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MALC Hardware Installation Guide

MALC 723, MALC 719, and MALC 319

For software version 1.16.4

October 2012

Document Part Number: 830-00989-26

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2 MALC Hardware Installation Guide

Zhone Technologies@Zhone Way7195 Oakport StreetOakland, CA 94621USA510.777.7000www.zhone.com

[email protected]

COPYRIGHT C2000-2012 Zhone Technologies, Inc. and its licensors. All rights reserved.

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

Bitstorm, EtherXtend, EZ Touch, 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 hereofand specifically disclaims any implied warranties of merchantability, non infringement, orfitness for a particular purpose.

Further, Zhone Technologies reserves the right to revise this publication and to make changesfrom 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]:[email protected]://www.zhone.com/

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MALC Hardware Installation Guide 3

TABLEOFCONTENTS

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

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

Related documentation .............................................................................................8

Acronyms ......................................................................................................................9

Contacting Global Service and Support .............................................................10

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

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

MALC Overview .........................................................................................................13

Hardware overview ...................................................................................................16Chassis ....................................................................................................................16

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

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

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

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

Control bus ....................................................................................................... 20Supervisory bus ................................................................................................20Metallic test access bus ....................................................................................20Ring voltage bus...............................................................................................20TDM bus...........................................................................................................20Packet bus.........................................................................................................21

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Chapter 2 Instal ling the MALC ..............................................................................................23

Installation Overview ...............................................................................................23Pre-Installation Preparation ....................................................................................23Installing the MALC...............................................................................................24

General safety precautions ....................................................................................26

Safety ......................................................................................................................26Preventing electrostatic damage .............................................................................27Power supply safety information ............................................................................28

Installation precautions ..........................................................................................29

Environmental specifications ...............................................................................30

Power requirements and specifications .............................................................33Cabling rules ........................................................................................................... 33Power specifications ...............................................................................................33Chassis power consumption....................................................................................34

Grounding and isolation .........................................................................................35

Selecting the system location ...............................................................................35Tools needed .............................................................................................................36

Compliance and certif ications ..............................................................................37

Unpacking the system.............................................................................................38

Installing mounting brackets on the MALC .......................................................38

Installing the chassis in a rack .............................................................................40

Wall mount ing the MALC 319 chassis ................................................................42

Connecting power and grounding the chassis ................................................44

Installing slot cards ................................................................................................52Installation guidelines .............................................................................................52

Logging into the serial (craft) port .......................................................................55

Chapter 3 System cables and connectors .......................................................................57

Cabling guidelines....................................................................................................57

Connecting optical ATM trunking cables...........................................................58

Dressing DSL and POTS cables ...........................................................................59 Down cabling.........................................................................................................59UP line card cabling................................................................................................62

Dressing UP DSL and POTS cables.................................................................63

Cable descriptions ............................................................................................65Cable descriptions...................................................................................................65

Alarm cable and contacts guidelines ..................................................................67

Uplink card pinouts ..................................................................................................70Serial (craft) port pinouts........................................................................................70Ethernet port pinouts...............................................................................................71Redundant GigE port pinouts..................................................................................71

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Fiber optic maintenance and handling ...............................................................73Laser radiation ........................................................................................................73Handling optical fibers............................................................................................74Selecting cleaning materials ...................................................................................74

Chapter 4 Managing the MALC .............................................................................................77

Logging into the serial (craft) port .......................................................................77

Configuring a management interface..................................................................79Uplink card 10/100 BaseT Ethernet interface.........................................................79ATM management connection................................................................................81Managing the MALC with ZMS.............................................................................82

Adding, changing and deleting card pro fi les ...................................................84

Chapter 5 Hardware Maintenance........................................................................................85

Reading the LEDs .....................................................................................................85Installing slot cards ................................................................................................88

Installation guidelines .............................................................................................88

Replacing running redundant uplink cards .......................................................91

Removing s lot cards ................................................................................................93

Cleaning and replacing the air fil ter....................................................................95

Replacing fan tray ....................................................................................................99Removing and replacing the fan tray for a MALC 723 ..........................................99Removing and replacing the fan tray for a MALC 719 ........................................100Removing and replacing fans for a MALC 319....................................................102

Index ....................................................................................................................................................107

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Table of Contents


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ABOUTTHISGUIDE

This guide is intended for use by installation technicians, systemadministrators, network administrators. It explains how to install the MALCchassis and cards, but not how to provision the physical interfaces. Allconfiguration information is in the MALC Configuration Guide. Forinformation on configuring voice, data, and video services on the MALC,refer to theMALC Configuration Guide.

