Unequal Flange Rack Installation Instructions

Unequal Flange Rack Installation Instructions Content Page INTRODUCTION............................................................................. 2 Revision History........................................................................ 2 Trademark Information................................................................... 2 Admonishments........................................................................ 3 1 DESCRIPTION.......................................................................... 3 1.1 Network Unequal Flange Rack......................................................... 4 1.2 Non-Network Unequal Flange Rack..................................................... 8 2 BASIC INSTALLATION............................................................... 11 2.1 Floor Mounting.................................................................. 11 2.1.1 Concrete Floor Mounting.................................................... 11 2.1.2 Raised Floor Mounting...................................................... 13 2.2 Rack-Top Support................................................................ 16 2.2.1 Water Pipe Support........................................................ 17 2.2.2 Support to Cable Racking.................................................... 18 2.3 Rack Grounding................................................................. 19 2.3.1 Ground Kits With Two-Hole Lugs............................................... 20 2.3.2 Equipment Termination Points................................................ 20 2.4 Designation Card Holder........................................................... 21 3 NETWORK ACCESSORIES............................................................ 22 3.1 AC Raceway, Raceway Filler, and Guard Rail Extender....................................... 22 3.2 Filler Guard Box................................................................. 22 3.3 Raised Floor Filler Guard Box........................................................ 23 3.3.1 Open Guard Box Installation.................................................. 24 3.3.2 Double Trough Installation................................................... 25 3.3.3 Single Trough Installation................................................... 27 3.4 Rack Spacers................................................................... 29 3.5 Filler Panel.................................................................... 30 3.6 Interbay Fiber Management Panel..................................................... 31 3.7 Filler Trough.................................................................... 34 3.8 Rear Fiber Storage Panel........................................................... 35 4 NON-NETWORK ACCESSORIES......................................................... 36 4.1 Guard Box Cover................................................................. 36 4.2 Second Guard Box................................................................ 36 4.3 Rack Spacer Box................................................................. 38 4.4 Rack Spacers................................................................... 38 (continued) 1017778 Rev B Page 1

Content Page 4.5 Filler Panel.................................................................... 40 4.6 Interbay Fiber Management Panel..................................................... 40 5 COMMON ACCESSORIES............................................................. 40 5.1 End Guard Panel................................................................. 40 5.2 Rack Extenders.................................................................. 42 6 CUSTOMER INFORMATION AND ASSISTANCE................................................... 43 INTRODUCTION This guide describes the ADC unequal flange rack and provides procedures for installing the rack and rack accessories. Note: Figures and dimensions in this guide are for the more common 23-inch rack. The rack is also available in a 19-inch version. For dimensions and other specifics for the 19-inch rack, call ADC Customer Service (1-800-366-3891). The unequal flange rack is available in two types, network and non-network, covered in this guide as follows: Basic rack installation procedures are the same for both types, and are covered together in Section 2. Rack accessories, except for end guard panel and rack extender, are different for the two types and are covered in separate sections (Sections 3 and 4). The end guard panel and rack extender are identical for both types of racks and are covered together in Section 5. This guide also includes sections describing ADC system integration services and customer support services. Revision History ISSUE DATE REASON FOR CHANGE Issue 1 09/1997 Original Issue 2 01/1998 Revised paragraph 3.05 Issue 3 04/1998 Updated for sectionalized interbay fiber management panel Issue 4 02/2001 Non-technical update Trademark Information ADC is a registered trademark of ADC Telecommunications, Inc. Page 2

Admonishments Important safety admonishments are used throughout this manual to warn of possible hazards to persons or equipment. An admonishment identifies a possible hazard and then explains what may happen if the hazard is not avoided. The admonishments in the form of Dangers, Warnings, and Cautions must be followed at all times. These warnings are flagged by use of the triangular alert icon (seen below), and are listed in descending order of severity of injury or damage and likelihood of occurrence. Danger: Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Warning: Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Caution: Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided. 1 DESCRIPTION The ADC unequal flange rack is a standard equipment rack conforming to telephone company specifications. The unequal flange rack is used to hold equipment chassis in a number of ADC applications including DSX-1, DSX-3, Broadband Cross-Connect, Fiber Distribution Frame, and Fiber Splice Frame. The unequal flange rack is available in either of two types, network or non-network, compared in Figure 1. As shown, the main visible difference between the network and non-network rack is in items at the base of the rack. The items at the base of the non-network rack, including the guard box, are taller and more boxlike. All ADC unequal flange racks (network and non-network) have top channel weld nuts and cabling access under uprights. Rack options include: Three available heights: 7 foot (213.36 cm), 9 foot (274.32 cm), or 11.5 foot (350.52 cm). (Non-standard heights may be ordered for customized applications.) EIA (1.75 inch, 4.45 cm) or WECO (2 inch, 5.08 cm) hole spacing. Front or rear guard box (for front-connect or rear-connect system). The following topics provide specific information for each type of rack, including an illustration identifying the rack accessories documented in this guide and schematics of rack footprints and top channels. Page 3

