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After positioning, anchoring and connecting bays for either a 2 or 4-bay configuration, the backplanes of the adjacent bays are joined (refer to Figure 7-1).
Figure 7-1. 2 Bay (TSR to TSR II)
If this is a 4-bay configuration, connect the 2 front bays and continue on with the instructions for "Connecting 4-Bay Configurations (TSR/TSR II to TSR II)."
Connecting Backplanes - Live Upgrade
The live upgrade of the 2-Bay Configuration requires physically joining the backplanes of two adjacent bays using switchable flex connectors. Switchable flex connectors physically connect the backplanes of adjacent bays and extend the toroidal mesh by providing the pathway for module communication between bays. Switchable flex connectors have two possible settings, X Not Extended and X Extended. When in X Not Extended position, communication between modules is restricted to one bay or one backplane. When in X Extended position, communication between modules in adjacent bays is extended to one or more bays or backplanes. As router module pairs are installed in additional bays, the switchable flex connector knob is set to X Extended to provide the pathway through which the newly installed module can communicate with modules in the existing bay. This unique design allows additional bays to be populated incrementally without further hardware installation.
When joining the backplanes of adjacent TSR and TSR II bays in live upgrades, the steps are as follows:
- Remove EMI enclosure from the rear of the adjoining bays
- Shut down fabric link pathway (X axis) between the bays (in live upgrades) for each router module in Bay 1 (live bay) that will connect to new router module pairs in Bay 3.
- Remove loopback connectors from the rear of the adjoining bays.
- Install switchable flex connectors between the bays to connect the backplanes.
- Determine backplane connection locations of communication pathway (X axes) providing connectivity between Bays 1 and 3 for modules being installed.
- Remove switch knobs from the switchable flex connectors.
- Install labeling on the EMI enclosures.
- Reinstall the EMI enclosures over the flex connectors
- Reinstall the switch knobs on the switchable flex connectors.
- Set the switchable flex connector knob to X Extended for modules being installed in Bay 3.
- Install and cable router modules in Bay 3.
- Bring up router modules in the Bay 3.
- Bring up fabric link pathway (X axis) between the bays for each router module in Bay 1 connecting to router module pairs in Bay 3.
Bay Numbering
In Multi-Bay Configurations, the bays are numbered 1 and 3 in the front and 2 and 4 in the rear (refer to Figure 7-2.)
Figure 7-2. Bay Numbering
Installing the Antistatic Wrist Strap
A grounded antistatic wrist strap must be used while installing components to protect the TSR system from damage caused by static. Use the ESD jack when installing loopbacks, flex connectors, EMI enclosures, and OTT cables. In TSR bays, there are two rear ESD jacks (refer to Figure 7-3). In TSR II bays, there are ESD jacks at each shelf level (refer to Figure 7-4).
PROCEDURE: Use the following procedure to install the antistatic wrist strap in either the TSR or TSR II bays:
Step 1 Remove the alligator clip from the grounding pin on the antistatic wrist strap.
Step 2 For TSR bays, insert the grounding pin into the electrostatic discharge (ESD) jack on the rear of the TSR (refer to Figure 7-3).
Step 3 For TSR II bays, insert the grounding pin into the electrostatic discharge (ESD) jack on the appropriate front shelf (refer to Figure 7-4).
Step 4 Use the ESD jack while installing EMI enclosures, loopback connectors, flex connectors, and OTT cables.
Figure 7-3. TSR - Rear ESD Jack Location
Figure 7-4. TSR II - ESD Jack Locations
Removing EMI Enclosures
Removal of EMI enclosures from the rear of the bays allows access to loopback connectors, which are removed to allow for installation of the switchable flex connectors.
TSR EMI enclosures are located on the outer edges of the upper backplanes. Only the EMI enclosures adjacent to Bay 1 are removed (refer to Figure 7-6).
TSR II bays have 2 large EMI enclosures encasing the upper backplane and four smaller EMI enclosures on the bottom rear of the bay. Both the top EMI enclosures and the bottom two EMI enclosures adjacent to Bay 1 are removed (refer to Figure 7-5).
PROCEDURE: Beginning at the top rear of Bay 3, use these steps to remove the EMI enclosures from the TSR II bay:
Step 1 Hand loosen the seven captive screws on the top EMI enclosure on the upper backplane.
Step 2 Remove the EMI enclosure from the bay.
