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    Connecting DC Power Cables to the ACX4000 Router

    To connect power to the router, you need the following tools:

    • Phillips (+) screwdriver, number 2
    • ESD grounding wrist strap
    • M3 screws and flat washers
    • DC power source cables, minimum 14 AWG or as required by local code (not provided)
    • Ring lugs, Molex 190700067 or equivalent (not provided)

    The DC power supply has four terminals on the front panel, covered by a clear plastic cover.

    Warning: You must ground the router before connecting the DC power cables.

    To connect the power cables:

    1. Switch off the dedicated customer site circuit breakers. Ensure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cable leads might become active during installation.
    2. Remove the clear plastic cover protecting the terminal on the faceplate.
    3. Verify that the DC power cables are correctly labeled before making connections to the power supply. In a typical power distribution scheme where the return is connected to chassis ground at the battery plant, you can use a multimeter to verify the resistance of the –48V and return DC cables to chassis ground:

      For –48V and -60V:

      1. The cable with very high resistance (indicating an open circuit) to chassis ground is the DC input cable (-).
      2. The cable with very low resistance (indicating a closed circuit) to chassis ground is the return cable (+).

      For +24V:

      1. The cable with very low resistance (indicating a closed circuit) to chassis ground is the DC input cable (-).
      2. The cable with very high resistance (indicating an open circuit) to chassis ground is the return cable (+).
    4. Remove the screws and flat washers from the terminals.
    5. Secure each power cable lug to the terminal with the flat washers and screw (see Figure 1). Apply between 8 lb-in. (0.9 Nm) and 9 lb-in. (1.02 Nm) of torque to each screw. Do not overtighten the screw. (Use a number 2 Phillips screwdriver.)
      1. Secure the positive DC source power cable lug to the return (+) terminal.
      2. Secure the negative DC source power cable lug to the input () terminal.

      Caution: Ensure that each power cable lug seats flush against the surface of the terminal block as you are tightening the screws. Ensure that each screw is properly threaded into the terminal. Applying installation torque to the screw when improperly threaded may result in damage to the terminal.

      Caution: The maximum torque rating of the terminal screws on the DC power supply is 9 lb-in. (1.02 Nm). The terminal screws may be damaged if excessive torque is applied. Use only a torque-controlled driver to tighten screws on the DC power supply terminals. Use an appropriately-sized driver, with a maximum torque capacity of 9 lb-in. or less. Ensure that the driver is undamaged and properly calibrated and that you have been trained in its use. You may wish to use a driver that is designed to prevent overtorque when the preset torque level is achieved.

    6. Replace the clear plastic cover over the terminals on the faceplate.
    7. Connect each DC power cable to the appropriate external DC power source.

      Note: For information about connecting to external DC power sources, see the instructions for your site.

    8. Switch on the external circuit breakers to provide voltage to the DC power source cable leads. Observe the system LED on the front of the router. If the DC power cable is correctly installed and functioning normally, the system LED lights green steadily. If the status LED indicates that the power supply is not functioning normally, repeat the installation and cabling procedures.

    Figure 1: Connecting DC Power to the Router

    Connecting DC Power
to the Router

    Published: 2013-08-29