Style and notation conventions

The following conventions are used in this document to alert users toinformation that is instructional, warns of potential damage to systemequipment or data, and warns of potential injury or death. Carefully read andfollow 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 amplifiedinformation.

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

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

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

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About This Guide


Typographical conventions

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

Related documentation

Refer to the following publications for additional information:

MALC Configuration Guideexplains how to configure voice, data, andvideo services on the MALC.

MALC Quick Installation Instructions (for each chassis type)gives a quickoverview for installling the MALC chassis.

Zhone CLI Reference Guideexplains how to use the Zhone command lineinterface (CLI) and describes the system commands and parameters.

Refer to the release notes for software installation information and forchanges 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 (orsheets). Also used for commands, options, parameters in

body text, and user input in body text.

Fi xed Used in code examples for computer output, file names, pathnames, 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 UPPERCASE

Used for environment variables.

Command Syntax Brackets [ ] indicate optional syntax.

Vertical bar | indicates the OR symbol.

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Acronyms


Acronyms

The following acronyms are related to Zhone products and may appearthroughout this manual:

Table 1: Acronyms and their descriptions

Acronym Descr iption

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

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About This Guide


Contacting Global Service and Support

If your product is under warranty (typically one year from date of purchase)or you have a valid service contract, you can contact Global Service andSupport (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 servicecontract, 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 supportengineers who can answer questions, assist with service requests, and helptroubleshoot systems.

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

Hardware repair

If the product malfunctions, all repairs must be authorized by Zhone with aReturn 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 7to submit and track ServiceRequests (SR's)

www.zhone.com/support
mailto:[email protected]://www.zhone.com/supporthttp://www.zhone.com/supportmailto:[email protected]

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manufacturer or a Zhone-authorized agent. It is the responsibility of usersrequiring 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 berepaired.

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

Zhone will verify the warranty and provide a repair quote for anything notunder warranty. Zhone requires a purchase order or credit card forout-of-warranty fees.

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About This Guide


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MALC

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

MALC Overview, page 13

Hardware overview, page 16

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

The MALC is a next generation design Multi-Service Access Platform(MSAP) which carries voice, data and video services over multiple transportlevel 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 subscribersand upstream networking devices. The MALC aggregates local loop trafficfrom a variety of media and sends it to an upstream device, such as ATMswitch, PSTN switch, or IP router. The MALC supports edge connectiontechnologies:

ADSL

SHDSL

EFM SHDSL

VDSL

DS3/E3

T1/E1

GPON

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MALC


Active Ethernet

ISDN

POTS

Voice Gateway

MTAC

Figure 1: MALC configurations

The MALC can be deployed in Central Office environments, outdoorcabinets, 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 copperinfrastructure 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 OldTelephone Service (POTS) and Digital Subscriber Line (DSL).

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MALC Overview


System services cards such as the Metallic Test Access (MTAC) cardsprovide 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 1suggests the different types of network configurations andtrechnologies supported by the MALC.

For configuration information about network configuration options, see theMALC Configuration Guide.

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MALC


Hardware overview

This sections describes the MALC hardware, including:

Chassis on page 16

MALC uplink cards on page 17

MALC line cards on page 18

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 chassis

The 17-slot unit and the 21-slot unit are functionally equivalent, the onlydifference is the number of slots supported.

The far left slot (slot 1) is for uplink cards only. Any other type of card can beinstalled in slots 2 through 21. Cables and connectors are accessed from thefront of the chassis. Power is supplied by dual 48V DC input power. At thetop 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 thesystem, can be installed in a redundant pair to provide card-level redundancy.

Figure 2: MALC 21-slot chassis

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Hardware overview


MALC 319 chassis

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

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

The top left slot (slot 1) is reserved for uplink cards. uplink cards can onlybe 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 frontof 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 isfrom left to right. The chassis is Network Equipment Building System

(NEBS) level 3-compliant. (See Figure 3).

