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Product Numbers: PWR-GSR8-DC=
This document presents procedures for adding, removing, or replacing a DC-input power supply for the Cisco 12008 Gigabit Switch Router. It contains the following sections:
Use this document in conjunction with the Cisco 12008 Gigabit Switch Router Installation and Configuration Guide (document number 78-4953-01), which shipped with your Cisco 12008 Gigabit Switch Router.
Before you begin the installation or replacement procedures for the DC-input power supply, review the safety guidelines in this section to prevent injury to yourself or damage to the equipment. This section also lists the tools needed to perform the power supply installation or replacement procedures.
Figure 1 is a representation of the Cisco 12008 router.
The following list does not identify all the potentially hazardous conditions that you may encounter in the workplace; accordingly, you should be alert at all times and exercise care when working with electrical and electronic components.
To ensure your safety and protect the equipment, observe the following general guidelines:
Observe the following electrical safety guidelines when working with the electrical and electronic components of the router:
In addition, observe the following guidelines when working with equipment connected to telephone wiring or other network cabling.
 | Warning Do not work on the system or connect/disconnect cables during an electrical storm. |
| Warning Before working on the router, disconnect all telephone network cables to avoid exposure to network voltages. |
Electrostatic discharge (ESD) damage to circuit boards and electronic components can occur if they are touched or handled improperly. ESD damage can result in intermittent or complete failure of electronic components.
To prevent ESD damage to router components, observe the following guidelines:
To add, remove, or replace a DC-input power supply, you will need the following:
The Cisco 12008 can operate with either one or two DC-input power supplies. Although the router supports an online insertion and removal (OIR) capability for field replaceable units (FRUs), you must observe the following rules regarding the DC-input power supplies:
The DC-input power supply for the Cisco 12008 Gigabit Switch Router provides the following operating voltages to the router backplane:
The DC-input power supply (see Figure 2) has the following characteristics:
 | Caution You cannot use an AC-input power supply and a DC-input power supply in the same chassis. |
For additional information about the DC-input power supply, see the document entitled Cisco 12008 Gigabit Switch Router Installation and Configuration Guide (document number 78-4953-01).
The following sections present the procedures for adding, removing, or replacing a DC-input power supply.
In the following procedure, it is assumed that you will be adding a second (redundant) DC-input power supply to the router. It is also assumed that a blank filler panel is presently installed in the vacant power supply bay.
| Warning Before attempting to install a redundant DC-input power supply, you must have a second, independent source of DC power available to service the unit. |
To install a second (redundant) DC-input power supply, you must first satisfy the following requirements:
| Caution AC-input and DC-input power supplies cannot be used together in the same router. Such a configuration is not supported and may damage the system. |
To add a second (redundant) DC-input power supply to the router, perform the following steps:
Step 1 Locate the source DC circuit breaker that will service the DC-input power supply; ensure that this circuit breaker is set to the OFF position. For added safety, tape the circuit breaker handle in the OFF position.
| Warning To be completely sure that power has been removed from the source DC circuit that will be used in servicing the new power supply, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts. |
Step 2 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the blank filler panel covering the vacant (upper) power supply bay; remove the filler panel and retain it for possible future use.
Presumably, you will be installing the new power supply in the upper power supply bay, since, by convention, a single DC-input power supply is installed in the lower bay.
Step 3 Ensure that the rotary power switch on the faceplate of the new power supply that you will be installing is set to the OFF (O) position.
Step 4 Grasp the carrying handle on the new power supply with one hand; while lifting the power supply, place your free hand beneath the unit to support its weight.
| Warning The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to install the unit in the power supply bay. |
Step 5 Position the power supply appropriately for insertion into the vacant upper bay.
Step 6 Gently slide the unit into the bay, carefully seating it so that the power supply faceplate rests flush against the sheet metal of the power supply bay.
| Caution To prevent damage to the blind-mating connector at the rear of the power supply, do not use excessive speed or force when inserting the power supply into the bay. |
Step 7 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the power supply faceplate (see Figure 4).
Step 8 Remove the plastic safety shield (see Figure 4) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield, take the following actions:
(a) Loosen the knurled thumbwheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
Step 9 Unscrew the loosely mounted lockwashers and nuts from all six terminals on the power supply faceplate; set this hardware aside temporarily.
Step 10 As an added safety precaution, it is recommended that you add a length of shrink tubing to the crimp area on each power cable lug (see Figure 3) before connecting the leads to the power supply.
The shrink tubing acts as an insulator to prevent the crimp area on the source DC power cable lugs from coming in contact with the metal faceplate of the DC-input power supply.
Step 11 Connect the source DC power leads to the terminals on the power supply faceplate. In so doing, you must strictly observe the following order of connection for the power supply cables:
(a) Ground
(b) + (positive)
(c) - (negative)
Step 12 Using the lockwashers and nuts removed from the terminals in Step 9, connect each power supply cable to the appropriate terminals on the power supply faceplate.
Observe the order shown in Figure 5 in connecting the source DC power cables.
