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Product Numbers:
PWR-3620-AC=, PWR-3620-DC=, PWR-3640-AC=, PWR-3640-DC=, PWR-CISCO3660-AC=, PWR-CISCO3660-DC=
This document describes how to replace the AC or DC power supply in a Cisco 3620, 3640, or 3660 router.
This document is intended for the power supply installer, who should be familiar with electronic circuitry and wiring practices and have experience as an electronic or electromechanical technician. Use this document in conjunction with the Cisco 3600 Series Hardware Installation Guide and the Regulatory Compliance and Safety Information document for your router.
If you have questions or need help, refer to the "Obtaining Service and Support" section.
This document contains the following sections:
 | Warning Before working on a chassis or working near power supplies, unplug the power cord on AC units; disconnect the power at the circuit breaker on DC units. |
| Warning Before working on a system that has an on/off switch, turn OFF the power and unplug the power cord. |
The following warning applies to routers with a DC power supply:
| Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position. |
| Warning Ultimate disposal of this product should be handled according to all national laws and regulations. |
 | Caution To avoid damaging electrostatic discharge (ESD)-sensitive components, ensure that you have discharged all static electricity from your body before opening the chassis. Before performing procedures described in this document, review the next section, "Safety Recommendations." |
Follow these guidelines to ensure general safety:
| Warning The ISDN connection is regarded as a source of voltage that should be inaccessible to user contact. Do not attempt to tamper with or open any public telephone operator (PTO)-provided equipment or connection hardware. Any hardwired connection (other than by a nonremovable, connect-one-time-only plug) must be made only by PTO staff or suitably trained engineers. |
| Warning The Ethernet 10BaseT, Token Ring, serial, console, and auxiliary ports contain safety extra-low voltage (SELV) circuits. BRI circuits are treated like telephone-network voltage (TNV) circuits. Avoid connecting SELV circuits to TNV circuits. |
| Warning Before working on equipment that is connected to power lines, remove jewelry (including rings, necklaces, and watches). Metal objects will heat up when connected to power and ground and can cause serious burns or weld the metal object to the terminals. |
Follow these guidelines when working on equipment powered by electricity:
Electrostatic discharge (ESD) can damage equipment and impair electrical circuitry. It occurs when electronic printed circuit cards are improperly handled and can result in complete or intermittent failures. Always follow ESD prevention procedures when removing and replacing cards. Ensure that the router chassis is electrically connected to earth ground. Wear an ESD-preventive wrist strap, ensuring that it makes good skin contact. Connect the clip to an unpainted surface of the chassis frame to safely channel unwanted ESD voltages to ground. To properly guard against ESD damage and shocks, the wrist strap and cord must operate effectively. If no wrist strap is available, ground yourself by touching the metal part of the chassis.
| Caution For safety, periodically check the resistance value of the antistatic strap, which should be between 1 and 10 megohms (Mohm). |
Figure 1 shows AC and DC power supplies for the Cisco 3620 router, Figure 2 shows AC and DC power supplies for the Cisco 3640 router, and Figure 3 shows AC and DC power supplies for the Cisco 3660 router.
Figure 4 through Figure 6 show the location of the power supply in each of the Cisco 3600 series routers. The AC or DC power supply occupies the same location in the router.
Table 1 lists AC and DC power supply specifications for the Cisco 3600 series routers.
| Type | Cisco 3660 | Cisco 3640 | Cisco 3620 |
|---|---|---|---|
Input voltage, AC power supply | 100 to 240 VAC, autoranging | 100 to 240 VAC, autoranging | 100 to 240 VAC, autoranging |
Input voltage, DC power supply | -48 to -60 VDC | -48 to -60 VDC | -48 to -60 VDC |
Wire gauge for DC-input power connections | 14 AWG1 | 14 AWG | 14 AWG |
Disspation | 380W | 220W | 95W |
Output | 250W (maximum) | 140W (maximum) | 60W (maximum) |
| 1AWG = American Wire Gauge. |
You need the following tools and equipment to remove and install power supplies in a Cisco 3600 series router:
To access power supplies on the Cisco 3620 and Cisco 3640 routers, remove the router cover as described in the "Removing the Router Cover" section. Power supplies on the Cisco 3660 router are hot-swappable as described in the "Removing the Cisco 3660 Power Supply" section.
