Cisco 7606-S Installation Manual
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Cisco 7606-S Installation Manual

Field-replaceable units (frus)
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See also: Configuration Manual , User Manual
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 5-2
•
Removing and Replacing the Power Supply, page 5-2
•
Removing and Replacing the PEM, page 5-106
•
Removing and Replacing the Fan Assembly, page 5-113
•
•
Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional),
page 5-119
•
Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional),
page 5-119
•
Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional), page 5-124
Installing the Thermistor Module on a Cisco 7606-S Router, page 5-125
•
•
Installing the Thermistor Module on a Cisco 7609-S Router, page 5-126
Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL, page 5-128
•
Only trained and qualified personnel should be allowed to install, replace, or service this equipment.
Warning
Use two hands to support the power supply during removal and replacement procedures.
Caution
During this procedure, wear grounding wrist straps to avoid ESD damage to the card. Do not directly
Warning
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.
OL-4503-24
C H A P T E R
Cisco 7600 Series Router Installation Guide
5
5-1

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Summary of Contents for Cisco 7606-S

  • Page 1 Removing and Replacing the Fan Assembly, page 5-113 • • Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional), page 5-119 • Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional), page 5-119 •...

  • Page 2: Preventing Electrostatic Discharge Damage

    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. In systems with redundant power supplies, you can replace the faulty supply while the system is Note operating.
  • Page 3 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.
  • Page 4 Loosen the captive installation screws on the power supply. (See Figure 5-2 for the Cisco 7603 router, Step 4 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 Router—Power Supply Captive Installation Screws...
  • Page 5 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 router—Grasp both power supply handles, as shown in Figure 5-7, and slide the power supply completely out of the chassis.
  • Page 6 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Power Supply Figure 5-5 Cisco 7603 Router—Handling an AC-Input Power Supply Cisco 7600 Series Router Installation Guide OL-4503-24...
  • Page 7 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Power Supply Figure 5-6 Cisco 7609 Router, Cisco 7609-S, and Cisco 7613 Router— Handling an AC-Input Power Supply INPUT OUTPUT FAIL INPUT OUTPUT FAIL INPUT OUTPU T FAIL Cisco 7600 Series Router Installation Guide...
  • Page 8 Figure 5-7 Cisco 7604, Cisco 7606, Cisco 7606-S Routers—Handling an AC-Input Power Supply If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco Step 6 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.

  • Page 9: Table Of Contents

    5-7. Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the bay. If you are installing a PWR-2700-AC power supply in a Cisco 7606 router, you must remove any Note preinstalled PEMs.
  • Page 10 • Removing a WS-CDC-2500W Power Supply from a Cisco 7613 Router, page 5-24 • Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router, page • 5-26 Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router, page 5-29 •...

  • Page 11: Step 3

    Figure 5-10 Cisco 7603 Router—Handling a DC-Input Power Supply If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco Step 4 part number 800-16727-01 for the Cisco 7603 router) over the opening and secure it with the captive installation screws.
  • Page 12 (top to bottom) Loosen the captive installation screws on the power supply (Figure 5-12). Step 2 Figure 5-12 Cisco 7606-S Router—Power Supply Captive Installation Screws P W R - 1 5 0 0 - D C Status LEDs A LL FA...

  • Page 13: Removing Pwr-2700-Dc/4 Power Supply From A Cisco 7604 Router

    Removing and Replacing the Power Supply Figure 5-13 Cisco 7603-S Router—Handling an DC-Input Power Supply If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 4 800-28728-01 for the Cisco 7603-S router) over the opening and secure it with the captive installation screws.
  • Page 14 Loosen the captive installation screws on the power supply (Figure 5-14). Step 6 Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply Caution weighs 13.5 pounds (6.6 kg). Cisco 7600 Series Router Installation Guide 5-14 OL-4503-24...

