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Cisco Product Number: PWR-GSR16-DC-SH=
This publication explains how to remove and replace the DC-input power shelf in the Cisco 12016 Gigabit Switch Router (GSR). This publication also includes instructions for verifying the operation of the system after you replace the DC-input power shelf.
The following sections are included in this publication:
Your router and the Cisco IOS software running on it contains extensive features and functionality, which are documented in the following resources:
The DC-input power subsystem consists of a DC-input power shelf with bays for four DC-input power entry modules. (See Figure 1.) A Cisco 12016 GSR ordered with the DC-input power subsystem ships with four DC-input power entry modules (full redundant power) installed in the DC-input power shelf. In the full redundant power configuration, modules A1 and B1 provide redundant power for system load zone 1 (the upper blower module and the upper card cage). Modules A2 and B2 provide redundant power for system load zone 2 (the switch fabric card cage, the lower card cage, and the lower blower module).

The DC-input power shelf is a modular sheet metal enclosure that attaches to the top of the Cisco 12016 GSR chassis and is secured to the chassis at both the front and back of the power shelf. Two captive screws on each of the power shelf front flanges fasten the power shelf to the rack-mounting flanges on each side of the Cisco 12016 GSR chassis. Guide pins on the power interface panel provide support for the back of the power shelf and ensure correct insertion alignment between the connectors on the back panel of the power shelf and the connectors on the chassis power interface panel.
![]() | Caution A Cisco 12016 GSR configured for source DC operation must be operated with four DC-input power entry modules installed at all times for electromagnetic compatibility (EMC). |
The back of the DC-input power shelf has nine pairs of threaded M6 DC-input terminal studs. (See Figure 2.) The far right pair (looking at the power shelf back panel with the power cable cover removed) is for attaching the protective earth connection, as indicated by the earth symbol (IEC417, Number 5019). The remaining eight pairs represent the power module bays in the power shelf (two pairs for each power module bay). Two central office power cable leads (positive and negative) attach to each power module bay (A1, A2, B2, and B1). One terminal stud pair receives the central office source DC return (positive) cable lead; the second pair receives the central office source DC (negative) cable lead.

