish to remove and lift the SIMM from the socket (Figure 5-13).

Step 7 When both ends of the SIMM are released from the socket, use your thumb and forefinger to grasp the ends of the SIMM and pull the SIMM completely out of the socket. Handle the edges of the SIMM only; avoid touching the memory module, pins, or metal traces (fingers) along the socket edge.

Step 8 Place the SIMM in an antistatic bag to protect it from ESD damage.

Step 9 Repeat steps 5 through 8 for the remaining SIMMs, as required for your upgrade.

Installing an NSP SIMM Module

To replace a SIMM module:

Step 1 Keep the NSP in the same orientation as in the previous procedure (with the handle facing away and the edge connector toward you).

Step 2 Remove a new SIMM from the antistatic bag.

Caution Handle SIMMs by the card edges only. SIMMs are sensitive components that can short out if mishandled.

Step 3 Hold the SIMM component side up with the connector edge (the metal fingers) closest to you.

Step 4 Hold the sides of the SIMM between your thumb and middle finger, with your forefinger against the far edge, opposite the connector edge (Figure 5-13).

Step 5 Tilt the SIMM to approximately the same angle as the socket, and insert the entire connector edge into the socket. Insert the first SIMM in the socket farther from you.

Caution When inserting SIMMs, use firm but not excessive pressure. If you damage a socket, you must return the NSP to the factory for repair.

Step 6 Gently push the SIMM into the socket until the spring clips snap over the ends of the SIMM. If necessary, rock the SIMM gently back and forth to seat it properly.

Step 7 Repeat Steps 2 through 6 for the remaining SIMM. Insert the second SIMM in the socket closer to you.

Step 8 When both SIMMs are replaced, check all four alignment holes (two on each SIMM) and ensure that each spring retainer is visible. If it is not, the SIMM is not seated properly. If a SIMM appears misaligned, carefully remove it and reseat it in the socket. Push the SIMM firmly back into the socket until the retainer springs snap into place.

Verifying SIMM Operation

If the system fails to boot properly, or if the console terminal displays a checksum or memory error, check the following:

Ensure that all SIMMs are installed correctly. Check the SIMMs by looking straight down on them and then observe them at eye level. The SIMMs should both be aligned at the same angle and should be at the same height. If one SIMM appears to stick out or rests in the socket at an angle different from the other, remove the SIMM and reinsert it. Replace the NSP and reboot the system for another installation check.
Each DRAM SIMM bank must contain SIMMs of the same size and speed, or the system does not operate. Contact Cisco Systems to order the NSP DRAM upgrade package. Other vendors' parts might not work properly. (To contact Cisco Systems, see the "Obtaining Technical Assistance" section.)

If the system fails to restart properly after several attempts, contact a service representative for assistance. Before you contact Cisco Systems, make note of any error messages, unusual LED states, or any other indications that might help identify the problem.

Replacing an NRP Module

NRP modules can be installed in slots 1 through 8 in the Cisco 6400 chassis. The procedure for replacing an NRP module is basically the same for the NRP-1 and NRP-2SV modules. The only difference is that for the NRP-1, the attached cables are directed up to wire restraints; and for the NRP-2SV, the cable is directed down to cable management brackets. This is clarified in Step 8 in the "Installing an NRP-2SV Module" section.

Removing an NRP Module

To remove an NRP module from the Cisco 6400 chassis:

Step 1 Attach an ESD-preventive wrist strap.

Step 2 Disconnect any cables connected to the NRP module that you are about to remove.

Step 3 Unfasten the upper and lower retaining screws.

Step 4 Grasp the upper and lower extraction levers. Pull up on the upper lever while pushing down on the lower lever. This action disengages the NRP carrier from the connectors on the backplane.

Step 5 Slide the module out of the slot.

Step 6 Place the NRP module on an antistatic surface. If it will be out of the chassis for several minutes or longer, put it in a static-shielding bag or in a box lined with antistatic material.

Step 7 Insert another NRP module or a blank faceplate in the empty slot.

Warning Blank faceplates (filler panels) serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they reduce 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 and faceplates are in place. To see translations of this warning, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Installing an NRP-2SV Module

To install an NRP-2SV module in the Cisco 6400 chassis:

Step 1 Remove the blank filler panel from the selected slot if a blank panel is present.

Step 2 Hold the NRP-2SV module vertically with the NRP-2SV faceplate toward you and the backplane connectors away from you. Ensure that the module is right side up by noting the lettering on the faceplate.

Step 3 Carefully align the upper and lower edges of the NRP-2SV carrier with the upper and lower guides in the chassis. See Figure 5-14 for an example of inserting an NRP-2SV module in the chassis.

Figure 5-14 Inserting an NRP-2SV into the Chassis

The following warnings apply to the NRP-2SV module.

Warning Class 1 laser product. To see translations of this warning, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Because invisible radiation may be emitted from the aperture of the port when no fiber cable is connected, avoid exposure to radiation and do not stare into open apertures. To see translations of this warning, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Warning Invisible laser radiation present. To see translations of this warning, refer to the Regulatory Compliance and Safety Information document that accompanied this device.