  • Page 15: Removing Pwr-1900-Dc Power Supply From A Cisco 7606 Router

    Verify that power is off to the DC circuit connected to the DC PEM for the power supply you are Step 1 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. Cisco 7600 Series Router Installation Guide 5-15...
  • Page 16 SM IR Loosen the captive installation screws on the power supply (Figure 5-18). Step 2 Figure 5-18 Cisco 7606 Router—Power Supply Captive Installation Screws Status LEDs Captive installation screws Grasp both power supply handles, as shown in Figure 5-19, and slide the power supply completely out Step 3 of the chassis.

  • Page 17: Removing Pwr-2700-Dc Power Supply From A Cisco 7606 Router

    Removing and Replacing the Power Supply Figure 5-19 Cisco 7606 Router—Handling an DC-Input Power Supply If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 4 800-19193-01 for the Cisco 7606 router) over the opening and secure it with the captive installation screws.
  • Page 18 Loosen the captive installation screws on the power supply (Figure 5-20). Step 6 Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply Caution weighs 13.5 pounds (6.6 kg). Cisco 7600 Series Router Installation Guide 5-18 OL-4503-24...
  • Page 19 GA GE PO W ER SU PP LY If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Note 700-03104-01) over the opening, and secure it with the captive installation screws.
  • Page 20 Loosen the captive installation screws on the power supply (Figure 5-22). Step 6 Use both hands to install and remove power supplies. Each PWR-2700-DC DC-input power supply Caution weighs 13.5 pounds (6.6 kg). Cisco 7600 Series Router Installation Guide 5-20 OL-4503-24...
  • Page 21 GA GE PO W ER SU PP LY If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Note 800-28533-01) over the opening, and secure it with the captive installation screws...
  • Page 22 Disconnect the DC-input wires from the terminal block (Figure 5-25) in this order: Step 4 Positive (+) • • Negative (-) • Ground When installing the unit, the ground connection must always be made first and disconnected last. Warning Cisco 7600 Series Router Installation Guide 5-22 OL-4503-24...
  • Page 23 Place your other hand underneath the power supply, as shown in Figure 5-26, and slide the power supply completely out of the chassis. Figure 5-26 Handling a DC-Input Power Supply INPU T OUT PUT FAIL Cisco 7600 Series Router Installation Guide 5-23 OL-4503-24...
  • Page 24 Removal and Replacement Procedures Removing and Replacing the Power Supply If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 7 700-03104-01) over the opening, and secure it with the captive installation screws.
  • Page 25 Grasp the power supply handle with one hand and slide the power supply part of the way out of the Step 6 chassis. Place your other hand underneath the power supply, as shown in Figure 5-29, and slide the power supply completely out of the chassis. Cisco 7600 Series Router Installation Guide 5-25 OL-4503-24...
  • Page 26 INPU T OUT PUT FAIL If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 7 700-03104-01) over the opening, and secure it with the captive installation screws. Removing a PWR-4000-DC Power Supply from a Cisco 7609 Router or a Cisco 7609-S Router Before performing any of the following procedures, ensure that power is removed from the DC circuit.
  • Page 27 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 5-65. Remove the two screws securing the left inner terminal block cover and one screw securing the right Step 5 inner terminal block cover.
  • Page 28 Loosen the captive installation screw on the power supply (Figure 5-31). Use both hands to install and remove power supplies. Each DC-input power supply weighs between 22 Caution pounds (9.9 kg) and 33 pounds (15 kg). Cisco 7600 Series Router Installation Guide 5-28 OL-4503-24...
  • Page 29 INPU T OK OUTP UT FAIL If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 11 700-03104-01) over the opening, and secure it with the captive installation screws. Removing a PWR-6000-DC Power Supply from a Cisco 7609 or a Cisco 7609-S Router Before performing any of the following procedures, ensure that power is removed from the DC circuit.
  • Page 30 Remove the two A4 screws securing the terminal block cover, and remove the cover from the power Step 3 supply (Figure 5-33). Cut any cable tie-wraps being careful not to cut the DC-input wires. Step 4 Cisco 7600 Series Router Installation Guide 5-30 OL-4503-24...
  • Page 31 Note 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 5-74. Disconnect the DC-input wires from the terminal block in this order:...
