MNLC RT-420 E5-100 Installation Guide

© Copyright 2008 TXP Corporation

MNLC RT-420

E5-100 Installation Guide

April 17, 2008

Document Number: 805-0042-900 Revision: A4

MNLC RT-420 E5-100 Upgrade Installation Guide • 805-0042-900-a4 • April 2008

© Copyright 2008 TXP Corporation of 26

Document Information Copyright: Copyright © 2008 TXP Corporation, Inc. All rights reserved. Trademarks: TXP Corporation, Inc. and the TXP logo are trademarks of TXP Corporation,

Inc. This document is copyright 2008 by TXP Corporation. It contains proprietary

information, not for disclosure without written permission from TXP For additional information or permissions of use see the following contact information:

TXP Corporation 1299 Commerce Drive, Richardson, TX 75081 Phone: 1-800-924-9650 FAX: 214.575.9314 www.txpcorp.com

Description: This document describes the procedure to retrofit the E5-100 in an MNLC

RT-420 cabinet.

Required Documents: The following documents are required before the work begins: TXP Corporation SYSTEM SCHEMATIC, E5-100 MNLC RT-420

#805-0042-500 Revisions:

Rev Date Description A1 12/03/07 Initial release A2 12/21/07 Added updated ordering matrix A3 1/18/2008 Added power matrix A4 4/17/2008 FOA Updates

24 x 7 Installation and Technical Support 1-800-924-9650



Admonishments: Throughout this document there will be important admonishments used to warn of possible hazards to persons or equipment. An admonishment will identify a possible hazard and then explain what may happen if the hazard is not avoided. The Danger, Warning, and Caution statements should be followed at all times to ensure safe and proper installation, operation, and reliability of the product. When multiple admonishments are present they will be listed in order of severity as follows:

Danger! Indicates that a certain risk is associated with the task that will cause severe personal injury, death, or substantial property damage if the procedure is not adhered to as written.

Warning! Indicates that a certain risk is associated with the task that can cause

personal injury, death, or substantial property damage if the procedure is not adhered to as written.

Caution! Indicates that a certain risk is associated with the task that can or will cause personal injury or property damage if the procedure is not adhered to as written.



Safety Guidelines

For Your Safety: This install requires substantial knowledge of Telecom equipment and Outside Plant Cabinets (OSP). DO NOT attempt to perform any procedure described in this manual without: 1) A clear understanding of the procedure, 2) A careful review of the scope of work, 3) A complete inventory of all items required to complete this work

and, 4) Direct authorization to perform this work.

Alert! Some of the equipment discussed within this document is subject to damage from Electrostatic Discharge (ESD). Ensure that all proper precautions are taken to protect yourself and the equipment.

Warning! All OSP cabinets contain HAZARDOUS VOLTAGES. All national and local codes must be carefully followed when dealing with the AC service.

Alert! Call the Network Operations Center and Center Office to report entry into the cabinet.

Caution! DO NOT lift or move any equipment without proper support and lifting equipment.

Various warnings appear throughout this document at certain steps. Extreme caution should be taken during these steps to ensure installer safety and to avoid possible equipment damage.



Basic Tools This installation requires many specialized tools as noted in subsequent sections. Following is the minimum list of tools that should be available before work commences.

Materials: • Cleaning towels • No-Ox type anti-corrosion grease • Electrical tape Tools: • Digital Volt Meter (DVM) • Ground lug compression or crimping tool • Wire-wrap tool • Vacuum cleaner • Electric drill with magnetic drill bits in 1/64” increments to 3/8” • #2 Phillips head and flat head screwdrivers • Heavy duty cable cutters • Wire stripper

• Tie-wrap cutters • Small Grinder.



