600W AC-Input Power Supply and Fan Tray Replacement Instructions

In the Cisco 7010, the Route Processor (RP) and Switch Processor (SP) (or the Silicon Switch Processor [SSP]) are required system components and occupy the two top slots. In the Cisco 7505, the Route Switch Processor (RSP1) is a required system component and occupies the top slot.

In both chassis, the remaining interface slots (three in the Cisco 7010 and four in the Cisco 7505) support any combination of available interface types: Ethernet, Token Ring, FDDI, serial, HSSI, and so forth.

The interface processor end of the router also contains the AC power receptacle, the system power on/off switch, and the DC OK power status LED, all of which are part of the power supply but accessible through cutouts in the chassis frame. (See Figure 1.) To the left of the power switch and receptacle cutout is a ground screw that provides a chassis ground connection for ESD equipment or a grounding wire.

Figure 1 : Cisco 7010---Interface Processor End

The noninterface processor end of the chassis has a removable panel that provides access to the internal components discussed in this publication.Two captive slotted fasteners secure the panel.

Following are the power supply and fan tray product numbers:

• Cisco 7010 600W, AC-input power supply---PWR-7010AC=
  

• Cisco 7010 fan tray---ACS-7010FAN=
  

• Cisco 7505 600W, AC-input power supply---PWR/5-AC=
  

• Cisco 7505 fan tray---MAS/5-FAN=
  

Figure 2 shows the noninterface processor end of the chassis with the cover removed and with the power supply and fan tray in their normal operating positions. The power supply, which rests on the interior chassis floor, operates on AC input and provides DC voltages to the system components. The six individual fans on the fan tray move cooling air through the chassis interior to prevent components from overheating. The backplane contains the data buses for information exchange and distributes power throughout the system.

Figure 2 : Chassis Internal Components---Noninterface Processor End (Chassis Cover Removed)

Power Supply

The Cisco 7010 and Cisco 7505 come equipped with one 600W, AC-input power supply. Table 1 lists the power specifications for the Cisco 7010 and Cisco 7505.

The following sections describe the 600W, AC-input power supply and the fan tray. For descriptions of other system components, refer to the Cisco 7010 Hardware Installation and Maintenance or Cisco 7505 Hardware Installation and Maintenance publications.

Table 1 : Cisco 7010 and Cisco 7505 AC-Input Power Specifications

Power supply	600W maximum
Power dissipation	600W maximum configuration, 540W typical with maximum configuration
Heat dissipation	715W (2440 Btu/hr)
Input voltage	100 to 240 VAC, wide input with power factor corrector (PFC)
AC current rating	9A maximum at 100 VAC, 4A maximum at 240 VAC at 600W
Frequency	50 to 60 Hz
Power distribution	70A maximum @ +5 VDC, 15A maximum @ +12 VDC, 3A maximum @ --12 VDC, and 5A maximum @ +24 VDC

On the noninterface processor end of the power supply, two handles provide grip points for pulling the power supply out of the chassis. (See Figure 2.) Two Phillips screws secure the power supply to the chassis interior. Inside the power supply, two small fans draw cooling air through the power supply interior. The air flows in one side of the supply and out the other side, following the same direction as the chassis cooling air.

The power supply delivers DC power to the internal components through a wiring harness that plugs into a polarized receptacle to the noninterface processor side of the backplane. An aluminum cover shields the harness and power connection. The backplane then distributes the DC voltages to the fan tray, arbiter, and interface processor bus connectors.

The AC power receptacle, power on/off switch, and DC OK status LED are on the opposite (interface processor) end of the power supply, and are accessible through cutouts in the chassis below the processor slots. (See Figure 1.) A modular power cable connects the power supply to the site power source. A cable retention clip on the power supply AC receptacle prevents the cable from being pulled out accidentally. The rocker-type on/off switch turns the power supply on and starts the system. Figure 3 shows a detail view of the interface processor end of the power supply.

Figure 3 : AC-Input Power Supply---Interface Processor End

The green DC OK LED indicates the status of the power supply and internal DC voltages. The DC OK LED stays on when all of the following conditions are met:

• Power supply is on and receiving 100 to 240 VAC, 50 to 60 Hz source power
  

• Power supply is providing the +5, +12, -12, and +24 VDC to internal components
  

• All internal DC voltages are within tolerance
  

If the AC source power or any of the internal DC voltages exceeds allowable tolerances, the DC OK LED goes off and the system environmental monitor messages indicate the line that is out of tolerance. Because the RP (which uses +5, +12, -12 VDC), and the fan tray (which uses +24 VDC) are both required for operation, the system will probably shut down if any internal voltages reach an out-of-tolerance state.

In addition to the environmental monitoring performed by the system software, the power supply monitors its own temperature and internal voltages. If the supply detects an overvoltage or overtemperature condition, it shuts down to avoid damage to the power supply or other system components.

Fan Tray

The fan tray comprises six individual axial fans and a printed circuit board (with the control circuits) mounted on a metal plate. (See Figure 2.) The fans draw cooling air through the chassis interior to maintain an acceptable operating temperature for the internal components. The fan tray slides into the right side of the chassis from the noninterface processor end of the router. The fans draw air in through the inlet vents on the opposite side of the chassis, across the processor modules and other internal components, and out through the exhaust vents adjacent to the fan tray. Figure 4 shows a top-down view of the chassis, with the fan tray on the far right, and the airflow path created by the fans. The sides of the chassis must remain unobstructed to ensure adequate airflow and prevent overheating inside the chassis.

