Cisco 12016, Cisco 12416, and Cisco 12816 Router Installation and Configuration Guide
Chapter 7 - Maintaining the Router
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Maintaining the Router

Table Of Contents

Maintaining the Router

Prerequisites and Preparation

Powering Off the Router

Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12000 Series Routers

Removing the Front Covers

Installing the Front Covers

Attaching Bezel Extenders to the Front Cover

Removing and Replacing the Air Filter Door Front Cover

Removing and Installing Front Doors on Cisco 12016 Enhanced Series Routers

Cleaning or Replacing the Chassis Air Filter

Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Original Series Routers

Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Enhanced Series Routers

Removing and Replacing Blower Modules

Upper and Lower Blower Module Orientation

Troubleshooting the Blower Installation

Removing and Replacing AC and DC Power Subsystem Components

Installation Guidelines

Power Supply and Power Shelf Compatibility

Installing Upgrade Kits

Removing and Replacing an AC Power Supply

Troubleshooting the AC Power Supply Installation

Removing and Replacing the Standard AC-Input Power Shelf

Removing and Replacing the Optional 2-Level AC-Input Power Shelf

Troubleshooting the AC Power Shelf Installation

Upgrading the AC-Input Power Shelf

Removing and Replacing a DC PEM

Troubleshooting the DC PEM Installation

Removing and Replacing the DC-Input Power Shelf

Troubleshooting the DC Power Shelf Installation

Removing and Replacing Cards from the Chassis

Removing and Replacing RP and Line Cards from the Upper and Lower Card Cages

Removing and Replacing an Alarm Card

Removing and Replacing Switch Fabric Cards

Upgrading the Switch Fabric

Upgrade Requirements

Upgrade Procedures

Removing and Installing a Chassis

Preparing the Replacement Chassis

Preparing the Installed Chassis for Removal

Removing and Installing System Components

Removing the Chassis from the Equipment Rack

Installing the Replacement Chassis

Removing and Replacing a Power Bus Board Fuse


Maintaining the Router


Your router is equipped as ordered and is ready for installation and startup when it is shipped. As your networking requirements change, you may need to upgrade the system by adding or changing components. This chapter describes how to maintain router components.

Procedures for maintaining the router are described in the following sections:

Powering Off the Router

Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12000 Series Routers

Removing and Installing Front Doors on Cisco 12016 Enhanced Series Routers

Cleaning or Replacing the Chassis Air Filter

Removing and Replacing Blower Modules

Removing and Replacing AC and DC Power Subsystem Components

Removing and Replacing an AC Power Supply

Removing and Replacing the Standard AC-Input Power Shelf

Removing and Replacing the Optional 2-Level AC-Input Power Shelf

Upgrading the AC-Input Power Shelf

Removing and Replacing a DC PEM

Removing and Replacing the DC-Input Power Shelf

Removing and Replacing Cards from the Chassis

Upgrading the Switch Fabric

Removing and Installing a Chassis

Removing and Replacing a Power Bus Board Fuse

Prerequisites and Preparation

Before you perform any of the procedures in this chapter, be sure that you:

Review the "Safety Guidelines" section on page 2-2.

Read the safety and ESD-prevention guidelines described in the "Preventing Electrostatic Discharge Damage" section on page 2-4.

Ensure that you have all of the necessary tools and equipment before beginning the procedure.

Have access to the following documents during the installation:

Regulatory Compliance and Safety Information for Cisco 12000 Series Routers publication that shipped with the router (PN 78-4347-xx)

Powering Off the Router

Most Cisco 12016, Cisco 12416, and Cisco 12816 Router field-replaceable units (FRUs) can be removed and replaced with the power on and the system operating. This is known as online insertion and removal (OIR). Power supplies, line cards, the RP, CSCs, SFCs, and alarm cards all support OIR. Unless otherwise noted, the maintenance tasks described in this chapter can be performed while the router remains powered on.

In some cases it may be necessary to power off the router, for example, to upgrade power supplies or to replace a power shelf. Use the following procedure to power off the router.


Step 1 Set the power switch on each power supply to the off (0) position.

Step 2 Power off all circuit breakers for the source power lines connected to the power supplies.

Step 3 Verify that the PWR OK indicator on each power supply is off.

Step 4 Verify that the OK indicator on each blower module is off.


Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12000 Series Routers

The chassis front covers for the power shelf and upper blower module, upper card cage, lower card cage, and lower blower module are fastened to the chassis by ball studs that insert into ball stud clips on the front of the chassis (Figure 7-1).

The partial front cover on the air filter door is fastened to the air filter door by four screws inserted from the back side of the air filter door. This partial front cover is referred to as the air filter door front cover.


Note Recently released routers have bezel extenders installed on the front covers (bezels) for the upper and lower card cages to bring the covers out an additional 2 inches (50.8 mm) to allow more room for cables. If your chassis does not have these extenders and you want to purchase them, contact Cisco sales. (See the "Attaching Bezel Extenders to the Front Cover" section if you are installing the bezel extenders.)


Removing the Front Covers

The front covers are held in place by ball studs that snap into clips on the chassis. Refer to Figure 7-1 and use the following procedure to remove the snap-on front covers.


Step 1 Grasp the outside edges of the upper blower module front cover and pull it straight out to detach the front cover from the chassis.

Step 2 Repeat Step 1 for the remaining front covers.


Installing the Front Covers

Refer to Figure 7-1 and use the following procedure to install the front covers.


Step 1 Hold the upper blower module front cover by its outside edges and align the ball studs with the ball stud clips on the front of the chassis.

Step 2 Push the front cover into the ball stud clips and the front cover is flush with the front of the chassis.

Step 3 Repeat Step 1 and Step 2 for the remaining front covers.


Figure 7-1 Router Chassis Front Covers

1

Ball stud

2

Ball stud clip


Attaching Bezel Extenders to the Front Cover

Use the following procedure to attach the bezel extenders to the card cage front cover.


Step 1 Remove the front covers from the chassis as described in the "Removing the Front Covers" section.

Step 2 Remove the four ball studs from the front cover.

Step 3 Screw the four ball studs into the threaded holes on the bezel extenders (two ball studs for each bezel extender) using a wrench to secure them (Figure 7-2, item 3).


Caution Do not overtighten the ball studs. Overtightening the ball studs could damage the threaded hole on the bezel extender.

Step 4 Attach the bezel extenders to the front cover:

a. Facing the inside of the front cover, align the screw holes in the left side bezel extender with the mounting screw holes in the front cover (Figure 7-2, item 4).


Note If you cannot align both screw holes on the front cover inserts, you have the incorrect bezel extender. Try the other bezel extender on this side.


b. Fasten the bezel extender to the front cover with the mounting screws (Figure 7-2, item 2).


Caution Do not overtighten the screws. Overtightening the screws could damage the threaded holes in the front cover.

c. Repeat Steps a and b to fasten the right side bezel extender to the other side of the front cover (Figure 7-2, item 4).

Figure 7-2 Attaching the Bezel Extenders to a Card Cage Front Cover

1

Line card and RP card cage front cover (bezel)

3

Ball studs

2

Mounting screws

4

Right and left side bezel extender


Step 5 Hold the card cage front cover by its outside edges and align the ball studs with the ball stud clips on the front of the chassis (Figure 7-3).

Figure 7-3 Attaching the Front Covers Using Bezel Extenders

1

Ball stud

2

Ball stud clip


Step 6 Push the front cover into the ball stud clips so that the front cover is flush with the front of the chassis.


Removing and Replacing the Air Filter Door Front Cover

Use the following procedure to remove and replace the air filter door front cover.


Step 1 Loosen the captive screws on the air filter door and pivot the door open (Figure 7-4).


Caution If the router uses an extended front cover bezel, the air filter door does not have enough space to open completely. Before you open the air filter door, you must remove the extended front cover.

Figure 7-4 Opening the Chassis Air Filter Door


Caution Be especially careful not to damage the honeycomb screen on the back of the air filter door and on the inside of the switch fabric card cage. Damaging the honeycomb screen can restrict the air flow and cause overheating in the router. It can also diminish EMI protection.

Step 2 Remove the (4) screws from each corner that fasten the partial front cover to the air filter door (Figure 7-5).

