Table Of Contents
Replacing Cards in the Cisco 3230 ISR Rugged Enclosure
Card Replacement Process
Disconnecting All Cables from the Enclosure
Removing the Antenna End Cap
Removing the I/O End Cap
Removing the Wiring Card
Removing the Card Stack
Replacing or Adding a New Card
Adding a New WMIC
Replacing a WMIC
Replacing the FESMIC
Replacing the SMIC
Replacing the MARC
Replacing the MRPC
Inserting the Card Stack into the Extrusion
Reattaching the Wiring Card
Attaching Version 1 of the Wiring Card
Attaching the Version 2 of the Wiring Card
Reattaching the I/O End Cap
Reattaching the Antenna End Cap
Applying New I/O End Cap Function Labels
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. Insert the card stack into the enclosure.
8. Reattach the wiring card.
9. Reattach the I/O end cap.
10. Reattach the antenna end cap.
11. Apply new I/O end cap function labels, if needed.
These steps are described in the following sections.
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 card replacement process.
Caution To avoid damaging the cables, make sure that you do not crimp or pinch the cables when you press the cards together or when you attach the end caps.
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. Statement 1008
To remove the antenna end cap of a Cisco 3230 Rugged Enclosure, follow these steps:
Caution Attach an ESD-preventive wrist strap to your wrist and to a bare metal surface on the chassis.
Step 1 Using a 3/8-inch socket wrench to loosen the four 1/4-20 bolts on the end cap. Figure 2-1 shows these bolts.
Figure 2-1 Antenna End Cap Bolts
Step 2 Carefully pull off the end cap without disconnecting the antenna cables, if present. Figure 2-2 shows the antenna cables.
Caution Support the end cap to prevent damage to the antenna connectors.
Figure 2-2 Removing the Antenna End Cap
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WMIC 1 primary antenna cable
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2
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WMIC 1 secondary antenna cable
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3
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WMIC 2 primary antenna cable
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4
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WMIC 2 secondary antenna cable
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5
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WMIC 3 primary antenna cable
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6
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WMIC 3 secondary antenna cable
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7
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Power cable
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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.
Use the labels on the exterior of the antenna end cap for reference. Figure 2-3 shows an antenna end cap for a rugged enclosure with three Wireless Mobile Interface Cards (WMICs), as indicated by the six labels ((2) for each WMIC) on the end cap exterior.
Figure 2-3 Antenna End Cap Labels
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W3 (P)
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2
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W3 (S)
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3
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W2 (P)
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4
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W2 (S)
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5
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W1 (P)
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6
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W1 (S)
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If the rugged enclosure contains only one WMIC, the WMIC Primary and Secondary antenna cables are connected to ports W1 (P) and W1 (S).
If WMIC 2 is also present, its primary and secondary cables are connected to W2 (P) and W2 (S).
If the rugged enclosure contains the maximum number of WMICs (3 WMICs), the primary and secondary cables of WMIC 3 are connected to W3 (P) and W3 (S).
Step 4 If antenna cables are present, disconnect them from the end cap.
Step 5 Place the end cap on your work surface.
Step 6 Disconnect the power cable from the MRPC card.
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.
Note If a protective end cap cover (see Figure 2-16) is used to provide weatherproof protection for the ports on the I/O end cap, loosening the four 1/4-20 mounting bolts on the protective end cap allows you to remove the protective end cap and the I/O end cap from the extrusion.
Step 2 Carefully remove the I/O end cap and pull the end cap I/O cable out from under the card stack to free the end cap (see Figure 2-4).
Figure 2-4 I/O End Cap Removal
Step 3 Place the end cap on your work surface.
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
Step 3 Remove the wiring card.
Removing the Card Stack
To remove the card stack, follow these steps:
Step 1 Use a Phillips screwdriver to loosen the screws of the two alignment tabs that hold the wiring card to the extrusion.
Step 2 Loosen the 14 Wedge Loks that are holding the card stack in place using a 3/32-inch hex blade to release the clamping mechanism.
Note After loosening the screws for the Wedge Loks, the locks sometimes do not relax. The screws just back out. You need to lightly tap on the screw heads to relax the locks. The tension bracket screws for the wedge locks (seen at the edge of the card) are not very strong and can break very easily.
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).
Caution To ensure that cards can be installed properly, prevent the card pins from getting bent.
Adding a New WMIC
To add a new WMIC card to the card stack, follow these steps:
Step 1 Attach the antenna cables to the WMIC.
We recommend that you label the free end of the antenna cables as primary and secondary, and that you identify the WMIC to which they are associated. We recommend that you associate the primary cable with MAIN and the secondary cable with AUX.
