Cisco Carrier Routing System Cisco CRS-1, CRS Installation Manual

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Cisco CRS Carrier Routing System 4-Slot

Line Card Chassis

Installation Guide

July 2011

Americas Headquarters

Cisco Systems, Inc. 170 West Tasman Drive San Jose, CA 95134-1706 USA http://www.cisco.com Tel: 408 526-4000

800 553-NETS (6387)

Fax: 408 527-0883

Text Part Number: OL-10971-10

Page 2

THE SPECIFICATIONS AND INFORMATION REGARDING THE PRODUCTS IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE. ALL STATEMENTS, INFORMATION, AND RECOMMENDATIONS IN THIS MANUAL ARE BELIEVED TO BE ACCURATE BUT ARE PRESENTED WITHOUT WARRANTY OF ANY KIND, EXPRESS OR IMPLIED. USERS MUST TAKE FULL RESPONSIBILITY FOR THEIR APPLICATION OF ANY PRODUCTS.

THE SOFTWARE LICENSE AND LIMITED WARRANTY FOR THE ACCOMPANYING PRODUCT ARE SET FORTH IN THE INFORMATION PACKET THAT SHIPPED WITH THE PRODUCT AND ARE INCORPORATED HEREIN BY THIS REFERENCE. IF YOU ARE UNABLE TO LOCATE THE SOFTWARE LICENSE OR LIMITED WARRANTY, CONTACT YOUR CISCO REPRESENTATIVE FOR A COPY.

The following information is for FCC compliance of Class A devices: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio-frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case users will be required to correct the interference at their own expense.

The following information is for FCC compliance of Class B devices: The equipment described in this manual generates and may radiate radio-frequency energy. If it is not installed in accordance with Cisco’s installation instructions, it may cause interference with radio and television reception. This equipment has been tested and found to comply with the limits for a Class B digital device in accordance with the specifications in part 15 of the FCC rules. These specifications are designed to provide reasonable protection against such interference in a residential installation. However, there is no guarantee that interference will not occur in a particular installation.

Modifying the equipment without Cisco’s written authorization may result in the equipment no longer complying with FCC requirements for Class A or Class B digital devices. In that event, your right to use the equipment may be limited by FCC regulations, and you may be required to correct any interference to radio or television communications at your own expense.

You can determine whether your equipment is causing interference by turning it off. If the interference stops, it was probably caused by the Cisco equipment or one of its peripheral devices. If the equipment causes interference to radio or television reception, try to correct the interference by using one or more of the following measures:

• Turn the television or radio antenna until the interference stops.

• Move the equipment to one side or the other of the television or radio.

• Move the equipment farther away from the television or radio.

• Plug the equipment into an outlet that is on a different circuit from the television or radio. (That is, make certain the equipment and the television or radio are on circuits controlled by different circuit breakers or fuses.)

Modifications to this product not authorized by Cisco Systems, Inc. could void the FCC approval and negate your authority to operate the product.

The Cisco implementation of TCP header compression is an adaptation of a program developed by the University of California, Berkeley (UCB) as part of UCB’s public domain version of the UNIX operating system. All rights reserved. Copyright © 1981, Regents of the University of California.

NOTWITHSTANDING ANY OTHER WARRANTY HEREIN, ALL DOCUMENT FILES AND SOFTWARE OF THESE SUPPLIERS ARE PROVIDED “AS IS” WITH ALL FAULTS. CISCO AND THE ABOVE-NAMED SUPPLIERS DISCLAIM ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THOSE OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT OR ARISING FROM A COURSE OF DEALING, USAGE, OR TRADE PRACTICE.

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Cisco CRS Carrier Routing System 4-Slot Line Card Chassis Installation Guide

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CONTENTS

Preface vii

Objective vii

Audience vii

Document Organization vii

Document Conventions viii

Related Documentation

For complete planning, installation, and configuration information, refer to the following documents:

• Cisco CRS Carrier Routing System 4-Slot Line Card Chassis System Description

• Cisco CRS Carrier Routing System 4-Slot Line Card Chassis Site Planning Guide

• Cisco CRS Carrier Routing System 4-Slot Line Card Chassis Unpacking, Moving, and Securing

Guide

• Cisco CRS Carrier Routing System Ethernet Physical Layer Interface Module (PLIM) Installation

Note

• Cisco CRS Carrier Routing System Packet-over-SONET Physical Layer Interface Module (PLIM)

Installation Note

• Cisco CRS Fiber-Optic Cleaning Kit Quick Start Guide

• Cisco CRS Carrier Routing System Hardware Documentation Guide

• Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information

For a complete listing of software documentation available, refer to About Cisco IOS XR Software Documentation, available online at

Statement 1074

http://www.cisco.com/univercd/cc/td/doc/product/core/crs/xrabout.htm.

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Changes to This Document

Table 1-1 lists the technical changes made to this document since it was first printed.

Table 1-1 Changes to This Document

Revision Date Change Summary

OL-10971-10 July 2011 Added information about new CRS-LSP Label Switch

OL-10971-09 April 2011 Added information about new CRS-4-PRP-6G and

OL-10971-08 October 2010 Added information about the new MSC-140G and FP-140

OL-10971-07 September 2009 Added additional information about plug styles for different

May 2008 Added new procedures on installing and removing a pillow

OL-10971-06 March 2008 Minor editorial changes.

OL-10971-05 August 2007 Technical updates were made to Chapter 2, “Installing and

OL-10971-04 June 2007 Added “Recommended Chassis Installation Task Sequence”

OL-10971-03 March 2007 Added “DC Power Systems on the Cisco CRS 4-Slot

OL-10971-02 November 2006 Added Chapter 5, “Installing and Removing the Doors and

OL-10971-01 November 2006 Initial release of the document

Preface

Processor (LSP) card to the following sections:

• Chapter 1, “Overview”

• Chapter 4, “Installing and Removing SFCs, RPs, MSCs,

FPs, LSPs, PLIMs, and Associated Components”

CRS-4-PRP-12G Performance Route Processor (PRP) cards. Technical updates and minor editorial changes were also made.

line cards, and QQ123-140G switch fabric cards. Minor editorial changes were also made.

countries on the Cisco CRS Carrier Routing System 4-Slot Line Card chassis. See Chapter 2, “AC Power Supply Cord

Illustrations and Plug Types”

block to Chapter 4, “Installing and Removing SFCs, RPs,

MSCs, FPs, LSPs, PLIMs, and Associated Components.”

Removing Power Components.”

in Chapter 1, “Overview,” and reorganized and revised

Chapter 4, “Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components.” Also

added “Removing a DC Power Shelf” in Chapter 2,

“Installing and Removing Power Components.”

Router”, “Installing a DC Power Shelf”, in Chapter 2, “Installing and Removing Power Components.” Also

updated Appendix A, “Cisco CRS 4-Slot Line Card Chassis

System Specifications,” with DC power specifications and

other updates.

Grille.”

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Preface

Obtaining Documentation and Submitting a Service Request

For information on obtaining documentation, submitting a service request, and gathering additional information, see the monthly What’s New in Cisco Product Documentation, which also lists all new and revised Cisco technical documentation, at:

http://www.cisco.com/en/US/docs/general/whatsnew/whatsnew.html

Subscribe to the What’s New in Cisco Product Documentation as a Really Simple Syndication (RSS) feed and set content to be delivered directly to your desktop using a reader application. The RSS feeds are a free service and Cisco currently supports RSS version 2.0.

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Preface

Cisco CRS Carrier Routing System 4-Slot Line Card Chassis Installation Guide

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CHAP T ER

Overview

This chapter introduces the Cisco CRS Carrier Routing System 4-Slot Line Card Chassis at the highest level. It contains illustrations of the front and back of the chassis, complete with callouts to each hardware component. For details on each subsystem discussed in this chapter, see Cisco CRS Carrier Routing System 4-Slot Line Card Chassis System Description. This chapter also provides the recommended task sequence for installing the major components in the chassis.

This chapter presents the following topics:

• Chassis Overview, page 1-1

• Chassis Components, page 1-2

• Chassis Slot Numbers, page 1-5

• Chassis Cable Management, page 1-7

• Chassis Cooling System, page 1-7

• Chassis Power System, page 1-8

• Safety Guidelines, page 1-8

• Preventing Electrostatic Discharge, page 1-9

• Recommended Chassis Installation Task Sequence, page 1-10

• CRS Hardware Compatibility, page 1-10

Chassis Overview

The Cisco CRS 4-slot routing system can be installed in locations where the 16-slot or 8-slot systems may not fit (for example, colocation facilities, data centers, and many Tier II and Tier III locations). The routing system consists of a single rack-mounted chassis that contains the following system components:

• Switch fabric cards (SFCs) (up to four)

• Route processor (RP) cards (up to two) or performance route processor (PRP) cards (up to two)

• Up to four modular services cards (MSCs), forwarding processor (FP) cards, or label switch

processor (LSP) cards (also called line cards)

• Physical layer interface modules, or PLIMs, (up to four, one for each MSC or FP)

• A chassis midplane that connects line cards to their associated PLIMs and to the SFCs

The Cisco CRS 4-slot line card chassis has its own power and cooling subsystems. The power shelf (AC or DC as ordered) is pre-installed in the chassis when you receive the routing system.

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Chassis Components

STATUS

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Chassis Components

This section lists the main components of a Cisco CRS 4-slot line card chassis. It primarily identifies the components that are considered field-replaceable units (FRUs), but where additional detail is useful this section identifies subassemblies that are not field replaceable.

Figure 1-1 and Figure 1-2 show the Cisco CRS 4-slot line card chassis from both the front (PLIM) and

rear (SFC) sides.

Figure 1-1 Front (PLIM) View of Cisco CRS 4-Slot Line Card Chassis

Chapter 1 Overview

1 PLIM slots 4 Air intake

2 RP slots 5 Power supplies (behind air filter)

3 MSC slots

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Chapter 1 Overview

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Chassis Components

Figure 1-2 Rear (SFC) View of the Cisco CRS 4-Slot Line Card Chassis

1 Fan tray 3 Switch fabric card slots

2 AC power plug connectors

The Cisco CRS 4-slot line card chassis contains the following components:

• As many as four MSCs, FPs, or LSPs and four PLIMs. The line card and PLIM are an associated

pair of cards that mate through the chassis midplane. The line card provides the forwarding engine for Layer 3 routing of user data, and the PLIM provides the physical interface and connectors for the user data.

Each line card can be associated with several different PLIMs that provide different interface speeds and technologies. For a full list of available PLIMs, please contact your Cisco sales representative.

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Chassis Components

Chapter 1 Overview

• A chassis midplane that connects line cards to their associated PLIMs. The midplane design allows

a line card to be removed from the chassis without having to disconnect the cables that are attached to the associated PLIM. The midplane distributes power, connects the line cards to the switch fabric cards, and provides control plane interconnections. The midplane is not field replaceable by the customer.

• One or two route processor cards (RPs). The RPs function as the Cisco CRS 4-slot line card chassis

system controller and provide route processing.

Only one RP is required for system operation. For redundant operation, you can order a second RP as an option (CRS-4-RP/R). When two RPs are used, only one RP is active at a time. The second RP acts as a “standby” RP, serving as a backup if the active RP fails.

The RP also monitors system alarms and controls the system fans. LEDS on the front panel indicate active alarm conditions.

A Performance Route Processor (PRP) is also available for the Cisco CRS 8-slot line card chassis. Two PRPs perform the same functions as RPs, but provide enhanced performance for both route processing and system controller functionality.

Note A chassis may not be populated with a mix of RP and PRP cards. Both route processor cards

should be of the same type (RP or PRP).

• Fan tray. The fans pull cool air through the chassis. A removable air filter is located below the PLIM

card cage at the front of the chassis. The fan tray has four fans that provide n+1 redundancy.

• Four switch fabric cards (SFCs). These cards provide the three-stage Benes switch fabric for the

routing system. The switch fabric performs the cross-connect function of the routing system, connecting every line card (and its associated PLIM) with every other line card (and its associated PLIM) in the system.

The switch fabric receives user data from one line card and PLIM pair and performs the switching necessary to route the data to the appropriate egress line card and PLIM pair. The switch fabric is divided into eight logical planes (four physical planes) that are used to evenly distribute the traffic across the switch fabric. Each switch fabric card implements two planes of the switch fabric.

• A power system that provides redundant power to the chassis. The power system consists of an AC

power shelf, which contains four AC rectifier modules, or a DC power shelf, which encloses four DC power supplies. The power shelf (AC or DC as ordered) is pre-installed in the chassis when you receive the routing system.

The PLIM side of the chassis is considered the front of the chassis, where user data cables attach to the PLIMs and cool air enters the chassis. The switch fabric card side, which is where warm air is exhausted, is considered to be the rear of the chassis.

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Chapter 1 Overview

Chassis Slot Numbers

This section identifies the location and slot numbers for major cards and modules (primarily the field-replaceable units) that plug into the Cisco CRS 4-slot line card chassis.

Figure 1-3 shows the slot numbering on the front (PLIM) side of the Cisco CRS 4-slot line card chassis.

