Nortel Passport 7400 Operating instructions

Passport 7400
Hardware Installation,
Maintenance, and Upgrade
241-7401-240

Passport 7400
Hardware Installation, Maintenance, and
Upgrade
Publication: 241-7401-240
Document status: Standard
Document version: 5.2S1
Document date: November 2003
Copyright © 2003 Nortel Networks.
All Rights Reserved.
Printed in Canada
NORTEL, NORTEL NETWORKS, the globemark design, the NORTEL NETWORKS corporate logo, DPN, and
PASSPORT are trademarks of Nortel Networks.

5
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Publication history
November 2003
5.2S1 Standard
General availability. Contains information on Passport 7400 for the PCR5.2
GA release.

6Publication history
241-7401-240 5.2S1

7
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Contents
About this document 23
Who should read this document and why 23
What you need to know 23
How this document is organized 24
What’s new in this document 26
Notational conventions 26
Related documents 27
How to get more help 27
Chapter 1
3-slot Passport switch installation 29
Prerequisites to 3-slot Passport switch installation 29
3-slot Passport switch installation task flow 30
3-slot Passport switch installation supporting information 31
Chapter 2
3-slot Passport switch shelf replacement 33
Prerequisites to 3-slot Passport switch shelf replacement 33
3-slot Passport switch shelf replacement task flow 34
Chapter 3
5-slot Passport switch installation 37
Prerequisites to 5-slot Passport switch installation 37
5-slot Passport switch installation task flow 38
5-slot Passport switch installation supporting information 41

8Contents
241-7401-240 5.2S1
Chapter 4
5-slot Passport switch shelf replacement 43
Prerequisites to 5-slot Passport switch shelf replacement 43
5-slot Passport switch shelf replacement task flow 44
Chapter 5
16-slot Passport switch installation 49
Prerequisites to 16-slot Passport switch installation 49
16-slot Passport switch installation task flow 50
16-slot Passport switch installation supporting information 53
Chapter 6
16-slot Passport switch shelf replacement 61
Prerequisites to replacing a 16-slot Passport switch shelf 61
16-slot Passport switch shelf replacement task flow 62
Chapter 7
Air filter replacement 67
Air filter replacement task flow 67
Chapter 8
Alarm hardware installation 69
Prerequisites to alarm hardware installation 69
Alarm hardware installation task flow 69
Chapter 9
Alarm hardware replacement 71
Alarm hardware replacement task flow 71
Chapter 10
BITS cable replacement 75
Prerequisites to BITS cable replacement 75
BITS cable replacement task flow 75
Task flow navigation 76
Chapter 11
BITS termination panel replacement 77
Prerequisites to BITS termination panel replacement 77

Contents 9
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
BITS termination panel replacement task flow 77
Chapter 12
Cabinet installation 81
Prerequisites to cabinet installation 81
Cabinet installation task flow 81
Chapter 13
Cable replacement 85
Prerequisites to cable replacement 85
Cable replacement task flow 85
Chapter 14
Cable routing and labeling 89
Prerequisites to cable routing and labeling 89
Cable routing and labeling task flow 89
Chapter 15
Control processor addition 91
Prerequisites to control processor addition 91
Control processor addition task flow 91
Chapter 16
Control processor upgrade 93
Prerequisites to control processor upgrade 93
Control processor upgrade task flow 94
Chapter 17
Cooling unit replacement 97
Cooling unit replacement prerequisites 97
Cooling unit replacement task flow 97
Chapter 18
Ethernet cable replacement 99
Prerequisites to Ethernet cable replacement 99
Ethernet cable replacement task flow 100

10 Contents
241-7401-240 5.2S1
Chapter 19
External timing addition 103
Prerequisites to external timing addition 103
External timing addition task flow 103
Chapter 20
Failed FP cable replacement 107
Prerequisites to failed FP cable replacement 107
Failed FP cable replacement task flow 107
Chapter 21
FP cable upgrade 111
Prerequisites to FP cable upgrade 111
FP cable upgrade task flow 112
Chapter 22
Failed control processor replacement 115
Prerequisites to failed control processor replacement 115
Failed control processor replacement task flow 116
Chapter 23
Failed function processor replacement 119
Prerequisites to failed function processor replacement 119
Failed function processor replacement task flow 120
Chapter 24
Function processor addition 123
Prerequisites to function processor addition 123
Function processor addition task flow 125
Chapter 25
Function processor decommissioning 129
Prerequisites to function processor decommissioning 129
Function processor decommissioning task flow 129
Chapter 26
Function processor upgrade 133
Prerequisites to function processor upgrade 133

