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Removal and Replacement, Procedures

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CH A P T E R 5 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, page 5-2 • Removing and Replacing the Fan Assembly, page 5-12 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. OL-5079-04 Cisco 7609 Internet Router Installation Guide 5-1

Section	Page
Cisco7609 Internet Router Installation Guide	1
contents	3
Prefacevii	3
chapter 1	3
Product Overview1-1	3
chapter 2	4
Preparing for Installation2-1	4
chapter 3	4
Installing the Cisco7609 Internet Router3-1	4
chapter 4	5
Troubleshooting4-1	5
chapter 5	5
Removal and Replacement Procedures5-1	5
appendix A	5
Technical SpecificationsA-1	5
appendix B	5
Connector and Cable SpecificationsB-1	5
appendix C	6
Repacking theCisco7609 Internet RouterC-1	6
index	6
Preface	7
Audience	7
Organization	7
Conventions	8
Related Documentation	13
Obtaining Documentation	13
World Wide Web	13
Documentation CD-ROM	14
Ordering Documentation	14
Documentation Feedback	14
Obtaining Technical Assistance	15
Cisco.com	15
Technical Assistance Center	16
Cisco TAC Web Site	16
Cisco TAC Escalation Center	17
1	19
Product Overview	19
Warning # 1017	20
Cisco 7609 Internet Router	22
Figure1-1 Cisco 7609 Internet Router	23
System Features	24
Bandwidth and Port Density	24
Table1-1 Cisco 7609 Internet Router Bandwidth and Port Density	25
Redundancy	25
Component Hot Swapping	26
Cisco 7600 Internet Router Components	26
Fan Assembly	26
Figure1-2 Cisco 7609 Internet Router Internal Airflow	27
Power Supplies	27
Figure1-3 AC-Input Power Supply	28
Figure1-4 DC-Input Power Supply	29
Load Sharing	29
Environmental Monitoring of the Power Supply	30
Table1-2 Power Supply Front Panel LEDs	30
Power Supply Fan Assembly	31
2	33
Preparing for Installation	33
Safety	33
Site Requirements	34
Environmental Requirements	34
Table2-1 Chassis Airfow Requirements	34
Table2-2 AC Power Requirements and Heat Dissipation	35
Table2-3 DC Power Requirements and Heat Dissipation	37
Table2-4 Sample Calculation	39
Power Requirements	40
Power Connection Guidelines	40
AC-Powered Systems	41
Figure2-1 AC Power Cord Plugs and Appliance Coupler for the 2500W Power Supply	42
Figure2-2 AC Power Cord Connectors for the 4000W Power Supply	42
Table2-5 AC-Input Power Cord Options	43
DC-Powered Systems	43
Site Preparation Checklist	43
Table2-6 Site Planning Checklist	44
3	45
Installing the Cisco7609 Internet Router	45
Unpacking the Cisco 7609 Internet Router	46
Installing the Rack-Mount Kit	47
Table3-1 Rack-MountKit Checklist	47
Rack-Mounting Guidelines	47
Required Tools	48
Installing the Shelf and Crossbar Brackets	48
Step 1 Position one of the two shelf brackets in the rack as shown in Figure3-1.	48
Step 2 Secure the shelf bracket to the rack by using three 12-24 x 3/4-inch or 10-32x3/4-inch s...	48
Step 3 Repeat Steps 1 and 2 for the second shelf bracket. Make sure that the second shelf bracket...	48
Step 4 Attach the crossbar bracket to the back of the shelf brackets using two M3screws as shown...	48
Figure3-1 Installing the ShelfBrackets	49
Figure3-2 Attaching the Crossbar Bracket to the Shelf Brackets	49
Installing the L Brackets and Cable Guides	50
Step 1 Position one of the Lbrackets against the Cisco 7609 chassis side and align the screw hol...	50
Step 2 Secure the Lbracket to the Cisco 7609 chassis with the four M4 screws.	50
Step 3 Repeat Steps 1 and 2 for the other Lbracket. If you used the + set of holes for the first...	50
Step 1 Position the cable guide against the front of the chassis and align the four screw holes a...	50
Step 2 Secure the cable guide with four M4 screws.	50
Figure3-3 Attaching L Brackets and CableGuides	51
Installing the Cisco 7609 Chassis in the Rack	52
Step 1 With a person standing at each side of the chassis, grasp the chassis handle with one hand...	52
Step 2 Position the chassis in the rack as follows. (See Figure3-4.)	52
Step 3 Rest the chassis on the shelf brackets and crossbar bracket.	52
Step 4 Align the mounting holes in the Lbracket with the mounting holes in the equipment rack.	52
Figure3-4 Installing the Cisco 7609 Chassis intheRack	53