Figure 1-3 Cisco CRS 4-Slot Chassis Slot Numbering—Front (PLIM) Side

Chassis Slot Numbers

1 MSC slot 0 7 PLIM slot 2

2 MSC slot 1 8 PLIM slot 3

3 MSC slot 2 9 RP slot (RP0)

4 MSC slot 3 10 RP slot (RP1)

5 PLIM slot 0 11 Air intake

6 PLIM slot 1 12 Power shelf (AC or DC)

As shown in Figure 1-3, the Cisco CRS 4-slot line card chassis numbers on the PLIM side of the chassis include the card cage with the following assignments:

• Four MSC slots (left to right, 0, 1, 2, 3) for MSCs and FPs

• Four PLIM slots (left to right, 0, 1, 2, 3)

• Two route processor card slots, RP0 and RP1

Figure 1-4 shows the slot numbers on the rear (Switch Fabric Card) side of the Cisco CRS 4-slot line

card chassis.

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Chassis Slot Numbers

158317

Chapter 1 Overview

Figure 1-4 Cisco CRS 4-Slot Chassis Slot Numbering—Rear (SFC) Side

1 Fan tray (FT0) 4 Switch fabric card slot (SM1)

2 Switch fabric card slot (SM3) 5 Switch fabric card slot (SM0)

3 Switch fabric card slot (SM2)

As shown in Figure 1-4, the slot numbers on the SFC side of the chassis include:

• Fan tray

• Card cage, including four reduced-height SFC slots (SM0 to SM3, right to left)

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Chapter 1 Overview

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Chassis Cable Management

The Cisco CRS 4-slot line card chassis has cable management features for the front (PLIM) side of the chassis, just above the card cage. The horizontal cable management trays have a special telescoping feature that allows them to be extended when the chassis is upgraded with higher-density cards. This extension also helps when installing the cables in the chassis.

Figure 1-5 shows the cable management bracket for the chassis.

Figure 1-5 Cable Management Bracket

Chassis Cable Management

Chassis Cooling System

The Cisco CRS 4-slot line card chassis has a single fan tray containing four fans that cool the chassis card cage. Cool air flows in at the bottom front of the chassis and flows through the chassis card cage and through the fans in the fan tray before being expelled through the top rear of the chassis (see

Figure 1-6).

In addition, each power module at the bottom of the chassis has self-contained fans that pull in cool air from the front of the chassis and exhaust warm air out the rear. Air also flows under the midplane, through the SFCs, and then the fans to be expelled. There are these two parallel paths for air flow.

A replaceable air filter is located inside the chassis below the PLIM card cage at an angle. In addition, there is a removable air filter on the front of the power tray air intake grille on the front (PLIM) side of the chassis.

How often the air filters should be replaced depends on the facility environment. In a dirty environment, or when you start getting frequent temperature alarms, you should always check the intake grille for debris, and then check the air filters to see if they need to be replaced.

Note We recommend that you check the air filters once a month. Replace a filter when you notice a significant

amount of dust.

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Chassis Power System

Air exhaust

Front Rear

210072

Chassis

air inlet

Power supplies

and power shelf

Power shelf

air inlet

Air exhaust

Air filter

Fan tray

Midplane

Chapter 1 Overview

Figure 1-6 Airflow Through the Cisco CRS 4-Slot Line Card Chassis

The Cisco CRS 4-slot line card chassis airflow volumes are as follows:

• Chassis airflow: Up to 880 cubic feet (24,919 liters) per minute

• Power system airflow: Up to 60 cubic feet (1,699 liters) per minute

Chassis Power System

The Cisco CRS Carrier Routing System 4-Slot Line Card Chassis can be configured with either an AC-input power subsystem or a DC-input power subsystem. The AC power trays are configured for single-phase AC power module wiring. The power modules and power trays have separate Cisco part numbers. For additional information, see the appropriate sections in Chapter 2, “Installing and

Removing Power Components.”

Safety Guidelines

Before you perform any procedure in this document, review the safety guidelines in this section to avoid injuring yourself or damaging the equipment.

The following guidelines are for your safety and to protect equipment. The guidelines do not include all hazards. Be alert.

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Chapter 1 Overview

Note Review the safety warnings listed in Regulatory Compliance and Safety Information that are applicable

Preventing Electrostatic Discharge

to your router before installing, configuring, or troubleshooting any installed card.

• Keep the work area clear and dust-free during and after installation. Do not allow dirt or debris to

enter into any laser-based components.

• Do not wear loose clothing, jewelry, or other items that could get caught in the router while working

with line cards, PLIMs, or their associated components.

• Cisco equipment operates safely when used in accordance with its specifications and product-usage

instructions.

Warning

This unit is intended for installation in restricted access areas. A restricted access area is where access can only be gained by service personnel through the use of a special tool, lock and key, or other means of security, and is controlled by the authority responsible for the location.

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

Statement 49

High leakage current—earth connection essential before connecting to system power supply.

The chassis should be mounted on a rack that is permanently affixed to the building.

Statement 1049

Statement 37

Statement 342

Preventing Electrostatic Discharge

Electrostatic discharge (ESD) damage, which can occur when electronic cards or components are improperly handled, results in complete or intermittent failures. We recommend to use an ESD-preventive strap whenever you handle network equipment or one of its components.

Following are guidelines for preventing ESD damage:

• Always use an ESD-preventive wrist or ankle strap and ensure that it makes good skin contact.

Connect the equipment end of the connection cord to an ESD connection socket on the router or to a bare metal surface on the chassis.

• Handle a card by its ejector levers, when applicable, or the card’s metal carrier only; avoid touching

the board or connector pins.

• Place a removed card board-side-up on an antistatic surface or in a static-shielding bag. If you plan

to return the component to the factory, immediately place it in a static-shielding bag.

• Avoid contact between the card and clothing. The wrist strap protects the board only from ESD

voltage on the body; ESD voltage on clothing can still cause damage.

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Recommended Chassis Installation Task Sequence

This section provides the recommended task sequence for installing a new Cisco CRS 4-slot line card chassis.

Step 1 If your system was shipped with AC power, remove the four AC power cords from the box, and do the

following:

a. Insert all four power cords into the AC power source.

b. Insert the power cords into the AC power plugs at the base of the rear of the chassis.

Step 2 Turn the power enable switches (for your AC or DC power system) to the ON position. For details, see

the “AC Power Supply Cord Illustrations and Plug Types” section on page 2-4.

All power should come up properly. The LEDs above the enable switches should be lit green. The fans in the front of the chassis should start operating.

Step 3 Install the switch fabric cards (SFCs). For the procedure, see the “How to Install or Remove a Switch

Fabric Card” section on page 4-18.

Step 4 Install the route processors (RPs). For the procedure, see the “How to Install or Remove a Route

Processor Card” section on page 4-24.

Step 5 Install the MSCs, FPs, and LSP line cards. For the procedure, see the “How to Install or Remove an MSC,

FP, or LSP” section on page 4-32.

Step 6 Install the physical layer interface modules (PLIMs). For the procedure, see the “How to Install or

Remove a Physical Layer Interface Module” section on page 4-42.

Chapter 1 Overview

Step 7 If the system was shipped with the grille and doors, install the inlet grille. See the “Installing the Inlet

Grille” section on page 5-1.

Step 8 Install the doors. See the “Installing the Doors” section on page 5-4.

CRS Hardware Compatibility

Table 1-1 lists the compatibility of 40G CRS and 140G CRS fabric, forwarding, and line card

components for the CRS 4-slot system.

Note A router with a mix of 40G and 140G fabric cards is not a supported mode of operation. Such a mode is

temporarily allowed only during the upgrade process.

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Chapter 1 Overview

CRS Hardware Compatibility

Table 1-1 CRS Compatibility Matrix

Switch Fabric RP/DRP MSC/FP/LSP PLIMS Note

CRS-4-FC/S (40G)

CRS-4-FC140/S (140G)

RP-A (CRS-4-RP), DRP-B (CRS-DRP-B)

CRS-MSC-B 1OC768-DPSK/C

1OC768-ITU/C 1OC768-POS-SR 4-10GE-ITU/C 8-10GBE CRS1-SIP-800 |4-10GE 42-1GE 20-1GE-FLEX 2-10GE-WL-FLEX 4-10GBE-WL-XFP 8-10GBE-WL-XFP

CRS-FP40 4-10GE

42-1GE 20-1GE-FLEX 2-10GE-WL-FLEX

CRS-MSC-B 1OC768-DPSK/C

1OC768-ITU/C 1OC768-POS-SR 4-10GE-ITU/C 8-10GBE CRS1-SIP-800 4-10GE 42-1GE 20-1GE-FLEX 2-10GE-WL-FLEX 4-10GBE-WL-XFP 8-10GBE-WL-XFP

RP-A (CRS-4-RP), DRP-B (CRS-DRP-B)

PRP (CRS-4-PRP-6G, CRS-4-PRP-12G)

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CRS-FP40 4-10GE

42-1GE 20-1GE-FLEX 2-10GE-WL-FLEX

CRS-MSC-140G 14X10GBE-WL-XFP

20X10GBE-WL-XFP 1x100GBE

CRS-FP140 14X10GBE-WL-XFP

20X10GBE-WL-XFP 1x100GBE

CRS-LSP 14X10GBE-WL-XFP

20X10GBE-WL-XFP 1x100GBE

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CRS Hardware Compatibility

Chapter 1 Overview

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CHAP T ER

Installing and Removing Power Components

This chapter provides instructions on how to install and remove the Cisco CRS Carrier Routing System 4-Slot Line Card Chassis power components.

This chapter presents the following topics:

• About Installing and Removing the Power Components, page 2-1

• DC Power Systems on the Cisco CRS 4-Slot Router, page 2-7

• Installing a DC Power Shelf, page 2-14

• Removing a DC Power Shelf, page 2-20

• Installing an AC Power Shelf, page 2-24

• Removing an AC Power Shelf, page 2-26

• Installing a Power Supply, page 2-28

• Removing a Power Supply, page 2-30

About Installing and Removing the Power Components

This section contains some general information about the power components.

• Basic Chassis Power Recommendations, page 2-1

• Supplemental Unit Bonding and Grounding Guidelines, page 2-2

• AC Power Supply Cord Illustrations and Plug Types, page 2-4

• Powering the Chassis Up or Down, page 2-6

Basic Chassis Power Recommendations

The Cisco CRS Carrier Routing System 4-Slot Line Card Chassis can be configured with either an AC-input power subsystem or a DC-input power subsystem. Site power requirements differ depending on the source voltage used. Follow these precautions and recommendations when planning power connections to the router:

• Check the power at your site before installation and periodically after installation to ensure that you

are receiving clean power. Install a power conditioner, if necessary.

• Install proper grounding to avoid damage from lightning and power surges.

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About Installing and Removing the Power Components

Caution A Cisco router must be operated with all its power modules installed at all times for electromagnetic

compatibility (EMC).

The Cisco CRS 4-slot line card chassis requires that at least the power shelves and their components be installed to operate properly. Two types of power shelves exist: an AC shelf and a DC shelf. An AC power shelf houses AC rectifiers, while a DC power shelf houses the DC power input module (PIM) and DC power input shelf (which encloses the DC power supplies). We recommend that you use only one type of power shelf in a chassis at a time.

Chapter 2 Installing and Removing Power Components

Warning

This unit might have more than one power supply connection. All connections must be removed to de-energize the unit.

Statement 1028

The Cisco CRS 4-slot line card chassis is shipped fully populated with a power shelf that contains four power supplies for power redundancy. See the appropriate installation section (see “Installing a DC

Power Shelf” section on page 2-14 or “Installing an AC Power Shelf” section on page 2-24) for detailed

installation information.

As viewed from the front (PLIM) side of the chassis, the left two power supplies feed output A, while the right two power supplies feed output B.

For 2N redundancy, the power input on rear (SFC) side of the chassis should be from two different branch sources, with the left two input connections to one branch source and the right two to the other branch source. With this configuration the router remains fully powered in case one branch source fails. In normal operation all power supplies should be installed.

Be sure to install the power shelf before installing the power supplies.

Caution If you install a non-Cisco power supply in the chassis, upon its detection as a non-compliant power

supply, the system will shut down. Using non-Cisco power supplies MAY RESULT IN COMPLETE CHASSIS SHUTDOWN due to insufficient power.

Supplemental Unit Bonding and Grounding Guidelines

Although the router chassis has a safety earth ground connection as part of the power cabling to the power shelf, the chassis includes an option that allows you to connect the central office ground system or interior equipment ground system to the supplemental bonding and grounding receptacles on the router chassis. Two ground studs are located on the rear (SFC) side of the chassis. (see Figure 2-1). This ground point is also called the network equipment building system (NEBS) bonding and grounding stud.

Note These bonding and grounding receptacles satisfy the Telcordia® NEBS requirements for supplemental

bonding and grounding connections. If you are not installing the router in a NEBS environment, you can choose to bypass these guidelines and rely on the safety earth ground connection for the power shelf.