Before you begin the replacement procedure, review the safety guidelines in this section to avoid injuring yourself or damaging the equipment.
In addition, review the safety warnings listed in the document Regulatory Compliance and Safety Information for the Cisco 12000 Gigabit Switch Router Series (Document Number 78-4347-xx) that accompanied your Cisco 12016 GSR before installing, configuring, or maintaining the router.
Safety warnings appear throughout this publication in procedures that, if performed incorrectly, may harm you. A warning symbol precedes each warning statement. The following paragraph is an example of a safety warning. It identifies the warning symbol and associates it with a bodily injury hazard. The remaining paragraphs in this section are translations of the initial safety warning.
![]() | Warning This warning symbol means danger. You are in a situation that could cause bodily injury. Before you work on any equipment, be aware of the hazards involved with electrical circuitry and be familiar with standard practices for preventing accidents. To see translations of the warnings that appear in this publication, refer to the Regulatory Compliance and Safety Information document that accompanied this device. |
Waarschuwing Dit waarschuwingssymbool betekent gevaar. U verkeert in een situatie die lichamelijk letsel kan veroorzaken. Voordat u aan enige apparatuur gaat werken, dient u zich bewust te zijn van de bij elektrische schakelingen betrokken risico's en dient u op de hoogte te zijn van standaard maatregelen om ongelukken te voorkomen. Voor vertalingen van de waarschuwingen die in deze publicatie verschijnen, kunt u het document Regulatory Compliance and Safety Information (Informatie over naleving van veiligheids- en andere voorschriften) raadplegen dat bij dit toestel is ingesloten.
Varoitus Tämä varoitusmerkki merkitsee vaaraa. Olet tilanteessa, joka voi johtaa ruumiinvammaan. Ennen kuin työskentelet minkään laitteiston parissa, ota selvää sähkökytkentöihin liittyvistä vaaroista ja tavanomaisista onnettomuuksien ehkäisykeinoista. Tässä julkaisussa esiintyvien varoitusten käännökset löydät laitteen mukana olevasta Regulatory Compliance and Safety Information -kirjasesta (määräysten noudattaminen ja tietoa turvallisuudesta).
Attention Ce symbole d'avertissement indique un danger. Vous vous trouvez dans une situation pouvant causer des blessures ou des dommages corporels. Avant de travailler sur un équipement, soyez conscient des dangers posés par les circuits électriques et familiarisez-vous avec les procédures couramment utilisées pour éviter les accidents. Pour prendre connaissance des traductions d'avertissements figurant dans cette publication, consultez le document Regulatory Compliance and Safety Information (Conformité aux règlements et consignes de sécurité) qui accompagne cet appareil.
Warnung Dieses Warnsymbol bedeutet Gefahr. Sie befinden sich in einer Situation, die zu einer Körperverletzung führen könnte. Bevor Sie mit der Arbeit an irgendeinem Gerät beginnen, seien Sie sich der mit elektrischen Stromkreisen verbundenen Gefahren und der Standardpraktiken zur Vermeidung von Unfällen bewußt. Übersetzungen der in dieser Veröffentlichung enthaltenen Warnhinweise finden Sie im Dokument Regulatory Compliance and Safety Information (Informationen zu behördlichen Vorschriften und Sicherheit), das zusammen mit diesem Gerät geliefert wurde.
Avvertenza Questo simbolo di avvertenza indica un pericolo. La situazione potrebbe causare infortuni alle persone. Prima di lavorare su qualsiasi apparecchiatura, occorre conoscere i pericoli relativi ai circuiti elettrici ed essere al corrente delle pratiche standard per la prevenzione di incidenti. La traduzione delle avvertenze riportate in questa pubblicazione si trova nel documento Regulatory Compliance and Safety Information (Conformità alle norme e informazioni sulla sicurezza) che accompagna questo dispositivo.
Advarsel Dette varselsymbolet betyr fare. Du befinner deg i en situasjon som kan føre til personskade. Før du utfører arbeid på utstyr, må du vare oppmerksom på de faremomentene som elektriske kretser innebærer, samt gjøre deg kjent med vanlig praksis når det gjelder å unngå ulykker. Hvis du vil se oversettelser av de advarslene som finnes i denne publikasjonen, kan du se i dokumentet Regulatory Compliance and Safety Information (Overholdelse av forskrifter og sikkerhetsinformasjon) som ble levert med denne enheten.
Aviso Este símbolo de aviso indica perigo. Encontra-se numa situação que lhe poderá causar danos físicos. Antes de começar a trabalhar com qualquer equipamento, familiarize-se com os perigos relacionados com circuitos eléctricos, e com quaisquer práticas comuns que possam prevenir possíveis acidentes. Para ver as traduções dos avisos que constam desta publicação, consulte o documento Regulatory Compliance and Safety Information (Informação de Segurança e Disposições Reguladoras) que acompanha este dispositivo.
¡Advertencia! Este símbolo de aviso significa peligro. Existe riesgo para su integridad física. Antes de manipular cualquier equipo, considerar los riesgos que entraña la corriente eléctrica y familiarizarse con los procedimientos estándar de prevención de accidentes. Para ver una traducción de las advertencias que aparecen en esta publicación, consultar el documento titulado Regulatory Compliance and Safety Information (Información sobre seguridad y conformidad con las disposiciones reglamentarias) que se acompaña con este dispositivo.
Varning! Denna varningssymbol signalerar fara. Du befinner dig i en situation som kan leda till personskada. Innan du utför arbete på någon utrustning måste du vara medveten om farorna med elkretsar och känna till vanligt förfarande för att förebygga skador. Se förklaringar av de varningar som förkommer i denna publikation i dokumentet Regulatory Compliance and Safety Information (Efterrättelse av föreskrifter och säkerhetsinformation), vilket medföljer denna anordning.
The following guidelines will help ensure your safety and protect the equipment. This list is not inclusive of all potentially hazardous situations, so be alert.
Follow these basic guidelines when working with any electrical equipment:
In addition, observe the following guidelines when working with any equipment that is disconnected from a power source but still connected to telephone or network wiring:
Many router components can be damaged by static electricity. Some components can be damaged by voltages as low as 30V, while static voltages as high as 35,000V can be generated just by handling plastic or foam packing material, or by sliding assemblies across plastic and carpets. Not exercising the proper electrostatic discharge (ESD) precautions can result in intermittent or complete component failures. To minimize the potential for ESD damage, observe the following guidelines:
![]() | Caution You should periodically check the resistance value of the ESD-preventive strap. The measurement should be between 1 and 10 megohms. |

You need the following tools and parts to install or replace a DC-input power shelf:
You can use the power cables from the removed power shelf for the replacement power shelf.
This section provides six procedures:
Figure 4 shows the steps in removing a DC-input power entry module from the power shelf.

