Cisco 7200 Series Subchassis and Fan Tray Replacement Instructions

This document explains how to remove and replace the subchassis and the fan tray in the Cisco 7200 series routers. It includes instructions for powering down the router, removing the subchassis, removing the fan tray from the subchassis, installing a new fan tray in a new subchassis, and installing the new subchassis in the router. This document also includes steps for verifying a successful router boot after powering up the router.

The fan tray is housed in the subchassis; therefore, you must remove the subchassis from the router to gain access to the fan tray. The router midplane is part of the subchassis. To replace the router midplane, you must replace the entire subchassis.

Note Use this document in conjunction with the Cisco 72xx Installation and Configuration Guide that shipped with your Cisco 7200 series router.

The following sections are included in this document:

Additional Information

The Cisco Internetwork Operating System (Cisco IOS) software running your router contains extensive features and functionality. The effective use of many of these features is easier if you have more information at hand.

Cisco documentation and additional literature are available on a CD-ROM called Cisco Connection Documentation, Enterprise Series, which ships with your chassis. The CD is updated and shipped monthly, so it might be more up to date than printed documentation. To order additional copies of the Cisco Connection Documentation, Enterprise Series CD, contact a Cisco Sales or Customer Service representative. You can also access Cisco technical documentation on the World Wide Web URL http://www.cisco.com.

For additional information on configuring the Cisco 7200 series routers, the following documentation resources are available to you:

Cisco Connection Documentation, Enterprise Series CD-ROM
For systems with Cisco IOS Release 11.1(6), a Cisco-approved Release 11.1(6) beta software version, or a later Cisco IOS release, refer to the following modular configuration and modular command reference publications, as appropriate for your configuration:
- Configuration Fundamentals Configuration Guide
- Configuration Fundamentals Command Reference
- Wide-Area Networking Configuration Guide
- Wide-Area Networking Command Reference
- Network Protocols Configuration Guide
- Network Protocols Command Reference
- Bridging and IBM Networking Configuration Guide
- Bridging and IBM Networking Command Reference
- Configuration Builder Getting Started Guide
- Troubleshooting Internetworking Systems
For hardware installation and maintenance information on the Cisco 7200 series routers, refer to the Cisco 72xx Installation and Configuration Guide that shipped with your router.
To obtain general information about documentation, refer to the section "Cisco Connection Online," on page 31, or call Customer Service at 800 553-6387 or 408 526-7208. Customer Service hours are 5:00 a.m. to 6:00 p.m. Pacific time, Monday through Friday (excluding Cisco-observed company holidays). You can also send e-mail to cs-rep@cisco.com. You can also refer to the Cisco Information Packet that shipped with your router.

Product Overview

The following sections give brief overviews of the Cisco 7200 series routers, the subchassis, and the fan tray.

Cisco 7200 Series Overview

The Cisco 7200 series consists of the four-slot Cisco 7204 and the six-slot Cisco 7206. The Cisco 7200 series routers support multiprotocol, multimedia routing and bridging with a wide variety of protocols and any combination of Ethernet, Fast Ethernet, Token Ring, Fiber Distributed Data Interface (FDDI), and serial media. Network interfaces reside on port adapters that provide a connection between the routers' three Peripheral Component Interconnect (PCI) buses and external networks. Port adapters can be placed in any available port adapter slot, in any desired combination.

The front of the Cisco 7200 series routers provides access to an Input/Output (I/O) controller and up to four or six network interface port adapters. The I/O controller has a local console port for connecting a data terminal (or data terminal equipment [DTE]) and an auxiliary port for connecting a modem (or other data communications equipment [DCE]) or other devices for configuring and managing the router; two Personal Computer Memory Card International Association (PCMCIA) slots for Flash memory cards; and an optional Fast Ethernet port. The Fast Ethernet port provides a 100-Mbps connection to the network. Figure 1 shows the Cisco 7204. Figure 2 shows the Cisco 7206.

Note The I/O controller is available with or without a Fast Ethernet port. Figure 1 and Figure 2 show an I/O controller with a Fast Ethernet port.

Figure 1 : Cisco 7204---Front View

Figure 2 : Cisco 7206---Front View

The port adapters installed in the Cisco 7200 series routers are of the same type as those installed on the second-generation Versatile Interface Processors (VIP2s) in the Cisco 7000 family routers. The port adapters installed in the Cisco 7200 series routers support online insertion and removal (OIR).

