David, At this time doing some kind of configure command is required. There is however no need to edit or change the config file prior to configuring it on the new chassis. There are a couple different options that can be used. I'll try to briefly outline them. (not really good at brief) One option is the following: On the replacement unit: Add any require license configure bonding chassis and system id configure bonding ports enable bonding At this point, connect the replacement unit to the existing VSB switch. Bonding should come up and be functional, but no configuration will be present on the replacement unit(other than the bonding lines you added). Assuming you have a copy of the config on the still configured VSB switch(switch 1), use the configure command with the append option to reload the entire config (does not require a reboot) 'configure slot1/filename append' While some lines in the config will error out because they are already in the config this should allow the entire config to get pushed to the replacement unit (switch 2) and begin functioning normally without a reboot. If you don't have a copy of the config on the box, you will need to either TFTP it onto the still configured unit(switch 1), or you can utilize a USB stick(with an adapter) in the micro/mini USB port on the front of the unit. ---------------- The second option requires a little less configuration work but you have to get the configuration file on the replacement unit. As you had stated, this can be done either via TFTP or via the micro/mini usb port on the front of the switch. Once the configuration is either on the box, or is seen on the USB stick when attached (will show up when doing a 'dir' command), you can run one of the following commands. 'configure usb2/filename chassis-id 2' or 'configure slot2/filename chassis-id 2' (depends on where the file is) The chassis-id option tells the replacement unit which part of the configuration it should use. Once the unit reboots with the correct config, it can be connected to the other VSB switch and bond normally. Engineering is considering providing a method to indicate you want to override the replacement device's configuration (it has a non default config in order to start the bond.) Or possibly automate the configuration when a completely unconfigured replacement is connected to bond ports of a chassis that is missing its partner. I hope this information is helpful. Chris