Juniper T1600 Installation and operation manual

T1600 Internet Routing Node Upgrade
Guide
28 April 2008
Part Number: 530-021924-01
Revision 2
This guide provides procedures for upgrading an operational T640 Internet routing
node to a T1600 Internet routing node. These procedures include preparing the site,
replacing hardware, and verifying operation.
NOTE: Before you upgrade, the T640 routing node must be running JUNOS Release
8.5 or later.
Contents T1600 Routing Node Overview .......................................................................3
T1600 Upgrade Kit ..........................................................................................5
Power Supplies .........................................................................................6
Three-Input 240-A Power Supplies .....................................................6
T1600-SIBs ...............................................................................................9
T1600 Routing Node Upgrade Overview .......................................................10
Verifying the Hardware Version of the Rear Fan Tray ...................................11
Preparing the Site ..........................................................................................12
Typical Power Distribution ......................................................................12
Provisioning Additional Power for the T1600 Routing Node ...................13
Replacing the Rear Fan Tray .........................................................................13
Removing the Rear Fan Tray ..................................................................14
Installing a Rear Fan Tray .......................................................................15
Upgrading the DC Power Supplies .................................................................17
Preparing the DC Power Cables ..............................................................17
Tools and Parts Required ........................................................................17
Removing a Two-Input 160-A Power Supply ...........................................18
Setting the Input Mode Switch on a Three-Input 240-A Power
Supply ..............................................................................................21
■1

Installing a Three-Input 240-A Power Supply ..........................................22
Replacing the Cable Restraint on a Three-Input 240-A Power Supply ......23
Removing the Standard Cable Restraint from a Three-Input 240-A
Power Supply .............................................................................24
Installing the Optional Cable Restraint on a Three-Input 240-A Power
Supply ........................................................................................24
Connecting a Three-Input 240-A Power Supply .......................................25
Powering On a Three-Input 240-A Power Supply ....................................26
Upgrading SIBs ..............................................................................................27
Overview of Upgrading the SIBs .............................................................28
Preparing to Upgrade the SIBs ................................................................29
Tools Required ........................................................................................30
Removing a Standard SIB or SIB Version B .............................................30
Installing a T1600-SIB .............................................................................32
Verifying the Installation of a T1600-SIB .................................................33
Preparing to Exit Upgrade Mode .............................................................33
Exiting Upgrade Mode ............................................................................34
Verifying Operation ................................................................................35
Removing the Upper Front Fan Tray .............................................................39
Replacing the Craft Interface .........................................................................40
Removing the Craft Interface ..................................................................40
Installing the Craft Interface ....................................................................41
Installing the Upper Front Fan Tray ...............................................................42
Attaching the T1600 Agency Label ................................................................42
Registering Your T1600 Upgrade ...................................................................43
T1600 Routing Node Environmental Specifications .......................................43
T1600 Routing Node DC Power Specifications ..............................................44
Power System Electrical Specifications ...................................................44
Three-Input 240-A Power Supply Specifications ......................................45
DC Power Cable Specifications ...............................................................46
Preventing Electrostatic Discharge Damage ..................................................47
List of Technical Publications ........................................................................48
Documentation Feedback ..............................................................................54
Requesting Technical Support .......................................................................55
Revision History ............................................................................................56
2■
T1600 Routing Node Upgrade Guide

