Catalyst 4000 Series Installation Guide
Removal and Replacement Procedures
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Removing and Replacing FRUs

Table Of Contents

Removing and Replacing FRUs

Removing and Replacing the Power Supply

Required Tools

Removing the AC-Input Power Supply

Installing an AC-Input Power Supply

Removing a DC-Input Power Supply

Installing a DC-Input Power Supply

Removing and Replacing the Chassis Fan Assembly

Required Tools

Removing the Fan Assembly

Installing the Fan Assembly

Verifying the Installation

Required Tools

Installing the External Power Shelf and Power Supplies

Required Tools


Removing and Replacing FRUs



Warning Read the installation instructions before connecting the system to the power source. Statement 1004



Warning Only trained and qualified personnel should be allowed to install, replace, or service this equipment. Statement 1030



Warning This equipment must be grounded. Never defeat the ground conductor or operate the equipment in the absence of a suitably installed ground conductor. Contact the appropriate electrical inspection authority or an electrician if you are uncertain that suitable grounding is available. Statement 1024



Warning Ultimate disposal of this product should be handled according to all national laws and regulations. Statement 1040


This chapter describes how to remove and replace Catalyst 4000 series field-replaceable units (FRUs) and contains these sections:

Removing and Replacing the Power Supply

Removing and Replacing the Chassis Fan Assembly

Installing the External Power Shelf and Power Supplies

For instructions on installing and replacing supervisor engine and switching modules, refer to the Catalyst 4500 Series Module Installation Guide.

Removing and Replacing the Power Supply

This section describes how to remove and install the 400 W AC-input power supply, the 400 W DC-input power supply, and the 650 W DC-input power supply for the Catalyst 4000 series switches. This information is presented in the following sections:

Required Tools

Removing the AC-Input Power Supply

Installing an AC-Input Power Supply

Removing a DC-Input Power Supply

Installing a DC-Input Power Supply


Warning Hazardous voltage or energy is present on the backplane when the system is operating. Use caution when servicing. Statement 1034


Figures 4-1, 4-2, and 4-3 show the three types of power supplies. Locate your power supply and notice the location of the captive installation screws.

Figure 4-1 400 W AC-Input Power Supply

Figure 4-2 400 W DC-Input Power Supply

Figure 4-3 650 W DC-Input Power Supply

Required Tools

You will need a flathead or Phillips screwdriver to perform these procedures.

Removing the AC-Input Power Supply

Follow these steps to remove the AC-input power supply:


Step 1 Disconnect the power cord from the outlet.

Step 2 Disconnect the power cord from the power supply being removed.

Step 3 Loosen the two captive installation screws (see Figure 4-1).


Caution Use both hands to grasp power supplies.

Step 4 Grasp the power supply handle with one hand. Place your other hand beneath the power supply for support, as shown in Figure 4-4.

Figure 4-4 Handling a Power Supply

Step 5 Pull the supply out of the bay and set it aside.


Warning Blank faceplates and cover panels serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain electromagnetic interference (EMI) that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, faceplates, front covers, and rear covers are in place. Statement 1029


Step 6 If the power supply bay is to remain empty, install a blank power supply filler plate over the opening. Secure the filler plate with the two mounting screws, and tighten them with a screwdriver.


Installing an AC-Input Power Supply


Note Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "Connecting System Ground" section on page 2-6.


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


Step 1 Ensure that the power supply you are installing is not plugged in to a power outlet and that the power cord is not connected to the power supply.

Step 2 Remove the two Phillips-head screws from the power supply filler plate.

Step 3 Remove the power supply filler plate and set it aside.


Caution Use both hands to grasp power supplies.

Step 4 Grasp the power supply handle with one hand. Place your other hand beneath the power supply for support, as shown in Figure 4-4.

Step 5 Slide the power supply all the way into the power supply bay.

Step 6 Use a screwdriver to tighten the two captive installation screws (see Figure 4-1) on the front panel of the AC-input power supply.

Step 7 Before you connect the power supply to a power source, ensure that all site power and grounding requirements have been met.

Step 8 Plug the power cord into the power supply.

Step 9 Connect the other end of the power cord to an AC-power input source.


Caution In a system with multiple power supplies, connect each power supply to a separate AC power source. In the event of a power source failure, if the second source is still available, it can maintain maximum overcurrent protection for each power connection.

