Field Notice: FN - 22253 - Catalyst 4500 Series Chassis Fan Tray Recall

Revised March 5, 2006
December 9, 2002

---

NOTICE:

THIS FIELD NOTICE IS PROVIDED ON AN "AS IS" BASIS AND DOES NOT IMPLY ANY KIND OF GUARANTEE OR WARRANTY, INCLUDING THE WARRANTY OF MERCHANTABILITY. YOUR USE OF THE INFORMATION ON THE FIELD NOTICE OR MATERIALS LINKED FROM THE FIELD NOTICE IS AT YOUR OWN RISK. CISCO RESERVES THE RIGHT TO CHANGE OR UPDATE THIS FIELD NOTICE AT ANY TIME.

---

Products Affected

Product	Printed Circuit Assembly		Comments
	Part Number	Rev.
WS-C4503	800-21376-01	A0	Removeable Fan Tray Controller assembly for the Catalyst 4503 Chassis (3-Slot),
WS-C4506	800-21732-01	A0	Removeable Fan Tray Controller assembly for the Catalyst 4506 Chassis (6-Slot)
WS-C4507R	800-16725-01	A0	Removeable Fan Tray Controller assembly for the Catalyst 4507R Chassis (7-Slot)

Problem Description

Cisco is recalling removable fan trays in the Catalyst 4500 series of chassis due to two recently discovered issues. Fan tray related issues are as follows:

Potential fan tray failure

Removable fan trays in the Catalyst 4503/4506/4507R chassis have a potential to fail in the field due to internal shorting of the fan tray controller assembly. If a failure occurs, the fan tray will cease to function and will likely disrupt the operation of the Catalyst 4503/4506/4507R chassis in which it is installed. In the event of a failure, the switch backplane may also suffer damage rendering the system inoperable. This problem was discovered at Cisco's manufacturing site during routine "elevated temperature" burn-in testing affecting a small number of units. During burn-in testing, an internal shorting of the fan tray controller assembly resulted in a power surge that created excess heat, which charred the edge of the fan tray, creating smoke. All three affected Catalyst 4500 chassis and fan trays remain in compliance with appropriate safety standards. As of December 9, 2002, the frequency of field failure has been measured at 0.03% of the worldwide installed base. The statistical probability of this problem occurring in the field has been very low. Cisco will be replacing fan tray units at no charge.

Problem related to fan tray hot-swap in Catalyst 4506 with Supervisor III or IV and Catalyst 4507R with Supervisor IV

There is a problem related to fan tray hot-swap in the Catalyst 4506 with Supervisor Engine III or IV and Catalyst 4507R with Supervisor IV. Removing a fan tray from an operating Catalyst 4506 with a Supervisor Engine III or IV or a Catalyst 4507R with Supervisor IV will result in system disruption. A reboot is required to return to normal operation. A Catalyst 4506 installed with a Supervisor Engine II is not affected by this issue. The Catalyst 4503 is not affected by this issue.

As a precautionary measure, Cisco is recalling and replacing the affected field replaceable fan trays. All 3 affected Catalyst 4500 chassis and fan trays remain in compliance with appropriate safety standards.

Background

Both issues have been traced to the fan tray controller assembly. The fix for these problems requires a new revision of the fan tray controller assembly which will require a hardware version change. The affected version was produced between September 2002, and November 2002. Units produced during or after December 2002 will have the corrected hardware version. See How To Identify Hardware Levels to determine how to identify the new hardware version. Orderable product numbers for the Catalyst 4500 chassis and spare fan tray FRUs will not change.

Problem Symptoms

Potential fan tray failure

Problem symptoms upon fan tray failure are as follows:

1. The short may cause the fan trays to go into overcurrent shutdown and may potentially cause them to smoke.
2. The following syslog message may be generated in IOS upon fan tray failure: Too few working fans, the chassis will overheat
3. The following syslog message may be generated in CatOS upon fan tray failure: %SYS-2-FAN_FAIL:Fan failed
4. If there is a fan tray failure in a Catalyst 4500 deployed with a Supervisor II the supervisor status LED will turn to Amber.

Problem related to fan tray hot-swap in Catalyst 4506 with Supervisor III or IV and Catalyst 4507R with Supervisor IV

Problem symptoms upon fan tray hot-swap in a Catalyst 4506 with Supervisor III or IV and Catalyst 4507R with Supervisor IV are as follows:

1. The following error message may occur: %C4K_LINECARDMGMTPROTOCOL-4-INITIALTIMEOUTWARNING
2. The following error message may occur: %C4K_HWPORTMAN-4-BLOCKEDTXQUEUE
3. System reboot is required to return to proper operation.

Workaround/Solution

Cisco Systems is recalling and replacing field replaceable fan trays for the Catalyst 4503, 4506 and 4507R sold worldwide and installed with the affected hardware version. The affected fan trays are field replaceable units (FRUs) that can be replaced without the need to return the entire chassis. In the case of the Catalyst 4503 installed with any supported supervisor engine or Catalyst 4506 installed with Supervisor II, the affected fan trays are hot swappable and can be replaced without interruption of service to the switch. All 3 chassis have different fan trays, therefore, they have unique replacement fan tray FRU product numbers. A list of replacement fan tray FRU product numbers are outlined in the following table:

Chassis Product Number	Corresponding Replacement Fan Tray FRU Number
WS-C4503	WS-X4593=
WS-C4506	WS-X4596=
WS-C4507R	WS-X4597=

Cisco is expected to begin shipping new fan tray hardware revisions on the following dates:
Upgrade replacements will be subject to standard manufacturing leadtimes.