  • Page 32 Step 10 chassis. Place your other hand underneath the power supply, as shown in Figure 5-36 (without IPM) and Figure 5-37 (with IPM), and slide the power supply completely out of the chassis. Cisco 7600 Series Router Installation Guide 5-32 OL-4503-24...
  • Page 33 OU TPU FAI L 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. Removing a PWR-4000-DC Power Supply from a Cisco 7613 Router Before performing any of the following procedures, ensure that power is removed from the DC circuit.
  • Page 34 Remove the two A4 screws securing the outer terminal block cover, and remove the cover from the power Step 3 supply (Figure 5-38). Cut any cable tie-wraps being careful not to cut the DC-input wires. Step 4 Cisco 7600 Series Router Installation Guide 5-34 OL-4503-24...
  • Page 35 Some configurations require cable tie-wraps. For more information, refer to Installing a PWR-4000-DC Power Supply in a Cisco 7613 Router, page 5-86. Remove the two screws securing the left inner terminal block cover and one screw securing the right Step 5 inner terminal block cover.
  • Page 36 Grasp the power supply handle with one hand and slide the power supply part of the way out of the Step 10 chassis. Place your other hand underneath the power supply, as shown in Figure 5-40, and slide the power supply completely out of the chassis. Cisco 7600 Series Router Installation Guide 5-36 OL-4503-24...
  • Page 37 INPU T OK OUTP UT FAIL If the power supply bay is to remain empty, install a blank power supply filler plate (Cisco part number Step 11 700-03104-01) over the opening, and secure it with the captive installation screws. Removing a PWR-6000-DC Power Supply from a Cisco 7613 Router Before performing any of the following procedures, ensure that power is removed from the DC circuit.
  • Page 38 Remove the two A4 screws securing the terminal block cover, and remove the cover from the power Step 3 supply (Figure 5-41). Cut any cable tie-wraps being careful not to cut the DC-input wires. Step 4 Cisco 7600 Series Router Installation Guide 5-38 OL-4503-24...
  • Page 39 Note 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 5-74. Disconnect the DC-input wires from the terminal block in this order:...
  • Page 40 Step 10 chassis. Place your other hand underneath the power supply, as shown in Figure 5-44 (without IPM) and Figure 5-45 (with IPM), and slide the power supply completely out of the chassis. Cisco 7600 Series Router Installation Guide 5-40 OL-4503-24...
  • Page 41 INP UT OU TPU FAI L 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. Installing DC-Input Power Supplies...
  • Page 42 • Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router, page 5-63 • Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router, page • 5-65 Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router, page 5-74 •...
  • Page 43 Verify power supply operation by checking that the power supply front panel LEDs are in the following Step 7 states: INPUT OK LED is green • FAN OK LED is green • OUTPUT FAIL LED is not lit • Cisco 7600 Series Router Installation Guide 5-43 OL-4503-24...
  • Page 44 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 Before performing any of the following procedures, ensure that power is removed from the DC circuit. Warning...
  • Page 45 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. Cisco 7600 Series Router Installation Guide...
  • Page 46 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Power Supply When using a PWR-2700-DC/4 power supply in a Cisco 7604 router, you must always connect Note the PWR-2700-DC/4 power supply ground. For redundant power supplies, you must connect the PWR-2700-DC/4 power supply ground for Note both power supplies.
  • Page 47 For multiple DC input power supply, each DC input must be protected by dedicated circuit breaker or Note fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements. Cisco 7600 Series Router Installation Guide 5-47 OL-4503-24...
  • Page 48 Use only copper wire. The maximum width of a lug is 0.600 inch (15.2 mm). For 2700 W power supplies, use fine-stranded copper conductors rated for 90-degrees Celsius Note for North American installations. Cisco 7600 Series Router Installation Guide 5-48 OL-4503-24...
  • Page 49 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. Cisco 7600 Series Router Installation Guide 5-49 OL-4503-24...
  • Page 50 G E D E R S U P P LY Installing a PWR-1900-DC Power Supply in a Cisco 7606 Router Before performing any of the following procedures, ensure that power is removed from the DC circuit. Warning Follow these steps to install a DC-input power supply: Step 1 Ensure that the system (earth) ground connection has been made.