Figure 3: MALC 319 chassis

MALC uplink cards

Note: Only one type of uplink interface can be active in the system ata 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

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MALC


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 ADSLAnnex 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 ADSLAnnex A/M card with splitters)

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

MALC-ADSL+POTS-PKT-BCM-48B-2S (Broadcom, 2-slot, 48-portADSL 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-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 POTSsupport)

MALC-POTS-TDM-48 (48-port POTS card with TDM POTS and packetvoice support and international metering support)

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Hardware overview


MALC-POTS-TDM/PKT-48 (48-port POTS card with TDM POTS andpacket 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)

Act ive Ethernet

MALC-ACTIVE-ETH-FE/GE-10 (1 port card supports Ethernet trafficover 10 SFPs that provide 10/100/1000 Base-T, fiber 100FX or GigabitEthernet interfaces)

ISDN

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

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

MTAC

MALC-MTAC/RING (Metallic Test Access card with including testaccess)

MALC-MTAC/RING-ENH (Metallic Test Access card with ringinggenerator)

MALC-MTAC/RING-FC (Metallic Test Access card with fan controller

and ringing generator). Supported on the MALC 319 only.

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MALC


Resetting cards

The resetholdand resetreleasecommands are available to place a card onhold in the system configuration, while the card is still in the MALC chassis.These commands may be used for diagnostic requirements when a cardconfiguration should be placed on hold while the physical card remains inthe chassis.

Refer to theZhone CLI Reference Guidefor a detailed command description

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 bus

This bus is used for program loading and high-level message transfer betweenMALC cards.

Supervisory bus

This bus is used by the active uplink cards for low-level control andmonitoring of the other cards.

Metallic test access bus

The metallic test access bus is used by the MTAC card to gain access to cardsand the buses in the system.

Ring voltage bus

The ring voltage bus provides ringing voltage to the cards, such as the POTScard, that require it. The MTAC card generates the ringing voltage andcontrols access to the ring voltage bus.

TDM bus

The 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 theTDM-to-GR-303 and TDM to ATM conversions to send the TDM data to the

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Hardware overview


Class 5 switch or ATM network. Each TDM channel on the bus is assigned toa fixed channel on a POTS card. VoIP signals do not use the TDM bus.

Packet bus

The 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 packetprocessors capable of forwarding bridged or routed frames at 5 Gbps as well.

Each card has full access to the backplane of 5 Gbps.

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MALC


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INSTALLINGTHEMALC

This chapter explains how to install the MALC hardware.

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

Pre-Installation Preparation, page 23

Installing the MALC, page 24

Note: Before installing the MALC, read General safety precautionson page 26for important safety and power information.

Installation Overview

Before installing the MALC you should read the pre-installation preparationsfor important safety, power and environmental precautions and have anunderstanding of the installation procedures.

Pre-Installation Preparation

Important pre-installation steps include:

General safety precautions, page 26

Installation precautions, page 29

Environmental specifications, page 30

Power requirements and specifications, page 33

Power specifications, page 33

Grounding and isolation, page 35

Selecting the system location, page 35 Tools needed, page 36

Cabling rules, page 33

Compliance and certifications, page 37

Unpacking the system, page 38

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Installing the MALC


Installing the MALC

Before installing the MALC, please read through the following overview as itwill take you from a chassis just out of the box through installing andverifying the uplink and line cards. Once you have completed the installationsteps described below, proceed to the MALC Configuration Guide toconfigure the software which runs the MALC.

Installation overview

1 Install the MALC Chassis

Note: You may mount a MALC 319 to a wall, please see Wallmounting the MALC 319 chassis, page 42.

a Install rack mount ears

Installing mounting brackets on the MALC on page 38

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 40

d Secure the chassis to the mounting rack.

2 Connect power and provide ground

Connecting power and grounding the chassis on page 44

3 Install uplink and line cards

Installing slot cards on page 52

4 Conduct visual hardware verification tests

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

b Does the uplink cards green active light blink, then stay on solid?

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

5 Conduct out of band management tests

a Logging into the serial (craft) port on page 55

bIn 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 frompower lines. If the MALC is installed in an inside plant, the cablesmust be shielded and grounded at both ends.

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Installation Overview


b Use Zhone cable mounting brackets where appropriate. Follow theguidelines outlined in Cabling guidelines on page 57

7 Provision the MALC

a Add card profiles for cards to be provisioned.

