> Chassis Installation
> This chapter provides information on rack configurations and instructions for installing and removing the chassis and its sub-components: the upper and lower fan trays and the Power Filter Units (PFUs).
> IMPORTANT: Prior to installation, personnel should review and be familiar with all recommendations for Central Office installations, as found in Telcordia GR-1275-CORE Central Office Environment Installation/Removal Generic Requirements, Issue 3, December 2001.
> WARNING: The PFUs each have two power supply cables (-48VDC and RTN). To reduce the risk of electric shock, exercise caution when working within the chassis if one PFU is still cabled. To fully de-energize the PFU, disconnect both power supply cables from each PFU.
> Beide Netzteile (Power Filter Units, PFU) haben 2 Stromversorgungsanschluesse (-48 VDC und RTN). Vorsicht is geboten bei Arbeiten am Chassis, solange noch ein Netzteil verkabelt ist. Um die PFU komplett stromlos zu schalten muessen beide Kabel entfernt werden.
> Equipment Rack Configuration
> The chassis is designed for installation in a standard 19-inch (48.26 cm) equipment rack. Additional rack hardware, such as extension brackets, may be used to install the chassis in a standard 23-inch (58.42 cm) rack. Each chassis is 24.50 inches (62.23 cm) high. This equates to roughly 14 Rack Mount Units (RMUs: 1 RMU = 1.75 in (4.45 cm).
> You can mount a maximum of three chassis in a standard 48 RMU (7 feet) equipment rack or telco cabinet provided that all system cooling and ventilation requirements are met. A fully-loaded rack with three chassis installed has approximately 5.5 inches (13.97 cm, 3.14 RMUs) of vertical space remaining.
> CAUTION: When planning chassis installation, take care to ensure that equipment rack or cabinet hardware does not hinder air flow at any of the intake or exhaust vents. Additionally, ensure that the rack/cabinet hardware, as well as the ambient environment, allow the system to function within the required limits. Refer to the Ventilation Considerations section of this chapter for more information.
> Ventilation Considerations
> Airflow within the system is designed per Telcordia recommendations to ensure the proper vertical convection cooling of the system.
> As shown in the following figure, the lower fan tray pulls fresh air in from the front and side intake vents located near the bottom of the chassis. The air is forced upwards through the system and cools installed components as it passes over them. The airflow through the chassis, as measured by the speed of the airflow across the various card slots, maintains an average of 290 feet per minute (fpm).
> The upper fan tray pulls heated air up through the chassis. The air is forced through the side and rear exhaust vents located near the top of the chassis before it is expelled from the system.
> System Airflow & Ventilation
> Proper ventilation and cooling must allow the chassis to operate within the temperature and humidity levels described in the following table.

> Operating Temperature and Humidity Recommendations
> Operating Temperature | 0 oC to +55oC
> Operating Humidity Levels | 5 to 85% non-condensing

> Mounting Options
> There are two options for mounting the chassis in a standard equipment rack or telecommunications cabinet:

> l | Standard: In this configuration, the flanges of the mounting brackets are flush with the front of the chassis. This is the default configuration as shipped. Refer to the Standard Installation of the Chassis section of this chapter.

> l | Mid-mount: In this configuration, the flanges of the mounting brackets are recessed from the front of the chassis. To do this, install the mounting brackets toward the middle of the chassis on either side. Refer to the Mid-Mount Installation of the Chassis section of this chapter.

> Weight Considerations
> The shipping weight of the chassis is approximately 160 pounds (72.57 kg). Please consider the following recommendations before proceeding:

> l | If available, use an equipment lift to lift and move the chassis during the installation process.

> l | If no lift is available, reduce the weight according to the instructions in the Reducing the Weight of the Chassis Prior to Installation section that follows. This reduces the weight of the chassis to approximately 125 lbs. (56.7 kg).

> l | It is recommended that at least two people perform the installation. These individuals should be physically able to lift and control the weight of the chassis.

> l | When lifting any heavy object, it is important to remember to bend at the knees and lift with your legs. Bending at the waist and lifting with your back could cause personal injury.

> Installing the Chassis
> IMPORTANT: If you are installing more than one chassis in an equipment rack, to ensure an easier installation, begin by installing the first chassis near the bottom of the rack.
> CAUTION: When handling or moving the chassis, lift the chassis from the bottom only. Lifting it by any other part could result in damage to the chassis.
> Reducing the Weight of the Chassis Prior to Installation
> To make the installation process easier, you can reduce the weight of the chassis prior to installation by removing the upper and lower fan trays and the PFUs. Follow the instructions below to safely remove these components prior to installation.
> ESD During installation, maintenance, and/or removal, wear grounding wrist and/or heel straps to avoid ESD damage to the components. Failure to do so could result in damage to electrical components and could potentially void your warranty.

