7600 SERIES 2 de 4

Chapter 3
Installing the Cisco 7600 Series Router Installing the Cable Management System (Cisco 7609 Router and Cisco 7609-S Router Only)
Step 3
Loosen the two captive installation screws on the front panel. (See Figure 3-18.)
Figure 3-17 Removing the Front Panel
CISCO 7609
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Captive installation screws

Step 4 Step 5 Step 6 Step 7
Remove the front panel and set it aside. Attach the interface cables to the modules and route the cables through the cable guide. Install the front panel by hooking the top of the front panel over the cable guide. Tighten the two captive installation screws. (See Figure 3-18.)
Replacing the Cable Guide

To replace the cable guides on the cable management system, perform these steps:
Step 1
Loosen the two captive installation screws on the front panel. (See Figure 3-18.)
STA TU S
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Chapter 3 Installing the Cable Management System (Cisco 7609 Router and Cisco 7609-S Router Only)
Installing the Cisco 7600 Series Router
Figure 3-18
Removing the Front Panel
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Step 2 Step 3
Remove the front panel and set it aside. Remove the two screws that secure the cable guide to the back panel and remove the cable guide by lifting it up and away from the back panel. (See Figure 3-19.)
Figure 3-19 Removing the Cable Guide
FAN STATUS
FAN 1 FAN 2
ST
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Note
The installation of the cable guide module is shipped alongwith the chassis. The unit should slid into the grooves on the chassis as shown in Figure 3-19.
Step 4 Step 5
Install the standard cable guide to the back panel by hooking the lip of the cable guide to the back panel. (See Figure 3-19.) Install the two screws to secure the cable guide to the back plate. (See Figure 3-19.)
Cisco 7600 Series Router Installation Guide
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Installing the Cisco 7600 Series Router System Ground Connection
Note
Before installing the front panel, attach the interface cables to the modules and route the cables through the cable guide. See the Attaching the Interface Cables section on page 3-25 for information on attaching the interface cables.
Step 6 Step 7 Step 8
Attach the interface cables to the modules and route the cables through the cable guide. Install the front panel by hooking the top of the front panel over the cable guide. Tighten the two captive installation screws. (See Figure 3-20.)
Figure 3-20 Front Panel Installation
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System Ground Connection

This section describes how to connect a system (earth) ground to the Cisco 7600 series router.
Note
You must connect the system ground on both AC- and DC-powered systems to an earth ground if Foreign Exchange Station (FXS) modules are installed or if this equipment is installed in a US or European Central Office
Note
For the Cisco 7603 router, Cisco 7604 router, Cisco 7606 router, and Cisco 7606-S DC-powered systems, the system ground is also the power supply ground. The DC ground must be installed with a permanent connection to an earth ground according to NEC guidelines.
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Chapter 3 System Ground Connection
Note
There are additional grounding requirements necessary when using the PWR-2700-DC power supply in the Cisco 7606 router and Cisco 7606-S router, the PWR-2700-DC/4 power supply in the Cisco 7604 router, the PWR-4000-DC power supply in Cisco 7609 or Cisco 7613 routers, and the PWR-6000-DC power supply in the Cisco 7609-S router. See Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router, page 5-46, Installing a PWR-2700-DC Power Supply in a Cisco 7606 Router, page 5-53, Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router, page 5-57, Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page 5-70, Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-91 and Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80. On the Cisco 7603 router, Cisco 7603-S router, Cisco 7604 router, Cisco 7606 router, Cisco 7606-S router, and Cisco 7613 router, two threaded M4 holes are provided on the chassis frame to attach the ground cable. (See Figure 3-21 for the Cisco 7603 router and Cisco 7606 router, Figure 3-22 for the Cisco 7604 router, Figure 3-23 for the Cisco 7606-S router, and Figure 3-24 for the Cisco 7613 router.) On the Cisco 7609 router and Cisco 7609-S router, three threaded M4 holes are provided on each side of the chassis frame to attach the ground cable. Use any set of two M4 holes to install the ground cable horizontally or vertically. (See Figure 3-25.)
Required Tools and Equipment

To connect the system ground, you need the following tools and materials:

One grounding lug. Two M4 (metric) hex-head screws with locking washers.
Note
The grounding lug and M4 hex-head screws with locking washers are provided in kit 69-0815-01.
Note
The Cisco 7609-S router uses the 4AWG grounding lug and M6 hex-head screws with locking washers provided in kit 69-1713-02. One grounding wire. The grounding wire must be sized according to local and national installation requirements. Depending on the power supply and system, a 12 AWG conductor or larger size wire is required for U.S. installations. Number 2 Phillips-head screwdriver. Crimping tool (must be large enough to accommodate the girth of the grounding lug when crimping the grounding cable into the lug). Wire-stripping tool.
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Figure 3-21
Cisco 7603 Router, Cisco 7603-S Router, and Cisco 7606 RouterSystem Ground Location
System ground connector
Grounding lug
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Note
The Cisco 7609-S router uses the 4AWG grounding lug and M6 hex-head screws with locking washers provided in kit 69-1713-02.
Figure 3-22 Cisco 7604 RouterSystem Ground Location
Grounding lug
System ground connector System ground connector
Wire
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Figure 3-23
Cisco 7606-S RouterSystem Ground Location
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Chapter 3
Figure 3-24
Cisco 7613 RouterSystem Ground Location
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Grounding lug Screws (M4)
Note
The system ground connection is not accessible with the PWR-4000-DC power supply; the power supply itself provides the system ground. You must use an industry standard 2-hole compression lug for the power supply ground terminal. For information, see Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-91.
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Figure 3-25
Cisco 7609 Router and Cisco 7609-S RouterSystem Ground Location
Wire System ground connector System ground connector OR Wire Grounding lug System ground connector
Grounding lug
Note
The system ground connection with the PWR-4000-DC power supply in a Cisco 7609 router and a Cisco 7609-S router is provided by the PWR-4000-DC power supply ground. Additionally, you can connect a system (earth) ground. For information, see Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page 5-70. The system ground connection with the PWR-6000-DC power supply in a Cisco 7609-S router is provided by the PWR-6000-DC power supply ground. Additionally, you can connect a system (earth) ground. For information, see Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80.
Note
When using a PWR-4000-DC power supply in a Cisco 7609 router, you must always connect the PWR-4000-DC power supply ground.
Note
When using a PWR-6000-DC power supply in a Cisco 7609-S router, you must always connect the PWR-6000-DC power supply ground.
Connecting the System Ground

You must complete this procedure before connecting system power or turning on the Cisco 7600 series router. To attach the grounding lug and cable to the grounding pad, perform these steps:
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Installing the Cisco 7600 Series Router Installing the Power Supplies in the Router Chassis
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7
Use a wire-stripping tool to remove approximately 0.75 inch (19 mm) of the covering from the end of the grounding wire. Insert the stripped end of the grounding wire into the open end of the grounding lug. Use the manufacturer recommended crimping tool to secure the grounding wire in place in the grounding lug. Locate and remove the adhesive label from the system grounding pad on the chassis. Place the grounding wire lug against the grounding pad, making sure there is solid metal-to-metal contact. Secure the grounding lug to the chassis with two M4 screws. Ensure that the grounding lug will not interfere with other hardware or rack equipment. Prepare the other end of the grounding wire, and connect it to an appropriate grounding point in your site to ensure adequate earth ground for the Cisco 7600 series router.
Installing the Power Supplies in the Router Chassis

The power supply (AC or DC) is shipped separately from the chassis. Remove the power supply from its shipping packaging. Install and connect it to the site power by referring to the Installing an AC-Input Power Supply section on page 5-8 or the Installing DC-Input Power Supplies section on page 5-42.
Note
There are additional grounding requirements necessary when using PWR-4000-DC power supply in Cisco 7609 or Cisco 7613 routers. See Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page 5-70 and Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-91. There are additional grounding requirements necessary when using PWR-6000-DC power supply in Cisco 7609-S router. See Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80.
Attaching the Interface Cables

Warning
During this procedure, wear grounding wrist straps to avoid ESD damage to the card. Do not directly touch the backplane with your hand or any metal tool, or you could shock yourself.
This section provides general information on attaching interface cables to the supervisor engines and to the modules. Depending on the modules you have installed in your chassis, you will have different styles of connectors to attach.
Note
Refer to the Cisco 7600 Series Router Module Installation Guide for additional module information.
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Chapter 3 Attaching the Interface Cables
Warning
Do not work on the system or connect or disconnect cables during periods of lightning activity.
Warning
To avoid electric shock, do not connect safety extra-low voltage (SELV) circuits to telephone-network voltage (TNV) circuits. LAN ports contain SELV circuits, and WAN ports contain TNV circuits. Some LAN and WAN ports both use RJ-45 connectors. Use caution when connecting cables.
Connecting the Supervisor Engine Console Port