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Chapter 2 Installing and Removing Power Components

158392

Figure 2-1 NEBS Bonding and Grounding Points (Rear of Chassis)

About Installing and Removing the Power Components

1 NEBS bonding and grounding stud

If you plan to connect the Cisco CRS 4-slot line card chassis system to a network equipment building system (NEBS)-compliant supplemental bonding and grounding system at the site, you must have the following:

• A minimum of one ground lug that has two M6 bolt holes with 0.625-inch (15.86-mm) spacing

between them, and a wire receptacle large enough to accept a 6-AWG or larger multistrand copper wire. The lug is similar to the type used for the DC-input power supply leads. This ground lug is not available from Cisco Systems. This type of lug is available from electrical-connector vendors, such as Panduit.

• Two M6 nuts with locking washers (nickel-plated brass is ideal). This hardware is not available

from Cisco Systems; they are available from any commercial hardware vendor.

• A commensurately rated ground wire. The actual wire diameter and length depend on your router

location and site environment. This wire is not available from Cisco Systems; it is available from any commercial cable vendor.

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Cordset rating: 16 A, 250 V

Length: 14 ft 0 in. (4.26 m)

Connector: IEC 60320 C19

Plug: AU20S3

About Installing and Removing the Power Components

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

DC Return).

AC Power Supply Cord Illustrations and Plug Types

This section contains the AC power cord illustrations and a table of power plug types for the Cisco CRS Carrier Routing System 4-Slot Line Card Chassis for Australia (AU), European (EU), Italy (IT), United Kingdom (UK), United States (USA), and Japan.

Table 2-1 AC Power Supply Plug Types

Plug Type Country

AU20S3 Australia—Figure 2-2

CEE 7/7 European—Figure 2-3

CEI 23-50 Italian—Figure 2-4

BS 1363 United Kingdom—Figure 2-5

NEMA L6-20 United States and Japan—Figure 2-6

Figure 2-2 CAB-CRS4AC-AU

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Chapter 2 Installing and Removing Power Components

Cordset rating: 16 A, 250 V

Length: 14 ft 0 in. (4.26 m)

Connector: IEC 60320 C19

Plug: CEE 7/7

Cordset rating: 16 A, 250 V

Length: 14 ft 0 in. (4.26 m)

Connector:

(EN 60320/C19)

Plug: (CEI 23-50)

Cordset rating: 13 A, 250 V

Length: 14 ft 0 in. (4.26 m)

Plug: BS 1363

13A replaceable fuse

Connector: IEC 60320 C19

Figure 2-3 CAB-CRS4AC-EU

Figure 2-4 CAB-CRS4AC-IT

About Installing and Removing the Power Components

Figure 2-5 CAB-CRS4AC-UK

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Cordset rating: 20 A, 250 V

Length: 14 ft 0 in. (4.26 m)

Connector: IEC 60320 C19

Plug: NEMA L6-20

Figure 2-6 CAB-CRS4AC-US and Japan

Powering the Chassis Up or Down

The chassis does not have a single enable switch that powers the entire chassis and all its components up and down. (These switches are called enable switches because they enable the power supplies to produce output voltage and power). Most components on the chassis, such as the power supplies, MSCs, FPs, PLIMs, and fan trays can be removed or installed in the chassis while it is running.

Before you can power the chassis up, you must complete the following tasks:

Chapter 2 Installing and Removing Power Components

Step 1 Install the appropriate power shelf for your system (see the “Installing a DC Power Shelf” section on

page 2-14 or the “Installing an AC Power Shelf” section on page 2-24).

Step 2 Install the power supplies (see the “Installing a Power Supply” section on page 2-28).

Step 3 Install the route processor (RP) card (see the “Installing an RP or PRP Card” section on page 4-26).

Step 4 Install the input power cables to the input power connectors on the rear of the chassis, and the other end

(plug side) to the AC or DC power source.

Step 5 Activate your power source.

Step 6 Turn the two power shelf enable switches on the rear (SFC) side of the power shelf (see Figure 2-7) to

the ON position.

Note The two enable switches on the rear (SFC) side of the AC power shelf (Figure 2-7) put the chassis in

standby mode; in other words, they only power down the -54VDC output from the power supplies.

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STATUS

158455

Figure 2-7 AC Power Enable Switches

DC Power Systems on the Cisco CRS 4-Slot Router

For an illustration of the DC power enable switches, see Figure 2-19.

Note All power cords must be unplugged from wall power to fully remove power from the chassis.

DC Power Systems on the Cisco CRS 4-Slot Router

The Cisco CRS 4-slot line card chassis DC power shelf consists of two major components, as shown in

Figure 2-8:

• DC power input shelf (Cisco product number: CRS-4-DC-INPUT)

Figure 2-8 shows the power supplies installed in the DC power input shelf.

• DC power input module (PIM) (Cisco product number: CRS-4-DC-PIM)

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DC Power Systems on the Cisco CRS 4-Slot Router

Figure 2-8 DC Power Shelf: DC Power Input Shelf and DC Power Input Module (PIM)

Chapter 2 Installing and Removing Power Components

Front orientation

Rear orientation

210772

1 DC power input shelf 2 Power input module (PIM)

When installing the DC power shelf, these two components are mated to create the complete DC power shelf (see the “Installing a DC Power Shelf” section on page 2-14 for details).

The Cisco CRS 4-slot line card chassis DC power system provides 4,000 watts to power the chassis. (To provide power redundancy, up to 8,000 watts are available.) Each DC-powered chassis contains four DC power supplies for 2N redundancy. The power input module (PIM) provides the input power connections. Note that each power connection has two cables: –48 VDC and return. The power input module (PIM), DC power input shelf, and the power supplies are field replaceable.

The Cisco CRS 4-slot line card chassis requires a total of four dedicated pairs of 60-A DC input power connections, one pair for each of the power supplies, to provide redundant DC power to the Cisco CRS 4-slot line card chassis midplane.

For full 2N redundancy, we recommend that you have two independent –48 VDC power sources to provide power to the Cisco CRS 4-slot line card chassis. Connect the two 60-A DC inputs on the left to one wiring block, and the two 60-A DC inputs on the right to the other wiring block.

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DC Power Shelf Guidelines

At sites where the Cisco CRS 4-slot line card chassis is equipped with a DC power input shelf and power supplies, observe the following guidelines:

• All power connection wiring should follow the rules and regulations in the National Electrical Code

(NEC) and any local codes.

• Each DC-input power entry module connection is rated at 60 A maximum. A dedicated,

commensurately rated DC power source is required for each power supply connection.

• Each power supply requires one –48 VDC input, or four inputs for each power shelf (in which each

input consists of a pair of positive and negative wires), and one power-shelf grounding wire.

• For DC power cables, we recommend that you use commensurately rated, high-strand-count copper

wire cable. Each DC power supply requires one –48 VDC input, which means that there are two wires for each power supply, or eight total wires (four pairs) for each power shelf, plus the grounding wire. The length of the wires depends on the router’s location. These wires are not available from Cisco Systems; they are available from any commercial vendor.

• DC power cables must be terminated by cable lugs at the power-shelf end. The lugs should be dual

hole and able to fit over M6 terminal studs at 0.625-in (15.88-mm) centers (for example, Panduit part number LCD2-14A-Q or equivalent) (see Figure 2-9).

DC Power Systems on the Cisco CRS 4-Slot Router

Figure 2-9 DC Power Cable Lug

End View

0.60

Ø 0.27

2 holes

0.25 0.380.63

0.10

Color Coding of the Source DC Power Cable

The color coding of the source DC power cable leads depends on the color coding of the site DC power source. Typically, green or green and yellow indicates that the cable is a ground cable. Because no color code standard exists for the source DC wiring, you must ensure that the power cables are connected to the DC-input power shelf terminal studs in the proper positive (+) polarity and negative (–) polarity.

DC Cable Polarity Labels

Sometimes, the source DC cable leads might have a positive (+) or a negative (–) label. This label is a relatively safe indication of the polarity, but you must verify the polarity by measuring the voltage between the DC cable leads. When making the measurement, the positive (+) lead and the negative (–) lead must always match the (+) and (–) labels on the power shelf.

All measurements in inches

2.40

Crimp area

210840

Caution The DC-input power supplies contain circuitry to prevent damage due to reverse polarity, but you should

correct a reverse-polarity condition immediately.

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DC Power Systems on the Cisco CRS 4-Slot Router

210614

(RTN) (-48V/-60V)

–

B0B1

Side B

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

A0A1

Side A

SIDE A

SIDE B

Table 2-2 DC Input Current and Voltage Information

Nominal input voltage Supports –48 VDC and –60 VDC systems

Input line current 50 A maximum at –48 VDC

Inrush current 60 A peak at –75 VDC

Note When wiring the DC power shelf, be sure to attach the ground wire first. When removing the wiring, be

sure to remove the ground wire last. The ground wire must be attached with a torque value of 30 in-lb. The power cables should also be attached with a torque value of 30 in-lb.

Chapter 2 Installing and Removing Power Components

(range: –40 to –72 VDC)

Note The turn-on voltage of the DC power supplies

is –43.5 +/- 0.5 VDC. When a power supply is powered on, it continues to operate down to an input voltage of –40 VDC.

40 A maximum at –60 VDC

(maximum for 1 ms)

Wiring Block on the PIM

Each wiring block on the power input module (PIM) contains four sets of terminals, two positive and two negative (see Figure 2-10). Each wiring block is covered by a plastic block cover that snaps onto the wiring block and is secured by a screw to a torque value of 50 in.-lb.

You must remove the block cover before you work with the wires.

Figure 2-10 Power Input Module (PIM)

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1 Power supply B1 wiring block 4 Power supply A1 wiring block

2 Power supply B0 wiring block 5 Power supply A0 wiring block

3 Power shelf coupling screw 6 Ground lug nuts

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(RTN) (-48V/-60V)

–

B0B1

SIDE B

Side B

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

A0A1

Side A

SIDE A

A0A1

B0B1

Input-Power-Present LEDs

The DC power Input-Power-Present LEDs provide a visual indication to service personnel that there is voltage present across the input terminal’s connections (see Figure 2-11). The LED provides a warning to the service person that there is power present.

Note Power should be disconnected before servicing the input power connections. Always check for

hazardous voltage with a multimeter device before servicing the router.

Figure 2-11 Input-Power-Present LEDs

DC Power Systems on the Cisco CRS 4-Slot Router

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

Note If an input-power-present LED is not lit, check for: 1) the presence of voltage, and 2) the polarity

of the corresponding wiring block.

DC Power Wire Characteristics

For signal degradation to be averted, a conductor must be large enough to prevent its impedance from creating a voltage drop equal to 2 percent of the reference voltage. Also, the gauge of the earth conductor must be equal to or larger then that of the –48 VDC (or –48 VDC return) conductor. This latter requirement is for safety. Full fault redundancy is achieved by having conductors of equal size for the protective earth ground and the –48 VDC return of the switch.

For site preparation, proper wire size and insulation must be selected. For a planned power distribution, calculation must be done prior to distribution to meet the proper voltage drop and temperature rise.

For wire gauges that prevent unacceptable voltage drops over different lengths of copper wire, see

Table 2-3. For the resistance of 1000 feet of copper wire for each gauge of wire, see Table 2 - 4. These

references are for planning purposes and might be further subject to local laws and practices.

Table 2-3 provides the gauges of wire needed for wire lengths and DC power currents. The units of

measurement are in American wire gauge (AWG).

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DC Power Systems on the Cisco CRS 4-Slot Router

Note Table 2-3 and Table 2-4 are for reference; we recommend using at least 50 A of DC current and 6-gauge

wire.

Table 2-3 Wire Gauge for Current Loads Over Copper Wire Lengths

DC Current (Amps) 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 200 Feet 400 Feet

5 A 18 AWG 14 AWG 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG

10 A 14 AWG 12 AWG 10 AWG 8 AWG 8 AWG 6 AWG 2 AWG

15 A 14 AWG 10 AWG 8 AWG 8 AWG 6 AWG 4 AWG 2 AWG

20 A 12 AWG 8 AWG 8 AWG 6 AWG 4 AWG 2 AWG 0 AWG

25 A 12 AWG 8 AWG 6 AWG 4 AWG 4 AWG 2 AWG 0 AWG

30 A 10 AWG 8 AWG 6 AWG 4 AWG 2 AWG 2 AWG 00 AWG

35 A 10 AWG 6 AWG 4 AWG 2 AWG 2 AWG 1 AWG 000 AWG

40 A 8 AWG 6 AWG 2 AWG 2 AWG 2 AWG 0 AWG 000 AWG

45 A 8 AWG 6 AWG 4 AWG 2 AWG 1 AWG 0 AWG 0000 AWG

50 A 8 AWG 4 AWG 4 AWG 2 AWG 1 AWG 00 AWG N/A

55 A 8 AWG 4 AWG 2 AWG 2 AWG 0 AWG 00 AWG N/A

60 A 8 AWG 4 AWG 2 AWG 2 AWG 0 AWG 00 AWG N/A

65 A 6 AWG 4 AWG 2 AWG 1 AWG 0 AWG 000 AWG N/A

70 A 6 AWG 4 AWG 2 AWG 1 AWG 00 AWG 000 AWG N/A

75 A 6 AWG 4 AWG 2 AWG 1 AWG 00 AWG 000 AWG N/A

100 A 4 AWG 2 AWG 1 AWG 00 AWG 000 AWG N/A N/A

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Table 2-4 provides the correlation between wire gauge and the resistance (in Ohms for each 1000 feet

of wire) for copper wire.