To remove a DC-input power entry module, use Figure 4 as a reference and follow these steps:
Step 1 Grasp the outside edges of the front cover over the upper blower module bay and power shelf and pull it straight out to detach the four ball studs on the front cover from the ball stud sockets on the front of the upper blower module bay and power shelf.
Step 2 Attach an ESD-preventive wrist strap to your wrist and connect the leash to one of the ESD connection sockets on the front of the chassis or to a bare metal surface on the chassis. (See Figure 3.)
Step 3 To turn off the power entry module and eject it from the power shelf backplane connector, follow these steps:
(a) Loosen the ejector lever captive screw to release the ejector lever from the power entry module faceplate. (See Figure 4a.)
(b) Pivot the ejector lever away from the power entry module faceplate to eject the power entry module from the power shelf backplane connector. (See Figure 4b.)
Step 4 Grasp the power entry module handle and pull the power entry module halfway out of the bay. (See Figure 4c.)
![]() | Caution The DC-input power entry module weighs 6.4 lb (2.9 kg). Because of the weight of the power entry module and the elevated position of the power shelf, you should use two hands when handling the power entry module. |
Step 5 Use your free hand to support the power entry module while you slide it completely out of the bay.
Step 6 Set the power entry module safely aside.
Repeat Step 3 through Step 6 for the remaining power entry modules.
To remove the DC-input power shelf from the chassis, follow these steps:
Step 1 Attach an ESD-preventive wrist strap to your wrist and connect the leash to one of the ESD connection sockets on the front of the chassis or to a bare metal surface on the chassis. (See Figure 3.)
![]() | Warning Before performing the following steps, turn off power to the DC circuits that provide power to the DC-input power shelf. To ensure that power is OFF, locate the circuit breaker on the electrical panel that services the DC circuits, switch the circuit breaker to the OFF position, and tape the switch handle of the circuit breaker in the OFF position. |
Step 2 Loosen the screw that secures the source DC power cable cover to the back panel of the power shelf. Slide the cover down to free the screw head from the keyhole slot in the cover. Pull the cover away from the power shelf back panel. (See Figure 5.) Set the cover safely aside.

Step 3 Measure the voltages across the leads attached to each of the cable pairs on the back panel of the power shelf. All readings should be zero volts.
Step 4 Disconnect the DC power negative (-) and positive (+) cable pairs from the DC-input terminal studs on the back panel of the power shelf. Use Figure 6 as a reference and follow the steps outlined below.

(a) Remove only the outer nut and washer from both terminal studs to which the negative (-) cable lug is connected.
(b) Pull the source DC negative (-) cable lug from the terminals and put it safely aside.
![]() | Caution As an added precaution, we strongly recommend that you place electrical tape or insulated shrink tubing over the exposed cable lugs to prevent accidental contact between the lugs, or between the lugs and ground. |
(c) Remove only the outer nut and washer from both terminal studs to which the positive (+) cable lug is connected.
(d) Pull the source DC power positive (+) cable lug away from the terminals and put it safely aside.
(e) Reinstall the washers and outer nuts on the terminal studs.
Repeat Step 4 for each of the remaining source DC power cable pairs (- and +) on each set of terminals (A1, A2, and B2).
Step 5 Remove the outer nut and washer from the two ground terminal studs and remove the power shelf earth ground cable lug from the terminal studs.
Step 6 Loosen the captive screws (two on each side) that fasten the two power shelf flanges to the rack-mounting flanges on the chassis. (See Figure 7.)

Step 7 Grasp the flanges on the power shelf and pull the power shelf straight out approximately three inches to disconnect the power shelf from the connectors on the chassis power interface panel. Slide the power shelf halfway out of the rack. (See Figure 8.)

