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Connecting DC Power to the T4000 Router (Three 80-A DC Power Cables to Six 60-A Inputs)

 

You connect DC power to the router by using a terminal jumper to attach one DC power cable from the DC power source to two terminal studs on the power supply faceplate. Use the terminal jumper kit (model number PWR-T-BUS-BAR-S) to perform this procedure (terminal jumpers might also be referred to as bus bars). The terminal jumper kit contains the terminal jumpers and the new clear plastic cover required to accommodate the terminal jumpers. Six terminal jumpers are required for each power supply. You must provide power cables (the cable lugs are supplied with the router).

Caution

When using a terminal jumper for this procedure, terminate only a single DC power cable to the two input terminals using the terminal jumper as shown in Figure 4 and Figure 5. Do not connect two DC power cables using a terminal jumper to two inputs as shown in Figure 1. Connecting two DC power cables using a terminal jumper to two inputs will cause a short across the inputs and trip your external circuit breaker.

Figure 1: Incorrect Cable Connection to INPUT 1
Incorrect Cable
Connection to INPUT 1
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 80-A DC source power cables to six inputs using a terminal jumper, follow this procedure for each DC power supply:

  1. Check your planned hardware configuration, and verify that three 80-A DC source power cables will provide sufficient power. See the DC power requirements for your router for more information.
  2. 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.
  3. 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.
  4. 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.
  5. Switch the power switch on the power supply faceplate to the standby position.
  6. Remove the clear plastic cover protecting the terminal studs on the faceplate.Note

    You will replace this cover with the new cover provided in the terminal jumper kit (model number PWR-T-BUS-BAR-S). The new cover is labeled 2 in Figure 7.

  7. 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.
  8. Remove the captive screws on all three cable restraints on the right edge of the power supply faceplate (using a Phillips (+) screwdriver, number 2).
  9. Place one terminal jumper over the negative (–) DC INPUT 0 and INPUT 1 terminals on the right.Note

    The terminal jumpers are located in the terminal jumper kit (model number PWR-T-BUS-BAR-S).

    Figure 2: Terminal Jumper
    Terminal Jumper
  10. Place a washer, and then a nut on the negative (–) DC INPUT 0 terminal.

    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 DC Power Cables
    Connecting DC Power Cables
  11. Route the negative (–) DC source power cable for INPUT 1 over the smallest cable restraint on the far right. Note

    The smallest cable restraint is marked as follows from top to bottom: INPUT 0, INPUT 1, INPUT 3, and INPUT 4. You must route the cables in the locations as marked to be able to install the new clear plastic cover over the terminal studs.

    Attach the negative (–) DC source power cable lug to the –48 V (input) INPUT 1 terminal on the right. Secure the cable lug to the terminal stud, first with the washer, then with the nut.

  12. Place one terminal jumper over the negative (–) DC INPUT 2 and INPUT 3 input terminals on the right.
  13. Place a washer, and then a nut on the negative (–) DC INPUT 2 terminal.

    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 the nut.

  14. Route the negative (–) DC source power cable for INPUT 3 over the smallest cable restraint on the far right.

    Attach the negative (–) DC source power cable lug to the –48 V (input) INPUT 3 terminal on the right. 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 nut. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to the nut.

    Figure 4: Negative (–) DC Power Cables Connected to INPUT 1 and INPUT 3
    Negative (–)
DC Power Cables Connected to INPUT 1 and INPUT 3
  15. Replace the smallest cable restraint on the far right, and tighten the captive screw to hold the power cables for INPUT 1 and INPUT 3 in place.
  16. Place one terminal jumper over the negative (–) DC INPUT 4 and INPUT 5 input terminals on the right.
  17. Place a washer, and then a nut on the negative (–) DC INPUT 4 terminal.

    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 the nut.

  18. Route the negative (–) DC source power cable for INPUT 5 through the middle cable restraint. Note

    The middle cable restraint is marked as follows from top to bottom: INPUT 2, RTN 2, RTN 5, and INPUT 5. 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 lug to the –48 V (input) INPUT 5 terminal on the right. Secure the cable lug 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 5: Connecting Negative (–) DC Power Cable to INPUT 5
    Connecting Negative
(–) DC Power Cable to INPUT 5
  19. Place one terminal jumper over the positive (+) DC RTN 4 and RTN 5 input terminals on the left
  20. Place a washer, and then a nut on RTN 4.

    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.

  21. Route the positive (+) DC source power cable for the RTN 5 input terminal through the middle cable restraint. Note

    The middle cable restraint is marked as follows from top to bottom: INPUT 2, RTN 2, RTN 5, and INPUT 5. 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 5 RTN (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 each nut.

  22. Replace the middle cable restraint, and tighten the captive screw to hold the power cables for INPUT 5 and RTN 5 in place.
  23. Place one terminal jumper over RTN 0 and RTN 1.
  24. Place a washer, and then a nut on RTN 0.

    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.

  25. Route the positive (+) DC source power cable for RTN 1 over the largest cable restraint on the left. Note

    The large left cable restraint is marked as follows from top to bottom: RTN 0, RTN 1, RTN 3, and RTN 4. 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 1 terminal on the left. Secure the cable lugs to the terminal stud, 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.

  26. Place terminal jumper over RTN 2 and RTN 3.
  27. Place a washer, and then a nut on RTN 2.

    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.

  28. Route the positive (+) DC source power cable for RTN 3 over the largest cable restraint on the left. Note

    The large left cable restraint is marked as follows from top to bottom: RTN 0, RTN 1, RTN 3, and RTN 4. 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 3 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 each nut.

  29. Replace the large left cable restraint, and tighten the captive screw to hold the power cables for RTN 1 and RTN 3 in place.
    Figure 6: Positive (+) DC Power Cables Connected to RTN 1, RTN 3, and RTN 5
    Positive (+) DC Power Cables Connected to RTN 1, RTN
3, and RTN 5
  30. 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.
  31. Install the clear plastic terminal jumper cover (labeled 2 in Figure 7) located in the terminal jumper kit (model number PWR-T-BUS-BAR-S) to protect the terminal studs on the faceplate. Note

    You must use the terminal jumper cover provided in the terminal jumper kit (model number PWR-T-BUS-BAR-S) to ensure there is no access to the terminal jumpers and for proper cable alignment. The terminal jumper cover (labeled 2 in Figure 7) has three cable openings and is longer than the original clear plastic cover (labeled 1 in Figure 7) that has six cable openings.

    Figure 7: Power Supply Covers
    Power Supply Covers