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Replacing T640 Power System Components

The router has either one nonredundant power supply or two redundant, load-sharing DC power supplies. Each redundant power supply is hot-insertable and hot-removable. When a redundant power supply is powered down or removed, the other power supply automatically assumes the entire electrical load for the router. If you have only one power supply, you must power off the system before removing the power supply. See Powering Off the T640 Router.

To replace a power system component, perform the following procedures:

Replacing a T640 Two-Input 160-A Power Supply

Removing a T640 Two-Input 160-A Power Supply

The power supplies are located at the rear of the chassis below the SIBs. Each two-input 160-A power supply weighs approximately 23 lb (10.5 kg).

Caution: Do not leave a power supply slot empty for more than 30 minutes while the router is operational. For proper airflow, the power supply must remain in the chassis, or a blank panel must be used in an empty slot.

To remove a power supply:

  1. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during the removal process.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  2. For a nonredundant power supply, power off the system. See Powering Off the T640 Router. For redundant power supplies, check that the other power supply is functional.
  3. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  4. Switch the circuit breakers on the power supply faceplate to the off position (O).

    Note: After powering off a power supply, you must wait at least 60 seconds before turning it back on.

  5. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  6. Using a 7/16-in. (11 mm) nut driver, remove the nuts and washers from the terminal studs (see Figure 1).

    Figure 1: Disconnecting Power Cables from a Two-Input 160-A DC Power Supply

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  7. Remove the cable lugs from the terminal studs.
  8. Loosen the captive screws on the cable restraints on the right edge of the power supply faceplate.
  9. Carefully move the power cables out of the way.
  10. Loosen the captive screws on the lower corners of the power supply faceplate completely. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
  11. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
  12. Grasp the handle on the power supply faceplate, and pull firmly to start removing the power supply. Slide it halfway out of the chassis (see Figure 2).

    Warning: Do not touch the power connectors on the rear of the power supply (see Figure 3). They can contain dangerous voltages.

  13. Place one hand underneath the power supply to support it, and slide it completely out of the chassis.

    Caution: Each two-input 160-A power supply weighs approximately 23 lb (10.5 kg). Be prepared to support the full weight of the power supply as you remove it from the router.

Figure 2: Removing a Power Supply

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Figure 3: Rear of the Power Supply Showing Midplane Connectors

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Installing a T640 Two-Input Power Supply

To install a power supply (see Figure 4):

  1. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during installation.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  3. Switch the circuit breakers on the power supply faceplate to the off position (O).
  4. Using both hands, slide the power supply into the chassis until you feel resistance.
  5. Twist the ejector handles at the upper corners of the power supply faceplate clockwise until they stop.
  6. Tighten the captive screws at the lower corners of the power supply faceplate to secure the power supply in the chassis.
  7. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  8. Remove the nut and washer from each power terminal stud. If no washers and nuts are already installed, they should be in the accessory box.
  9. Secure the cable lug on the DC power cable to the terminal stud, first with a washer, then with a nut (see Figure 5). Use a 7/16-in. (11 mm) nut driver or wrench to tighten the nut (see Figure 4). Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut:
    1. Secure each positive (+) DC source power cable lug to a RTN (return) terminal.
    2. Secure each negative (–) DC source power cable lug to a –48V (input) terminal.

    Note: All inputs on the two-input 160-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and all inputs on the two-input 160-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    Note: INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  10. Loosen the captive screws on the cable restraints on the right edge of the power supply faceplate.
  11. Route the positive and negative DC power cables through the top and bottom of each cable restraint.
  12. Tighten the cable restraint captive screws to hold the power cables in place.
  13. Verify that the power cabling is correct, that the cables are not touching or blocking access to router components, and that they do not drape where people could trip on them.
  14. Replace the clear plastic cover over the terminal studs on the faceplate.
  15. Switch the circuit breakers on the power supply to the on position (|).

    Note: If you have only one power supply, or the system is completely powered off when you power on the power supply, the Routing Engine boots as the power supply completes its startup sequence.

  16. Check the LEDs on the power supply faceplate. If the power supply is correctly installed and is functioning properly, the DC OK LED lights steadily, and the CB ON LED blinks momentarily, then lights steadily.

    Note: After a power supply is powered on, it can take up to 60 seconds for status indicators—such as the output status LEDs on the power supply, the show chassis command display, and messages on the LCD on the craft interface—to indicate that the power supply is functioning normally. Ignore error indicators that appear during the first 60 seconds.