1880-A 1881-B Network Rack with Front Guard Box Non-Network Rack with Rear Guard Box Figure 1. Two Types of Unequal Flange Racks 1.1 Network Unequal Flange Rack The network unequal flange rack meets telephone industry standards for network bays. Also, it meets requirements for earthquake-braced bays. Figure 2 gives dimensions for the 23-inch network rack. Figure 3 shows top channel and foot-print details. (For 19-inch rack dimensions, contact ADC.) Figure 4 shows the main components of the network unequal flange rack and typical rack accessories. Rack accessories shown here and documented in this manual include: Filler panel (with or without hinges) Interbay fiber management panel (IMP) Rack spacers End guard Rack extender Page 4

1.5 IN. (3.81 CM) TOP AREA 5.00 IN. (12.7 CM).75 IN. (1.9 CM) 2.19 IN. (5.6 CM) 78.0 IN. (198.12 CM) 39 2-INCH (5.08 CM) MOUNTING SPACES 1.25 IN. (3.2 CM) Y X #12-24 AREA 4.5 IN. (11.43 CM) TO BOTTOM OF FIRST MOUNTING SPACE 7-FOOT (213.36 CM) (WECO) 1.00 IN. (2.54 CM) 2 IN. (5.1 CM) 5.00 IN. (12.7 CM) COVER 4.0 IN. (10.16 CM) HEIGHT 25.88 IN. (65.7 CM) DIMENSION X 7 FT. (2.1 M) 9 FT. (2.7 M) 11.5 FT. (3.5 M) 12.00 IN. (30.5 CM) DIMENSION Y 78.0 IN. (198.1 CM) 100.0 IN. (254.0 CM) 130.0 IN. (330.2 CM) 6617-C Figure 2. 23-Inch Network Rack Dimensions Page 5

2.69 IN. (6.83 CM) 5/8-11 WELD NUT (OPPOSITE 3 PLACES) 2.69 IN. (6.83 CM) 0.78 IN. DIA (1.98 CM) (2 PLACES) 5/8-11 WELD NUT (OPPOSITE 3 PLACES) 5.38 IN. (13.62 CM) 5.19 IN. (13.18 CM) 3.0 IN. (7.62 CM) 5.16 IN. (13.11 CM) (2 PLACES) 4.31 IN. (10.57 CM) (4 PLACES) 3.0 IN. (7.62 CM) TOP DETAIL 7 FT FRAMES 4.38 IN. (11.13 CM) 5.25 IN. (13.34 CM) 3.0 IN. (7.62 CM) 1.63 IN. X 3.16 IN. (4.14 CM X 8.03 CM) SLOT (2 PLACES) 4.00 IN. X 8.00 IN. (10.16 CM X 20.32 CM) SLOT FOR 23 IN. (SHOWN) 4.00 IN. (10.16 CM) DIA FOR 19 IN. 3.0 IN. (7.62 CM) TOP DETAIL 9 & 11.5 FT FRAMES 5.25 IN. (13.34 CM) 2.00 IN. (5.08 CM) 45 (4 PLACES) 7.82 IN. (18.87 CM) 4.81 IN. (2 PLACES) (12.22 CM) (3 PLACES) 1.00 IN. X 2.76 IN. (2.54 CM X 7.01 CM) SLOT (4 PLACES) BOTTOM DETAIL ALL FRAMES 1.81 IN. (5.56 CM) (2 PLACES) 10064-A Figure 3. 23-Inch Network Rack Footprints and Top Channel A filler guard box (also shown) is included in the kits for the first four items (but not with rack extender). A rear fiber storage panel is also available, but not shown. Rack top support, if desired, must be separately ordered. Other items shown in the figure are either integral to the rack itself or contained within the rack installation kit. Floor mounting hardware is available for either a concrete floor or raised floor. A raised floor guard box is also available. The IMP and rear fiber storage panel (not shown) are only used in fiber applications. For more information, refer to other topics in this manual. Page 6

