Cisco 7600 Series Router Installation Guide
Removal and Replacement Procedures
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Removal and Replacement Procedures

Table Of Contents

Removal and Replacement Procedures

Preventing Electrostatic Discharge Damage

Removing and Replacing the Power Supply

Required Tools

Clearance Guidelines

Chassis Air Flow Requirements

Removing an AC-Input Power Supply

Installing an AC-Input Power Supply

Removing a DC-Input Power Supply

Removing PWR-950-DC Power Supply from a Cisco 7603 Router

Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router

Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router

Removing PWR-1900-DC Power Supply from a Cisco 7606 Router

Removing PWR-2700-DC Power Supply from a Cisco 7606 Router

Removing PWR-2700-DC Power Supply from a Cisco 7606-S Router

Removing PWR-4500-DC Power Supply from a Cisco 7606-S Router

Removing a WS-CDC-2500W Power Supply from a Cisco 7609 Router

Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router

Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router

Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router

Removing a PWR-4000-DC Power Supply from a Cisco 7613 Router

Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router

Installing DC-Input Power Supplies

Installing a PWR-950-DC Power Supply in a Cisco 7603 Router

Installing a PWR-1500-DC Power Supply in a Cisco 7603-S Router

Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router

Installing a PWR-1900-DC Power Supply in a Cisco 7606 Router

Installing a PWR-2700-DC Power Supply in a Cisco 7606 Router

Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router

Installing a PWR-4500-DC Power Supply in a Cisco 7606-S Router

Installing a WS-CDC-2500W Power Supply in a Cisco 7609 Router

Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router

Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router

Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router

Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router

Installing a PWR-6000-DC Power Supply in a Cisco 7613 Router

Removing and Replacing the PEM

Required Tools

Removing the AC-Input PEM

Installing the AC-Input PEM

Removing a DC-Input PEM

Installing a DC-Input PEM

Removing and Replacing the Fan Assembly

Removing the Fan Assembly

Installing the Fan Assembly

Checking the Installation

Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional)

Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)

Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)

Cleaning or Replacing the Chassis Air Filter and Intake Panel

Air Filter Maintenance

Intake Panel Maintenance

Air Filters in C7603-S Chassis

Installing the Thermistor Module on a Cisco 7606-S Router

Installing the Thermistor Module on a Cisco 7609-S Router

Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL


Removal and Replacement Procedures


This chapter describes how to perform removal and replacement procedures for Cisco 7600 series router field-replaceable units (FRUs). It contains the following sections:

Preventing Electrostatic Discharge Damage

Removing and Replacing the Power Supply

Removing and Replacing the PEM

Removing and Replacing the Fan Assembly

Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional)

Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)

Installing the Thermistor Module on a Cisco 7606-S Router

Installing the Thermistor Module on a Cisco 7609-S Router

Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL


Warning Only trained and qualified personnel should be allowed to install, replace, or service this equipment.

Caution Use two hands to support the power supply during removal and replacement procedures.


Warning During this procedure, wear grounding wrist straps to avoid ESD damage to the card. Do not directly touch the backplane with your hand or any metal tool, or you could shock yourself.

For instructions on installing and replacing modules, refer to the Cisco 7600 Series Internet Router Module Installation Guide.

Preventing Electrostatic Discharge Damage

Electrostatic discharge (ESD) damage, which can occur when electronic cards or components are improperly handled, results in complete or intermittent failures. Port adapters and processor modules consist of printed circuit boards that are fixed in metal carriers. Electromagnetic interference (EMI) shielding and connectors are integral components of the carrier. Although the metal carrier helps to protect the board from ESD, use a preventive antistatic strap during handling.

Following are guidelines for preventing ESD damage:

Always use an ESD wrist or ankle strap and ensure that it makes good skin contact.

Connect the equipment end of the strap to an unfinished chassis surface.

When installing a component, use any available ejector levers or captive installation screws to properly seat the bus connectors in the backplane or midplane. These devices prevent accidental removal, provide proper grounding for the system, and help to ensure that bus connectors are properly seated.

When removing a component, use any available ejector levers or captive installation screws to release the bus connectors from the backplane or midplane.

Handle carriers by available handles or edges only; avoid touching the printed circuit boards or connectors.

Place a removed component board-side-up on an antistatic surface or in a static shielding container. If you plan to return the component to the factory, immediately place it in a static shielding container.

Avoid contact between the printed circuit boards and clothing. The wrist strap only protects components from ESD voltages on the body; ESD voltages on clothing can still cause damage.

Never attempt to remove the printed circuit board from the metal carrier.


Caution For safety, periodically check the resistance value of the antistatic strap. The measurement should be between 1 and 10 megohm (Mohm).

Removing and Replacing the Power Supply

This section describes how to remove and install power supplies for the Cisco 7600 series routers.


Note In systems with redundant power supplies, you can replace the faulty supply while the system is operating.


Required Tools

A flat-blade or number 2 Phillips-head screwdriver is required to perform these procedures. Additionally, a wire cutter or scissors is necessary for cutting cable tie-wraps.

Clearance Guidelines

Use the following clearance guidelines when planning to install or remove power supplies at the rear of the Cisco 7600 series routers:

Allow atleast 3 to 4 feet of clearance behind the rack for maintenance. If the rack is mobile, you can push it back within one foot of a wall or cabinet for normal operation and pull it out when necessary for maintenance (installing or replacing power supplies) on the Cisco 7606, Cisco 7606-S and Cisco 7604 routers.

Chassis Air Flow Requirements

Table 5-1 lists the chassis air flow architecture and requirements for the Cisco 76xxx routers.

Table 5-1

Chassis Model
Airflow Intake
Airflow Exhaust
Air Volume

76xxx

Right Side

Left Side

 

7609

Bottom

Top (back)

630 cfm

7606-S

Side to side

Right to left

705 cfm with 45 ppi filter; 758 cfm with 25 ppi filter

7603

Side to side

Right to left

270 cfm

7603-S

Side to side

Right to left

282 cfm

7604

Side to side

Right to left

300 cfm

7606

Side to side

Right to left

500 cfm

7609

Front to back

Bottom to top

630 cfm

7609-S

Front to back

Bottom to top

705 with 45 ppi filter; 758 with 25 ppi filter

7613

Side to side

Right to left

1090 cfm


Chassis Air Flow Requirements

Removing an AC-Input Power Supply

This section covers the AC-input power supply removal procedure for the following AC power supplies and Cisco 7600 series routers:

950 W AC and 1400 W AC power supplies for the Cisco 7603 router

2700 W AC power supply for the Cisco 7604 route

1900 W AC power supply for the Cisco 7606 router

2700 W AC power supply for the Cisco 7606 router

2700 W AC power supply for the Cisco 7606-S router

3000 W AC and 4000 W AC power supplies for the Cisco 7609 and Cisco 7613 routers

4000 W AC power supply for the Cisco 7609-S router

6000 W AC power supply for the Cisco 7609, Cisco 7609-S, and Cisco 7613 routers


Warning Hazardous voltage or energy is present on the backplane when the system is operating. Use caution when servicing.

Note In systems with redundant power supplies, you can replace the faulty supply while the system is operating.



Note This procedure covers the removal of the power supply only. For information on removing the power entry module (PEM), see the "Removing and Replacing the PEM" section.


Follow these steps to remove a power supply:


Step 1 Turn the power switch to the Off (0) position on the power supply or PEM for the power supply you are removing.


Note Figure 5-1 shows the location of the AC-input PEMs on the Cisco 7603 router. The location of the PEMs is the same for AC and DC PEMs on the Cisco 7603 router and Cisco 7606 router.



Note If you are planning on installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any PEMs and install a blank PEM filler plate. See Removing and Replacing the PEM.


Figure 5-1 PEM Location

Step 2 Disconnect the power cord from the power source. Do not touch the metal prongs on the power cord when it is still connected to the power supply or PEM.

Step 3 Remove the power cord from the power connection on the PEM. Do not touch the metal prongs embedded in the PEM.


Note The AC power cord for the 4000 W power supply is hard-wired and cannot be removed from the supply.


Step 4 Loosen the captive installation screws on the power supply. (See Figure 5-2 for the Cisco 7603 router, Figure 5-3 for the Cisco 7604 router, Cisco 7606 router, andCisco 7606-S router, Figure 5-4 for the Cisco 7609 router, Cisco 7609-S router, and Cisco 7613 router.)

Figure 5-2 Cisco 7603 Router—Power Supply Captive Installation Screws

Figure 5-3 Cisco 7604 Router , Cisco 7606 Router, Cisco 7606-S—Power Supply Captive Installation Screws

Figure 5-4 Cisco 7609 Router, Cisco 7609-S Router, and Cisco 7613 Router— Power Supply Captive Installation Screws

Step 5 Cisco 7603 router, Cisco 7609 router, Cisco 7609-S, and Cisco 7613 router—Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply (see Figure 5-5 for Cisco 7603 router, and Figure 5-6 for Cisco 7609, Cisco 609-S, and Cisco 7613 routers), and slide the power supply completely out of the chassis.

Cisco 7604, Cisco 7606 router, Cisco 7606-S router—Grasp both power supply handles, as shown in Figure 5-7, and slide the power supply completely out of the chassis.

Figure 5-5 Cisco 7603 Router—Handling an AC-Input Power Supply

Figure 5-6 Cisco 7609 Router, Cisco 7609-S, and Cisco 7613 Router— Handling an AC-Input Power Supply

Figure 5-7 Cisco 7604, Cisco 7606, Cisco 7606-S Routers—Handling an AC-Input Power Supply

Step 6 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-16727-01 for the Cisco 7603 router, 800-19193-01 for the Cisco 7606 router, 800-28533-01 for the Cisco 7606-S router, and 700-03104-01 for the Cisco 7609 and Cisco 7613 routers) over the opening and secure it with the captive installation screws.


Installing an AC-Input Power Supply

This section covers the AC-input power supply installation procedure for the Cisco 7600 series routers.


Warning This product requires short-circuit (over current) protection, to be provided as part of the building installation. Install only in accordance with national and local wiring regulations.

