Power Supply Installation

This chapter describes how to remove and install a new or replacement power supply. Your router ships with at least one installed power-supply module (AC or DC, depending on your order).

The power-supply modules are field-replaceable units (FRUs) and are hot-swappable when deployed in non-hazardous locations.

Power Supply Installation

This chapter describes how to remove and install a new or replacement power supply. Your router ships with at least one installed power-supply module (AC or DC, depending on your order).

The power-supply modules are field-replaceable units (FRUs) and are hot-swappable when deployed in non-hazardous locations.

Power-Supply Modules

The following table lists the supported power supply modules. For detailed specifications, see the data sheet.

Table 1. Power Supply Modules

Model

Description

PWR-RGD-AC-DC-H

High-voltage AC or DC, 100-240VAC 50-60Hz/100-250VDC input, 150 watt output

PWR-RGD-DC-LOW-H

Low-voltage DC, 24-60VDC input, 150 watt output

PWR-RGD-AC-DC-250

High-voltage AC or DC, 100-240VAC 50-60Hz/100-250VDC input, 250 watt output


Note
The power supplies listed are recommended for new installations. The older PWR-RGD-LOW-DC and PWR-RGD-AC-DC power supplies (without the -H suffix) are supported for users who already own them.
Figure 1. PWR-RGD-AC-DC Power-Supply Module

1

Power-supply module

3

Captive screw

2

PSU OK LED

Figure 2. PWR-RGD-LOW-DC Power-Supply Module

1

Power-supply module

3

Captive screw

2

PSU OK LED

For a description of the PSU OK LEDs, see Power-Supply Module LEDs.

Power-Supply Module LEDs

The router power-supply module LEDs are labeled PSU1 and PSU2 (on the router) and PSU OK (on the power-supply module). They show whether power-supply modules 1 and 2 are receiving power.

Table 2. Power Supply Module LEDs

Color

System Status

Off

Power-supply module (1 or 2) is not installed.

Green

Valid input is present, and the output is within the operating range.

Red

Valid input is present, and the output is outside the operating range or is not present.

Blinking red

Power-supply module (1 or 2) is installed but valid input is not present.

Power-Supply Module Installation

Installation Guidelines

Observe these guidelines when removing or installing a power-supply module:

A power-supply module that is only partially connected to the router disrupts the system operation.


Warning

Statement 1029—Blank Faceplates and Cover Panels

Blank faceplates and cover panels serve three important functions: they reduce the risk of electric shock and fire, they contain electromagnetic interference (EMI) that might disrupt other equipment, and they direct the flow of cooling air through the chassis. Do not operate the system unless all cards, faceplates, front covers, and rear covers are in place.

Installing a Power-Supply Module

This procedure is for installing a power-supply module in the PSU1 or PSU2 slot.


Warning

Statement 1028—More Than One Power Supply

This unit might have more than one power supply connection. To reduce risk of electric shock, remove all connections to de-energize the unit.


Caution

Equipment installation must comply with local and national electrical codes.

Equipment That You Need

  • Torque driver(s) capable of 5 to 35 in-lbs
  • Ring, spade, or flanged spade terminal (terminals should be insulated)
    • Ring terminal (such as Tyco part number 2-34158-1 for 16– 14 AWG or 2-34852-1 for 12– 10 AWG wire)
    • Spade terminal (such as Tyco part number 54367-2 for 16– 14 AWG wire)
    • Flanged spade terminal (such as Tyco part number 2-324165-1 for 16– 14 AWG wire or 1-324581-1 for 12– 10 AWG wire)
  • Use the 16-14 AWG wire and appropriate terminals for the AC or high-voltage DC power supply
  • Use the12-10 AWG wire and appropriate terminals for the low-voltage DC power supply
  • Crimping tool (such as Thomas & Bett part number WT2000, ERG-2001)
  • 6-gauge copper ground wire
  • 12-AWG wire (minimum) for the low-voltage power-supply module and 16-AWG (minimum) wire for the high-voltage power-supply module
  • For power source connections, use wires rated for at least 194°F (90°C).
  • UL- and CSA-rated style 1007 or 1569 twisted-pair copper wire
  • Wire-stripping tools for stripping 6-, 10-, 12-, 14-, and 16-gauge wires.
  • Number-2 Phillips screwdriver
  • Flat-blade screwdriver

Grounding the router

Follow the grounding procedures at your site and observe these warnings:


Warning

Statement 1024—Ground Conductor

This equipment must be grounded. To reduce the risk of electric shock, never defeat the ground conductor or operate the equipment in the absence of a suitably installed ground conductor. Contact the appropriate electrical inspection authority or an electrician if you are uncertain that suitable grounding is available.


