Table Of Contents
Maintaining the Cisco 12008
Cleaning the Air Filter
Installing and Removing a Blank Filler Panel
Adding, Removing, or Replacing an AC-Input Power Supply
Adding an AC-Input Power Supply
Removing an AC-Input Power Supply
Replacing an Existing AC-Input Power Supply
Verifying the Installation of an AC-Input Power Supply
Adding, Removing, or Replacing a DC-Input Power Supply
Adding a DC-Input Power Supply
Removing a DC-Input Power Supply
Replacing a DC-Input Power Supply
Verifying the Installation of a DC-Input Power Supply
Removing and Replacing the Fan Trays
Removing the Fan Tray from the Lower Card Cage
Installing a Fan Tray in the Lower Card Cage
Removing the Power Supply Fan Tray
Installing the Power Supply Fan Tray
Checking the Installation of a Fan Tray
Status LEDs for the Fan Trays
Removing and Replacing the RP
Removing the RP
Installing the RP
Checking the Installation of the RP
Removing and Replacing Line Cards
Removing and Replacing Switch Cards
Removing an SFC
Installing an SFC
Removing a CSC
Installing a CSC
Checking the Installation of Switch Cards
Removing and Replacing the Cable Management System
Removing a Cable-Management Tray
Installing a Cable-Management Tray
Removing a Cable-Management Bracket
Installing a Cable-Management Bracket
Upgrading Memory on a Line Card
Removing a Line Card from the Router
Removing a DIMM from a Line Card
Installing a New DIMM on a Line Card
Reinstalling a Line Card in the Router
Checking the Installation of Line Card Memory
Upgrading Memory on the RP
Maintaining the Cisco 12008
After your Cisco 12008 has been operational for a period of time, you might need to perform specific maintenance tasks, replace certain field replaceable units (FRUs), upgrade memory components, or perform other tasks to ensure that the router continues to operate properly and reliably.
This chapter includes the following sections:
•
Cleaning the Air Filter
•Installing and Removing a Blank Filler Panel
•Adding, Removing, or Replacing an AC-Input Power Supply
•Adding, Removing, or Replacing a DC-Input Power Supply
•Removing and Replacing the Fan Trays
•Removing and Replacing the RP
•Removing and Replacing Line Cards
•Removing and Replacing Switch Cards
•Removing and Replacing the Cable Management System
•Upgrading Memory on a Line Card
•Upgrading Memory on the RP
Caution
Before performing any of the procedures in this chapter, review the section entitled "
Safety Recommendations" in
Chapter 2 to prevent problems, damage to equipment, or injury to personnel.
Cleaning the Air Filter
The Cisco 12008 has a removable air filter assembly that forms part of the outer enclosure of the lower card cage (see ). This card cage accommodates a fan tray containing six fans that provide cooling air for all of the router's internal electronic circuitry, including all of the cards installed in the upper card cage slots and the optional set of three SFCs that you can install in the lower card cage slots.
The air filter assembly removes dust and particulate matter from the ambient air being drawn into the router by the card cage fan tray. Once a month (or more often in dusty environments) you should examine the air filter and replace it if it is dirty. You can clean or replace the air filter while the Cisco 12008 remains powered up and fully operational.
A new air filter (product number GSR8-FILTER=) is the only part that you will need if you decide that the old filter needs replacing.
Note When ordering spare air filters, keep in mind that they have a shelf life of approximately 6 months.
To service the air filter, you need only remove the plastic bezel to gain access to the filter proper (see ). A vacuum cleaner is the only tool you need to perform air filter maintenance.
The closure for the lower card cage is designed in a way that permits you to detach the plastic bezel and the air filter without removing the underlying EMI frame. Thus, you can perform filter maintenance without disrupting the EMI integrity of the router enclosure.
The EMI frame, which contains a honeycomb screen for EMI suppression, should remain in place at all times during normal router use to ensure EMI compliance. However, this frame can be removed at any time should it become necessary to access the components in the lower card cage. The EMI frame is secured to the router by means of two panel fasteners (see ).
To remove or replace the air filter, perform the following steps:
Step 1 Using both hands, exert upward pressure on the two lower spring clips (see ) to disengage them from the body of the bezel; swing the bezel upward to release it from the upper spring clips. Set the bezel aside temporarily.
Step 2 Inspect the condition of the air filter and decide if it should be removed and cleaned.
Step 3 To remove the filter, slide it off the two panel fasteners (see ).
Caution
Exercise care to prevent damage to the honeycomb screen in the EMI frame. Damage to the honeycomb screen might reduce its EMI suppression characteristics and restrict the flow of cooling air through the router.
Step 4 Vacuum both sides of the filter thoroughly.
Note Do not vacuum the filter without removing it from the EMI frame; also, do not vacuum a removed filter in the proximity of the lower card cage. Either action might dislodge particulate matter that could be drawn into the interior of the router.
If the filter is damaged or cannot be adequately cleaned, discard it and replace it with a new one.
Step 5 As appropriate, reinstall the old filter or install the new filter in the EMI frame; grasp the filter by its sides, position it for insertion over the two panel fasteners, and seat it against the EMI frame.
