Cisco 6500e Manual

							1-43
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Figure 1-29 DC Power Cable Lug
CautionUse both hands to install and remove the power supplies. Each DC-input power supply weighs 32 pounds 
(14.5 kg). 
Step 5Grasp the power supply handle with one hand, and place your other hand underneath the power supply. 
Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the 
bay. (See Figure 1-30.)
Figure 1-30 Handling a 4000 W DC-Input Power Supply 
Step 6
Tighten the power supply captive installation screw. (See Figure 1-26.)
Step 7Remove the two screws that secure the outer terminal block cover. Lift the cover up to detach the cover 
tabs from the slots in the power supply. Set the cover and the screws aside.
Crimp area
120563
2.25
.25 .37.63 Ø .267
2 holes
All measurements in inches
104978INPUT OK
FA N
OKOUTPUT
FA I L
I0
1
3 2
+VE-1-VE-1+VE-2-VE-2
+VE-3-VE-3 
						

							1-44
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Step 8Remove the two screws that secure the left inner terminal block cover. Lift up on the cover to detach the 
cover tab from the slot in the power supply. Set the cover and the screws aside.
Step 9Remove the one screw that secures the right inner terminal block cover. Lift up on the cover to detach 
the cover tab from the slot in the power supply. Set the cover and the screw aside.
Step 10Remove the two plastic insulators from the plastic bag that shipped with the power supply. Position the 
larger plastic insulator (eight holes) over the eight-post terminal block (VE-1/VE-2). Align the holes in 
plastic with the terminal block posts. The end flap on the insulator should face away from the DC source 
cable entry direction. 
Step 11Position the smaller plastic insulator (four holes) over four-post terminal block VE-3. Align the holes in 
the plastic with the terminal block posts. The end flap on the insulator should face away from the DC 
source cable entry direction.
Step 12Fold the end flaps down on both insulators to cover the open side of the terminal blocks (opposite side 
from cable entry). 
NoteBe sure to place a plastic insulator over both terminal blocks, even if you are not attaching source 
DC cables to it; this ensures that the plastic insulator is available for future use.
Step 13From the left side of the power supply, connect the power supply ground cable and the source DC cables 
to the power supply terminal blocks in this order (Figure 1-31):
1.Ground cable lug to the ground terminal posts
2.Negative (–) source DC cables to any two pairs of (–) terminal posts (VE-1 and VE-2, VE-1 and 
VE-3, or VE-2 and VE-3)
3.Positive (+) source DC cables to any two pairs of (+) terminal posts (VE-1 and VE-2, VE-1 and 
VE-3, or VE-2 and VE-3)
CautionWhen you tighten the terminal nuts, make sure that they are snug. Do not overtighten them. 
Overtightening the terminal nuts can damage the terminal block. The recommended torque values for 
tightening the terminal nuts are 15 inch-pounds (1.7 newton-meters) (minimum) and 20 inch-pounds 
(2.2 newton-meters) (maximum). 
						

							1-45
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Figure 1-31 DC-Input Wire Connections for 2700 W Operation (Left-Side Power Bay)
Step 14
Wrap the large perforated flaps of the insulators around each pair of source DC cables, inserting each 
locking tab into the rear of the slot. Pull the tab until the cover is secured around the power cabling trim, 
and discard excess tab plastic. 
Step 15Position and secure the left inner terminal block cover with two screws. Position and secure the right 
inner terminal block cover with one screw. 
Step 16Install and secure the outer terminal block cover with the two screws.
Step 17If you are installing a second power supply operating at 2700 W in the right-side power supply bay, 
proceed to “Installing the 4000 W Power Supply (Wiring for 2700 W Operation; Right Power Bay)” 
section on page 1-46; otherwise, go to Step 18.
CautionTo prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal 
block covers.
Step 18After you confirm that all installation steps are completed correctly, remove any safety flags, lockout 
devices, or adhesive tape from the source DC circuit breakers, and energize the input circuits to the 
power supplies. 
114010
3
INPUT OK
FA N
OKOUTPUT
FAIL
I
0
1
2
Captive 
installation
screw
(+)  Positive
( - ) Negative
Power
switch
(   ) Ground (+)  Positive
( - ) Negative
Power leads
attached to
terminal block
Terminal
block cover Plastic
insulator 
						