  • Page 51 Verify that all connections to the DC PEM are secure. Step 4 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker Step 5 switch handle to the On (|) position. Cisco 7600 Series Router Installation Guide 5-51 OL-4503-24...
  • Page 52 Before performing any of the following procedures, ensure that power is removed from the DC circuit. Warning If you are installing a PWR-2700-DC power supply in a Cisco 7606 router, you must remove any Note preinstalled PEMs. You must also install a blank PEM filler plate for each power supply you are installing.
  • Page 53 P P LY Captive installation screws Note This illustration shows the terminal block barriers and terminal block guards attached. Warning Power supply captive installation screws must be tight to ensure protective grounding continuity. Cisco 7600 Series Router Installation Guide 5-53 OL-4503-24...
  • Page 54 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). Step 6 The wire should be sized according to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-54 OL-4503-24...
  • Page 55 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. Cisco 7600 Series Router Installation Guide 5-55 OL-4503-24...
  • Page 56 G E D E R S U P P LY Installing a PWR-2700-DC Power Supply in a Cisco 7606-S Router Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. Follow these steps to install a DC-input power supply: Ensure that the system (earth) ground connection has been made.
  • Page 57 P P LY Captive installation screws Note This illustration shows the terminal block barriers and terminal block guards attached. Warning Power supply captive installation screws must be tight to ensure protective grounding continuity. Cisco 7600 Series Router Installation Guide 5-57 OL-4503-24...
  • Page 58 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.600 inch (15.2 mm). Step 6 The wire should be sized according to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-58 OL-4503-24...
  • Page 59 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. Cisco 7600 Series Router Installation Guide 5-59 OL-4503-24...
  • Page 60 G E D E R S U P P LY Installing a WS-CDC-2500W Power Supply in a Cisco 7609 Router Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. Follow these steps to install a DC-input power supply: Ensure that the system (earth) ground connection has been made.
  • Page 61 Attach the appropriate lugs to the DC-input wires. The maximum width of a lug is 0.300 inch (7.6 mm). Step 6 The wire should be sized according to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-61 OL-4503-24...
  • Page 62 Remove the tape from the circuit breaker switch handle, and restore power by moving the circuit breaker Step 9 switch handle to the On (|) position. Step 10 Verify power supply operation by checking that the power supply front panel LEDs are in the following states: Cisco 7600 Series Router Installation Guide 5-62 OL-4503-24...
  • Page 63 If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page 4-2. Installing a WS-CDC-2500W Power Supply in a Cisco 7613 Router Before performing any of the following procedures, ensure that power is removed from the DC circuit. Warning...
  • Page 64 Connect the DC-input wires to the 2500 W power supply terminal block (Figure 5-69) in this order: Step 7 Ground • Negative (-) • • Positive (+) Warning When installing the unit, the ground connection must always be made first and disconnected last. Cisco 7600 Series Router Installation Guide 5-64 OL-4503-24...
  • Page 65 If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page 4-2. Installing a PWR-4000-DC Power Supply in a Cisco 7609 Router or a Cisco 7609-S Router Before performing any of the following procedures, ensure that power is removed from the DC circuit. Warning...
  • Page 66 Power supply ground is required. Step 1 Note The system ground connection with the PWR-4000-DC power supply in a Cisco 7609 router is provided by the PWR-4000-DC power supply ground. Additionally, you can connect a system (earth) ground. 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.
  • Page 67 (Figure 5-70). Figure 5-70 Handling a DC-Input Power Supply VE-1 VE-3 VE-1 VE-3 VE-2 VE-2 INPU T OK OUTP UT FAIL Step 4 Tighten the power supply captive installation screw (Figure 5-71). Cisco 7600 Series Router Installation Guide 5-67 OL-4503-24...
  • Page 68 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according Step 7 to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-68 OL-4503-24...
