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Avici Systems Inc.

Installing TSR II Bay Components

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

Tools Needed

Use the following tools for installing TSR II Bay components:

TSR II Bay Grounding Requirements

This section describes the grounding requirements for the TSR II bay.

Each TSR II bay frame must be safety grounded with two #2 AWG protective earthing conductor. The safety ground wire must be terminated with a UL listed two hole compression lug with hole size and spacing as shown in Figure 4-1.

CAUTION (C:4-1) The protective earthing conductor MUST be attached to the bay frame at the two locations shown in Figure 4-2 prior to installing the power and return feeds.

Supplier Part No. Description

Panduit

LCC2-14A

#2 AWG - Flared barrel

Figure 4-1. Frame Ground Compression Lug

There are two locations for the required safety grounds. The required protective earthing conductors are attached directly to the bay frame at the rear top left corner of the frame next to the power input terminals and also at the lower left bottom corner. Both grounds are required. Figure 4-2 shows the location of the safety ground connections.

Figure 4-2. Required Main Safety Power Frame Grounds

CAUTION (C:4-2) The protective earthing conductor MUST be attached to the bay frame at the two locations shown in Figure 4-2 prior to installing the power and return feeds.

NOTE The safety ground MUST be attached to the bay frame at the two locations shown in Figure 4-2 prior to installing the power and return feeds.

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

Step 1 Arrange the washers and screws as shown in Figure 4-2 to secure the safety ground lug.

Step 2 Torque the Phillips pan head screws to 85-in.-lb.

Installing the Removable BIP

Installing the BIP on the bay requires aligning the guide pins on the bay into the guide pin holes located on the bottom of the BIP (see Figure 4-3). Aligning the BIP properly requires two men. After installation of the BIP, secure the BIP to the bay using the four M5 Phillips screws located at each corner flange of the BIP (see Figure 4-4). The BIP chassis interface side connectors include paths for the BIP output power cables heading down to the shelves (left side of TSR II chassis) and for signal cables heading to the bay controller backplane (right side of TSR II chassis).

NOTE The BIP chassis interface connectors have their own smaller guide pins to aid in proper mating of the upper and lower BIP chassis interface connector.

Figure 4-3. Location of Alignment Pins on Bay and BIP

PROCEDURE: Use the following procedure to install the removable BIP:

WARNING (W:4-1) Risk of personal injury. Placing the BIP on top of the TSR II chassis is a two-man operation.

Step 1 Verify that the antistatic wrist strap you are wearing is properly grounded.

Step 2 Verify that the four large alignment guide pins installed on top of the TSR II chassis are secure. If they are not, use a 9mm wrench to tighten them (refer to Figure 4-3).

Step 3 Placing the BIP subassembly on a protective foam pad, remove the two protective covers on the BIP chassis interface connectors on the bottom of the BIP by removing two M4 X 6 Phillips head screws per cover. These protective covers protect the connector pins protruding from the connectors on the bottom of the BIP.

Step 4 Orient the front of the BIP (alarm panel and circuit breakers) facing the front of the TSR II bay. Have two people slowly carry the BIP up two insulated step ladders positioned on either side of the TSR II chassis.

Step 5 Align the BIP over the four BIP guide pins (see Figure 4-3 and Figure 4-4).

NOTE There are two guide pins per side. There are four large holes in the bottom of the BIP chassis which accept the BIP alignment pins.

Figure 4-4. Alignment of BIP on Bay

Step 6 Slowly lower the BIP onto the alignment guide pins, taking care that the small alignment pins (facing down) on the two BIP chassis interface connectors mate with the corresponding holes in the TSR II chassis (see Figure 4-3 and Figure 4-4).

NOTE Note that these smaller alignment pins and BIP chassis interface connectors "float" slightly to aid in mating with the other corresponding connector half. Be careful not to bend any connector pins during this process.

Step 7 Wiggle the BIP slightly to make sure it is securely seated.

