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Network Equipment Compliance and Installation Challenges

Network Equipment Compliance and Installation Challenges. Robert E. Fuller Lead Member of Technical Staff AT&T Labs October 2014. Topics. Lead Free Solder/RoHS 6/6 Compliance Thermal Management, Airflow Requirements, Impacts, and Solutions Cable Management Power Distribution

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Network Equipment Compliance and Installation Challenges

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  1. Network EquipmentCompliance and Installation Challenges • Robert E. FullerLead Member of Technical StaffAT&T Labs • October 2014

  2. Topics • Lead Free Solder/RoHS 6/6 Compliance • Thermal Management, Airflow Requirements, Impacts, and Solutions • Cable Management • Power Distribution • Equipment Size and Weight

  3. Lead Free Solder/RoHS 6/6 Compliance Challenges • Industry concerns about solder joint reliability in lead free products remain • EU Exemption expires July 2016 • Vendors need to provide clear understanding of • what products are currently compliant, what will be discontinued, and what will be re-designed to be compliant • The impacts on sparing and maintenance procedures

  4. Topics • Lead Free Solder/RoHS 6/6 Compliance • Thermal Management, Airflow Requirements, Impacts, and Solutions • Cable Management • Power Distribution • Equipment Size and Weight

  5. Thermal Management, Air Flow Requirements, Impact, and Solutions • Heat and Power Estimation - Manufacturer’s Specified Heat Values vs. Actual Measured Values. • Cooling the Chassis – Difficult to air cool equipment beyond 20 – 25 KW heat loads within acoustic noise limits. Trade off: air flow vs. electronics. • Removing the Heat – How to cool and re-circulate the hot exhaust air from air cooled equipment. Older building are not designed for high heat loads. • Improving PUE (Power Usage Effectiveness) • AT&T Standards

  6. Heat and Power Estimation • Challenges of Heat and Power estimation • Manufacturer’s Specified Heat Values vs. Actual Measured Values • Results reporting Requirements • AT&T ESP (Engineering and Space Planning) Form – Requires separate and distinct values for Nominal and Maximum • Part specific values (e.g., chassis, cards, etc.) • ATIS (Alliance for Telecommunications Industry Solutions)– Charts heat and power at 0, 25%, 50%, 75%, 100% (max) equipmentutilization • System total values (measured, calculated or estimated)

  7. Cooling The Chassis • Air Cooling: Difficult to air cool equipment beyond 20 – 25 KW heat loads within acoustic noise limits, power, air impedance (rear door, grill, etc. issues), high speed exhaust. Chassis design trade off: air flow vs. electronics. • Liquid cooling (submersive, direct contact) • Hybrid: Air cooling with liquid cooling to hottest components

  8. Removing the Heat:Efficiency Improvements • Increased hot/cold aisle temperature gradient leads to greater cooling efficiency. This can be achieved by: • Consistent front to rear airflow • In cabinet hot/cold isolation • Hot or cold aisle containment

  9. Consistent Airflow: Typical Solution for Side Airflow Chassis Airflow Redirector - Plenum

  10. Consistent Airflow: Typical Solution for Fuse Panels Heat Ramp Rear View Front View

  11. Cabinet Modifications:Hot/Cold Aisle Isolation Filler panels, top air blocking panel, silicon pass-through inserts, foam inserts

  12. Cabinet Modifications: Top Panel Isolation Top panel brush and cover plate kit

  13. Hot/Cold Aisle Containment • “Bathtub” Solutions • Can be hot or cold aisle isolation depending upon the particular cooling infrastructure • 3 sided containment • 5 sided containment

  14. Hot/Cold Aisle Containment • All distributed cooling systems require containment to effectively separate the supply and return air. Containment increase the temperature gradient (delta T) between these air masses by reducing mixing of supply and return air.

  15. Hot/Cold Aisle Containment • Three sided containment will provide 70% effectiveness in separating supply and return air.

  16. Hot/Cold Aisle Containment Five sided containment will provide 96% effectiveness in separating supply and return air. It is not necessary to provide difficult top containment to get significant results from adding containment to equipment areas.

  17. Aisle Containment Installation Challenges Aisle Containment in Partial Cabinet Line-Ups

  18. Aisle Containment Installation Challenges • Containment Doors and Panels

  19. Distributed Refrigerant Cooling(DRC) • DRC Solutions • In row cooling - requires hot/cold aisle separation • Back of cabinet cooling • DRC direct to equipment

  20. Distributed Cooling Installation Challenges • Equipment may not have the necessary airflow to support passive rear door coolers nor air flow re-directors to push air down and to the sides to in-row cooler intakes. Small, high speed exhaust outlets compound the problems. • Possible solutions include active doors (not currently commercially available), placing in-row coolers in adjacent aisles directly behind the equipment, or making aisle space into a giant in-row cooler plenum.