  • Page 69 (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power. If you are wiring for 2700 W for a single power supply, proceed to Step 9; if you are wiring 2700 W for Note a redundant power supply, proceed to Step 9 and then Step 11.
  • Page 70 Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic. From the left side of the power supply, connect the ground wire to the ground (Figure 5-73). Cisco 7600 Series Router Installation Guide 5-70 OL-4503-24...
  • Page 71 The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry). Cisco 7600 Series Router Installation Guide 5-71 OL-4503-24...
  • Page 72 The protective end flap on the plastic cover is opposite the wire entry area. The protective end flap must fold down and cover the open side of the terminal (opposite side from wire entry). Cisco 7600 Series Router Installation Guide 5-72 OL-4503-24...
  • Page 73 When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Note Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds). Cisco 7600 Series Router Installation Guide 5-73 OL-4503-24...
  • Page 74 If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page 4-2. Installing a PWR-6000-DC Power Supply in a Cisco 7609 or a Cisco 7609-S Router With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) Note (previously removed) with the DC-input wires and the ground wires still connected.
  • Page 75 Follow these steps to install a DC-input power supply: The PWR-6000-DC power supply ground provides the system ground connection when the Note PWR-6000-DC power supply is installed in a Cisco 7609-S router. Install the ground as described in this procedure. Note For redundant power supplies, you must connect the PWR-6000-DC power supply ground for both power supplies.
  • Page 76 5-76). Figure 5-76 Handling a DC-Input Power Supply CIS CO SY ST EM S, INC INP UT OU TPU FAI L Step 3 Tighten the power supply captive installation screw (Figure 5-77). Cisco 7600 Series Router Installation Guide 5-76 OL-4503-24...
  • Page 77 (Figure 5-77). Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according Step 5 to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-77 OL-4503-24...
  • Page 78 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.
  • Page 79 Secure outer block cover. Wire for 4500 W (left side of power supply bay) as follows: Step 7 From the left side of the power supply, connect the ground wire to the ground (Figure 5-79). Cisco 7600 Series Router Installation Guide 5-79 OL-4503-24...
  • Page 80 Secure outer block cover. Step 8 Wire for 6000 W (left side of power supply bay) as follows: From the left side of the power supply, connect the ground wire to the ground (Figure 5-80). Cisco 7600 Series Router Installation Guide 5-80 OL-4503-24...
  • Page 81 (Maximum torque: 36 inch-pounds). Wire for 2800 W (right side of power supply bay) as follows: Step 9 From the right side of the power supply, connect the ground wire to the ground (Figure 5-81). Cisco 7600 Series Router Installation Guide 5-81 OL-4503-24...
  • Page 82 For multiple DC input power supply, each DC input must be protected by dedicated circuit Note breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements. Cisco 7600 Series Router Installation Guide 5-82 OL-4503-24...
  • Page 83 6000W DC-input power supply must come from the same battery system (A feed); three pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed). Cisco 7600 Series Router Installation Guide 5-83 OL-4503-24...
  • Page 84 When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Note Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds). Cisco 7600 Series Router Installation Guide 5-84 OL-4503-24...
  • Page 85 Verify power supply operation by checking that the power supply front panel LEDs are in the following Step 15 states: INPUT OK LED is green • FAN OK LED is green • OUTPUT FAIL LED is not lit • Cisco 7600 Series Router Installation Guide 5-85 OL-4503-24...
  • Page 86 The PWR-4000-DC power supply ground provides the system ground connection when the Note PWR-4000-DC power supply is installed in a Cisco 7613 router. Install the ground as described in this procedure. For redundant power supplies, you must connect the PWR-4000-DC power supply ground for both Note power supplies.
  • Page 87 (Figure 5-85). Figure 5-85 Handling a DC-Input Power Supply VE-1 VE-3 VE-1 VE-3 VE-2 VE-2 INPU T OK OUTP UT FAIL Tighten the power supply captive installation screw (Figure 5-86). Step 3 Cisco 7600 Series Router Installation Guide 5-87 OL-4503-24...
  • Page 88 Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according Step 6 to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-88 OL-4503-24...