Port adapter slots in the Cisco 7200 series are numbered from left to right, beginning with port adapter slot 1 and continuing through port adapter slot 4 for the Cisco 7204, and slot 6 for the Cisco 7206. Port adapter slot 0 is the Fast Ethernet port on the I/O controller. Figure 3 shows the port adapter slot numbering for the Cisco 7206.

Note In Figure 3, a blank port adapter is installed in port adapter slot 5. To ensure adequate airflow across the router's internal components, ensure that each port adapter slot is filled with either a port adapter or a blank port adapter.

Figure 3 : Port Adapter Slot Numbering---Cisco 7206 Shown

The rear of the Cisco 7200 series routers provides access to the network processing engine and up to two 280W, AC-input or DC-input power supplies (refer to Figure 4).

Figure 4 : Cisco 7200 Series Router---Rear View

The network processing engine has no external connectors or LEDs. There are two handles for removing and installing the network processing engine and two captive installation screws for securing it to the chassis.

A fully configured Cisco 7200 series router operates with only one installed power supply; however, a second, optional power supply provides hot-swappable, load-sharing, redundant power. The power supply has the router's main power switch and either an AC-input power receptacle, or a hardwired DC-input power cable (depending on the type of installed power supply). Adjacent to the power supply bays there is a 10 x 32-inch chassis ground receptacle that provides a chassis ground connection for ESD equipment or a grounding wire (refer to Figure 4).

Note The Cisco 7200 routers come equipped with either one 280W AC-input or one 280W DC-input power supply; a second 280W AC-input or DC-input power supply is available for the router. Figure 4 shows the rear of a Cisco 7200 series router that is configured with a single 280W AC-input power supply. (A power supply filler plate is installed over the second power supply bay.)

Three internal fans draw cooling air into the chassis interior and across internal components to maintain an acceptable operating temperature (refer to Figure 4). The three fans are enclosed in a tray that is located in the subchassis.

The I/O controller, port adapters, power supplies, and network processing engine slide into their respective chassis slots and connect directly to the router's midplane; there are no internal cables to connect. The midplane distributes DC power from the power supplies to the I/O controller, port adapters, fan tray, and network processing engine.

Subchassis Overview

The Cisco 7200 series subchassis, shown in Figure 5, has one slot for the network processing engine, two bays for up to two 280W AC-input or two 280W DC-input power supplies, and one slot for the fan tray. The subchassis also houses the router midplane. To replace the router midplane, you must replace the entire subchassis. The fan tray, network processing engine, and AC-input and DC-input power supplies are field-replaceable units (FRUs), which means they can be replaced independently of the subchassis.

Figure 5 : Cisco 7200 Series Subchassis

Fan Tray Overview

The fan tray, shown in Figure 6, consists of three fans enclosed in a metal case. The fan tray is located on the right side of the router when viewing the router from the rear (refer to Figure 4). The fan tray receives DC-input power through a power harness that connects to the router midplane.

Figure 6 : Cisco 7200 Series Fan Tray

The fan tray draws cooling air in through the intake vent on the right side of the chassis (when viewing the router from the front [the port adapter end]), and moves the air across the internal components and out the exhaust vent on the left side of the chassis. Figure 7 shows the air flow through the router.

Figure 7 : Cisco 7200 Series Thermal Airflow---Top View

The left and right sides of the router must remain unobstructed to ensure adequate airflow and to prevent overheating inside the router. Maintain at least three inches of clearance on both sides of the router.

Installation Prerequisites

This section provides a list of parts and tools you need to remove and replace the subchassis and fan tray in the Cisco 7200 series routers. This section also includes safety and ESD-prevention guidelines to help you avoid injury to yourself and damage to the equipment.

List of Parts and Tools

You need the following tools and parts to remove and replace the subchassis and fan tray. If you need additional equipment, contact a service representative for ordering information.

A new subchassis
A new fan tray
Number 2 Phillips screwdriver
3/16-inch flat-blade screwdriver
Several cable ties (if the router is mounted in an equipment rack)
Your own ESD-prevention equipment or the disposable grounding wrist strap included with all upgrade kits, FRUs, and spares
An antistatic mat or surface

Safety Guidelines

Following are safety guidelines that you should follow when working with any equipment that connects to electrical power or telephone wiring.