EXTENDER TOP CHANNEL (WITH WELD NUTS) TOP SUPPORT (SEVERAL OPTIONS) GROUNDING KIT INTERBAY FIBER MANAGEMENT PANEL GLK GROUNDING KIT FILLER PANEL (WITH OR WITHOUT HINGES) SPACERS DESIGNATION CARD HOLDER GUARD BOX RACEWAY GUARD RAIL EXTENDER BUMPER GUARD END GUARD FILLER GUARD BOX (FLOOR MOUNT OR RAISED FLOOR) FLOOR MOUNTING HARDWARE (CONCRETE OR RAISED FLOOR) FILLER TROUGH 10026-E Figure 4. Network Rack Components and Accessories Page 7

1.2 Non-Network Unequal Flange Rack The non-network unequal flange rack is equivalent to the telephone industry standard rack. This rack has been designed and tested to support typical switch gear in a Zone 4 earthquake area. Figure 5 gives dimensions for the 23-inch non-network rack. Figure 6 shows top channel and footprint details. (For 19-inch rack dimensions, contact ADC.) 5.00 IN. (12.7 CM).75 IN. (1.9 CM) 2.19 IN. (5.6 CM) 1.5 IN. (3.81 CM) TOP AREA 1.25 IN. (3.2 CM) 76.0 IN. (193.04 CM) 38 2-INCH (5.08 CM) MOUNTING SPACES Y X #12-24 AREA (WECO) 1.00 IN. (2.54 CM) 6.5 IN. (16.51 CM) TO BOTTOM OF FIRST MOUNTING SPACE 7-FOOT (213.36 CM) 6.0 IN. (15.24 CM) HEIGHT 25.94 IN. (65.9 CM) 9.94 IN. (25.25 CM) 7.0 IN. (17.78 CM) SPACER BOX DIMENSION X 7 FT. (2.1 M) 9 FT. (2.7 M) 11.5 FT. (3.5 M) DIMENSION Y 78.0 IN. (198.1 CM) 100.0 IN. (254.0 CM) 130.0 IN. (330.2 CM) 10028-C Figure 5. 23-Inch Non-Network Rack Dimensions Page 8

2.69 IN. (6.83 CM) 5/8-11 WELD NUT (OPPOSITE 3 PLACES) 0.687 IN. (1.75 CM) DIA. 1.5 IN. (3.81 CM) 1.0 IN. (2.54 CM) DIA. 0.687 IN. (1.75 CM) DIA. 5.38 IN. (13.62 CM) 3.0 IN. (7.62 CM) 3.0 IN. (7.62 CM) TOP DETAIL 7 FT FRAMES 3.2 IN. (8.13 CM) 1.62 IN. (4.11 CM) 1.62 IN. (4.11 CM) 2.5 IN. (6.35 CM) 3.0 IN. (7.62 CM) 3.0 IN. (7.62 CM) 2.5 IN. (6.35 CM) TOP DETAIL 9 & 11.5 FT FRAMES 5.24 IN. (13.31 CM) (2 PLACES) 25.94 IN. (65.89 CM) 10.61 IN. (26.95 CM) 6.72 IN. (17.07 CM) (2 PLACES) 4.72 IN. (11.99 CM) 5.18 IN. (13.16 CM) (2 PLACES) 4.19 IN. (10.64 CM) (2 PLACES) 5.31 IN. (13.49 CM) (2 PLACES) 4.79 IN. (12.17 CM) (2 PLACES) 5.09 IN. (12.93 CM) (2 PLACES) 2.17 IN. (5.51 CM) (2 PLACES) 45 (4 PLACES) 0.44 IN.DIA (1.12 CM) (2 PLACES) 0.49 IN.DIA (1.24 CM) (4 PLACES) 2.16 IN. (5.49 CM) (2 PLACES) 1.62 IN. X 3.16 IN. (4.11 CM X 8.03 CM) SLOT (2 PLACES) 1.00 IN. X 2.76 IN. (2.54 CM X 7.01 CM) SLOT (4 PLACES) BOTTOM DETAIL 10062-B Figure 6. 23-Inch Non-Network Rack Footprints and Top Channel Figure 7 shows the main components of the non-network unequal flange rack and typical rack accessories. Rack accessories shown here and documented in this manual include: Rack spacer box (open or closed) Rack spacers, filler panel, and end guard Rack extender Guard box cover Second guard box Rack-top support must be separately ordered. Other items shown are either integral to the rack itself or contained within the rack installation kit. Page 9

EXTENDER TOP CHANNEL (WITH WELD NUTS) TOP SUPPORT (SEVERAL OPTIONS) GROUNDING KIT GLK GROUNDING KIT SPACERS DESIGNATION CARD HOLDER FILLER PANEL SECOND INTEGRAL (FRONT OR REAR FLANGE) COVER END GUARD SPACER BOX (OPEN OR CLOSED) FLOOR MOUNTING HARDWARE (CONCRETE OR RAISED FLOOR) 10027-D Figure 7. Non-Network Rack Components and Accessories Page 10