T1600 Routing Node Overview
The T1600 Internet routing node is a complete routing system that provides Gigabit
Ethernet, SONET/SDH, and other high-speed interfaces for large networks and network
applications, such as those supported by Internet service providers (ISPs). The routing
node accommodates up to eight Flexible PIC Concentrators (FPCs), which can each
be configured with a variety of network media types. The T1600 routing node provides
up to 800 gigabits per second (Gbps), full duplex (1600 Gbps of any-to-any,
non-blocking, half-duplex switching).
The routing node architecture cleanly separates control operations from packet
forwarding operations. This design eliminates processing and traffic bottlenecks,
permitting the routing node to achieve high performance.
■Control operations in the routing node are performed by the host subsystem,
which runs JUNOS Internet software to handle routing protocols, traffic
engineering, policy, policing, monitoring, and configuration management.
■Forwarding operations in the routing node are performed by the Packet
Forwarding Engines, which consist of hardware, including ASICs, designed by
Juniper Networks. Application-specific integrated circuits (ASICs) are a definitive
part of the routing node design; these ASICs enable the routing node to achieve
data forwarding rates that match current fiber-optic capacity. The T1600 routing
node provides up to a total of 1600 million packets per second (Mpps) of
forwarding.
Figure 1 on page 4 and Figure 2 on page 5 illustrate the front and rear of a T1600
routing node.
T1600 Routing Node Overview ■3
T1600 Routing Node Overview

Figure 1: Front View of the T1600 Routing Node
4■T1600 Routing Node Overview
T1600 Routing Node Upgrade Guide

Figure 2: Rear View of the T1600 Routing Node
T1600 Upgrade Kit
To upgrade a T640 routing node to a T1600 routing node, you install the following
hardware components:
■Two redundant, load-sharing, three-input 240-A power supplies that connect to
the rear of the midplane
■Five T1600-SIBs
■One T1600 craft interface panel
You can order these components individually or order a T1600 upgrade kit that
contains all the components. You must supply four additional DC power cables.
T1600 Upgrade Kit ■5
T1600 Upgrade Kit

NOTE: These components must be installed before you can install a T1600-FPC in
the T1600 routing node.
Power Supplies
Two redundant, load-sharing DC power supplies are located at the lower rear of the
chassis in slots PEM0 and PEM1 (top to bottom). For power specifications for the
system, power supplies, and power cables, see “T1600 Routing Node DC Power
Specifications”on page 44.
Three-Input 240-A Power Supplies
Each three-input 240-A power supply weighs approximately 25 lb. (11.3 kg) and
consists of three inputs, three 80-A circuit breakers, a fan, and LEDs to monitor the
status of the power supply. Figure 3 on page 6 shows the three-input 240-A power
supply.
Figure 3: Three-Input 240-A Power Supply
Three-Input 240-A Power Supply Inputs
The three-input 240-A DC power supply inputs are labeled INPUT 0, INPUT 1, and
INPUT 2, from top to bottom. Each input consists of –48 VDC and return—each with
its own 80-A circuit breaker. The input mode switch on the faceplate allows you to
set the DC power supply to either two-input or three-input mode mode. Three-input
mode is required for the T1600 routing node. Two-input mode is not currently
supported.
Table 1 on page 7 describes which components are powered by each input.
6■T1600 Upgrade Kit
T1600 Routing Node Upgrade Guide

Table 1: Components Powered by Each Three-Input 240-A Power Supply Input
Two-Input ModeThree-Input ModeInput
FPCs in slots FPC0 and FPC1, SIBs, T-CBs,
fan trays, and Routing Engines
T1600-SIBs, T-CBs, fan trays, and
Routing Engines
INPUT 0
FPCs in slots FPC2 and FPC7FPCs in slots FPC4 through FPC7INPUT 1
Not applicable
FPCs in slots FPC0 through FPC3INPUT 2
Three-Input 240-A Power Supply Load Sharing and Fault Tolerance
When the routing node is operating normally and both power supplies are switched
on, load sharing between them occurs automatically. When one power supply fails
or is turned off, the other power supply immediately assumes the entire electrical
load for the system. A single power supply can provide full power for as long as the
routing node is operational. Table 2 on page 7 describes the behavior of the power
supply if one of the inputs fails.
Table 2: Fault Tolerance
Two-Input ModeThree-Input ModeInput
If this input fails, INPUT 0 and INPUT 1
shut down. The power supply shuts
down, and the other power supply
assumes the electrical load of INPUT 0
and INPUT 1.
If this input fails, INPUT 0, INPUT 1,
and INPUT 2 shut down. The power
supply shuts down, and the other
power supply assumes the electrical
load for all three inputs.
INPUT 0
If this input fails, INPUT 0 is
unaffected and INPUT 1 shuts down.
The other power supply assumes the
electrical load of INPUT 1.
If this input fails, INPUT 0 is
unaffected and INPUT 1 and INPUT 2
shut down. The other power supply
assumes the electrical load of INPUT 1
and INPUT 2.
INPUT 1
Not applicable
If this input fails, INPUT 0 is
unaffected and INPUT 1 and INPUT 2
shut down. The other power supply
assumes the electrical load of INPUT 1
and INPUT 2.
INPUT 2
Three-Input 240-A Power Supply LEDs
LEDs on each power supply faceplate (see Figure 4 on page 8) indicate the status
of the power supply. In addition, a power supply failure triggers the red alarm LED
on the craft interface. Table 3 on page 8 describes the functions of the power supply
LEDs.
T1600 Upgrade Kit ■7
T1600 Upgrade Kit