Table of Contents 1. Introduction......................................................................................................................7

1.1 Kit Description.................................................................................................................8 1.2 Unpacking the Retrofit Kit ..............................................................................................8

2. Installing the new equipment..........................................................................................9 2.1 Installation Procedure ....................................................................................................9

3. System Schematic...........................................................................................................21 4. MNLC RT-420 Cooling Matrix ....................................................................................24 5. MNLC RT-420 Power Matrix ......................................................................................25 6. Warranty Information ..................................................................................................26

Table of Figures Figure 1. MNLC RT-420 AC Panel..........................................................................................9 Figure 2. Removed Battery Connection .................................................................................10 Figure 3. Existing Bus Bar......................................................................................................10 Figure 4. Argus Rectifier Blank Plate.....................................................................................11 Figure 5. New Power Bus Bar Location .................................................................................12 Figure 6. Fuse Panel Removal ................................................................................................13 Figure 7. USAM Shelf Backplane Access..............................................................................14 Figure 8. Fuse Panel Bracket Location...................................................................................15 Figure 9. E5-100 Installation Location ...................................................................................16 Figure 10. E5-100 Phoenix Connector ...................................................................................17 Figure 11. E5-100 RJ21 Cable Interface ................................................................................17 Figure 12. Calix E5 DB-9 Alarm Port ....................................................................................18 Figure 13. High Temp Thermostat .........................................................................................18 Figure 14. Alarm Terminal Block...........................................................................................19 Figure 15. MNLC RT-420 Door Switch.................................................................................19



1. Introduction This document describes the procedure on how to upgrade an existing MNLC RT-420 cabinet with an E5-100 using a TXP retrofit kit. Although this procedure can support the addition of two E5-100’s, this MOP will cover the addition of a single E5-100 chassis. If the cabinet requires more than one unit, follow the same steps in the MOP for the second E5-100. The optional spider cable kit 805-0051-000 is required when expanding the cabinet to two E5-100’s.This step by step instruction will cover the addition of equipment in a service effecting manner. The steps include the following:

• Movement of the existing Equipment • Addition of new power bus assembly • Addition of E5-100 and supporting power wiring • RJ-21 Interface instructions • System Schematic



1.1 Kit Description

This 805-0042-000 kit contains all the supporting components required to perform a E5-100 retrofit into an MNLC RT-420 cabinet.

1.2 Unpacking the Retrofit Kit

1. Immediately upon delivery of the container, carefully inspect for any visible damage. Note the time of delivery and any damage on the delivery manifest given to you by the driver.

2. Do not remove the kit from its shipping container until you are ready to install it.

3. Carefully remove or cut the tape that seals the shipping container and open the top of the outer shipping container.

4. Carefully lift the pieces of the kit out of the shipping carton and place on a firm, level surface and carefully inspect it for shipping damage. Contact the shipper immediately if any damage exists. Do not discard the carton or packing material.

5. Locate the packing list and check that all of the components are present and undamaged.



2. Installing the new equipment The following procedure is service effecting. Ensure all proper approvals have been received before performing the retrofit. There are two wiring options for the E5-100; the Spider cable and the Octopus cable. When following this MOP, skip the procedures that are irrelevant to the method being utilized.

2.1 Installation Procedure

1. At the AC Panel located on the side of the cabinet, switch the main service breaker to the OFF position.

Figure 1. MNLC RT-420 AC Panel

2. Open the battery compartment to access the batteries.



3. Disconnect the batteries from the cabinet at the Anderson connectors located in the battery compartment.

Alert! Verify that the battery cables are wired properly with the red leads on the negative posts and the black leads on the positive posts. If the batteries are not wired in this manner, the batteries either need to be rewired or the cables going to the Anderson connectors from the batteries can be reversed at the connector.

►Note: Do not proceed with this MOP until this step is complete.

Figure 2. Removed Battery Connection

4. At the bottom of the cabinet locate the battery bus bar and fuse distribution.

5. Remove the power leads from the existing bus bar and remove the bus bar from the cabinet. It is no longer required.

Note: The existing battery cables are labeled with positive and negative labels. Use these markings to identify the position on the new power bus bar.