2 BASIC INSTALLATION This section contains procedures for installing a network or non-network unequal flange rack. The procedures included here are those done using the rack installation kit including mounting the rack on the floor, installing rack-top support, installing ground kits, and installing the designation card holder. After the rack is installed as described here, rack accessories can be installed following procedures provided in other sections of this guide. 2.1 Floor Mounting The rack can be installed on either a concrete floor or raised floor. Different hardware kits are used. The following procedures are for concrete floor mounting and raised floor mounting. Caution: Always use protective eye wear, gloves, and clothing when working with tools such as electrical drills for installing equipment. 2.1.1 Concrete Floor Mounting Ensure the appropriate hardware is available for concrete floor mounting. Typically four anchors are used when racks are floor supported. Two anchors may sometimes be used when the rack is supported from overhead. In earthquake zones, always use four floor anchors if possible. The anchor has a torque nut with a breakaway cap that breaks away when tightened to the proper torque pressure. Anchor the rack to the floor using the following procedures. 1. Position the rack in its designated floor location. 2. Mark the mounting hole locations on the floor. Use the holes with the widest spacing to provide the greatest stability. Figure 8. Note: To achieve maximum anchor-holding strength, select exact drill size for hole drilling. 3. Move the rack out of the way. At each mounting hole location, drill an 18 mm (.07 inch) diameter hole to a depth of 80 mm (3.15 inches) in the concrete. Clean out the hole with compressed air or a blow-out bulb. Check the hole depth with a tape measure or by placing the assembled anchor bolts in each hole. If a reinforcing bar is encountered while drilling, relocate the hole. Fill the unusable hole with locally approved filling product. 5806-A Figure 8. Rack Base Mounting Hole Pattern Page 11

4. Ready a floor anchor by placing the components on the stud in the order shown in Figure 9. Ensure that the stud is not extending beyond the bottom of the wedge. Insert the anchor into any of the mounting holes just drilled and tap it in with a hammer until the shoulder of the anchor is just even with the floor. BREAKAWAY CAP PLASTIC- ENCLOSED TORQUE NUT STUD NOTE: FOR FUTURE REMOVAL OF TORQUE NUT AND/OR THREADED ROD, USE A SCREWDRIVER TO SNAP OFF THE PLASTIC COVER EXPOSING THE TORQUE NUT. ALWAYS REPLACE NUT WITH A NEW TORQUE NUT. WASHER SHOULDER PLASTIC COVER TORQUE NUT WEDGE DISCARD BREAKAWAY CAP 8013-C Figure 9. Floor Anchor 5. Using a deep socket or box-end wrench, secure the anchor in the floor by tightening the torque nut breakaway cap until it just starts to feel snug. (Do not tighten until the breakaway cap breaks away from the plastic-enclosed torque nut.) Remove the washer, plastic-enclosed torque nut, and attached breakaway cap from the stud. 6. Repeat steps 4 and 5 above for each of the remaining floor anchors to secure them in the remaining mounting hole locations. Depending on the type of installation, you will have either two or four anchors in total to install. 7. After securing all the anchors in the floor as just described, position the rack over the anchors. Level the rack using shim plates, if necessary, as shown in Figure 10. Page 12

PLASTIC-ENCLOSED TORQUE NUT WITH BREAKAWAY CAP WASHER HOLD DOWN BAR BASE SQUARE WASHERS HOLD DOWN PLATES AND SQUARE WASHERS SHIM AS REQUIRED BASE SHIM AS REQUIRED FLOOR LINE 8633-C Figure 10. Rack Shim and Hold Down Bars 8. Place a hold down bar and one or two square washers, as required, on each stud. Replace the flat washers and torque nuts removed in the previous steps. Tighten each torque nut until the breakaway cap breaks away, indicating that the anchor is properly set. Discard the breakaway caps. 2.1.2 Raised Floor Mounting Consult local staff for regulations regarding mounting equipment racks on raised floors. Various methods are available to mount equipment racks to a raised floor. The method described here uses mounting hardware available in a kit from ADC. For other methods, follow the instructions provided with that equipment. Table 1 lists the ADC kit contents. The length of threaded rod required will depend on the raised floor height above the regular floor. Page 13