Step 3 Repeat Step 1 and Step 2 for the second large EMI enclosure on the upper backplane (refer to Figure 7-5).
Step 4 Use a #2 Phillips screwdriver to loosen the captive screws on the two small bottom EMI enclosures. Only the EMI enclosures adjacent to Bay 1 are removed (refer to Figure 7-5).
Step 5 Remove the two small EMI enclosure from Bay 3.
Step 6 Beginning at the top of Bay 1 (TSR bay) on the side adjacent to Bay 3, use a #2 Phillips screwdriver to loosen the captive screws on the top small EMI enclosure.
Step 7 Remove the four EMI enclosures from the bay (refer to Figure 7-6). Only the EMI enclosures providing the adjacency are removed.
Step 8 Repeat Step 6 through Step 7 for the remaining three EMI enclosures on Bay 1.
Figure 7-5. EMI Enclosure Removal - TSR II Bay
Figure 7-6. EMI Enclosure Removal - TSR Bay
Performing Live Upgrades
The TSR design designates an active portion of the switch fabric to each router module. In the live bay upgrade, the axis that transverses the bays horizontally is the X axis. For each router module pair there is a corresponding backplane connection through either the X Not Extended (in one bay or backplane) or the switchable flex connector (one or more bay or backplane).
Because Bay 1 is live, the X axes must be temporarily shut down for each module pair one at a time, the loopback removed, the switchable flex connector installed, and the X axes be brought up. With the axis shut down, the loopback connectors can be removed and the switchable flex connector installed. Then the X axis can be brought up. Proceeding in this manner ensures an optimized toroidal mesh operating throughout the upgrade process.
Upon initial installment, all flex connectors must be in the X Not Extended position. In X Not Extended position, the switch indicator points toward the bay that is being extended (refer to Figure 7-18). As router modules are added to adjacent bays, the flex connector switch is set to X Extended to allow communication between modules to extend to the adjacent bay. Once installed, switchable flex connectors allow the future addition of router module pairs without additional hardware installation.
PROCEDURE: The procedure to prepare to install switchable flex connectors in a live bay upgrade is as follows:
Step 1 Determine the backplane connection for each router module pair in Bay 1.
Step 2 Temporarily shut down the X axis for each router module pair in Bay 1.
Step 3 Remove the loopback connector for the corresponding modules.
Step 4 Install the switchable flex connector and EMI enclosure(s).
Step 5 Bring up the X axis for the module pair in Bay 1.
Step 6 Repeat Step 1 through Step 5 for each router module pair in the live bay until all 20 switchable flex connectors are installed.
The router module pair 35 and 36 serves as an example throughout this procedure.
Determining Backplane Connection Locations
For each router module pair, there is a corresponding loopback connector on the backplane. Before removing the loopback connector on the backplane, it is necessary to determine the corresponding loopback connector location for each router module pair. Each router module in a bay has a specific slot number. In addition, each loopback/switchable flex connector position on the backplane is numbered.
Each axis within the toroidal mesh has a positive and a negative axis. Because the X axis travels horizontally, modules either have a plus OR a minus pathway to bays in adjacent positions. Labeled numbering on the EMI enclosures on the backplane identify which X axis (minus or plus) must be temporarily shut down for each module in each bay.
NOTE Because EMI enclosures are not installed until after the switchable flex connectors, refer to Figure 7-7 for a representational diagram of the labeled EMI numbering.
The X axis must be shut down for each module pair individually before removing the loopback connector and installing the switchable flex connector. Refer to Table 7-1 "Backplane Locations/Axes Designation"."
In order to install the switchable flex connectors, determine which X axis must be shut down for each module before removing the loopback and installing the switchable flex connector. Table 7-2 "Module to Backplane Connections" lists the router module pairs and the corresponding X axis pathways.L
Temporarily Shutting Down The X Axes
Each module's X axis must be temporarily shut down before removing the remove the corresponding loopback and installing the switchable flex connector. The router module pair in slots 35 and 36 is used as an example throughout this procedure.
In live bay upgrades, the each pair of loopbacks (one from each bay) is removed one at a time, after the X axis has been temporarily shut down. Before beginning, verify that each backplane location is the specified pathway for the module whose X axis has been temporarily shut down. Refer to Figure 7-7 "Representation of Numbering Labels on EMI Enclosures".
