PREV NEXT INDEX

Avici Systems Inc.

Preinstallation

The TSR bay is delivered to your receiving dock secured upright on a shipping pallet inside in a wooden crate. Antistatic packaging covers the entire bay. Additional crates contain the modules ordered for your system and the cables needed to interconnect the modules and servers.

Preinstallation Tools

Inspecting the Shipping Contents

Before installing a new TSR system, remove the invoice/packing slip from the envelope on the shipping crate and check the contents of each shipping carton against the invoice.

NOTE If any parts are missing or there is evidence of physical damage, contact your sales representative immediately.

Unpacking the TSR System

Before transporting the TSR system equipment to the installation location, remove the sides and top of the wooden shipping crate.

NOTE Do not remove the bay from the attached pallet. The pallet is used to move and position the TSR system.

PROCEDURE: Use the following steps to remove the bay from the crate:

Step 1 Read and comply with all shipment monitoring labels attached to the exterior of the shipping crate.

Step 2 Inspect the crate for damage. If the crate appears to be undamaged, proceed to open the crate as described in Step 3. If the crate appears damaged, contact Customer Service. See "Support Services" in the Preface for Avici Customer Service contact information.

Step 3 Use the claw of the hammer, or pry-bar to pry off the temporary metal klimps along the top cover of the crate.

Step 4 Using a step ladder to reach the top, lift the cover straight up and off the top of the crate. Refer to Figure 2-1.

Figure 2-1. Lifting Crate Cover Off Crate

Step 5 Pry off the klimps from any one side wall of the crate.

Step 6 Use a #2 Phillips head screwdriver to remove any klimps attaching the side wall to the crate and remove the side wall. Refer to Figure 2-2 to see locations of klimps.

Figure 2-2. Klimp Locations

Step 7 Repeat Step 5 for each side wall. Note than when two sides have been removed from the crate, the remaining two sides become unstable.

Step 8 Remove the four bolts securing the wooden top support to the frame and lift the support up and off the unit. Refer to Figure 2-3.

NOTE Remove any miscellaneous hardware from the top or immediate area of the system.

Figure 2-3. Removing Wooden Top Support

The TSR bay ships with the side and rear panels, cooling modules, and filler modules already installed.

All server, router, and bay controller modules ordered with the system are packaged and shipped separately. Refer to "Installing TSR Bay Components."

Moving the Bay

The TSR bay is delivered to the receiving dock secured upright on a shipping pallet inside a crate. To transport the bay to the installation floor requires a hydraulic pallet truck.

WARNING The TSR system weighs 635 kg (1400 lb). To reduce the risk of injury, the TSR system should be moved only by experienced movers or trained installation crews.

PROCEDURE: Use the following steps to secure the truck to the pallet holding the bay, move the bay to the installation area, and remove the truck from the pallet.

Step 1 Lower the hydraulic pallet truck to just below the pallet.

Step 2 Insert the pallet truck into the rear of the pallet opening. When the TSR is fully crated, the rear can be determined by locating the serial number, which has be written on the front right side of the palate. Refer to Figure 2-4.

Figure 2-4. TSR Serial Number Location

NOTE The TSR bay is heavier at the rear of the bay; therefore, position the pallet truck toward the rear of the pallet to balance the load.

Step 3 Raise the pallet truck just enough to maneuver the bay.

Step 4 Transport the bay to within a few feet of the installation area. If the bay must be transported up a ramp to a raised floor, see "Transporting the Bay Up a Ramp to a Raised Floor" on page 13.

Step 5 Lower the pallet and remove the pallet truck.

Transporting the Bay Up a Ramp to a Raised Floor

This section describes the procedure to safely transport the bay up an inclined ramp used to move equipment from grade level to a raised floor area.

Using a Pallet Truck

A typical hydraulic pallet truck may be used to transport the bay up a ramp to a raised floor. If a hydraulic pallet truck is used, the following precautions must be taken to avoid personal injury and damage to equipment:

WARNING Pallet trucks typically come in two standard widths across the forks, 21- and 27-inch. Only the wider, 27-inch, pallet trucks should be used to transport the bay up an inclined ramp. The narrower, 21-inch, pallet truck will cause the bay to be unsteady when raised and could cause personal injury or damage to equipment. If a 27-inch pallet truck is not available, use the custom dolly procedure to move the bay up a ramp.

PROCEDURE: Use the following steps to transport a bay up a ramp using a hydraulic pallet truck:

Step 1 Using ONLY a 27-inch pallet truck, insert the forks into the pallet openings at the rear of the bay. Raise the pallet truck until there is a 11/2 to 2-inch clearance between the pallet and floor. This will allow the pallet to clear the top edge of the ramp as it transitions to the raised floor.

Step 2 The bay must be moved up the ramp back side first. The handle of the pallet truck should be used to pull the bay up the ramp, and at least one additional person should be at the front of the bay to help steady the bay and to push if needed.