Figure 4: Three-Input 240-A Power Supply LEDs
Table 3 on page 8 describes the three-input 240-A power supply LEDs.
Table 3: Three-Input 240-A Power Supply LEDs
DescriptionStateColorLED
Circuit breaker is on.On steadilyGreen
CB ON—One per
input
Circuit breaker is not turned on, or
host subsystem has detected a
failure and has turned the circuit
breaker off.
Off
When the power supply is correctly
set to three-input mode mode and
all three inputs are properly
energized, the DC OK LED indicates
that the power supply is
functioning normally.
When the power supply is correctly
set to two-input mode and INPUT 0
and INPUT 1 are both properly
energized, the DC OK LED indicates
that the power supply is
functioning normally.
On steadilyBlue
DC OK—One per
power supply
Power supply is starting up, is not
functioning, is not properly
installed, or is not operating
properly.
Blinking
Input is receiving voltage.On steadilyGreen
INPUT
PRESENT—One
per input Input voltage is not present.Off
Power supply has exceeded
recommended temperature.
On steadilyAmber
OVER
TEMP—One per
power supply
Power supply is within the
recommended temperature or the
power supply is not on.
Off
8■T1600 Upgrade Kit
T1600 Routing Node Upgrade Guide

T1600-SIBs
Figure 5 on page 9 shows a T1600-SIB.
Figure 5: T1600-SIB
Each T1600-SIB consists of the following components:
■Switch fabric ASICs.
■High-speed links to each FPC.
■SIB online/offline button, located on the SIB faceplate.
■Three LEDs located on the SIB faceplate that display the status of the SIB.
Table 4 on page 9 describes the functions of the SIB LEDs. If all three LEDs are
off, the SIB is not receiving power. The craft interface has three additional LEDs
that show the status of each T1600-SIB. The OK and FAIL LEDs are replicated on
the craft interface.
Table 4: SIB LEDs
DescriptionStateColorLabel
SIB is in active mode.On steadilyGreen
ACTIVE
SIB is functioning normally.On steadilyGreen
OK
SIB is starting up.Blinking
SIB has failed.On steadilyAmber
FAIL
Each SIB weighs approximately 6.5 lb (3 kg).
T1600 Upgrade Kit ■9
T1600 Upgrade Kit

T1600 Routing Node Upgrade Overview
NOTE: The T640 routing node can be upgraded while the routing node is powered
on and operational.
NOTE: During the SIB upgrade:
■The routing node should not experience packet loss if the traffic is less than
50 percent per Packet Forwarding Engine in each FPC.
■The routing node might experience some packet loss if the traffic is more than
50 percent per Packet Forwarding Engine in each FPC, depending on the
operational environment.
For more information, contact your customer support representative.
To upgrade the T640 routing node, use the following procedures:
1. If you have not already done so, install JUNOS Release 8.5 or later in the T640
routing node.
2. Verify that the required hardware version of the rear fan tray is installed. If
needed, order a new rear fan tray.
3. Prepare the site. Provision additional power as needed.
4. Remove one two-input 160-A power supply.
5. Install a three-input 240-A power supply.
6. Replace the other power supply.
7. Upgrade the existing standard SIBs to T1600-SIBs.
8. Remove the upper fan tray.
9. Replace the craft interface.
10. Reinstall the upper fan tray.
11. Verify the installation of components.
12. Attach the T1600 agency label.
13. Register your T1600 upgrade.
NOTE: Do not install T1600-FPC4s until after all upgrade procedures are completed.
10 ■T1600 Routing Node Upgrade Overview
T1600 Routing Node Upgrade Guide