Contents 11
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Function processor upgrade task flow 134
Chapter 27
Local operator terminal replacement 137
Local operator terminal task flow 137
Chapter 28
Modem installation 139
Prerequisites to modem installation 139
Modem installation task flow 139
Modem installation supporting information 141
Chapter 29
Modem replacement 143
Modem replacement task flow 143
Chapter 30
Multiport aggregate device replacement 145
Prerequisites to multiport aggregate device replacement 145
Multiport aggregate device replacement task flow 145
Chapter 31
Passport cabinet door removal and installation 147
Passport cabinet door removal and installation task flow 147
Chapter 32
Power cable replacement 149
Power cable replacement task flow 149
Chapter 33
Power supply addition 153
Prerequisites to power supply addition 153
Power supply addition task flow 153
Chapter 34
Power supply replacement 157
Prerequisites to power supply replacement 157
Power supply replacement task flow 158

12 Contents
241-7401-240 5.2S1
Chapter 35
Sparing addition 161
Prerequisites to sparing addition 161
Sparing addition task flow 162
Chapter 36
Termination or sparing panel replacement 165
Prerequisites to termination or sparing panel replacement 165
Termination or sparing panel replacement task flow 166
Chapter 37
Hardware procedures 169
Anchoring a seismic cabinet using an inside-mount anchoring kit 169
Anchoring a seismic cabinet using an outside-mount anchoring
kit 172
Avoid damage from static electricity 174
Changing fasteners on an MSA32 sparing panel 178
Configuring the modem software 182
Connecting a cable between a modem and a Passport switch 184
Connecting a local operator terminal to a Passport 7400 switch 186
Disconnecting a local operator terminal or modem from a Passport
switch 189
Grounding a 16-slot Passport switch 190
Grounding a dc-powered 3-slot Passport switch 192
Grounding a dc-powered 5-slot Passport switch 194
Grounding a Passport cabinet 196
Installing 5-slot Passport switch covers 198
Installing a 13” termination panel in a 3-slot Passport switch 201
Installing a 13” termination panel in a 5-slot Passport switch 203
Installing a 19” rack-mounted termination panel 205
Installing a 3-slot Passport switch in a rack or cabinet 207
Installing a 3-slot Passport switch in a seismic rack or cabinet 210
Installing a 5-slot Passport switch cooling unit 214
Installing a 5-slot Passport switch in a rack or cabinet 215
Installing a 5-slot Passport switch power supply 218
Installing a 16-slot Passport switch cooling unit 220

Contents 13
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Installing a 16-slot Passport switch power supply 222
Installing a 16-slot Passport switch shelf 225
Installing a BITS wire 230
Installing a blank processor card 231
Installing a control processor 232
Installing a desk-top mounted 3-slot Passport switch 234
Installing a floor-mounted 5-slot Passport switch 236
Installing a function processor 237
Installing a multiport aggregate device 242
Installing a Passport cabinet door 246
Installing a Passport cabinet door alarm cable 247
Installing a rack-mounted alarm panel 250
Installing a shelf interconnect cable 251
Installing a vertical-mount 3-slot Passport switch 252
Installing ac power cables on a multiport aggregate device 254
Installing an ac power cable 255
Installing an Ethernet cable 259
Installing an external alarm 261
Installing an MSA32 sparing panel cable cover 262
Installing CP cables for BITS 265
Installing dc power cables in a 3-slot Passport switch 268
Installing dc power cables in a 5-slot Passport switch 270
Installing dc power cables in a 16-slot Passport switch 272
Installing dc power cables on a multiport aggregate device 275
Installing FP cables 278
Installing ferrite beads onto dc power cables 283
Installing multiple MSA32 sparing panels (DB15 or BNC) 286
Installing multiple MSA32 sparing panels (RJ45) 289
Installing seismic hardware 294
Making a BITS wire 296
Making a braided shield 300
Making customer equipment cables 303
Moving a door hinge to the other side of a cabinet 304
Packing a processor card 307
Placing and anchoring a Passport cabinet 309

