Field Notice: FN - 63390 - GSR PRP-2 Might Fail While in Operation after Extended Period of Time - Replace on Failure

Notice

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Revision History

Products Affected

Defect Information

Problem Description

PRP-2 board may fail in GSR Router while in operation for extended period of time. The failure symptoms may be several such as PRP-2 failure, switchover to standby PRP-2, router reload, traffic outage, or PRP-2 board in indeterminate state.

Background

PRP-2 in GSR router is the central processor and performs various functions such as routing, traffic management, line card monitoring, and more. The PRP-2 board is made up of CPU, memory, controllers, FPGAs, and other active and discrete components. The FPGA on PRP-2 receives slightly higher voltage on the PLL VCC pins than recommended by the vendor, leading to electrical stress over the long term, reducing reliability of the device and eventually causing failure of PLL circuit and FPGA.

The FPGA converts processor bus to interface the IO devices such as Flash, NVRAM, compact disk, and memory and implements MBUS Mailbox functionality. Failure of FPGA PLL circuit leads to very slow heat up of the FPGA device over time resulting in logic lock-up condition thereby leading to PRP-2 board failure. Since the PLL circuit of FPGA is not used on PRP-2, no hard failure or symptom of the PRP-2 board can be predicted, the failures may manifest different ways due to logic lock-up condition of the FPGA.

Problem Symptom

PRP-2 board may fail in GSR Router while in operation for extended period of time. There may be several different failure symptoms such as PRP-2 failure, switchover to standby PRP-2, router reload, traffic outage, or PRP-2 board in indeterminate state.

Workaround/Solution

PRP-2s shipped between March 2006 to November 2010 are suspect. PRP-2 boards shipped post November 2010 contain new PCB design to correct VCC_PLL ping voltage. Alternatively, refurbished PRP-2 boards shipped by Cisco service under RMA or upgrade program will not have the issue, since the issue is fixed by interposer adaptor.

This table helps you identify if PRP-2 board are suspect or good board.

**If TAN information is not available, use Serial Number Tool(SN Tool) to verify if board is affected. SN Tool is updated monthly.

Note: PRP-2 with TAN 800-27058-11 are good boards ( not affected) even when the PRP-2 board falls within the serial number listed in tool as affected. PRP-2 boards shipped to customer with TAN 800-27058-09 and deviation D113342, D113851, D115209, D115427 are good boards (not affected). PRP-2 boards with TAN 800-27058-10 were not shipped to customer.

The replacement of PRP-2 is recommended during maintenance window. Customer are requested to retain DIMM(Memory), PCMCIA Flash card as it will be needed for plugin to replacement PRP-2.

How To Identify Affected Products

Illustrated below are two methods that can be used to distinguish the different revisions of the PRP-2: A) CLI, and B) Physical inspection.

A) CLI Method

Note: You must login to GSR router with admin privileges to run the IOS commands.

Information: Your command prompt setting will determine [router-name] shown in example below.

Good PRP-2 Version:

Below is sample CLI and output: show diagnostic

i)

SLOT 9 (RP/LC 9): Performance Route Processor
MAIN: type 96, 800-27058-11 rev A0 => Good board TAN
Deviation 
HW config: 0x10 SW key: 00-00-00
PCA: 73-10242-13 rev A0 ver 5
Design Release 0.0 S/N SADnnnnnnn ->Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

OR

SLOT 9 (RP/LC 9): Performance Route Processor
MAIN: type 96, 800-27058-09 rev A0 
Deviation D115209 => Good PRP-2 board shipped under Deviation D113342, D113851, D115209, D115427.
HW config: 0x10 SW key: 00-00-00
PCA: 73-10242-13 rev A0 ver 5
Design Release 0.0 S/N SADnnnnnnn ->Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

Legacy PRP-2 boards shipped prior to March 2006 are good board. See below on how to identify.

GSR#sh diag 5
SLOT 5 (RP/LC 5 ): Performance Route Processor
MAIN: type 96, 800-23469-08 rev B0 <- TAN for Good board 
Deviation: 0
HW config: 0x10 SW key: 00-00-00
PCA: 73-8812-11 rev B0 ver 4 <-- PCA for good board 
Design Release 0.0 S/N SADnnnnnnnn
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0
HW version 0.1 S/N CAT073703QC
Test hist: 0x00 RMA#: 00-00-00 RMA hist: 0x00
DIAG: Test count: 0x00000000 Test results: 0x00000000
FRU: Linecard/Module: PRP-2=
Route Memory: MEM-PRP/LC-2048=
MBUS Agent Software version 2.70 (RAM) (ROM version is 3.68)
ROM Monitor version 1.8(2.83)
Primary clock is CSC 1
Board State is IOS Running ACTIVE (ACTV RP )
Insertion time: 8w4d (24w3d ago)
DRAM size: 2147483648 bytes
Suspect PRP-2 Cards: 

Below is CLI of show diags:

SLOT 9 (RP/LC 9 ): Performance Route Processor
MAIN: type 96, 800-27058-09 rev A0 => Affected Board TAN 
Deviation 
HW config: 0x10??? SW key: 00-00-00
PCA: 73-10242-09 rev B0 ver 5
Design Release 0.0 S/N SAnnnnnnnn --> Serial number
MBUS: MBUS Agent (1) 73-8048-06 rev A0 dev 0

B) Physical Inspection method

Below are few images to identify the PRP-2 board PID, version, and serial number location.

a) New PCB respin PRP-2 board(good board) and suspect PRP-2 board.

b) Good PRP-2: New PCB respin PRP-2 board shipped under deviation

c) Good PRP-2 board with Interposer PCB installed.

Additional Information

D113342, D113851, D115209, D115427

For More Information

If you require further assistance, or if you have any further questions regarding this field notice, please contact the Cisco Systems Technical Assistance Center (TAC) by one of the following methods:

• Open a service request on Cisco.com
• By email
• By telephone

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