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    Replacing M320 Power System Components

    Replacing an M320 AC Power Supply

    1. Removing an M320 AC Power Supply
    2. Installing an M320 AC Power Supply

    Removing an M320 AC Power Supply

    The power supplies are located at the rear of the chassis below the SIBs. Each power supply weighs approximately 10 lb (4.5 kg).

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

    To remove an AC 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 power switch on the AC power supply faceplate to the off position (O).
    3. Unplug the power cord from the power source receptacle.
    4. Remove the cable restraint from the right edge of the power supply faceplate by removing its retainer screw.
    5. Unplug the power cord from the appliance inlet on the power supply faceplate.
    6. Loosen the captive screw on each side of the power supply faceplate completely.
    7. Grasp the flange on each side of the power supply faceplate, placing your hand between the flange and the chassis.
    8. Pull firmly to start removing the power supply. Slide it halfway out of the chassis (see Figure 1).

      Warning: Do not touch the power connectors on the rear of the power supply (see Figure 2). They can contain dangerous voltages.

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

      Caution: Each power supply weighs approximately 10 lb (4.5 kg). Be prepared to support the full weight of the power supply as you remove it from the router.

    Figure 1: Removing an AC Power Supply

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    Figure 2: Rear of the Power Supply Showing Midplane Connector

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    Installing an M320 AC Power Supply

    To install an AC power supply (see Figure 3):

    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 the power switch on the AC power supply faceplate to the off position (O).
    3. Using both hands, slide the power supply into the chassis until you feel resistance.
    4. Firmly push the power supply into the chassis until it comes to a stop. The power supply faceplate should be flush with any adjacent power supply faceplates.
    5. Tighten the captive screws on each side of the power supply faceplate to secure the power supply in the chassis.
    6. Insert the appliance coupler end of a power cord into the appliance inlet on the power supply faceplate.
    7. Remove the cable restraint from the right edge of the power supply faceplate by removing its retainer screw.
    8. Wrap the cable restraint around the power cord, then slide it along the power cord to a position that enables you to reinstall it in the power supply faceplate.
    9. Reinstall the cable restraint by tightening its retainer screw partway into the power supply faceplate.
    10. Carefully pull the AC power cord through the cable restraint until you have the desired amount of slack in the power cord.
    11. Tighten the cable restraint retainer screw to hold the power cord in place.
    12. Insert the power cord plug into an AC power source receptacle. Verify that the power cord does not block access to router components or drape where people could trip on it.
    13. Switch the powers seitch on the power supply faceplate to the on position (|). Verify that the OUTPUT OK status LED on the power supply faceplate blinks, then lights steadily approximately 1 minute after you switch the power switch on.

    Figure 3: Installing an AC Power Supply

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    Replacing an M320 DC Power Supply

    1. Removing an M320 DC Power Supply
    2. Installing an M320 DC Power Supply

    Removing an M320 DC Power Supply

    The power supplies are located at the rear of the chassis below the SIBs. Each power supply weighs approximately 10 lb (4.5 kg).

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

    To remove 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 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 breaker on the DC power supply faceplate to the off position (O).
    4. Remove the clear plastic cover protecting the terminal studs on the faceplate.
    5. Remove the nuts and washers from the terminal studs (see Figure 4). (Use a 7/16-in. (11 mm) nut driver.)

      Figure 4: 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 screws on the cable restraints on the right edge of the power supply faceplate.
    8. Carefully move the power cables out of the way.
    9. Loosen the captive screw on each side 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. Pull firmly to start removing the power supply. Slide it halfway out of the chassis (see Figure 5).

      Warning: Do not touch the power connectors on the rear of the power supply (see Removing an M320 AC Power Supply). They can contain dangerous voltages.

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

      Caution: Each power supply weighs approximately 10 lb (4.5 kg). Be prepared to support the full weight of the power supply as you remove it from the router.