    Note: After powering on a power supply, wait at least 60 seconds before turning it off. If you have only one power supply, power off the system before turning off the power supply. See Powering Off the T640 Router.

Figure 4: Installing a Replacement Power Supply

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Figure 5: Connecting Power Cables to the Power Supply

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Replacing a T640 Three-Input 240-A Power Supply

To replace a three-input 240-A power supply, perform the following procedures:

Removing a T640 Three-Input 240-A Power Supply

To remove a three-input 240-A power supply:

  1. Switch off the external circuit breakers to the power supply being removed. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during the removal process.
  2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  3. Switch the circuit breakers on the power supply faceplate to the off position (O).

    Figure 6: Three-Input 240-A Power Supply

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    Note: After powering off a power supply, wait at least 60 seconds before turning it back on.

  4. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  5. Using a 7/16-in. (11 mm) nut driver or wrench, remove the nuts and washers from the terminal studs (see Figure 7).

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

    Figure 7: Disconnecting Power Cables from the DC Power Supply

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  6. Remove the cable lugs from the terminal studs.
  7. Loosen the captive screw or screws on the cable restraint on the right edge of the power supply faceplate.
  8. Carefully move the power cables out of the way.
  9. Loosen the captive screws on the lower corners of the power supply faceplate completely.
  10. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
  11. Grasp the handle on the power supply faceplate and pull firmly. Slide it halfway out of the chassis (see Figure 9).
  12. Place one hand underneath the power supply to support it, and slide it completely out of the chassis.

    Warning: Do not touch the power connectors on the rear of the power supply (see Figure 8). They can contain dangerous voltages.

    Figure 8: Rear of the Power Supply Showing Midplane Connectors

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    Caution: Each three-input 240-A power supply weighs approximately 25 lb (11.3 kg). Be prepared to support the full weight of the power supply as you remove it from the routing platform.

Caution: Do not leave a power supply slot empty for more than a short time while the router is operational. For proper airflow, the power supply must remain in the chassis or a blank panel must be used in an empty slot.

Figure 9: Removing a Power Supply

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Setting the T640 Input Mode Switch on a Three-Input 240-A Power Supply

Note: Do not set the input mode switch if the power supply is installed in the chassis. If the power supply is already installed, you must disconnect all cables and remove the power supply before setting the input mode switch.

To set the input mode switch (see Figure 10):

  1. Using a screwdriver, loosen the captive screw holding the metal cover over the input mode switch (see Figure 10).
  2. Rotate the metal cover away from the input mode switch to expose the switch.
  3. Check the setting of the input mode switch. Use a flashlight, if necessary. In Two-INPUT mode, the switch must be located all the way to the right.
  4. If the input mode switch is not set correctly, use a sharp, nonconductive object to slide the switch all the way to the right to set the power supply to Two-INPUT.

    Caution: Do not use a pencil, because fragments can break off and cause damage to the power supply.

  5. Rotate the metal cover over the input mode switch, and use a screwdriver to tighten the captive screw.

Figure 10: Three-Input 240-A Power Supply

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Installing a T640 Three-Input 240-A Power Supply

Each three-input 240-A power supply weighs approximately 25 lb (11.3 kg). To install a three-input 240-A power supply:

  1. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during installation.
  2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  3. Switch the circuit breakers on the power supply faceplate to the OFF position (O).
  4. Using both hands, slide the power supply into the chassis until you feel resistance (see Figure 11).
  5. Twist the ejector handles at the upper corners of the power supply faceplate clockwise until they stop.
  6. Tighten the captive screws at the lower corners of the power supply faceplate to secure the power supply in the chassis.

Figure 11: Installing a Three-Input 240-A Power Supply

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Replacing the T640 Cable Restraint on a Three-Input 240-A Power Supply

Each three-input 240-A power supply is shipped with the standard cable restraint, as shown in Standard Cable Restraint on a Three-Input 240-A Power Supply. Two optional cable restraints are shipped in the accessory box.

If your DC power cables are too large or inflexible to fit into the standard cable restraint, we recommend that you remove the standard cable restraint and install the optional cable restraint (see Optional Cable Restraint on a Three-Input 240-A Power Supply) on each three-input 240-A power supply.

Note: Before you remove a chassis from a rack or cabinet, you must remove the optional cable restraint from the three-input 240-A power supply.

