Cisco OL-6256-17 User Manual

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide

January 2014

Cisco Systems, Inc.

www.cisco.com

Cisco has more than 200 offices worldwide. Addresses, phone numbers, and fax numbers are listed on the Cisco website at www.cisco.com/go/offices.

Text Part Number: OL-6256-17

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The following information is for FCC compliance of Class B devices: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If the equipment causes interference to radio or television reception, which can be determined by turning the equipment off and on, users are encouraged to try to correct the interference by using one or more of the following measures:

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• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

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

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Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide

Preface xiii

Objective xiii

Audience xiii

Document Organization xiii

Document Conventions xiv

Preface

This preface explains the objectives, intended audience, and organization of the Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide and describes the conventions that convey

instructions and other information.

The preface contains the following sections:

• Objective, page xiii

Objective

Audience

• Audience, page xiii

• Document Organization, page xiii

• Document Conventions, page xiv

• Related Documentation, page xv

• Changes to This Document, page xv

• Obtaining Documentation and Submitting a Service Request, page xvii

This installation guide describes how to install power, air circulation, line card, and external components into and remove them from a Cisco CRS Carrier Routing System 8-Slot Line Card Chassis.

This guide is for customers who are responsible for installing the line card chassis components. The reader is expected to have installed networking hardware in the past. No additional knowledge of routing or the Cisco IOS-XR software is assumed.

Document Organization

This guide contains the following chapters and appendixes:

• Chapter 1, “Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview,” introduces the

various line card chassis systems and components.

• Chapter 2, “Installing and Removing Power Components,” details how to bring power to and install

power components in the line card chassis.

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• Chapter 3, “Installing and Removing Air Circulation Components,” describes how to install the fan

trays and air filters.

• Chapter 4, “Installing and Removing Line Cards, PLIMs, and Associated Components,” provides

instructions on how to install various cards, including modular services cards, switch fabric cards, route processor cards, and the physical layer interface modules.

• Chapter 5, “Installing and Removing Exterior Components,” provides instructions on how to install

the chassis exterior components.

• Appendix A, “Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Specifications,” lists the

specifications for the line card chassis.

• Appendix B, “Product IDs for the Cisco CRS 8-Slot Line Card Chassis” lists the product IDs for

components of the Cisco CRS Carrier Routing System 8-Slot LCC.

Document Conventions

This guide uses the convention where the symbol ^ represents the key labeled Control. For example, the key combination ^z means hold down the Control key while you press the z key.

Command descriptions use these conventions:

• Examples that contain system prompts denote interactive sessions, indicating the commands that

you should enter at the prompt. The system prompt indicates the current level of the EXEC command interpreter. For example, the prompt level, and the prompt privileged level usually requires a password. Refer to the related software configuration and reference documentation listed in Related Cisco CRS Series Documentation for additional information.

router> indicates that you should be at the user

router# indicates that you should be at the privileged level. Access to the

• Commands and keywords are in boldface font.

• Arguments for which you supply values are in italic font.

• Elements in square brackets ([ ]) are optional.

• Alternative but required keywords are grouped in braces ({}) and separated by vertical bars (|).

Examples use these conventions:

• Terminal sessions and sample console screen displays are in screen font.

• Information you enter is in boldface screen font.

• Nonprinting characters, such as passwords, are in angle brackets (< >).

• Default responses to system prompts are in square brackets ([]).

• Exclamation points (!) at the beginning of a line indicate a comment line.

Note Means reader take note. Notes contain helpful suggestions or references to materials not contained in

this manual.

Timesaver Means the described action saves time. You can save time by performing the action described in the

paragraph.

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Caution Means reader be careful. You are capable of doing something that might result in equipment damage or

loss of data.

Warning

This warning symbol means danger. You are in a situation that could cause bodily injury. Before you work on any equipment, be aware of the hazards involved with electrical circuitry and be familiar with standard practices for preventing accidents. To see translations of the warnings that appear in this publication, refer to the Regulatory Compliance and Safety Information document that accompanied this device.

Changes to This Document

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

Table 1 Changes to This Document

Revision Date Change Summary

OL-6256-17 January 2014 Added updates to support the Cisco CRS-X, which includes

OL-6256-16 June 2013 Added information about how to replace a SFP on a line card

OL-6256-17

new line cards, switch fabric cards, and PLIMs.

that uses an articulated bracket.

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide

Table 1 Changes to This Document (continued)

Revision Date Change Summary

OL-6256-15 July 2011 Added information about new CRS-LSP Label Switch

Processor (LSP) card to the following sections:

• Chapter 1, “Cisco CRS Carrier Routing System 8-Slot

Line Card Chassis Overview”

• Chapter 4, “Installing and Removing Line Cards, PLIMs,

and Associated Components”

• Appendix A, “Cisco CRS Carrier Routing System 8-Slot

Line Card Chassis Specifications”

OL-6256-14 July 2011 Added new modular configuration AC cord clamp. Updated

Appendix A and added Appendix B. Minor editorial and technical changes were also made.

OL-6256-13 April 2011 Added information about new CRS-8-PRP-6G and

CRS-8-PRP-12G Performance Route Processor (PRP) cards. Technical updates and minor editorial changes were also made.

OL-6256-12 November 2010 Updated grounding and modular configuration power

sections. Minor editorial and technical changes were also made.

OL-6256-11 October 2010 Added information about the new MSC140 and FP140 line

cards; FQ123-140G switch fabric card; 20-port, 14-port, 8-port, and 4-port 10-GE XFP PLIMs; and the 1-port 100-GE CFP PLIM. Minor editorial and technical changes were also made.

OL-6256-10 September 2010 Added new procedures on installing and removing modular

configuration power components to Chapter 2, “Installing

and Removing Power Components.”

OL-6256-09 Jan 2010 Added installation of rear exhaust screen.

OL-6256-08 May 2008 Added new procedures on installing and removing a pillow

block to Chapter 4, “Installing and Removing Line Cards,

PLIMs, and Associated Components.”

OL-6256-07 February 2008 Minor technical changes.

OL-6256-06 August 2007 Updated the document with technical corrections. Also added

procedures in Chapter 5, “Installing and Removing Exterior

Components,” on installing the updated inlet grille.

OL-6256-05 October 2006 Updated the document with technical corrections. Also added

procedures in Chapter 5, “Installing and Removing Exterior

Components,” on installing and removing the front and rear

doors, installing and removing the inlet and exhaust grilles, and added procedures for changing the location of the door hinge and adjusting the width of the chassis doors if the doors do not latch properly.

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Table 1 Changes to This Document (continued)

Revision Date Change Summary

OL-6256-04 April 2006

OL-6256-03 December 2005 Updated Chapter 2, “Unpacking and Mounting the Chassis”

OL-6256-02 March 2005

OL-6256-01 December 2004 Initial release of the document.

• Removed Chapter 2, “Unpacking and Mounting the

Chassis” from this guide to consolidate this information in the Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Unpacking, Moving, and Securing Guide.

• Changed the book title to Cisco CRS Carrier Routing

System 8-Slot Line Card Chassis Installation Guide.

to reflect new packaging.

• Updated Chapter 2, “Unpacking and Mounting the

Chassis” to include information on mounting the chassis in the rack from the rear.

• Updated Chapter 3, “Installing and Removing Power

Components” to include new wiring information.

• Updated Chapter 5, “Installing and Removing MSCs,

PLIMs, and Associated Components” to include information on installing and removing slot covers and impedance carriers.

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

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CHA P T ER

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

This installation guide describes how to install the power, air circulation, line card, and external components into and remove them from a Cisco CRS Carrier Routing System 8-Slot Line Card Chassis.

This chapter introduces the Cisco CRS 8-slot line card chassis at the highest level. It contains illustrations of the front and rear 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 8-Slot Line Card Chassis System Description.

This chapter presents the following topics:

• Chassis Overview, page 1-1

• Chassis Components, page 1-2

• Chassis Slot Numbers, page 1-9

• Chassis Cable Management, page 1-10

• Chassis Cooling System, page 1-11

• Chassis Power System, page 1-12

• Safety Guidelines, page 1-12

• Preventing Electrostatic Discharge, page 1-13

Chassis Overview

The Cisco CRS 8-slot line card chassis can be installed in locations where the 16-slot system 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-mount chassis that contains the following major system components:

• Up to eight modular services cards (MSCs), forwarding processor (FP) cards, and label switch

processor (LSP) cards, also called line cards (up to eight)

• Physical layer interface modules, or PLIMs (up to eight, one for each line card)

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

• Switch fabric cards (four required)

• SPA Interface Processors (SIPs) and Shared Port Adapters (SPAs) which can be installed instead of

PLIMs

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1-1

Chassis Components

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

–

SIP is a carrier card that is similar to a PLIM and inserts into a line card chassis slot and interconnects to an MSC, FP, or LSP like a PLIM. Unlike PLIMs, SIPs provide no network connectivity on their own.

–

SPA is a modular type of port adapter that inserts into a subslot of a compatible SIP carrier card to provide network connectivity and increased interface port density. A SIP can hold one or more SPAs, depending on the SIP type and the SPA size. POS/SDH and Gigabit Ethernet SPAs are available.

• A chassis midplane that connects MSCs, FPs, or LSPs to their PLIMs and to switch fabric cards.

The LCC supports 40G, 140G, and 200G fabric cards, as follows:

• The Cisco CRS-1 Carrier Routing System uses fabric cards designed for 40 G operation

(CRS-8-FC/S or CRS-8-FC/M cards).

• The Cisco CRS-3 Carrier Routing System uses fabric cards designed for 140G operation

(CRS-8-FC140/S or CRS-8-FC140/M cards).

• The Cisco CRS-X Carrier Routing Sytsem uses fabric cards designed for 200G operation

(CRS-8-FC400/S cards in 200G mode).

A mixture of 40G, 140G, and 200G fabric cards is not supported except during migration.

Note Throughout this document, the generic term Cisco CRS Carrier Routing system refers to the Cisco

CRS-1, Cisco CRS-3, and Cisco CRS-X Carrier Routing Systems, unless otherwise specified.

Chassis Components

This section lists the main components of a Cisco CRS 8-slot line card chassis. It primarily identifies the components that are considered field-replaceable units (FRUs), but where additional detail is useful identifies subassemblies that are not field replaceable.

Figure 1-1 shows the front view of a Cisco CRS 8-slot line card chassis with a fixed configuration AC

power system installed. The front view of a Cisco CRS 8-slot line card chassis with a fixed configuration DC power system installed is similar.

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Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

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P O

W E

F L

A C F A I

C B T M

L L

P O

W E

R O K

F L

C F A

C B T M

L L

CISCO CRS-1

S E

R I E

LINECARD CHASSIS

Figure 1-1 Front (PLIM) View of Line Card Chassis—Fixed Configuration Power Shown

Chassis Components

1 Cable management bracket 4 Air filter

2 Chassis vertical mounting brackets 5 Power System

3 PLIM and RP slots (RPs in middle 2 slots)

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Chassis Components

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CRS 8-Slot DC Rear

CRS 8-Slot AC Rear

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

Figure 1-2 shows the rear view of a Cisco CRS 8-slot line card chassis with fixed configuration AC and

DC power systems installed.

Figure 1-2 Rear (MSC) View of Line Card Chassis—Fixed Configuration Power Shown

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Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

CRS 8-Slot DC Front

CRS 8-Slot AC Front

CISCO CRS-1

SER

I E S

LINECARD CHASSIS

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CISCO CRS-1

S ERIES

LINECARD CHASSIS

Figure 1-3 shows the front view of a Cisco CRS 8-slot line card chassis with modular configuration AC

and DC power systems installed.

