Replacing T640 Packet Forwarding Engine Components

Replacing a T640 FPC

The FPCs are hot-insertable and hot-removable. When you remove an FPC, the router continues to function, although the PIC interfaces installed on the FPC being removed no longer function.

The router holds up to eight FPCs, which are installed vertically in the front of the router. An empty FPC weighs approximately 25 lb (11.3 kg) and a fully configured FPC can weigh up to 32 lb (14.5 kg).

1. Removing a T640 FPC
2. Installing a T640 FPC

Removing a T640 FPC

To remove an FPC (see Figure 1):

1. Have ready a replacement FPC or FPC blank panel and an antistatic mat for the FPC. Also have ready rubber safety caps for each PIC using an optical interface on the FPC that you are removing.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
3. Label the cables connected to each PIC on the FPC so that you can later reconnect the cables to the correct PICs.
4. Use one of the following methods to take the FPC offline:
   • Press and hold the FPC online/offline button. The green OK LED next to the button begins to blink. Hold the button down until the LED goes out. The LEDs and online/offline button for each FPC are located directly above it on the craft interface.
   • Issue the CLI command:
     user@host>request chassis fpc slot slot-number offline

     For more information about the command, see the Junos OS System Basics and Services Command Reference .

5. Disconnect the cables from the PICs installed in the FPC. Immediately cover each fiber-optic transceiver and the end of each cable with a rubber safety cap. Arrange the disconnected cables in the cable management system, to prevent the cables from developing stress points.

   Warning: Do not look directly into the ends of fiber-optic cables or into the transceivers on the PIC faceplate. Fiber-optic transceivers and cable connected to transceivers emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

6. If you are removing a Type 2 FPC or Type 3 FPC, loosen the screws inside the ejector handles at the top and bottom of the FPC faceplate.
7. Simultaneously turn both the ejector handles counterclockwise to unseat the FPC.
8. Grasp the handles, and slide the FPC straight out of the card cage halfway.
9. Place one hand around the front of the FPC (the PIC housing) and the other hand under it to support it. Slide the FPC completely out of the chassis, and place it on the antistatic mat or in the electrostatic bag.

   Caution: The weight of the FPC is concentrated in the back end. Be prepared to accept the full weight—up to 32 lb (14.5 kg)—as you slide the FPC out of the chassis. When the FPC is out of the chassis, do not hold it by the ejector handles or edge connectors. They cannot support its weight. Do not stack FPCs on top of one another after removal. Place each one individually in an electrostatic bag or on its own antistatic mat on a flat, stable surface.

10. If necessary, remove each installed PIC from the FPC. For information about removing a PIC, see Removing a T640 PIC.
11. After you remove each PIC, immediately place it on an antistatic mat or in an electrostatic bag.
12. If you are not reinstalling a FPC into the emptied FPC slot within a short time, install a blank FPC panel over the slot to maintain proper airflow in the FPC card cage.

    Caution: After removing an FPC from the chassis, wait at least 30 seconds before reinserting it, removing an FPC from a different slot, or inserting an FPC into a different slot.

Figure 1: Removing a T640 FPC

Installing a T640 FPC

To install an FPC (see Figure 3):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
2. Place the FPC on an antistatic mat.
3. Take each PIC to be installed in the replacement FPC out of its electrostatic bag, and identify the slot on the FPC where it will be connected.
4. Verify that each fiber-optic PIC has a rubber safety cap covering the PIC transceiver. If it does not, cover the transceiver with a safety cap.
5. Install each PIC into the appropriate slot on the FPC. For information on installing a PIC, see Installing a T640 PIC.
6. Locate the slot in the FPC card cage in which you plan to install the FPC.
7. Inspect the slot in the FPC card cage to verify that there are no missing or bent pins on the midplane.
8. Inspect the FPC to verify that the connectors are not misaligned or damaged.

   Caution: When the FPC is out of the chassis, do not hold it by the ejector handles or edge connectors. They cannot support its weight.

9. Verify that the FPC is right-side up, with the components on the right of the FPC.
10. Lift the FPC into place and carefully align the bottom and top of the FPC with the guides inside the card cage.

    Figure 2: Installing an FPC

    
11. Gently rest the bottom edge of the FPC on the bottom edge of the slot opening, making contact a short distance forward of the power connector.

    Caution: Take care not to bend or otherwise damage the power connector prongs.

12. Slowly slide the FPC all the way into the card cage until you feel resistance.

    Caution: To avoid damaging the FPC, make sure that you keep the bottom of the FPC flat as you slide it into the slot.