Follow these steps to install an AC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection instructions, see the "System Ground Connection" section.

Step 2 If necessary, remove the blank power supply filler plate from the chassis power supply bay opening by loosening the captive installation screws.

Step 3 If your power supply has a power switch (see Figure 5-4), verify that the power switch is in the Off (0) position.

Step 4 Cisco 7603 router, Cisco 7609 router, and Cisco 7613 router—Grasp the power supply handle with one hand. Place your other hand underneath the power supply (see Figure 5-5 for Cisco 7603 router and Figure 5-6 for Cisco 7609 and Cisco 7613 routers). Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Cisco 7604, Cisco 7606, Cisco 7606-S routers—Grasp both power supply handles, as shown in Figure 5-7. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.


Note If you are installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any preinstalled PEMs. You must also install a blank PEM filler plate for each power supply you are installing. See Removing and Replacing the PEM.


Step 5 Securely tighten the power supply captive installation screws. (See Figure 5-2 for the Cisco 7603 router, Figure 5-3 for the Cisco 7604 router, the Cisco 7606 router, and the Cisco 7606-S router, and Figure 5-4 for the Cisco 7609 and the Cisco 7613 routers.)


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 6 Plug the power cord into the power supply or PEM.

Step 7 Connect the other end of the power cord to an AC-input power source.


Caution In a system with dual power supplies, connect each power supply to a separate input source. In case of a power source failure, the second source will most likely still be available.

Step 8 Turn the switch on the power supply or PEM to the On (|) position.

Step 9 Verify power supply operation by checking that the power supply LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section for troubleshooting information.


Removing a DC-Input Power Supply

This section describes the DC-input power supply removal procedure for the Cisco 7600 series routers:

Removing PWR-950-DC Power Supply from a Cisco 7603 Router

Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router

Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router

Removing PWR-1900-DC Power Supply from a Cisco 7606 Router

Removing PWR-2700-DC Power Supply from a Cisco 7606 Router

Removing PWR-2700-DC Power Supply from a Cisco 7606-S Router

Removing PWR-4500-DC Power Supply from a Cisco 7606-S Router

Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router

Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router

Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router

Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router

Removing PWR-950-DC Power Supply from a Cisco 7603 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-8).

Figure 5-8 PEM Location

Step 2 Loosen the captive installation screws on the power supply (Figure 5-9).

Figure 5-9 Cisco 7603 Router—Power Supply Captive Installation Screws

Step 3 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-10, and slide the power supply completely out of the chassis.

Figure 5-10 Cisco 7603 Router—Handling a DC-Input Power Supply

Step 4 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-16727-01 for the Cisco 7603 router) over the opening and secure it with the captive installation screws.

Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-11).

Figure 5-11 PEM Locations

Step 2 Loosen the captive installation screws on the power supply (Figure 5-12).

Figure 5-12 Cisco 7603-S Router—Power Supply Captive Installation Screws

Step 3 Grasp the power supply handle, as shown in Figure 5-13, and slide the power supply completely out of the chassis.

Figure 5-13 Cisco 7603-S Router—Handling an DC-Input Power Supply

Step 4 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number  800-28728-01 for the Cisco 7603-S router) over the opening and secure it with the captive installation screws.


Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-14).

Figure 5-14 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   

Step 3 Remove the two screws securing each of the cable holder covers, and remove the cable holder covers off the cable holders (Figure 5-14).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-14) in this order:

Positive (+)

Negative (-)

Ground

Step 5 Remove the two tie-wraps from the ground cable. If there is a long cable tie securing the cable holders as shown in Figure 5-14, remove that as well.


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

Step 6 Loosen the captive installation screws on the power supply (Figure 5-14).


Caution Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply weighs 13.4 pounds (6.1 kg).

Step 7 Grasp both power supply handles, as shown in Figure 5-15, and slide the power supply completely out of the chassis.

Figure 5-15 Handling a DC-Input Power Supply

Figure 5-16 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws

Removing PWR-1900-DC Power Supply from a Cisco 7606 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-17). The location of the PEMs is the same for AC and DC PEMs on the Cisco 7603 and Cisco 7606 routers.

Figure 5-17 PEM Locations

Step 2 Loosen the captive installation screws on the power supply (Figure 5-18).

Figure 5-18 Cisco 7606 Router—Power Supply Captive Installation Screws

Step 3 Grasp both power supply handles, as shown in Figure 5-19, and slide the power supply completely out of the chassis.

Figure 5-19 Cisco 7606 Router—Handling an DC-Input Power Supply

Step 4 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number  800-19193-01 for the Cisco 7606 router) over the opening and secure it with the captive installation screws.


Removing PWR-2700-DC Power Supply from a Cisco 7606 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-20).

Figure 5-20 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   

Step 3 Remove the two screws securing each of the cable holder covers, and remove the cable holder covers off the cable holders (Figure 5-20).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-20) in this order:

Positive (+)

Negative (-)

Ground

Step 5 Remove the two tie-wraps from the ground cable. If there is a long cable tie securing the cable holders as shown in Figure 5-20, remove that as well.


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

Step 6 Loosen the captive installation screws on the power supply (Figure 5-20).


Caution Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply weighs 14.1 pounds (6.4 kg).

Step 7 Grasp both power supply handles, as shown in Figure 5-21, and slide the power supply completely out of the chassis.

Figure 5-21 Handling a DC-Input Power Supply


Note If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.


Removing PWR-2700-DC Power Supply from a Cisco 7606-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-22).

Figure 5-22 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   

Step 3 Remove the two screws securing each of the cable holder covers, and remove the cable holder covers off the cable holders (Figure 5-22).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-22) in this order:

Positive (+)

Negative (-)

Ground

Step 5 Remove the two tie-wraps from the ground cable. If there is a long cable tie securing the cable holders as shown in Figure 5-22, remove that as well.


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

Step 6 Loosen the captive installation screws on the power supply (Figure 5-22).


Caution Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply weighs 14.1 pounds (6.4 kg).

Step 7 Grasp both power supply handles, as shown in Figure 5-23, and slide the power supply completely out of the chassis.

Figure 5-23 Handling a DC-Input Power Supply


Note If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-28533-01) over the opening, and secure it with the captive installation screws


Removing PWR-4500-DC Power Supply from a Cisco 7606-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing. The power ON/Off switch on the PWR-4500-DC power supply should be off (marked as the 0 position).

Step 2 Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-24).

Figure 5-24 DC-Input Front Panel for 4500-W DC-Input Power Supply

1

DC power cable terminal block

6

Tie-wrap

2

Cable holder

7

DC power cable terminal block

3

Captive installation screw

8

Cable holder cover

4

Ground

9

Power Switch

5

Status LEDs

10

DC power cable terminal block cover


Step 3 Remove the two screws securing each of the cable holder covers, and remove the cable holder covers off the cable holders (Figure 5-22).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-22) in this order:

Positive (+)

Negative (-)

Ground

Step 5 Remove the two tie-wraps from the ground cable. If there is a long cable tie securing the cable holders as shown in Figure 5-22, remove that as well.


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

Step 6 Loosen the captive installation screws on the power supply (Figure 5-22).


Caution Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply weighs 14.1 pounds (6.4 kg).

Step 7 Grasp both power supply handles, as shown in Figure 5-25, and slide the power supply completely out of the chassis.

Figure 5-25 Handling a DC-Input Power Supply


Note If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-28533-01) over the opening, and secure it with the captive installation screws


Removing a WS-CDC-2500W Power Supply from a Cisco 7609 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-26). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-26 DC-Input Front Panel for 2500-W DC-Input Power Supply

Step 3 Remove the two screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-26).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-27) in this order:

Positive (+)

Negative (-)

Ground


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

Figure 5-27 DC-Input Wire Connections on the Terminal Block

Step 5 Loosen the captive installation screws on the power supply (Figure 5-27).


Caution Use both hands to install and remove power supplies. Each WS-CDC-2500W DC-input power supply weighs 22 pounds (9.9 kg).

Step 6 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-28, and slide the power supply completely out of the chassis.

Figure 5-28 Handling a DC-Input Power Supply

Step 7 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.


Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-29). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-29 DC-Input Front Panel for 2500-W DC-Input Power Supply

Step 3 Remove the two screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-29).

Step 4 Disconnect the DC-input wires from the terminal block (Figure 5-30) in this order:

Positive (+)

Negative (-)

Ground


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

Figure 5-30 DC-Input Wire Connections on the Terminal Block

Step 5 Loosen the captive installation screws on the power supply (Figure 5-30).


Caution Use both hands to install and remove power supplies. Each WS-CDC-2500W DC-input power supply weighs 22 pounds (9.9 kg).

Step 6 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-31, and slide the power supply completely out of the chassis.

Figure 5-31 Handling a DC-Input Power Supply

Step 7 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.


Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-32). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-32 DC-Input Front Panel for 4000-W DC-Input Power Supply


Note Figure 5-32 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.


1

Inner terminal block cover

7

Power switch

2

Plastic insulator

8

Outer terminal block cover

3

DC power cable terminal block 2 (TB2)

9

Inner terminal block cover

4

Ground

10

Plastic insulator

5

Status LEDs

11

DC power cable terminal block 1 (TB1)

6

Captive installation screw

   

Step 3 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-32).

Step 4 Cut any cable tie-wraps being careful not to cut the DC-input wires.


Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W for single and redundant configurations. Some configurations require cable tie-wraps. For more information, refer to Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router.


Step 5 Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover. Remove both inner terminal block covers.


Note You must remove three terminal block covers for the 4000 W DC-input power supply.The left-side inner terminal block cover has two securing screws and the right-side inner terminal block cover has one securing screw.


Step 6 Remove the plastic insulator from over the terminal area (Figure 5-33).

Step 7 Disconnect the DC-input wires from the terminal block in this order:

Positive (+)

Negative (-)


Note You must remove DC-input wires from two terminal blocks for the 4000 W DC-input power supply (if both terminal blocks are used).


Step 8 Disconnect the PWR-4000-DC power supply ground.