To replace the cable restraint on a three-input 240-A power supply:

Removing the T640 Standard Cable Restraint from a Three-Input 240-A Power Supply

The cable restraint is located on the right edge of the power supply faceplate. To remove the standard cable restraint from a three-input 240-A power supply:

  1. Loosen the captive screw on the standard cable restraint or captive screws on the optional cable restraint.
  2. Remove the cable restraint from the power supply.

Figure 12: Standard Cable Restraint on a Three-Input 240-A Power Supply

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Installing the T640 Optional Cable Restraint on a Three-Input 240-A Power Supply

To install the optional cable restraint on a three-input 240-A power supply:

  1. Align the two captive screws on the optional cable restraint with the two threaded holes located at the right edge of the power supply faceplate.
  2. Fasten the captive screws.

Figure 13: Optional Cable Restraint on a Three-Input 240-A Power Supply

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Connecting DC Power to a Three-Input 240-A Power Supply in a T640 Router

To connect a three-input 240-A power supply to the power sources:

  1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  2. Verify that a licensed electrician has attached cable lugs to the power cables that you supply.
  3. Verify that the voltage across the DC power source cables leads is 0 V and that there is no chance that the cables might become active during installation. If needed, switch off the customer site circuit breakers.
  4. Verify that the circuit breakers on the power supply faceplate are in the OFF position (O).
  5. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  6. Remove the nut and washer from each power terminal stud.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  7. Secure the cable lugs to the terminal studs, first with a washer, then with a nut (see Figure 14).
    1. Attach the positive (+) DC source power cable lugs to the RETURN (return) terminals.
    2. Attach the negative (–) DC source power cable lugs to the –48V (input) terminals.

    Use a 7/16-in. (11-mm) nut driver or wrench to tighten the nut. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut.

    Note: For power supplies set to 2-INPUT mode (required for the T640 routing node), connect two DC power cables, one for RETURN and one for -48 V to Input 0 and two DC power cables, one for RETURN and one for -48 V to Input 1.

    Note: INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

  8. Loosen the captive screw or screws on the cable restraint on the right edge of the power supply faceplate.
  9. Route the DC power cables through the cable restraint.
  10. Tighten the cable restraint captive screw or screws to hold the power cables in place.
  11. Verify that the power cabling is correct, that the power cables are not touching or blocking access to other hardware components, and that they do not drape where people could trip on them.
  12. Replace the clear plastic cover over the terminal studs on the faceplate.

Figure 14: Connecting Power Cables to the Power Supply

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Powering On a T640 Three-Input 240-A Power Supply

To power on a three-input 240-A power supply:

  1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis. For more information about ESD, see Preventing Electrostatic Discharge Damage to an M Series, MX Series, or T Series Routing Platform.
  2. Switch on the customer site circuit breakers to provide voltage to the DC power source cables.
  3. Verify that the INPUT PRESENT LEDs on the power supply faceplate are lit steadily, indicating that the inputs are receiving power.
  4. Switch the circuit breakers on the power supply to the ON position (|).

    Note: After a power supply is powered on, it can take up to 60 seconds for status indicators—such as the LEDs on the power supply, the show chassis command display, and messages on the LED display on the craft interface—to indicate that the power supply is functioning normally. Ignore error indicators that appear during the first 60 seconds.

  5. Verify that the CB ON LEDs on the power supply faceplate are lit steadily. The CB ON LEDs blink momentarily, then light steadily to indicate that the circuit breakers are on.
  6. Verify that the DC OK LED on the power supply faceplate is lit steadily, indicating that the power supply is correctly installed and is functioning properly.

Note: After powering on a power supply, wait at least 60 seconds before turning it off. If the system is completely powered off when you power on the power supply, the Routing Engine boots as the power supply completes its startup sequence. If the Routing Engine finishes booting and you need to power off the system again, first issue the CLI request system halt command.

After powering off a power supply, wait at least 60 seconds before turning it back on.

Replacing a T640 Four-Input 240-A DC Power Supply

  1. Removing a T640 Four-Input 240-A DC Power Supply
  2. Installing a T640 Four-Input 240-A DC Power Supply

Removing a T640 Four-Input 240-A DC Power Supply

The router has two redundant, load-sharing DC power supplies. Each power supply is hot-insertable and hot-removable. When one power supply is powered down or removed, the other power supply automatically assumes the entire electrical load for the router.

To remove a four-input 240-A DC power supply:

  1. Switch off the customer site circuit breakers to the power supply being removed. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during the removal process.
  2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
  3. Switch the circuit breakers on the power supply faceplate to the off position (O).

