Avici Systems Inc.

Field Replacement Procedure

TSR Packing Procedure

03073-00 Rev. CA

The following procedure outlines the Terabit Switch Router (TSR®) packing procedure. This procedure can be used for TSRs that have been uninstalled from the floor or TSRs that are already bolted to the shipping pallet. The bay ships with filler modules and cooling modules only. Server, bay controller, and router modules must ship separately.

To repack a TSR that is not currently bolted to a shipping pallet, go to "Packing a TSR that is not Bolted to a Pallet". To pack a TSR that is currently on a shipping pallet go to "Packing a TSR that is Bolted to a Pallet".

CAUTION When handling modules, wear a grounded antistatic wrist strap or equivalent protection to avoid damaging electronic parts.

Supplies Needed

The supplies needed to pack a TSR consist of a crate kit and additional packing materials. Refer to Table 1 for a complete list of TSR crating materials.


Table 1. TSR Packaging Materials List 
Part Name Quantity

Crate Kit

1

    Plywood top support

1

    Plywood sides (2 front and 2 back)

4

    Crate top

1

    M12 bolts

4

    M12 flat washers

4

   Klimps (Qty 20)

   Hex head bolts (1/2 in. by 2 1/4 in.)

4

Anti-static shroud

1

Plastic film

As req.

Shipping label

1

Packing slip

1

Tip N Tells

As req.

Tools Needed

Use the following tools for installing TSR bay components:

Support Services

To obtain information on customer service and training, there are three ways to contact Avici Customer Service:

Packing a TSR that is not Bolted to a Pallet

If a TSR has been unbolted from a floor and needs to be repacked for shipping, it must first be rebolted to a pallet. This procedure assumes that the air intake assemblies, short vertical doors, cooling modules, bay controllers, baseplate, and rear air intake assemblies have been removed.

Within a few feet of the shipping pallet, mount the custom dolly to the bay.

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 1 shows one set or half of the custom dolly hardware:

Figure 1. 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 loading the bay on 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 crank 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.

Figure 2. 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 3.

Figure 3. 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 4.

Figure 4. 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 5.

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

Figure 5. 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.

Moving the Bay to the Shipping Pallet

PROCEDURE: Use the following steps to move the bay to the shipping pallet using the custom dolly:

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

Step 2 Adjust the dolly casters until the TSR system clears the floor by approximately a half-inch. Figure 6 shows the dolly casters in the lowered position. Further rotation of the crank handles will transfer the weight of the bay to the casters.

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.

Figure 6. Fully Installed Custom Dolly (lowered position)

Step 3 Walk very slowly when pushing the dolly to pallet area.

WARNING 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 4 From the side of the shipping pallet, adjust the dolly to a high approximately 1/2 in. above shipping pallet. Carefully slide the dolly holding the TSR over the side of the pallet centering the bay over the existing bolt holes.

NOTE Make sure that the front of the bay faces the edge of the pallet marked FRONT.

Step 5 Lower bay onto shipping pallet.

Step 6 Using a 3/4-in. socket and ratchet handle, install the four 1/2 in. by 2 1/4 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 7.

Figure 7. Installing Four Hex Bolts from TSR Base

Packing a TSR that is Bolted to a Pallet

PROCEDURE: Use the following steps to package a TSR that is already bolted to a shipping pallet.

Step 1 Verify that all filler modules are locked in place. If any modules are loose, use a 1/4-inch slotted screwdriver to tighten the top and bottom latches located on the front. Refer to Figure 8 and Figure 9.

NOTE Filler modules must not be locked too tightly when securing them into place. Overtightening could bend both the latches or locks they latch into.

Figure 8. Filler Module Latches

Figure 9. Lock Filler Modules Into Place

Step 2 Remove front air intake assembly. Refer to the Terabit Switch Router Install Guide for removal instructions.

Step 3 Push cooling modules firmly back into controller module backplane to ensure modules are locked in place.

Step 4 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 10 and Figure 11.