							1-46
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Step 19Turn the power switch to the on (|) position on the power supply. Turning on the power switch also 
engages a pawl that locks the power supply in the chassis.
Step 20Verify the power supply operation by ensuring that the power supply front panel LEDs are in the 
following states:
INPUT OK 1 LED—If you have source DC cables attached to the VE-1 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing.
INPUT OK 2 LED—If you have source DC cables attached to the VE-2 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing. 
INPUT OK 3 LED—If you have source DC cables attached to the VE-3 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing. 
FAN OK LED is green.
OUTPUT FAIL LED is not lit.
If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page A-3.
Installing the 4000 W Power Supply (Wiring for 2700 W Operation; Right Power Bay)
See Figure 1-26 for item location and identification on the 4000 W DC-input power supply.
NoteYou should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the 
power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed 
to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables 
can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact 
amount of space required depends upon the gauge and flexibility of the DC-input power cables that you 
are using.
NoteFor proper 2700 W DC-input redundant power configurations, source DC for one 4000 W DC-input 
power supply must come from the same battery system (A feed); source DC for the other 4000 W 
DC-input power supply must come from another battery system (B feed).
NoteFor multiple DC-input power supplies, each DC input must be protected by a dedicated circuit breaker 
or a fuse. The circuit breaker or fuse must be sized according to the power supply input rating and the 
local or national electrical code requirements. 
						

							1-47
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
To install a 4000 W DC-input power supply and wire it for 2700 W operation in the right power supply 
bay (POWER 2), follow these steps:
Step 1Ensure that the system (earth) ground connection has been made. 
For ground connection installation instructions, see the “Establishing the System Ground” section on 
page 1-52.
Step 2Remove the power supply from its shipping container and remove any packaging.
Step 3Verify that source DC is off to the DC circuit that feeds the power supply that you are installing. As an 
added precaution, place the appropriate safety flag and lockout devices at the source power circuit 
breaker, or place a piece of adhesive tape over the circuit breaker handle to prevent accidental power 
restoration while you are working on the circuit.
Step 4Prepare the source DC power cables by attaching the appropriately sized lugs. 
The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are 
centered 0.63 inches (15.88 mm) apart and have a 1/4-20 thread. We recommend that you use an 
appropriately sized industry standard 2-hole, standard barrel compression lug. (See Figure 1-32.) The 
power supply ground posts, located below the terminal block, also have 1/4-20 threads and require two 
1/4-inch split-ring washers and two 1/4-20 hex nuts. 
The DC-input wires and the DC power supply ground wires should be sized according to the local and 
national installation requirements. Use only copper wire. For North American installations, use 
90°C-rated, fine-strand copper conductors.
Figure 1-32 DC Power Cable Lug
CautionUse both hands to install and remove power supplies. Each DC-input power supply weighs 32 pounds 
(14.5 kg). 
Step 5Grasp the power supply handle with one hand, and place your other hand underneath the power supply. 
Slide the supply into the right-side power supply bay. Make sure that the power supply is fully seated in 
the bay. (See Figure 1-33.)
Crimp area
120563
2.25
.25 .37.63 Ø .267
2 holes
All measurements in inches 
						

							1-48
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Figure 1-33 Handling a 4000 W DC-Input Power Supply 
Step 6
Tighten the power supply captive installation screw.
Step 7Remove the two screws that secure the outer terminal block cover. Lift the cover up to detach the cover 
tabs from the slots in the power supply. Set the cover and the screws aside.
Step 8Remove the two screws that secure the left inner terminal block cover. Lift up on the cover to detach the 
cover tab from the slot in the power supply. Set the cover and the screws aside.
Step 9Remove the one screw that secures the right inner terminal block cover. Lift up on the cover to detach 
the cover tab from the slot in the power supply. Set the cover and the screw aside.
Step 10Remove the two plastic insulators from the plastic bag that shipped with the power supply. Position the 
larger plastic insulator (eight holes) over terminal block VE-1/VE-2. Align the holes in plastic with the 
terminal block posts. The end flap on the insulator should face away from the DC source cable entry 
direction. 
Step 11Position the smaller plastic insulator (four holes) over the four-post terminal block VE-3. Align the holes 
in the plastic with the terminal block posts. The end flap on the insulator should face away from the 
source DC cable entry direction.
Step 12Fold the end flaps down on both insulators to cover the open side of the terminal block (opposite side 
from cable entry). 
NoteBe sure to place a plastic insulator over both terminal blocks, even though you might not attach 
source DC cables to the terminal block; installing both of the insulators ensures that they are 
available for future use.
104978INPUT OK
FAN
OKOUTPUT
FA I L
I0
1
3 2
+VE-1-VE-1+VE-2-VE
-2
+V
E-3-VE-3 
						