    Figure 5: Removing a DC Power Supply

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    Installing an M320 DC Power Supply

    To install a DC power supply (see Figure 6):

    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.
    3. Switch the circuit breaker on the DC power supply faceplate to the off position (O).
    4. Using both hands, slide the power supply into the chassis until you feel resistance.
    5. Firmly push the power supply into the chassis until it comes to a stop. The power supply faceplate should be flush with any adjacent power supply faceplates.
    6. Tighten the captive screws on each side 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 nuts and washers from the terminal studs.
    9. Attach the lugs on the DC source power cables to the terminal studs.
      1. Attach the lugs on the positive (+) DC source power cables to the terminal studs.
      2. Attach the lugs on the negative (–) DC source power cables to the terminal studs.

      Secure each cable lug to the terminal stud, first with a washer, then with a nut. Use a 7/16-in. (11 mm) nut driver or socket 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: The DC power supplies in slots PEM0 and PEM1 must be powered by dedicated power feeds derived from feed A, and the DC power supplies in slots PEM2 and PEM3 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    10. Loosen the captive screw on the cable restraint on the right edge of the power supply faceplate.
    11. Route the positive and negative DC power cables through the top and bottom of the cable restraint.
    12. Tighten the cable restraint captive screw to hold the power cables in place.
    13. Verify that the ground and power 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.
    14. Replace the clear plastic cover over the terminal studs on the faceplate.
    15. Switch on the external circuit breakers to provide voltage to the DC power source cable leads.
    16. Switch the circuit breaker on the power supply faceplate to the on position (|). Verify that the OUTPUT OK status LED on the power supply faceplate blinks, then lights steadily approximately 1 minute after you switch the power supply circuit breaker on.

    Figure 6: Installing a DC Power Supply

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    Figure 7: Connecting Power Cables to the DC Power Supply

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    Replacing an M320 AC Power Supply Cord

    To replace the power cord for an AC power supply:

    1. Locate a replacement power cord with the type of plug appropriate for your geographical location (see M320 AC Power Cord Specifications).
    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 power switch on the power supply faceplate to the off position (O).
    4. Unplug the power cord from the power source receptacle.
    5. Remove the cable restraint from the right edge of the power supply faceplate by removing its retainer screw.
    6. Remove the cable restraint from the power cord and save it so you can use it on the replacement power cord.
    7. Unplug the power cord from the appliance inlet on the power supply faceplate.
    8. Insert the appliance coupler end of the replacement power cord into the appliance inlet on the power supply faceplate.
    9. Wrap the cable restraint around the power cord, then slide it along the power cord to a position that enables you to reinstall it in the power supply faceplate.
    10. Reinstall the cable restraint by tightening its retainer screw partway into the power supply faceplate.
    11. Carefully pull the AC power cord through the cable restraint until you have the desired amount of slack in the power cord.
    12. Tighten the cable restraint retainer screw to hold the power cord in place.
    13. Insert the power cord plug into an AC power source receptacle. Verify that the power cord does not block access to router components or drape where people could trip on it.
    14. Switch the power switch on the power supply faceplate to the on position (|). Verify that the OUTPUT OK status LED on the power supply faceplate blinks, then lights steadily approximately 1 minute after you switch the power switch on.

    Replacing an M320 DC Power Supply Cable

    To replace a power cable for a DC power supply:

    1. Locate a replacement power cable that meets the specifications defined in M320 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 (for example, by causing a short circuit).

    2. 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.

    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.
    4. Switch the circuit breaker on the DC power supply faceplate to the off position (O).
    5. Remove the power cable from the DC power source.
    6. Remove the clear plastic cover protecting the terminal studs on the faceplate.
    7. Remove the nuts and washers from the terminal studs (see Figure 8). (Use a 7/16-in. (11 mm) nut driver.)
    8. Remove the cable lug from the terminal studs.
    9. Loosen the captive screw on the cable restraint on the right edge of the power supply faceplate.
    10. Carefully move the power cable out of the way.
    11. Attach the lug on the replacement power cable to the terminal studs, making sure the cable is not touching or in the way of any router components.
    12. Attach the lugs on the DC source power cables to the terminal studs.
      1. Attach the lugs on the positive (+) DC source power cables to the terminal studs.
      2. Attach the lugs on the negative (–) DC source power cables to the terminal studs.