Figure 1-3 Front (PLIM) View of Line Card Chassis—Modular Configuration Power Shown

Chassis Components

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Chassis Components

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CRS 8-Slot DC Rear

CRS 8-Slot AC Rear

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

Figure 1-4 shows the rear view of a Cisco CRS 8-slot line card chassis with modular configuration AC

and DC power systems installed.

Figure 1-4 Rear (MSC) View of Line Card Chassis—Modular Configuration Shown

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Figure 1-5 shows the rear view of a Cisco CRS 8-slot line card chassis with a fixed configuration AC

power system installed.

Figure 1-5 Rear (MSC) View of Line Card Chassis—Fixed Configuration Shown

Chassis Components

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1 Upper fan tray (beneath cover) 5 Lower fan tray

2 Chassis vertical mounting brackets 6 Rear exhaust screen

3 Switch fabric card (half-height) slots 7 Power system

4 MSC slots

The Cisco CRS 8-slot line card chassis contains:

• As many as eightMSC, FP or LSP cards (all types are also called line cards), and eightPLIMs. 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. The line card can be associated with several different PLIMs, which provide different interface speeds and technologies.

Note For a complete list of line cards, route processors, SPAs and SIPs, and interface modules supported in

the Cisco CRS 8-slot line card chassis, go to the Cisco Carrier Routing System Data Sheets at: http://www.cisco.com/en/US/products/ps5763/products_data_sheets_list.html.

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide

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Chassis Components

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis 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 provide the intelligence of the system by

functioning as the Cisco CRS 8-slot line card chassis system controller (serving as part of the control plane in multi-chassis systems) and providing route processing. Only one RP is required for system operation. For redundant operation, you can order a second RP as an option (CRS-8-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 two 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).

• Upper and lower fan trays. 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.

• Four half-height 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 MSC (and its associated PLIM) with every other MSC (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 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. Two types of power systems are

available: fixed configuration power and modular configuration power. Both power configurations use either AC or DC power. The fixed configuration power solution contains two power distribution units (PDUs), with either one AC rectifier or one DC power entry modules (PEM) per PDU. The modular configuration power solution contains two power shelves with either up to four DC power modules (PMs) or up to three AC PMs per power shelf.

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 MSC side, which is where warm air is exhausted, is considered the rear of the chassis.

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Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis 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 chassis.

Figure 1-6 shows the slot numbering on the front (PLIM) side of the Cisco CRS 8-slot line card chassis.

Figure 1-6 Line Card Chassis Slot Numbering—Front (PLIM) Side

012

RP 0

RP 1

456

Chassis Slot Numbers

Power A Power B

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As shown, the Cisco CRS 8-slot line card chassis numbers on the PLIM side of the chassis include the card cage with:

• Eight PLIM slots: left to right, 0, 1, 2, 3, 4, 5, 6, 7

• Two route processor card slots, RP0 and RP1

• Power shelf A and power shelf B

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Chassis Cable Management

Figure 1-7 shows the slot numbers on the rear (MSC) side of the Cisco CRS 8-slot line card chassis.

Figure 1-7 Line Card Chassis Slot Numbers—Rear (MSC) Side

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

FAN 0

7654SM 0 SM 2

Power B Power A

SM 1 SM 33210

FAN 1

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As shown, the slot numbers on the MSC side of the chassis include:

• Fan tray 0 and fan tray 1

• Card cage, including:

–

Eight line card slots (0, 1, 2, 3, 4, 5, 6, 7)

–

Four half-height switch fabric card slots (SM0, SM1, SM2, and SM3)

• Power shelf A and Power shelf B

The MSC slot numbers are reversed from the PLIM slot numbers on the other side of the chassis. Because an MSC mates with its associated PLIM through the midplane, MSC slot 0 is on the far right side of the chassis looking at it from the rear (MSC) side.

PLIM slot 0 is on the far left side of the chassis, looking at if from the front (PLIM) side. MSC slot 0 and PLIM slot 0 mate with each other through the midplane, and so do all other MSC and PLIM slots (0 through 7).

Chassis Cable Management

The Cisco CRS 8-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.

Note Do not install the front cover on the chassis when the telescoping feature is in use.

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Figure 1-8 shows the cable management bracket.

Figure 1-8 Cable Management Bracket

Chassis Cooling System

The chassis has two fan trays, each with four fans, that cool the chassis card cages. Cool air flows in at the bottom front of the chassis and flows through the chassis card cages and through the fans in the fan trays before being exhausted through the bottom rear of the chassis (see Figure 1-9). In addition, each AC or DC 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.

A replaceable air filter is located on the front of the chassis below the PLIM card cage. Each fixed configuration power module also has a replaceable air filter that attaches to the module at 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 grills 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

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Fan

Air enters

PLIM side

Power system

Fan

Air exits MSC and fabric card side

Front Rear

Air filter

Chapter 1 Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

Figure 1-9 Airflow Through 8-Slot Line Card Chassis

Chassis Power System

Two types of power systems are available for the Cisco CRS 8-slot line card chassis: fixed configuration power and modular configuration power. Both power systems can be powered by either AC or DC power. The chassis power system takes the facility power and converts it to the DC voltage necessary to power chassis components.

For more information, refer to 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.

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

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, or their associated components.

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

instructions.

• Be sure to power down a fixed configuration PDU or modular configuration power shelf before

removing it from the chassis.

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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.

Preventing Electrostatic Discharge

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Preventing Electrostatic Discharge

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Installing and Removing Power Components

This chapter provides instructions on how to install and remove Cisco CRS Carrier Routing System 8-slot line card chassis power components.

Power Systems Overview

There are two options for power systems: the fixed configuration power system and the modular configuration power system. Power components are not interchangeable between the fixed and modular configuration power system.

• Fixed configuration power system consists of two power distribution units (PDUs) and either DC

power entry modules (PEMs) or AC rectifiers. The AC version requires 3-phase AC-Delta or AC-Wye input power to the PDU. The PDU distributes facility power to the AC rectifier or DC PEM, which in turn provides processed power to the chassis. A removable air filter is located on the front of each DC PEM and AC rectifier. The fixed configuration power system includes SNMP MIBS and XML support.

CHA P T ER

• Modular configuration power system consists of two power shelves and either AC or DC power

modules (PMs). However, unlike the fixed configuration power system, the AC version of the modular configuration power system requires single-phase AC input power to power the shelves. If you have 3-phase AC-Delta or AC-Wye at your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC input power for the power shelf. At the shelf level, the power system provides 2N redundancy; the PMs themselves provide load-share redundancy. The modular configuration power system also includes SNMP MIBs and XML support.

Note In a fixed configuration AC or DC power system, PDU refers to the power component that connects to

the AC rectifier or DC PEM.

Note In a modular configuration AC power system, PDU refers to the Cisco CRS PDU that converts 3-phase

AC-Wye or AC-Delta input power to single-phase AC input power for the modular configuration AC power shelf. For further information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

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Chapter 2 Installing and Removing Power Components

Power Component Information Common to Two Types of Power System

This chapter presents the following topics:

• Power Component Information Common to Two Types of Power System, page 2-2

• How to Install or Remove Fixed Configuration Power Components, page 2-13

• How to Install or Remove Modular Configuration Power Components, page 2-25

• Converting a Chassis from Fixed Configuration Power to Modular Configuration Power, page 2-54

Power Component Information Common to Two Types of Power System

This section contains information shared by the fixed configuration power components and the modular configuration power components in the following topics:

• Basic Chassis Power Details, page 2-2

• Bonding and Grounding Guidelines, page 2-4

• How to Install the Chassis Ground Cable, page 2-5

• DC Power Systems, page 2-6

• AC Power Systems, page 2-11

Basic Chassis Power Details

The Cisco CRS 8-slot line card chassis can be configured with either a DC-input power subsystem or an AC-input power subsystem. The chassis power system provides the necessary power for chassis components. Site power requirements differ, depending on the source voltage used.

A fixed configuration AC PDU connects to an AC rectifier, while a fixed configuration DC PDU connects to a DC PEM. A modular configuration AC power shelf houses up to 3 AC PMs, while a modular configuration DC power shelf houses up to 4 DC PMs. It is required that you use only one type of power shelf in a chassis at a time.

Note In a modular configuration power system, both AC and DC power supplies are referred to as power

modules (PMs).

Warning

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

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Fixed Configuration Power System

Three types of PDUs exist for fixed configuration power system:

• AC Wye PDU

• AC Delta PDU

• DC PDU

The AC PDU connects to the AC rectifier, while the DC PDU connects to the DC PEM. Although there are differences among the different PDU types (AC Wye, AC Delta, and DC), they are installed in the same manner. For detailed information, see the “How to Install or Remove Fixed Configuration Power

Components” section on page 2-13.

Note The fixed configuration PDUs arrive preassembled in the chassis. AC power cords arrive preattached but

the DC power cables need to be installed.

Caution Use only one type of fixed configuration PDU—AC Wye, AC Delta, or DC—and its mating AC rectifier

or DC PEM in a chassis at one time.

Power Component Information Common to Two Types of Power System

Modular Configuration Power System

The modular configuration AC power shelves connect to AC PMs, while the modular configuration DC power shelves connect to DC PMs. Although there are differences between the two different power shelf types (AC and DC), they are installed in the same manner. Similarly, the modular configuration AC and DC PMs are installed in the same manner. For detailed information, see the “How to Install or Remove

Modular Configuration Power Components” section on page 2-25.

Caution Use only one type of modular configuration power shelf—AC or DC—and its mating AC or DC PMs in

a chassis at one time.

Precautions and Recommendations

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.

• Properly ground your system to avoid damage from lightning and power surges.

Note For the fixed configuration power system, although PDUs may be installed or removed without powering

down the system, for safety purposes we recommend that you power down the system before you install or remove a PDU.

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For the modular configuration power system, although power shelves may be installed or removed without powering down the system, for safety purposes we recommend that you power down the system before you install or remove a power shelf.

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Power Component Information Common to Two Types of Power System

Bonding and Grounding Guidelines

The router chassis has safety earth ground connections in conjunction with the power cabling to the fixed configuration PDUs. Modular configuration power supports chassis grounding only. The chassis allows you to connect the central office ground system or interior equipment ground system to the bonding and grounding receptacles on the router chassis, when either a fixed or modular configuration power system is installed. Six chassis grounding points are provided at the rear (MSC) side of the chassis, as shown in

Figure 2-1. Each side of the chassis has one pair of threaded ground studs located on the inside of the

chassis and two sets of grounding receptacles located on the outside of the chassis. These ground points are also called the network equipment building system (NEBS) bonding and grounding points.

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

grounding connections.

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

Power Shown

Chapter 2 Installing and Removing Power Components

1 NEBS bonding and grounding points (inside chassis)

2 NEBS bonding and grounding points (outside chassis)

Caution Do not remove the chassis ground cable unless the chassis is being replaced.

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How to Install the Chassis Ground Cable

This section describes how to install the ground cable on the Cisco CRS 8-slot line card chassis.

Prerequisites

To connect the routing system to a network equipment building system (NEBS)-compliant bonding and grounding system at the site, you must have the following:

• Minimum of one grounding lug that has two M6 bolt holes with 0.63-inch (5/8 inch) (1.6 cm) of

spacing between them, center to center, and a 6-AWG multistrand copper cable. The lug is similar to the type used for the DC-input power supply leads, as shown in Figure 2-4.

• Four M6 or equivalent hex-head nuts with integrated locking washers are shipped pre-installed on

the inside of the chassis.

• Eight M6 or equivalent hex-head bolts with integrated locking washers are shipped pre-installed on

the outside of the chassis.

• Ground cable routed upwards or downwards, per customer installation requirements. Although we

recommend at least 6-AWG multistrand copper cable, the actual cable diameter and length depend on your router location and site environment. This cable is not available from Cisco Systems; it is available from any commercial cable vendor. The ground cable should be sized according to local and national installation requirements.