Table 2-4 Resistance for Each Gauge of Copper Wire

Wire Gauge (AWG) Ohms for Each 1000 Feet of Wire

0000 AWG 0.0489

000 AWG 0.0617

00 AWG 0.0778

0 AWG 0.098

1 AWG 0.1237

2 AWG 0.156

3 AWG 0.1967

4 AWG 0.248

5 AWG 0.3128

6 AWG 0.3944

7 AWG 0.4971

8 AWG 0.6268

9 AWG 0.7908

10 AWG 0.9968

11 AWG 1.257

12 AWG 1.5849

13 AWG 1.9987

14 AWG 2.5206

15 AWG 3.1778

16 AWG 4.0075

17 AWG 5.0526

18 AWG 6.3728

19 AWG 8.0351

20 AWG 10.1327

21 AWG 12.7782

22 AWG 16.1059

DC Power Systems on the Cisco CRS 4-Slot Router

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Installing a DC Power Shelf

This section describes how to install a DC power shelf in the Cisco CRS 4-slot line card chassis.

The DC power shelf encloses four power supplies and the power distribution connections and wiring. The DC power input shelf is installed in the front of the chassis; the power input module (PIM) is installed in the rear of the chassis.

We recommend that you have two separate, redundant –48 VDC power battery sources to provide power to the Cisco CRS 4-slot line card chassis. Connect the two input pair 60-A DC inputs on the left to one –48 VDC power source, and the input pair 60-A DC inputs on the right to the other –48 VDC power source.

Sequence of Tasks

The sequence of tasks required to install the DC power shelf is:

1. Remove the rear power access panels.

2. Install the DC power input module (PIM).

3. Install the DC power input shelf.

4. Mate and secure the power input module to the DC power input shelf.

5. Connect the grounding cable and the power input cables.

Chapter 2 Installing and Removing Power Components

6. Install the DC power supplies.

Prerequisites

Power down the Cisco CRS 4-slot line card chassis.

Tip We recommend that you do this procedure with the line card chassis mounted in a rack with sufficient

space for bottom and side access to the screws.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

• Number 1 Phillips screwdriver

• Number 2 Phillips screwdriver

• 5-mm Allen wrench

• 10-mm hex socket wrench

• DC power input shelf (Cisco product number: CRS-4-DC-INPUT)

• DC power input module (PIM) (Cisco product number: CRS-4-DC-PIM)

• DC power supplies (Cisco product number: CRS-4-DC-SUPPLY)

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Note This procedure assumes that the Cisco CRS 4-slot line card chassis is already mounted in a rack with

sufficient room to access the sides and the bottom of the chassis.

Steps

To install the DC power shelf, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 If the AC power shelf is currently installed, remove it from the front of the chassis. (For details, see the

“Removing an AC Power Shelf” section on page 2-26.)

Removing the Rear Power Access Panels

Before you can install the power input module, you must remove the rear power access panels.

Step 3 From the rear of the chassis, use a medium Phillips screwdriver to remove the rear power access panels

(located on the bottom right and bottom left rear of the chassis). Remove the screws shown in

Figure 2-12.

Installing a DC Power Shelf

Tip One screw on each side is located under the chassis (as shown in Figure 2-12). To access this screw

safely, the chassis must be in a rack with adequate space below the chassis.

Figure 2-12 Removing the Rear Power Access Panels

TAT

Step 4

Unscrew the coupling screw from each panel with a medium flat-blade screwdriver. Set aside the access

S U T

TA S

S U T

TA S

SIDE A

panels and their screws.

210619

Note You will need these screws later when you install the power input module (PIM).

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Installing a DC Power Shelf

Installing the DC Power Input Module

Step 5 From the rear of the chassis, insert the DC power input module (PIM) into the open power bay (see

Figure 2-13).

Note The PIM weighs 6.5 lb (2.9 kg).

Figure 2-13 Inserting the DC Power Input Module (PIM)

(RTN) (-48V/-60V)

Chapter 2 Installing and Removing Power Components

STATUS

–

(RTN)

–

(-48V/-60V)

SIDE B

Side B

SIDE A

Side A

(RTN)

–

(-48V/-60V)

A0A1

(RTN)

–

(-48V/-60V)

210622

Step 6 Reinsert the No. 2 Phillips screws taken from the rear power access panels into their respective holes:

one on each side, three in front, and one underneath the chassis.

Installing the DC Power Input Shelf

Caution The DC power input shelf can only be inserted into the chassis when all power is removed from the

chassis.

Step 7 Go to the front of the chassis. To install the DC power input shelf, follow these steps:

a. To prepare the chassis for installing the DC power input shelf, remove the inlet grille from the

bottom of the chassis (for the procedure, see the “Removing the Inlet Grille” section on page 5-3).

b. Holding the DC power input shelf underneath with one hand and steadying it with the other, lift the

DC power input shelf up and slide it part way into the power shelf slot on the front (PLIM) side of the chassis. Be sure to center the DC power input shelf in the slot when you slide it in (see

Figure 2-14).

Caution An empty DC power input shelf weighs about 15.5 lb (7 kg). To prevent injury when lifting

the shelf, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves.

c. Slide the DC power input shelf fully into the chassis. Be sure that the lever handles are aligned with

the lever handle catches on the chassis casing.

d. To lock the power input shelf into position, lift the lever handles up.

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STA

210621

210623

)

(-4

/-6

V )

–

Side B

)

(-4

/-6

)

–

(

)

6 0

)

–

( R

)(-4

/-6

)

–

A0A1

Side A

SIDE A

SIDE B

1 2

Figure 2-14 Inserting the DC Power Input Shelf

Securing the PIM to the DC Power Input Shelf

Step 8 Go to the rear of the chassis. To mate the PIM to the DC power input shelf, push the PIM firmly but

carefully into the power input shelf.

Step 9 To secure the input power module connections to the power input shelf, use a 5-mm Allen wrench to

tighten the power shelf coupling screw into the DC power input shelf (see Figure 2-15).

Installing a DC Power Shelf

Figure 2-15 Power Shelf Coupling Screw

1 Power shelf coupling screw 2 Ground lug nuts

Connecting the Grounding Cable and Power Input Cables

Step 10 On the PIM, use a 10-mm hex socket wrench to connect the grounding cable (see item 2 in Figure 2-15).

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Installing a DC Power Shelf

210613

(RTN

)

(-48V/-60V)

–

B0B1

Side B

(RTN

)

(-48V/-60V)

–

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

Side A

SIDE A

SIDE B

Note When wiring the power shelf, be sure to attach the ground wire first. When removing the wiring,

Step 11 On the PIM, use a 10-mm hex socket wrench to hook up the DC input power cables. Connect the four

60 A DC cables (two cables per input) on the left to one wiring block, and the four 60A DC cables on the right to the other wiring block (see Figure 2-16).

Note The DC input power cables should also be attached with a torque value of 30 in-lb.

Color Coding of the Source DC Power Cable. The color coding of the source DC power cable leads depends on the color coding of the site’s DC power source. Typically, green or green and yellow indicates that the cable is a ground cable. Because no color code standard exists for the source DC wiring, you must ensure that the power cables are connected to the DC-input power shelf terminal studs in the proper positive (+) polarity and negative (–) polarity.

DC Cable Polarity Labels. Sometimes, the source DC cable leads might have a positive (+) or a negative (–) label. This label is a relatively safe indication of the polarity, but you must verify the polarity by measuring the voltage between the DC cable leads. When making the measurement, the positive (+) lead and the negative (–) lead must always match the (+) and (–) labels on the power shelf.

Chapter 2 Installing and Removing Power Components

be sure to remove the ground wire last. The ground wire must be attached with a torque value of 30 in-lb.

Figure 2-16 DC Power Shelf Cable Cabling

Step 12

Reattach both wiring block covers (see Figure 2-16).

a. Snap the cover over the wiring block so that it snaps closed.

b. Use a number 1 Phillips screwdriver to tighten the capture screw.

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210620

Note The wiring block covers can be oriented to route the wire cabling from the top or the bottom of

the covers.

Installing the DC Power Supplies

Step 13 Go to the front of the chassis. Install the four DC power supplies into the power input shelf (see

Figure 2-17). For details, see the “Installing a Power Supply” section on page 2-28.

Note Each DC power supply weighs 4.5 lb (2 kg).

Figure 2-17 Installing DC Power Supplies

Installing a DC Power Shelf

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Step 14

Install the air filter (see Figure 2-18). For the procedure, see the “Installing the Chassis Air Filter”

section on page 3-7.

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Figure 2-18 Chassis Air Filter

Chapter 2 Installing and Removing Power Components

1 Chassis air filter 3 Power tray and power supplies

2 Air intake grille 4 Power tray air filter

Step 15

Install the inlet grille. See the “Installing the Inlet Grille” section on page 5-1.

Removing a DC Power Shelf

This section describes how to remove a DC power shelf from the Cisco CRS 4-slot line card chassis. The DC power shelf is comprised of both the DC power input shelf and the DC power input module (PIM). The DC power shelf encloses four power supplies and the power distribution connections and wiring blocks.

The DC power input shelf is in the front of the chassis; the power input module (PIM) is in the rear of the chassis.

Sequence of Tasks

The sequence of tasks required to remove the DC power shelf is as follows:

1. Bring down all power to the chassis.

2. Disconnect the input power cables.

3. Disconnect the grounding cable.

4. Remove the air intake (inlet) grille.

5. Remove all DC power supplies.

6. Remove the DC power input shelf.

7. Remove the DC power input module (PIM).

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Prerequisites

Power down the Cisco CRS 4-slot line card chassis (as described in the steps below).

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

• Number 1 Phillips screwdriver

• Number 2 Phillips screwdriver

• 5-mm Allen wrench

• 10-mm hex socket wrench

Note This procedure assumes that the Cisco CRS 4-slot line card chassis is already mounted in a rack with

sufficient room to access the sides and the bottom of the chassis.

Removing a DC Power Shelf

Steps

To remove the DC power shelf, follow these steps:

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 or a bare metal surface on the chassis.

Bring Down All Power to the Chassis

Step 2 Power down the chassis:

a. Go to the rear of the chassis. On the PIM, set both power shelf enable switches to OFF (see

Figure 2-19). Now the system’s boards and fans have no power.

b. Unplug the DC power supplies.

c. Disconnect input power from the customer source.

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Removing a DC Power Shelf

210861

)

V )

–

Side B

)

(-4

/-6

)

–

)

6 0

)

–

)(-

/-6

)

–

A0A1

Side A

SIDE A

SIDE B

Figure 2-19 DC Power Shelf Enable Switches

Chapter 2 Installing and Removing Power Components

1 DC power shelf enable switches

Step 3

Remove both wiring block covers (see Figure 2-20).

a. Use a number 1 Phillips screwdriver to loosen the capture screw.

b. Snap off the cover over the wiring block.

Disconnect the Input Power Cables and Grounding Cable

Step 4 Use a 10-mm hex socket wrench to disconnect the DC input power cables.

Disconnect the four 60 A DC cables (two cables per input) on the left from one wiring block, and the four 60 A DC cables on the right from the other wiring block (see Figure 2-20).

Step 5 Use a 10-mm hex socket wrench to disconnect the grounding cable (see Figure 2-20).

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(RTN

)

(-48V/-60V)

–

B0B1

Side B

(RTN

)

(-48V/-60V)

–

(RTN) (-48V/-60V)

–

(RTN) (-48V/-60V)

–

Side A

SIDE A

SIDE B

Figure 2-20 Removing Wiring Block Covers and DC Input Power Cables

Removing a DC Power Shelf

1 Power shelf coupling screw 2 Grounding lug nuts

Step 6

With a 5-mm Allen wrench, loosen the power shelf coupling screw (see item 1 in Figure 2-20). This will allow you to remove the DC power input shelf from the chassis (as described below).

Step 7 Go to the front of the chassis. Remove the inlet grille. For the procedure, see the “Removing the Inlet

Grille” section on page 5-3.

Step 8 Remove the four DC power supplies. For the procedure, see the “Removing a Power Supply” section on

page 2-30.

Remove the DC Power Input Shelf

Step 9 While still in the front of the chassis, you can now remove the DC power input shelf. To remove the DC

power input shelf, follow these steps:

Caution An empty DC power input shelf weighs about 15.5 lb (7 kg). To prevent injury when lifting

the shelf, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves.

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a. To unlock the power input shelf, pull the lever handles down (see Figure 2-21).

b. Holding the DC power input shelf underneath with one hand and steadying it with the other, lift the

DC power input shelf up and slide it part way out of the power shelf slot.

c. Slide the DC power input shelf fully out of the chassis. Set the power input shelf carefully aside.

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Figure 2-21 Removing the DC Power Input Shelf

Remove the DC Power Input Module (PIM)

Step 10 Go to the rear of the chassis. Remove the DC power input module (PIM).

a. With a Number 2 Phillips screwdriver, remove the first set of eight screws—six screws in the front

of the chassis, two on the outside right and left sides of the chassis (see Figure 2-22).

b. Remove the additional two screws underneath the chassis (one on the left side, one on the right side)

(see Figure 2-22).