    Figure 15: Four-Input 240-A DC Power Supply

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    Note: After powering off a power supply, wait at least 60 seconds before turning it back on.

  4. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  5. Using a 7/16-in. (11 mm) nut driver, remove the nuts and washers from the terminal studs (see Figure 16).

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

    Figure 16: Disconnecting Power Cables from the Four-Input 240-A DC Power Supply

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  6. Remove the cable lugs from the terminal studs.
  7. Loosen the captive screw or screws on the cable restraint on the right edge of the power supply faceplate.
  8. Carefully move the power cables out of the way.
  9. Loosen the captive screws on the lower corners of the power supply faceplate completely.
  10. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
  11. Grasp the handle on the power supply faceplate and pull firmly. Slide it halfway out of the chassis (see Figure 17).
  12. Place one hand underneath the power supply to support it and slide it completely out of the chassis.

    Caution: Each four-input 240-A DC power supply weighs approximately 26.6 lb. (12.0 kg). Be prepared to support the full weight of the power supply as you remove it from the routing platform.

    Figure 17: Removing a Four-Input 240-A DC Power Supply

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    Warning: Do not touch the power connectors on the rear of the power supply (see Figure 18). They can contain dangerous voltages.

    Figure 18: Rear of the Power Supply Showing Midplane Connectors

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Installing a T640 Four-Input 240-A DC Power Supply

Each four-input 240-A DC power supply weighs approximately 26.6 lb. (12.0 kg). To install a four-input 240-A DC power supply:

  1. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during installation.
  2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
  3. Switch the circuit breakers on the power supply faceplate to the OFF position (O).
  4. Using both hands, slide the power supply into the chassis until you feel resistance (see Figure 20).
  5. Twist the ejector handles at the upper corners of the power supply faceplate clockwise until they stop.
  6. Tighten the captive screws at the lower corners of the power supply faceplate to secure the power supply in the chassis.
  7. Verify that a licensed electrician has attached cable lugs to the power cables that you supply.
  8. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  9. Remove the nut and washer from each power terminal stud.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  10. Attach the lugs on the DC source power cables to the terminal studs.
    1. Attach the positive (+) DC source power cable lugs to the RETURN (return) terminals.
    2. Attach the negative (–) DC source power cable lugs to the –48V (input) terminals.

    Secure the cable lugs to the terminal studs, first with a washer, then with a nut (see Figure 19). Use a 7/16-in. (11-mm) nut driver to tighten the nut. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut.

    Caution: You must use an appropriate torque-controlled tool to tighten the nuts. Applying excessive torque damages the terminal studs and the power supply. The absolute maximum torque that may be applied to this nut is 45 in-lb (5.0 Nm).

    Figure 19: Connecting a Power Cable to a Four-Input 240-A DC Power Supply

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  11. Loosen the captive screws on the cable restraint on the right edge of the power supply faceplate.
  12. Route the DC power cables through the cable restraint.
  13. Tighten the cable restraint captive screws to hold the power cables in place.
  14. Verify that the power cabling is correct, that the power cables do not touch or block access to other hardware components, and that they do not drape where people could trip on them.
  15. Replace the clear plastic cover over the terminal studs on the faceplate.
  16. Switch on the customer site circuit breakers to provide voltage to the DC power source cables.
  17. Verify that the INPUT PRESENT LEDs on the power supply faceplate are lit steadily, indicating that the inputs are receiving power.
  18. Switch the circuit breakers on the power supply to the ON position (|).

    Note: After a power supply is powered on, it can take up to 60 seconds for status indicators—such as the LEDs on the power supply, the command output displays, and messages on the LED display on the craft interface—to indicate that the power supply is functioning normally. Ignore error indicators that appear during the first 60 seconds.

  19. Verify that the CB ON LEDs on the power supply faceplate are lit steadily, indicating that the circuit breakers are on.
  20. Verify that the DC OK LED on the power supply faceplate is lit steadily, indicating that the power supply is correctly installed and is functioning properly. The DC OK LED blinks momentarily, then lights steadily.

Figure 20: Installing a Four-Input 240-A DC Power Supply

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Replacing a T640 Power Supply Cable

Removing a T640 DC Power Supply Cable

You can use this procedure to remove a DC power cable from a Two-Input 160-A power suply, Three-Input 240-A DC power supply, or a Four-Input 240-A DC power supply. To remove a T640 DC Power Supply Cable:

  1. Locate a replacement power cable that meets the specifications defined in T640 DC Power Cable Specifications.

    Caution: A licensed electrician must attach a cable lug to the power cable that you supply. A cable with an incorrectly attached lug can damage the router.