![]() | Caution An empty DC-input power shelf weighs 10.2 lb (4.6 kg). Because of the rack-mounted height of the Cisco 12016 GSR chassis, you should be especially careful while lifting and removing the power shelf. To prevent injury, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves. |
Step 8 Grasping the power shelf flanges with both hands (see Figure 8), slowly lift the power shelf off the chassis and pull it out of the rack.
Step 9 Set the power shelf safely aside.
If you plan to return the defective power shelf to the factory, repackage it in the shipping container you received with the replacement power shelf.
To install the replacement DC-input power shelf, follow these steps:
Step 1 Attach an ESD-preventive wrist strap to your wrist and connect the leash to one of the ESD connection sockets on the front of the chassis or to a bare metal surface on the chassis. (See Figure 3.)
![]() | Caution An empty DC-input power shelf weighs 10.2 lb (4.6 kg). Because of the rack-mounted height of the Cisco 12016 GSR chassis, you should be especially careful while lifting and removing the power shelf. To prevent injury, keep your back straight and lift with your legs, not your back. Avoid sudden twists or lateral moves. |
Step 2 Grasp the power shelf front flanges with both hands, lift the power shelf to the top of the chassis, and set the bottom edges of the power shelf sides into the tracks on the top edges of the chassis. (See Figure 9.)

Step 3 Slide the power shelf halfway onto the top of the chassis. (See Figure 9.)
Step 4 Seat the power shelf in the chassis power interface panel connectors. Use Figure 10 as a reference and follow the steps outlined below:

(a) Verify that the two guide pins on the chassis power interface panel are correctly aligned with the two holes on the back of the power shelf.
(b) Carefully push the power shelf until the two connectors on the back of the power shelf contact the two connectors on the chassis power interface panel.
(c) Firmly push the power shelf until the connectors are completely seated and the front flanges on the power shelf make contact with the rack-mounting flanges on the chassis.
Step 5 Insert and tighten the captive screws (two on each side) on each power shelf front flange to secure the power shelf to the rack-mounting flanges on the chassis. (See Figure 7.)
Figure 11 shows how to reconnect source DC power cables to the DC-input terminal studs on the back panel of the DC-input power shelf after it has been installed on the Cisco 12016 GSR chassis.

To reconnect source DC to the power shelf, use Figure 11 as a reference and follow these steps:
Step 1 Attach an ESD-preventive wrist strap to your wrist and connect the leash to one of the ESD connection sockets on the front of the chassis or to a bare metal surface on the chassis. (See Figure 3.)
Step 2 Loosen the screw that secures the power cable cover to the back panel of the power shelf. Slide the cover down to free the screw head from the keyhole slot in the cover. Pull the cover away from the power shelf back panel. (See Figure 5.) Set the cover safely aside.
Step 3 Remove only the outer nut and washer from each of the terminal studs on the back panel of the power shelf.
![]() | Warning When installing the source DC power cable leads, always make the ground connection first and disconnect the ground connection last. |
Step 4 Attach the power shelf ground cable. Use Figure 11 as a reference and follow these steps:
(a) Position the power shelf ground cable lug on the ground terminal studs.
(b) Install washers and nuts on both terminals and finger tighten the nuts.
(c) Verify that the ground cable lug is on straight and does not interfere with other cables.
(d) Use a 10-mm wrench or nutdriver to tighten the nuts.
Step 5 Install the source DC power module cable leads. Use Figure 11 as a reference and follow these steps:
(a) For each power entry module cable lead pair, identify the source DC return (positive) and source DC (negative) cable leads.
(b) Select the source DC return (positive) cable lead and fit the holes in the cable lug over the source DC return (positive) terminal studs on the power shelf.
(c) Install and tighten the locking washers and nuts to secure the cable lug.
(d) Select the source DC (negative) cable lead and fit the holes in the cable lug over the source DC (negative) terminal studs on the power shelf.
(e) Install and tighten the locking washers and nuts to secure the cable lug.
Repeat Step 5a through Step 5e for the source DC cable lead pairs for the remaining power entry module bays.
Step 6 Verify that all the terminal stud connections on the power shelf are tight.
Step 7 Switch on the source DC circuit breakers for the four power module circuits and verify that the polarity of the source DC wiring from the source DC breaker to the power shelf is correct.
![]() | Caution The DC-input power entry module contains circuitry to trip the breaker on the power entry module if it detects a reverse polarity condition. No damage should occur due to reverse polarity, but you should correct a reverse polarity condition immediately. |
Step 8 Switch off the source DC circuit breakers for the four power module circuits.
Step 9 Position the power shelf terminal stud cover so that the cable openings are over the cables and the standoff keyhole is over the standoff screw on the power shelf. Slide the cover upward slightly to engage the screw head in the keyhole slot and then secure the cover by tightening the screw.
Figure 12 shows the steps in installing a DC-input power entry module in the power shelf.

