Wall Mount Swing Rack Installation

The optional Wall-Mount Swing Rack, when ordered as a separate accessory, is shipped flat and must be assembled before mounting on a wall or other surface.

Once assembled and mounted on the wall, the CBA1048 and accessories can be installed in it.

The CBA1048 and accessories install in the Wall-Mount Swing Rack more or less like any rack equipment installs in a standard rack. The main difference is that each item must be installed in a particular location in the swing rack. Top to bottom:

• Rectifier Shelf
• CBA1048 card cage
• Fan Tray

Installation will generally include the following tasks:

1. Assembling the Wall-Mount Swing Rack
2. Mounting the swing rack on the wall or other surface
3. Connecting ground, and DC power and fan alarm wiring to the CBA1048 card cage
4. Installing the fuse block in the swing rack
5. Installing the CBA1048 card cage, Fan Tray, and Rectifier Shelf in the swing rack
6. Connecting the DC cable assembly to the Rectifier Shelf
7. Installing Rectifier Module(s) in the Rectifier Shelf
8. Installing the EMI front cover

Assembling the Wall Mount Swing Rack

The optional Wall-Mount Swing Rack, when ordered as a separate accessory, is shipped flat and must be assembled before mounting on a wall or other surface.

The accessory Wall-Mount Swing Rack package contains:

• One left-side panel with a grounding bar preinstalled
• One right-side panel with three wall mounting brackets preattached
• Four channel-stock crossmembers with a PEM nut at each end
• Eight 12-24, 5/16-inch Hex/Slot-head screws with captive star washers

Assembling the swing rack consists of attaching the four channel-stock crossmembers between the left and right side panels with screws. It requires only a few minutes and a medium slot screwdriver or a 5/16-inch nut driver, and can be completed before arriving, or at the installation location.

There is no particular order that must be observed when assembling the swing rack. The only requirement is that the crossmember with the cable-relief notch must be at the lower front crossmember location and oriented such that the notch is on the right side.

The crossmembers go inside the swing rack side panels and are attached with screws that go through holes in the top and bottom flanges of the side panels and into PEM nuts that are on each end of the crossmember.

The picture below details the suggested assembly steps.

1. Select a work area that is large enough to lay the swing rack parts out in their relative positions. The empty swing rack weighs about 11 pounds and has lots of pointy corners and some exposed hex screw heads, so pick a work surface that will not matter if it gets some scratches and a few gouges as the swing rack is assembled.
2. Lay the swing rack parts out in their approximate relative positions on the work surface, paying attention to the orientation of the side panels.
3. If the Left Side Panel stiffening screws (top and bottom) are not already installed (at the rear of the panel, near the hinge), install them now and tighten securely.
4. Identify the crossmember with the cable relief notch.
5. Orient the right side panel so that it is resting on the three wall mount brackets and the flanges are to the left.
6. Place the notched end of the crossmember in the lower front crossmember position (now nearest you) of the right side panel. Attach with a 12-24 hex-head screw from the bottom flange of the side panel. Tighten finger tight, only.
7. Attach the other three crossmembers to the right side panel in any order. Tighten each screw finger tight.
8. Orient the right side panel/crossmember assembly so that it rests on the three wall mounting brackets and hinge again if its orientation has been changed.
9. Place the left side panel in its approximate final position, with the flanges to the right and the crossmembers inside the flanges.
10. Attach the left side of the crossmembers to the left side panel flanges with screws. Tighten finger tight.
11. Orient the swing rack assembly so that it is resting on the three wall mounting brackets and hinge again. Make sure that the hinge leaf is open. Loosen each crossmember screw one turn or so.
12. Make sure that the swing rack is sitting on a flat, level surface. Gently twist the assembly this way and that to make sure that the crossmembers are in their correct positions. Check to see that swing rack ends up square.
13. Tighten all crossmember screws a little at a time in sequence making sure that the swing rack remains square and does not rock after all screws are tightened.
14. Check to see that all three wall mounting brackets are perpendicular to the long axis of the right side panel. If any are not, loosen the thumbscrew(s) and reposition. Tighten all thumbscrews securely so the wall mounting brackets cannot twist out of position during handling and installation.

