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This chapter describes how to perform the following removal and replacement procedures for Catalyst 5000 series field-replaceable units (FRUs):
For instructions on installing and replacing switching modules, refer to the Catalyst 5000 Series Module Installation Guide.
For instructions on upgrading a Supervisor Engine III with the NetFlow Feature Card (NFFC), refer to the Catalyst 5000 Series Multilayer Switching User Guide.
Warning Do not touch the power supply when the power cord is connected. For systems with a power switch, note that 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, note that line voltages are present within the power supply when the power cord is connected.
Warning This unit might have more than one power cord. To reduce the risk of electric shock, disconnect the two power supply cords before servicing the unit.
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 See the installation instructions before you connect the system to its power source.
Caution The Catalyst 5000 series switch is intended for installation in restricted access areas.
Caution The supervisor engine is a required system component. If only one supervisor engine is present, removing a supervisor engine while the system is operating causes the system to halt.
Caution To avoid erroneous failure messages, note the current configuration of all interfaces before you remove or replace another switching module, and allow at least 15 seconds for the system to reinitialize after a module has been removed or replaced.
The ejector levers on the supervisor engine and switching modules align and seat the module connectors in the backplane (see Figure 7-1). Failure to use the ejector levers to insert the module can disrupt the order in which the pins make contact with the backplane. Follow the installation and removal instructions carefully.
When removing a module, use the ejector levers to ensure that the module connector pins disconnect from the backplane properly. Any supervisor engine or switching module that is only partially connected to the backplane can disrupt the system. Detailed instructions for removing and installing switching modules are described in the Catalyst 5000 Series Module Installation Guide.
Use a flat-blade screwdriver to remove any filler (blank) modules and to tighten the captive installation screws that secure the modules in their slots. When you handle modules, use a wrist strap or other grounding device to prevent electrostatic discharge (ESD) damage. See Appendix C, "Preventing ESD Damage," for ESD details including the locations of the ESD connectors on the Catalyst 5000 series switches.
Before you remove a supervisor engine, you should first upload the current configuration to a server. This saves time when bringing the module back online. You can recover the configuration by downloading it from the server to the nonvolatile memory of the supervisor engine.
To remove a supervisor engine, perform these steps:
Step 1 If you do not plan to immediately reinstall the supervisor engine you are removing, disconnect any network interface cables attached to the module ports.
Step 2 Use a screwdriver to loosen the captive installation screws at the left and right sides of the module.
Step 3 Grasp the left and right ejector levers and simultaneously pull the left lever to the left and the right lever to the right to release the module from the backplane connector.
Step 4 Grasp the handle of the module with one hand and place your other hand under the carrier to support and guide the module out of the slot. Avoid touching the module itself.
Step 5 Carefully pull the module straight out of the slot, keeping your other hand under the carrier to guide it. Keep the module at a 90-degree orientation to the backplane.
Step 6 Place the removed module on an antistatic mat or antistatic foam.
Step 7 If the slot is to remain empty, install a module filler plate to keep dust out of the chassis and to maintain proper airflow through the module compartment.
Caution Always install a switching module filler plate in empty switching module slots to maintain the proper flow of cooling air across the modules.
To replace the supervisor engine, follow Steps 1 through 7 in the section "Removing the Supervisor Engine," in reverse order. Note that the supervisor engine must go in a specific slot:
This section describes how to remove and replace supervisor engine uplink modules. If you have a supervisor engine with an uplink module already installed and you are replacing the uplink module, use the "Replacing an Uplink Module" procedure. If you are installing an uplink module into a supervisor engine with no uplink module, use the "Adding an Uplink Module" procedure.
Use this procedure to remove and replace an uplink module:
Step 1 If not already removed, remove the supervisor engine from the Catalyst 5000 series switch following the "Removing the Supervisor Engine" procedure in this chapter.
Step 2 Use a Phillips-head screwdriver to remove the four screws securing the uplink module to the supervisor engine as shown in Figure 7-2.
Step 3 Carefully pull the uplink module up and out of the supervisor engine. Note that the rear of the uplink module connects to the supervisor engine through connectors on the bottom side of the uplink module. Use care when unseating the uplink module from these connectors.
Step 4 Place the removed uplink module in an antistatic bag.
Step 5 Remove the new uplink module from the its antistatic bag and install it in the supervisor engine. Use care when seating the rear of the uplink module into the connectors.
Step 6 Ensure that the uplink module is securely seated in the supervisor engine.
Step 7 Use a Phillips-head screwdriver to install the four screws that secure the uplink module to the supervisor engine.