Power Component Information Common to Two Types of Power System

Caution The DC Return of the Cisco CRS 8-slot chassis should remain isolated from the system frame and

chassis (DC-I: Isolated DC Return).

Required Tools and Equipment

You need the following tools to perform this task:

• One ground lug for equipment-side ground connection. In a rack application, the rack-side of the

ground cable will also require a lug.

• Ground cable

• Crimping tool and lug specific die

• 10-mm 6 pt. combination wrench

• Torque wrench with 10-mm 6 pt. socket and rated accuracy at 30 in.-lb (3.39 N-m)

Steps

To attach the ground cable to the chassis, perform the following steps:

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

Step 2 Using the 10-mm wrench, attach the ground cable to one of the grounding points at the rear of the

chassis. Then use the torque wrench to tighten to a torque of 30 in.-lb (3.39 N-m). Figure 2-2 shows how the ground cable is attached to the ground points on the outside of the chassis.

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Power Component Information Common to Two Types of Power System

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Figure 2-2 Ground Cables Attached to Chassis Grounding Points

Chapter 2 Installing and Removing Power Components

1 NEBS bonding and grounding points (inside chassis)

2 NEBS bonding and grounding points (outside chassis)

DC Power Systems

Each DC powered chassis contains two fixed configuration PDUs or two modular configuration power shelves for 2N redundancy.

• In the fixed configuration power system, each PDU accepts one DC PEM for 2N redundancy. The

PDUs and PEMs are field replaceable. The PDUs contain the input power connectors.

• In the modular configuration power system, each power shelf accepts up to four DC PMs. The power

shelves and DC PMs are field replaceable. The power shelves contain the input power connectors.

Note Depending on the hardware deployed at your site, your system may not consume the maximum

power supplied by the power system.

Fixed Configuration DC Power

The Cisco CRS 8-slot line card chassis DC power system provides 7,500 watts to power the chassis. Each DC PDU is connected to three pairs of DC power feeds and powers a single DC PEM. Input DC power enters the PDU and is passed to the PEM, which provides power to the components in the chassis.

• Each DC PEM has its own circuit breaker.

• The fixed configuration power system distributes power in power zones.

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• The DC PDUs and DC PEMs are field replaceable.

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Unlike the Cisco CRS 16-slot line card chassis, the Cisco CRS 8-slot line card chassis does not contain an alarm module. A microprocessor in the DC PEM monitors the status of each DC PEM. The microprocessor communicates with the system controller on the route processor (RP) card. LEDs on the front panel of the RP card indicate active alarm conditions.

The DC PDU is shipped with a plastic safety cover over the input terminal block, as shown in Figure 2-3. This safety cover has two parts, each part held on to the PDU with a Phillips screw. We recommend removing the safety cover only when wiring and unwiring the chassis. The safety cover is slotted in such a way that the cables can only come out on the bottom portion of the cover.

Figure 2-3 Fixed Configuration DC PDU with Plastic Safety Cover

Power Component Information Common to Two Types of Power System

1 Each set of cables (RTN and –48 V/–60 V) is a single VDC input.

Each PDU requires three DC inputs of –48/–60 VDC (nominal), 60 A service. The PDU has three sets of double-stud terminals (-48/-60 VDC Lines and -48/-60 VDC Returns) for connecting to the VDC inputs.

Each DC PDU should be connected to a different central office DC power source:

• One PDU should be connected to three –48/–60 VDC “A” buses.

• Other PDU should be connected to three –48/–60 VDC “B” buses.

If DC power to a PDU fails, the other PDU provides enough power for the chassis. This 2N power redundancy enables the routing system to operate in spite of single power failure.

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

Note All six -48/-60 VDC Return input cables for one chassis should have the same cable gauges and the

lengths should be matched within 10 percent of deviation.

The grounding lugs should be dual-hole and able to fit over M6 terminal studs at 0.63 in (1.6 cm) centers, as shown in Figure 2-4 (for example, Panduit part number LCD2-14A-Q, or equivalent).

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Power Component Information Common to Two Types of Power System

Crimp area

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2.40

+/- .06

0.60

+/- .04

0.10

+/- .01

0.25

+/- .04

0.380.63

+/- .02

End View

Ø 0.27

+/- .02

2 holes

All measurements in inches

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2.11 REF

0.60

+/- .04

0.25

+/- .04

0.38 REF

0.88

+/- .04

.10

+/- .01

1.18 REF

45° +/- 5°

0.63

+/- .02

Ø 0.27

+/- .02

2 holes

All measurements in inches

Figure 2-4 DC Power Grounding Cable Lug

The terminal lugs (in other words, all lugs not used for grounding) should be 45-degree angled, industry-standard dual-hole compressions lugs, and able to fit over M6 terminal studs at 0.63 in (1.6 cm) centers, as shown in Figure 2-5.

Note In the fixed configuration power system, power cables have a 20 in.-lb (2.26 N-m) torque value and

ground cables have a 30 in.-lb (3.39 N-m) torque value. The PDU mounting screws have a 9 in.-lb (1.04 N-m) torque value.

Chapter 2 Installing and Removing Power Components

Figure 2-5 DC Power Cable Lug

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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. Follow your local practices for cable color code and markings. You must ensure that the power cables are connected to the DC-input power shelf terminal studs in the proper positive (+) and negative (–) polarity.

In some cases, the source DC cable leads might have a positive (+) or negative (–) label, but you must verify the polarity by measuring the voltage between the DC cable leads. When making the measurement, the positive (+) lead and negative (–) lead must always match the (+) and (–) labels on the PDU.

Caution When installing DC power cables, make sure that the polarity of the DC input wiring is correct.

For additional power details, see Appendix A, “Cisco CRS Carrier Routing System 8-Slot Line Card

Chassis Specifications” or Cisco CRS Carrier Routing System 8-Slot Line Card Chassis System

Description.

Modular Configuration DC Power

The Cisco CRS 8-slot line card chassis modular configuration DC power system can provide up to 8,400 W to power the line card chassis. The modular configuration DC power system uses A or B power shelves to provide reliable, 2N redundant power to all chassis components.

Power Component Information Common to Two Types of Power System

Note Depending on the hardware deployed at your site, your system may not consume the maximum power

supplied by the power system.

The Cisco CRS 8-slot line card chassis does not contain an alarm module. The DC PM monitors PM status and processes alarm functions. The PM distributes power and passes PM status signals to the system. Alarms are processed through the route processor (RP). LEDs on the front panel of the RP card indicate active alarm conditions.

If DC power to one modular configuration power shelf fails, the other power shelf provides enough power for the chassis. This 2N power redundancy enables the routing system to operate in spite of single power failure.

Each power shelf operates with up to four DC inputs of –48/–60 VDC (nominal), 60 A. The power shelf accepts input DC power in the range –40 to –72 VDC.

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Power Component Information Common to Two Types of Power System

Figure 2-6 shows the wiring on the rear of a modular configuration DC power shelf.

Figure 2-6 Modular Configuration DC Power Shelf Wiring

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We recommend that the terminal block covers, shown in Figure 2-6, should only be removed when wiring and unwiring the power shelf. The terminal block cover is slotted in such a way that cables can only come out the bottom portion of each cover.

The power supply terminal block lug opening width is 0.63 inch (1.6 cm). The terminal posts are centered 0.63 inches (5/8 inch) (1.6 cm) apart and are M6-threaded. We recommend that you use an appropriately sized 180-degree angle (straight) industry standard 2-hole, standard barrel compression lug, as shown in Figure 2-7, or an appropriately sized 45-degree angle industry standard 2-hole, standard barrel compression lug, as shown in Figure 2-8.

Figure 2-7 180-Degree (Straight) DC Power Cable Lug

All measurements in inches

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End View

0.60

+/- .04

0.10

+/- .01

Ø 0.27

+/- .02

2 holes

0.25

+/- .04

2.40

+/- .06

Crimp area

0.380.63

+/- .02

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Figure 2-8 45-Degree DC Power Cable Lug

All measurements in inches

Power Component Information Common to Two Types of Power System

2.11 REF

0.60

+/- .04

.10

+/- .01

Ø 0.27

+/- .02

2 holes

0.25

+/- .04

0.63

+/- .02

+/- .04

2.11 REF

0.38 REF

0.88

1.18 REF

45° +/- 5°

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Note In the modular configuration power system, DC power cables have a torque value of 20 in.-lb (2.26 N-m)

and chassis ground cable connectors have a torque value of 30 in.-lb (3.39 N-m).

For additional power details, see Appendix A, “Cisco CRS Carrier Routing System 8-Slot Line Card

Chassis Specifications” or Cisco CRS Carrier Routing System 8-Slot Line Card Chassis System

Description.

AC Power Systems

Each AC powered chassis contains two fixed configuration AC PDUs or two modular configuration AC power shelves for 2N redundancy.

• In the fixed configuration power system, each PDU accepts one AC power rectifier. The PDUs and

AC power rectifiers are field replaceable.

• In the modular configuration power system, each power shelf can contain up to three AC PMs. The

power shelves and the AC PMs are field replaceable.

Note Depending on the hardware deployed at your site, your system may not consume the maximum power

supplied by the power system.

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Power Component Information Common to Two Types of Power System

Fixed Configuration AC Power

An AC-powered Cisco CRS 8-slot line card chassis contains two AC power distribution units (PDUs) and two AC rectifier modules. Each AC PDU is connected to a 3-phase (200 to 240) input VAC power source and connects to a single 7500-watt AC rectifier module that is field replaceable. Each AC rectifier module converts input AC power to the 54.5 VDC used by the Cisco CRS 8-slot line card chassis. Each rectifier has its own circuit breaker.

To provide 2N power redundancy for the Cisco CRS 8-slot line card chassis, each PDU and AC rectifier pair is connected to a different AC power source. During normal operation when both power sources are operational, both PDUs and rectifiers function together to power the chassis. However, if a power source fails, the other power source provides the other PDU and rectifier pair with enough input power to power the chassis. This 2N power redundancy enables the routing system to operate despite the power failure.

Two versions of the AC PDU are available to accommodate AC input power in either the Delta or Wye configuration. Each PDU has a different Cisco part number. The PDUs are shipped with AC power cords that are 14 feet (4.3 m) long.

Unlike the Cisco CRS 16-slot line card chassis, the Cisco CRS 8-slot line card chassis does not contain an alarm module. A microprocessor in the AC rectifier monitors the status of each AC rectifier. The microprocessor communicates with the system controller on the RP card. LEDs on the front panel of the RP card indicate active alarm conditions.

Chapter 2 Installing and Removing Power Components

The AC PDUs have the following input VAC power requirements:

• AC Wye input: 3-phase, 200 to 240 VAC nominal (phase-to-neutral), 50 to 60 Hz,

16 A (International) or 20 A (North America). The PDU is rated for 14-amp service, and accepts AC input of 16 or 20 A.

The Wye power cord has a 5-pin IEC 60309 plug that is rated for 400 VAC, 16 or 20 A, (3W + N + PE). The power cord plugs into a similarly rated IEC 60309 receptacle.

• AC Delta input: 3-phase, 200 to 240 VAC nominal (phase-to-phase), 50 to 60 Hz, 30 A. The PDU is

rated for 24-amp service, and accepts AC input of 30 A.

The Delta power cord has a 4-pin NEMA L15-30P plug that is rated for 250 VAC, 30 A (3W + PE). The power cord plugs into a similarly rated NEMA L15-30R locking-type receptacle.

For additional power details, see Appendix A, “Cisco CRS Carrier Routing System 8-Slot Line Card

Chassis Specifications” or Cisco CRS Carrier Routing System 8-Slot Line Card Chassis System

Description.

Modular Configuration AC Power

The Cisco CRS 8-slot line card chassis modular configuration AC power system can provide up to 9,000 W to power the line card chassis.

Note Depending on the hardware deployed at your site, your system may not consume the maximum power

supplied by the power system.

