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Avici Systems Inc.

Preinstallation

The TSR II bay is delivered to your receiving dock secured upright on a shipping pallet inside in a wooden crate. Antistatic packaging covers the entire bay. A second shipping box contains the removable BIP. 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 II 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 Support Services immediately.

Unpacking the TSR II System

Before transporting the TSR II 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 II 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 (see 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 the claw of the hammer to remove any klimps attaching the side wall to the crate and remove the side wall (see Figure 2-2 to see locations of klimps.

Figure 2-2. Klimp Locations

Step 7 Repeat Step 5 for each side wall.

NOTE 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 with a 19 mm wrench and lift the support up and off the unit, see Figure 2-3.

Step 9 Remove the antistatic shroud.

Figure 2-3. Removing Wooden Top Support

The TSR II bay ships with the cooling modules and filler modules already installed.

All server, router, and bay controller modules ordered with the system are packaged and shipped separately.

Unpacking the Removable Breaker Interface Panel (BIP)

The TSR II has been fitted with a detachable BIP to aid the system through low-clearance areas (for example a low doorway). The system is shipped with the BIP in a separate fiberboard box; therefore the BIP has been designed to be installed on site. The BIP shipping box holds an inner high-impact foam liner (a-box-within-a-box) and is also wrapped in plastic bubble wrapping (see Figure 2-4).

NOTE Do not use sharp instruments to open the box which could protrude into the shipping container.

The main chassis bay ships in its own separate large crate.

Figure 2-4. BIP Shipping Box (with inner high impact foam liner)

Moving the Bay

The TSR II 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 (W:2-1) Risk of personal injury. The free standing TSR II system weighs approximately 499kg (1100 lb). To reduce the risk death or of injury, the TSR II 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 II is fully crated, the rear can be determined by locating the serial number on the front right side of the pallet (see Figure 2-5).

Figure 2-5. TSR II Serial Number Location

NOTE The TSR II 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".

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 from grade level to a raised floor area.

Using a Pallet Truck

A 27" 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 (W:2-2) Risk of personal injury. 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 death or 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 (see Figure 2-6).

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 Move the bay to the location where it is to be installed. Lower the pallet and remove the pallet truck.

Figure 2-6. Pallet Tuck (27" wide forks)

Using Custom Dolly

Due to overhead clearance, width, or other constraints it may not be possible to transport the bay up a raised floor ramp with the pallet truck prior to removing from the shipping pallet. In these cases, the custom dolly is used (see Figure 2-7).

NOTE Note that the BIP is removable to enhance overhead clearance.

The custom designed dolly is used to:

Figure 2-7. Half of Custom Dolly

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

Step 1 See "Using Custom Dolly to Remove Bay from Shipping Pallet" as well as "Using Custom Dolly" before loading the bay onto the dolly.

Step 2 Raise both front and rear dollies evenly until the bay is about 1 1/2 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.

CAUTION (C:2-1) Risk of service interruption or equipment damage. The custom dolly is designed to operate on smooth surfaces only. Moving the TSR II system over uneven surfaces can cause personal injury and damage to equipment.

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 from the Shipping Pallet

To access the bolts that attach the bay to the shipping pallet, you must remove the front EMI covers, front grill, front air plenum assembly, and cooling modules.

In addition, the lower cable guides, long vertical doors, and lowermost hinge-pin assemblies for the vertical doors need to be removed in order to use the custom dolly.

Removing the Subassemblies

The following assembles are removed prior to anchoring the bay to the floor:

EMI Cover Removal

Each TSR II bay ships with two Electro-Magnetic Interference (EMI) shelf covers. The shelf covers fit easily onto the TSR bay and requires no hardware. Removal of EMI covers is necessary to access and cable routers and servers.

PROCEDURE: Use the following procedure to remove the front EMI covers:

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

Step 2 Simultaneously, pull the knobs on the bottom of the EMI cover outward from the bay to release the bottom of the cover from the bay (see Figure 2-8).

Figure 2-8. EMI Shelf Cover Removal - 1

Step 3 Grasp the shelf cover and lift it off the latch screws on the bay frame (see Figure 2-9).

Figure 2-9. EMI Shelf Cover Removal - 2

Step 4 Set covers aside for reinstallation.

Removing the Front Air Plenum Assembly and Cooling Modules

The cooling unit at the bottom of the TSR II 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 metal rails just above the bay controller modules in the bottom of the bay. Both cooling modules and bay controllers are field replaceable units (FRUs). Before you can access the two cooling modules you must first remove the EMI covers, front grille, and front air intake assembly.

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

Step 1 Remove the front grille by turning four winged screws 1/4 turn counterclockwise (see Figure 2-10).

Figure 2-10. Front Grill Removal

Step 2 Remove the front air intake plenum assembly. The front air plenum assembly attaches at the top center with two Phillips screws and pivots down on two tabs at the bottom.Use a #2 Phillips screwdriver to remove the screws, see Figure 2-11. Tilt the plenum outward from the top and lift up to remove the lower tabs from the lower bracket.

