Cisco 3200 Series Router Hardware Upgrade Guide September, 2008 Americas Headquarters Cisco Systems, Inc. 170 West Tasman Drive San Jose, CA 95134-1706 USA http://www.cisco.
THE SPECIFICATIONS AND INFORMATION REGARDING THE PRODUCTS IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL STATEMENTS, INFORMATION, AND RECOMMENDATIONS IN THIS MANUAL ARE BELIEVED TO BE ACCURATE BUT ARE PRESENTED WITHOUT WARRANTY OF ANY KIND, EXPRESS OR IMPLIED. USERS MUST TAKE FULL RESPONSIBILITY FOR THEIR APPLICATION OF ANY PRODUCTS.
REVIEW DRAFT—CISCO CONFIDENTIAL C O N T E N T S About This Guide v Audience and Scope Related Documentation v v Obtaining Documentation and Submitting a Service Request CHAPTER 1 Introduction vi 1-1 Cisco 3230 Rugged Enclosure 1-1 Fully Assembled Cisco 3230 Rugged Enclosure 1-2 Exploded View of the Cisco 3230 Rugged Enclosure 1-2 Cisco 3230 Router Card Stack 1-4 Cisco 3270 Rugged ISR 1-5 Fully Assembled Cisco 3270 Rugged Enclosure 1-5 Exploded View of the Cisco 3270 Rugged Enclosure 1-6 Cisco 327
Contents REVIEW DRAFT—CISCO CONFIDENTIAL Attaching Version 1 of the Wiring Card 2-13 Attaching the Version 2 of the Wiring Card 2-14 Reattaching the I/O End Cap 2-17 Reattaching the Antenna End Cap 2-19 Applying New I/O End Cap Function Labels 2-19 CHAPTER Replacing Cards in the Cisco ISR 3270 Rugged Enclosure 3 3-1 Card Replacement Process 3-1 Disconnecting All Cables from the Enclosure 3-2 Removing the Antenna End Cap 3-2 Removing the I/O End Cap 3-4 Removing the Wiring Card 3-5 Removing the Card St
About This Guide This guide describes how to perform basic maintenance of your Cisco 3230 Rugged Integrated Services Router (ISR) or Cisco 3230 Rugged ISR. The basic maintenance described in this guide includes replacing old or faulty cards and adding Wireless Mobile Interface Cards (WMICs). Basic maintenance also includes replacing the small form-factor pluggable (SFP) module.
About This Guide • Release Notes for the Cisco 3200 Series Mobile Access Routers (OL-78-13975-18)—Provides information about accessing documentation and technical assistance for the Cisco 3200 series ISR. • Cisco 3200 Series Wireless MIC Software Configuration Guide (OL-6415-04)—Provides sample procedures for using the IOS commands to configure Wireless Mobile Interface Cards (WMICs).
CH A P T E R 1 Introduction This chapter provides an overview of the Cisco 3230 and 3270 Rugged Integrated Services Routers (ISRs) and lists the router components that you can replace in the field. This chapter also lists the tools you need to replace these components. Cisco 3230 Rugged Enclosure The Cisco 3230 Rugged Enclosure houses a rugged wireless router that offers secure data, voice, and video communication, and supports multiple wired and wireless links, including integrated 802.11b/g and 4.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Fully Assembled Cisco 3230 Rugged Enclosure Figure 1-1 shows two views of a fully assembled Cisco 3230 Rugged Enclosure. Cisco 3230 Rugged Enclosure 270442 Figure 1-1 1 2 1 Front of the enclosure (I/O end cap)1 2 Back of the enclosure (antenna end cap) 1. This end cap shows four serial ports, but the typical configuration has two serial ports.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Figure 1-2 Exploded View of the 3230 Rugged Enclosure 4 1 270438 3 2 5 1 I/O end cap1 2 Wiring card (version 2) 3 Card stack 4 Extrusion (body of the enclosure) 5 Antenna end cap 1. This end cap shows four serial ports, but the typical configuration has two serial ports.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Cisco 3230 Router Card Stack The Cisco 3230 Rugged Enclosure houses a router card stack bundle of up to (7) cards.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Cisco 3270 Rugged ISR The Cisco 3270 Rugged Enclosure is approximately double the size of the Cisco 3230 Rugged Enclosure. The larger enclosure is needed to accommodate the Cisco 3270 MARC, which is longer than the Cisco 3230 MARC and has greater port density, performance, fiber, and Gigabit Ethernet capabilities. This section provides an overview of the Cisco 3270 Rugged Enclosure.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Exploded View of the Cisco 3270 Rugged Enclosure Figure 1-5 shows an exploded view of the Cisco 3270 Rugged Enclosure. Figure 1-5 Exploded View of the 3270 Rugged Enclosure 4 270439 3 1 2 5 1 I/O end cap1 2 Wiring card (version 2) 3 Card stack 4 Extrusion (body of the enclosure) 5 Antenna end cap 1. This end cap shows four serial ports, but the typical configuration has two serial ports.