> 1 | Remove the upper fan tray.

> a | Remove the plastic bezel from the upper-front of the chassis by placing your fingers in the notches on the sides of the bezel and pulling it toward you. Place it to the side for re-installation later.

> b | Loosen the four screws that secure the fan tray in place using a #1 Phillips screwdriver.

> c | Grasp the two bezel mounts on the front of the fan tray and pull. The fan tray should easily slide out of the chassis. Place it to the side for re-installation later.

> WARNING: To avoid personal injury and/or damage to the fan tray, be sure to support the fan tray’s weight from its front and back as you slide it completely out of the chassis.
> Vorsicht beim Herausziehen der Luefter-Schublade: um eine Beschaedigung des Moduls und eventuelle Verletzungen zu vermeiden, sollte diese hinten und vorne unterstuetzt werden.

> 2 | Remove the lower fan tray assembly.

> a | Remove the plastic bezel from the lower-front of the chassis by placing your fingers in the notches on the sides of the bezel and pulling it toward you. Place it to the side for re-installation later.

> b | Remove the fan tray cover by loosening the four screws that secure it in place using a #1 Phillips screwdriver and pulling it away from the chassis.

> c | Pull the fan tray toward you using the handle. The fan tray should easily slide out of the chassis. Place it to the side for re-installation later.

> WARNING: To avoid personal injury and/or damage to the fan tray, be sure to support the fan tray’s weight from its front and back as you slide it completely out of the chassis.
> Vorsicht beim Herausziehen der Luefter-Schublade: um eine Beschaedigung des Moduls und eventuelle Verletzungen zu vermeiden, sollte diese hinten und vorne unterstuetzt werden.

> 3 | Remove the PFUs located in the lower-rear of the chassis.

> a | Locate the PFU bay labeled Power Filter Unit 1 on the lower-left rear of the chassis.

> b | Use a #2 Phillips screwdriver to loosen the four screws that secure the PFU in to the chassis.

> c | Grasp the handle on the PFU and gently pull the PFU toward you. The PFU should slide easily out of the chassis. Place it to the side for re-installation later.

> d | Repeat step b and step c for the PFU located in the bay labeled Power Filter Unit 2 located on the lower-right side of the chassis.

> 4 | Proceed to either the Standard Installation of the Chassis or Mid-Mount Installation of the Chassis section that follows, based on the mounting option you are using.

> Standard Installation of the Chassis
> Follow the instructions below to perform the standard installation of the chassis.
> ESD During installation, maintenance, and/or removal, wear grounding wrist and/or heel straps to avoid ESD damage to the components. Failure to do so could result in damage to electrical components and could potentially void your warranty.

> 1 | Position the chassis in the equipment rack so that the flanges of the mounting brackets at the front of the chassis are flush with the mounting rails of the equipment rack.

> 2 | Mount the chassis to the rails of the equipment rack. Use the hardware that was supplied with the equipment rack. Begin with the two bottom holes and work your way up until all four holes on each flange are secured.

> 3 | Repeat step 1 and step 2 for any additional chassis you are installing in the equipment rack.

> 4 | If you took steps to reduce the weight of the chassis prior to installation, refer to the instructions in the Re-Installing Chassis Sub-components section to re-install the components. Otherwise, proceed to Application Card Installation.

> Mid-Mount Installation of the Chassis
> Follow the instructions below to perform the mid-mount installation of the system.
> ESD During installation, maintenance, and/or removal, wear grounding wrist straps to avoid ESD damage to the components. Failure to do so could result in damage to electrical components and could potentially void your warranty.

> 1 | On the side of the chassis, unfasten the eight #2 Phillips screws that secure the mounting bracket to the chassis.

> 2 | Place the mounting bracket over the middle set of mounting holes on the side of the chassis and secure it to the chassis with the screws you removed in step 1.

> 3 | Repeat step 1 and step 2 for the bracket on the opposite side of the chassis.

> 4 | Position the chassis in the equipment rack so that the flanges of the mounting brackets are flush with the mounting rails of the equipment rack.

> 5 | Mount the chassis to the rails of the equipment rack with the hardware that was supplied with the equipment rack. Begin with the two bottom holes and work your way up until all seven holes on each flange are secured.

