Cisco CRS Series User manual

Installing Power Components
This chapter provides instructions on how to install Cisco CRS Enhanced 16-Slot Line Card Chassis power
components.
This chapter presents the following topics:
•Power Systems Overview, page 1
•How to Install Power Components, page 9
•Power Up and Power Down a Chassis, page 50
Power Systems Overview
The chassis power system provides power to chassis components and is made up of two AC or DC power
shelves that contain AC or DC power modules (PMs) and alarm modules.
The AC power system requires single-phase AC input power to the power shelves. If you have 3-phase AC
Delta or AC Wye at your equipment, a Cisco CRS power distribution unit (PDU) will be required to convert
3-phase AC input power to single-phase AC input power for the power shelf. The power system also includes
SNMP MIBS and XML support.
In the AC power system, PDU refers to the Cisco CRS PDU which is required to convert 3-phase AC-Wye
or AC-Delta input power to single-phase AC input power for the AC power shelf. For further information
and installation instructions, refer to the Cisco CRS 3-Phase AC Power Distribution Unit Installation
Guide .
Note
This section contains the following topics:
Basic Chassis Power Details
The Cisco CRS Series Enhanced 16-slot Line Card Chassis can be configured with either an AC-input power
system or a DC-input power system. Site power requirements differ, depending on the source voltage used.
Follow these precautions and recommendations when planning power connections to the router:
•Check the power at your site before installation to ensure that you are receiving clean power. Install a
power conditioner, if necessary.
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•Install proper grounding to avoid damage from lightning and power surges.
The Cisco CRS Series Enhanced 16-slot Line Card Chassis requires that at least one power shelf and its
components be installed to operate properly; however, if you install only one power shelf and its components,
your system will not be 2N redundant.
Two types of power shelves exist: an AC shelf and a DC shelf. An AC power shelf houses the AC PMs, while
a DC power shelf houses the DC PMs. It is required that you use only one type of power shelf, either AC or
DC, in a chassis at a time.
The chassis might have more than one power connection. All connections must be removed to de-energize
the chassis. Statement 1028
Danger
Bonding and Grounding Guidelines
The router chassis has two safety earth ground connections. The chassis allows you to connect the central
office ground system or interior equipment grounding system to the bonding and grounding receptacles on
the router chassis. Threaded ground inserts are located on top of the chassis rear (MSC) side panel to the right
of the lower power shelf. There are also two sets of grounding studs located at the bottom of the rear (MSC)
side of the chassis.
Figure 1: NEBS Bonding and Grounding Points—Top Rear (MSC) Side of Chassis, on page 3 shows the
grounding points at the top on the rear (MSC) side of the chassis. This grounding point is also referred to as
the network equipment building system (NEBS) bonding and grounding point.
These bonding and grounding receptacles are provided to satisfy the Telcordia NEBS requirements for
bonding and grounding connections.
Note
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Bonding and Grounding Guidelines

Do not remove the chassis ground cable unless the chassis is being replaced.Caution
Figure 1: NEBS Bonding and Grounding Points — Top Rear (MSC) Side of Chassis
Two Torx security screws1
The two bolts below the NEBS bonding and grounding points at the top of the chassis are required for
proper bonding and grounding of the chassis and should not be removed.
Note
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Bonding and Grounding Guidelines

Figure 2: NEBS Bonding and Grounding Points—Bottom Rear (MSC) Side of Chassis, on page 4 shows
the NEBS and grounding points at the bottom on the rear (MSC) side of the chassis.
Figure 2: NEBS Bonding and Grounding Points — Bottom Rear (MSC) Side of Chassis
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Bonding and Grounding Guidelines

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Installing Power Components
Bonding and Grounding Guidelines