Figure 2-6 shows a WMIC with the primary cable attached to the MAIN antenna cable connector and the secondary cable attached to the AUX antenna cable connector.
Figure 2-6 Antenna Connectors
Step 2 Route the antenna cables under the WMIC, as shown in Figure 2-7.
Figure 2-7 Routing the Antenna Cables Under the WMIC
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.
Step 4 Add the WMIC to the stack by aligning the ISA and PCI connectors and firmly pressing the card in place.
•If there are no WMICs on the card stack, connect the WMIC to the MRPC at the bottom of the stack.
•If you are installing a second WMIC (WMIC 2), connect it to the FESMIC on top of the card stack.
•If you are installing a third WMIC (WMIC 3), connect it to WMIC 2 on top of the card stack.
Replacing a WMIC
To replace a WMIC, follow these steps:
Step 1 Carefully remove from the card stack the WMIC card that you want to replace. Use a flat blade screwdriver to loosen up the card.
•To replace WMIC 1 or WMIC 3, just remove the card from the bottom or top of the stack.
•To replace WMIC 2, first remove WMIC 3 from the top of the stack. Then remove WMIC 2.
Step 2 Install the new WMIC in place of the old one, as described in the "Adding a New WMIC" section.
If you are replacing WMIC 2, first install WMIC 2 on top of the FESMIC. Then install WMIC 3 on top of WMIC 2.
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.
For example, if the SMIC rotary switch is set to 1, then set the FESMIC switch to 0, and vice versa.
Figure 2-8 FESMIC and SMIC Rotary Switches
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FESMIC rotary switch.
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SMIC rotary switch.
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Step 5 Verify that all ISA and PCI connector pins on the new FESMIC are straight and not bent.
Step 6 Connect the new FESMIC card to the SMIC card by aligning the bus headers and firmly pressing the cards together.
Note Be sure not to bend any exposed pins on the card while squeezing the cards together.
Step 7 Connect WMIC 2 (or WMIC 2 and WMIC 3 as one unit) to the FESMIC card as described in the "Adding a New WMIC" section.
Step 8 Connect the LED cable to the back of the FESMIC.
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.
If the FESMIC rotary switch is set to 1, set the SMIC switch to 0, and vice versa.
Step 5 Verify that all ISA and PCI connector pins on the new card are straight and not bent.
Step 6 Connect the new SMIC to the MARC on top of the card stack.
Step 7 Connect the FESMIC and any card above it as one unit and connect this unit to the SMIC.
Step 8 Connect the serial console cable to the back of the SMIC.
Replacing the MARC
To replace the Mobile Access Router Card (MARC), follow these steps:
Step 1 Remove the WMIC 1 (if present) and MRPC as one unit.
Step 2 Remove the MARC from the card stack.
Step 3 Verify that all ISA and PCI connector pins on the new MARC are straight and not bent.
Step 4 Connect the new MARC to the SMIC at the bottom of the stack.
Step 5 Connect the MRPC and WMIC 1 (if present) as one unit and connect this unit to the MARC.
Replacing the MRPC
To replace the MRPC, follow these steps:
Step 1 Remove WMIC 1 (if present) from the bottom of the card stack.
Step 2 Remove the MRPC.
Step 3 Verify that all ISA and PCI connector pins on the new MRPC are straight and not bent.
Step 4 Connect the new MRPC card to the MARC.
Step 5 If a WMIC1 is present connect it to the new MRPC.
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.
Figure 2-9 Wedge Lok Alignment
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Wedge Lok alignment
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2
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Wedge Lok rail
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Step 4 Place the extrusion on a sturdy, flat surface with the I/O end cap side facing up.
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.
Figure 2-10 Extrusion (or Body) of the Enclosure
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End cap mounting holes
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Large rail for MARC
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Standard rail
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Drill hole for wiring card
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Step 6 Center the cards in the extrusion, so that the holes in the MARC thermal plate align with the drill holes above the large rail. Verify that the flange is fully seated against the extrusion.
Step 7 Tighten the Wedge Loks with a 3/32-inch hex blade. The sequence for tightening the Wedge Loks is indicated by the uncircled numbers in Figure 2-5. Use a torque range of 5.5 to 5.7 in-lb when tightening the Wedge Loks.
Caution Make sure that all the Wedge Loks are secure. Thermal transfer will not occur if any Wedge Lok is loose.
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. Align the wiring card connectors with the headers on the card stack at the front of the extrusion.
b. Secure the wiring card to the extrusion with the eight Phillips pan-head screws that were provided in the enclosure assembly kit. The sequence to use for tightening the wiring card is indicated by the numbers in Figure 2-11. Use the torque range of 5.5 to 5.7 in-lb when tightening the wiring card.
