Cisco 3600 Series Routers Hardware Installation Guide - Installing the Router [Cisco 3600 Series Multiservice Platforms]

Table Of Contents

Installing the Router

Installing Modules, Interface Cards, and Power Supplies

Installing the Chassis

Setting the Chassis on a Desktop

Rack-Mounting the Chassis

Attaching Brackets to the Router

Mounting the Router in the Rack

Wall-Mounting the Cisco 3620 Router

Attaching Rubber Feet to the Router

Attaching Wall-Mount Brackets to the Router

Mounting the Router on the Wall

Installing Chassis Ground Connection

Cisco 3620 and Cisco 3640 Chassis Ground Connection

Cisco 3631 Chassis Ground Connection

Cisco 3660 Chassis Ground Connection

Power Connections

Connecting Routers to AC Power

Connecting Routers to a DC-Input Power Supply

Wiring the DC-Input Power Supply in Cisco 3620 and Cisco 3640 Routers

Wiring the DC-Input Power Supply in Cisco 3631 Routers

Wiring the DC-Input Power Supply in Cisco 3660 Routers

Connecting Routers to the Cisco Redundant Power System

Connecting WAN, LAN, and Voice Cables

Ports and Cabling

Connections for Cisco 3620, Cisco 3640, and Cisco 3631 Routers

Connections for Cisco 3660 Routers

Connecting WAN, LAN, and Voice Cables (Without Chassis Shield)

Connecting WAN, LAN, and Voice Cables (With Chassis Shield—Telco Only)

Connecting to a Console Terminal or Modem

Connecting to the Console Port

Connecting to the Auxiliary Port

Identifying a Rollover Cable

Powering Up the Router

Checklist for Power Up

Front Panel Indicators

Power-Up Procedure

Configuring the Router

Initial Configuration Using SDM

Initial Configuration Using the Setup Command Facility

Initial Configuration Using the CLI (Manual Configuration)

Installing the Router

This chapter describes how to install your Cisco 3600 series router and connect it to networks and external devices. It contains the following sections:

•Installing Modules, Interface Cards, and Power Supplies

•Installing the Chassis

•Installing Chassis Ground Connection

•Power Connections

•Connecting WAN, LAN, and Voice Cables

•Connecting to a Console Terminal or Modem

•Powering Up the Router

•Configuring the Router

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

Warning This unit is intended for installation in restricted access areas. A restricted access area can be accessed only through the use of a special tool, lock and key, or other means of security. Statement 1017

Note See the "Tools and Equipment for Installation and Maintenance" section for a list of tools and equipment that might be required for your installation.

Installing Modules, Interface Cards, and Power Supplies

Cisco routers are normally shipped with network modules, WAN interface cards (WICs), voice interface cards (VICs), advanced integration modules (AIMs), and power supplies already installed. If you need to remove or install any of these items, refer to the applicable documents online.

For network modules:

•Quick Start Guide: Network Modules for Cisco 2600 Series, Cisco 3600 Series, and Cisco 3700 Series Routers

•Cisco Network Modules Hardware Installation Guide

For WICs and VICs:

•Quick Start Guide: Interface Cards for Cisco 1600, 1700, 2600, 3600, and 3700 Series

•Cisco Interface Cards Hardware Installation Guide

For AIMs:

•AIM Installation Quick Start Guide: Cisco 2600, 3600, and 3700 Series

•Installing Advanced Integration Modules in Cisco 2600 Series, Cisco 3600 Series, and Cisco 3700 Series Routers

For internal power supplies:

•Installing Power Supplies in Cisco 3600 Series Routers

•Installing Power Supplies in Cisco 3631 Routers

•Installing Universal DC Power Supplies in Cisco 3631 Routers

•Installing Universal DC Power Supplies in Cisco 3660 Routers

For external power supplies:

•Cisco RPS Hardware Installation Guide

Note If there are modules, interface cards, or power supplies to be removed or installed, Cisco suggests that you perform the installation or removal before you install the chassis. If a chassis cover needs to be removed, the chassis may have to be removed from the rack to permit cover removal.

Note The Cisco 3660 accommodates two AC or two DC hot-swappable power supplies (PS1 and PS2) in bays at the rear of the unit. Each unit provides up to 250 W of power, and a single installed power supply meets the router's requirements. The second installed power supply provides redundancy, load sharing, and increased system availability. It can be removed without affecting system operation.

If the required network modules, interface cards, and power supplies are already installed, proceed to the "Installing the Chassis" section.

Installing the Chassis

Depending on your router, you can set the chassis on a desktop, install it in a rack, or mount it on a wall or other flat surface. Select the procedure that best meets the needs of your network:

•Setting the Chassis on a Desktop

•Rack-Mounting the Chassis

•Wall-Mounting the Cisco 3620 Router

Note The Cisco 3640, Cisco 3661 and the Cisco 3660 routers cannot be wall-mounted.

Setting the Chassis on a Desktop

You can place Cisco 3600 series routers on a desktop or shelf. For Cisco 3620 routers only, attach the rubber feet supplied in the accessory kit. The procedure is as follows:

Step 1 Place the router upside-down on a smooth, flat surface.