Step 5 Install the eight or ten (four or five per side) 12-24 x 3/4-inch or 10-32 x 3/4-inch scre...	53
Step 6 Use a tape measure and level to verify that the chassis is installed straight and level.	53
Installing the Stabilizer Kit	54
Table3-2 Stabilizer Kit Contents	54
Step 1 Have one person tilt and hold the chassis to one side.	54
Step 2 With the chassis tilted, attach the stabilizer bracket to the side of the chassis with the...	54
Figure3-5 Installing the Stabilizer Brackets	55
Step 3 Tilt the chassis to the other side.	55
Step 4 Attach the second stabilizer bracket to the other side of the chassis with eight M4 screws.	55
Step 5 Lower the chassis so that it rests on both stabilizer brackets.	55
System Ground Connection	56
Required Tools and Equipment	56
Figure3-6 System Ground Location	57
Connecting the System Ground	58
Step 1 Use a wire-stripping tool to remove approximately 0.75 inch (19 mm) of the covering from t...	58
Step 2 Insert the stripped end of the grounding wire into the open end of the grounding lug.	58
Step 3 Use a crimping tool to secure the grounding wire in place in the grounding lug.	58
Step 4 Locate and remove the adhesive label from the system grounding pad on the Cisco7609 chassis.	58
Step 5 Place the grounding wire lug against the grounding pad, making sure there is good metal-to...	58
Step 6 Secure the grounding lug to the chassis with two M4 screws. Ensure that the grounding lug ...	58
Step 7 Prepare the other end of the grounding wire and connect it to an appropriate grounding poi...	58
Installing the Power Supplies in the Cisco 7609 Chassis	58
Attaching the Interface Cables	59
Connecting the Supervisor Engine Console Port	59
Figure3-7 Supervisor Engine Console Port Connector	60
Step 1 Place the console port mode switch in the in position (factory default).	60
Step 2 Connect to the port using the RJ-45-to-RJ-45 cable and RJ-45-to-DB-25 DTE adapter or RJ-45...	60
Step 3 Position the cable in the cable guide (if installed). Make sure that there are no sharp be...	60
Step 4 Check the terminal documentation to determine the baud rate. The baud rate of the terminal...	60
Step 1 Place the console port mode switch in the out position.	61
Step 2 Connect to the port using the Supervisor Engine III cable and the appropriate adapter for ...	61
Step 3 Position the cable in the cable guide (if installed). Make sure there are no sharp bends i...	61
Step 4 Check the terminal documentation to determine the baud rate. The baud rate of the terminal...	61
Step 1 Place the console port mode switch in the in position.	61
Step 2 Connect to the port using the RJ-45-to-RJ-45 rollover cable and the RJ-45-to-DB-25 DCE ada...	61
Step 3 Position the cable in the cable guide (if installed). Make sure there are no sharp bends i...	61
Connecting the Supervisor Engine Uplink Ports	62
Step 1 Remove the plugs from the Gigabit Interface Converter (GBIC) optical bores; store them for...	62
Step 2 Remove the plugs from the SC-type connector on the fiber-optic cable. Insert the connector...	62
Figure3-8 Connecting the Supervisor Engine Uplink Ports	62
Connecting to the Interface Ports	63
Figure3-9 SC-Type Fiber-Optic Connector	63
Figure3-10 LC Fiber-Optic Connector	64
Figure3-11 MT-RJ Fiber-Optic Connector	64
Figure3-12 RJ-45 Connectors	64
Verifying Cisco 7609 Chassis Installation	65
Step 1 Verify that the ejector levers of each module are fully closed (parallel to the faceplate)...	65
Step 2 Check the captive installation screws of each module, the power supply, and the fan assemb...	65
Step 3 Verify that all empty module slots have blank faceplates (WS-X6K-SLOT-CVR) installed and t...	65
Step 4 Turn on the power supply switches to power up the system.	65
4	67
Troubleshooting	67
Getting Started	68
Problem Solving to the System Component Level	68
Identifying Startup Problems	69
Step 1 Turn on the power supplies. You should immediately hear the system fan assembly begin to o...	69
Step 2 Check that the LEDs on the supervisor engine light as follows:	70
Step 3 Verify that the STATUS LEDs on the supervisor engine and on each switching module are gree...	70
Step 4 If the boot information and system banner are not displayed, refer to the Cisco7600Serie...	70
