Curtiss-Wright DuraMAR 5915 User manual

USER MANUAL
DuraMAR 5915
Rugged Cisco 5915 Mobile IP Router Subsystem
MAR-5915-0x and MAR-5915-1x
MNL-0596-01 Rev A6 ECO-5813 Effective: 25 Apr 19

DuraMAR 5915 User Manual
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Disclaimer
Although the information contained herein has been carefully verified, Curtiss-Wright Corporation assumes no responsibility for
errors that might appear in this document or for damage to property or persons resulting from improper use of this manual or related
software. Curtiss-Wright reserves the right to change the contents and form of this document, as well as the features and
specifications of its products, at any time without notice. The information in this publication does not represent a commitment on the
part of Curtiss-Wright. This document contains proprietary information that is protected by copyright. All rights are reserved. No part
of this document may be photocopied, reproduced, or translated into another language without the prior written consent of Curtiss-
Wright.
Contact Information
Curtiss-Wright Corporation
3222 S. Washington St.
Salt Lake City, Utah, USA 84115
Phone: [phone]
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Email:
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Trademarks
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All trademarks, both marked and not marked, appearing in this document are the property of their respective owners.
Copyright
© 2019 Curtiss-Wright Corporation
WEEE
The information below is issued in compliance with the regulations as set out by the 2002/96/CE directive, subsequently superseded
by 2003/108/CE. It refers to electrical and electronic equipment and the waste management of such products. When disposing of a
device, including all of its components, subassemblies, and materials that are an integral part of the product, you should consider
the WEEE directive.
This symbol has been attached to the equipment or, if that was not possible, on the packaging,
instruction literature, and/or the guarantee sheet. Using this symbol states that the device has been
marketed after August 13th 2005, and implies that you must separate all of its components when
possible, and dispose of them in accordance with local waste disposal legislation.
Because of the substances present in the equipment, an improper use or disposal of the refuse can cause damage to human
health and to the environment.
With reference to WEEE, it is compulsory not to dispose of the equipment with normal urban refuse. Arrangements should be
instigated for separate collection and disposal.
Contact your local waste collection body for more detailed recycling information.
In case of illicit disposal, sanctions may be levied on transgressors.
RoHS
This device, including all its components, subassemblies, and the consumable materials that are an integral part of the product, has
been manufactured in compliance with the European directive 2002/95/EC known as the RoHS directive (Restrictions on the use of
certain Hazardous Substances). This directive targets the reduction of certain hazardous substances previously used in electrical
and electronic equipment (EEE).

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Table of Contents
Chapter 1 Introduction............................................................................................................7
About This Document....................................................................................................................................7
Manual Organization ..............................................................................................................................7
Description of Safety Symbols................................................................................................................8
Overview .......................................................................................................................................................9
Features................................................................................................................................................10
Cisco Technology...........................................................................................................................10
Scalability.......................................................................................................................................10
Ruggedization ................................................................................................................................10
Functional Description.................................................................................................................................11
Configurations.......................................................................................................................................11
Base Module.........................................................................................................................................11
Expansion Modules ..............................................................................................................................12
Cisco 5915 Router................................................................................................................................12
Parvus Power Supply ...........................................................................................................................13
Chapter 2 Operating Description.........................................................................................14
Cable and Connector Identification.............................................................................................................14
Starter Cableset for Base Module ........................................................................................................14
Base Module Connectors and LEDs ....................................................................................................15
Mounting the System............................................................................................................................16
Basic Operating Procedures.......................................................................................................................16
Starting the Cisco Console...................................................................................................................16
Zeroization............................................................................................................................................17
Enabling Zeroization in Cisco 5915 IOS ........................................................................................17
Initiating Zeroization.......................................................................................................................17
Zeroization Recovery .....................................................................................................................17
Loading Cisco Files.....................................................................................................................................18
Command Conventions........................................................................................................................18
Loading the IOS Image After Zeroization.............................................................................................18
Host PC Setup ...............................................................................................................................18
Load Procedure..............................................................................................................................18
Loading the IOS Configuration After Zeroization..................................................................................19
Upgrading to a New IOS Image............................................................................................................20
Host PC Setup ...............................................................................................................................20
Upgrade Procedure........................................................................................................................20
Chapter 3 Connector Descriptions ......................................................................................21
Connector Identification........................................................................................................................21
J1 Power Connector Pinouts................................................................................................................21
J2 Ethernet 0 Connector Pinouts..........................................................................................................22
5915-0x Ethernet Connector Pinout...............................................................................................22
5915-1x Connector Pinout .............................................................................................................23
J3 Console Connector Pinouts.............................................................................................................24
Chapter 4 Specifications ......................................................................................................25
Chassis........................................................................................................................................................25
Physical Specifications.........................................................................................................................25
Dimensions...........................................................................................................................................25