Step 2 Peel the rubber feet off the black adhesive strip and place them adhesive-side down at each corner of the underside of the chassis.

Step 3 Place the router top-side up on a flat, smooth, secure surface.

The following warning applies to Cisco 3660 routers:

Warning To prevent personal injury or damage to the chassis, never attempt to lift or tilt the chassis using the handles on modules (such as power supplies, fans, or cards); these types of handles are not designed to support the weight of the unit. Statement 1032

Caution Do not place anything on top of the router that weighs more than 10 pounds (4.5 kg). Excessive weight on top could damage the chassis.

After the router has been installed, you must connect the chassis to a reliable earth ground. For the chassis ground connection procedures, see the "Installing Chassis Ground Connection" section.

Rack-Mounting the Chassis

If you are planning to rack-mount the router, do so before making network and power connections. If you need to install network modules or WAN and voice interface cards, you can do so either before or after rack-mounting the router. Ideally, you would install modules or WAN interface cards when you have the best access to the router's rear panel.

Note You need a number 2 Phillips screwdriver to mount the chassis in a rack.

The router is shipped with one set of brackets and the screws to attach the brackets to the router chassis.

Figure 3-1 through Figure 3-5 show both sizes of brackets for the various routers.

Figure 3-1 Cisco 3620 Rack-Mount Brackets

Figure 3-2 Cisco 3631 Rack-Mount Brackets for 19-Inch Rack

Figure 3-3 Cisco 3631 Rack-Mount Brackets for 23-Inch Rack

Figure 3-4 Cisco 3640 Rack-Mount Brackets

Figure 3-5 Cisco 3660 Rack-Mount Brackets

Attaching Brackets to the Router

You can rack-mount a Cisco 3600 series router with either the front or the rear of the chassis facing forward. See the following sections for bracket installation instructions for each chassis orientation:

•Front-Panel-Forward Installation

•Rear-Panel-Forward Installation

•Center-Mount Installation

Note Use the screws supplied with the brackets for this installation.

Note If you are installing a Cisco 3620 or Cisco 3640 router in a 19-inch rack with a 17.5-inch opening, orient the brackets so that they will not need to slide between the chassis and the rack; the 17.5-inch rack opening is not wide enough for the chassis plus the bracket thickness. (See Figure 3-6, Figure 3-7, Figure 3-12 and Figure 3-13.)

Note In this publication, references to Cisco 3660 routers include both Cisco 3661 and Cisco 3662 models.

Front-Panel-Forward Installation

Figure 3-6 through Figure 3-11 show the front-panel-forward bracket attachment locations.

Note When installed in a 19-inch rack with a 17.5-inch opening, the Cisco 3620 and Cisco 3640 routers protrude beyond the front of the rack.

Figure 3-6 Cisco 3620 or Cisco 3640 Bracket Attachment—Front Panel Forward
(19-Inch Rack with a 17.5-Inch Opening or 17.75-Inch Opening)

Figure 3-7 Cisco 3620 or Cisco 3640 Bracket Attachment—Front Panel Forward
(19-Inch Rack with a 17.75-Inch Opening)

Figure 3-8 Cisco 3620 or Cisco 3640 Bracket Attachment—Front Panel Forward
(23- or 24-Inch Rack)

Figure 3-9 Cisco 3631 Bracket Attachment—Front Panel Forward (19- and 23-Inch Racks)

Figure 3-10 Cisco 3660 Bracket Attachment—Front Panel Forward (19-Inch Rack)

Figure 3-11 Cisco 3660 Bracket Attachment—Front Panel Forward (23-Inch Rack)

Rear-Panel-Forward Installation

Figure 3-12 through Figure 3-17 show the rear-panel-forward bracket attachment locations.

Figure 3-12 Cisco 3620 or Cisco 3640 Bracket Attachment—Rear Panel Forward
(19-Inch Rack with a 17.5-Inch Opening)

Figure 3-13 Cisco 3620 or Cisco 3640 Bracket Attachment—Rear Panel Forward
(19-Inch Rack with a 17.75-Inch Opening)

Figure 3-14 Cisco 3620 or Cisco 3640 Bracket Attachment—Rear Panel Forward
(23- or 24-Inch Rack)

Figure 3-15 Cisco 3631 Bracket Attachment—Rear Panel Forward (19- or 23-Inch Rack)

Figure 3-16 Cisco 3660 Bracket Attachment—Rear Panel Forward (19-Inch Rack)

Figure 3-17 Cisco 3660 Bracket Attachment—Rear Panel Forward (23-Inch Rack)

Center-Mount Installation

Figure 3-18 through Figure 3-22 show how to install brackets for a center-mounted rack installation.