Table 1. Raised Floor Mounting Kit (FDF-ACC136) Contents ITEM QUANTITY Unistrut (feet) 10 Flat washer 0.625 in. (16 mm) 12 Lock washer 0.50 in. (12.7 mm) 12 Threaded rod 1 2 13 30 in. (76 cm) 4 Insulating shoulder washer 4* Anchor kit 1 Flat washer 0.50 in. (12.7 mm) 12 Hex nut ( 1 2 13) 12 Spring nuts ( 1 2 13) 4 * = Optional Ensure the appropriate hardware is available to satisfy raised floor mounting requirements. The following procedures cover a single equipment rack placement. If more racks in a line-up are being placed, the Unistrut lengths and positions of anchors in the lower floor must be adjusted accordingly. The anchor placed in the concrete floor is designed with a threaded stud and torque nut with a cap that will break away when tightened to the proper torque pressure. Prepare the raised floor support and anchoring hardware using the following procedures. 1. Position the rack in its designated floor location. Mark the mounting holes as shown on the equipment rack footprint. See Figure 11. 2. Move the rack out of the way. Drill four 16 mm (0.625 inch) clearance holes in the raised floor panel(s). MARK HERE EQUIPMENT FOOTPRINT RAISED FLOOR PANEL EXTENDED CENTER LINE UNISTRUT ANCHOR HOLE UNISTRUT ANCHOR HOLE MOUNTING REFERENCE HOLES 8632-A Figure 11. Rack Mounting Hole Markings Page 14

3. Remove any adjacent floor panels as needed to gain access to the lower floor. 4. Mark the lower floor in line with the holes in the raised floor panels. Use a plumb line or equivalent for an accurate mark. See Figure 11. 5. Draw an extended line through the centers of the mounting hole marks. 6. Cut two pieces of Unistrut into 36.0 inch (91.4 cm) lengths. Drill two 16 mm (0.625 inch) holes located 6.0 inches (15.2 cm) from each end. 7. Place the Unistrut on the lines made in step 5. Center along the line and mark the floor for the Unistrut anchor holes. Move the Unistrut out of the way for now. 8. Drill an 18 mm (.07 inch) diameter hole to a depth of 3.15 inches (80 mm) in the concrete at the marks made in step 7. Clean out the hole with compressed air or a blow-out bulb. Check the hole depth with a tape measure or by placing an assembled anchor in each hole. If a reinforcing bar is encountered while drilling, relocate the hole. Fill the unusable hole with locally approved filling product. 9. Insert the anchors into each hole. Check that each anchor shoulder is even with the floor. Use a deep socket or box-end wrench and tighten the torque nut until the anchor is just snug. Do not tighten until the torque nut cap breaks way. Repeat for each anchor. Refer to Figure 9. 10. Remove the nut and washer from the studs. Position the Unistrut over the studs. Replace the flat washer and torque nut onto the stud. Tighten the torque nut until the torque cap breaks away, indicating the anchor is properly set. Discard the break-away portion of the torque nut. Repeat for each anchor. 11. Insert spring-nuts into the Unistrut, aligning them with marks on the floor made in step 4. See Figure 12. 12. Replace as many floor panels as possible while still allowing access to the lower floor. Position the equipment rack over the clearance holes in the floor panel. 13. Cut two lengths of Unistrut approximately 12.0 inches (30.5 cm) long. Mark the Unistrut at the hole positions of the raised floor made in step 2. Drill two 16 mm (0.625 inch) holes in the Unistrut. 14. Measure from the lower floor to the base of the equipment rack allowing sufficient length for leveling shims, hold down bar, washers, and nuts. 15. Place onto one end of the threaded rods, in order: 5/8-inch (16 mm) flat washer, 1/2-inch (12.7 mm) flat washer, 1/2-inch (12.7 mm) lock washer, two - 1/2-inch (12.7 mm) hex nuts, 1/2-inch (12.7 mm) lock washer, 1/2-inch (12.7 mm) flat washer, 5/8-inch (16 mm) flat washer. On top of the pile up, place the shorter length Unistrut over the threaded rods. You may find it easier to have someone hold the Unistrut beneath the raised floor panel for step 16. See Figure 12. 16. Hold the above arrangement in place while inserting the threaded rod up through the floor panel from below, up into the equipment rack base. Thread the rod down into the floor Unistrut spring nuts, then hand-tighten the lower hex nut. Repeat for each rod. 17. Thread the upper hex nut upward until the shorter Unistrut touches the bottom of the raised floor panel. Page 15