  • Page 89 (+)/negative (-) terminal pairs in any sequence. Select 4000 W by wiring all three terminals. The Cisco IOS software detects the wired inputs and sets the proper system power. If you are wiring for 2700 W for a single power supply, proceed to Step 8; if you are wiring 2700 W for Note a redundant power supply, proceed to Step 8 and then Step 10.
  • Page 90 Pull the tab until the cover is secured around the power cabling trim and discard excess tab plastic. From the left side of the power supply, connect the ground wire to the ground (Figure 5-88). Cisco 7600 Series Router Installation Guide 5-90 OL-4503-24...
  • Page 91 Using the cable tie provided, place the cable tie through the slot at the top of the left terminal block cover and secure the wiring going to TB2. Place and secure left and right inner terminal block cover. Secure outer block cover. Cisco 7600 Series Router Installation Guide 5-91 OL-4503-24...
  • Page 92 Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block cover and secure the wiring to the left terminal block. Secure outer block cover. Cisco 7600 Series Router Installation Guide 5-92 OL-4503-24...
  • Page 93 When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Note Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds). Cisco 7600 Series Router Installation Guide 5-93 OL-4503-24...
  • Page 94 If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page 4-2. Installing a PWR-6000-DC Power Supply in a Cisco 7613 Router With the PWR-6000-DC power supply, you have the option of installing an Input Power Module (IPM) Note (previously removed) with the DC-input wires and the ground wires still connected.
  • Page 95 Follow these steps to install a DC-input power supply: The PWR-6000-DC power supply ground provides the system ground connection when the Note PWR-6000-DC power supply is installed in a Cisco 7609-S router. Install the ground as described in this procedure. Note For redundant power supplies, you must connect the PWR-6000-DC power supply ground for both power supplies.
  • Page 96 5-91). Figure 5-91 Handling a DC-Input Power Supply CIS CO SY ST EM S, INC INP UT OU TPU FAI L Tighten the power supply captive installation screw (Figure 5-92). Step 3 Cisco 7600 Series Router Installation Guide 5-96 OL-4503-24...
  • Page 97 (Figure 5-92). Attach the appropriate lugs to the DC-input wires and ground wire. The wires should be sized according Step 5 to local and national installation requirements. Use only copper wire. Cisco 7600 Series Router Installation Guide 5-97 OL-4503-24...
  • Page 98 2800 W by wiring any two positive (+)/negative (-) terminal pairs in any sequence. Select 4500 W by wiring any three positive (+)/negative (-) terminal pairs in any sequence. Select 6000 W by wiring all four terminals. The Cisco IOS software detects the wired inputs and sets the proper system power.
  • Page 99 Secure outer block cover. Wire for 4500 W (left side of power supply bay) as follows: Step 7 From the left side of the power supply, connect the ground wire to the ground (Figure 5-94). Cisco 7600 Series Router Installation Guide 5-99 OL-4503-24...
  • Page 100 Secure outer block cover. Step 8 Wire for 6000 W (left side of power supply bay) as follows: From the left side of the power supply, connect the ground wire to the ground (Figure 5-95). Cisco 7600 Series Router Installation Guide 5-100 OL-4503-24...
  • Page 101 (Maximum torque: 36 inch-pounds). Wire for 2800 W (right side of power supply bay) as follows: Step 9 From the right side of the power supply, connect the ground wire to the ground (Figure 5-96). Cisco 7600 Series Router Installation Guide 5-101 OL-4503-24...
  • Page 102 For multiple DC input power supply, each DC input must be protected by dedicated circuit Note breaker or fuse. The circuit breaker or fuse should be sized according to the power supply input rating and local or national electrical code requirements. Cisco 7600 Series Router Installation Guide 5-102 OL-4503-24...
  • Page 103 6000W DC-input power supply must come from the same battery system (A feed); three pairs of input wires for the other 6000W DC-input power supply must come from another battery system (B feed). Cisco 7600 Series Router Installation Guide 5-103 OL-4503-24...
  • Page 104 When you tighten the terminal nuts, make sure they are snug. Do not over tighten them. Note Recommended torque strength is 20 inch-pounds. Over tightening the terminal nuts can break the terminal block (Maximum torque: 36 inch-pounds). Cisco 7600 Series Router Installation Guide 5-104 OL-4503-24...
  • Page 105 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. Cisco 7600 Series Router Installation Guide 5-105 OL-4503-24...