2-12

The modular configuration power system provides the following features:

• AC power shelf redundancy

• PM load-share redundancy

• Elimination of power zone distribution, while maintaining zone protection

• Capacity for future growth

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Chapter 2 Installing and Removing Power Components

The modular configuration AC power systems use A or B power shelves to provide reliable, 2N redundant power to all chassis components.

The Cisco CRS 8-slot line card chassis does not contain an alarm module. The AC PM monitors PM status and processes alarm functions. The AC PM distributes power and passes PM status signals to the system. Each PM has its own integrated fuse to protect the system, and each PM is plugged into its own power outlet. Alarms are processed through the RP. LEDs on the front panel of the RP indicate active alarm conditions.

Unlike the fixed configuration AC power system, which requires 3-phase AC Delta or AC Wye input power, the modular configuration AC power system requires single-phase AC input power. If you have 3-phase AC Delta or AC Wye at your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC input power for the power shelf. For further information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

The modular configuration AC power shelf has the following input VAC power requirements:

• Single-phase, 200 to 240 VAC nominal, 50 to 60 Hz, 16 A.

Each power shelf contains three IEC-320-C22 receptacles which can accept up to three IEC-320-C21 connector female cords.

How to Install or Remove Fixed Configuration Power Components

Note In order to maintain a balanced 3-phase power load, three AC PMs are required to be installed in a Cisco

CRS 8-slot line card chassis AC modular configuration power shelf.

Note If single-phase AC power is available at your site, we recommend that you use appropriate short-circuit

protection in compliance with national and local electrical codes.

For additional power details, see Appendix A, “Cisco CRS Carrier Routing System 8-Slot Line Card

Chassis Specifications” or Cisco CRS Carrier Routing System 8-Slot Line Card Chassis System

Description.

How to Install or Remove Fixed Configuration Power Components

This section contains the following procedures:

• Before Powering the Chassis Up or Down, page 2-14

• Converting from One Fixed Configuration Power System to Another, page 2-14

• Installing a PDU

• Removing a PDU

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• Installing DC PDU Cables, page 2-19

• Removing DC PDU Wiring, page 2-21

• Installing a DC PEM or AC Rectifier

• Removing a DC PEM or AC rectifier

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How to Install or Remove Fixed Configuration Power Components

Note Although there are differences among the different fixed configuration PDU types (AC Wye, AC Delta,

and DC), they are installed in the same manner.

Note Although there are differences between the AC rectifier and DC PEM (AC Wye, AC Delta, and DC), they

are installed in the same manner.

Before Powering the Chassis Up or Down

While the line card chassis does not have a single power switch that powers the entire chassis and all its components up and down, the AC rectifier or DC PEM linkage cuts power to the chassis as a whole when both power components are turned off. Most components on the chassis, such as the power modules, MSCs, PLIMs, and fan trays can be removed or installed in the chassis while it is running.

Before you can power the chassis up, perform the following steps:

Chapter 2 Installing and Removing Power Components

Step 1 Install and wire the PDUs (see the “Installing a PDU” section on page 2-15).

Step 2 Install the DC PEMs or AC rectifiers (see the “Installing a DC PEM or AC Rectifier” section on

page 2-22).

Step 3 Install the RP card (see the “Installing an RP, PRP, or DRP Card” section on page 4-38).

Step 4 Activate your power source.

Step 5 Turn the PEM switches to the on position.

To power down the chassis entirely, you must power down each of the two DC PEMs or AC rectifiers; you move each power switch to the off position by pulling it toward you. Both DC PEMs or AC rectifiers must be disconnected or the PDUs unplugged to de-energize the chassis completely.

Note After powering off the AC rectifier, wait a minimum of 20 seconds before powering it on again.

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

Converting from One Fixed Configuration Power System to Another

2-14

To convert a Cisco CRS 8-slot line card chassis with a fixed configuration power system from AC to DC power, or from DC to AC power, perform the following steps:

Step 1 Power down the chassis completely. See the “How to Install or Remove Fixed Configuration Power

Components” section on page 2-13.

Step 2 Remove the DC PEMs or AC rectifiers. See the “Removing a DC PEM or AC rectifier” section on

page 2-23.

Step 3 Remove the PDUs. See the “Removing a PDU” section on page 2-17.

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Step 4 Install the new PDUs. See the “Installing a PDU” section on page 2-15.

If you are converting from AC to DC power, you must wire the PDU properly. See the “Installing DC

PDU Cables” section on page 2-19.

Step 5 Install the DC PEMs or AC rectifiers. See the “Installing a DC PEM or AC Rectifier” section on

page 2-22.

Step 6 Power the chassis back up. See the “How to Install or Remove Fixed Configuration Power Components”

section on page 2-13.

Caution Use only one type of fixed configuration PDU—AC Wye, AC Delta, or DC—and its mating AC rectifier

or DC PEM in a chassis at one time.

Installing a PDU

This section describes how to install a PDU in the Cisco CRS 8-slot line card chassis. For information on the difference between the power types, see the “DC Power Systems” section on page 2-6 and the “AC

Power Systems” section on page 2-11.

The PDU is installed into the back of the chassis. After the PDU is installed, you can slide the DC PEMs or AC rectifiers into the chassis and connect them to the PDU to provide power to the chassis (see the

“Installing a DC PEM or AC Rectifier” section on page 2-22 for details). Although there are differences

among the different PDU types (AC Wye, AC Delta, and DC), they are installed in the same manner.

Figure 2-9 shows a fixed configuration AC Wye PDU.

How to Install or Remove Fixed Configuration Power Components

Figure 2-9 Fixed Configuration AC Wye PDU

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How to Install or Remove Fixed Configuration Power Components

Prerequisites

Before performing this task, remove any front cosmetic covers.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• 3/8-in. ratchet wrench with 10-mm socket

• 3/8-in. ratchet wrench with 8-mm socket or open (box end) wrench

• Fixed configuration PDU

–

AC Wye PDU Cisco product number CRS-8-LCC-PDU-ACW=, or

–

AC Delta PDU Cisco product number CRS-8-LCC-PDU-ACD=, or

–

DC PDU Cisco product number CRS-8-LCC-PDU-DC=

Steps

Chapter 2 Installing and Removing Power Components

To install a PDU, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Make sure that the PDU is unplugged.

Step 3 Grasp the PDU by the side and set it carefully into place in a PDU slot on the rear (MSC) side of the

chassis. Be sure to lift the PDU over the lip on the edge of the chassis, and align the guide pins on the chassis with the guide holes on the PDU.

Caution Do not lift the PDU by the power cord—doing so can damage the PDU or the cord.

Step 4 If needed, put the second PDU into place in the other PDU slot on the chassis.

Note The PDU holding plate bolts to both PDUs and the side of the interior of the chassis.

Step 5 Install the PDU holding plate.

a. Slide the holding plate into place on top of the PDU, using the guide bolts on the side of the chassis

to place it correctly.

b. Use the socket wrench to bolt the holding plate to the top of the PDUs with the eight 10-mm bolts

(four for each PDU).

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c. Use the socket wrench to bolt the holding plate to the interior of the side of the chassis with the four

8-mm bolts (two for each side).

Step 6 Use the socket wrench to install the 8-mm center holding bolt and the 10-mm nut.

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What to Do Next

After performing this task, install the DC PEMs or AC rectifiers (see the “Installing a DC PEM or AC

Rectifier” section on page 2-22).

Note After installing a DC PDU, you need to connect the DC input wiring before installing the DC PEMs. For

more information, see the “Installing DC PDU Cables” section on page 2-19.

Removing a PDU

This section describes how to remove a PDU in the Cisco CRS 8-slot line card chassis. For information on the difference between the power types, see the “DC Power Systems” section on page 2-6 and the “AC

Power Systems” section on page 2-11.

The PDU is located at the back of the chassis. Although there are differences among the different PDU types (AC Wye, AC Delta, and DC), they are installed in the same manner. Figure 2-10 shows a fixed configuration AC Wye PDU.

How to Install or Remove Fixed Configuration Power Components

Prerequisites

Figure 2-10 Fixed Configuration AC Wye PDU

Before performing this task, remove any front cosmetic covers, power down and remove the DC PEMs or AC rectifiers, and unplug the PDU. See the “How to Install or Remove Fixed Configuration Power

Components” section on page 2-13, and the “Removing a DC PEM or AC rectifier” section on page 2-23.

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If you are removing a DC PDU, see the “DC Power Systems” section on page 2-6; if you are removing an AC PDU, see the “AC Power Systems” section on page 2-11 for more information.

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How to Install or Remove Fixed Configuration Power Components

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 3/8 in. ratchet wrench with 10-mm socket

• 3/8 in. ratchet wrench with 8-mm socket or open (box end) wrench

Steps

To remove a fixed configuration PDU, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Turn the DC PEM or AC rectifier power switch to the off position.

Step 3 Disconnect the PDU from the power source.

Step 4 Remove the DC PEM or AC rectifiers from the PDU that you are removing from the chassis (see the

“Removing a DC PEM or AC rectifier” section on page 2-23).

Step 5 For fixed configuration DC only, remove the power cables and ground cable connected to the rear of the

DC PDU. See the “Removing DC PDU Wiring” section on page 2-21.

Step 6 On the rear (MSC) side of the chassis, Use the socket wrench to remove the 8-mm center holding bolt

and 8-mm nut from the PDU holding plate.

Chapter 2 Installing and Removing Power Components

Step 7 Remove the PDU holding plate.

Step 8 Grasp the PDU and lift it carefully over the lip at the back of the chassis and set it carefully aside.

Caution Do not lift the PDU by the power cord—doing so can damage the PDU or the cord.

What to Do Next

a. Use the socket wrench to unbolt the four 8-mm bolts (two for each side) that attach the holding plate

to the interior of the side of chassis.

b. Use the socket wrench to unbolt the eight 10-mm bolts (four for each PDU) that attach the holding

plate to the top of the PDUs.

c. Carefully remove the holding plate from the top of the PDUs and set it aside.

After performing this task, you may install a new PDU, if needed (see the “Installing a PDU” section on

page 2-15), and replace any cosmetic covers.

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Installing DC PDU Cables

This section describes how to wire the fixed configuration DC PDU. For more detailed information on chassis DC power systems, see the “DC Power Systems” section on page 2-6.

Figure 2-11 shows the power cable connections at the rear of the fixed configuration DC PDU.

Figure 2-11 Fixed Configuration DC PDU Power Cable Connections

How to Install or Remove Fixed Configuration Power Components

Caution When wiring the PDU, be sure to attach the ground cable first and tighten the nuts to a torque of 30 in-lb

Prerequisites

Note Before installing wiring on the power shelf, make sure that the input power cables are not energized.

Note If cables are wrapped with black electrical tape, be sure to remove tape from cables before installing

1 Each set of cables (RTN and –48 V/–60V) is a single VDC input.

(3.39 N-m). When removing the wiring, be sure to remove the ground cable last.

Before performing this task, ensure that both power shelves are installed in the chassis.

cabling on the power shelf.

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How to Install or Remove Fixed Configuration Power Components

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Crimping tool and lug specific die

• 3/8 in. ratchet wrench with 10-mm socket

• Torque wrench with 10-mm 6 pt. socket and rated accuracy at 30 in.-lb (3.39 N-m)

• Torque wrench with 10-mm 6 pt. socket and rated accuracy at 20 in.-lb (2.26 N-m

Steps

To wire the DC PDU, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Remove the upper plastic terminal block safety cover (leave the lower safety cover in place; as shown in

Figure 2-11). Using a standard Phillips screwdriver, remove the four screws holding the upper plastic

safety cover to the wiring terminal block.

Step 3 Use the crimping tool mandated by the lug manufacturer to crimp the lugs to the DC-input cables and

the ground cable. For details on lugs, see the “DC Power Systems” section on page 2-6.

