Cisco 12012 Installation and Configuration Guide
Maintaining the Router
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Maintaining the Cisco 12012

Table Of Contents

Maintaining the Cisco 12012

Cleaning and Replacing the Air Filter Assembly

Removing the Air Filter

Cleaning the Air Filter

Replacing the Air Filter Assembly

Removing the Old Air Filter Assembly

Installing A New Air Filter Assembly

Removing and Replacing an AC-Input Power Supply

Removing an AC-Input Power Supply

Installing a New or Replacement AC-Input Power Supply

Checking the Replacement of an AC-Input Power Supply

Removing and Replacing a DC-Input Power Supply

Removing a DC-Input Power Supply

Installing a New or Replacement DC-Input Power Supply

Checking the Replacement of a DC-Input Power Supply

Removing and Replacing a Blower Module

Removing and Replacing the Card Cage Assembly

Powering Down the Cisco 12012

Removing the Power Supplies

Removing the Cards from the Upper Card Cage

Removing a Line Card from the Upper Card Cage

Removing a RP from the Upper Card Cage

Removing an Alarm Card from the Upper Card Cage

Removing the Cards from the Lower Card Cage

Removing the System Grounding

Removing the Card Cage Assembly

Installing a New Card Cage Assembly

Replacing the Cards in the Lower Card Cage

Replacing the Cards in the Upper Card Cage

Reattaching the System Grounding

Replacing the Power Supplies

Removing and Replacing a Route Processor

Removing and Replacing an Alarm Card

Removing and Replacing a Clock and Scheduler Card or Switch Fabric Card

Upgrading RP and Line Card Memory


Maintaining the Cisco 12012


After you install and configure your Cisco 12012, you might need to perform specific maintenance procedures and operations to ensure that the router continues to operate properly, to upgrade specific system components or replace field replaceable units (FRUs). This chapter describes procedures and maintenance operations required to maintain your Cisco 12012. (Where appropriate, you are referred to specific procedures in the chapter ".")

Your Cisco 12012 is configured to your order and is ready for installation and startup when it leaves the factory. In the future, as your networking requirements change, you might need to upgrade your system, add components, replace components, or change the initial hardware configuration.

Following are specific maintenance procedures you might require for your Cisco 12012:

Cleaning and replacing the air filter assembly

Replacing the following components:

AC-input power supply

DC-input power supply

Blower module

Card cage assembly

Route Processor (RP)

Alarm card

Clock and scheduler card and switch fabric card

Upgrading CPU memory on the RP


Note   Line card specific information is included in the individual configuration notes that ship with the line cards.


To prevent problems, before performing any procedures in this chapter, review the section "Safety Recommendations" in the chapter "Preparing for Installation."

Review the safety warnings listed in the document Regulatory Compliance and Safety Information for the Cisco 12012 Gigabit Switch Router (Document Number 78-4347-xx) that accompanied your Cisco 12012 before you reconfigure or perform maintenance procedures for your router.

Cleaning and Replacing the Air Filter Assembly

The Cisco 12012 has a serviceable air filter assembly mounted in a hinged tray on the front of the lower card cage. The air filter removes dust from the room air drawn into the Cisco 12012 by the two blower modules. There are two components to the air filter assembly:

Air filter

Air filter tray

The air filter should be inspected for any rips or tears during the initial installation and then checked one time per year thereafter. If the air filter appears dirty during these inspections, you can vacuum it. For instructions on cleaning the air filter, see "Cleaning the Air Filter" on page 7.


Note   The air filter has a normal life of 10 years when the chassis is installed in a clean-room environment.


You need the following tools to complete the air filter maintenance procedure:

3/16-inch Phillips screwdriver

M3 Phillips, pan head screws

ESD-preventive wrist strap

Vacuum cleaner

Replacement air filter (Product Number GSR12-FLTR-ENH=)

Air filter assembly (Product Number GSR12-FLT-UPG=)


Note   You can perform this procedure while the Cisco 12012 remains powered up.


Removing the Air Filter

Perform the following steps to remove the air filter:


Step 1 Attach an ESD-preventive wrist strap to yourself and to one of the two ESD connection sockets located on the front edges of the card cage or to bare metal on the card cage frame. (See Figure 7-1.)

Figure 7-1 Connecting an ESD-Preventive Strap to the Cisco 12012


Caution   
Do not place any tools on the air filter tray or within the lower card cage. Damaging the honeycomb screen on the air filter tray or with the lower card cage could restrict the airflow causing an overtemperature condition in the router.

Step 2 Use the 3/16-inch flat-blade screwdriver to loosen the two captive screws on the air filter tray.

Step 3 Pivot the air filter tray down, away from the card cage.


Warning   

There might be exposed line or fabric cards. Extreme caution is advised when working around an open card cage.


Step 4 Grasp the old air filter with your fingers and gently pull it out of the air filter tray. (See Figure 7-2.)


Note   An indentation on each side of the old air filter tray holds the old air filter inside the tray.


Figure 7-2 Removing the Air Filter

Step 5 Visually check the condition of the air filter.