This section describes how to connect to the supervisor engine console port from a terminal or modem. The console port on the supervisor engine allows you to perform the following functions:

Configure the Cisco 7600 series router from the CLI Monitor network statistics and errors Configure SNMP agent parameters Download software updates to the Cisco 7600 series router or distribute software images residing in Flash memory to attached devices
The console port, located on the front panel of the supervisor engine, is shown in Figure 3-26.
Figure 3-26
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Note
The accessory kit that shipped with your router contains the necessary cable and adapters to connect a terminal or modem to the console port. To connect a terminal to the console port using the cable and adapters provided, perform these steps:
Place the console port mode switch in the in position (factory default). Connect to the port using the RJ-45-to-RJ-45 cable and RJ-45-to-DB-25 DTE adapter or RJ-45-to-DB-9 DTE adapter (labeled Terminal). Position the cable in the cable guide (if installed). Make sure that there are no sharp bends in the cable. Check the terminal documentation to determine the baud rate. The baud rate of the terminal must match the default baud rate (9600 baud) of the console port. Set up the terminal as follows:
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9600 baud 8 data bits No parity 2 stop bits
To connect a terminal using a Catalyst 5000 family Supervisor Engine III console cable, perform these steps:
Place the console port mode switch in the out position. Connect to the port using the Supervisor Engine III cable and the appropriate adapter for the terminal connection. Position the cable in the cable guide (if installed). Make sure there are no sharp bends in the cable. Check the terminal documentation to determine the baud rate. The baud rate of the terminal must match the default baud rate (9600 baud) of the console port. Set up the terminal as follows:

9600 baud 8 data bits No parity 2 stop bits
To connect a modem to the console port, perform these steps:

Place the console port mode switch in the in position. Connect to the port using the RJ-45-to-RJ-45 rollover cable and the RJ-45-to-DB-25 DCE adapter (labeled Modem). Position the cable in the cable guide (if installed). Make sure there are no sharp bends in the cable.
Connecting the Supervisor Engine Uplink Ports

This section describes how to connect to the supervisor engine uplink ports.
Warning
Because invisible laser radiation may be emitted from the aperture of the port when no cable is connected, avoid exposure to laser radiation and do not stare into open apertures.
Note
In a redundant configuration with two supervisor engines, the uplink ports on the redundant (standby) supervisor engine are active and can be used for normal traffic, like any other ports in the chassis. To connect to the supervisor engine uplink ports, perform these steps:
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Chapter 3 Attaching the Interface Cables
Step 1 Step 2
Remove the plugs from the Gigabit Interface Converter (GBIC) optical bores; store them for future use. Remove the plugs from the SC-type connector on the fiber-optic cable. Insert the connector into the GBIC. (See Figure 3-27.)
Figure 3-27 Connecting the Supervisor Engine Uplink Ports
PORT 1
LIN
Note
When you plug the SC-type connector into the GBIC, make sure that both the transmit (Tx) and receive (Rx) fiber-optic cables are fully inserted into the SC-type connector.
Note
If you are using the LX/LH GBIC with MMF, you need to install a patch cord between the GBIC and the MMF cable.
Connecting to the Interface Ports

Note
For connector specifications, see Appendix B, Connector and Cable Specifications.
Note
For information on cleaning optical interfaces, see http://www.cisco.com/warp/public/127/cleanfiber2.html. The Optical Services Modules (OSMs) and supported Catalyst 6500 series modules have the following interface ports:

SC-Type fiber-optic connectors. (See Figure 3-28.) LC fiber-optic connectors. (See Figure 3-29.) MT-RJ fiber-optic connector. (See Figure 3-30.) Mini-SMB cable connector. (See Figure 3-31.) RJ-45Catalyst 6500 series 48-port 10/100TX switching modules. (See Figure 3-32.)
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Figure 3-28
SC-Type Fiber-Optic Connector
Figure 3-29
LC Fiber-Optic Connector
Figure 3-30
MT-RJ Fiber-Optic Connector
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Figure 3-31
Mini-SMB Cable Connector
Figure 3-32
RJ-45 Connectors
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Chapter 3 Verifying Router Chassis Installation
Verifying Router Chassis Installation

After you finish connecting the modules, you need to verify that the modules, power supplies, power entry modules (PEMs), and fan assemblies are correctly and securely installed. To verify the chassis installation, perform these steps:
Step 1 Step 2
Verify that the ejector levers of each module are fully closed (parallel to the faceplate) to ensure that the supervisor engine and all modules are fully seated in the backplane connectors. Check the captive installation screws of each module, power supply, PEM, and fan assembly. Tighten any loose captive installation screws.
Note
On the Cisco 7603 Router and Cisco 7606 Router, PEM 1 connects the site power source to power supply 1; PEM 2 connects the site power source to power supply 2. If there is only one PEM and one power supply installed in the chassis, verify that they are in the correct bays before powering up the system. See the PEM section on page 1-32 for PEM and power supply locations.
Warning Step 3 Step 4
Power supply captive installation screws must be tight to ensure protective grounding continuity.
Verify that all empty module slots have blank faceplates (WS-X6K-SLOT-CVR) installed and that the screws holding the plates in place are tight. For AC-powered systems, turn the switch on the PEM or power supply to the On (|) position to power up the system. For DC-powered systems, move the circuit breaker switch handle to the On (|) position to power up the system.
Warning
Blank faceplates and cover panels serve three important functions: they prevent exposure to hazardous voltages and currents inside the chassis; they contain EMI that might disrupt other equipment; and they direct the flow of cooling air through the chassis. Do not operate the system unless all modules, faceplates, front covers, and rear covers are in place.
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CH A P T E R
Troubleshooting
This chapter describes how to troubleshoot the Cisco 7600 series router hardware installation and contains these sections:

Getting Started, page 4-1 Problem Solving to the System Component Level, page 4-2 Identifying Startup Problems, page 4-2 Troubleshooting the Power Supply, page 4-3 Troubleshooting the Cooling Sub-System, page 4-5 Troubleshooting Modules, page 4-7 Contacting Customer Service, page 4-8
If your system has problems starting up, use the information in this chapter to help isolate the cause. Problems with the initial startup are often caused by a module that has become dislodged from the backplane or a power supply that has been disconnected from the power cord connector. Although temperature conditions above the maximum acceptable level rarely occur at initial startup, you may encounter these conditions during extended operation. Long-term monitoring functions also include independent reporting of DC-output voltage problems.
Note
This chapter covers only the chassis component hardware aspects of troubleshooting. For module-specific information, refer to the Cisco 7600 Series Internet Router Module Installation Guide.
Getting Started
When the initial system boot is complete, verify the following:

Power supplies are supplying power to the system. The system fan assembly is operating. System software boots successfully. The supervisor engine and all modules are installed properly in their slots, and each was initialized without problems.
If each of these conditions is met and the hardware installation is complete, refer to the Cisco 7600 Series Internet Router Software Configuration Guide, the Cisco 7600 Series Internet Router IOS Software Configuration Guide, the Cisco 7600 Series Internet Router IOS Command Reference, or
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Chapter 4 Problem Solving to the System Component Level
Troubleshooting
the Cisco 7600 Series Internet Router IOS Command Reference publications to troubleshoot the software. However, if any of these conditions are not met, use the procedures in this chapter to isolate and, if possible, resolve the problem.
Problem Solving to the System Component Level

The key to success when troubleshooting the system is to isolate the problem to a specific system component. The first step is to compare what the system is doing to what it should be doing. Because a startup problem can usually be attributed to a single component, it is more efficient to isolate the problem to a subsystem rather than troubleshoot each separate component in the system. The router consists of the following subsystems:

