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Avici Systems Inc.

Installing TSR Bay Components

This chapter describes the procedures for installing TSR bay components, including:

Tools Needed

Use the following tools for installing TSR Bay components:

Removing the Top Rear Panel

Prior to grounding the TSR bay, the top rear panel must be removed to allow access to the safety ground and power and return feeds at the rear of the bay. Once removed, set the top rear panel aside for later reinstallation.

PROCEDURE: Use the following steps to remove the top rear panels from the TSR bay:

Step 1 Use a #2 Phillips screwdriver to loosen the four captive screws on the top rear panel. Refer to Figure 4-1.

Step 2 Disconnect the ground wire connector on the upper left hand corner of the panel.

Step 3 Lift the top rear panel away from the TSR bay and set aside.

Figure 4-1. Top Rear Panel Removal

Grounding Requirements

This section describes the grounding requirements for the TSR bay.

CAUTION If a console terminal is required as part of your installation, check that the outlet used to power the terminal has its DC ground connected to the same DC distribution panel ground as the equipment bay or frame.

Installing Safety Ground to the TSR Bay

Each TSR bay frame must be safety grounded with a minimum of #6 AWG ground wire. The safety ground wire must be terminated with a UL listed two hole compression lug with hole size and spacing as shown in Figure 4-2.

Figure 4-2. Frame Ground Compression Lug

The safety ground wire is attached directly to the bay frame at the rear top left corner of the frame next to the power input terminals. Figure 4-3 shows the location of the safety ground connection, which go to earth ground.

Figure 4-3. TSR Bay Main Power Ground

The safety ground MUST be attached to the bay frame prior to installing the power and return feeds.

PROCEDURE: Use the following steps to attach the safety ground connection to the TSR bay:

Step 1 Arrange the washers and screws as shown in Figure 4-4 to secure the safety ground lug.

Step 2 Torque the hex screws to 150 in. lb.

Figure 4-4. Safety Ground Connection

Power Requirements

The TSR system uses dual -48V power inputs that filter and distribute redundantly throughout the chassis. Redundancy prevents the failure of one power input from affecting another, and minimizes power outages.

Main power from customers battery packs and rectifier stacks (customer's power distribution system) supplies the TSR power at the BIP.

At the shelf level, there are a redundant pair of power supply inputs (one for each power feed bank), which interface -48V power to the backplane.

Primary power is distributed to TSR bays in one of two methods:

In either method above, all feeds (A and B) to a TSR system lineup must be sourced from a single (dedicated) power plant, preferably one source for both A and B feeds.

Power Input

The following are the power input, cable sizing and upstream breaker requirements for the TSR bay:

Figure 4-5. Power and Return Compression Lug

Power and return feeds must enter the breaker input terminals from the top. The cables can be routed from overhead or from beneath raised flooring. If routed from beneath raised flooring, there are cable channels on both sides of the bay underneath the side panels. The side panels can be temporarily removed to access the cable channels for cable routing.

Installing Power and Return Feeds to the TSR Bay

PROCEDURE: Use the following steps to attach the power and return feeds to the BIP:

Step 1 Flip all breaker switches located on the top-front of the bay to the OFF position.

Step 2 Attach the eight power feeds (4 A and 4 B) and the eight power return feeds to the appropriate locations using crimp-style two-hole lugs. Refer to Figure 4-6 for the location of the power and return feeds.

Figure 4-6. Power and Return Feeds (rear)

Step 3 Secure the power and return feeds with the lock washers and nuts using a nut driver. Refer to Figure 4-7.

Figure 4-7. Power Lug Attachment Points

Step 4 Arrange the lock washers and nuts as shown in Figure 4-8.

Figure 4-8. Power Lug Washer Stack-up

Step 5 Torque to 85 in. lb.

Step 6 Install the BIP cable guard block and guard plate. The cable guard block and guard plate are safety features and must be installed. Refer to Figure 4-9 for correct installation and hardware.

Figure 4-9. Installing the Breaker Interface and Cable Guards

Step 7 Power on the TSR bay by first flipping the bay controller switch and the remaining breaker switches to the ON position on the BIP. Refer to Figure 4-10.

Figure 4-10. Breaker Interface Panel Breaker Switches (front view)

Installing the Cooling Assembly

The cooling assembly was removed when the bay was anchored to the floor.

PROCEDURE: Use the following steps to reinstall the cooling assembly:

Step 1 Reinstall the metal baseplate in the bottom of the bay

Step 2 Reinstall the short vertical doors

Step 3 Install the bay controller

Step 4 Reinstall the cooling modules

Step 5 Reinstall the front air intake assembly

Installing the Baseplate

CAUTION When installing the baseplate, ensure that it is pushed firmly into the alignment pins in the backplate. Proper seating of the baseplate is absolutely critical to ensure proper operation of the system.

Be careful not to dislodge the alignment pins by using too much force. You should be able to "feel" when the alignment pins are engaged; only then should you slide it all the way into place.