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Standalone Router Dimensions .....................................................................................................26
Router with Expansion Module Dimensions ..................................................................................29
Mounting Instructions ...........................................................................................................................33
5915 Router Specifications.........................................................................................................................34
Cisco Technology.................................................................................................................................34
Ports .....................................................................................................................................................34
Management and Monitoring................................................................................................................34
Voice Support.......................................................................................................................................34
Routing/Bridging...................................................................................................................................34
Security.................................................................................................................................................35
Information Assurance..........................................................................................................................35
QoS.......................................................................................................................................................35
Status Indication...................................................................................................................................35
Power....................................................................................................................................................35
Environmental.......................................................................................................................................36
EMI/EMC ..............................................................................................................................................36
Reliability ..............................................................................................................................................36
Chapter 5 Troubleshooting ..................................................................................................37
Product Identification...................................................................................................................................37
Technical Assistance ..................................................................................................................................37
Returning for Service ..................................................................................................................................37
Chapter 6 Contact Info..........................................................................................................38
Expansion Module....................................................................................................... 39
Addendum A: Gigabit Ethernet Switches ................................................................ 39
A1 Introduction .....................................................................................................................40
About This Document..................................................................................................................................40
COM-1268 Manuals .............................................................................................................................40
Addendum Organization.......................................................................................................................40
Overview .....................................................................................................................................................41
Features................................................................................................................................................41
Scalability.......................................................................................................................................41
Ruggedization ................................................................................................................................41
Functional Description.................................................................................................................................42
Configurations.......................................................................................................................................42
Block Diagram ......................................................................................................................................42
Internal Ethernet Connections..............................................................................................................43
A2 Operational Description..................................................................................................44
Cables and Connectors...............................................................................................................................44
1268 EM Starter Cableset ....................................................................................................................44
COM-1268 EM Connectors and LEDs .................................................................................................45
Basic Operating Procedures.......................................................................................................................46
Console Session Setup ........................................................................................................................46
Zeroization............................................................................................................................................46
Initiating Zeroization.......................................................................................................................46
Zeroization Recovery .....................................................................................................................46

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A3 Connector Descriptions..................................................................................................47
Connector Identification........................................................................................................................47
COM-1268 Port Numbers.....................................................................................................................47
J4 Ethernet 1 Connector Pinouts..........................................................................................................48
J5 Ethernet 2 Connector Pinouts..........................................................................................................50
A4 Specifications..................................................................................................................52
Physical Specifications................................................................................................................................52
Size.......................................................................................................................................................52
Power....................................................................................................................................................52
Status Indication...................................................................................................................................52
Ports .....................................................................................................................................................52
Technical Specifications..............................................................................................................................52
Switching Architecture..........................................................................................................................52
Port Features........................................................................................................................................53
Management and Monitoring................................................................................................................53
Declassification.....................................................................................................................................53
Protocol Standards......................................................................................................................................54