  21. Economization • Economization is using the natural exterior temperature as a cooling source and is becoming a requirement for all cooling systems. • The key to effective “Economization” is to increase supply air temperatures modestly and drive return air temperatures as high as possible to allow for the greatest window of “economization hours” in any climate. • Economization can be done with heat exchangers to address air quality concerns or may be done with direct air exchange. • The use of “Economization” and “Containment” will generate an average 40% improvement of PUE in a mild climate. Cool climates will see a greater savings while warm climate will see less but still significant savings.

  22. AT&T Thermal Standard • AT&T’s Thermal Standard is ATT-812-000-705. The standard details traditional cooling systems, raised floor systems, DRC systems, multiple containment strategies, economization and thermal management space solutions. • A support document numbered ATT-812-000-705 ANNEX has been created to discuss and illustrate manufacture specific solutions and products in support of ATT-812-000-705. • AT&T’s Thermal Standards are proprietary documents and require approval for access.

  23. Topics • Lead Free Solder/RoHS 6/6 Compliance • Thermal Management, Airflow Requirements, Impacts, and Solutions • Cable Management • Power Distribution • Equipment Size and Weight

  24. Cable Management Challenges • Office cable racking and chassis cable management are size constrained • Typical cable types are cat 5/6 cable and 1.6/2.0 mm breakouts/jumpers • Fiber cable management may not accommodate fiber drip loops • Chassis may support up to 600 cat 5/6 or 1000 individual fiber ports (2000 strands) • High density MPO connectors used to increase port density require the use of breakout cables to the optical distribution frame • Rack mount equipment may not have any vertical cable management • Large quantities of cat 5/6 require custom cable management • Large quantities of fiber are difficult to house in vertical FPS • Distribution cable with 900 micron fiber used on front is upjacketed to 2.0 mm • Breakout cable uses 1.6mm cordage end-to-end • Smaller within bay, but more costly and takes more rack space

  25. Cat 5/6 UTP Less congestion on card faces, in equipment and rack cable managers, and in overhead ladder racking leading to lower installation costs and improved ease of maintenance “Thin” versions of Cat 6 cable are approximately 20% smaller, 10% lighter, and more flexible than standard Cat 6 cable

  26. Fiber Initiatives – 1.2 mm Jumpers (Simplex and Duplex) Fiber Cordage Used to Manufacture Jumpers 3.0mm, 2.0mm, 1.6mm, 1.2mm simplex BIF cordage 3.0mm, 2.0mm, 1.2mm duplex BIF cordage

  27. Fiber Initiatives – 1.2 mm Jumpers (Simplex and Duplex) 1.2 mm jumpers are 44% smaller than 1.6mm jumpers = 1.5 times more fibers in the same space 1.2 mm jumpers are 64% smaller than 2.0 mm jumpers = 2.8 times more fibers in the same space 72 fibers 72 fibers 1.2 mm 1.6mm Both 1.2mm simplex (shown) and duplex jumpers successfully trialed in AT&T network and now in production use

  28. Fiber Initiatives – 1.2 mm Breakout Cable Currently 1.6mm breakout cable is used when 900 micron distribution cable up-jacketed to 2.0 mm is too large • 1.2mm 12 fiber breakout cable • Penalty: 40% larger than 900 micron for 72 count cable • 1.6mm 12 fiber breakout cable • Penalty: 80% larger than 900 micron for 72 count cable 1.2 mm is 42% smaller, 30% lighter than 1.6mm and allows 2.8X more 1.2 mm fibers in the same space than 2.0 mm up-jacketed fiber

  29. Fiber Initiatives – 96 Strand Micro-Cables Eight subgroups each with twelve 250 micron fibers

  30. Fiber Initiatives – Backbone Micro Cables Prototype 72f Micro Cable – 250 micron fiber: 7.2 mm Diameter 12f 1.2mm Breakout Cable: 6.4 mm Diameter 12f 1.6mm Breakout Cable: 7.6 mm Diameter 72f Distribution Cable – 900 micron fiber 18.5mm dia.: 6.6x cross-sectional area of microcable 72f Breakout Cable – 1.2mm fiber 22.0mm dia.: 9x cross-sectional area of microcable 72f Breakout Cable – 1.6mm fiber 24.9mm dia.: 12x cross-sectional area of microcable

  31. Fiber Initiatives – MPO Connectors • Used to increase density and versatility of physical ports compared to SC and LC connectors • High density low speed (1 GE) ports where card faceplate does not have sufficient room for LC connectors • 10 x 10 GE CFP in 100 GE “electrical” port adds versatility and reduces costs for composite 100 GE signal compared to full 100GE • 2 x 4 x 10GE in 100 GE “electrical” port adds versatility and reduces costs for composite 40 GE signal compared to full 40GE

  32. Fiber Challenges – MPO Pin Outs

  33. Fiber Challenges – MPO Pin Outs

  34. Fiber Challenges – MPO Pin Outs Back to back roll over cable Receive Receive 1 1 10 10 10 1 10 1 Transmit Transmit OR Back to back hybrid cable Back to back cross over cable 10 x 10GE