Power supplyIncludes the power supplies and power supply fans. Power entry module (PEM)On the Cisco 7603 Router and Cisco 7606 Router, there is one PEM for each power supply. The PEM connects the site source to the power supply. Fan assemblyThe chassis fan assembly should operate whenever system power is on. You should see the FAN LED turn green and should be able to hear the fan assembly to determine whether or not it is operating. If the FAN LED is red, this indicates that one or more fans in the fan assembly is not operating. You should immediately contact a customer service representative. (See the Contacting Customer Service section on page 4-8.) There are no installation adjustments that you can make if the fan assembly does not function properly at initial startup. Supervisor engineThe supervisor engine contains the system operating software, so check the supervisor engine if you have trouble with the system software. Status LEDs on the supervisor engine indicate whether or not the supervisor engine is able to initialize the module. If you have a redundant supervisor engine, refer to the Cisco 7600 Series Internet Router Software Configuration Guide or the Cisco 7600 Series Internet Router IOS Software Configuration Guide publications for descriptions of how the redundant supervisor engine comes online and how the software images are handled.
ModulesStatus LEDs on each module indicate if the module has been initialized by the supervisor engine. A module that is partially installed in the backplane can cause the system to halt.
Identifying Startup Problems

LEDs indicate all system states in the startup sequence. By checking the LEDs, you can determine when and where the system failed in the startup sequence. Perform these steps to identify startup problems:
Step 1
Turn on the power supplies. You should immediately hear the system fan assembly begin to operate. If you do not, see the Troubleshooting the Power Supply section on page 4-3. If you determine that the power supplies are functioning normally and that the fan assembly is faulty, contact a customer service representative. If the system fan assembly does not function properly at initial startup, there are no installation adjustments that you can make. To replace the fan assembly, see the Removing and Replacing the Fan Assembly section on page 5-119. Check that the LEDs on the supervisor engine light as follows:
Step 2
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Troubleshooting Troubleshooting the Power Supply
The STATUS LED flashes orange once and stays orange during diagnostic boot tests. It turns green when the module is operational (online). If the system software is unable to start up, this LED stays orange. The SYSTEM LED turns green, indicating that all chassis environmental monitors are reporting that the system is OK. If one or more environmental monitor reports a problem, the SYSTEM LED is orange or red. The ACTIVE LED turns green, indicating that the supervisor engine is operational and active. If the supervisor engine is in standby mode, the ACTIVE LED is orange. Each LINK LED flashes orange once, stays orange during diagnostic boot tests, and turns green when the module is operational (online). If no signal is detected, the LINK LED turns off. The LINK LED blinks orange if the port is bad.
If any LEDs on the supervisor engine front panel are red or orange, see the Troubleshooting Modules section on page 4-7. If you have a redundant supervisor engine, refer to the Cisco 7600 Series Internet Router Software Configuration Guide or the Cisco 7600 Series Internet Router IOS Software Configuration Guide for descriptions of how the redundant supervisor engine comes online and how the software images are handled. For a complete description of the supervisor engine LEDs, refer to the Cisco 7600 Series Internet Router Module Installation Guide.
Step 3
Verify that the STATUS LEDs on the supervisor engine and on each module are green when the supervisor engine completes initialization. This LED indicates that the supervisor engine or modules are receiving power, have been recognized by the supervisor engine, and contain a valid Flash code version. This LED does not indicate the state of the individual interfaces on the modules. If a STATUS LED is red or orange, see the Troubleshooting Modules section on page 4-7. If the boot information and system banner are not displayed, refer to the Cisco 7600 Series Internet Router Module Installation Guide to verify that the terminal is set correctly and that it is connected properly to the supervisor engine console port.
Step 4
Troubleshooting the Power Supply

Perform these steps when troubleshooting the power supply to isolate a power subsystem problem:
Step 1
Verify that the INPUT OK LED on the power supply is green.

If the INPUT OK LED is green, the AC or DC source is good and the power supply is functional. If the INPUT OK LED is off, first ensure that the power supply is flush with the back of the chassis. Turn the AC power supply or AC PEM power switch or DC circuit breaker to the Off position, tighten the captive installation screw(s), and then turn the power on. If the INPUT OK LED remains off, there might be a problem with the AC source, the DC source, or the power cable. Turn off the power to the router, connect the power cord to another power source if one is available, and turn the power On.
If the INPUT OK LED is green, the problem is the first power source.
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Chapter 4 Troubleshooting the Power Supply Sub-System
Troubleshooting
Note
The INPUT OK LED is green and the OUTPUT FAIL LED glows if there is bad power supply or internal problem in the chassis or the cards. Troubleshoot the power suppply on an empty chassis that has no card inserted.

If the INPUT OK LED fails to light after you connect the power supply to a new power source, replace the power cord, and turn the switch On. If the INPUT OK LED then goes on, return the first power cord for replacement.
If this unit has more than one power cord, repeat Step 1 for each power supply. If the INPUT OK LED still fails to light when the power supply is connected to a different power source with a new power cord, the power supply is probably faulty. If a second power supply is available, install it in the second power supply bay and contact a customer service representative for further instructions.
Step 2
If you have a second (redundant) power supply, repeat Step 1 for this power supply.
If you are unable to resolve the problem or if you determine that either a power supply or backplane connector is faulty, see the Contacting Customer Service section on page 4-8.
Troubleshooting the Power Supply Sub-System

Table 4-1 lists the solutions for the various issues associated with power supply sub-systems.
Table 4-1
Troubleshooting Power Supply
Problem Power supply is disabled
Solution
1. 2. 3. 4. 5. 6.
Ensure that the power supply is disconnected from the chassis. Ensure that all the system cards are removed from the backplane. Connect the safety ground wiring to each power shelf, if not done. Before connecting the power cables to the stud terminals, verify that power inputs are not shorted-circuited with the ground or the chassis. To enable the power supply systems, ensure that the AC power supply knob is switched on. Once the power is enabled, measure the voltage at the input terminal block. Verify that the DC voltage between the negative and positive terminal is between 37 VDC and 56 VDC. The acceptable range for AC power supply is 110V-230V.
Table 4-2 maps the LED indicator information in a power supply sub-system.
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Table 4-2
Power Supply Indicator Information
Color Green Red
Indicator
Description
Power input Power is available; however if the LED is OFF, it indicates lack of power. Output fail Power is not available; however, if the LED is OFF, it indicates the presence of the output power.
Troubleshooting Inadequate Power for all the Modules

If there is not enough power to initiate all the modules, follow the solutions listed in Table 4-3.
Table 4-3 Troubleshooting Lack of Power for all the Modules
Problem Not enough power to initiate all the modules
Solution
1. 2.
Use the power redundancy-mode combined command to combine the two power supplies in the config terminal mode OR If dual RP is not required, apply the value of the POWERNORESERVE=1 on ROMMON mode.
Troubleshooting Power Latch Up

When two power supplies are present in the system, they work in redundant mode where 50% of the power is drawn from each power supply. Table 4-4 lists the solutions for the power latch issues.
Table 4-4 Troubleshooting Power Latch Up Issues
Problem Lost redundancy and system operates on a single power supply source.
Solution
1. 2. 3.
Check if the power drawn by the system is more than 5/3 of the power supply output. Reduce the system power. Reload the system or re-insert the power supply module.
Troubleshooting the Cooling Sub-System

The cooling system dissipates the heat generated by the chassis and controls the temperature of chassis components. The cooling system has a fully redundant architecture that allows the chassis to continue operating with a single-fault failure (such as a single fan or fan tray failure). The chassis cooling system includes:

One or Two fan trays (depending upon the chassis). Temperature sensors on cards and modules throughout the chassis. Control software Air filter, inlet and outlet air vents, and bezels.
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Troubleshooting
Impedance carriers for empty chassis slots.
The AC and DC power supplies have their own self-contained cooling fans. So, depending on the required airflow, all the fans in the tray increase or decrease their rotation speed collectively. Thermal sensors (inlet, exhaust, and hot-spot) located throughout the chassis are used to monitor temperature readings and correct system cooling errors and faults. The supervisor software controls the speed of the fan and the related alarms raised. Table 4-5 lists the solutions for power loss in the sub-system.
Table 4-5 Troubleshooting the Cooling Sub-System
Problem Power Loss output in the cooling sub-system
Solution
1. 2. Note
Ensure that the fan-tray is installed and functional Insert fan-tray and the air filters in the designated slot. Except for 7609S, all C7600 routers have fan tray slots located on the left side of the chassis near to the exhaust side. Ensure that the inlet temperature to the chassis does not exceed 40 degree celsius. Install fillers or blanks in the empty slots. Ensure that the air filters are not choked and are clean.
3. 4. 5.
Troubleshooting the Fan Assembly

The chassis fan assembly should operate whenever the system power is on. You should see the FAN LED turn green and should be able to hear the fan assembly to determine whether or not it is operating. If the FAN LED is red, this indicates that one or more fans in the fan assembly is not operating. You should contact TAC immediately. See Obtaining Technical Assistance, page 6-3, to contact a customer service representative. There are no installation adjustments to make if the fan assembly does not function properly at the initial startup.
Troubleshooting An Old Fan Module

Table 4-6 lists the solutions to force an old fan module to work in single RPs only.
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Table 4-6
Troubleshooting An Old Fan Module
Problem Old fan module does not work
Solution Set the following in ROMMON mode:
ALLOWALLFANS=1 ALLOWALLFAN=1 ALLOWANYFAN=1 ALLOWANYPS=1 sync
Perform these steps when troubleshooting the fan assembly to isolate a fan assembly problem:
Step 1
Verify that the FAN LED on the fan assembly is green. If it is not, see the Problem Solving to the System Component Level section on page 4-2 to determine whether the power subsystem is functioning properly.
Step 2
Verify that the FAN LED is red.