Step 8 Then attach four M5 Phillips head screws at the corners of the BIP perimeter to secure the BIP to the TSR II chassis top frame (refer to Figure 4-4).

Figure 4-5. Installed BIP on the TSR II Chassis

Power Requirements

Power distribution systems providing primary power for TSR II bays must meet the requirements specified in this section.

Power from the customer's power distribution system is supplied to the TSR II bay at the rear of the (BIP), located at the top of the TSR II bay.

At the shelf level, a redundant pair of power supply inputs (one for each power feed bank) further filter and interface -48V/-70Vdc power to the backplane.

Primary power is distributed to TSR II bays using the following methods:

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

When a power distribution center is used, it must be dedicated to the TSR II system. Power distribution centers and power must be equipped with stability filters (capacitors) on each feed from the power plant. These large capacitors act as low-frequency filters to limit voice-band noise feedback to the battery.

The TSR II bay contains a fully-redundant chassis with load sharing power inputs provided by a separate power source to the BIP. The TSR II system uses dual -48V/-70V power inputs that are filtered and distributed redundantly throughout the chassis. Redundancy prevents the failure of one power input from affecting another and minimizes power outages.

Power Input for BIP

The following describes requirements for the BIP:

Supplier Part No. Description

Panduit

LCC4-14A

#4 AWG - Flared barrel

Figure 4-6. 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 BIP

After installing the power guard block, secure the power and return feeds located at the rear of the TSR II BIP. Because the Keps and jam nuts ship on the power and return posts, unscrew them prior to attaching the lug.

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.

WARNING (W:4-2) Verify that the site power feeds and return feeds are turned off prior to installing the TSR II. Use LOCK-OUT and TAG-OUT procedures.

Failure to do so may cause electrical shock or burns.

Step 2 Unscrew the Keps from each post to prepare to connect the power lugs.

Step 3 Position the BIP cable guard block on top of the bay. Stack the lock and flat washers and secure the block with four (4) M4 X 30mm socket headed screws (see Figure 4-7).

Figure 4-7. Cable Guard Block Installation

Step 4 Attach the ten power feeds and the ten power return feeds to the appropriate locations using crimp-style two-hole lugs. (AF and BF are 20 AMP inputs - all others are 70 AMP. Spare input(s) (SP) are not to be used.) See Figure 4-8 and Figure 4-9 for the location of the power and return feeds.

Figure 4-8. Power and Return Feeds - 1 (rear of BIP)

Figure 4-9. Power and Return Feeds - 2

WARNING (W:4-3) Use only a torque wrench when tightening the Keps nuts. Failure to do so may cause equipment damage.

Step 5 Secure the power and return feeds with the Keps nuts using a torque wrench and torque to 65-in.-lb. (see Figure 4-10).

Figure 4-10. Power Lug Attachment

Step 6 Position the guard plate over the power input assembly and stack the flat and lock washers as shown in Figure 4-11. Secure the plate using the four (4) M3 X 6 pan head screws with flat washers (see Figure 4-11).

WARNING (W:4-4) The cable guard block and guard plate are safety features and must be installed.

Figure 4-11. Installing the Breaker Interface and Cable Guards

Step 7 Power on the TSR II bay by first flipping the bay controller switch and the remaining breaker switches to the ON position on the front of the BIP.

Reinstalling the Subassemblies

The following assembles were removed when the bay was anchored to the floor and must be reinstalled.

Reinstalling the Vertical Doors

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

Step 1 Re-install the single Phillips head screw removed (each side) of the vertical door lower cable channel - taken off during the dolly adapter engagement.

Step 2 Line up the vertical doors with the front of the bay.

Step 3 Each door (left door and right door) attach with three spring loaded thumb-operated easily removable hinge pins. The receiving holes for the pins are located on the inside of the doors. The hinges for the pins are located on each the cable channel framework. The uppermost pin on each door faces upwards; the rest of the pins face downwards.