Electrical Equipment Guidelines

Follow these basic guidelines when working with any electrical equipment:

Before beginning any procedures requiring access to the chassis interior, locate the emergency power-off switch for the room in which you are working.
Disconnect all power and external cables before moving a chassis.
Do not work alone when potentially hazardous conditions exist.
Never assume that power has been disconnected from a circuit; always check.
Do not perform any action that creates a potential hazard to people or makes the equipment unsafe.
Carefully examine your work area for possible hazards such as moist floors, ungrounded power extension cables, and missing safety grounds.

Telephone Wiring Guidelines

Use the following guidelines when working with any equipment that is connected to telephone wiring or to other network cabling:

Never install telephone wiring during a lightning storm.
Never install telephone jacks in wet locations unless the jack is specifically designed for wet locations.
Never touch uninsulated telephone wires or terminals unless the telephone line has been disconnected at the network interface.
Use caution when installing or modifying telephone lines.

Preventing Electrostatic Discharge Damage

Electrostatic discharge (ESD) damages equipment and impairs electrical circuitry. ESD occurs when printed circuit boards are improperly handled and results in complete or intermittent failures.

The I/O controller, network processing engine, and port adapters consist of a printed circuit board that is fixed in a metal carrier. Electromagnetic interference (EMI) shielding, connectors, and a handle are integral components of the carrier. Handle the I/O controller, network processing engine, and port adapters by their carrier edges and handle; never touch the printed circuit board or connector pins.

Figure 8 shows how to handle the I/O controller and the network processing engine.

Figure 8 : Handling the I/O Controller and the Network Processing Engine

Figure 9 shows how to handle a port adapter.

Figure 9 : Handling a Port Adapter

Although the metal carrier helps to protect the printed circuit boards from ESD, wear a preventive antistatic strap whenever handling the I/O controller, network processing engine, or port adapters. Ensure that the strap makes good skin contact and connect the strap's clip to an unpainted chassis surface to safely channel unwanted ESD voltages to ground.

If no wrist strap is available, ground yourself by touching the metal part of the chassis.

Caution Make sure to tighten the captive installation screws on the network processing engine and the I/O controller (use a number 2 Phillips's screwdriver). These screws prevent accidental removal, provide proper grounding for the router, and help to ensure that the network processing engine and the I/O controller are properly seated in the router midplane.

Following are guidelines for preventing ESD damage:

Always use an ESD wrist strap or ankle strap when installing or replacing the I/O controller, network processing engine, or port adapters. Ensure that the ESD strap makes contact with your skin.
Handle the I/O controller, network processing engine, or port adapters by their metal carrier edges and handles only; avoid touching the printed circuit board components or any connector pins.
When removing the I/O controller, network processing engine, or port adapters, place them on an antistatic surface with the printed circuit board components facing upward, or in a static shielding bag. If you are returning an I/O controller, network processing engine, or port adapter to the factory, immediately place it in a static shielding bag.

Caution Periodically check the resistance value of the antistatic strap. The measurement should be within the range of 1 and 10 megohms.

Ensuring Easy Access to the Router

If your Cisco 7200 series router is installed in a standard 19-inch rack or in a 19-inch Telco rack, cables from other equipment in the rack may obstruct access to the rear of the router. Also, rack power strips or other permanent fixtures may obstruct access to the router. Review the following guidelines to ensure easy access to the rear of the router when it is installed in a rack. If the router is not installed in a rack, or if you already have clear access to the rear of the router, proceed to the following section "Removing and Replacing the Subchassis and Fan Tray."

Use the following guidelines to ensure easy access to the rear of the router when it is installed in a rack:

Ensure that you have at least three to four feet of working space at the rear of the router.
If cables from other equipment in the rack fall in front of the rear end of the router, carefully gather the cables (using care not to strain them) and use cable ties to anchor them away from the rear of the router.
If access to the rear of the router is partially blocked by a power strip or some other permanent rack fixture, detach the router from the rack and carefully slide it forward until there is enough clearance to remove the power supply, the network processing engine, and the subchassis from the router. Detailed steps for detaching the router from the rack are contained in the following section "Removing and Replacing the Subchassis and Fan Tray."