If it is red, the fan assembly is not seated in the backplane or has malfunctioned. To ensure that the fan assembly is seated properly, loosen the captive installation screws, remove the fan assembly, and reinstall it. Tighten all captive installation screws, and then restart the system. If the FAN LED is still red, the system detects a fan assembly failure. Contact a customer service representative for instructions.
Troubleshooting Modules
Perform these steps when troubleshooting the modules to isolate a supervisor engine or module problem:
Step 1 Step 2
Verify that all status LEDs are on. If any status LEDs on the supervisor engine or any modules are red or off, the module might have shifted out of its slot. Reseat the module until both ejector levers are at 90 degrees to the rear of the chassis. Tighten the captive installation screws at the left and right of the module front panel, and restart the system.
If the status LED on a module is orange, the module might be busy or disabled. Refer to the Cisco 7600 Series Internet Router Software Configuration Guide, the Cisco 7600 Series Internet Router IOS Software Configuration Guide, the Cisco 7600 Series Internet Router IOS Command Reference or the Cisco 7600 Series Internet Router IOS Command Reference publications to configure or enable the interfaces. After the system reinitializes the interfaces, the status LED on the module should be green.
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Troubleshooting
If you still experience trouble with the startup, see the Contacting Customer Service section on page 4-8.
Contacting Customer Service

If you are unable to solve a startup problem after using the troubleshooting suggestions in this chapter, contact a customer service representative for assistance and further instructions. Before you call, have the following information ready to help your service provider assist you as quickly as possible:

Date you received the router Chassis serial number (located on a label on the right of the rear panel of the chassis) Type of software and release number Maintenance agreement or warranty information Brief description of the problem Brief explanation of the steps you have already taken to isolate and resolve the problem
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Removal and Replacement Procedures

This chapter describes how to perform removal and replacement procedures for Cisco 7600 series router field-replaceable units (FRUs). It contains the following sections:

Preventing Electrostatic Discharge Damage, page 5-1 Removing and Replacing the Power Supply, page 5-2 Removing and Replacing the PEM, page 5-112 Removing and Replacing the Fan Assembly, page 5-119 Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional), page 5-126 Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional), page 5-131 Installing the Thermistor Module on a Cisco 7606-S Router, page 5-133 Installing the Thermistor Module on a Cisco 7609-S Router, page 5-134 Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL, page 5-136
Warning
Only trained and qualified personnel should be allowed to install, replace, or service this equipment.
Caution
Use two hands to support the power supply during removal and replacement procedures.
Warning
During this procedure, wear grounding wrist straps to avoid ESD damage to the card. Do not directly touch the backplane with your hand or any metal tool, or you could shock yourself.
For instructions on installing and replacing modules, refer to the Cisco 7600 Series Internet Router Module Installation Guide.
Preventing Electrostatic Discharge Damage

Electrostatic discharge (ESD) damage, which can occur when electronic cards or components are improperly handled, results in complete or intermittent failures. Port adapters and processor modules consist of printed circuit boards that are fixed in metal carriers. Electromagnetic interference (EMI) shielding and connectors are integral components of the carrier. Although the metal carrier helps to protect the board from ESD, use a preventive antistatic strap during handling.
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Chapter 5 Removing and Replacing the Power Supply
Following are guidelines for preventing ESD damage:

Always use an ESD wrist or ankle strap and ensure that it makes good skin contact. Connect the equipment end of the strap to an unfinished chassis surface. When installing a component, use any available ejector levers or captive installation screws to properly seat the bus connectors in the backplane or midplane. These devices prevent accidental removal, provide proper grounding for the system, and help to ensure that bus connectors are properly seated. When removing a component, use any available ejector levers or captive installation screws to release the bus connectors from the backplane or midplane. Handle carriers by available handles or edges only; avoid touching the printed circuit boards or connectors. Place a removed component board-side-up on an antistatic surface or in a static shielding container. If you plan to return the component to the factory, immediately place it in a static shielding container. Avoid contact between the printed circuit boards and clothing. The wrist strap only protects components from ESD voltages on the body; ESD voltages on clothing can still cause damage. Never attempt to remove the printed circuit board from the metal carrier.
Caution
For safety, periodically check the resistance value of the antistatic strap. The measurement should be between 1 and 10 megohm (Mohm).
Removing and Replacing the Power Supply

This section describes how to remove and install power supplies for the Cisco 7600 series routers.
Note
In systems with redundant power supplies, you can replace the faulty supply while the system is operating.
Required Tools
A flat-blade or number 2 Phillips-head screwdriver is required to perform these procedures. Additionally, a wire cutter or scissors is necessary for cutting cable tie-wraps.
Clearance Guidelines
Use the following clearance guidelines when planning to install or remove power supplies at the rear of the Cisco 7600 series routers:
Allow atleast 3 to 4 feet of clearance behind the rack for maintenance. If the rack is mobile, you can push it back within one foot of a wall or cabinet for normal operation and pull it out when necessary for maintenance (installing or replacing power supplies) on the Cisco 7606, Cisco 7606-S and Cisco 7604 routers.
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Removal and Replacement Procedures Removing and Replacing the Power Supply
Removing an AC-Input Power Supply

This section covers the AC-input power supply removal procedure for the following AC power supplies and Cisco 7600 series routers:

950 W AC and 1400 W AC power supplies for the Cisco 7603 router 2700 W AC power supply for the Cisco 7604 route 1900 W AC power supply for the Cisco 7606 router 2700 W AC power supply for the Cisco 7606 router 2700 W AC power supply for the Cisco 7606-S router 3000 W AC and 4000 W AC power supplies for the Cisco 7609 and Cisco 7613 routers 4000 W AC power supply for the Cisco 7609-S router 6000 W AC power supply for the Cisco 7609, Cisco 7609-S, and Cisco 7613 routers
Warning
Hazardous voltage or energy is present on the backplane when the system is operating. Use caution when servicing.
Note
In systems with redundant power supplies, you can replace the faulty supply while the system is operating.
Note
This procedure covers the removal of the power supply only. For information on removing the power entry module (PEM), see the Removing and Replacing the PEM section on page 5-112. Follow these steps to remove a power supply:
Step 1
Turn the power switch to the Off (0) position on the power supply or PEM for the power supply you are removing.
Note
Figure 5-1 shows the location of the AC-input PEMs on the Cisco 7603 router. The location of the PEMs is the same for AC and DC PEMs on the Cisco 7603 router and Cisco 7606 router.
Note
If you are planning on installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any PEMs and install a blank PEM filler plate. See Removing and Replacing the PEM, page 5-112.
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Figure 5-1
PEM Location
PEM 1
PEM 2
WS-X6K-SUP2-2GE
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ST
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4 PORT OC-12 POS SM
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RT
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Step 2 Step 3
Disconnect the power cord from the power source. Do not touch the metal prongs on the power cord when it is still connected to the power supply or PEM. Remove the power cord from the power connection on the PEM. Do not touch the metal prongs embedded in the PEM.
Note
The AC power cord for the 4000 W power supply is hard-wired and cannot be removed from the supply.
Step 4
Loosen the captive installation screws on the power supply. (See Figure 5-2 for the Cisco 7603 router, Figure 5-3 for the Cisco 7604 router, Cisco 7606 router, andCisco 7606-S router, Figure 5-4 for the Cisco 7609 router, Cisco 7609-S router, and Cisco 7613 router.)
Figure 5-2 Cisco 7603 RouterPower Supply Captive Installation Screws
Status LEDs
INPUT FAN OUTPUT OK OK FAIL
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Figure 5-3
Cisco 7604 Router , Cisco 7606 Router, Cisco 7606-SPower Supply Captive Installation Screws
Status LEDs
Figure 5-4
Cisco 7609 Router, Cisco 7609-S Router, and Cisco 7613 Router Power Supply Captive Installation Screws
63895
Power switch
0
INPUT OK FAN OK OUTPUT FAIL
Status LEDs Captive installation screw
Step 5
Cisco 7603 router, Cisco 7609 router, Cisco 7609-S, and Cisco 7613 routerGrasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply (see Figure 5-5 for Cisco 7603 router, and Figure 5-6 for Cisco 7609, Cisco 609-S, and Cisco 7613 routers), and slide the power supply completely out of the chassis. Cisco 7604, Cisco 7606 router, Cisco 7606-S routerGrasp both power supply handles, as shown in Figure 5-7, and slide the power supply completely out of the chassis.
85756
IN T PU
N FA
IL FA UT TP OU OK
OK
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Figure 5-5
Cisco 7603 RouterHandling an AC-Input Power Supply
Power Supply 2 (redundant)
Power Supply 1
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Removing and Replacing the Power Supply
WS-X6K-SUP2-2GE
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Figure 5-6
INPUT OK
RR CA AR AL
NK LI IER M
FAN OK
OUTPUT FAIL