14 Contents
241-7401-240 5.2S1
Powering down a 16-slot Passport switch 312
Powering up a 3-slot Passport switch 313
Powering up a 5-slot Passport switch 315
Powering up a 16-slot Passport switch 318
Preparing the floor for a Passport cabinet 320
Preparing the floor for a seismic cabinet 323
Removing a 13” termination panel from a 3-slot Passport switch 325
Removing a 13” termination panel from a 5-slot Passport switch 327
Removing a 19” rack-mounted termination panel 329
Removing a 3-slot Passport switch shelf 330
Removing a 5-slot Passport switch cooling unit 335
Removing a 5-slot Passport switch front cover 338
Removing a 5-slot Passport switch power supply 340
Removing a 5-slot Passport switch rear cover 345
Removing a 5-slot Passport switch shelf 347
Removing a 16-slot Passport switch cooling unit 350
Removing a 16-slot Passport switch power supply 353
Removing a 16-slot Passport switch shelf 357
Removing a blank processor card 359
Removing a control processor 360
Removing a function processor 364
Removing a multiport aggregate device 366
Removing a Passport cabinet door 367
Removing a Passport cabinet door alarm cable 368
Removing a Passport cabinet from a pallet 370
Removing a rack-mounted alarm panel 375
Removing a shelf interconnect cable 376
Removing an Ethernet cable 378
Removing an MSA32 sparing panel cable cover 379
Removing CP cables for BITS 381
Removing FP cables 382
Removing power cables 384
Replacing a 5-slot Passport switch air filter 386
Replacing a 16-slot Passport switch air filter 389
Replacing a 16-slot Passport switch cooling unit power cord 394

Contents 15
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Replacing an external alarm cable 396
Resetting the alarm hardware 397
Routing cables out of a cabinet 399
Routing cables through a 3-slot Passport switch 401
Routing cables through a 5-slot Passport switch 403
Routing cables through a 16-slot Passport switch 405
Setting modem dip switches 407
Setting switches on a HSSI function processor 408
Setting switches on a V.11 function processor 410
Turning on power 413
Unpacking a 3-slot Passport switch 414
Unpacking a 5-slot Passport switch 417
Unpacking a 16-slot Passport switch 420
Unpacking a horizontally-packaged cabinet 423
Unpacking a processor card 426
Unpacking a vertically-packaged cabinet 428
Unpacking and removing a seismic cabinet from a pallet 432

16 Contents
241-7401-240 5.2S1
List of figures
Figure 1 Sample task flow 25
Figure 2 3-slot Passport switch installation task flow 30
Figure 3 3-slot Passport switch shelf replacement task flow: part
134
Figure 4 3-slot Passport switch shelf replacement task flow: part
235
Figure 5 5-slot Passport switch installation task flow: part 1 39
Figure 6 5-slot Passport switch installation task flow: part 2 40
Figure 7 5-slot Passport switch shelf replacement task flow: part
145
Figure 8 5-slot Passport switch shelf replacement task flow: part
246
Figure 9 16-slot Passport switch installation task flow: part 1 51
Figure 10 16-slot Passport switch installation task flow: part 2 52
Figure 11 Floor space requirements for Passport cabinets 56
Figure 12 Floor space requirements for a seismic cabinet 58
Figure 13 16-slot Passport switch shelf replacement taskflow: part
163
Figure 14 16-slot Passport switch shelf replacement taskflow: part
264
Figure 15 Regular maintenance task flow 68
Figure 16 Alarm hardware installation task flow 70
Figure 17 Alarm hardware replacement task flow 72
Figure 18 BITS cable replacement task flow 76
Figure 19 BITS termination panel replacement task flow 78
Figure 20 Cabinet installation task flow 82
Figure 21 Cable replacement task flow 86
Figure 22 Cable routing and labeling task flow 90
Figure 23 Control processor addition task flow 92
Figure 24 Control processor upgrade task flow 95
Figure 25 Cooling unit replacement task flow 98
Figure 26 Ethernet cable replacement task flow 100
Figure 27 External timing addition task flow 104
Figure 28 Failed FP cable replacement task flow 108
Figure 29 FP cable upgrade task flow 113
Figure 30 Failed control processor replacement task flow 117
Figure 31 Failed function processor replacement task flow 121
Figure 32 Function processor addition task flow: part 1 126
Figure 33 Function processor addition task flow: part 2 127