Figure 7-7. Representation of Numbering Labels on EMI Enclosures
PROCEDURE: Beginning with router modules 35 and 36 in Bay 1, use the following procedure to temporarily shut down the X axis, remove the loopback connectors for that axis in Bay 1 and Bay 3, install the switchable flex connector, and bring up the X axis for that router module pair.
Step 1 Use the CLI command, shutdown fabric link to shutdown the X minus OR X plus axis for router module pair 35, 36 in Bay 1 (refer to Table 7-1 to determine if the module's X orientation is plus or minus).
Step 2 Use the shutdown fabric link command to shut down the fabric link on the X minus axis for modules 35 and X plus for module 36.
Step 3 Use the end command to return to exit configuration mode.
Table 7-1.
router(config)#module 1/35
router(config-module)# shutdown fabric link xminus
router(config)#module 1/36
router(config-module)# shutdown fabric link xplus
Backplane Locations/Axes Designation
Bay 1 (Live) - Router Module Slots - Bay 1 Loopback/Flex Connector Location X Axis Designation - Plus or Minus 1 - 5
11 - 15
21 - 25
31 - 35
X minus
6 - 10
16 - 20
26 - 30
36 - 40
X plus
Step 4 Using Figure 7-7 "Representation of Numbering Labels on EMI Enclosures", remove the appropriate loopback connector from Bay 1 and the corresponding connector from Bay 3. Refer to Figure 7-10.
NOTE Exercise care when removing the loopback connectors. Loopbacks must be pulled straight off the TSR bay (refer to Figure 7-9 and Figure 7-10).
Figure 7-8. Loopback Connector
Step 5 Grasp the handle on the loopback connector and firmly pull straight back to remove the loopback (refer to Figure 7-9 and Figure 7-10).
Figure 7-9. Side View of Loopback Removal
Step 6 Repeat Step 5 for the corresponding loopback connector on the adjacent bay (refer to Figure 7-10).
Figure 7-10. Loopback Removal
Installing Switchable Flex Connectors
Switchable flex connectors physically connect the backplanes of adjacent bays and extend the toroidal mesh by providing the pathway for module communication between adjacent bays. Switchable flex connectors have two possible settings, X Not Extended and X Extended. When in X Not Extended position, communication between modules is restricted to one bay or one backplane. When in X Extended position, communication between modules in adjacent bays is extended to one or more bays or backplanes.
Upon initial installment, all flex connectors must be in the X Not Extended position. In 2-bay configurations, the switch side (X Not Extended position) is installed on Bay 1 (refer to Figure 7-11 and Figure 7-12). As router modules are added to adjacent bays, the flex connector switch knob is set to X Extended to allow communication between modules to extend to the adjacent bay. Once installed, switchable flex connectors allow the future addition of router module pairs without additional hardware installation (refer to Figure 7-18).
PROCEDURE: Beginning at the top rear of Bays 1 and 3 and working downward in groups of five, use the following procedure to install the switchable flex connectors between the bays:
NOTE When installing switchable flex connectors, ensure that the switch side of the flex connector is installed in Bay 1 (refer to Figure 7-12 and Figure 7-13).
Step 1 Carefully position the guides of the switchable flex connector onto the guide pins on the backplane connectors on Bay 1 and Bay 3 (refer to Figure 7-12 and Figure 7-13).
Figure 7-11. Switchable Flex Connector
Figure 7-12. Switchable Flex Connector Installation - 1
Step 2 Carefully push the switchable flex connector onto the backplane connectors to seat the connector (refer to Figure 7-12).
Step 3 Use the no shutdown fabric link command to bring up the fabric link on the X minus for router modules 35 and 36.
- For example:
router(config)#module 1/35
router(config-module)# no shutdown fabric link xminus
router(config)#module 1/36
router(config-module)# no shutdown fabric link xplus
Step 4 Use the end command to exit configuration mode.
Step 5 Repeat Step 1 through Step 4 for each router module pair in Bay 1.
Figure 7-13. Switchable Flex Connector Installation - 2
Securing EMI Enclosures
After installing the switchable flex connectors, labels are attached to each of the four EMI enclosures. Each label corresponds to a shelf in the bay and the module pathways between bays. When populating in multi-bay configurations, these labels instruct users which communication pathways to switch to X Extended.
