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Connecting DC Power to the T1600 Router (Five 60-A Inputs to Six-Input DC Power Supplies)

 

You connect DC power to the router by attaching power cables from the DC power sources to the terminal studs on the power supply faceplates. You must provide power cables (the cable lugs are supplied with the router).

Caution

Do not use a terminal jumper for 60-A DC power cables. Using a terminal jumper is not supported for this procedure. Doing so will cause a short across the inputs and trip your external circuit breaker.

Caution

All connected inputs on the DC power supply in slot PEM0 must be powered by dedicated power feeds derived from feed A, and all connected inputs on the 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 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).

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.

Note

We recommend that the positive (+) DC source power cables to be connected to the RTN (return) terminals be 2.6 in. (6.6 cm) longer than the negative (–) DC source power cables to be connected to the –48 V (input) terminals.

To connect five 60-A DC source power cables to the router, follow this procedure for each DC power supply:

  1. Verify that a properly rated customer site circuit breaker for each DC power cable has been installed. See the DC power electrical safety guidelines for your router for more information.
  2. Switch off the 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.
  3. Verify that a licensed electrician has attached appropriate cable lugs to the DC power cables. See the DC power cable and lug specifications for your router for more information.
  4. Switch the power switch on the power supply faceplate to the standby position.
  5. Remove the clear plastic cover protecting the terminal studs on the faceplate.
  6. Remove the nut and washer from each power terminal stud to be connected. If no washers and nuts are already installed, they should be in the accessory box.
  7. Remove the captive screws on all three cable restraints on the right edge of the power supply faceplate (using a Phillips (+) screwdriver, number 2).
  8. Route the negative (–) DC source power cables for INPUT 0, INPUT 1, INPUT 3, and INPUT 4, over the smallest cable restraint on the far right. The cable restraint is marked as follows top to bottom: INPUT 0, INPUT 1, INPUT 3, and INPUT 4,Note

    You must route the cables in the locations as marked to be able to replace the clear plastic cover over the terminal studs.

    Attach the negative (–) DC source power cable lugs to the –48V (input) terminals on the right: INPUT 0, INPUT 1, INPUT 3, and INPUT 4. Secure the cable lugs to the terminal studs, first with the washers, then with the nuts. Using a 7/16-in. (11 mm) nut driver, tighten the nuts. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut.

    Figure 1: Connecting DC Power Cables
    Connecting DC Power Cables
    Figure 2: Connecting Negative (–) DC Power Cables to INPUT 0, INPUT 1, INPUT 3, and INPUT 4
    Connecting Negative (–) DC Power Cables to INPUT 0,
INPUT 1, INPUT 3, and INPUT 4
  9. Replace the smallest cable restraint on the far right, and tighten the captive screw to hold the power cables for INPUT 0, INPUT 1, INPUT 3, and INPUT 4 in place.
  10. Route the negative (–) DC source power cables for INPUT 2, through the middle cable restraint. The middle cable restraint is marked as follows from top to bottom: INPUT 2, RTN 2, RTN 5, and INPUT 5.Note

    You must route the cable in the location as marked to be able to replace the clear plastic cover over the terminal studs.

    Attach the negative (–) DC source power cable lugs to the INPUT 2 –48 V (input) terminal on the right. Secure the cable lug to the terminal studs, first with the washer, then with the nut. Using a 7/16-in. (11 mm) nut driver, tighten the nut. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut.

    Figure 3: Connecting Negative (–) DC Power Cable to INPUT 2
    Connecting Negative (–) DC Power Cable to INPUT
2
  11. Route the positive (+) DC source power cables for RTN 2 over the middle cable restraint. The middle cable restraint is marked as follows from top to bottom: INPUT 2, RTN 2, RTN 5, and INPUT 5,Note

    You must route the cables as marked to be able to replace the clear plastic cover over the terminal studs.

    Attach the positive (+) DC source power cable lug to the RTN 2 (return) terminal on the left. Secure the cable lug to the terminal stud, first with the washer, then with the nut. Using a 7/16-in. (11 mm) nut driver, tighten the nuts. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to the nut.

  12. Replace the middle cable restraint, and tighten the captive screw to hold the power cables for INPUT 2 and RTN 2 in place.
  13. Route the positive (+) DC source power cables for RTN 0, RTN 1, RTN 3, and RTN 4 over the largest cable restraint on the left. The left cable restraint is marked as follows from top to bottom RTN 0, RTN 1, RTN 3, and RTN 4,Note

    You must route the cables as marked to be able to replace the clear plastic cover over the terminal studs.

    Attach the positive (+) DC source power cable lugs to the RTN terminals on the left: RTN 0, RTN 1, RTN 3, and RTN 4. Secure the cable lugs to the terminal studs, first with the washers, then with the nuts. Using a 7/16-in. (11 mm) nut driver, tighten the nuts. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut.

  14. Replace the left cable restraint, and tighten the captive screw to hold the power cables for RTN 0, RTN 1, RTN 3, and RTN 4 in place.
    Figure 4: Connecting Positive (+) DC Power Cable to RTN 2, RTN 0, RTN 1, RTN 3, RTN 4
    Connecting Positive (+) DC Power Cable to RTN 2,
RTN 0, RTN 1, RTN 3, RTN 4
  15. Verify that the power cabling is correct, that the power cables are not touching or blocking access to router components, and that they do not drape where people could trip on them.
  16. Replace the clear plastic cover over the terminal studs on the faceplate.