Chapter 2 Installing and Removing Power Components

c. With one hand gripping the handle and one hand underneath the module, carefully remove the PIM

from the chassis, then set it aside.

Figure 2-22 Removing the DC Power Input Module (PIM)

STATUS

(RTN) (-48V/-60V)

–

(RTN)

–

(-48V/-60V)

SIDE B

Side B

SIDE A

Side A

(RTN)

–

(-48V/-60V)

A0A1

(RTN)

–

(-48V/-60V)

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Installing an AC Power Shelf

This section describes how to install an AC power shelf in the Cisco CRS 4-slot line card chassis. The power shelf encloses four power supplies and the power distribution connections and wiring. The AC power shelf is installed in the front (PLIM) side of the chassis.

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The AC-powered chassis contains a single AC power shelf containing four AC power supplies. Each AC power supply converts input AC power to the –54 VDC used by the Cisco CRS 4-slot line card chassis.

The AC power shelf is configured for single-phase AC power supply wiring (two wires + ground), and is safety-rated at 110 to 240 VAC nominal, 50 to 60 Hz (4x) 11A.

For additional power details, see Cisco CRS Carrier Routing System 4-Slot Line Card Chassis System Description, or in this document, see Appendix A, “Cisco CRS 4-Slot Line Card Chassis

System Specifications.”

For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

Prerequisites

Remove the air intake grille from the bottom of the chassis.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

Installing an AC Power Shelf

• AC Power shelf (Cisco product number: CRS-4-AC-SHELF)

Figure 2-23 shows the AC power shelf.

Figure 2-23 AC Power Shelf

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Steps

Step 1 Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection

Step 2 Remove the air intake grille from the bottom of the chassis.

Step 3 Holding the AC power shelf underneath with one hand and steadying it with the other, lift the shelf up

Step 4 Slide the AC power shelf fully into the chassis. Be sure that the lever handles are aligned with the lever

Chapter 2 Installing and Removing Power Components

To install an AC power shelf, use Figure 2-23 as a reference and follow these steps:

sockets on the front (PLIM) side of the chassis or a bare metal surface on the chassis.

and slide it partway into the power shelf slot on the front (PLIM) side of the chassis. Be sure to center the shelf in the slot when you slide it in.

Caution An empty AC power shelf weighs about 7.0 lb (3.2 kg). To prevent injury when lifting the

shelf, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves.

handle catches on the chassis casing.

Caution When inserting the power shelf, carefully guide the shelf in to prevent the power switch from

hitting the edge of the power shelf opening. If possible, have a second person guide the power shelf from the rear of the unit.

Step 5 Lift the lever handles up to lock the tray into position.

Step 6 Use the flat-blade screwdriver to turn the two captive screws that connect the rear of the chassis to the

power shelf, and tighten them fully.

Caution Be sure to attach the plugs carefully; incorrectly attached plugs can damage the chassis.

What to Do Next

After performing this task, install the power supplies (see the “Installing a Power Supply” section on

page 2-28), and replace any chassis cosmetic cover plates.

Removing an AC Power Shelf

This section describes how to remove an AC power shelf from the Cisco CRS 4-slot line card chassis. The AC power shelf encloses four power supplies and the power distribution connections and wiring. The AC power shelf is installed in the front (PLIM) side of the chassis. For more details on the power systems see the “About Installing and Removing the Power Components” section on page 2-1. For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

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Caution Prior to removing the AC power shelf, to reduce the risk of damage, ensure that the rear panel fasteners

are disengaged, the input power cables are disconnected, and the air intake (inlet) grille is removed.

See Figure 2-23 for an illustration of the AC power shelf.

Prerequisites

Before performing this task, you must first remove the air intake grille from the bottom of the chassis, power down the chassis (see the “AC Power Supply Cord Illustrations and Plug Types” section on

page 2-4), and detach the power cords.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

Removing an AC Power Shelf

Steps

To remove an AC power shelf, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Remove all four power supplies from the shelf you are removing. (See the “Removing a Power Supply”

section on page 2-30.)

Step 3 Remove the power cables from the power from the four power inlets.

Step 4 While facing the rear (SFC) side of the chassis, use the screwdriver to loosen the two captive screws that

connect the rear of the chassis to the power shelf by turning them counterclockwise.

Step 5 Pull the lever handles down with both hands and slide the AC power shelf partway from the slot in the

chassis.

Caution An empty AC power shelf weighs about 7.0 lb (3.2 kg). To prevent injury when lifting the

shelf, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves.

Step 6 Placing one hand underneath the AC power shelf and pulling on it and steadying it with the other hand,

slide the shelf completely from the chassis. (If attached, be sure to thread the power cable through the chassis carefully.)

Step 7 Set the AC power shelf carefully aside.

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What to Do Next

After performing this task, you may install a replacement power shelf (see the “Installing an AC Power

Shelf” section on page 2-24), install the power supplies (see the “Installing a Power Supply” section on page 2-28), and replace any front chassis cosmetic covers.

Installing a Power Supply

This section describes how to install an AC or DC power supply in the Cisco CRS 4-slot power shelf. The AC power supply converts facility AC power into the DC power necessary to power the cards and modules in the chassis. Each AC and DC power supply has its own pair of cooling fans, which draws air through the power supply.

For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

Figure 2-24 shows a power supply.

Figure 2-24 Power Supply

Chapter 2 Installing and Removing Power Components

Prerequisites

Before performing this task, make sure that the power shelf has been installed (see the “Installing an AC

Power Shelf” section on page 2-24 or the “Installing a DC Power Shelf” section on page 2-14); remove

any cosmetic covers.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Power supply

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Steps

To install a power supply, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Using two hands to support and guide the power supply, slide it partway into the power tray on the front

(PLIM) side of the chassis.

Step 3 Make sure that the power supply door grille is in the open position (see Figure 2-25).

Figure 2-25 Power Supply Door Grille in Open Position

Installing a Power Supply

1 Power supply door grille 2 Power supply door latch

Step 4

Slide the power supply into the power shelf until the connector on the back of the module meets the connector on the backplane of the AC or DC power shelf.

Caution A power supply weighs about 4.5 lb (2 kg). You should use two hands when handling a

module.

Step 5 Close the power supply door grille to seat the power supply fully against the AC or DC power shelf.

Make sure that the power supply door grille latch clicks into place.

Tip The power supply door can be latched while it is still outside of the power shelf; if that occurs,

the power supply will not function according to specification. To ensure proper functionality, the power supply door must be latched only after the power supply is fully engaged into the AC power shelf.

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Caution To prevent damage to the AC or DC power shelf-to-power supply connections, do not use

excessive force when seating a power supply to its power shelf.

What to Do Next

After performing this task, you may connect the power shelf to the power source (see the “About

Installing and Removing the Power Components” section on page 2-1, replace any front cosmetic

covers, and power up the chassis (see the “AC Power Supply Cord Illustrations and Plug Types” section

on page 2-4).

Removing a Power Supply

This section describes how to remove a power supply in the Cisco CRS 4-slot line card chassis. The power supplies can be an AC or DC power supplies (however, mixed types are not permitted). The AC power supply converts facility AC power into the DC power necessary to power the cards and modules in the chassis. Each AC power supply has its own pair of cooling fans, which draws air through the power supply.

For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

Chapter 2 Installing and Removing Power Components

See Figure 2-24 for an illustration of a power supply.

Prerequisites

Before operating the power shelf ejectors and removing the power shelf, take the following precautions:

• For an AC power shelf, ensure that the rear panel fasteners are disengaged.

• For a DC power shelf, unlock the power input shelf by pulling the lever handles down.

• Disconnect the input power cables.

• Remove the air intake (inlet) grille.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

Steps

To remove a power supply, follow these steps:

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 or a bare metal surface on the chassis.

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Step 2 To unseat the power supply from the power shelf connector, unlatch the power supply door grille latch

and open it completely. See Figure 2-25 for an illustration of the power supply grille and door latch.

Note The power supply fans may continue to turn at high speed for a few seconds after they are

unseated from the power shelf.

Step 3 Grasp the power supply door grille and gently pull the power supply halfway from the bay.

Caution Take care when handling a power supply that has recently been in use; it can be hot to the

touch.

Caution A power supply weighs about 4.6 lb (2.1 kg). You should use two hands when handling a

power supply.

Step 4 Use your free hand to support the power supply while you slide the power supply completely from the

bay, then set the power supply safely aside.

Removing a Power Supply

What to Do Next

After performing this task, you may install a new power supply, if needed (see the “Installing a Power

Supply” section on page 2-28), and replace any front cosmetic covers.

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Installing and Removing Air Circulation Components

This chapter provides instructions on how to install and replace the Cisco CRS Carrier Routing System 4-Slot Line Card Chassis air circulation components.

This chapter presents the following topics:

• About Line Card Chassis Airflow, page 3-1

• How to Install or Remove Air Circulation Components, page 3-3

About Line Card Chassis Airflow

Figure 3-1).

CHAP T ER

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In addition, each power module at the bottom of the chassis has self-contained fans that pull in cool air from the front of the chassis and exhaust warm air out the rear. There is parallel path for airflow through the fabric cards.

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Air exhaust

Front Rear

210072

Chassis

air inlet

Power supplies

and power shelf

Power shelf

air inlet

Air exhaust

Air filter

Fan tray

Midplane

Figure 3-1 Airflow Through the Cisco CRS 4-Slot Line Card Chassis

Chapter 3 Installing and Removing Air Circulation Components

Air Filter Replacement Frequency Recommendation

How often the air filters should be replaced depends on the facility environment. In a dirty environment, or when you start getting frequent temperature alarms, you should always check the intake grilles for debris, and then check the air filters to see if they need to be replaced.

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Figure 3-2 System Air Filters

How to Install or Remove Air Circulation Components

1 Chassis air filter 3 Power tray and power supplies

2 Air intake grille 4 Power tray air filter

Note We recommend that you check the air filters once a month. Replace a filter when you notice a significant

amount of dust.

Caution To remain NEBS compliant, the chassis air filter can be replaced only when the fan trays are not running.

The Cisco CRS 4-slot line card chassis airflow volumes are as follows:

• Chassis airflow: Up to 880 cubic feet (24,919 liters) per minute

• Power system airflow: Up to 60 cubic feet (1699 liters) per minute

How to Install or Remove Air Circulation Components

This section contains the following procedures:

• Installing a Fan Tray, page 3-4

• Removing a Fan Tray, page 3-5

• Installing the Chassis Air Filter, page 3-7

• Removing the Chassis Air Filter, page 3-9

• Installing a Power Tray Air Filter, page 3-10

• Removing a Power Tray Air Filter, page 3-12

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HANDLE TO BE USED ONLY FOR LIFTING OR POSITIONING THE BLOWER MODULE

Installing a Fan Tray

This section describes how to install a fan tray in the Cisco CRS 4-slot line card chassis. For information on the chassis airflow and circulation, see the “About Line Card Chassis Airflow” section on page 3-1. The fan tray installs into the rear (SFC) side of the chassis (see Figure 3-3). For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

Figure 3-3 Fan Tray

Chapter 3 Installing and Removing Air Circulation Components

Prerequisites

No prerequisites exist for this task.

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Required Tools and Equipment

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

• ESD-preventive wrist strap

• Large flat-blade screwdriver

• Fan tray (Cisco product number CRS-4-FAN-TR=)

Steps

To install a fan tray, follow these steps:

Step 1 Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection

sockets on the rear (SFC) side of the chassis or a bare metal surface on the chassis.

Step 2 Holding the fan tray by the handles, position it in front of the fan tray bay on the upper rear (SFC) side

of the chassis. Slide the tray partway into its slot.

How to Install or Remove Air Circulation Components

Caution A fan tray weighs about 16 lb (7 kg.). Use two hands when handling a fan tray.

Caution Do not set the fan tray down on the connector; doing so could damage it.

Step 3 Slide the fan tray all the way in. Press it firmly into the chassis so that the connector on the back of the

fan tray is seated firmly against the connector on the interior of the chassis.

Caution To prevent damage to the chassis connector, do not use excessive force when inserting a fan

Step 4 Using the screwdriver, tighten the four captive screws (one for each corner).

Note All electrical and control line connections are made automatically when the connectors mate.

Removing a Fan Tray

This section describes how to remove a fan tray from the Cisco CRS 4-slot line card chassis. For information on the chassis airflow and circulation, see the “About Line Card Chassis Airflow” section

on page 3-1.

The fan tray installs into the rear (SFC) side of the chassis (see Figure 3-4). For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

tray into its bay.

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HANDLE TO BE USED ONLY FOR LIFTING OR POSITIONING THE BLOWER MODULE

Caution The chassis automatically powers down if the fan tray is unseated from its connector for more than one

minute. If you plan on hot swapping the fan tray, have the replacement fan tray readily available and be sure to insert it and seat it against its connector within 45 seconds. Familiarize yourself with the procedure in the “Installing a Fan Tray” section on page 3-4 before attempting to hot swap the fan tray.

Figure 3-4 Fan Tray

Chapter 3 Installing and Removing Air Circulation Components

Prerequisites

No prerequisites exist for this task.