Step 8 Install the supervisor engine into the Catalyst 5000 series switch following the "Replacing the Supervisor Engine" procedure in this chapter.
Use this procedure to add an uplink module to a supervisor engine with no uplink module:
Step 1 If not already removed, remove the supervisor engine from the Catalyst 5000 series switch following the "Removing the Supervisor Engine" procedure in this chapter.
Step 2 Use a Phillips-head screwdriver to remove the two screws securing the blank uplink module filler plate from the supervisor engine. Set the screws in a secure place as they will be reused.
Step 3 Use a Phillips-head screwdriver to remove the two screws from the two standoffs that will secure the rear of the uplink module. Set the screws in a secure place as they will be reused.
Step 4 Remove the new uplink module from the its antistatic bag and install it in the supervisor engine. Use care when seating the rear of the uplink module into the connectors.
Step 5 Ensure that the uplink module is securely seated in the supervisor engine.
Step 6 Use a Phillips-head screwdriver to install the four screws that secure the uplink module to the supervisor engine (see Figure 7-2).
Step 7 Install the supervisor engine into the Catalyst 5000 series switch following the "Replacing the Supervisor Engine" procedure in this chapter.
The Flash memory (PCMCIA) card slots on the front panel of Supervisor Engine III are for additional PCMCIA-based Flash memory. You can use this Flash memory to store and run Cisco IOS images, or to serve as an I/O device. Occasionally, it might be necessary to remove and replace Flash memory cards; however, removing Flash memory cards is not required and is not recommended after the cards are installed in the slots.
Supervisor Engine III has two PCMCIA slots: slot 0 (bottom) and slot 1 (top). The following procedure is generic and can be used for a Flash memory card in either slot position.
Before you install a card, verify that the Flash memory card is set with write protection off. The write-protect switch is located on the front edge of the card when oriented with the printing right side up and the edge connector end away from you. (See Figure 7-3.)
Use this procedure for installing and removing a Flash memory card:
Step 1 Face the front panel of the switch and hold the Flash memory card with the connector end of the card toward the slot. The connector end of the card is opposite the end with the write-protection switch, which is shown in Figure 7-3.
Step 2 Insert the card into the appropriate slot until the card completely seats in the connector at the back of the slot and the eject button pops out toward you. Note that the card does not insert all the way inside the slot; a portion of the card remains outside the slot. Do not attempt to force the card past this point.
Step 3 To eject a card, press the appropriate ejector button until the card is free of the connector at the back of the slot.
Step 4 Remove the card from the slot and place it in an antistatic bag.
This section describes how to remove and install power supplies for the Catalyst 5000, Catalyst 5505, and Catalyst 5500 switches. A flat-blade screwdriver is required to perform these procedures.
Warning This warning applies to Catalyst 5500 AC-input power supplies only. To remove a Catalyst 5000 or Catalyst 5505 power supply, use the procedure following this warning.
There is a design problem that might affect a small percentage of Catalyst 5500 AC-input power supplies. Potentially affected are AC-input power supplies shipped as spares and AC-input power supplies shipped with chassis orders between December 1996 and December 1997. If these power supplies are not handled with caution, you might experience a mild shock. We do not believe that the risk associated with this design problem is significant. We believe that the current design is safe when the power supply is handled correctly. Use the following procedure to safely remove AC-input power.
Remove power from the AC-input power supply as follows:
Step 1 Remove the power cord from the building power receptacle. Do not touch the metal prongs (see Figure 7-4) on the power cord when it is still connected to the power connection on the power supply.
Step 2 Turn OFF the power switch on the power supply you are removing.
Step 3 Remove the power cord from the power connection on the supply. Do not touch the metal prongs embedded in the power supply.
Step 4 Continue the power supply removal with Step 4 in the following procedure.
The power supply manufacturer, with technical assistance from Cisco, has implemented a design change to correct the problem. In addition, we will provide replacement AC-input power supplies to any customer upon request at no cost to the customer. To arrange for a replacement, please contact Cisco Systems Customer Services at 800 553-NETS (6387), 408 526-7208, or e-mail cs-rep@cisco.com. If you need further technical assistance, please contact the Technical Assistance Center (TAC) at 800 553-24HR (2447) or e-mail tac@cisco.com.
Caution Do not mix AC- and DC-input power supplies in the same switch.
Follow these steps to remove an AC-input power supply:
Step 1 Turn OFF the power switch on the power supply you are removing (see Figure 7-4). (For Catalyst 5500 power supplies, follow the procedure in the above warning.)
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.
Caution Failure to turn off the power supply could result in equipment damage.
Step 2 Disconnect the power cord from the power source.
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.