> 6 | Proceed to the Grounding the Chassis section that follows to ground the chassis.

> Grounding the Chassis
> Make sure that the chassis is properly grounded prior to installing any chassis sub-components or cards. The chassis and the equipment rack or telecommunications cabinet that it is installed in must be connected to the same ground.
> CAUTION: Failure to properly ground the chassis could result in personal injury and/or damage to the chassis and its components.
> There are two sets of grounding terminals located at the lower-rear of the chassis. The following figure and the table that follows show the location of these terminals and provide specifications for the appropriate lug and cable size.

> Terminal and Cable specifications
> Item | Description
> 1 | Ground Terminal: 2-hole lug required. Ground has 0.186-inch D posts, spaced 0.630-inch on center. The method of connection is: chassis - lug - flat washer - nut (3/8-inch). The nut(s) must be torqued to 50 in-lb (5.65 n-m). Recommendation: Use Panduit terminal type LCC6-10A-L with Panduit crimp tool part number CT-1700 (die color: blue 24).
> 2 | Ground Cable: Cable length: Not more than 70 feet (21.336 meters) one way. Cable size: 6 AWG (minimum).

> Follow the instructions below to connect the chassis to earth ground.

> 1 | Locate the ground terminal on the lower-left corner at the rear of the chassis next to the PFU bay labeled Power Filter Unit 1.

> 2 | Use a 3/8-inch nut driver or socket wrench to remove the nuts and washers from each of the two posts.

> 3 | Insert the lug connected to the grounding cable over the two terminals.

> 4 | Secure the lug to the ground terminals with the nuts and washers you removed in step 2. The nuts should be torqued to 50 in-lb (5.65 n-m).

> 5 | Repeat step 2 through step 4 to connect the ground cable to the grounding posts on the lower-right corner at the rear of the chassis next to the bay labeled Power Filter Unit 2.

> 6 | If you took steps to reduce the weight of the chassis prior to installation, refer to the instructions in the Re-Installing Chassis Sub-components section to re-install the components. Otherwise, proceed to Application Card Installation.

> Re-Installing Chassis Sub-components
> If you performed the procedure in the Reducing the Weight of the Chassis Prior to Installation section, perform the instructions below to re-install the sub-components of the chassis that were removed.
> ESD During installation, maintenance, and/or removal, wear grounding wrist straps to avoid ESD damage to the components. Failure to do so could result in damage to electrical components and could potentially void your warranty.

> 1 | Re-install the PFUs into the chassis.

> a | Locate the PFU bays at the lower-rear of the chassis. The bays are labeled from left to right Power Filter Unit 1 and Power Filter Unit 2.

> b | Slide the PFU assembly into the PFU bay labeled Power Filter Unit 1 until it is flush against the chassis.

> c | Use a #2 Phillips screwdriver to tighten each of the four screws on the PFU to secure it to the chassis.

> d | Re-install the second PFU in the PFU bay labeled Power Filter Unit 2 by repeating step b and step c.

> 2 | Re-install the lower fan tray assembly into the chassis.

> a | Hold the front of the fan tray by its handle with one hand and use your other hand to align it with the lower fan tray bay of the chassis. The lower fan tray bay is located at the bottom front of the chassis.

> b | Slowly slide the fan tray into the chassis along the guides using its handle until it is seated firmly in the chassis and can go no further.

> c | Verify that the particulate filter is securely in place. Its front should be flush with the front of the fan tray assembly and its tab should be lowered to keep it in place.

> d | Use a #1 Phillips screwdriver to replace the fan tray bay cover. Tighten each of the four screws to secure it to the chassis.

> IMPORTANT: The fan tray bay cover is keyed and can only be installed in one direction.

> e | Replace the lower plastic bezel: align it over the bezel mounts that protrude from the fan tray bay cover and snap it in place.

> 3 | Re-install the upper fan tray.

> a | Hold the front of the fan tray by its sides and align it with the upper fan tray bay of the chassis. The upper fan tray bay is located at the upper-front of the chassis.

> b | Slowly slide the fan tray into the chassis along the guides until its face plate is firmly against the chassis.

> c | Use a #1 Phillips screwdriver to tighten the four screws on the face of the fan tray to secure it.

> d | Replace the upper plastic bezel: align it over the bezel mounts that protrude from the face of the fan tray and snap it in place.

> 4 | Proceed to the next chapter for instructions on installing application cards in the chassis.

Cisco Systems Inc.
Tel: 408-526-4000
Fax: 408-527-0883