Avici Systems Inc.

Field Replacement Procedure

TSR® Series II Replacement Packaging

04258-00 Rev. AA

About This Document

This document describes the steps to pack the Terabit Switch Router Series II (TSR II) chassis for shipping.

The TSR II ships with filler modules and cooling modules only.

NOTE This document assumes the TSR II has been de-commissioned, removed from the lineup, and the circuit breaker pack, routing modules, servers and bay controllers have been removed.

Refer to the following documents for the steps to remove the circuit breaker pack, routing modules, servers, and bay controllers, disconnect the TSR-to-floor anchoring, and move the TSR II out of the lineup.

Support Services

There are three ways to obtain information on customer service and training:

Supplies Needed

You will need the following supplies to pack a TSR II:


Table 1. Packaging Materials List 
Part Name/Description 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

20

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

4

Anti-static shroud

1

36 inch wide plastic film

1 roll

Shipping label

1

Packing slip

1

Tip N Tells

As req.

Tools Needed

You will need the following tools to pack a TSR II:

Move the TSR II to a Pallet

NOTE This procedure assumes that the air intake assemblies, vertical doors, and bay controllers, have been removed.

Attaching the Custom Dolly

PROCEDURE: These section describes the procedures to attach the custom dolly to 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 1).

Figure 1. 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 bottom-front of the bay frame. The screw heads are first inserted into the wide, bottom portion of the keyhole slots.

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).

Figure 2. 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 (see Figure 3).

Figure 3. Fully Tightened Screw Heads

CAUTION (1) 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.

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 4).

Step 5 Repeat Steps 1 through 4 to attach the rear custom dolly half to the rear uprights of the bay (see Figure 4).

Figure 4. Fully Installed Custom Dolly (raised position)

Step 6 Turn the crank handles clockwise on all wheels simultaneously until the casters make contact with the floor.

Step 7 Adjust the dolly casters until the TSR II system clears the floor by approximately 1/2 inch.

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.

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 5 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 5. Fully Installed Custom Dolly (lowered position)

Moving the TSR II onto a Shipping Pallet

PROCEDURE: Use the following steps to move the bay to the shipping pallet:

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

Step 1 Position the shipping pallet so that the front of the bay faces the edge of the shipping pallet marked FRONT.

Step 2 SLOWLY push the dolly into position next to the shipping pallet.

WARNING (1) 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 Adjust the dolly height so that the bottom of the TSR II is approximately 1/2 inch above the shipping pallet.

Step 4 Carefully position the dolly and TSR II over the pallet, centering the bay over the existing bolt holes.

Step 5 Lower bay onto shipping pallet.

Disengage the Dolly from the Bay

PROCEDURE: Use the following steps to disengage the dolly from the TSR II frame:

Step 1 Loosen the hex handles located on the opposite end of screw heads and near the wheels of the dolly (clockwise) to disengage the connection between the dolly screw heads and the keyhole slots in the bay.

Step 2 Loosen special engagement bolts.

Step 3 Lower the dolly jacks four full turns to disengage the screw heads from the keyhole slots.

Step 4 Pull dolly halves from key holes on bay frame.

Attach the TSR II to the Pallet

Step 1 Install the four 1/2 in. by 2 1/4 in. hex head bolts through the bolt holes into the top of the pallet using a 3/4-in. socket and ratchet handle.

NOTE The 4 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 6).

Figure 6. Installing Four Hex Bolts from TSR II Base

Securing the Filler and Cooling Modules

PROCEDURE: Use the following steps to secure the filler and cooling modules.

Step 1 Inspect every slot to verify that all filler modules are locked in place.

Step 2 If any modules are loose, use a 1/4-inch slotted screwdriver to tighten the top and bottom latches located on the front (see Figure 7 and Figure 8).

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 7. Filler Module Latches

Figure 8. Lock Filler Modules Into Place

Step 3 Install the front air intake assembly. Refer to the TSR Series II Hardware Installation Guide.

Step 4 Push the cooling modules firmly back into controller module backplane to ensure modules are locked in place.

Step 5 Close and latch the vertical doors located on the front left and right sides of the TSR II (see Figure 9).

Figure 9. TSR II Ready for Shroud

Installing the Shipping Shroud

PROCEDURE: Use the following steps to install the shipping shroud.

NOTE This procedure assumes that the removable Breaker Interface Panel (BIP) and the BIP alignment pins have been removed. Refer to TSR Series II Circuit Breaker Pack Field Replacement Procedure for the steps to remove the BIP and BIP alignment pins.

Step 1 Wipe down the exterior surfaces of the TSR II to ensure that it is free of dirt and fingerprints.

Step 2 Verify that the serial number of the TSR II bay is written on the base on the front, right side (see Figure 10).

Figure 10. TSR Serial Number on Base

Step 3 Place anti-static shroud over the TSR II, centering the shroud seam on the side panel of the TSR (see Figure 11).

Figure 11. TSR with Shroud

Step 4 When the shroud is in place, cut four holes in the shroud over the threaded holes on the top of the TSR II frame.

Step 5 Place plywood top support on top of bay, lining up the holes in the plywood with the holes in the top of the bay frame (see Figure 12 and Figure 13).

Figure 12. Plywood Top Support (bottom view)

Figure 13. Place Top Support on TSR II

Step 6 Secure plywood top support with the four M12 bolts and washers provided:

Figure 14. Installing Bolts in Top Support

Step 7 Wrap plastic film around the base of the TSR II three times (see Figure 15).

Figure 15. Wrap Plastic Film Around TSR II Base

Step 8 Position two of the plywood sides on the base: the front/back piece (B) is narrower than the side piece (A).

Step 9 Secure the corner with the 3 klimps provided. The writing on the plywood goes on the outside, arrows pointing up (see Figure 16 and Figure 18).

Figure 16. Side Placement
See Figure 17 for a picture of klimps.

Figure 17. Klimps

Step 10 Place three klimps on each of the four crate corners (see Figure 18).

Figure 18. Crate (front) with Klimps Placement

Step 11 Install the remaining two plywood sides and place the klimps in the positions indicated in Figure 18.

Step 12 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.

Step 13 Secure top with four klimps, one per side in the center (see Figure 19).

Figure 19. Klimp Positions on Crate Top

Step 14 Attach four klimps to the base of the crate: two on the front and two in the back.

Moving the TSR

PROCEDURE: Use the following procedure to move the crated TSR II to the shipping area and attach the required labelling.

NOTE Moving the bay requires a hydraulic hand truck.

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 II 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 II.

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

Step 5 Lower the pallet and remove the hand truck.

Step 6 Complete and attach the required labelling.

Step 7 Attach Tip 'n Tell shipping monitors as required.

Figure 20. Tip N Tell Shipping Monitor

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 13:51:50

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