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Replace Power Supply Modules on the PTX12008

Maintaining the PTX12008 includes removing and installing the power supply modules.

The power supply modules (PSMs) in the PTX12008 are hot-removable and hot-insertable field-replaceable units (FRUs). You can remove and replace the PSMs without powering off the PTX12008 or disrupting the router functions.

Remove an AC/HVAC/HVDC PSM from the PTX12008

Before you remove an AC/HVAC/HVDC PSM:

  • Ensure that you understand how to prevent electrostatic discharge (ESD) damage. See Prevention of Electrostatic Discharge Damage.

  • Ensure that you have the following parts and tools available:

    • An antistatic bag or an antistatic mat—not provided

    • An ESD grounding strap—not provided

    • A pair of heat-protective gloves—not provided

    • A replacement PSM or a cover for the PSM slot

CAUTION:

Before you remove a PSM, ensure that you have PSMs remaining in the chassis sufficient to power the router. See the Power Calculator.
CAUTION:

Do not leave the PSM slot empty for a long time while the router is operational. Either replace a PSM promptly or install a cover over the empty slot.
Warning:

Extreme burn danger—Do not handle a PSM running in the chassis without wearing heat-protective gloves.

To remove an AC/HVAC/HVDC PSM:

  1. Place the antistatic bag or the antistatic mat on a flat, stable surface.
  2. Wrap and fasten one end of the ESD grounding strap around your bare wrist and connect the other end of the strap to an ESD point on the rear panel of the chassis.
    Figure 1: ESD Point on the Rear Panel of the Chassis ESD Point on the Rear Panel of the Chassis
  3. Set the power switch on the PSM to the off (O) position.
  4. Disconnect input power to the PSM. If the input power source outlet has a power switch, set it to the off (O) position.
  5. Gently pull out the plug end of the power cord connected to the power source outlet.
    CAUTION:

    The PSM surfaces are hot.
  6. Wear the heat-protective gloves.
  7. There is a release tab on the power cord end connected to the power source inlet on the PSM. Press the tab to release the cable from the inlet connector and gently pull out the power cord.
  8. Slide the ejector lever on the PSM toward the handle until it stops.
  9. Grasp the PSM handle with one hand and pull the PSM halfway out of the chassis. Allow a few minutes for the PSM to cool.
  10. Place one hand under the PSM to support it. Grasp the PSM handle with your other hand and pull the PSM completely out of the chassis.
  11. Store the PSM in the antistatic bag or on the antistatic mat.
  12. If you are not replacing a PSM, install a cover over the slot. To install the cover, place the cover in the slot and press it until it is fully seated. Do not operate the chassis without a PSM or a cover in place.

Install an AC/HVAC/HVDC PSM on the PTX12008 and Connect to Power

Before you install an AC/HVAC/HVDC PSM and connect it to power:

CAUTION:

Do not install AC/HVAC/HVDC and DC PSMs in the same chassis.
Note:

For redundancy, always plug the two power cords for each PSM:

  • INP0 into the public electricity supply

  • INP1 into an alternative or independent power source
Warning:

The router is pluggable type A equipment installed in a restricted-access location. It has a separate protective earthing terminal on the chassis that must be connected to earth ground permanently to ground the chassis adequately and protect the operator from electrical hazards.
CAUTION:

You must connect the PSM to a dedicated power source and a dedicated circuit breaker. We recommend that you use a customer-site 2-pole circuit breaker rated for 20 A, 300 VAC for HVAC and 20 A, 400 VAC HVDC, or as required by local electrical code.
CAUTION:

Before you begin installing the router, ensure that a licensed electrician has attached an appropriate grounding lug to the grounding cable that you supply. Using a grounding cable with an incorrectly attached lug can damage the router.
Note:

Route all the PSM cords away from the PSM vents and fan trays. Make sure that the power cords do not obstruct the fan trays or block the air inlets of the chassis.