Figure 3. Existing Bus Bar



6. Open the right hand blank plate covering on the existing Argus rectifier system as shown.

Figure 4. Argus Rectifier Blank Plate

7. Using a long extension and 7/16 nut driver, remove the existing bulk DC power leads from the Argus shelf.

8. Once disconnected, remove the existing bulk power lead harness from the cabinet. This power cable is no longer required. Keep the 7/16 hardware.



9. Mount the new battery bus on the right hand side of the cabinet using the #12 self drilling screws. The location is in the rear of the cabinet next to the existing fuse panel.

Figure 5. New Power Bus Bar Location

10. Locate the leads removed from the existing bus bar for the fuse panel and the batteries and re terminate them to the new power bus bar using the schematic.

11. Connect the new bulk power lead for the Argus to the new battery bus using the schematic and connect the other end of the cable back to the bulk outputs on the Argus using the 7/16 mounting hardware.

12. Install the blank plate for the Argus.



13. Remove the mounting hardware for the FAA (Fuse and Alarm Assembly) and pull the fuse panel from its position in the rack. This is so access can be gained to the rear section of the cabinet.

Note: This may require tie wraps to be cut that secure the existing power leads to the fuse panel. When sliding the fuse panel out of position be careful to not dislodge the cable inputs from their positions on the fuse panel.

Figure 6. Fuse Panel Removal

14. Locate the USAM shelf being utilized for the delivery of service from the E5-100 and remove the mounting hardware from the rack holding the shelf in place.



15. After the mounting hardware is removed for the shelf, pull the shelf forward halfway out of the cabinet to access the rear section.

Note: The power lead will hold this up. If the power lead is disconnected, ensure the cable is secure and doesn’t fall behind the equipment.

Figure 7. USAM Shelf Backplane Access

16. If utilizing the Octopus cable, route the protection panel interface cables over to the protection compartment of the cabinet. Leave the E5 interface ends accessible at the bottom of the cabinet to be used when the E5 is installed.

17. If utilizing the Spider cable option, locate the two MS2 connections on the rear of the USAM.

18. Disconnect the MS2 from the protection panel leads. Secure the leads with a tie wrap so they do not fall behind the equipment.

►Note: Follow the schematic to determine which two MS2 leads to disconnect.

19. Locate the E5-100 spider cable 455-0014-000. Label the RJ21 side of the cable (protection vs. USAM) to identify the cable when installing it on the E5-100.

20. Connect to the USAM MS2 and drop the RJ21 interface through the back side of the cabinet to the floor.



Connect the other E5-100 MS2 interface cables to the protection panel leads that were connect to the USAM. Once again, drop the RJ21 interface through the back side of the cabinet.

21. Connect the USAM power cable back into place.

22. Secure the USAM back into its rack position.

23. Move the mounting location of the brackets on the fuse panel as shown and install back in its original position on the rack.

Figure 8. Fuse Panel Bracket Location

24. Locate the E5-100 ground cable and connect it to the very last mounting position at the bottom of the front rack.

25. Route the E5-100 RJ21 interface cables to the front of the cabinet directly above the existing fuse panel.



26. Outside of the cabinet, connect the ground lead to the E5-100.

27. Mount the E5-100 above the fuse panel.

Figure 9. E5-100 Installation Location

28. Connect the E5-100 power cable to the existing fuse panel using the schematic.



29. Connect the E5-100 power cable to the Phoenix connector according to the schematic. The Phoenix connector may be removed from the E5-100 to ease installation of the cable.

30. Connect the Phoenix connector back into position on the E5-100 as shown in figure 10.

Figure 10. E5-100 Phoenix Connector

31. Connect the RJ21 cables (User and CO) to the E5-100 RJ21 interface on the front. Use the schematic for the cable designation and assignments on the E5-100.

