Cluster Module Assembly Guide

Table of Contents

1 Assembly Overview

This document explains a series of images and steps to assist with the construction of BitScope Cluster Modules. The exploded view of the Cluster Module:


Assembly assumes the use of completed BitScope Cluster Packs (the construction of these is not described here). Cluster Packs are supplied fully provisioned and tested with the Raspberry Pi 3 installed:


These are delivered as part of a flat pack product as a sub-assembly in kit form including metalwork and related mechanical materials. Network Switches and cabling are supplied by the VAR per customer requirements.


The Cluster Module when fully assembled looks like this:


The steps and images below identify the parts and outline the construction process.

2 Power Distribution

2.1 Power Distribution Module

Cluster Power distribution board attaches to rear cluster support. Three clusters and three Switch cables plug along the top. PSU modules plug in either side with 4 way connectors.


2.2 Power Indicator Cable Attachment

Front Indicator LEDs attach to Quick Release connectors to monitor both PSU circuits.


2.3 Cluster Unit Power Attachment

Power Distribution assembly shown in place. Note that the two PSU circuits are split and Clusters are not all connected to one PSU.

Left Circuit :- 60 + 30 + Switch

Right Circuit :- 60 + Switch + Switch

This configuration balances the load on the two PSU.


3 Cluster Wiring

3.1 Cluster Unit Wiring Loom

Wiring Loom detail showing the Anderson Polarized connector for each Cluster assembly. Fasten to side panel with M2.5 CSK screw.


3.2 Cluster Power Lead Sockets

Prepare Cluster power cables before assembly


3.3 Pre-Assemble Wire Loom Detail

Cluster units attached to side rail, pre-wired rail ready for attachment. Use Cable Ties and Clips to hold wiring in place.


3.4 Side Rail Ready Attach


3.5 Loom Assembly Layout


4 Power Supply

4.1 Power Supply Assembly


4.2 Power Supply Wiring Detail


4.3 Rear Panel View

Exposed detail showing Rear Panel, Power Distribution, PSU Assembly, Front Panel.


4.4 AC Power Detail

AC wiring detail. Dual PSU connect to Cluster Power board.


4.4.1 Detail Left

Screw Terminal connections to Left PSU


4.4.2 Detail Right

Screw Terminal connections to Right PSU


4.4.3 Cable Left

4-way connector for Left PSU. Cluster Power PCB has common ground but separate circuits for dual PSU + outputs.


4.4.4 Cable Right


4.5 Fan Connection

24V 80mm Fans have flying leads. Crimp the 3-way connector with RED (+) to center pin, BLACK (-) to either outer pin.


4.6 AC Detail Left

AC Line, Neutral, GND connect to Rear Panel IEC Fused Socket with protective Boot.


4.7 Cable Sets Rear Cluster

Clusters and side rails in place. Place 15 x 4-way 50cm Network Cables into rear Cluster RJ-45 sockets. Use Cable Ties to hold the sets of four cables in place - which will make orderly connection to the switch easier.


4.8 PSU Assembly

The PSU assembly now fits over the rear Network Cable loom. The PSU assembly should be pre-wired so that only the AC wires and two 4-way power leads need connection.


5 Network Fabric

5.1 Rear Switch in Place

With the PSU Assembly in place, mount the rear switch above it. Note the Network Cables in fifteen groups of four.


5.2 Rear Switch Populate Ports

Working from the rear-most nodes, connect 48 cables to the switch ports. Leave the remaining 12 of the inner nodes ready for connection to the final switch when mounted.


5.3 Cable Sets Front Cluster

Repeat the 15 x 4 Network Cable sets for the front cluster. Secure these also with Cable Ties to hold them in place so port connection is easier.


5.4 Front Lower Switch Populate Ports

As for the first switch, connect 48 of these 60 cables to the switch ports. Again you should have 12 unconnected which can be loosely grouped and placed with the spare 12 from the previous switch.


5.5 Ready for Final Switch

The last switch may be placed now, since the first two are fully populated with 48/60 cables from the front and back 60 node cluster assemblies.


5.6 Middle Cluster 24 Ports

The third switch is mounted. The 12 spare cables from the front cluster connect to the lower middle 12 ports. 12 nodes each side from the middle cluster connect to the outer 12 ports on the final switch. This image shows the upper middle 12 ports ready to accept the 12 spare cables from the rear 60-way cluster (22-rear-switch-populate-ports)


5.7 All Switch Ports Populated

All Network Cables now in place. The white cables are the spare 6 nodes from the middle cluster.


6 Final Steps

6.1 Spare 6 Nodes Wired Rear Panel

Spare nodes may be wired to rear panel Keystones.


6.2 Power Socket Detail

Before assembling the Rear Panel push on the AC wires making sure Line and Neutral are correct as marked on the back of the IEC socket. The IEC socket has an internal fuse which is 10A SLOW.


6.3 All Devices Connected to 24v

Fit the Boot over the IEC socket and attach the Back Panel. Fan flying leads may be attached last from top of the module. Make sure the Switch 24V leads are attached to the Switches.


7 References

Document ID VQQDTCML 02
Copyright © 2018-2019 BitScope Designs
Revision Update
02 [2019-05-09 Thu] updated
01 [2018-11-30 Fri] created