Cisco 7609 Router Installation Guide (OSR-7609) - Removal and Replacement Procedures [Cisco 7600 Series Routers]

Table Of Contents

Removal and Replacement Procedures

Removing and Replacing the Power Supply

Required Tools

Removing an 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 Fan Assembly

Removing the Fan Assembly

Installing the Fan Assembly

Checking the Installation

Removal and Replacement Procedures

Note This document describes the Cisco 7609 Internet Router (OSR-7609) and not the Cisco 7609 Internet Router (CISCO7609).

This chapter describes how to perform the following removal and replacement procedures for Cisco 7609 Internet Router (OSR-7609) field-replaceable units (FRUs):

•Removing and Replacing the Power Supply

•Removing and Replacing the Fan Assembly

Warning Before you install, operate, or service the system, read the Site Preparation and Safety Guide. This guide contains important safety information you should know before working with the system.

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

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

Removing and Replacing the Power Supply

This section describes how to remove and install power supplies for the Cisco 7609 Internet Router.

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.

Removing an AC-Input Power Supply

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 an AC-input power supply:

Step 1 Turn the power switch to the Off (0) position on the power supply you are removing. (See Figure 5-1.) Turning the power switch to the Off (0) position also disengages a pawl that unlocks the power supply from the chassis.

Step 2 Disconnect the power cord from the power source.

Figure 5-1 AC-Input Power Supply Front Panel

Step 3 Loosen the screw on the cable retention device and disconnect the power cord from the power supply being removed.

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

Step 4 Loosen the captive installation screw. (See Figure 5-1.)

Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router AC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg).

Step 5 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 5-2, and slide the power supply completely out of the chassis.

Figure 5-2 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 700-03104-01) over the opening and secure it with the captive installation screw.

Installing an AC-Input Power Supply

Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router AC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg).

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 on page 3-12.

Step 2 If necessary, remove the blank power supply filler plate (Cisco part number 700-03104-01) from the chassis power supply bay opening by loosening the captive installation screw.

Step 3 Verify that the power switch is in the Off (0) position on the power supply you are installing. (See Figure 5-1.)

Step 4 Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-2 . Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.

Step 5 Tighten the power supply captive installation screw. (See Figure 5-1.)

Step 6 Plug the power cord into the power supply and tighten the screw on the cable retention device.

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

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 power switch to the On (|) position on the power supply. Switching the power switch to On also engages a pawl that locks the power supply in the bay.

Step 9 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 for troubleshooting information.

Removing a DC-Input Power Supply

Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position.

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 on the power supply you are removing.

Step 2 Turn the power switch to the Off (0) position on the power supply you are removing. (See Figure 5-3.) Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.

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

Figure 5-3 DC-Input Power Supply Front Panels

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

•Positive (+)

•Negative (-)

•Ground

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

Figure 5-4 DC-Input Wire Connections on the Terminal Block

Step 5 Loosen the captive installation screw on the power supply. (See Figure 5-4.)

Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router DC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg).

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

Figure 5-5 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 screw.

Installing a DC-Input Power Supply

Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position.

Note You must isolate the DC return connection from the system frame and chassis.

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 on page 3-12.

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

Step 3 Verify that the power switch is in the Off (0) position on the power supply you are installing. (See Figure 5-3.)

Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router DC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg).

Step 4 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. (See Figure 5-5 .)

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

Step 6 Remove the two screws securing the terminal block cover and slide the cover off of the terminal block. (See Figure 5-3.)

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 per local and national installation requirements. Use only copper wire.

Note For 2500W power supplies, use 90-degree C copper conductors for North American installations.

Step 8 Connect the DC-input wires to the terminal block (see Figure 5-6) in the following order:

•Ground

•Negative (-)

•Positive (+)

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

Figure 5-6 DC-Input Power Supply Connectors

Step 9 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 10 Remove the tape from the circuit breaker switch handle and restore power by moving the circuit breaker switch handle to the On (|) position.

Step 11 Turn the power switch to the On (|) position on the power supply. Turning the power switch on also engages a pawl that locks the power supply in the chassis.

Step 12 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 7609 Internet Router. A flat-blade or number 2 Phillips-head screwdriver is required to perform this procedure.

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 located above the card cage. (See Figure 5-7.)

Figure 5-7 Fan Assembly

Step 2 Loosen the two captive installation screws by turning them counterclockwise.

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 place 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 down and the FAN STATUS LED on the left. (See Figure 5-7.)

Step 2 Place the fan assembly into the front chassis cavity so 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.

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 are 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.