DC Power Systems
The Cisco CRS Series Enhanced 16-slot Line Card Chassis DC power system can provide up to 16,800 watts
to power the chassis. However, by default, the power capability of a system when shipped, with six DC PMs
per power shelf, is 12,600 watts.
Depending on the hardware deployed at your site, your system may not consume the maximum power
supplied by the power system.
Note
Each DC powered chassis contains two DC power shelves for 2N redundancy. The shelves contain the input
power connectors. Each shelf can accept up to eight DC PMs. The power shelves and DC PMs are field
replaceable.
Figure 3: DC Power Shelf Cable Wiring for Power Shelf , on page 6 shows the cable wiring for the power
shelf.
Figure 3: DC Power Shelf Cable Wiring for Power Shelf
Each power shelf operates with up to eight DC inputs of –48/–60 VDC (nominal), 60A. The power shelf
accepts input DC power in the range –40 to –72 VDC.
Table 1: DC Input Current and Voltage Information, on page 7 lists the DC input current and voltage
specifications.
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DC Power Systems

Table 1: DC Input Current and Voltage Information
–48 VDC North America–60 VDC European
Community(range: –40 VDC to –72 VDC)
Nominal input voltage
50 A maximum at –48 VDC40 A maximum at –60
VDC60 A maximum at –40 VDC
Input line current
Each wiring block on the DC power shelf contains two sets of terminals, one positive and one negative, and
is covered by a plastic terminal block cover that is secured by a screw to a torque of 5 to 7 in.-lb (0.56 to 0.79
N-m). Each DC power cable is connected to the power shelf with a torque of 20 in.-lb (2.26 N-m). Maximum
wire size at the DC input terminal block is 2 AWG.
The power supply terminal posts are centered 0.63 inches (5/8 inch) (1.60 cm) apart and are M6-threaded.
We recommend that you use an appropriately sized 180-degree angle (straight) industry standard 2-hole,
standard barrel compression lug, as shown in Figure 4: DC Power Cable Lug, on page 7.
Figure 4: DC Power Cable Lug
For additional power details, see Appendix A, “Cisco CRS Series Carrier Routing System 16-Slot EC Line
Card Chassis Specifications”or the Cisco CRS Series Carrier Routing System 16-Slot Line Card Chassis
System Description .
Input-Power-Present LEDs
The DC input-power-present LEDs provide a visual indication to service personnel that there is voltage present
across the input terminal connection.
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DC Power Systems

Figure 5: Input-Power-Present LEDS, on page 8 shows the input-power-present LEDs on the rear of the
DC power shelf.
Figure 5: Input-Power-Present LEDS
Power should be disconnected before servicing the input power connection.Note
The input-power-present LED starts to light up when the input voltage reaches –20 VDC and the LED gets
brighter as voltage increases; the input-power-present LED is fully lit when the input voltage reaches –38
VDC.
If the input voltage polarity is reversed, or if the LED circuit fails, the LED will not light. When this is
the case, service personnel should check for hazardous voltages before working on the unit.
Caution
AC Power Systems
The Cisco CRS Series Enhanced 16-slot Line Card Chassis AC power system can provide up to 18,000 watts
to power the chassis. However, by default, the power capability of a system when shipped, with five AC PMs
per power shelf, is 15,000 watts.
Depending on the hardware deployed at your site, your system may not consume the maximum power
supplied by the power system.
Note
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AC Power Systems