If the air filter appears dirty, you can vacuum it. For instructions on cleaning the air filter, see "Cleaning the Air Filter" on page 7.

If the filter appears worn or is torn, you must replace it. For instructions on replacing the air filter assembly, see "Replacing the Air Filter Assembly" on page 7.

Cleaning the Air Filter

Perform the following steps clean the air filter with a vacuum cleaner:


Step 1 Move the air filter away from the lower card cage opening.

Step 2 Vacuum the surface of the filter thoroughly.


Caution   
Do not vacuum the filter while it is installed or near the lower card cage opening; doing so can dislodge substantial amounts of dust, which could be drawn into the card cage assembly. Never wash a filter and install it in the system. Moisture drawn into the system can damage the components.

Replacing the Air Filter Assembly

The following sections describe how to remove and install a replacement air filter assembly. The air filter assembly includes a new air filter and air filter tray.

Removing the Old Air Filter Assembly

Installing A New Air Filter Assembly

Removing the Old Air Filter Assembly

The following procedure guides you through the removal of the old air filter assembly.


Caution   
To prevent damage, do not place any tools on the air filter tray or inside the card cage. Laying tools inside either the card cage or on the air filter tray could restrict the air flow and cause an overtemperature condition in the Cisco 12012.


Warning   

There might be exposed line or fabric cards. Extreme caution is advised when working around an open card cage.



Step 1 Set the old air filter aside.

Step 2 Close the air filter tray and use only finger pressure to tighten the two captive screws to the chassis.

Step 3 Use the Number 1 Phillips screwdriver to remove the five screws used to attach the bottom hinge of the old air filter tray to the chassis. (See Figure 7-3.)


Note   Save the five screws when removing the old air filter tray. They will be used to secure the new air filter tray to the chassis.


Step 4 Put the screws in a safe place away from the card cage.

Figure 7-3 Removing the Screws from the Old Air Filter Tray

Step 5 Loosen the two captive screws at the top of the old air filter tray until it is no longer attached to the card cage and chassis. Keep these screws for use later.


Note   Hold the old air filter tray firmly with one hand because it will be completely disconnected from the chassis.


Step 6 Move the old air filter tray away from the front of the card cage and chassis so that any dislodged dust will not be drawn into the card cage.

Installing A New Air Filter Assembly

This procedure guides you through installing a new air filter assembly for the Cisco 12012 Gigabit Switch Router. The new air filter tray is open on all sides and the bottom to increase the cooling capacity of the Cisco 12012 Gigabit Switch Router.


Step 1 While holding the new air filter tray firmly with one hand, ensure that the five holes in the hinge, located at the bottom of the new air filter tray, align with the holes in the chassis.

Step 2 Use finger pressure only to tighten the two captive screws at the top of the new air filter tray. (See Figure 7-4.)

Figure 7-4 New Air Filter Hinge Holes and Chassis Holes Alignment

Step 3 Use the Number 1 Phillips screwdriver and all five of the screws you saved earlier to fasten the bottom hinge of the new air filter tray to the chassis.

Step 4 After tightening all five screws, give each screw an additional one quarter turn to ensure a tight seal between the new air filter tray and the chassis.

Step 5 Verify that the two captive screws at the top of the air filter tray are loosened. (See Figure 7-4.)

Step 6 Allow the bottom hinge to hold the air filter tray in the full open position.

Step 7 Gently slide the new air filter, with the filter fabric facing downward, toward the floor, and the open side of the filter facing upward, into the new air filter tray until it is firmly seated against the bottom of the new air filter tray. (See Figure 7-5.)

Figure 7-5 Installing the New Air Filter in the New Air Filter Tray

Step 8 Raise the new air filter tray until it touches the chassis.

Step 9 With one hand apply pressure to the top of the new air filter tray. While holding the pressure, use the 3/16-inch flat-blade screwdriver to tighten the captive screws to ensure a good seal of the new air filter tray against the chassis.

Step 10 After tightening both captive screws with the 3/16-inch flat-blade screwdriver, give each screw an additional one quarter turn to ensure a tight seal between the new air filter tray and the chassis.

Step 11 Discard the old air filter and the old air filter tray.

Removing and Replacing an AC-Input Power Supply

The Cisco 12012 supports up to four AC-input power supplies. While the AC-input power supplies support online insertion and removal, you must observe the following conditions:

If your Cisco 12012 is configured with two AC-input power supplies, you must power off the system before removing and replacing a defective power supply.

If your Cisco 12012 is configured with three or four AC-input power supplies, you can remove and replace one power supply while the system remains powered up.


Warning   

AC operation requires a minimum configuration of two AC-input power supplies.


You need the following tools to perform this procedure:

1/4-inch flat-blade screwdriver

ESD wrist strap

The replacement AC-input power supply (Product Number PWR-GSR12-AC=) and the applicable AC power cord for your site


Caution   
Do not mix AC-input and DC-input power supplies in a Cisco 12012.

Removing an AC-Input Power Supply

Perform the following steps to remove an AC-input power supply:


Step 1 Attach an ESD wrist strap to your wrist and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 If you have not already done so, turn the power switch to the STANDBY position on the power supply you want to remove. (See a.)


