Avici Systems Inc.

Field Replacement Procedure

TSR® Series II 70amp Circuit Breaker Pack

05899-00 Rev. AC

Before beginning, carefully inspect the package to ensure no damage occurred during shipping or delivery. If you suspect any possible damage, contact Avici Support Services immediately. The Terabit Switch Router Series II (TSR II) Breaker Interface Panel (BIP) contains two individual breaker modules accessible from the top-front of the system for removal and replacement.

WARNING (1) Follow safety precautions to ensure all power feeds for both breakers have been disconnected at the power distribution center or DC power plant.

Use LOCK-OUT/TAG-OUT procedures. Failure to do so could result in personal injury.

Tools Needed

Support Services

Avici Customer Service offers three contact methods:

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 (see Figure 1). Replace breaker modules one at a time.

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WARNING (2) Turn off all ten 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 both breaker modules is OFF (see Figure 1).

Use LOCK-OUT/TAG-OUT procedures. Failure to do so could result in personal injury.

Ensure that the power feeds to both breaker modules has been turned off at the power distribution center. It is imperative to use LOCK-OUT/TAG-OUT procedures and to double check that power to the breaker module is off.

During transport, cable ties inside the BIP hold the breaker module cables stationary. Removal of these cable ties is necessary prior to breaker module removal. After removing the cable ties, disengage the breaker module and pull it out from the BIP to allow disconnection of the cable connections.

PROCEDURE: Use the following procedure to remove the breaker module:

Step 1 Turn off all ten power feeds at the DC power plant, or at the power distribution center, depending on which is used at the site. Use LOCK-OUT/TAG-OUT procedures.

Step 2 On both breaker modules, flip all ten power switches to the off position (Figure 1).

WARNING (3) Turn off all ten 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 both breaker modules is OFF (see Figure 1).

Use a voltage meter at both the power feeds and the breaker panel to ensure power is off to both breaker modules.

Use LOCK-OUT/TAG-OUT procedures. Failure to do so could result in personal injury.

Figure 1. Breaker Modules - Power Off -

Step 3 Secure the step ladder and using the #2 Phillips screwdriver, remove the fourteen (14) M4 x 8mm screws securing the BIP cover (see Figure 2).

WARNING (4) Verify that the site power feed is turned off prior to removal of the BIP cover.

Use LOCK-OUT/TAG-OUT procedures. Failure to do so could result in personal injury.

Figure 2. Removal of BIP Cover

Step 4 Set cover and hardware aside for reinstallation.

Step 5 Locate the four (4) plastic tie wraps on the four (4) input cables for each breaker module (see Figure 3). The illustration shows breaker module A.

Figure 3. Removal of Plastic Tie Wraps

Step 6 Carefully snip the plastic tie wrap on each of the breaker module cables to release the breaker module and remove (see Figure 3).

Step 7 Position the BIP top cover back on the BIP and secure it using the fourteen (14) M4 x 8mm screws (see Figure 2).

Step 8 Using a #2 Phillips screwdriver, loosen the four M4 screws on the front corners of the breaker module being replaced. Set the screws and split lock washers aside for re-installation (see Figure 4).

Figure 4. Breaker Module Removal

Step 9 Carefully pull the breaker module forward through the BIP chassis.

Step 10 Remove the power in cables from the top five power in connector pins (see Figure 5).

Step 11 Remove the two small spade lug receptacle connectors from each of the five breaker auxiliary switches (see Figure 5).

Step 12 Remove the five shelf power cables from the bottom five shelf connector pins (see Figure 5). Dispose of module following all environmental guidelines.

Figure 5. Removal of Cables and Spade Lug Connectors

Installing a Breaker Module

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

WARNING (5) Turn off all ten 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 both breaker modules is OFF (see Figure 1).

Use a voltage meter at both the power feeds and the breaker panel to ensure power is off to both breaker modules.

Use LOCK-OUT/TAG-OUT procedures. Failure to do so could result in personal injury.

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 (see Figure 6).

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. See Figure 6 for breaker auxiliary switches and Figure 7 for lug receptacle locations. Table 1 "Lug Receptacle Connections" shows the wire run list.

Figure 6. Reattaching Cables and Spade Lug Connectors

Figure 7. 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 3 Push the power-in cables onto the top five power-in connector pin (see Figure 6).

Step 4 Verify that each cable is connected to the correct breaker input: 1, 2, 3, 4, or 5. See Figure 7 for lug receptacle locations and Table 1 "Lug Receptacle Connections" 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.

Step 6 Turn on all ten power feeds at the DC power plant, or the power distribution center, for both breaker modules.

Copyright © 2005 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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    Last Updated: 06/14/05 at 11:05:50

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