Figure 2-11 Installing Cables
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See Step 2b
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See Step 2d and Step 2e
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See Step 2a
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See Step 2f and Step 2g
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See Step 2c
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Step 2 Install the cables. The wiring card has a label beside to each port (J3, J4, and so forth). The following steps provide the procedures for referring to these labels to determine which cable to install in which port. Refer to Figure 2-11 when you perform step 2a through step 2g.
a. Attach the 10/100 Fast Ethernet cable (72-4282-01) to the J4 connector on the wiring card and the FE2x (typically FE2/21 ) port at the back of the 4-port FESMIC.
b. If there is a second WMIC in the card stack, attach a 10/100 Fast Ethernet cable (72-4282-01) to the FE3x (typically FE2/3) port on the 4-port FESMIC and the 10/100 Fast Ethernet port on the second WMIC.
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. Connect the LED ribbon cable to J5 of the wiring card and to the FESMIC LED header on the card stack at the back of the extrusion.
f. Route the power cable from the I/O end cap under the card stack, toward the back of the extrusion.
g. Connect the power cable to the header on the MRPC.
Attaching the Version 2 of the Wiring Card
If you are using the newer version 2 of the wiring card (see Figure 1-8 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. Align the wiring card connectors with the headers on the card stack at the front of the extrusion.
b. Secure the wiring card to the extrusion with the card's eight Phillips pan-head screws. The sequence use for tightening the wiring card is indicated by the circled numbers in Figure 2-5. Use a torque range of 5.5 to 5.7 in-lb when tightening the wiring card.
Step 2 Install the cables. The wiring card has a label beside to each port (J3, J4, and so forth).
For a (0-) or 1-WMIC configuration, connect the cables to the wiring card as shown in Figure 2-12.
Figure 2-12 0- or 1-WMIC Configuration
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Connect the FESMIC 10-pin FE3X cable to WMIC 1, if WMIC is present.
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Connect the FESMIC 10-pin FE1X cable to port J14 on the wiring card.
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For a 2-WMIC configuration, connect cables to the wiring card as shown in Figure 2-13.
Figure 2-13 2-WMIC Configuration
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Connect the FESMIC 10-pin FE1X cable to port J14 on the wiring card.
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Connect the FESMIC10-pin FE2X cable to WMIC 2.
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Connect the FESMIC 10-pin FE3X cable to WMIC 1.
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Connect the WMIC 2 24-pin cable to port J2 on the wiring card.
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For a 3-WMIC configuration, connect cables to the wiring card as shown in Figure 2-12.
Figure 2-14 3-WMIC Configuration
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Connect FESMIC 10-pin FE1X cable to WMIC 3.
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Connect the FESMIC 10-pin FE2X cable to WMIC 2.
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Connect the FESMIC's 10-pin FE3X cable to WMIC 1.
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Connect WMIC 3 24-pin cable to port J3 on the wiring card.
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Connect the WMIC 2 24-pin cable to port J2 on the wiring card.
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Step 3 Route the 20-pin LED cable over the other cables to secure them, and connect the LED cable to port J5 on the wiring card.
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.
Figure 2-15 I/O End Cap
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power cables
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I/O transition board
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I/O end cap groove and gasket
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Step 2 Fit the I/O transition board with the wiring card. Figure 2-4 shows the I/O transition board.
Step 3 Verify that the gasket is fully centered in the groove (shown in Figure 2-4).
Step 4 Press the I/O end cap in place.
Step 5 Use a 3/8-inch socket wrench to secure the I/O end cap with (4) 1/4-20x1 1/4-inch- long bolts. The torque range for the I/O end cap bolts is from 58 to 68 in-lb.
Note 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. Figure 2-16 shows the parts of a protective end cap cover.
Figure 2-16 Cisco 3200 Rugged Enclosure Protective End Cap Cover
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Hinge point
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NEC cable pass-through
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Holes for 8/32-inch-long protective end cap cover screws
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4
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Hinge/mounting bracket
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5
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Mounting bolt
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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.
Step 4 Use a 3/8-inch socket wrench to secure the antenna end cap with 4 1/4-20x1.25-inch-long bolts. The torque range for the antenna end cap bolts are 58 to 68 in-lb.
Applying New I/O End Cap Function Labels
To apply new I/O end cap function labels, follow these steps:
Step 1 Label the WMIC console ports.
Step 2 If you have more than one WMIC installed in the router, remove the W2 plate on the I/O end cap and replace it with the DB-9 console connector.
1 The port designations are determined by the settings on the card. Your port designations might be different. The ports are on the back of the card stack.
