malc 1.16.3.205 hardware installation guide

MALC Hardware Installation GuideMALC 723, MALC 719, and MALC 319

For software version 1.16.3November 2010Document Part Number: 830-00989-24

2 MALC Hardware Installation Guide

Zhone Technologies@Zhone Way7001 Oakport StreetOakland, CA [email protected]

COPYRIGHT C2000-2010 Zhone Technologies, Inc. and its licensors. All rights reserved.

This publication is protected by copyright law. No part of this publication may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or translated into any human or computer language in any form or by any means, electronic, mechanical, magnetic, manual or otherwise, or disclosed to third parties without the express written permission from Zhone Technologies, Inc.

Bitstorm, EtherXtend, IMACS, MALC, MXK, Raptor, SLMS, Z-Edge, Zhone, ZMS, zNID and the Zhone logo are trademarks of Zhone Technologies, Inc.

Zhone Technologies makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability, non infringement, or fitness for a particular purpose.

Further, Zhone Technologies reserves the right to revise this publication and to make changes from time to time in the contents hereof without obligation of Zhone Technologies to notify any person of such revision or changes.

http://www.zhone.com

mailto:[email protected]

MALC Hardware Installation Guide 3

TABLE OF CONTENTS

About This Guide ...............................................................................................................................7

Style and notation conventions..............................................................................7Typographical conventions.......................................................................................8

Related documentation .............................................................................................8Acronyms......................................................................................................................9Contacting Global Service and Support.............................................................10

Technical support....................................................................................................10Hardware repair .....................................................................................................10

Chapter 1 MALC ..........................................................................................................................13

MALC Overview.........................................................................................................13Hardware overview...................................................................................................15

Chassis ....................................................................................................................15MALC 17- and 21-slot chassis.........................................................................15MALC 319 chassis ...........................................................................................16

MALC uplink cards ................................................................................................17Ethernet ............................................................................................................17

MALC line cards.....................................................................................................17ADSL................................................................................................................17SHDSL ............................................................................................................17VDSL2..............................................................................................................18POTs.................................................................................................................18Voice Gateway .................................................................................................18 T1/E1 DS3/E3 .................................................................................................18PON..................................................................................................................18Active Ethernet.................................................................................................18ISDN.................................................................................................................18MTAC ..............................................................................................................19

Resetting cards ........................................................................................................19MALC busses..........................................................................................................20

Control bus .......................................................................................................20Supervisory bus ................................................................................................20Metallic test access bus ....................................................................................20Ring voltage bus...............................................................................................20TDM bus...........................................................................................................20Packet bus.........................................................................................................20

Table of Contents


Chapter 2 Installing the MALC ..............................................................................................21

Installation Overview ...............................................................................................21Pre-Installation Preparation ....................................................................................21Installing the MALC...............................................................................................22

General safety precautions....................................................................................23Safety ......................................................................................................................23Preventing electrostatic damage .............................................................................24Power supply safety information ............................................................................25

Installation precautions ..........................................................................................25Environmental specifications ...............................................................................26Power requirements and specifications.............................................................28

Cabling rules ...........................................................................................................28Power specifications ...............................................................................................29Chassis power consumption....................................................................................29

Grounding and isolation .........................................................................................30Selecting the system location ...............................................................................30Tools needed .............................................................................................................30Compliance and certifications ..............................................................................31Unpacking the system.............................................................................................32Installing mounting brackets on the MALC .......................................................32Installing the chassis in a rack .............................................................................34Wall mounting the MALC 319 chassis ................................................................36Connecting power and grounding the chassis ................................................37Installing slot cards ................................................................................................46

Installation guidelines .............................................................................................46Logging into the serial (craft) port .......................................................................49

Chapter 3 System cables and connectors .......................................................................51

Cabling guidelines....................................................................................................51Connecting optical ATM trunking cables...........................................................52Dressing DSL and POTS cables ...........................................................................52

Down cabling .........................................................................................................52UP line card cabling................................................................................................55

Dressing UP DSL and POTS cables.................................................................56Cable descriptions ............................................................................................58

Cable descriptions...................................................................................................58Alarm cable and contacts guidelines..................................................................60Uplink card pinouts..................................................................................................62

Serial (craft) port pinouts ........................................................................................62Ethernet port pinouts...............................................................................................63Redundant GigE port pinouts..................................................................................64


Fiber optic maintenance and handling ...............................................................65Laser radiation ........................................................................................................65Handling optical fibers............................................................................................66Selecting cleaning materials ...................................................................................67

Chapter 4 Managing the MALC .............................................................................................69

Logging into the serial (craft) port .......................................................................69Configuring a management interface..................................................................70

Uplink card 10/100 BaseT Ethernet interface.........................................................70ATM management connection................................................................................72Managing the MALC with ZMS.............................................................................74

Adding, changing and deleting card profiles ...................................................75

Chapter 5 Hardware Maintenance........................................................................................77

Reading the LEDs .....................................................................................................77Installing slot cards ................................................................................................79

Installation guidelines .............................................................................................79Replacing running redundant uplink cards.......................................................82Removing slot cards................................................................................................84Cleaning and replacing the air filter ....................................................................86Replacing fan tray ....................................................................................................90

Removing and replacing the fan tray for a MALC 723 ..........................................90Removing and replacing the fan tray for a MALC 719 ..........................................91Removing and replacing fans for a MALC 319......................................................93

Table of Contents



ABOUT THIS GUIDE

This guide is intended for use by installation technicians, system administrators, network administrators. It explains how to install the MALC chassis and cards, but not how to provision the physical interfaces. All configuration information is in the MALC Configuration Guide. For information on configuring voice, data, and video services on the MALC, refer to the MALC Configuration Guide.

Style and notation conventionsThe following conventions are used in this document to alert users to information that is instructional, warns of potential damage to system equipment or data, and warns of potential injury or death. Carefully read and follow the instructions included in this document.

Caution: A caution alerts users to conditions or actions that could damage equipment or data.

Note: A note provides important supplemental or amplified information.

Tip: A tip provides additional information that enables users to more readily complete their tasks.

WARNING! A warning alerts users to conditions or actions that could lead to injury or death.

WARNING! A warning with this icon alerts users to conditions or actions that could lead to injury caused by a laser.

About This Guide


Typographical conventions

The following typographical styles are used in this guide to represent specific types of information.

Related documentationRefer to the following publication for additional information:

MALC Configuration Guide—explains how to configure voice, data, and video services on the MALC.

Zhone CLI Reference Guide—explains how to use the Zhone command line interface (CLI) and describes the system commands and parameters.

Refer to the release notes for software installation information and for changes in features and functionality of the product (if any).

Bold Used for names of buttons, dialog boxes, icons, menus, profiles when placed in body text, and property pages (or sheets). Also used for commands, options, parameters in body text, and user input in body text.

Fixed Used in code examples for computer output, file names, path names, and the contents of online files or directories.

Fixed Bold Used in code examples for text typed by users.

Fixed Bold Italic

Used in code examples for variable text typed by users.

Italic Used for book titles, chapter titles, file path names, notes in body text requiring special attention, section titles, emphasized terms, and variables.

PLAIN UPPER CASE

Used for environment variables.

Command Syntax Brackets [ ] indicate optional syntax.Vertical bar | indicates the OR symbol.

Acronyms


AcronymsThe following acronyms are related to Zhone products and may appear throughout this manual:

Table 1: Acronyms and their descriptions

Acronym Description

ADSL Asymmetrical digital subscriber line

ARP Address resolution protocol

ATM Asynchronous Transfer Mode

BAN Broadband Access Node

CID Channel identifier

DSL Digital subscriber line

EFM Ethernet in the First Mile

SHDSL Symmetric high-bit-rate digital subscriber line

IAD Integrated access device

MALC Multi-access line concentrator

MIB Management information bases

MTAC Metallic Test Access Card

MTAC-FC Metallic Test Access Card with fan controller

PBX Private branch exchange

POTS Plain old telephone service

RIP Routing Information Protocol

SDSL Symmetric digital subscriber line

SHDSL Symmetric high-bit-rate digital subscriber line

SLMS Single Line Multi-Service

SNMP Simple Network Management Protocol

TFTP Trivial File Transfer Protocol

VCI Virtual channel identifier

VCL Virtual channel link

VPI Virtual path identifier

ZMS Zhone Management System

About This Guide


Contacting Global Service and SupportIf your product is under warranty (typically one year from date of purchase) or you have a valid service contract, you can contact Global Service and Support (GSS) with questions about your Zhone product or other Zhone products, and for for technical support or hardware repairs.

Before contacting GSS, make sure you have the following information:

• Zhone product you are using

• System configuration

• Software version running on the system

• Description of the issue

• Your contact information

If your product is not under warranty or you do not have a valid service contract, please contact GSS or your local sales representative for a quote on a service plan. You can view service plan options on our web site at

http://www.zhone.com/support/services/warranty.

Technical support

The Technical Assistance Center (TAC) is available with experienced support engineers who can answer questions, assist with service requests, and help troubleshoot systems.

If you purchased the product from an authorized dealer, distributor, Value Added Reseller (VAR), or third party, contact that supplier for technical assistance and warranty support.

Hardware repair

If the product malfunctions, all repairs must be authorized by Zhone with a Return Merchandise Authorization (RMA) and performed by the

Hours of operation Monday - Friday, 8 a.m. to 5 p.m, Pacific (excluding U.S. holidays)

Telephone (North America) 877-ZHONE20 (877-946-6320)

Telephone (International) 510-777-7133

E-mail [email protected]

The Web is also available 24 x 7 to submit and track Service Requests (SR's)

www.zhone.com/support

mailto:[email protected]

http://www.zhone.com/support

Contacting Global Service and Support


manufacturer or a Zhone-authorized agent. It is the responsibility of users requiring service to report the need for repair to GSS as follows:

• Complete the RMA Request form (http://www.zhone.com/account/sr/submit.cgi) or contact Zhone Support via phone or email:

Hours of operation: Monday Friday, 6:30am-5:00pm (Pacific Time)E-mail: [email protected] (preferred)Phone: 877-946-6320 or 510-777-7133, prompt #3, #2

• Provide the part numbers and serial numbers of the product(s) to be repaired.

• All product lines ship with a minimum one year standard warranty (may vary by contract).

• Zhone will verify the warranty and provide a repair quote for anything not under warranty. Zhone requires a purchase order or credit card for out-of-warranty fees.

About This Guide



MALC

This chapter provides an overview of the MALC. It includes the following sections:

• MALC Overview, page 13

• Hardware overview, page 15

MALC OverviewThe Multi-Access Line Concentrator (MALC) platform provides low-cost, high-density subscriber access concentration in the Zhone Single Line Multi-Service (SLMS) architecture.

The MALC is a next generation design Multi-Service Access Platform (MSAP) which carries voice, data and video services over multiple transport level technologies:

• Asynchronous Transfer Mode (ATM)

• Time-division multiplexing (TDM) uplinks

• Internet Protocol (IP) uplinks

• Fast Ethernet and Gigabit Ethernet (FE and FEGE) uplinks

• Bridges

MALC uplinks are the primary communication channel between subscribers and upstream networking devices. The MALC aggregates local loop traffic from a variety of media and sends it to an upstream device, such as ATM switch, PSTN switch, or IP router. The MALC supports edge connection technologies:

• ADSL

• SHDSL

• EFM SHDSL

• VDSL

• DS3/E3

• T1/E1

• GPON

MALC


• Active Ethernet

• ISDN

• POTS

• Voice Gateway

• MTAC

Figure 1: MALC configurations

The MALC can be deployed in Central Office environments, outdoor cabinets, or controlled environmental vaults for remote terminal applications. The MALC is intended for restricted access locations only.

The single uplink from the MALC enables network providers to provision all classes of services in a single platform and leverage the existing copper infrastructure going to the Digital Loop Carrier (DLC) locations.

MALC cards are divided into the following general types:

• Uplink cards provide Ethernet, Gigabit Ethernet, TDM or IP uplinks

• Access line cards provide customer interfaces such as Plain Old Telephone Service (POTS) and Digital Subscriber Line (DSL).

Hardware overview


• System services cards such as the Metallic Test Access (MTAC) cards provide services to the MALC

The MALC supports the following types of uplinks:

• DS3/E3 UNI mode

• Ethernet

• Gigabit Ethernet

• GR-303 or V5.2

Figure 1 suggests the different types of network configurations and trechnologies supported by the MALC.