![]() | Caution The DC-input power entry module weighs 6.4 lb (2.9 kg). Because of the weight of the power entry module and the elevated position of the power shelf, you should use two hands when handling the power entry module. |
To reinstall a DC-input power entry module, use Figure 12 as a reference and follow these steps:
Step 1 Attach an ESD-preventive wrist strap to your wrist and connect the leash to one of the ESD connection sockets on the front of the chassis or to a bare metal surface on the chassis. (See Figure 3.)
Step 2 Loosen the captive screw on the ejector lever on the replacement power entry module and pivot the ejector lever away from the power entry module faceplate until it is perpendicular to the power entry module faceplate. (See Figure 12a.)
![]() | Caution To prevent damage to the power shelf backplane connector, do not use excessive force when inserting a power entry module into its power shelf bay. |
Step 3 Using two hands to support and guide the power entry module, slide it into the power shelf bay until the connector on the back of the power entry module makes contact with the connector in the back of the power shelf.
Step 4 Seat the power entry module in the backplane connector by pivoting the ejector lever to engage the slot in the floor of the power shelf and then pushing the ejector lever until it is flush with the power entry module faceplate. (See Figure 12c.)
Step 5 Tighten the captive screw on the ejector lever.
Repeat Step 2 through Step 5 for the remaining three power entry modules.
![]() | Caution A Cisco 12016 GSR must be operated with all of its power modules installed at all times for electromagnetic compatibility. |
Step 6 Replace the front cover over the upper blower module bay and power shelf.
Step 7 Verify that the source DC circuit breakers servicing the power cables for the power shelf are switched on.
To check router operation after replacing the DC-input power shelf, follow these steps:
Step 1 Verify that each of the following conditions is true:
Step 2 Visually check that the green LED labeled PWR OK goes on and stays on. This LED indicates that the source DC voltage is within the correct range.
If the LED labeled PWR OK is off, verify that the following conditions are true:
Step 3 Verify that the amber LEDs labeled FAULT and TEMP are off.
If the LED labeled FAULT remains on, replace the existing power entry module with a spare power entry module. If the LED labeled PWR OK on the spare power entry module goes on, return the faulty power entry module for replacement.
If the LED labeled FAULT on the spare power entry module remains on, suspect a faulty power shelf backplane connector in that power shelf bay.
Step 4 Replace the front cover over the upper blower module bay and power shelf.
If a power entry module fails to operate properly after several attempts to power it up, contact a Cisco service representative for assistance.
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio-frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case users will be required to correct the interference at their own expense.
You can determine whether your equipment is causing interference by turning it off. If the interference stops, it was probably caused by the Cisco equipment or one of its peripheral devices. If the equipment causes interference to radio or television reception, try to correct the interference by using one or more of the following measures:
Modifications to this product not authorized by Cisco Systems, Inc. could void the FCC approval and negate your authority to operate the product.
This class A digital apparatus complies with Canadian ICES-003.
Cet appareil numerique de la classe A est conforme a la norme NMB-003 du Canada.
This is a class B product based on the standard of the Voluntary Control Council for Interference from Information Technology Equipment (VCCI). If this is used near a radio or television receiver in a domestic environment, it may cause radio interference. Install and use the equipment according to the instruction manual.

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You can access CCO in the following ways:
For a copy of CCO's Frequently Asked Questions (FAQ), contact cco-help@cisco.com. For additional information, contact cco-team@cisco.com.

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Posted: Tue Nov 30 17:03:20 PST 1999
Copyright 1989-1999©Cisco Systems Inc.