To install an AC/HVAC/HVDC PSM and connect it to power:

  1. Wrap and fasten one end of the ESD grounding strap around your bare wrist and connect the other end of the strap to the ESD point on the rear panel of the chassis.
    Figure 2: ESD Point on the Rear Panel of the Chassis ESD Point on the Rear Panel of the Chassis
    Note:

    You can install the PSMs in any slot labeled PSM 0 through PSM 19 on the rear panel.
  2. If the PSM slot has a cover on it, pull the cover out of the slot by using your fingers. Store the cover for later use.
    Figure 3: Remove the PSM Slot Cover Remove the PSM Slot Cover Remove the PSM Slot Cover
  3. If the PSM has a protective plastic wrap, peel and remove the plastic wrap from all the sides of the PSM.
  4. Using both hands, place the PSM straight into the PSM slot on the rear panel of the chassis.
  5. Slide the PSM straight into the chassis until the PSM is fully seated in the slot. Ensure that the PSM faceplate is flush with any adjacent PSM faceplates or PSM covers.
    Note: You must connect each PSM to a dedicated power source outlet.
  6. Locate the power cord or cords that are appropriate for your geographical location.
  7. Insert the coupler end of the power cord into the power cord inlet on the PSM faceplate.
  8. If the power source outlet has a power switch, set it to the off (O) position.
  9. Insert the power cord plug into a power source outlet.
  10. Dress the power cord and ensure that it does not touch or block access to other router components and that it does not drape where people could trip over it.
  11. Ensure that the router is adequately grounded.
  12. If the power source outlet has a power switch, set it to the on (|) position.
  13. Set the power switch on the PSM to the on (|) position.
  14. Verify that the INP0, INP1, and OK LEDs on the PSM are lit green. If any LED is lit amber, remove power from the PSM and replace the PSM. Do not remove the PSM until you have a replacement PSM ready.
  15. (Optional): Attach the power cable management system. Align the power cable management system brackets with the holes on either sides of the power shelf and tighten the screws by using your fingers.
  16. (Optional): Organize and route the power cables attached to the PSMs to prevent them from dislodging or developing stress points. This step also ensurea proper airflow through the chassis. Secure the cables so that they are not supporting their own weight as they hang to the floor. Place excess cables out of the way in a neatly coiled loop. Placing fasteners on the loop helps to maintain the cable shape.

Remove a DC PSM from the PTX12008

Before you remove a DC PSM:

  • Ensure that you understand how to prevent ESD damage. See Prevention of Electrostatic Discharge Damage.

  • Ensure that you have the following parts and tools available:

    • An antistatic bag and an antistatic mat—not provided

    • An ESD grounding strap—not provided

    • A pair of heat-protective gloves—not provided

    • A Phillips (+) screwdriver, number 1—not provided

    • A 13/32-in. (10 mm) nut driver or socket wrench—not provided

    • A replacement PSM or a cover for the PSM slot

CAUTION:

Before you remove a PSM, ensure that you have PSMs remaining in the chassis sufficient to power the router. See the Power Calculator.
CAUTION:

Do not leave the PSM slot empty for a long time while the router is operational. Either replace a PSM promptly or install a cover over the empty slot.
Warning:

Extreme burn danger—Do not handle a PSM running in the chassis without wearing heat-protective gloves.

To remove a DC PSM:

  1. Place the antistatic bag and the antistatic mat on a flat, stable surface.
  2. Wrap and fasten one end of the ESD grounding strap around your bare wrist and connect the other end of the strap to the ESD point on the rear panel of the chassis.
    Figure 4: ESD Point on the Rear Panel of the Chassis ESD Point on the Rear Panel of the Chassis
  3. Make sure that the voltage across the DC power source cable leads is 0 V. Also ensure that there is no chance that the cables might become active during the removal process.
  4. Set the power switch on the PSM to the off (O) position.
    CAUTION:

    The PSM surfaces are hot.
  5. Wear the heat-protective gloves.
  6. Slide the ejector lever on the PSM toward the PSM handle until the lever stops.
  7. Grasp the PSM handle with one hand and pull the PSM halfway out of the chassis. Allow a few minutes for the PSM to cool.
  8. Loosen the captive screws that secure the input tray by using the Phillips (+) screwdriver, number 1.
  9. Hold the input tray handle and gently pull the input tray out of the PSM. Place the input tray on the antistatic mat.
  10. Place one hand under the PSM to support it. Grasp the PSM handle with your other hand and pull the PSM completely out of the chassis.
  11. Store the PSM in the antistatic bag or on the antistatic mat.
  12. If you are installing a replacement PSM, install it and attach the input tray in the new PSM. See Install a DC PSM on the PTX12008 and Connect to Power.
  13. If you are not installing a replacement PSM:

    • Install a cover over the PSM slot on the chassis. To install the cover, place the cover in the slot and press it until it is fully seated. Do not operate the chassis without a PSM or a cover in place.

    • Use Phillips (+) screwdriver, number 1 to remove the clear plastic cover from the input tray.