Chapter 1 Introduction Cisco 3230 Rugged Enclosure Cisco 3270 Router Card Stack The Cisco 3270 Rugged Enclosure houses a card stack bundle of up to 7 cards. Each bundle contains a base configuration of the following: • One Cisco MARC • One Cisco SMIC • One Cisco FESMIC • One Cisco MRPC • (Fiber-enabled units only) One SFP module In addition, a card stack bundle can contain from one to three Cisco WMICs.
Chapter 1 Introduction Wiring Cards Wiring Cards The Cisco 3230 Rugged Enclosure supports versions 1 and 2 of the wiring card. Figure 1-7 shows version 1 of the wiring card.
Chapter 1 Introduction What You Can Upgrade or Replace For more information about the difference between the two versions of the wiring card, see Field Notice: FN - 62845 at: www.cisco.com/en/US/products/hw/routers/ps272/products_field_notice09186a00808fbc72.
Chapter 1 Introduction Required Tools Cisco 3200 Series Router Hardware Upgrade Guide 1-10 OL-15983-01
CH A P T E R 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure This chapter describes how to replace cards in the Cisco 3230 Integrated Services Router (ISR) Rugged Enclosure. Card Replacement Process To replace a card in the Cisco 3230 Rugged Enclosure card stack, follow these steps: 1. Disconnect all cables from the enclosure. 2. Remove the antenna end cap. 3. Remove the I/O end cap. 4. Remove the wiring card. 5. Remove the card stack from the enclosure. 6. Replace the card. 7.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Disconnecting All Cables from the Enclosure Warning Before you start working on rugged enclosures, disconnect all cables, including power, to avoid damage to the unit. Removing the Antenna End Cap Warning Class 1 laser product.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Step 2 Caution Carefully pull off the end cap without disconnecting the antenna cables, if present. Figure 2-2 shows the antenna cables. Support the end cap to prevent damage to the antenna connectors.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Step 3 If antenna cables are present, label the cables. Every Wireless Mobile Interface Card (WMIC) has two antenna cables, primary (P) and secondary (S), connected to the end cap. Labeling the cables will be useful later when you reconnect them to the end cap. Labels help you determine which ports on the antenna end cap you should connect the cables to.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Removing the I/O End Cap To remove the I/O end cap, follow these steps: Step 1 Using a 3/8-inch socket wrench to loosen the four 1/4-20 bolts on the end cap.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Removing the Wiring Card To remove the wiring card, follow these steps: Step 1 Disconnect all cables from the wiring card. Step 2 Using a Phillips screwdriver, loosen the wiring card screws. See Figure 2-5. Figure 2-5 Removing the Wiring Card Screws 1 270468 1 1 1 Step 3 Wring card screws Remove the wiring card.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Step 3 Slide the card stack out from the I/O end cap side. Step 4 Carefully place the card stack on its side on a rugged flat surface. Replacing or Adding a New Card This section describes how to add a WMIC to the stack and how to replace a WMIC, Mobile Router Power Care (MRPC), Serial Mobile Interface Card (SMIC), or Fast Ethernet Switch Mobile Interface Card(FESMIC).