Step 6 Grasp the plastic bezel by its sides; position the two slots in the lower surface of the bezel over the two lower spring clips of the EMI frame.
Step 7 Rotate the bezel upward, making sure that the two slots in the upper surface of the bezel are properly aligned with the two spring clips at the top of the EMI frame.
Step 8 Exert inward pressure on the bezel to snap it firmly into place.
Figure 7-1 Removing and Replacing the Air Filter Assembly
Installing and Removing a Blank Filler Panel
The Cisco 12008 must be fully enclosed to ensure that cooling air is circulated properly throughout the interior of the router. Fully enclosing the router prevents overheating of electronic components in the upper and lower card cages and suppresses EMI radiation.
To cover any vacant slot in the upper card cage of the Cisco 12008, you must install a blank filler panel (see ).
To install a blank filler panel, perform the following steps:
Step 1 Grasp the filler panel and position it vertically for insertion into the vacant slot.
Step 2 Slide the filler panel into the slot until its faceplate is flush against the top and bottom of the card cage.
Step 3 Tighten the captive installation screws on the faceplate of the filler panel to secure it in place.
If you need to install a circuit board in place of the blank filler panel, remove the panel by performing the reverse of the procedure outlined above.
Figure 7-2 Installing a Blank Filler Panel in the Upper Card Cage
Adding, Removing, or Replacing an AC-Input Power Supply
The Cisco 12008 can operate with either one or two AC-input power supplies. Although the router supports an online insertion and removal (OIR) capability for field replaceable units (FRUs), you must observe the following rules regarding the AC-input power supplies:
•If your Cisco 12008 is configured with a single AC-input power supply, you must power down the system before replacing the unit.
•If your Cisco 12008 is configured with two AC-input power supplies, you can remove and replace one of the power supplies while the other unit continues to supply power to the router.
You need the following to add, remove, or replace an AC-input power supply:
•1/4-inch flat-blade screwdriver (to loosen/tighten the captive installation screw on the power supply faceplate)
•A replacement AC-input power supply and the applicable AC power cord for your site
Note To find out which type of AC-input power supply you need for your Cisco 12008, refer to the Cisco 12008 Gigabit Switch Router AC-Input Power Supply Replacement Instructions publication.
Caution
You cannot use an AC-input power supply and a DC-input power supply in the same chassis.
Adding an AC-Input Power Supply
In the following procedure, it is assumed that you will be adding a second AC-input power supply to the router. In this case, it is also assumed that a blank filler panel has previously been installed in the vacant power supply bay.
Note A vacant power supply bay must always be covered with a blank filler panel to ensure EMI compliance and the proper flow of cooling air through the router.
Note It is recommended that you connect each AC-input power supply to an independent source of power with a 20A service. It is also recommended that you use an uninterruptable power source (UPS) for your site to protect against a site power failure.
To add a second (redundant) AC-input power supply to the router, perform the following steps:
Step 1 Locate the source AC circuit breaker that will service the AC-input power supply; ensure that this circuit breaker is set to the OFF position.
For added safety, tape the circuit breaker handle in the OFF position.
Step 2 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the blank filler panel covering the vacant (upper) power supply bay; remove the filler panel and retain it for possible future use.
Presumably, you will install the new power supply in the upper power supply bay, since, by convention, a single AC-input power supply is installed in the lower bay.
Step 3 Ensure that the rotary power switch on the faceplate of the new power supply that you intend to install is set to the standby (OFF) position (see ).
Step 4 Grasp the carrying handle on the new power supply with one hand; while lifting the power supply, place your free hand beneath the unit to support its weight.
Warning
The AC-input power supply weighs 17 lb (7.73 kg). For safety, use both hands to install the unit in the power supply bay.
Step 5 Position the power supply appropriately for insertion into the vacant upper bay.
Step 6 Gently slide the unit into the bay, carefully seating it so that the power supply faceplate rests flush against the sheet metal of the power supply bay.
Figure 7-3 Faceplate of the AC-Input Power Supply
Caution
To prevent damage to the blind-mating connector at the rear of the power supply, do not use excessive speed or force when inserting the power supply into the bay.
Note All necessary electrical connections between the power supply and the backplane are accomplished automatically by means of the blind-mating connector at the rear of the power supply.
Step 7 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the faceplate of the power supply (see ).
Step 8 Connect the source AC power cord to the AC receptacle on the power supply faceplate (see a). Secure the bail latch over the source AC power cord (see b).
Step 9 Connect the other end of the source AC power cord to its power source (see c).
Step 10 Set the rotary power switch on the new AC-input power supply to the ON (1) position.
To verify that the new AC-input power supply is operating properly, proceed to the section entitled "Verifying the Installation of an AC-Input Power Supply."
Figure 7-4 Connecting Power to an AC-Input Power Supply
Removing an AC-Input Power Supply
For the following procedure, it is assumed that you will remove an AC-input power supply from a Cisco 12008 that is equipped with a single such unit. In this case, you must power down the router before removing the power supply.