For configuration information about network configuration options, see the MALC Configuration Guide.

Hardware overviewThis sections describes the MALC hardware, including:

• Chassis on page 15

• MALC uplink cards on page 17

• MALC line cards on page 17

• MALC busses on page 20

Chassis

There are three types of MALC chassis:

• a 23-inch wide, 7U high unit containing 21 slots (MALC 723)

• a 19-inch wide 7U high unit contains 17 slots (MALC 719)

• a 19-inch wide 3U high unit contains 10 slots (MALC 319)

MALC 17- and 21-slot chassisThe 17-slot unit and the 21-slot unit are functionally equivalent, the only difference is the number of slots supported.

The far left slot (slot 1) is for uplink cards only. Any other type of card can be installed in slots 2 through 21. Cables and connectors are accessed from the front of the chassis. Power is supplied by dual –48V DC input power. At the top of the unit is a removable fan tray. Airflow through the unit is from front bottom to top rear. The chassis is Network Equipment Building System (NEBS) level 3-compliant. (See Figure 2).

The uplink cards, the primary control and management functions for the system, can be installed in a redundant pair to provide card-level redundancy.

MALC


Figure 2: MALC 21-slot chassis

MALC 319 chassisThe MALC 319 supports all the same slot cards as the MALC with the exception of the MTAC-FC card. The MTAC-FC card is only supported in the MALC 319 and each MALC 319 must contain an MTAC-FC card.

The following guidelines must be observed when installing slot cards into the MALC 319 chassis:

• The top left slot (slot 1) is reserved for uplink cards. uplink cards can only be installed in one of these slots.

• The MTAC-FC card must be installed in the bottom right slot (slot 10).

• Any other type of card can be installed in slots 2 through 9.

Cables and connectors (except for power cables) are accessed from the front of the chassis. Power cables enter the device at the lower right rear of the unit. Power is supplied by dual –48V DC input power. Airflow through the unit is from left to right. The chassis is Network Equipment Building System (NEBS) level 3-compliant. (See Figure 3).

Figure 3: MALC 319 chassis

Hardware overview


MALC uplink cards

Note: Only one type of uplink interface can be active in the system at a time.

The MALC supports the following uplink cards:

Ethernet• MALC-UPLINK-2-FE/GE

• MALC-UPLINK-2-FE/GE-TDM

• MALC-UPLINK-2-GE

• MALC-UPLINK-2-GE-ONLY

MALC line cards

The MALC supports the following line cards:

ADSL• MALC-ADSL-48A/M (single-slot, 48-port ADSL Annex A/M card)

• MALC-ADSL-48B (single-slot, 48-port ADSL Annex B card)

• MALC-ADSL+SPLTR-48A/M-2S (single-slot, 48-port ADSL Annex A/M card with splitters)

• MALC-ADSL+POTS-TDM/PKT-48A/M-2S (2-slot, 48-port ADSL Annex A/M card with TDM POTS and packet voice support)

• MALC-ADSL-BCM-48A (single slot ADSL Annex A/M Bond)

• MALC-ADSL-BCM-48B (single slot ADSL Annex B Bond)

• MALC-ADSL+SPLTR-BCM-48A-2S (Broadcom, 2-slot, 48-port ADSL Annex A/M card with splitters)

• MALC-ADSL+POTS-PKT-BCM-48A-2S (Broadcom, 2-slot, 48-port ADSL Annex A/M Bond card with TDM POTS and packet voice support)

• MALC-ADSL+POTS-PKT-BCM-48B-2S (Broadcom, 2-slot, 48-port ADSL Annex B Bond card with TDM POTS and packet voice support)

• MALC-REACHDSL-24 (24-port)

• MALC-REACHDSL+SPLTR-24-2S (24-port with Splitter)

SHDSL • MALC-G.SHDSL-4W-12 (12-port G.SHDSL 4-wire card)

MALC


• MALC-EFM-SHDSL-24-NT

• MALC-EFM-SHDSL-24-NTP

• MALC-SHDSL-48 (48-port G.SHDSL line card)

VDSL2• MALC-VDSL2-17A-24 (24 port VDSL2 line card)

POTs• MALC-POTS-GBL-TDM/PKT-24 (24-port POTS card with TDM POTS

support)

• MALC-POTS-TDM-48 (48-port POTS card with TDM POTS and packet voice support and international metering support)

• MALC-POTS-TDM/PKT-48 (48-port POTS card with TDM POTS and packet voice support)

Voice Gateway• MALC-VG-T1/E1 (2-slot voice gateway card with 8, 32 ports)

T1/E1 DS3/E3• MALC-T1/E1-ATM-32 (32 port T1/E1 card)

• MALC-T1/E1-CES-12 (12 port T1/E1 Circuit Emulation Service card)

• MALC-EFM-T1/E1-24 (24-port T1/E1 EFM line card)

• MALC-DS3/E3-4 (4 port DS3/E3 card)

• MALC-PWE-T1/E1-24 (24 port PseudoWire card)

PON• MALC-GPON-SC1 (1-port GPON card)

Active Ethernet• MALC-ACTIVE-ETH-FE/GE-10 (1 port card supports Ethernet traffic

over 10 SFPs that provide 10/100/1000 Base-T, fiber 100FX or Gigabit Ethernet interfaces)

ISDN• MALC-ISDN-2B1Q-24 (24-port ISDN card with 2B1Q signaling)

• MALC-ISDN-4B3T-24 (24-port ISDN card with 4B3T signaling)

Hardware overview


MTAC• MALC-MTAC/RING (Metallic Test Access card with including test

access)

• MALC-MTAC/RING-ENH (Metallic Test Access card with ringing generator)

• MALC-MTAC/RING-FC (Metallic Test Access card with fan controller and ringing generator). Supported on the MALC 319 only.

Resetting cards

The resethold and resetrelease commands are available to place a card on hold in the system configuration, while the card is still in the MALC chassis. These commands may be used for diagnostic requirements when a card configuration should be placed on ‘hold’ while the physical card remains in the chassis.

Refer to the Zhone CLI Reference Guide for a detailed command description

MALC


MALC busses

The MALC chassis contains the following buses.

• Control bus

• Supervisory bus

• Metallic test access bus

• Ring voltage bus

• TDM bus

• Packet bus

Control busThis bus is used for program loading and high-level message transfer between MALC cards.

Supervisory busThis bus is used by the active uplink cards for low-level control and monitoring of the other cards.

Metallic test access busThe metallic test access bus is used by the MTAC card to gain access to cards and the buses in the system.

Ring voltage busThe ring voltage bus provides ringing voltage to the cards, such as the POTS card, that require it. The MTAC card generates the ringing voltage and controls access to the ring voltage bus.

TDM busThe TDM bus is used by the POTS cards to send pulse code modulation (PCM)-encoded voice traffic to the uplink card. The uplink card performs the TDM-to-GR-303 and TDM to ATM conversions to send the TDM data to the Class 5 switch or ATM network. Each TDM channel on the bus is assigned to a fixed channel on a POTS card. VoIP signals do not use the TDM bus.

Packet busThe system packet bus is comprised of two 2.5 Gbps buses which combine to produce a total throughput of 5 Gbps. The uplink cards contain packet processors capable of forwarding bridged or routed frames at 5 Gbps as well. Each card has full access to the backplane of 5 Gbps.


INSTALLING THE MALC

This chapter explains how to install the MALC hardware.

This chapter describes how to prepare your site for installation and to install the MALC. It includes the following topics:

• Pre-Installation Preparation, page 21

• Installing the MALC, page 22

Note: Before installing the MALC, read General safety precautions on page 23 for important safety and power information.

Installation OverviewBefore installing the MALC you should read the pre-installation preparations for important safety, power and environmental precautions and have an understanding of the installation procedures.

Pre-Installation Preparation

Important pre-installation steps include:

• General safety precautions, page 23

• Installation precautions, page 25

• Environmental specifications, page 26

• Power requirements and specifications, page 28

• Power specifications, page 29

• Grounding and isolation, page 30

• Selecting the system location, page 30

• Tools needed, page 30

• Cabling rules, page 28

• Compliance and certifications, page 31

• Unpacking the system, page 32

Installing the MALC


Installing the MALC

Before installing the MALC, please read through the following overview as it will take you from a chassis just out of the box through installing and verifying the uplink and line cards. Once you have completed the installation steps described below, proceed to the MALC Configuration Guide to configure the software which runs the MALC.

Installation overview1 Install the MALC Chassis

Note: You may mount a MALC 319 to a wall, please see Wall mounting the MALC 319 chassis, page 36.

a Install rack mount ears

Installing mounting brackets on the MALC on page 32

b Choose a rack postion

c Carefully lift the chassis with the front of the chassis facing outward.

Installing the chassis in a rack on page 34

d Secure the chassis to the mounting rack.

2 Connect power and provide ground

Connecting power and grounding the chassis on page 37

3 Install uplink and line cards

Installing slot cards on page 46

4 Conduct visual hardware verification tests

a Are the chassis power lights lit for the power you have connected?

b Does the uplink card’s green active light blink, then stay on solid?

c Do the line cards’ green active lights blink? (The amber fault light should stay on upon first start up because there is no line card profile loaded yet.)

5 Conduct out of band management tests

a Logging into the serial (craft) port on page 49

b In the Zhone CLI, enter slots, then carriage return. Within the display, each card which is installed should be displayed.

6 Connect cables

a Communication cables should be at least two inches away from power lines. If the MALC is installed in an inside plant, the cables must be shielded and grounded at both ends.

General safety precautions


b Use Zhone cable mounting brackets where appropriate. Follow the guidelines outlined in Cabling guidelines on page 51

7 Provision the MALC

a Add card profiles for cards to be provisioned.

b See the MALC Configuration Guide for IP Routing, Bridging, or technology specific topics.

General safety precautionsThe equipment is designed and manufactured in compliance with the following safety standards: UL 60950, EN 60950, IEC 60950, ACA TS001. However, the following additional precautions should be observed to ensure personal safety during installation or service, and to prevent damage to the equipment or equipment to which it is connected.

Safety

The precautions to take before installing or servicing the product are as follows:

WARNING! Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to manufacturer’s instructions.

WARNING! Do not stare into the optical interface laser beam or view it directly with optical instruments.

Caution: Current limiting protectors

The MALC is intended to be protected by 3-mil carbon blocks and current limiting protectors with a continuous carry current rating of 350 milliamperes. The current limiting protectors must be applied on the equipment side of the voltage limiting protector.

• Read and follow all warning notices and instructions marked on the product or included in this guide.

• Never install telephone wiring during a lightning storm.

• Never install this product in a wet location.

• Never install telephone jacks in wet locations unless the jacks are specifically designed for this purpose only.

• Never touch uninsulated telephone wires or terminals unless the telephone line has first been disconnected at the network interface.

Installing the MALC


• Use caution when installing or modifying telephone lines.

• Never attempt to service this product unless you are an authorized service technician. Doing so can expose you to dangerous high-voltage points or other risks and may result in injury or damage to the unit and void all warranties.

• The MALC system chassis requires a dedicated ground connection to the building ground. If more than one MALC chassis is to be installed on a rack, each one requires its own direct connection to the building ground.

• Slots and openings in the product are provided for ventilation. To ensure reliable operation of the product and to protect it from overheating, these slots and openings must not be blocked or covered.

• DO NOT allow anything to rest on the power cord and do not locate the product where anyone could step or walk on the power cord.

• Special cables, which may be required by the regulatory inspection authority for the installation site, are the responsibility of the buyer.

• When installed in the final configuration, the product must comply with the applicable Safety Standards and regulatory requirements of the country in which it is installed. If necessary, consult with the appropriate regulatory agencies and inspection authorities to ensure compliance.

• A rare phenomenon can create a voltage potential between the earth grounds of two or more buildings. If products installed in separate buildings are interconnected, the voltage potential may cause a hazardous condition. Consult a qualified electrical consultant to determine whether or not this phenomenon exists and, if necessary, implement corrective action prior to interconnecting the product.

• Install the MALC in accordance with national and local electric codes to meet central office requirements. Consult a qualified electrical consultant.

• Invisible laser radiation may be emitted from the optical ports of the MALC when no cable is connected. Avoid exposure and do not stare into open apertures.

