The DC input-power-present LEDs provide a visual indication to service personnel that there is voltage present across the input terminal connection.

Figure 1 shows the input-power-present LEDs on the rear of the DC power shelf.

Figure 5. Input-Power-Present LEDS

Note	Power should be disconnected before servicing the input power connection.

The input-power-present LED starts to light up when the input voltage reaches –20 VDC and the LED gets brighter as voltage increases; the input-power-present LED is fully lit when the input voltage reaches –38 VDC.

Caution

If the input voltage polarity is reversed, or if the LED circuit fails, the LED will not light. When this is the case, service personnel should check for hazardous voltages before working on the unit.

There are no prerequisites for this task.

You need the following tool to perform this task:

• 6-in. long number 1 Phillips screwdriver

1.    To release the Power A bus bar from the shipping position, loosen the six captive screws that attach the bus bar shipping bracket to the rear of the chassis. There are two screws on the right side, two screws on the front, and two screws on the left side of the Power A bus bar shipping bracket. See Figure 1.

2.    Remove the Power A bus bar shipping bracket form the chassis and set it aside.

3.    Remove the Power A bus bar from the rear of the chassis. See Figure 2.

4.    Remove the cover from the Power A bus bar by loosening the two captive screws that attach the cover to the bus bar. See Figure 2.

5.    Position the power block vertically. Mate the power block pivot and chassis pivot point together. See item 2 in Figure 3.

6.    Unscrew the two handle screws on the power bus bar and open the handle. See item 3 on Figure 3.

7.    Hold the power block cable to the side to keep clear of the power block connectors while seating the power block.

8.    Seat the power block and tighten the two screws on the handle. See item 3 in Figure 3.

9.    Tighten the Phillips captive screw that secures the tab on the left side of the power block to the chassis. See item 1 in Figure 3.

Step 1	To release the Power A bus bar from the shipping position, loosen the six captive screws that attach the bus bar shipping bracket to the rear of the chassis. There are two screws on the right side, two screws on the front, and two screws on the left side of the Power A bus bar shipping bracket. See Figure 1. Note    The Power A bus bar is pre-attached to the top rear of the chassis in a horizontal position using a bus bar shipping bracket, due to shipping height restrictions. Figure 6. Removing the Power A Bus Bar Shipping Bracket 1 Captive screws securing Power A bus bar bracket to rear of chassis
Step 2	Remove the Power A bus bar shipping bracket form the chassis and set it aside.
Step 3	Remove the Power A bus bar from the rear of the chassis. See Figure 2. Note    The Power A bus bar is connected to the chassis with an internal cable. Be careful not to drop the power bus bar.
Step 4	Remove the cover from the Power A bus bar by loosening the two captive screws that attach the cover to the bus bar. See Figure 2. Figure 7. Removing the Cover From the Power A Bus Bar 1 Internal cable connection 2 Screws attaching cover to Power A bus bar
Step 5	Position the power block vertically. Mate the power block pivot and chassis pivot point together. See item 2 in Figure 3.
Step 6	Unscrew the two handle screws on the power bus bar and open the handle. See item 3 on Figure 3.
Step 7	Hold the power block cable to the side to keep clear of the power block connectors while seating the power block.
Step 8	Seat the power block and tighten the two screws on the handle. See item 3 in Figure 3. Figure 8. Power A Bus Bar Installed in Chassis 1 Captive screw securing Power A bus bar to chassis 2 Chassis pivot point 3 Two screws securing handle to Power A bus bar
Step 9	Tighten the Phillips captive screw that secures the tab on the left side of the power block to the chassis. See item 1 in Figure 3.

After the Power A bus bar has been installed, install the upper grille support. Continue to the Installing the Upper Grille Support for more information.

Before performing this task, perform the following procedure:

You need the following tools and equipment to perform this task:

• 6-in. long number 1 Phillips screwdriver
• Upper grille support

1.    Attach the upper grille support to the front of the chassis. Use the screwdriver to install the six M4 flat head screws, three on each side, to the chassis. See Figure 1.

Attach the upper grille support to the front of the chassis. Use the screwdriver to install the six M4 flat head screws, three on each side, to the chassis. See Figure 1. Figure 9. Attaching the Upper Grille Support to the Chassis

After the upper grille support has been installed, attach the unistruts. Continue to the Installing the Unistruts for more information.