Warning

Statement 1046—Installing or Replacing the Unit

To reduce risk of electric shock, when installing or replacing the unit, the ground connection must always be made first and disconnected last.

If your unit has modules, secure them with the provided screws.


Caution

Follow the grounding procedure instructions, and use an appropriately Listed or certified lug (included with the router) for number-6 AWG wire and 10-32 ground-lug screws.


Note
You can use the grounding lug to attach a wrist strap for ESD protection during servicing.

Follow these steps to install a dual-hole lug on the router. Be sure to follow any grounding requirements at your site.

Procedure

Step 1

Use a Phillips screwdriver or a ratcheting torque screwdriver with a Phillips head to remove the ground screws from the cable side of the router. You need the screws in Step 4.

Step 2

Strip the 6-gauge ground wire to 0.5 inch (12.7 mm) ± 0.02 inch (0.5 mm). See the following figure. Stripping more than the recommended amount of wire can leave exposed wire from the connector.

Figure 3. Stripping the Ground Wire

Step 3

Insert the ground wire into the terminal lug, and crimp the terminal to the wire. (see the following figure).

Figure 4. Crimping the Terminal Lug

Step 4

Slide the ground screws from Step 1 through the terminal lug. Insert the ground screws into the opening on the cable side.

1

Ground lug mounting points

2

Terminal lug

3

M4 screws (2)

Step 5

Use a ratcheting torque screwdriver to tighten the ground screws to 11 to 14 in-lbs.

Step 6

Attach the other end of the ground wire to an appropriate ground.

Installing the Power Supply Module in the Router

Procedure

Step 1

Ensure that the power is off at the AC or DC circuits.

Locate the circuit breakers, turn them OFF, and lock out the circuit.

Warning

 

If the power is not off at the AC or DC circuit breaker, do not touch the power-input terminal.

Step 2

Use a Phillips screwdriver to loosen the two captive screws of the blank power-supply module and gently pull it out.

Step 3

Insert the power supply module into the slot, and gently push it in. Make sure that the alignment tabs of the module fit into the chassis, as shown in the following figure.

1

Power supply modules

2

Power supply slots

3

LED panel

4

Captive screws

5

Alignment tabs

Step 4

After the module is properly inserted, tighten the module plate to the router with the two captive screws. The screws should be torqued to 10 to 12 in-lbs.

Installing the DC Power Supply in the Router

To remove and install a DC-powered power supply module, follow these steps:

Procedure

Step 1

Turn off power at the DC circuits. To ensure that power is removed from the DC circuits, locate the circuit breakers for the DC circuits, switch the circuit breakers to the OFF position, and tape the circuit-breaker switches in the OFF position.

Step 2

Use a number-2 Phillips screwdriver to remove the plastic safety cover from the power supply terminal blocks.

Step 3

Use a number-1 Phillips screwdriver to remove the DC-input power wires from the power terminals.

Use a Phillips screwdriver to loosen the two captive screws at the lower edge that secure the power supply module to the router chassis.

Step 4

Remove the power supply module from the power slot by pulling on the extraction handle.

Step 5

Insert the new power supply into the power supply slot, and gently apply pressure while pushing the module into the slot (see the following figure). When correctly inserted, the power supply is flush with the router rear panel.

Step 6

Use a ratcheting torque screwdriver to torque each screw to 8–10 in-lb (4-6.5 in-lb for 250 W PSU).

Wiring the Power Source

Before you wire the power source, review these warnings:


Warning

Statement 1005—Circuit Breaker

This product relies on the building’s installation for short-circuit (overcurrent) protection. To reduce risk of electric shock or fire, ensure that the protective device is rated not greater than: AC: 10 A, DC: 15 A


Warning

Statement 1022—Disconnect Device

To reduce the risk of electric shock and fire, a readily accessible disconnect device must be incorporated in the fixed wiring.


Warning

Statement 1086—Replace Cover on Power Terminals

Hazardous voltage or energy may be present on power terminals. To reduce the risk of electric shock, make sure the power terminal cover is in place when the power terminal is not being serviced. Be sure uninsulated conductors are not accessible when the cover is in place.

Procedure

Step 1

Ensure that the power is off at the AC or DC circuits.

Locate the circuit breakers, turn them OFF, and lock out the circuit.

Warning

 

If the power is not off at the AC or DC circuit breaker, do not touch the power-input terminal.

Step 2

Use a Phillips screwdriver to loosen the captive screw on the power-input terminal, and open the cover.

Figure 5. Opening the Power-Input Terminal Cover

The terminal screws labels are on the power-input terminal cover. See the following figure.