Caution Make sure that at least one other person is available to support the front of the router as you slide it out from the rack and, if necessary, to continue to support it while you remove and insert the power supply, network processing engine, or subchassis.

Removing and Replacing the Subchassis and Fan Tray

Removing and replacing the subchassis and fan tray in the Cisco 7200 series routers involves the following tasks:

These tasks are described in detail in the following subsections.

Note The tasks for removing and replacing the subchassis and fan tray in the Cisco 7204 and the Cisco 7206 are the same. Therefore, the illustrations in the following sections show the Cisco 7206, unless indicated otherwise.

Powering Down the Router and Disconnecting Input Power

To power down a Cisco 7200 series router that has an installed AC-input power supply, complete the following steps:

Note Before powering down the router, use the copy running-config startup-config command to save the router's running configuration to nonvolatile memory.

Step 1 Facing the rear of the router, place the power switch (on the power supply) in the OFF (0) position. Repeat this action if a second power supply is installed in the router.

Step 2 Observe the following items:

The green OK LED on the power supply turns off
The fans stop operating
The LEDs on the I/O controller turn off
The LEDs on the port adapters turn off

To disconnect AC-input power to a Cisco 7200 series router, complete the following steps:

Step 1 Unplug the input power cable from the power source.

Step 2 Push down on the cable-retention clip that secures the input power cable to the router's power supply.

Step 3 Unplug the other end of input power cable from the power supply (refer to Figure 10).

Figure 10 : Disconnecting Power from a Cisco 7200 Series AC-Input Power Supply

Step 4 Repeat Step 2 through Step 1 if a second power supply is installed.

This completes the procedure for powering down the router and disconnecting input power. Proceed to the following section "Removing a Power Supply and the Network Processing Engine."

Removing a Power Supply and the Network Processing Engine

The following sections explain how to remove an AC-input power supply and the network processing engine from a Cisco 7200 series router. The power supply and the network processing engine reside in the subchassis; therefore, you must remove them before you remove the subchassis from the router.

Removing an AC-Input Power Supply from a Cisco 7200 Series Router

To remove an AC-input power supply from a Cisco 7200 series router, complete the following steps:

Step 1 Ensure that the power switch on the power supply is in the OFF (0) position and AC input power is disconnected from the power supply and its power source. (Refer to the section "Powering Down the Router and Disconnecting Input Power" earlier in this document.)

Step 2 Using a number 2 Phillips screwdriver, loosen the two captive screws on the faceplate of the power supply (refer to Figure 11).

If the router is not installed in a standard 19-inch rack or in a Telco rack, skip to Step 6. If the router is installed in a rack, determine if any permanent rack fixtures, such as a power strip, are obstructing access to the power supply. If a rack fixture is obstructing access to the power supply, proceed to Step 3.

Figure 11 : AC-Input Power Supply Captive Installation Screws and Handle

Step 3 Using a 3/16-inch flat-blade screwdriver, loosen the screws that secure the router to the front mounting strips of the rack.

Step 4 Position at least one person in front of the rack to support the front underside of the router.

Step 5 From the rear of the rack, carefully push the front of the router out of the rack until there is enough clearance to remove the power supply.

Step 6 Grasp the power supply handle and pull the power supply from the router.

Caution To maintain agency compliance requirements and meet EMI emissions standards for the Cisco 7200 series chassis with a single power supply, the power supply filler plate must remain in the power supply bay adjacent to the installed power supply. Do not remove this filler plate from the router unless you intend to install a redundant power supply.

Step 7 Repeat Step 1 through Step 6 for the other installed AC-input power supply (if present).

This completes the procedure for removing an AC-input power supply from a Cisco 7200 series router. Proceed to the following section "Removing the Network Processing Engine."

Removing the Network Processing Engine

To remove the network processing engine from a Cisco 7200 series router, complete the following steps:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface.

Step 2 Using a number 2 Phillips screwdriver, loosen the two captive installation screws on the faceplate of the network processing engine (refer to Figure 12).

Step 3 Grasp the two network processing engine handles and carefully pull the network processing engine from its chassis slot.

Caution Handle the network processing engine by the carrier edges and handles only; never touch the printed circuit board components or connector pins (refer to Figure 8).