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List of Figures
Figure 1. Standalone Router (MAR-5915-0x)..............................................................................................9
Figure 2. Router with Expansion Module (MAR-5915-1x)...........................................................................9
Figure 3. Standalone Router Block Diagram .............................................................................................11
Figure 4. Router with Expansion Module Block Diagram (example) .........................................................12
Figure 5. Base Module Starter Cableset (CBL-5915-00)...........................................................................14
Figure 6. Base Module Connectors and LEDs...........................................................................................15
Figure 7. J2 LED Mapping to J2 Signal Name and Cisco Port Name .......................................................15
Figure 8. Connector J1 Power ...................................................................................................................21
Figure 9. Connector J2 Ethernet 0.............................................................................................................22
Figure 10. Connector J3 Console ..............................................................................................................24
Figure 11. Standalone Router Angle View.................................................................................................26
Figure 12. Standalone Router Front View..................................................................................................26
Figure 13. Standalone Router Top View....................................................................................................27
Figure 14. Standalone Router Side View...................................................................................................28
Figure 15. Router with EM Angle View ......................................................................................................29
Figure 16. Router with EM Front View.......................................................................................................30
Figure 17. Router with EM Top View .........................................................................................................31
Figure 18. Router with EM Side View ........................................................................................................32
Figure 19. Standalone Router Side Boss Mounting...................................................................................33
Figure 20. Router with Expansion Module Side Boss Mounting................................................................33
Figure 21. Router Back View Showing Optional Grounding Boss Location ..............................................33
Figure 22. MAR-5915-1x with Integrated COM-1268 EM..........................................................................41
Figure 23. Router with COM-1268 EM Block Diagram..............................................................................42
Figure 24. 1268 EM Internal Connections .................................................................................................43
Figure 25. 1268 EM Starter Cableset (CBL-5915-01) ...............................................................................44
Figure 26. COM-1268 EM Connectors and LEDs......................................................................................45
Figure 27. Connector J4 Ethernet 1...........................................................................................................48
Figure 28. Connector J5 Ethernet 2...........................................................................................................50

DuraMAR 5915 User Manual
Chapter 1 Introduction
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Chapter 1 Introduction
The DuraMAR® 5915 is a rugged Commercial-Off the Shelf (COTS) Cisco IOS-managed mobile router
integrated with Cisco’s 5915 Embedded Services Router (ESR) card in an ultra-rugged chassis optimized
for harsh military and civil vehicle/aircraft installations. The DuraMAR 5915 has configurations as a
standalone 5-port network router (-0x) or with the Parvus Dual Gigabit Ethernet Switches (COM-1268s)
expansion module integrated into a common chassis (-1x). For details, contact the Parvus Sales
department.
About This Document
This manual provides a functional description of the DuraMAR 5915, both as a standalone Cisco 5915
router and with integrated switch modules.
Note: This manual is not a comprehensive guide to the Cisco 5915 or IOS. That information is
available directly from Cisco Systems at www.cisco.com.
Manual Organization
Chapters 1 through 6, the base manual, cover the MAR-5915-0x base router, which includes the Cisco
5915, chassis, and Parvus power supply.
Chapter 1 provides a functional description of the DuraMAR 5915, and explains how expansion
modules are integrated with the Cisco 5915 in a common chassis.
Chapter 2 explains how to operate the base router. It describes the cables, connectors, and
LEDs, and includes procedures for starting the Cisco console, performing zeroization, and
loading Cisco files.
Chapter 3 contains connector pinouts for the base module.
Chapter 4 provides chassis specifications, dimensions, and mounting instructions for all
DuraMAR 5915 modules. In addition, it provides the specifications for the Cisco 5915 router.
Chapters 5 and 6 provide troubleshooting and Parvus contact information, and apply to all
DuraMAR 5915 modules.
Each expansion module (EM) is described in a separate addendum that follows the same general
organization as the base manual. Chapters in the addendum are identified by the addendum letter; for
example, "A3 Connector Descriptions."
Addendum A describes MAR-5915-1x, the Parvus Dual Gigabit Ethernet Switches (COM-1268s)
expansion module, referred to as the COM-1268 EM.

Chapter 1 Introduction
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Description of Safety Symbols
The following safety symbols are used in this manual and indicate potentially dangerous situations.
Warning! Danger, electrical shock hazard!
Personal injury or death could occur. Also damage to the system, connected peripheral devices, or
software could occur if the warnings are not followed carefully.
Caution! Hazard to individuals, environment, devices, or data!
If you do not adhere to the safety advice next to this symbol, there is obvious hazard to individuals, to
environment, to materials, or to data.
Note: This symbol highlights important information or instructions that should be observed.