Figure 3-18 Cisco 3620 Center-Mount Bracket Attachment

Figure 3-19 Cisco 3631 Center-Mount Bracket Attachment—Front Panel Forward (19- or 23-Inch Rack)

Figure 3-20 Cisco 3631 Center-Mount Bracket Attachment—Rear Panel Forward (19- or 23-Inch Rack)

Figure 3-21 Cisco 3640 Center-Mount Bracket Attachment (Requires Optional NEBS/ETSI Kit)

Figure 3-22 Cisco 3660 Center-Mount Bracket Attachment

Mounting the Router in the Rack

After you attach the brackets to the router, slide the router into the rack in the position shown in one of the following illustrations. Using your own screws, fasten the chassis to the rack.

Warning

To prevent bodily injury when mounting or servicing this unit in a rack, you must take special precautions to ensure that the system remains stable. The following guidelines are provided to ensure your safety:
•This unit should be mounted at the bottom of the rack if it is the only unit in the rack.

•When mounting this unit in a partially filled rack, load the rack from the bottom to the top with the heaviest component at the bottom of the rack.

•If the rack is provided with stabilizing devices, install the stabilizers before mounting or servicing the unit in the rack. Statement 1006

Warning To prevent personal injury or damage to the chassis, never attempt to lift or tilt the chassis using the handles on modules (such as power supplies, fans, or cards); these types of handles are not designed to support the weight of the unit. Statement 1032

Figure 3-23 through Figure 3-25 show the Cisco 3640 router in a standard 19-, 23-, or 24-inch rack. The procedure is the same for the Cisco 3620 router.

Figure 3-26 through Figure 3-29 show the Cisco 3631 and Cisco 3660 router in a standard 19- or 23-inch rack.

Figure 3-23 Mounting the Cisco 3620 or Cisco 3640 Router (19-Inch Rack with a 17.5-Inch Opening)

Figure 3-24 Mounting the Cisco 3620 or Cisco 3640 Router (19-Inch Rack with a 17.75-Inch Opening)

Figure 3-25 Mounting the Cisco 3620 or Cisco 3640 Router (23- or 24-Inch Rack)

Figure 3-26 Mounting the Cisco 3631 Router (19-Inch Rack)

Figure 3-27 Mounting the Cisco 3631 Router (23- Inch Rack)

Figure 3-28 Mounting the Cisco 3660 Router (19-Inch Rack)

Figure 3-29 Mounting the Cisco 3660 Router (23-Inch Rack)

After the router has been installed, you must connect the chassis to a reliable earth ground. For the chassis ground connection procedures, see the "Installing Chassis Ground Connection" section.

Wall-Mounting the Cisco 3620 Router

This section explains how to mount the Cisco 3620 router on a wall.

Tip When choosing a wall-mounting location, consider cable limitations and wall structure.

The router is shipped with 19-inch rack-mount brackets, which can also be used for wall-mounting. If you ordered the 23- or 24-inch brackets, either pair could be used to wall-mount your router. The rubber feet are required to provide spacing between the wall and the router for ventilation and proper cooling.

Attaching Rubber Feet to the Router

Attach the rubber feet supplied in the accessory kit. Peel the rubber feet off the black adhesive strip and attach one rubber foot at each corner of the underside of the chassis.

Attaching Wall-Mount Brackets to the Router

To install the Cisco 3620 router on a wall, first attach the brackets on each side of the chassis as shown in Figure 3-30, using plastic washers and slotted hex-head screws. Position the washers so that the narrow shoulder faces the router chassis.

Note The hex-head screws and plastic washers are used only for wall-mounting the router. For rack-mounting, the brackets are attached using Phillips-head screws, without washers.

Figure 3-30 Attaching Wall-Mount Brackets to the Cisco 3620 Router

Mounting the Router on the Wall

After fastening the brackets to the chassis, mount the chassis on the wall:

•Orient the front and rear of the chassis vertically.

•Position the end nearest the power cable at the top.

•Align the screws (not included) with a wall stud, or use wall anchors.

After the router is installed, you must connect the chassis to a reliable earth ground. For the chassis ground connection procedures, see the "Installing Chassis Ground Connection" section.

Installing Chassis Ground Connection

All Cisco 3600 series router chassis require a reliable earth ground connection. You must connect the chassis to a reliable earth ground; the ground wire must be installed in accordance with local electrical safety standards.

•For NEBS-compliant grounding, use size AWG 6 (13 mm²) wire and the ground lug provided in the accessory kit.

•For NEC-compliant grounding, use size AWG 14 (2 mm²) or larger wire and an appropriate user-supplied ring terminal.

•For EN/IEC 60950-compliant grounding, use size AWG 18 (1 mm²) or larger wire and an appropriate user-supplied ring terminal.

For chassis grounding instruction, see one of the following sections:

•Cisco 3620 and Cisco 3640 Chassis Ground Connection

•Cisco 3631 Chassis Ground Connection

•Cisco 3660 Chassis Ground Connection

Cisco 3620 and Cisco 3640 Chassis Ground Connection

To connect a Cisco 3620 or Cisco 3640 chassis to ground, perform this procedure:

Step 1 Attach the ground-lug bracket to the power supply as shown in Figure 3-31 or Figure 3-32. Use a number 2 Phillips screwdriver and the screw or screws that are already in the router chassis.