Troubleshooting the Power Supply	71
Step 1 Verify that the INPUT OK LED on the power supply is green.	71
Step 2 If you have a second (redundant) power supply, repeat Step 1 for this power supply.	71
Troubleshooting the Fan Assembly	72
Step 1 Verify that the FAN LED on the fan assembly is green.	72
Step 2 Verify that the FAN LED is red.	72
Troubleshooting Modules	72
Step 1 Verify that all status LEDs are on.	72
Step 2 If any status LEDs on the supervisor engine or any modules are red or off, the module migh...	72
Contacting Customer Service	73
5	75
Removal and Replacement Procedures	75
Removing and Replacing the Power Supply	76
Required Tools	76
Removing an AC-Input Power Supply	76
Step 1 Turn the power switch to the Off (0) position on the power supply you are removing. (SeeF...	76
Step 2 Disconnect the power cord from the power source.	76
Figure5-1 AC-InputPower Supply Front Panel	77
Step 3 Loosen the screw on the cable retention device and disconnect the power cord from the powe...	77
Step 4 Loosen the captive installation screw. (See Figure5-1.)	77
Step 5 Grasp the power supply handle with one hand and slide the power supply part of the way out...	77
Figure5-2 Handling an AC-Input Power Supply	78
Step 6 If the power supply bay is to remain empty, install a blank power supply filler plate (Cis...	78
Installing an AC-Input Power Supply	79
Step 1 Ensure that the system (earth) ground connection has been made. For ground connection inst...	79
Step 2 If necessary, remove the blank power supply filler plate (Cisco partnumber 700-03104-01) ...	79
Step 3 Verify that the power switch is in the Off (0) position on the power supply you are instal...	79
Step 4 Grasp the power supply handle with one hand. Place your other hand underneath the power su...	79
Step 5 Tighten the power supply captive installation screw. (SeeFigure5-1.)	79
Step 6 Plug the power cord into the power supply and tighten the screw on the cable retention dev...	79
Step 7 Connect the other end of the power cord to an AC-input power source.	79
Step 8 Turn the power switch to the On (\|) position on the power supply. Switching the power swit...	80
Step 9 Verify power supply operation by checking that the power supply front panel LEDs are in th...	80
Removing a DC-Input Power Supply	80
Step 1 Verify that power is off to the DC circuit on the power supply you are removing.	80
Step 2 Turn the power switch to the Off (0) position on the power supply you are removing. (See F...	80
Step 3 Remove the two screws securing the terminal block cover, and slide the cover off the termi...	80
Figure5-3 DC-InputPower Supply Front Panels	81
Step 4 Disconnect the DC-input wires from the terminal block (see Figure5-4) in the following or...	81
Figure5-4 DC-Input Wire Connections on the Terminal Block	82
Step 5 Loosen the captive installation screw on the power supply. (See Figure5-4.)	82
Step 6 Grasp the power supply handle with one hand and slide the power supply halfway out of the ...	82
Figure5-5 Handling a DC-Input Power Supply	83
Step 7 If the power supply bay is to remain empty, install a blank power supply filler plate (Cis...	83
Installing a DC-Input Power Supply	84
Step 1 Ensure that the system (earth) ground connection has been made. For ground connection inst...	84
Step 2 Verify that power is off to the DC circuit on the power supply you are installing.	84
Step 3 Verify that the power switch is in the Off (0) position on the power supply you are instal...	84
Step 4 Grasp the power supply handle with one hand and place your other hand underneath the power...	84
Step 5 Tighten the power supply captive installation screw. (SeeFigure5-3.)	84
Step 6 Remove the two screws securing the terminal block cover and slide the cover off of the ter...	84
Step 7 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.300 inc...	84
Step 8 Connect the DC-input wires to the terminal block (see Figure5-6) in the following order:	85
Figure5-6 DC-InputPower Supply Connectors	85
Step 9 After ensuring that all wire connections are secure, reinstall the terminal block cover.	86
Step 10 Remove the tape from the circuit breaker switch handle and restore power by moving the ci...	86