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

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Installing the MALC


General safety precautions

The equipment is designed and manufactured in compliance with thefollowing 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 asfollows:

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

manufacturers instructions.

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

Caution: Current limiting protectors

The MALC is intended to be protected by 3-mil carbon blocks andcurrent limiting protectors with a continuous carry current rating of350 milliamperes. The current limiting protectors must be applied onthe equipment side of the voltage limiting protector.

Read and follow all warning notices and instructions marked on theproduct 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 arespecifically designed for this purpose only.

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

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 orother risks and may result in injury or damage to the unit and void allwarranties.

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

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General safety precautions


Slots and openings in the product are provided for ventilation. To ensurereliable operation of the product and to protect it from overheating, theseslots and openings must not be blocked or covered.

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

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

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

A rare phenomenon can create a voltage potential between the earthgrounds of two or more buildings. If products installed in separate

buildings are interconnected, the voltage potential may cause a hazardouscondition. Consult a qualified electrical consultant to determine whether

or not this phenomenon exists and, if necessary, implement correctiveaction prior to interconnecting the product.

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

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

Preventing electrostatic damage

The system slot cards are susceptible to electrostatic discharge (ESD). ESDcan cause component failure and degraded system performance. Takeadequate precautions to prevent electrostatic discharge (ESD) with thesecards. Always wear a properly-grounded wrist strap or equivalent protectionwhen 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 allowcards to come into contact with one another.

To prevent damage to system cards when not in use, store and handle thecards in their original antistatic bags. Keep the cards in their original packingcartons to prevent damage caused by dust or dirt. Be sure to store the cards in

areas that are free from excessive humidity and temperatures.

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Installing the MALC


Power supply safety information

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

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Installation precautions


Installation precautions

Avoid creating a hazardous condition by maintaining even weight distributionwithin the chassis.

WARNING! Two people are required to lift the MALC 719 or

MALC 723 systems because they weigh too much for one personto 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 whencreating intra-building connections.

WARNING! The intra-building port(s) of the equipment orsubassembly 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). Thetemperature of the rack environment may be greater than ambient roomtemperature when the system is installed in a closed or multiunit rackassembly. Observe the maximum recommended operating temperature asindicated here.

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

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

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 mountingbrackets, and damaging the system, do not use the MALC chassis to supportother 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 powersupply connections for grounding instead of branch circuitry (such as powerstrips).

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Environmental specifications

Table 2describes the MALC chassis environmental specifications.

Figure 4 on page 31and Figure 5 on page 31show the MALC chassisdimensions.

Table 2: MALC chassis environmental specifications

Description Specification

Chassis dimensions MALC 723

23 in. (58.42 cm) wide by 12.25 in. (31.12 cm) high(7U) by 11.625 in. (29.53 cm) deep.

MALC 719


MALC 319


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 relativehumidity

5% to 95% noncondensing

Storage relativehumidity

Up to 95% noncondensing

Altitude Operating altitude: Up to 4,000 m (13,123 ft.)Airflow MALC 319: Left to right

MALC 719 and MALC 723: Bottom front to top rear.

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Environmental specifications


Figure 4: MALC 19-inch chassis dimensions

Figure 5: MALC 23-inch chassis dimensions

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Figure 6: MALC 319 chassis dimensions

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Power requirements and specifications


Power requirements and specifications

Separate A and B power feeds allow two individual 48V DC power sourcesto be connected to the MALC system. The Return (+) terminals arecommon.For the 19- and 23-inch MALC chassis, the power wiring isfield-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, suchas 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 anexternal, auxiliary, or emergency source. When power is routed from a

power distribution frame, the disconnect device can be used as a powercutoff (for example, an ON/OFF switch or breaker).

Connect all disconnect devices so that they disconnect all ungroundedconductors 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 lessfrom the central power distribution bus.

Power specifications

Table 3describes the MALC power specifications.

Table 3: MALC power supply specifications


Rated voltage -41.75V to -60.0V DC

Separate 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 maximum

MALC 319: 16A maximum

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Installing the MALC


Chassis power consumption

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

DC-input cable AWG 10 (5.27 mm2) maximum

Listed circuit breaker or

fuse

MALC: 30 A maximum

MALC 319: 20 A maximum

A listed circuit breaker or fuse must be installed from acentral DC power source and wired in accordance with

NEC, ANSI/NFPA 70 and Canadian electrical code,Part 1, C22.1.