Before performing this task, perform the following procedures:

You need the following tools and equipment to perform this task:

• 8mm hex bit socket
• 3/8-in. drive ratchet wrench
• Torque wrench with 13-mm hex key and rated accuracy at 40 to 50 in.-lb (4.52 to 5.65 N-m)
• Unistruts

1.    Attach each unistrut to the top of the chassis by inserting four M12 hex head bolts and washers, two for each strut, into the bolt holes on the inside of the strut, and tightening with the 8mm hex bit socket and ratchet wrench. The closed end of a unistrut faces the front (PLIM) side of the chassis. See Figure 1.

Attach each unistrut to the top of the chassis by inserting four M12 hex head bolts and washers, two for each strut, into the bolt holes on the inside of the strut, and tightening with the 8mm hex bit socket and ratchet wrench. The closed end of a unistrut faces the front (PLIM) side of the chassis. See Figure 1. Note    The left unistrut (as you face the front [PLIM] side of the chassis) has a cutaway in the rear to admit the chassis ground cable; the right unistrut does not. The right unistrut as viewed from the front PLIM side of the router has a bolt position that is 6.5 inches from the end at the rear of the router. Caution    Cisco recommends an install torque range for the unistrut bolts between 40 and 50 to in.-lb (between 4.52 N-m and 5.65 N-m). Figure 10. Attaching the Unistrut 1 Upper grille support 3 Cutaway for ground cable 2 Unistruts

After the upper grille support has been installed, install the chassis ground cable. Continue to the Installing the Chassis Ground Cable for more information.

Before performing this task, perform the following procedures:

You need the following tools and equipment to perform this task:

• Ground lug
• Ground cable
• Crimping tool and lug specific die
• 3/8 in. drive socket wrench
• 10-mm 6 pt. socket
• Torque wrench with 10-mm 6 pt. socket and rated accuracy at 30 in.-lb (3.39 N-m)

To ensure a satisfactory ground connection, you also need the following parts:

• One 180-degree angle (straight) grounding lug that has two M6 bolt holes with 0.63 inches (5/8 inch) (1.60 cm) of spacing center to center between them and a 6 AWG or larger multistrand copper wire.See Figure 1.

Figure 11. 180-Degree (Straight) Chassis Ground Lug

• Two M6 hex head bolts and integrated locking washers are pre-installed on the chassis.
• Cisco recommend at least 6 AWG multistrand copper ground cable. This cable is not available from Cisco Systems; it is available from any commercial cable vendor. The cable should be sized according to local and national installation requirements.

Note	The DC return of this system should remain isolated from the system frame and chassis (DC-I: Isolated DC Return).

1.    Use the crimping tool mandated by the lug manufacturer to crimp the lug to the ground cable.

2.    Using the 10-mm wrench, attach the ground cable to the upper grounding point as shown in Figure 1 for overhead grounding. Use the optional lower grounding point, as shown in Figure 2 if the ground cable is run from under a raised floor.

3.    Use the torque wrench to tighten to a torque of 30 in.-lb (3.39 N-m).

4.    Connect the other end of the ground cable to a grounding point at your site, according to site requirements.

Step 1	Use the crimping tool mandated by the lug manufacturer to crimp the lug to the ground cable.
Step 2	Using the 10-mm wrench, attach the ground cable to the upper grounding point as shown in Figure 1 for overhead grounding. Use the optional lower grounding point, as shown in Figure 2 if the ground cable is run from under a raised floor. Figure 12. NEBS Bonding and Grounding Points—Top of Chassis 1 Two Torx security screws Note    The two bolts below the NEBS bonding and grounding points at the top of the chassis are required for proper bonding and grounding of the chassis and should not be removed. Figure 13. NEBS Bonding and Grounding Points—Bottom of Chassis
Step 3	Use the torque wrench to tighten to a torque of 30 in.-lb (3.39 N-m).
Step 4	Connect the other end of the ground cable to a grounding point at your site, according to site requirements.

After the chassis ground cable has been attached, remove the exhaust air deflector from the rear of the chassis. Continue to the “Removing the Exhaust Air Deflector” section on page 7-45 for instructions.