For Cisco 3620 routers, use the power-supply retaining screw at the bottom of the power supply.

For Cisco 3640 routers, use the two power-supply retaining screws: one at the lower left and one at the upper right.

DC power supply is shown. The bracket attachment for the AC power supply and the Cisco Redundant Power System (RPS) is similar.

Figure 3-31 Required Ground-Lug Bracket Attachment on a Cisco 3620 Router (DC Power Supply Shown)

Figure 3-32 Required Ground-Lug Bracket Attachment on a Cisco 3640 Router (DC Power Supply Shown)

Step 2 Strip one end of the ground wire to the length required for the ground lug or terminal.

–For the NEBS ground lug—approximately 0.75 in. (20 mm)

–For user-provided ring terminal—as required

Step 3 Crimp the ground wire to the ground lug or ring terminal, using a crimp tool of the appropriate size.

Step 4 Attach the ground lug to the ground-lug bracket as shown in Figure 3-33, Figure 3-34, or Figure 3-35, or attach the ring terminal to the ground-lug bracket as shown in Figure 3-36, Figure 3-37, or Figure 3-38. For the ground lug, use the two screws with captive locking washers provided. For a ring terminal, use one of the screws provided. Use a number 2 Phillips screwdriver, and tighten the screws to a torque of 8 to 10 in-lb (0.9 to 1.1 N-m).

Where a DC power supply is shown, AC power supply attachment is similar.

Diagonal attachment of the ground lug to the bracket provides clearance for the RPS power cable.

Step 5 Connect the other end of the ground wire to a suitable grounding point at your site.

Figure 3-33 NEBS-Compliant Ground Lug Attachment on a Cisco 3620 Router with Internal AC or DC Power Supply

Figure 3-34 NEBS-Compliant Ground Lug Attachment on a Cisco 3620 Router with Redundant Power Supply (Cisco RPS)

Figure 3-35 NEBS-Compliant Ground Lug Attachment on a Cisco 3640 Router

Figure 3-36 Ground Lug Attachment Using Ring Terminal on a Cisco 3620 Router with Internal AC or DC Power Supply

Figure 3-37 Ground Lug Attachment Using Ring Terminal on a Cisco 3620 Router with Redundant Power Supply (Cisco RPS)

Figure 3-38 Ground Lug Attachment Using Ring Terminal on a Cisco 3640 Router

After the router has been installed and properly grounded, you can connect the power wiring; the WAN, LAN, and voice cables; and the cables for administrative access, as required for your installation. For cable connection procedures, see the "Power Connections" section, the "Connecting WAN, LAN, and Voice Cables" section, and the "Connecting to a Console Terminal or Modem" section.

Cisco 3631 Chassis Ground Connection

To connect a Cisco 3631 chassis to ground, perform this procedure:

Step 1 Strip one end of the ground wire to the length required for the ground lug or terminal.

–For the NEBS ground lug—approximately 0.75 in. (20 mm)

–For user-provided ring terminal—as required

Step 2 Crimp the ground wire to the ground lug or ring terminal, using a crimp tool of the appropriate size.

Step 3 Attach the ground lug or ring terminal to the chassis as shown in Figure 3-39 or Figure 3-40. For the ground lug, use the two screws with captive locking washers provided. For a ring terminal, use one of the screws provided. Use a number 2 Phillips screwdriver, and tighten the screws to a torque of 8 to 10 in-lb (0.9 to 1.1 N-m).

Step 4 Connect the other end of the ground wire to a suitable grounding point at your site.

Figure 3-39 NEBS-Compliant Ground Lug Attachment on a Cisco 3631 Router

Figure 3-40 Chassis Ground Connection Using Ring Terminal on a Cisco 3631 Router

After the router has been installed and properly grounded, you can connect the power wiring; the WAN, LAN, and voice cables; and the cables for administrative access, as required for your installation. For cable connection procedures, see the "Power Connections" section, the "Connecting WAN, LAN, and Voice Cables" section, and the "Connecting to a Console Terminal or Modem" section.

Cisco 3660 Chassis Ground Connection

To connect a Cisco 3660 chassis to ground, perform this procedure:

Step 1 Strip one end of the ground wire to the length required for the ground lug or terminal.

–For the NEBS ground lug—approximately 0.75 in. (20 mm)

–For user-provided ring terminal—as required

Step 2 Crimp the ground wire to the ground lug or ring terminal, using a crimp tool of the appropriate size.

Step 3 Attach the ground lug or ring terminal to the chassis as shown in Figure 3-41 or Figure 3-42. For the ground lug, use the two screws with captive locking washers provided. For a ring terminal, use one of the screws provided. Use a number 2 Phillips screwdriver, and tighten the screws to a torque of 8 to 10 in-lb (0.9 to 1.1 N-m).

Step 4 Connect the other end of the ground wire to a suitable grounding point at your site.