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Step 2 Route the antenna cables under the WMIC, as shown in Figure 2-7. Routing the Antenna Cables Under the WMIC 270457 Figure 2-7 Routing the antenna cables under the WMIC allows them to reach the antenna connectors on the antenna end cap. Step 3 Verify that all ISA and PCI connector pins on the card are straight and not bent.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Replacing the FESMIC To replace the FESMIC, follow these steps: Step 1 If WMIC 3 is present, remove WMIC 3 and WMIC 2 as one unit. If only WMIC 2 is present, remove it. Step 2 Disconnect the LED cable from the back of the FESMIC. Step 3 Remove the FESMIC. Step 4 Make sure that the rotary switch on the new FESMIC (see Figure 2-8) is set opposite to the rotary switch on the SMIC.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Replacing the SMIC To replace the SMIC, follow these steps: Step 1 Remove the FESMIC and any card above it as one unit. Step 2 Disconnect the serial console cable from the back of the SMIC. Step 3 Remove the SMIC. Step 4 Make sure that the rotary switch on the new SMIC (see Figure 2-8) is set opposite to the rotary switch on the FESMIC.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Inserting the Card Stack into the Extrusion To insert the card stack into the extrusion, follow these steps: Step 1 Make sure that the LED cable is connected to the FESMIC. Step 2 Route the FESMIC LED cable over the top of the stack. Step 3 Align each card’s Wedge Loks so that the angles on the Wedge Loks match the angle of the Wedge Lok rail. Figure 2-9 shows proper Wedge Lok alignment.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Step 5 Slide the card stack into the front of the extrusion (or body) adjusting the spacing of the cards as necessary to fit the slots. You can use a flat-blade screwdriver to make adjustments. Figure 2-10 shows the extrusion (or body) of the rugged enclosure.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Reattaching the Wiring Card The Cisco 3230 Rugged Enclosure supports the version 1 and version 2 of the wiring card. Attaching Version 1 of the Wiring Card If you are using version 1 of the wiring card (see Figure 1-7 on page 1-8), follow these steps to reattach it to the card stack: Step 1 Install the wiring card (shown attached to the front of the card stack in Figure 2-11). a.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process c. If there is a second WMIC in the stack, attach a console cable (72-4281-01) to the J2 header on the wiring card. Attach the other end of the cable to the LED header on the second WMIC (at the top of the card stack). d. Route the LED ribbon cable (72-4279-01) over the top of the card stack. The connector closest to the label should be toward the back of the extrusion. e.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process For a 2-WMIC configuration, connect cables to the wiring card as shown in Figure 2-13. Figure 2-13 2-WMIC Configuration 1 2 3 270463 4 1 Connect the FESMIC 10-pin FE1X cable to port J14 on the wiring card. 2 Connect the FESMIC10-pin FE2X cable to WMIC 2. 3 Connect the FESMIC 10-pin FE3X cable to WMIC 1. 4 Connect the WMIC 2 24-pin cable to port J2 on the wiring card.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process For a 3-WMIC configuration, connect cables to the wiring card as shown in Figure 2-12. Figure 2-14 3-WMIC Configuration 1 2 3 270464 5 4 Step 3 1 Connect FESMIC 10-pin FE1X cable to WMIC 3. 2 Connect the FESMIC 10-pin FE2X cable to WMIC 2. 3 Connect the FESMIC’s 10-pin FE3X cable to 4 WMIC 1. Connect WMIC 3 24-pin cable to port J3 on the wiring card.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Reattaching the I/O End Cap To reattach the I/O end cap, follow these steps: Step 1 Align the guide pins of the I/O end cap with the front of the extrusion. (The antenna end cap does not have guide pins. The extrusion does not have holes for the guide pins in the back of the extrusion.) Figure 2-15 shows the I/O end cap.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process If a protective end cap cover is used to provide weatherproof protection for the ports on the I/O end cap, align the holes of the hinge brackets of the protective end cap to the I/O end cap with the holes of the mounting bolts on the I/O end cap. Then, insert the (4) mounting bolts through the hinge bracket and I/O end cap holes to attach the I/O end cap and its protective cover to the extrusion.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Reattaching the Antenna End Cap To reattach the antenna end cap, follow these steps: Step 1 If you have added one or more WMICs, remove two of the corresponding plugs from the antenna end cap and replace them with RP-TNC connectors. Step 2 Attach the antenna cables to the antenna end cap, as shown in Figure 2-2. Step 3 Attach the identification labels for the antennas to the antenna end cap.