It is also assumed that the power supply to be removed is installed in the lower power supply bay, which, by convention, is the normal configuration for a single power supply. Lastly, in such a single power supply configuration, it is assumed that the upper power supply bay has been previously covered by a blank filler panel to ensure EMI compliance and the proper flow of cooling air through the router.
To remove the AC-input power supply from the router, perform the following steps:
Step 1 Set the rotary power switch on the power supply faceplate to the standby (OFF) position.
Note Turning the power supply switch counterclockwise to the standby (OFF) position also releases the mechanical interlock (latching mechanism) that secures the power supply in the bay.
Step 2 Locate and turn off the source AC circuit breaker that is currently servicing the AC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an added safety precaution.
Step 4 Release the bail latch that secures the source AC power cord to the AC receptacle on the power supply faceplate.
Step 5 Disconnect the source AC power cord from the AC receptacle.
Step 6 Using a flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate that secures the power supply in the bay.
Step 7 With one hand, grasp the power supply carrying handle and pull the unit halfway out of the bay to disengage the female blind-mating connector at the back of the power supply from the backplane.
Warning
The AC-input power supply weighs 17 lb (7.73 kg). For safety, use both hands to remove the unit from the power supply bay.
Step 8 Place your free hand beneath the power supply to support its weight and withdraw the unit completely from the bay.
Step 9 Set the power supply aside, pending further disposition.
If you intend to return the removed power supply to the factory for repair or replacement, repackage the unit properly for return shipment using the original packing materials, if available.
Replacing an Existing AC-Input Power Supply
In the following procedure, it is assumed that you will replace an existing power supply in a router that is configured with two (redundant) AC-input power supplies.
In this configuration, the router's online insertion and removal (OIR) capability enables you to replace one of the power supplies without removing power from the other. Thus, the router can remain fully operational during the power supply replacement procedure.
To replace one of the AC-input power supplies in a redundant power supply configuration, perform the following steps:
Step 1 On the power supply to be replaced, set the rotary power switch to the standby (OFF) position.
Note Turning the power supply switch counterclockwise to the standby (OFF) position also releases the mechanical interlock (latching mechanism) that secures the power supply within in the bay.
Step 2 Locate and turn off the source AC circuit breaker that is currently servicing the AC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an added safety precaution.
Step 4 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate.
Step 5 Release the bail latch that secures the source AC power cord to the AC receptacle on the power supply faceplate.
Step 6 Remove the power cord from the AC receptacle.
Step 7 Grasp the power supply carrying handle with one hand and pull the unit halfway out of the bay to disengage the blind-mating connector at the back of the power supply from the backplane.
Warning
The AC-input power supply weighs 17 lb (7.73 kg). For safety, use both hands to withdraw the unit from the bay.
Step 8 Place your free hand beneath the power supply to support its weight and withdraw the unit completely from the bay.
Step 9 Pending further action, set the unit aside.
If you intend to return the removed power supply to the factory for repair or replacement, repackage the unit properly for return shipment using the original packing materials, if available.
Step 10 On the new AC-input power supply that you intend to install in the now vacant bay, set the rotary power switch on the new power supply to the standby (OFF) position.
Step 11 Grasp the carrying handle on the power supply with one hand; place your free hand beneath the unit to support its weight.
Step 12 Position the unit appropriately for insertion into the power supply bay.
Step 13 Gently slide the new power supply into the bay, carefully seating it so that the power supply faceplate is flush against the sheet metal of the power supply bay. Doing so ensures that the blind-mating connector at the rear of the power supply is firmly seated in the backplane connector.
Caution
To prevent damage to the blind-mating connectors, do not use excessive speed or force when inserting the new power supply into the bay.
Note All the necessary electrical connections between the power supply and the backplane are accomplished automatically by means of the blind-mating connectors.
Step 14 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the power supply faceplate.
Step 15 Connect the source AC power cord to the AC receptacle on the power supply faceplate.
Step 16 Secure the bail latch over the source AC power cord to secure it in the AC receptacle.
Step 17 Set the rotary power switch on the new AC-input power supply to the ON (|) position.
To verify that the new power supply is operating properly, perform the procedure in the following section.
Verifying the Installation of an AC-Input Power Supply
To verify the operation of a newly-installed AC-input power supply, first apply power to the unit and then observe the status of the LEDs on the power supply faceplate.
To verify the operation of a newly-installed AC-input power supply, perform the following steps:
Step 1 First, verify that the following conditions have been satisfied:
•The power supply is completely inserted into the bay and secured in place with its captive installation screw.
•A vacant power supply bay is covered with a blank filler panel to ensure EMI compliance and the proper flow of cooling air through the router enclosure.
•The source AC power cable is properly connected to the AC receptacle on the power supply faceplate.
•The source end of the AC power cable is properly connected to the main source AC circuit breaker.
•The main source AC circuit breaker servicing the AC-input power supply is ON.
•The source AC voltage is within the range specified on the power supply faceplate.
•When two AC-input power supplies are installed, each power cord is connected to a separate AC power source.