Note   Turning the power supply switch to the STANDBY position also releases a latch that secures the power supply in the power supply bay.


Step 3 Disconnect the AC power cord from the source AC receptacle. (See b.)

Step 4 Release the spring clip on the power supply faceplate. (See c.)

Step 5 Disconnect the AC power cord from the power supply AC receptacle. (See d.)

Step 6 Loosen the captive screw on the power supply faceplate. (See e.)

Figure 7-6 Disconnecting an AC-Input Power Supply

Step 7 Grasp the power supply handle and pull straight out to disconnect the power supply from the backplane connector. Slide the power supply halfway out of the bay. (See .)

Figure 7-7 Removing an AC-Input Power Supply


Caution   
The AC-input power supply weighs 18 lb (8 kg). Use two hands when handling the power supply.

Step 8 Place your free hand underneath the power supply for support and slide the power supply completely out of the bay.

If you plan to return the old power supply to the factory, repackage it in the shipping container you received with the replacement power supply.

Installing a New or Replacement AC-Input Power Supply

If you plan to upgrade your system by installing additional power supplies, you can install the power supply without removing power from the system.


Note   We recommend attaching each AC-input power supply to an independent power source for full redundancy. We also recommend that you use an uninterruptable power source (UPS) to protect against power failures at your site. Each AC-input power supply operating between 200 VAC and 240 VAC requires a dedicated 20A service for North American use, or a 10A or 16A service for international use.



Caution   
The AC-input power supply weighs 18 lb (8 kg). Use two hands when handling the power supply.

Perform the following steps to install a new or replacement AC-input power supply:


Step 1 Attach an ESD wrist strap to your wrist and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 Verify that the power switch on the replacement supply is in the STANDBY position. (See .)

Step 3 If you are upgrading your Cisco 12012 with an additional AC-input power supply, you must remove the power supply blank covering the empty power supply bay before installing the power supply. To remove a power supply blank, complete the following steps:

(a) Loosen the captive screw on the power supply blank faceplate.

(b) Slide the power supply blank out the front of the power supply bay.

(c) Retain the blank for possible future use.


Caution   
To prevent damaging the power supply backplane connector, do not use excessive force when installing a power supply into the bay.


Note   The power supply bays are designated A1, A2, B1, and B2, from left to right. Install power supplies in the bays in the following order: A1, B1, A2, and B2. Any bay that does not have a power supply installed must have a power supply blank installed to maintain airflow and for EMI considerations.


Step 4 Using two hands to support and guide the power supply, slide it into the vacant bay. Push the power supply all the way into the power supply bay until the faceplate makes contact with the front of the bay.


Note   All electrical connections between the power supply and the backplane are made automatically when the power supply is fully inserted in the power supply bay.


Step 5 Tighten the captive screw on the power supply faceplate.

Step 6 Connect the AC power cord to the power supply AC receptacle. Clip the spring clip over the power cord plug.

Step 7 Connect the other end of the AC power cord to the source AC receptacle.

Step 8 Verify that any empty power supply bays have power supply blanks installed.

Step 9 Turn the power switch on each AC-input power supply to ON (|).


Note   Turning the power supply switch to ON (|) also engages a latch that secures the power supply in the power supply bay.


Checking the Replacement of an AC-Input Power Supply

To complete the power supply replacement, observe the LEDs on the power supply faceplate to verify that the power supply is operating properly. Then perform the following steps:


Step 1 Check the following to make sure they are secure:

Each power supply is inserted all the way into its bay, and the captive screw is tightened.

All power supply cords are attached to the power supply receptacles and secured with spring clips.

At the AC power-source end of the power cord, the cord is securely attached to the AC power connector.

The source AC voltage is within the range indicated on the power supply faceplate.

When two or more supplies are installed, each power cord is connected to a separate AC power source if possible.

All unused power supply bays have power supply blanks installed.

Step 2 Verify that the Cisco 12012 powers up correctly. Visually check that the green AC OK LED on the power supply faceplate is on: This indicates that the source AC voltage is within the range of 180 to 264 VAC.

If the AC OK LED is off, check for the following:

Verify that the source AC circuit breaker is on.

Verify that the AC power cord is firmly connected from the source AC circuit breaker to the power supply.

Check that the power supply power switch in the ON (|) position.

Step 3 Visually check that the red output fail LED flashes on and off for five seconds, then goes off.

If the output fail LED goes on and stays on, move the power supply to another bay if possible and turn the power switch ON (|). If the LEDs go on properly when the power supply is installed in another bay, suspect a faulty backplane connector in the power supply in which it was originally installed.

If the output fail LED goes on and stays on when the power supply is installed in a second bay, suspect a power supply failure or an adverse environmental condition (for example, the power supply has detected an overvoltage or overtemperature condition and has shut down).

If the output fail LED goes on only on one power supply, assume that the power supply or AC source (for that power supply) is faulty.

If the output fail LED goes on and stays on, on multiple power supplies connected to separate AC sources, suspect that an overvoltage or possibly an overtemperature condition has occurred in the power supply bay causing the power supplies to fail.