Set aside the screws; you will need them to install the replacement front cover.

Figure 7-5 Removing the Air Filter Door Front Cover

Step 3 Hold the replacement front cover by its outside edges and align the screw holes in the front cover with the holes on the air filter door.

Step 4 Secure the front cover to the air filter door using the (4) screws that you removed in Step  2.


Caution Do not overtighten the screws. Overtightening the screws can damage the threaded holes in the air filter door.

Step 5 Close the air filter door and tighten the captive screws (Figure 7-6).

Figure 7-6 Closing the Air Filter Door


Caution Align and seat the door carefully to avoid damaging the EMI-preventive gaskets on the door. The air filter door must be closed and secured at all times to maintain correct EMI performance.


Removing and Installing Front Doors on Cisco 12016 Enhanced Series Routers

The Cisco 12016 enhanced series routers have new front doors. The router ships with the door hinges mounted on the left side of the chassis so that they open from right-to-left. This section describes how to change the front doors to open from left-to-right by installing the hinges on the opposite side.

Use the following procedure to change the location of the hinges.


Note The illustrations in this procedure show the top front door, but the procedure is the same for either the top or bottom door.



Step 1 Open the top front door by pressing the right latch button (Figure 7-7).

Figure 7-7 Opening the Front Door

1

Front door latches


Step 2 Remove the front door by lifting the (top and bottom) hinge pins to free the door from the chassis (Figure 7-8).


Caution Make sure you are holding the front door securely so it does not drop when you release it from the chassis.

Figure 7-8 Removing or Installing Hinge Pins

Reinstall the hinge pins into the chassis hinge brackets

Step 3 Remove the bumpers and pivot blocks from the door as shown in Figure 7-9.

Figure 7-9 Removing the Bumpers and Pivot Blocks

1

Bumpers

2

Pivot blocks


Step 4 Reinstall the hardware to the opposite sides of the front door:

a. Mount pivot blocks to the left side and tighten the screws until snug.

b. Mount the bumpers to the right side and tighten the screws until snug.

Step 5 Attach the front door to the chassis:

a. Remove the hinge pins from the hinges on the right side of the chassis.

b. Align the pivot blocks on the front door with the hinges on the right side of the chassis and install the hinge pins to hold the door in place (see Figure 7-8).

c. Close the front door by pressing the latch button, allowing the door latch to engage with the hinge pins on the chassis.

Step 6 Repeat Step 1 through Step 5 for the bottom door.


Cleaning or Replacing the Chassis Air Filter

The Cisco 12016 series routers are equipped a user-serviceable air filter that removes dust drawn into the router. One time per month (or more often in dusty environments), examine the air filter for damage and cleanliness.


Caution Damage to the air filter can restrict the airflow, cause overheating in the router, and degrade EMI performance. Be careful when cleaning and replacing the filter.

The following procedures describe how to replace the air filter on original series routers and enhanced series routers.

Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Original Series Routers

Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Enhanced Series Routers

Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Original Series Routers

Use the following procedure to clean or replace an original series air filter.


Step 1 Loosen the captive screws on the air filter door and pivot open the door (Figure 7-10).


Caution If the router uses an extended front cover bezel, the air filter door does not have enough space to open completely. Before you open the air filter door, you must remove the extended front cover.

Figure 7-10 Opening the Chassis Air Filter Door

Step 2 Lift up the air filter and carefully slide it out the door (Figure 7-11).


Caution Be careful not to damage the honeycomb screens on the back of the air filter door and in the fabric card cage. Damage to the honeycomb screens can restrict airflow, cause overheating, and affect EMI performance.

Figure 7-11 Removing the Chassis Air Filter

Step 3 Visually check the condition of the air filter to determine whether to clean it or install a new replacement.

Dirty—You can vacuum or replace the filter.


Caution Do not vacuum the air filter while it is installed in the chassis. You must remove the air filter completely before you clean it to prevent contaminants from being drawn into the bays or cage.

Worn or torn—If the filter appears worn or torn, dispose of it in a responsible manner and install a replacement air filter (ACS-GSR16-FLTR=).

Step 4 Position the metal braces on the back of the air filter to face toward the switch fabric and alarm card cage. Slide the new or cleaned air filter into the air filter door (Figure 7-12).

Figure 7-12 Installing the Chassis Air Filter

Step 5 Lift up the air filter door so that the four guide pins are inserted in the corresponding holes on each side of the switch fabric card cage (Figure 7-13).


Caution Align and seat the door carefully to avoid damaging the EMI-preventive gasket contacts on the door.

Figure 7-13 Closing the Chassis Air Filter Door

Step 6 Tighten the captive screws to secure the door to the chassis.


Caution The air filter door must be closed and secured at all times to maintain correct EMI performance.


Cleaning or Replacing the Chassis Air Filter on Cisco 12016 Enhanced Series Routers

Use the following procedure to clean or replace the enhanced series air filter.


Step 1 Loosen the 4 captive screws on the air filter door and pivot the door open (Figure 7-10).

Figure 7-14 Opening the Chassis Air Filter Door

Step 2 Lift up the air filter and carefully slide it out of the door (Figure 7-11).


Caution Be careful not to damage the honeycomb screens on the back of the air filter door and in the fabric card cage. Damage to the honeycomb screens can restrict airflow, cause overheating, and affect EMI performance.

Figure 7-15 Removing the Chassis Air Filter

Step 3 Visually check the condition of the air filter to determine whether to clean it or install a new replacement.

Dirty—You can vacuum or replace the filter.


Caution Do not vacuum the air filter while it is installed in the chassis. You must remove the air filter completely before you clean it to prevent contaminants from being drawn into the bays or cage.

Worn or torn—If the filter appears worn or torn, dispose of it in a responsible manner and install a replacement air filter (12000/16-FILTER=).

Step 4 Slide the new or cleaned air filter into the air filter door.

Step 5 Close the air filter door and tighten the 4 captive screws.


Caution Align and seat the door carefully to avoid damaging the EMI-preventive gasket contacts on the door. The air filter door must be closed and secured at all times to maintain correct EMI performance.


Removing and Replacing Blower Modules

The illustrations in this procedure represent both the original and newer enhanced capacity blower modules for Cisco 12016 series routers. Depending on your system, these components may not look exactly like those in your chassis, but the removal and replacement procedures are essentially the same.

There are currently two types of blower modules in use for the Cisco 12016 series routers; blowers that shipped with original systems, and enhanced capacity blowers that ship with current systems.

If you are replacing an:

Original blower module (GSR16-BLOWER=)—Use an original blower module or enhanced capacity blower modules as replacements.

Enhanced capacity blower module (12000/10/16-BLWER=)—Use an enhanced capacity blower module as a replacement.


Note If you upgraded your router with a power supply upgrade kit (2500 W AC or 2400 W DC PEMs) and your system is required to meet NEBS extended temperature range requirements, you must install the enhanced capacity blower module (12000/10/16-BLWER=) to meet those requirements.



Caution You cannot mix original and enhanced capacity blower modules in the same chassis. Both the upper and lower blower modules must be identical.

The blower modules support online insertion and removal (OIR), so you can remove and install a blower module while the system remains powered on without presenting an electrical hazard or damage to the system. You can replace a blower module while the system maintains all routing information and ensures session preservation.


Caution Although the blower module supports OIR and can be replaced without interruption to system operation, the system should not operate without a blower module for more than 3 minutes to prevent overheating.

Upper and Lower Blower Module Orientation

Illustrations in this procedure show the removal and replacement of the upper blower module. The procedure to replace the lower blower module is the same except for the orientation of the blower module.

Heads-up orientation—Install the blower module in the upper bay in the "heads-up" orientation with the three fan air intake openings face down.

Heads-down orientation—Install the blower module in the lower blower module bay in the "heads-down" orientation with the three fan air intake openings face up.

Use the following procedure to remove and replace the blower modules.


Step 1 Remove the blower module from the chassis (Figure 7-16):

a. Loosen the captive screw on each side of the blower module.

b. Pull out the blower module halfway from the module bay.

c. Slide out the blower module completely from the module bay while supporting it with your other hand.


Warning The blower module weighs approximately 20 pounds (9 kg). Use two hands when handling the blower module.