Mounting the Swing Rack on a Wall

When the optional Wall-Mount Swing Rack is ordered as a separate accessory, it should be mounted on the wall or other surface before any equipment is installed in it.

When the CBA1048 is ordered as a complete, preassembled unit, it can be mounted on the wall or other surface with all the equipment installed in it.

The Wall-Mount Swing Rack is installed on the wall or other surface using twelve fasteners: six through the hinge leaf on the left side and two through each of the three wall mounting brackets on the right side. Mounting hardware should be selected to match the wall material and the weight of the swing rack when it is fully loaded (about 40 pounds (18.1 kg)).

Read and understand the wall material and fastener requirements outlined in the Site Selection section above.

Installation will be a little quicker and easier if a helper is available to hold the swing rack in position as the first few screws are started, particularly if a fully assembled CBA1048 is being installed.

A D-size (22 inch by 34 inch) sheet of paper containing a template showing the size of the required open wall area and the location of the swing rack mounting holes is supplied in the package. The 14-inch by 29-inch template must be cut from the larger sheet with scissors along the dashed line before use.

Have the assembled swing rack, paper template, scissors, and the tools and fasteners that will be needed for this task nearby.

1. Select the general location for the installation in accordance with the details in the Site Selection section, above (wall material, proximity to power and other equipment).
2. Unfold the sheet of paper containing the template and prepare it by using scissors to cut out the actual template (about 29 inches by 14 inches) from the larger sheet of paper. Cut carefully on the dashed lines where indicated.
3. Find a flat area on the wall (or other surface) large enough to fit the 29-inch by 14-inch paper template. (This is the minimum space needed to install the swing rack so that it can swing all the way out.)
4. Tape each corner of the template to the wall taking care that the template is level and that there are no wrinkles in it.
5. Hold the assembled swing rack up to the template and check to see that the swing rack mounting holes line up with the mounting holes marked on the template. If any do not line up, determine why they do not line up (wall mount brackets twisted out of position, etc.) and correct. Or, if nothing can be found that is out of place, mark the correct drilling locations on the template through the swing rack mounting holes. Then set the swing rack aside.
6. Drill a pilot hole through the center of each of the indicated mounting holes in the template and into the wall or other surface. Make sure that the holes are drilled perpendicular to the mounting surface.
7. Remove the paper template from the wall.
8. If installing masonry anchors, use the correct drill bit size for the anchors and drill out the pilot holes to the correct depth. Install the anchors in the holes in accordance with the anchor manufacturer instructions.
9. Label the swing rack wall mounting brackets 1, 2, 3, from top to bottom, then mark the outboard hole (furthest to the right) on each. Loosen and disengage the thumbscrews from the three wall mount brackets along the right side of the swing rack.
10. Position the top wall mounting bracket over the top pair of holes, with the marked hole furthest to the right.
11. Start screws into the wall material (or anchors), and drive each screw until just before it contacts the flat of the wall mount bracket.
12. Do this for the remaining two wall mount brackets. The brackets should be able to move around slightly.
13. Position the swing rack on the wall with the thumbscrews over their holes in the wall mounting brackets. Hold the swing rack up, in the correct position, and screw each thumbscrew into its hole. Do not tighten.
14. While continuing to hold the swing rack in the correct position, start a screw in the top hole in the hinge leaf and drive it until just before it contacts the flat surface of the leaf.
15. Start a screw in each of the remaining holes in the hinge leaf and drive it until just before it contacts the flat surface of the hinge leaf. The swing rack should be able to move around slightly on its mounting screws.
16. Place a level on a crossmember.
17. Position the swing rack so that it is level and carefully tighten the screws on the left side.
18. Tighten the screws on the right side of the wall brackets.
19. Loosen and disengage the thumbscrews from the wall mounting brackets, swing the rack out of the way, and carefully tighten the screws on the left side of the three wall mounting brackets without moving the brackets.

Grounding the Swing Rack

Have the swing rack mounted on the wall, and swung open.

