Replacing Parts on the IGX

This chapter covers replacing a single card, a power supply, or a complete node.

Moving a Node

The requirements for moving a node depend on the distance involved. In all cases however, the node must be disconnected from the network by:

Removing connections (delcon).
Downing trunk lines (deltrk, dntrk)
Downing circuit lines (delcln, dncln).
Removing all data cables.
Turning off power. For DC-powered systems, do this at the building site's dedicated branch circuit breakers rather than at the PEM circuit breaker.
Removing any bolts holding the cabinet to the floor or any other structure.

The remainder of the task is the physical move of the unit. Use the pallet and box that shipped with the original packing to move the node a long distance. For shorter moves of a standalone unit, screw the feet up into the unit to expose the wheels then roll the unit.

Replacing Front Cards

This section describes how to perform a hot replacement of a front card. Read the following list before proceeding with front card replacement:

The FRM and NTM frond cards come in either a one- or two-piece version. The versions are interchangeable; nevertheless, make sure that sufficient parts are available.
Before you replace an NPM with an NPM B version, make sure that the system software supports the B version. Check the Release Note that comes with this manual to see the required version, or call the Cisco TAC through Customer Engineering. For more information, refer to the "Obtaining Technical Assistance" section.
When a system has only one NPM and you need to remove it, you should first insert the new NPM and place it in standby so that, when you remove the old NPM, the standby NPM becomes active. In this way, connections remain intact.
With one exception, any front card can be replaced without the requirement of first deleting logical connections. The exception is when the card type is changed (for example, when an HDM replaces an FRM). In this case, applicable ports are brought down and then deleted before connections are deleted with the delcon command).
Use a 5/32-in. Allen wrench to open the front door. Also, front card faceplate screws require a
No. 1 Phillips screwdriver or the Cisco combination tool (PN 218705).

Step 3 Operate the extractor handles to disconnect the card from the backplane.

Step 5 Installing a front card requires that the card be inserted into the card track and pushed firmly, but gently, into the connector on the back card (or the backplane connector if the card is an NPM).

Step 6 Hold the extractor handles in the open position until they contact the shelf supports, and then rotate them into the closed position.

Step 7 Tighten the captive screws on the card's faceplate just enough to secure the card.

Replacing Back Cards

Step 2 Verify that the SCM jumpers W5 and W6 are configured correctly for your IGX node. Remove or add jumpers if necessary.

Note SCM jumpers W5 and W6 determine the total number of cards the switch software will sense (W5 in and W6 out = IGX-8; W5 out and W6 in = IGX-16; W5 and W6 out = IGX-32). For an illustrated view of SCM jumpers W5 and W6, see the "Preparing the Cards" section 3-1.

Step 3 Verify that there are no alarms on the IGX LEDs by using the dspalms command. Clear all alarms on target node, if possible.

Step 4 Reset the standby NPM if the target IGX has CC redundancy. Allow the module to come back to standby mode.

Note Resetting the Standby NPM can take 30 minutes or longer depending on the size and complexity of the network. This activity can be completed during a maintenance window 12 hours in advance of the SCM replacement, as long as there are no provisioning or changes to the target IGX during those 12 hours.

Step 5 Use the switchcc command to verify that both NPMs can control IGX functionality.

Step 8 Disconnect all cables to the SCM. Identify and mark any cable locations before removing them.

Step 9 Loosen the captive mounting screws on the top and bottom of the IGX SCM faceplate.

Step 11 Inspect the backplane (upper portion of the IGX chassis) and the utility bus (lower portion of the IGX chassis) to verify that there are no bent pins or other defects.

Step 13 Tighten captive mounting screws on the top and bottom of the IGX SCM faceplate.

Step 14 Operate the extractor levers and slide the SCM into the cabinet. Verify that extractor levers do not get wedged behind the SCM faceplate on insertion.

Note Verify that the IGX displays no new alarms after startup. It can take 10 to 15 minutes for all the cards in the IGX to clear alarm status. Do not power the node off and on to clear alarms. If alarms do not clear, contact the Cisco TAC (see the "Obtaining Technical Assistance" section). If the IGX clears alarm state, but does not recognize the correct number of cards in the chassis, a jumper might need to be changed on the SCM. If this happens, contact the Cisco TAC to obtain the correct jumper position.