Figure 12 : Cisco 7200 Series Network Processing Engine Captive Screws and Handles

Step 4 Place the network processing engine on an antistatic surface with its components facing upward, or in a static shielding bag.

This completes the procedure for removing the network processing engine. Proceed to the following section "Disengaging the Input/Output Controller and the Port Adapters."

Disengaging the Input/Output Controller and the Port Adapters

The following sections explain how to disengage the port adapters and I/O controller from the router midplane. The I/O controller and the port adapters are not located in the subchassis; therefore, you do not have to remove them from the router when removing the subchassis. However, the I/O controller and the port adapters connect directly to the router midplane, so you must disengage them from the router midplane to remove the subchassis from the router.

Disengaging the Port Adapters

To disengage a port adapter from the router midplane, complete the following steps:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface.

Step 2 Move the port adapter lever to the unlocked position (Figure 13).

Figure 13 : Port Adapter Lever---Unlocked Position

Step 3 Grasp the handle on the port adapter.

Step 4 With the port adapter lever in the unlocked position, pull the port adapter from the midplane about half way out of its slot. Do not remove the port adapter from the slot (refer to Figure 14).

Figure 14 : Disengaging a Port Adapter

Step 5 Repeat Step 3 through Step 4 for each port adapter that is installed in the router.

This completes the procedure for disengaging a port adapter from the router midplane. Proceed to the following section "Disengaging the Input/Output Controller."

Disengaging the Input/Output Controller

To disengage the I/O controller from the router midplane, complete the following steps:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface.

Step 2 Using a number 2 Phillips screwdriver, loosen the two captive installation screws on the faceplate of the I/O controller.

Step 3 Grasp the handle on the I/O controller and pull the controller from the midplane about half way out of its slot (refer to Figure 15).

Figure 15 : Disengaging the I/O Controller from the Router Midplane

This completes the procedure for disengaging the I/O controller from the router midplane. Proceed to the following section "Removing the Subchassis."

Removing the Subchassis

To remove the subchassis from a Cisco 7200 series router, complete the following steps:

Step 1 Using a number 2 Phillips screwdriver, reach into a power supply bay and loosen the four subchassis captive installation screws (refer to Figure 16).

Figure 16 : Subchassis Captive Installation Screws

Step 2 Place one hand on the subchassis center post and your other hand on top of the router, and pull the subchassis from the router (refer to Figure 17).

The subchassis fits tightly in the router. Be prepared to use your hand on top of the router for leverage.

Figure 17 : Pulling the Subchassis from the Router

This completes the steps for removing the subchassis. Proceed to the following section "Removing the Fan Tray from the Subchassis."

Removing the Fan Tray from the Subchassis

To remove the fan tray from the subchassis, complete the following steps:

Step 1 Disconnect the fan tray's DC power harness from the router midplane. (Squeeze the DC connector while pulling it from the midplane.) (Refer to Figure 18.)

Step 2 Using a number 2 Phillips screwdriver, remove the two screws that secure the fan tray to the subchassis (refer to Figure 18). Save the screws.

Figure 18 : Fan Tray DC Power Harness and Screws

Step 3 Grasp the fan tray with one hand and the subchassis with the other hand.

Step 4 In one motion, rock the fan tray backward slightly to disengage it from the subchassis wall, then pull the fan tray upward to remove it from the subchassis (refer to Figure 19).

Figure 19 : Removing the Fan Tray From the Subchassis

This completes the steps for removing the fan tray from the subchassis.

Proceed to the following section "Installing a New Fan Tray in the Subchassis."

Installing a New Fan Tray in the Subchassis

To install a new fan tray in the subchassis, complete the following steps:

Step 1 Orient the fan tray so the fans face the subchassis and the DC power harness is at the top of the fan tray (refer to Figure 20).

Step 2 Guide the fan tray into the subchassis making sure the DC power harness rests in its subchassis slot and the fan tray alignment tabs mate with the subchassis wall.

Figure 21 shows the fan tray alignment tabs with the subchassis wall.

Figure 20 : Installing a New Fan Tray in the Subchassis

Figure 21 : Fan Tray Alignment Tabs and the Subchassis Wall

Step 3 Secure the fan tray to the subchassis using the screws you saved when removing the fan tray (refer to Figure 22).

Step 4 Connect the DC power harness to the midplane.