Each AC powered chassis contains two AC power shelves for 2N redundancy. The shelves contain the input
power connectors. Each shelf can contain up to six AC PMs. The power shelves and the AC PMs are field
replaceable.
The AC power system requires single-phase AC input power. If you have 3-phase AC Delta or AC Wye at
your equipment, a Cisco CRS PDU will be required to convert 3-phase AC input power to single-phase AC
input power for the power shelf. For further information and installation instructions, refer to the Cisco CRS
3-Phase AC Power Distribution Unit Installation Guide .
The AC power shelf has the following input VAC power requirements:
•Single-phase, 200 to 240 VAC nominal, 50 to 60 Hz, 16 A.
•Each power shelf contains six IEC-320-C22 receptacles which can accept up to six IEC-320-C21
connector plugs.
If you have a Cisco CRS 3-Phase AC PDU installed, six AC PMs are required to be installed in each Cisco
CRS Series Enhanced 16-slot Line Card Chassis AC power shelf to maintain a balanced 3-phase power
load.
Note
We recommend that you use appropriate short-circuit protection in compliance with national and local
electrical codes.
Note
For additional power details, see Appendix A, “Cisco CRS Series Carrier Routing System 16-Slot EC Line
Card Chassis Specifications”or the Cisco CRS Series Carrier Routing System 16-Slot Line Card Chassis
System Description .
How to Install Power Components
This section describes how to install power components in the Cisco CRS Series Enhanced 16-slot Line Card
Chassis.
Although there are differences between the different types of power shelves and PMs (AC and DC), they
are installed using the same procedures.
Note
We recommend that you install the power components in the order outlined in this section. This section
contains the following procedures:
Installing the Power A Bus Bar
This section describes how to install the Power A bus bar on the rear (MSC) side of the Cisco CRS Series
Enhanced 16-slot Line Card Chassis. For complete information on regulatory compliance and safety, see
Regulatory Compliance and Safety Information for the Cisco CRS Carrier Routing System .
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How to Install Power Components

Prerequisites
There are no prerequisites for this task.
Required Tools and Equipment
You need the following tool to perform this task:
•6-in. long number 1 Phillips screwdriver
Steps
To install the Power A bus bar on the chassis, perform the following steps:
SUMMARY STEPS
1. To release the Power A bus bar from the shipping position, loosen the six captive screws that attach the
bus bar shipping bracket to the rear of the chassis. There are two screws on the right side, two screws on
the front, and two screws on the left side of the Power A bus bar shipping bracket. See Figure 6: Removing
the Power A Bus Bar Shipping Bracket, on page 11.
2. Remove the Power A bus bar shipping bracket form the chassis and set it aside.
3. Remove the Power A bus bar from the rear of the chassis. See Figure 7: Removing the Cover From the
Power A Bus Bar, on page 12.
4. Remove the cover from the Power A bus bar by loosening the two captive screws that attach the cover to
the bus bar. See Figure 7: Removing the Cover From the Power A Bus Bar, on page 12.
5. Position the power block vertically. Mate the power block pivot and chassis pivot point together. See item
2 in Figure 8: Power A Bus Bar Installed in Chassis, on page 14.
6. Unscrew the two handle screws on the power bus bar and open the handle. See item 3 on Figure 8: Power
A Bus Bar Installed in Chassis, on page 14.
7. Hold the power block cable to the side to keep clear of the power block connectors while seating the power
block.
8. Seat the power block and tighten the two screws on the handle. See item 3 in Figure 8: Power A Bus Bar
Installed in Chassis, on page 14.
9. Tighten the Phillips captive screw that secures the tab on the left side of the power block to the chassis.
See item 1 in Figure 8: Power A Bus Bar Installed in Chassis, on page 14.
DETAILED STEPS
Step 1 To release the Power A bus bar from the shipping position, loosen the six captive screws that attach the bus bar shipping
bracket to the rear of the chassis. There are two screws on the right side, two screws on the front, and two screws on the
left side of the Power A bus bar shipping bracket. See Figure 6: Removing the Power A Bus Bar Shipping Bracket, on
page 11.
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Installing Power Components
Installing the Power A Bus Bar

The Power A bus bar is pre-attached to the top rear of the chassis in a horizontal position using a bus bar shipping
bracket, due to shipping height restrictions.
Note
Figure 6: Removing the Power A Bus Bar Shipping Bracket
Captive screws securing Power A bus bar bracket to rear
of chassis
1
Step 2 Remove the Power A bus bar shipping bracket form the chassis and set it aside.
Step 3 Remove the Power A bus bar from the rear of the chassis. See Figure 7: Removing the Cover From the Power A Bus
Bar, on page 12.
The Power A bus bar is connected to the chassis with an internal cable. Be careful not to drop the power bus
bar.
Note
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Installing the Power A Bus Bar