Each AC power source must be on a dedicated circuit rated at 20A (for North America) or 10 or 16A (for the International area).
Step 2 Set the rotary power switch on the newly-installed power supply to the ON position.
Step 3 Observe the behavior of the green AC INPUT OK LED on the power supply faceplate for the following conditions:
•The AC INPUT OK LED illuminates if the source AC voltage is within the proper operating range (see the label on the power supply faceplate).
•If the green AC INPUT OK LED fails to illuminate, determine if
(a) The source AC circuit breaker is on.
(b) The source AC power cord is securely connected from the source AC circuit breaker to the AC receptacle on the power supply faceplate.
•If the AC INPUT OK LED illuminates as expected, proceed to Step 4.
•If the AC INPUT OK LED fails to illuminate after power is applied to the unit, contact a Cisco service representative for assistance.
Step 4 Observe the behavior of the red OUTPUT FAIL LED on the power supply faceplate after you apply power to the unit. This LED should flash on momentarily, then go off and remain so.
•If the OUTPUT FAIL LED behaves as expected, proceed with normal system operations.
•If the OUTPUT FAIL LED remains on when the new power supply is installed and powered up, the power supply may be faulty, or an adverse environmental condition may exist in the router, such as an overvoltage or overtemperature condition that causes the power supply to shut down.
•If two AC-input power supplies are installed and the OUTPUT FAIL LED illuminates on only one power supply, the associated power supply itself may be faulty, or source power for that unit may be faulty.
•If the OUTPUT FAIL LEDs on both power supplies go on, each of which is connected to a separate AC power source, you can assume that an overvoltage or overtemperature condition in the router is causing both power supplies to fail. Also, the OUTPUT FAIL LEDs could be on due to a defective MBus controller or an old version of MBus code.
If the new AC-input power supply fails to operate properly after several attempts to power it up as described above, contact your Cisco service representative for assistance.
Adding, Removing, or Replacing a DC-Input Power Supply
The Cisco 12008 can operate with either one or two DC-input power supplies. Although the router supports an online insertion and removal (OIR) capability for field replaceable units (FRUs), you must observe the following rules regarding the DC-input power supplies:
•If your Cisco 12008 is configured with a single DC-input power supply, you must power down the system before replacing the unit.
•If your Cisco 12008 is configured with two DC-input power supplies, you can remove and replace one of the power supplies while the other unit remains operational.
To add, remove, or replace a DC-input power supply, you need the following tools:
•A 1/4-inch flat-blade screwdriver (to loosen/tighten the captive installation screw on the power supply faceplate).
•A 10 mm, hollow-shaft nutdriver (to secure the source DC power cables to the terminals on the power supply with the lock washers and nuts). A 1/4-inch socket wrench with a 10 mm deep-well socket will also suffice for this purpose.
•A voltmeter (to test the voltages across the source DC power cables).
The replacement DC-input power supply (product number PWR-GSR8-DC=) is the only part that you will need during the following procedures.
Caution
You cannot use an AC-input power supply and a DC-input power supply in the same chassis.
Adding a DC-Input Power Supply
In the following procedure, it is assumed that you will be adding a second DC-input power supply to the router. It is also assumed that a blank filler panel is installed in the vacant power supply bay.
Note A vacant power supply bay must always be covered with a blank filler panel to ensure EMI compliance and the proper flow of cooling air through the router.
Warning
Before attempting to install a redundant DC-input power supply, you must have a second, independent DC power source available to service the unit.
To install a second (redundant) DC-input power supply, you must first satisfy the following requirements:
•Ensure that a dedicated 40A service is available for the second power supply.
•Ensure that the power cables from the source DC service circuit breaker to the DC-input power supply are made of 4 AWG, high-strand-count copper wire.
•Ensure that the lugs on the source DC power cables (see ) have dual-holes, centered 0.625 inch apart, and that they will fit over the 0.25-inch M6 (metric) threaded terminals on the DC power supply faceplate (see ).
Caution
AC-input and DC-input power supplies cannot be used together in the same router. Such a configuration is not supported and may damage the system.
Note If you are adding a second (redundant) DC-input power supply to your router, you will need to obtain the proper source DC power cables and terminal lugs from a commercial supplier in order to connect source DC power to the new DC-input power supply. These parts are not available from Cisco Systems.
Figure 7-5 Dimensions of the Lugs Used with the Source DC Power Cables
Figure 7-6 Faceplate of the DC-Input Power Supply
To add a second (redundant) DC-input power supply to the router, perform the following steps:
Step 1 Locate the source DC circuit breaker that will service the DC-input power supply; ensure that this circuit breaker is set to the OFF position. For added safety, tape the circuit breaker handle in the OFF position.
Note The color coding scheme used for the source DC power cables for the DC-input power supply depends on the scheme used for the site DC power source. Typically, green or green/yellow is used for earth ground, red is used for positive (+), and black is used for negative (-). Make certain that you properly map the color coding scheme used at the site for the DC power source to the proper terminals on the DC-input power supply faceplate.
Warning
To be completely sure that power has been removed from the source DC circuit that will be used to service the new power supply, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads to be connected to the power supply. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts.