    • Unscrew the nuts from the input terminal studs in the input tray. Turn the nuts counterclockwise using the 13/32-in. (10 mm) nut driver or socket wrench to unscrew them.

    • Remove the cable lugs from the input terminal studs and label them.

    • Replace the nuts and tighten them.

    • Replace the clear plastic cover.

    • Slide the input tray into the input tray slot on the PSM. Use Phillips (+) screwdriver, number 1 to tighten the captive screws that secure the input tray.

Install a DC PSM on the PTX12008 and Connect to Power

Before you install a DC PSM and connect it to power:

  • Ensure that you have followed the following safety warnings and cautions:

    Warning:

    Before performing DC power procedures, ensure that power is removed from the DC circuit. To ensure that all power is off, locate the circuit breaker on the panel board that services the DC circuit, switch the circuit breaker to the off position, and tape the switch handle of the circuit breaker in the off position.
    CAUTION:

    Before you connect power to the router, a licensed electrician must attach a cable lug to the grounding and power cables that you supply. A cable with an incorrectly attached lug can damage the router (for example, by causing a short circuit).
    CAUTION:

    Do not install AC/HVAC/HVDC and DC PSMs in the same chassis.
    CAUTION:

    To meet safety and electromagnetic interference (EMI) requirements and to ensure proper operation, you must connect the chassis to earth ground before you connect to power. For installations that require a separate grounding conductor to the chassis, use the protective earthing terminal on the router chassis to connect to earth ground.
    Note:

    You must connect the battery returns of the DC PSM as an isolated DC return (DC-I).
    CAUTION:

    The PSM requires a dedicated circuit breaker for each input DC feed. Choose a breaker that delivers 80 A (80 V) of input current, or as required by local electrical code.
    Warning:

    Extreme burn danger—Do not handle a PSM running in the chassis without wearing heat-protective gloves.
    Warning:

    The router has a separate protective earthing terminal on the chassis that must be connected to earth ground permanently to ground the chassis adequately and protect the operator from electrical hazards.
    CAUTION:

    Before you begin installing the router, ensure that a licensed electrician has attached an appropriate grounding lug to the grounding cable that you supply. Using a grounding cable with an incorrectly attached lug can damage the router.
    Note:

    Route all the PSM cords away from the PSM vents and fan trays. Make sure that the power cords do not obstruct the fan trays or block the air inlets of the chassis.

  • Ensure that you understand how to prevent ESD damage. See Prevention of Electrostatic Discharge Damage.

  • Ensure that you have the following parts and tools available:

    • An antistatic bag or an antistatic mat—not provided

    • An ESD grounding strap—not provided

    • DC power source cables (not provided) with the cable lugs (provided) attached

      The cable lugs (Panduit LCD4-14A-L or equivalent) are sized for 4-AWG (21.1 mm2) power source cables. When you are using the DC PSMs in the chassis, the DC power source cables that you provide must be 4-AWG (21.1 mm2) stranded wire. We recommend that you install heat-shrink tubing insulation around the crimped section of the power cables and lugs.

      The provided terminal lugs for the DC are Panduit LCD4-14A-L, or equivalent, and sized for 4-AWG (21.1 mm2) power source cables. The 4-AWG (21.1 mm²) stranded wire must be rated 90 °C, or according to local electrical code.

    • A 13/32-in. (10 mm) nut driver or socket wrench—not provided

    • A Phillips (+) screwdriver, number 1—not provided

    • A multimeter—not provided

To install a DC PSM and connect it to power:

  1. Place the antistatic mat on a flat, stable surface.
  2. Wrap and fasten one end of the ESD grounding strap around your bare wrist and connect the other end of the strap to an ESD point on the rear panel of the chassis.
    Figure 5: ESD Point on the Rear Panel of the Chassis ESD Point on the Rear Panel of the Chassis
  3. If the PSM has a protective plastic wrap, peel and remove the plastic wrap from all the sides of the PSM.
  4. Loosen the captive screws that secure the input tray by using the Phillips (+) screwdriver, number 1. Hold the input tray handle and gently pull the input tray out of the PSM.
  5. Place the PSM and input tray on the antistatic mat.
  6. Install heat-shrink tubing insulation around the power cables.

    • Slide the tubing over the portion of the cable where it is attached to the lug barrel. Ensure that the tubing covers the end of the wire and the attached lug barrel.

      CAUTION:

      Do not overheat the tubing.