							1-49
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Step 13From the right side of the power supply, connect the power supply ground cable and the source DC cables 
to the DC-input wires to the terminal block (Figure 1-34) in this order:
1.Ground cable lug to the ground terminal posts
2.Negative (–) source DC cables to any two pairs of (–) terminal posts (VE-1 and VE-2, VE-1 and 
VE-3, or VE-2 and VE-3)
3.Positive (+) source DC cables to any two pairs of (+) terminal posts (VE-1 and VE-2, VE-1 and 
VE-3, or VE-2 and VE-3)
CautionWhen you tighten the terminal nuts, make sure that they are snug. Do not overtighten them. 
Overtightening the terminal nuts can damage the terminal block. The recommended torque values for 
tightening the terminal nuts are 15 inch-pounds (1.7 newton-meters) (minimum) and 20 inch-pounds 
(2.2 newton-meters) (maximum).
Figure 1-34 DC-Input Wire Connections for 2700 W Operation (Right-Side Power Bay)
Step 14
Wrap the large perforated flaps of the insulators around each pair of source DC cables, inserting each 
locking tab into the rear of the slot. Pull the tab until the cover is secured around the power cabling trim, 
and discard excess tab plastic. 
Step 15Position and secure the left inner terminal block cover with two screws. Position and secure the right 
inner terminal block cover with one screw. 
Step 16Using the cable tie provided, place the cable tie through the slot at the top of the right terminal block 
cover, and secure the wiring to the left terminal block.
Step 17Install and secure outer terminal block cover with the two screws.
CautionTo prevent a short circuit or shock hazard after wiring the DC-input power supply, reinstall the terminal 
block covers.
1140113
INPUT OK
FA N
OKOUTPUT
FAIL
I
0
1
2
Captive 
installation
screw
Power
switch
Plastic
insulator
(   ) Ground
Power leads
attached to
terminal block
(+)  Positive
( - ) Negative
(+)  Positive
( - ) Negative
Terminal
block cover 
						

							1-50
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Step 18After you confirm that all installation steps are completed correctly, remove any safety flags, lockout 
devices, or adhesive tape from the source DC circuit breakers, and energize the input circuits to the 
power supplies. 
Step 19Turn the power switch to the on (|) position on the power supply. Turning on the power switch also 
engages a pawl that locks the power supply in the chassis.
Step 20Verify the power supply operation by ensuring that the power supply front panel LEDs are in the 
following states:
INPUT OK 1 LED—If you have source DC cables attached to the VE-1 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing.
INPUT OK 2 LED—If you have source DC cables attached to the VE-2 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing. 
INPUT OK 3 LED—If you have source DC cables attached to the VE-3 pair of power supply inputs, 
verify that the LED is green. If source DC cables are attached and the LED is not lit, source DC 
might not be on or the source DC voltage is less than or equal to –33 VDC. If the source DC voltage 
is between –33 VDC and –40.5 VDC, the LED can be either on, off, or flashing. 
FAN OK LED is green.
OUTPUT FAIL LED is not lit.
If the LEDs indicate a power problem, see the “Identifying Startup Problems” section on page A-3.
Installing the 4000 W Power Supply (Wiring for 4000 W Operation; Left Power Bay)
See Figure 1-26 for item location and identification on the 4000 W DC-input power supply.
NoteYou should allow a minimum of 2.5 to 3 inches (63.5 mm to 76.2 mm) of space between the side of the 
power supply and any obstructions (such as the side of an enclosed equipment rack). This space is needed 
to install and secure the DC-input power cables correctly. Incorrectly routing the DC-input power cables 
can cause airflow blockage into the power supply and inadequate strain relief in the cables. The exact 
amount of space required depends upon the gauge and flexibility of the DC-input power cables you are 
using.
NoteFor proper 4000 W DC-input redundant power configurations, source DC for one 4000 W DC-input 
power supply must come from the same battery system (A feed); source DC for the other 4000 W 
DC-input power supply must come from another battery system (B feed).
NoteFor multiple DC-input power supplies, each DC input must be protected by a dedicated circuit breaker 
or a fuse. The circuit breaker or fuse must be sized according to the power supply input rating and the 
local or national electrical code requirements. 
						