Step 2 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the blank filler panel covering the vacant (upper) power supply bay; remove the filler panel and retain it for possible future use.
Presumably, you will be installing the new power supply in the upper power supply bay, since, by convention, a single DC-input power supply is installed in the lower bay.
Step 3 Ensure that the rotary power switch on the faceplate of the new power supply that you will be installing is set to the OFF (O) position.
Step 4 Grasp the carrying handle on the new power supply with your left hand; while lifting the power supply, place your right hand beneath the unit to support its weight.
Note The carrying handle on the DC-input power supply is designed to be grasped with your left hand, rather than your right hand. Using your left hand eliminates the potential for catching your fingers in the limited space between the plastic safety shield (see ) and the carrying handle.
Warning
The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to install the unit in the power supply bay.
Step 5 Position the power supply appropriately for insertion into the vacant upper bay.
Step 6 Gently slide the unit into the bay, carefully seating it so that the power supply faceplate rests flush against the sheet metal of the power supply bay.
Caution
To prevent damage to the blind-mating connector at the rear of the power supply, do not use excessive speed or force when inserting the power supply into the bay.
Note All necessary electrical connections between the power supply and the backplane are accomplished automatically by means of the blind-mating connector at the rear of the power supply.
Step 7 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the power supply faceplate (see ).
Step 8 Remove the plastic safety shield (see ) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield, take the following actions:
(a) Loosen the knurled thumb wheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
Figure 7-7 Plastic Safety Shield on the DC-Input Power Supply
Step 9 Unscrew the loosely mounted lock washers and nuts from all six terminals on the power supply faceplate; set this hardware aside temporarily.
Step 10 As an added safety precaution, it is recommended that you add a length of shrink tubing to the crimp area on each power cable lug (see ) before connecting the leads to the power supply.
The shrink tubing acts as an insulator to prevent the crimp area on the source DC power cable lugs from coming in contact with the faceplate of the DC-input power supply.
Step 11 Connect the source DC power leads to the terminals on the power supply faceplate. In so doing, strictly observe the following order in connecting the leads to the power supply:
(a) Ground
(b) + (positive)
(c) - (negative)
Step 12 Using the lock washers and nuts removed from the terminals in Step 9, connect each power supply cable to the appropriate terminals on the power supply faceplate.
Observe the order shown in in connecting the source DC power cables to the terminals on the power supply.
Step 13 After installing each cable, securely tighten the associated lock washers and nuts on the power supply terminals using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket).
Caution
Do not overtighten the nuts on the power supply terminals.
Step 14 If you intend to attach an external alarm monitoring facility to the alarm terminal block on the power supply, connect the leads from the external monitoring facility to the circuit breaker alarm terminal block. shows an example of how these leads can be connected.
Note The circuit breaker alarm terminal block enables you to attach an external monitoring facility to the power supply to detect when the power supply circuit breaker trips during an electrical event, such as an overvoltage condition in the power supply.
The functions and uses of the circuit breaker alarm terminal block are described in detail in the subsection entitled "Circuit Breaker Alarm Terminal Block" in Chapter 1.
Figure 7-8 Connecting Source DC Power Cables to the DC-Input Power Supply
Figure 7-9 Connecting Leads to the Circuit Breaker Alarm Terminal Block
Step 15 Reinstall the plastic safety shield (see ) on the power supply faceplate by taking the following actions:
(a) Seat the shield over the standoffs on the power supply faceplate.
(b) Move the shield to the left and obliquely downward so that it registers properly on the three standoffs on the power supply faceplate.
(c) Tighten the knurled thumbscrew on the bottom left standoff to secure the shield to the power supply faceplate.
Step 16 Remove the tape from the main circuit breaker supplying source power to the new power supply (see Step 1).
Step 17 Set the circuit breaker to the ON position.
Step 18 Set the rotary power switch on the new DC-input power supply to the ON (|) position.
To verify that the new DC-input power supply is operating properly, proceed to the section below entitled "Verifying the Installation of a DC-Input Power Supply."
Removing a DC-Input Power Supply
For the following procedure, it is assumed that you will be removing a DC-input power supply from a Cisco 12008 router that is equipped with a single such unit. In this case, you must power down the router before removing the power supply.
It is assumed further that the power supply to be removed is installed in the lower power supply bay, which, by convention, is the recommended bay for installing a single power supply.
To remove the DC-input power supply from the router, perform the following steps:
Step 1 Set the rotary power switch on the power supply faceplate to the OFF (O) position.
Note Turning the power supply switch counterclockwise to the OFF (O) position also releases the mechanical interlock (latching mechanism) that secures the power supply in the bay.
Step 2 Locate and turn off the source DC circuit breaker that is servicing the DC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an added safety precaution.
Step 4 Remove the plastic safety shield (see ) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield (see ), take the following actions:
(a) Loosen the knurled thumb wheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
Warning
To be completely sure that power has been removed from the source DC circuit that is presently servicing the power supply, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads on the power supply. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts.