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Figure 5-7
Cisco 7604, Cisco 7606, Cisco 7606-S RoutersHandling an AC-Input Power Supply
Step 6
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-16727-01 for the Cisco 7603 router, 800-19193-01 for the Cisco 7606 router, 800-28533-01 for the Cisco 7606-S router, and 700-03104-01 for the Cisco 7609 and Cisco 7613 routers) over the opening and secure it with the captive installation screws.
Installing an AC-Input Power Supply

This section covers the AC-input power supply installation procedure for the Cisco 7600 series routers.
Warning
This product requires short-circuit (over current) protection, to be provided as part of the building installation. Install only in accordance with national and local wiring regulations.
Follow these steps to install an AC-input power supply:

Ensure that the system (earth) ground connection has been made. For ground connection instructions, see the System Ground Connection section on page 3-19. If necessary, remove the blank power supply filler plate from the chassis power supply bay opening by loosening the captive installation screws. If your power supply has a power switch (see Figure 5-4), verify that the power switch is in the Off (0) position.
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Step 4
Cisco 7603 router, Cisco 7609 router, and Cisco 7613 routerGrasp the power supply handle with one hand. Place your other hand underneath the power supply (see Figure 5-5 for Cisco 7603 router and Figure 5-6 for Cisco 7609 and Cisco 7613 routers). Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay. Cisco 7604, Cisco 7606, Cisco 7606-S routersGrasp both power supply handles, as shown in Figure 5-7. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.
Note
If you are installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any preinstalled PEMs. You must also install a blank PEM filler plate for each power supply you are installing. See Removing and Replacing the PEM, page 5-112. Securely tighten the power supply captive installation screws. (See Figure 5-2 for the Cisco 7603 router, Figure 5-3 for the Cisco 7604 router, the Cisco 7606 router, and the Cisco 7606-S router, and Figure 5-4 for the Cisco 7609 and the Cisco 7613 routers.)
Step 5
Warning Step 6 Step 7
Plug the power cord into the power supply or PEM. Connect the other end of the power cord to an AC-input power source.
Caution
In a system with dual power supplies, connect each power supply to a separate input source. In case of a power source failure, the second source will most likely still be available. Turn the switch on the power supply or PEM to the On (|) position. Verify power supply operation by checking that the power supply LEDs are in the following states:

Step 8 Step 9
INPUT OK LED is green FAN OK LED is green OUTPUT FAIL LED is not lit
If the LEDs indicate a power problem, see the Identifying Startup Problems section on page 4-2 for troubleshooting information.
Removing a DC-Input Power Supply

This section describes the DC-input power supply removal procedure for the Cisco 7600 series routers:

Removing PWR-950-DC Power Supply from a Cisco 7603 Router, page 5-10 Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router, page 5-11 Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router, page 5-13 Removing PWR-1900-DC Power Supply from a Cisco 7606 Router, page 5-15 Removing PWR-2700-DC Power Supply from a Cisco 7606 Router, page 5-17 Removing PWR-2700-DC Power Supply from a Cisco 7606-S Router, page 5-19
5-9
Removing PWR-4500-DC Power Supply from a Cisco 7606-S Router, page 5-21 Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router, page 5-26 Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router, page 5-28 Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router, page 5-31 Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router, page 5-38
Removing PWR-950-DC Power Supply from a Cisco 7603 Router

Warning
Before performing any of the following procedures, ensure that power is removed from the DC circuit.
Warning
Voltage is present on the backplane when the system is operating. To reduce risk of an electric shock, keep hands and fingers out of the power supply bays and backplane areas.
Follow these steps to remove a DC-input power supply:

Step 1
Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-8).
Figure 5-8 PEM Location
DC PEM 1 DC PEM 1 terminal block screws
DC PEM 2
Cable clips
WS-X6K-SUP2-2GE
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Step 2
Loosen the captive installation screws on the power supply (Figure 5-9).
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Figure 5-9
Cisco 7603 RouterPower Supply Captive Installation Screws
Status LEDs

Step 3
Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-10, and slide the power supply completely out of the chassis.
Figure 5-10 Cisco 7603 RouterHandling a DC-Input Power Supply
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Power Supply 1
Step 4
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-16727-01 for the Cisco 7603 router) over the opening and secure it with the captive installation screws.
Removing PWR-1500-DC Power Supply from a Cisco 7603-S Router

Warning
Warning
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Step 1
Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-11).
Figure 5-11 PEM Locations
PEM 1 PEM 2
PEM 1 PEM 2
-48 TO -60V 50A MAX
Supervisor Engine
PEM-DC
FAN STATU S
-48 TO -60V 50A MAX
PEM-DC
7600-ES20-10G3
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CLASS 1 LASER
A/L A/L
U AT ST S
CLASS 1 LASER
A/L
Fan assembly
Slots 1-3 (top to bottom)
Step 2
Figure 5-12 Cisco 7603-S RouterPower Supply Captive Installation Screws
PWR-1
500-DC
Status LEDs
ALL FA ST PRIOR ENERS MUST TO OPER BE FULLY ATING OF POWE ENGAGED\ R SUPP Y
IN
PU
OK OK AIL F N FA UT TP OU

Step 3
Grasp the power supply handle, as shown in Figure 5-13, and slide the power supply completely out of the chassis.
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Figure 5-13
Cisco 7603-S RouterHandling an DC-Input Power Supply
Power Supply 1
Step 4
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-28728-01 for the Cisco 7603-S router) over the opening and secure it with the captive installation screws.
Removing PWR-2700-DC/4 Power Supply from a Cisco 7604 Router

Warning
Warning

Step 1 Step 2
Verify that power is off to the DC circuit connected to the DC-input power supply you are removing. Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-14).
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Figure 5-14
DC-Input Front Panel for 2700-W DC-Input Power Supply
1 2 3
PWR-2 700-DC
/6
-VE-1
-VE-1
INPUT 1 INP UT2 OK FAN OU OK 48V-60V TPUT OK FAIL =40A 48V-60V =40A
-VE-2
-VE-2
6 5 7
9 10
11
1 2 3 4 5 6
Step 3 Step 4
Captive installation screw DC power cable terminal block Status LEDs DC power cable terminal block cover Cable holder cover Ground
7 8 9
Cable holder cover Cable holder Tie-wrap
10 Cable holder 11 Tie-wrap
Remove the two screws securing each of the cable holder covers, and remove the cable holder covers off the cable holders (Figure 5-14). Disconnect the DC-input wires from the terminal block (Figure 5-14) in this order:

Positive (+) Negative (-) Ground
Step 5
Remove the two tie-wraps from the ground cable. If there is a long cable tie securing the cable holders as shown in Figure 5-14, remove that as well.
Warning
When installing the unit, the ground connection must always be made first and disconnected last.
Step 6
Caution
Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply weighs 13.4 pounds (6.1 kg).
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Step 7
Grasp both power supply handles, as shown in Figure 5-15, and slide the power supply completely out of the chassis.
Figure 5-15 Handling a DC-Input Power Supply
PWR-27
00-DC/
+VE-1 +VE-1
INPUT1 INPUT2 OK FAN OUT PUT 48V-60V OK 48V-60V OK FAIL =40A =40A
-VE-1
+VE-2
-VE-1
-VE-2
+VE-2
-VE-2
ALL FAS PRIOR TENERS MUS TO OPE T RATING BE FULLY ENG THE POW AGE ER SUP D PLY
PWR-27
00-DC/
+VE-1 +VE-1
-VE-1
+VE-2
-VE-1
-VE-2
+VE-2
-VE-2
Power Supply 1
Figure 5-16
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws

