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Replacing a T1600 Three-Input 240-A DC Power Supply

 

The T1600 router has either one nonredundant power supply or two redundant, load-sharing 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.

  1. Removing a T1600 Three-Input 240-A DC Power Supply

  2. Setting the Input Mode Switch on a T1600 Three-Input 240-A DC Power Supply

  3. Installing a T1600 Three-Input 240-A DC Power Supply

  4. Replacing a Cable Restraint on the T1600 Three-Input 240-A DC Power Supply

  5. Connecting a Replacement T1600 Three-Input 240-A DC Power Supply

  6. Powering On a Replacement T1600 Three-Input 240-A DC Power Supply

Removing a T1600 Three-Input 240-A DC Power Supply

To remove a three-input 240-A DC 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.
  3. Switch the circuit breakers on the power supply faceplate to the off position (O).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 1).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 1: Disconnecting Power Cables from the DC Power Supply
    Disconnecting
Power Cables from the DC Power Supply
  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 3).Caution

    Each three-input 240-A DC 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 router.

  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 2). They can contain dangerous voltages.

    Figure 2: Rear of the Power Supply Showing Midplane Connectors
    Rear of the Power
Supply Showing Midplane Connectors
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 3: Removing a Three-Input 240-A DC Power Supply
Removing a Three-Input 240-A DC Power Supply

Setting the Input Mode Switch on a T1600 Three-Input 240-A DC 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 remove it before setting the input mode switch.

Note

For the T1600 router, you must set the input-mode switch to 3-INPUT mode.

To set the input mode switch:

  1. Using a screwdriver, loosen the captive screw holding the metal cover over the input mode switch (see Figure 4).
  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 3-INPUT mode, the switch is located all the way to the left.
  4. Use a sharp, nonconductive object to slide the switch all the way to the left to set the power supply to 3-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 4 shows the input mode switch.

Figure 4: Three-Input 240-ADC Power Supply
Three-Input 240-ADC Power
Supply

Installing a T1600 Three-Input 240-A DC Power Supply

Each three-input 240-A DC power supply weighs approximately 25 lb (11.3 kg). To install a three-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 5).
  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 5: Installing a Three-Input 240-ADC Power Supply
Installing
a Three-Input 240-ADC Power Supply

Replacing a Cable Restraint on the T1600 Three-Input 240-A DC Power Supply

  1. Removing the Standard Cable Restraint from the T1600 Three-Input 240-A Power Supply

  2. Installing the Optional Cable Restraint on the T1600 Three-Input 240-A DC Power Supply

Removing the Standard Cable Restraint from the T1600 Three-Input 240-A Power Supply

Each three-input 240-A power supply is shipped with the standard cable restraint, as shown in Figure 6. Two optional cable restraints are shipped in the accessory box for the T1600 router and in the T1600 upgrade kit.

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 Figure 7) 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.

The cable restraint is located on the right edge of the power supply faceplate. To remove the standard cable restraint:

  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 6: Three-Input 240-A Power Supply with the Standard Cable Restraint
Three-Input 240-A Power Supply with the Standard Cable Restraint
Figure 7: Three-Input 240-A Power Supply with the Optional Cable Restraint
Three-Input 240-A Power Supply with the Optional Cable Restraint

Installing the Optional Cable Restraint on the T1600 Three-Input 240-A DC Power Supply

To install the optional cable restraint:

  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.

Connecting a Replacement T1600 Three-Input 240-A DC Power Supply

To connect a three-input 240-A DC 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.
  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. 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 8). 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 lb-in. (5.0 Nm).

    Note

    For power supplies set to 3-INPUT mode (required for the T1600 router), connect two DC power cables, one for RETURN and one for -48 V, to each of the three inputs.

  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 ground and power cabling are correct, that they 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 8: Connecting DC Power Cables to the Three-Input 240-A DC Power Supply (PWR-T1600-3-80-DC-S)
Connecting
DC Power Cables to the Three-Input 240-A DC Power Supply (PWR-T1600-3-80-DC-S)

Powering On a Replacement T1600 Three-Input 240-A DC Power Supply

To power on a replacement 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.
  2. Switch on the customer site circuit breakers to provide voltage to the DC power source cables.Note

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

  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 command output displays, and messages on the LCD 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, indicating 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. The DC OK LED blinks momentarily, then lights steadily.