Preventing electrostatic damage

The system slot cards are susceptible to electrostatic discharge (ESD). ESD can cause component failure and degraded system performance. Take adequate precautions to prevent electrostatic discharge (ESD) with these cards. Always wear a properly-grounded wrist strap or equivalent protection when handling system cards.

Handle each card by its front panel or stiffener. Never touch the solder side, connector pins, or components on a printed circuit card, and do not allow cards to come into contact with one another.

To prevent damage to system cards when not in use, store and handle the cards in their original antistatic bags. Keep the cards in their original packing

Installation precautions


cartons to prevent damage caused by dust or dirt. Be sure to store the cards in areas that are free from excessive humidity and temperatures.

Power supply safety information

Install an equipment grounding conductor not smaller in size than the ungrounded branch-circuit supply conductors as part of the circuit that supplies the product or system. Bare, covered, or insulated grounding conductors are acceptable. Individually covered or insulated equipment grounding conductors should have a continuous outer finish that is either green, or green with one or more yellow stripes. Connect the equipment-grounding conductor to ground at the service equipment.

Installation precautionsAvoid creating a hazardous condition by maintaining even weight distribution within the chassis.

WARNING! Two people are required to lift the MALC 719 or MALC 723 systems because they weigh too much for one person to lift. Do not attempt to lift the system chassis without assistance or personal injury can result.

Avoid creating a hazardous condition by following proper procedures when creating intra-building connections.

WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or subassembly MUST NOT be metallically connected to interfaces that connect to the OSP or its wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition of primary protectors is not sufficient protection in order to connect these interfaces metallically to OSP wiring.

Maximum operating temperature should not exceed 650C (1490F). The temperature of the rack environment may be greater than ambient room temperature when the system is installed in a closed or multiunit rack assembly. Observe the maximum recommended operating temperature as indicated here.

Do not block system air vents; this will deprive the system of the airflow required for proper cooling. Sufficient clearance must exist on all sides of the rack to permit equipment access.

Zhone recommends using cabling ducts for cable routing in rack mounts.

Installing the MALC


To facilitate proper cooling, cover unpopulated slots with a blank front panel. All slots must have a card or a blank panel installed at all times for EMC, safety and cooling requirements.

The system ships with mounting brackets. To avoid overloading the mounting brackets, and damaging the system, do not use the MALC chassis to support other equipment after it is mounted in the rack.

Connect the system to the power supply circuit as described in this document. Do not overload the system or power supply circuit.

Ensure that proper system grounding is performed and maintained. Use power supply connections for grounding instead of branch circuitry (such as power strips).

Environmental specificationsTable 2 describes the MALC chassis environmental specifications.

Table 2: MALC chassis environmental specifications

Description Specification

Chassis dimensions MALC 72323 in. (58.42 cm) wide by 12.25 in. (31.12 cm) high (7U) by 11.625 in. (29.53 cm) deep.MALC 71919 in. (48.26 cm) wide by 12.25 in. (31.12 cm) high (7U) by 11.625 in. (29.53 cm) deep.MALC 31919 in. (48.26 cm) wide by 5.219 in. (13.26 cm) high (3U) by 11.30 in. (28.70 cm) deep.

Weight 80 lbs. (36.29 kg) fully loaded

Operating temperature -400C to +650C (-400F to +1490F).

Storage temperature –400C to +850C (–400F to +1850F)

Operating relative humidity

5% to 95% noncondensing

Storage relative humidity

Up to 95% noncondensing

Altitude Operating altitude: Up to 4,000 m (13,123 ft.)

Airflow MALC 319: Left to rightMALC 719 and MALC 723: Bottom front to top rear.

Environmental specifications


Figure 4 on page 27 and Figure 5 on page 27 show the MALC chassis dimensions.

Figure 4: MALC 19-inch chassis dimensions

Figure 5: MALC 23-inch chassis dimensions

Installing the MALC


Figure 6: MALC 319 chassis dimensions

Power requirements and specificationsSeparate A and B power feeds allow two individual –48V DC power sources to be connected to the MALC system. The Return (+) terminals are common.For the 19- and 23-inch MALC chassis, the power wiring is field-terminated inside the lower front of the chassis. The MALC 319 chassis is provided with factory-terminated power cables.

Note: The installation site must include overcurrent protection, such as fuses or circuit breakers, that will limit current at the A and B power inputs.

Cabling rules

Following are power cabling rules applicable to the MALC system.

• Provide an appropriate disconnect device as part of the building installation for systems such as the MALC that receive power from an external, auxiliary, or emergency source. When power is routed from a power distribution frame, the disconnect device can be used as a power cutoff (for example, an ON/OFF switch or breaker).

• Connect all disconnect devices so that they disconnect all ungrounded conductors of a DC power circuit when placed in the OFF position.

• All power cables must be rated VW-1 or higher.

• Use power cabling of 10 AWG for applications of 25 feet (7.62 m) or less from the central power distribution bus.

Power requirements and specifications


Power specifications

Table 3 describes the MALC power specifications.

Chassis power consumption

Table 4 describes the power consumption of the MALC system components.

Table 3: MALC power supply specifications

Description Specification

Rated voltage -41.75V to -60.0V DCSeparate A/B power feeds for –48V DC protection

Rated power MALC 719: 1,200 watts, maximum MALC 723: 1,300 watts, maximumMALC 319: 700 watts, maximum

Rated current MALC: 28A maximumMALC 319: 16A maximum

DC-input cable AWG 10 (5.27 mm2) maximum

Listed circuit breaker or fuse

MALC: 30 A maximum MALC 319: 20 A maximumA listed circuit breaker or fuse must be installed from a central DC power source and wired in accordance with NEC, ANSI/NFPA 70 and Canadian electrical code, Part 1, C22.1.

Table 4: MALC power consumption

Component Specification

19 inch chassis 58 W

23 inch chassis 60 W

MALC 319 chassis With an MTAC-FC card installed, the chassis draws 31 watts maximum with no ringing, 45 watts maximum at full ringing load.

Installing the MALC


Grounding and isolationThe MALC system cards and subassemblies use an integrated frame and logic ground system as follows:

• The MALC system chassis and logic ground are bonded.

• The two-wire power supply feed is not connected to the chassis.

• Cable shielding is terminated on the MALC system chassis ground.

For more infomation about grounding, see Connecting power and grounding the chassis, page 37.

Selecting the system locationEnsure that the environment is free of dust and excessive moisture, not exposed to the elements or temperature extremes, and has sufficient ventilation.

Install the system in reasonable proximity to all equipment with which it will connect. Ensure that proper cable grades are used for all system and network connections. For best results, use the cables and connectors recommended in this document.

Tools neededThe required equipment listed in Table 5 should be available before beginning the installation of the MALC system.

Table 5: Equipment required to install the MALC system

Qty Equipment Details Use

1 Mounting shelf or rack, 19 or 23 inch width as required.

Powered as indicated in attached specifications.

MALC chassis mounting

1 VT-100-compatible terminal or PC used as a VT-100 terminal emulator

Connected to the MALC through RJ45 craft port.

Commission and configuration

1 11/32-inch nutdriver For ground stud hex nuts. General installation

1 Pliers General installation

1 Cable prep tools Pressfit and crimpers Cable installation

- Cables System connections

Compliance and certifications


Compliance and certifications

2 #1 and #2 Phillips-head and 1/8-inch flat-blade screwdrivers

N/A Locking and unlocking cards, front panels and chassis brackets

2 Antistatic wrist strap N/A Static electricity prevention

Table 5: Equipment required to install the MALC system

Qty Equipment Details Use

Table 6: Compliance and certifications

NEBS Specification

Safety ACA TS001AS/NZS 3260CB Report CSA 22.2 No. 950EN 60950IEC 60950UL 60950

EMC emissions FCC Part 15 Class AGR-1089-Core Level 3CE EN55022A

EMC immunity GR-1089-Core Level 3CE EN55024CE EN 50082

Environmental GR-63-Core Level 3ETS 300 019-2-xISTA Transportation and Handling

Network FCC Part 68CTR-12CTR-13DOC CS-03NTR-4TSO-16

Installing the MALC


Unpacking the systemUse the following procedure to unpack the MALC system components from the shipping cartons.

• On system receipt, check the shipping cartons for physical damage.

• Unpack the shipping cartons, and check the contents for physical damage.

• If the equipment appears damaged, immediately contact the shipping company to file a claim.

The shipping company representative will give instructions on how to submit a claim, where to send the unit, and any special instructions that may be required.

If you need to return the equipment, pack the equipment in its original packing materials and send it by prepaid freight to the address given by the claims representative. If the original packing materials are unavailable, ship the equipment in a sturdy carton, wrapping it with shock-absorbing material.

Installing mounting brackets on the MALC

Note: Units are shipped with the rack ears installed and secured to shipping pallet. When unpacking the unit, remove the bottom two screws that secure the shipping bracket to the rack ears and replace them with the correct rack ear screws from the accessory kit.

This section contains the following information:

• Installing the mounting brackets onto the MALC system chassis on page 32

• Installing the mounting brackets onto the MALC 319 system chassis on page 33

Installing the mounting brackets onto the MALC system chassisThe MALC mounting brackets are designed for use in a 19-inch or 23-inch rack. Use the following procedure to install the mounting brackets onto the system chassis:

1 Carefully place the system chassis right side up and facing forward on a clean, flat, sturdy work surface.

2 Align the bracket so that the rack mount flange is toward the front, centered vertically on the chassis and the 4 screw holes in the chassis align with the 4 screw holes in the bracket.

Installing mounting brackets on the MALC


Note: Use an 8-32 flathead UNC x 0.25 screw when attaching the brackets to the unit. Using the wrong screw type will result in a poorly-secured system. These screws are provided in the installation kit.

3 Secure the two brackets to both sides of the system chassis with the screws provided in the installation kit. See Figure 7 on page 35.

Caution: To prevent damage to the system, use only the screws provided in the installation kit.

Installing the mounting brackets onto the MALC 319 system chassisThe MALC 319 mounting brackets are designed for use in a 19-inch rack. Use the following procedure to install the mounting brackets onto the system chassis:

1 Carefully place the system chassis right side up and facing forward on a clean, flat, sturdy work surface.

2 Align the bracket so that the rack mount flange is toward the front, centered vertically on the chassis and the 4 screw holes in the chassis align with the 4 screw holes in the bracket.

Note: Use a 6-32 flathead UNC x 0.25 screw when attaching the brackets to the unit. Using the wrong screw type will result in a poorly-secured system. These screws are provided in the installation kit.



Installing the MALC


Installing the chassis in a rackThis section contains the following information:

• Mounting the MALC system chassis in a rack on page 34

• Mounting the MALC 319 system chassis in a rack on page 35

Mounting the MALC system chassis in a rackThe system chassis can be mounted in a 19-inch or 23-inch rack that is connected to an earth ground.

WARNING! Two people are required to pick up the system because it weighs too much for one person to lift. Do not attempt to lift the system chassis without assistance or personal injury can result.

Use the following procedure to mount the system chassis in a rack:

1 Choose a rack position for the system chassis.

2 Carefully lift the system chassis into the rack with the front of the system facing outward.

3 Secure the system chassis to the mounting rack with the screws provided in the installation kit.

Note: Use a 12-24 UNC x 0.5-inch screw when mounting the system to the rack. Using the wrong screw type will result in a poorly-secured system. These screws are provided in the installation kit.

Installing the chassis in a rack


Figure 7: Installing the MALC in a rack

Mounting the MALC 319 system chassis in a rackThe system chassis can be mounted in a 19-inch rack that is connected to an earth ground. Use the following procedure to mount the system chassis in a rack:

1 Choose a rack position for the system chassis.

2 Carefully lift the system chassis into the rack with the front of the system facing outward.

3 Secure the system chassis to the mounting rack with the screws provided in the installation kit.

Note: Use a 12-24 UNC x 0.5-inch screw when mounting the system to the rack. Using the wrong screw type will result in a poorly-secured system. These screws are provided in the installation kit.

Installing the MALC


Figure 8: Installing the MALC 319 in a rack

Wall mounting the MALC 319 chassisWARNING! Two people are required to pick up the system because it weighs too much for one person to lift. Do not attempt to lift the system chassis without assistance or personal injury can result.

Use the following procedure to wall mount the system chassis.

Wall mounting the MALC 319 chassis1 Choose a position for the system chassis.

2 Remove the rack ears from the front of the unit.

3 Align the bracket so that the rack mount flange is in the middle of the unit and the 2 screw holes in the chassis align with the 2 screw holes in the bracket nearest the flange.