Table 3: MALC power supply specifications


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, thechassis draws 31 watts maximum with noringing, 45 watts maximum at fullringing load.

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Grounding and isolation


Grounding and isolation

The MALC system cards and subassemblies use an integrated frame and logicground 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 groundingthe chassis, page 44.

Selecting the system location

Ensure that the environment is free of dust and excessive moisture, notexposed to the elements or temperature extremes, and has sufficient

ventilation.Install the system in reasonable proximity to all equipment with which it willconnect. Ensure that proper cable grades are used for all system and networkconnections. For best results, use the cables and connectors recommended inthis document.

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Installing the MALC


Tools needed

The required equipment listed in Table 5should be available before beginningthe installation of the MALC system.

Table 5: Equipment requi red to install the MALC system

Qty Equipment Details Use

1 Mounting shelf or rack,19 or 23 inch width asrequired.

Powered as indicated in attachedspecifications.

MALC chassis mounting

1 VT-100-compatibleterminal or PC used as aVT-100 terminal emulator

Connected to the MALC through RJ45craft 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

2 #1 and #2 Phillips-headand 1/8-inch flat-bladescrewdrivers

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

brackets

2 Antistatic wrist strap N/A Static electricity prevention

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Compliance and certifications


Compliance and certifications

Table 6: Compliance and certif ications

NEBS Specification

Safety ACA TS001

AS/NZS 3260

CB Report

CSA 22.2 No. 950

EN 60950

IEC 60950

UL 60950

EMC emissions FCC Part 15 Class A

GR-1089-Core Level 3

CE EN55022A

EMC immunity GR-1089-Core Level 3

CE EN55024

CE EN 50082

Environmental GR-63-Core Level 3

ETS 300 019-2-x

ISTA Transportation and Handling

Network FCC Part 68

CTR-12

CTR-13DOC CS-03

NTR-4

TSO-16

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Unpacking the system

Use the following procedure to unpack the MALC system components fromthe 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 shippingcompany to file a claim.

The shipping company representative will give instructions on how to submita claim, where to send the unit, and any special instructions that may berequired.

If you need to return the equipment, pack the equipment in its originalpacking materials and send it by prepaid freight to the address given by theclaims representative. If the original packing materials are unavailable, shipthe 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 toshipping pallet. When unpacking the unit, remove the bottom twoscrews that secure the shipping bracket to the rack ears and replacethem 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 onpage 38

Installing the mounting brackets onto the MALC 319 system chassis onpage 39

Installing the mounting brackets onto the MALC systemchassis

The MALC mounting brackets are designed for use in a 19-inch or 23-inchrack. Use the following procedure to install the mounting brackets onto thesystem chassis:

1Carefully place the system chassis right side up and facing forward on aclean, 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 chassisalign with the 4 screw holes in the bracket.

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Installing mounting brackets on the MALC


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

3 Secure the two brackets to both sides of the system chassis with thescrews provided in the installation kit. See Figure 7 on page 41.

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

Installing the mount ing brackets onto the MALC 319 systemchassis

The MALC 319 mounting brackets are designed for use in a 19-inch rack.Use the following procedure to install the mounting brackets onto the systemchassis:

1 Carefully place the system chassis right side up and facing forward on aclean, 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 chassisalign with the 4 screw holes in the bracket.

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



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Installing the MALC


Installing the chassis in a rack


Mounting the MALC system chassis in a rack on page 40

Mounting the MALC 319 system chassis in a rack on page 41

Mounting the MALC system chassis in a rack

The system chassis can be mounted in a 19-inch or 23-inch rack that isconnected to an earth ground.

WARNING! Two people are required to pick up the systembecause 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 systemfacing outward.

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

Note: Use a 12-24 UNC x 0.5-inch screw when mounting thesystem to the rack. Using the wrong screw type will result in a

poorly-secured system. These screws are provided in theinstallation kit.

