Maintaining the
Five-Slot Chassis

Your chassis is configured as specified in your order and is ready for installation and startup when it leaves the factory. As your communication requirements change, you can upgrade your system, add components, or change the initial configuration. Software and component upgrades require specific documents and other frequently updated information; therefore, only basic replacement guidelines are included in this publication.

There are two kinds of replaceable system components: those that support hot swapping and those that require the system power to be shut down before they are replaced. Redundant power supplies, line modules and the fan assembly are hot-swappable.

This chapter contains the following sections:

Removing and Installing the Switch Processor and
Line Modules

All line modules support hot swapping which allows you to remove, install, and rearrange the line modules without turning off the system power. When the system detects that a line module has been installed or removed, it automatically runs diagnostic and discovery routines, acknowledges the presence or absence of the line module, and resumes system operation without any operator intervention.

Caution The switch processor is a required system component. Removing a switch processor while the system is operating causes the system to shut down and can damage the switch processor.

For detailed switch processor and line module installation, replacement, and upgrade instructions, refer to the Catalyst 8510 Campus Switch Router Processor and Line Module Installation Guide.

Removing and Installing Power Supplies

The chassis is configured to your order and is ready for installation and startup when it leaves the factory. As your communication requirements change, you might want to upgrade your system and add or replace a power supply. This section includes the following power supply information:

Power Supply LEDs

The green LED (see Figure 3-1) indicates the status of the power supply and internal
DC voltages. The LED stays on when the power supply is on and receiving source power, providing +5, +12, and +24 VDC to internal components, and shows that all internal voltages are within tolerance.

If the source power or any of the internal DC voltages exceed allowable tolerances, the LED goes off and the system environmental monitor messages indicate the out-of-tolerance line. Because the system requires all three output voltages for operation, the system malfunctions or shuts down if any of the internal DC voltages reach an
out-of-tolerance state.

An AC power supply is shown in Figure 3-1.

Figure 3-1: Power Supply LED

Switch Processor Power Supply LEDs

On the campus switch router front panel, the PS0 LED goes on when the power supply in the left bay, labeled PS0, is installed and supplying power to the system. The PS1 LED goes on when the power supply in the right bay, labeled PS1, is installed and supplying power to the system. Both the LEDs should be on in systems with redundant power. The processor LEDs are shown in Figure 3-2 and are described in Table 3-1 .

Figure 3-2:
Switch Processor Power Supply LEDs

Table 3-1: Switch Processor Power Supply LEDs

LED Description

PS0

If the left bay power supply is operational, the PS0 LED is green.
If the left bay power supply is turned off or is not operational, the PS0 LED is red.
If the left bay power supply is not installed, the PS0 LED is off.

PS1

If the right bay power supply is operational, the PS1 LED is green.
If the right bay power supply is turned off or not operational, the PS1 LED is red.
If the right bay power supply is not installed, the PS1 LED is off.

LED	Description
PS0	If the left bay power supply is operational, the PS0 LED is green. If the left bay power supply is turned off or is not operational, the PS0 LED is red. If the left bay power supply is not installed, the PS0 LED is off.
PS1	If the right bay power supply is operational, the PS1 LED is green. If the right bay power supply is turned off or not operational, the PS1 LED is red. If the right bay power supply is not installed, the PS1 LED is off.

Overvoltage and Overtemperature Protection

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.

Note If the power supply shuts down, wait several minutes for the supply to cool, then turn the power switch off (0), then on (-). If the power supply shuts down again, remove and replace it.

Removing and Installing AC Power Supplies

The 376W power supplies (AC-input) support redundant hot swapping. When two power supplies are installed, you can remove or install one of the supplies without affecting system operation. When power is removed from one supply, the redundant power feature causes the second supply to ramp up to full power and maintain uninterrupted system operation. In systems with dual power supplies, connect each power supply to separate input lines so that, in case of a line failure, the second source is available and can maintain maximum overcurrent protection for each power connection.

A modular power cord should connect each AC power supply to a separate site
power source.

Caution Use both hands to remove and install power supplies.

Caution To avoid problems or damage to the chassis, do not mix DC-input power supplies with AC-input power supplies in individual units.

Note Each AC-input power supply weighs 11 pounds (4.98 kilograms).

Caution Keep hands and fingers out of the power supply bays. Voltage is present on the chassis backplane when the system is operating.