  35. Fiber Challenges – MPO Pin Outs 1 1 10 10 Receive Receive OR Transmit Transmit 10 1 10 1 10 x 10GE

  36. Fiber Challenges – MPO Pin Outs 4 1 Receive Receive 1 4 4 1 1 4 Transmit Transmit 2 x 4 x 10GE 1 4 4 4 1 1 4 1 4 x 10GE 4 x 10GE Legs are a straight and roll over cable variant

  37. Fiber Challenges – MPO Pin Outs Receive Receive 1 1 12 12 1 12 1 12 Transmit Transmit OR 8 x 12 x 1GE (e.g. 96 port 1 GE card)

  38. Fiber Challenges – MPO Pin Outs OR Receive 1 12 1 12 Transmit 4 5 3 2 2 5 3 4 OR ???

  39. MPO Cable and Connector Challenges Cable and breakout must be compatible with chassis cable management, FPS, and rack installations Optics “Pin outs” vary by manufacturer Connector numbering varies by manufacturer KEY MP01 MPO13 MPO14 MPO2 MPO3 B1 MPO15 B2 MPO16 MPO4 B3 MPO17 MPO5 A4 B4 MPO18 MPO6 A5 B5 MPO19 MPO7 B6 MPO20 MPO8 B7 MPO21 MPO9 B8 MPO22 MPO10 B9 MPO23 MPO11 MPO24 MPO12 B11 LOWER ROW UPPER ROW

  40. Fiber Challenges – MPO Breakout Cables to LGX • Pin outs can vary for the same size and speed connector and will vary for same size connector for different speeds. • MPO – MPO cable pin outs are specific to the optics at each end and can be plugged in with the ends backwards. • Need different breakout cable pin outs (MPO – SC/LC) based on connector pin out and size. • Fiber strand colors must correspond to the T/R pairs at the breakout end. This means different cable builds, not just different labeling. (slide?)

  41. Fiber Initiatives – MPO Breakout Cables 900 micron breakout to LGX 1.6 mm breakout to equipment front panel

  42. Fiber Initiatives – MPO to MPO Cables • Pin out varies by both application and optics • Straight • Cross-over • Rolled • Hybrid • And more ? And how do you know 24 fiber MPO-MPO

  43. Topics • Lead Free Solder/RoHS 6/6 Compliance • Thermal Management, Airflow Requirements, Impacts, and Solutions • Cable Management • Power Distribution • Equipment Size and Weight

  44. Power Cable Management Challenges • Chassis may require up to 36 DC power cable pairs or 24 single phase 220 VAC cords • Typically no power cable management is provided • AC cords typically do not “lock” into the chassis receptacles • N + 1 power supply redundancy schemes are not practical to implement in the field (would require N + 1 BDFB loads) • A + B power feed redundancy to each power module results in double the number of feeds and little reliability improvement

  45. Solution: Distributed Architecture (DA) Power Plant • A DA Plant is located near the equipment it serves, saving copper • Scalable from 850A – 3800A depending upon required battery reserve • In some cases, requires a new battery technology Sodium Metal Halide, aka “Sodium Salt” • At room temperature, battery is table salt, nickel, iron, and alumina

  46. DC Power Plant Architecture Features Centralized Architecture Distributed Architecture (DA) • Single large DC power plant for office • Large DC batteries in the power room (basement) • Long DC primary power circuits • Requires BDFBs • Requires short secondary distribution • Requires bay FAPs for most NEs • Voltage drop from BDFB to NE is typically limited to 0.5V loop • Short AC feeds to rectifiers • Heavy lead acid battery technology • Multiple small DC power plants for areas • Small DC batteries in the equipment area • “Primary” distribution in the traditional sense is eliminated • BDFBs are eliminated • “Secondary” distribution technically becomes primary • Bay FAPs can be eliminated for most NEs • Voltage drop from PBD to NE = 1.75V loop, effectively eliminating all transition devices; i.e., cable size is #2 AWG for most 125A circuits • Longer AC feeds to rectifiers – more PDSCs • Lighter alternate battery technology DA Plants = less copper

  47. Solution: Mini “BDFB” Six 600A loads, 10 fuse positions/load Equipment Cost Savings of ~50%

  48. Bridging Clips are used on Demarcation Fuse Panels to provide 2 or more outputs for a single input. Bridging clips are used with high current (125A) BDFBs where individual power inputs are fused at >50A and the total load of multiple fuse outputs will not exceed 125A. Special cases include planning for growth and redundant chassis power supply inputs. This saves secondary power cable installation costs, BDFB fuse positions, cable rack and cable hole congestion = $$$. Solution: Bridging Clips

  49. 2:1 Bridging Clips

  50. 2:1 Bridging Clip Example

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