Step 5 Before removing the power cables, write the name of each cable on a piece of tape, as follows:
•Ground
•+ (positive)
•- (negative)
Step 6 Attach each piece of tape to the appropriate cable to identify it for later reconnection.
Step 7 Remove the power cables from the power supply terminals; strictly observe the following order in removing the cables:
(a) - (negative)
(b) + positive)
(c) Ground
Step 8 Using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket) loosen the nuts securing the negative (-) power cable to the bottom terminals on the power supply faceplate; remove the nuts and locking washers from the terminals and set this hardware aside temporarily.
Step 9 Proceed in like manner to remove the remaining power cables from the positive (+) terminals and the grounding terminals, making sure that you remove the earth ground cable last.
Step 10 For added safety, place tape over the exposed lugs of the power cables to prevent contact between the leads.
Step 11 If leads are attached to the circuit breaker alarm terminal block on the power supply faceplate (see ), make a note of how these leads are connected so that they can be properly reconnected later.
Step 12 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate (see ).
Step 13 Grasp the power supply carrying handle with your left hand and pull the unit halfway out of the bay to disengage the blind-mating connector at the back of the power supply from the backplane.
Warning
The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to remove the unit from the power supply bay.
Step 14 Place your right hand beneath the power supply to support its weight; withdraw the unit completely from the bay.
Step 15 Set the power supply aside in a safe place, pending further disposition.
If you intend to return the removed power supply to the factory for repair or replacement, repackage the unit properly for return shipment using the original packing materials, if available.
Replacing a DC-Input Power Supply
In the following procedure, it is assumed that you will be replacing an existing power supply in a router containing redundant DC-input power supplies. In this configuration, the router's online insertion and removal (OIR) capability enables you to replace a given power supply without removing power from the router.
To replace a power supply in a redundant DC-input power supply configuration, perform the following steps:
Step 1 Set the rotary power switch on the faceplate of the power supply to be removed to the OFF (O) position.
Note Turning the power supply switch to the OFF (O) position also releases the mechanical interlock (latching mechanism) that secures the power supply in the bay.
Step 2 Locate and turn off the source DC circuit breaker that is currently servicing the DC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an additional safety precaution.
Step 4 Remove the plastic safety shield (see ) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield, take the following actions:
(a) Loosen the knurled thumb wheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
Warning
To be completely sure that power has been removed from the source DC circuit presently servicing the power supply that you intend to remove, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts.
Step 5 Before removing the power cables, write the name of each cable on a piece of tape, as follows:
•Ground
•+ (positive)
•- (negative)
Step 6 Attach each piece of tape to the appropriate cable to identify it for later reconnection.
Step 7 Remove the power cables from the power supply terminals, strictly observing the following order of removal:
(a) - (negative)
(b) + (positive)
(c) Ground
Step 8 Using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket), loosen the nuts securing the negative (-) power cable to the bottom terminals on the power supply faceplate; remove the nuts and locking washers from the terminals; set this hardware aside temporarily and remove the power cable from the negative terminals.
Step 9 Proceed in like manner to remove the positive (+) and grounding cables from the power supply terminals, making sure that you remove the ground cable last.
Step 10 For added safety, place tape over the exposed lugs of the power cables to prevent contact between the leads.
Step 11 If an external alarm monitoring facility is attached to the circuit breaker alarm terminal block on the power supply faceplate (see ), make a note of how the leads are connected. Doing so enables you to properly identify each lead for later reconnection.
Step 12 Disconnect the leads from the circuit breaker alarm terminal block.
Step 13 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate (see ).
Step 14 Grasp the power supply carrying handle with your left hand and pull the unit halfway out of the bay to disengage the blind-mating connector at the back of the power supply from the backplane.
Warning
The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to withdraw the unit from the bay.
Step 15 Place your right hand beneath the power supply to support its weight and completely withdraw the unit from the bay.
Step 16 Pending further action, set the unit aside in a safe place.
If you intend to return the removed power supply to the factory for repair or replacement, restore the nuts and lock washers to the power supply terminals, and reinstall the plastic safety shield (see ) on the faceplate standoffs. Repackage the unit properly for return shipment using the original packing materials, if available.
Step 17 On the new DC-input power supply that you intend to install in the now vacant power supply bay, set the rotary power switch on the power supply faceplate to the OFF (0) position.
Step 18 Grasp the carrying handle on the power supply with one hand; place your free hand beneath the unit to support its weight.
Step 19 Position the unit appropriately for insertion into the power supply bay.
Step 20 Gently slide the new power supply into the vacant bay, carefully seating it so that the power supply faceplate is flush against the sheet metal of the power supply bay. This action ensures that the blind-mating connector at the rear of the power supply is firmly seated into the backplane connector.
Caution
To prevent damage to the blind-mating connectors, do not use excessive speed or force when inserting the new power supply into the bay.
Note All the necessary electrical connections between the power supply and the backplane are accomplished automatically by means of the blind-mating connectors.
Step 21 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the power supply faceplate.
Step 22 Remove the plastic safety shield (see ) from the new power supply, taking the same actions as specified in Step 4 above.