Figure 7-16 Removing the Upper Blower Module

Step 2 Install the new blower module into the chassis (Figure 7-17):

a. Lift the blower module (with two hands) and slide it halfway into the module bay.

b. Slowly push the blower module into the chassis until it mates with the backplane connector at the back of the module bay.


Caution To prevent damage to the connectors, do not use excessive force when inserting the blower module into the chassis.

c. Tighten the captive screws on the blower module to secure it to the chassis.

The (green) OK status indicator on the front of the blower module should light. If the OK indicator does not light, see the "Troubleshooting the Blower Installation" section.

Figure 7-17 Installing the Upper Blower Module


Troubleshooting the Blower Installation

Use the following procedure to troubleshoot a blower module if it is not operating properly after installation.


Step 1 Be sure the router is powered on and that all power cords are connected properly.

Step 2 Loosen the captive screws and reseat the blower module to the chassis.

Retighten the captive screws to ensure the blower module is properly seated to the backplane connector.

Step 3 Check the blower module status indicators:

OK (green)—Indicates that the blower module is operating normally. This indicator should light as soon as the blower module is installed and receives power from the backplane connector.

If this indicator remains on, and the blower module fans fail to operate after several attempts to reseat the blower module, replace it with a spare.

If the spare blower module also fails, power off the router and contact a Cisco service representative for assistance.

FAIL (red)—During normal operation, this indicator remains off. If this indicator is on, the system has detected a fan failure or other fault in the blower module.

If this indicator remains on, and the blower module fans fail to operate after several attempts to reseat the blower module, replace it with a spare.

If the spare blower module also fails, power off the router and contact a Cisco service representative for assistance.


Removing and Replacing AC and DC Power Subsystem Components

This section contains removal and replacement procedures for the AC and DC power systems used with the Cisco 12016, Cisco 12416, and Cisco 12816 series routers. If you ordered an upgrade kit, you can use these same procedures to upgrade all of the power system components.

The illustrations in this procedure represent both original and upgraded power supplies and power shelves shipping with the Cisco 12016 series routers. Depending on your system, these components may not look exactly like those in your chassis, but the removal and replacement procedures are essentially the same. Multiple illustrations are presented to represent original and new models where appropriate.

The following tools and equipment are required to remove and install power equipment:

Number 1 Phillips screwdriver

3/16-inch flat-blade screwdriver

An ESD-preventive wrist strap

Installation Guidelines

The Cisco 12016 series routers support online insertion and removal (OIR). If you are replacing a redundant power supply, you can remove and install the power supply while the system remains powered on without causing an electrical hazard or damage to the system. This feature enables you replace a power supply while the system maintains all routing information and ensures session preservation.

However, to maintain operational redundancy, proper cooling, and meet EMI compliance standards, you must have all three (standard) or four (optional) working power supplies installed. When you remove a failed power supply with the router in operation, perform the replacement as quickly as possible. Make sure you have the tools and the replacement power supply ready before beginning the removal and installation procedure.

Power Supply and Power Shelf Compatibility

Cisco 12016 series routers are available with either an AC or a DC power supply system. Two types of power supplies are available for these systems:

Original power supplies (rated at 2000 W)—Shipped with original systems

Upgraded replacement power supplies (rated at 2500 W AC or 2400 W DC)—Ships currently

Removal and replacement procedures are the same for either type of power supply, but because of their capacity and physical differences, you cannot mix different types of power supplies within the same power shelf.


Caution Newer power supplies (AC and DC) require upgraded power shelves. You cannot install a new power supply using the original power shelf. If you are replacing an older power supply with a new unit, you must replace all of the power supplies and the power shelf.

Before you attempt to install or replace them, be sure you know the power supplies and associated power shelf your system has (Table 7-1).

Table 7-1 Original and Replacement Components

Original Component
Replacement Component

AC Power Shelf (PWR-GSR16-AC-SH=)

Compatible only with 2000 W AC power supplies. Do not use with newer, 2500 W power supplies.

AC Power Shelf (12000/16-AC-SHELF=)

Compatible only with newer, 2500 W AC power supplies. Do not use with older, 2000 W power supplies.

Optional AC Power Shelf (PWR-GSR16-AC4-SH=)

Compatible only with 2000 W AC power supplies. Do not use with newer, 2500 W power supplies.

Optional AC Power Shelf (12000/16-AC4-SHLF=)

Compatible only with newer, 2500 W AC power supplies. Do not use with older, 2000 W power supplies.

AC Power Supply (PWR-GSR16-AC=)

Use to replace original 2000 W AC power supplies only. All power supplies in the power shelf must be 2000 W. Do not mix with newer, 2500 W power supplies.


Note The power supplies PWR-GSR16-AC, PWR-GSR16-AC= do not electrically store unit detials like serial number, firmware version, and part number. Hence, the software is unable to display serial number, firmware version, and part number details for these power supplies.


AC Power Supply (12000/16-AC-PWR=)

Used to replace existing AC power supplies. All power supplies in the power shelf must be 2500 W. Do not mix with older, 2000 W power supplies.

Caution: 2500 W AC power supplies require new power shelves (GSR16-SHLF-AC= or GSR16-SHLF-AC4=).


Note This enhanced power supply can read and display serial number, firmware version, and part number details of the units as they can electronically store this information.


DC Power Shelf (PWR-GSR16-DC-SH=)

Compatible only with 2000 W DC PEMs. Do not use with newer, 2400 W PEMs.

DC Power Shelf (12000/16-DC-SHELF=)

Compatible only with newer, 2400 W DC PEMs. Do not use with older, 2000 W PEMs.

DC Power Supply (PWR-GSR16-DC=)

Use to replace original 2000W DC PEMs only. All PEMs in the power shelf must be 2000 W. Do not mix with newer, 2400 W PEMs.


Note The power supplies PWR-GSR16-DC, PWR-GSR16-DC= do not electrically store unit detials like serial number, firmware version, and part number. Hence, the software is unable to display serial number, firmware version, and part number details for these power supplies.


DC Power Supply (12000/16-DC-PWR=)

Used to replace existing DC power supplies. All PEMs must be 2400 W. Do not mix with older, 2000W PEMs.

Caution: 2400 W DC PEMs require new power shelves (GSR16-SHLF-DC=).


Note This enhanced power supply can read and display serial number, firmware version, and part number details of the units as they can electronically store this information.



Installing Upgrade Kits

When installing a power system upgrade kit, you replace the following components:

AC power upgrades (12000/16-AC-UP=, 12000/16-AC4-UP=):

Power supplies (Removing and Replacing an AC Power Supply).

Standard power shelf (Removing and Replacing the Standard AC-Input Power Shelf) or optional power shelf (Removing and Replacing the Optional 2-Level AC-Input Power Shelf)

DC power upgrade (12000/10-DC-UP=):

Power supplies (Removing and Replacing a DC PEM)

Power shelf (Removing and Replacing the DC-Input Power Shelf)


Note A blower upgrade (not included in the power upgrade kit) is also required to meet NEBS extended temperature range requirements. To order the blower upgrade (12000/10/16-BLWER=), contact your Cisco representative.


Removing and Replacing an AC Power Supply

This section provides the procedure to remove an AC power supply from the standard single-level AC power shelf. The procedure to remove an AC-input power supply from the optional double-level AC-input power shelf are identical to these; only the slot locations for AC-input power supplies are different. Figure 7-18 shows AC power shelves housing original series 2000 W power supplies.

Figure 7-18 Standard and Optional AC Power Shelves

Figure 7-19 identifies the components of a 2000 W AC power supply.

Figure 7-19 2000 W AC Power Supply Components

Figure 7-20 identifies the components of a 2500 W AC power supply.

Figure 7-20 2500 W AC Power Supply Components

1

Ejector handle

2

Captive screw


To remove and replace an AC power supply, use the following procedure.


Caution You cannot mix power supply types within the chassis. If you plan to replace a 2000 W power supply from an original system with a newer, 2500 W power supply, you must replace all of the power supplies and the power shelf (see Table 7-1). You must shut down the router to perform the upgrade. Be sure to notify the appropriate personnel that all routing traffic will stop while the upgrade takes place.


Step 1 Unplug the power supply cord from its AC outlet.

Step 2 Power off the circuit breaker assigned to that AC outlet.