Before performing this task, perform the following procedures:

• Installing the Power A Bus Bar
• Installing the Upper Grille Support
• Installing the Unistruts
• Installing the Chassis Ground Cable
• Removing the Exhaust Air Deflector, page 7-45 (if the lower power shelf is being installed)
• Removing the Upper Rear Air Grille, page 7-21 (if installed)
• Removing the Front Upper Grille, page 7-28 (if installed)
• Removing the Upper Grille Support, page 7-52 (if installed)
• Verify that the power shelf that you are about to install is the correct power shelf, either AC or DC.

Note	Do not install the power shelf in the chassis with AC or DC PMs, or alarm module installed in the power shelf.

You need the following tools to perform this task:

• 6-in. long number 2 Phillips screwdriver
• Torque screwdriver with number 2 Phillips head and rated accuracy at 15 in.-lb (1.69 N m) to 20 in.-lb (2.26 N m)
• AC or DC power shelf
  • AC power shelf (Cisco product number CRS-16-PWRSH-AC=), or
  • DC power shelf (Cisco product number CRS-16-PWRSH-DC=)

1.    Unpack the shelves to be installed.

2.    Using two people, one to support the power shelf underneath and the other to keep it steady, lift the power shelf up and slide it partway into the power shelf slot on the front (PLIM) side of the chassis. See Figure 2.

3.    Unscrew the ejector handles from the front face of the shelf, one on each side. See Figure 1.

4.    Grasping both handles simultaneously, push both the left and right handles up and in at the same time to push the shelf into the chassis. Slide the shelf all the way into the chassis, until both power shelf handles hook around the pins.

5.    Using the screwdriver, tighten the captive screw on both power shFigure 3 Figure 3-20 .

6.    Using the torque screwdriver, tighten the two screws that attach the bottom of the power shelf, one on each side, to the chassis to a torque value of 15 in.-lb (1.69 N m) to 20 in.-lb (2.26 N m). See Figure 3.

7.    Install the second power shelf, following through Step 3 through Step 6.

Step 1	Unpack the shelves to be installed.
Step 2	Using two people, one to support the power shelf underneath and the other to keep it steady, lift the power shelf up and slide it partway into the power shelf slot on the front (PLIM) side of the chassis. See Figure 2.
Step 3	Unscrew the ejector handles from the front face of the shelf, one on each side. See Figure 1. Figure 18. Power Shelf Ejector Handles on Front of Power Shelf 1 Power shelf ejector handle pushed up to slide shelf into chassis 2 Power shelf ejector handle pulled away from shelf 3 Screws that attach power shelf to chassis Caution    Because of the weight of the power shelf, 40 lbs (18 kg), and the height that the power shelf is installed in the chassis, you should be especially careful while lifting and installing the power shelf. To prevent injury, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves. Note    Although you can install the power shelves in any order that you prefer, Cisco suggests that you install the upper power shelf first and then install the lower power shelf. Ensure that the first power shelf is properly seated before attempting to install the second power shelf. Figure 19. Installing the Power Shelf in the Chassis 1 Power shelf being installed
Step 4	Grasping both handles simultaneously, push both the left and right handles up and in at the same time to push the shelf into the chassis. Slide the shelf all the way into the chassis, until both power shelf handles hook around the pins. Caution    Make sure both handles swing straight up. Use care not to bend the handles sideways. Figure 20. Installing and Securing Power Shelf
Step 5	Using the screwdriver, tighten the captive screw on both power shFigure 3 Figure 3-20 .
Step 6	Using the torque screwdriver, tighten the two screws that attach the bottom of the power shelf, one on each side, to the chassis to a torque value of 15 in.-lb (1.69 N m) to 20 in.-lb (2.26 N m). See Figure 3. Note    The screws that secure the power shelf to the chassis are relied upon for power shelf bonding and grounding.
Step 7	Install the second power shelf, following through Step 3 through Step 6.

After the power shelves have been installed in the chassis, install the AC or DC power shelf wiring. Continue to the Installing AC or DC Power Shelf Wiring for instructions.

This section describes how to connect the DC input wiring to the rear of the power shelf and install the DC terminal block covers on the Cisco CRS Series Enhanced 16-slot Line Card Chassis.

Figure 1 shows the cable wiring for the DC power shelf.