  2. Turn off the customer site circuit breaker that provides voltage to the DC power cable being replaced. Make sure that the voltage across the DC power source cable leads is 0 V and that there is no chance that the cables might become active during the removal process. Follow your site's safety and ESD procedures.
  3. Remove the power cable from external DC power source.
  4. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to one of the ESD points on the chassis.
  5. Switch the circuit breakers on the power supply faceplate to the off position (O).
  6. Remove the clear plastic cover protecting the terminal studs on the faceplate.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  7. Remove the nut and washer from the terminal stud (see Figure 21, Figure 22, and Figure 23). (Use a 7/16-in. (11 mm) nut driver or wrench.)
  8. Remove the cable lug from the terminal studs.
  9. Loosen the captive screw or screws on the cable restraint on the right edge of the power supply faceplate.
  10. Carefully move the power cable out of the way.

Figure 21: Disconnecting a DC Power Cable from a Two-Input 160-A DC Power Supply

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Figure 22: Disconnecting a DC Power Cable from a Three-Input 240-A DC Power Supply

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Figure 23: Disconnecting a DC Power Cable from a Four-Input 240-A DC Power Supply

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Installing a T640 DC Power Supply Cable

Note: Only INPUT 0 and INPUT 1 are supported for the T640 router. INPUT 2 on the three-input 240-A power supply is not supported. Do not connect the replacement cable to INPUT 2.

  1. Slide the replacement power cable lug onto the terminal stud.
  2. Secure the cable lug on the DC power cable to the terminal stud, first with a washer, then with a nut (see Figure 24, Figure 25, and Figure 26). Use a 7/16-in. (11 mm) nut driver or wrench to tighten the nut. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut:
    1. Secure each positive (+) DC source power cable lug to a RTN (return) terminal.
    2. Secure each negative (–) DC source power cable lug to a –48V (input) terminal.

    Note: All inputs on the two-input 160-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and all inputs on the two-input 160-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    Note: INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and INPUT 0 and INPUT 1 on the three-input 240-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    Note: All inputs on the four-input 240-A DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and all inputs on the four-input 240-A DC power supply in slot PEM1 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    Caution: You must ensure that power connections maintain the proper polarity. The power source cables might be labeled (+) and (–) to indicate their polarity. There is no standard color coding for DC power cables. The color coding used by the external DC power source at your site determines the color coding for the leads on the power cables that attach to the terminal studs on each power supply.

  3. Route the power cable through the cable restraint.
  4. Tighten the cable restraint captive screw or screws to hold the power cable in place.
  5. Verify that the DC source power cabling and grounding cabling are correct, that they are not touching or blocking access to router components, and that they do not drape where people could trip on them.
  6. Replace the clear plastic cover over the terminal studs on the faceplate.
  7. Attach the power cable to the external DC power source.
  8. Switch on the external circuit breaker that provides voltage to the DC power source cable that has been replaced.
  9. For a three-input 240-A power supply, verify that the INPUT PRESENT LED is lit steadily, indicating that the input is receiving power.
  10. Switch the circuit breakers on the power supply to the on position (|).

    Note: After a power supply is powered on, it can take up to 60 seconds for status indicators—such as the output status LEDs on the power supply, the show chassis command display, and messages on the LCD on the craft interface—to indicate that the power supply is functioning normally. Ignore error indicators that appear during the first 60 seconds.

  11. Verify that the CB ON LED on the power supply faceplate is lit steadily. The CB ON LED blinks momentarily, then lights steadily to indicate that the circuit breakers are on.
  12. Verify that the DC OK LED on the power supply faceplate is lit steadily, indicating that the power cable is correctly installed and the power supply is functioning normally.

Figure 24: Connecting a DC Power Cable to a Two-Input 160-A DC Power Supply

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Figure 25: Connecting a DC Power Cable to a Three-Input 240-A DC Power Supply

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Figure 26: Connecting a DC Power Cable to a Four-Input 240-A DC Power Supply

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Replacing a T640 Power Supply Filter Element

To replace a power supply filter element (see Figure 27):

  1. Grasp the filter cover on the power supply faceplate and pull it straight off the power supply.
  2. Remove the filter element.
  3. Install a new filter element.
  4. Press the filter cover straight onto the power supply faceplate until all four sides click into place.

Figure 27: Replacing the Power Supply Filter Cover

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Published: 2009-11-25

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