Contents 17
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Figure 34 Function processor decommissioning task flow 130
Figure 35 Function processor upgrade task flow 135
Figure 36 Local operator terminal replacement task flow 138
Figure 37 Modem installation task flow 140
Figure 38 Modem replacement task flow 144
Figure 39 Multiport aggregate device replacement task flow 146
Figure 40 Passport cabinet door removal and installation task
flow 148
Figure 41 Power cable replacement task flow 150
Figure 42 Power supply addition task flow 154
Figure 43 Power supply replacement task flow 159
Figure 44 Adding sparing task flow 163
Figure 45 Termination or sparing panel replacement task
flow 167
Figure 46 Anchoring a seismic cabinet using an inside-mount
anchoring kit 171
Figure 47 Seismic cabinet mounting—front view 173
Figure 48 16-slot Passport switch ESD jack location 175
Figure 49 5-slot Passport switch ESD jack location 176
Figure 50 3-slot Passport switch ESD jack location 177
Figure 51 Location of MSA32 connectors to have screws changed
on a one-for-one configuration 179
Figure 52 MSA32 screw connectors to be changed on the bottom
one-for-n sparing panel 180
Figure 53 MSA32 sparing panel cable connector screws 181
Figure 54 Control processor faceplate 185
Figure 55 Local operator port on the CP faceplate 188
Figure 56 Shelf assembly grounding stud 191
Figure 57 Grounding a 3-slot Passport switch dc power
supply 193
Figure 58 Grounding a 5-slot Passport switch dc power
supply 195
Figure 59 Passport cabinet grounding points 197
Figure 60 Installing a front cover on a 5-slot Passport switch 199
Figure 61 Installing a rear cover on a 5-slot Passport switch 200
Figure 62 3-slot Passport switch termination panel mounting
brackets 201
Figure 63 3-slot Passport switch termination panel
installation 202
Figure 64 Installing a 13” termination panel 204
Figure 65 Grounding 19” termination panels 206

18 Contents
241-7401-240 5.2S1
Figure 66 Securing the rack-mounting brackets to the 3-slot
Passport switch 208
Figure 67 Securing the rack-mounting brackets to the front vertical
rails 209
Figure 68 Securingtherearseismicbracketstothe3-slotPassport
switch 211
Figure 69 Securing the rack-mounting brackets to the front vertical
rails 212
Figure 70 Securing the rack-mounting brackets to the front vertical
rails 213
Figure 71 Securing the rack-mounting brackets to a rack 216
Figure 72 Securing the switch to a rack 217
Figure 73 Inserting a power supply into a 5-slot Passport
switch 219
Figure 74 Installing a cooling unit 221
Figure 75 Installing a power supply in a 16-slot Passport
switch 224
Figure 76 16-slot Passport switch cooling unit chassis 227
Figure 77 16-slot Passport switch shelf assembly 228
Figure 78 16-slot Passport switch cable management
assembly 229
Figure 79 Securing the feet to a desk-top mounted 3-slot Passport
switch 234
Figure 80 Cable guide on desk-top mounted 3-slot Passport
switch 235
Figure 81 Securing the feet to the bottom of a floor-mounted
switch 236
Figure 82 Locking and unlocking processor card latches 239
Figure 83 Disengaging a processor card 240
Figure 84 Installing brackets on a multiport aggregate device 245
Figure 85 Cabinet door alarm connector 248
Figure 86 16-slot Passport switch alarm connectors 249
Figure 87 Rack-mounted alarm panel 250
Figure 88 Attaching the plate to the shelf assembly 253
Figure 89 Installing 5-slot Passport switch ac power cords 257
Figure 90 Installing 16-slot Passport switch ac power cords 258
Figure 91 Example of a control processor faceplate 260
Figure 92 Cable cover for MSA32 BNC or DB15 sparing
panels 263
Figure 93 Location of a cable cover on MSA32 sparing
panels 264