The cable should be sized according to local and national installation requirements.

Chapter 2 Installing and Removing Power Components

Note The terminal posts are centered 0.63 inches (5/8 inch) (1.60 cm) apart and are M6-threaded. We

recommend that you use an appropriately sized 45-degree angled industry standard 2-hole, standard barrel compression lug.

Step 4 Using the 10-mm socket wrench, attach the ground cable to the ground cable terminal. Then use the

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

Step 5 Using the 10-mm socket wrench, attach the three negative cables (the red cables as shown in

Figure 2-11) and the three positive cables (the black cables as shown in Figure 2-11) to the terminal

block. Then use the torque wrench to tighten to a torque of 20 in.-lb (2.26 N-m).

Step 6 Reattach the upper plastic safety cover with a Phillips screwdriver. Insert and tighten the four screws

holding the cover to the wiring terminal block.

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Removing DC PDU Wiring

This section describes how to remove the wiring from the fixed configuration DC PDU. For more detailed information on chassis DC power systems, see the “DC Power Systems” section on page 2-6.

Caution When removing DC wiring from the fixed configuration DC PDU be sure to remove the ground cable

last.

Prerequisites

Before performing this task, power down and remove DC PEMs in the shelf you want to disconnect.

Note Before removing wiring from the power shelf, make sure that the power cord is not plugged into the

facility power.

Required Tools and Equipment

How to Install or Remove Fixed Configuration Power Components

Steps

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 3/8-in. ratchet wrench with 10-mm socket

To remove the wiring from the DC PDU, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Remove the upper plastic terminal block safety cover (leave the lower safety cover in place; as shown in

Figure 2-11). Using a standard Phillips screwdriver, remove the four screws holding the upper plastic

safety cover to the wiring terminal block.

Step 3 Using the 10-mm socket wrench, remove the three positive and three negative cables from the terminal

block.

Step 4 Using the 10-mm socket wrench, remove the ground cable from the ground cable terminal.

Note When a cable is removed from the rear of the fixed configuration DC power shelf, we

recommend that it should be wrapped with standard black electrical tape.

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Step 5 Reattach the upper plastic safety cover with a Phillips screwdriver. Insert and tighten the four screws

holding the cover to the wiring terminal block.

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Installing a DC PEM or AC Rectifier

This section describes how to install a DC PEM or AC rectifier in the Cisco CRS 8-slot line card chassis. For information on the difference between the power types, see the “DC Power Systems” section on

page 2-6 and the “AC Power Systems” section on page 2-11.

The DC PEM or AC rectifier is installed into the front of the chassis, and mates with the PDU that is installed on the back of the chassis (see the “Installing a PDU” section on page 2-15 for information). Although there are differences among the different DC PEM or AC rectifiers (AC Wye, AC Delta, and DC), they are installed in the same manner. (Figure 2-12 shows an AC Wye rectifier for reference.)

Figure 2-12 Fixed Configuration AC Wye Rectifier

Chapter 2 Installing and Removing Power Components

1 Power switch 3 Handle

2 Module air filter 4 Captive screws

Prerequisites

Before performing this task, make sure that the PDU has been installed (see the “Installing a PDU”

section on page 2-15) and remove any cosmetic covers.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

• Fixed configuration power module

–

AC rectifier Cisco product number CRS-8-AC-RECT=

–

DC PEM Cisco product number CRS-8-DC-PEM=

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Steps

To install a DC PEM or AC rectifier, perform the following 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 Make sure that the power switch is in the off position.

Step 3 Grasp the handle on the top of the module firmly, and lift it partway up.

Step 4 Using two hands to support and guide the DC PEM or AC rectifier, slide it into the chassis power bay

on the front (PLIM) side of the chassis until the connector on the back of the module meets the connector on the backplane of the PDU.

Caution An AC rectifier weighs 36 lbs (13.44 kg); a DC PEM weighs 38 lbs (17.24 kg). You should

use both hands when handling a DC PEM or AC rectifier.

Step 5 Press the DC PEM or AC rectifier in firmly to seat it against the PDU.

How to Install or Remove Fixed Configuration Power Components

Caution To prevent damage to the PDU-to-module connections, do not use excessive force when

seating a DC PEM or AC rectifier to its PDU.

Step 6 Tighten the two captive screws on the face of the DC PEM or AC rectifier to seat it snugly against the

PDU.

Step 7 Push the power tab at the bottom front of the module in to the on position.

What to Do Next

After performing this task, you may connect the PDU to the power source (see the “DC Power Systems”

section on page 2-6 and the “AC Power Systems” section on page 2-11) and power up the chassis (see

the “How to Install or Remove Fixed Configuration Power Components” section on page 2-13).

Removing a DC PEM or AC rectifier

This section describes how to remove a DC PEM or AC rectifier from the Cisco CRS 8-slot line card chassis in a fixed configuration power system. For information on the difference between the power types, see the “DC Power Systems” section on page 2-6 and the “AC Power Systems” section on

page 2-11.

The DC PEM or AC rectifier is located on the front of the chassis, and mates with the PDU that is installed on the back of the chassis (see the “Installing a PDU” section on page 2-15 for information). Although there are differences among the DC PEMs or AC rectifiers (AC Wye, AC Delta, and DC), they are removed in the same manner. (Figure 2-13 shows an AC Wye rectifier for reference.)

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Figure 2-13 Fixed Configuration AC Wye Rectifier

1 Power switch 3 Handle

2 Module air filter 4 Captive screws

Chapter 2 Installing and Removing Power Components

Prerequisites

Before performing this task, make certain that the PDU has been installed and any cosmetic covers removed.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

Steps

To remove a DC PEM or AC rectifier, perform the following 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 On the front side of the chassis, pull the power tab on the bottom front of the DC PEM or AC rectifier

out to the off position.

Step 3 Use the screwdriver to loosen the two captive screws on the front of the DC PEM or AC rectifier.

Step 4 Grasp the DC PEM or AC rectifier handle and pull the DC PEM or AC rectifier halfway from the bay.

Be sure to pull the module by the handle only.

Caution Take care when handling a DC PEM or AC rectifier that has been recently used—it can be hot

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to the touch.

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How to Install or Remove Modular Configuration Power Components

Caution An AC rectifier weighs 36 lbs (13.44 kg); a DC PEM weighs 38 lbs (17.24 kg). You should

use both hands when handling a DC PEM or AC rectifier.

Step 5 Use your free hand to support the DC PEM or AC rectifier while you slide the module completely from

the bay, then set the module safely aside.

What to Do Next

After performing this task, you may install a new DC PEM or AC rectifier, if needed (see the “Installing

a DC PEM or AC Rectifier” section on page 2-22), and replace any front cosmetic covers.

How to Install or Remove Modular Configuration Power Components

This section describes how to install and remove modular configuration power components in the Cisco CRS Carrier Routing System 8-Slot line card chassis.

Before you install the modular configuration power components, you must install the modular configuration power shelf into the chassis. After installing the power shelf, you can install the AC or DC PMs into the power shelf.

Note Although there are differences between the different types of modular configuration power shelves and

PMs (AC and DC), they are installed and removed using the same procedures.

If you are replacing a fixed configuration power supply with a modular configuration power supply, you must change the entire power shelf before you can install the power components. For more information, refer to the “Converting a Chassis from Fixed Configuration Power to Modular Configuration Power”

section on page 2-54.

This section contains the following procedures:

• Installing a Modular Configuration Power Shelf, page 2-26

• Installing AC Power Cords or DC Power Shelf Wiring, page 2-35

• Installing AC or DC PMs, page 2-40

• Removing AC or DC PMs, page 2-42

• Removing AC Power Cords or DC Power Shelf Wiring, page 2-45

• Removing a Modular Configuration Power Shelf, page 2-48

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• Power Up and Power Down a Chassis with a Modular Configuration AC or DC Power Shelf,

page 2-51

• Converting from One Modular Configuration Power System to Another, page 2-53

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Installing a Modular Configuration Power Shelf

This section describes how to install a modular configuration power shelf.

The modular configuration power shelf is installed into the front of the chassis. Although there are differences between the different power shelf types (AC and DC), they are installed in the same manner.

Note If you have a fixed configuration PDU installed and before you can install a modular configuration power

shelf, you must remove the fixed configuration PDU. See “Converting a Chassis from Fixed

Configuration Power to Modular Configuration Power” section on page 2-54 for more information.

Figure 2-14 shows the front view of the modular configuration AC power shelf.

Figure 2-14 Modular Configuration AC Power Shelf, Front View

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Figure 2-15 shows the rear view of the modular configuration AC power shelf.

Figure 2-15 Modular Configuration AC Power Shelf, Rear View

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How to Install or Remove Modular Configuration Power Components

Figure 2-16 and Figure 2-17 show the front and rear views of the modular configuration DC power shelf.

Figure 2-16 Modular Configuration DC Power Shelf, Front View

Chapter 2 Installing and Removing Power Components

Figure 2-17 Modular Configuration DC Power Shelf, Rear View

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Chapter 2 Installing and Removing Power Components

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

• 5/32 x 6-in. flat blade screwdriver

• Two 10-mm 6-pt. combination wrenches

• Modular configuration power shelf

–

DC power shelf (Cisco product number CRS-8-PSH-DC=), or

–

AC power shelf (Cisco product number CRS-8-PSH-AC=)

Steps

To install the modular configuration power shelf, go to the rear of the chassis and perform the following steps:

How to Install or Remove Modular Configuration Power 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 rear (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Ensure that all power cords are disconnected from the power shelf.

Step 3 Remove the power shelf cross bracket from the chassis. See Figure 2-18.

Figure 2-18 Modular Configuration Power Shelf Cross Bracket

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How to Install or Remove Modular Configuration Power Components

Step 4 Using the flat-blade screwdriver, remove the rear mounting brackets from the power shelves being

installed, as shown in Figure 2-19. Set the screws aside in a safe place.

Figure 2-19 Removing Rear Mounting Bracket from Power Shelf

Chapter 2 Installing and Removing Power Components

Step 5

254857

Attach the power shelf rear mounting brackets to the chassis, as shown in Figure 2-20.

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Figure 2-20 Attaching Rear Mounting Brackets

How to Install or Remove Modular Configuration Power Components

279999

1 Bolts to secure bracket to chassis 2 Wrench to tighten bolts

Step 6

Remove the ESD-preventive wrist strap from the rear (MSC) side of the chassis. Go to the front of the chassis and reattach to one of the ESD connection sockets on the front (PLIM) side of the chassis or a bare metal surface on the chassis.

Step 7 Insert the modular configuration power shelf so that it stops against the rear mounting bracket, then

fasten the power shelf to the chassis. (There are two screws per shelf, see Figure 2-21).

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Figure 2-21 Fastening the Power Shelf to the Chassis

Chapter 2 Installing and Removing Power Components

1 Screws to tighten and secure power shelf to chassis.

Step 8

Remove the ESD-preventive wrist strap from the front (PLIM) side of the chassis. Go to the rear of the chassis and reattach to one of the ESD connection sockets on the rear (MSC) side of the chassis or a bare metal surface on the chassis.

Step 9 Using the 10-mm wrench, install the hex head bolts to secure the power shelf to the cross bracket, as

shown in Figure 2-25.

Step 10 Insert the modular configuration power shelf cross bracket on the mounting studs, two on each side of

the chassis, as shown in Figure 2-22. Then install the four M6 nuts, two on each chassis side, and tighten with the 10-mm combination wrench as shown in Figure 2-23.

Figure 2-22 Installing Modular Configuration Power Shelf Cross Bracket

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2 3

Figure 2-23 Securing Nuts on Mounting Studs

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1 M6 hex nuts that secure bracket to chassis (two on each side of the chassis)

2 10-mm wrench to secure hex nuts

Step 11

Using a 10-mm wrench on the bolt side and a 10-mm wrench on the nut side, secure the cross bracket to the chassis. See Figure 2-24.