Step 5 Tighten the (center) M4 panhead Phillips screw on the blower assembly with a #2 Phillips screwdriver.

The blower assembly hood tabs on the bottom of the front blower assembly hood engage the top of each cooling module. Refer to Figure 10 for a view of the uninstalled hood assembly.

Figure 10. 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. Refer to Figure 11.

Figure 11. Installed Blower Assembly Hood

Step 6 Verify all four Keps nuts on the top of the side panels are secure. If required, use an 8mm wrench to tighten Keps nuts.

Step 7 Verify that the vertical doors located on the front left and right sides of the TSR are latched. Refer to Figure 12.

Figure 12. Open and Closed Vertical Doors
Press on the vertical door to latch or unlatch. On the inside of the door is a latch that snaps into place. Refer to Figure 13.

.

Figure 13. Interior Vertical Door Latch

Step 8 Wipe down bay to ensure that the outside of the TSR is free of dirt and fingerprints. If this bay is being reshipped, skip Step 9.

Step 9 Verify bay serial number is written on the base (front, right side). After crating, the serial number written on the base ensures identification of the crated TSR. Refer to Figure 14.

Figure 14. TSR Serial Number on Base

Step 10 Place anti-static shroud over the TSR, centering the shroud seam on the side panel of the TSR. Refer to Figure 16.

Figure 15. TSR with Shroud

Step 11 When the shroud is in place, cut four holes in the shroud over the M12 nuts, which are found on the top of the TSR frame.

Step 12 Place plywood top support on top of bay, lining up the holes in the plywood with the M12 nuts. Refer to Figure 17 and Figure 18.

Figure 16. Plywood Top Support (bottom view)

Step 13 When positioning the plywood top support, ensure that the 2x4s run front to back on the TSR. Refer to Figure 17.

Figure 17. Place Top Support on TSR

Step 14 Secure plywood top support with the four M12 bolts and washers provided. Place each bolt in one of the four pre-drilled holes in the top of the plywood top support. Use a 19mm wrench to secure top support to the TSR frame. Refer to Figure 18.

Figure 18. Installing Bolt in Top Support

Step 15 Wrap plastic film around the base of the TSR three times. This seals the shroud and helps to keep the front and rear air intake assemblies in place during shipping. Refer to Figure 19.

Figure 19. Wrap Plastic Film Around TSR Base

Step 16 Place two of the plywood sides on the base, one narrower (A) piece on the side, and one wider (B) piece on the front. Secure the corner with the 3 klimps provided. The writing on the plywood goes on the outside, arrows pointing up. Refer to Figure 20 and Figure 22.

Figure 20. Side Placement
Refer to Figure 21 for a picture of a Klimp.

Figure 21. Klimp

The front/back piece (B) is narrower than the side piece (A). Three Klimps are placed on each of the four crate corners. Refer to Figure 22 for Klimps placement.

Figure 22. Crate (front) with Klimps Placement

Step 17 Install the remaining two plywood sides and place the Klimps in the positions indicated on Figure 22.

Step 18 Place the crate top over the top support. Slide the top into place, popping the rim over the sides. When in place, crate top edges should be flush with the sides of the crate. Secure top with four Klimps, one per side in the center. Refer to Figure 22.

Figure 23. Crate Top

Step 19 Attach four Klimps to the base of the crate. Two on the front and two in the back. Refer to Figure 22 for positioning reference.

Step 20 Move crated TSR to shipping and receiving for shipping label, packing slip, and Tip N Tells shipping monitor.

Figure 24. Tip N Tell Shipping Monitor

Moving the bay requires a hydraulic hand truck.

Moving the TSR

PROCEDURE: Use the following procedure to move the bay to the shipping and receiving area.

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

Step 2 Insert the hand truck into the pallet opening from the rear side of the crate.

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

Step 3 Raise the hand truck just enough to maneuver the crated TSR.

Step 4 Transport the crated TSR to shipping and receiving area.

Step 5 Lower the pallet and remove the hand truck.

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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    Last Updated: 05/08/01 at 15:18:13

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