Verifying the Hardware Version of the Rear Fan Tray
The rear fan tray, model number FAN-REAR-TX-T640-S, has eight fans and is required
to support the additional thermal power generation of the T1600 routing node. Model
number RHTREARTRAY-T-S has five blowers and does not provide sufficient cooling
for the T1600 routing node. To verify that FAN-REAR-TX-T640-S is installed:
1. Issue the show chassis environment command:
In this example, the output shows that the rear fan tray has five blowers,
indicating that RHTREARTRAY-T-S is installed. The last five lines of the output
for the fans each include Blower in the description.
user@host> show chassis environment
Fans Top Left Front fan OK Spinning at normal speed
Top Left Middle fan OK Spinning at normal speed
Top Left Rear fan OK Spinning at normal speed
Top Right Front fan OK Spinning at normal speed
Top Right Middle fan OK Spinning at normal speed
Top Right Rear fan OK Spinning at normal speed
Bottom Left Front fan OK Spinning at normal speed
Bottom Left Middle fan OK Spinning at normal speed
Bottom Left Rear fan OK Spinning at normal speed
Bottom Right Front fan OK Spinning at normal speed
Bottom Right Middle fan OK Spinning at normal speed
Bottom Right Rear fan OK Spinning at normal speed
Fourth Blower from top OK Spinning at normal speed
Bottom Blower OK Spinning at normal speed
Middle Blower OK Spinning at normal speed
Top Blower OK Spinning at normal speed
Second Blower from top OK Spinning at normal speed
In this example, the output shows that the rear fan tray has eight fans, indicating
that FAN-REAR-TX-T640-S is installed. The last eight lines of the output for the
fans each begin with Rear Tray and include fan in the description.
Fans Top Left Front fan OK Spinning at normal speed
Top Left Middle fan OK Spinning at normal speed
Top Left Rear fan OK Spinning at normal speed
Top Right Front fan OK Spinning at normal speed
Top Right Middle fan OK Spinning at normal speed
Top Right Rear fan OK Spinning at normal speed
Bottom Left Front fan OK Spinning at normal speed
Bottom Left Middle fan OK Spinning at normal speed
Bottom Left Rear fan OK Spinning at normal speed
Bottom Right Front fan OK Spinning at normal speed
Verifying the Hardware Version of the Rear Fan Tray ■11
Verifying the Hardware Version of the Rear Fan Tray

Bottom Right Middle fan OK Spinning at normal speed
Bottom Right Rear fan OK Spinning at normal speed
Rear Tray Top fan OK Spinning at normal speed
Rear Tray Second fan OK Spinning at normal speed
Rear Tray Third fan OK Spinning at normal speed
Rear Tray Fourth fan OK Spinning at normal speed
Rear Tray Fifth fan OK Spinning at normal speed
Rear Tray Sixth fan OK Spinning at normal speed
Rear Tray Seventh fan OK Spinning at normal speed
Rear Tray Bottom fan OK Spinning at normal speed
2. If RHTREARTRAY-T-S is installed, order FAN-REAR-TX-T640-S and install it before
installing the three-input 240-A power supplies.
Preparing the Site
The following sections describe how to prepare your site so that you can install
upgrade components.
■Typical Power Distribution on page 12
■Provisioning Additional Power for the T1600 Routing Node on page 13
Typical Power Distribution
Most sites distribute DC power through a main conduit that leads to frame-mounted
DC power distribution panels, one of which might be located at the top of the rack
that houses the T1600 routing node. A pair of cables (one input and one return)
connects each set of terminal studs to the power distribution panel.
The DC power supply in slot PEM0 must be powered by a dedicated power feed
derived from feed A, and the DC power supply in slot PEM1 must be powered by a
dedicated power feed derived from feed B. This configuration provides the commonly
deployed A/B feed redundancy for the system.
Figure 6 on page 13 shows a typical DC source cabling arrangement.
12 ■Preparing the Site
T1600 Routing Node Upgrade Guide