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Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Large flat-blade screwdriver

Steps

To remove a fan tray, follow these steps:

Step 1 Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection

sockets on the rear (SFC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using the large flat-blade screwdriver, loosen the four captive screws on the fan tray (one for each

corner).

Caution A fan tray weighs about 16 lb (7 kg.). Use two hands when handling a fan tray.

How to Install or Remove Air Circulation Components

Step 3 Grasp the fan tray by the handles and pull it gently straight out to disconnect the fan tray from the

connector mounted on the back of the fan tray.

Step 4 Remove the fan tray completely from the fan tray bay. Set the fan tray safely aside.

Caution Do not set the fan tray down on the connector; doing so could damage it.

Installing the Chassis Air Filter

This section describes how to install the air filter in the Cisco CRS 4-slot line card chassis. For further information, see the “About Line Card Chassis Airflow” section on page 3-1. For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

The Cisco CRS 4-slot line card chassis has a serviceable air filter that plugs into the front (PLIM) side of the chassis (see item 1 in Figure 3-5) just inside the air intake slot. During operation, the air filter access is hidden by the lower chassis grille.

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Figure 3-5 Chassis Air Filter

Chapter 3 Installing and Removing Air Circulation Components

1 Chassis air filter 3 Power tray and power supplies

2 Air intake grille 4 Power tray air filter

Prerequisites

Before performing this task, you must first remove any chassis front cosmetic covers, the lower chassis air intake grille and power tray air filter cover (see the “Installing a Power Tray Air Filter” section on

page 3-10).

Caution Never operate the Cisco CRS 4-slot line card chassis without an air filter. Doing so can damage the

hardware.

Required Tools and Equipment

You need the following part to perform this task:

• Chassis air filter (Cisco product number: CRS-4-FILTER=)

• Medium flat-blade screwdriver

Steps

To install the chassis air filter, follow these steps:

Step 1 If an air filter is currently in the slot, remove it.

Step 2 Slide the new air filter into the air filter slot until it is seated fully within the slot.

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Step 3 Replace the lower chassis grille:

a. Position the grille in front of the air intake slot on the lower front side of the chassis and press it

gently into place. Make sure that you align the guide pins on the lower corners of the grille with the guide pin holes on the chassis.

b. Use a medium flat-blade screwdriver to tighten the two captive screws (on for each side) that hold

the grille to the front of the chassis.

Removing the Chassis Air Filter

This section describes how to remove the air filter in the Cisco CRS 4-slot line card chassis. For further information, see the “About Line Card Chassis Airflow” section on page 3-1. For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

The chassis has a serviceable air filter that plugs into the front (PLIM) side of the chassis (see item 1 in

Figure 3-6) just inside the air intake slot. During operation, the air filter access is hidden by the lower

chassis grille.

How to Install or Remove Air Circulation Components

Figure 3-6 Chassis Air Filter

1 Chassis air filter 3 Power tray and power supplies

2 Air intake grille 4 Power tray air filter

Caution To remain NEBS compliant, the chassis air filter can be replaced only when the fan tray is not running.

The chassis powers down one minute after the fan tray is removed, so we recommend using two people to replace the chassis air filter at NEBS-compliant sites. Familiarize yourself with the steps in the

“Installing a Fan Tray” section on page 3-4 and the “Removing a Fan Tray” section on page 3-5 prior to

replacing the chassis air filter.

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Prerequisites

Before performing this task, you must first remove the lower chassis grille and power tray air filter cover (see the “Installing a Power Tray Air Filter” section on page 3-10).

Caution Never operate the line card chassis without an air filter. Doing so can damage the hardware.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist straps

• Large flat-blade screwdriver

Steps

To remove the chassis air filter, follow these steps:

Chapter 3 Installing and Removing Air Circulation Components

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 or a bare metal surface on the chassis.

Step 2 Unscrew the two captive screws that connect the air intake grille to the front (PLIM) side of the chassis.

Step 3 Set the air intake grille carefully aside.

Step 4 Grasp the air filter and carefully slide it from the slot. Set the air filter carefully aside.

Step 5 Install the replacement air filter (if necessary). See the “Installing the Chassis Air Filter” section on

page 3-7.

What to Do Next

After performing this task, replace the lower chassis grille (see the “Installing a Power Tray Air Filter”

section on page 3-10) and the front cover plates.

Installing a Power Tray Air Filter

This section describes how to install a power tray air filter for the Cisco CRS 4-slot line card chassis. For further information, see the “About Line Card Chassis Airflow” section on page 3-1. For complete information on regulatory compliance and safety, see Cisco CRS Carrier Routing System Regulatory Compliance and Safety Information.

The power tray has a serviceable air filter that is inserted into the lower chassis grille, just in front of the power tray (see item 4 in Figure 3-7).

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Figure 3-7 Power Tray Air Filter

How to Install or Remove Air Circulation Components

1 Chassis air filter 3 Power tray and power modules

2 Air intake grille 4 Power tray air filter

Prerequisites

No prerequisites exist for this task.

Caution Never operate the line card chassis without an air filter. Doing so can damage the hardware.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

• Power tray air filter

Steps

To install a power tray air filter, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Remove the lower chassis grille:

• Use the medium flat-blade screwdriver to loosen the two captive screws (one for each side) that hold

the grille to the front of the chassis.

• Gently remove the grille from the chassis.

Step 3 Slide the air filter into the air filter slot on the grille (see Figure 3-7).

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Step 4 Reinstall the lower chassis grille:

a. Position the grille in front of the air intake slot on the lower front side of the chassis and press it

gently into place. Make sure that you align the guide pins on the lower corners of the grille with the guide pin holes on the chassis.

b. Use a medium flat-blade screwdriver to tighten the two captive screws (on for each side) that hold

the grille to the front of the chassis.

Removing a Power Tray Air Filter

This section describes how to remove a power tray air filter. For further information, see the “About Line

Card Chassis Airflow” section on page 3-1. For complete information on regulatory compliance and

safety, see Regulatory Compliance and Safety Information for the Cisco CRS Carrier Routing System.

The power tray has a serviceable air filter that is inserted into the lower chassis grille, just in front of the power tray (see item 4 in Figure 3-8).

Chapter 3 Installing and Removing Air Circulation Components

Prerequisites

Figure 3-8 Power Tray Air Filter

1 Chassis air filter 3 Power tray and power modules

2 Air intake grille 4 Power tray air filter

No prerequisites exist for this task.

Caution Never operate the line card chassis without an air filter. Doing so can result in damage to the hardware.

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Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Medium flat-blade screwdriver

Steps

To remove a power tray air filter, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Remove the lower chassis grille (if necessary):

a. Use a medium flat-blade screwdriver to tighten the two captive screws (one for each side) that hold

the grille to the front of the chassis.

b. Gently remove the grille from the chassis.

How to Install or Remove Air Circulation Components

Step 3 Slide the air filter from the air filter slot on the grille (see Figure 3-8).

What to Do Next

After performing this task, you may install a new air filter (see the “Installing a Power Tray Air Filter”

section on page 3-10).

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CHAP T ER

Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

This chapter provides instructions on how to install and remove the Cisco CRS Carrier Routing System 4-Slot Line Card Chassis switch fabric cards (SFCs), route processor (RP) or performance route processor (PRP) cards, modular services cards (MSCs), forwarding processor a(FP) cards, label switch processor (LSP) cards, physical layer interface modules (PLIMs), and the associated components.

This chapter presents the following topics:

• About Installing and Removing Cards and Associated Components, page 4-1

• How to Remove or Install an Impedance Carrier, page 4-5

• How to Remove or Install a Card Slide-Assistance Arm (Handle), page 4-11

• How to Install or Remove a Pillow Block, page 4-14

• How to Install or Remove a Switch Fabric Card, page 4-18

• How to Install or Remove a Route Processor Card, page 4-24

• How to Install or Remove an MSC, FP, or LSP, page 4-32

• How to Install or Remove a Physical Layer Interface Module, page 4-42

• How to Install or Remove a PCMCIA Card, page 4-51

• How to Install or Remove a Small Form-Factor Pluggable (SFP) Module, page 4-53

About Installing and Removing Cards and Associated Components

This section contains some general information about installing and removing cards, PLIMs, and the associated components.

• Guidelines for Card Installation and Removal, page 4-2

• PCMCIA Cards, page 4-4

• Small Form-Factor Pluggable (SFP) Modules, page 4-4

• Cable Management Brackets, page 4-5

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About Installing and Removing Cards and Associated Components

Guidelines for Card Installation and Removal

This section contains the general guidelines for card installation and removal.

Online insertion and removal (OIR) is supported, enabling you to remove and install cards while the Cisco CRS 4-slot line card chassis is operating. OIR is seamless to users on the network, maintains all routing information, and ensures session preservation. Notifying the software or resetting the power is not required. However, you have the option of using the shutdown command before removing a card.

The different cards in the line card chassis are all attached to the chassis itself using a pair of ejector levers and captive screws. The two ejector levers release the card from its midplane connector. The exact location of the ejector levers and captive screws varies slightly from card to card, but are in general in the same location: on the upper and bottom of the faceplate of the card. Figure 4-1 shows the location of the ejector levers and captive screws on an MSC.

Figure 4-1 Ejector Levers and Captive Screws

4-2

1 Captive screw 2 Ejector lever

Figure 4-2 shows how to operate the ejector levers. Be sure to operate both levers simultaneously.

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About Installing and Removing Cards and Associated Components

Figure 4-2 Operating Ejector Levers

Recommended Order for Installing Cards

Although it is not critical for you to install the cards in a certain order, following the card installation recommendations in this section will make your installation process easier. We recommend that you install cards in the Cisco CRS 4-slot chassis in the following order:

• Switch fabric cards (SFCs)

Caution Removing more than one switch fabric card at a time can misalign the chassis and may damage the card

or chassis when reinserting the cards. Remove and reinsert only one card at a time.

• Route processors (RPs) or performance route processors (PRPs)

• Modular services cards (MSCs), forwarding processors (FPs), and label switch processor (LSP)

cards

• Physical layer interface modules (PLIMs)

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About Installing and Removing Cards and Associated Components

Note See the instructions in this chapter for details on how to install the individual cards.

Guidelines

When you install or remove cards on the Cisco CRS 4-slot line card chassis, follow these guidelines:

• Do not operate the Cisco CRS 4-slot line card chassis with any slots completely empty; doing so can

lead to an airflow bypass condition that diverts airflow from slots containing heat-generating electronics. This situation can cause thermal alarms to occur at lower-than-expected ambient temperatures. To avoid airflow bypass, make sure that all slots are filled with their appropriate cards or impedance carriers. If you have to replace a card, we recommend leaving the card in place in the chassis until you are ready to install the new one.

• When you remove a card, always use the ejector levers to ensure that the connector pins disconnect

from the midplane in the sequence expected by the router.

• To lessen the possibility of damaging the connectors on the chassis midplane, you should visually

inspect the connector pins on the cards before you insert them into the chassis.

PCMCIA Cards

Optional and replaceable PCMCIA cards are available for the RP cards. The RP cards provide two PCMCIA flash slots, each card providing up to 1 GB of flash storage. One of the PCMCIA flash subsystems is accessible externally, is removable, and allows you to transfer system images and configurations by plugging in a PCMCIA flash card. The other subsystem is fixed to the RP, is not removable, and is used for permanent storage of configurations and system images.

Note Only the original route processor (RP) card uses a PCMCIA card. The performance route processor

(PRP) card has a USB connector for using a flash drive.

Small Form-Factor Pluggable (SFP) Modules

The SFP module for the Cisco CRS 4-slot line card chassis uses the bale-clasp latch type.

Caution Protect the SFP modules by inserting clean dust covers into them after the cables are removed from them.

Be sure to clean the optic surfaces of the fiber cables before you plug them back into the optical ports of another SFP module. Avoid getting dust and other contaminants into the optical ports of the SFP modules: The optics do not work correctly when obstructed with dust.

Note Shared port adapters (SPAs) and the 16-port OC-48c/STM-16c PLIM use SFP modules.

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Cable Management Brackets

The Cisco CRS 4-slot line card chassis includes a cable management system that organizes the interface cables entering and exiting the different cards, keeping them out of the way and free of sharp bends.

Caution Excessive bending of interface cables can damage the cables.

The Cisco CRS 4-slot line card chassis arrives preinstalled with a horizontal cable management bracket on the front of the chassis; this bracket cannot be removed or replaced.

Figure 4-3 shows the chassis cable management bracket.

Figure 4-3 Cable Management Bracket

How to Remove or Install an Impedance Carrier

This section contains the following procedures:

• Removing an Impedance Carrier, page 4-10

• Installing an Impedance Carrier, page 4-10

When shipped, some slots in the chassis may contain impedance carriers to help ensure that the chassis is undamaged during shipment. Four different types of impedance carriers exist for the four different sizes of slots in the chassis (see Figure 4-4, Figure 4-5, Figure 4-6, and Figure 4-7).