Note: Use a 6-32 flathead UNC x 0.25 screw when attaching the brackets to the unit. Using the wrong screw type will result in a poorly-secured system. These screws are provided in the installation kit.



5 Orient the unit with the power cables facing up. See Figure 9

Connecting power and grounding the chassis


Figure 9: Wall mounting the MALC 319 chassis

6 Secure the system chassis to the wall with the screws provided in the installation kit.

Connecting power and grounding the chassisThis section contains the following information:

• Grounding requirements on page 38

• Connecting power to the MALC and grounding the chassis on page 40

• Connecting power to the MALC 319 and grounding the chassis on page 43

Note: Bare, covered, or insulated grounding conductors must comply with Underwriters Laboratory (UL) standards. Individually covered or insulated grounding conductors shall have a continuous outer finish that is either green or green with one or more yellow stripes. The equipment grounding conductor should be connected to the ground at the service equipment. The grounding cable must be rated at VW-1 or higher.

Zhone recommends grounding the MALC using minimum 10 gauge copper wire and NRTL-listed two hole compression-type connectors (such as Amphenol part number 1527272-3).

Installing the MALC


Grounding requirementsUse the guidelines in this section to provide a system ground for the MALC.

Before concluding a MALC installation and applying DC power, measure the impedance of the building ground reference and ensure that it is less than 25 ohms, for safety. Use an ECOS 1023 POW-R-MATE or an EMC Instrument Model 3710 or similar meter to do this. Zhone recommends that the impedance be 1 ohm or less for proper equipment operation.

If the ground path connected to the MALC has an impedance of more than 1 ohm, make improvements to the grounding system before installing the MALC equipment.

Other grounding requirements are as follows:

– The earth ground rod is normally buried in the ground at the site. Observe local electrical codes for buried grounding techniques and requirements. Ensure that the ground rod has been installed per local, telco, and NEC code requirements.

– Use a dedicated power source that is only shared with other isolated bonding network (IBN)-configured equipment to provide power to the MALC and all other related equipment. This prevents interference from possible high surge or noise currents present in some industrial buildings. Otherwise, you must ensure a proper grounding path of less than 1ohms to the building ground.

– Use the ground bus of a dedicated AC service panel as the location/site ground of the MALC equipment. This ground bus must already be connected to the main service panel ground or main building ground reference.

– The impedance of the link between the ground terminal of the MALC and the location/site ground to which it is connected must be less than 0.25 ohms.

– The rack the MALC is installed in must be properly grounded. To verify proper grounding of the rack and the chassis to the rack, please see Verifying proper grounding between the chassis and the rack, page 45.

– Never connect a single-point-ground conductor from the MALC to structural steel members or electrical conduits. Specifically, never tie this conductor to a ground source or grounded electrode that is not hard-wired to the building ground reference conductor.

– It is recommended to avoid running in-building cabling near fluorescent lights and other sources of high frequency radiation such as transformers.

– Avoid spliced conductors. Use continuous conductors, which have lower impedance and are more reliable than spliced ones.



– Terminate all conductors in a permanent manner. Ensure all terminations are easily visible and accessible for maintenance purposes.

– Tag ground connections clearly with a message such as “CRITICAL CONNECTION: DO NOT REMOVE OR DISCONNECT.”

– Although some electrical codes permit the use of a conduit as the sole ground conductor between equipment, it is still recommended to use a separate insulated ground conductor through the same conduit. The separate insulated ground conductor maintains the safety ground connection if the conduit is corroded or disconnected.

– Avoid a ground path via serial craft interface RS-232C. The MALC RS-232C local craft interface has pins referenced to ground. To prevent undesirable ground path via an attached computer, it is recommended that you only use a portable computer. If only a desktop computer or VT-100 type monitoring equipment is available, use it in conjunction with a UL/CSA Certified RS-232 Opto-Isolator.

– The thumbscrews for cards must be screwed in.

– Blank face plates must be used in slots that do not have slot cards present.

Ground conductors for the MALC must meet the following requirements:

– No smaller than 10 AWG at any point.

– Does not carry current under normal operating conditions.

– Must be tied to the +48V battery return at the main power Distribution Center. Absence of this connection can cause malfunctions on some cards, including generation of the MALC-MTAC/RINGER-ENH card error message “Internal ringer not detected”.

– Should be hardwired to the main ground reference.

Installing the MALC


Connecting power to the MALC and grounding the chassisUse the following procedure to connect the wiring between the MALC terminal block and the power supplies.

1 Remove the MALC lower bezel.

2 Remove the air filter.

Figure 10: Removing the front bezel and air filter

3 Locate the terminal block in the lower portion of the chassis.

4 Loosen the screws that attach the terminal block to the chassis.

5 Carefully remove the terminal block from the chassis.

Caution: Use care when removing the terminal block from the chassis so as not to detach the wires connecting the terminal block to the chassis.

6 Thread the wires (minimum 10 AWG) through the hole on the right side of the chassis.

Figure 11: Removing terminal block



Note: Some MALC terminal blocks have a quarter-turn screw. For these units, turn the screw 1/4 turn counterclockwise to loosen.

Note: If the MALC is installed so that the thread hole on the side of the unit is inaccessible, thread the power supply and grounding cables behind the front bezel as illustrated in Figure 12.

Figure 12: Threading the power and grounding cables behind the front bezel

7 Connect the negative wire from power supply A to the terminal marked –VA.

8 Connect the positive wire from power supply A to the terminal marked VA+.

9 Connect the negative wire from power supply B to the terminal marked –VB.

10 Connect the positive wire from power supply B to the terminal marked VB+.

Note: If using a single power source, place jumpers between terminals –VA and –VB.

11 Reinstall the terminal block into the chassis.

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Installing the MALC


Figure 13: Connecting power cables

12 Secure the terminal block to the chassis.

13 Route a 10 AWG conductor from each chassis to a common 2 AWG frame ground collector that connects to the single point building ground in an IBN. Ensure that there are no sharp bends in the conductors and that they touch bare metal. Do not connect the cables to the single point building ground at this time.

14 Strip the 10 AWG conductor and crimp a grounding lug to the end of the conductor.

15 Attach the ground lug with two hex bolts to the grounding lugs, as shown in Figure 14 on page 43.

16 Secure the hex bolts to the chassis.

17 To verify proper grounding, please see Verifying proper grounding between the chassis and the rack, page 45.

Caution: This procedure is service affecting and requires that ground be isolated from the equipment. Perform this procedure during a maintenance window.

18 Connect the ground cable(s) routed in Step 13 and tighten the bolt. Use a minimum torque of 12 inch-lbs to ensure that the grounding cable is securely fastened.



Figure 14: Securing the terminal block and grounding the chassis

Note: Some MALC terminal blocks have a quarter-turn screw. For these units, turn the screw 1/4 turn clockwise to tighten.

19 Reinstall the air filter.

20 Replace the lower bezel.

Figure 15: Replacing the air filter and bezel

21 Turn on the power to power supply A (and to power supply B, if present).

The system is now live and ready to initialize the slot cards as they are installed. In the absence of any slot cards, there is no activity on the system. The Power A and Power B LEDs on the front panel of the unit should be solid green, indicating power is normal. For information on the chassis LEDs, see Reading the LEDs on page 77.

Connecting power to the MALC 319 and grounding the chassisThe MALC 319 comes with 10 AWG power cables pre-installed. To connect the MALC 319 power cables:

1 Connect the wire marked - 48 A to the power supply A negative terminal.

2 Connect the wire marked + RTN A to the power supply A positive terminal.

Installing the MALC


3 Connect the wire marked - 48 B to the power supply B negative terminal.

4 Connect the wire marked + RTN B to the power supply B positive terminal.

5 Route a 10 AWG conductor from each chassis to a common 2 AWG frame ground collector that connects to the single point building ground in an IBN. Ensure that there are no sharp bends in the conductors and that they touch bare metal. Do not connect the cables to the single point building ground at this time.

6 Remove the screw from the grounding connector and secure a compression-type connector. See Figure 16.

7 To verify proper grounding, please see Verifying proper grounding between the chassis and the rack, page 45.

Caution: This procedure is service affecting and requires that ground be isolated from the equipment. Perform this procedure during a maintenance window.

8 Connect the ground cable(s) routed in Step 5 and tighten the bolt. Use a minimum torque of 12 inch-lbs to ensure that the grounding cable is securely fastened.

Note: Some MALC terminal blocks have a quarter-turn screw. For these units, turn the screw 1/4 turn clockwise to tighten.

9 Tighten the nut on the chassis ground lug to secure the cable in place. Use a minimum torque of 12 inch-lbs to ensure that the grounding cable is securely fastened.

Figure 16: Grounding the MALC 319

10 Turn on the power to power supply A (and to power supply B, if present).

The system is now live and ready to initialize the slot cards as they are installed.



Verifying proper grounding between the chassis and the rackProper grounding reduces the effect of line surges and limits the voltages and RF interference that may affect communication among network devices.

1 Test the impedance from the grounding cable or bar (point 1 in the graphic) to the rack (point 2 in the graphic)

The impedance should be less than 1 ohm.

2 Test the impedance from the MALC chassis (point 3 in the graphic) to the grounding rack.

The impedance must be less than 0.25 ohms.

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Installing the MALC


Installing slot cards This section contains the following information:

• Installation guidelines on page 46

• Installing a slot card in the MALC chassis on page 46

• Installing a slot card in the MALC 319 chassis on page 47

Installation guidelines

Observe the following rules when handling MALC slot cards:

• Handle each card by its front panel or stiffener. Never touch the solder side, connector pins, or components on a printed circuit card, and do not allow cards to come into contact with one another.

• To prevent damage to slot cards when not in use, store and handle the cards in their original containers. Keep the cards in their original packing cartons to prevent damage caused by dust or dirt. Be sure to store the cards in areas that are free from excessive humidity and temperatures.

Caution: The MALC system slot cards are susceptible to electrostatic discharge (ESD). ESD can cause component failure and degraded system performance. Take adequate precautions to prevent electrostatic discharge with these cards. Always wear a properly grounded wrist strap, or equivalent protection, when handling system cards.

Note: MALC and MALC 319 use the same slot cards with the exception of the MTAC/Ring-FC card, which is only used in the MALC 319.

Installing a slot card in the MALC chassis

Note: You must install the uplink card in slot 1 or slot 2 (the 2 left-most slots).

1 Put on an antistatic wrist strap that touches the skin. Make sure it is properly grounded to the ESD jack on the front of the unit.

2 Carefully remove the card from its antistatic packaging.

3 Visually inspect the card for damage. Check the label and part number on the card to verify the type of card being installed is the type needed for the particular application.

4 Holding the card by its faceplate, carefully insert the card into a slot. Hold the bottom ejector open and slowly slide the card onto the backplane pins.

5 Close the bottom ejector to firmly seat the card.

Installing slot cards


Caution: To prevent damage to the backplane pins, do not force cards onto the backplane pins when seating the cards. If you have trouble seating a card, check that it is in the correct slot, pull the card out, and try seating it again by pressing gently.

6 Slide the card lock down.

The card will not boot if the card lock is not in the down position.

7 Tighten the top and bottom screws to seat the card in the backplane.

Figure 17 illustrates installing slot cards.

Figure 17: Installing slot cards in the MALC

Installing a slot card in the MALC 319 chassis

Note: You must install the MTAC/Ring card in the bottom right slot.







Installing the MALC


6 Slide the card lock to the left.




Figure 18: Installing slot cards in the MALC 319

Logging into the serial (craft) port



Note: Do not use the serial craft port of a standby card to modify its configuration.

The MALC unit provides an out-of-band RS232 D serial (craft) interface for managing the unit. To access the serial port, configure your terminal interface software with the following settings:

• 9600bps

• 8 data bits

• No parity

• 1 stop bit

• No flow control

Tip: The serial (craft) port settings can be changed by modifying the rs232-profile.

You must perform the initial configuration of the system using the serial (craft) interface. After you have completed the initial configuration, you can manage the MALC unit over the network through a telnet session over the Ethernet interface or over the management PVC.

Note: The MALC supports 6 concurrent management sessions, 5 telnet sessions and a single local session through the serial (craft) port.