1. Run a length of heavy-gauge ground wire from the facility grounding system connection point to the swing rack, observing the existing cable routing in the room.
2. Route the near end of the ground wire into the left side of the swing rack from the top or the bottom as required, and leave about 6 inches or so of excess length to allow the swing rack to swing throughout its full range of motion with the ground wire connected to it.
3. Strip about 1/2 inch of insulation from the swing rack end of the ground wire and twist the wire strands together tightly. Loosen the screw of an unused hole in the swing rack grounding block on the inside of the left side panel, insert the stripped end of the ground wire, and tighten the screw using a medium slot or a #2 Robertson square drive screwdriver or bit.
4. Secure the ground wire to the wall or other vertical surface near the swing rack at several points using wire staples or other attachments as appropriate to the surface material. Take care to allow enough slack in the wire to accommodate the full range of motion of the swing rack.
5. Swing the rack back into its normal closed position, then engage and tighten the thumbscrews.
6. Prepare the far end of the ground wire as required and connect it to the grounding system.

Connecting the DC Power/Alarm Wiring to CBA1048 Backplane

The DC/Alarm/Fuse Block Cable Assembly routes DC power from the Rectifier Shelf to the CBA1048 backplane and Fan Tray, and the fan alarm signal from the Fan Tray to the backplane.

DC supply A and B wires have Molex connectors that match those on the Rectifier Shelf on the input, and end in ring terminals that must be attached to the DC power input terminal block on the CBA1048 backplane. The fan alarm cable ends in a small Nylon connector that plugs into the backplane.

Have the CBA1048 on an open work surface, sitting on its front panel.

1. Using a #2 Phillips screwdriver, remove the two screws holding the CBA1048 rear cover to the card cage. Remove the rear cover.
2. Orient the card cage so that the barrier terminal strip (J27) is on the left.
3. Unbundle the DC/Alarm Cable Assembly and lay it out on the work surface. Untangle the wires and group them according to their destinations.
   1. It may be helpful to secure the wire groups with cable ties for ease of handling during installation. Velcro cable ties or untightened Nylon cable ties can be used. The Velcro ties can be replaced with Nylon cable ties, or the Nylon cable ties can be tightened later after installation is complete and the final layout of the cable is determined.

      

4. Using a #2 Phillips or medium slot screwdriver, loosen the following five screws from the CBA1048 barrier terminal strip (J27):

   A N-	B N-
   A P+	B P+
   FGND

   

5. Find the backplane DC power A and B DC power feed wires and attach them to the appropriate terminal strip screws.

   Note 1: The wire color/terminal name assignments are different from those used when the CBA1048 is installed in the Wall-Mount Swing Rack.

   Note 2: If the DC power polarity is reversed, the Tellabs equipment will NOT be damaged. It just will not operate until the DC power polarity is corrected.

   1. FGND = Green (x2)
   2. A/B N- = Red
   3. A/B P+ = Black
6. Plug the fan alarm cable connector (P30) into the P30 connector on the CBA1048 backplane.
7. Hold the CBA1048 rear cover near its installed position and route the wires of the cable assembly through the exit hole in the rear cover at the top, left. Make sure that the two ferrite beads are on the outside of the cover.
8. Install two screws to hold the rear cover in place.

Installing the Fuse Block Assembly

The Fuse Block Assembly is part of the DC/Alarm/Fuse Block Cable Assembly, which is generally used only with the Wall-Mount Swing Rack. The fuse block assembly must be installed on the left side panel, inside the swing rack:

1. Gather or coil the DC/Alarm/Fuse Block Cable Assembly and place it on top of the swing rack. It may be helpful to hold the cable assembly together with a large Velcro cable tie.
2. Slide the CBA1048 card cage into the bottom of the (empty) swing rack until it is about two-thirds of way in, and is sitting on the two lower crossmembers.
3. Loosen and disengage the three thumbscrews on the right side of the swing rack and swing the rack to the left as far as it will go.
4. Take the cable assembly coil off the top of the card cage and remove the cable tie. Straighten the wires.
5. Using a #2 Phillips screwdriver, loosen and remove the two screws near the grounding bar on the inside of the left side panel, near the back.
6. Locate the fuse block assembly on the cable assembly and separate it from the remaining wires of the cable.
7. Make a small bundle of the red wires connected to the fuse socket lugs inside the metal housing of the fuse block assembly. Use a Nylon cable tie to hold the bundle together, if necessary. Route the bundle out the exit hole in the side of the metal fuse assembly housing before tightening the cable tie. Take care to not dislodge the protective plastic grommet from the metal housing or disconnect any of the wires from the lugs of the fuse sockets.