  • Page 106: Removing And Replacing The Pem

    Removing and Replacing the PEM Removing and Replacing the PEM This section describes how to remove and install the PEMs for the Cisco 7603, Cisco 7603-S, and Cisco 7606 routers. The PEM provides an input power connection on the front of the chassis to connect the site power source to the power supply.

  • Page 107: Required Tools

    Chapter 5 Removal and Replacement Procedures Removing and Replacing the PEM Figure 5-102 Cisco 7603-S Router—Power Supply Location Power supply 2 (redundant) Power supply 1 Figure 5-103 Cisco 7606 Router—Power Supply Location Power supply 2 (redundant) Cisc o Sys tem s Inc.
  • Page 108 OSM-4OC1 2 POS-SI 4 PORT OC-12 POS SM If the PEM bay is to remain empty, install a blank PEM filler plate (Cisco part number 800-16719-01) Step 6 over the opening, and secure it with the captive installation screws. See Figure 5-106.
  • Page 109 Step 1 see the “System Ground Connection” section on page 3-19. If necessary, remove the blank PEM filler plate (Cisco part number 800-16719-01) from the chassis PEM Step 2 bay opening by loosening the captive installation screws. See Figure 5-106.
  • Page 110 Disconnect the DC-input wires from the PEM terminal block in the following order: Step 4 Positive (+) • Negative (–) • Note It is not necessary to disconnect the system ground connection. Cisco 7600 Series Router Installation Guide 5-110 OL-4503-24...
  • Page 111 4 PORT OC-12 POS SM OSM-4OC1 2 POS-SI 4 PORT OC-12 POS SM If the PEM bay is to remain empty, install a blank PEM filler plate (Cisco part number 800-16719-01) Step 6 over the opening and secure it with the captive installation screws.
  • Page 112 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. Cisco 7600 Series Router Installation Guide 5-112 OL-4503-24...

  • Page 113: Removing And Replacing The Fan Assembly

    Removing and Replacing the Fan Assembly Removing and Replacing the Fan Assembly This section describes how to remove and replace fan assemblies for the Cisco 7600 series router. A flat-blade or number 2 Phillips-head screwdriver is required to perform this procedure.
  • Page 114 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Fan Assembly Figure 5-113 Cisco 7603-S Router—Fan Assembly -48 TO -60 V 50 A MA PE M- DC -48 TO -60 V 50 A MA PE M- DC PE M 1 PE...
  • Page 115 4 PORT OC-12 POS SM OSM-4OC1 2 POS-SI 4 PORT OC-12 POS SM OSM-4OC1 2 POS-SI 4 PORT OC-12 POS SM Captive installation screws Figure 5-116 Cisco 7606-S Router—Fan Assembly 7600- ES20- 10G3C XL Cis co 760 FA N ETHE RNET...
  • Page 116 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Fan Assembly Figure 5-117 Cisco 7613 Router—Fan Assembly WS-X6K-SUP2- 2GE Switch CONSOLE 100% Load PORT PORT 1 CONSOLE MODE SUPERVISOR2 PORT 2 PCMCIA EJECT WS-X6K-SUP2- 2GE Switch Load CONSOLE 100%...
  • Page 117 Chapter 5 Removal and Replacement Procedures Removing and Replacing the Fan Assembly Figure 5-119 Cisco 7609 Router and Cisco 7609-S Router—Fan Assembly Captive installation screw Captive installation screw INPUT OUTPUT FAIL INPUT OUTPUT FAIL Cisco 7600 Series Router Installation Guide...