Logging in and out of the systemLog into the system (the default user name is admin, the default password is zhone):

login:adminpassword: zSH>

To log out of the system, enter the logout command:zSh> logout

Tip: The system automatically logs you out after a period of inactivity. The default logout time is 10 minutes, but can be changed with the timeout command. Refer to the Zhone CLI Reference Guide for information on the timeout command.

Installing the MALC


Enabling and disabling loggingBy default logging is enabled on the serial craft port and disabled over telnet sessions. To enable or disable logging for the session, using the following command:zSh> log session on | off

The log session command only applies to the current session. You can also enable or disable logging for all serial craft port sessions using the following command:zSh> log serial on | off

This command setting persists across system reboots.


SYSTEM CABLES AND CONNECTORS

This chapter explains how to connect the MALC cables and connectors. It contains the following sections:

• Cabling guidelines, page 51

• Connecting optical ATM trunking cables, page 52

• Dressing DSL and POTS cables, page 52

• Securing amphenol connectors, page 57

• Cable descriptions, page 58

• Alarm cable and contacts guidelines, page 60

• Uplink card pinouts, page 62

• Fiber optic maintenance and handling, page 65

Cabling guidelinesTo be in compliance with NEC article 800, ensure that the power lines are placed at least two inches away from the communication cables. This can be accomplished by tie-wrapping and routing the power lines behind the rack (route the communication cables in front of the rack).

Note: To comply with FCC regulations, cables and connectors must be shielded. If you intend to install cable covers, the maximum height of the connector head and cable should be two inches.

If the MALC is going to be installed in an inside plant, the cables must be shielded and grounded at both ends.

MALC system connectors are located in the front of the chassis. No cables are included with the installation kit. You must order any cables that are required.

System cables and connectors


Connecting optical ATM trunking cablesWARNING! The single-mode fiber optic interfaces on the OC-3c/STM1 and OC-12c/STM4 uplink cards emit invisible laser radiation that may cause harm. When an optical cable is connected to the card, the radiation is confined to the cable and does not present a hazard. However, if you are servicing the OC-3c/STM1 uplink or OC-12c/STM4 uplink cards, always use the following precautions:

• Disconnect the card from the MALC before installing or removing cables

• Ensure that the protective rubber tips cover the SC connectors when not in use

• Never look directly into the optical ports

1. Disengage the OC-3c/STM1 uplink card from the MALC backplane to ensure that the optic interface is not emitting laser radiation.

2. Remove the protective rubber tips from the SC connectors on one end of the fiber optic cable or cables.

3. Remove the protective rubber tips from the SC connectors on the OC-3c/STM1 uplink card.

4. Gently insert the SC on the cable into the Tx and Rx ports on the uplink card.

5. Connect the other end of the cable that is connected to the uplink card Tx connector to the Rx port on the ATM device.

6. Connect the other end of the cable that is connected to the uplink card Rx connector into the Tx port on the ATM device.

Dressing DSL and POTS cablesCables can be mounted so that they are placed in a down or up position. Use 50-pin connectors to connect the DSL and POTS cards.

Down cabling

Dress the cables to the side of the unit. See Figure 19.

Dressing DSL and POTS cables


Figure 19: Dressing MALC cables

The optional cable management bracket can be installed to facilitate installing and managing cables. See Figure 20 on page 53.

Figure 20: Installing the cable management bracket

The cable management bracket installation kit also includes mounting clips intended to secure cable connectors to the card. See Figure 21.



Figure 21: Installing bracket clip

To remove the connectors from a card, remove the top portion of the connector, then gently rock the bottom portion of the connector until it’s freed from the clip. See Figure 22.

Figure 22: Removing connectors



UP line card cabling

The MALC supports UP cabling for the following ADSL-48 and POTS-48 cards:

• MALC-ADSL-48A/M

• MALC-ADSL-48B

• MALC-ADSL+SPLTR-48A/M-2S

• MALC-ADSL+POTS-TDM/PKT-48A/M-2S

• MALC-ADSL-BCM-48A

• MALC-ADSL-BCM-48B

• MALC-ADSL+SPLTR-BCM-48A-2S

• MALC-ADSL+POTS-PKT-BCM-48A-2S

• MALC-ADSL+POTS-TDM/PKT-BCM-48A-2S

The following cables are available for up cabling for the:

• MALC-CBL-ADSL-48-UP-30FT






Dressing UP DSL and POTS cablesUse 96-pin connectors to connect the ADSL-48 cards, POTS-48, and ADSL-POTS Combo cards. Dress the cables to the side of the unit. See Figure 19.

Figure 23: Dressing MALC cables

Secure the cable connectors to the card. See Figure 21.

Figure 24: Installing connector

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To remove the connectors from a card, remove the top portion of the connector, then gently rock the bottom portion of the connector until it’s freed from the clip. See Figure 22.

Figure 25: Removing connectors

Securing amphenol connectorsThe MALC accessory kit contains tie-wraps, tie-wrap holders, and screws that can be optionally used to secure Amphenol connectors to MALC cards. See Figure 26 on page 58.

Securing the Amphenol connectors1 Remove one of the hexagonal standoffs from the slot card connector.

2 Install the tie-wrap holder into the space where the hexagonal standoff has been removed.

3 Attach the male end of the Amphenol connector into slot card connector.

4 Hand-tighten the Amphenol connector hold-down screw.

5 Once the Amphenol connector is firmly seated, secure the connector by looping a tie-wrap through the tie-wrap holder and around the Amphenol connector.

6 Fasten the tie-wrap.

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Figure 26: Securing 50-pin Amphenol connectors

Cable descriptionsTable 8 lists specifications for the cables used with the MALC system. For pinout information for these cables, refer to the chapters for each card, later in this manual.

Cable descriptions

Table 8 lists specifications for the cables used with the MALC system. For pinout information for these cables, refer to the chapters for each card, later in this manual.

Table 7: Summary of cable specifications

Cable description Interfaces the MALC to Cable type Connector type

Upward cabling for ADSL-48 and POTS-48 subscribers

ADSL-48 and POTS-48 cards 48-pair Category 2, 3, 4 or 5

Molex 96-pin connector

Table 8: Summary of cable specifications


ADSL subscriber ADSL-32 cards 32-pair Category 2, 3, 4 or 5

Female 64-pin amphenol.

ADSL subscriber multi-connector

Three ADSL-32 cards 96-pair Category 2, 3, 4 or 5

Three Female 64-pin amphenol.



Chassis alarms Alarm relay contact on chassis (MALC 723 or MALC 719)Alarm relay contact on MTAC/Ring-FC card

20 AWG minimum (0.8 mm)24 AWG (0.5 mm) recommended

Blank wire in to screw terminals.

DSL, POTS, or ISDN subscriber

DSL, POTS, or ISDN connectors on line cards

25 pair Category 2, 3, 4 or 5

Male 50-pin amphenol.

Management (IP) Ethernet port on uplink card. 4 pair Category 5 RJ45 plug

Management (serial craft port)

RS-232D connector on uplink card.

4-wire minimum 26 AWG (0.4 mm)

RJ45 plug

MTAC/Ring BITS External BITS clock Standard T1 4-wire cable

RJ48C

MTAC/Ring external alarms

External alarm connector on MTAC/Ring card

20 AWG minimum (0.8 mm)24 AWG (0.5 mm) recommended

26 pin D-Sub

MTAC/Ring external ringer

External ring generator on MTAC/Ring card

22 AWG (0.6 mm) Screw terminals

MTAC/Ring external test access

External test access connector on MTAC/Ring card

2-wire or 4-wire (depending on the test being run). Minimum 26 AWG (0.4 mm)

RJ45 plug

Optical trunk cir-cuits

PON OLT card Single mode 9/125 fiber (ITU G.652)

Square Connector (SC)

T1/E1 TDM circuits TDM T1/E1 connector on the Voice Gateway card (non-redundant)

32-pair Category 2, 3, 4 or 5

128 pin telco connector.

TDM T1/E1 connector on the Voice Gateway card (redundant)

32-pair Category 2, 3, 4 or 5

128 pin telco connector.

Table 8: Summary of cable specifications (Continued)




Alarm cable and contacts guidelinesThe MALC 719 and MALC 723 chassis alarms are located in the lower left of the chassis, behind the bezel. See Figure 27.

MALC 319 chassis alarms are located on the MTAC-FC card.

Figure 27: MALC chassis alarms

The specifications and requirements for the MALC chassis alarm cable and alarm relay contacts are as follows:

• The alarm cable must be rated at VW-1 or higher. To comply with Part 15 of FCC regulations, all cables to DB connectors must be foiled with braided shielding.

• One cable is required to interface to the alarms connector. The minimum gauge for this cable is 20 AWG (24 AWG recommended). To limit alarm cable signal losses, its length should not exceed 60 feet.

• Alarm relay contacts are rated at 62.5 VA (defined as being capable of switching 1 amp at 62.5 volts). The maximum switching current of the relay is 1 amp.

Note: Temperature alarms appear in Farenheit (°F), while the shelfctrl command displays temperature in Celsius (°C)

The following tables describe the MALC chassis alarms.

Table 9: System alarms

Event Type of alarm

Fan Tray up/down Critical

Power A/B up/down Critical (if nonredundant)Minor (if redundant)

System control bus error Critical

Alarm cable and contacts guidelines


Power Threshold (power out of acceptable range)

Minor

Thermal threshold Minor

Table 10: Card alarms

Event Type of alarm

Card Up/Down Major For uplink and MTAC/Ring card:Critical (if nonredundant)Minor (if redundant)

Table 11: Interface alarms

Event Type of alarm

Frames too long Minor

Physical line up/down Major

Table 12: Uplink card alarms

Event Type of alarm

BER threshold Critical

Card up/down Critical (if nonredundant)Minor (if redundant)

IMA up/down Critical

Network clocking fault Critical (if no fallback provided)Minor (if fallback provided by internal clock)

Flash memory threshold Minor

Internal BITS clock fault Minor (if fallback to line clocking is provisioned, or if the clock source is currently provisioned as secondary source)

T1/E1 threshold Minor

Table 9: System alarms

Event Type of alarm



Uplink card pinoutsThis section lists the pinouts for the following interfaces that are common on all the uplink cards:

• Serial (craft) port pinouts

• Ethernet port pinouts

• Redundant GigE port pinouts

For information about other port pinouts for uplink cards, refer to the chapters for each type of card, later in this manual.

Serial (craft) port pinouts

Table 15 lists the uplink cards’ serial (craft) port pinouts. The serial (craft) port is an RS232 D type configured as DTE.

Table 13: POTS card alarms

Event Type of alarm

Continuity test fault Minor

Ground fault Minor

Loop resistance fault Minor

Power cross test fault (polarity reversal failure)

Minor

Table 14: MTAC/Ring alarms

Event Type of alarm

Ring Generator Up/Down Critical (if nonredundant)Minor (if redundant)

BITS clock Up/Down (only if provisioned active)

Minor

External Ring Generator Up/Down (only if provisioned active)

Minor

Uplink card pinouts


Table 16 lists the pinouts to connect a DB9 connector to the MALC RJ45 serial craft port.

Ethernet port pinouts

Table 17 lists the Ethernet port pinouts on the uplink cards.

Table 15: Uplink card serial (craft) port pinouts

Pin Function

1 DCE Ready, Ring Indicator (DSR/RI)

2 Received Line Signal Detector (DCD)

3 DTE Ready (DTR)

4 Signal Ground (SGND)

5 Received Data (RD)

6 Transmitted Data (TD)

7 Clear To Send (CTS)

8 Request To Send (RTS)

Table 16: RJ45 to DB9 adapter pinouts

RJ-45 pin Color Function DB-9 pin

1 N/A DCE Ready, Ring Indicator (DSR/RI)

not used

2 N/A Received Line Signal Detector (DCD)

not used

3 N/A DTE Ready (DTR) not used

4 Red Signal Ground (SGND) 5

5 Green Received Data (RD) 2

6 Yellow Transmitted Data (TD) 3

7 N/A Clear To Send (CTS) Looped to pin 8

8 N/A Request To Send (RTS) Looped to pin 7

Table 17: Uplink card Ethernet port pinouts

Pin Function

1 Tx +

2 Tx -



Redundant GigE port pinouts

Table 18 lists the GigE port pinouts on the cable connecting redundant GigE uplink cards.