Figure 2-24 Securing Cross Bracket to Chassis and Power Supply

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1 M6 nut/bolt to tighten 3 10-mm wrench

2 10-mm wrench

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2 222222 2

111 1

Step 12 Using the flat-blade screwdriver, install power shelf mounting screws, to secure power shelf to rear

mounting bracket. See Figure 2-25.

Figure 2-25 Securing Power Supplies to Cross Bracket and Rear Mounting Brackets

Chapter 2 Installing and Removing Power Components

What to Do Next

1 Power shelf mounting screws, two slotted screws per shelf

2 M6 hex head bolts to secure power shelf, four per shelf

After installing the modular configuration power shelf, install the DC input wiring and DC terminal block covers or install the AC cords, as described in “Installing AC Power Cords or DC Power Shelf

Wiring” section on page 2-35.

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How to Install or Remove Modular Configuration Power Components

Installing AC Power Cords or DC Power Shelf Wiring

This section describes how to install the DC input wiring, DC terminal block covers and the AC power cords on the Cisco CRS Carrier Routing System 8-Slot line card chassis.

Installing Modular Configuration DC Power Shelf Wiring

This section describes how to wire the modular configuration DC power shelf. For more detailed information on chassis DC power systems, see the “Modular Configuration DC Power” section on

page 2-9.

Figure 2-26 shows the power cable connections at the rear of the modular configuration DC power shelf.

Figure 2-26 Modular Configuration DC Power Shelf Power Cable Connections

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Caution When wiring the power shelf, be sure to attach the chassis ground cable to the chassis first and tighten

the nuts to a torque of 30 in-lb (3.39 N-m). For more information, see the “Bonding and Grounding

Guidelines” section on page 2-4.

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How to Install or Remove Modular Configuration Power Components

Prerequisites

Before performing this task, ensure that both power shelves are installed in the chassis.

Caution Before installing wiring on the power shelf, make sure that the input power cables are not energized.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Crimping tool and lug specific die

• 3/8 in. ratchet wrench with 10-mm socket

• Torque wrench with 10-mm 6 pt. socket and rated accuracy at 20 in.-lb (2.26 N-m)

Steps

Chapter 2 Installing and Removing Power Components

To wire the modular configuration DC power shelf, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Remove the terminal block cover.

Step 3 Use the crimping tool mandated by the lug manufacturer to crimp the lugs to the DC-input cables. For

details on lugs, see the “DC Power Systems” section on page 2-6.

The cable should be sized according to local and national installation requirements. Use only copper cable.

Note The power supply terminal block lug opening width is 0.63 inch (1.60 cm). The terminal posts

are centered 0.63 inches (5/8 inch) (1.60 cm) apart and are M6-threaded. We recommend that you use an appropriately sized 180-degree (straight) or 45-degree angle industry standard 2-hole, standard barrel compression lug.

Step 4 Using the 10-mm socket wrench, attach the positive and negative cable pairs to each terminal block. Use

the torque wrench to tighten to a torque of 20 in.-lb (2.26 N-m).

Caution Make sure that the polarity of the DC input wiring is correct.

Step 5 Reattach the terminal block covers.

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Installing DC Terminal Block Covers

Figure 2-27 shows the DC terminal block cover.

Figure 2-27 DC Terminal Block Cover

How to Install or Remove Modular Configuration Power Components

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

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

Steps

To install the DC terminal block covers, go to the rear of the chassis and perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Align the DC terminal block cover with the cover latch tab.

Step 3 Use the Phillips screwdriver to secure the screw into the mounting standoff, see Figure 2-28.

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How to Install or Remove Modular Configuration Power Components

Figure 2-28 Securing the DC Terminal Block Cover

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345

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1 Mounting Standoff 5 Opening to align over mounting pins

2 Screwdriver securing the cover 6 Screw to tighten

3 Opening to align over mounting pins 7 Cover latch tab

4 Terminal block cover

Installing Modular Configuration AC Power Shelf Wiring

This section describes how to install input AC power cords on the modular configuration AC power shelf.

Note When wiring the power shelf, be sure to connect the chassis ground cable first.

Prerequisites

Before performing this task, ensure that both power shelves are installed in the chassis.

If you have AC Delta or AC Wye at your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC input power for the power shelf. For further information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

Note Before installing input AC power cords, make sure that the AC power cords are not energized.

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3 4 213 4 21

Required Tools and Equipment

You need the following tools to perform this task:

• 6-in. long number 1 Phillips screwdriver

Note You can use an offset number 1 Phillips screwdriver to tighten the AC cord clamp that was available

pre-June 2011, but this is optional. An offset screwdriver is not required to tighten the AC cord clamp that is available from June 2011 onwards. See Figure 2-29.

Steps

To install the AC cords, go to the rear of the chassis and perform the following steps:

Step 1 Insert the AC cords into the AC cord clamps, as shown in Figure 2-29.

Note If you have a Cisco CRS PDU installed, the AC cords must be installed as labelled. For further

information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

How to Install or Remove Modular Configuration Power Components

Figure 2-29 Inserting AC Cord into Cord Clamp

1 Cord clamp 3 Screw that secures the cord in clamp

2 Cord to be inserted into clamp 4 Screwdriver that tightens screw

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Note In Figure 2-29, the AC cord clamp shown on the left was available until June 2011, and the AC

cord clamp shown on the right is available from June 2011 onwards. The location of the screw that secures the cord in the cord clamp is different.

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How to Install or Remove Modular Configuration Power Components

Step 2 Use the Phillips screwdriver to tighten the screw that clamps the cord in place, see Figure 2-29.

What to Do Next

After you install the DC wiring and DC terminal block covers or AC input cords, install the AC or DC PMs, as described in “Installing AC or DC PMs” section on page 2-40.

Installing AC or DC PMs

This section describes how to install modular configuration AC or DC PMs.

The modular configuration AC or DC PMs are installed into the front of the chassis. Although there are differences between the AC and DC PMs, they are installed in the same manner.

Required Tools and Equipment

Chapter 2 Installing and Removing Power Components

Steps

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

• Torque screwdriver with number 1 Phillips bit and rated accuracy at 5.5 in-lb (0.62 N-m)

• Modular configuration AC or DC PM

–

AC PM (Cisco product number CRS-PM-AC=)

–

DC PM (Cisco product number CRS-PM-DC=)

To install the AC or DC PMs in the power shelf, go to the front of the chassis and perform the following 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 PM, slide it into the power shelf.

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Figure 2-30 Sliding PM Into Power Shelf

How to Install or Remove Modular Configuration Power Components

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1 Ejector pulled away from the PM.

Step 3 Flip up the ejector and with nominal install torque of 5.5 in-lb (0.62 N m) of torque, screw the PM into

the shelf (see Figure 2-30). Do not exceed an install torque value of 10 in-lb (1.13 N-m).

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Figure 2-31 Securing the Ejector Into the PM

Chapter 2 Installing and Removing Power Components

1 Screw the ejector into the PM

Step 4

Install the second PM and fill the power shelf to the required configuration.

What to Do Next

After installing the PMs, you can install the cosmetic covers. For more information, see Chapter 5,

“Installing and Removing Exterior Components.”

Removing AC or DC PMs

This section describes how to remove AC or DC PMs from the Cisco CRS 8-slot line card chassis.

Note Although there are differences between the AC and DC PMs, they are removed in the same manner.

Required Tools and Equipment

You need the following tools to perform this task:

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• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

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Steps

To remove the AC or DC PMs, perform the following 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 At the front of the chassis, unscrew the ejectors from the PMs, as shown in Figure 2-32.

Figure 2-32 Unscrew Ejectors from PM

How to Install or Remove Modular Configuration Power Components

1 Ejector on PM

Step 3

After unscrewing the ejector, carefully slide the PM out of the power shelf, as shown in Figure 2-33.

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How to Install or Remove Modular Configuration Power Components

Figure 2-33 Removing the PM

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1 Ejector on PM

After the PMs have been removed from the chassis, you can remove the power shelf wiring. Continue to

“Removing AC Power Cords or DC Power Shelf Wiring” section on page 2-45 for instructions.

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How to Install or Remove Modular Configuration Power Components

Removing AC Power Cords or DC Power Shelf Wiring

This section describes how to remove the DC input wiring, DC terminal block covers and the AC power cords from the Cisco CRS Carrier Routing System 8-Slot line card chassis.

Removing Modular Configuration DC Power Shelf Wiring

This section describes how to remove the DC wiring from the modular configuration DC power shelf. For more detailed information on chassis DC power systems, see the “DC Power Systems” section on

page 2-6.

Figure 2-34 shows the power cable connections at the rear of the modular configuration DC power shelf.

Figure 2-34 Modular Configuration DC Power Shelf Power Cable Connections

Prerequisites

Before performing this task, power down and remove DC PMs in the shelf you want to disconnect.

Note Before removing wiring from the power shelf, make sure that the input power cables are not energized.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

• 10-mm socket wrench

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How to Install or Remove Modular Configuration Power Components

Steps

To remove the wiring from the modular configuration DC power shelf, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Use the screwdriver to remove the screw that secures the terminal block cover into the mounting

standoff, see Figure 2-35.

Figure 2-35 Removing the DC Terminal Block Cover

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1 Mounting Standoff 5 Opening that aligns over mounting pins

2 Screwdriver removing the cover 6 Screw to remove

3 Opening that aligns over mounting pins 7 Cover latch tab

4 Terminal block cover

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Step 3 Remove the terminal block cover.

Step 4 Using the 10-mm socket wrench, remove the positive cables from the terminal block.

Step 5 Using the 10-mm socket wrench, remove the negative cables from the terminal block.

Note When a cable is removed from the rear of the modular configuration DC power shelf, we

recommend that it should be wrapped with standard black electrical tape.

Step 6 Reattach the terminal block cover.

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How to Install or Remove Modular Configuration Power Components

Removing Modular Configuration AC Power Shelf Wiring

This section describes how to remove input AC cords from the modular configuration AC power shelf.

Prerequisites

Before performing this task, power down and remove AC PMs in the shelf you want to disconnect.

Note Before removing wiring from the power shelf, make sure that the input power cables are not energized.

Required Tools and Equipment

You need the following tools to perform this task:

• 6-in. long number 1 Phillips screwdriver

Note You can use an offset number 1 Phillips screwdriver to tighten the AC cord clamp that was available

pre-June 2011, but this is optional. An offset screwdriver is not required to tighten the AC cord clamp that is available from June 2011 onwards. See Figure 2-36.

Steps

To remove the input AC cords, go to the rear of the chassis and perform the following steps:

Step 1 Use the screwdriver to loosen the screw that clamps the cord in place, see Figure 2-36.

Step 2 Remove the cord from the cord clamp, as shown in Figure 2-36.

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How to Install or Remove Modular Configuration Power Components

Figure 2-36 Removing Cord from Cord Clamp

Chapter 2 Installing and Removing Power Components

1 Cord Clamp 3 Screw that secures the cord in clamp

2 Cord removed from clamp 4 Screwdriver that loosens screw

Note In Figure 2-36, the AC cord clamp shown on the left was available until June 2011, and the AC

cord clamp shown on the right is available since June 2011. The location of the screw that secures the cord in the cord clamp is different.

What to Do Next

After you remove the DC wiring and DC terminal block covers or AC cords, remove the power shelf. See the “Removing a Modular Configuration Power Shelf” section on page 2-48.

Removing a Modular Configuration Power Shelf

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This section describes how to remove a modular configuration power shelf from the Cisco CRS 8-slot line card chassis.

Although there are differences between the AC and DC power shelves, they are removed in the same manner.