Figure 22 : Securing the Fan Tray and Connecting the DC Power Harness

This completes the steps for installing a new fan tray in the subchassis. Proceed to the following section "Replacing the Subchassis."

Replacing the Subchassis

To replace the subchassis in the router, complete the following steps:

Step 1 Align the fan tray between the router stopper and the chassis wall (refer to Figure 23).

Step 2 Carefully slide the subchassis into the router until the subchassis is flush with the rear panel of the router. You may have to shift the subchassis a little to get it into the router.

Figure 23 : Aligning the Subchassis

Step 3 Using a number 2 Phillips screwdriver, reach into a power supply bay and tighten the subchassis captive installation screws (refer to Figure 24).

Note The subchassis is not fully seated in the router midplane until you tighten its captive installation screws (use a number 2 Phillips screwdriver).

Figure 24 : Securing the Subchassis in the Router

This completes the steps for replacing the subchassis in the router. Proceed to the following section "Replacing the Network Processing Engine and Power Supply."

Replacing the Network Processing Engine and Power Supply

The following sections explain how to replace the network processing engine and an AC-input power supply in a Cisco 7200 series router.

Replacing the Network Processing Engine

To replace the network processing engine in the router, complete the following steps:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface.

Step 2 Using both hands, grasp the network processing engine by its metal carrier edges and orient the network processing engine so that its printed circuit board components are upward (refer to Figure 8).

Caution Always handle the network processing engine by the carrier edges and handles only; never touch the printed circuit board components or connector pins.

Step 3 Align the left and right edge of the network processing engine printed circuit board between the guides in the network processing engine slot (refer to Figure 25).

Figure 25 : Aligning the Network Processing Engine between the Slot Guides

Caution Do not align the network processing engine's metal carrier between the slot guides. Doing so will damage components on the network processing engine's printed circuit board as you slide the network processing engine into its chassis slot.

Step 4 Gently slide the network processing engine all the way into its slot until you feel the connectors mate with the midplane.

Step 5 Seat the network processing engine in the midplane by tightening its captive screws with a number 2 Phillips screwdriver.

Note The network processing engine is not fully seated in the router midplane until you tighten its captive installation screws (use a number 2 Phillips screwdriver).

This completes the procedure for installing the network processing engine. Proceed to the following section "Replacing an AC-Input Power Supply."

Replacing an AC-Input Power Supply

To install an AC-input power supply in a Cisco 7200 series router, complete the following steps:

Step 1 Make sure the power switch on the power supply is in the OFF (0) position.

Step 2 Grasp the power supply handle with one hand and place your other hand underneath the power supply for support (refer to Figure 26).

Figure 26 : Holding the AC-Input Power Supply

Step 3 Align the power supply to the power supply bay.

Step 4 Slide the power supply completely in to the power supply bay until its faceplate is flush with the router's rear panel.

Caution When inserting a power supply into the router, do not use unnecessary force; slamming the power supply into the bay can damage the connectors on the rear of the supply and on the midplane.

Step 5 Seat the power supply in the router by tightening its captive screws with a number 2 Phillips screwdriver.

Note The power supply is not fully seated in the router midplane until you tighten its captive installation screws (use a number 2 Phillips screwdriver).

Step 6 Repeat Step 1 through Step 5 for a second power supply (if present).

Step 7 If there is no second power supply, replace the filler plate on the empty power supply bay. Using a number 2 Phillips screwdriver, tighten the filler plate's captive screws.

Step 8 If you pushed the router from the rack, slowly guide the router back into the rack.

Step 9 Use a 3/16-inch flat-blade screwdriver to tighten the screws that secure the router to front mounting strips of the rack.

Caution To maintain agency compliance requirements and meet EMI emissions standards for the Cisco 7200 series routers with a single power supply, the power supply filler plate must remain in the power supply bay adjacent to the installed power supply. Do not remove this filler plate from the router unless you intend to install a redundant power supply.

This completes the procedures for replacing an AC-input power supply in a Cisco 7200 series router. Proceed to the following section "Reseating the I/O Controller and the Port Adapters."

Reseating the I/O Controller and the Port Adapters

The following sections explain how to reseat the I/O controller and port adapters that you disengaged from the router midplane earlier in these procedures.