Warning To ensure that power remains off while you are performing this procedure, tape the circuit breaker switch in the off (0) position.


Step 3 Remove the power supply from the power shelf.

For 2000 W PEM—Go to Step 4.

For 2500 W PEM—Go to Step 5.

Step 4 Remove the 2000 W PEM (Figure 7-21):

a. Release the ejector lever by lifting the spring clip.

b. Pivot the lever down to eject the power supply from its backplane connector.

c. Slide the power supply out of its bay while supporting it with your other hand.


Caution The power supply weighs approximately 12 pounds (5.4 kg). Use two hands when handling the power supply.

Figure 7-21 Removing a 2000 W AC Power Supply

Step 5 Remove the 2500W PEM (Figure 7-22):

a. Loosen the captive screw to release the ejector handle.

b. Pivot the ejector handle down to eject the power supply from its backplane connector.

c. Slide the power supply out of its bay while supporting it with your other hand.

Figure 7-22 Removing a 2500 W AC Power Supply

Step 6 Install the power supply:

For 2000 W PEM—Go to Step 7.

For 2500 W PEM—Go to Step 8.

Step 7 Install the 2000W PEM (Figure 7-23):

a. Slide the power supply into the bay until it mates with its backplane connector.


Caution To prevent damage to the power shelf backplane connector, do not use excessive force when inserting the power supply into its power shelf bay.

b. Lift up the ejector lever to hook it over the bottom edge of the power shelf.

c. Pivot the ejector lever until it is flush with the power supply and the spring clip locks the lever in place.


Caution If the spring clip does not lock the lever in place, the power supply is not completely seated. Eject the power supply and push it in firmly to reseat it.

Figure 7-23 Installing a 2000 W AC Power Supply

Step 8 Install the 2500 W power supply (Figure 7-24):

a. Slide the power supply into the bay until it mates with its backplane connector.


Caution To prevent damage to the power shelf backplane connector, do not use excessive force when inserting the power supply into its power shelf bay.

b. Lift up the ejector handle to hook it over the bottom edge of the power shelf.

c. Tighten the captive screw to secure the power supply in the shelf.

Figure 7-24 Installing a 2500 W AC Power Supply

Step 9 Plug the power supply cable into its AC outlet.

Step 10 Power on the circuit breaker to that AC outlet.

After the power-on sequence completes, the (green) PWR OK indicator on the front of the power supply should light. If the indicator does not light, see the "Troubleshooting the AC Power Supply Installation" section.


Troubleshooting the AC Power Supply Installation

Use the following procedure to troubleshoot the AC power supply if it is not operating properly after installation.


Step 1 Make sure the power supply is seated properly as follows:

Eject and reseat the PEM.

The ejector lever is locked into place by its spring clip.

Step 2 Make sure the router is powered on and that all power cords are connected properly:

Power cords on the back panel of the power shelf are secured in place with their retention clips.

Power cords at the power source end are securely plugged into their own AC power outlet.

The source AC circuit breaker is switched on.

Step 3 Check the power supply status indicators:

PWR OK (green)—Indicates the power supply is operating normally, and the source AC voltage is within the nominal operating range of 200 VAC to 240 VAC. This indicator lights when the power supply is properly seated in position.

FAULT (yellow)—Indicates the system detected a fault within the power supply or the incoming voltage is too low. During normal operation, this indicator remains off.

If the indicator is on:

Check that the source voltage is within the correct range: 170 to 262 VAC

Remove and then apply power to the power supply by disconnecting its power cord. If the indicator remains on, replace the existing power supply with a spare.

If the spare power supply also fails, the problem could be a faulty power shelf backplane connector. Power off the router and contact a Cisco service representative for assistance.

TEMP (yellow)—Indicates that the power supply is in an overtemperature condition, causing a shut-down to occur.


Note If the temp indicator is on, the fault indicator also goes on.


Verify that the power supply fan is operating properly.

Verify that the blower modules are operating properly.

If the power supply fan and blower modules are operating properly, replace the existing power supply with a spare.

TEMP (flashing yellow—2500 W PEM only)—Indicates that a power supply fan is locked or malfunctioning.


Note If the temp indicator is flashing, the fault indicator also goes on.


Check to see if the fan is operating. Remove any obstructions to the fan.

If the fan is not operating, replace the power supply.

ILIM (2000 W PEM only) (yellow)—Indicates the power supply is operating in a current-limiting condition.

Each power cord should be connected to a dedicated AC power source. Each AC power supply operating in the nominal range of 200 to 240 VAC requires a minimum service of 20 A, North America (or 13 A, international).

OC (2500 W PEM only) (steady, or flashing yellow after 10 seconds)—Indicates the output current of the power supply has exceeded its limit and that an overload or short circuit has occurred.


Note If the OC indicator is on or flashing, the fault indicator also goes on.


Remove and then apply power to the power supply by disconnecting its power cord.

If the indicator remains on, try reseating the power supply.

If the indicator remains on, replace the power supply.


Removing and Replacing the Standard AC-Input Power Shelf

Use the following procedure to remove and replace the standard AC-input power shelf.


Caution To remove and replace the power shelf, the system must be powered off. Be sure to notify the network administrator and other appropriate personnel that all routing traffic stops while the upgrade takes place.


Caution If you are upgrading to a new power shelf, you cannot use old power supplies. You must upgrade to newer, 2500 W power supplies (see Table 7-1).


Step 1 Remove all of the power supplies as described in "Removing and Replacing an AC Power Supply" section.

Step 2 Disconnect each of the AC power cords from the back panel of the power shelf by lifting the retention clip and unplugging the cord (Figure 7-25).

Figure 7-25 Disconnecting AC Power Cords

Step 3 Unseat the power shelf from the chassis (Figure 7-26):

a. Loosen the two captive screws on each side of the power shelf.

b. Loosen the ejector jackscrew to unseat the power shelf from the power interface panel connectors.

Figure 7-26 Unseating the Power Shelf

Step 4 Remove the power shelf by grasping the flanges on each side and slowly pulling the shelf along the chassis track to remove it (Figure 7-27):


Warning The AC-input power shelf weighs approximately 21 pounds (9.5 kg). Use two hands to remove the power shelf.


Figure 7-27 Removing the AC-Input Power Shelf

Step 5 Insert the new power shelf halfway into the chassis.

Step 6 Connect the power shelf to the chassis power interface panel connectors (Figure 7-28):

a. Be sure the holes on each side of the power shelf are aligned with the guide pins on each side of the chassis.

b. Carefully slide the power shelf into place until its two connectors just mate with the power interface panel connectors.


Caution To prevent damage to the interface connectors, do not use excessive force when inserting the power shelf into the chassis.

Figure 7-28 Connecting the AC-Input Power Shelf

Step 7 Seat the power shelf to the chassis (Figure 7-29):

a. Tighten the ejector jackscrew.

b. Tighten the captive screws on each flange.

Figure 7-29 Seating the Power Shelf

Step 8 Reconnect each of the AC power cords to the back panel of the power shelf and secure them in place with their retention clips (Figure 7-30).

Figure 7-30 Reconnecting AC Power Cords

Step 9 Reinstall the power supplies as described in "Removing and Replacing an AC Power Supply" section.


Removing and Replacing the Optional 2-Level AC-Input Power Shelf

Use the following procedure to remove and replace the optional 2-level AC-input power shelf.


Caution To remove and replace the power shelf, the system must be powered off. Notify the network administrator and other appropriate personnel that all routing traffic stops while the upgrade takes place.


Caution If you are upgrading to a new power shelf, you cannot use original power supplies. You must upgrade to newer, 2500 W power supplies (see Table 7-1).


Step 1 Remove all of the power supplies as described in Removing and Replacing an AC Power Supply.

Step 2 Disconnect each of the AC power cords from the back panel of the power shelf by lifting the retention clip and unplugging the cord (Figure 7-31).

Figure 7-31 Disconnecting the AC Power Cords

Step 3 Loosen the two captive screws on each side of the power shelf.

Step 4 Loosen the ejector jackscrew to unseat the power shelf from the connectors on the chassis power interface panel.

Step 5 Remove the power shelf by grasping the flanges on each side and slowly pulling the shelf along the chassis track to remove it (Figure 7-32).