For additional power shelf details, see the Cisco CSR-1 Series Carrier Routing System Description or Appendix A, “Cisco CRS Series Carrier Routing System 16-Slot EC Line Card Chassis Specifications.”

Note	When wiring the power shelf, be sure to connect the chassis ground cable first. For more information, see the Bonding and Grounding Guidelines and the Installing the Chassis Ground Cable.

Figure 1 shows the DC terminal block cover.

Figure 22. DC Terminal Block Cover

Caution

Install the terminal block cover after the input wiring is installed, but before power has been energized.

This section describes how to install input AC cords on the rear of the power shelf.

Note	When installing AC power cords on the power shelf, be sure to connect the chassis ground cable first. For more information, see the Bonding and Grounding Guidelines and the Installing the Chassis Ground Cable.

Before performing this task, perform the following procedures:

You need the following tools and equipment to perform this task:

• 6-in. long number 2 Phillips screwdriver
• Rear exhaust air deflector (set aside earlier)

1.    Locate the mounting position standoffs on each side of the exhaust opening.

2.    Position the lower cutouts on the bottom of the air deflector with the lower standoffs.

3.    Rotate the air deflector forward until it is seated on the upper standoff.

4.    Tighten the captive screw on both sides.

Step 1	Locate the mounting position standoffs on each side of the exhaust opening.
Step 2	Position the lower cutouts on the bottom of the air deflector with the lower standoffs. Figure 25. Positioning the Lower Cutouts
Step 3	Rotate the air deflector forward until it is seated on the upper standoff. Figure 26. Rotating the Air Deflector Forward
Step 4	Tighten the captive screw on both sides. Figure 27. The Captive Screw Figure 4 shows the exhaust air deflector installed on the chassis. Figure 28. Installed Exhaust Air Deflector

After the exhaust air deflector has been re-installed on the rear (MSC) side of the chassis, install the alarm module and power modules in both power shelves. Continue to the Installing an Alarm Module and the Installing a Power Module for instructions.

Before performing this task, perform the following procedures:

Caution

Do not attempt to install the alarm module until the power shelf is in place and screwed into the chassis.

You need the following tools to perform this task:

• ESD-preventive wrist strap
• 6-in. long number 1 Phillips screwdriver
• Alarm module (Cisco product number CRS-16-ALARM-B=)

1.    Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.

2.    Hold the alarm module such that the ejector handle is on the lower left front side. See Figure 1.

3.    Slide the alarm module into the bay on the right side of the power shelf. As you slide the module in, hold the ejector and gently push until it engages the chassis. See Figure 1.

4.    Continue to push the alarm module gently and rotate alarm module ejector upwards to seat the alarm module. Be careful not to pinch fingers between the ejector handle and the alarm module. See Figure 2.

5.    Hand tighten the captive screw on the lower right corner of the alarm module.

6.    Use the number 1 Phillips screwdriver to securely fasten captive screw that secures the alarm module to the power shelf.

Step 1	Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.
Step 2	Hold the alarm module such that the ejector handle is on the lower left front side. See Figure 1.
Step 3	Slide the alarm module into the bay on the right side of the power shelf. As you slide the module in, hold the ejector and gently push until it engages the chassis. See Figure 1. Figure 30. Installing Alarm Module in Power Shelf 1 Alarm module
Step 4	Continue to push the alarm module gently and rotate alarm module ejector upwards to seat the alarm module. Be careful not to pinch fingers between the ejector handle and the alarm module. See Figure 2. Figure 31. Rotating Alarm Module Ejector Upwards to Seat Alarm Module
Step 5	Hand tighten the captive screw on the lower right corner of the alarm module.
Step 6	Use the number 1 Phillips screwdriver to securely fasten captive screw that secures the alarm module to the power shelf.

After the alarm modules are installed in the power shelves, install the AC or DC power modules. Continue to the Installing a Power Module for instructions.

Before performing this task, perform the following procedures:

Caution

Do not attempt to install the PM until the power shelf is in place and screwed into the chassis.

You need the following tools to perform this task:

• ESD-preventive wrist strap
• 6-in. long number 1 Phillips screwdriver
• Torque screwdriver with number 1 Phillips bit and rated accuracy at 5.5 in.-lb (0.62 N-m)
• AC or DC PM
  • AC PM (Cisco product number CRS-PM-AC=), or
  • DC PM (Cisco product number CRS-PM-DC=)

1.    Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.