Reseating the I/O Controller

Complete the following steps to reseat the I/O controller:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface (if necessary).

Step 2 Make sure the left and right edges of the I/O controller's printed circuit board are aligned between the guides in its slot.

Warning Do not align the I/O controller metal carrier between the guides in the slot. Doing so will damage components on the I/O controller's printed circuit board as you slide the I/O controller into its chassis slot.

Step 3 Using both hands, grasp the I/O controller by its metal carrier edges and gently slide the controller all the way into its slot until you feel the connectors mate with the midplane.

Step 4 Seat the I/O controller in the midplane by tightening its captive screws with a number 2 Phillips screwdriver.

Note The I/O controller is not fully seated in the router midplane until you tighten its captive installation screws (use a number 2 Phillips screwdriver).

This completes the procedure for reseating an I/O controller. Proceed to the following section "Reseating the Port Adapters."

Reseating the Port Adapters

Complete the following steps to reseat the port adapters:

Step 1 Attach an ESD-preventative wrist strap between you and an unfinished chassis surface (if necessary).

Step 2 With the port adapter still in the unlocked position, grasp the handle on the port adapter and gently push the port adapter all the way into its slot until you feel the connectors mate with the midplane.

Step 3 Move the port adapter lever to the locked position. Figure 27 shows the port adapter lever in the locked position. Repeat this step for each port adapter installed in the router.

Figure 27 : Port Adapter Lever---Locked Position

This completes the procedure for reseating a port adapter. Proceed to the following section "Reconnecting Input Power and Powering Up the Router."

Reconnecting Input Power and Powering Up the Router

The following procedures explain how to reconnect AC-input power to a Cisco 7200 series router, power up the router, and verify a successful system boot.

To connect AC-input power to a Cisco 7200 series router, complete the following steps:

Step 1 At the rear of the router, check that the power switch on the power supply is in the OFF (0) position.

Step 2 Slide the cable-retention clip down, away from the AC receptacle, and plug in the power cable.

Step 3 Secure the cable in the power supply AC receptacle by sliding the cable-retention clip up until it snaps around the connector. The cable-retention clip provides strain relief for the AC power cable (refer to Figure 28).

Figure 28 : Connecting AC-Input Power to a Cisco 7200 Series Router

Step 4 Plug the AC power supply cable into the AC power source.

Note Each AC-input power supply operating at 120 VAC requires a minimum of 5A service. We recommend powering the Cisco 7200 series routers from a 15A receptacle at the power source.

Step 5 Repeat Step 1 through Step 4 for the second power supply (if present).

This completes the steps for connecting AC input power to a Cisco 7200 series router. To power up a Cisco 7200 series router that has an installed AC-input power supply, complete the following steps:

Step 1 Check for the following:

Each port adapter is inserted in its slot and its respective port adapter lever is in the locked position
The network processing engine and the I/O controller are inserted in their respective slots, and their captive installation screws are tightened
All network interface cables are connected to the port adapters
A Flash memory card is installed in its PCMCIA slot (if present)
Each power cable is connected and secured with the cable-retention clip
The console terminal is turned on

Step 2 At the rear of the router, place the power switch on the power supply in the ON (|) position. Repeat this step if a second power supply is installed in the router. The green OK LED on the power supply turns on.

Step 3 Listen for the fans; you should immediately hear them operating.

Step 4 During the boot process, observe the system's LEDs. The LEDs on most of the port adapters go on and off in irregular sequence. Some may go on, go out, and go on again for a short time. On the I/O controller, the IO Power OK LED comes on immediately.

Step 5 Observe the initialization process. When the system boot is complete (a few seconds), the network processing engine begins to initialize the port adapters and the I/O controller. During this initialization, the LEDs on each port adapter behave differently (most flash on and off). The enabled LED on each port adapter goes on when initialization is completed, and the console screen displays a script and system banner similar to the following:


Cisco Internetwork Operating System Software


IOS (tm) 7200 Software (C7200-J-M), Version 11.1(6)CA [kpfjrgiu 100]


Copyright (c) 1986-1996 by cisco Systems, Inc.


Compiled Sun 21-Apr-96 04:10 by

This completes the procedures for reconnecting input power and powering up the router. This also completes the procedure for replacing the subchassis and fan tray in a Cisco 7200 series router.

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