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Installing the chassis in a rack


Figure 7: Installing the MALC in a rack

Mounting the MALC 319 system chassis in a rack

The system chassis can be mounted in a 19-inch rack that is connected to anearth ground. Use the following procedure to mount the system chassis in arack:

1 Choose a rack position for the system chassis.

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

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

Note: Use a 12-24 UNC x 0.5-inch screw when mounting thesystem to the rack. Using the wrong screw type will result in a

poorly-secured system. These screws are provided in theinstallation kit.

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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 systembecause 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 chassis

1 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 unitand 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 thebrackets to the unit. Using the wrong screw type will result in apoorly-secured system. These screws are provided in theinstallation kit.



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

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Wall mounting the MALC 319 chassis


Figure 9: Wall mounting the MALC 319 chassis

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

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Installing the MALC


Connecting power and grounding the chassis


Grounding requirements on page 44

Connecting power to the MALC and grounding the chassis on page 46

Connecting power to the MALC 319 and grounding the chassis onpage 49

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

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

Grounding requirements

Use the guidelines in this section to provide a system ground for theMALC.

Before concluding a MALC installation and applying DC power, measurethe impedance of the building ground reference and ensure that it is lessthan 25 ohms, for safety. Use an ECOS 1023 POW-R-MATE or an EMC

Instrument Model 3710 or similar meter to do this. Zhone recommendsthat the impedance be 1 ohm or less for proper equipment operation.

If the ground path connected to the MALC has an impedance of morethan 1 ohm, make improvements to the grounding system beforeinstalling 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 andrequirements. 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 isolatedbonding network (IBN)-configured equipment to provide power tothe MALC and all other related equipment. This prevents interferencefrom possible high surge or noise currents present in some industrial

buildings. Otherwise, you must ensure a proper grounding path ofless than 1ohms to the building ground.

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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 buildingground 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 than0.25 ohms.

The rack the MALC is installed in must be properly grounded. Toverify proper grounding of the rack and the chassis to the rack, pleasesee Verifying proper grounding between the chassis and the rack,

page 51.

Never connect a single-point-ground conductor from the MALC tostructural steel members or electrical conduits. Specifically, never tiethis conductor to a ground source or grounded electrode that is nothard-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 suchas transformers.

Avoid spliced conductors. Use continuous conductors, which havelower impedance and are more reliable than spliced ones.

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

purposes.

Tag ground connections clearly with a message such as CRITICALCONNECTION: DO NOT REMOVE OR DISCONNECT.

Although some electrical codes permit the use of a conduit as the soleground conductor between equipment, it is still recommended to use aseparate insulated ground conductor through the same conduit. Theseparate insulated ground conductor maintains the safety groundconnection if the conduit is corroded or disconnected.

Avoid a ground path via serial craft interface RS-232C. The MALCRS-232C local craft interface has pins referenced to ground. To

prevent undesirable ground path via an attached computer, it isrecommended that you only use a portable computer. If only adesktop 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 cardspresent.

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.

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Installing the MALC


Must be tied to the +48V battery return at the main powerDistribution Center. Absence of this connection can causemalfunctions on some cards, including generation of theMALC-MTAC/RINGER-ENH card error message Internal ringernot detected.

Should be hardwired to the main ground reference.

Connecting power to the MALC and grounding the chassis

Use the following procedure to connect the wiring between the MALCterminal 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 thechassis 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 sideof the chassis.

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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 toloosen.

Note: If the MALC is installed so that the thread hole on the sideof the unit is inaccessible, thread the power supply and groundingcables 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 markedVA.

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

9 Connect the negative wire from power supply B to the terminal markedVB.

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

Note: If using a single power source, place jumpers betweenterminals VA and VB.

ma0220

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Installing the MALC


11 Reinstall the terminal block into the chassis.

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 AWGframe ground collector that connects to the single point building groundin an IBN. Ensure that there are no sharp bends in the conductors and thatthey 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 theconductor.

15 Attach the ground lug with two hex bolts to the grounding lugs, as shownin Figure 14 on page 49.

16 Secure the hex bolts to the chassis.

17 To verify proper grounding, please see Verifying proper groundingbetween the chassis and the rack, page 51.

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

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

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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 areinstalled. 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 solidgreen, indicating power is normal. For information on the chassis LEDs, seeReading the LEDs on page 85.

Connecting power to the MALC 319 and grounding thechassis

The MALC 319 comes with 10 AWG power cables pre-installed. To connectthe 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 positiveterminal.