Tools Required

You need the following tools to remove and install a power supply:

A 1/4-inch flat-blade screwdriver to remove and install filler plates and to loosen or tighten the captive installation screws on the AC power supply
Filler plates to install over empty power supply bays to protect the connectors
from contamination

Removing AC Power Supplies

Take the following steps to remove an AC power supply:

Step 1 Turn OFF the power switch on the power supply you are removing.
(See Figure 3-3.)

Caution Failure to turn off the AC power supply could result in equipment damage.

Figure 3-3: AC Power Supply Switch, AC Connection, and Captive Screws

Step 2 Disconnect the AC power cord from the power source.

Step 3 Remove the AC power cord from the power inlet.

Step 4 Loosen the captive installation screws on the sides of the supply with a screwdriver. (See Figure 3-3.)

Caution Alternate tightening of the captive installation screws every one or two turns to avoid skewing the power supply.

Step 5 Grasp the AC power supply handle with one hand and slowly pull the power supply out of the chassis toward you. (See Figure 3-4.)

Step 6 While holding the AC power supply handle with one hand, place your other hand underneath to support the bottom of the supply, as shown in Figure 3-5.

Step 7 Pull the supply out of the bay and put it aside.

Step 8 If the power supply bay is to remain empty, install a blank power supply filler plate over the opening and secure it with the mounting screws. This protects the inner chassis from dust and prevents accidental contact with live voltage at the rear of the bay.

Figure 3-4: Power Supply Removal and Installation

Figure 3-5: Handling an AC Power Supply

Installing the AC Power Supply

Take the following steps to install an AC power supply:

Caution To avoid problems or damage to the chassis, do not mix DC-input power supplies with AC-input power supplies in individual units.

Step 1 Grasp the AC power supply handle with one hand and place your other hand underneath to support the bottom of the supply, as shown in Figure 3-5.

Step 2 Place the AC power supply into the power supply bay and push the AC power supply into the bay until the power supply faceplate is flush with the cover.

Step 3 Tighten each of the two captive installation screws by turning them clockwise.

Caution Alternate tightening of the captive installation screws, every one or two turns, to avoid skewing the power supply.

Caution Keep hands and fingers out of the power supply bays. Voltage is present on the chassis backplane when the system is operating.

Connecting AC Power

Connect an AC-input power supply as follows:

Step 4 Plug a power cord into the power inlet of one AC power supply.
(See Figure 3-6.)

Step 5 Connect the other end of the AC power supply cord to an input line.

To complete the installation, see the section "Powering On the AC Power Supply."

Figure 3-6: Power Cord Connections

Connecting Redundant AC Power

Connect the redundant AC power supply to a separate input line. Connect the redundant AC-input power supply as follows:

Step 1 Plug in the AC power cord on the redundant AC power supply. (See Figure 3-6.)

Step 2 Connect the redundant AC power supply cord to an input line other than the initial AC power supply line.

Powering On the AC Power Supply

Perform the following steps to power on the AC-input power supply and confirm the installation:

Step 1 Turn the power switch of the power supply ON (-).

Step 2 Verify that the green LED on the power supply front panel is on (see Figure 3-1). This indicates that the power supply is on and is receiving AC source power, providing +5, +12, and +24 VDC to internal components, and showing that all internal voltages are within tolerance.

Step 3 Verify that the appropriate switch processor PS0 and PS1 LEDs are green. (See Figure 3-2.)

Step 4 Use the show environment command to display the power supply and system status, as shown in this screen example:

8510>show environment
Temperature:                        OK
Fan:                                OK
Voltage:                            OK
Power Supply#0 type: Astec,  status:    OK
8510>

If the LEDs or show environment command indicate a power problem or other system problem is indicated, refer to the section "Confirming the Installation" in the chapter "Installing the Five-Slot Chassis" and Figure 2-10 for troubleshooting information.

Removing and Installing DC Power Supplies

This section provides removal and installation procedures for DC-input power supplies. The five-slot chassis is configured to your order and is ready for installation and startup when it leaves the factory. As your communication requirements change, you might want to upgrade your system and add or replace a power supply.

The five-slot chassis DC power supplies (DC-input) support redundant hot swapping. When two power supplies are installed, you can install, remove, or replace one of the supplies without affecting system operation. When power is removed from one supply, the redundant power feature causes the second supply to ramp up to full power and maintain uninterrupted system operation. In systems with dual power supplies, connect each power supply to separate DC-input lines; in the event of a line failure, the second source is still available.

The DC power supply is required by many telcos because their wiring closets are equipped with DC power outlets. From an operational perspective, the DC power supply has the same characteristics as the AC version.