Figure 11. E5-100 RJ21 Cable Interface



32. Locate the E5-100 alarm cable.

Note: The J1002 interface of this cable assembly is not required until the Valere is installed in the cabinet. Please bag and tie wrap for future use.

33. Connect the DB9 connection to the E5-100.

Figure 12. Calix E5 DB-9 Alarm Port

34. Locate the over temperature kit and mount the thermostat bracket and thermostat in the top section of the cabinet.

Figure 13. High Temp Thermostat

35. Locate the terminal block kit 770-0007-000 and connect the “High Temp” lead from the alarm harness to the terminal inputs.



36. Following the schematic, connect the over temperature thermostat alarm wire to the terminal block.

Figure 14. Alarm Terminal Block

37. Locate the existing door switch and connect the door alarm cable from the harness to the switch.

Figure 15. MNLC RT-420 Door Switch



38. Connect power to the cabinet by turning on the AC breaker on the pedestal and connecting the Anderson connectors in the base for the battery strings.

39. With a volt meter, measure the dc voltage on the new bus bar. These readings should be -48 to -54 vdc.

40. Install a 10 AMP GMT fuse in the fuse panel for the E5-100 and verify the LED’s on the E5-100.

41. Turn up the E5-100 according to the provisioning manual and verify service.

42. Move to the Valere Upgrade MOP (815-0023-900) if installing the power upgrade in the cabinet.

43. End of procedure.

This completes the retrofit kit installation. The cabinet is now ready to be powered-up, and the subscriber cards may now be installed in the shelves. Please see the OEM equipment turn-up guide for details on configuring the cabinet for traffic.



3. System Schematic



4. MNLC RT-420 Cooling Matrix MNLC 420 CABINET

(1) E5-110 Produces 90 Watts


(1) E5-111Produces 180 Watts






Region 1 (Max. Env.

Temp. of 85oF)

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5. MNLC RT-420 Power Matrix MNLC 420 CABINET

(1) E5-110 (2) E5-110 (1) E5-111 (2) E5-111 (1) E5-120 (2) E5-120 (1) E5-121 (2) E5-121 Amps 2.0 Amps 4.0 Amps 4.0 Amps 7.0 Amps 2.0 Amps 3.0 Amps 3.0 Amps 5.0

Configuration 1

100% ADSL Line Count

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Configuration 3

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6. Warranty Information Texas Prototypes, Inc. (TXP) warrants all components within out retrofit kits for a period of 3 years against defects in material and workmanship when paid for and properly installed and properly maintained under normal use and service, and as specified in the TXP method of procedure (MOP). Costs associated with the removal or installation of the failed component are not covered in the warranty. TXP also warrants that the kit will perform as specified in the TXP Specification Sheet and Installation “MOP” with regard to fit, thermal capacity, rectifier power capacity, and battery reserve. This warranty does not make claims about the performance of the network equipment that this kit is design to support. This warranty will expired three (3) years from date of shipment by TXP. No warranty is given for products or components which have been subject to misuse, improper installation, corrosion, or which have not been installed, maintained, modified or repaired, or monitored in accordance with applicable industry standards and/or in accordance with the installation “MOP” that is included with each kit. Materials found by TXP to be defective shall either be repaired or replaced, at TXP’s sole option. TXP neither assumes, nor authorizes any person to assume for it, any other obligation in connection with the sale or products or parts of products. TXP shall not be responsible for failures or damages caused by inaccurate or incomplete information supplied by the customer. In no event shall TXP be liable, in contract, tort, strict liability or under any other legal theory, for incidental, indirect, special or consequential damages, including but not limited to labor charges, regardless of whether TXP was informed about the possibility of such damages, and in no event shall TXP’s liability exceed an amount equal to sales price of the individual kit.

MNLC RT-420 E5-100 Installation Guide

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Transcript of MNLC RT-420 E5-100 Installation Guide