Figure 3-41 NEBS-Compliant Ground Lug Attachment on a Cisco 3660 Router

Figure 3-42 Chassis Ground Connection Using Ring Terminal on a Cisco 3660 Router

After the router has been installed and properly grounded, you can connect the power wiring; the WAN, LAN, and voice cables; and the cables for administrative access, as required for your installation. For cable connection procedures, see the "Power Connections" section, the "Connecting WAN, LAN, and Voice Cables" section, and the "Connecting to a Console Terminal or Modem" section.

Power Connections

This section explains how to connect AC or DC power to Cisco 3600 series routers. It covers the following topics:

•Connecting Routers to AC Power

•Connecting Routers to a DC-Input Power Supply

•Connecting Routers to the Cisco Redundant Power System

Connecting Routers to AC Power

If your router uses AC power, connect it to a 15 A, 120 VAC (10 A, 240 VAC) circuit with overcurrent protection.

Note The input voltage tolerance limits for AC power are 85 and 264 VAC.

Warning AC connected units must have a permanent ground connection in addition to the power cable ground wire. NEBS-compliant grounding satisfies this requirement. Statement 284

Warning This product relies on the building's installation for short-circuit (overcurrent) protection. Ensure that the protective device is rated not greater than:
15A, 120VAC (10A, 240VAC). Statement 1005

Connecting Routers to a DC-Input Power Supply

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

Warning This product relies on the building's installation for short-circuit (overcurrent) protection. Ensure that the protective device is rated not greater than:
15A, 60VDC. Statement 1005

Warning Use copper conductors only. Statement 1025

Note The installation must comply with the 1996 National Electric Code (NEC) and other applicable codes.

If your router has a DC-input power supply, follow the directions in this section for proper wiring. A router with a DC-input power supply has a terminal block for the DC power connections.

Depending on the type of router you are installing, see one of the following procedures:

•Wiring the DC-Input Power Supply in Cisco 3620 and Cisco 3640 Routers

•Wiring the DC-Input Power Supply in Cisco 3631 Routers

•Wiring the DC-Input Power Supply in Cisco 3660 Routers

Wiring the DC-Input Power Supply in Cisco 3620 and Cisco 3640 Routers

If your router has a DC-input power supply, follow the directions in this section for proper wiring.

DC Wiring Requirements

Cisco 3620 and Cisco 3640 routers with a DC-input power supply require copper wire for the power connections.

For Cisco 3640 routers, DC power connections require crimp-type ring terminals or spade terminals with upturned lugs.

Table 3-1 DC Wiring Requirements for Cisco 3620 and Cisco 3640 Routers

DC Power Source

DC Input

DC Input Wire Size

Safety Ground Wire Size

Overcurrent Protection

Nominal 48 VDC

-48 to -60 VDC¹, 4 A

AWG 14 (2.0 mm2)

AWG 14 (2.0 mm2)

15 A, maximum

¹The input voltage tolerance limits for nominal 48-V power supplies are 38 and 72 VDC.

Wiring Procedure for Nominal 48 VDC Input

To connect the router to a DC power source, perform this procedure.

Step 1 Remove power from the DC circuit. To ensure that power is removed from the DC circuit, locate the circuit breaker for the DC circuit, switch the circuit breaker to the OFF position, and tape the circuit-breaker switch in the OFF position.

Tip Secure all power cabling when installing this unit to avoid disturbing field-wiring connections.

Step 2 For Cisco 3620 routers, strip the wires to the appropriate length for the terminal block on the power supply.

For Cisco 3640 routers, crimp appropriate ring terminals or spade terminals to the DC power input wires. Strip the wires to the appropriate length for the terminals used. The following warning applies to Cisco 3640 routers:

Warning When stranded wiring is required, use approved wiring terminations, such as closed-loop or spade-type terminals with upturned lugs. These terminations should be the appropriate size for the wires and should clamp both the insulation and conductor. Statement 1002

Step 3 Connect the DC power input wires to the terminal block as shown in Figure 3-43 or Figure 3-44.

Warning The illustration shows the DC power supply terminal block. Wire the DC power supply as illustrated. The proper wiring sequence is ground to ground, positive to positive, and negative to negative. The ground wire should always be connected first and disconnected last. Statement 239

Caution The terminal arrangement on your router may not be identical to the arrangement shown in Figure 3-43 or Figure 3-44. You must connect the positive, negative, and ground wires according to the labels on the terminals.

Caution Do not overtorque the terminal block captive thumbscrew or terminal block contact screws. The recommended torque is 8.2 ± 0.4 in-lb (0.9 ± 0.05 N-m).

Figure 3-43 DC Power Connections for Cisco 3620 Routers (Typical)

Figure 3-44 DC Power Connections for Cisco 3640 Routers (Typical)

Step 4 Secure the wires using cable ties.

Step 5 Turn on power to the DC circuit.

Wiring the DC-Input Power Supply in Cisco 3631 Routers

If your router has a DC-input power supply, follow the directions in this section for proper wiring.

DC Wiring Requirements

A Cisco 3631 router with a DC-input power supply requires copper wire and crimp-type terminals for the power connections. Table 3-2 summarizes the wiring requirements.