3 Rx +

4 Not used

5 Not used

6 Rx -

7 Not used

8 Not used

Table 17: Uplink card Ethernet port pinouts

Pin Function

Table 18: Redundant GigE port pinouts

Pair Signal Color From To

1 TX 1 Tip WHT/BLU P1-16 P2-26

TX 1 Ring BLU/WHT P1-1 P2-1

2 RX 1 Tip WHT/ORG P1-17 P2-2

RX 1 Ring ORG/WHT P1-2 P2-27

3 TX 2 Tip WHT/GRN P1-18 P2-30

TX 2 Ring GRN/WHT P1-3 P2-5

4 RX 2 Tip WHT/BRN P1-19 P2-6

RX 2 Ring BRN/WHT P1-4 P2-31

5 TX 3 Tip WHT/GRY P1-20 P2-34

TX 3 Ring GRY/WHT P1-5 P2-9

6 RX 3 Tip RED/BLU P1-21 P2-10

RX 3 Ring BLU/RED P1-6 P2-35

7 TX 4 Tip RED/ORG P1-22 P2-38

TX 4 Ring ORG/RED P1-7 P2-13

8 RX 4 Tip RED/GRN P1-23 P2-14

RX 4 Ring GRN/RED P1-8 P2-39

9 TX 5 Tip RED/BRN P1-24 P2-42

TX 5 Ring BRN/RED P1-9 P2-17

Fiber optic maintenance and handling


Fiber optic maintenance and handlingThis section describes how to clean the optical connectors and receptacles used with Zhone Technologies equipment. These processes should be applied to optical components only in instances where degraded performance is evidence that the connection is contaminated.

This section contains the following information:

• Laser radiation on page 65

• Handling optical fibers on page 66

• Selecting cleaning materials on page 67

• Cleaning a connector on page 67

• Cleaning a receptacle on page 68

• Repairing optical fibers on page 68

Laser radiation

Zhone equipment and associated optical test sets use laser sources that emit light energy into fiber cables. This energy is within the red (visible) and infrared (invisible) regions of the electromagnetic spectrum.

10 RX 5 Tip RED/GRY P1-25 P2-18

RX 5 Ring GRY/RED P1-10 P2-43

11 TX 6 Tip BLK/BLU P1-26 P2-46

TX 6 Ring BLU/BLK P1-11 P2-21

12 RX 6 Tip BLK/ORG P1-27 P2-22

RX 6 Ring ORG/BLK P1-12 P2-47

13 TX 7 Tip BLK/GRN P1-28 P3-26

TX 7 Ring GRN/BLK P1-13 P3-1

14 RX 7 Tip BLK/BRN P1-29 P3-2

RX 7 Ring BRN/BLK P1-14 P3-27

15 TX 8 Tip BLU/GRY P1-30 P3-30

TX 8 Ring GRY/BLU P1-15 PE-5

16 RX 8 Tip YEL/BLU P1-44 P3-6

RX 8 Ring BLU/YEL P1-43 P3-31

Table 18: Redundant GigE port pinouts (Continued)

Pair Signal Color From To



Laser products are subject to federal and state or provincial regulations, and local practices. Regulation 21 CFR 1040 of the U.S. Bureau of Radiological Health requires manufacturers to certify each laser product as Class I, II, III, or IV, depending upon the characteristics of the laser radiation emitted. In terms of health and safety, Class I products present the least hazard (none at all), while Class IV products present the greatest hazard.

Read and observe the following precautions to decrease the risk of exposure to laser radiation.

WARNING! Risk of eye damage. At all times when handling optical fibers, follow the safety procedures recommended by your company.

Although Zhone optical products have a Class I certification, hazardous exposure to laser radiation can occur when fibers connecting system components are disconnected or broken. Certain procedures carried out during testing require the handling of optical fibers without dust caps and therefore increase the risk of exposure. Exposure to either visible or invisible laser light can damage your eyes under certain conditions.

During service, maintenance, repair, or removal of cables or equipment, follow these rules:

• Avoid direct exposure to fiber ends or optical connector ends. Laser radiation may be present and can damage your eyes.

• Follow the manufacturer’s instructions when using an optical test set. Incorrect calibration or control settings can result in hazardous levels of radiation.

Handling optical fibers

When you work with optical fibers, you must take these precautions:

• Wear safety glasses when you install optical fibers.

• Clean your hands after you handle optical fibers. Small pieces of glass are not always visible and can damage your eyes. If you have a piece of a glass in your eye, get medical assistance immediately.

• Never look into an active optical fiber or a optical fiber connector opening of an active or powered-up unit.

• Prevent direct exposure to optical fiber ends or optical connector ends where you can directly access the laser signal. Do not handle pieces of optical fiber with your fingers. Use tweezers or adhesive tape to lift and discard any loose optical fiber ends.

• Wear rubber gloves when you clean optical connectors. The gloves prevent direct contact with the isopropyl alcohol and prevent contamination of the ferrules with skin oils.

Fiber optic maintenance and handling


• Place all optical fiber clippings in a plastic container provided for that purpose.

• Handle optical fibers with caution. Place the optical fibers in a safe location during installation.

• Protect all optical fiber connectors with clean dust caps at all times.

• Follow the manufacturer instructions when you use an optical test set. Incorrect calibration or control settings can create hazardous levels of radiation.

Selecting cleaning materials

Materials used for cleaning Zhone Technologies equipment should be high quality and suitable for the purpose.

• Disconnect the cable end to be cleaned.

• Using inert dusting gas, blow accumulated dust and debris off the cylindrical and end-face surfaces of the connector.

• Apply optical-grade isopropyl alcohol to a cleaning tissue.

• Gently wipe the tissue over the cylindrical and end face surfaces of the connector perpendicular to the cable, then fold the cloth and repeat the operation. Always use a clean tissue. Reusing the same portion of the tissue may result in recontamination.

• Dry the connector by blowing it with inert dusting gas for two seconds, holding the nozzle approximately inch from the end of the connector.

• Recap or reconnect the connector promptly to avoid contamination. Check for proper system function.

Optical cleaning kits are available from optical supply sources.

Cleaning a connector1 Disconnect the cable end to be cleaned.

2 Using inert dusting gas, blow accumulated dust and debris off the cylindrical and end-face surfaces of the connector.

3 Apply optical-grade isopropyl alcohol to a cleaning tissue.

4 Gently wipe the tissue over the cylindrical and end face surfaces of the connector perpendicular to the cable, then fold the cloth and repeat the operation. Always use a clean tissue. Reusing the same portion of the tissue may result in recontamination.

5 Dry the connector by blowing it with inert dusting gas for two seconds, holding the nozzle approximately inch from the end of the connector.

6 Recap or reconnect the connector promptly to avoid contamination. Check for proper system function.



Cleaning a receptacleClean the optical ports on modules only if there is evidence of contamination or reduced performance. To minimize contamination and cleaning, keep all optical ports securely covered with a connector or a dust cap.

1 Using the extension tube supplied with the inert dusting gas, blow into the optical port to remove any accumulated dust and debris. Do not allow the tube to touch the bottom of the optical port.

2 Using a swab with a small head, such as TexWipe Microswab, and optical-grade isopropyl alcohol, wipe out the optical port.

3 Recap or reconnect the receptacle promptly to avoid contamination. Check for proper system function.

Repairing optical fibersWhen an accidental break in the fiber feeder cable occurs, take the following steps:

1 Notify both central-office and field-repair personnel of the problem.

2 Identify to central-office personnel what fibers are damaged.

3 Power off all laser sources related to the damaged fibers (whether located at the central office, subscriber premises, or remote location).


MANAGING THE MALC

This chapter describes how to log into the MALC and add a remote management channel. It includes the following sections:

• Logging into the serial (craft) port, page 69

• Configuring a management interface, page 70


Note: Do not use the serial craft port of a standby card to modify its configuration.

The MALC unit provides an out-of-band RS232 D serial (craft) interface for managing the unit. To access the serial port, configure your terminal interface software with the following settings:

• 9600bps

• 8 data bits

• No parity

• 1 stop bit

• No flow control

Tip: The serial (craft) port settings can be changed by modifying the rs232-profile.

You must perform the initial configuration of the system using the serial (craft) interface. After you have completed the initial configuration, you can manage the MALC unit over the network through a telnet session over the Ethernet interface or over the management PVC.

Note: The MALC supports 6 concurrent management sessions, 5 telnet sessions and a single local session through the serial (craft) port.

Logging in and out of the systemLog into the system (the default user name is admin, the default password is zhone):

Managing the MALC


login:adminpassword: zSH>

To log out of the system, enter the logout command:zSh> logout

Tip: The system automatically logs you out after a period of inactivity. The default logout time is 10 minutes, but can be changed with the timeout command. Refer to the Zhone CLI Reference Guide for information on the timeout command.

Enabling and disabling loggingBy default logging is enabled on the serial craft port and disabled over telnet sessions. To enable or disable logging for the session, using the following command:zSh> log session on | off

The log session command only applies to the current session. You can also enable or disable logging for all serial craft port sessions using the following command:zSh> log serial on | off

This command setting persists across system reboots.

Configuring a management interfaceThis section describes how to configure the following interfaces to remotely manage the MALC:

• Uplink card 10/100 BaseT Ethernet interface on page 70

• ATM management connection on page 72

• Managing the MALC with ZMS on page 74

Note: If you want to manage the MALC over an ATM PVC, first configure the Uplink ATM interface as described later in this manual.

Uplink card 10/100 BaseT Ethernet interface

The MALC has a 10/100 BaseT Ethernet interface on the Uplink card. The ip-interface-record for the Uplink card is named ethernet1. This interface is shared between the two Ethernet ports on redundant Uplink cards (if they exist). The system can be reached using the address configured in the ethernet1 ip-interface-record, no matter which card is active.

Configuring a management interface


Caution: The Uplink card Ethernet interface must be configured before any other interfaces on the system, even if you do not intend to manage the unit over the Ethernet.

Configuring the Ethernet IP interfaceThe following example configures the IP address for the system. Refer to the CLI Reference Guide for a complete description of the command options and syntax.

zSH> interface add 1-1-1-0/ethernetcsmacd static 192.168.8.21 255.255.255.0Created ip-interface-record ethernet1/ip

Note: If you have problems with IP interfaces not automatically binding, refer to the MALC Configuration Guide for more information.

Verifying the interfaceUse the interface show command to verify that the Ethernet interface was configured correctly:

zSH> interface showInterface Status Rd/Address Media/Dest Address IfName---------------------------------------------------------------------------1/1/1/0/ip UP 1 192.168.8.21/24 00:01:47:65:02:f2 1-1-1-0

Creating a default routeThe following example creates a default route using the gateway 192.168.8.1 with a cost of 1 (one):route add default 192.168.8.1 1

Verifying the routeUse the route show command to verify that the routes were added:

zSH> route showDest Nexthop Cost Owner------------------------------------------------------------0.0.0.0/0 192.168.8.1 1 STATICLOW192.168.8.0/24 1/1/1/0/ip 1 LOCAL

Use the ping command to verify connectivity to the default gateway:zSH> ping 192.168.8.1PING 192.168.8.1: 64 data bytes!!!!!----192.168.8.1 PING Statistics----5 packets transmitted, 5 packets receivedround-trip (ms) min/avg/max = 0/0/0

Managing the MALC


To stop the ping, press CTRL+C.

Adding a route to the remote LANAfter creating the IP interface, you might need to create a route to the remote device’s LAN interface using the route add command. The command uses the following syntax:

route add destination mask next-hop cost

For example, in the following configuration, add a route to the 192.168.10.0 network using the MALC Uplink interface as the gateway.

Figure 28: Adding a remote route to LAN

route add 192.168.10.0 255.255.255.0 192.168.8.1 1

ATM management connection

The MALC can terminate an ATM PVC and route it over an Ethernet interface for management traffic.

The following table summarizes the configuration tasks for creating an ATM management connection.

ATM

192.168.8.21 192.168.8.1192.168.10.0

Task Command

Create a traffic descriptor. See Creating the ATM traffic descriptor on page 73.

new atm-traf-descr index

Multiple connections can use the same traffic descriptors and a single VCL must use the same traffic descriptor for both transmit and receive.

Create the VCL. See Creating the ATM management VCL on page 73.

interface add interface/atm vc vpi/vci td td_index static IpAddress Netmask

This command creates the ATM VCL and the IP interface for the management PVC.