EQUIPMENT BASE (FRONT) 1/2 IN. HEX NUT 1/2 IN. LOCK WASHER 1/2 IN. FLAT WASHER NYLON SHOULDER WASHER HOLD DOWN BAR SHIM AS REQUIRED RAISED FLOOR PANEL 5/8 IN. FLAT WASHER 1/2 IN. FLAT WASHER 1/2 IN. LOCK WASHER 1/2 IN. HEX NUT SPRING NUT UNISTRUT 1/2 IN. THREADED ROD ANCHOR ASSEMBLY ;;;;; UNISTRUT CONCRETE FLOOR 8599-A Figure 12. Typical Raised Floor Anchor Arrangement 18. Place onto the upper end of the threaded rod (rack base end) the following items: 5/8-inch (16 mm) flat washer, 1/2-inch (12.7 mm) flat washer, 1/2-inch (12.7 mm) lock washer, 1/2- inch (12.7 mm) hex nut. 19. Align the equipment rack and tighten securely. Start with the floor Unistrut, then the Unistrut under the raised floor and last the rack base. 2.2 Rack-Top Support Various methods are available depending on the existing support structure and how the lineups are spatially arranged. All methods use a bracket of some type to fasten the top of the rack to an external support. The bracket is typically a V-bolt, J-bolt, or threaded bolt with clips. The external support may be a water pipe, overhead cable racking, or office superstructure (for example, a ceiling beam). If possible, the overhead support and lineup should be perpendicular to one another since this arrangement provides the most room for cabling. The following topics provide examples of two common methods, water pipe support and support to cable racking. Page 16

2.2.1 Water Pipe Support Racks nine feet (274.32 cm) and higher have a top angle that fits over one-inch pipe. The rack is secured to the pipe using a V-bolt or similar hardware. Figure 13 shows an example using a V-bolt. Various types of V-bolts are available for different applications. TOP ANGLE SUPPORT PIPE V-BOLT 5829-B Figure 13. Rack Secured to Water Pipe Using V-Bolt Page 17

2.2.2 Support to Cable Racking Various combinations of hardware can be used to secure a rack to overhead racking. Figure 14 shows an example using a V-bolt with threaded rods and clips. As shown, the V-bolt is secured to the top angle as in the previous example. 1.68 IN. MINIMUM TO 8.0 IN. MAXIMUM 5830-A Figure 14. V-Bolt With Threaded Rods and Clips Page 18

Figure 15 shows an example using a threaded rods and clips fastened to the rack top channel. For other options, consult with ADC. 5831-B Figure 15. Threaded Rods Fastened to Rack Top Channel 2.3 Rack Grounding ADC ground kits are available for grounding racks to the office common ground or to one another. A typical grounding kit consists of some length of wire with two-hole lugs on either end, as shown in Figure 16. GLK-1 termination points, also shown in Figure 16, are available for grounding any installed equipment to the rack. Page 19

TWO HOLE LUG 5832-C GLK Figure 16. Rack to Office Ground and Equipment Ground Termination (GLK-1) 2.3.1 Ground Kits With Two-Hole Lugs All grounding connections to the rack using two-hole lugs should be made tight to bare metal to ensure low resistance. Some grounding wires have one stub end with a loose two-hole lug. This is to allow the wire to be trimmed to the correct length before attaching the two-hole lug. Two screws should always be used for two-hole lugs. Use the following procedure (see Figure 17). 1. Remove the paint at each connection point and apply a thin layer of non-oxidizing paste (not provided) on the bare metal surface. 2. If the grounding wire has a stub end, trim the wire to the correct length, then attach the spare two-hole lug using a crimper. 3. Fasten the two-hole lugs to the rack and source of ground using two screws per lug. Screw down tightly to make solid contact with the rack. 2.3.2 Equipment Termination Points Use the following procedure to install GLK-1 equipment termination points. 1. Remove the paint at each connection point and apply a thin layer of non-oxidizing paste (not provided) on the bare metal surface. 2. Place a star washer between the GLK-1 and the rack. 3. Insert the screw and tighten it securely. Page 20

OFFICE GROUND H OR C TAP TWO HOLE LUG REMOVE PAINT FROM AT CONNECTION 5900-D Figure 17. Grounding Kit Example 2.4 Designation Card Holder The designation card holder mounts at the top of the rack to identify equipment in the rack. Mount with the two screws provided (see Figure 18). 5902-B Figure 18. Designation Card Holder Page 21