Contents 19
Passport 7400 Hardware Installation, Maintenance, and Upgrade 5.2S1
Figure 94 Connections for CP-with-BITS 266
Figure 95 Control processor with BITS faceplate 267
Figure 96 3-slot Passport switch dc power cables 269
Figure 97 5-slot Passport switch dc power cables 271
Figure 98 16-slot Passport switch dc power cables 274
Figure 99 Connecting power wires to the terminal connector 276
Figure 100 Connecting the terminal connector 277
Figure 101 Connecting and disconnecting cables 282
Figure 102 Location of ferrite beads on dc power cables 285
Figure 103 Inter-panel flexi-cable for MSA32 sparing panels with
BNC or DB15 connectors 287
Figure 104 Locationof MSA32 inter-panelflexi-cable connectors for
BNC and DB15 288
Figure 105 Inter-panel flexi-cable for MSA32 sparing panels with
RJ45 connectors 291
Figure 106 Cable connections of MSA32 sparing panels with RJ45
connectors 292
Figure 107 Bottomflexi-cableconnectionsofMSA32sparingpanels
with RJ45 connectors 293
Figure 108 Seismic cabinet mounting—rear view 295
Figure 109 D-sub pinout for BITS cables for DS1 or E1
balanced 299
Figure 110 Steps for making a braided shield 301
Figure 111 Braided shield assembly 302
Figure 112 Cabinet door with hinges on the left 305
Figure 113 Cabinet door with hinges on the right 306
Figure 114 Passport cabinet anchoring (concrete and raised
floors) 311
Figure 115 3-slot Passport power switch 314
Figure 116 5-slot Passport switch power supply 317
Figure 117 Passport cabinet footprint 321
Figure 118 Floor cutout position and size for under floor cable
routing 322
Figure 119 Seismic cabinet footprint 324
Figure 120 3-slot Passport switch termination panel removal 326
Figure 121 Removing 13” termination panels from the rear of a 5-
slot Passport switch 328
Figure 122 Rack-mounting brackets on 3-slot Passport switch 331
Figure 123 Removing vertical mount shelf hardware 332
Figure 124 Removing the feet on a desk-top mounted 3-slot
Passport switch 333

20 Contents
241-7401-240 5.2S1
Figure 125 Cable guide on desk-top mounted 3-slot Passport
switch 334
Figure 126 Unlocking a 5-slot Passport switch cooling unit 336
Figure 127 Removing a 5-slot Passport switch cooling unit 337
Figure 128 Removing a 5-slot Passport switch front cover 339
Figure 129 5-slot Passport switch power supply 341
Figure 130 5-slot Passport switch dc wiring 342
Figure 131 Unlocking and removing a 5-slot Passport switch power
supply 343
Figure 132 Removing a 5-slot Passport switch ac power
supply 344
Figure 133 Removing a 5-slot Passport switch rear cover 346
Figure 134 Removing the switch from a rack 348
Figure 135 Removing the feet from the bottom of a floor-mounted
switch 349
Figure 136 16-slot Passport switch cooling unit lock 351
Figure 137 Removing a 16-slot Passport switch cooling unit 352
Figure 138 Unlockedpower supplywith powerswitch inthe standby
position 355
Figure 139 Locking and unlocking processor card latches 362
Figure 140 Disengaging a processor card 363
Figure 141 Door alarm connectors 369
Figure 142 Unanchoring a Passport cabinet from a pallet 371
Figure 143 Unloading a Passport cabinet from a pallet 373
Figure 144 Rack-mounted alarm panel 375
Figure 145 Dual alarm shelf interconnection 377
Figure 146 Location of a cable cover NTPS07 on MSA32 sparing
panels with DB15 connectors 380
Figure 147 Removing a 5-slot Passport switch air filter 387
Figure 148 Installing a 5-slot Passport switch air filter 388
Figure 149 Removing a 16-slot Passport switch air filter
assembly 391
Figure 150 Changing a 16-slot Passport switch air filter pad 392
Figure 151 Installing a 16-slot Passport switch air filter
assembly 393
Figure 152 Cooling unit power cord 395
Figure 153 5-slot Passport switch alarm connector and cutoff
switch 398
Figure 154 Cable routing through the top or bottom of a
cabinet 400
Figure 155 3-slot Passport cable routing 402