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

Figure 5-33 DC-Input Wire Connections for 4000-W DC-Input Power Supply


Note Figure 5-33 shows a 4000 W configuration that requires cable tie-wraps.


Step 9 Loosen the captive installation screw on the power supply (Figure 5-33).


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg).

Step 10 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-34, and slide the power supply completely out of the chassis.

Figure 5-34 Handling a DC-Input Power Supply

Step 11 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.


Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Note With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. Read through this procedure carefully before removing your power supply.


Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-35). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-35 DC-Input Front Panel for 6000-W DC-Input Power Supply

1

Terminal block cover

6

Captive installation screw

2

DC power cable terminal block

7

Input Power Module (IPM)

3

Ground

8

IPM captive screws

4

Status LEDs

9

IPM latches

5

Power switch

   


Note With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. To use this option, do not perform steps 3 through 6 and go to step 7.


Step 3 Remove the two A4 screws securing the terminal block cover, and remove the cover from the power supply (Figure 5-35).

Step 4 Cut any cable tie-wraps being careful not to cut the DC-input wires.


Note The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W for single and redundant configurations. Some configurations require cable tie-wraps, depending on available DC input pairs. For more information, refer to Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router.


Step 5 Disconnect the DC-input wires from the terminal block in this order:

Positive (+)

Negative (-)

Step 6 Disconnect the PWR-6000-DC power supply ground.


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

Figure 5-36 DC-Input Wire Connections for 6000-W DC-Input Power Supply (2800W DC-input shown)


Note If you are not going to remove the IPM, skip steps 7 and 8 and go to step 9.


Step 7 Loosen the IPM captive installation screws on the power supply. See Figure 5-35.

Step 8 Lift up on both IPM latches and remove the IPM. See Figure 5-37.

Figure 5-37 Removing the IPM Module

Step 9 Loosen the captive installation screw on the power supply (Figure 5-36).


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs 35 pounds (16 kg).

Step 10 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-38 (without IPM) and in Figure 5-39 (with IPM), and slide the power supply completely out of the chassis.

Figure 5-38 Handling a DC-Input Power Supply without IPM

Figure 5-39 Handling a DC-Input Power Supply with IPM

If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.

Removing a PWR-4000-DC Power Supply from a Cisco 7613 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-40). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-40 DC-Input Front Panel for 4000-W DC-Input Power Supply


Note Figure 5-40 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.


1

Inner terminal block cover

7

Power switch

2

Plastic insulator

8

Outer terminal block cover

3

DC power cable terminal block 2 (TB2)

9

Inner terminal block cover

4

Ground

10

Plastic insulator

5

Status LEDs

11

DC power cable terminal block 1 (TB1)

6

Captive installation screw

   

Step 3 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-40).

Step 4 Cut any cable tie-wraps being careful not to cut the DC-input wires.


Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W for single and redundant configurations. Some configurations require cable tie-wraps. For more information, refer to Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router.


Step 5 Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover. Remove both inner terminal block covers.


Note You must remove three terminal block covers for the 4000 W DC-input power supply.The left-side inner terminal block cover has two securing screws and the right-side inner terminal block cover has one securing screw.


Step 6 Remove the plastic insulator from over the terminal area (Figure 5-41).

Step 7 Disconnect the DC-input wires from the terminal block in this order:

Positive (+)

Negative (-)


Note You must remove DC-input wires from two terminal blocks for the 4000 W DC-input power supply (if both terminal blocks are used).


Step 8 Disconnect the PWR-4000-DC power supply ground.


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

Figure 5-41 DC-Input Wire Connections for 4000-W DC-Input Power Supply


Note Figure 5-41 shows a 4000 W configuration that requires cable tie-wraps.


Step 9 Loosen the captive installation screw on the power supply (Figure 5-41).


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg).

Step 10 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-42, and slide the power supply completely out of the chassis.

Figure 5-42 Handling a DC-Input Power Supply

Step 11 If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.


Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Note With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. Read through this procedure carefully before removing your power supply.


Follow these steps to remove a DC-input power supply:


Step 1 Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-43). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

Figure 5-43 DC-Input Front Panel for 6000-W DC-Input Power Supply

1

Terminal block cover

6

Captive installation screw

2

DC power cable terminal block

7

Input Power Module (IPM)

3

Ground

8

IPM captive screws

4

Status LEDs

9

IPM latches

5

Power switch

   


Note With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. To use this option, do not perform steps 3 through 6 and go to step 7.


Step 3 Remove the two A4 screws securing the terminal block cover, and remove the cover from the power supply (Figure 5-43).

Step 4 Cut any cable tie-wraps being careful not to cut the DC-input wires.


Note The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W for single and redundant configurations. Some configurations require cable tie-wraps, depending on available DC input pairs. For more information, refer to Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router.


Step 5 Disconnect the DC-input wires from the terminal block in this order:

Positive (+)

Negative (-)

Step 6 Disconnect the PWR-6000-DC power supply ground.


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

Figure 5-44 DC-Input Wire Connections for 6000-W DC-Input Power Supply (2800W DC-input shown)


Note If you are not going to remove the IPM, skip steps 7 and 8 and go to step 9.


Step 7 Loosen the IPM captive installation screws on the power supply. See Figure 5-43.

Step 8 Lift up on both IPM latches and remove the IPM. See Figure 5-45.

Figure 5-45 Removing the IPM Module

Step 9 Loosen the captive installation screw on the power supply (Figure 5-43).


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs 35 pounds (16 kg).

Step 10 Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-46 (without IPM) and in Figure 5-47 (with IPM), and slide the power supply completely out of the chassis.

Figure 5-46 Handling a DC-Input Power Supply without IPM

Figure 5-47 Handling a DC-Input Power Supply with IPM

If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.

Installing DC-Input Power Supplies

This section covers the DC-input power supply installation procedure for the Cisco 7600 series routers:

Installing a PWR-950-DC Power Supply in a Cisco 7603 Router

Installing a PWR-1500-DC Power Supply in a Cisco 7603-S Router

Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router

Installing a PWR-1900-DC Power Supply in a Cisco 7606 Router

Installing a PWR-2700-DC Power Supply in a Cisco 7606 Router

Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router

Installing a WS-CDC-2500W Power Supply in a Cisco 7609 Router

Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router

Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router

Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router

Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router

Installing a PWR-6000-DC Power Supply in a Cisco 7613 Router

For information on installing a 4500W DC for 7606-S, see "Cisco 7606-S DC Power Supply Configurations."


Note The DC return is to remain isolated from the system frame and chassis (DC-I).


Installing a PWR-950-DC Power Supply in a Cisco 7603 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are installing.

Step 3 Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-48. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-48 Handling the Power Supply

Step 4 Tighten the power supply captive installation screws (Figure 5-49).

Figure 5-49 Power Supply Captive Installation Screws


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 5 Verify that all connections to the DC PEM are secure.

Step 6 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 7 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-1500-DC Power Supply in a Cisco 7603-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are installing.

Step 3 Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-50. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-50 Handling the Power Supply

Step 4 Tighten the power supply captive installation screws (Figure 5-51).

Figure 5-51 Power Supply Captive Installation Screws


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 5 Verify that all connections to the DC PEM are secure.

Step 6 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 7 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Power supply ground is required.


Note The system ground connection with the PWR-2700-DC/4 power supply in a Cisco 7604 router is provided by the PWR-2700-DC/4 power supply ground. Additionally, you can connect a system (earth) ground.



Note When using a PWR-2700-DC/4 power supply in a Cisco 7604 router, you must always connect the PWR-2700-DC/4 power supply ground.



Note For redundant power supplies, you must connect the PWR-2700-DC/4 power supply ground for both power supplies.


a. Install the PWR-2700-DC/4 power supply ground as described in this procedure.

b. If you intend to use an additional system (earth ground), ensure that the system ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Remove the plastic bag attached to the front panel and put aside. This bag contains two plastic terminal block barriers, two cable ties, and two cable holder covers.

Step 3 Verify that power is off to the DC circuit connected to the power supply you are installing.

Grasp both power supply handles, as shown in Figure 5-52. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-52 Handling the Power Supply


Note This illustration shows the terminal block barriers and terminal block guards attached.


Step 4 Tighten the power supply captive installation screws (Figure 5-53).

Figure 5-53 Power Supply Captive Installation Screws


Note This illustration shows the terminal block barriers and terminal block guards attached.



Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note For proper 2700 W DC-input redundant power configuration, all two pairs of input wires for one 2700W DC-input power supply must come from the same battery system (A feed); all two pairs of input wires for the other 2700 W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Figure 5-54 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the four screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-54).

Step 6 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according to local and national installation requirements. Use only copper wire. The maximum width of a lug is 0.600 inch (15.2 mm).


Note For 2700 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.



Note The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are centered 0.625 inches (15.88 mm) apart and are 1/4-20 threaded. We recommend that you use an appropriately sized industry standard 2-hole, standard barrel compression lug. The power supply ground studs, located below the terminal block, are also threaded 1/4-20 and require two 1/4-inch split-ring washers and two 1/4-20 hex nuts.


Step 7 Connect the DC-input wires to the 2700 W power supply terminal block (Figure 5-54) in this order:

Ground

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Depending on which side you are connecting the DC-input wires, be sure that the DC-input wires rest in the appropriate cable holder. Figure 5-55 shows DC-input wires coming in from the left side.

Step 8 Secure the ground cable to the cable holder with the two cable-ties.


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

Step 9 Retrieve the cable holder covers from the plastic bag and attach to the front panel at the locations shown in Figure 5-54.


Note If the cable holder illustrated as number 5 and 8 in Fig 5-35 is loose on the DC input cables, please use a long cable tie to secure the cable holders as shown in Figure 5-54.


Step 10 Secure the terminal block cover using four screws and the terminal block barriers with two screws each.

Step 11 Turn on the DC inputs and verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Figure 5-55 DC-Input Wires on Left Side

Installing a PWR-1900-DC Power Supply in a Cisco 7606 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are installing.

Grasp both power supply handles, as shown in Figure 5-56. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-56 Handling the Power Supply

Step 3 Tighten the power supply captive installation screws (Figure 5-57).