3 NETWORK ACCESSORIES This subsection contains procedures for installing network rack accessories including AC raceway, raceway filler, guard rail extender, standard filler guard box, raised floor filler guard box, rack spacers, filler panel, hinged filler panel, interbay fiber management panel, and rear fiber storage panel. 3.1 AC Raceway, Raceway Filler, and Guard Rail Extender The AC raceway provides a protective enclosure for electrical wires routed along the base of network racks. Raceways are available with or without AC receptacles for power access at the rack. The raceway filler spans the gap between adjacent racks. The guard rail extender is an outer protective guard at the base of the rack. If not already mounted, mount using the screws provided. Figure 19 shows a raceway, raceway filler, and guard rail extender. RACEWAY WITH RECEPTACLES RACEWAY FILLER GUARD RAIL EXTENDER 5844-C Figure 19. Raceway, Raceway Filler, and Guard Rail Extender 3.2 Filler Guard Box The filler guard box is included in the kits for network rack spacers, filler panels, and interbay fiber management panels. It can only be used with racks mounted on a concrete floor. (For raised-floor applications, see subsection 3.3, Raised Floor Filler Guard Box.) 1. Remove the guard box cover from the adjacent rack; set aside the screws for re-use. 2. Place the filler guard box against the base of the rack; align the side mounting holes in the filler guard box and spacer with the side mounting hole in the rack. 3. Loosely secure the filler guard box and spacer to the base of the adjacent frame using the 3/8-16 3/4-inch cap screw, 3/8-inch lock washer, and 3/8-16 hex nut provided. Note: Figure 1 shows the 4-inch guard box. The 6-inch guard box looks different but mounts in the same way using the same mounting location and hardware. Page 22

SIDE MOUNTING HOLES REAR GUARD RAIL SPACER LOCKWASHER & HEX NUT COVER 6315-E FILLER CAP SCREW FILLER COVER Figure 20. Filler Guard Box Installation 4. Insert the 1/8-inch spacer provided between the frame base filler and the frame base. When the spacer is in place, tighten the 3/8-16 cap screw and nut. 5. Replace the guard box cover that was removed in step 2; secure it to bottom of frame with original mounting screws. 6. Secure the rear guard rail to the rear of the frame base filler. 7. Secure the filler guard box cover to the top and front of the frame base filler. 3.3 Raised Floor Filler Guard Box The raised floor filler guard box kit can be used with network racks mounted on a raised floor or in any situation where cables are routed down through the floor. The filler guard box included in this kit has an open top for routing through cables. The kit may also include a trough plate and one or two radius limiters depending on the application. The installation procedure is divided into three parts: open guard box installation (always done); double trough installation (if between racks); and single trough installation (end of lineup). Page 23

3.3.1 Open Guard Box Installation Use the following procedure to install the open guard box (Figure 21). 1. Remove the guard box cover from the adjacent rack; set aside the two screws for later use. ADJACENT REAR GUARD RAIL SIDE MOUNTING HOLE SIDE MOUNTING HOLE RAISED FLOOR OPENING OPEN GUARD BOX SPACER FLAT WASHER, LOCKWASHER, AND HEX NUT COVER 9055-B CAP SCREW AND FLAT WASHER COVER Figure 21. Installing the Open Guard Box 2. Place the open filler guard box against the base of the adjacent rack, as shown, and line it up with the raised floor opening. 3. Align the side mounting holes in the open guard box and spacer with the side mounting hole in the adjacent rack. 4. Fasten guard box to rack using cap screw and flat washer. Page 24

3.3.2 Double Trough Installation Use the following procedure to install a double trough between adjacent racks. You must have already installed the open guard box (previous procedure). 1. Mount the double rear trough plate on two radius limiters oriented as shown in Figure 22. Use the four screws provided. DOUBLE REAR TROUGH PLATE RADIUS LIMITERS 9059-B Figure 22. Mounting Double Rear Trough Plate on Radius Limiters Page 25

2. Mount the trough and radius limiter to the racks on either side, as shown in Figure 23. 9057-B Figure 23. Installing Double Trough Assembly on Rack Page 26

3.3.3 Single Trough Installation Use the following procedure to install a single trough. You must have already installed the open guard box (for procedure, see above). Note: A single trough is oriented differently depending on whether it is on the left or right side of a lineup. 1. Mount a single rear trough plate to one radius limiter using the screws provided. Figure 24 shows the two direction orientations, for the left and right sides of a lineup. SINGLE REAR TROUGH PLATE RADIUS LIMITER 10068-A LEFT SIDE RIGHT SIDE Figure 24. Mounting Single Rear Trough Plate on Radius Limiter Page 27

2. Mount the trough and radius limiter to the racks on either side as shown in Figure 25. TROUGH AND RADIUS LIMITER 9061-C END GUARD Figure 25. Installing Single Trough Assembly on Rack Page 28

3.4 Rack Spacers Rack spacers are installed between racks to separate the racks from one another. Rack spacers are available in three widths: 2.5, 5.0, or 10.0 inches (6.35, 12.7, or 25.4 cm). The rack spacers kit includes a filler guard box, which should be already installed (if not, refer to subsection 3.2 or 3.3). Install the rack spacers from the rear side of the rack using four 12-24 0.25 inch Phillips-head screws per rack spacer, as shown in the detail bubble in Figure 26. SPACER (3 PLACES) SPACER COVER 10029-C FILLER COVER Figure 26. Installing Rack Spacers Page 29