You can connect a single DC power source to either the A input or the B input. If there are dual power sources, connect one source to the A input and one source to the B input; both sources must be the same polarity and voltage.

Table 3-2 DC Wiring Requirements for Cisco 3631 Routers

Installed Power Supply

DC Input

DC Input Wire Size

Safety Ground Wire Size

Wire Terminal (Lug)

Overcurrent Protection

Nominal 24/48 VDC¹

Identified by a printed label near the DC wire terminals:

24 - 36 V, 8 A,
positive or negative, single or dual sources

AWG 14 (2.0 mm²)

AWG 14
(2.0 mm²)

AMP part number 324159-0, or equivalent

15 A maximum

36 - 60 V, 4 A,
positive or negative, single or dual sources

AWG 18 (1.0 mm²)

AWG 14
(2.0 mm²))

Source DC: Molex part number 19193-0009, or equivalent

Ground: AMP part number 324159-0, or equivalent

15 A maximum

Nominal 48 VDC²

Identification stamped near the DC wire terminals:

48 - 60 V, 4 A,
positive or negative, single or dual sources

AWG 18 (1.0 mm²)

AWG 14
(2.0 mm²)

Source DC: Molex part number 19193-0009, or equivalent

Ground: AMP part number 34119, or equivalent

15 A maximum

¹The input voltage tolerance limits for nominal 24/48-V power supplies are 18 and 72 VDC.

²The input voltage tolerance limits for nominal 48-V power supplies are 38 and 72 VDC.

Wiring Procedure for DC Input

To connect the router to a DC power source, perform the following steps:

Step 1 Remove power from the DC circuit. To ensure that power is removed from the DC circuit, locate the circuit breaker for the DC circuit, switch the circuit breaker to the OFF position, and tape the circuit-breaker switch in the OFF position.

Tip Secure all power cabling when installing this unit to avoid disturbing field-wiring connections.

Step 2 Strip the wires to the appropriate length for the terminals. The strip length is 1/8 to 3/16 inch (3 to 5 mm) for Molex number 19193-0009 and for AMP number 324159-0 terminals.

Step 3 Crimp the terminals to the DC power input wires.

Warning When stranded wiring is required, use approved wiring terminations, such as closed-loop or spade-type with upturned lugs. These terminations should be the appropriate size for the wires and should clamp both the insulation and conductor. Statement 1002

Step 4 Remove the plastic covers from the terminal block. Save them for reinstallation after you finish wiring.

Note Do not remove the colored screw at either end of the terminal block. Those are the terminal mounting screws.

Step 5 Connect the DC power input wires to the terminal block as shown in Figure 3-45 or Figure 3-46. To avoid interference with the on/off switches, and to bring the wires close to the cable-tie attachment point, organize the wires downward from the terminal block.

Warning The illustration shows the DC power supply terminal block. Wire the DC power supply as illustrated. The proper wiring sequence is ground to ground, positive to positive, and negative to negative. The ground wire should always be connected first and disconnected last. Statement 239

Caution Do not overtorque the terminal block contact screws. Recommended torque is 8.0 ± 0.5 in-lb (0.93 ± 0.05 N-m).

Figure 3-45 DC Power Connections for -DC Input to Cisco 3631 Routers

Figure 3-46 DC Power Connections for +DC Input to Cisco 3631 Routers

Step 6 Install the plastic covers over the terminal block. (See Figure 3-47.)

Warning The safety cover is an integral part of the product. Do not operate the unit without the safety cover installed. Operating the unit without the cover in place will invalidate the safety approvals and pose a risk of fire and electrical hazards. Statement 117

Step 7 Secure the wires using cable ties as shown in Figure 3-47. The chassis has a cable-tie attachment below and to the right of the terminal block.

Step 8 Turn on power to the DC circuit.

Figure 3-47 Wire Routing and Attachment for Cisco 3631 Routers

Wiring the DC-Input Power Supply in Cisco 3660 Routers

If your router has a DC-input power supply, follow the directions in this section for proper wiring.

DC Wiring Requirements

A Cisco 3660 router with a DC-input power supply requires copper wire for the power connections. Table 3-3 summarizes the wiring requirements.

Table 3-3 DC Wiring Requirements for Cisco 3660 Routers

Installed Power Supply

DC Input

Wire Size

Wire Termination Method

Safety Ground Wire Size

Overcurrent Protection

Nominal 24/48 VDC¹

Identified by a terminal block and the following printed label:

24 - 36 V, 16 A

AWG 12
(3.0 mm²)

Terminal block; wires retained by retention screws

AWG 12
(3.0 mm²)

20 A maximum

36 - 60 V, 7 A

AWG 14
(2.0 mm²), minimum

Terminal block; wires retained by retention screws

AWG 12 or 14
(3.0 or 2.0 mm²)

15 A maximum

Nominal 48 VDC²

Identified by a plug connector and the following printed label:

48 - 60 V, 8 A

AWG 14
(2.0 mm²), minimum

Plug connector; wires retained by spring-loaded receptacle

AWG 12 or 14
(3.0 or 2.0 mm²)

15 A maximum

¹The input voltage tolerance limits for nominal 24/48-V power supplies are 18 and 72 VDC.