13. Starting with the ejector handles on the FPC faceplate nearly horizontal, simultaneously turn both ejector handles clockwise to seat the FPC.
14. If you are installing a Type 2 FPC or Type 3 FPC, tighten the screws inside the ejector handles to secure the FPC. Do not overtighten them.
15. Remove the rubber safety cap from each fiber-optic transceiver and cable.

    Warning: Do not look directly into the ends of fiber-optic cables or into the transceivers on the PIC faceplate. Fiber-optic transceivers and cable connected to transceivers emit laser light that can damage your eyes.

16. Insert the appropriate cable into the cable connector ports on each PIC on the FPC. Secure the cables so that they are not supporting their own weight. Place excess cable out of the way in a neatly coiled loop, using the cable management system. Placing fasteners on a loop helps to maintain its shape.

    Caution: Do not let fiber-optic cable hang free from the connector. Do not allow fastened loops of cable to dangle, which stresses the cable at the fastening point.

    Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

17. Use one of the following methods to bring the FPC online:
    • Press and hold the FPC online/offline button until the green OK LED next to the button lights steadily, in about 5 seconds. The LEDs and online/offline button for each FPC are located directly above it on the craft interface.
    • Issue the CLI command:
      user@host>request chassis fpc slot slot-number online

      For more information about the command, see the Junos OS System Basics and Services Command Reference .

    Caution: After the OK LED lights steadily, wait at least 30 seconds before removing the FPC again, removing an FPC from a different slot, or inserting an FPC in a different slot.

You can verify correct FPC and PIC functioning by issuing the show chassis fpc and show chassis fpc pic-status commands, as described in Maintaining T640 FPCs and Maintaining T640 PICs and PIC Cables.

Figure 3: Installing a T640 FPC

Replacing a T640 PIC

1. Removing a T640 PIC
2. Installing a T640 PIC

Removing a T640 PIC

1. Place an electrostatic bag or antistatic mat on a flat, stable surface to receive the PIC. If the PIC connects to fiber-optic cable, have ready a rubber safety cap for each transceiver and cable.
2. Attach an electrostatic discharge ESD grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
3. Use one of the following methods to take the PIC offline:
   • Press and hold the online/offline button until the PIC LED goes out (about 5 seconds).

     For a PIC installed in a Type 1 FPC, use a tool—such as a flat-blade screwdriver—to press the button slightly beneath the faceplate of the PIC. For a PIC installed in a Type 2 FPC or Type 3 FPC, use a narrow-ended tool that fits inside the opening that leads to the button.

   • Issue the following CLI command:
     user@host> request chassis pic fpc-slot fpc-slot pic-slot pic-slot offline

     For more information about the command, see the Junos OS System Basics and Services Command Reference .

4. Label the cables connected to the PIC so that you can later reconnect each cable to the correct PIC.
5. Disconnect the cables from the PIC. If the PIC uses fiber-optic cable, immediately cover each transceiver and the end of each cable with a rubber safety cap.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

6. Arrange the cable in the cable management system to prevent it from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

7. Unseat the PIC:
   • Type 1 or Type 2 PIC—Loosen the captive screws at the top and bottom of the PIC faceplate.
   • Type 3 PIC—Loosen the captive screw at the bottom of the PIC faceplate, then twist the ejector handle at the top of the faceplate and counterclockwise to unseat the PIC.
   • Type 4 PIC—Twist the ejector handle at the bottom of the PIC faceplate, then twist the ejector handle at the top of the faceplate and counterclockwise to unseat the PIC.
8. Slide the PIC out of the FPC card carrier, and place it in the electrostatic bag or on the antistatic mat.
9. If you are not reinstalling a PIC into the emptied PIC slot within a short time, install a blank PIC panel over the slot to maintain proper airflow in the FPC card cage.

Figure 4: Removing a PIC

Installing a T640 PIC

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
2. If the PIC uses fiber-optic cable, verify that there is a rubber safety cap over each transceiver on the faceplate. Install a cap if necessary.
3. Align the notches in the connector at the rear of the PIC with the notches in the PIC slot in the FPC and then slide the PIC in until it lodges firmly in the FPC.

   Caution: Slide the PIC straight into the slot to avoid damaging the components on the bottom of the PIC.