2.    Using two hands to support and guide the PM, slide it into the power shelf. Install PM0 first.

3.    Rotate the ejector lever upwards to seat the PM into the power shelf. Tighten the ejector lever to nominal install torque of 5.5 in.-lb (0.62 N m), screw the PM into the shelf (see Figure 1). Do not exceed a maximum install torque of 10 in.-lb (1.13 N-m).

4.    Fill the power shelf, in PM ascending order, to the required configuration.

Step 1	Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.
Step 2	Using two hands to support and guide the PM, slide it into the power shelf. Install PM0 first.
Step 3	Rotate the ejector lever upwards to seat the PM into the power shelf. Tighten the ejector lever to nominal install torque of 5.5 in.-lb (0.62 N m), screw the PM into the shelf (see Figure 1). Do not exceed a maximum install torque of 10 in.-lb (1.13 N-m). Figure 33. Securing the PM to the Shelf
Step 4	Fill the power shelf, in PM ascending order, to the required configuration.

After performing this task, install power module slot covers into empty power module slots in the power shelf, if any. For more information, see the Installing a Power Module Slot Cover. Other wise, re-install the upper grille on the front (PLIM) side of the chassis, if applicable.

Before performing this task, you must first remove the upper grille on the front (PLIM) side of the chassis, if installed, and install the alarm module and power modules to the required configuration in each power shelf. See Installing an Alarm Module and Installing a Power Module.

You need the following tools to perform this task:

• ESD-preventive wrist strap
• AC or DC PM Slot Cover
  • AC PM slot cover (Cisco product number 700–29097–xx), or
  • DC PM slot cover (Cisco product number 700–29098–xx)

1.    Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.

2.    Align the PM slot cover with the empty PM slot in the power shelf.

3.    Insert the two tabs on the right side of the PM slot cover into the two holes on the right side of the PM slot. See Figure 1.

4.    Push the left side of the PM slot cover gently until it clicks into place. See Figure 1.

Step 1	Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection sockets: on the front (PLIM) side of the chassis there is one ESD connection socket right above the fan controllers. On the rear (MSC) side of the chassis there are two ESD connection sockets right above the cable management tray in the center of the chassis (left and right). You can also connect the ESD-preventive wrist strap leash to any bare metal surface on the chassis.
Step 2	Align the PM slot cover with the empty PM slot in the power shelf.
Step 3	Insert the two tabs on the right side of the PM slot cover into the two holes on the right side of the PM slot. See Figure 1.
Step 4	Push the left side of the PM slot cover gently until it clicks into place. See Figure 1. Figure 34. Installing PM Slot Cover

After performing this task, re-install the upper grille on the front (PLIM) side of the chassis, if applicable.

Before performing this task, perform the following procedures:

If you have a DC power system installed, wiring at the BDFB or at the power plant should be complete.

1.    Make sure all boards (RPs, PLIMs, SFCs, and FPs) are pulled-out and disconnected from the backplane. Verify that the three status LEDs on the front of each power module are off.

2.    Make sure that I/O switches on the rear of the upper (Power A) and lower (Power B) power shelves are in the OFF position.

3.    If you have a DC power system installed, perform the following steps:

4.    If you have an AC power system installed, perform the following steps:

5.    Verify that the fan tray and fan controller LEDs are on and that the fans are running.

6.    Turn the I/O switch at the rear of both upper power shelves (Power A and Power B) to the OFF position. Verify that none of the Output_OK LEDs on the PMs installed in the shelf are green.

7.    Install all boards (RPs, PLIMs, SFCs, and FPs) in the chassis. For more information, see Chapter 6, “Installing Line Cards, PLIMs, and Associated Components.”

8.    Turn the I/O switch at the rear of both power shelves (Power A and Power B) to the ON position.

Note	For appropriate SFC LED information, see the appropriate section in Chapter 6, “Installing Line Cards, PLIMs, and Associated Components.” or the specific documentation for the card.

1.    Turn the I/O switches at the rear of both power shelves, Power A and Power B, to the OFF position.

2.    If you have a DC power system installed, remove the power fuse at the BDFB or power plant for each power module on both power shelves.

3.    If you have an AC power system installed, turn off the source circuit breakers to de-energize the power modules in the upper and lower power shelves.