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Overview
The DuraMAR® 5915 is a rugged Commercial-Off-the-Shelf (COTS) Cisco IOS-managed mobile router
integrated with Cisco’s 5915 Embedded Services Router (ESR) card in an ultra-rugged chassis optimized
for harsh military and civil vehicle/aircraft installations. The DuraMAR 5915 is an ideal solution for IP
networking technology refresh and situational awareness applications, including those seeking a
migration path for legacy Cisco 3200 (3230/3250/3270)-based router subsystems.
Optimized for Size, Weight and Power (SWaP) sensitivity as well as mechanical robustness under
extreme environmental conditions per MIL-STD-810G (thermal, shock, vibration, humidity, exposure to
dust, water), the DuraMAR 5915 enables prime contractors and civilian agencies to deploy Cisco Mobile
Ready Net capabilities, including data, video, and voice services virtually anywhere LAN or WAN
connectivity may be required, especially in mobile, airborne, ground, manned or unmanned vehicle
applications.
Leveraging stackable PC/104 subassemblies and a modular enclosure design, the unit is completely
sealed, requires no active cooling, provides interfaces over MIL-C-38999 style connectors, and features a
military-grade power supply supporting aircraft (MIL-STD-704F) and ground/marine (MIL-STD-1275D)
vehicle voltage inputs, spikes, and transient levels, as well as MIL-STD-461F EMI/EMC filtering.
The DuraMAR 5915 features dual WAN uplinks and is available as either:
A standalone 5-port network router (Figure 1)
The base router with one or more expansion modules (EM) factory-installed, such as the
integrated Parvus Dual Gigabit Ethernet Switches (COM-1268s EM) (Figure 2)
Figure 1. Standalone Router
(MAR-5915-0x)
Figure 2. Router with Expansion Module
(MAR-5915-1x)
With software built upon the Cisco 3270 IOS architecture, the DuraMAR 5915 delivers the performance,
security, advanced Quality of Service (QoS), high availability, and manageability that customers expect
from Enterprise IOS-based routing technology. The unit supports extensive IPv4 and IPv6 routing
protocols, IP multicasting, Radio Aware Routing (RAR), Dynamic Link Exchange Protocol (DLEP) and
Mobile IP routing for transparent connectivity to a roaming vehicle network in Comms-on-the-Move
(COTM) applications. An onboard AES hardware encryption engine offloads encryption processing from
the router to provide highly secure yet scalable data, video, and voice services.

Chapter 1 Introduction
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Features
Cisco Technology
Ruggedized Cisco 5915 Router with Enterprise IOS Software for robust security, management,
QoS, VLAN, IPv4/IPv6 routing, IP mobility, interoperability
Integrated Services Router (ISR) features support concurrent data, video, and voice services, as
well as firewall and hardware AES encryption acceleration
Scalability
Modular, open-architecture rugged COTS PC/104 hardware design
Standalone Router provides 5 Ethernet ports (3x 10/100 switched, 2x 10/100 routed)
Router plus COM-1268 EM provides integrated Parvus Dual Gigabit Ethernet Switches (two
COM-1268s).
Scales port density to 19 Ethernet ports for higher-port-density application requirements
Provides 19 Ethernet ports total (15 GigE switched, 2x 10/100 switched, 2x 10/100 routed)
Additional expansion modules upon request
Ruggedization
Qualified to MIL-STD-810G Shock, Vibration, Thermal, Altitude, Humidity
-40 to +71C fanless extended temperature operation with no moving parts
Corrosion-resistant, aluminum chassis sealed against water, dust, EMI
Circular MIL-DTL-38999 connectors for reliable network connections
Filtered, transient-protected power supply for aircraft and vehicle use
Qualified to MIL-STD-461F Conducted/Radiated Emissions and Conducted/Radiated
Susceptibility
Data Zeroization support to erase sensitive information
Conformal coating for humidity/tin-whisker mitigation
Flexible, robust mounting –base flange mount or side boss mount