Step 4 Close the vertical door panels on the left and right sides of the bay (front).

Step 5 Slide the black plastic finger latch to the left or right as appropriate to latch (see Figure 4-12).

Figure 4-12. Reinstalling Vertical Doors (left door shown)

Reinstalling Lower Cable Guide Assemblies

PROCEDURE: Use the following procedure to install the lower cable guide assembles (left and right):

Step 1 Position cable guide onto the bay and line up two screw holes.

NOTE There are unique left and right cable guides.

Step 2 Install two Phillips head screws, flat washers, and lock washers per cable guide (see Figure 4-13).

Figure 4-13. Reinstalling Lower Cable Guides (left cable guide shown)

Installing the Bay Controllers

The bay controller modules are shipped separately and need to be installed. To avoid damage to the backplane, a detailed inspection of the bay controller module VHDM connector is required each time a module is removed or inserted.

NOTE Do not insert bay controller modules from the SSR into the TSR II, as the modules are of a different length.

PROCEDURE: Use the following steps to install the bay controller modules:

Step 1 Remove the bay controller module from its packaging and static protection bag.

Step 2 Before inserting the bay controller module, remove the VHDM protective cap from the end of the module before use. Set the protective cap aside in a safe place (see Figure 4-14).

Figure 4-14. Remove VHDM Protective Cap Before Use
A detailed inspection of the VHDM connector on the back of the bay controller module is required prior to insertion. Lay the module gently on a flat surface so you can perform a VHDM connector inspection.

Figure 4-15. Place Bay Controller Module on Flat Surface

Step 3 Carefully inspect the VHDM connector for damage such as deformed sockets, holes between socket columns, and deformed guide fins on top and bottom of the socket columns.

NOTE If the VHDM connector has any signs of damage, DO NOT insert it into a bay. Mark the module as damaged and call TSR-BY-AVICI (877-292-8424) to request an RMA.

.

Figure 4-16. Bay Controller Module VHDM Connector

Step 4 Look into bay controller slot to ensure bay controller path is free of obstruction; for example, packing materials.

Step 5 Disengage the release latches on the bay controller module.

Step 6 Align the bay controller module with the nylon rails above the baseplate.

Step 7 Slide the bay controller modules into the left or right card guides from the front of the bay (see Figure 4-17).

Figure 4-17. Reinstalling the Bay Controllers

Step 8 Engage the latches to seat the connector at the rear of the module firmly in the controller backplane.

Step 9 Repeat Step 5 through Step 8 for the remaining bay controller.

Reinstalling the Cooling Modules

PROCEDURE: Use the following steps to install the two 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 (see Figure 4-18).

Figure 4-18. Cooling Module Installation

CAUTION (C:4-3) Risk of service interruption or equipment damage. To avoid damage to the hardware components during installation, observe the standard electrostatic discharge (ESD) precautions.

Reinstalling the Front Air Plenum Assembly and Grille

PROCEDURE: Use the following procedure to install the front grill and air plenum assembly:

Step 1 Lay the front air plenum assembly in a horizontal position with the two tabs facing the receiving slots in the bottom of the TSR II chassis.

Step 2 Engage the tabs and swing the front air plenum assembly up until it contacts the TSR II chassis

Step 3 Secure air plenum assembly at the top with two Phillips head screws.

Step 4 Secure the front grille with four winged 1/4 turn screws.Turn clockwise to secure (see Figure 4-19 and Figure 4-20).

Figure 4-19. Installing Front Air Plenum Assembly

Figure 4-20. Installing Front Grille

Reinstalling the Bay Controller Protective Cover

PROCEDURE: Reinstallation simply involves the installation of two Phillips head screws, split washers, and flat washers.

Step 1 Engage the three tabs of the upper cover with the three tab holes in the lower cover.

Step 2 Install the cover half with two Phillips head screws, split washers, and flat washers.