If the power supply fails to operate properly after several attempts to power it up, contact a service representative for assistance.

Removing and Replacing a DC-Input Power Supply

The Cisco 12012 supports up to two DC-input power supplies. If one power supply fails in systems configured with two DC-input power supplies, the second supply has sufficient capacity to maintain uninterrupted operation of the router while you replace the defective power supply.

You need the following tools to install or replace a DC-input power supply:

1/4-inch flat-blade screwdriver

ESD wrist strap

Voltmeter

10-mm nutdriver

The replacement DC-input power supply (Product Number PWR-GSR12-DC=)


Caution   
Do not mix AC-input and DC-input power supplies in a Cisco 12012.


Note   If you are upgrading your Cisco 12012 with a second DC-input power supply, you will need a source DC power cable and lead terminals to connect source DC power to the DC-input power supply. These parts are not available from Cisco Systems; they are available commercially. (For details on the type of DC power cable to use, refer to the section "Installing a New or Replacement DC-Input Power Supply" in this chapter.)


Removing a DC-Input Power Supply

Perform the following steps to remove a DC-input power supply:


Step 1 Attach an ESD wrist strap to your wrist and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 If you have not already done so, turn OFF (O) the power switch on the DC-input power supply.


Warning   

Voltages might be present on the DC-input power supply terminals. Turn off the power source circuit breaker and remove the power supply before accessing the terminals.



Note   Turning the power supply switch to OFF (O) releases a latch that secures the power supply in the power supply bay.


Step 3 Locate and turn off the source DC circuit breaker that services the power supply you want to remove. As an added precaution, tape the circuit breaker handle in the off position.

Step 4 Using a flat-blade screwdriver or a 10-mm nutdriver, turn the captive jackscrew counterclockwise (eject) on the power supply faceplate to unseat the power supply from the backplane power connector. Continue turning the jackscrew to disengage the jackscrew from the power supply bay (approximately 12 revolutions).

Step 5 Grasp the power supply handle and slide the power supply halfway out of the bay. (See .)

Figure 7-8 Removing a DC-Input Power Supply


Caution   
The DC-input power supply weighs 19 lb (8.3 kg). Use two hands when handling the power supply.

Step 6 Place your free hand underneath the power supply for support and slide the power supply completely out of the bay. Place the power supply face up on the floor in front of you.

Step 7 Loosen the two screws that secure the DC-input power supply front cover in place. Lift up slightly, then pull the front cover away from the power supply faceplate. Set the front cover aside. (See .)

Figure 7-9 Removing the DC-Input Power Supply Front Cover

Step 8 Remove the two screws that secure the power cable bracket to the power supply faceplate and remove the cable bracket. (See .) Set the bracket and screws aside.

Figure 7-10 Removing the Power Cable Bracket


Caution   
Before proceeding to the next step, verify that the source DC circuit breaker servicing the DC power supply you are removing is in the OFF position. Also verify that the power switch on the DC-input power supply is OFF (O). As an additional check, measure the voltages across the leads attached to the power supply you have removed. All readings should be zero volts.

Step 9 Disconnect the source DC power cable leads from the power supply lugs in the following order: negative (-), positive (+), and ground. (See .)

Figure 7-11 Disconnecting the DC-Input Power Supply

Step 10 Pull the DC power cable leads down through the power supply handle and set the power cable aside.


Caution   
As an added precaution, we strongly recommend that you place electrical tape over the exposed metal terminals on the power cable to prevent accidental contact between the leads, or the leads and ground.

Step 11 If leads are attached to the power supply circuit breaker external alarm terminal block, record on a piece of paper which terminals the leads are attached to for later reconnection.

Step 12 Disconnect the leads attached to the circuit breaker alarm terminal block. (Some sites might not have an external alarm system for the power supply circuit breaker.)

If you plan to return the old power supply to the factory, repackage it in the shipping container you received with the replacement power supply.

Installing a New or Replacement DC-Input Power Supply

This section provides the procedures for replacing a defective DC-input power supply or installing a second DC-input power supply. If you are upgrading your Cisco 12012 with a second DC-input power supply for power supply redundancy, you must meet the following site power and source DC power cable requirements prior to installing the second power supply:

A dedicated 60-amp service is available for the second power supply.

Three power cables—4 AWG, 0.204-inch (5.18-mm) diameter, high strand count. The cable's length is dependent on your router location. This cable is not available from Cisco Systems: it is available from any commercial cable vendor.

Three power lugs—Must be dual-hole with 0.625-inch (15.86-mm) centers and able to fit over M6 terminal studs. (See .) This type of lug is not available from Cisco Systems; electrical-connector vendors, such as Panduit, provide this type of lug.

Figure 7-12 DC Power Cable Lug

If you plan to upgrade your Cisco 12012 with a second DC-input power supply, you must remove the two power supply blanks covering the empty power supply bays before installing the power supply.

Perform the following steps to install a new or replacement DC-input power supply:


Step 1 Attach an ESD wrist strap to your wrist and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.