Catalyst 4503 and 4506: December 19, 2002
Catalyst 4507R: December 20, 2002

Please contact Cisco TAC for replacement of affected units, which will be replaced by regular RMA process.

How To Identify Hardware Levels

As all 3 chassis have different fan trays, they all have unique component part numbers. A summary of the corresponding product numbers and affected/corrected hardware versions are summarized below:

Chassis/Fan Tray	Affected ASY Part Number/PCA Part Number	Affected Hardware Version	Corrected ASY Part Number/PCA Part Number	Corrected Hardware Version
WS-C4503/WS-X4593=	800-21376-01 / 73-8056-02	1.0	800-21376-02 / 73-8056-03	2.0 or higher
WS-C4506/WS-X4596=	800-21732-01 / 73-8106-01	1.0	800-21732-02 / 73-8106-02	2.0 or higher
WS-C4507R/WS-X4597=	800-16725-01 / 73-7163-02	1.0	800-16725-02 / 73-7163-03	2.0 or higher

Visual identification

Externally, the corrected hardware version can be identified with the addition of a color coded white strip on the bottom of the fan tray label around the finger screw. This can be identified without pulling the fan tray out of a chassis. Refer to the photographs below:

Affected Fan Tray Hardware Version

Corrected Fan Tray Hardware Version

Alternatively, the new hardware level can be identified by pulling out the fan tray from the chassis and viewing the component part numbe r and hardware version located on the left side near the back of the fan tray. This should not be attempted in an operating Catalyst 4506 with Supervisor III or IV or a Catalyst 4507R with Supervisor IV.

Software based identification

Cisco IOS® software uses the command show idprom fan-tray to display the idprom of the fan tray which will display the hardware version. CatOS based supervisor engines do not have the ability to display the hardware version.

To verify if you have the affected or corrected Fan Tray, note the "Part Number" and "Hardware Revision" and compare it to the table above. All corrected fan trays will report a "Hardware Revision" of 2.0 or higher.

SW-KIF-TRF-4503-0# show idprom fan-tray
Fan Tray Idprom :
Common Block Signature = 0xABAB
Common Block Version = 1
Common Block Length = 144
Common Block Checksum = 4084
Idprom Size = 256
Block Count = 1
FRU Major Type = 0x4002
FRU Minor Type = 4
OEM String = Cisco Systems, Inc.
Product Number = WS-X4593
Serial Number = FOC06330S9Y
Part Number = 73-8056-02
Part Revision = A0
Manufacturing Deviation String =
Hardware Revision = 1.0
Manufacturing Bits = 0x0000
Engineering Bits = 0x0000
Snmp OID = 0.0.0.0.0.0.0.0
Power Consumption = 0
RMA Failure Code = 0 0 0 0

Removing and Replacing the Affected Fan Tray Assembly

1. Removing and replacing a fan tray in a Catalyst 4503 or 4506 with Supervisor II. The affected fan trays are hot swappable, field replaceable units (FRUs) that can be replaced without interruption of service to the switch. Procedure is as follows:
   
   1. Loosen finger screws and remove the fan tray
   2. The following syslog message will be generated in CatOS upon fan tray removal: %SYS-2-FAN_FAIL:Fan failed
   3. New fan tray must be inserted within 4 minutes. If not inserted within 4 minutes, line card operation will be removed sequentially starting with line card slot 2.
   4. Insert new fan tray and tighten finger screws
2. 
   
3. Removing and replacing a fan tray in a Catalyst 4503 with Supervisor III or IV. The affected fan trays are hot swappable, field replaceable units (FRUs) that can be replaced without interruption of service to the switch.
   
   1. Loosen finger screws and remove the fan tray
   2. The following syslog message may be generated by Cisco IOS software upon fan tray failure: Too few working fans, the chassis will overheat
   3. New fan tray must be inserted within 4 minutes.
   4. Insert new fan tray and tighten finger screws
4. 
   
5. Removing and replacing a fan tray in a Catalyst 4506 Supervisor III or IV or Catalyst 4507R with Supervisor IV. The affected fan trays are not hot swappable. Field replaceable units (FRUs) should be replaced during scheduled downtime.
   
   1. Power down the chassis
   2. Loosen finger screws and remove the fan tray.
   3. Insert new fan tray and tighten finger screws
   4. Power on chassis
   5. Normal boot up procedure should occur

The replacement fan tray units will ship with a hard copy of instructions for removing and replacing the fan tray assembly. Instructions are available on Cisco.com under Removing and Replacing FRUs.

Revision History

Revision	Date	Comment
1.2	05-MAR-2006	Removed Umpire Form
1.1	23-JAN-2003	Maintenance Update
1.0	10-DEC-2002	Initial Public Release

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

---