Cisco 6400 User manual

CHAPTER
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5
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 on page xiv.
Note The illustrations in this guide depict the original Cisco 6400 chassis. Your chassis may appear or look
slightly different.
Contents
This document includes the following sections:
•Tools and Equipment Required, page 5-2
•General Safety Precautions and Maintenance Guidelines, page 5-2
•Cisco 6400 System Components—Front View, page 5-5
•Replacing the Front Cover, page 5-5
•Powering Down the System, page 5-8
•Backing Up the PCMCIA Card, page 5-9
•Maintaining the Air Filter, page 5-9
•Replacing an NSP Module, page 5-11
•Replacing an NRP Module, page 5-18
•Installing or Replacing a Half-Height Node Line Card, page 5-28
•Installing or Replacing a Full-Height Node Line Card, page 5-36
•Replacing a DC Power Entry Module, page 5-41

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Chapter 5 Maintaining the Cisco 6400
Tools and Equipment Required
•Replacing an AC Power Entry Module, page 5-44
•Replacing the Blower Module, page 5-47
•Verifying Plug-In Module and Component Installation, page 5-51
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 on page xiv.
•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.

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Chapter 5 Maintaining the Cisco 6400 General Safety Precautions and Maintenance Guidelines
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
Warning Statement for Finland
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.
Varning!
Osynlig laserstrålning när denna del är öppen och förregleringen är urkopplad. Rikta inte blicken
in mot strålen.
Varoitus
Alleviates ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Äjä katso
säteeseen.

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Chapter 5 Maintaining the Cisco 6400
General Safety Precautions and Maintenance Guidelines
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.
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Whenhot swapping this fan tray,
removaland replacement must
bedone in under two minutes or
systemshutdown will occur.
CAUTION
PCMCIA
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Chapter 5 Maintaining the Cisco 6400 Cisco 6400 System Component Identification
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.
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When hot swapping this fan tray,
removal and replacement must
be done in under two minutes or
system shutdown will occur.
CAUTION
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Slot 2 Slot 0A Slot 0B
Slot 3 Slot 5
Slot 6
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Chapter 5 Maintaining the Cisco 6400
Replacing the Front Cover
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.
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Chapter 5 Maintaining the Cisco 6400 Replacing the Front Cover
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
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When hot swapping this fan tray,
removal and replacement must
be done in under two minutes or
system shutdown will occur.
CAUTION
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Chapter 5 Maintaining the Cisco 6400
Powering Down the System
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).
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Chapter 5 Maintaining the Cisco 6400 Backing Up the PCMCIA Card
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."
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Chapter 5 Maintaining the Cisco 6400
Maintaining 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.)
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When hot swapping this fan tray,
removal and replacement must
be done in under two minutes or
system shutdown will occur.
CAUTION
PCMCIA
Slot 1
Slot 0
ACO
CRITICAL
MAJOR
MINOR
ALARMS
STATUS
FAIL
30257