	Cisco 7609 Router Installation Guide (OSR-7609)
	Removal and Replacement Procedures
Cisco 7609 Router Installation Guide (OSR-7609) Preface Product Overview Preparing for Installation Installing the Cisco 7609 Internet Router Troubleshooting Removal and Replacement Procedures Technical Specifications Connector and Cable Specifications Repacking the Cisco 7609 Internet Router Index	Download this chapter Removal and Replacement Procedures Download the complete book Cisco 7609 Internet Router Installation Guide (OSR-7609) Book-Length PDF (PDF - 2 MB) Table Of Contents Removal and Replacement Procedures Removing and Replacing the Power Supply Required Tools Removing an 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 Fan Assembly Removing the Fan Assembly Installing the Fan Assembly Checking the Installation Removal and Replacement Procedures Note This document describes the Cisco 7609 Internet Router (OSR-7609) and not the Cisco 7609 Internet Router (CISCO7609). This chapter describes how to perform the following removal and replacement procedures for Cisco 7609 Internet Router (OSR-7609) field-replaceable units (FRUs): •Removing and Replacing the Power Supply •Removing and Replacing the Fan Assembly Warning Before you install, operate, or service the system, read the Site Preparation and Safety Guide. This guide contains important safety information you should know before working with the system. Warning Only trained and qualified personnel should be allowed to install, replace, or service this equipment. For instructions on installing and replacing modules, refer to the Cisco 7600 Series Internet Router Module Installation Guide. Removing and Replacing the Power Supply This section describes how to remove and install power supplies for the Cisco 7609 Internet Router. 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. Removing an AC-Input Power Supply 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 an AC-input power supply: Step 1 Turn the power switch to the Off (0) position on the power supply you are removing. (See Figure 5-1.) Turning the power switch to the Off (0) position also disengages a pawl that unlocks the power supply from the chassis. Step 2 Disconnect the power cord from the power source. Figure 5-1 AC-Input Power Supply Front Panel Step 3 Loosen the screw on the cable retention device and disconnect the power cord from the power supply being removed. Note The AC power cord for the 4000W power supply is hard wired and cannot be removed from the supply. Step 4 Loosen the captive installation screw. (See Figure 5-1.) Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router AC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg). Step 5 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 5-2, and slide the power supply completely out of the chassis. Figure 5-2 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 700-03104-01) over the opening and secure it with the captive installation screw. Installing an AC-Input Power Supply Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router AC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg). 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 on page 3-12. Step 2 If necessary, remove the blank power supply filler plate (Cisco part number 700-03104-01) from the chassis power supply bay opening by loosening the captive installation screw. Step 3 Verify that the power switch is in the Off (0) position on the power supply you are installing. (See Figure 5-1.) Step 4 Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-2 . Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay. Step 5 Tighten the power supply captive installation screw. (See Figure 5-1.) Step 6 Plug the power cord into the power supply and tighten the screw on the cable retention device. Note The AC power cord for the 4000W power supply is hard wired and cannot be removed from the supply. 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 power switch to the On (\|) position on the power supply. Switching the power switch to On also engages a pawl that locks the power supply in the bay. Step 9 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 for troubleshooting information. Removing a DC-Input Power Supply Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position. 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 on the power supply you are removing. Step 2 Turn the power switch to the Off (0) position on the power supply you are removing. (See Figure 5-3.) Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis. Step 3 Remove the two screws securing the terminal block cover, and slide the cover off the terminal block. (See Figure 5-3.) Figure 5-3 DC-Input Power Supply Front Panels Step 4 Disconnect the DC-input wires from the terminal block (see Figure 5-4) in the following order: •Positive (+) •Negative (-) •Ground Warning When installing the unit, the ground connection must always be made first and disconnected last. Figure 5-4 DC-Input Wire Connections on the Terminal Block Step 5 Loosen the captive installation screw on the power supply. (See Figure 5-4.) Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router DC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg). Step 6 Grasp the power supply handle with one hand and slide the power supply halfway out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-5, and slide the power supply completely out of the chassis. Set the power supply aside. Figure 5-5 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 screw. Installing a DC-Input Power Supply Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position. Note You must isolate the DC return connection from the system frame and chassis. 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 on page 3-12. Step 2 Verify that power is off to the DC circuit on the power supply you are installing. Step 3 Verify that the power switch is in the Off (0) position on the power supply you are installing. (See Figure 5-3.) Caution Use both hands to install and remove power supplies. Each Cisco 7609 Internet Router DC-input power supply weighs between 22 pounds (9.9 kg) and 28 pounds (12.6 kg). Step 4 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. (See Figure 5-5 .) Step 5 Tighten the power supply captive installation screw. (See Figure 5-3.) Step 6 Remove the two screws securing the terminal block cover and slide the cover off of the terminal block. (See Figure 5-3.) 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 per local and national installation requirements. Use only copper wire. Note For 2500W power supplies, use 90-degree C copper conductors for North American installations. Step 8 Connect the DC-input wires to the terminal block (see Figure 5-6) in the following order: •Ground •Negative (-) •Positive (+) Warning When installing the unit, the ground connection must always be made first and disconnected last. Figure 5-6 DC-Input Power Supply Connectors Step 9 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 10 Remove the tape from the circuit breaker switch handle and restore power by moving the circuit breaker switch handle to the On (\|) position. Step 11 Turn the power switch to the On (\|) position on the power supply. Turning the power switch on also engages a pawl that locks the power supply in the chassis. Step 12 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 7609 Internet Router. A flat-blade or number 2 Phillips-head screwdriver is required to perform this procedure. 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 located above the card cage. (See Figure 5-7.) Figure 5-7 Fan Assembly Step 2 Loosen the two captive installation screws by turning them counterclockwise. 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 place 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 down and the FAN STATUS LED on the left. (See Figure 5-7.) Step 2 Place the fan assembly into the front chassis cavity so 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. 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 are 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.
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