    • Shrink the tubing with a heat gun. Ensure that you evenly heat all sides of the tubing so that it shrinks around the cable tightly.

  7. Loosen the screws that secure the cover over the input tray by using the Phillips (+) screwdriver, number 1 and remove the cover.
    Figure 6: Remove the Input Tray Cover Remove the Input Tray Cover
  8. Loosen the nuts from each DC power input terminal by using the 13/32-in. (10 mm) nut driver or socket wrench and remove the nuts.
  9. Ensure that the power source circuit breaker is open so that the voltage across the cable leads of each DC power source cable is 0 V. Also ensure that there is no chance that the cable leads might become active while you are connecting DC power.
  10. Install each power cable lug on the DC power input terminal, securing it with the nuts. Apply between 23 lb-in. (2.6 Nm) and 25 lb-in. (2.8 Nm) of torque to each nut by using the 13/32-in. (10 mm) nut driver or socket wrench.

    1. Secure each positive (+) DC source power cable lug to the RTN (return) DC power input terminal.

    2. Secure each negative (–) DC source power cable lug to the –48V (input) DC power input terminal.

    Figure 7: Connect the DC Power Source Cables Connect the DC Power Source Cables

    Each PSM has two independent sets of DC power input terminals (INPUT 1: RTN -48V/-60V and INPUT 2: RTN -48V/60V). For feed redundancy, you must power each PSM with dedicated power feeds from INPUT 1 and INPUT 2. This configuration provides the commonly deployed INPUT 1/INPUT 2 feed redundancy for the router. There is basic insulation between the input feeds and the chassis ground and between the RTN input feeds.

  11. Verify that the DC power cables are correctly labeled before connecting power to the PSM. In a typical power distribution scheme where the return conductor is connected to the chassis ground at the battery plant, you can use a multimeter to verify the resistance. Measure the resistance of the –48V cable and each RTN DC cable to the chassis ground to determine polarity:

    • The cable with very high resistance (indicating an open circuit) to chassis ground is negative (–). You install this cable on the –48V (input) DC power input terminal.

    • The cable with very low resistance (indicating a closed circuit) to chassis ground is positive (+). You install this cable on e RTN (return) DC power input terminal.

    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.
  12. Install the plastic cable cover over each set of power cables by using the Phillips (+) screwdriver, number 1 to tighten the screw.
  13. Slide the input tray into the input tray slot on the PSM. Tighten the captive screws by turning them clockwise using the Phillips (+) screwdriver, number 1 or your fingers. Do not overtighten—do not apply more than 4.7 lb-in (0.53 Nm) of torque to the screws.
  14. Ensure that the power switch on the PSM is set to the off (O) position. This switch turns off the output voltage; it does not interrupt DC power feed.
    Note:

    You can install the PSMs in any slot labeled PSM 0 through PSM 19 on the rear panel.
  15. If the PSM slot has a cover on it, pull the cover out of the slot. Store the cover for later use.
    Figure 8: Remove the PSM Slot Cover Remove the PSM Slot Cover
  16. Using both hands, place the PSM in the PSM slot on the rear panel of the router.
  17. Slide the PSM straight into the chassis until the PSM is fully seated in the slot. Ensure that the PSM faceplate is flush with any adjacent PSM faceplates or PSM covers.
    Figure 9: Install a DC PSM Install a DC PSM
    Note:

    Ensure that the ejector is fully open, to avoid scratching the chassis.
  18. Dress the power cables and ensure that they do not touch or block access to other router components and that they do not drape where people could trip over them.
  19. Ensure that the router is adequately grounded.
  20. The PSM is shipped with the dual inline package (DIP) switch set to 80 amperes (A). If your battery or power distribution unit is rated lower, set the DIP switch to 60 A.
  21. Press the power switch to the on (|) position.
  22. Verify that the input 0 (INP0) and input 1 (INP1) LEDs on the PSM faceplate are lit green and are on steadily.
  23. (Optional): Attach the power cable management system. Align the power cable management system brackets with the holes on either sides of the power shelf and tighten the screws by using your fingers.
  24. (Optional): Organize and route the power cables attached to the PSMs by using the power cable management system to prevent them from dislodging or developing stress points. This step also ensures proper airflow through the chassis. Secure the cables so that they are not supporting their own weight as they hang to the floor. Place excess cables out of the way in a neatly coiled loop. Placing fasteners on the loop helps to maintain the cable shape.