Before positioning and securing the EMI enclosures, the switch knob must be removed from each of the flex connectors. A small set screw secures the switch knob on each of the flex connectors. After removing the knobs from each of the flex connectors, attach labels to each EMI enclosure, secure the corresponding EMI enclosure over each set of five switchable flex connectors, and reattach the switch knob.
NOTE EMI enclosures are positioned on bays with the captive fasteners on the right side of the enclosure. Before positioning labels on the EMI enclosures, check to make sure the top of the label is going on the top of the EMI enclosure (refer to Figure 7-16).
In side-to-side configurations of TSR and TSR II bays, the EMI covers consist of two pieces, a base plate and an EMI labeled cover. This design protect against potential EMI interference.
PROCEDURE: Beginning at the top of the bays and working downwards, use the following procedure to remove knobs, attach labels to EMI enclosures, secure the EMI enclosures, and reinstall the switch knobs:
Step 1 Position the four EMI enclosure labels on the four EMI enclosures with the right side facing up (refer to Figure 7-16).
Step 2 Using a .050 allen wrench, loosen the set screw on the switchable flex connector and remove the switch knob on the top flex connector (refer to Figure 7-14).
Figure 7-14. Switch Knob Removal
Step 3 Working downward, repeat Step 2 for the next four flex connectors.
Step 4 Repeat Step 2 and Step 3 for the remaining three sets of flex connectors.
Step 5 Position the EMI base plate so that it surrounds the top five flex connectors on Bay 3 (refer to Figure 7-15).
Step 6 Tighten the four captive screws to secure the EMI enclosure base plate to Bay 3.
Step 7 Repeat Step 5 and Step 6 for the remaining three EMI enclosure base plates.
Figure 7-15. EMI Base Plate Installation
Step 8 Position the EMI enclosure with the correct label for the shelf over the top 5 switchable flex connectors between the bays (refer to Figure 7-16).
Figure 7-16. Installation of Labeled EMI Enclosures
Step 9 Tighten the four captive screws on the EMI enclosure (refer to Figure 7-17).
Step 10 Use two nut plates to secure the EMI enclosure to the studs on Bay 3.
Step 11 Using a .050 allen wrench, reattach the switch knob to the flex connector and tighten the set screw to secure the switch knob. Ensure that the switch indicator faces the bay that is being extended. Ensure that the set screw tightens against the flat of the switch shaft (refer to Figure 7-18).
Step 12 Repeat Step 2 through Step 11 for the remaining three sets of flex connectors.
.
Figure 7-17. Side View of EMI Enclosure (Switch Knobs Removed)
Figure 7-18. EMI Enclosures Installation
Installing the Thinnet Ethernet
In multi-bay configurations, the installation of a thinnet Ethernet cable connects the bay controller backplanes of adjacent TSRs in multi-bay installations.
2-Bay Configuration
The procedure to install the thinnet Ethernet cable in side-to-side installations is the same whether the installation is a cold installation a or live bay upgrade.
PROCEDURE: Use the following procedure to install the thinnet Ethernet cable to connect bay controller backplanes in side-by-side bays:
Step 1 Remove the terminator BNC connectors from Port 5 on Bay 1 and Port 7 on Bay 3.
Step 2 Connect the thinnet Ethernet cable to the BNC connector on P7 on Bay 3. Connect the other end of the thinnet Ethernet cable to the BNC connector on P5 of Bay 1 (refer to Figure 7-19).
Figure 7-19. Thinnet Ethernet Connection
Populating Bay 3 - Live Upgrades
In the 2-bay Configuration, router module population rules require that Bay 1 be fully populated before installing additional router modules in Bay 3. For each router module pair, there is a corresponding backplane connection through the switchable flex connector. The switch knob on the flex connector is set to X Extended only for router modules being installed.
To ensure optimization of the toroidal mesh during the upgrade procedure, the X axis from the router module pairs in Bay 1 are temporarily shut down before setting the switchable flex connector.
Router Module Population Rules for Bay 3 - Live
The location of router modules within the TSR bay creates the "toroidal mesh." It is critical to install router module pairs in predefined positions. All router modules must be inserted in pairs.
Populate Bay 3 with router module pairs in the following slot order:
- 35, 36, 25, 26, 15, 16, 5, 6, 34, 37, 24, 27, 14, 17, 4, 7, 33, 38, 13, 18, 3, 8, 32, 39, 22, 29, 12, 19, 2, 9, 31, 40, 21, 30, 11, 20, 1, 10.