Warning The AC-input power shelf weighs approximately 42 pounds (19.05 kg). Use two hands to remove the power shelf.


Figure 7-32 Removing the AC-Input Power Shelf

Step 6 Insert the new power shelf halfway into the chassis.

Step 7 Connect the power shelf to the chassis power interface panel connectors (Figure 7-33):

a. Be sure the holes on each side of the power shelf are aligned with the guide pins on each side of the chassis.

b. Carefully slide the power shelf into place until its two connectors just mate with the power interface panel connectors.


Caution To prevent damage to the interface connectors, do not use excessive force when inserting the power shelf into the chassis.

Figure 7-33 Connecting the AC-Input Power Shelf

Step 8 Install the power shelf by grasping the flanges on each side and slowly sliding the shelf into the chassis along the track (Figure 7-34):

a. Tighten the ejector jackscrew.

b. Tighten the two captive screws on each flange.

Figure 7-34 Installing the AC-Input Power Shelf

Step 9 Reconnect each of the AC power cords to the back panel of the power shelf and secure them in place with their retention clips (Figure 7-35).

Figure 7-35 Reconnecting AC Power Cords

Step 10 Reinstall the power supplies as described in "Removing and Replacing an AC Power Supply" section beginning with Step 6.


Troubleshooting the AC Power Shelf Installation

Use the following procedure to troubleshoot the AC power shelf if it does not operate properly after installation.


Step 1 Make sure that the power shelf is seated properly:

The jackscrew is tightened securely.

The captive screws on the flanges are tightened securely.

Step 2 Make sure each power supply is seated properly:

The ejector lever is locked into place by its spring clip.

Step 3 Make sure the router is powered on and that all power cords are connected properly:

Power cords on the back panel of the power shelf are secured in place with their retention clips.

Power cords at the power source end are securely plugged into its own AC power outlet.

Make sure the source AC circuit breaker is switched on.

Step 4 Check the power supply status indicators:

PWR OK (green)—Indicates that the power supply is operating normally, and the source AC voltage is within the nominal operating range of 200 VAC to 240 VAC. When the power supply is properly seated, this indicator is on.

FAULT (yellow)—Indicates that the system has detected a fault within the power supply or the incoming voltage is too low. During normal operation, this indicator remains off.

If the indicator is on:

Check that the source voltage is within the correct range: 170 to 262 VAC

Remove and then apply power to the power supply by disconnecting its power cord. If the indicator remains on, replace the existing power supply with a spare.

If the spare power supply also fails, the problem could be a faulty power shelf backplane connector. Power off the router and contact a Cisco service representative for assistance.

TEMP (yellow)—Indicates that the power supply is in an overtemperature condition, causing a shut-down to occur.


Note If the temp indicator is on, the fault indicator also goes on.


Verify that the power supply fan is operating properly.

Verify that the blower modules are operating properly.

If the blower modules are operating properly, replace the existing power supply with a spare.

TEMP (flashing yellow—2500 W PEM only)—Indicates that a power supply fan is locked or malfunctioning.


Note If the temp indicator is flashing, the fault indicator also goes on.


Check to see if the fan is operating. Remove anything that may be obstructing the fan.

If the fan is not operating, replace the power supply.

ILIM (2000 W PEM only) (yellow)—Indicates the power supply is operating in a current-limiting condition.

Each power cord should be connected to a dedicated AC power source. Each AC power supply operating in the nominal range of 200 to 240 VAC requires a minimum service of 20 A, North America (or 13 A, international).

OC (2500 W PEM only) (steady, or flashing yellow after 10 seconds)—Indicates the output current of the power supply exceeded its limit and an overload or short circuit has occurred.


Note If the OC indicator is on or flashing, the fault indicator also goes on.


Remove and then apply power to the power supply by disconnecting its power cord.

If the indicator remains on, try reseating the power supply.

If the indicator remains on, replace the power supply.


Upgrading the AC-Input Power Shelf

Use the following procedure to upgrade your router from the standard, 1-level AC power shelf to an optional, 2-level AC power shelf.


Note A router with an optional, 2-level power shelf is 77.5 inches (196.85 cm) in height and does not fit into a standard 7-foot rack.



Step 1 Remove the standard one-level power shelf following the procedures in "Removing and Replacing the Standard AC-Input Power Shelf" section through Step 4.

Step 2 Install the optional, 2-level power shelf following the procedures in "Removing and Replacing the Optional 2-Level AC-Input Power Shelf" section beginning with Step 6.

Step 3 Replace the old cover with the new cover you received in the upgrade kit.

a. Hold the front cover by its outside edges and align the four ball studs on the back of the cover with the sockets on the front of the chassis.

b. Push in the front cover until all four ball studs snap into their sockets and the front cover is flush against the front of the chassis.


Removing and Replacing a DC PEM

This section contains the procedure to remove and replace an DC PEM from the chassis. Before you begin this procedure, read the "Installation Guidelines" section.

Figure 7-36 identifies the components of a 2000 W DC power supply.

Figure 7-36 2000 W DC Power Supply Components

Figure 7-37 identifies the components of a 2400 W DC power supply.

Figure 7-37 2400 W DC Power Supply Components

1

Handle

3

Ejector lever

2

Fan

4

Power switch



Caution You cannot mix power supply types within the chassis. If you plan to replace a 2000 W PEM from an original system with a new 2400 W PEM, you must replace all of the older PEMs and the power shelf (see Table 7-1). To perform the upgrade, you must shut down the router. Be sure to notify the system administrator and other appropriate personnel that all routing traffic stops while the upgrade takes place.

Use the following procedure to remove and replace a DC PEM.


Step 1 Power off the PEM by switching its circuit breaker off.

Step 2 Power off the DC circuit breaker assigned to that PEM.


Warning To ensure that power remains off while you are performing this procedure, tape the circuit breaker switch in the off (0) position.


Step 3 Loosen the captive screw on the ejector handle and pivot the lever down to eject the PEM from its bay (Figure 7-38).

Step 4 Remove the PEM from the power shelf (Figure 7-38):

a. Pull the PEM halfway out of its bay.

b. Slide the PEM out of its bay while supporting it with your other hand.


Warning The DC PEM weighs approximately 6 pounds (2.7 kg). Use two hands to remove the power supply.


Figure 7-38 Removing a DC PEM

Step 5 Install the new DC PEM into the power shelf (Figure 7-39):

a. Slide the PEM halfway into the chassis.

b. Slowly push the power supply into the chassis until it mates with the backplane connector at the back of the bay.

c. Position the bottom of the ejector lever in the slot on the bottom of the power shelf and lift the ejector lever into place to seat the PEM to the backplane connector.


Caution To prevent damage to the power shelf backplane connector, do not use excessive force when inserting the PEM into its power shelf bay.

d. Tighten the captive screw to secure the PEM in the power shelf.


Note Because the PEM is powered redundantly by other PEMs in its power load zone, the fault indicator may go on. This can happen even if the circuit breaker for that PEM is switched off, or if there is no DC source power to the PEM. When power is supplied to the PEM and the circuit breaker is switched on, the fault indicator should go off and the PWR OK indicator should light.


Figure 7-39 Installing a DC PEM

Step 6 Power on the DC circuit breaker assigned to that PEM.

Step 7 Power on the PEM by switching on its circuit breaker.

After the power-on sequence completes, the (green) PWR OK indicator on the front of the PEM should light. If the indicator does not light, see the "Troubleshooting the DC PEM Installation" section.


Troubleshooting the DC PEM Installation

Use the following procedure to troubleshoot the DC PEM if it is not operating properly after installation.


Step 1 Make sure the PEM is seated properly:

Eject and reseat the PEM.

The captive screw on the ejector lever are tightened securely.

The power switch is in the on (1) position (2400 W only).

Step 2 Make sure the router is powered on and that all power cords are connected properly:

All power cables are securely connected to their terminal studs on the back panel.

Each pair of PEM power cables are connected to a dedicated 60 A DC service.

The source DC circuit breaker is switched on.

The PEM circuit breaker is switched on (2000 W only).

If circuit breaker does not stay switched on, replace the PEM.

Step 3 Check the PEM status indicators:

PWR OK (green) — Indicates that the PEM is operating normally, and the source DC voltage is within the nominal operating range of -48 to -60 VDC. This indicator should light when the PEM circuit breaker is switched on.