Step 11 Turn the power switch to the On (\|) position on the power supply. Turning the power switc...	86
Step 12 Verify power supply operation by checking that the power supply front panel LEDs are in t...	86
Removing and Replacing the Fan Assembly	86
Removing the Fan Assembly	87
Step 1 Locate the fan assembly located above the card cage. (See Figure5-7.)	87
Figure5-7 Fan Assembly	87
Step 2 Loosen the two captive installation screws by turning them counterclockwise.	88
Step 3 Grasp the fan assembly with both hands and pull it outward; rock it gently if necessary to...	88
Step 4 Pull the fan assembly clear of the chassis and place it in a safe place.	88
Installing the Fan Assembly	88
Step 1 Hold the fan assembly with the fans facing down and the FAN STATUS LED on the left. (See F...	88
Step 2 Place the fan assembly into the front chassis cavity so it rests on the chassis, and then ...	88
Step 3 Push the fan assembly into the chassis until the power connector seats in the backplane an...	88
Step 4 Tighten the captive installation screws.	88
Checking the Installation	89
Step 1 Listen for the fans; you should immediately hear them operating. If you do not hear them, ...	89
Step 2 Verify that the FAN STATUS LED is green. If the LED is red, one or more fans are faulty.	89
Step 3 If after several attempts the fans do not operate or you experience trouble with the insta...	89
A	91
Technical Specifications	91
Cisco 7609 Internet Router	92
TableA-1 Cisco 7609 Internet Router Specifications	92
Cisco7609Internet Router Power Supplies	93
TableA-2 Cisco7609Internet Router Power Supply Specifications	93
Regulatory Standards Compliance	94
B	95
Connector and Cable Specifications	95
Connector Specifications	95
RJ-45	97
FigureB-1 RJ-45 Interface Cable Connector	97
MT-RJ	97
FigureB-2 MT-RJ Connector	97
Step 1 Use a lint-free tissue soaked in 99 percent pure isopropyl alcohol to gently wipe the face...	98
Step 2 Carefully wipe the faceplate with a dry lint-free tissue.	98
Step 3 Remove any residual dust from the faceplate with compressed air before installing the cable.	98
LC	99
FigureB-3 LC Fiber-Optic Connector	99
SC-Type	99
FigureB-4 SC-Type Fiber-Optic Connector	99
Gigabit Interface Converters	100
FigureB-5 GBIC Physical Styles	100
TableB-1 GBIC Optical Model List	100
WS-G5484	100
WS-G5486	101
WS-G5487	101
Cable Specifications	102
Console Port Mode Switch	102
Identifying a Rollover Cable	103
FigureB-6 Identifying a Rollover Cable	103
Console Port Mode 1 Signaling and Pinouts	103
DB-9 Adapter (for Connecting to a PC)	104
TableB-2 Port Mode 1 Signaling and Pinouts (DB-9 Adapter)	104
DB-25 Adapter (for Connecting to a Terminal)	104
TableB-3 Port Mode 1 Signaling and Pinouts (DB-25 Adapter)	105
Modem Adapter	105
TableB-4 Port Mode 1 Signaling and Pinouts (Modem Adapter)	105
Console Port Mode 2 Signaling and Pinouts	106
TableB-5 Port Mode 2 Signaling and Pinouts (Port Mode Switch Out)	106
Mode-Conditioning Patch Cord	107
Patch Cord Configuration Example	107
FigureB-7 Patch Cord Configuration	107
Patch Cord Installation	108
FigureB-8 Patch Cord Installation	108
Differential Mode Delay	108
FigureB-9 LED Transmission Compared to Laser Transmission	109
C	111
Repacking theCisco7609 Internet Router	111
Step 1 Set the chassis in the bottom pallet. (SeeFigureC-1.)	111
Step 2 Place the packing bag over the chassis.	111
Step 3 Place the front-packing material and power supply packing material around the chassis.	111
Step 4 Place the power supplies in the spaces provided in the power supply packing material. (See...	111
Step 5 Place the top-packing material over the top of the chassis and power supplies.	111
Step 6 Place the rack-mount kit and the accessories box on the top-packing material.	111
Step 7 Place the outside carton over the entire package.	112
Step 8 Fold the outside carton down over the top and seal with packing tape.	112
Step 9 Wrap three packing straps tightly around the top and bottom of the package to hold the out...	112
FigureC-1 PackingMaterial	112
FigureC-2 Final Package	113
index	115
Numerics	115
A	115
B	115
C	115
D	116
E	116
F	116
G	117
H	117
I	117
L	117
M	117
O	118
P	118
R	118
S	119
T	119
V	119