Figure 2-11. Removing Front Air Plenum Assembly

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 (see Figure 2-12).

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 (see Figure 2-12).

Figure 2-12. Cooling Module Removal

Step 6 Repeat previous steps to remove the remaining cooling module.

Removing the Bay Controller Backplane Cover

Removing the bay controller backplane protective cover will aid the dolly installation process.

PROCEDURE: Removing this cover simply involves the removal of two Phillips head screws, split washers, and flat washers(see Figure 2-13).

Step 1 Remove the upper cover half with two Phillips head screws, split washers, and flat washers.

Step 2 Disengage the three tabs of the upper cover with the three tab holes in the lower cover (see Figure 2-13).

Figure 2-13. Bay Controller Protective Cover Assembly Removal

Using Custom Dolly to Remove Bay from Shipping Pallet

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

The procedure for engaging the first half of the dolly to the front of the bay is the same as for the one for the rear, except that the rear installation does not involve the removal of vertical doors or lower cable guides. To engage the dolly to the rear, the sheet metal bay controller backplane protective cover must be removed.

Removing Vertical Doors

PROCEDURE: Use the following steps to remove the vertical cable doors and the lower pin assemblies:

Step 1 Open the front vertical door panels on the left and right sides of the bay by sliding the black plastic concave finger latch located at the middle of each door to the left or right as appropriate (see Figure 2-15).

Step 2 Detach the removable vertical doors by pressing on the three spring-loaded hinge pin knurled thumb latches located on each door. The receptacle holes for the pins are located on the vertical doors. Each door (left door and right door) attaches with three spring loaded thumb-operated easily removable hinge pins. The uppermost pin on each door faces upward; the rest of the pins face downwards (see Figure 2-15).

Step 3 Lay the vertical door panels aside and out of the way.

Step 4 Remove the two Phillips head screws from the innermost hinge pin assemblies on the bottom only. Remove the bottom hinge. Removal provides an obstacle free path when attaching the dolly to the bay frame

Step 5 Additionally, in the front only remove the three cable channel Phillips head screws (three on each side). Two of these screws on each side attach the lower cable guides (see Figure 2-14).

Figure 2-14. Cable Channel Phillips Head Screws

Step 6 Remove the two front cable guides.

Figure 2-15. Removing Vertical Doors)

Using Custom Dolly

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

Installing the Front Dolly

PROCEDURE: Use the following steps to engage the custom dolly to the front of the TSR II bay:

Step 1 Raise the dolly wheels to the fully retracted (raised) position by turning the crank handles in the counter clockwise direction (see Figure 2-16).

Figure 2-16. Custom Dolly in (raised position)

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 (see Figure 2-17).

Step 3 Crank up the dolly to engage the screw heads from the large part of the keyhole to the top narrow section of the keyhole slots (see Figure 2-17).

Figure 2-17. Lift Dolly Into Top of Keyhole Slots

Step 4 Tighten the hex handles clockwise on the engagement bolts (on the opposite end of screw heads of the bolt, near the wheels of the dolly) 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 (see Figure 2-18).

CAUTION (C:2-2) Risk of service interruption or equipment damage. 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 2-18. Fully Tightened Screw Heads

Step 5 In the front dolly only, secure the four M5 screws (two on each side of the adapter plate) 4) to the bay (see Figure 2-17).

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 (see Figure 2-19).

Step 6 To disengage dolly from bay:

Figure 2-19. Fully Engaged Custom Dolly (raised position)

Be sure to adhere to all cautions and warnings.

CAUTION (C:2-3) Risk of service interruption or equipment damage. The custom dolly MUST be in the lowered position for transporting the bay.

Installing the Rear Dolly

The procedure for engaging the rear dolly is similar but less involved as no vertical doors or lower cable guides must be removed. The keyhole slots are in similar positions as the front. Please note that you should remove the bay controller backplane cover prior to installing the rear dolly.

Removing the Shipping Pallet

PROCEDURE: Use the following steps to remove the shipping pallet from a TSR II bay:

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 II 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 (see Figure 2-20).

Figure 2-20. Removing Four Hex Bolts from TSR II Base

Step 3 Adjust the dolly casters until the TSR II system clears the pallet by approximately a half-inch. Figure 2-21 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 2-21. Fully Engaged 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 II 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.

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 (C:2-4) Risk of service interruption or equipment damage. Failure to lower the base of the TSR II bay to slightly above the floor can result in serious injury.

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.

WARNING (W:2-3) Risk of personal injury. Avoid excessive tilting of the TSR II bay, adjusting each castor only slightly before adjusting the other castors to raise the bay to a level height.

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.

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Copyright © 2006 Avici Systems Inc.
Avici® and TSR® is a registered trademark of Avici Systems Inc.
IPriori™, Composite Links™, SSR™, QSR, and NSR™ are trademarks of Avici Systems Inc.

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