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How to Remove or Install an Impedance Carrier

Figure 4-4 Switch Fabric Slot Impedance Carrier

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Figure 4-5 RP Slot Impedance Carrier

How to Remove or Install an Impedance Carrier

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Figure 4-6 PLIM Slot Impedance Carrier

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Figure 4-7 MSC Slot Impedance Carrier

How to Remove or Install an Impedance Carrier

For more information, see the “Removing an Impedance Carrier” section on page 4-10 and “Installing

an Impedance Carrier” section on page 4-10.

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How to Remove or Install an Impedance Carrier

Removing an Impedance Carrier

This section describes how to remove an impedance carrier from the Cisco CRS 4-slot line card chassis. All impedance carrier types are removed in the same manner.

Prerequisites

There are no prerequisites for this task.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Number 1 Phillips screwdriver

Steps

To remove an impedance carrier, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Identify the impedance carrier to be removed from the card cage. Use the screwdriver to turn the two

captive screws on the front panel of the card counterclockwise to loosen it from the slot.

Step 3 Grasp the impedance carrier handle with one hand and gently pull it halfway from the slot.

Step 4 Place one hand under the impedance carrier to guide it.

Step 5 Holding the impedance carrier underneath and by the handle, pull it from the slot and set it carefully

aside.

What to Do Next

After performing this task, store the impedance carrier for future use. You may now install a card in the uncovered slot. See the “Installing an MSC, FP, or LSP” section on page 4-33, the “Installing a PLIM”

section on page 4-42, or the “Installing an RP or PRP Card” section on page 4-26 for further details.

Installing an Impedance Carrier

This section describes how to install an impedance carrier into the Cisco CRS 4-slot line card chassis. The chassis is shipped with impedance carriers installed in the MSC, PLIM, RP, and SFC slots. All impedance carrier types are installed in the same manner.

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How to Remove or Install a Card Slide-Assistance Arm (Handle)

Prerequisites

Before performing this task, open the doors if they are installed and ensure that the slot in which you are about to install the impedance carrier is empty. Depending on the slot in which you are installing an impedance carrier, see the “Removing an MSC, FP, or LSP” section on page 4-37, the “Removing a

PLIM” section on page 4-48, or the “Removing an RP or PRP Card” section on page 4-29.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Number 1 Phillips screwdriver

• Impedance carrier

–

SFC impedance carrier (Cisco product number: CRS-4-FC-BLANK)

–

MSC impedance carrier (Cisco product number: CRS-MSC-IMPEDANCE=)

–

PLIM impedance carrier (Cisco product number: CRS-INT-IMPEDANCE=)

–

RP impedance carrier (Cisco product number: CRS-RP-4-BLANK=)

Steps

To install an impedance carrier, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Use both hands while inserting an impedance carrier. Use one hand on the faceplate and the other hand

along the base of the impedance carrier to guide it into a slot.

Step 3 Slide the impedance carrier into the chassis until the captive screw plates are flush with the chassis.

Step 4 Partially tighten the two captive screws on the front panel of the impedance carrier (either by hand or

with the screwdriver) to make sure that they are both engaged.

Step 5 Use the screwdriver to fully tighten the captive screws to seat the impedance carrier firmly in the slot.

How to Remove or Install a Card Slide-Assistance Arm (Handle)

This section contains the following procedures:

• Removing a Card Slide-Assistance Arm

• Installing a Card Slide-Assistance Arm

All line cards, PLIMs, and RPs are shipped with slide-assistance arms (sometimes called handles) attached. SPAs, the SIP-800, and SFCs are not shipped with slide-assistance arms. Figure 4-8 shows a slide-assistance arm attached to an MSC.

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Figure 4-8 Modular Services Card (CRS-MSC) with Slide-Assistance Arm Attached

Removing a Card Slide-Assistance Arm

This section describes how to remove a slide-assistance arm (handle) from a line card, PLIM, or RP card. For details about installing or removing the cards themselves, see the “How to Install or Remove an

MSC, FP, or LSP” section on page 4-32, the “How to Install or Remove a PCMCIA Card” section on page 4-51, and the “How to Install or Remove a Physical Layer Interface Module” section on page 4-42.

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How to Remove or Install a Card Slide-Assistance Arm (Handle)

Prerequisites

No prerequisites exist for this task.

Caution Do not lift cards by the slide-assistance arm. Rotate cards onto their vertical axes, then lift them from

the bottom, using the slide-assistance arm only as an aid for balance.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Number 3 Phillips screwdriver.

Steps

To remove a slide-assistance arm, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Using the small Phillips screwdriver, turn the two captive screws (one top, one bottom) on the

slide-assistance arm counter-clockwise to detach the arm from the card face.

Step 3 Set the slide-assistance arm carefully aside. We recommend storing it in the original Cisco packaging.

What to Do Next

After performing this task, you may install or remove the card as necessary.

Installing a Card Slide-Assistance Arm

This section describes how to install a slide-assistance arm on a line card, PLIM, or RP card. For details about installing or removing the cards themselves, see the “How to Install or Remove an MSC, FP, or

LSP” section on page 4-32, the “How to Install or Remove a PCMCIA Card” section on page 4-51, and

the “How to Install or Remove a Physical Layer Interface Module” section on page 4-42.

Prerequisites

Before performing this task, be sure to remove the slide-assistance arm and its attachment screws from the packaging, and have the appropriate card available for attachment.

Caution Do not lift cards by the slide-assistance arm. Rotate cards onto their vertical axes, then lift them from

the bottom, using the slide-assistance arm only as an aid for balance.

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How to Install or Remove a Pillow Block

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Number 2 Phillips screwdriver

• Card:

–

MSC (CRS-MSC, CRS-MSC-B, or CRS-MSC-140G;

–

FP (CRS-FP40 or CRS-FP-140);

–

LSP (CRS-LSP);

–

RP card (CRS-4-RP) or PRP card (CRS-4-PRP-6G or CRS-4-PRP-12G);

–

PLIM (Refer to the product data sheets for ordering details.)

Steps

To install a slide-assistance arm, follow these steps:

Chapter 4 Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

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 or a bare metal surface on the chassis.

Step 2 Place the slide-assistance arm against the card face so that the screw holes on the card align with the

captive screws on the slide-assistance arm.

Step 3 Using the screwdriver, turn the two screws (one top, one bottom) clockwise to attach the slide-assistance

arm to the card face.

Note We recommend keeping the original Cisco packaging for future storage of the slide-assistance

arm, should it become necessary.

What to Do Next

After performing this task, you may install or remove the card as necessary.

How to Install or Remove a Pillow Block

This section contains the following procedures:

• Installing a Pillow Block, page 4-15

• Removing a Pillow Block, page 4-16

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Installing a Pillow Block

This section describes how to install a replacement pillow block on the chassis after removing a damaged pillow block. A pillow block is a bracket with a pin that is attached to the chassis above and below each card slot. When you install or remove a card from the chassis, the card ejector levers hook into the pillow blocks above and below the card slot to secure the cards to the slot and allow you to install and remove the cards.

Prerequisites

Before performing this task, you must first open the front cosmetic doors (if installed). Have the pillow block replacement kit (Cisco product number: CRS-4-PILLBLK=) at hand.

Required Tools and Equipment

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

• ESD-preventive wrist strap

How to Install or Remove a Pillow Block

Steps

• Phillips screwdriver

• Pillow block replacement kit (Cisco product number: CRS-4-PILLBLK=)

The following items are included in the CRS-4-PILLBLK= pillow block replacement kit:

• 2 replacement pillow blocks

• 6 Phillips-head screws

Note A Phillips screwdriver is not included in the CRS-4-PILLBLK= pillow block replacement kit.

To install a pillow block, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Locate the slot where the pillow block was removed.

Step 3 Have the replacement Phillips-head screws near at hand.

Step 4 Position the pillow block and align the screw holes.

Step 5 Use a Phillips screwdriver to install the top left screw (located above the pillow block pin). (See item 1

in Figure 4-9.)

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Figure 4-9 Installing a Pillow Block

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Step 6

Step 7 Install the lower left screw (located below the pillow block pin). (See item 3 in Figure 4-9.)

Step 8 Repeat this procedure for the card slot’s other pillow block if necessary.

Install the lower right screw (see item 2 in Figure 4-9).

What to Do Next

After performing this task, replace any cosmetic covers.

Removing a Pillow Block

This section describes how to remove a damaged pillow block from the chassis. A pillow block is a bracket with a pin that is attached to the chassis above and below each card slot. When you install or remove a card from the chassis, the card ejector levers hook into the pillow blocks above and below the card slot to secure the cards to the slot and allow you to install and remove the cards.

Prerequisites

Before performing this task, you must first open the front cosmetic doors (if installed). Have the pillow block replacement kit (Cisco product number: CRS-4-PILLBLK=) at hand.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Phillips screwdriver

• Pillow block replacement kit (Cisco product number: CRS-4-PILLBLK=)

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The following items are included in the CRS-4-PILLBLK= pillow block replacement kit:

• 2 replacement pillow blocks

• 6 Phillips-head screws

Note A Phillips screwdriver is not included in the CRS-4-PILLBLK= pillow block replacement kit.

Steps

To remove a pillow block, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Locate the pillow block to be replaced. Use a Phillips screwdriver to remove the lower right screw. (See

item 1 in Figure 4-10.)

Figure 4-10 Removing a Pillow Block

How to Install or Remove a Pillow Block

Step 3

Step 4 Remove the top left screw (located above the pillow block pin). (See item 3 in Figure 4-10.)

Step 5 Remove the pillow block and set it aside.

Step 6 Repeat this procedure for the card slot’s other pillow block if necessary.

What’s Next

Remove the lower left screw (located below the pillow block pin). (See item 2 in Figure 4-10.)

After performing this task, you may install a new pillow block (see the “Installing a Pillow Block”

section on page 4-15).

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How to Install or Remove a Switch Fabric Card

This section contains the following procedures:

• Switch Fabric Card Location and Slot Numbers

• Installing a Switch Fabric Card

• Removing a Switch Fabric Card

• Verifying the Installation of a Switch Fabric Card

Switch Fabric Card Location and Slot Numbers

The switch fabric cards are installed in the rear of the chassis in the card cage below the fan tray.

Figure 4-11 shows the location and slot numbers assigned to the switch fabric cards.

Figure 4-11 Cisco CRS 4-Slot Line Card Chassis Slot Numbers—Rear (SFC) Side

1 Fan tray (FT0) 4 Switch fabric card slot (SM1)

2 Switch fabric card slot (SM3) 5 Switch fabric card slot (SM0)

3 Switch fabric card slot (SM2)

Installing a Switch Fabric Card

This section describes how to install a switch fabric card in the Cisco CRS 4-slot line card chassis (see

Figure 4-12). For more detailed information on the switch fabric card, see Cisco CRS Series Carrier

Routing System 4-Slot Line Card Chassis System Description.

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There are two types of switch fabric cards: QQ123 and QQ123-140G. Figure 4-12 shows the QQ123-140G switch fabric card.

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Figure 4-12 Switch Fabric Card (QQ123-140G)

How to Install or Remove a Switch Fabric Card

Prerequisites

Before performing this task, remove the switch fabric card (if there is already one installed) or the switch fabric impedance carrier from the slot in which you plan on installing the switch fabric card. See the

“Removing an Impedance Carrier” section on page 4-10 and the “Removing a Switch Fabric Card” section on page 4-22.

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STA

TUS

STATUS

158462

TATU

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Number 3 Phillips screwdriver

• Switch fabric card:

–

QQ123 (Cisco product number: CRS-4-FC/S=)

–

QQ123-140G (Cisco product number: CRS-4-FC140/S=)

Note Only one type of switch fabric card should be installed in a system. A router with a mix of QQ123 and

QQ123-140G SFCs is not a supported mode of operation. A mix of QQ123 and QQ123-140G is only allowed during a switch fabric upgrade.

Steps

To install a switch fabric card, see Figure 4-13 and follow these steps:

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Figure 4-13 Installing a Switch Fabric Card

1 Captive screw 2 Ejector lever

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Step 1 Go to the rear of the chassis. Attach the ESD-preventive wrist strap to your wrist and connect its leash

to one of the ESD connection sockets on the rear (SFC) side of the chassis or a bare metal surface on the chassis.

Step 2 Remove the switch fabric card from its antistatic packaging.

Step 3 Use a medium Phillips screwdriver to remove the switch fabric card from its protective carrier.

Step 4 Visually inspect the connector pins on the card before you insert it into the chassis.

Note Do not attempt to install a card with bent pins, because this may damage the chassis midplane

connectors.

Step 5 Identify the card slot in the card cage where the switch fabric card should be installed.

a. If there is an impedance carrier in the slot, remove it (see the “Removing an Impedance Carrier”

section on page 4-10.)

b. If there is a switch fabric card already installed in the slot, remove the card (see the “Removing a

Switch Fabric Card” section on page 4-22).

Step 6 Grasp the face plate of the card with one hand and place your other hand under the card to support and

guide it into the correct slot.

Step 7 Orient the route processor card so that the status display is on top, then position the card for insertion

into the card cage slot. Avoid touching the card circuitry or any connectors.

How to Install or Remove a Switch Fabric Card

Note There are alignment grooves on each slot in the card cage. When you install a card, make sure

that you align both the top and bottom edges of the card carrier in the slot grooves.

Step 8 Grasp both card ejector levers simultaneously, then push them both outward until they are fully extended

in the open position.