Board-Level Revision Number

The manufacturing board-level revision number, also known as the manufacturing 800 number, provides the maximum information possible about a given card. The ability to remotely identify the manufacturing board-level revision number assists in troubleshooting, maintenance, and sparing. Prior to Switch Software Release 9.3.0, there was no mechanism to remotely identify the board-level revision number without physically removing the card from the slot. Now, the board-level revision number is stored in each card's NVRAM, and the Cisco WAN switch software is able to read the board-level revision number and store it in the SNMP MIB. This project provides the capability to identify the board-level revision number through CLI, Cisco WAN Manager, or CiscoView for IGX front cards.

You can view the board revision number, also called the top assembly number, using the dspcd command. Use the dspnovram command to view NVRAM information for the interface cards. To configure NVRAM use the setnovram command. Use the cnfnpmparm command to view and configure the NVRAM information for the NPM cards. For a description of how to use these commands, refer to the Cisco WAN Switching Command Reference and the Cisco WAN Switching SuperUser Command Reference.

Replacing a DC Power Entry Module

A DC power entry module (PEM) contains few active components, so it rarely needs replacement. To replace a PEM, refer to Figure 5-1 and proceed as follows:

Step 3 Grasp the pluggable terminal block and disconnect it from the module.

Step 6 Pull the power entry module out of the power entry back card (PE-BC).

Step 7 Slide in the replacement module until it seats in the D-connector on the PE-BC.

Step 12 Re-attach the cable guard after confirming correct system operation.

Replacing an AC Power Supply

This section contains separate descriptions for replacing an AC power supply in IGX 8410,
IGX 8420, and IGX 8430 nodes.

Replacing an AC Power Supply in an IGX 8410 Node

When a power supply has failed, a red FAIL light on the SCM comes on and one or more "okay" LEDs on the power supply go off. Before replacing a power supply, check if it needs only to be reseated. The following describes first how to reseat, then how to replace, a supply.

Step 3 Grip the hinged handle on the supply, slightly pull out the supply, then reseat it. This resets the supply's internal power-monitoring circuit. See Figure 5-3 .

Step 4 Check the supply-monitoring circuit on the SCM. First, enter the command resetcd 0 at the control terminal (this resets the power supply monitor on the SCM). After waiting about 10 seconds or more, enter the dsppwr command and see if the FAIL indicator for the supply comes on. Note which power supply has failed.

Installing an AC Power Supply in an IGX 8410 Node

Step 4 Use the dsppwr command to check the status and output voltage of the replacement power supply. Make sure that the status is OK and the output voltage is 50 V ±2 V.

Replacing an AC Power Supply in an IGX 8420 or IGX 8430 Node

When a power supply has failed, a red FAIL light on the SCM comes on. Before replacing a power supply, check to see if it needs only to be reseated. The following steps describe how to reseat a supply then how to replace it.

Step 3 Rotate the screwdriver to release the spring latch holding the air intake grille (see "Release" in Figure 5-4).

Step 4 Tilt the air inlet grille down to approximately a 45\xb0 angle, then lift if out and set it aside. This exposes the power supply retainer bracket (a hinged door).

Step 5 With a flat-bladed screwdriver, unscrew the retainer screw in the center of the hinged door and tilt the door down.

Step 6 Identify which power supply needs replacement. The power supply lettering begins with A on the far left and continues through F on the far right.

Step 7 Loosen the captive screw at the front bottom of the power supply. See Figure 5-5.

Step 8 Move the supply slightly out, then reseat it and tighten the captive screw. This resets the supply's internal power-monitoring circuit.

Step 9 Check the supply-monitoring circuit on the SCM. First, enter the resetcd 0 command at the control terminal (this resets the power supply monitor on the SCM). After waiting about 10 seconds or more, enter the dsppwr command and see if the FAIL indicator for the supply comes on again. Note which power supply has failed.

Step 10 Loosen the captive screw that secures a supply to the power supply tray.

Step 11 Pull out the power supply with one hand on the handle and one hand under the supply.

Installing an AC Power Supply in an IGX 8420 or IGX 8430 Node

Step 4 Install the air intake grille and press firmly on the top, then center, of the air intake grille until the latch snaps into place.

Step 5 Use the dsppwr command to check the status and output voltage of the power supply. Make sure that the status is OK and that the output voltage is 50 V ±2 V.

Replacing a Fan Assembly

This section contains separate descriptions for replacing the cooling units in IGX 8410 and
IGX 8420 or IGX 8430 nodes.

Replacing a Fan Assembly in an IGX 8410 Node

The fan assembly resides below the card cage and has four fans. Individual fans cannot be replaced, so the whole assembly must be replaced when a failure occurs. See Figure 5-6.