Figure 6. Power-Input Terminal

1

Line connection for high-voltage AC (PSU1)

8

Line connection for high-voltage AC (for PSU2)

2

Neutral connection for high-voltage AC (PSU1)

9

Neutral connection for high-voltage AC (PSU2)

3

Positive connection for high-voltage DC (PSU1)

10

Positive connection for high-voltage DC (PSU2)

4

Negative connection for high-voltage DC (PSU1)

11

Negative connection for high-voltage DC (PSU2)

5

PSU1 (power-supply module 1)

12

PSU2 (power-supply module 2)

6

Positive connection for low-voltage DC (PSU1)

13

Positive connection for low-voltage DC (PSU2)

7

Negative connection for low-voltage DC (PSU1)

14

Negative connection for low-voltage DC (PSU2)

Note

 
The power-supply module 1 connection is labeled PSU1, and the power-supply module 2 connection is labeled PSU2. Make sure that you connect the wires to the correct terminal screws.

Step 3

Use twisted-pair copper wire to connect from the power-input terminal to the power source.

Step 4

Strip each of the two wires to 0.25 inch (6.3 mm) ± 0.02 inch (0.5 mm).

Note

 
Do not strip more than 0.27 inch (6.8 mm) of insulation from the wire. Stripping more than the recommended amount of wire can leave exposed wire from the connector after installation.
Figure 7. Stripping the Input Power Source Wire

Step 5

Insert the wire into a spade terminal, and crimp it to the wire.

You can also use a ring or flanged spade terminal as listed in Equipment That You Need.

Figure 8. Crimping the Spade Terminal Lug

Step 6

Loosen the terminal screw, and slide the terminal under the screw and washer. See Connecting the Wires to the Low-Voltage DC Power (PSU2).

Note

 
Use the appropriate terminal screws based on power supply type: high-voltage (AC or DC) or low-voltage (DC).

Step 7

Make the power connection:

AC Power Connection

  • Connect the line wire into the terminal screw labeled L and the neutral wire into the terminal screw labeled N to complete the AC connection.

Figure 9. Connecting the Wires to the High-Voltage AC Power (PSU1)

DC Power Connection

  • Connect the positive wire into the terminal screw labeled “+” , and the negative wire into the terminal screw labeled “– ”.

Low-voltage DC Power-Supply Module

  • Connect the wires to the terminals labeled Lo.

High-voltage DC Power-Supply Module

  • Connect the wires to the terminals labeled Hi.

Note

 
Ensure that you cannot see any wire lead. Only wire with insulation should extend from the terminal screw.
Figure 10. Connecting the Wires to the Low-Voltage DC Power (PSU2)

Step 8

Torque the captive screws (above the wires) to 8.5 in-lb (± 0.5 in-lb).

Step 9

Complete the power connection:

AC Power Connection

  • Connect the other end of the line wire (the one connected to L ) to the line terminal on the AC-power source, and connect the other end of the neutral wire (the one connected to N ) to the neutral terminal on the AC power source.

DC Power Connection

  • Connect the other end of the positive wire (the one connected to “+” ) to the positive terminal on the DC-power source, and connect the other end of the negative wire (the one connected to “–” ) to the negative terminal on the DC power source.

Note

 
Ensure that you cannot see any wire lead. Only wire with insulation should extend from the terminal screw.

If you have two power supplies, repeat steps 1 through 10.

Step 10

Close the power-input terminal cover.

Step 11

Use a ratcheting torque screwdriver to torque the screw to 7 in-lb (± 1 in-lb).

Step 12

Turn on the power at the AC or DC circuit.

Step 13

Verify that the PSU1 or PSU2 LED on the router and PSU OK LED on the power-supply module are green.

See the router software guide for information on how to configure the power supply settings.

Removing the Power Supply Module

The power-supply modules are hot-swappable. By removing the power supply modules, you can power off the router without disconnecting the wiring from the power-input terminal.

Procedure

Step 1

Ensure that the power is off at the AC or DC circuits.

Locate the circuit breakers, turn them OFF, and lock out the circuit.

Warning

 

If the power is not off at the AC or DC circuit breaker, do not touch the power-input terminal.

Step 2

Verify that the PSU LED and PSU OK LED is blinking red or is off.

Step 3

Use a Phillips screwdriver to loosen the captive screws that secure the power-supply module to the router.

Warning

 

Statement 1079—Hot Surface

This icon is a hot surface warning. To avoid personal injury, do not touch without proper protection.

Step 4

Remove the power-supply module from the power slot. The power-supply module might be hot. See the following figure.

Step 5

Install a new power-supply module or a blank cover.

Caution

 

To prevent exposure to hazardous voltages and to contain electromagnetic interference (EMI), either a power-supply module or a blank cover must be in each power-supply module slot at all times.