FAULT (yellow) — Indicates that the system has detected a fault within the PEM or the incoming voltage is too low. During normal operation, this indicator remains off.

Check that the source voltage is within the correct range: -40 to -72 VDC.

Toggle the PEM circuit breaker off and then on. If the indicator remains on after several attempts to power it on, replace the existing PEM with a spare.

If the spare PEM also fails, the problem could be a faulty power shelf backplane connector. Power off the router and contact a Cisco service representative for assistance.

TEMP (yellow)—Indicates that the PEM is in an overtemperature condition causing a shut-down to occur.


Note If the temp indicator is on, the fault indicator also goes on.


Verify that the power supply fan is operating properly.

Verify that the blower modules are operating properly.

If the power supply fan and the blower modules are operating properly, replace the existing PEM with a spare.

TEMP (flashing yellow—2400 W PEM only)—Indicates that a power supply fan is locked or malfunctioning.


Note If the temp indicator is flashing, the fault indicator also goes on.


Check to see if the fan is operating. Remove any obstructions to the fan.

If the fan is not operational, replace the power supply.

OC (2400 W PEM only) (steady, or flashing yellow after 10 seconds)—Indicates the output current of the power supply has exceeded its limit and that an overload or short circuit has occurred.


Note If the OC indicator is on or flashing, the fault indicator also goes on.


Remove and then apply power to the power supply by disconnecting its power cord.

If the indicator remains on, try reseating the power supply.

If the indicator remains on, replace the power supply.


Removing and Replacing the DC-Input Power Shelf

Use the following procedure to remove and replace the DC-input power shelf.


Caution To remove and replace the power shelf, the system must be powered off. Notify the network administrator and other appropriate personnel that all routing traffic stops while the upgrade takes place.


Caution If you are upgrading to a new power shelf, you cannot use old power supplies. You must upgrade to newer, 2400 W PEMs (see Table 7-1).


Step 1 Remove all of the DC PEMs as described in the "Removing and Replacing a DC PEM" procedure through Step 4.

Step 2 Remove the power cable cover by loosening its retaining screw (Figure 7-40).

Figure 7-40 Removing the Source DC Power Cable Cover

Step 3 Measure the voltage across each pair of positive (+) and negative (-) terminals of the power shelf to be sure they are not receiving power.

All readings should be 0 VDC.


Warning Do not proceed if all readings are not 0 (zero) volts. Make sure that the router is powered off and that all source DC circuit breakers are switched off. Repeat Step 3 before continuing.


Step 4 Disconnect each pair of power cables and the ground cable from the DC-input terminal studs as follows (Figure 7-41):


Caution Before removing cables, be sure to note the color for each type of cable (positive, negative, and ground). Because there is no color code standard for source DC wiring, you must be sure which power cables are connected to the proper positive (+) and negative (-) terminal studs. Typically, green (or green and yellow) indicate a ground cable, while power cable leads may be labeled positive (+) or negative (-). Because this is not always the case, the safest way to indicate the polarity of a cable is to note its color and identify it as described in this procedure.


Warning When disconnecting source DC power cables, always disconnect the ground cable last.


Beginning with terminal studs A1 (Figure 7-41):

a. Remove the nut and washer from the negative (-) terminal studs and disconnect the cable.

Label the cable. For example: A1-.

b. Remove the nut and washer from the positive (+) terminal studs and disconnect the cable.

Label the cable. For example: A1+.

Repeat steps a. and b. for the remaining pairs of terminal studs.

c. After all power cables are disconnected, remove the nut and washer from the ground terminal studs and disconnect the ground cable.

Label the cable as "ground".

Figure 7-41 Disconnecting the Source DC Power Cables

Step 5 Unseat the power shelf from the chassis (Figure 7-42):

a. Loosen the two captive screws on each side of the power shelf.

b. Loosen the ejector jackscrew to unseat the power shelf from the connectors on the chassis power interface panel.


Warning The DC-input power shelf weighs approximately 10.2 pounds (4.6 kg). Use two hands to remove the power shelf.


Figure 7-42 Unseating the Power Shelf

Step 6 Remove the power shelf by grasping the flanges on each side and slowly pulling the shelf along the chassis track to remove it (Figure 7-43):

Figure 7-43 Removing the DC-Input Power Shelf

Step 7 Insert the new power shelf halfway into the chassis.

Step 8 Connect the power shelf to the chassis power interface panel connectors (Figure 7-44):

a. Be sure the holes on each side of the power shelf are aligned with the guide pins on each side of the chassis.

b. Carefully slide the power shelf into place until its two connectors just mate with the power interface panel connectors.


Caution To prevent damage to the interface connectors, do not use excessive force when inserting the power shelf into the chassis.

Figure 7-44 Connecting the DC-Input Power Shelf

Step 9 Seat the power shelf to the chassis (Figure 7-45):

a. Tighten the ejector jackscrew.

b. Tighten the captive screws on each flange.


Warning The DC-input power shelf weighs approximately 10.2 pounds (4.6 kg). Use two hands to remove the power shelf.


Figure 7-45 Seating the DC-Input Power Shelf

Step 10 Reconnect the ground and each pair of power cables to the DC-input terminal studs as follows (Figure 7-46):


Caution Be sure to connect the cables according to the color coding notes and labels you made in Step 4.


Warning When reconnecting source DC power cables, always connect the ground cable first.


a. Reconnect the ground cable to the ground terminal studs.

Beginning with terminal studs B2:

b. Reconnect the positive cable to the positive (+) terminal studs. For example: B2+.

c. Reconnect the negative cable to the negative (-) terminal studs. For example: B2-.

Repeat steps b and c for the remaining pairs of terminal studs.

Figure 7-46 Reconnecting the Source DC Power Cables to the Power Shelf

Step 11 Power on the source DC circuit breakers for the PEMs.

Step 12 Verify the polarity and voltage readings across the pairs of positive and negative terminal studs:

All voltage readings should be -48 to -60 VDC


Caution If any of the voltage readings are not within the specified range, do not proceed. Check for correct polarity and DC source voltage.

Step 13 Reinstall the power cable cover (Figure 7-47).

Figure 7-47 Reinstalling the Source DC Power Cable Cover

Step 14 Power off the source DC circuit breakers for the PEMs.

Step 15 Install all of the DC PEMs as described in the "Removing and Replacing a DC PEM" procedure beginning with Step 5.


Troubleshooting the DC Power Shelf Installation

Use the following procedure to troubleshoot the DC power shelf if it is not operating properly after installation.


Step 1 Make sure that the power shelf is seated properly:

The jackscrew is tightened securely.

The captive screws on the flanges are tightened securely.

Step 2 Make sure each power supply is seated properly:

Eject and reseat the PEM.

The captive screw on the ejector lever is tightened securely.

The power switch is in the on (1) position (2400 W only).

Step 3 Make sure the router is powered on and that all power cords are connected properly:

All power cables are securely connected to their terminal studs on the back panel.

Each pair of PEM power cables is connected to a dedicated 60 A DC service.

The source DC circuit breaker is switched on.

The PEM circuit breaker is switched on (2000 W only).

If the circuit breaker does not stay switched on, check the polarity of the power cables to the PEM.


Note A PEM trips its circuit breaker if it detects a reverse-polarity condition. This condition does not damage the PEM and it should operate properly after the polarity is corrected.


Step 4 Check the power supply status indicators:

PWR OK (green)—Indicates that the PEM is operating normally, and the source DC voltage is within the nominal operating range of -48 to -60 VDC. When the PEM circuit breaker is switched on, this indicator lights.

FAULT (yellow)—Indicates that the system detected a fault within the PEM or the incoming voltage is too low. During normal operation, this indicator remains off.

If the indicator is on:

Check that the source voltage is within the correct range: -40 to -72 VDC.

Toggle the PEM circuit breaker off and then on. If the indicator remains on after several attempts to power it on, replace the existing PEM with a spare.

If the spare PEM also fails, the problem could be a faulty power shelf backplane connector. Power off the router and contact a Cisco service representative for assistance.

TEMP (yellow)—Indicates that the PEM is in an overtemperature condition, causing a shut-down to occur.