Warning
Warning

Step 1
Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are removing (Figure 5-17). The location of the PEMs is the same for AC and DC PEMs on the Cisco 7603 and Cisco 7606 routers.
5-15
126567
Figure 5-17
PEM Locations
DC PEM 1 DC PEM 1 terminal block screws
DC PEM 2
Cable clips
WS-X6K-SUP2-2GE
ST
AT
ST
NS
RE
SUPERVISOR2
CONSOLE
Switch 100%
Load PORT 1
PORT 2
1%
LI
LI
NK
1 US 2
IR
AC T
TIV
E RX TX RX TX AC TIV E RX TX 1 RX IE M RR AR CA AL R RT 2 R IE M RR AR CA AL TX AC TIV E RX TX RX RT 3 R IE M RR AR CA AL TX AC TIV E RX TX RX RT 4 TX
ST
AT
4 K 1 2 LIN K LIN
RE K 3 4 LIN
SE
4 PORT OC-12 POS SM
LIN
R IE M RR AR CA AL
PO
RT
PO
PO
PO
OSM-4OC12 POS-SI
1 S 2
IR
3 A
IV CT
E RX TX RX TX AC TIV E RX TX 1 RX R IE M RR AR CA AL RT 2 R IE M RR AR CA AL TX T AC IV E RX TX RX RT 3 R IE M RR AR CA AL TX AC TIV E RX TX RX RT 4 TX
ST
U AT
4 K 1 2 LIN K LIN
RE K 3 4 LIN
SE
T R IE M RR AR CA AL
4 PORT OC-12 POS SM
LIN
PO
RT
PO
PO
PO
Step 2
Figure 5-18 Cisco 7606 RouterPower Supply Captive Installation Screws
Status LEDs

Step 3
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OSM-4OC12 POS-SI
NK
IN PU TO
FA N OK K
OU TP UT FA IL
Chapter 5
Figure 5-19
Cisco 7606 RouterHandling an DC-Input Power Supply
Step 4
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 800-19193-01 for the Cisco 7606 router) over the opening and secure it with the captive installation screws.

Warning
Warning

Step 1 Step 2
63901
IN PU TO K FA N OK OU TP UT FA IL
IN T PU
N FA
IL FA UT TP OU OK
OK
5-17
Figure 5-20
1 2 3
PWR-2 700-DC
/6
-VE-1
-VE-1
-VE-2
-VE-2
6 5 7
9 10
11
1 2 3 4 5 6
Step 3 Step 4
7 8 9

Step 5
Warning
Step 6
Caution
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Step 7
PWR-27
00-DC/
-VE-1
-VE-1
INPUT1 INPUT2 OK FAN OU OK TPUT 48V-60 OK V 48V-60 FAIL V =40A =40A
-VE-2 CHASS IS GROU ND
-VE-2
ALL FAS TENERS PRIOR MUST TO OP ERATIN BE FULLY ENGAG G THE POWE ED R SUP PLY
PWR-27
00-DC/
-VE-1
-VE-1
-VE-2
-VE-2
Note
If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-03104-01) over the opening, and secure it with the captive installation screws.

Warning
Warning

Step 1 Step 2
5-19
119627
CHASS IS GROU ND
Figure 5-22
1 2 3
PWR-2 700-DC
/6
-VE-1
-VE-1
-VE-2
-VE-2
6 5 7
9 10
11
1 2 3 4 5 6
Step 3 Step 4
7 8 9

Step 5
Warning
Step 6
Caution
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Step 7
PWR-27
00-DC/
-VE-1
-VE-1
-VE-2 CHASS IS GROU ND
-VE-2
PWR-27
00-DC/
-VE-1
-VE-1
-VE-2
-VE-2
Note

Warning
Warning

Step 1 Step 2
Verify that power is off to the DC circuit connected to the DC-input power supply you are removing. The power ON/Off switch on the PWR-4500-DC power supply should be off (marked as the 0 position). Remove the four screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-24).
5-21
119627
CHASS IS GROU ND
Figure 5-24
1 2 3
+VE-1 48V-60V 40A -VE-1
+VE-1 48V-60V 40A -VE-1
+VE-2 48V-60V 40A -VE-2
+VE-2 48V-60V 40A -VE-2
REMOVE
+VE-3 48V-60V
INSTALL
SWITC H MUST -VE-3 BE IN TO INS OFF O TALL/R POSIT EMOVE ION FASTEN POWER ERS MU SUPPLY ST BE PRIOR . FULLY TO OP ENGAG ERATIN ED G POW ER SUP PLY.
40A
+VE-3 48V-60V 40A -VE-3
PWR-4
500-DC
INPUT1 OK
OUTPU T FAIL
9 10 8
5 4
1 2 3 4 5
Step 3 Step 4
DC power cable terminal block Cable holder Captive installation screw Ground Status LEDs
6 7 8 9
Tie-wrap DC power cable terminal block Cable holder cover Power Switch
10 DC power cable terminal block cover

Step 5
Warning
Step 6
Caution
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INPUT2 OK
FAN OK
Chapter 5
Step 7
+VE-1 48V-60 V 40A -VE-1
+VE-2 48V-60 V 40A -VE-2
REMOVE
INSTALL
+VE-3 48V-60 V
SWITCH MUST -VE-3 BE IN TO INST OFF O ALL/REM POS SITIO SIT ITION OVE POW FASTEN ERS MUS ER SUP UPP PPL PPLY PP PLY. T BE FUL PRIOR . TO OPE LY ENG RATING AGED POWER SUPPLY.
40A
PWR-45
00-DC
INPUT1 OK
INPUT2 OK
FAN OK
OUTPUT FAIL
REMOVE
INSTALL
SWITCH MUST BE IN TO INST OFF O ALL/REM POS SITIO SI ITION OVE POW FASTEN ERS MUS ER SUP UP UPP PPLY P PLY. T BE FUL LY. PRIOR . TO OPE LY ENG RATING AGED POWER SUPPLY.
40A -VE-3
PWR-45
00-DC
INPUT1 OK
INPUT2 OK
FAN OK
OUTPUT FAIL
Note
Removing a WS-CDC-2500W Power Supply from a Cisco 7609 Router

Warning
Warning

Step 1 Step 2
Verify that power is off to the DC circuit connected to the DC-input power supply you are removing. Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-26). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.
5-23
252584
Figure 5-26
Terminal block cover
DC power cable terminal block

85906
I 0
Power switch

Step 3 Step 4
Remove the two screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-26). Disconnect the DC-input wires from the terminal block (Figure 5-27) in this order:

Warning
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Figure 5-27
DC-Input Wire Connections on the Terminal Block

DC-input cable
Power leads attached to terminal block ( - ) Negative (+) Positive ( ) Ground

85907
Power switch
Captive installation screw
Step 5
Caution
Use both hands to install and remove power supplies. Each WS-CDC-2500W DC-input power supply weighs 22 pounds (9.9 kg). Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-28, and slide the power supply completely out of the chassis.
Step 6
I 0
INPUT OK
FAN OK
OUTPUT FAIL
85741
5-25
Step 7
Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router

Warning
Warning

Step 1 Step 2
Figure 5-29 DC-Input Front Panel for 2500-W DC-Input Power Supply
DC power cable terminal block

85906
I 0
Power switch

Step 3 Step 4
Remove the two screws securing the terminal block cover, and slide the cover off the terminal block (Figure 5-29). Disconnect the DC-input wires from the terminal block (Figure 5-30) in this order:

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Warning
Figure 5-30 DC-Input Wire Connections on the Terminal Block
DC-input cable
Power leads attached to terminal block ( - ) Negative (+) Positive ( ) Ground

85907
Power switch
Step 5
Caution
Use both hands to install and remove power supplies. Each WS-CDC-2500W DC-input power supply weighs 22 pounds (9.9 kg). Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-31, and slide the power supply completely out of the chassis.
Step 6
5-27
Figure 5-31
Handling a DC-Input Power Supply
I 0
INPUT OK
FAN OK
OUTPUT FAIL
Step 7
Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router
Warning
Warning