Step 3 Disconnect the power cord from the power supply being removed.
Step 4 Use a flat-blade screwdriver to loosen and remove the captive installation screw(s) (see Figure 7-4).
Caution Catalyst 5505 and Catalyst 5000--Make sure you turn the captive installation screws simultaneously. If you fail to do this, the power supply might stick in the chassis and damage the captive installation screws.
Caution Use both hands to install and remove power supplies.
Step 5 Grasp the power supply handle with one hand and place your other hand underneath to support the bottom of the supply, as shown in Figure 7-5 (Catalyst 5000 supply shown).
Warning Keep your hands and fingers out of the power supply bays. High current is present on the power backplane when the system is operating.
Step 6 Pull the supply out of the bay and put it aside.
Step 7 If the power supply bay is to remain empty, install a blank power supply filler plate over the opening; secure it with the mounting screws.
Caution Always install a filler plate over an empty power supply bay, not only to protect the inner chassis and connectors from dust or other contamination, but to prevent possible contact with the high current levels of those connectors when the chassis is powered on.
Follow these steps to install an AC-input power supply:
Step 1 Turn OFF the power switch on the power supply you are installing (see Figure 7-4).
Caution Failure to turn off the power supply could result in equipment damage.
Caution Use both hands to install and remove power supplies. Each power supply weighs as follows:
Warning Keep your hands and fingers out of the power supply bays. High current is present on the power backplane when the system is operating.
Step 2 Grasp the power supply handle with one hand and place your other hand underneath to support the bottom of the supply, as shown in Figure 7-5.
Step 3 Slide the power supply all the way into the power supply bay.
Step 4 Use a flat-blade screwdriver to tighten the captive installation screw(s) (see Figure 7-4).
Caution Catalyst 5505 and Catalyst 5000--Make sure you turn the captive installation screws simultaneously. If you fail to do this, the power supply might stick in the chassis and damage the captive installation screws.
Step 5 Prior to connecting the power supply to a power source, ensure that all site power and grounding requirements described in Chapter 3, "Site Planning" have been met.
Step 6 Plug the power cord into the power supply.
Step 7 Connect the other end of the power cord to an AC-power input source.
Caution In a system with dual power supplies, connect each power supply to a separate input source. In case of a power source failure, the second source will most likely still be available and can maintain maximum overcurrent protection for each power connection.
Step 8 Turn the power switch to the ON position on the power supply.
Step 9 Verify power supply operation.
Catalyst 5505 and Catalyst 5000--Verify that the green LED on the power supply front panel is ON. This indicates that the power supply is on and receiving AC source power, providing +5, +12, and +24 VDC to internal components, and all internal voltages are within tolerance.
Catalyst 5500--Verify that the power supply front panel LEDs are in the following states:
Catalyst 5505, Catalyst 5000, and Catalyst 5500--Verify that the appropriate supervisor engine module PS1 and PS2 LEDs are ON and green.
Enter the show system command to display the power supply and system status.
If the LEDs or show system command indicate a power or other system problem, see Chapter 6, "Troubleshooting the Installation," for troubleshooting information.
Follow these steps to remove a DC-input power supply:
Step 1 Verify that power is OFF to the DC circuit on the power supply you are removing.
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 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.
Step 2 Turn the power switch to the OFF (0) position on the power supply you are removing (see Figure 7-6).
Step 3 Remove the terminal block cover as follows (see Figure 7-6):
Catalyst 5505 and Catalyst 5000--Press down the two plastic levers on each side of the terminal block cover and then remove the cover.
Catalyst 5500--Remove the two screws securing the terminal block cover and slide the cover straight off the terminal block.
Step 4 Disconnect the DC-input wires from the terminal block. Disconnect the ground wire last.
Step 5 Disconnect the central office (CO) ground from the CO ground connector shown in Figure 7-7.
Step 6 Use a screwdriver to loosen and remove the captive screw(s) on the power supply (see Figure 7-6).
Caution Catalyst 5505 and Catalyst 5000--Make sure you turn the captive installation screws simultaneously. If you fail to do this, the power supply might stick in the chassis and damage the captive installation screws.
Caution Use both hands to remove and install power supplies.
Step 7 Grasp the power supply handle with one hand and place your other hand underneath as you slowly pull the power supply out of the bay (see Figure 7-8).
Warning Keep hands and fingers out of the power supply bays. High voltage is present on the power backplane when the system is operating.
Step 8 If the bay is to remain empty, install a blank power supply filler plate (Cisco part number 700-00177-01) 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.
Caution Always install a filler plate over an empty power supply bay, not only to protect the inner chassis and connectors from dust or other contamination, but to prevent possible contact with the high current levels of those connectors when the chassis is powered on.