4. Secure the PIC to the FPC faceplate:
   • Type 1 or Type 2 PICs—Tighten the captive screws at the top and bottom of the faceplate.
   • Type 3 PICs—Turn the ejector handle at the top of the PIC faceplate clockwise, then tighten the captive screw at the bottom of the faceplate.
   • Type 4 PIC—Twist the ejector handle at the bottom of the PIC faceplate, then twist the ejector handle at the top of the faceplate and counterclockwise to unseat the PIC.
5. If the PIC uses fiber-optic cable, remove the rubber safety cap from each transceiver and the end of each cable.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

6. Insert the appropriate cables into the cable connectors on the PIC.
7. Arrange each cable in the cable management system to prevent the cable from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Do not let fiber-optic cable hang free from the connector. Do not allow fastened loops of cable to dangle, which stresses the cable at the fastening point.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

8. Use one of the following methods to bring the PIC online:
   • Press the PIC offline/online button until the PIC LED lights green. For a PIC installed in a Type 1 FPC, use a tool—such as a flat-blade screwdriver—to press the button slightly beneath the faceplate of the PIC. For a PIC installed in a Type 2 FPC or Type 3 FPC, use a narrow-ended tool that fits inside the opening that leads to the button.
   • Issue the following CLI command:
     user@host> request chassis pic fpc-slot fpc-slot pic-slot pic-slot online

     For more information about the command, see the Junos OS System Basics and Services Command Reference .

   The normal functioning status LED confirms that the PIC is online. You can also verify correct PIC functioning by issuing the show chassis fpc pic-status command.

Figure 5: Installing a PIC

Replacing T640 PIC Cables

Removing and installing PIC cables do not affect router function, except that a PIC does not receive or transmit data while its cable is disconnected. To replace a PIC cable, , perform the following procedures:

1. Removing a T640 PIC Cable
2. Installing a T640 PIC Cable

Removing a T640 PIC Cable

1. If the PIC connects to fiber-optic cable, have ready a rubber safety cap for each cable and transceiver.
2. If removing all cables connected to the PIC, use one of the following methods to take the PIC offline:
   • Press its online/offline button. For a PIC installed in a Type 1 FPC, use a tool—such as a flat-blade screwdriver—to press the button slightly beneath the faceplate of the PIC. For a PIC installed in a Type 2 FPC or Type 3 FPC, use a narrow-ended tool that fits inside the opening that leads to the button. Press and hold the button until the PIC LED goes out (about 5 seconds).
   • Issue the CLI command:
     user@host> request chassis pic fpc-slot fpc-slot pic-slot pic-slot offline

     For more information about the command, see the Junos OS System Basics and Services Command Reference .

3. Unplug the cable from the cable connector port. If the PIC uses fiber-optic cable, immediately cover each transceiver and the end of each cable with a rubber safety cap.

   Warning: Do not look directly into the ends of fiber-optic cables or into the transceivers on the PIC faceplate. Fiber-optic transceivers and cable connected to transceivers emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

4. Remove the cable from the cable management system and detach it from the destination port.

Installing a T640 PIC Cable

1. Have ready a length of the type of cable used by the PIC. For cable specifications, see the T640 Core Router PIC Guide .
2. If the PIC cable connector port is covered by a rubber safety plug, remove the plug.

   Warning: Do not look directly into the ends of fiber-optic cables or into the transceivers on the PIC faceplate. Fiber-optic transceivers and cable connected to transceivers emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

3. Insert the cable connector into the cable connector port on the PIC faceplate.
4. Arrange the cable in the cable management system, to prevent it from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

   Caution: Do not let fiber-optic cable hang free from the connector. Do not allow fastened loops of cable to dangle, which stresses the cable at the fastening point.

5. Insert the other end of the cable into the destination port.
6. Repeat the previous steps for any additional cables.
7. If the PIC is offline (its failure indicator LED is lit), use one of the following methods to bring the PIC online:
   • Press the PIC offline/online button until the PIC LED lights green. For a PIC installed in a Type 1 FPC, use a tool—such as a flat-blade screwdriver—to press the button slightly beneath the faceplate of the PIC. For a PIC installed in a Type 2 FPC or Type 3 FPC, use a narrow-ended tool that fits inside the opening that leads to the button.
   • Issue the CLI command:
     user@host>request chassis pic fpc-slot fpc-slot pic-slot pic-slot online

     For more information about the command, see the Junos OS System Basics and Services Command Reference .

   The normal functioning indicator LED confirms that the PIC is online. You can also verify correct PIC functioning by issuing the show chassis fpc pic-status command described in Maintaining T640 PICs and PIC Cables.

Figure 6: Connecting Fiber-Optic Cable to a PIC

Replacing a T640 SFP

1. Removing a T640 SFP
2. Installing a T640 SFP

Removing a T640 SFP

Small form-factor pluggables (SFPs) are transceivers that can be removed from a PIC. SFPs are hot-insertable and hot-removable. Removing an SFP does not interrupt PIC functioning, but the removed SFP no longer receives or transmits data.