²The input voltage tolerance limits for nominal 48-V power supplies are 38 and 72 VDC.

Wiring Procedure for DC Input

To connect the router to a DC power source, perform the following steps:

Step 1 Remove power from the DC circuit. To ensure that power is removed from the DC circuit, locate the circuit breaker for the DC circuit, switch the circuit breaker to the OFF position, and tape the circuit-breaker switch in the OFF position.

Tip Secure all power cabling when installing this unit to avoid disturbing field-wiring connections.

Step 2 Cut the wires to length. Allow enough length for attachment to the bracket and for a service loop. (See Figure 3-47.)

Step 3 Strip the insulation to expose approximately 0.4 inch (10 mm) of conductor.

Step 4 If the power supply in your router has screw terminals, first connect the safety ground wire to the safety ground terminal of the DC terminal block, and then connect the power wires to the appropriate terminals of the DC terminal block. (See Figure 3-48 or Figure 3-49.) Tighten the terminal screw to a torque of 8.0 ± 0.5 in-lb (0.93 ± 0.05 N-m).

Warning The illustration shows the DC power supply terminal block. Wire the DC power supply as illustrated. The proper wiring sequence is ground to ground, positive to positive, and negative to negative. The ground wire should always be connected first and disconnected last. Statement 239

Figure 3-48 Terminal Block Connections for -DC Input Power to Cisco 3660 Routers

Figure 3-49 Terminal Block Connections for +DC Input Power to Cisco 3660 Routers

If the power supply in your router has a plug connector, press the corresponding orange-colored release, and insert the positive, negative, and ground wires into the corresponding receptacles of the plug connector. (See Figure 3-50.) Then plug the wired plug connector into the receptacle on the power supply at the rear of the router. (See Figure 3-51.)

Note To remove wires from a plug connector, press the orange-colored release next to each receptacle.

Figure 3-50 DC Power Connections for Plug Connector to Cisco 3660 Routers

Step 5 Secure the wires to the wire management bracket (recommended method) or to the equipment rack (optional method). The wire management bracket has holes for attaching cable ties. Make sure that the service loop does not extend above or below the power supply. (See Figure 3-51 or Figure 3-52.)

Caution Power wires must exit to the right, and the service loop must not extend above or below the power supply.

Note The power wires may pass in front of the power supply cooling vents. The wires do not restrict ventilation.

Figure 3-51 DC Wiring—Power Supply with Plug Connector in Cisco 3660 Routers

Figure 3-52 DC Wiring—Power Supply with Terminal Block in Cisco 3660 Routers

Step 6 If your router has two power supplies installed, repeat Step 1 through Step 5 for the second power supply.

Step 7 Turn on power to the DC circuit.

Connecting Routers to the Cisco Redundant Power System

If your router uses the Cisco Redundant Power System (RPS), refer to the Cisco RPS Hardware Installation Guide for instructions about the power connections. You can access this document at the location described in the "Obtaining Documentation" section.

Connecting WAN, LAN, and Voice Cables

This chapter describes how to connect the WAN, LAN, and voice interface cables. It includes the following sections:

•"Ports and Cabling" section

•"Connections for Cisco 3620, Cisco 3640, and Cisco 3631 Routers" section

•"Connections for Cisco 3660 Routers" section

Note One or two Ethernet cables are typically provided with the router. Additional cables and transceivers can be ordered from Cisco. For ordering information, refer to the Cisco Product Catalog at http://www.cisco.com/en/US/products/products_catalog_links_launch.html. For cable pinouts, refer to the Cisco Modular Access Router Cable Specifications document available online and on the Documentation CD-ROM.

Warning Do not work on the system, or connect or disconnect cables during periods of lightning activity. Statement 1001

Ports and Cabling

Table 3-4 summarizes some typical WAN, LAN, and voice connections for Cisco 3600 series routers.

The connections summarized here are also described in detail in the following documents:

•Cisco Modular Access Router Cable Specifications

•Cisco Network Modules Hardware Installation Guide

•Cisco Interface Cards Hardware Installation Guide

You can access these documents at the location described in the "Obtaining Documentation" section.

Table 3-4 WAN, LAN, and Voice Connections

Port or Connection

Port type, color

Connected to:

Cable

Ethernet

RJ-45, yellow

Ethernet hub

Straight-through Ethernet

T1/E1 WAN

RJ-48C/CA81A,
blue

Network demarcation (telco demarc or equivalent)

RJ-48 T1

Cisco serial

60-pin D-sub

CSU/DSU and serial network or equipment

Cisco serial transition cable that matches the signaling protocol (EIA/TIA-232, EIA/TIA-449, V.35, X.21, or EIA/TIA-530) and the serial port operating mode (DTE or DCE).

Refer to the Cisco Modular Access Router Cable Specifications document for information about selecting these cables.