      Secure each cable lug to the terminal stud, first with a washer, then with a nut. Use a 7/16-in. (11 mm) nut driver or socket 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: The DC power supplies in slots PEM0 and PEM1 must be powered by dedicated power feeds derived from feed A, and the DC power supplies in slots PEM2 and PEM3 must be powered by dedicated power feeds derived from feed B. This configuration provides the commonly deployed A/B feed redundancy for the system.

    13. Route the power cable through the cable restraint.
    14. Tighten the cable restraint captive screw to hold the power cable in place.
    15. Replace the clear plastic cover over the terminal studs on the faceplate.
    16. Attach the power cable to the DC power source.
    17. 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.
    18. Switch the circuit breaker on the DC power supply faceplate to the on position (|). Verify that the OUTPUT OK status LED on the power supply faceplate blinks, then lights steadily approximately 1 minute after you switch the power supply circuit breaker on.

    Figure 8: Disconnecting or Connecting a Power Cable from a DC Power Supply

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    Replacing an M320 Fuse

    Warning: You must power off the router before removing or installing a fuse.

    To replace a fuse, you remove the power supply in slot PEM0—while the router is powered on—to determine which fuse has blown. Before you remove the fuse, you must power off the router, then remove the power supply in slot PEM1 to access the fuse.

    To replace a fuse (see Figure 9):

    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. Power off and remove the power supply in slot PEM0. For complete instructions, see Replacing an M320 AC Power Supply or Replacing an M320 DC Power Supply.

      Caution: Consider the following before you remove a power supply:

      • An AC-powered router can continue to provide power for all router hardware configurations with three operating power supplies. If removing the power supply from slot PEM0 leaves only two power supplies in the router, you must first ensure that the router does not consume more than 2500 W. If the router does not consume more than 2500 W, you can safely operate the router with a total of two AC power supplies. To calculate the power consumption for various hardware configurations, see M320 Power Requirements.
      • If you remove a DC power supply from slot PEM0, slot PEM2 must contain an operating DC power supply in order to keep the router operating.

        For more information about power supply redundancy, see M320 AC Power Supplies Description and M320 DC Power Supplies Description.

    3. Determine which fuse has blown. The yellow LED under the fuse lights and the indicator bulb becomes visible through the clear cover on the fuse.
    4. Power off the router as described in Powering Off the M320 Router.
    5. Remove the power supply in slot PEM1. For complete instructions, see Replacing an M320 AC Power Supply or Replacing an M320 DC Power Supply.
    6. Grasp the blown fuse by the edges and rock it up and down in its slot until it disconnects. If the cover slips off the fuse, snap the cover back into place and begin again.

      Note: We recommend that you use an insulated fuse removal tool to remove fuses.

    7. Remove the appropriate fuse from the selection of spare fuses labeled SPARE in Figure 9. (The labels shown in the figure do not appear on the actual fuses—the clear cover on every fuse reads BUSS GMT-X—and might not match the labels on the midplane. Ignore the labels on the midplane.) Verify that the spare has the same rating and color coding as the fuse it is replacing, as specified in M320 Fuse Specifications. To see the indicator bulb and printed rating, look at the fuse from the side.
    8. Orient the replacement fuse over the slot so that the text on the fuse cover (BUSS GMT-X) reads from bottom to top.
    9. Press the new fuse into the slot.
    10. Reinstall the power supply into slot PEM1. For complete instructions, see Installing an M320 AC Power Supply or Installing an M320 DC Power Supply.
    11. Power on the router as described in Powering On the M320 Router.
    12. Verify that the yellow LED under the replacement fuse is no longer lit.
    13. Reinstall the power supply into slot PEM0 and power it on. For complete instructions, see Installing an M320 AC Power Supply or Installing an M320 DC Power Supply.
    14. Order new fuses from an electrical supply house to replace the spare fuses. The Cooper Bussman product number for each fuse is GMT-X, where X is the amperage rating. For example, product number GMT-15 is a 15-A fuse, required for an FPC.

    Figure 9: Fuses in the Midplane

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    Published: 2011-03-02