Step 10 Verify power supply operation by checking the power supply's front panel LEDs:

The LED labeled GOOD is green.

The LED labeled FAIL is not on.

Step 11 Check the power supply and system status from the system console by entering the show system command. For more information on this command, refer to the command reference publication for your switch.

Step 12 If the LEDs or the show system command output indicate a power problem or other system problem, see Chapter 5, "Troubleshooting the Installation," for more information.


Removing a DC-Input Power Supply


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. Statement 1003


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


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

Step 2 Disconnect the DC-input wires from the terminal block. Disconnect the ground wire last.


Warning When installing or replacing the unit, the ground connection must always be made first and disconnected last. Statement 1046


Step 3 Using a screwdriver, loosen and remove the captive screw on the power supply (see Figure 4-2).


Caution Use both hands to grasp power supplies.

Step 4 Grasp the power supply handle with one hand. Place your other hand beneath the power supply as you slowly pull it out of the bay (see Figure 4-4).


Warning Blank faceplates and cover panels serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain electromagnetic interference (EMI) that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, faceplates, front covers, and rear covers are in place. Statement 1029


Step 5 If the bay is to remain empty, install a power supply filler plate over the opening and secure it with the mounting screws. This plate protects the inner chassis from dust and prevents accidental contact with live voltage at the rear of the bay.


Installing a DC-Input Power Supply


Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. Statement 1003



Note You will need a small flat-blade screwdriver for the terminal block wiring.



Note Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the "Connecting System Ground" section on page 2-6.


Follow these steps to install a DC-input power supply, connect it to a power source, and verify its operation:


Step 1 Verify that power is off to the DC circuit on the power supply you are installing.

Step 2 Grasp the power supply handle with one hand. Place your other hand beneath the power supply as you slowly insert it into the bay (see Figure 4-4).

Step 3 Using a screwdriver, tighten the captive screws on the power supply (see Figure 4-2).

Step 4 Strip the input wiring insulation approximately 0.2 inch (5 mm) from the end and attach the wire to the input terminal block using the small, flat-blade screwdriver.

Step 5 Connect the DC-input wires to the DC-input power supply connector.

Step 6 Connect the DC-input wires to the terminal block. The proper wiring sequence is ground to ground, positive to positive, and negative to negative.


Warning When installing or replacing the unit, the ground connection must always be made first and disconnected last. Statement 1046


Step 7 Before you connect the power supply to a power source, ensure that all site power and grounding requirements have been met.

Step 8 Connect the other end of the power cord to a DC-power input source.


Caution In a system with multiple power supplies, connect each power supply to a separate DC power source. In the event of a power source failure, if the second source is still available, it can maintain maximum overcurrent protection for each power connection.

Step 9 Verify power supply operation by checking the power supply's front panel LEDs:

The LED labeled GOOD is green.

The LED labeled FAIL is not on.

Step 10 Check the power supply and system status from the system console by entering the show system command. For more information on this command, refer to the command reference publication for your switch.

Step 11 If the LEDs or the show system command output indicate a power problem or other system problem, see Chapter 5, "Troubleshooting the Installation," for more information.


Removing and Replacing the Chassis Fan Assembly

This section describes how to remove and install the chassis fan assembly for the Catalyst 4003 and 4006 switches (see Figure 4-5 for the Catalyst 4003 fan assembly and Figure 4-6 for the Catalyst 4006 fan assembly).

Figure 4-5 Catalyst 4003 System Fan Assembly

Figure 4-6 Catalyst 4006 System Fan Assembly

Required Tools

You will need a Phillips screwdriver for this procedure.

Removing the Fan Assembly


Caution Never operate the system for an extended period if the fan assembly is removed or if it is not functioning properly. An overtemperature condition can cause severe equipment damage.

Follow these steps to remove the existing chassis fan assembly:


Step 1 Loosen the two captive installation screws on the fan assembly 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. Statement 258


Step 2 Grasp the fan assembly with both hands and pull it outward; wiggle it, if necessary, to unseat it from the backplane. Slide the fan assembly completely out of the chassis and place it in a safe place.


Installing the Fan Assembly

Follow these steps to install the new fan assembly:


Step 1 Hold the fan assembly with the fans facing to the right.

Step 2 Place the fan assembly into the fan assembly bay so that it rests on the chassis, and then lift the fan assembly up slightly, aligning the top and bottom guides.