Figure 5-57 Power Supply Captive Installation Screws


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 4 Verify that all connections to the DC PEM are secure.

Step 5 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 6 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-2700-DC Power Supply in a Cisco 7606 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note If you are installing a PWR-2700-DC power supply in a Cisco 7606 router, you must remove any preinstalled PEMs. You must also install a blank PEM filler plate for each power supply you are installing. See Removing and Replacing the PEM.



Note When you use 2700 W DC-input redundant power configurations and if there is a system load that is greater than 5/3 of lower power capacity on any one power supply, the system supervisor generates latch signal to the power supply with lower power capacity. The lower power capacity on any power supply may be because one of the DC-inputs of the power supply is disabled. Since the power supply gets into latch mode in the system, the power supply should be removed out of chassis and put it back to turn it on.


Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Remove the plastic bag attached to the front panel and put aside. This bag contains two plastic terminal block barriers, two cable ties, and two cable holder covers.

Step 3 Verify that power is off to the DC circuit connected to the power supply you are installing.

Grasp both power supply handles, as shown in Figure 5-58. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-58 Handling the Power Supply


Note This illustration shows the terminal block barriers and terminal block guards attached.


Step 4 Tighten the power supply captive installation screws (Figure 5-59).

Figure 5-59 Power Supply Captive Installation Screws


Note This illustration shows the terminal block barriers and terminal block guards attached.



Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note For proper 2700 W DC-input redundant power configuration, all two pairs of input wires for one 2700W DC-input power supply must come from the same battery system (A feed); all two pairs of input wires for the other 2700 W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Figure 5-60 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the four screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-60).

Step 6 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 2700 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.


Step 7 Connect the DC-input wires to the 2700 W power supply terminal block (Figure 5-60) in this order:

Ground

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Depending on which side you are connecting the DC-input wires, be sure that the DC-input wires rest in the appropriate cable holder. Figure 5-61 shows DC-input wires coming in from the left side.

Step 8 Secure the ground cable to the cable holder with the two cable-ties.


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

Step 9 Retrieve the cable holder covers from the plastic bag and attach to the front panel at the locations shown in Figure 5-60.


Note If the cable holder illustrated as number 5 and 8 in Figure 5-60 is loose on the DC input cables, please use a long cable tie to secure the cable holders as shown in Figure 5-60.


Step 10 Secure the terminal block cover using four screws and the terminal block barriers with two screws each.

Step 11 Turn on the DC inputs and verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Figure 5-61 DC-Input Wires on Left Side

Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Remove the plastic bag attached to the front panel and put aside. This bag contains two plastic terminal block barriers, two cable ties, and two cable holder covers.

Step 3 Verify that power is off to the DC circuit connected to the power supply you are installing.

Grasp both power supply handles, as shown in Figure 5-62. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-62 Handling the Power Supply


Note This illustration shows the terminal block barriers and terminal block guards attached.


Step 4 Tighten the power supply captive installation screws (Figure 5-63).

Figure 5-63 Power Supply Captive Installation Screws


Note This illustration shows the terminal block barriers and terminal block guards attached.



Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note For proper 2700 W DC-input redundant power configuration, all two pairs of input wires for one 2700W DC-input power supply must come from the same battery system (A feed); all two pairs of input wires for the other 2700 W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Figure 5-64 DC-Input Front Panel for 2700-W DC-Input Power Supply

1

Captive installation screw

7

Cable holder cover

2

DC power cable terminal block

8

Cable holder

3

Status LEDs

9

Tie-wrap

4

DC power cable terminal block cover

10

Cable holder

5

Cable holder cover

11

Tie-wrap

6

Ground

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the four screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-64).

Step 6 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 2700 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.


Step 7 Connect the DC-input wires to the 2700 W power supply terminal block (Figure 5-64) in this order:

Ground

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Depending on which side you are connecting the DC-input wires, be sure that the DC-input wires rest in the appropriate cable holder. Figure 5-65 shows DC-input wires coming in from the left side.

Step 8 Secure the ground cable to the cable holder with the two cable-ties.


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

Step 9 Retrieve the cable holder covers from the plastic bag and attach to the front panel at the locations shown in Figure 5-60.


Note If the cable holder illustrated as number 5 and 8 in Figure 5-64 is loose on the DC input cables, please use a long cable tie to secure the cable holders as shown in Figure 5-64.


Step 10 Secure the terminal block cover using four screws and the terminal block barriers with two screws each.

Step 11 Turn on the DC inputs and verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Figure 5-65 DC-Input Wires on Left Side

Installing a PWR-4500-DC Power Supply in a Cisco 7606-S Router


Note There are different power supply configurations available for the Cisco 7606-S router. See the appendix, Cisco 7606-S DC Power Supply Configurations, for more information.



Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note When you use 4500 W DC-input redundant power configurations and if there is a system load that is greater than 5/3 of lower power capacity on any one power supply, the system supervisor generates latch signal to the power supply with lower power capacity. The lower power capacity on any power supply may be because one of the DC-inputs of the power supply is disabled. Since the power supply gets into latch mode in the system, the power supply should be removed out of chassis and put it back to turn it on.


Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Remove the plastic bag attached to the front panel and put aside. This bag contains two plastic terminal block barriers, two cable ties, and two cable holder covers.

Step 3 Verify that power is off to the DC circuit connected to the power supply you are installing.

Grasp both power supply handles, as shown in Figure 5-66. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Figure 5-66 Handling the Power Supply


Note This illustration shows the terminal block barriers and terminal block guards attached.


Step 4 Tighten the power supply captive installation screws (Figure 5-67).

Figure 5-67 Power Supply Captive Installation Screws


Note This illustration shows the terminal block barriers and terminal block guards attached.



Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note For proper 4500 W DC-input redundant power configuration, all two pairs of input wires for one 4500W DC-input power supply must come from the same battery system (A feed); all two pairs of input wires for the other 4500 W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Figure 5-68 Input Front Panel for 4500-W DC-Input Power Supply

1

DC power cable terminal block

6

Tie-wrap

2

Cable holder

7

DC power cable terminal block

3

Captive installation screw

8

Cable holder cover

4

Ground

9

Install/Removal Switch

5

Status LEDs

10

DC power cable terminal block cover



Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the four screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-66).

Step 6 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 4500 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.


Step 7 Connect the DC-input wires to the 4500 W power supply terminal block (Figure 5-66) in this order:

Ground

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Depending on which side you are connecting the DC-input wires, be sure that the DC-input wires rest in the appropriate cable holder.

Step 8 Secure the ground cable to the cable holder with the two cable-ties.


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

Step 9 Retrieve the cable holder covers from the plastic bag and attach to the front panel at the locations shown in Figure 5-60.


Note If the cable holder illustrated as number 2 and 8 in Figure 5-66 is loose on the DC input cables, please use a long cable tie to secure the cable holders as shown in Figure 5-66.


Step 10 Secure the terminal block cover using four screws and the terminal block barriers with two screws each.

Step 11 Turn on the DC inputs and verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a WS-CDC-2500W Power Supply in a Cisco 7609 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit that is connected to the power supply you are installing.


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg).

Step 3 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-69).

Figure 5-69 Handling a DC-Input Power Supply

Step 4 Tighten the power supply captive installation screws. (See Figure 5-70.)

Figure 5-70 2500 W DC-Input Power Supply


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the two screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-70).

Step 6 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.300 inch (7.6 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 2500 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.


Step 7 Connect the DC-input wires to the 2500 W power supply terminal block (Figure 5-71) in this order:

Ground

Negative (-)

Positive (+)


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

Figure 5-71 DC-Input Wire Connections for 2500 W DC-Input Power Supply

Step 8 After ensuring that all wire connections are secure, reinstall the terminal block cover.


Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block cover.


Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 9 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 10 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input power supply:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit that is connected to the power supply you are installing.


Caution Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg).

Step 3 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-72).

Figure 5-72 Handling a DC-Input Power Supply

Step 4 Tighten the power supply captive installation screws (Figure 5-73).

Figure 5-73 2500 W DC-Input Power Supply Front Panel


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the two screws securing the terminal block cover, and slide the cover off of the terminal block (Figure 5-73).

Step 6 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.300 inch (7.6 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 2500 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.


Step 7 Connect the DC-input wires to the 2500 W power supply terminal block (Figure 5-74) in this order:

Ground

Negative (-)

Positive (+)


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

Figure 5-74 DC-Input Wire Connections for 2500 W DC-Input Power Supply

Step 8 After ensuring that all wire connections are secure, reinstall the terminal block cover.


Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block cover.


Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 9 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 10 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note For proper 4000W DC-input redundant power configuration, all three pairs of input wires for one 4000W DC-input power supply must come from the same battery system (A feed); all three pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W. Select 2700 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note The procedure that follows provides instructions for installing PWR-4000-DC power supplies in redundant 2700 W or 4000 W configurations. If you are installing a single power supply, install it in the left-side position that corresponds to the chassis labeling "Power 1."



Note You should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact amount of space required depends upon the gauge and flexibility of the DC-input power cables you are using.



Note If you install the PWR-4000-DC power supply in slot 2 and power supply is not present in slot 1, then the power supply capacity is limited to 2940W.


Follow these steps to install a DC-input power supply:


Step 1 Power supply ground is required.


Note The system ground connection with the PWR-4000-DC power supply in a Cisco 7609 router is provided by the PWR-4000-DC power supply ground. Additionally, you can connect a system (earth) ground.



Note When using a PWR-4000-DC power supply in a Cisco 7609 router, you must always connect the PWR-4000-DC power supply ground.



Note For redundant power supplies, you must connect the PWR-4000-DC power supply ground for both power supplies.


a. Install the PWR-4000-DC power supply ground as described in this procedure.

b. If you intend to use an additional system (earth ground), ensure that the system ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.

Step 2 Verify that power is off to the DC circuit that is connected to the power supply you are installing. Place appropriate safety flag and lockout devices at power switch handle to avoid any circuit inputs from becoming energized.