							1-51
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
To install a 4000 W DC-input power supply and wire it for 4000 W operation in the left power bay 
(POWER 1), follow these steps:
Step 1Ensure that the system (earth) ground connection has been made. 
For ground connection installation instructions, see the “Establishing the System Ground” section on 
page 1-52.
Step 2Remove the power supply from its shipping container and remove any packaging.
Step 3Verify that source DC power is off to the DC circuit that feeds the power supply that you are installing. 
As an added precaution, place the appropriate safety flag and lockout devices at the source power circuit 
breaker, or place a piece of adhesive tape over the circuit breaker handle to prevent accidental power 
restoration while you are working on the circuit.
Step 4Prepare the source DC power cables by attaching the appropriately sized lugs. 
The power supply terminal block lug opening width is 0.62 inch (15.8 mm). The terminal posts are 
centered 0.63 inches (15.88 mm) apart and have a 1/4-20 thread. We recommend that you use an 
appropriately sized industry standard 2-hole, standard barrel compression lug. (See Figure 1-35.) The 
power supply ground posts, located below the terminal block, also have 1/4-20 threads and require two 
1/4-inch split-ring washers and two 1/4-20 hex nuts. 
The DC-input wires and the DC power supply ground wires should be sized according to the local and 
national installation requirements. Use only copper wire. For North American installations, use 
90°C-rated, fine-strand copper conductors.
Figure 1-35 DC Power Cable Lug
CautionUse both hands to install and remove power supplies. Each DC-input power supply weighs 32 pounds 
(14.5 kg). 
Step 5Grasp the power supply handle with one hand, and place your other hand underneath the power supply. 
Slide the power supply into the power supply bay. Make sure that the power supply is fully seated in the 
bay. (See Figure 1-36.)
Crimp area
120563
2.25
.25 .37.63 Ø .267
2 holes
All measurements in inches 
						

							1-52
Catalyst 6500 Series Switches Installation Guide
OL-5781-08
Chapter 1      Removal and Replacement Procedures
  Removing and Installing the DC-Input Power Supplies
Figure 1-36 Handling a 4000 W DC-Input Power Supply 
Step 6
Tighten the power supply captive installation screw. 
Step 7Remove the two screws that secure the outer terminal block cover. Lift the cover up to detach the cover 
tabs from the slots in the power supply. Set the cover and the screws aside. (See Figure 1-26.)
Step 8Remove the two screws that secure the left inner terminal block cover. Lift up on the cover to detach the 
cover tab from the slot in the power supply. Set the cover and the screws aside.
Step 9Remove the one screw that secures the right inner terminal block cover. Lift up on the cover to detach 
the cover tab from the slot in the power supply. Set the cover and the screw aside.
Step 10Remove the two plastic insulators from the plastic bag that shipped with the power supply. Position the 
larger plastic insulator (eight holes) over terminal block VE-1/VE-2. Align the holes in plastic with the 
terminal block posts. The end flap on the insulator should face away from the DC source cable entry 
direction. 
Step 11Position the smaller plastic insulator (four holes) over the four-post terminal block VE-3. Align the holes 
in the plastic with the terminal block posts. The end flap on the insulator should face away from the 
source DC cable entry direction.
Step 12Fold the end flaps down on both insulators to cover the open side of the terminal block (opposite side 
from cable entry). 
Step 13From the left side of the power supply, connect the power supply ground cable and the source DC cables 
to the DC-input wires to the terminal block (see Figure 1-37) in this order:
1.Ground cable lug to the ground terminal posts
2.Negative (–) source DC cables to terminal posts –VE-1 and –VE-2
3.Positive (+) source DC cables to terminal posts +VE-1 and +VE-2
CautionWhen you tighten the terminal nuts, make sure that they are snug. Do not overtighten them. 
Overtightening the terminal nuts can damage the terminal block. The recommended torque values for 
tightening the terminal nuts are 15 inch-pounds (1.7 newton-meters) (minimum) and 20 inch-pounds 
(2.2 newton-meters) (maximum).
104978INPUT OK
FA N
OKOUTPUT
FAIL
I0
1
3 2
+VE-1-V
E-1+VE-2-VE
-2
+V
E-3-V
E-3