Caution   
The DC-input power supply weighs 19 lb (8.3 kg). Use two hands when handling the power supply.

Step 2 Remove the replacement DC-input power supply from its shipping container.

Step 3 Verify that the power switch on the replacement power supply is in the OFF (O) position.

Step 4 Loosen the two screws that secure the DC-input power supply front cover in place. Lift up slightly then pull the front cover away from the power supply faceplate. Set the front cover aside. (See .)

Step 5 Remove the two screws that secure the source DC power cable bracket to the power supply faceplate and remove the bracket.


Caution   
Before proceeding to the next step, verify that the source DC circuit breaker servicing the DC power supply you are replacing is in the OFF position. Also verify that the power switch on the DC-input power supply is OFF (O). As an additional check, measure the voltages across the DC power cable leads you intend to attach to the power supply. All readings should be zero volts.

Step 6 Thread the source DC power cable leads up underneath the power supply handle. Allow sufficient slack in the power cable for strain relief.


Note   The color coding of the source DC power cable leads to the DC-input power supply depends on the color coding of the site DC power source. Typically, green or green/yellow is used for ground. Since there is no color code standard for the DC wiring, you must ensure that the proper polarity is connected to the DC-input power supply. In some cases, the source DC cables might have a (+) or a (-) label. This is a relatively safe indication of the cable polarity.



Warning   

When installing the unit, the ground connection must always be made first and disconnected last.


Step 7 Remove the nut and locking washer from each power supply threaded terminal and attach the source DC power cable lugs to the power supply terminals in the following order: ground to ground, positive (+) to positive (+), and negative (-) to negative (-). (See .)

Step 8 Thread the power supply circuit breaker external alarm leads (if present) up through the power supply handle and attach them to the circuit breaker alarm terminal block on the power supply faceplate according to the notes you made in a previous step. (Some sites might not be equipped with a power supply circuit breaker external alarm.)

Step 9 Position the source DC power cable leads underneath the power supply handle on the power supply faceplate in the following order from left to right: negative (-), positive (+), and ground. Place the DC power cable bracket over the power cable leads and secure the cable leads and the cable bracket to the power supply faceplate with the two screws that you removed earlier. (See .)

Step 10 Verify that the source DC wiring from the source DC breaker to the power supply is correct and that the terminal connections on the power supply are correct and tight.

Step 11 Place the power supply front cover so that the keyholes are positioned over the two standoff screws on the power supply faceplate. Slide the cover down slightly to engage the two screws and secure it in place by tightening the two screws.

Step 12 If you plan to upgrade your Cisco 12012 with a second DC-input power supply, you must remove the two power supply blanks covering the empty power supply bays before installing the power supply. To remove a power supply blank, complete the following steps:

(a) Loosen the captive screw on the power supply blank faceplate that secures the power supply blank to the card cage assembly.

(b) Slide the power supply blank out of the front of the power supply bay.

(c) Repeat steps (a) and (b) to remove the second power supply blank. Retain the two power supply blanks for possible future use.


Caution   
To prevent damaging the backplane power connector, do not use excessive force when sliding the power supply into the bay.

Step 13 Using two hands to support and guide the power supply, slide it into the vacant bay. (See .) Push the power supply into the bay until the power supply captive jackscrew makes contact with the power supply bay.

Figure 7-13 Installing a DC-Input Power Supply


Note   To prevent connector alignment problems, apply even pressure to the power supply by pushing at the top of the power supply with one hand while you turn the captive jackscrew with the other hand.


Step 14 Using a flat-blade screwdriver or a 10-mm nutdriver, turn the captive jackscrew on the power supply faceplate clockwise (insert) to seat the power supply into the backplane power connector. Do not overtighten the jackscrew.


Note   All electrical connections between the power supply and the backplane are made automatically when the power supply is fully inserted in the power supply bay.


Checking the Replacement of a DC-Input Power Supply

Visually check the following before turning the power supply power switch ON (|):

Each power supply is inserted all the way into its bay, and the captive jackscrew is tightened.

Any unused power supply bays have power supply blanks installed.

All source DC power cables are securely attached to the power supply threaded terminals.

At the DC power-source end of the power cable, the cable is securely attached to the source DC circuit breaker.

The source DC voltage is within the range indicated on the power supply faceplate.

When two supplies are installed, each power supply must be connected to a separate 60-amp DC service.


Note   To complete the installation, turn on the source DC circuit breaker servicing the DC-input power supply.


Perform the following steps to verify that the DC-input power supply powers up correctly.


Step 1 Turn the power supply power switch to ON (|).


Note   Turning the power supply switch to ON (|) engages a latch that secures the power supply in the power supply bay.


Step 2 Verify that the Cisco 12012 powers up correctly. Visually check that the DC-input power supply input OK LED goes on and stays on.

Step 3 Visually check that the power supply output fail LED flashes on and off for five seconds, then goes off.

If the output fail LED remains on, suspect a power supply failure or an adverse environmental condition (the power supply has detected an overvoltage or overtemperature condition and has shut down).