Step 3 Slide the fan assembly into the chassis until the two captive installation screws make contact with the chassis.

Step 4 Using a screwdriver, tighten the two captive installation screws by turning them clockwise.


Verifying the Installation


Note To check the operation of the fans, you need to power on the chassis.


Follow these steps to verify that the new fan assembly was 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 into the chassis and that the faceplate is flush with the switch back panel.

Step 2 If after several attempts the fans do not operate, or if 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.



Note The design of the PEM prevents it from being a single point of failure in the external power system. Fuses and redundant circuits help to ensure that the failure of a single power supply unit does not cause other power supply units to fail.


Required Tools

You will need a Phillips screwdriver for this procedure.


Installing the External Power Shelf and Power Supplies

The external power supply (see Figure 4-7) allows you to operate voice power-enabled switching modules in the Catalyst 4006 switch chassis. The external power supply is a single-phase, AC-DC, 1050 W, 52 V output power supply. You install the external power supply in an external power shelf (see Figure 4-8) that fits into a standard equipment rack. Up to three external power supplies can be installed in the external power shelf.

Figure 4-7 External Power Supply

Figure 4-8 External Power Shelf


Note To use an external power supply, you must first install a PEM. If you have not already installed a PEM, see the "Power Entry Module" section on page 4-13 for more information.


Required Tools

You will need the following tools to perform this procedure:

12-24 x 3/4-inch screws

Tape measure

Level


Note Ensure that you install the external power shelf close enough to your Catalyst 4006 switch so that you can connect all power cords to the PEM and to the power outlet. We recommend that you install the external power shelf directly above your Catalyst 4006 switch or in a directly adjacent rack.


Follow these steps to mount the external power shelf on an equipment rack:


Step 1 Align the mounting holes in the L brackets with the mounting holes in the equipment rack.

Step 2 Secure the external power shelf using four (three per side) 12-24 x 3/4-inch screws through the elongated holes in the L bracket and into the threaded holes in the mounting post. (See Figure 4-9.)

Figure 4-9 Mounting the External Power Shelf on the Rack

Step 3 Using a tape measure and a level, ensure that the external power shelf is mounted straight and level.



Step 1 external power shelf on the equipment rack, you can install the external power supplies in the chassis. If you have not mounted the external power shelf, see the .external power supplyEnsure that the external power supply you are installing is not plugged into a power outlet or into the PEM.

Step 2 Loosen the screws on the attachment plates on the upper left and right corners of the external power supply and slide the attachment plates down. (See Figure 4-10.)

Figure 4-10 Attachment Plates on the External Power Supply

Step 3 Grasp the external power supply with two hands, placing one hand beneath the power supply for support, as shown in Figure 4-11.

Figure 4-11 Handling an External Power Supply


Caution Use both hands to grasp the external power supply.

Step 4 Slide the external power supply all the way into the external power shelf bay, aligning the attachment plates with the slots on the top of the external power shelf.

Step 5 Slide each attachment plate up so that the upper edge is wedged into the external power shelf slot and using a screwdriver, tighten the two screws on each attachment plate. (See Figure 4-12.)

Figure 4-12 Tightening the Attachment Plates

Step 6 Before you connect the external power supply to a power source, ensure that all site power and grounding requirements have been met.

Step 7 Plug one end of the 2-pin Molex cord into the external power supply. (See Figure 4-13.)

Figure 4-13 Connecting the External Power Supply to the PEM

Step 8 Connect the other end of the 2-pin Molex cord to the PEM.


Note Up to three external power supplies can be connected to one PEM.


Step 9 Plug the IEC power cord, shown in Figure 4-14, into the external power supply.

Figure 4-14 Connecting the Power Cord


Caution In a system with multiple external power supplies, connect each external power supply to a separate AC power source. In the event of a power source failure, if the second source is still available, it can maintain maximum overcurrent protection for each power connection.

Step 10 Connect the other end of the IEC power cord to an AC-power input source.

Step 11 Verify that the external power supply is operating by checking the power supply front panel LEDs:

The LED labeled INPUT OK is on.

The LED labeled OUTPUT OK is on.

Step 12 Check the external power supply and system status from the system console by entering the show system command. For more information on this command, refer to the command reference publication for your switch.

Step 13 If the LEDs or the show system command output indicate a power problem or other system problem, see Chapter 5, "Troubleshooting the Installation," for more information.