| Warning Before working on a chassis or working near power supplies, unplug the power cord on AC units; disconnect the power at the circuit breaker on DC units. |
| Warning Do not work on the system or connect or disconnect cables during periods of lightning activity. |
| Warning Before opening the chassis, disconnect the telephone-network cables to avoid contact with telephone-network voltages. |
| Warning Network hazardous voltages are present in the BRI cable. If you detach the BRI cable, detach the end away from the router first to avoid possible electric shock. Network hazardous voltages also are present on the system card in the area of the BRI port (RJ-45 connector), regardless of when power is turned off. |
The power supply and cabling in these router models is contained inside the chassis. In order to replace the power supply, complete these procedures:
To gain access to the Cisco 3620 or Cisco 3640 power supply, you must first remove the chassis cover:
Step 1 Turn OFF power to the router.
Step 2 Remove all network interface cables from the rear panel.
Step 3 If you have an AC-powered router, remove the power cord.
The following warnings apply to routers with DC power supplies:
| Warning Before performing any of the following procedures, ensure that power is removed from the DC circuit. To ensure that all power is OFF, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position. |
| Warning When installing the unit, the ground connection must always be made first and disconnected last. |
If you have a DC-powered router, follow these steps to remove the power cables:
(a) Use a screwdriver to loosen the captive installation screws on the terminal block cover.
(b) Lift and remove the terminal block cover.
(c) Use a screwdriver to remove the three power leads from the terminal block, in this order: negative, positive, then ground.
Step 4 If the router is rack- or wall-mounted, remove it from the rack or wall.
Step 5 Place the router so the front panel is closest to you. Remove the three screws located on top of the cover near the front edge. (See Figure 7 and Figure 8.) Set the screws aside in a safe place.
Step 6 Lift the front edge of the cover about 1 inch (2.5 cm) above the chassis, as shown in Figure 9.
Step 7 Pull the cover toward you until the metal tabs on the rear edge separate from the chassis bottom. (See Figure 7 and Figure 8.)
Step 8 Lift the cover completely off and set it aside.
When you are ready to replace the cover, see the "Replacing the Router Cover" section.
After you remove the cover from the chassis, follow this procedure to remove the power supply:
Step 1 Find the power cable harness located on the rear of the power supply (toward the front of the router). (See Figure 10 and Figure 11.)
Step 2 Find the large power connector on the motherboard and remove it. On a Cisco 3620 router, you can simply lift the plug away from the receptacle. (See Figure 12.) On a Cisco 3640 router, press the sides of the plug in toward the middle and lift it away from the receptacle. (See Figure 13.)
Step 3 Find the two small two-pin connectors used to power the fans. Grasp the two halves of each connector firmly and pull them apart. (See Figure 10 and Figure 11.)
Step 4 The Cisco 3620 power supply is held in the chassis by one external mounting screw at the rear of the router. (See Figure 14.) The Cisco 3640 power supply is held by two mounting screws. (See Figure 15.) Remove the screw or screws and set them aside.
Step 5 Slide the power supply forward slightly in the chassis. This disengages the hooks built into the chassis that help secure the power supply. The Cisco 3620 router has two hooks. (See Figure 16.) The Cisco 3640 router has one hook. (See Figure 17.)
Step 6 Lift the power supply out of the chassis.
Follow these steps to install a power supply in the chassis:
Step 1 Place the power supply in the chassis, with the power supply rear panel slightly separated from the chassis rear panel. This position allows the hooks in the chassis to engage the cutouts in the bottom of the power supply. (See Figure 18 and Figure 19.)
Step 2 Slide the power supply toward the rear of the chassis, engaging the hooks in the chassis.
Step 3 Replace the external rear mounting screws. (See Figure 14 and Figure 15.)