   

8. While holding the wire bundle in the exit hole, orient the fuse block assembly so that the exit hole of the housing is toward the front of the swing rack. Place the fuse block assembly metal housing in its place against the left side panel.
9. Make ABSOLUTELY CERTAIN that all the wires go through the exit hole and none are under the edges or flanges of the fuse block assembly metal housing.
10. Hold the fuse block assembly metal housing flanges against the left side panel and position it so that its mounting holes are over the holes on the left side panel. Again, make sure that no wires are under the edge of the metal housing.
11. Using the two screws that were removed earlier, attach the fuse block assembly to the left side panel.
12. Return the swing rack to its normal position, and engage and tighten the thumb screws.

Installing the CBA1048 Card Cage

The CBA1048 card cage is two-thirds inside the swing rack, sitting on the lower crossmembers at this point, after the installation of the cable assembly and fuse block.

1. Raise the CBA1048 card cage up to the center position in the swing rack and push it all the way in so that it is against the rails of the swing rack. If grounding wires are in the way
2. While holding the CBA1048 card cage in position, secure it to the swing rack rails with four 12-24 rack screws.
3. Loosen and disengage the thumb screws from the wall mount brackets and swing the rack to the left as far as it will go.
4. Untangle and separate the wires that end in the Fan Tray connector. Route them under the lower crossmember at the rear of the swing rack, and over the lower crossmember at the front of the swing rack so that they sit in the notch of the forward crossmember. Have about 6 inches of cable out in front of the swing rack as a service loop.
5. Return the swing rack to its normal position and engage and tighten the thumb screws.

Installing the Fan Tray

The Fan Tray is installed in the bottom position of the Wall-Mount Swing Rack:

1. Make sure the wires ending in the Fan Tray connector are in the notch on the right side of the lower crossmember.
2. Place the Fan Tray in the swing rack at the bottom position and push it all the way in, making sure that the wires ending in the Fan Tray connector are in the notch of the lower crossmember.
3. While holding the Fan Tray in position, secure it to the swing rack rails with four 12-24 rack screws.
4. Attach the Fan Tray connector on the end of the wires to the Fan Tray front panel connector
5. Push excess wire length back into the swing rack, leaving a service loop.
6. Loosen and disengage the thumb screws from the wall mount brackets and swing the rack to the left as far as it will go.
7. Find the ground wire that is attached to the rear surface of the Fan Tray.
8. Strip about 1/2 inch of insulation from the ground cable (if not already stripped) and twist the wire strands together tightly.
9. Insert the ground wire into an unused hole in the grounding block and tighten the screw using a medium slot or a #2 Robertson square drive screwdriver or bit.
10. Return the swing rack to its normal position and engage and tighten the thumb screws.

Installing the Rectifier Shelf

The Rectifier Shelf is installed in the top position of the Wall-Mount Swing Rack:

1. Place the Rectifier Shelf in the swing rack at the top position and push it all the way in.
2. While holding the Rectifier Shelf in position, secure it to the swing rack rails with four 12-24 rack screws.
3. Loosen and disengage the thumb screws from the wall mount brackets and swing the rack to the left as far as it will go.
4. Untangle and separate the remaining wires of the cable assembly.
5. Consider how to best arrange and store excess wire length behind the CBA1048 card cage and accessories and position the wires of the cable assembly accordingly with enough length on the DC input wires to reach the back of the Rectifier Shelf easily.
6. Plug the DC A plug of the DC cable assembly into the right-hand socket (when viewed from the rear) on the back panel of the Rectifier Shelf, and the DC B plug into the left-hand socket.
7. Find the ground wire that is attached to the left side of the Rectifier Shelf.
8. Strip about 1/2 inch of insulation from the ground cable (if not already stripped) and twist the wire strands together tightly.
9. Insert the ground wire into an unused hole in the grounding block and tighten the screw using a medium slot or a #2 Robertson square drive screwdriver or bit.
10. Plug the AC line cord(s) into the IEC AC connector(s) on the rear surface of the Rectifier Shelf. DO NOT plug the AC line cord(s) into the building mains at this time.
11. Bundle or coil the cable assembly excess wire length at the back of the swing rack and secure with cable ties.
12. Return the swing rack to its normal position and engage and tighten the thumb screws.

