Avici Systems Inc.

Field Replacement Procedure

TSR® Series II Circuit Breaker Pack

04116-00 Rev. AA

Before beginning this procedure, carefully inspect the package to ensure no damage occurred during shipping or delivery. If you suspect any possible damage to any field replacement unit, contact Avici Support Services immediately.

The Terabit Switch Router Series II (TSR II) Breaker Interface Panel (BIP) contains two individual breaker modules. Breaker modules are accessible from the top-front of the system for removal and replacement.

WARNING (1) Follow safety precautions and ensure power feeds have been disconnected at the power distribution center or DC power plant. Failure to do so may result in personal injury or death.

Tools Needed

You will need a #2 Phillips screwdriver.

Support Services

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

Removing the Breaker Module

The breaker modules are accessible from the top-front of the system for removal and replacement. Each breaker module supports one side of the TSR II bay. Each breaker module contains five breakers, one for each of four (4) bay shelves and one for the bay controller module (refer to Figure 1). Breaker modules are replaced one at a time.

Ensure that the power feeding the breaker module being replaced has been turned off at the customer's power distribution center. It is necessary to pull out and disengage the breaker module from the BIP to allow disconnection of the cable connections.

WARNING (2) Turn off the four power feeds at the DC power plant, or at the power distribution center, depending on which is used at the site. Double check that the power to the breaker module you are replacing is off (refer to Figure 1). Failure to do so may result in personal injury or death.

Figure 1. Breaker Module - A and B Sources
PROCEDURE: Use the following procedure to remove the breaker module:

Step 1 If you are replacing breaker module A, turn off all four power feeds from the customer's power distribution center supplying this module. If you are replacing breaker module B, turn off all four power feeds from the customer's power distribution center supplying this module (refer to Figure 1).

Step 2 Using a #2 Phillips screwdriver, loosen the four M4 screws on the front corners of the breaker module. Set the screws and split lock washers aside for re-installation (refer to Figure 2).

Figure 2. Breaker Module Removal

Step 3 Carefully pull the breaker module forward through the BIP chassis.

Step 4 Remove the power in cables from the top four power in connector pins (refer to Figure 3).

Step 5 Remove the two small spade lug receptacle connectors from each of the five breaker auxiliary switches (refer to Figure 3).

Step 6 Remove the five shelf power cables from the bottom five shelf connector pins (refer to Figure 3).

Figure 3. Removal of Cables and Spade Lug Connectors

Installing a Breaker Module

PROCEDURE: Use the following steps to install and connect the replacement breaker module:

Step 1 Push the shelf power cables firmly onto the bottom five shelf connector pins. Verify that each cable is connected to the correct breaker: 1, 2, 3, 4, and the bay controller (refer to Figure 4).

Step 2 Reattach the two small spade lug receptacle connectors to each of the five breaker auxiliary switches, verifying that the labels on each connector are attached to the correct breaker: 1C, 1NC, 2C, 2NC, etc. Refer to Figure 4 for breaker auxiliary switches and Figure 5 for lug receptacle locations.

Figure 4. Reattaching Cables and Spade Lug Connectors

Step 3 Push the power-in cables onto the top four power-in connector pin (refer to Figure 4).

Step 4 Verify that each cable is connected to the correct breaker input: 1, 2, 3, or 4. Refer to Figure 5 for lug receptacle locations and Table 1 for lug receptacle connections.

Step 5 Slowly push the breaker module and attached cables back into the BIP chassis being careful not to kink or damage the cables. Using the #2 Phillips screwdriver, reinstall the four M4 screws and split lock washers the front of the breaker module.

Figure 5. Lug Receptacle Locations

Table 1. Lug Receptacle Connections
Wire Run List
Cable 01459-00 Cable 01460-00
From: To: From:

To:

J4-1

5A-C

J5-1

5A-NO

J4-2

4A-C

J5-2

4A-NO

J4-3

3A-C

J5-3

3A-NO

J4-4

2A-C

J4-5

2A-NO

J4-5

1A-C

J5-5

1A-NO

J4-6

5B-C

J5-6

5B-NO

J4-7

4B-C

J5-7

4B-NO

J4-8

3B-C

J5-8

3B-NO

J4-9

2B-C

J5-9

2B-NO

J4-10

1B-C

J5-10

1B-NO

Step 6 Turn on the four power feeds at the DC power plant, or the power distribution center, for the breaker module you replaced (Source A or Source B).

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: 10/24/01 at 13:36:18

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