Step 4 Insert the large power connector into the receptacle on the motherboard. (See Figure 12 and Figure 13.)
Step 5 Join the small (two-pin) connectors used to power the fans. Either connector can go to either fan. (See Figure 10 and Figure 11.)
Step 6 Using tie-wraps, fasten the power cables into a bundle that clears the edge of the chassis and keeps the cables away from the fan. Be sure that cables to the fans are routed under the hook in the bottom of the chassis. (See Figure 10 and Figure 11.)
After you finish replacing the power supply, follow these steps to replace the cover:
Step 1 Place the chassis bottom so the front panel is closest to you.
Step 2 Hold the cover so the tabs at the rear of the cover are aligned with the chassis bottom, as shown in Figure 20 and Figure 21.
Step 3 Push the cover toward the rear, making sure that the cover tabs fit under the chassis back panel, and the back panel tabs fit under the cover.
Step 4 Lower the front of the cover onto the chassis, making sure that the cover side tabs fit under the chassis side panels, and the chassis tabs fit under the cover side panels.
Step 5 Fasten the cover with the three screws you set aside earlier.
Step 6 Reinstall the chassis on a rack, wall, desktop, or table.
Step 7 Reinstall network interface cables.
Step 8 Proceed to the "Electrical Connections for Cisco 3600 Series Routers" section.
The Cisco 3660 accommodates two AC or two DC hot-swappable power supplies (PS1 and PS2) in bays at the rear of the unit (see Figure 6). Each unit provides up to 250W of power, and a single installed power supply meets the router's requirements. The second installed power supply provides redundancy, load sharing, and increased system availability. It can be removed without affecting system operation.
| Warning Do not touch the power supply when the power cord is connected. For systems with a power switch, line voltages are present within the power supply even when the power switch is off and the power cord is connected. For systems without a power switch, line voltages are present within the power supply when the power cord is connected. |
Use the following procedure to remove a power supply:
Step 1 Identify the failed power supply by checking the power supply LEDs (PS1 and PS2) on the router's front panel.
Step 2 Facing the rear panel, identify the failed power supply by checking the bay (PS1 or PS2) that it is installed in, and checking that the LED on the power supply is orange or off. (See Figure 22 for the location of the power supply LED.)
Step 3 Turn OFF power to the failed power supply and unplug the power cable.
Step 4 Loosen the two captive screws holding the power supply in the chassis bay, using the Phillips or flat-blade screwdriver. (See Figure 22.)
Step 5 Slide the power supply out of the bay.
Use the following procedure to install a power supply:
Step 1 Check that the power switch on the power supply is in the OFF position.
Step 2 Align the power supply with the chassis bay, and slide it in until the center hole (between the captive screws) is aligned with the hole in the bay's lower shelf. (See Figure 22.)
Step 3 Tighten the two captive screws that secure the power supply in the chassis bay, using the Phillips or flat-blade screwdriver.
Step 4 Connect the power cord to the replacement power supply.
Step 5 If you are replacing a power supply, continue with Step 6 of this sequence; if you are installing a power supply for the first time, proceed to the "Electrical Connections for Cisco 3600 Series Routers" section.
Step 6 Turn ON power to the replacement power supply.
Step 7 Check that the LED on the power supply is green. (See Figure 22 for the location of the power supply LED.)
Step 8 Check that the corresponding power supply LED (PS1 or PS2) on the front panel is green.
This section explains how to connect AC or DC power to Cisco 3600 series routers, and how to power up both AC- and DC-powered routers.
If you have a DC-powered router, see "Connecting Routers to a DC-Input Power Supply" section. If you have an AC-powered router, see "Powering On the Router" section.
| Warning This product relies on the building's installation or power supply for short circuit (overcurrent) protection. Ensure that a listed and certified fuse or circuit breaker no larger than 60 VDC, 15A U.S. is used on all current-carrying conductors. |
If you ordered the router with a DC-input power supply, follow the directions in this section for proper wiring. A router with a DC-input power supply has a terminal block cover in place of a three-pronged connector for an AC power cord.