Add a route to the Ethernet interface. See Adding a default route to the ATM network on page 73.

route add destination netmask nexthop cost

This enables the MALC to route from the IP management interface to the Ethernet interface

Configuring a management interface


Creating the ATM traffic descriptorCreate a new atm-traf-descr profile and specify a unique index:

zSH> new atm-traf-descr 200Please provide the following: [q]uit.td_type: ------------- {atmNoClpNoScr}: enter traffic descriptor typetd_param1: ----------- {0}: enter PCR td_param2: ----------- {0}: enter PCR (for CLP=0 traffic) or SCRtd_param3: ----------- {0}: enter MBS td_param4: ----------- {0}: enter CDVTtd_param5: ----------- {0}:cac-divider: -------------> {1}:td_service_category: - {ubr}: rtvbr | nrtvbr | ubr | cbrtd_frame_discard: --------> {false}:usage-parameter-control: -> {true}: ....................Save new record? [s]ave, [c]hange or [q]uit: sNew record saved.

Creating the ATM management VCLThe following example configures an ATM connection with a VPI/VCI of 0/35 that uses the atm-traf-descr profile you just configured (with an index of 200). The VCL uses the Uplink interface. Refer to the CLI Reference Guide for a complete description of the command options and syntax.

zSH> interface add uplink1/atm vc 0/35 td 200 static 192.168.1.1 255.255.255.0Created ip-interface-record uplink1-0-35/ip

This command creates the ip-interface-record and the associated VCL:

zSH> list ip-interface-recordip-interface-record ethernet1/ipip-interface-record uplink1-0-35/ip2 entries found.

zSH> list atm-vclatm-vcl uplink1/atm/0/351 entry found.

Adding a default route to the ATM networkAfter adding the IP interface for management, create a default route to the ATM network:

route add default 192.168.1.254 1

Verifying the interfaceUse the interface show command to verify that the interfaces are active:

zSH> interface showInterface Status Rd/Address Media/Dest Address IfName

Managing the MALC


---------------------------------------------------------------------------------1/1/1/0/ip UP 1 192.168.8.21/24 08:00:3e:03:02:01 1-1-1-0 1/1/2/0/ip UP 1 192.168.1.1/24 0/35 uplink1-0-35---------------------------------------------------------------------------------2 interfaces

Managing the MALC with ZMS

Note: For details on using ZMS, refer to the ZMS Administrator's Guide and the NetHorizhon User's Guide.

The system profile contains parameters that configure the system contact information for the MALC and connection information for the ZMS. This profile does not need to be modified in order to manage the MALC with ZMS.

CLI provisioning and ZMSCLI configuration of a device being managed by the ZMS is disabled by default. Attempting to configure the device results in an error:zSH> update system 0

Provisioning via CLI is currently not available.

If you need to configure the device from the CLI, use the resetcliprov command.

If you plan to use a script to provision the device from the CLI while it is being managed by the ZMS:

1 Update the system profile to disable partial config syncs to ZMS:

zSH> update system 0Please provide the following: [q]uit.syscontact: ----------> {Zhone Global Services and Support 7001 Oakport Road Oakland Ca. (877) Zhone20 (946-6320) Fax (510)777-7113 [email protected]}:sysname: -------------> {Zhone MALC}:syslocation: ---------> {Oakland}:enableauthtraps: -----> {disabled}: setserialno: ---------> {0}:zmsexists: -----------> {true}: falsezmsconnectionstatus: -> {inactive}:zmsipaddress: --------> {192.168.210.28}:configsyncexists: ----> {false}:configsyncoverflow: --> {false}:configsyncpriority: --> {high}:configsyncaction: ----> {noaction}:configsyncfilename: --> {192.168.8.21_4_1014067321329}:configsyncstatus: ----> {synccomplete}:configsyncuser: ------> {cfgsync}:configsyncpasswd: ----> {}: ** private ** numshelves: ----------> {1}:shelvesarray: --------> {}:

Adding, changing and deleting card profiles


numcards: ------------> {3}:ipaddress: -----------> {192.168.8.21}: alternateipaddress: --> {0.0.0.0}:countryregion: -------> {us}:primaryclocksource: --> {0/0/0/0/0}:ringsource: ----------> {internalringsourcelabel}:revertiveclocksource: -> {true}voicebandwidthcheck: --> {false} ....................Save changes? [s]ave, [c]hange or [q]uit: sRecord updated.

2 After the provisioning is complete, perform a full config sync from ZMS.

Adding, changing and deleting card profilesThe card command enables users to add, change, update, and delete card profiles. Optional parameters are available software load filename, card group ID, linetype, line card voltage (ISDN cards only), and status. By default, new card profiles are enabled and use the system assigned software load file.

When you have physically added a card to the MALC, you will need to provision the card with software.

The card change command can be used to change a card profile settings, for example using a different card type. By default, the system validates that there is a match between the software load file and the card type. An optional parameter is available to override validation to use a software load file that does not match the card type. One use of this feature is to reuse profiles and configurations when replacing Annex A cards with Annex A/M cards. Replacement Annex A/M cards can be used as spares or backup for existing Annex A cards.

The card update command can be used to modify card-profile settings after the initial card configuration.

Refer to the Zhone CLI Reference Guide for a detailed command description

Managing the MALC



HARDWARE MAINTENANCE

This chapter describes how to maintain your MALC. It includes the following topics:

• Reading the LEDs, page 77

• Installing slot cards, page 79

• Replacing running redundant uplink cards, page 82

• Removing slot cards, page 84

• Cleaning and replacing the air filter, page 86

• Replacing fan tray, page 90

Reading the LEDsThe MALC 719 and MALC 723 system LEDs are located on the front bezel (see Figure 29 on page 77). The MALC 319 LEDs are located on the MTAC-FC card (see Figure 30 on page 78).

Figure 29: MALC 719 and MALC 723 LEDs

Hardware Maintenance


Figure 30: MALC 319 LEDs

These LEDs illuminate to reflect the most significant alarm in the system. For example, if there were five major alarms and one critical alarm in the system, only the critical LED would be lit.

Table 19 describes the MALC system LEDs.

Uplink cards and MTAC/RING card each have Active LEDs which illuminate to indicate their redundancy status. A solid green LED indicates the card is active, a blinking green LED indicates the card is standby.

The LED shows very fast green flashes when the uplink cards are between working and standby-ready modes.

Table 19: MALC system LED descriptions

LED Description

Power A (green) Bat OK A (green) (MALC 319)

ON: battery “A” voltage is within tolerance.OFF: battery “A” is not operational.

Power B (green)Bat OK B (green) (MALC 319)

ON: battery “B” voltage is within tolerance.OFF: battery “B” is not operational.

Fan fault (yellow) ON: fan tray fault has been detected.OFF: fan is operating normally.

Minor (yellow) ON: the highest alarm being reported by one or more slot cards is a minor alarm.OFF: no alarm conditions.

Major (yellow) ON: the highest alarm being reported by one or more slot cards is a major alarm. OFF: no alarm conditions.

Critical (yellow) ON: the highest alarm being reported by one or more slot cards is a critical alarm.OFF: no alarm conditions.



Table 20 describes the MALC card LEDs.

Installing slot cards This section contains the following information:

• Installation guidelines on page 79

• Installing a slot card in the MALC chassis on page 80

• Installing a slot card in the MALC 319 chassis on page 81

Installation guidelines

Observe the following rules when handling MALC slot cards:

• Handle each card by its front panel or stiffener. Never touch the solder side, connector pins, or components on a printed circuit card, and do not allow cards to come into contact with one another.

Table 20: MALC card LED descriptions

LED Description

Active (Green) ON: The card has booted properly. BLINKING: The card is booting. Each uplink card and MTAC/Ring card have Active LEDs which illuminate to indicate their redundancy status. A solid green LED indicates the card is active, a blinking green LED indicates the card is standby.For uplink cards, the Active LED should blink during POST and then remain ON after it has booted up. The LED should stop blinking after approximately 5 minutes

Fault (Yellow) ON: The card detected a hardware failure or the card is not provisioned. If the LED is ON for a provisioned card: The card need to be repaired.If the LED is ON for a standby uplink card: It indicate the standby uplink is not running, or one of the ethernet ports on the standby uplink card does not have link.

Pwr Fail ON: The card has detected a local on-board power failure. While the card may operate properly, it needs repair as soon as possible. For System power status, refer to the appropriate chassis LEDs.



• To prevent damage to slot cards when not in use, store and handle the cards in their original containers. Keep the cards in their original packing cartons to prevent damage caused by dust or dirt. Be sure to store the cards in areas that are free from excessive humidity and temperatures.

Caution: The MALC system slot cards are susceptible to electrostatic discharge (ESD). ESD can cause component failure and degraded system performance. Take adequate precautions to prevent electrostatic discharge with these cards. Always wear a properly grounded wrist strap, or equivalent protection, when handling system cards.

Note: MALC and MALC 319 use the same slot cards with the exception of the MTAC/Ring-FC card, which is only used in the MALC 319.

Installing a slot card in the MALC chassis

Note: You must install the uplink card in slot 1 or slot 2 (the 2 left-most slots).













Figure 31: Installing slot cards in the MALC

Installing a slot card in the MALC 319 chassis

Note: You must install the MTAC/Ring card in the bottom right slot.







6 Slide the card lock to the left.






Figure 32: Installing slot cards in the MALC 319

Replacing running redundant uplink cardsThis section provides the procedures about how to replace running uplink cards in a powered chassis:

• Removing a running uplink card on page 82

• Installing an uplink card on page 84

Removing a running uplink cardUse the following procedure to remove an active uplink card or a standby uplink card:

1 Before removing an uplink card, use “slot” command to verify that there are two uplink cards in the chassis, and both unplink cards are in the running state.

zSH> slotsUplinks1:*MALC FEGE RPR TDM (RUNNING)2: MALC FEGE RPR TDM (RUNNING)

Cards11: MALC POTS 48/with Packet Voice (RUNNING)15: MALC XDSL 48/with Packet Voice POTS (RUNNING) 17:*MALC MTAC (RUNNING)

Replacing running redundant uplink cards


2 Identify the active uplink card by one of these two methods:

a Look the Active LED on the uplink card faceplate.

The uplink card with the Active LED solid green is the active uplink card. The uplink card with the Active LED blinks once a second is the standby uplink card.

b Use "slots" command to identify the active uplink card. The active uplink card is marked with "*".

3 To remove a standby uplink card, proceed to Step 5.

4 To remove an active uplink card, force this uplink card to become standby by one of these two methods:

a Use the "slotreboot" command on the active uplink card to force the active uplink card become standby:

zSH> slotreboot 1The slot address and THIS card address are the same.Do you want to reboot slot 1? (yes or no) [no] yesDo you want to exit from this request? (yes or no) [yes] noAre you sure? (yes or no) [no] yes

b Use the "resethold" command on the active uplink card to disable the active uplink card. And the another uplink card will become active:

zSH> slotsUplinks 1:*MALC FEGE RPR TDM (RUNNING) 2: MALC FEGE RPR TDM (RUNNING)

Cards

11: MALC POTS 48/with Packet Voice (RUNNING)

15: MALC XDSL 48/with Packet Voice POTS (RUNNING)

17:*MALC MTAC (RUNNING)

zSH> resethold 1

The slot address and THIS card address are the same.

Do you want to reset hold slot 1? (yes or no) [no] yes

Do you want to exit from this request? (yes or no) [yes] no

Are you sure? (yes or no) [no] yes


6 Disconnect the cables from the faceplate of the standby uplink card to be removed.

7 Loosen the top and bottom screws of the standby uplink card.



8 Unscrew the top and bottom screws from the standby uplink card.

9 Push the slide lock on the bottom of the standby uplink card up.

10 Lift the top and bottom ejectors.

11 Slide the standby uplink card out.

Installing an uplink cardUse the following procedure to insert an uplink card back to chassis:


2 Holding the uplink card by its faceplate, carefully insert the uplink card into a slot 1 or slot 2. Hold the bottom ejector open and slowly slide the card onto the backplane pins.



The uplink card will not boot if the card lock is not in the down position.

5 Tighten the top and bottom screws to seat the uplink card in the backplane.

6 If step 4b “resethold” was used when removing the active uplink card, then send the "resetrelease" command so that the uplink card boots up and becomes standby.

Removing slot cardsThis section contains the following information:

• Removing a slot card from the MALC chassis on page 84

• Removing a slot card from the MALC 319 chassis on page 85

Removing a slot card from the MALC chassis1 Put on an antistatic wrist strap that touches the skin. Make sure it is

properly grounded to the ESD jack on the front of the unit.