Note If the temp indicator is on, the fault indicator is also on.


Verify that the power supply fan is operating properly.

Verify that the blower modules are operating properly.

If the blower module is operating properly, replace the existing PEM with a spare.

TEMP (flashing yellow—2400 W PEM only)—Indicates that a power supply fan is locked or malfunctioning.


Note If the temp indicator is flashing, the fault indicator is also on.


Check to see if the fan is operating. Remove any obstructions to the fan.

If the fan does not operate, replace the power supply.

OC (2400 W PEM only) (steady, or flashing yellow after 10 seconds)—Indicates the output current of the power supply exceeded its limit and an overload or short circuit has occurred.


Note If the OC indicator is on or flashing, the fault indicator is also on.


Remove and then apply power to the power supply by disconnecting its power cord.

If the indicator remains on, try reseating the power supply.

If the indicator remains on, replace the power supply.


Removing and Replacing Cards from the Chassis

This section contains the procedures to remove cards from the card cages in the chassis. For additional information about specific types of cards, see Chapter 1, "Product Overview."

Removing and Replacing RP and Line Cards from the Upper and Lower Card Cages

This section describes the procedures for removing and installing a router processor (RP) card or a line card from the upper or lower card cage. The upper and lower card cages have 9 slots, and the lower card cage is a reverse image of the top card cage. Alarm cards can only be installed in their specific slots which are labeled as "Alarm Card". See the "Removing and Replacing an Alarm Card" section for information about replacing an alarm card.


Caution If you are upgrading your router from a GRP to a PRP, you must power off the router to switch the RP cards. If you are replacing a nonredundant RP you should back up the running configuration file to a TFTP server or a flash disk so that you can retrieve it later. If the configuration file is not saved, you will have to reenter the entire configuration manually for the new RP.


Caution Handle all cards by the metal card carrier edges only; avoid touching the board or any connector pins. After removing a card, carefully place it in an antistatic bag or similar environment to protect it from ESD and dust in the optic ports (fiber-optic line cards).

Use the following procedure to remove and replace a line card or RP from the card cage:


Step 1 Disconnect any cables from the card.

Step 2 Remove the card:

a. Loosen the captive screws at the top and bottom of the front panel (Figure 7-48a).

b. Pivot the ejector levers to unseat the card from the backplane connector (Figure 7-48b.)

c. Slide the card out of the slot (Figure 7-48c) and place it directly into an antistatic bag or other ESD-preventive container.

Step 3 Replace the card by reversing the procedures in Steps 1 and 2.


Figure 7-48 Removing a Line Card from the Line Card and RP Card Cage

Removing and Replacing an Alarm Card

The router is equipped with two alarm cards. One card occupies the dedicated far left slot of the upper card cage; the second occupies the dedicated far right slot of the lower card cage (Figure 7-49). The alarm card slot differs from the rest of the card cage slots: it is physically narrower, has a different backplane connector, and is labeled as an "Alarm Card" slot. Alarm cards can only be installed in these two slots.

Figure 7-49 Alarm Card Locations in the Upper and Lower Card Cages

Use the following procedure to remove and replace an alarm card from either the top or bottom card cage.


Caution To ensure proper alarm card screw alignment, line card slots adjacent to the alarm cards must always be populated.


Step 1 Disconnect any cables from the alarm card.

Step 2 Remove the alarm card:

a. Loosen the captive screws at the top and bottom of the front panel (Figure 7-50a).

b. Pull the card out of the slot (Figure 7-50b) and place it directly into an antistatic bag or other ESD-preventive container.

Figure 7-50 Removing an Alarm Card from the Upper Card Cage

Step 3 Replace the card by reversing the procedures in Steps 1 and 2.


Removing and Replacing Switch Fabric Cards

The switch fabric card cage is located behind the air filter door on the front of the chassis. The card cage has five keyed, vertical card slots for the CSCs and SFCs. CSCs are installed in the left two card slots (labeled CSC 0 and 1); SFCs are installed in the right three card slots (labeled SFC 0, 1, and 2).

Use the following procedure to remove and replace switch fabric cards.


Step 1 Loosen the captive screws on the air filter door and pivot the door open (Figure 7-10).


Caution If the router uses an extended front cover bezel, the air filter door does not have enough space to open completely. Before you open the air filter door, you must remove the extended front cover.

Figure 7-51 Opening the Chassis Air Filter Door

Step 2 Remove the card:

a. Pivot the ejector levers to unseat the card from the backplane connector.

b. Grasp the card by its metal card carrier and slide the card out of the slot (Figure 7-52).

Place the card directly into an antistatic bag or other ESD-preventive container.

Figure 7-52 Removing a Card from the Switch Fabric Card Cage

Step 3 To install the card, reverse the procedure in Step 2.

Step 4 Close the air filter door and tighten the captive screws.


Upgrading the Switch Fabric

The switch fabric on the Cisco 12016 and the Cisco 12416 routers can be upgraded in the field.

Cisco 12016 Routers can be upgraded from a 2.5 Gbps switch fabric to a 10 Gbps or 40 Gbps switch fabric.

Cisco 12416 Routers can be upgraded from a 10 Gbps switch fabric to a 40 Gbps switch fabric.

Table 7-2 lists the Cisco router model numbers, their corresponding switch fabric speed, and the available upgrade path for each router model.

Table 7-2 Switch Fabric Upgrade Paths

Router Model
Switch Fabric Speed
Upgrade Path

Cisco 12016 router

2.5 Gbps

Cisco 12416 router

or

Cisco 12816 router

Cisco 12416 router

10 Gbps

Cisco 12816 router

Cisco 12816 router

40 Gbps

NA


Upgrade Requirements

Review the following the following upgrade requirements before performing the switch fabric upgrade:

You need a complete switch fabric card set. You cannot mix 2.5- Gbps 10 Gbps, and 40 Gbps CSCs and SFCs.

When upgrading to a 10 Gbps switch fabric with a GRP installed, the flash memory card must be loaded with Cisco IOS Release 12.0(16)S or later.

When upgrading to a 10 Gbps switch fabric with a PRP installed, the flash memory card must be loaded with Cisco IOS Release 12.0(22)S or later.

When upgrading to a 40 Gbps switch fabric, a PRP must be installed and the flash memory card must be loaded with Cisco IOS Release 12.0(27)S or later.

Upgrade Procedures

To upgrade the switch fabric, follow these steps:


Step 1 Power off the router.

Step 2 Remove all CSCs and SFCs from the switch fabric card cage. See the "Removing and Replacing Switch Fabric Cards" section.

Step 3 Install the new CSCs and SFCs.


Note Although they perform similar functions, you cannot intermix SFCs and CSCs. The switch fabric is a card set. You must use either the 10- or 40-Gbps switch fabric card set.


Step 4 Insert a flash memory card into the GRP or PRP, making sure that it is loaded with the appropriate Cisco IOS Release.

Step 5 Power on the router and wait for all installed line cards to boot completely before proceeding to the next step.


Note Be sure the router returns to full operation before proceeding to the next step. This may take a considerable amount of time depending upon the configuration of the router.


Step 6 Enter the configure terminal command to enter global configuration mode.

Step 7 If you are using a Cisco IOS Release prior to 12.0(27)S, enter the service upgrade all command.

Go to Step 10

If you are not using a Cisco IOS Release prior to 12.0(27)S, go to the next step.

Step 8 If you are using Cisco IOS Release 12.0(27)S or later, enter the service upgrade mbus-agent-rom command.

Step 9 Enter the service upgrade fabric-downloader command.

Step 10 After the commands have finished running, press Ctrl-Z to exit configuration mode.

Step 11 Run the show gsr command to verify that the new switch fabric cards are detected by the system.


Note The show gsr command output varies slightly between each switch fabric card set.



The switch fabric upgrade kit does not include a new label to identify the upgraded router model, so the label on the side of the chassis still identifies the chassis as a Cisco 12016 or Cisco 12416 router.

You can identify an upgraded router by:

Reading the numbers on the switch fabric card labels.

Using the show gsr command to generate the switch fabric card identification numbers. Table 7-3 lists the router model and the corresponding switch fabric card number on the identification label.