Before performing this task, remove DC input power wiring or AC input cords from the shelf that you want to disconnect. For more information, see the “Removing AC Power Cords or DC Power Shelf

Wiring” section on page 2-45.

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Chapter 2 Installing and Removing Power Components

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• 6-in. long number 1 Phillips screwdriver

• 5/32 x 6 in. flat-blade screwdriver

• Two 10-mm 6 pt. combination wrenches

Steps

To remove the modular configuration power shelf, perform the following 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using a 10-mm wrench, remove the hex head bolts that secure the power shelf to the cross bracket, as

shown in Figure 2-38.

How to Install or Remove Modular Configuration Power Components

Step 3 Using the 10-mm wrench, loosen the nuts that secure the cross bracket to the chassis, as shown in

Figure 2-37.

Figure 2-37 Loosening Nuts on Mounting Studs

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1 M6 hex nuts that secure cross bracket to chassis (two on each side of the chassis)

2 10-mm wrench to loosen hex nuts

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Step 4

Using the flat-blade screwdriver, remove the power shelf mounting screws, as shown in Figure 2-38.

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2 222222 2

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2 3

Figure 2-38 Securing Power Supplies to Cross Bracket to Rear Mounting Brackets

Chapter 2 Installing and Removing Power Components

1 Power shelf mounting screws, two slotted screws per shelf

2 M6 Hex head bolts to secure power shelf, four per shelf

Step 5 Using a 10-mm wrench on the bolt side and a 10-mm wrench on the nut side, remove the nut and bolt

that secure the cross bracket to the chassis. See Figure 2-39. Remove the cross bracket from the mounting studs.

Figure 2-39 Removing Cross Bracket Nut and Bolt

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1 Nut/bolt to remove 2 10-mm wrench 3 10-mm wrench

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Step 6 Remove the ESD-preventive wrist strap from the rear (MSC) side of the chassis. Go to the front of the

chassis and reattach to one of the ESD connection sockets on the front (PLIM) side of the chassis or a bare metal surface on the chassis.

Step 7 Remove the screws, two per shelf, that secure the power shelf to the chassis. Carefully remove the power

shelf. See Figure 2-40.

Figure 2-40 Removing Screws that Secure Shelf to Chassis

How to Install or Remove Modular Configuration Power Components

1 Screws that secure power shelf to chassis.

What to Do Next

After performing this task, replace any front (PLIM) side cosmetic covers.

Power Up and Power Down a Chassis with a Modular Configuration AC or DC Power Shelf

This section describes how to power up and power down a chassis with a modular configuration AC or DC power shelf. For details on the chassis power systems, see the “Basic Chassis Power Details” section

on page 2-2, the “DC Power Systems” section on page 2-6, and the “AC Power Systems” section on page 2-11.

Most components on the chassis, such as the PMs and fan trays, can be removed or installed in the chassis while it is running. Although it is possible to install or remove a power shelf while the chassis is running, it is recommended to remove power from the chassis completely, if possible, for service protection and safety.

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How to Install or Remove Modular Configuration Power Components

Power Up a Chassis with a Modular Configuration AC or DC Power Shelf

This section describes how to power up a chassis with a modular configuration AC or DC power shelf.

Prerequisites

Before performing this task, you must install the power shelves, wire the power shelves, install the PMs, and install the route processor (RP) card. See the “Installing a Modular Configuration Power Shelf”

section on page 2-26, the “Installing AC Power Cords or DC Power Shelf Wiring” section on page 2-35the “Installing AC or DC PMs” section on page 2-40, and the “Installing an RP, PRP, or DRP Card” section on page 4-38 for more information.

Steps

To power up the chassis, perform the following steps:

Step 1 Turn the facility breaker for both power shelves (Power A and Power B) to the ON position.

Step 2 Turn the power shelf power output breakers to the ON position.

Note There is no required order in which you must turn on the power shelves.

Power Down a Chassis with a Modular Configuration AC or DC Power Shelf

This section describes how to power down a chassis with a modular configuration AC or DC power shelf.

Prerequisites

Before performing this task, you must ensure that the system software has been shut down.

Steps

To power down the chassis, perform the following steps:

Step 1 Turn the power shelf power output breakers to the OFF position.

Note There is no required order in which you must turn off the power shelves.

Step 2 Turn the facility breaker for both power shelves (Power A and Power B) to the OFF position.

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Note To power down the chassis entirely, both power shelves must be disconnected to de-energize the chassis

completely.

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Table 2-1 shows the LED status indicator lights for the AC and DC PMs in a modular configuration

power supply.

Table 2-1 PM LED Status Indicator Lights—Modular Configuration Power

LED Name Color Function or Meaning

Input_OK Green On: The input voltage is present and within regulation range.

Output_OK Green On: The output voltage is on.

Fault Red On: An internal fault is detected within the PM.

How to Install or Remove Modular Configuration Power Components

Blinking: The input voltage is present but out of regulation range.

Off: The input voltage is not present.

Blinking: The PM is in a power limit or an OC condition.

Off: The output voltage is off.

Off: The PM has no internal fault.

Converting from One Modular Configuration Power System to Another

To convert a Cisco CRS 8-slot line card chassis with a modular configuration power system from AC to DC power, or from DC to AC power, perform the following steps:

Step 1 Power down the chassis completely.

Step 2 Remove the AC or DC PMs from the power shelves. See the “Removing AC or DC PMs” section on

page 2-42,

Step 3 Remove the AC or DC wiring from the rear of the power shelves. See the “Removing AC Power Cords

or DC Power Shelf Wiring” section on page 2-45.

Step 4 Remove the power shelves. See the “Removing a Modular Configuration Power Shelf” section on

page 2-48.

Step 5 Install the new power shelves. See the “Installing a Modular Configuration Power Shelf” section on

page 2-26.

Step 6 Install the power shelf wiring. See the “Installing AC Power Cords or DC Power Shelf Wiring” section

on page 2-35.

Note If you are converting from modular configuration DC to modular configuration AC power, and if you

have 3-phase AC Delta or AC Wye power at your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC input power for the power shelf. For further information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

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Step 7 Install the AC or DC PMs. See the “Installing AC or DC PMs” section on page 2-40.

Step 8 Power the chassis back up. See the “Power Up and Power Down a Chassis with a Modular Configuration

AC or DC Power Shelf” section on page 2-51.

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Converting a Chassis from Fixed Configuration Power to Modular Configuration Power

Caution Use only one type of modular configuration power shelf—AC or DC—and its mating AC or DC PM in

a chassis at one time.

Converting a Chassis from Fixed Configuration Power to Modular Configuration Power

Caution Do not attempt to convert from fixed configuration power to modular configuration power while the

Cisco CRS 8-slot line card chassis is powered up and running. Ensure that you have powered down the system and all power is disconnected from the system.

This section lists the steps to be performed to convert the Cisco CRS 8-Slot line card chassis from fixed configuration power to modular configuration power.

To convert a Cisco CRS 8-slot line card chassis from fixed configuration power to modular configuration power, you must:

Step 1 Power down the chassis completely.

Step 2 Remove the DC PEMs or AC rectifiers. See the “Removing a DC PEM or AC rectifier” section on

page 2-23.

Step 3 For fixed configuration DC only, first remove the DC wiring, and then the ground cable from the rear of

the PDUs. See the “Removing DC PDU Wiring” section on page 2-21.

Step 4 Remove the PDUs. See the “Removing a PDU” section on page 2-17.

Step 5 Install the new modular configuration power shelf. See “Installing a Modular Configuration Power

Shelf” section on page 2-26.

Note Do not connect ground cables directly to a modular configuration power shelf. For more

information, see the “Bonding and Grounding Guidelines” section on page 2-4.

Step 6 Install the power shelf wiring. See the section “Installing AC Power Cords or DC Power Shelf Wiring”

section on page 2-35.

Note If you are converting from fixed configuration AC or DC power to modular configuration AC

power, and if you have 3-phase AC Delta or AC Wye power at your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC input power for the power shelf. For further information, refer to Cisco CRS 3-Phase AC Power Distribution Unit Installation Guide.

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Step 7 Install the PMs. See the section “Installing AC or DC PMs” section on page 2-40.

Step 8 Power the chassis back up. See the “Power Up and Power Down a Chassis with a Modular Configuration

AC or DC Power Shelf” section on page 2-51.

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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 8-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 3-2

About Line Card Chassis Airflow

The Cisco CRS 8-slot line card chassis has two fan trays, each with four fans, that cool the chassis card cages.

CHA P T ER

The top fan pulls air into the lower portion of the front of the chassis, up across the cards in the front of the chassis, and through the upper fan tray. Air flows out of the upper fan tray and down across all the modular service cards and switch fabric cards through the lower fan tray; air is then exhausted out the bottom of the rear of the chassis (see Figure 3-1).

In addition, each AC or DC 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 the warm air out the rear of the chassis.

A replaceable air filter is located on the front of the chassis below the PLIM card cage. Each power module also has a replaceable air filter that attaches to the module at 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 grills 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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Fan

Air enters

PLIM side

Power system

Fan

Air exits MSC and fabric card side

Front Rear

Air filter

Figure 3-1 Airflow Through the Cisco CRS 8-Slot Line Card Chassis

Chapter 3 Installing and Removing Air Circulation Components

The Cisco CRS 8-slot line card chassis airflow volumes are:

• Chassis airflow: Up to 900 cubic feet (25,485 liters) per minute

• Power system airflow: Up to 240 cubic feet (6,800 liters) per minute

How to Install or Remove Air Circulation Components

This section contains the following procedures:

• Installing a Lower Fan Tray, page 3-2

• Installing a Rear Exhaust Screen, page 3-4

• Removing a Lower Fan Tray, page 3-5

• Installing an Upper Fan Tray, page 3-7

• Removing an Upper Fan Tray, page 3-8

• Installing the Chassis Air Filter, page 3-9

• Removing the Chassis Air Filter, page 3-11

• Installing a Power Module Air Filter, page 3-12

• Removing a Power Module Air Filter, page 3-13

Installing a Lower Fan Tray

This section describes how to install a fan tray in the lower fan tray slot of the Cisco CRS 8-slot line card chassis. For information on the chassis airflow and circulation, 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.

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A Cisco CRS 8-slot line card chassis fan tray operates in either the upper or lower fan tray slot. Each fan tray installs into the rear (MSC) side of the chassis (see Figure 3-2). Each fan tray contains four fans.

Figure 3-2 Fan Tray

1 Captive screws 3 Fan tray handle

2 Fan tray rail

How to Install or Remove Air Circulation Components

Prerequisites

Before performing this task, you must first open the chassis doors and remove any front cover plates.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Large Phillips screwdriver

• Fan tray (Cisco product number CRS-8-LCC-FAN-TR=)

Steps

To install a lower 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using two hands to support the fan tray, position it in front of the fan tray bay so that the rails on the

sides of the fan tray are aligned with the rail guides on the interior of the chassis.

Caution A fan tray weighs approximately 19.15 pounds (8.69 kg). Use both hands when handling a fan

tray.

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

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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

tray into its bay.

Step 4 Make sure that the fan tray handle is rotated closed.

Step 5 Using the screwdriver, tighten the two captive screws (one for each side).

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

What to Do Next

After performing this task, replace the front cover plates.

Chapter 3 Installing and Removing Air Circulation Components

Installing a Rear Exhaust Screen

This section describes how to install a rear exhaust screen on the Cisco CRS 8-slot line card chassis.

Prerequisites

There are no prerequisites for this task.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Large screwdriver

• Rear Exhaust Screen

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Steps

To install a rear exhaust screen, follow these steps:

Figure 3-3 Install rear exhaust screen

How to Install or Remove Air Circulation Components

1 Rear Exhaust Screen

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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Attach the screen to the rear of the chassis using the five panel fasteners

Removing a Lower Fan Tray

This section describes how to remove a fan tray from the lower fan tray slot of the Cisco CRS 8-slot line card chassis. For information on the chassis airflow and circulation, 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.