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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 positiveterminal.

5 Route a 10 AWG conductor from each chassis to a common 2 AWGframe ground collector that connects to the single point building ground

in an IBN. Ensure that there are no sharp bends in the conductors and thatthey 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 acompression-type connector. See Figure 16.

7 To verify proper grounding, please see Verifying proper groundingbetween the chassis and the rack, page 51.

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

8 Connect the ground cable(s) routed in Step 5and tighten the bolt. Use aminimum torque of 12 inch-lbs to ensure that the grounding cable issecurely 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. Usea minimum torque of 12 inch-lbs to ensure that the grounding cable issecurely 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 areinstalled.

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Verifying proper grounding between the chassis and therack

Proper grounding reduces the effect of line surges and limits the voltages andRF interference that may affect communication among network devices.

1 Test the impedance from the grounding cable or bar (point 1 in thegraphic) 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 thegrounding rack.

The impedance must be less than 0.25 ohms.

1

2

3

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Installing the MALC


Installing slot cards


Installation guidelines on page 52

Installing a slot card in the MALC chassis on page 52

Installing a slot card in the MALC 319 chassis on page 53

Installation guidelines

Observe the following rules when handling MALC slot cards:

Handle each card by its front panel or stiffener. Never touch the solderside, connector pins, or components on a printed circuit card, and do notallow 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 packingcartons to prevent damage caused by dust or dirt. Be sure to store thecards in areas that are free from excessive humidity and temperatures.

Caution: The MALC system slot cards are susceptible toelectrostatic discharge (ESD). ESD can cause component failure anddegraded system performance. Take adequate precautions to preventelectrostatic discharge with these cards. Always wear a properlygrounded wrist strap, or equivalent protection, when handling systemcards.

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

Installing a slot card in the MALC chassis

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

1 Put on an antistatic wrist strap that touches the skin. Make sure it isproperly 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 theparticular application.

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

5 Close the bottom ejector to firmly seat the card.

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Installing slot cards


Caution: To prevent damage to the backplane pins, do not forcecards onto the backplane pins when seating the cards. If you havetrouble seating a card, check that it is in the correct slot, pull thecard 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 17illustrates 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.

1 Put on an antistatic wrist strap that touches the skin. Make sure it isproperly 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 onthe 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. Holdthe bottom ejector open and slowly slide the card onto the backplane pins.

5 Close the bottom ejector to firmly seat the card.

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

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Installing the MALC


6 Slide the card lock to the left.

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 17illustrates installing slot cards.

Figure 18: Installing slo t cards in the MALC 319

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Logging into the serial (craft) port


Logging into the serial (craft) port

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

The MALC unit provides an out-of-band RS232 D serial (craft) interface formanaging the unit. To access the serial port, configure your terminal interfacesoftware 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 thers232-profile.

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

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

port.

Logging in and out of the system

Log into the system (the default user name is admin, the default passwordis zhone):

l ogi n: adminpassword:zSH>

To log out of the system, enter the logoutcommand:

zSh> logout

Tip: The system automatically logs you out after a period ofinactivity. The default logout time is 10 minutes, but can be changedwith the timeoutcommand. Refer to theZhone CLI Reference Guidefor information on the timeoutcommand.

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Installing the MALC


Enabling and disabling logging

By default logging is enabled on the serial craft port and disabled overtelnet sessions. To enable or disable logging for the session, using thefollowing command:

zSh> log session on | off

The log sessioncommand only applies to the current session. You canalso enable or disable logging for all serial craft port sessions using thefollowing command:

zSh> log serial on | off

This command setting persists across system reboots.

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SYSTEMCABLESANDCONNECTORS

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

Cabling guidelines, page 57

Connecting optical ATM trunking cables, page 58

Dressing DSL and POTS cables, page 59

Securing amphenol connectors, page 64

Cable descriptions, page 65

Alarm cable and contacts guidelines, page 67

Uplink card pinouts, page 70

Fiber optic maintenance and handling, page 73

Cabling guidelines

To 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 beaccomplished 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 mustbe shielded. If you intend to install cable covers, the maximum heightof the connector head and cable should be two inches.

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

MALC system connectors are located in the front of the chassis. Nocables are included with the installation kit. You must order any

cables that are required.