Only a DC power source that complies with the safety extra low voltage (SELV) and requirements in UL 1950, CSA C22.2 No. 950, EN 60950 and IEC 950 can be connected to the DC-input power supplies.

Caution The five-slot chassis must be installed only in restricted access areas (dedicated equipment rooms, equipment closets, or the like), in accordance with articles 110-16, 110-17 and 110-18 of the National Electrical Code, ANSI/NFPA 70.

Note The installation must comply with all applicable codes. In North America, installation must comply with NEC (ANSI/NFPA 70) and CEC (OArt1, C22.1). Installation is approved for use with copper connectors only. Make the attachment of the chassis ground M4 pemnuts to the central office or other interior ground system with a number 10-12 AWG copper ground connector as a minimum. The chassis employs two threaded M4x7 chassis ground M4 pemnuts. These pemnuts must connect directly to the central office or other interior ground system, and are located on the front of the chassis. The grounded chassis M4 pemnuts require M4 bolts and locking hardware, which are not included.

Figure 3-7 shows the location of the DC-input power supplies in a redundant configuration. In a nonredundant configuration, the power supply goes in the slot labeled Power Supply 0.

Figure 3-7: DC Power Supply Location

Caution Use both hands to remove and install power supplies.

Caution Keep hands and fingers out of the power supply bays. Voltage is present on the chassis backplane when the system is operating.

Caution Always install a filler plate over an empty power supply bay to protect the connectors from contamination.

Removing the DC Power Supply

Follow these steps to remove a DC-input power supply:

Caution To prevent problems with the chassis, do not mix DC-input power supplies with AC-input power supplies in individual units.

Step 1 Verify that power is off to the DC-input circuit furnishing power to the power supply you are removing.

Step 2 Turn OFF the power switch on the power supply you are removing (see
Figure 3-8).

Figure 3-8: DC Power Supply Power Switch and LED

Step 3 Remove the terminal block cover by depressing the two plastic levers on each side of the terminal block (see Figure 3-9).

Figure 3-9: Terminal Block and Captive Screws

Step 4 Disconnect the DC-input wires from the terminal block. (See Figure 3-9.)

Caution Disconnect the ground wire last.

Step 5 Loosen and remove the captive screws on the sides of the power supply with a screwdriver. (See Figure 3-9.)

Caution Alternate loosening the captive installation screws every one or two turns to avoid skewing the power supply.

Step 6 Grasp the DC power supply handle with one hand and slowly pull the power supply out of the chassis toward you. (See Figure 3-10.)

Figure 3-10: Power Supply Removal and Installation

Step 7 While holding the power supply handle with one hand, place your other hand underneath to support the bottom of the supply, as shown in Figure 3-11.

Figure 3-11: Handling a DC Power Supply

Installing the DC Power Supply

Take the following steps to install a DC power supply:

Caution To avoid problems or damage to the chassis, do not mix DC-input power supplies with AC-input power supplies in individual units.

Step 1 Grasp the DC power supply handle with one hand and place your other hand underneath to support the bottom of the supply, as shown in Figure 3-11.

Step 2 Place the DC power supply into the power supply bay and push the DC power supply into the bay until the power supply faceplate is flush with the cover.

Step 3 Tighten each of the two captive installation screws by turning them clockwise (see Figure 3-9).

Caution Alternate tightening the captive installation screws every one or two turns to avoid skewing the power supply.

Caution Keep hands and fingers out of the power supply bays. Voltage is present on the chassis backplane when the system is operating.

After the installation is complete, continue with the following section, "Connecting DC Power."

Connecting DC Power

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.

Follow these steps to connect the DC power supply to the DC voltage source:

Step 1 Verify that power is off to the DC-input circuit.

Step 2 Ensure that the power switch is OFF (0) on the power supply. (See Figure 3-12.)

Figure 3-12: Power Switch and Terminal Block Connections

Step 3 Remove the terminal block cover by depressing the two plastic levers on each side of the terminal block.

Step 4 Attach the appropriate lugs to the DC-input wires.

Step 5 From the top of the terminal block, wire the DC-input power supply to the terminal block as follows. (See Figure 3-12.)

Caution Connect the ground wire first.

Ground wire to ground connector
Return wire to "+" connector
Battery wire to "-" connector

Note Use 10-12 AWG copper conductor for the above connections.

Note Be sure to route the wires from the top of the terminal block, so that you do not obstruct access to the chassis power switch.

Step 6 After ensuring that all wire connections are secure, reinstall the terminal block cover.