Chapter 2 Replacing Cards in the Cisco 3230 ISR Rugged Enclosure Card Replacement Process Cisco 3200 Series Router Hardware Upgrade Guide 2-20 OL-15983-01
CH A P T E R 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure This chapter describes how to replace cards in the Cisco 3270 Integrated Services Router (ISR) Rugged Enclosure cards. Card Replacement Process To replace a card in the Cisco 3270 Rugged Enclosure card stack, follow these steps: 1. Disconnect all cables from the enclosure. 2. Remove the antenna end cap. 3. Remove the I/O end cap. 4. Remove the wiring card. 5. Remove the card stack from the enclosure. 6.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Disconnecting All Cables from the Enclosure Warning Before you start working on rugged enclosures, disconnect all cables, including power, to avoid damage to the unit. Removing the Antenna End Cap Warning Class 1 laser product.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Step 3 If antenna cables are present, label the cables. Use the labels on the exterior of the antenna end cap for reference. Figure 3-2 shows the exterior and interior of an antenna end cap for a rugged enclosure with three Wireless Mobile Interface Cards (WMICs), as indicated by the six labels (two for each (WMIC)) on the end cap exterior.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Removing the I/O End Cap To remove the I/O end cap, follow these steps: Use a 3/8-inch socket wrench to loosen the four 1/4-20 bolts on the end cap using a torque range of 58 to 68 in-lb.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Removing the Wiring Card To remove the wiring card, follow these steps: Step 1 Disconnect all cables from the wiring card. Step 2 Using a Phillips screwdriver, remove (torque 5.5 to 5.7 in-lb) the 7 or 8 wiring card screws, as shown in Figure 3-4. Figure 3-4 Removing the Wiring Card Screws 1 270468 1 1 1 Wiring screws Step 3 In the case of a 0-WMIC configuration, remove screw #2 which is not used.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Step 4 Slide the card stack out from the antenna end cap side, as shown in Figure 3-5. Sliding Out the Card Stack 270469 Figure 3-5 Step 5 Carefully place the card stack on its side on a flat surface.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Replacing or Adding a New Card To replace or add new cards, follow the steps in the “Replacing or Adding a New Card” section on page 2-23.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Step 5 Slide the card stack into the front of the enclosure, as shown in Figure 3-7, adjusting the spacing of the cards as necessary to fit the slots. You can use a flat-blade screwdriver to make adjustments. Inserting the Card Stack Into the (or Body) of the Rugged Enclosure 270471 Figure 3-7 Step 6 Place the extrusion horizontally on the flat surface.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Figure 3-8 2 270472 1 Attaching Alignment Tabs 4 3 1 Serial console cable 2 LED cable 3 Right alignment tab 4 Right alignment tab Step 9 Slowly slide the card stack back until the alignment tabs are flush against the extrusion. Step 10 Using a small Phillips screw driver, reattach the alignment tabs to the extrusion. Use a torque range of 2.5 to 3.5 in-lb.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Figure 3-9 Tightening Wedge Loks 14 11 12 7 8 5 6 1 2 3 4 9 10 270473 13 Step 12 Tighten the two Wedge Loks of the MARC on the antenna end cap side (see Figure 3-10) with a 3/32-inch hex blade. Use a torque range of 5.5–5.7 in-lb when tightening the Wedge Loks.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Reattaching the Wiring Card To reattach the wiring card to the card stack, follow these steps: Step 1 Attach the wiring card to the front of the card stack by aligning ports and firmly pressing the card into the stack. Step 2 If WMICs are present, make sure that the WMIC mounting boss is within 0.01 inch of the wiring card. Step 3 Using a Phillips screwdriver, tighten the wiring card screws using 5.5 to 5.