Module Population Rules

This section describes TSR II router module and route controller module slot locations and Full Bay and Split Bay Population rules.

Preparing to Install Router and Route Controller Modules

In order to prevent damage to the TSR II system from static electricity, use the following precautions:

CAUTION (C:4-4) Risk of service interruption or equipment damage. 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 II system modules and components from damage caused by ESD.

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 top left of any the TSR II bay shelf (see Figure 4-21).

Step 3 Use the ESD jack while handling modules.

Figure 4-21. ESD Jack Locations

Bay Numbering

All bays are numbered odd in the first row; for example: 1 and 3 and even in the second row; for example: 2 and 4.

Figure 4-22. Bay Numbering

TSR II Bay Shelf and Slot Numbering

Each TSR II bay has four shelves numbered from 1 (top) to 4 (bottom). There are 10 router module slots and 1 route controller module slot on each shelf for a total of 11 slots per shelf. All router modules must be inserted in pairs.

The four shelves and their slots are numbered as follows:

Figure 4-23. TSR II Bay Shelf and Slot Numbering

Router Module Population

The location of the routing modules within the bay creates the TSR II system's "toroidal" mesh. To maximize the performance of the toroidal mesh, the installation of router modules follows predefined rules.

In addition, the TSR II accepts router modules from two module families. Because each user's configuration differs in its combination of Family 1 and Family 2 modules, the CLI command - show population- displays the order of router module population. Use of the show population command allows a user to populate a bay and maximize the capacity of the toroidal mesh.

Roman numerals on the faceplate label identify Family 2 router modules. Figure 4-26 shows a 4-Port OC-48c faceplate label identifying the module as a Family 2 module.

Figure 4-24. Family 2 Label Identification

Table 4-1 shows module family designations.

Table 4-1. Router Module Families
Module Name Family 1 Family 2

1-Port OC-192c

X

1-Port (Dual-Slot) OC-192c

X

1-Port OC-48c

X

2-Port OC-48c

X

4-Port OC-48c

X

4-Port OC-12c

X

4-Port OC-3c

X

16-Port OC-3c

X

1-Port 10Gigabit Ethernet

X

2-Port Gigabit Ethernet

X

8-Port Gigabit Ethernet

X

All MSC modules

X

Router Module Population Rules - Single Bay

The CLI show population command dynamically assesses each configuration and instructs users where to install the next module pair. Because there may be instances where an installer does not have immediate access to the CLI command line upon installation, this document addresses the initial installation of four router modules.

NOTE The CLI command show population always takes precedence.

Router modules in a TSR II use the chassis and slot number as their identifier. For example, in a single-chassis system, module 1/5 identifies the module that resides in chassis 1, slot 5.

CAUTION (C:4-5) Risk of electrostatic damage. When handling modules, wear a grounded antistatic wrist strap or equivalent protection to avoid damaging electrostatic parts.

NOTE It is critical to install routing modules and route controller modules in predefined position.

The rules for populating the TSR II bay with route controllers and router module pairs are as follows:

Figure 4-25. Sample Initial Installation of Module
(4 Family 2 modules)

Table 4-2. Initial Router Module Population
Module Family Combinations Family 1 Family 2 Initial Population

1

4

35&36, 25&26

2

4

33&38, 23&28

3

2

2

Family 1: 35&36

Family 2: 33&38

NOTE Do not insert router modules into a dedicated server module slot as this may damage the VHDM connector. If you accidentally insert a router module into a dedicated server slot, you must inspect the VHDM connector for damage prior to inserting the module into a module slot.