Figure 6: Typical DC Source Cabling to the T1600 Routing Node
Provisioning Additional Power for the T1600 Routing Node
For a maximally configured T1600 routing node, we recommend that you provision
at least 64 A @ –48 VDC for each power supply input in the system.
We recommend that you provision a facility circuit breaker for each DC power supply
input rated for at least 125% of the continuous current that the input draws at
–48 VDC.
Replacing the Rear Fan Tray
NOTE: If the rear fan tray (model number FAN-REAR-TX-T640-S) is already installed,
replacing the rear fan tray is not necessary. Proceed to “Upgrading the DC Power
Supplies”on page 17.
The rear fan tray is hot-insertable and hot-removable. To replace a fan tray, use the
following procedures:
■Removing the Rear Fan Tray on page 14
■Installing a Rear Fan Tray on page 15
Replacing the Rear Fan Tray ■13
Replacing the Rear Fan Tray

Removing the Rear Fan Tray
The rear fan tray is mounted vertically on the right side of the rear of the chassis.
The rear fan tray (model number RHTREARTRAY-T-S) weighs about 12 lb (5.4 kg).
To remove the rear fan tray, follow this procedure (see Figure 7 on page 15):
1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist and
connect the strap to one of the ESD points on the chassis. See “Preventing
Electrostatic Discharge Damage”on page 47.
2. Loosen the captive screws on the top and bottom of the fan tray faceplate, using
a Phillips (+) screwdriver, number 2.
3. Grasp the handles and pull the fan tray halfway out of the chassis.
WARNING: To avoid injury, keep tools and your fingers away from the fans as you
slide the fan tray out of the chassis. The fans might still be spinning.
4. When the fans stop spinning, grasp the handles and pull the fan tray completely
out of the chassis.
CAUTION: To maintain proper cooling, do not operate the T1600 routing node with
the rear fan tray removed for more than one minute.
14 ■Replacing the Rear Fan Tray
T1600 Routing Node Upgrade Guide

Figure 7: Removing the Rear Fan Tray
Installing a Rear Fan Tray
The rear fan tray (model number FAN-REAR-TX-T640-S) weighs about 10 pounds
(4.5 kg). To install a replacement rear fan tray, follow this procedure (see
Figure 8 on page 16):
1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist and
connect the strap to one of the ESD points on the chassis. See “Preventing
Electrostatic Discharge Damage”on page 47.
2. Grasp the fan tray by its handles and insert it straight into the chassis.
3. Tighten the captive screws on the fan tray faceplate to secure it in the chassis,
using a Phillips (+) screwdriver, number 2.
Replacing the Rear Fan Tray ■15
Replacing the Rear Fan Tray

Figure 8: Installing a Rear Fan Tray
16 ■Replacing the Rear Fan Tray
T1600 Routing Node Upgrade Guide