Caution Use both hands to install and remove power supplies. Each PWR-4000-DC weighs 33 pounds (15 kg).

Step 3 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-75).

Figure 5-75 Handling a DC-Input Power Supply

Step 4 Tighten the power supply captive installation screw (Figure 5-76).

Figure 5-76 4000 W DC-Input Power Supply Front Panel


Note Figure 5-76 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.


1

Inner terminal block cover

7

Power switch

2

Plastic insulator

8

Outer terminal block cover

3

DC power cable terminal block 2 (TB2)

9

Inner terminal block cover

4

Ground

10

Plastic insulator

5

Status LEDs

11

DC power cable terminal block 1 (TB1)

6

Captive installation screw

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 5 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-76).

Step 6 Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover.


Note You must remove three terminal block covers for the 4000 W DC-input power supply: one outer terminal block cover and two inner terminal block covers.


Step 7 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according to local and national installation requirements. Use only copper wire.


Note The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are centered 0.625 inches (15.88 mm) apart and are 1/4-20 threaded. We recommend that you use an appropriately sized industry standard 2-hole, standard barrel compression lug. The power supply ground studs, located below the terminal block, are also threaded 1/4-20 and require two 1/4-inch split-ring washers and two 1/4-20 hex nuts.


Step 8 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 4000 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.



Note You must install plastic insulators that are shipped with the power supply as described below.



Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W. Select 2700 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note If you are wiring for 2700 W for a single power supply, proceed to Step 9; if you are wiring 2700 W for a redundant power supply, proceed to Step 9 and then Step 11. If you are wiring for 4000 W for a single power supply, proceed to Step 10; if you are wiring 4000 W for a redundant power supply, proceed to Step 10 and then Step 12.


Step 9 Wire for 2700 W (left side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).


Note Be sure to place a plastic insulator over the smaller terminal block even if you are not attaching DC-input wires to it; this ensures that the plastic insulator is available for future use.


b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the left side of the power supply, connect the ground wire to the ground (Figure 5-77).

Figure 5-77 DC-Input Wire Connections for 2700-W DC-Input Power Supply for Left Side of Power Bay

d. From the left side of the power supply, connect the DC-input wires to TB1 (Figure 5-76 and Figure 5-77) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Place and secure left and right inner terminal block cover.

e. Secure outer block cover.

Step 10 Wire for 4000 W (left side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).

b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the left side of the power supply, connect the ground wire to the ground (Figure 5-78).

Figure 5-78 DC-Input Wire Connections for 4000-W DC-Input Power Supply for Left Side of Power Bay

d. From the left side of the power supply, connect the DC-input wires to TB1 in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


e. From the left side of the power supply, connect the DC-input wires to TB2 in this order:

Negative (-)

Positive (+)

f. Using the cable tie provided, place the cable tie through the slot at the top of the left terminal block cover and secure the wiring going to TB2.

g. Place and secure left and right inner terminal block cover.

h. Secure outer block cover.

Step 11 Wire for 2700 W (right side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).


Note Be sure to place a plastic insulator over the smaller terminal block even if you are even if you are not attaching DC-input wires to it; this ensures that the plastic insulator is available for future use.


b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the right side of the power supply, connect the ground wire to the ground (Figure 5-79).

Figure 5-79

DC-Input Wire Connections for 2700-W DC-Input Power Supply, Right Side of Power Bay

d. From the right side of the power supply, connect the DC-input wires to TB1 (Figure 5-76 and Figure 5-79) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


e. Place and secure left and right inner terminal block cover.

f. Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block cover and secure the wiring to the left terminal block.

g. Secure outer block cover.

Step 12 Wire for 4000 W (right side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).

b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the right side of the power supply, connect the ground wire to the ground (Figure 5-80).

Figure 5-80

DC-Input Wire Connections for 4000-W DC-Input Power Supply, Right Side of Power Bay

d. From the right side of the power supply, connect the DC-input wires to the right power supply terminal block (Figure 5-76 and Figure 5-80) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


e. From the right side of the power supply, connect the DC-input wires to TB1 (Figure 5-80) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


f. Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block cover and secure the wiring going to the left terminal block.

g. Place and secure left and right inner terminal block cover.

h. Secure outer block cover.


Note For proper 4000W DC-input redundant power configuration, all three pairs of input wires for one 4000W DC-input power supply must come from the same battery system (A feed); all three pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block covers.

Step 13 After confirming all installation steps are correctly completed, safety flags and lockout devices can be removed, and the input circuits to the supplies can be energized.

Step 14 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router


Note With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) (previously removed) with the DC-input wires and the ground wires still connected. You can then install your power supply and insert the fully-wired IPM. Read through this procedure carefully before installing your power supply.



Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note For proper 6000W DC-input redundant power configuration, all input wires (two pairs for 2800W DC-input, three pairs for 4500W DC-input, and four pairs for 6000W DC-input) for one 6000W DC-input power supply must come from the same battery system (A feed); all input wires (two pairs for 2800W DC-input, three pairs for 4500W DC-input, and four pairs for 6000W DC-input) for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Note The 6000 W DC-input power supply provides power of 2800 W, 4500 W, or 6000 W. Select 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four positive (+)/negative (-) terminal pairs. The Cisco IOS software detects the wired inputs and sets the proper system power.


Follow these steps to install a DC-input power supply:



Note The PWR-6000-DC power supply ground provides the system ground connection when the PWR-6000-DC power supply is installed in a Cisco 7609-S router. Install the ground as described in this procedure.



Note For redundant power supplies, you must connect the PWR-6000-DC power supply ground for both power supplies.



Note You should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact amount of space required depends upon the gauge and flexibility of the DC-input power cables you are using.



Step 1 Verify that power is off to the DC circuit that is connected to the power supply you are installing. Place appropriate safety flag and lockout devices at power switch handle to avoid any circuit inputs from becoming energized.


Caution Use both hands to install and remove power supplies. Each PWR-6000-DC weighs 35 pounds (16 kg).

Step 2 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-81).

Figure 5-81 Handling a DC-Input Power Supply

Step 3 Tighten the power supply captive installation screw (Figure 5-82).

Figure 5-82 6000 W DC-Input Power Supply Front Panel

1

Terminal block cover

6

Captive installation screw

2

DC power cable terminal block

7

Input Power Module (IPM)

3

Ground

8

IPM captive screws

4

Status LEDs

9

IPM latches

5

Power switch

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) (previously removed) with the DC-input wires and the ground wires still connected. You can then install your power supply and insert the fully-wired IPM. If you are going to install an IPM with DC-input wires and ground wires still connected, skip steps 4 through 12 and go directly to step 13.


Step 4 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-82).

Step 5 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according to local and national installation requirements. Use only copper wire.


Note 6000 W power supplies ship with AWG #4 lugs with 45-degree angled, 2-hole compression lug for both power and ground wiring. Additional lugs for different wire size should be purchased seperately.



Note The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are centered 0.625 inches (15.88 mm) apart and are 1/4-20 threaded. We recommend that you use an appropriately sized industry standard 45 degree angled, 2-hole, standard barrel compression lug for both power and ground lugs (for example, on AWG #4 wires, Panduit part number LCC4-14AWH-L or equivalent). The power supply ground studs, located beside the terminal block.



Note For 6000 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.



Note The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W. Select 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note If you are wiring for 2800 W for a single power supply, proceed to Step 7; if you are wiring 2800 W for a redundant power supply, proceed to Step 7 and then Step 10. In either case, proceed to step 14 upon completion.



Note If you are wiring for 4500 W for a single power supply, proceed to Step 8; if you are wiring 4500 W for a redundant power supply, proceed to Step 8 and then Step 11. In either case, proceed to step 14 upon completion.



Note If you are wiring for 6000 W for a single power supply, proceed to Step 9; if you are wiring 6000 W for a redundant power supply, proceed to Step 9 and then Step 12. In either case, proceed to step 14 upon completion.


Step 6 Wire for 2800 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-83).

Figure 5-83 DC-Input Wire Connections for 2700-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-82 and Figure 5-83) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.

Step 7 Wire for 4500 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-84).

Figure 5-84 DC-Input Wire Connections for 4000-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-82 and Figure 5-84) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.

Step 8 Wire for 6000 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-85).

Figure 5-85 DC-Input Wire Connections for 6000-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-82 and Figure 5-85) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Step 9 Wire for 2800 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-86).

Figure 5-86

DC-Input Wire Connections for 2700-W DC-Input Power Supply, Right Side of Power Bay

b. From the right side of the power supply, connect the DC-input wires to the terminal block (Figure 5-82 and Figure 5-86) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.


Note For proper 2800W DC-input redundant power configuration, both pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); both pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Step 10 Wire for 4500 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-87).

Figure 5-87

DC-Input Wire Connections for 4000-W DC-Input Power Supply, Right Side of Power Bay

b. From the right side of the power supply, connect each of the DC-input wires to the right power supply terminal block (Figure 5-82 and Figure 5-87) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.


Note For proper 4500W DC-input redundant power configuration, three pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); three pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Step 11 Wire for 6000 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-88).

Figure 5-88 DC-Input Wire Connections for 6000-W DC-Input Power Supply for Right Side of Power Bay

b. From the right side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-82 and Figure 5-88) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).



Note For proper 6000W DC-input redundant power configuration, all four pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); all four pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block covers.

Step 12 If you are installing a previously-wired IPM, insert the IPM firmly into the power supply and tighten the IPM captive screws. See Figure 5-89.

Figure 5-89 Inserting Previously-Wired IPM (2700W DC-input shown)

Step 13 After confirming all installation steps are correctly completed, safety flags and lockout devices can be removed, and the input circuits to the supplies can be energized.

Step 14 Use the power switch to turn the power supply on.

Step 15 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note For proper 4000W DC-input redundant power configuration, all three pairs of input wires for one 4000W DC-input power supply must come from the same battery system (A feed); all three pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W. Select 2700 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note The procedure that follows provides instructions for installing PWR-4000-DC power supplies in redundant 2700 W or 4000 W configurations. If you are installing a single power supply, install it in the left-side position that corresponds to the chassis labeling "Power 1."


