Hardware Installation Guide for Cisco 8300 Series Secure Routers

Remove and replace the power supplies

Updated: July 31, 2025

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Explains methods for removing and replacing AC and DC power supplies, presenting overviews of each type, step-by-step replacement instructions, DC input power installation, and wiring guidelines to ensure safe handling.

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.

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.

Warning
Care should be taken while removing the power supplies (especially in boost mode of operation). If the total power consumption is higher than can be supported by one power supply alone and in this condition a power supply is removed, the hardware can be damaged. This may then result in the system being unstable or unusable.

AC power supplies

The Cisco 8300 Series Secure Routers device have two different AC power supply types and they are the same physical size. The power supplies cannot be interchanged.

Overview of the AC power supply

The AC power supplies for the Cisco 8300 Series Secure Routers device are:

PWR-CC1-400WAC
PWR-CC1-760WAC

The two supplies are physically similar and a diagram is shown in this figure.

Figure 1. 400W AC power supply for C8375-E-G2

Sl. No	Module
1	PSU1
2	PSU0

Figure 2. 760W AC power supply for C8375-E-G2


1	Handle	2	Strain relief
3	Latch	4	Fail LED
5	Status LED	6	Power socket

Remove and replace the AC power supply

To remove an AC power supply from the Cisco 8300 Series Secure Routers, perform these steps:

Procedure

	1.	Read the safety warnings section of this document.
	2.	If there is only one power supply in the system, shut down the device before removing the power supply.
	3.	If there are redundant power supplies in use the device does not have to be shut down prior to replacing the power supply. The power supply may be replaced while the device is in service.
	4.	If in use, remove the strain relief securing the power supply cable to the power supply latch.
	5.	Remove the AC power cord from the power socket.
	6.	Depress the power supply latch and use the handle to pull the supply out of the device. Figure 3. Step 4 Figure 4. Step 5 Figure 5. Step 6

To replace or install an AC power supply into the Cisco 8300 Series Secure Routers, perform these steps:

Procedure

	1.	Use the handle to push the power supply into the router. The power supply latch should provide an audible click when the supply is fully seated.
	2.	Install the AC power cord into the power socket on the power supply.
	3.	If used, reapply the strain relief strap around the power cord and the power supply latch.
	4.	If the device was turned off, turn the power back on to the device.

DC power supplies

The Cisco 8300 Series Secure Routers have one DC power supply type. As with the AC power supplies, the DC power supplies are not of the same size and cannot be interchanged.

Overview of the DC power supplies

The DC power supply for Cisco 8300 Series Secure Routers devices is shown in the figure:

PWR-CC1-500WDC

Figure 6. 500WDC power supply for C8375-E-G2


1	Handle	2	Strain relief
3	Latch	4	Fail LED
5	Status LED	6	Terminal block

Remove and Replace the DC Power Supply

To remove a DC power supply from a Cisco 8300 Series Secure Routers, perform these steps:

Procedure

	1.	Read the safety warnings section of this document.
	2.	If there is only one power supply in the system, shut down the device before removing the power supply.
	3.	If there are redundant power supplies in use the device does not have to be shut down prior to replacing the power supply. The power supply may be replaced while the device is in service.
	4.	At the power distribution panel or at the local circuit breaker, remove the power from the DC power leads (label 1)attached to the power supply to be replaced.
	5.	Remove the terminal block cover and loosen the terminal screws (label 1) securing the power cabling. Remove the power cabling from the terminal block.
	6.	Depress the power supply latch and use the handle to pull the supply out of the device. Figure 7. Remove a DC Power Supply from the C8375-E-G2 Figure 8. Step 5 Figure 9. Step 6

To replace or install a DC power supply from a C8375-E-G2, perform these steps:

Procedure

	1.	Use the handle to push the power supply into the router. The power supply latch should provide an audible click when the supply is fully seated.
	2.	If this is an initial installation, please see the section on preparing the DC power leads below.
	3.	Install the DC power leads into the terminal block and tighten the terminal block screws to secure the cables. For the PWR-CC1-400WDC power supply the negative lead installs into the left terminal position and the positive lead installs into the right terminal position. The polarity is marked on the faceplate of the power supply. Caution Do not over torque the terminal block captive screws. Ensure that the connection is snug, but the wire is not crushed. Verify by tugging lightly on each wire to ensure that they do not move.
	4.	Reinstall the terminal block cover.
	5.	If the device was turned off, turn the power back on to the device.

Install the DC input power

This section describes how to install the DC power supply input power leads to the Cisco 8300 Series Secure Routers DC input power supply. Before you begin, read these important notices:

The color coding of the DC input power supply leads depends on the color coding of the DC power source at your site. Ensure that the lead color coding you choose for the DC input power supply matches the lead color coding used at the DC power source and verify that the power source is connected to the negative (–) terminal and to the positive (+) terminal on the power supply.
Ensure that the chassis ground is connected on the chassis before you begin installing the DC power supply. Follow the steps provided in the Chassis Grounding .

Warning

Statement 1003—DC Power Disconnection

To reduce risk of electric shock or personal injury, disconnect DC power before removing or replacing components or performing upgrades.

Prepare the wire for connecting to the DC power supply

In the Cisco 8300 Series Secure Routers, the DC power supply has a terminal block that is installed into the power supply terminal block header.

Use these steps to prepare the wire for connection to the terminal source:

Procedure

Turn off the circuit breaker from the power source to be connected to the power source. Ensure the wires to be attached to the power supply are not energized.

The wires connecting to the power supply can be stripped back and terminated directly to the power supply terminal block. Alternately a crimp style spade terminal lug can be attached to the end of the wire. If using a terminal lug, follow the manufacturer's instructions for terminating the lug to the wire. If terminating directly to the terminal block using bare wire, following the directions shown below.

Use a wire-stripping tool to strip each of the two wires coming from the DC input power source to approximately 0.39 inch (10 mm) +/- 0.02 inch (0.5 mm). It is recommended that 14 AWG insulated wire be used. Do not strip more than the recommended length of wire because doing so could leave the wire exposed from the terminal block and shows a stripped DC input power source wire.

Figure 10. Stripped DC input power source wire


1	0.39 inch (10 mm) is the recommended wire-strip length for the terminal block.

Identify the positive and negative feed positions for the terminal block connection of C8375-E-G2:

Positive (+) lead wire (right)
Negative (–) lead wire (left)

Figure 11. DC power supply with lead wires

Table 1.
1	Negative (-) lead wire
2	Positive (+) lead wire

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