Step 13 After installing each cable, securely tighten the two lockwashers and nuts on the power supply terminals using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket).
| Caution Do not overtighten the nuts on the power supply terminals. |
Step 14 If you intend to attach an external alarm monitoring facility to the alarm terminal block on the power supply, connect the leads from the alarm monitoring facility to the circuit breaker alarm terminal block. Figure 6 shows a representative example of how the leads can be connected to the alarm terminal block.
The functions and uses of the circuit breaker alarm terminal block are described in greater detail in Chapter 1 of the document entitled Cisco 12008 Gigabit Switch Router Installation and Configuration Guide (document number 78-4953-01).
Step 15 Reinstall the plastic safety shield on the power supply faceplate by taking the following actions:
(a) Seat the shield over the standoffs on the power supply faceplate.
(b) Move the shield to the left and obliquely downward so that it registers properly on the three standoffs on the power supply faceplate.
(c) Tighten the knurled thumbscrew on the bottom left standoff to secure the shield to the power supply faceplate.
Step 16 Remove the tape from the main circuit breaker supplying source power to the new power supply (see Step 1).
Step 17 Set the circuit breaker to the ON position.
Step 18 Set the rotary power switch on the new DC-input power supply to the ON (|) position.
To verify that the new DC-input power supply is operating properly, proceed to the section entitled "Verifying the Installation of a Power Supply," page 16.
For the following procedure, it is assumed that you will remove a DC-input power supply from a Cisco 12008 that is equipped with a single such unit. In this case, you must power down the router before removing the power supply.
It is also assumed that the power supply to be removed is installed in the lower power supply bay, which, by convention, is the normal configuration for a single power supply.
Lastly, in such a single power supply configuration, it is assumed that the vacant upper power supply bay has previously been covered by a blank filler panel to ensure EMI compliance and the proper flow of cooling air through the router. However, if such is not the case, it is recommended that you either install a second (redundant) power supply in the vacant bay or cover it with a blank filler panel.
To remove the DC-input power supply from the router, perform the following steps:
Step 1 Set the rotary power switch on the power supply faceplate to the OFF (O) position.
Step 2 Locate and turn off the source DC circuit breaker that is currently servicing the DC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an additional safety precaution.
Step 4 Remove the plastic safety shield (see Figure 2) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield, take the following actions:
(a) Loosen the knurled thumbwheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
| Warning To be completely sure that power has been removed from the source DC circuit presently servicing the power supply to be removed, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts. |
Step 5 Before removing the power cables, write the name of each cable on a piece of tape, as follows:
Step 6 Attach each piece of tape to the appropriate cable to identify it for later reconnection.
Step 7 Remove the power cables from the power supply terminals; strictly observe the following order in removing the cables:
(a) - (negative)
(b) + (positive)
(c) Ground
Step 8 Using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket), loosen the nuts securing the negative (-) power cable to the bottom terminals on the power supply faceplate; remove the nuts and locking washers from the terminals and set this hardware aside temporarily.
Step 9 Proceed in like manner to remove the remaining power cables from the positive (+) terminals and the grounding terminals, making sure that you remove the earth ground cable last.
Step 10 For added safety, place tape over the exposed lugs of the power cables to prevent contact between the leads.
Step 11 If leads are attached to the circuit breaker alarm terminal block on the power supply faceplate (see Figure 6), make a note of how these leads are connected so that they can be properly reconnected later.
Step 12 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate (see Figure 4).
Step 13 Grasp the power supply carrying handle with one hand and pull the unit halfway out of the bay to disengage the blind-mating connector at the back of the power supply from the backplane.
| Warning The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to remove the unit from the power supply bay. |
Step 14 Place your free hand beneath the power supply to support its weight; withdraw the unit completely from the bay.
Step 15 Set the power supply aside in a safe place, pending further disposition.
If you intend to return the removed power supply to the factory for repair or replacement, repackage the unit properly for return shipment using the original packing materials, if available.
In the following procedure, it is assumed that you will be replacing an existing power supply in a router containing redundant DC-input power supplies. In this configuration, the router's online insertion and removal (OIR) capability enables you to replace a given power supply without removing power from the router.
To replace a power supply in a redundant DC-input power supply configuration, perform the following steps:
Step 1 Set the rotary power switch on the faceplate of the power supply to be removed to the OFF (O) position.
Step 2 Locate and turn off the source DC circuit breaker that is currently servicing the DC-input power supply.
Step 3 Tape the circuit breaker handle in the OFF position as an additional safety precaution.
Step 4 Remove the plastic safety shield (see Figure 2) that covers the alarm terminal block and the positive (+) and negative (-) terminals on the power supply faceplate.
To remove the plastic safety shield, take the following actions:
(a) Loosen the knurled thumbwheel on the bottom left standoff that secures the safety shield to the power supply faceplate.
(b) Grasp the safety shield and move it to the right and obliquely upward, positioning the shield so that it can be freed from the three standoffs on the power supply faceplate.
(c) Remove the shield from the standoffs and set it aside temporarily.
| Warning To be completely sure that power has been removed from the source DC circuit presently servicing the power supply to be removed, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts. |
Step 5 Before removing the power cables, write the name of each cable on a piece of tape, as follows:
Step 6 Attach each piece of tape to the appropriate cable to identify it for later reconnection.