PROCEDURE: Use the following steps to install and verify the proper installation of the baseplate:

Step 1 Carefully slide the baseplate into the base of the bay. Do not force the baseplate against the alignment pins; instead, carefully slide the baseplate until it makes light contact against the alignment pins. Move the rear of the baseplate side to side until you feel the alignment pins engage the holes in the rear of the baseplate. Once the alignment pins engage, continue to slide the baseplate back until fully seated and flush against the backplate. Refer to Figure 4-11.

Figure 4-11. TSR System Baseplate Installation

Step 2 Insert the two M6x16 mm hex head flange bolts into the bolt holes located at the front of the baseplate. Tighten the bolts with a 10 mm socket ratchet to secure the baseplate to the frame.

Step 3 Use a Feeler Gauge (for example, the Sears Craftsman 26 blade Master Offset Gauge), as illustrated in Figure 4-12, to measure the gap between the baseplate and the backplate (see Figure 4-13).

NOTE The gap between the baseplate and the backplate should be no more than .75 mm (.03 in.); the baseplate should be as snug as possible to the backplate.

Figure 4-12. Master Offset Feeler Gauge

Figure 4-13. Where to Measure Baseplate Gap

CAUTION If the baseplate has been slammed into the backplate and hit the alignment pins, there is a possibility that one or both alignment pins were driven into the backplate (alignment pins pushed back) and thus cannot perform their alignment function. Check to verify that the alignment pins have not been pushed back through the backplate towards rear of TSR (see Figure 4-14).

Step 4 Finally, check the rear of the TSR, under the bay controller backplane to ensure that the alignment pins have NOT been pushed out (i.e., protruding) from the metal plate that holds them (refer to Figure 4-14).

Figure 4-14. TSR Rear View: Pushed-Back Alignment Pin

These alignment pins should be flush when viewed from the rear of the TSR.

Reinstalling the Short Vertical Doors

PROCEDURE: Use the following steps to reinstall the short vertical doors:

Step 1 Attach the short vertical doors and cable guides on the vertical cable channels and door panels located at the front of the bay. These are the parts and hardware removed prior to installation of the bay. Refer to Figure 4-15.

Figure 4-15. Short Vertical Door

Step 2 Close the cable channel door panels on the left and right sides of the bay (front).

Installing the Bay Controller

The bay controller modules are shipped separately and need to be installed.

CAUTION Risk of electrostatic damage. When handling circuit cards, wear a grounded antistatic wrist strap or equivalent protection to avoid damaging electrostatic parts.

PROCEDURE: Use the following steps to install the TSR bay controllers:

Step 1 Disengage the release latches on the bay controller module.

Step 2 Align the bay controller module with the nylon rails above the baseplate.

Step 3 Slide the bay controller modules into the left or right card guides from the front of the bay. Refer to Figure 4-16.

Figure 4-16. TSR Bay Controller Installation

Step 4 Engage the latches to seat the connector at the rear of the module firmly in the controller backplane.

Step 5 Repeat Step 1 through Step 4 for the remaining bay controller.

Installing the Cooling Modules

PROCEDURE: Use the following steps to install the cooling modules:

Step 1 Lift and align the cooling module on the nylon rails.

Step 2 Grasp the faceplate handle with one hand and slowly slide the cooling module toward the rear of the bay until it is connects firmly in the backplane. Refer to Figure 4-17.

Figure 4-17. Cooling Module Installation

Step 3 Slide down blower assembly hood into place on cooling module. Insert blower assembly hood tabs into the slots on top of each cooling module. Refer to Figure 4-18.

Figure 4-18. Uninstalled Blower Assembly Hood

Step 4 Tighten the (center) M4 panhead Phillips screw on the blower assembly with a #2 Phillips screwdriver.

The blower assembly hood tabs insert into the top of each cooling module to secure modules in place during shipping. The gasket at the edge of the blower assembly hood fits snugly against the cooling modules to eliminate air leakage. Refer to Figure 4-19.

Figure 4-19. Installed Blower Assembly Hood

Installing the Front Air Intake Assembly

PROCEDURE: Use the following procedure to install the front air intake assembly:

Step 1 Align the ball studs in the assembly with the receptacles on the bay frame.

Figure 4-20. Front Air Intake Assembly Installation

Step 2 Carefully press on the air intake assembly until it snaps in place.

CAUTION To avoid damage to the hardware components during installation, observe the standard electrostatic discharge (ESD) precautions.

Removing Shelf Covers

Before populating the TSR with modules, you will need to remove the shelf covers.

PROCEDURE: Beginning at the top shelf of the bay, use the following procedure to remove the shelf covers on shelves 1-4:

NOTE Technically, you can remove any shelf cover. They do not need to be removed in any order.

Step 1 Open the door panels on each side of the bay.

Step 2 Grasp the bottom of the top shelf on each side and lift 1/8" to detach the bottom screws. No tools are required. Refer to Figure 4-21.