Warning
To be completely sure that power has been removed from the source DC circuit that you intend to reconnect to the new power supply, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the negative and positive leads should be zero (0) volts.
Step 23 Unscrew the loosely mounted lock washers and nuts from all six terminals on the new power supply faceplate; set this hardware aside temporarily.
Step 24 Before connecting each cable to the appropriate terminals on the power supply faceplate, remove the tape (that you applied in Step 10 above) from the lug. Strictly observe the following order in reconnecting the leads to the power supply terminals:
(a) Ground
(b) + (positive)
(c) - (negative)
Step 25 Secure each cable to the terminals using the previously removed lock washers and nuts. Tighten the lock washers and nuts on each terminal using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket).
Caution
Do not overtighten the nuts on the power supply terminals.
Step 26 If you intend to reconnect the external alarm monitoring facility to the circuit breaker alarm terminal block on the new power supply, reconnect the leads as they were on the old power supply (see Step 11).
Step 27 Remove the tape securing the main source DC circuit breaker in the OFF (0) position (see Step 3).
Step 28 Set the main source DC circuit breaker to the ON (1) position.
Step 29 Set the rotary power switch on the new DC-input power supply to the ON (|) position.
To verify that the new DC-input power supply is operating properly, perform the procedure in the following section.
Verifying the Installation of a DC-Input Power Supply
To verify the operation of a newly-installed DC-input power supply, first apply power to the unit and observe the status of the LEDs on the power supply faceplate.
To verify the operation of a newly-installed DC-input power supply, perform the following steps:
Step 1 First, verify that the following conditions are satisfied:
•The power supply is completely inserted into the bay and secured in place with the captive installation screw.
•A vacant power supply bay is covered with a blank filler panel.
•The source DC power cables are connected properly to the terminals on the power supply faceplate.
•The source end of the DC power cable is properly connected to the main source DC circuit breaker.
•The main source DC circuit breaker servicing the DC-input power supply is in the ON (|) position.
•The source DC voltage is within the range indicated on the power supply faceplate.
•If two DC-input power supplies are installed, each power supply is being serviced by a separate 40A DC power source.
Step 2 Assuming that you have not already done so, set the rotary power switch of the newly installed power supply to the ON position.
Step 3 Observe the behavior of the green INPUT OK LED on the power supply faceplate for the following conditions:
•If the source DC voltage is within the proper range, the INPUT OK LED goes on.
•If the green INPUT OK LED does not go on, determine if
(a) The main source DC circuit breaker is on.
(b) The source DC power cables are connected properly to the terminals on the power supply faceplate.
•If the INPUT OK LED goes on, proceed to Step 4.
•If the INPUT OK LED does not go on after you apply power to the unit and verify the conditions outlined in Step 1, contact your local Cisco service representative for assistance.
Step 4 Observe the behavior of the red OUTPUT FAIL LED on the power supply faceplate after applying power to the unit. This LED should flash on momentarily, then go off and remain so.
•If the OUTPUT FAIL LED on the new power supply behaves as expected, proceed with normal system operations.
•If the OUTPUT FAIL LED remains on when the new power supply is installed and powered up, the power supply may be faulty, or an adverse environmental condition may exist in the router, such as an overvoltage or overtemperature condition that causes the power supply to shut down.
•If two power supplies are installed and the OUTPUT FAIL LED on only one power supply goes on, you can assume that the power supply itself is faulty, or that the DC source for that power supply is faulty.
•If the OUTPUT FAIL LEDs on both power supplies go on, each of which is connected to a separate DC power source, you can assume that an overvoltage or overtemperature condition in the router is causing both power supplies to fail. Also, the OUTPUT FAIL LEDs could be on due to a defective MBus controller or an old version of MBus code.
If the new DC-input power supply fails to operate properly after several attempts to power it up as described above, contact your Cisco service representative for assistance.
Removing and Replacing the Fan Trays
This section presents the procedures for removing and installing the following fan trays incorporated into the Cisco 12008:
•Card cage fan tray—Located in the lower card cage behind the air filter assembly
•Power supply fan tray—Located in the lower right corner of the router enclosure
The Cisco 12008 supports online insertion and removal of field-replaceable units (FRUs); thus, you can remove and replace a fan tray while the rest of the system remains powered up and fully operational.
Note If you replace a defective fan tray while the router is running, you must do so quickly to minimize the risk of overheating router components. The system shuts down approximately 2 minutes after reaching the shutdown temperature threshold; therefore, you should replace a defective fan tray within this time span.
You will need the following tools and parts to remove or install a fan tray:
•1/4-inch flat-blade screwdriver
•ESD-preventive wrist strap
•Lower card cage fan tray—product number GSR8-SYSBLOWER=
•Power supply fan tray—product number GSR8-PWRBLOWER=
Removing the Fan Tray from the Lower Card Cage
To remove the fan tray from the lower card cage, perform the following steps.
Step 1 Loosen the two panel fastener screws on each side of the air filter assembly (see ); remove the assembly to expose the interior of the lower card cage and set it aside.
Step 2 Loosen the two captive installation screws at the sides of the fan tray.