Figure 4 : Internal Air Flow---Top-Down View of Chassis

A fan control board on the fan tray monitors and controls the operation of the variable-speed fans. The variable-speed feature enables quieter operation by allowing the fans to operate at less than maximum speed when doing so provides adequate cooling air to maintain an acceptable operating temperature for the internal components.

When the internal air temperature is within the normal operating range, the fans operate at the slowest speed, which is 55 percent of the maximum speed. If the temperature inside the chassis exceeds the normal range, the fan control board increases the fan speed to provide additional cooling air to the internal components. If the temperature continues to rise, the fan control board linearly increases the fan speed until the fans reach full speed (100 percent). If the internal temperature exceeds the specified threshold, the system environmental monitor shuts down all internal power to prevent equipment damage from excessive heat.

The fan control board also relays the status of the fans to the system software. All six fans in the array must be operational. If the system detects a failed or failing fan, it displays a warning message on the console screen. If the condition is not corrected within two minutes, the entire system will shut down to protect the internal components against damage from excessive heat. For an example of this display, refer to the following section, "Prerequisites."

Prerequisites

Before you begin this installation, review the safety guidelines in this section to avoid injuring yourself or damaging the equipment. This section also provides a list of the tools that you need to perform this replacement.

Safety Guidelines

When working with any electrical equipment, the following guidelines will help to ensure your safety and protect the equipment. This list is not inclusive of all potentially hazardous situations, so be alert.

• Never try to lift an object that is too heavy for you to lift safely by yourself.
  

• Keep tools and chassis components away from walk areas.
  

• Do not work alone when potentially hazardous conditions exist.
  

• Do not wear loose clothing, jewelry (including rings and chains), or other items that could get caught in the chassis. Fasten your tie or scarf and sleeves.
  

• Never install equipment that appears damaged.
  

• Before beginning any procedures requiring access to the chassis interior, locate the emergency power-off switch for the room in which you are working.
  

• Disconnect all power and external cables before moving a chassis.
  

• Never assume that power has been disconnected from a circuit; always check.
  

• Do not perform any action that creates a potential hazard to people or makes the equipment unsafe.
  

• Carefully examine your work area for possible hazards such as moist floors, ungrounded power extension cables, and missing safety grounds.
  

In addition, use the guidelines that follow when working with any equipment that is connected to telephone wiring or other network cabling:

• Never install telephone wiring during a lightning storm.
  

• Never install telephone jacks in wet locations unless the jack is specifically designed for wet locations.
  

• Never touch uninsulated telephone wires or terminals unless the telephone line has been disconnected at the network interface.
  

• Use caution when installing or modifying telephone lines.
  

Opening the chassis and removing the power harness cover exposes the power distribution wiring on the backplane. If the power is not shut down, the high current present on the backplane becomes a hazard. Also, removing the cover compromises the electromagnetic interference (EMI) integrity of the system. Therefore, always make sure that the system power switch is turned off before removing the chassis cover panel or replacing any internal components.

Tools and Equipment

This section lists the tools and equipment you will need to complete these replacement procedures.

Have the following tools on hand so that you can complete the replacement without interruption:

• 3/16-inch, flat-blade screwdriver to loosen the captive screws on the chassis cover panel
  

• Number 1 Phillips screwdriver to remove the M3 Phillips screws on the power harness cover (you must remove the power harness cover to replace the power supply)
  

• Number 2 Phillips screwdriver to remove the M4 Phillips screw on the power supply and the fan tray
  

• Antistatic mat or antistatic foam pad if you are replacing the fan tray
  

• Your own ESD grounding strap or the disposable ESD strap that is included with all spares
  

If the chassis is mounted in an equipment rack, ensure that there is at least 1 foot of clearance at the noninterface processor end to remove the power supply or fan tray, both of which you must pull straight out of the chassis.

If a power strip or other equipment obstructs access, you will have to remove the chassis from the rack before replacing the component. Refer to the Cisco 7010 Hardware Installation and Maintenance or Cisco 7505 Hardware Installation and Maintenance publications for the tools you will need and descriptions of the rack mounting hardware.

Preventing Electrostatic Discharge (ESD) Damage

Electrostatic discharge (ESD) damage, which can occur when electronic boards or components are handled improperly, can result in complete or intermittent failures. The RP, SP, and interface processors each comprise a printed circuit board that is fixed in a metal carrier. EMI shielding, connectors, and a handle are integral components of the carrier. However, the fan control board is a printed circuit board that is not intended to be handled and has no frame or shielding. Handle a processor module or fan tray by the metal frame or carrier only; avoid touching the board (particularly avoid touching any components, traces, or the metal fingers on the edge connector).

Following are guidelines for preventing ESD damage:

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

• When removing or installing a fan tray, connect the equipment end of a ground strap to an unpainted surface of the chassis, such as a handle on the power supply.
  

• When removing or installing a power supply, connect the equipment end of a ground strap to the chassis ground screw on the interface processor end of the chassis, or to an unpainted surface inside the noninterface processor end of the chassis, such as the chassis frame.
  

• Handle printed circuit boards, such as the arbiter, by the edges only; avoid touching the board components, traces, or connector pins.
  

• Place removed printed circuit boards or components that contain boards on an antistatic surface or in a static shielding bag. Place a removed board component-side-up; place a removed processor module or fan tray board-side-up.
  

• If you are returning a replaced part to the factory, immediately place it in a static shielding bag to avoid ESD damage to the board.
  

• Avoid contact between the board and clothing. The wrist strap only protects the board from ESD voltages on the body; ESD voltages on clothing can still cause damage.