Figure 4-21. Shelf Installation - 2

Step 3 Slide the cover down to disengage top notches of the shelf from the screws on each side of the bay frame. Refer to Figure 4-22.

Figure 4-22. Shelf Installation - 1

Step 4 Set the shelf cover aside in a safe place.

Step 5 Repeat Step 2 through Step 4 for the remaining three shelf covers.

TSR Bay Module Population Rules

Each TSR bay has four shelves numbered from 1 (top) to 4 (bottom). Each shelf has 10 slots to house the router and server modules. All router modules must be inserted in pairs.

TSR Bay Shelf and Slot Numbering

The four shelves and their slots are illustrated in Figure 4-23.

Figure 4-23. TSR Bay Shelf and Slot Numbering

Module Orientation

Slots are labeled with red circles and blue squares to help you identify how to orient the module for that slot:

The module color label is located on the top side of the module.

Populating The First Bay

The rules for populating the first TSR full bay with module pairs are as follows:

Preparing to Install Modules

This section describes the procedure to prevent damage to the TSR system from static electricity.

Use these precautions to prevent damage from static electricity:

CAUTION Risk of electrostatic damage. When handling circuit cards, wear a grounded antistatic wrist strap or equivalent protection to avoid damaging electrostatic parts.

Installing the Antistatic Wrist Strap

A grounded antistatic wrist strap must be used to protect the TSR system modules and components from damage caused by static.

PROCEDURE: Use the following steps to install the antistatic wrist strap:

Step 1 Remove the alligator clip from the grounding pin on the antistatic wrist strap.

Step 2 Insert the grounding pin into the electrostatic discharge (ESD) jack on the front of the TSR bay shelf. Refer to Figure 4-24.

Step 3 Use the ESD jack while handling modules.

Figure 4-24. ESD Jack Location

Installing Router Modules

The TSR system ships with 36 filler modules, which ensures proper cooling and elimination of electromagnetic interference during operation and four shelf covers. Remove filler modules from slots intended for router modules. Refer to Figure 4-25. For directions on how to remove shelf covers, refer to "Removing Shelf Covers".

Figure 4-25. Filler Module

Removing Filler Modules

PROCEDURE: Use the following steps to remove a filler module:

Step 1 Use a 1/2-in. flat-blade screw driver to loosen the lock latch on the filler module.

Step 2 Pull the filler module out of the slot. Refer to Figure 4-26.

Step 3 Store the filler module in a dry, cool area.

Figure 4-26. Removing Filler Modules

Installing Router Modules

Filler modules are only removed from a slot where you intend to install a router module. All slots will be filled when this procedure is completed. Router modules must be installed in an assigned slot location. See "TSR Bay Module Population Rules"

NOTE When the thumb latch lever is in the open position, do not use the lever to lift or adjust the module in the card guide.

PROCEDURE: Use the following steps to install router modules:

Step 1 Remove the router module from its static protection packaging.

Step 2 Check the color indicator on the top of the module to determine if it is the right type for this slot (red circle or blue square). If it is not the correct color and there is no other slot of that color expecting a module of this type, contact Avici Customer Service. For Customer Service contact information see "Support Services" in the Preface for more information. Ensure that the cable trays on the router module being inserted and on the adjacent router modules are fully closed.

Step 3 Close the thumb latches completely. Refer to Figure 4-27.

Figure 4-27. Router Module Installation

Step 4 Align the module with the card guides.

Step 5 Slide the module into the slot until the thumb latch lever hits the lip of the shelf. Refer to Figure 4-28.

Figure 4-28. Router Module Insertion -1

Step 6 Open the thumb latches and slide the module in until the thumb latch levers slide into position behind the lip of the shelf. Refer to Figure 4-29.

Figure 4-29. Router Module Insertion - 2

Step 7 Push the thumb latches to the closed position to further insert the module and to ensure proper seating in the connector backplane. Refer to Figure 4-27.

Installing Server Modules

A single server module is installed in slot 11.

PROCEDURE: Use the following steps to install the server module:

Step 1 Remove the server module from its static protection packaging.

Step 2 Check that the door of the server module is closed. If the door is open, close it.

Step 3 Check the color indicator on the top of the module to determine if it is a match for this slot (red circle or blue square). If it is not the correct color, contact Customer Service. See "Support Services" in the Preface for Avici Customer Service contact information.

Step 4 Position the metal tabs of the lock latch release levers under the lip of the server.

Step 5 Align the module with card guides of the slot and slide the server module into the slot.

Step 6 Use the 1/2-inch flat-blade screwdriver to tighten the screws on the face of the server to seat the module firmly in the backplane. The lock latches lock into position and secure the server. Refer to Figure 4-30.

Figure 4-30. Server Module Installation

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Copyright © 2001 Avici Systems Inc.
Avici® and TSR® are registered trademarks of Avici Systems Inc.
IPriori™ is a trademark of Avici Systems Inc.

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