Cooling fan trays are hot-swappable. However, the operation must proceed swiftly to keep the system cool enough. Otherwise, the system power must be off. Having the replacement fan tray and tools in the immediate vicinity of the system helps ensure that the procedure goes quickly. The required tools are a flat-blade screwdriver and a Phillips screwdriver.

Step 2 Remove the air intake grille at the front of the system by operating the toggle latch at the top-center of the grille with a screwdriver, tilting the grille forward, and lifting it out.

Step 3 Examine the front and back of the fan tray to be familiar with the setup. Note the power connectors attached to the fan tray: the connectors at the fan tray itself are to be disconnected rather than the D-connector at the PE-BC. Also note that the captive screws that hold the fan tray in place are at the front of the fan tray.

Step 5 At the back of the IGX 8410 node, remove the clamp that secures the power cable for the fans to the chassis.

Step 6 Use a small screw driver or fingertip in this step. For each of the fan power connectors, press in the small plastic latch that locks the connector halves together. With the other hand, grip the part of the connector that is attached to the fan tray and separate the cord from the fan tray. The fan tray now has no power.

Step 7 Push a finger or thumb through the square holes in the chassis to start the fan tray toward the front of the system. Go to the front of the system.

Replacing a Fan Assembly in IGX 8420 or IGX 8430 Nodes

An IGX node contains either one or two cooling units. In an IGX 8420 node, the single cooling unit resides immediately below the card cage. In an IGX 8430 node, one unit resides below the lower card cage (Fan Tray 1). The booster unit (Fan Tray 2) resides above the upper card cage. If a fan failure occurs, the whole assembly must be replaced.

Fan trays are hot-swappable. However, the swap must go swiftly to keep the system cool. Replacement must take less than two minutes, and this is relatively easy. Otherwise, system power must be off. In an IGX 8430 node, the fan tray that remains while the other tray is out helps keep the system cool. Have the replacement fan tray and tools nearby to help the swap go quickly. The required tools are a flat-blade screwdriver and Phillips screwdriver.

Step 2 For the bottom fan tray, remove the air intake grille at the front of the system by turning the internal screw at the top center of the grille a quarter turn, tilting the grille forward, and lifting it out. (Fan tray 2 at the upper end of an IGX 8430 node does not have an air intake grille.)

Step 3 Examine the front and back of the fan tray to be familiar with the setup. Note the power connectors attached to the fan tray. The connectors at the fan tray itself are to be disconnected rather than the D connector at the PE-BC. Also note that the captive screws that hold the fan tray in place are at the front of the bottom fan tray (fan tray 1) and at the back of the booster fan tray (fan tray 2) in an IGX 8430 node.

Step 5 At the back of the IGX node, remove the clamp that secures the power cable for the fans to the chassis.

Step 6 Use a small screwdriver or fingertip in this step. For each of the fan power connectors, press in the small plastic latch that locks the connector halves together. With the other hand, grip the part of the connector that is attached to the fan tray and separate the cord from the fan tray. The fan tray now has no power.

Step 7 Push a finger or thumb through the square holes in the chassis to ease the fan tray towards the front of the system. Go to the front of the system.

Step 9 Plug the power connectors into the fan tray. Make sure that plug P1 connects to connector P1, and plug P2 connects to connector P2.

Step 11 Use the dsppwr command to see if system software recognizes correct operation.

Backplane Fuses

Backplane fuses rarely, if ever, need replacement. Backplane fuses are intended to prevent catastrophic damage to the backplane in the event of accidental shorting of -48 VDC on the backplane to chassis ground. This type of event could be caused by bent backplane pins, contact of conductive elements (EMI cans, EMI gaskets, and so on) to power pins. These events would most likely happen during a factory build or initial system installation.

Because of design constraints, these fuses need to be in sockets on the backplane and are, therefore, not readily accessible. A special tool (Cisco P/N 218090-00) and set of instructions are required for fuse replacement. Cisco recommends that only factory-trained personnel do the procedure.

In the IGX 8410 node, backplane fuses exist only on the back of the backplane. In an IGX 8420 or
IGX 8430 node, the location of the fuse depends on the version of the backplane. In older
IGX 8420 or IGX 8430 backplanes, the fuses reside on the front. Figure 5-8 shows the location of each fuse in an IGX 8410 backplane. The fuse numbers are F1-F8. Two spare fuses are also present. Figure 5-9 and Figure 5-10 show current and early backplane fuse locations in the IGX 8420 backplane.

Where to Go Next

For more information on switch software commands, refer to the Cisco WAN Switching Command Reference, Chapter 1, "Command Line Fundamentals ."

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