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System cables and connectors


Connecting optical ATM trunking cables

WARNING! 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 anddoes 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 orremoving cables

Ensure that the protective rubber tips cover the SC connectorswhen not in use

Never look directly into the optical ports

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

2. Remove the protective rubber tips from the SC connectors on one end ofthe 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 uplinkcard.

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

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

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Dressing DSL and POTS cables



Cables can be mounted so that they are placed in a down or up position. Use50-pin connectors to connect the DSL and POTS cards.

Down cabling

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

Figure 19: Dressing MALC cables

The optional cable management bracket can be installed to facilitate installingand managing cables. See Figure 20 on page 60.

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Figure 20: Installing the cable management bracket

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

Figure 21: Installing bracket clip

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To remove the connectors from a card, remove the top portion of theconnector, then gently rock the bottom portion of the connector until its freedfrom the clip. See Figure 22.

Figure 22: Removing connectors

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UP line card cabl ing

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

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




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Dressing UP DSL and POTS cables

Use 96-pin connectors to connect the ADSL-48 cards, POTS-48, andADSL-POTS Combo cards. Dress the cables to the side of the unit. SeeFigure 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 theconnector, then gently rock the bottom portion of the connector until its freedfrom the clip. See Figure 22.

Figure 25: Removing connectors

Securing amphenol connectors

The MALC accessory kit contains tie-wraps, tie-wrap holders, and screwsthat can be optionally used to secure Amphenol connectors to MALC cards.See Figure 26 on page 65.

Securing the Amphenol connectors

1 Remove one of the hexagonal standoffs from the slot card connector.

2 Install the tie-wrap holder into the space where the hexagonal standoff hasbeen 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 bylooping a tie-wrap through the tie-wrap holder and around the Amphenolconnector.

6 Fasten the tie-wrap.

ma0706

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Figure 26: Securing 50-pin Amphenol connectors

Cable descriptions

Table 8lists specifications for the cables used with the MALC system. Forpinout information for these cables, refer to the chapters for each card, later inthis manual.

Cable descriptions

Table 8lists specifications for the cables used with the MALC system. Forpinout information for these cables, refer to the chapters for each card, later inthis manual.

Table 7: Summary of cable specifications

Cable description Interfaces the MALC to Cable type Connector type

Upward cabling forADSL-48 and

POTS-48 subscribers

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

Molex 96-pin connector

Table 8: Summary of cable specifications


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

Female 64-pin amphenol.

ADSL subscribermulti-connector

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

Three Female 64-pinamphenol.

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Chassis alarms Alarm relay contact on chassis(MALC 723 or MALC 719)

Alarm relay contact on MTAC/Ring-FC card

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

recommended

Blank wire in to screwterminals.

DSL, POTS, orISDN subscriber

DSL, POTS, or ISDN connectorson line cards

25 pair Category 2, 3, 4or 5

Male 50-pin amphenol.

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

Management (serialcraft port)

RS-232D connector on uplinkcard.

4-wire minimum26 AWG (0.4 mm)

RJ45 plug

MTAC/Ring BITS External BITS clock Standard T1 4-wirecable

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/Ringexternal ringer

External ring generator on MTAC/Ring card

22 AWG (0.6 mm) Screw terminals

MTAC/Ringexternal test access

External test access connector onMTAC/Ring card

2-wire or 4-wire(depending on the test

being run). Minimum26 AWG (0.4 mm)

RJ45 plug

Optical trunk cir-

cuits

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

Square Connector (SC)

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

32-pair Category 2, 3, 4or 5

128 pin telco connector.

TDM T1/E1 connector on theVoice Gateway card(redundant)

32-pair Category 2, 3, 4or 5

128 pin telco connector.

Table 8: Summary of cable specifications (Continued)


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Alarm cable and contacts guidelines



The MALC 719 and MALC 723 chassis alarms are located in the lower left ofthe 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 andalarm relay contacts are as follows:

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

braided shielding.

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

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

Note: Temperature alarms appear in Farenheit (F), while theshelfctrl 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

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Power Threshold (powerout 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)


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)


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 isprovisioned, or if the clock source is currently

provisioned as secondary source)

T1/E1 threshold Minor

Table 9: System alarms

Event Type of alarm

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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)


BITS clock Up/D

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830-00989-26_Malc hardware