Follow these steps to install a DC-input power supply:



Note The PWR-4000-DC power supply ground provides the system ground connection when the PWR-4000-DC power supply is installed in a Cisco 7613 router. Install the ground as described in this procedure.



Note For redundant power supplies, you must connect the PWR-4000-DC power supply ground for both power supplies.



Note You should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact amount of space required depends upon the gauge and flexibility of the DC-input power cables you are using.



Step 1 Verify that power is off to the DC circuit that is connected to the power supply you are installing. Place appropriate safety flag and lockout devices at power switch handle to avoid any circuit inputs from becoming energized.


Caution Use both hands to install and remove power supplies. Each PWR-4000-DC weighs 33 pounds (15 kg).

Step 2 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-90).

Figure 5-90 Handling a DC-Input Power Supply

Step 3 Tighten the power supply captive installation screw (Figure 5-91).

Figure 5-91 4000 W DC-Input Power Supply Front Panel


Note Figure 5-91 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.


1

Inner terminal block cover

7

Power switch

2

Plastic insulator

8

Outer terminal block cover

3

DC power cable terminal block 2 (TB2)

9

Inner terminal block cover

4

Ground

10

Plastic insulator

5

Status LEDs

11

DC power cable terminal block 1 (TB1)

6

Captive installation screw

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Step 4 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-91).

Step 5 Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover.


Note You must remove three terminal block covers for the 4000 W DC-input power supply: one outer terminal block cover and two inner terminal block covers.


Step 6 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according to local and national installation requirements. Use only copper wire.


Note The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are centered 0.625 inches (15.88 mm) apart and are 1/4-20 threaded. We recommend that you use an appropriately sized industry standard 2-hole, standard barrel compression lug. The power supply ground studs, located below the terminal block, are also threaded 1/4-20 and require two 1/4-inch split-ring washers and two 1/4-20 hex nuts.


Step 7 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.300 inch (7.6 mm). The wire should be sized according to local and national installation requirements. Use only copper wire.


Note For 4000 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.



Note You must install plastic insulators that are shipped with the power supply as described below.



Note The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W. Select 2700 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note If you are wiring for 2700 W for a single power supply, proceed to Step 8; if you are wiring 2700 W for a redundant power supply, proceed to Step 8 and then Step 10. If you are wiring for 4000 W for a single power supply, proceed to Step 9; if you are wiring 4000 W for a redundant power supply, proceed to Step 9 and then Step 11.


Step 8 Wire for 2700 W (left side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).


Note Be sure to place a plastic insulator over the smaller terminal block even if you are not attaching DC-input wires to it; this ensures that the plastic insulator is available for future use.


b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the left side of the power supply, connect the ground wire to the ground (Figure 5-92).

Figure 5-92 DC-Input Wire Connections for 2700-W DC-Input Power Supply for Left Side of Power Bay

d. From the left side of the power supply, connect the DC-input wires to TB1 (Figure 5-91 and Figure 5-92) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Place and secure left and right inner terminal block cover.

e. Secure outer block cover.

Step 9 Wire for 4000 W (left side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).

b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the left side of the power supply, connect the ground wire to the ground (Figure 5-93).

Figure 5-93 DC-Input Wire Connections for 4000-W DC-Input Power Supply for Left Side of Power Bay

d. From the left side of the power supply, connect the DC-input wires to TB1 in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


e. From the left side of the power supply, connect the DC-input wires to TB2 in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


f. Using the cable tie provided, place the cable tie through the slot at the top of the left terminal block cover and secure the wiring going to TB2.

g. Place and secure left and right inner terminal block cover.

h. Secure outer block cover.

Step 10 Wire for 2700 W (right side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).


Note Be sure to place a plastic insulator over the smaller terminal block even if you are even if you are not attaching DC-input wires to it; this ensures that the plastic insulator is available for future use.


b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the right side of the power supply, connect the ground wire to the ground (Figure 5-94).

Figure 5-94

DC-Input Wire Connections for 2700-W DC-Input Power Supply, Right Side of Power Bay

d. From the right side of the power supply, connect the DC-input wires to TB1 (Figure 5-91 and Figure 5-94) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


e. Place and secure left and right inner terminal block cover.

f. Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block cover and secure the wiring to the left terminal block.

g. Secure outer block cover.

Step 11 Wire for 4000 W (right side of power supply bay) as follows:

a. Place both plastic insulators over the terminal areas, aligning the circular holes in insulating cover with terminal posts. The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry).

b. Wrap the large perforated flaps around each pair of conductors, inserting each locking tab into rear of slot. Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic.

c. From the right side of the power supply, connect the ground wire to the ground (Figure 5-95).

Figure 5-95

DC-Input Wire Connections for 4000-W DC-Input Power Supply, Right Side of Power Bay

d. From the right side of the power supply, connect the DC-input wires to the right power supply terminal block (Figure 5-91 and Figure 5-95) in this order:

Negative (-)

Positive (+)

e. From the right side of the power supply, connect the DC-input wires to TB1 (Figure 5-91 and Figure 5-95) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


f. Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block cover and secure the wiring going to the left terminal block.

g. Place and secure left and right inner terminal block cover.

h. Secure outer block cover.


Note For proper 4000W DC-input redundant power configuration, all three pairs of input wires for one 4000W DC-input power supply must come from the same battery system (A feed); all three pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block covers.

Step 12 After confirming all installation steps are correctly completed, safety flags and lockout devices can be removed, and the input circuits to the supplies can be energized.

Step 13 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Installing a PWR-6000-DC Power Supply in a Cisco 7613 Router


Note With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) (previously removed) with the DC-input wires and the ground wires still connected. You can then install your power supply and insert the fully-wired IPM. Read through this procedure carefully before installing your power supply.



Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Note For proper 6000W DC-input redundant power configuration, all input wires (two pairs for 2800W DC-input, three pairs for 4500W DC-input, and four pairs for 6000W DC-input) for one 6000W DC-input power supply must come from the same battery system (A feed); all input wires (two pairs for 2800W DC-input, three pairs for 4500W DC-input, and four pairs for 6000W DC-input) for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Note The 6000 W DC-input power supply provides power of 2800 W, 4500 W, or 6000 W. Select 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four positive (+)/negative (-) terminal pairs. The Cisco IOS software detects the wired inputs and sets the proper system power.


Follow these steps to install a DC-input power supply:



Note The PWR-6000-DC power supply ground provides the system ground connection when the PWR-6000-DC power supply is installed in a Cisco 7609-S router. Install the ground as described in this procedure.



Note For redundant power supplies, you must connect the PWR-6000-DC power supply ground for both power supplies.



Note You should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact amount of space required depends upon the gauge and flexibility of the DC-input power cables you are using.



Step 1 Verify that power is off to the DC circuit that is connected to the power supply you are installing. Place appropriate safety flag and lockout devices at power switch handle to avoid any circuit inputs from becoming energized.


Caution Use both hands to install and remove power supplies. Each PWR-6000-DC weighs 35 pounds (16 kg).

Step 2 Grasp the power supply handle with one hand, and place your other hand underneath the power supply. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay (Figure 5-96).

Figure 5-96 Handling a DC-Input Power Supply

Step 3 Tighten the power supply captive installation screw (Figure 5-97).

Figure 5-97 6000 W DC-Input Power Supply Front Panel

1

Terminal block cover

6

Captive installation screw

2

DC power cable terminal block

7

Input Power Module (IPM)

3

Ground

8

IPM captive screws

4

Status LEDs

9

IPM latches

5

Power switch

   


Warning Power supply captive installation screws must be tight to ensure protective grounding continuity.

Note With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) (previously removed) with the DC-input wires and the ground wires still connected. You can then install your power supply and insert the fully-wired IPM. If you are going to install an IPM with DC-input wires and ground wires still connected, skip steps 4 through 12 and go directly to step 13.


Step 4 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-97).

Step 5 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according to local and national installation requirements. Use only copper wire.


Note 6000 W power supplies ship with AWG #4 lugs with 45-degree angled, 2-hole compression lug for both power and ground wiring. Additional lugs for different wire size should be purchased seperately.



Note The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are centered 0.625 inches (15.88 mm) apart and are 1/4-20 threaded. We recommend that you use an appropriately sized industry standard 45 degree angled, 2-hole, standard barrel compression lug for both power and ground lugs (for example, on AWG #4 wires, Panduit part number LCC4-14AWH-L or equivalent). The power supply ground studs, located beside the terminal block.



Note For 6000 W power supplies, use fine-stranded copper conductors rated for 45-degrees Celsius for North American installations.



Note The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W. Select 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.



Note If you are wiring for 2800 W for a single power supply, proceed to Step 7; if you are wiring 2800 W for a redundant power supply, proceed to Step 7 and then Step 10. In either case, proceed to step 14 upon completion.



Note If you are wiring for 4500 W for a single power supply, proceed to Step 8; if you are wiring 4500 W for a redundant power supply, proceed to Step 8 and then Step 11. In either case, proceed to step 14 upon completion.



Note If you are wiring for 6000 W for a single power supply, proceed to Step 9; if you are wiring 6000 W for a redundant power supply, proceed to Step 9 and then Step 12. In either case, proceed to step 14 upon completion.


Step 6 Wire for 2800 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-98).

Figure 5-98 DC-Input Wire Connections for 2700-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-98 and Figure 5-99) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.

Step 7 Wire for 4500 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-99).

Figure 5-99 DC-Input Wire Connections for 4000-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-97 and Figure 5-99) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.

Step 8 Wire for 6000 W (left side of power supply bay) as follows:

a. From the left side of the power supply, connect the ground wire to the ground (Figure 5-100).

Figure 5-100 DC-Input Wire Connections for 6000-W DC-Input Power Supply for Left Side of Power Bay

b. From the left side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-97 and Figure 5-100) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


Step 9 Wire for 2800 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-101).

Figure 5-101

DC-Input Wire Connections for 2700-W DC-Input Power Supply, Right Side of Power Bay

b. From the right side of the power supply, connect the DC-input wires to the terminal block (Figure 5-97 and Figure 5-101) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.