Step 1 Step 2
5-28
85741
OL-4503-26
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Figure 5-32
11 10 9
0 I
4
INPUT OK
+ VE-1 + VE-3
FAN OUTPUT OK FAIL
-VE-1 -VE-3
+ VE-2
7 8
-VE-2
Note
Figure 5-32 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.
1 2 3 4 5 6
Step 3 Step 4
Inner terminal block cover Plastic insulator DC power cable terminal block 2 (TB2) Ground Status LEDs Captive installation screw
7 8 9
Power switch Outer terminal block cover Inner terminal block cover
10 Plastic insulator 11 DC power cable terminal block 1 (TB1)
Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-32). Cut any cable tie-wraps being careful not to cut the DC-input wires.
Note
The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W for single and redundant configurations. Some configurations require cable tie-wraps. For more information, refer to Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page 5-70. Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover. Remove both inner terminal block covers.
Step 5
Note
You must remove three terminal block covers for the 4000 W DC-input power supply.The left-side inner terminal block cover has two securing screws and the right-side inner terminal block cover has one securing screw.
101397
5-29
Step 6 Step 7
Remove the plastic insulator from over the terminal area (Figure 5-33). Disconnect the DC-input wires from the terminal block in this order:

Positive (+) Negative (-)
Note
You must remove DC-input wires from two terminal blocks for the 4000 W DC-input power supply (if both terminal blocks are used).
Step 8
Disconnect the PWR-4000-DC power supply ground.
Warning
Figure 5-33 DC-Input Wire Connections for 4000-W DC-Input Power Supply
Power leads attached to terminal block (+) Positive ( - ) Negative
Terminal block cover Plastic insulator
Plastic insulator
Power leads attached to terminal block (+) Positive ( - ) Negative (+) Positive ( - ) Negative
( ) Ground
Power switch
1
INPUT OK 2 3
FAN OUTPUT OK FAIL
( ) Ground Captive installation screw
Note Step 9
Figure 5-33 shows a 4000 W configuration that requires cable tie-wraps. Loosen the captive installation screw on the power supply (Figure 5-33).
Caution
Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg).
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Step 10
Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-34, and slide the power supply completely out of the chassis.
I 0
INPUT OK 1 2 3
FAN OUTPUT OK FAIL
Step 11
Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router
Warning
Warning
Note
With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. Read through this procedure carefully before removing your power supply. Follow these steps to remove a DC-input power supply:
Step 1 Step 2
97522
5-31
Figure 5-35
2 3
9
INS TA RUN L
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
5 6 4
FAN OK
OUTPU T FAIL
1 2 3 4 5
Terminal block cover DC power cable terminal block Ground Status LEDs Power switch
6 7 8 9
Captive installation screw Input Power Module (IPM) IPM captive screws IPM latches
Note
With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. To use this option, do not perform steps 3 through 6 and go to step 7. Remove the two A4 screws securing the terminal block cover, and remove the cover from the power supply (Figure 5-35). Cut any cable tie-wraps being careful not to cut the DC-input wires.
Step 3 Step 4
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Note
The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W for single and redundant configurations. Some configurations require cable tie-wraps, depending on available DC input pairs. For more information, refer to Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80. Disconnect the DC-input wires from the terminal block in this order:

Step 5
Step 6
Warning
Figure 5-36 DC-Input Wire Connections for 6000-W DC-Input Power Supply (2800W DC-input shown)
Input power module Power leads attached to terminal block ( - ) Negative (+) Positive ( - ) Negative (+) Positive
INS TA RUN L
Power switch
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPU T FAIL
( ) Ground
Note Step 7
If you are not going to remove the IPM, skip steps 7 and 8 and go to step 9. Loosen the IPM captive installation screws on the power supply. See Figure 5-35.
191287
5-33
Step 8
Lift up on both IPM latches and remove the IPM. See Figure 5-37.
Figure 5-37 Removing the IPM Module
INS TA RUN L
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPU T FAIL
Step 9
Loosen the captive installation screw on the power supply (Figure 5-36).
Caution
Use both hands to install and remove power supplies. Each DC-input power supply weighs 35 pounds (16 kg). Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-38 (without IPM) and in Figure 5-39 (with IPM), and slide the power supply completely out of the chassis.
Step 10
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Figure 5-38
Handling a DC-Input Power Supply without IPM
INS T RUN AL
CISCO SYSTE
MS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPUT FAIL
Figure 5-39
Handling a DC-Input Power Supply with IPM
INS TA RUN L
CISCO SYST
EMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPUT FAIL
Removing a PWR-4000-DC Power Supply from a Cisco 7613 Router

Warning
Warning

Step 1
Verify that power is off to the DC circuit connected to the DC-input power supply you are removing.
191308
5-35
Step 2
Turn the power switch to the Off (0) position on the power supply you are removing (Figure 5-40). Turning the power switch off also disengages a pawl that unlocks the power supply from the chassis.
11 10 9
0 I
4
INPUT OK
+ VE-1 + VE-3
FAN OUTPUT OK FAIL
-VE-1 -VE-3
+ VE-2
7 8
-VE-2
Note
Figure 5-40 shows PWR-4000-DC with an outer terminal block cover; an earlier version of this power supply does not have an outer terminal block cover. To order a retrofit kit use part number CVR-4000DC-TERM=.
1 2 3 4 5 6
Step 3 Step 4
Inner terminal block cover Plastic insulator DC power cable terminal block 2 (TB2) Ground Status LEDs Captive installation screw
7 8 9
Power switch Outer terminal block cover Inner terminal block cover
10 Plastic insulator 11 DC power cable terminal block 1 (TB1)
Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power supply (Figure 5-40). Cut any cable tie-wraps being careful not to cut the DC-input wires.
Note
The 4000 W DC-input power supply provides voltages of 2700 W or 4000 W for single and redundant configurations. Some configurations require cable tie-wraps. For more information, refer to Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-91. Remove the two screws securing the left inner terminal block cover and one screw securing the right inner terminal block cover. Remove both inner terminal block covers.
Step 5
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Note
You must remove three terminal block covers for the 4000 W DC-input power supply.The left-side inner terminal block cover has two securing screws and the right-side inner terminal block cover has one securing screw.
Step 6 Step 7
Remove the plastic insulator from over the terminal area (Figure 5-41). Disconnect the DC-input wires from the terminal block in this order:

Note
You must remove DC-input wires from two terminal blocks for the 4000 W DC-input power supply (if both terminal blocks are used).
Step 8
Warning
Figure 5-41 DC-Input Wire Connections for 4000-W DC-Input Power Supply
Power leads attached to terminal block (+) Positive ( - ) Negative
Terminal block cover Plastic insulator
Plastic insulator
Power leads attached to terminal block (+) Positive ( - ) Negative (+) Positive ( - ) Negative
( ) Ground
Power switch
1
INPUT OK 2 3
FAN OUTPUT OK FAIL
( ) Ground Captive installation screw
Note Step 9
Figure 5-41 shows a 4000 W configuration that requires cable tie-wraps. Loosen the captive installation screw on the power supply (Figure 5-41).
114008
5-37
Caution
Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 pounds (9.9 kg) and 33 pounds (15 kg). Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-42, and slide the power supply completely out of the chassis.
Step 10
I 0
INPUT OK 1 2 3
FAN OUTPUT OK FAIL
Step 11
Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router

Warning
Warning
Note
With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. Read through this procedure carefully before removing your power supply. Follow these steps to remove a DC-input power supply:
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Step 1 Step 2
2 3
9
INS TA RUN L
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
5 6 4
FAN OK
OUTPU T FAIL
1 2 3 4 5
Terminal block cover DC power cable terminal block Ground Status LEDs Power switch
6 7 8 9
Captive installation screw Input Power Module (IPM) IPM captive screws IPM latches
Note
With the PWR-6000-DC power supply, you have the option of removing the Input Power Module (IPM) without disconnecting the DC-input wires and the ground wires. You can then replace your power supply and insert the fully-wired IPM. To use this option, do not perform steps 3 through 6 and go to step 7. Remove the two A4 screws securing the terminal block cover, and remove the cover from the power supply (Figure 5-43).
Step 3
5-39
Step 4
Cut any cable tie-wraps being careful not to cut the DC-input wires.
Note
The 6000 W DC-input power supply provides voltages of 2800 W, 4500 W, or 6000 W for single and redundant configurations. Some configurations require cable tie-wraps, depending on available DC input pairs. For more information, refer to Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80. Disconnect the DC-input wires from the terminal block in this order:

Step 5
Step 6
Warning
Figure 5-44 DC-Input Wire Connections for 6000-W DC-Input Power Supply (2800W DC-input shown)
Input power module Power leads attached to terminal block ( - ) Negative (+) Positive ( - ) Negative (+) Positive
INS TA RUN L
Power switch
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPU T FAIL
( ) Ground
Note
If you are not going to remove the IPM, skip steps 7 and 8 and go to step 9.
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Step 7 Step 8
Loosen the IPM captive installation screws on the power supply. See Figure 5-43. Lift up on both IPM latches and remove the IPM. See Figure 5-45.
Figure 5-45 Removing the IPM Module
INS TA RUN L
CISCO SY
STEMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPU T FAIL
Step 9
Loosen the captive installation screw on the power supply (Figure 5-43).
Caution
Use both hands to install and remove power supplies. Each DC-input power supply weighs 35 pounds (16 kg). Grasp the power supply handle with one hand and slide the power supply part of the way out of the chassis. Place your other hand underneath the power supply, as shown in Figure 5-46 (without IPM) and in Figure 5-47 (with IPM), and slide the power supply completely out of the chassis.
Step 10
191309
5-41
Figure 5-46
Handling a DC-Input Power Supply without IPM
INS TA RUN L
CISCO SYST
EMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPUT FAIL
Figure 5-47
Handling a DC-Input Power Supply with IPM
INS TA RUN L
CISCO SYST
EMS, INC
1 2 INPUT 3 OK 4
FAN OK
OUTPUT FAIL
Installing DC-Input Power Supplies

This section covers the DC-input power supply installation procedure for the Cisco 7600 series routers:

Installing a PWR-950-DC Power Supply in a Cisco 7603 Router, page 5-43 Installing a PWR-1500-DC Power Supply in a Cisco 7603-S Router, page 5-45 Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router, page 5-46
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Installing a PWR-1900-DC Power Supply in a Cisco 7606 Router, page 5-51 Installing a PWR-2700-DC Power Supply in a Cisco 7606 Router, page 5-53 Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router, page 5-57 Installing a WS-CDC-2500W Power Supply in a Cisco 7609 Router, page 5-65 Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router, page 5-67 Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page 5-70 Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-80 Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-91 Installing a PWR-6000-DC Power Supply in a Cisco 7613 Router, page 5-99
Note
The DC return is to remain isolated from the system frame and chassis (DC-I).
Installing a PWR-950-DC Power Supply in a Cisco 7603 Router

Warning
Follow these steps to install a DC-input power supply:

Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the System Ground Connection section on page 3-19. Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are installing. Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-48. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.
5-43
Figure 5-48
Handling the Power Supply
Power Supply 1
Step 4
Tighten the power supply captive installation screws (Figure 5-49).

Figure 5-49 Power Supply Captive Installation Screws
Status LEDs

Warning
Caution
In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available. Verify that all connections to the DC PEM are secure. Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position. Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

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If the LEDs indicate a power problem, see the Identifying Startup Problems section on page 4-2.
Installing a PWR-1500-DC Power Supply in a Cisco 7603-S Router

Warning

Ensure that the system (earth) ground connection has been made. For ground connection installation instructions, see the System Ground Connection section on page 3-19. Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are installing. Grasp the power supply handle with one hand. Place your other hand underneath the power supply, as shown in Figure 5-50. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.
Figure 5-50 Handling the Power Supply
Power Supply 1
Step 4
Tighten the power supply captive installation screws (Figure 5-51).
5-45
63032
Figure 5-51
Power Supply Captive Installation Screws
PWR-1
500-DC
Status LEDs
ALL FA ST PRIOR ENERS MUST TO OPER BE FULLY ATING OF POWE ENGAGED\ R SUPP Y
IN
PU
OK OK AIL F N FA UT TP OU
Warning
Caution
In a system with dual power supplies, connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available. Verify that all connections to the DC PEM are secure. Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker switch handle to the On (|) position. Verify power supply operation by checking that the power supply front panel LEDs are in the following states:

If the LEDs indicate a power problem, see the Identifying Startup Problems section on page 4-2.
Installing a PWR-2700-DC/4 Power Supply in a Cisco 7604 Router

Warning

Step 1
Power supply ground is required.
Note
The system ground connection with the PWR-2700-DC/4 power supply in a Cisco 7604 router is provided by the PWR-2700-DC/4 power supply ground. Additionally, you can connect a system (earth) ground.
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Note
When using a PWR-2700-DC/4 power supply in a Cisco 7604 router, you must always connect the PWR-2700-DC/4 power supply ground.
Note
For redundant power supplies, you must connect the PWR-2700-DC/4 power supply ground for both power supplies. Install the PWR-2700-DC/4 power supply ground as described in this procedure. If you intend to use an additional system (earth ground), ensure that the system ground connection has been made. For ground connection installation instructions, see the System Ground Connection section on page 3-19.
a. b.
Step 2 Step 3
Remove the plastic bag attached to the front panel and put aside. This bag contains two plastic terminal block barriers, two cable ties, and two cable holder covers. Verify that power is off to the DC circuit connected to the power supply you are installing. Grasp both power supply handles, as shown in Figure 5-52. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay.
Figure 5-52 Handling the Power Supply
PWR-27
00-DC/
+VE-1 +VE-1
-VE-1
+VE-2
-VE-1
-VE-2
+VE-2
-VE-2
PWR-27
00-DC/
+VE-1 +VE-1
-VE-1
+VE-2
-VE-1
-VE-2
+VE-2
-VE-2
Power Supply 1
Note Step 4
This illustration shows the terminal block barriers and terminal block guards attached. Tighten the power supply captive installation screws (Figure 5-53).
5-47
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Chapter 3

SWITCH FABRIC MDL

Captive installation screws

Replacing the Cable Guide

SWITCH FABRIC MDL

Cisco 7600 Series Router Installation Guide OL-4503-26

Installing the Cisco 7600 Series Router

Removing the Front Panel

SWITCH FABRIC MDL

Captive installation screws

Cisco 7600 Series Router Installation Guide

SWITCH FABRIC MDL

Standard Cable Guide

8 PORT OC3 POS

8 PORT OC3 POS MM

SWITCH FABRIC MDL

SWITCH FABRIC MDL

Installing the Cisco 7600 Series Router System Ground Connection

Step 6 Step 7 Step 8

SWITCH FABRIC MDL

Captive installation screws

System Ground Connection

SWITCH FABRIC MDL

Cisco 7600 Series Router Installation Guide OL-4503-26

Chapter 3 System Ground Connection

Installing the Cisco 7600 Series Router

Required Tools and Equipment

Cisco 7600 Series Router Installation Guide

Installing the Cisco 7600 Series Router System Ground Connection

Wire System ground connector

CONSOLE PORT MODE PCMCIA EJECT

E RX TX RX TX AC TIV E RX TX 1 RX IE M RR R CA ALA R RT 2 R IE M RR R CA ALA TX AC TIV E RX TX RX RT 3 R IE M RR R CA ALA TX AC TIV E RX TX RX RT 4 TX

4 PORT OC-12 POS SM

E RX TX RX TX T AC IV E RX TX 1 RX R IE M RR R CA ALA RT 2 R IE M RR R CA ALA TX AC TIV E RX TX RX RT 3 R IE M RR R CA ALA TX AC TIV E RX TX RX RT 4 TX

4 PORT OC-12 POS SM

System ground connector System ground connector

Cisco 7600 Series Router Installation Guide OL-4503-26

Chapter 3 System Ground Connection

Installing the Cisco 7600 Series Router

Cisco 7606-S RouterSystem Ground Location

System ground connector System ground connector

Cisco 7600 Series Router Installation Guide

Installing the Cisco 7600 Series Router System Ground Connection

Cisco 7613 RouterSystem Ground Location

Grounding pad Wire

Grounding pad location under lip

Grounding lug Screws (M4)

Cisco 7600 Series Router Installation Guide OL-4503-26

Chapter 3 System Ground Connection

Installing the Cisco 7600 Series Router

Cisco 7609 Router and Cisco 7609-S RouterSystem Ground Location

Connecting the System Ground

Cisco 7600 Series Router Installation Guide

Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Installing the Power Supplies in the Router Chassis

Attaching the Interface Cables

Cisco 7600 Series Router Installation Guide OL-4503-26

Chapter 3 Attaching the Interface Cables

Installing the Cisco 7600 Series Router

Connecting the Supervisor Engine Console Port

Supervisor Engine Console Port Connector

CONSOLE PORT MODE