Step 9 Reinstall the power supply terminal block cover.
Follow these steps to install a DC-input power supply:
Step 1 Verify that power is OFF to the DC circuit on the power supply you are installing.
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 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.
Step 2 Connect the switch to the CO ground through the CO ground connector shown in Figure 7-7. Remove the adhesive strip covering the CO ground connector on the switch.
Use the following guidelines when connecting the switch to the CO ground.
Step 3 Turn the power switch to the OFF (0) position on the power supply you are installing (see Figure 7-5).
Caution Use both hands to remove and install power supplies.
Warning Keep hands and fingers out of the power supply bays. High voltage is present on the power backplane when the system is operating.
Step 4 Grasp the power supply handle with one hand and place your other hand underneath as you slowly insert the power supply into the bay (see Figure 7-8).
Step 5 Use a screwdriver to tighten the captive screw(s) on the power supply (see Figure 7-6).
Caution Catalyst 5505 and Catalyst 5000--Make sure you turn the captive installation screws simultaneously. If you fail to do this, the power supply might stick in the chassis and damage the captive installation screws.
Step 6 Remove the terminal block cover as follows (see Figure 7-6):
Catalyst 5505 and Catalyst 5000--Press down the two plastic levers on each side of the terminal block cover and remove the cover.
Catalyst 5500--Remove the two screws securing the terminal block cover and slide the cover straight off the terminal block.
Step 7 Attach the appropriate lugs to the DC-input wires. Maximum width of the lugs is 0.300 inch (7.6 mm). Suggested lugs are AMP 322985 or 52941. Suggested DC-input wires are 8 AWG (Catalyst 5500) and 10 to 12 AWG (Catalyst 5000 and Catalyst 5505), 90-degree copper conductors.
Caution When stranded wiring is required, use approved wiring terminations, such as closed-loop or spade-type with upturned lugs. These terminations should be the appropriate size for the wires and should clamp both the insulation and conductor.
Step 8 Connect the DC-input wires to the terminal block.
Catalyst 5505 and Catalyst 5000--From the top of the terminal block, connect the DC-input wires to the terminal block as follows (see Figure 7-9):
Catalyst 5500--If not already done, route the DC-input power cable through the conduit from your power source, through the conduit bracket on the power supply and make a sufficient length of wire available to attach to the three terminal block connections.
Attach and tighten the conduit to the conduit bracket. How this conduit is attached depends on your site; its attachment is beyond the scope of this publication.
Connect the DC-input wires to the terminal block (see Figure 7-10). The proper wiring sequence is ground to ground, positive to positive (line to L), and negative to negative (neutral to N). You should always connect the ground wire first and disconnect the ground wire last.
Caution Connect the ground wire first.
Step 9 After ensuring that all wire connections are secure, reinstall the terminal block cover.
Caution To prevent a short-circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal block cover.
Caution The DC power supply terminal block is shown in Figure 7-10. Wire the DC power supply using the appropriate lugs at the wiring end, as illustrated. The proper wiring sequence is ground to ground, positive to positive (line to L), and negative to negative (neutral to N). You should always connect the ground wire first and disconnect the ground wire last.
Caution In a system with dual power supplies, use the modular power cord to connect each power supply to a separate input line. In case of a line failure, the second source will most likely still be available and can maintain maximum overcurrent protection for each power connection.
Step 10 Remove the tape from the circuit breaker switch handle and restore power by moving the circuit breaker switch handle to the ON position.
Warning See the installation instructions before you connect the system to its power source.
Step 11 Turn the power switch to the ON position on the power supply.
Step 12 Verify power supply operation.
Catalyst 5505 and Catalyst 5000--Verify that the green LED on the power supply front panel is ON. This indicates that the power supply is on and receiving DC source power, providing +5, +12, and +24 VDC to internal components, and all internal voltages are within tolerance.
Catalyst 5500--Verify that the power supply front panel LEDs are in the following states:
Catalyst 5505, Catalyst 5000, and Catalyst 5500--Verify that the appropriate supervisor engine module PS1 and PS2 LEDs are ON and green.
Enter the show system command to display the power supply and system status.
If the LEDs or show system command indicate a power or other system problem, see Chapter 6, "Troubleshooting the Installation."
Follow the steps in this section to connect the DC-input wires to the DC-input power supplies.
In addition to the warning statements in this procedure, ensure that the following safety requirements are met:
Warning This product relies on the building's installation for short-circuit (overcurrent) protection. Ensure that a Listed and Certified fuse or circuit breaker no larger than 60 VDC, 15 A is used on all current-carrying conductors.