Cisco Smart serial

Cisco Smart compact connector, blue

CSU/DSU and serial network or equipment

For WIC-2T and WIC-2A/S only

DSL

RJ-11C/CA111A, lavender

Network demarcation device for service provider's DSL interface

RJ-11

T1 Digital voice

RJ-48C/CA81A, tan

Digital PBX

RJ-48 T1 cable

Analog voice FXS

RJ-11, gray

Telephone, fax

RJ-11

Analog voice FXO

RJ-11, pink

Central office, analog PBX

RJ-11

Analog voice E&M

RJ-11, brown

Analog PBX

RJ-11

BRI S/T WAN
(external NT1)

RJ-48C/CA81A,
orange

NT1 device or private integrated network exchange (PINX)

RJ-48

BRI U WAN
(built-in NT1)

RJ-49C/CA-A11,
red

ISDN network

RJ-49

BRI S/T LL
(external NT1)

RJ-48C/CA81A,
orange

NT1 device

RJ-48

CT1/PRI

T1

External T1 CSU

DB-15 T1 serial cable

CT1/PRI-CSU

T1

RJ-48C/CA81A interface

RJ-48 straight-through

CTE/PRI

E1

E1 network

DB-15 to BNC, DB-15 to DB-15, DB-15 to twinax, or DB-15 to RJ-45

Token Ring

UTP, purple

STP, purple

Token Ring device

RJ-45 Token Ring cable

56/64-kbps DSU/CSU

8-pin modular, blue

RJ-48S interface

RJ-48 straight-through

Alarm interface controller

50-pin SCSI connectors

External alarm inputs

Alarm control relays

Serial transition cable

Connections for Cisco 3620, Cisco 3640, and Cisco 3631 Routers

Connect each WAN, LAN, and voice cable to the appropriate connector on the chassis or on a network module or interface card.

•Position the cables carefully, so that they do not put strain on the connectors.

•Organize cables in bundles such that cables do not intertwine.

•Inspect the cables to make sure that the routing and bend radiuses are satisfactory. Reposition cables, if necessary.

•Install cable ties in accordance with site requirements.

For cable pinouts, refer to the online document Cisco Modular Access Router Cable Specifications.

For more information about connecting and configuring network modules, WAN interface cards, and voice interface cards, refer to the following documents:

•Cisco Network Modules Hardware Installation Guide

•Cisco Interface Cards Hardware Installation Guide

Connections for Cisco 3660 Routers

Connecting WAN, LAN, and Voice Cables (Without Chassis Shield)

If your Cisco 3660 router does not use a chassis shield, perform this procedure:

Step 1 Connect each WAN, LAN, and voice cable to the appropriate connector on a network module or interface card.

Step 2 Route the cables to the left side of the router, and organize the cables in bundles. (See Figure 3-53.)

•Position the cables carefully, so that they do not put strain on the connectors.

•Organize cables in bundles such that cables do not intertwine.

Step 3 Inspect the cables to make sure that the routing and bend radiuses are satisfactory. Reposition cables, if necessary.

Step 4 Install cable ties in accordance with site requirements.

Figure 3-53 Typical Cable Arrangement

1

LAN, WAN, and voice cables

2

Power wires

Connecting WAN, LAN, and Voice Cables (With Chassis Shield—Telco Only)

To connect the cables, install the chassis shield, and organize the cables into bundles, perform this procedure:

Note The Cisco 3660 router telco chassis is identified by its part number, CISCO3662-xC-CO.

Step 1 Connect each WAN, LAN, and voice cable to the appropriate connector on a network module or interface card.

Note Do not organize the cables into bundles until after you install the chassis shield. Leave a generous length of cable to allow for installation of the cable shield.

Note You can route cables through the cutout at the left of the chassis, through the openings in the chassis shield, or through both areas. In each routing, all WAN, LAN, and voice cables must exit toward the left. (See Figure 3-55 and Figure 3-56.)

Step 2 If all of the cables are routed through the cutout at the left, leave the small panels in place on the chassis shield. If cables are routed through the openings in the chassis shield, remove the small panels as required to provide openings for the cables. (See Figure 3-54.)

Note If you are going to route cables through the upper openings in the chassis shield, you must remove the lower panels to permit chassis shield installation.

Figure 3-54 Removing Panels from Chassis Shield

Step 3 Hold the chassis shield at a 45-degree angle to the chassis, and attach it to the hinges at the right side.

Step 4 Position the cables to allow closing of the chassis shield, and close the chassis shield.

Note If cables are routed through the openings in the chassis shield, cables on the left side must exit through the left openings, and cables on the right side must exit through the right openings.

Step 5 Tighten the two captive screws at the left side of the shield.

Step 6 Reinstall the panels over any openings that are not used for cables.

Step 7 Route the cables to the left side of the router, and organize the cables in bundles (see Figure 3-55 and Figure 3-56):

•Position the cables carefully, so that they do not put strain on the connectors.

•Organize cables in bundles such that cables do not intertwine.

Step 8