Step 3 Once the bay is past the ramp and on the level raised floor, the pallet truck should be lowered so the pallet is just above the floor.

Step 4 Moved the bay to the location where it is to be installed. Lower the pallet and remove the pallet truck.

Using the Custom Dolly

Due to overhead clearance, width, or other constraints, it may not be possible to transport the bay up a raised floor ramp prior to removing from the shipping pallet.

PROCEDURE: The custom dolly can be used to transport the bay up the ramp with the following steps and cautions:

Step 1 See "Loading the Bay Onto the Custom Dolly" on page 20 to remove the bay from the shipping pallet before proceeding up the ramp.

Step 2 Raise both front and rear dollies evenly until the bay is about 11/2 to 2 inches above the floor. This will allow the bay to clear the top edge of the ramp as it transitions to the raised floor.

Step 3 The bay must be moved up the ramp back side first. One person should be at the rear of the dolly to guide the bay and help pull if needed. One or two additional people should push from the front and help guide the bay.

Step 4 Once the bay is past the ramp and on the level raised floor, lower the front and rear dollies evenly until the bay is just above the floor. The bay can then be moved to the location where it is to be installed.

Unloading the Bay

To access the bolts that attach the bay to the shipping pallet, you must remove the air intake assemblies, cooling modules, baseplate, short vertical door.

Removing the Front Air Intake Assembly

PROCEDURE: Use the following steps to remove the air intake assembly from the bottom-front of the bay:

Step 1 Press and release the cable routing channel door panels on the left and right sides of the bay (front) to open the doors and access the assembly. The release mechanism is on the doors level with the third shelf. Refer to Figure 2-5.

Figure 2-5. Opening Cable Routing Channel Door Panels

Step 2 Grasp the face of the assembly firmly by the air vents.

Step 3 Pull the assembly toward the front of the bay to release the four ball studs from the receptacles holding the assembly in place. Refer to Figure 2-6.

Figure 2-6. Front Air Intake Assembly Removal

Removing Short Vertical Cable Doors

PROCEDURE: Use the following steps to remove the short vertical cable doors:

Step 1 Press and release the cable channel door panels on the left and right sides of the bay (front) to open the doors and access the assembly.

Step 2 Detach the removable section of the short vertical door and the cable guides located at the front of the bay. Refer to Figure 2-7.

NOTE Only remove the top four screws.

Step 3 Save all parts and hardware removed for reinstallation after the bay is installed.

Figure 2-7. Short Vertical Door Removal

Removing the Cooling Module

The cooling unit is at the bottom of the TSR bay and consists of two cooling modules and two bay controller modules. Install the bay controllers after the bay is anchored.

The cooling modules reside on nylon rails just above the bay controller modules in the bottom of the bay. Both cooling modules and bay controllers are field replaceable units.

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

Step 1 Use a #2 Phillips screwdriver and turn counter-clockwise 1/4 turn to loosen the M4 panhead Phillips screw on the blower assembly hood.

Step 2 Disengage the blower assembly hood tabs, on the bottom of the front blower assembly hood, from the top of each cooling module. Refer to Figure 2-8.

Figure 2-8. Uninstalled Blower Assembly Hood
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 2-9.

Figure 2-9. Installed Blower Assembly Hood

Step 3 Grasp the faceplate handle with one hand and carefully pull the cooling module toward the front of the bay (a few inches) to disengage it from its slot in the rear power input panel.

Step 4 With one hand, pull the cooling module halfway out of the bay using the handle grip on the front of the unit.

NOTE The unit weighs approximately 16 lb. Use proper lifting procedures.

Step 5 Grasp the second handle grip on the top of the unit and slide it out of the bay. Refer to Figure 2-10.

Figure 2-10. Cooling Module Removal

Step 6 Repeat all steps to remove the remaining module.

Removing the Baseplate

The base or floor of the TSR bay contains a metal baseplate. Remove the baseplate to access the pallet bolts in the bay frame.

PROCEDURE: Use the following steps to remove the baseplate from the bottom of the bay:

Step 1 Use a 10 mm socket and ratchet handle to remove the two M6X16 mm hex head flange bolts securing the plate to the bay frame. Refer to Figure 2-11.

Step 2 Slide the baseplate forward to disengage it from the locating pins on the metal plate at the rear of the bay frame.

Step 3 Lift the plate enough to clear the frame and remove the plate through the front of the bay.

Figure 2-11. Baseplate Removal

Removing the Rear Air Intake Assembly

PROCEDURE: Use the following steps to remove the rear intake assembly from the bottom-rear of the bay:

Step 1 Grasp the rear intake assembly by the slot handles.

Step 2 Pull the assembly toward the back of the bay to release the four ball studs from the receptacles holding the assembly in place. Refer to Figure 2-12.

Step 3 Remove the green ground wire from the rear intake assembly. Move the green ground wire attached to the TSR system to the side.