Warning This unit is intended for installation in restricted access areas. A restricted access area is where access can only be gained by service personnel through the use of a special tool, lock and key, or other means of security, and is controlled by the authority responsible for the location.
Warning A readily accessible two-poled disconnect device must be incorporated in the fixed wiring.
The required tools and materials are as follows:
Perform the following steps to connect the DC-input wires:
Step 1 Turn power OFF to the DC-input circuit.
Warning Before performing this procedure, ensure that power is removed from the DC-input 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 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.
Step 2 Connect the switch to the CO ground through the CO ground point (located at the lower left side of the switch). First remove the adhesive strip covering the CO ground point on the switch, and then make your ground connection.
Step 3 Connect the DC-input wires to the terminal block as follows (see Figure 7-11):
(a) Using a small flathead screwdriver, loosen the three screws on the terminal block.
Warning When installing the unit, the ground connection must always be made first and disconnected last.
(b) From the top of the terminal block, insert the input wires as follows:
(c) Tighten the three screws, ensuring that each input wire is securely connected.
(d) Repeat steps 3a through 3c for the other terminal block.
Step 4 Remove the tape from the circuit breaker switch handle and restore power by moving the circuit breaker switch handle to the ON position.
Step 5 Verify power supply operation as follows:
(a) Listen for the system fans and ensure that the fan LED on the supervisor engine module is green.
(b) While the system initializes, check that the SYSTEM STATUS LED on the supervisor engine is orange until the boot is complete.
Some interface LEDs might go on or blink for a short time. Some LEDs, such as the LINK LED, stay on during the entire boot process. If you already configured an interface, the LEDs might be on steadily as they detect traffic on the line. Wait until the system boot is complete before attempting to verify the switching module LED indications.
(c) When the system boot is complete (it takes a few seconds), the supervisor engine begins to initialize the switching module.
During initialization, the LEDs on the switching module behave differently (most flash on and off). The STATUS LED on the switching module goes on when initialization is complete, and the console screen displays a script and system banner. When switching module LEDs are on, this does not necessarily mean that the interface ports are functional or enabled. Although the LEDs for many interface types go on at the initial system startup, they do not indicate an accurate status until you configure the interface. For detailed module-specific LED descriptions, refer to the Catalyst 5000 Series Module Installation Guide.
(d) Enter the show system command to display the power supply and system status.
(e) Check the LEDs or the show system command display for an indication of a power or other system problem. If a problem is observed, see Chapter 6, "Troubleshooting the Installation."
Install the terminal block cover as follows (see Figure 7-12):
Step 1 Remove the outer screw from each terminal block. Set the screws in a secure place as they will be reused.
Step 2 Screw the two standoff posts into the two outer screw holes. Do not overtighten the standoff posts.
Step 3 Position the terminal block cover over the terminal block while carefully routing the input wires out the side of the cover.
Step 4 Secure the terminal block cover using the two screws removed earlier.
Step 5 Return to step 4 of the installation procedure.
This section describes how to remove and install chassis fan assemblies for the Catalyst 5505, Catalyst 5000, and Catalyst 5500 switches. A flat-blade screwdriver is required to perform this procedure.
Perform these steps to remove the existing chassis fan assembly:
Caution Never operate the system if the fan assembly is removed or if it is not functioning properly. An overtemperature condition can result in severe equipment damage.
Step 1 Locate the fan assembly to the left of the card cage (see Figure 7-13 for the Catalyst 5505 and Catalyst 5000, Figure 7-14 for the Catalyst 5500).
Step 2 Loosen the two captive installation screws by turning them counterclockwise.
Step 3 Grasp the fan assembly with both hands and pull it outward, joggle it if necessary to unseat it from the backplane. Pull it clear of the chassis and place it in a safe place.
Perform these steps to install the new fan assembly:
Step 1 Hold the fan assembly with the fans facing to the right.
Step 2 Place the fan assembly into the front chassis cavity so it rests on the chassis, and then lift the fan assembly up slightly aligning the top and bottom guides.
Step 3 Push the fan assembly into the chassis until the captive installation screws meet the chassis.
Step 4 Tighten the captive installation screws by turning them clockwise.
Perform these steps to verify that the new fan assembly is installed correctly:
Step 1 Listen for the fans; you should immediately hear them operating. If you do not hear them, ensure that the fan assembly is completely inserted in the chassis and the faceplate is flush with the switch back panel.
Step 2 If after several attempts the fans do not operate, or if you experience trouble with the installation (for instance, if the captive installation screws do not align with the chassis holes), contact a Cisco customer service representative for assistance.
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