If two power supplies are installed, and the output fail LED goes on only on one power supply, assume that the power supply or DC source (for that power supply) is faulty.

If the output fail LED goes on, on two power supplies that are connected to separate DC sources, assume that an overvoltage or overtemperature condition is causing the power supplies to fail.

If the power supply fails to operate properly after several attempts to power it up, contact a service representative for assistance.

Removing and Replacing a Blower Module

The Cisco 12012 has two blower modules that provide cooling air to the card cage assembly. The blower modules slide into and out of the top and bottom of the frame and attach to the frame with two captive screws each. You need a replacement blower module (Product Number GSR12-BLOWER=) and the old blower module front cover to perform this procedure.


Note   Remove and replace the blower module according to the procedures in the sections "Removing the Blower Modules" and "Reinstalling the Blower Modules" in the chapter "." Then proceed to the following procedure to verify that the new blower module is operating properly.


To verify that the replacement blower module is operating properly, perform the following steps:


Step 1 Check that the blower module is inserted all the way into the frame, the two captive screws are tightened, and that the blower module front cover is securely installed on the front of the blower module.

Step 2 Observe the green OK LED visible through the blower module front cover. The LED should come on as soon as the blower module is installed and power is applied to the system.

Step 3 Observe the red fail LED visible through the blower module front cover:

The LED should remain off indicating the three fans are operating normally.

If the red LED comes on, check that the blower module is completely installed in the frame. Try reseating the blower module.

If the red LED comes on and the blower module is completely installed in the frame, the replacement blower module might be faulty or the frame connector might be damaged. Exchange the top and bottom blower modules and see if the problem is with the blower module or with the frame connector.

If the blower module fails to operate properly, contact a service representative for assistance.

Removing and Replacing the Card Cage Assembly

This section covers the removal and replacement of the card cage assembly.


Note   The replacement card cage is shipped with only a new air filter installed; you must remove all other components from the old card cage assembly and install them in the replacement card cage assembly.


The card cage assembly comprises a single assembly that includes the upper card cage, the lower card cage, and the power supply bays. The card cage assembly slides into and out of the frame and attaches to the frame with six captive screws.

For ease of removal, all components, with the exception of the air filter, must be removed from the old card cage assembly. A fully populated card cage assembly weighs approximately 230 lb (104.3 kg); removing the components reduces the weight to 65 lb (29.5 kg).


Note   Where appropriate, you are referred to specific procedures in this chapter and to specific procedures in the chapter "."


You need the following tools to perform this procedure:

ESD wrist strap

1/4-inch flat-blade screwdriver

3/16-inch flat-blade screwdriver

10-mm nutdriver or wrench

Antistatic card mat

The card cage assembly (Product Number GSR12-CARDCAGE=)

Powering Down the Cisco 12012

Perform the following steps to power down the Cisco 12012:


Step 1 Turn the DC-input power supply power switch counterclockwise to the OFF (O) position (on an AC-input power supply, turn the power switch to STANDBY) on each power supply installed in the Cisco 12012.

Step 2 Verify that the system has powered down by checking that the input OK LED on each DC-input power supply (AC OK LED on the AC-input power supply) is off and that the green LED on each blower module is off.

Removing the Power Supplies

If your system is configured with AC-input power supplies, remove each power supply according to the procedures in the section "Removing an AC-Input Power Supply" in this chapter.

If your system is configured with DC-input power supplies, remove each power supply by performing Step 1 through Step 6 of the procedure in the section "Removing a DC-Input Power Supply" in this chapter.

Removing the Cards from the Upper Card Cage

This section provides the procedures for removing the line cards, RP, and alarm card from the upper card cage.


Note   You must remove any blank cards installed in the upper card cage and retain them for use in the replacement card cage. Blank cards must be installed in slots without cards to maintain proper air flow and for EMI considerations.


Removing a Line Card from the Upper Card Cage

Perform the following steps to remove a line card from the upper card cage:


Step 1 Attach an ESD wrist strap to your wrist and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 Proceeding from left to right, identify each line card and write down the following information:

The line card slot number. When you install the line cards in the replacement card cage assembly, install them in the same card slots.

The interface cable connections to the line card ports. You must reconnect the interface cables to the same line card ports.

Step 3 Proceeding from left to right in the upper card cage, select a line card. Starting with the bottom port on the line card (on line cards with multiple ports), disconnect the network interface cable from the bottom port on the line card. (See a.)

Step 4 Carefully remove the interface cable from the vertical cable-management bracket clips. (See b.)

Step 5 Carefully remove the interface cable from the vertical cable-management bracket clip nearest the line card port. (See c.)

Figure 7-14 Removing the Interface Cables from a Line Card

Step 6 Carefully remove the interface cable from the horizontal cable-management tray and set the interface cable aside.


Note   Repeat Step 3 through Step 6 for rest of the interface cables on that line card; then proceed to the next line card in the upper card cage. Continue the procedure until you have disconnected and removed all the line card interface cables from the cable-management system. Do not remove the vertical cable-management bracket from the line card.


Step 7 Remove all the line cards according to the procedure in the section "Removing the Cards from the Upper Card Cage" in the chapter "."