Table 7-3 Identifying Switch Fabric Cards

Router Model
Switch Fabric Card Identification Label

Cisco 12016 router

SFC-80 and CSC-80

Cisco 12416 router

SFC-320 and CSC-320

Cisco 12816 router

SFC-1280 and CSC-1280


Removing and Installing a Chassis

This section provides the procedures to remove and replace a chassis. You may need to perform this procedure to replace a defective chassis or move it to another location. These instructions include the steps directing you to removal and replacement instructions for individual components such as power supplies and line cards.

Because you are removing all the components (except the air filter) from the defective chassis and then reinstalling them in the replacement chassis, the procedures that follow are based on the following prerequisites:

The replacement chassis, mounted on its own scissor-jack platform, is temporarily placed within reach of the rack in which the defective chassis is installed, and is temporarily connected to the same grounding system as the defective chassis.

A spare scissor-jack platform with the anchor clips and bolts (that came with the original chassis) is available to remove the defective chassis from the equipment rack.

Components are transferred from the defective chassis directly to the replacement chassis.

The replacement chassis is installed in the equipment rack after all components are installed.

This approach has the advantage of protecting system components against damage by eliminating the need to store them, even temporarily, outside their card cages. It also helps ensure that the physical configuration of the router is maintained because each transferred component is installed in the same location in the replacement chassis that it occupied in the defective chassis.

Procedures for removing and installing the chassis are described in the following sections:

Preparing the Replacement Chassis

Preparing the Installed Chassis for Removal

Removing and Installing System Components

Removing and Installing System Components

Removing the Chassis from the Equipment Rack

Installing the Replacement Chassis

Preparing the Replacement Chassis

Before you can begin to install components in the replacement chassis, you need to temporarily connect the central office grounding system or interior equipment grounding system. You can make this connection when the replacement chassis and scissor-jack platform has been placed near the rack site.

See "NEBS Supplemental Unit Bonding and Grounding Guidelines" section on page 2-22 for information about making these connections.

Preparing the Installed Chassis for Removal

Use the following procedure to prepare the installed chassis for removal.


Step 1 Power off the router (see Powering Off the Router).

Step 2 Power off the circuit breakers to the power supplies.

Step 3 Disconnect the power cords from the power shelf:

For a standard AC power shelf, see Step 2 of Removing and Replacing the Standard AC-Input Power Shelf.

For an optional AC power shelf, see Step 2 of Removing and Replacing the Optional 2-Level AC-Input Power Shelf.

For a CD power shelf, see Steps 2, 3, and 4 of Removing and Replacing the DC-Input Power Shelf.

Step 4 Remove the front covers (see Removing and Installing the Front Covers and Bezel Extenders on Original Cisco 12000 Series Routers, or Cleaning or Replacing the Chassis Air Filter).

Step 5 Disconnect RP cables connected to the console port, auxiliary port, or either of the Ethernet ports, RJ-45 or MII.

Label each of the RP cables before you disconnect the cables.

Step 6 Disconnect the cables from each alarm card.

Label each of the alarm card cables before you disconnect them.

Step 7 Disconnect the line card interface cables:

a. Identify the type of line card and its slot number. Write this information on a piece of paper before you disconnect the cables. You'll need this information when you reinstall the line cards.

b. Identify the line card cable and its port connection. Label the cable with this information.

c. Loosen the captive screw at each end of the line card cable-management bracket and pull the cable-management bracket away from the line card.

d. Carefully remove the cables from the cable tray and carefully place the cable bundle out of the way.

e. Repeat steps a through d for each line card.

Step 8 Remove the vertical cable-management troughs (see Attaching the Vertical Cable-Management Trough, page 3-25).


Removing and Installing System Components

Use the following procedure to remove and install system components from one chassis to another.


Step 1 Remove the blower modules and then install them into the replacement chassis. (see the "Removing and Replacing Blower Modules" section).

Step 2 Remove the power supplies and the power shelf and then install them into the replacement chassis (see "Removing and Replacing AC and DC Power Subsystem Components" section).

Step 3 Remove the cards from all three card cages and then install them into the replacement chassis (see "Removing and Replacing Cards from the Chassis" section).


Removing the Chassis from the Equipment Rack

Use the following procedure to remove the chassis from the equipment rack.


Warning Two people are required to remove the chassis from the equipment rack.



Step 1 Remove all grounding connections to the chassis (See "NEBS Supplemental Unit Bonding and Grounding Guidelines" section on page 2-22).

Step 2 Position the scissor-jack platform from the original router shipping package in front of the rack-mounting platform in the rack (Figure 7-53).

Step 3 Turn the scissor-jack screw counterclockwise to slowly raise the top of the scissor-jack platform to the same height as the top of the rack-mounting platform. (See Figure 7-53.)

Figure 7-53 Positioning the Scissor-Jack Platform to Extract the Chassis

Step 4 Working from the top of the chassis down, remove the screws that secure the chassis to the mounting flanges on the rack (Figure 7-54).

Set the screws aside for use to install the replacement chassis.


Warning The chassis is still supported by the rack-mounting platform installed in the bottom of the rack, but should be held to prevent the possibility of tipping out of the front of the rack.


Figure 7-54 Removing the Mounting Screws

Step 5 Position one person in front of the chassis to support and guide it while the second person slowly pushes the chassis to slide it off the rack-mounting table and onto the scissor-jack platform.

Step 6 Install the four chassis anchor clips through the slots in the bottom of the chassis:


Warning One person should be holding the side of the chassis to prevent it from tipping.


a. Align the holes with the bolt holes in the platform.

b. Insert and tighten the four bolts to prevent the chassis from shifting on the scissor-jack platform (Figure 7-55).

Figure 7-55 Securing the Chassis to the Scissor-Jack Platform

Step 7 Turn the scissor-jack screw clockwise to slowly lower the scissor-jack platform (Figure 7-56).

Figure 7-56 Closing the Scissor-Jack Platform to Lower the Chassis

Step 8 Slide the chassis and scissor-jack platform onto a safety hand truck with outrigger wheels and secure it with the locking safety strap.

Move the chassis to a level solid floor where the chassis can be repackaged for shipping.

Use the packaging and unpacking instructions that came with the replacement chassis to repack and ship a defective chassis to the factory.


Installing the Replacement Chassis

Use the following procedure to install the replacement rack in the chassis.


Step 1 Disconnect the temporary ground connections to the replacement chassis.

Step 2 Install the chassis into the rack (see Rack-Mounting the Router Chassis, page 3-8).

Step 3 Connect all ground connections to the chassis (see Supplemental Bonding and Grounding Connections, page 3-21).

Step 4 Attach the vertical cable management troughs (see Attaching the Vertical Cable-Management Trough, page 3-25).

Step 5 Connect all line card interface cables using the notes and labeling you created when disconnecting them from the defective chassis.

Step 6 Connect power cables to the router (see Connecting Power to the Power Shelf, page 3-41).

Step 7 Power on the router (see Powering On the Router and Observing the Boot Process, page 4-4).


Removing and Replacing a Power Bus Board Fuse

There are two user-replaceable fuses on the power bus board inside the power interface panel:

The fuse labeled F1 protects the MBus controller module.

The fuse labeled F2 protects the 5.1 VDC bias voltage for the current monitoring (Imon) signal and the voltage monitoring (Vmon) signals on AC power subsystems.


Note Fuse F2 is used only in AC-input power shelves. It is not used in DC-input power shelves. Spane fuses can be ordered from Cisco as part number: PWR-2A/125V-FUSE=.


Use the following procedure to replace a fuse on the power bus board.


Step 1 Power off the router (see Powering Off the Router).


Warning The router must be powered down before a fuse can be removed and replaced.


Step 2 Remove the power bus board MBus access cover by loosening the four captive screws (Figure 7-57).

Figure 7-57 MBus Controller Access Cover

Step 3 Remove the fuse from the fuse holder using a non-conducting fuse extraction tool (Figure 7-58).

Step 4 Insert the replacement fuse using the fuse extraction tool to hold the replacement fuse, align the fuse with the opening in the fuse holder.

Step 5 Reinstall the MBus access cover.

Step 6 Power on the router and return it to service (see Powering On the Router and Observing the Boot Process, page 4-4).


Figure 7-58 Removing and Replacing a Power Bus Board Fuse