Example: Use the show population f2 4 command to determine the next slots to be populated for 4 Family 2 modules. The following example shows 4 Family 2 modules.

router#show population f2 4





1. Insert Family 2 into slot 1/33

2. Insert Family 2 into slot 1/38

3. Insert Family 2 into slot 1/23

4. Insert Family 2 into slot 1/28



           Module Placement for Bay 1:



          21 22 23 24 25 26 27 28 29 30

===========================

Shelf 3 || -  - N - -   | - -  N  -  - S3

---------------------------

         31 32 33 34 35 36 37 38 39 40

Shelf 4 | -  -  N  -  - | - -  N  -  - S4

===========================

(-=Empty, P=Present,I=Identified, N=New Module Location, O=Occupied, S=Server, D=Dormant, U=Unknown

Refer to Ipriori CLI Reference Guide (Vol. 1) for further information on this command. An the online version of the manual is available at http://www.avici.com/documentation.

Populating the TSR II Split Bay

The TSR II Split Bay configuration contains an upper and a lower router which operate independently. Because each TSR configuration differs due to different ratios of Family 1 and Family 2 modules, the CLI command-- show population-- is required. The CLI show population command dynamically assesses each configuration and instructs users where to install the next module pair. Because there may be instances where an installer does not have immediate access to the CLI command line upon installation, this document addresses the initial installation of four router modules.

NOTE The CLI command show population always takes precedence.

Router modules in a TSR II use the chassis and slot number as their identifier. For example, in a single-chassis system, module 1/5 identifies the module that resides in chassis 1, slot 5.

CAUTION (C:4-6) Risk of electrostatic damage. When handling modules, wear a grounded antistatic wrist strap or equivalent protection to avoid damaging electrostatic parts.

NOTE It is critical to install routing modules and route controller modules in predefined position.

In addition, the TSR II accepts router modules from two module families. Roman numerals on the faceplate label identify Family 2 router modules. Figure 4-26 shows a 4-Port OC-48c faceplate label identifying the module as belonging to Family 2.

Figure 4-26. Family 2 Label Identification

Table 4-3 shows module family designations.

Table 4-3. Router Module Families
Module Name Family 1 Family 2

1-Port OC-192c

X

1-Port (Dual-Slot) OC-192c

X

1-Port OC-48c

X

2-Port OC-48c

X

4-Port OC-48c

X

4-Port OC-12c

X

4-Port OC-3c

X

16-Port OC-3c

X

1-Port Gigabit Ethernet

X

2-Port Gigabit Ethernet

X

8-Port Gigabit Ethernet

X

All MSC modules

Upper Router

The rules for populating the TSR II bay with route controllers and router module pairs are as follows:

Figure 4-27. Upper Router Sample Initial Installation
(4 Family 2 modules)

Table 4-4. Initial Router Module Population
Module Family Combinations Family 1 Family 2 Initial Population

1

4

Family 1: 15&16, 5&6

2

4

Family 2:13&18, 3&8

3

2

2

Family 1: 15&16

Family 2: 13&18

NOTE Do not insert router modules into a dedicated server module slot as this may damage the VHDM connector. If you accidentally insert a router module into a dedicated server slot, you must inspect the VHDM connector for damage prior to inserting the module into a module slot.

Example: Use the show population f2 4 command to determine the next slot to be populated for a Family 2 module. The following example shows 4 Family 1 modules and 2 Family 2 modules.

router#show population f2 4



New Module Placement Bay 1:



         1  2  3  4  5  6  7  8  9 10

===========================

Shelf 1 || -  - N- -  - | - - N  -  -   S|

---------------------------

         11 12 13 14 15 16 17 18 19 20

Shelf 2 |-  -   N  - - | - -  N  -  -  -S2

===========================

(-=Empty, I=Identified, N=New Module Location, O=Occupied, S=Server,D=Dormant, U=Unknown)

Refer to Ipriori CLI Reference Guide (Vol. 1) for further information on this command.