Upgrading the DC Power Supplies
NOTE: You must upgrade both power supplies. Follow these procedures for one
power supply, then immediately upgrade the other power supply. Mixing a two-input
160-A power supply and a three-input 240-A power supply is supported only during
the upgrade.
The power supplies are located at the lower rear of the chassis. Each power supply
is hot-insertable and hot-removable. When one power supply is powered down or
removed, the other power supply automatically assumes the entire electrical load
for the routing node. To upgrade each two-input 160-A power supply to a three-input
240-A power supply, use the following procedures:
■Preparing the DC Power Cables on page 17
■Tools and Parts Required on page 17
■Removing a Two-Input 160-A Power Supply on page 18
■Setting the Input Mode Switch on a Three-Input 240-A Power Supply on page 21
■Installing a Three-Input 240-A Power Supply on page 22
■Replacing the Cable Restraint on a Three-Input 240-A Power Supply on page 23
■Connecting a Three-Input 240-A Power Supply on page 25
■Powering On a Three-Input 240-A Power Supply on page 26
Preparing the DC Power Cables
The accessory box shipped with the installation kit includes the cable lugs that attach
to the terminal studs of each power supply (see Figure 25 on page 46).
CAUTION: Before the power supply installation begins, a licensed electrician must
attach cable lugs to the power cables that you supply. A cable with an incorrectly
attached lug can damage the power supply.
Tools and Parts Required
To upgrade the power supplies, you need the following tools and parts:
■Four additional DC power cables (two cables for each power supply)
■Electrostatic discharge (ESD) grounding wrist strap
■7/16-in. nut driver or pliers
Upgrading the DC Power Supplies ■17
Upgrading the DC Power Supplies

CAUTION: Do not substitute a metric nut driver or wrench. A tool that does not fit
the nuts exactly can damage them. If a 7/16-in. tool is not available, use pliers or an
adjustable wrench.
■Phillips (+) screwdrivers, numbers 1 and 2
■Flashlight
■Non-conductive sharp object to set the input-mode switch
■Wire cutters
Removing a Two-Input 160-A Power Supply
To remove a two-input 160-A power supply, follow this procedure:
1. Switch off the external circuit breakers to the power supply being removed. Make
sure that the voltage across the DC power source cable leads is 0 V and that there
is no chance that the cables might become active during the removal process.
2. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist and
connect the strap to one of the ESD points on the chassis. See “Preventing
Electrostatic Discharge Damage”on page 47.
3. Switch both circuit breakers on the power supply faceplate to the off position (O).
Figure 9: Two-Input 160-A Power Supply
NOTE: After powering off a power supply, wait at least 60 seconds before turning it
back on.
4. Remove the clear plastic cover protecting the terminal studs on the faceplate.
18 ■Upgrading the DC Power Supplies
T1600 Routing Node Upgrade Guide

CAUTION: You must ensure that power connections maintain the proper polarity.
The power source cables might be labeled (+) and (–)to indicate their polarity. There
is no standard color coding for DC power cables. The color coding used by the external
DC power source at your site determines the color coding for the leads on the power
cables that attach to the terminal studs on each power supply.
5. Using a 7/16-in. nut driver or pliers, remove the nuts and washers from the
terminal studs (see Figure 10 on page 19).
Figure 10: Disconnecting Power Cables From the DC Power Supply
6. Remove the cable lugs from the terminal studs.
7. Loosen the captive screws on the cable restraints on the right edge of the power
supply faceplate.
8. Carefully move the power cables out of the way.
9. Loosen the captive screws on the lower corners of the power supply faceplate
completely.
10. Twist the ejector handles on the upper corners of the faceplate counterclockwise
to unseat the power supply.
WARNING: Do not touch the power connectors on the rear of the power supply (see
Figure 11 on page 20). They can contain dangerous voltages.
Upgrading the DC Power Supplies ■19
Upgrading the DC Power Supplies

Figure 11: Rear of the Power Supply Showing Midplane Connectors
11. Grasp the handle on the power supply faceplate and pull firmly. Slide it halfway
out of the chassis (see Figure 12 on page 21).
CAUTION: Each two-input 160-A power supply weighs approximately 23 lb (10.5 kg).
Be prepared to support the full weight of the power supply as you remove it from
the routing platform.
12. Place one hand underneath the power supply to support it and slide it completely
out of the chassis.
CAUTION: Do not leave a power supply slot empty for more than a short time while
the routing node is operational. For proper airflow, the power supply must remain
in the chassis or a blank panel must be used in an empty slot.
20 ■Upgrading the DC Power Supplies
T1600 Routing Node Upgrade Guide