Step 3 With one hand, grasp the ring-shaped insertion/extraction tab in the middle of the fan tray carrier; gently slide the fan tray halfway out of the guide rails to disengage the fan tray connector from the backplane (see ).
Step 4 Place your free hand beneath the fan tray to support its weight and slide the module completely out of the card cage.
Step 5 Set the fan tray aside.
Caution
The card cage fan tray weighs approximately 12 lb (5.45 kg). For safety, use both hands when handling this assembly.
If you plan to return the removed fan tray to the factory for repair or replacement, repackage the unit in the original shipping container, if available, and prepare the package for return shipment.
Figure 7-10 Removing the Card Cage Fan Tray from the Router
Installing a Fan Tray in the Lower Card Cage
For the following procedure, it is assumed that you have removed a defective fan tray from the lower card cage and that you intend to replace it with a new one.
To install a new fan tray in the lower card cage, perform the following steps.
Caution
For safety, use both hands when handling the card cage fan tray.
Step 1 With one hand, grasp the ring-shaped insertion/extraction tab in the middle of the new fan tray carrier and raise the front end of the assembly.
Step 2 Place your free hand beneath the assembly to support its weight; position the assembly in front of the guide rails in the lower card cage.
Step 3 Carefully insert the assembly into the guiderails (see ).
Step 4 Using gentle pressure on the insertion/extraction tab, fully insert the assembly until the sheet metal carrier rests against the stops for the captive installation screws.
If the router is operational, you should hear the fans come up to normal rotational speed at this time.
Note All electrical connections are a made automatically when the fan tray and backplane connectors mate. The fan tray then immediately powers up.
Step 5 Tighten the two captive installation screws at the sides of the fan tray carrier.
Step 6 Restore the air filter assembly so that it covers the lower card cage and fully encloses the router. Secure the assembly in place by tightening its two panel fastener screws.
To verify that the card cage fan tray is operating properly, go to the section entitled "Checking the Installation of a Fan Tray."
Figure 7-11 Inserting the Card Cage Fan Tray into the Router
Removing the Power Supply Fan Tray
To remove the power supply fan tray from the router, perform the following steps.
Step 1 Loosen the captive installation screw on the honeycomb faceplate of the power supply fan tray (see ).
Step 2 With one hand, grasp the loosened installation screw on the power supply fan tray faceplate; gently pull the fan tray halfway out of the guide rails to disengage the fan tray connector from the backplane (see ).
Caution
For safety, make sure that the fans have stopped spinning before grasping the fan tray assembly. It will take several seconds for the fans to stop spinning once the assembly is disengaged from the backplane.
Step 3 Using one hand, grasp the fan tray from above and slide the assembly completely out of the router (see ).
Step 4 Set the fan tray aside.
If you plan to return the removed fan tray to the factory for repair or replacement, repackage the fan tray in the original shipping container, if available, and prepare the package for return shipment.
Figure 7-12 Removing the Power Supply Fan Tray from the Router
Installing the Power Supply Fan Tray
For the following procedure, it is assumed that you have already removed a defective power supply fan tray and that you intend to replace it with a new one.
To install the new power supply fan tray, perform the following steps.
Step 1 Using one hand, grasp the power supply fan tray from above (as shown in ).
Step 2 Position the assembly in front of the guide rails in the fan tray bay.
Step 3 Carefully insert the fan tray into the guide rails in the bay (see ).
Figure 7-13 Inserting the Power Supply Fan Tray into the Router
Step 4 Using gentle pressure, fully insert the assembly into the bay until the sheet metal carrier of the fan tray rests against the stop for the captive installation screw.
Step 5 Tighten the captive installation screw on the fan tray faceplate (see ).
To verify that the power supply fan tray is operating properly, proceed to the following section.
Checking the Installation of a Fan Tray
To verify that a replacement fan tray is operating properly, perform the following steps:
Step 1 Check the following components to make sure that they are secure:
•The power supply fan tray is inserted all the way into the bay and its captive installation screw is tightened.
•The card cage fan tray is inserted all the way into the lower card cage and its two captive installation screws are tightened.
•The air filter assembly is securely installed on the front of the lower card cage.
Step 2 Observe the status LEDs on the CSC faceplate (see the following section entitled "Status LEDs for the Fan Trays").
Step 3 Listen for the sound of the running cooling fans in the card cage fan tray and the power supply fan tray. In a noisy environment, it may be difficult to hear the fans running. If so, proceed to Step 4.
Step 4 Run your hand along the width of the top rear of the router enclosure to verify that air is being exhausted from the vents for the upper card cage and the power supply bays.
If either fan tray fails to operate properly, contact your Cisco service representative for assistance.
Status LEDs for the Fan Trays
The status LEDs for the fan trays are arranged side-by-side on the CSC faceplate (see ). The positions of these LEDs correspond to the positions of the fan trays in the router.
The left LED indicates the status of the card cage fan tray, and the right LED indicates the status of the power supply fan tray.
lists the status LEDs for the fan trays and describes their meaning in the on/off state.
Table 7-1