Note For proper 2800W DC-input redundant power configuration, both pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); both pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Step 10 Wire for 4500 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-102).

Figure 5-102

DC-Input Wire Connections for 4000-W DC-Input Power Supply, Right Side of Power Bay

b. From the right side of the power supply, connect each of the DC-input wires to the right power supply terminal block (Figure 5-97 and Figure 5-102) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).


c. Secure outer block cover.


Note For proper 4500W DC-input redundant power configuration, three pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); three pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.


Step 11 Wire for 6000 W (right side of power supply bay) as follows:

a. From the right side of the power supply, connect the ground wire to the ground (Figure 5-103).

Figure 5-103 DC-Input Wire Connections for 6000-W DC-Input Power Supply for Right Side of Power Bay

b. From the right side of the power supply, connect each of the DC-input wires to the terminal block (Figure 5-97 and Figure 5-103) in this order:

Negative (-)

Positive (+)


Note When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds).



Note For proper 6000W DC-input redundant power configuration, all four pairs of input wires for one 6000W DC-input power supply must come from the same battery system (A feed); all four pairs of input wires for the other 4000W DC-input power supply must come from another battery system (B feed).



Note For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements.



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

Caution To prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block covers.

Step 12 If you are installing a previously-wired IPM, insert the IPM firmly into the power supply and tighten the IPM captive screws. See Figure 5-104.

Figure 5-104 Inserting Previously-Wired IPM (2700W DC-input shown)

Step 13 After confirming all installation steps are correctly completed, safety flags and lockout devices can be removed, and the input circuits to the supplies can be energized.

Step 14 Use the power switch to turn the power supply on.

Step 15 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.

Removing and Replacing the PEM

This section describes how to remove and install the PEMs for the Cisco 7603, Cisco 7603-S, and Cisco 7606 routers.

The PEM provides an input power connection on the front of the chassis to connect the site power source to the power supply. In addition to providing an input power connection, the PEM also has an illuminated power switch (AC-input only), current protection, surge and EMI suppression, and filtering functions.

The PEM on the left (PEM 1) connects the site power source to power supply 1; the  PEM on the right (PEM 2) connects the site power source to power supply 2. See Figure 5-105 for the location of the PEM; see Figure 5-106 (Cisco 7603 router), Figure 5-107 (Cisco 7603-S router), and Figure 5-108 (Cisco 7606 router) for the location of the power supplies.

Figure 5-105 PEM Location

Figure 5-106 Cisco 7603 Router—Power Supply Location

Figure 5-107 Cisco 7603-S Router—Power Supply Location

Figure 5-108 Cisco 7606 Router—Power Supply Location

Required Tools

You need a flat-blade or number 2 Phillips-head screwdriver to perform these procedures.

Removing the AC-Input PEM

Follow these steps to remove an AC-input PEM:


Step 1 Turn the power switch to the Off (0) position on the PEM you are removing. (see Figure 5-105.)

Step 2 Disconnect the power cord from the power source. Do not touch the metal prongs on the power cord when it is still connected to the PEM.

Step 3 Remove the power cord from the power connection on the PEM. Do not touch the metal prongs embedded in the PEM.

Step 4 Loosen the captive installation screws (Figure 5-109).

Figure 5-109 AC-Input PEM

Step 5 Grasp the PEM with one hand, and slide it part of the way out of the chassis. Place your other hand underneath the PEM, as shown in Figure 5-110, and slide it completely out of the chassis.

Figure 5-110 Handling a PEM

Step 6 If the PEM bay is to remain empty, install a blank PEM filler plate (Cisco part number 800-16719-01) over the opening, and secure it with the captive installation screws. See Figure 5-111.


Figure 5-111 Blank PEM Filler Plate

Installing the AC-Input PEM

Follow these steps to install an AC-input PEM:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection instructions, see the "System Ground Connection" section.

Step 2 If necessary, remove the blank PEM filler plate (Cisco part number 800-16719-01) from the chassis PEM bay opening by loosening the captive installation screws. See Figure 5-111.

Step 3 Grasp the PEM with one hand. Place your other hand underneath the PEM, as shown in Figure 5-110. Slide the PEM into the PEM bay. Make sure that the PEM is fully seated in the bay.

Step 4 Tighten the PEM captive installation screws (Figure 5-109).

Step 5 Plug the power cord into the PEM.

Step 6 Connect the other end of the power cord to an AC-input power source.


Caution In a system with dual power supplies, connect each power supply to a separate input source. In case of a power source failure, the second source will most likely still be available.

Step 7 Turn the power switch to the On (|) position on the PEM.


Removing a DC-Input PEM


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Warning Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.

Follow these steps to remove a DC-input PEM:


Step 1 Verify that power is off to the DC circuit for the PEM you are removing.

Step 2 Loosen the captive installation screws on the PEM (Figure 5-112).

Figure 5-112 DC-Input PEM

Step 3 Slide the PEM part way out of the chassis so that you have access to the PEM terminal block screws (Figure 5-113).

Figure 5-113 DC-Input PEM Terminal Block Screws

Step 4 Disconnect the DC-input wires from the PEM terminal block in the following order:

Positive (+)

Negative (-)


Note It is not necessary to disconnect the system ground connection.



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

Step 5 Grasp the PEM with one hand, and place your other hand underneath the PEM, as shown in Figure 5-114, and slide the PEM completely out of the chassis. Set the PEM aside.

Figure 5-114 Handling a DC-Input PEM

Step 6 If the PEM bay is to remain empty, install a blank PEM filler plate (Cisco part number 800-16719-01) over the opening and secure it with the captive installation screws.


Installing a DC-Input PEM


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit.

Follow these steps to install a DC-input PEM:


Step 1 Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "System Ground Connection" section.


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

Step 2 Verify that power is off to the DC circuit for the PEM you are installing.

Step 3 Install the PEM part way in the chassis so you still have access to the PEM terminal block screws (Figure 5-115).

Figure 5-115 DC-Input PEM Terminal Block Screws

Step 4 Connect the DC-input wires to the terminal block in the following order:

Negative (-)

Positive (+)


Note For a Cisco 7603-S router with 1500W DC power supply, the size of the holes on the PEM into which the DC wires are input, is 0.6-inch in diameter.


Step 5 After ensuring that all wire connections are secure, install the PEM in the bay.

Step 6 Tighten the power supply captive installation screws (Figure 5-116).

Figure 5-116 DC-Input PEM


Caution In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available.

Step 7 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 8 Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

INPUT OK LED is green

FAN OK LED is green

OUTPUT FAIL LED is not lit

If the LEDs indicate a power problem, see the "Identifying Startup Problems" section.


Removing and Replacing the Fan Assembly

This section describes how to remove and replace fan assemblies for the Cisco 7600 series router. A flat-blade or number 2 Phillips-head screwdriver is required to perform this procedure.


Note The Cisco 7609 router and Cisco 7609-S router use redundant fan assemblies. The fan assemblies are installed one on top of the other.


Removing the Fan Assembly

The fan assembly is designed to be removed and replaced while the system is operating without presenting an electrical hazard or damage to the system.

Perform these steps to remove the existing fan assembly:


Step 1 Locate the fan assembly. (See Figure 5-117 for the Cisco 7603 router, Figure 5-118 for the Cisco 7603-S router, Figure 5-119 for the Cisco 7604 router, Figure 5-120 for the Cisco 7606 router, Figure 5-121 for the Cisco 7606-S router, Figure 5-122 for the Cisco 7613 router, and Figure 5-124 for the  Cisco 7609 router and the Cisco 7609-S router.)


Note On the Cisco 7609 router, the fan assembly is located behind the cable management system. You must first loosen the two captive installation screws located at the top of the cable management system and fold the cable guide down to access the fan assembly (see Figure 5-123).


Step 2 Loosen the two captive installation screws by turning them counterclockwise.


Warning When removing the fan tray, keep your hands and fingers away from the spinning fan blades. Let the fan blades completely stop before you remove the fan tray.

Figure 5-117 Cisco 7603 Router—Fan Assembly

Figure 5-118 Cisco 7603-S Router—Fan Assembly

Figure 5-119 Cisco 7604 Router—Fan Assembly

Figure 5-120 Cisco 7606 Router—Fan Assembly

Figure 5-121 Cisco 7606-S Router—Fan Assembly

Figure 5-122 Cisco 7613 Router—Fan Assembly

Figure 5-123 Accessing the Fan Assemblies

Figure 5-124 Cisco 7609 Router and Cisco 7609-S Router—Fan Assembly

Step 3 Grasp the fan assembly with both hands and pull it outward; rock it gently if necessary to unseat the power connector from the backplane.


Warning When removing the fan tray, keep your hands and fingers away from the spinning fan blades. Let the fan blades completely stop before you remove the fan tray.

Step 4 Pull the fan assembly clear of the chassis, and put it in a safe place.


Installing the Fan Assembly

Perform these steps to install the new fan assembly:


Step 1 Hold the fan assembly with the fans facing to the right and the FAN STATUS LED at the bottom (see Figure 5-117 for the Cisco 7603 router, Figure 5-118 for the Cisco 7603 router, Figure 5-119 for the Cisco 7604 router, Figure 5-120 for Cisco 7606 router, Figure 5-121 for Cisco 7606-S router, and Figure 5-122 for the Cisco 7613 router.) For the Cisco 7609 router and the Cisco 7609-S router, hold the fan assembly so that the handle is at the top of the assembly (see Figure 5-124).

Step 2 Place the fan assembly into the front chassis cavity so that it rests on the chassis, and then lift the fan assembly up slightly, aligning the top and bottom chassis guides.

Step 3 Push the fan assembly into the chassis until the power connector seats in the backplane and the captive installation screws make contact with the chassis.

Step 4 Tighten the captive installation screws.


Note On the Cisco 7609 router and the Cisco 7609-S router, fold the cable guide up and tighten the two captive installation screws at the top of the chassis (see Figure 5-123).