To complete the installation, see the section "Powering On the DC Power Supply"
in this chapter.

Connecting Redundant DC Power

To connect the redundant DC power supply to a separate input line, repeat the steps in the previous section, "Connecting DC Power," but connect the redundant unit to a different DC-input line than the initial power supply.

Powering On the DC Power Supply

Perform the following steps to power on the DC power supply and confirm the installation:

Step 1 Remove the tape from the circuit breaker switch handle, and restore power by moving the switch to the ON position.

Step 2 Connect the redundant DC power supply cord to an input line other than the initial DC power supply line.

Step 3 Turn the power supply power switch ON (-).

Step 4 Verify that the green LED on the power supply front panel is on
(see Figure 3-8). This indicates that the power supply is on and is receiving
DC source power, providing +5, +12, and +24 VDC to internal components, and ensuring that all internal voltages are within tolerance.

Step 5 Verify that the appropriate switch processor PS0 and PS1 LEDs are green (see Figure 3-2).

Step 6 Use the show environment command to display the power supply and system status, as in the following screen example:

8510>show environment
Temperature:                        OK
Fan:                                OK
Voltage:                            OK
Power Supply#0 type: Astec,  status:    OK
Power Supply#1 type: Astec,  status:    OK
8510>

If the LEDs or Show environment command indiacate a power problem or other system problem, refer to the section "Confirming the Installation" in the chapter "Installing the Five-Slot Chassis" and Figure 2-10 for troubleshooting information.

Replacing the Chassis Fan Assembly

This section describes how to replace the fan assembly (the chassis fans in a single unit that draw in cooling air and distribute it across the switch processor and line modules).

Note Each replaceable component ships with installation instructions. Refer to these instructions for updated procedures and information.

Caution Before performing any procedures in this chapter, review the sections "Safety Recommendations," "Ensuring Safety with Electricity," and "Preventing Electrostatic Discharge Damage" in the chapter "Installing the Five-Slot Chassis."

Caution If you are replacing the fan assembly while the unit is operating, make sure the replacement fan assembly is ready to be installed immediately.

The chassis fan assembly draws cooling air in through the front right side of the chassis and exhausts it through the back left side to cool the processor and line modules. The absence of cooling air can cause the interior of the chassis to heat up and can cause an overtemperature condition. Never operate the system if the fan assembly is not
functioning properly.

The fan assembly is located at the left of the chassis card cage. (See Figure 3-13.) The fan assembly is secured to the back panel with two captive installation screws.

Caution Never operate the system if the fan assembly is not functioning properly or if one is not reinstalled quickly. An overtemperature condition can result in severe equipment damage.

Figure 3-13: Chassis Fan Assembly

Tools Required

You need a 3/16-inch flat-blade screwdriver to remove the fan assembly.

Removing the Fan Assembly

Take the following steps to remove the existing chassis fan assembly:

Step 1 Locate the fan assembly (Figure 3-13), which is installed to the left of the card cage, under the power supply.

Step 2 Use a flat-blade screwdriver to loosen each of the two captive installation screws by turning them counterclockwise.

Step 3 loosen both screws and unscrew them from the chassis. These captive installation screws are fixed to the fan assembly; do not attempt to completely remove them.

Step 4 Grasp the fan assembly with both hands and pull it outward (toward you and away from the backplane) using steady pressure and jogging it until it frees the backplane.

Step 5 Lift the fan assembly out of the chassis and place it in a safe place.

If the power has not been turned off, quickly proceed to the following section to reinstall a fan assembly.

Caution Never operate the system if the fan assembly is not functioning properly or if a fan assembly is not quickly reinstalled. An overtemperature condition can result in severe equipment damage.

Installing a New Fan Assembly

Take the following steps to install the new fan assembly:

Step 1 Hold the fan assembly with the two fans facing to the right.

Step 2 Place the fan assembly into the front chassis cavity so it rests on the floor of the chassis, then lift the fan assembly up slightly and align the top and bottom guides.

Step 3 Push the fan assembly into the chassis until the screws meet the chassis.

Step 4 Tighten each of the two captive installation screws.

Checking the Installation

To verify that the new fan assembly is installed correctly, you should immediately hear it operating. If you do not hear it, turn off the system power and ensure that the fan assembly is completely inserted in the chassis and the faceplate is flush with the chassis back panel. If after several attempts the fan assembly does not operate, or if you experience trouble with the installation (for instance, if the captive installation screws do not align with the backplane holes), contact a customer service representative for assistance.

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