Step 4 Remove the cover from the Power A bus bar by loosening the two captive screws that attach the cover to the bus bar.
See Figure 7: Removing the Cover From the Power A Bus Bar, on page 12.
Figure 7: Removing the Cover From the Power A Bus Bar
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Installing the Power A Bus Bar

Internal cable connection1
Screws attaching cover to Power A bus bar2
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Installing Power Components
Installing the Power A Bus Bar

Step 5 Position the power block vertically. Mate the power block pivot and chassis pivot point together. See item 2 in Figure
8: Power A Bus Bar Installed in Chassis, on page 14.
Step 6 Unscrew the two handle screws on the power bus bar and open the handle. See item 3 on Figure 8: Power A Bus Bar
Installed in Chassis, on page 14.
Step 7 Hold the power block cable to the side to keep clear of the power block connectors while seating the power block.
Step 8 Seat the power block and tighten the two screws on the handle. See item 3 in Figure 8: Power A Bus Bar Installed in
Chassis, on page 14.
Figure 8: Power A Bus Bar Installed in Chassis
Captive screw securing Power A bus bar to chassis1
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Installing the Power A Bus Bar

Chassis pivot point2
Two screws securing handle to Power A bus bar3
Step 9 Tighten the Phillips captive screw that secures the tab on the left side of the power block to the chassis. See item 1 in
Figure 8: Power A Bus Bar Installed in Chassis, on page 14.
What to Do Next
After the Power A bus bar has been installed, install the upper grille support. Continue to the Installing the
Upper Grille Support, on page 15 for more information.
Installing the Upper Grille Support
This section describes how to install the upper grille support on the Cisco CRS Series Enhanced 16-slot Line
Card Chassis. For complete information on regulatory compliance and safety, see Regulatory Compliance
and Safety Information for the Cisco CRS Carrier Routing System .
Although the upper grille support is an exterior cosmetic component, it must be installed prior to installing
the upper chassis ground cable and the power shelves.
Prerequisites
Before performing this task, perform the following procedure:
Required Tools and Equipment
You need the following tools and equipment to perform this task:
•6-in. long number 1 Phillips screwdriver
•Upper grille support
Steps
To attach the upper grille support to the chassis, perform the following steps:
SUMMARY STEPS
1. Attach the upper grille support to the front of the chassis. Use the screwdriver to install the six M4 flat
head screws, three on each side, to the chassis. See Figure 9: Attaching the Upper Grille Support to the
Chassis, on page 16.
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Installing Power Components
Installing the Upper Grille Support

DETAILED STEPS
Attach the upper grille support to the front of the chassis. Use the screwdriver to install the six M4 flat head screws, three
on each side, to the chassis. See Figure 9: Attaching the Upper Grille Support to the Chassis, on page 16.
Figure 9: Attaching the Upper Grille Support to the Chassis
What to Do Next
After the upper grille support has been installed, attach the unistruts. Continue to the Installing the Unistruts,
on page 16 for more information.
Installing the Unistruts
This section describes how to install the unistruts on the Cisco CRS Series Enhanced 16-slot Line Card Chassis.
For complete information on regulatory compliance and safety, see Regulatory Compliance and Safety
Information for the Cisco CRS Carrier Routing System .
Although the unistruts are exterior cosmetic components, they should be installed prior to installing the upper
chassis ground cable and the power shelves.
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Installing Power Components
Installing the Unistruts