Checking the Installation

Perform these steps when checking the installation to verify that the new fan assembly is installed correctly:


Step 1 Listen for the fans; you should immediately hear them operating. If you do not hear them, ensure that the fan assembly is inserted completely in the chassis and the faceplate is flush with the switch back panel.

Step 2 Verify that the FAN STATUS LED is green. If the LED is red, one or more fans is faulty.

Step 3 If after several attempts the fans do not operate or you experience trouble with the installation (for instance, if the captive installation screws do not align with the chassis holes), contact a Cisco customer service representative for assistance.


Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional)

This section describes how to install the optional air filter assembly (CVPN7600FIPS/KIT=) for the Cisco 7606 and Cisco 7606-S routers.

Perform these steps to install the new filter assembly.


Step 1 Install filter assembly using thumscrews (see Figure 5-125). Enage thumbscrews only halfway.

Figure 5-125 Cisco 7606 and Cisco 7606-S Router Filter Assembly

1

Filter

3

Plastic rivets

2

Thumbscrews

4

Plastic fastener


Step 2 Insert plastic rivet through filter assembly into ventilation holes on chassis as shown. While holding the filter assembly and inserted rivet in place, insert the plastic fastener to the rivet.

Step 3 Fully secure the thumscrews.

Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)

This section describes how to install the optional air filter assembly for the Cisco 7609 router and the Cisco 7609-S router. The filter assembly is not included with the chassis or bundle configurations. The necessary parts can be ordered at listed in Table 5-2. The filter assembly installation requires INTAKEPNL-09= be installed on the chassis. This intake panel can be identified by the two filter assembly support loops extending from the bottom front of the panel and the thumbscrews of the front left and right sides of the panel (see Figure 5-127).


Note The use of air filter assembly provides the convenience of intake panel maintenance. The disposable form air filter fits on the intake panel and prevents dust, dirt and other impurities from entering the panel. You can replace the air filter when it wears out. The air filter should be used for intake panels in environments where settling of dust particles on intake panel is high.



Note If you are replacing an air filter and not installing a new air filter assembly, see Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional).


Table 5-2 Air Filter Part Numbers

Part Number
Description

INTAKEPNL-09=

Replacement Intake Panel

FLTRASSM-09=

Filter Cage Assembly, no filter inserts included

FLTRINSERTS-09=

Set of five replacement air filter inserts for FLTRASSM-09=


Perform these steps to install the new filter assembly. If INTAKEPNL-09= is already installed, skip to Step 3.


Step 1 Remove the intake panel by unscrewing four thumbscrews (see Figure 5-126).

Figure 5-126 Removing the Intake Panel

Step 2 Install the new intake panel (see Figure 5-127) by tightening four thumbscrews.

Figure 5-127 Installing the New Intake Panel

1

Thumbscrews

2

Fastening screw

3

Support loop

   

Step 3 Remove the inner filter retainer from the filter cage assembly (see Figure 5-128) by depressing the thumb loops and carefully sliding filter retainer outwards.

Figure 5-128 Removing the Inner Filter Retainer

1

Filter cage assembly

2

Filter retainer

3

Thumb loops

4

Tabs (on rear of filter cage assembly)


Step 4 Place the foam filter over the filter retainer (see Figure 5-129).

Step 5 Slide retainer and filter into cage assembly.

Figure 5-129

Placing the Foam Filter Over the Filter Retainer

1

Filter cage assembly

2

Filter

3

Filter retainer

4

Tabs (on rear of filter cage assembly)

5

Thumb loops

   

Step 6 Install filter assembly with tabs facing the floor as follows:

a. Fit tabs (see Figure 5-129) on bottom of filter cage assembly into lower support loops (see Figure 5-127).

b. Rotate the filter assembly towards the intake panel (see Figure 5-130).

c. Tighten two fastening screws.

Figure 5-130

Installing the Filter Assembly

1

Thumbscrews

2

Fastening screw



Note Cisco Systems recommends that air filters be changed every three months.


Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)


Step 1 Loosen the two fastening screws as shown in Figure 5-130 and lift the filter cage assembly off of the support loops (see Figure 5-127).

Step 2 Remove the inner filter retainer from the filter cage assembly (see Figure 5-131) by depressing the thumb loops and carefully sliding filter retainer outwards.

Figure 5-131

Replacing the Foam Filter on the Filter Retainer

1

Filter cage assembly

2

Filter

3

Filter retainer

4

Tabs (on rear of filter cage assembly)

5

Thumb loops

   

Step 3 Remove the foam filter and place a new foam filter over the filter retainer (see Figure 5-131).

Step 4 Slide retainer and filter into cage assembly.

Step 5 Install filter assembly with tabs facing the floor as follows:

a. Fit tabs (see Figure 5-129) on bottom of filter cage assembly into lower support loops (see Figure 5-127).

b. Rotate the filter assembly towards the intake panel (see Figure 5-130).

c. Tighten two fastening screws.


Note Cisco Systems recommends that air filters be changed every three months.


Cleaning or Replacing the Chassis Air Filter and Intake Panel

The Cisco 7609 Router and the Cisco 7609-S Router are equipped a user-serviceable air filter that removes dust drawn into the router and intake panel . One time per month (or more often in environments where routers are prone to dust particles), examine the air filter and intake panel for damage and cleanliness.


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

Air Filter Maintenance

Follow the procedure described in "Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional)" section to remove and reinstall the air filter on the air filter assembly. After taking out the air filter, visually check the condition of the air filter to determine whether to clean or install a new replacement. If the air filter is dirty, clean the filter. Change the air filter if it is torn or worn out.


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. The cleaning process should be performed outside the router installation area.

You can use the pressurized air to clean the air filter. If the filter appears worn or torn, dispose of it in a responsible manner and install a replacement air filter.

Intake Panel Maintenance

Visually check the condition of the intake panel (If the air filter assembly is fitted on the intake panel, remove it). If the intake panel is dirty, you need to clean the panel. Remove the intake panel from the router and take is outside the router installation area. Clean the intake panel using high presurrised air and replace it in the router.


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. The cleaning process should be performed outside the router installation area.

Air Filters in C7603-S Chassis

Do note that there are no air filters in a c7603-S chassis.

Installing the Thermistor Module on a Cisco 7606-S Router

This section describes how to install the thermistor module for the Cisco 7606-S router. The necessary parts can be ordered at listed in Table 5-3.

Table 5-3 Thermistor Module Part Numbers

Part Number
Description

THERM-7606S=

Replacement thermistor module


Perform these steps to replace a thermistor module.


Step 1 Remove the thermistor module by unscrewing two captive thumbscrews (see Figure 5-132) and sliding the termistor module out.

Step 2 Slide the replacement thermistor module into the chassis and tighten the two captive screws. the single captive screw that retains the thermistor module in the chassis. See Figure 5-132.

Figure 5-132 Thermistor Module Replacement

.

Installing the Thermistor Module on a Cisco 7609-S Router

This section describes how to install the thermistor module for the Cisco 7609-S router. The necessary parts can be ordered at listed in Table 5-4.

Table 5-4 Thermistor Module Part Numbers

Part Number
Description

THERM-7609S=

Replacement thermistor module


Perform these steps to replace a thermistor module.


Step 1 Remove the intake panel by unscrewing four captive thumbscrews (see Figure 5-133).

Figure 5-133 Removing the Intake Panel

Step 2 Unscrew the single captive screw that retains the thermistor module in the chassis. See Figure 5-134.

Figure 5-134 Thermistor Module

1

Thermistor slots

2

Captive screw

3

Flange

   

Step 3 Grasp the flange on the thermistor module (see Figure 5-134) and pull to remove the thermistor module. See Figure 5-135.

Figure 5-135 Thermistor Module Replacement

Step 4 Insert the thermistor module until the faceplate of the module bottoms out to the ramp in the chassis.

Step 5 Tighten the captive screw on the module into the chassis.

Step 6 Reinstall the intake panel by tightening four captive thumbscrews.

Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL

To perform the upgrade, you must shut down the system.

Before you shut down the system, you should first upload the current configuration to a server. This saves time when bringing the module back online. You can recover the configuration by downloading it from the server to the nonvolatile memory of the supervisor engine.

For information on installing the WS-SUP720-3BXL, see "Installing a Supervisor Engine or a Module" in the Cisco 7600 Series Router Module Installation Guide.

The SUP720-3BXL is supported with the following chassis. High-speed fans and larger power supplies are required for the WS-SUP720-3BXL. If your chassis has the low speed fan, you will need to upgrade them. For information on replacing the fans, see the "Removing and Replacing the Fan Assembly" procedure. For information on replacing the power supplies, see "Removing and Replacing the Power Supply" procedure.

Table 5-5

Supported Chassis
Low Speed Fan (Original Fan)
High Speed Fan (Required for the SUP720-3BXL)

Cisco 7603

FAN-MOD-3

FAN-MOD-3HS

Cisco 7604

N/A

FAN-MOD-4HS

Cisco 7606

FAN-MOD-6

FAN-MOD-6HS

Cisco 76091

N/A

FAN-MOD-09

Cisco 7613

WS-C6K-13SLOT-FAN

WS-C6K-13SLOT-FAN2

1 Model CISCO7609 is equipped with two tiered-speed fan trays. There is no replacement or adjustment required. For model OSR-7609, refer to http://www.cisco.com/univercd/cc/td/doc/product/core/cis7600/hardware/osrouter/index.htm.


Required Fan Upgrades for the WS-SUP720-3BXL

Table 5-6 Required Power Supply Upgrades for the WS-SUP720-3BXL

 
Supervisor 720 and Supervisor 3BXL
Supported Chassis
AC
DC

Cisco 7603

WS-CAC-950W

WS-CDC-950W

Cisco 7604

N/A

N/A

Cisco 7606

WS-CAC-1900W

WS-CDC-1900W

Cisco 7609

WS-CAC-3000W

WS-CAC-4000W

WS-CDC-2500W

PWR-4000-DC

Cisco 7613

WS-CAC-3000W

WS-CAC-4000W

WS-CDC-2500W

PWR-4000-DC