Removing a RP from the Upper Card Cage

The RP must be installed in upper card cage slot 0. If you have two RPs in your Cisco 12012, the second RP must be installed in slot 11 (from left to right). The factory configuration has the RP installed in slot 0. Identify the slot the RP occupies, make a note of it, disconnect the interface cables, and remove the RP according to the procedures in the section "Removing the Cards from the Upper Card Cage" in the chapter "."

After removing the RP, carefully place it on an antistatic mat. You must install the RP in the new card cage assembly.

Removing an Alarm Card from the Upper Card Cage

The alarm card occupies the rightmost slot (labeled Alarm card) in the upper card cage. Remove the alarm card according to the procedures in the section "Removing and Replacing an Alarm Card" in this chapter.

After removing the alarm card, carefully place it on an antistatic mat. You must install the alarm card in the new card cage assembly.

Removing the Cards from the Lower Card Cage

Perform the following steps to remove the clock and scheduler cards and the switch fabric cards from the lower card cage.


Note   The lower card cage is located behind the air filter tray on the front of the card cage assembly. The clock and scheduler cards and switch fabric cards in the lower card cage are located behind an air deflector panel. To remove the clock and scheduler cards and the switch fabric cards in the lower card cage, you must first open the air filter tray, then position and latch the air deflector panel up, out of the way.



Step 1 Remove all of the cards from the lower card cage according to the procedures in the section "Removing the Cards from the Lower Card Cage" in the chapter "."

Step 2 Release the air deflector latch (turn the latch clockwise) and lower the air deflector down to its stops.

Step 3 Pivot the air filter tray up so that it is flush with the front of the lower card cage and tighten the two captive screws.

Removing the System Grounding

Your system might have two system grounding lugs attached to two system receptacles located on the card cage assembly side flanges between the air filter tray and the power supply bays. You must remove the system grounding connector before you can remove the card cage assembly.

Perform the following steps to remove a system grounding lug from the card cage assembly:


Step 1 Remove the two screws, washers, and nuts that secure the system grounding lug to the card cage assembly. Save the mounting hardware, you will use it in a later procedure.

Step 2 Remove the system grounding cable and set it aside.

Repeat Step 1 and Step 2 for a second system grounding connector.

Removing the Card Cage Assembly

Remove the empty card cage assembly according to the procedures in the section "Removing the Card Cage Assembly" in the chapter "."


Caution   
An empty card cage assembly weighs 65 lb (29.5 kg). You need two people to safely lift the assembly. To prevent injury, keep your back straight and lift with your legs, not your back.

If you plan to return the old card cage assembly to the factory, repackage it in the shipping container you received with the replacement card cage assembly.

Installing a New Card Cage Assembly

The new card cage assembly is shipped with a new air filter. You must replace the components you removed from the old card cage assembly in the new card cage assembly. Install the replacement card cage assembly according to the procedures in the section "Reinstalling the Card Cage Assembly" in the chapter "."


Caution   
An empty card cage assembly weighs 65 lb (29.5 kg). You need two people to safely lift the assembly. To prevent injury, keep your back straight and lift with your legs, not your back.


Note   Proceed to the following sections to replace all components in the new card cage assembly.


Replacing the Cards in the Lower Card Cage

The lower card cage slots are keyed and color coded; clock and scheduler cards are installed in the upper two slots (light blue labels), and the switch fabric cards are installed in the lower three slots (magenta labels).

Install all of the cards from the lower card cage according to the procedures in the section "Removing and Replacing a Clock and Scheduler Card or Switch Fabric Card."

Replacing the Cards in the Upper Card Cage

Install the alarm card, RP, and the line cards in the upper card cage according to the following procedures:

Install the alarm card according to the procedures in the section "Removing and Replacing an Alarm Card" in this chapter.

Install the RP according to the procedures in the section "Reinstalling the Cards in the Upper Card Cage," in the chapter "."

Install the RP interface cables according to the procedures in section "Connecting Route Processor Cables," also in the chapter "."

Install the line cards according to the procedures in the section "Reinstalling the Cards in the Upper Card Cage," in the chapter "."

Install the line card interface cables according to the procedures in section "Connecting Line Card Cables," also in the chapter "."

Reattaching the System Grounding

Your system might have two system grounding cable lugs. The system grounding receptacles are located on the card cage assembly side flanges between the air filter tray and the power supply bays.

Perform the following steps to reattach the system grounding lugs to the card cage assembly:


Step 1 Position the system grounding lug over the card cage assembly system grounding receptacle.

Step 2 Secure the system grounding lug to the receptacle with two sets of screws, washers, and nuts.

Repeat Step 1 and Step 2 for a second system grounding connection.

Replacing the Power Supplies

If your system is configured with AC-input power supplies, install the power supplies according to the procedures in the section "Installing a New or Replacement AC-Input Power Supply" in this chapter.

If your system is configured with DC-input power supplies, install the power supplies according to the procedures in the section "Installing a New or Replacement DC-Input Power Supply" in this chapter.