Figure 2-12. Rear Air Intake Assembly Removal

Loading the Bay Onto the Custom Dolly

Within a few feet of the installation area, mount the custom dolly to transfer the bay from the pallet to the custom dolly and then remove the bolts securing the bay to the pallet.

The custom dolly consists of two sets of bracketed hardware with two adjustable wheels (casters) per set. One set attaches to the bottom-front of the bay frame, the other attaches to the bottom-rear of the frame. The custom designed dolly is used to:

Figure 2-13 shows one set or half of the custom dolly hardware:

Figure 2-13. One Side of the Custom Dolly Hardware

Using the Custom Dolly

This section provides the procedures for attaching the custom dolly to the TSR bay and unloading the bay from the shipping pallet.

PROCEDURE: Use the following steps to attach the custom dolly to the TSR bay:

Step 1 Raise the dolly wheels to the fully retracted position by turning the crack handles in the counter clockwise direction.

Step 2 Insert the two screw heads protruding from the welded aluminum section of the dolly into the keyhole slots on the frame (bottom-front) of the bay. The screw heads are first inserted into the wide, bottom portion of the keyhole slots. Refer to Figure 2-14.

Figure 2-14. Dolly Hardware Attachment Points

Step 3 Lift the dolly upward to engage the screw heads from the large part of the keyhole to the top narrow section of the keyhole slots. See Figure 2-15.

Figure 2-15. Lift Dolly Into Top of Keyhole Slots

Step 4 Tighten the hex handles located on the opposite end of screw heads and near the wheels of the dolly (clockwise) to secure the connection between the dolly screw heads and the keyhole slots in the bay. When tightened down, the screw head will be flush with the keyhole. Refer to Figure 2-16.

CAUTION If a wrench or socket wrench is used to tighten the hex handles, do not use excessive force or the clamp rods can break.

Figure 2-16. Fully Tightened Screw Heads

NOTE When the custom dolly is fully engaged in the keyhole slots, you should not be able to see the slot above the top of the aluminum blocks of the dolly. Refer to Figure 2-17.

Step 5 Repeat Step 1 through Step 4 to attach the second custom dolly to the rear uprights of the bay. Figure 2-17 shows the custom dolly installed and with the caster wheels in the raised position.

Figure 2-17. Fully Installed Custom Dolly (raised position)
The custom dolly will be in the lowered position for transporting the bay.
Be sure to adhere to all WARNING and CAUTION statements.

Removing the Shipping Pallet

PROCEDURE: Use the following steps to remove the shipping pallet from a TSR bay using the custom dolly:

Step 1 To lower the dolly casters, turn the crank handles on all wheels clockwise until the casters make contact with the floor.

Step 2 Using a 3/4-in. socket and ratchet handle, remove the four 1/2-in. by 21/4-in. hex head bolts attaching the base of the TSR system frame to the top of the pallet. These bolts are located inside the bottom of the bay and can be reached through the front opening where the cooling modules were removed. Refer to Figure 2-18.

Figure 2-18. Removing Four Hex Bolts from TSR Base

Step 3 Adjust the dolly casters until the TSR system clears the pallet by approximately a half-inch. Figure 2-19 shows the dolly casters in the lowered position. Further rotation of the crank handles will transfer the weight of the bay to the casters.

Figure 2-19. Fully Installed Custom Dolly (lowered position)

Step 4 Slide the pallet out the side of the bay until it clears the bay. It is recommended that the base of the TSR system be adjusted to a clearance of less than a half-inch above the floor surface before moving the bay, and that you walk very slowly when pushing the dolly. Adhere to the following safety information to avoid injuries that can result through misuse of the dolly.

CAUTION The custom dolly is designed to operate on smooth surfaces only. Moving the TSR system over uneven surfaces can cause personal injury and damage to equipment.

Step 5 Immediately after removing the pallet, lower the base of the bay to less than a half-inch above the floor, before attempting to move the bay.

CAUTION Failure to lower the base of the TSR bay to slightly above the floor can result in serious injury.

WARNING Avoid excessive tilting of the TSR bay, adjusting each castor only slightly before adjusting the other castors to raise the bay to a level height.

Ensure that during transport, the custom dolly attachment hardware remains fully seated in the keyhole slots at the base (front and rear) of the bay frame.

If the dolly becomes unseated, lower the bay to remove its weight from the custom dolly. Loosen the hex handles to readjust the dolly until the keyhole slots are no longer visible. Retighten the hex handles. The dolly is fully inserted when the top of the keyhole slots are hidden by the dolly. Resume movement of the bay after cranking the dolly to a level height.

PREV NEXT INDEX

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

   Source File Name: c-2preinst.fm
    HTML File Name: c-2preinst.html
    Last Updated: 06/11/01 at 10:48:23

Please email suggestions and comments to: doc@avici.com