Depending on the type of router you are installing, see one of the following:
Figure 23 and Figure 24 show the router DC-input power supply terminal block.
Take the following steps to wire the terminal block:
Step 1 Use 14-AWG copper wires to connect DC-input power to the power supply.
Step 2 Attach the appropriate lugs at the wire end of the power supply cord.
Step 3 Wire the DC-input power supply to the terminal block as shown in Figure 23 and Figure 24.
| Warning This warning applies only to units equipped with DC input power supplies. Wire the DC power supply using the appropriate lugs at the wiring end. The proper wiring sequence is ground to ground, positive to positive (line to L), and negative to negative (neutral to N). Note that the ground wire should always be connected first and disconnected last. |
| Caution Do not overtorque the terminal block captive thumbscrew or terminal block contact screws. The recommended torque is 8.2 ± 0.4 inch-lb. |
| Warning An exposed wire lead from a DC-input power source can conduct harmful levels of electricity. Be sure that no exposed portion of the DC-input power source wire extends from the terminal block plug. |
| Warning Secure all power cabling when installing this unit to avoid disturbing field-wiring connections. |
| Warning After wiring the DC power supply, remove the tape from the circuit breaker switch handle and reinstate power by moving the handle of the circuit breaker to the ON position. |
| Warning Voltages might be present on the DC-input power supply terminals. Turn off the power source circuit breaker and remove the power supply before accessing the terminals. |
The Cisco 3660 router DC power supply terminal blocks are located on the power cable connector. (See Figure 25.)
Step 1 Use 14-AWG copper wires to connect DC-input power to the terminal blocks. Strip the shielding to expose approximately 0.4 inch (10 mm) of the wire.
| Warning An exposed wire lead from a DC-input power source can conduct harmful levels of electricity. Be sure that no exposed portion of the DC-input power source wire extends from the terminal block plug. |
Step 2 Press the corresponding orange-colored release, and insert one wire in each receptacle of the power cable connector. The spring-loaded connector retains the wires.
| Warning This warning applies only to units equipped with DC input power supplies. Wire the DC power supply using the appropriate lugs at the wiring end. The proper wiring sequence is ground to ground, positive to positive (line to L), and negative to negative (neutral to N). Note that the ground wire should always be connected first and disconnected last. |
Step 3 Plug the connector and power cable into the power receptacle on the power supply.
| Warning Secure all power cabling when installing this unit to avoid disturbing field-wiring connections. |
| Warning After wiring the DC power supply, remove the tape from the circuit breaker switch handle and reinstate power by moving the handle of the circuit breaker to the ON position. |
| Warning Voltages might be present on the DC-input power supply terminals. Turn off the power source circuit breaker and remove the power supply before accessing the terminals. |
| Warning The plug-socket combination must be accessible at all times because it serves as the main disconnecting device. |
| Caution Never operate the router unless the unit is completely closed to ensure adequate cooling. |
Take the following steps to power on the router:
Step 1 For routers with AC input, plug the router's power cord into a three-terminal, single-phase power source that provides power within the acceptable range.
| Warning This product relies on the building's installation or power supply for short circuit (overcurrent) protection. Ensure that a listed and certified fuse or circuit breaker no larger than 60 VDC, 15A U.S. is used on all current-carrying conductors. |
Step 2 Power ON the router. The LED labeled SYSTEM on the front panel should go on.
If you encounter problems when you power on the router, see the "Troubleshooting" section.
Check the following items to help isolate problems with the power supply installation:
For service and support for a product purchased from a reseller, contact the reseller. Resellers offer a wide variety of Cisco service and support programs, which are described in the section "Service and Support" in the information packet that shipped with your chassis.
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Please use CCO to obtain general information about Cisco Systems, Cisco products, or upgrades. If CCO is not accessible, contact 800 553-6387, 408 526-7208, or cs-rep@cisco.com.
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Posted: Thu Jul 29 08:50:42 PDT 1999
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