When populating Bay 3, it is necessary to determine the corresponding switchable flex connector providing the pathway for the router module pair being installed. Installation of router module pairs follows predefined rules. It is critical to install router modules in predefined positions and to set to X Extended only the path through the switchable flex connector that supports that module pair.
To assist in determining the module to flex connector relationship, each router module installed in a bay has a specific slot number. Router module slots in each TSR bay are numbered 1 through 40. Refer to Figure 7-20 for slot numbering in TSR bays, and Figure 7-21 for slot numbering in TSR II bays. In addition, the switchable flex connector providing the pathway is labeled on the EMI enclosure on the rear of the bay. These numbers show router module pair numbers and predefine the paths between module pairs in adjoining bays (refer to Figure 7-22).
To aid in understanding this process, the router module pair 35 and 36 serve as an example throughout this section for module installation in Bay 3.
For example, in order to install router module pairs in slots 35 and 36 in Bay 3, it is necessary to turn the switchable flex connector to the X Extended position for this router module pair. For the pair in slots 35 and 36, the switchable flex connector labeled with these router module pairs provides the pathway between the modules. The switch on this flex connector needs to be turned to the X Extended position. Figure 7-22 shows the switch connector in the X Extended position for router modules 35 and 36.
Figure 7-20. TSR - Shelf and Slot Numbering
Figure 7-21. TSR II - Shelf and Slot Numbering
Figure 7-22. Switchable Flex Connector Numbering
Table 7-2 outlines the router module pairs and the corresponding locations of the switchable flex connector. Before installing modules, refer to Table 7-2 and Figure 7-23 "Representation of Numbered Labels on EMI Enclosures" to locate the predefined positions of flex connectors.
Figure 7-23. Representation of Numbered Labels on EMI Enclosures
Setting the Switchable Flex Connector
After identifying the correct switchable flex connector for each router module pair being installed, the router modules in Bay 3 are installed, cabled, and booted up. To ensure optimization of the toroidal mesh during this upgrade procedure, the X axis to the new modules is temporarily shut down before setting the switch knob on the flex connector to the X Extended position. Then, the X axis from the modules in Bay 1 to the modules in Bay 3 is re enabled and communication between the modules is established.
Upon initial installation, the switch knob on the switchable flex connector points towards Bay 1, X Not Extended position. In X Not Extended position, there is no communication pathway between the bays. In order to have an communication pathway between modules in the adjoining bays, the switch must be in X Extended position. In X Extended position, connectivity is established and the router modules in Bays 1 and 3 are able to communicate via the X axis.
Each module pair installed in an adjoining bay requires the switch knob to be set to X Extended position to support the communication between the module pairs of both bays. The EMI enclosure label identifies the slot numbers and the X Not Extended and X Extended positions.
PROCEDURE: The general procedure to install modules in Bay 3 and to set the switch knob on the switchable flex connectors is as follows:
Step 1 Following population rules, insert the module pair into the Bay 3. According to the population rules, this is router module pair 35 and 36.
Step 2 Connect fiber optic cabling to installed router module. If this is a SAM module in a TSR bay, install the Ethernet cable.
Step 3 Use the shutdown fabric link command to shut down the fabric link on the X minus axis for modules 35 and X plus for module 36 in Bay 1.
Step 4 Use the end command to exit configuration mode.
router(config)#module 1/35
router(config-module)# shutdown fabric link xminus
router(config)#module 1/36
router(config-module)# shutdown fabric link xplus
Step 5 Determine the corresponding switchable flex connector providing the pathway (X axis) between the bays. Refer to labels on EMI enclosures. For router module pair 35, 36, the connection marked +35/-36 in Bay 3 is the correct switch connector. Refer to Figure 7-22 "Switchable Flex Connector Numbering".
Step 6 Set the switchable flex connector knob to the X Extended position on the flex connector for modules being installed.
Step 7 Use the no shutdown fabric link command to bring up the fabric link on the X minus for router modules 35 and 36 Bay 1.
- For example:
router(config)#module 1/35
router(config-module)# no shutdown fabric link xminus
router(config)#module 1/36
router(config-module)# no shutdown fabric link xplus
The router modules in Bay 3 receive keepalive messages from the router modules in Bay 1 and communication is established.
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