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A Cisco CRS 8-slot line card chassis fan tray operates in either the upper or lower fan tray slot. Each fan tray is installed into the rear (MSC) side of the chassis (see Figure 3-4).

Figure 3-4 Fan Tray

1 Captive screws 3 Fan tray handle

2 Fan tray rail

Chapter 3 Installing and Removing Air Circulation Components

Prerequisites

Before performing this task, you must first remove any front cover plates.

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 lower 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using the screwdriver, loosen the two captive screws on the fan tray.

Caution A fan tray weighs approximately 19.15 pounds (8.69 kg). Use both hands when handling a fan

tray.

3-6

Step 3 Rotate the fan tray handle out.

Step 4 Grasp the fan tray handle and pull it straight out to disconnect the fan tray from the connector mounted

on the back of the fan tray. Slide the fan tray halfway from the fan tray bay.

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Step 5 Use your free hand to support the fan tray, then slide the fan tray completely from the fan tray bay.

Step 6 Set the fan tray safely aside.

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

What to Do Next

After performing this task, replace the front cover plates.

Installing an Upper Fan Tray

This section describes how to install a fan tray in the upper fan tray slot of the Cisco CRS 8-slot line card chassis. For information on the chassis airflow and circulation, 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.

How to Install or Remove Air Circulation Components

A Cisco CRS 8-slot line card chassis fan tray operates in either the upper or lower fan tray slot. Each fan tray installs into the rear (MSC) side of the chassis (see Figure 3-4).

Prerequisites

Before performing this task, you must first open the chassis doors and remove any front cosmetic covers.

Required Tools and Equipment

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

• ESD-preventive wrist strap

• Large Phillips screwdriver

• Fan tray (Cisco product number CRS-8-LCC-FAN-TR=)

Steps

To install an upper 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using the screwdriver, unscrew the two captive screws holding the fan tray bay door in place.

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Step 3 Lift the door up; you may need a second person to hold it in the open position.

Step 4 Rotate the handle on the fan tray to the open position.

Step 5 Using two hands to support the fan tray, position it in front of the fan tray bay so that the rails on the

sides of the fan tray are aligned with the rail guides on the interior of the chassis.

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Caution A fan tray weighs approximately 19.15 pounds (8.69 kg). Use both hands when handling a fan

tray.

Step 6 Slide the fan tray into the bay.

Step 7 Slide the fan tray into the fan tray bay. Stop when the fan tray meets the chassis connector in the back

of the fan tray bay.

Notice that the tray (and rail guides) drop just inside the fan tray bay door, so that the fan tray “drops” into its final position as it gets almost all the way into the chassis.

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

tray into its bay.

Step 8 Firmly push on the fan tray to seat the fan tray connector in the chassis connector.

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

Chapter 3 Installing and Removing Air Circulation Components

Step 9 Rotate the fan tray handle to the closed (flush) position.

Step 10 Replace the fan tray bay door and tighten the two captive screws on the fan tray bay door.

What to Do Next

After performing this task, replace the front cover plates.

Removing an Upper Fan Tray

This section describes how to remove a fan tray from the upper fan tray slot of the Cisco CRS 8-slot line card chassis. For information on the chassis airflow and circulation, 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.

A Cisco CRS 8-slot line card chassis fan tray operates in either the upper or lower fan tray slot. Each fan tray is installed into the rear (MSC) side of the chassis (see Figure 3-4).

Prerequisites

Before performing this task, you must first open the chassis doors and remove any front cosmetic covers.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

• Large Phillips screwdriver

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Steps

To remove an upper 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 (MSC) side of the chassis or a bare metal surface on the chassis.

Step 2 Using the screwdriver, unscrew the two captive screws holding the fan tray bay door in place.

Step 3 Lift the door up; you may need a second person to hold it in the open position.

Step 4 Rotate the handle on the fan tray to the open position.

Step 5 Pull firmly and steadily on the fan tray handle to unseat it from the chassis connector, and then slide it

partway from the fan tray bay.

Caution Do not pull too hard on the fan tray; too strong a pull can cause the tray to slide out too quickly,

causing your hand to scrape against the fan tray door.

Step 6 Place your hand under the fan tray to support it from beneath.

How to Install or Remove Air Circulation Components

Caution A fan tray weighs approximately 19.15 pounds (8.69 kg). Use both hands when handling a fan

tray.

Step 7 Slide the fan tray from the bay and set it carefully aside.

Step 8 Replace the fan tray bay door and tighten the two captive screws on the fan tray cover bay door.

What to Do Next

After performing this task, replace the front cover plates.

Installing the Chassis Air Filter

This section describes how to install the air filter in the Cisco CRS 8-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 Regulatory Compliance and Safety Information for the Cisco CRS Carrier Routing System.

The chassis has a serviceable air filter mounted in a slide-out tray, accessible from the rear of the chassis just above the lower fan tray. The Cisco CRS 8-slot line card chassis air filter plugs into the front (PLIM) side of the chassis (see Figure 3-5).

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Figure 3-5 Chassis Air Filter

1 Air filter cover plate (with captive screws) 2 Chassis air filter

Prerequisites

Chapter 3 Installing and Removing Air Circulation Components

Before performing this task, you must first remove any front cover plates.

Caution Never operate the Cisco CRS 8-slot 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

• Large Phillips screwdriver

• Chassis air filter (Cisco product number CRS-8-LCC-FILTER=)

Steps

To install the chassis 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 Using two hands to support the air filter, orient it so that the ridge on the front of the air filter faces

outward from the front of the chassis and the wire-grid backing support is facing up.

Step 3 Slide the air filter into the air filter slot until it is seated fully within the slot.

Step 4 Hold the air filter cover plate in place and tighten the two captive screws on the front of the plate.

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What to Do Next

After performing this task, replace the front cover plates.

Removing the Chassis Air Filter

This section describes how to remove the air filter in the Cisco CRS 8-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 Regulatory Compliance and Safety Information for the Cisco CRS Carrier Routing System.

The Cisco CRS 8-slot line card chassis air filter plugs into the front (PLIM) side of the chassis (see

Figure 3-5).

Prerequisites

Before performing this task, you must first remove any front cover plates.

How to Install or Remove Air Circulation Components

Caution Never operate the Cisco CRS 8-slot 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 strap

• Large Phillips screwdriver

Steps

To remove the chassis 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 Using the screwdriver, loosen the two captive screws on the air filter cover faceplate.

Step 3 Remove the cover faceplate and set it carefully aside.

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

Step 5 Set the air filter carefully aside.

What to Do Next

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Installing a Power Module Air Filter

This section describes how to install a power module air filter for the Cisco CRS 8-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 Regulatory Compliance and Safety Information for the Cisco CRS Carrier Routing System.

Each power module has a serviceable air filter that is attached to the front of the power module and is held in place by an air filter clip-on holder. The power module air filter faces outward from the front of the chassis (see Figure 3-6).

Figure 3-6 Power Module Air Filter

Chapter 3 Installing and Removing Air Circulation Components

1 Power module air filter 2 Air filter clip-on holder

Prerequisites

Before performing this task, you must first remove any front cover plates.

Caution Never operate the Cisco CRS 8-slot 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

• Air filter (Cisco product number CRS-8-PWR-FILTER=)

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Steps

To install a power module 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 Place the screwdriver under the edge of the air filter clip-on holder.

Step 3 Gently pry the holder loose with the screwdriver; it should pop off easily.

Step 4 Place the air filter in position on the front of the power module.

Step 5 Place the holder in position on the front of the power module over the air filter.

Step 6 Press the holder firmly but gently until it snaps into place.

What to Do Next

After performing this task, replace the front cover plates.

How to Install or Remove Air Circulation Components

Removing a Power Module Air Filter

This section describes how to remove a power module 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.

Prerequisites

Before performing this task, you must first remove any front cover plates.

Caution Never operate the Cisco CRS 8-slot line card chassis without an air filter. Doing so can result in damage

to the hardware.

Required Tools and Equipment

You need the following tools to perform this task:

• ESD-preventive wrist strap

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• Medium flat-blade screwdriver

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Steps

To remove a power module 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 Place the screwdriver under the edge of the air filter clip-on holder.

Step 3 Gently pry the holder loose with the screwdriver; it should pop off easily.

Step 4 Remove the air filter from the front of the power module and set it carefully aside.

What to Do Next

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

section on page 3-12) and replace the front cover plates.

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Specifications and Main Features

Frequently Asked Questions

User Manual

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Installation Guide

CONTENTS

Preface

Objective

Audience

Document Organization

Document Conventions

Related Documentation

Changes to This Document

Obtaining Documentation and Submitting a Service Request

Cisco CRS Carrier Routing System 8-Slot Line Card Chassis Overview

Chassis Overview

Chassis Components

Figure 1-1 Front (PLIM) View of Line Card Chassis—Fixed Configuration Power Shown

Figure 1-2 Rear (MSC) View of Line Card Chassis—Fixed Configuration Power Shown

Figure 1-3 Front (PLIM) View of Line Card Chassis—Modular Configuration Power Shown

Figure 1-4 Rear (MSC) View of Line Card Chassis—Modular Configuration Shown

Figure 1-5 Rear (MSC) View of Line Card Chassis—Fixed Configuration Shown

Chassis Slot Numbers

Figure 1-6 Line Card Chassis Slot Numbering—Front (PLIM) Side

Chassis Cable Management

Figure 1-7 Line Card Chassis Slot Numbers—Rear (MSC) Side

Figure 1-8 Cable Management Bracket

Chassis Cooling System

Chassis Power System

Figure 1-9 Airflow Through 8-Slot Line Card Chassis

Safety Guidelines

Preventing Electrostatic Discharge

Installing and Removing Power Components

Power Systems Overview

Power Component Information Common to Two Types of Power System

Basic Chassis Power Details

Fixed Configuration Power System

Modular Configuration Power System

Precautions and Recommendations

Bonding and Grounding Guidelines

How to Install the Chassis Ground Cable

Prerequisites

Required Tools and Equipment

Steps

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

Figure 2-2 Ground Cables Attached to Chassis Grounding Points

DC Power Systems

Fixed Configuration DC Power

Figure 2-3 Fixed Configuration DC PDU with Plastic Safety Cover

Figure 2-4 DC Power Grounding Cable Lug

Figure 2-5 DC Power Cable Lug

Modular Configuration DC Power

Figure 2-6 Modular Configuration DC Power Shelf Wiring

Figure 2-7 180-Degree (Straight) DC Power Cable Lug

Figure 2-8 45-Degree DC Power Cable Lug

AC Power Systems

Fixed Configuration AC Power

Modular Configuration AC Power

How to Install or Remove Fixed Configuration Power Components

Before Powering the Chassis Up or Down

Step 1 Install and wire the PDUs (see the “Installing a PDU” section on page 2-15).

Step 3 Install the RP card (see the “Installing an RP, PRP, or DRP Card” section on page 4-38).

Step 4 Activate your power source.

Step 5 Turn the PEM switches to the on position.

Converting from One Fixed Configuration Power System to Another

Step 3 Remove the PDUs. See the “Removing a PDU” section on page 2-17.

Step 4 Install the new PDUs. See the “Installing a PDU” section on page 2-15.

Installing a PDU

Figure 2-9 Fixed Configuration AC Wye PDU

Prerequisites

Required Tools and Equipment

Steps

Step 2 Make sure that the PDU is unplugged.

Step 4 If needed, put the second PDU into place in the other PDU slot on the chassis.

Step 5 Install the PDU holding plate.

Step 6 Use the socket wrench to install the 8-mm center holding bolt and the 10-mm nut.

What to Do Next

Removing a PDU

Prerequisites

Figure 2-10 Fixed Configuration AC Wye PDU