Caution   
To maintain agency compliance requirements and meet EMI emissions standards in a Cisco 12012 system with fewer than four AC-input power supplies or only one DC-input power supply installed, power supply blanks must be installed in all empty power supply bays.

Removing and Replacing a Route Processor

The RP (Product Number GRP= or PRP=) must be installed in upper card cage slot 0. If you have two RPs in your Cisco 12012, the second RP must be installed in slot 11 (from left to right). The factory configuration has the RP installed in slot 0.


Note   You must power down the Cisco 12012 when you remove and replace the RP.

If you plan to replace the currently installed RP with a new RP, we recommend that you save the system configuration file, which currently resides in RP NVRAM, to a Flash memory card; otherwise, your system configuration file will be lost when you replace the RP.

For instructions on copying configuration files to Flash memory, refer to the section "Copying System Configuration Files Between RP Memory and a Flash Memory Card," in the chapter "."


Disconnect any interface cables attached to the RP and remove the RP according to the procedures in the section "Removing the Cards from the Upper Card Cage" in the chapter "."


Note   Remove any Flash memory cards from the PCMCIA slots on the RP. Retain the cards for installation in the new RP.


If you plan to return the old RP to the factory, repackage it in the shipping container you received with the replacement RP.

Install the replacement RP according to the procedures in section "Replacing the Cards in the Upper Card Cage," in the chapter "."

Install the RP interface cables according to the procedures in the section "Connecting Route Processor Cables," in the chapter "."

Removing and Replacing an Alarm Card

The alarm card occupies the right-most slot in the upper card cage (labeled Alarm card). Unlike the RP and line cards, the alarm card can only be installed in this slot.

The Cisco 12012 supports online insertion and removal of FRUs, which means you can remove and replace an alarm card while the Cisco 12012 remains powered up.

You need the following tools and parts to perform this procedure:

1/4-inch flat-blade screwdriver

antistatic mat

ESD wrist strap

The replacement alarm card (Product Number GSR12-ALRM=)

Perform the following steps to remove an alarm card:


Step 1 Attach an antistatic wrist strap to yourself and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 Disconnect any cables attached to the alarm card connectors.

Step 3 Loosen the two captive screws at the top and bottom of the alarm card. (See .)


Note   Unlike the line cards and RP, the alarm card does not have card ejector levers. The alarm card backplane connector is smaller, has fewer pins, and is easier to seat and unseat than the line cards and RP.


Step 4 Using the screwdriver blade, gently pry at the top and bottom of the card to unseat the card from the backplane connector.

Step 5 Grasp the card carrier edge with one hand and place your other hand under the carrier to support it (see .) Slide the alarm card out of the card slot and place it immediately on the antistatic mat.

Figure 7-15 Removing an Alarm Card

If you plan to return the old alarm card to the factory, repackage it in the shipping container you received with the replacement alarm card.

Perform the following steps to install a replacement alarm card:


Step 1 Attach an antistatic wrist strap to yourself and to one of the two ESD connection sockets located on the front edges of the upper card cage or to bare metal on the frame.

Step 2 Grasp the alarm card faceplate with one hand and place your other hand under the card carrier to support and guide it into the card cage slot labeled Alarm card.

Step 3 Carefully slide the alarm card carrier into the slot until it makes contact with the backplane connector, then stop. Avoid touching the card circuitry or any connectors.

Step 4 Carefully push on the top and bottom of the alarm card to seat it in the backplane connector.

Step 5 Tighten the two captive screws to secure the alarm card in the card slot.

Step 6 Connect any external devices to their respective connectors on the alarm card.

Removing and Replacing a Clock and Scheduler Card or Switch Fabric Card

The Cisco 12012 supports a maximum of two clock and scheduler cards and three switch fabric cards in the lower card cage. You must power down the Cisco 12012 when you remove and replace a clock and scheduler card. The Cisco 12012 can remain powered up when you remove and replace a switch fabric card.

The lower card cage is located directly behind the air filter tray and an air deflector. When you access the lower card cage, you must first lower the air filter tray, then raise and secure the air deflector.

Remove a clock and scheduler card or a switch fabric card according to the procedures in the section "Removing the Cards from the Lower Card Cage" in the chapter "."

Install a clock and scheduler card (Product Number GSR12-CSC=) or a switch fabric card (Product Number GSR12-SFC=) according to the procedures in the section "Replacing the Cards in the Lower Card Cage" in the chapter "."

If you plan to return the old clock and scheduler card or switch fabric card to the factory, repackage it in the shipping container you received with the replacement card.

Upgrading RP and Line Card Memory

The Cisco 12000 Series Gigabit Switch Router Memory Replacement Instructions (78-4338-xx), which is available on-line and on the Cisco CDROM, contains the latest information about memory requirements and replacing memory on the Cisco 12000 series RPs and line cards. Refer to that document before replacing or adding memory to your RP or line card.

You can find the Cisco 12000 Series Gigabit Switch Router Memory replacement instructions at Cisco.com:

http://www.cisco.com/univercd/cc/td/doc/product/core/cis12012/bfrcfig/4338bmem.htm