Step 7 Remove the power cables from the power supply terminals, strictly observing the following order of removal:
(a) - (negative)
(b) + (positive)
(c) Ground
Step 8 Using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket), loosen the nuts securing the negative (-) power cable to the bottom terminals on the power supply faceplate; remove the nuts and locking washers from the terminals; set this hardware aside temporarily and remove the power cable from the negative terminals.
Step 9 Proceed in like manner to remove the positive (+) and grounding cables from the power supply terminals, making sure that you remove the ground cable last.
Step 10 For added safety, place tape over the exposed lugs of the power cables to prevent contact between the leads.
Step 11 If an external alarm monitoring facility is attached to the circuit breaker alarm terminal block on the power supply faceplate (see Figure 6), make a note of how the leads are connected. Doing so enables you to identify each lead properly for later reconnection.
Step 12 Disconnect the leads from the circuit breaker alarm terminal block.
Step 13 Using a 1/4-inch flat-blade screwdriver, loosen the captive installation screw on the power supply faceplate (see Figure 4).
Step 14 Grasp the power supply carrying handle with one hand and pull the unit halfway out of the bay to disengage the blind-mating connector at the back of the power supply from the backplane.
| Warning The DC-input power supply weighs 14 lb (6.36 kg). For safety, use both hands to withdraw the unit from the bay. |
Step 15 Place your free hand beneath the power supply to support its weight; withdraw the unit completely from the bay.
Step 16 Pending further action, set the unit aside in a safe place.
If you intend to return the removed power supply to the factory for repair or replacement, restore the nuts and lock washers to the power supply terminals, and reinstall the plastic safety shield on the faceplate standoffs. Repackage the unit properly for return shipment using the original packing materials, if available.
Step 17 On the new DC-input power supply that you intend to install in the now vacant power supply bay, set the rotary power switch on the power supply faceplate to the OFF (0) position.
Step 18 Grasp the carrying handle on the power supply with one hand; place your free hand beneath the unit to support its weight.
Step 19 Position the unit appropriately for insertion into the power supply bay.
Step 20 Gently slide the new power supply into the vacant bay, carefully seating it so that the power supply faceplate is flush against the sheet metal of the power supply bay. This action ensures that the blind-mating connector at the rear of the power supply is firmly seated into the backplane connector.
| Caution To prevent damage to the blind-mating connectors, do not use excessive speed or force when inserting the new power supply into the bay. |
Step 21 Using a 1/4-inch flat-blade screwdriver, tighten the captive installation screw on the power supply faceplate.
Step 22 Remove the plastic safety shield from the new power supply, taking the same actions as specified in Step 4 above.
| Warning To be completely sure that power has been removed from the source DC circuit that you intend to reconnect to the new power supply, use a voltmeter to measure the voltage across the negative (-) and positive (+) source DC leads. Set the voltmeter to a range that makes it capable of measuring up to 75 VDC. The measurement across the positive and negative leads should be zero (0) volts. |
Step 23 Unscrew the loosely mounted lockwashers and nuts from all six terminals on the new power supply faceplate; set this hardware aside temporarily.
Step 24 Before connecting each cable to the appropriate terminals on the power supply faceplate, remove the tape (that you applied in Step 10 above) from the lug. Strictly observe the following order in connecting the leads to the power supply terminals:
(a) Ground
(b) + (positive)
(c) - (negative)
Step 25 Secure each cable to the terminals using the previously removed lockwashers and nuts. Tighten the lockwashers and nuts on each terminal using a 10 mm nutdriver (or a 1/4-inch socket wrench with a 10 mm deep-well socket).
| Caution Do not overtighten the nuts on the power supply terminals. |
Step 26 If you intend to reconnect the external alarm monitoring facility to the circuit breaker alarm terminal block on the new power supply, reconnect the leads the same way they were on the old power supply (see Step 11).
Step 27 Remove the tape securing the main source DC circuit breaker in the OFF (0) position (see Step 3).
Step 28 Set the main source DC circuit breaker to the ON (1) position.
Step 29 Set the rotary power switch on the new DC-input power supply to the ON (|) position.
To verify that the new DC-input power supply is operating properly, perform the procedure in the following section.
To verify the operation of a newly-installed DC-input power supply, you first apply power to the unit and observe the status of the LEDs on the power supply faceplate.
To verify the operation of a newly-installed DC-input power supply, perform the following steps:
Step 1 First, verify that the following conditions are satisfied:
Step 2 Assuming that you have not already done so, set the rotary power switch of the newly installed power supply to the ON position.
Step 3 Observe the behavior of the green INPUT OK LED on the power supply faceplate for the following conditions:
(a) The main source DC circuit breaker is on.
(b) The source DC power cables are connected properly to the terminals on the power supply faceplate.
Step 4 Observe the behavior of the red OUTPUT FAIL LED on the power supply faceplate after you apply power to the unit. This LED should flash on momentarily, then go off and remain so.
If the new DC-input power supply fails to operate properly after several attempts to power it up as described above, contact your Cisco service representative for assistance.
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