2 Loosen the top and bottom screws of the slot card.

3 Unscrew the top and bottom screws from the card.

4 Push the slide lock on the bottom of the card up.


6 Slide the card out.

Figure 33 illustrates removing slot cards.

Removing slot cards


Figure 33: Removing slot cards

Removing a slot card from the MALC 319 chassis1 Put on an antistatic wrist strap that touches the skin. Make sure it is

properly grounded to the ESD jack on the front of the unit.

2 Loosen the top and bottom screws of the slot card.

3 Unscrew the top and bottom screws from the card.

4 Push the slide lock on the bottom of the card to the center of the unit.


6 Slide the card out.

Figure 34 illustrates removing slot cards.



Figure 34: Removing slot cards from the MALC 319 chassis

Cleaning and replacing the air filterZhone recommends you clean or replace the MALC air filter every 3 to 6 months.

Cleaning the air filterBefore cleaning the air filter, visually inspect it for damage. If the filter is damaged, replace it.

When cleaning the filter, avoid using harsh solvents or cleaning agents. Even though this type of filter may be cleaned, replacement is recommended every two to three years to ensure media durability and eliminate residual dust build-up and subsequent air flow resistance.

If the filter condition is good then, any of the following methods can be used to clean the filter:

– Vacuuming.

– Compressed air. Direct the compressed air in the opposite direction of normal air flow.

– Rinsing with cold water. Allow the filter to completely dry before reinstalling it in the MALC chassis.

Cleaning and replacing the air filter


– Soaking in warm water and mild detergent. Rinse thoroughly and allow the filter to completely dry before reinstalling it in the MALC chassis.

Removing the air filter with the cable management bracket installedReplacing the air filter requires you to temporarily remove the cable management bracket (if installed). Before performing this procedure, make sure the MALC connectors are securely fastened.


2 Carefully unscrew the cable management bracket, leaving the cables secured to the bracket.

3 Gently lift the bracket up and out until there is enough free space to remove the air filter.

Figure 35: Lifting the cable management bracket

4 Remove the bezel from the bottom of the MALC chassis by grasping both ends and gently pulling straight out.



Figure 36: Removing the front bezel

5 Remove the air filter by carefully sliding it out.

Figure 37: Removing the air filter

6 Replace the air filter.

7 Replace the front bezel.

8 Secure the cable management bracket to the installation rack.

Replacing the air filter with UP cabling1 Remove the MALC lower bezel.

2 Remove the air filter.

Cleaning and replacing the air filter


Figure 38: Removing the front bezel and air filter

3 Reinstall the air filter.

4 Replace the lower bezel.

Figure 39: Replacing the air filter and bezel



Replacing fan tray

Removing and replacing the fan tray for a MALC 723

The MALC 723 should be powered down before removing the fan tray. Power flows to the MALC through the fan tray, so removing the fan tray removes power from the unit, however, it is recommended that power be removed from the MALC, rather than by removing the fan tray.

Removing the fan tray for a MALC 7231 Remove upper activity lights facing.

2 Loosen and remove screws at either end of the upper inner facing.

3 Using thumb-pull ring, gently slide our the fan tray assembly.

Replacing the fan tray for a MALC 7231 Insert tray in the upper fan tray cavity.

2 Gently push the tray back in a even manner, so the power connector of the fan tray seats securely in the MALC chassis power connector.

The fan tray must be seated securely. As the fans are necessary to provide proper cooling all power to the MALC goes through the fan tray.

3 Reinsert screws on either end of the inner facing of the fan tray and gently tighten.

Replacing fan tray


4 Replace outer upper activity light facing.

5 Verify the fans.

Once the fan tray is installed back on the chassis, you should see the LEDs on the front powered on. Additionally you can run the CLI shelfctrl command to verify the fans are functional. The display for the shelfctrl command shows the temperature, status for fan power and fan status (shown in bold).

zSH> shelfctrl monitorShelf uptime: 1 minute

Shelf Monitor CPLD version: 0.5

Shelf Monitor Firmware version: 0.5

Outlet temperature sensor: 21 degrees C (normal)

Fan Power A: normal

Fan Power B: normal

Power Supply A: normal

Power Supply B: failure

Fan status: OK.

System: Major alarm set.

Card 1: Major alarm set.

Removing and replacing the fan tray for a MALC 719

The MALC 719 should be powered down before removing the fan tray. Power flows to the MALC through the fan tray, so removing the fan tray removes power from the unit, however, it is recommended that power be removed from the MALC, rather than by removing the fan tray.

Removing the fan tray for a MALC 7191 Loosen and remove screws at either end of the upper activity lights

facing.

2 By using firm pressure on either end of the fan tray, gently slide our the fan tray assembly.



Replacing the fan tray for a MALC 7191 Insert tray in the upper fan tray cavity.

2 By using firm pressure on either end of the fan tray, gently push the tray back in a even manner, so the power connector of the fan tray seats securely in the MALC chassis power connector.

The fan tray must be seated securely. As the fans are necessary to provide proper cooling all power to the MALC goes through the fan tray.

3 Reinsert screws on either end of the upper activity lights facing and gently tighten.

4 Verify the fans.






Fan Power A: normal

Fan Power B: normal



Fan status: OK.



Replacing fan tray


Removing and replacing fans for a MALC 319

Removing the failing fan for a MALC 3191 Remove all the cards from the MALC 319 chassis.

Zhone does not recommend performing the fan replacement on a MALC or RAPTOR 319 chassis which is populated with cards. For practical reasons, it is also necessary to remove the chassis from the rack as removing a fan requires removing the metallic skin which covers the unit.

2 Remove the screw on the sides of the chassis.



Using a screwdriver remove both screws on the side of the fan tray as indicated on the following images. There are 14 screws in the laterals and back of the chassis. It is necessary to remove all of them to lift the chassis metallic cover.

Do not discard the screws; they will be used to secure the chassis cover once the fan has been replaced.

3 Remove the metallic cover of the chassis.

Replacing fan tray


Once the screws on the side of the fan tray shelf have been removed, using both hands pull the chassis metallic cover to the side. The backplane and fans will be visible once the cover has been removed.

4 Remove the fan power connectors.

5 Remove the metal pieces securing the fan.

Using a screwdriver, remove the two screws that secure the metal plates which hold the fan in place. Once the screws have been removed, slide the metal plates to side of the rail. The fans will then be free to be removed from the fan cage.

6 Remove the failing fan.

Gently pull the fan up and remove it from the fan cage.



Replacing the fan for a MALC 3191 Insert the replacement fan.

2 Replace the metallic plates which hold the fan in place.

3 Attach the fan power connectors.

4 Replace the metallic chassis cover.

5 Replace the screws on the side of the chassis.

6 Replace the cards.

7 Verify the fans.






Fan Power A: normal

Fan Power B: normal



Fan status: OK.




INDEXA

acronyms, described 9air filter replacement, UP cabling 88air filter, replacing 87airflow, system requirements for 25alarm cables and contacts

guidelines 60specifications 60

ATM cell termination connectionadding IP route to remote LAN 72configuration 72creating ATM VCL 73creating IP interface 73defining ATM traffic descriptor 73verifying IP interface 72

ATM management connectioncreating IP interface 73

ATM traffic descriptor, definition of 73Bbackplane pins, installation of 47, 80, 81battery, safety precautions for 23Ccables

cleaning fiber optic 65installing cable management bracket 53management bracket installation 53

cables and connectorsalarm cables and contacts 60cabling guidelines 51

NEC article 800 51power lines 51

connecting OC3-c optical cables 52covers 51description 58FCC regulations 51ground minimum 42OC3-c/STM1 cables 52pinouts 62ratings 28rules 28shielded 51specifications 58

using ducts 25cabling, UP 55card command 75card profiles, adding, changing, deleting 75chassis

dedicated ground 24dimensions 26environmental specifications 26fans 26grounding and isolation 30maximum temperature 25number per rack 26operating altitude 26operating humidity 26operating temperature 26rack installation 34, 35storage altitude 26storage humidity 26storage temperature 26unpacking 32weight 26weight distribution 25

chassis dimensions 27circuit breaker, specifications 29cleaning components 65commands

ifxlate 73common return 28compliance, specifications supported 31configuration

ATM cell termination connection 72CLI disabled 74local management channel 49, 69logging in 49, 69logging out 49, 69

configuring ATM data connectionATM cell termination connection 72

configuring management interfaceaccessing the serial port 49, 69local management channel 49, 69logging in and out 49, 69

Index


connecting OC3-c optical cables 52connecting OC3-c/STM1 cables 52connecting power

power supplies 40procedure 40terminal block 40

craft interface 49, 69creating ATM VCL, description of 73creating IP interface

adding route to remote LAN 72description 73ifxlate 73specifying VPI/VCI pair 73verifying the interface 73

creating IP management interfacedescription 73

cutoff requirements 28DDC power sources 28Eelectrostatic discharge, see ESDenvironmental requirements

precautions 26specifications 26

ESDpreventing 24slot cards 24, 46, 80

Ethernet interfaceconfiguration 70creating a default route 71creating a route from management PVC to

73IP interface 70route show command 71verifying 71verifying the route 71

Ffiber

cleaning cables 65Ggrounding

acceptable conductors 25cable gauge 42conductor requirements 37dedicated 24power 25

specifications for 37system 38torque applied to connectors 42, 44two-wire power supply 30using power supply connection 26

Iinstallation

cable management bracket 53connecting power 40grounding conductors 37installing slot cards 46, 79LEDs 43mounting brackets 32, 33rack installation 34, 35removing slot cards 84, 85removing uplink cards 82unpacking the system 32

installation precautions 25airflow 25cables and connectors 25cabling ducts 25chassis weight 25environmental requirements 26grounding 26maximum temperature 25ventilation 25weight distribution 25

installing slot cardsbackplane pins 47, 80, 81description 46, 79procedure 46, 47, 80, 81

installing uplink cardsprocedure 84

IPaddresses for redundant Uplink cards 70

Llaser beam, safety precautions for 23LEDs

description 78, 79reading 43redundancy 78, 79system described 77

local management channel 49, 69logging

enabling/disabling for session 50, 70enabling/disabling over the serial craft port


50, 70logging in and out

description 49, 69logout command 49, 69timeout command 49, 69

Mmaintenance

cleaning toolkit 67replacing air filter 87

managementcreating route from management PVC to

Ethernet 73maximum temperature, precautions and 25metallic cables

alarms 58craft 58Ethernet 58G.SHDSL 58specifications 58

mounting bracketschassis 32, 33installation procedure 32, 33

Ppinouts, assignments for 62power

circuit breaker 29using jumper for single supply 41using supply for grounding 26

power connections 28power feeds 28, 29power specifications

cable ratings 28cables and connectors 28common return 28connections 28cutoff requirements 28DC power 29DC power sources 28description 29power feeds 28, 29rated current 29rated power 29system 28

preparing for installationgrounding and isolation 30installation precautions 25

safety precautions 23selecting the system location 30tools you need 30

Rrack installation

chassis 34, 35procedure 34, 35

rated current 29rated power 29redundancy

IP addresses and 70LEDs 78, 79

removing slot cards, procedure for 84, 85removing uplink cards, procedure for 82resethold command 19resetrelease command 19Ssafety

standards 23safety precautions

battery 23description 23laser beam 23

selecting the system location 30slot cards

ESD 46, 80installation 46, 79removing 84, 85storing 46, 80types supported 17

specificationschassis dimensions 27environmental 26system cables 58

storing slot cards 46, 80system

cables and connectors 51configuring management interface 49, 69environmental dimensions

chassis 26weight 26

Ethernet interface 70input power 28maximum temperature 25metallic cables 58profile

Index


updating 74system profile 74unpacking 32Uplink cards 70

system environmental dimensionschassis per rack 26fans 26operating altitude 26operating humidity 26operating temperature 26storage altitude 26storage humidity 26storage temperature 26

system input power 28Ttemperature, maximum 25terminal interface, settings for 49, 69tools for installation 30UUP cabling 55UP cabling, air filter replacment 88Uplink card

redundancy and IP addresses 70Uplink cards

configuration 70types supported 17

Uplinkstypes supported 15

Vventilation, requirements for 25ZZMS

CLI configuration disabled 74

malc 1.16.3.205 hardware installation guide

Documents