Lower Router

The rules for populating the TSR II bay with route controllers and router module pairs are as follows:

Figure 4-28. Lower Router Sample Initial Installation
(4 Family 2 modules)

Table 4-5. Initial Router Module Population
Module Family Combinations Family 1 Family 2 Initial Population

1

4

35&36, 254&26

2

4

33&38, 23&28

3

2

2

Family 1: 35&36

Family 2: 33&38

NOTE Do not insert router modules into a dedicated server module slot as this may damage the VHDM connector. If you accidentally insert a router module into a dedicated server slot, you must inspect the VHDM connector for damage prior to inserting the module into a module slot.

Example: Use the show population f2 4 command to determine the next slot to be populated for the initial 4 Family 2 modules. The following example shows four Family 2 modules.

router#show population f2 4



New Module Placement Bay 1:



          21 22 23 24 25 26 27 28 29 30

===========================

Shelf 3 || -  - N -  - | -  -  N  -  -    S3

---------------------------

         31 32 33 34 35 36 37 38 39 40

Shelf 4 |-  -   N  - - | -  -  N  -  -  - S4

===========================

(-=Empty, I=Identified, N=New Module Location, O=Occupied, S=Server, D=Dormant, U=Unknown

Refer to Ipriori CLI Reference Guide (Vol. 1) for further information on this command.

Removing Filler Modules

The TSR II system ships with 41 filler modules, which ensure proper cooling and elimination of electromagnetic interference during operation. Remove filler modules from slots intended for router modules or route controller modules (see Figure 4-29).

CAUTION (C:4-7) Risk of service interruption or equipment damage. Within five minutes of removal of a module, a replacement module or filler module must be installed in the empty slot to ensure proper air flow within the system.

Figure 4-29. 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 (see Figure 4-30).

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

Figure 4-30. Removing Filler Modules

Installing or Removing Router Modules

Router modules are shipped separately from the TSR II bay. Please refer to the specific router installation information that is packed with your router.

Installing or Removing Route Controller Modules

Route Controller modules are shipped separately from the TSR II bay. Please refer to the route controller module documentation that is packed with your route controller.

Installation Checklist

You should perform the following inspections as a minimum to make sure your TSR II system is safe, secured, and has been installed properly.

PROCEDURE: Use the following steps to check out your system:

Step 1 Main customer power breaker ("master breaker") in OFF position

Step 2 All BIP circuit Breakers in OFF position

Step 3 Main power frame ground wire attached properly to chassis frame and secured (rear of chassis - upper left corner).



CAUTION (C:4-8) Risk of service interruption or equipment damage. The TSR II chassis MUST be grounded to eliminate static, BEFORE installing any of the modules.

Step 4 "Removable" BIP securely fastened to main chassis top. Input and return power connections on rear of BIP secured. BIP power and signal cables secured.

Step 5 Overhead cables not positioned directly over the top of the TSR II system - heat damage to cabling considerations.



CAUTION (C:4-9) Risk of service interruption or equipment damage if cables positioned directly over top of TSR II.

Exception: If you allow at least 6 inches of clearance, it is permissible to have cables directly over TSR II system.

Step 6 TSR II in proper position on floor (clearances, alignment, etc.). Adjoining space made available for expansion of multiple units (if applicable).

Step 7 TSR II anchored to floor or secured to pedestal.



CAUTION (C:4-10) Risk of service interruption or equipment damage. For earthquake zones 3 and 4 you may need overhead support (long rods supplied by customer which attach to the top corners of the TSR II). Consult with your Avici Field Service representative if necessary.

9

Step 8 Sheet metal skins are secured.

Step 9 All Field Replaceable Units (FRUs), EMI covers, router modules, route controller modules, bay controllers, cooling modules, in place and in properly designated positions, and locked-down.

Step 10 Router modules in proper build-out sequence (population rules) and fiber connected.

Step 11 All electrical cables and fiber properly connected.

Step 12 CO Alarm cables connected.

Step 13 Check interconnections to other TSR IIs and/or TSRs (for Multi-bay set-ups) - in place and secured.

Step 14 Site dry and free of water, grease, etc.

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