Figure 7: Small Form-Factor Pluggable (SFP)

To remove an SFP (see Figure 7):

1. Place an electrostatic bag or antistatic mat on a flat, stable surface to receive the SFP. Have ready a rubber safety cap for the SFP transceiver and the cable.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
3. Label the cable connected to the SFP so that you can later reconnect it to the correct SFP.
4. Disconnect the cable from the SFP. Immediately cover the transceiver and the end of the cable with a rubber safety cap.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

5. Arrange the cable in the cable management system to prevent it from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

6. Pull the ejector handle away from the SFP faceplate to unseat the SFP from the PIC. Pull the SFP out of the PIC and place it on the antistatic mat or in the electrostatic bag.

Caution: After removing a transceiver from the chassis, wait at least 30 seconds before reinserting it or inserting a transceiver into a different slot.

Installing a T640 SFP

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
2. Verify that a rubber safety cap covers the SFP transceiver, installing one if necessary.
3. Orient the SFP over the port in the PIC so that the connector end will enter the slot first and the SFP connector faces the appropriate direction:
   • If the PIC has ten SFP ports, the ports are arranged in two columns. The SFP connector faces to the right for ports in the left column, and to the left for ports in the right column.
   • If the PIC has one or two SFP ports, the SFP connector faces to the left on platforms in which FPCs are installed vertically in the chassis, and faces upward on platforms in which FPCs are installed horizontally in the chassis.
4. Slide the SFP into the slot. If there is resistance, remove the SFP and flip it so that the connector faces the other direction.
5. Remove the rubber safety cap from the transceiver and the end of the cable, and insert the cable into the transceiver.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

6. Arrange the cable in the cable management system to prevent the cable from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Do not let fiber-optic cable hang free from the connector. Do not allow fastened loops of cable to dangle, which stresses the cable at the fastening point.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

7. Verify that the status LEDs on the PIC faceplate indicate that the SFP is functioning correctly (there is an LED for each SFP port). For more information about the PIC LEDs, see the T640 Core Router PIC Guide . You can also verify PIC functioning by issuing the show chassis fpc pic-status command.

Replacing a T640 XENPAK Module

XENPAK modules are optical transceivers that can be removed from a PIC.

XENPAK modules are hot-insertable and hot-removable. Removing a XENPAK module does not interrupt PIC functioning, but the removed module no longer receives or transmits data.

1. Removing a T640 XENPAK Module
2. Installing a T640 XENPAK Module

Removing a T640 XENPAK Module

1. Place an electrostatic bag or antistatic mat on a flat, stable surface to receive the XENPAK module. Have ready a rubber safety cap for the XENPAK transceiver and the cable.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
3. Label the cable connected to the XENPAK module so that you can later reconnect it to the correct module.
4. Disconnect the cable from the XENPAK module. Immediately cover the transceiver and the end of the cable with a rubber safety cap.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

5. Arrange the cable in the cable management system to prevent it from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

6. Unscrew the thumbscrews at the top and bottom of the XENPAK module.
7. Slide the module out of the PIC and place it in the electrostatic bag or on the antistatic mat.

Figure 8: Removing a XENPAK Module

Installing a T640 XENPAK Module

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
2. Verify that a rubber safety cap covers the XENPAK transceiver. Install one if necessary.
3. Orient the XENPAK module so that the optical port faces out, and the transmit (TX) port is above the receive (RX) port (see Figure 9).
4. Slide the XENPAK module into the slot.
5. Tighten the thumbscrews at the top and bottom of the XENPAK module. Verify that the module is seated properly.
6. Remove the rubber safety cap from the transceiver and the end of the cable. Insert the cable into the transceiver.

   Warning: Do not look directly into a fiber-optic transceiver or into the ends of fiber-optic cables. Fiber-optic transceivers and fiber-optic cable connected to a transceiver emit laser light that can damage your eyes.

   Caution: Do not leave a fiber-optic transceiver uncovered except when inserting or removing cable. The safety cap keeps the port clean and prevents accidental exposure to laser light.

7. Arrange the cable in the cable management system to prevent the cable from dislodging or developing stress points. Secure the cable so that it is not supporting its own weight as it hangs to the floor. Place excess cable out of the way in a neatly coiled loop in the cable management system. Placing fasteners on the loop helps to maintain its shape.

   Caution: Do not let fiber-optic cable hang free from the connector. Do not allow fastened loops of cable to dangle, which stresses the cable at the fastening point.

   Caution: Avoid bending fiber-optic cable beyond its minimum bend radius. An arc smaller than a few inches in diameter can damage the cable and cause problems that are difficult to diagnose.

8. Verify that the status LEDs on the PIC faceplate indicate that the XENPAK module is functioning correctly. For more information about the PIC LEDs, see the T640 Core Router PIC Guide . You can also verify PIC functioning by issuing the show chassis fpc pic-status command.

Figure 9: Installing a XENPAK Module