Prerequisites
Before performing this task, perform the following procedures:
Required Tools and Equipment
You need the following tools and equipment to perform this task:
•8mm hex bit socket
•3/8-in. drive ratchet wrench
•Torque wrench with 13-mm hex key and rated accuracy at 40 to 50 in.-lb (4.52 to 5.65 N-m)
•Unistruts
Steps
To attach the unistruts to the chassis, perform the following steps:
SUMMARY STEPS
1. Attach each unistrut to the top of the chassis by inserting four M12 hex head bolts and washers, two for
each strut, into the bolt holes on the inside of the strut, and tightening with the 8mm hex bit socket and
ratchet wrench. The closed end of a unistrut faces the front (PLIM) side of the chassis. See Figure 10:
Attaching the Unistrut, on page 18.
DETAILED STEPS
Attach each unistrut to the top of the chassis by inserting four M12 hex head bolts and washers, two for each strut, into
the bolt holes on the inside of the strut, and tightening with the 8mm hex bit socket and ratchet wrench. The closed end
of a unistrut faces the front (PLIM) side of the chassis. See Figure 10: Attaching the Unistrut, on page 18.
The left unistrut (as you face the front [PLIM] side of the chassis) has a cutaway in the rear to admit the chassis
ground cable; the right unistrut does not. The right unistrut as viewed from the front PLIM side of the router
has a bolt position that is 6.5 inches from the end at the rear of the router.
Note
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Installing the Unistruts

Cisco recommends an install torque range for the unistrut bolts between 40 and 50 to in.-lb (between 4.52
N-m and 5.65 N-m).
Caution
Figure 10: Attaching the Unistrut
Cutaway for ground cable3Upper grille support1
Unistruts2
What to Do Next
After the upper grille support has been installed, install the chassis ground cable. Continue to the Installing
the Chassis Ground Cable, on page 19 for more information.
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Installing the Unistruts

Installing the Chassis Ground Cable
This section describes how to install the chassis ground cable on the Cisco CRS Series Enhanced 16-slot Line
Card Chassis. For complete information on regulatory compliance and safety, see Regulatory Compliance
and Safety Information for the Cisco CRS Carrier Routing System .
Prerequisites
Before performing this task, perform the following procedures:
Required Tools and Equipment
You need the following tools and equipment to perform this task:
•Ground lug
•Ground cable
•Crimping tool and lug specific die
•3/8 in. drive socket wrench
•10-mm 6 pt. socket
•Torque wrench with 10-mm 6 pt. socket and rated accuracy at 30 in.-lb (3.39 N-m)
To ensure a satisfactory ground connection, you also need the following parts:
•One 180-degree angle (straight) grounding lug that has two M6 bolt holes with 0.63 inches (5/8 inch)
(1.60 cm) of spacing center to center between them and a 6 AWG or larger multistrand copper wire.See
Figure 11: 180-Degree (Straight) Chassis Ground Lug, on page 19.
Figure 11: 180-Degree (Straight) Chassis Ground Lug
•Two M6 hex head bolts and integrated locking washers are pre-installed on the chassis.
•Cisco recommend at least 6 AWG multistrand copper ground cable. This cable is not available from
Cisco Systems; it is available from any commercial cable vendor. The cable should be sized according
to local and national installation requirements.
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Installing the Chassis Ground Cable

The DC return of this system should remain isolated from the system frame and chassis (DC-I: Isolated
DC Return).
Note
Steps
To attach the ground cable to the chassis, perform the following steps:
SUMMARY STEPS
1. Use the crimping tool mandated by the lug manufacturer to crimp the lug to the ground cable.
2. Using the 10-mm wrench, attach the ground cable to the upper grounding point as shown in Figure 12:
NEBS Bonding and Grounding Points—Top of Chassis, on page 21 for overhead grounding. Use the
optional lower grounding point, as shown in Figure 13: NEBS Bonding and Grounding Points—Bottom
of Chassis, on page 22 if the ground cable is run from under a raised floor.
3. Use the torque wrench to tighten to a torque of 30 in.-lb (3.39 N-m).
4. Connect the other end of the ground cable to a grounding point at your site, according to site requirements.
DETAILED STEPS
Step 1 Use the crimping tool mandated by the lug manufacturer to crimp the lug to the ground cable.
Step 2 Using the 10-mm wrench, attach the ground cable to the upper grounding point as shown in Figure 12: NEBS Bonding
and Grounding Points—Top of Chassis, on page 21 for overhead grounding. Use the optional lower grounding point,
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Installing the Chassis Ground Cable