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Figure 3-12 1-WMIC Configuration 2 1 3 270476 4 1 Connect the FESMIC 10-pin FE1X cable to port J14 on the wiring card. 2 Connect the FESMIC 10-pin FE2X cable to port J4 on the wiring card. 3 Connect the FESMIC 10-pin FE3X cable to WMIC 1. 4 Thread the FE extender cable under the card stack to the antenna end cap side.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process For a 3-WMIC configuration, connect the cables to the wiring card as shown in Figure 3-14. Figure 3-14 3-WMIC Configuration 1 2 6 3 5 270478 4 1 Connect the FESMIC 10-pin FE1X cable to WMIC 3. 2 Connect the FESMIC 10-pin FE2X cable to WMIC 2. 3 Connect the FESMIC 10-pin FE3X cable to WMIC 1. 4 Thread the FE extender cable under the card stack to the antenna end cap side.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Adjusting the WMIC Jumper Settings If you add or remove WMIC cards, you must adjust the WMIC jumper settings on the I/O end cap as shown in Figure 3-15.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Reattaching the I/O End Cap To reattach the I/O end cap, follow these steps: Step 1 Thread the following cables under the card stack from the I/O end cap to the antenna end cap side: • USB • FE1 • FE0 and FE1 or GE0 and GE1 Step 2 Thread one of the power cables under the card stack from the Mobile Router Power Card (MRPC) card to the I/O end cap side.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Reattaching the Antenna End Cap To reattach the antenna end cap, follow these steps: Step 1 If you have added new WMICs, remove the corresponding antenna end cap plugs from the antenna end cap and replace them with RP-TNC connectors. Step 2 Attach the antenna cables to the antenna end cap, as shown in Figure 2-2.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Applying New I/O End Cap Function Labels To apply new I/O end cap function labels, follow these steps: Step 1 Identify the labels on the I/O end cap you want to change. Step 2 Peel off the new labels from the label set you received from Cisco. Step 3 Place the new labels over the old labels, as show in Figure 3-17. (Figure 3-17 shows one new label being applied over an old label.
Chapter 3 Replacing Cards in the Cisco ISR 3270 Rugged Enclosure Card Replacement Process Cisco 3200 Series Router Hardware Upgrade Guide 3-18 OL-15983-01
CH A P T E R 4 Replacing the SFP Module This chapter describes how to replace small-form-factor pluggable (SFP) modules. SFP modules are inserted into the SFP module slot on the Cisco 3270 Rugged Router card. These modules provide the uplink optical interfaces, laser send (TX) and laser receive (RX).
Chapter 4 Replacing the SFP Module SFP Module Replacement Process Caution To prevent electrostatic damage to cards in the rugged enclosure, attach an ESD-preventive wrist strap to your wrist and to a bare metal surface on the chassis of the enclosure before you start the SFP replacement process. SFP Module Replacement Process This section describes how to replace an SFP module. Warning Class 1 laser product.
Chapter 4 Replacing the SFP Module SFP Module Replacement Process Step 9 Grasp the SFP module between your thumb and index finger, and carefully remove it from the module slot. Step 10 Place the removed SFP module in an antistatic bag or other protective environment. Caution Step 11 Do not remove the rubber plugs from the SFP module port or the rubber caps from the fiber-optic cable until you are ready to connect the cable.
Chapter 4 Replacing the SFP Module SFP Module Replacement Process Cisco 3200 Series Router Hardware Upgrade Guide 4-4 OL-15983-01
I N D EX Numerics 3270 Rugged Enclosures 9 A Adding a New Card 45 Adding a New WMIC Card 25 Adjusting the WMIC Jumper Settings 52 Attaching New I/O End Cap Function Labels 55 audience v C Card Replacement Process 19, 39 Cisco 3230 Router Card Stack 12 Cisco 3230 Rugged Enclosure 9 Cisco 3270 Router Card Stack 15 Cisco 3270 Rugged Enclosure 13 E Earlier Version of the Wiring Card 31 Exploded View of the Cisco 3230 Rugged Enclosure 11 Exploded View of the Cisco 3270 Rugged Enclosure 14 F Fully Assembled Cisc
Index REVIEW DRAFT—CISCO CONFIDENTIAL Book Title IN-2 78-xxxxx-xx