  • Page 118: Installing The Fan Assembly

    Step 4 Tighten the captive installation screws. On the Cisco 7609 router and the Cisco 7609-S router, fold the cable guide up and tighten the Note two captive installation screws at the top of the chassis (see Figure 5-118).

  • Page 119: Checking The Installation

    Chapter 5 Removal and Replacement Procedures Installing the Air Filter Assembly on a Cisco 7606 Router and the Cisco 7606-S Router (Optional) Checking the Installation Perform these steps when checking the installation to verify that the new fan assembly is installed correctly: Listen for the fans;...
  • Page 120 Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional) This section describes how to install the optional air filter assembly for the Cisco 7609 router and the Cisco 7609-S router. The filter assembly is not included with the chassis or bundle configurations. The...
  • Page 121 Chapter 5 Removal and Replacement Procedures Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional) Figure 5-121 Removing the Intake Panel INPUT OUTPU T FAIL INPUT OUTPU T FAIL Install the new intake panel (see Figure 5-122) by tightening four thumbscrews.
  • Page 122 Chapter 5 Removal and Replacement Procedures Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional) Remove the inner filter retainer from the filter cage assembly (see Figure 5-123) by depressing the thumb Step 3 loops and carefully sliding filter retainer outwards.
  • Page 123 Chapter 5 Removal and Replacement Procedures Installing the Air Filter Assembly on a Cisco 7609 Router and the Cisco 7609-S Router (Optional) Figure 5-124 Placing the Foam Filter Over the Filter Retainer Filter cage assembly Filter Filter retainer Tabs (on rear of filter cage assembly)
  • Page 124 Chapter 5 Removal and Replacement Procedures Replacing the Air Filter on a Cisco 7609 Router and the Cisco 7609-S Router (Optional) Figure 5-125 Installing the Filter Assembly INPUT OUTPU T FAIL INPUT OUTPU T FAIL Thumbscrews Fastening screw Note Cisco Systems recommends that air filters be changed every three months.
  • Page 125 Cisco Systems recommends that air filters be changed every three months. Note Installing the Thermistor Module on a Cisco 7606-S Router This section describes how to install the thermistor module for the Cisco 7606-S router. The necessary parts can be ordered at listed in Table 5-2.
  • Page 126 MODU LE CLAS S 1 LASE Installing the Thermistor Module on a Cisco 7609-S Router This section describes how to install the thermistor module for the Cisco 7609-S router. The necessary parts can be ordered at listed in Table 5-3.
  • Page 127 Chapter 5 Removal and Replacement Procedures Installing the Thermistor Module on a Cisco 7609-S Router Figure 5-128 Removing the Intake Panel Unscrew the single captive screw that retains the thermistor module in the chassis. See Figure 5-129. Step 2 Figure 5-129 Thermistor Module...
  • Page 128 Chapter 5 Removal and Replacement Procedures Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL Figure 5-130 Thermistor Module Replacement Insert the thermistor module until the faceplate of the module bottoms out to the ramp in the chassis. Step 4 Tighten the captive screw on the module into the chassis.
  • Page 129 Chapter 5 Removal and Replacement Procedures Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL 1. Model CISCO7609 is equipped with two tiered-speed fan trays. There is no replacement or adjustment required. For model OSR-7609, refer to http://www.cisco.com/univercd/cc/td/doc/product/core/cis7600/hardware/osrouter/index.htm. Table 5-5...
  • Page 130 Chapter 5 Removal and Replacement Procedures Upgrading the Cisco 7600 Series Routers to a WS-SUP720-3BXL Cisco 7600 Series Router Installation Guide 5-130 OL-4503-24...

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