Step 9 Carefully slide the switch fabric card into the slot until the ejector levers meet the edges of the card cage,

then stop when the ejector lever hooks catch the lip of the card cage. If they do not catch, try reinserting the switch fabric card until the ejector lever hooks are fully latched.

Step 10 To fully seat the card in the midplane connector, grasp both card ejector levers simultaneously, then push

them both inward until they are flush against the front edge of the card carrier.

Caution Verify that the openings on the card ejector cams pass over the tabs; otherwise, one or both

ejector levers may bind when you attempt to close the levers, thereby damaging or breaking one or both of them.

Note Switch fabric cards have guide pins that make initial contact with the midplane connector as you

slide a card into its slot. After the guide pins make contact, continue pushing the card carrier until the card ejector levers begin pivoting forward.

Step 11 To seat the card firmly in the slot, use the screwdriver to tighten the captive screws.

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How to Install or Remove a Switch Fabric Card

What to Do Next

After performing this task:

• Place the impedance carrier in an antistatic bag for storage and future use.

• If you are performing the initial installation of the system, install the RPs or PRPs (see the

“Installing an RP or PRP Card” section on page 4-26).

Removing a Switch Fabric Card

This section describes how to remove a switch fabric card from the Cisco CRS 4-slot line card chassis. For more detailed information on the switch fabric card, see Cisco CRS Series Carrier Routing System 4-Slot Line Card Chassis System Description.

Prerequisites

There are no prerequisites for this task.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Number 1 Phillips screwdriver

Steps

To remove a switch fabric card, see Figure 4-14 and follow these steps:

Step 1 Attach the ESD-preventive wrist strap to your wrist and connect its leash to one of the ESD connection

sockets on the rear (SFC) side of the chassis or a bare metal surface on the chassis.

Caution Removing more than one switch fabric card at a time can misalign the chassis and may damage the card

or chassis when reinserting the cards. Remove and insert only one switch fabric card at a time.

Step 2 Identify the switch fabric card to be removed from the card cage. Use the screwdriver to turn the two

captive screws on the front panel of the card counterclockwise to loosen it from the slot.

Step 3 To unseat the card from the midplane connector, grasp the two card ejector levers and simultaneously

pivot both ejector levers outward from the front edge of the card slot. As you pivot the ejector levers outward, the switch fabric card is partially pulled from the slot.

Step 4 Touching only the metal card carrier, slide the card from the slot and place it directly into an antistatic

sack or other ESD-preventive container. If you plan to return the defective card to the factory, repackage it in its original shipping container.

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STATU

ATUS

158462

STATU

210068

1 2

Figure 4-14 Removing a Switch Fabric Card

How to Install or Remove a Switch Fabric Card

1 Captive screw 2 Ejector lever

Verifying the Installation of a Switch Fabric Card

This section describes how to verify that a QQ123 or QQ123-140G switch fabric card has been properly installed. Figure 4-15 shows the QQ123 switch fabric card front panel. The QQ123-140G card is similar.

Figure 4-15 Switch Fabric Card Front View (QQ123 Shown)

1 Status LED 2 Alphanumeric LEDs

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Understanding the LEDs

Alphanumeric LEDs

At one end of the faceplate, near an ejector lever, a switch fabric card has an alphanumeric LED display that shows a sequence of messages indicating the state of the card.

Note It is normal for some displayed messages to appear too briefly in the LED display to be read.

Status LEDs

Use the status LEDs, located on the switch fabric card faceplate, to verify the correct installation of the card:

• When the card is properly installed, the Status LED turns green. If this LED is off, make sure that

the card is installed correctly.

• When the Status is blinking yellow, a problem exists on the board.

• When the Status is off, the board state is unknown. Verify that there is power to the board by looking

at the indicators on the power module.

• If there is a failure during the board boot sequence, the two-row, four-character alphanumeric

display indicates the current boot phase, to assist you in debugging the board failure.

Chapter 4 Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

Troubleshooting the Switch Fabric Card

If the installed or replaced switch fabric card fails to operate or to power up on installation:

• Make sure that the card is seated firmly in the Cisco CRS 4-slot line card chassis slot. One easy way

to verify physical installation is to see whether the front faceplate of the switch fabric card is even with the fronts of the other cards installed in the card cage.

• Check whether the ejector levers are latched and that the captive screws are fastened properly. If

you are uncertain, unlatch the levers, loosen the screws, and attempt to reseat the switch fabric card.

• Examine the alarm LEDs to see if there are any active alarm conditions.

• Examine the power shelves to see whether the chassis, as a whole, is receiving power.

How to Install or Remove a Route Processor Card

This section contains the following procedures:

• Location and Slot Numbers for the RPs, MSCs, FPs, LSPs, and PLIMs, page 4-25

• Installing an RP or PRP Card, page 4-26

• Removing an RP or PRP Card, page 4-29

• Verifying the Installation of an RP or PRP Card, page 4-30

• Installing a PCMCIA Card, page 4-51

• Removing an RP PCMCIA Card, page 4-52

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How to Install or Remove a Route Processor Card

Location and Slot Numbers for the RPs, MSCs, FPs, LSPs, and PLIMs

The route processors, MSCs, FPs, LSPs, and PLIMs are installed in the front of chassis. Note that FP cards are installed in the MSC slots.

Figure 4-16 shows the location and slot numbers for these cards:

Figure 4-16 Cisco CRS 4-Slot Line Card Chassis Slot Numbers—Front (PLIM) Side

1 MSC slot 0 7 PLIM slot 2

2 MSC slot 1 8 PLIM slot 3

3 MSC slot 2 9 RP slot (RP0)

4 MSC slot 3 10 RP slot (RP1)

5 PLIM slot 0 11 Air intake

6 PLIM slot 1 12 AC or DC power shelf

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Installing an RP or PRP Card

This section describes how to install a route processor (RP) or performance route processor (PRP) card in the chassis (see Figure 4-17). For more detailed information on the route processor card, see Cisco CRS Carrier Routing System 4-Slot Line Card Chassis System Description.

Every Cisco CRS 4-slot line card chassis contains two RP or PRP cards in dedicated slots on the front (PLIM) side of the chassis (see Figure 4-17).

Note A chassis may not be populated with a mix of RP and PRP cards. Both route processor cards should be

of the same type (RP or PRP).

Note For enhanced immunity to external electromagnetic disturbance levels of 10V per meter and 10 V RMS,

you must use a shielded Ethernet (CAT5 or better STP) cable on the Management Ethernet connection of the RP card (CRS-4-RP) or PRP card (CRS-4-PRP-6G or CRS-4-PRP-12G).

Chapter 4 Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

RP Installation Guidelines

Chassis operation may be effected by the installation of a route processor card. A route processor card is normally installed under one of the following conditions:

• When you are certain that the second RP in the chassis is operational and, if not already the active

RP, ready to assume control (this happens automatically).

• When the chassis is undergoing scheduled maintenance.

• When the Cisco CRS 4-slot line card chassis is powered down.

Monitoring the RP Card Start-Up Process

Monitoring the RP card during its start-up process must be done through a console port connection. For details, see the latest release of the Cisco IOS XR Getting Started Guide on www.cisco.com.

To monitor the RP card during its start-up, follow these steps:

Step 1 Install the console port connection to the front of the RP.

Tip If you want to monitor the start-up process on the RP, you must physically attach the console

port connection and open the console port connection prior to inserting the RP into its designated slot.

Step 2 Insert the RP into its designated slot as described in this section.

Step 3 At the console, verify the status of the RP.

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Figure 4-17 Route Processor (RP) Card

How to Install or Remove a Route Processor Card

Prerequisites

There are no prerequisites for this task.

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Required Tools and Equipment

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

• ESD-preventive wrist strap

• Large (number 1) Phillips screwdriver

• Route processor card (CRS-4-RP) or PRP card (CRS-4-PRP-6 or GCRS-4-PRP-12G)

Steps

To install an RP or PRP card, follow these steps:

Step 1 Go to the front of the chassis. Attach the ESD-preventive wrist strap to your wrist and connect its leash

to one of the ESD connection sockets on the rear side of the chassis or a bare metal surface on the chassis.

Step 2 Remove the route processor card from its antistatic packaging.

Step 3 Use a medium (number 2) Phillips screwdriver to remove the route processor card from its protective

carrier.

Chapter 4 Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

Step 4 Visually inspect the connector pins on the card before you insert it into the chassis.

Caution Do not attempt to install a card with bent pins, because this may damage the chassis midplane

connectors.

Step 5 Identify the card slot in the card cage where the route processor card should be installed.

a. If there is an impedance carrier in the slot, remove it (see the “Removing an Impedance Carrier”

section on page 4-10.)

b. If there is an RP card already installed in the slot, remove any cables connected to the front panel

of an existing card in the slot, then remove the card (see the “Removing an RP or PRP Card” section

on page 4-29).

Step 6 Grasp the face plate of the card with one hand and place your other hand under the card to support and

guide it into the correct slot.

Step 7 Orient the route processor card so that the status display is on top, then position the card for insertion

into the card cage slot. Avoid touching the card circuitry or any connectors.

Note There are alignment grooves on each slot in the card cage. When you install a card in the card

cage, make sure that you align both the top and bottom edges of the card carrier in the slot grooves.

Step 8 Grasp both card ejector levers simultaneously, then push them both outward until they are fully extended

in the open position.

Step 9 Carefully slide the route processor card into the slot until the ejector levers meet the edges of the card

cage, then stop when the ejector lever hooks catch the lip of the card cage. If they do not catch, try reinserting the route processor card until the ejector lever hooks are fully latched.

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Step 10 To fully seat the card in the midplane connector, grasp both card ejector levers simultaneously, then push

them both inward until they are flush against the front edge of the card carrier. After the guide pins make contact, continue pushing the card carrier until the card ejector levers begin pivoting forward.

Caution Verify that the openings on the card ejector cams pass over the tabs; otherwise, one or both ejector levers

may bind when you attempt to close the levers, thereby damaging or breaking one or both.

Step 11 To seat the card firmly in the slot, use the screwdriver to tighten the captive screws.

Note To comply with the Telcordia GR-1089 NEBS standard for electromagnetic compatibility and

safety, connect the Ethernet interfaces only to intrabuilding or nonexposed wiring or cabling. The intrabuilding cable must be shielded and the shielding must be grounded at both ends.

What to Do Next

How to Install or Remove a Route Processor Card

After performing this task:

• Place the impedance carrier in an antistatic bag for storage and future use.

• Verify that the card has been installed properly (see the “Verifying the Installation of an RP or PRP

Card” section on page 4-30).

• Connect the console port and LAN port. For more information, see the latest release of the Cisco

IOS XR Getting Started Guide on www.cisco.com.

• If you are performing the initial installation of the system, install the MSCs (see the “Installing an

MSC, FP, or LSP” section on page 4-33).

Removing an RP or PRP Card

This section describes how to remove a route processor (RP) or performance route processor (PRP) card from the chassis. For more detailed information on the route processor card, see Cisco CRS Series Carrier Routing System 4-Slot Line Card Chassis System Description.

Every Cisco CRS 4-slot line card chassis contains two route processor cards in dedicated slots on the front (PLIM) side of the chassis (see Figure 4-17).

Prerequisites

Because chassis operation may be impacted by the removal of an RP card, perform these tasks only if one of the following conditions exists:

• When you are certain that the second RP in the chassis is operational and, if not already the active

RP, ready to assume control (this happens automatically).

• When the chassis is undergoing scheduled maintenance.

• When the Cisco CRS 4-slot line card chassis is powered down.

Failure to follow these guidelines can result in interruptions in data communications and network connectivity.

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Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Large (number 1) Phillips screwdriver

Steps

To remove an RP card, follow these steps:

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 or a bare metal surface on the chassis.

Step 2 Identify the card to be removed from the card cage. Remove any cables connected to the front panel of

the card.

Step 3 PRP cards only—Before removing a PRP card, you must first push the OIR button (using a pointed

object such as a pen), which causes the blue OIR Ready LED to start blinking. When the board is ready for removal, the blue LED glows solidly.

Step 4 Use the screwdriver to turn the two captive screws on the front panel of the card counterclockwise to

loosen the card from the slot.

Chapter 4 Installing and Removing SFCs, RPs, MSCs, FPs, LSPs, PLIMs, and Associated Components

Step 5 Grasp the two card ejector levers and simultaneously pivot both ejector levers 90 degrees away from the

front edge of the card carrier to unseat the card from the backplane connector.

Step 6 Touching only the metal card carrier, slide the card from the slot and place it directly into an antistatic

sack or other ESD-preventive container. If you plan to return the defective card to the factory, repackage it in the shipping container you received with the replacement card.

Verifying the Installation of an RP or PRP Card

This section describes how to verify and troubleshoot the installation of a route processor (RP) orperformance route processor (PRP) card in the Cisco CRS 4-slot line card chassis. For more detailed information on the RP or PRP card, see Cisco CRS Series Carrier Routing System 4-Slot Line Card Chassis System Description.

This section describes how to verify that the card has been properly installed. Status indicators on the RP front panel include:

• Alphanumeric LED display

• Status OK LED

• Active/Standby LED

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