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Replacing a T1600 DC Power Supply Cable on a Three-Input 240-A DC Power Supply or Four-Input 240-A DC Power Supply

 
  1. Removing a T1600 DC Power Supply Cable From a Three-Input 240-A DC Power Supply or Four-Input 240-A DC Power Supply

  2. Installing a T1600 DC Power Supply Cable on a Three-Input 240-A DC Power Supply or Four-Input 240-A DC Power Supply

Removing a T1600 DC Power Supply Cable From a Three-Input 240-A DC Power Supply or Four-Input 240-A DC Power Supply

You can use this procedure to remove a DC power cable from a three-input 240-A DC power supply or a four-input 240-A DC power supply. To remove a DC power supply cable:

  1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to an approved site ESD grounding point. See the instructions for your site.
  2. Switch off the customer site circuit breakers for all the cables attached to the power supply. 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.
  3. Remove the power cable from the 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.
  7. Remove the nut and washer from the terminal stud on the power supply (see Figure 1). (Use a 7/16-in. (11 mm) nut driver.)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 a Power Cable from a Three-Input 240-A DC Power Supply
    Disconnecting
a Power Cable from a Three-Input 240-A DC Power Supply
    Figure 2: Disconnecting a Power Cable from a Four-Input 240-A DC Power Supply
    Disconnecting
a Power Cable from a Four-Input 240-A DC Power Supply
  8. Remove the cable lug from the terminal stud on the power supply.
  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.

Installing a T1600 DC Power Supply Cable on a Three-Input 240-A DC Power Supply or Four-Input 240-A DC Power Supply

You can use this procedure to install a DC power cable on either a three-input 240-A DC power supply or a four-input 240-A DC power supply. To install a DC power supply cable:

  1. Locate a DC power cable that meets the specifications defined in T1600 DC Power Cables and Lugs.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. Route the power cable through the cable restraint.
  3. Attach the lug on the DC source power cable to the terminal stud.
    1. Attach a positive (+) DC source power cable lug to the RETURN (return) terminals.
    2. Attach a negative (–) DC source power cable lug to the –48V (input) terminals.

    Secure the cable lug to the terminal stud, first with a washer, then with a nut (see Figure 3 and Figure 4). 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).

    Figure 3: Connecting a Power Cable to a Three-Input 240-A DC Power Supply
    Connecting a Power Cable to a Three-Input 240-A DC Power Supply
    Figure 4: Connecting a Power Cable to a Four-Input 240-A DC Power Supply
    Connecting a Power Cable to a Four-Input 240-A DC Power Supply
  4. Tighten the cable restraint captive screw or screws to hold the power cable in place.
  5. Replace the clear plastic cover over the terminal studs on the faceplate.
  6. Verify that the DC source power cabling is correct, that the power cable is not touching or blocking access to router components, and it does not drape where people could trip on it.
  7. Attach the other end of the power cable to the external DC power source.
  8. Switch on the customer site circuit breakers.
  9. Verify that the INPUT PRESENT LEDs on the power supply faceplate are lit steadily, indicating that the inputs are receiving voltage.
  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 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.

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