Installing the Rectifier Modules in the Rectifier Shelf

The Rectifier Shelf has room for two Rectifier Modules. If only one module is being installed, it goes in the left slot.

1. Loosen and remove the four rack screws that hold the Rectifier Shelf in the swing rack. Pull the Rectifier Shelf out of the swing rack about an inch.
2. Using a IP8 Torx screwdriver remove the two black flat-head screws from the bottom of the left side Rectifier Module cover. 
   
   
    
3. Remove the two black flat-head screws from the top of the left side Rectifier Module cover and remove the cover.
4. The front panel of the Rectifier Module has an ejector lever on each side. Only the lever on the left side is used with the Rectifier Shelf.

   

5. Use a small slotted or #0 Phillips screwdriver to loosen the captive screw at the top of the left side ejection lever and pull the lever down to its fully open position - about 30° from vertical.
6. Slide the Rectifier Module into the left slot of the Rectifier Shelf most of the way.
7. Make sure that the ejection lever is still fully open and gently push the faceplate of the Rectifier Module the rest of the way in until the module seats in its connector at the back of the slot. (It maybe helpful to shift the module left and right as it is being pushed.)

   

8. Lock the Rectifier Module into the Rectifier Shelf slot by pushing the ejection lever the rest of the way up to its fully closed position and tightening the screw to hold it there. The ejection lever engages a small tab in the shelf bottom cover to hold the module in the slot.
9. If a second module is being installed at this time, repeat steps 2 through 7 for the right slot.
10. Reinstall the Rectifier Shelf front cover(s) taking care to not over tighten the screws and damage the plastic threads in the cover tabs.
     

    Note: The Rectifier Module cover fits properly only one way - rotate the cover 180° if the mounting holes do not line up with those of the shelf.

11. Push the Rectifier Shelf back onto the swing rack. Hold the shelf level and secure with four 12-24 rack screws.

Removing a Rectifier Module from the Rectifier Shelf

To remove a Rectifier Module:

1. Follow steps 1 through 3 of the Rectifier Module installation procedure, above.
2. Use a small slot or #0 Phillips screwdriver to loosen the captive screw at the top of the left side ejection lever of the module to be removed.
3. Pull the lever down to its fully open position - about 30° from vertical. This will cam the module out of the shelf about 1/8 of an inch and release the lock.
4. Grasp the ejection lever and gently pull the module out of the socket at the back of the slot. It may be helpful to wiggle the front of the module left and right wile pulling to help disengage it from the socket.
5. Grasp the Rectifier Module body and remove the module from the slot. Do not hold the ejection lever once the module is out of the slot.
6. Follow steps 4 through 10 of the Rectifier Module installation procedure, above, to install another Rectifier Module in the slot and reassemble the Rectifier Shelf.

Installing the EMI Front Cover

The EMI Front Cover is installed using the two left rack screws on the previously installed CBA1048. Installation is the same whether the CBA1048 is installed in a standard equipment rack or in the optional Wall-Mount Swing Rack.

1. Loosen and remove the two rack screws on the left side of the CBA1048 card cage.
2. Move the EMI Front Cover hinge leaf to the closed position and move the two latches on the right side of the EMI Front Cover to the left (open).
3. Place the EMI Front Cover on the CBA1048 with the two latch studs on the right side of the card cage through their holes in the cover. Slide the two latches to the right to close them.
4. Reinstall the two rack screws on the left, through the holes in the EMI Front Cover hinge leaf. Do not tighten the screws.
5. Hold the left side of the CBA1048 up in its correct position with everything centered, and tighten the rack screws.
6. Check to see that the cover latches operate smoothly and that the cover opens and closes without interference from the latch studs. Loosen the left side rack screws and adjust the position of the CBA1048 and/or EMI Front Cover as needed and tighten the rack screws.