3.5 Filler Panel A filler panel may be installed between two racks, or between a rack and an end guard. The filler panel kit includes a filler guard box, which should be already in place. If not, install the filler guard box before proceeding (refer to subsection 3.2 or 3.3). Use the following procedure to install a filler panel (Figure 27). JUNCTION PLATE (FILLER PANEL TO ) FILLER PANEL ANGLE BET (FILLER PANEL TO END GUARD) JUNCTION PLATE COVER 10030-B FILLER Figure 27. Installing a Filler Panel Page 30

1. Set the filler panel on top of the filler guard box and press it in flush against the rack front flange (on both sides if between two racks). 2. From the rear side of the rack, fasten the filler panel to the rear side of the rack front flange using three junction plates and twelve 12-24 0.25 inch Phillips-head metal screws (four per junction plate), as shown in the detail bubble in Figure 27. 3. If attaching to a second rack, repeat step 2 to fasten that panel, also, and omit the next step. 4. If attaching to an end guard, attach three angle mounting brackets instead in the same positions using twelve 12-24 0.25 inch Phillips-head metal screws (four per bracket, as shown in Figure 27). 3.6 Interbay Fiber Management Panel The Interbay Fiber Management Panel (IMP) is used in a fiber application only. It may be installed between two racks, or between a rack and an end guard. The kit includes a filler guard box, which should be already installed (if not, refer to subsection 3.2 or 3.3). Different heights are accommodated using various combinations of panel sections (Figure 28). TOP MID TOP TOP PANEL IDENTIFICATION STAMPED ON PANELS TOP MID MID MID TOP MID TOP TOP TOP SHORTER BOTTOM PANEL USED WITH 6-INCH 4-INCH BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM BOTTOM 6-INCH 5 FT. 8 IN. 6 FT. 6 FT. 4 IN. 7 FT. 8 FT. 2.6 M 9 FT. 11 FT. 5 IN. 11093-C Figure 28. Panel Section Combinations for Different Frame Heights Page 31

The panel sections are mounted using junction plates that connect the panel sections to the front flange of the frame. Each junction plate is secured using four #12-24 3/8-inch machine screws. When mounting the panels, start at the bottom and work up. Install the machine screws from the rear side of the frame. Use the following procedure to install the panel sections. 1. Set the bottom panel section on the filler guard box with the spools facing toward the front of the frame, as shown in Figure 29. JUNCTION PLATE DETAIL DRAWING INTERBAY FIBER MANAGEMENT PANEL 6316-D BOTTOM Figure 29. Bottom Panel Installation Page 32

2. Align the mounting holes in the panel section with the corresponding mounting holes in the front flange of the adjacent frame. Figure 30 shows a top view of panel position. 1/4-IN. 12-24 SCREW (4 PER BET) JUNCTION PLATE SPOOL FRONT OF FRAME TOP VIEW 11091-A Figure 30. Top View of Panel Position 3. Secure the bottom panel section to the front flange of the adjacent frame using two junction plates and six #12-24 3/8-inch machine screws. Use four screws in the lower junction plate and just two screws in the upper junction plate, as shown in Figure 29. Note: Remove bottom spool if frame has a 14- or 16-inch lower horizontal trough. 4. Select the next higher panel section ( mid or top ) and mount two junction plates on the side (left or right) that is going to be connected to the adjacent frame. Remember to mount the junction plates from the rear. Use only two machine screws in the upper junction plate if there is going to be another section above this one. 5. Position the panel section above the section that has already been installed, as shown in Figure 31. Secure it to the front flange of the rack using machine screws. 6. If there will be an additional panel section ( top ), repeat steps 4 and 5, above. Continue until all panel sections have been mounted to the adjacent rack. 7. If installing another frame on the other side of the panel just installed, proceed to install that frame now, as described in this guide. Connect to the frame to the panel using junction plates and machine screws, as in the above steps. 8. If installing an end guard on the other side of the panel just installed, proceed to install the end guard now, as described in this guide. Note that different hardware (angle irons instead of junction plates) are used to connect the interbay fiber management panel to an guard. Page 33

MOUNTING BETS TOP OR MID PANEL SECTION BOTTOM PANEL SECTION BACK VIEW 11092-A Figure 31. Mid or Top Panel Installation 3.7 Filler Trough A filler trough can be installed at the base of the interbay fiber management panel if the rack is floor-mounted. Use the following procedure to install the filler trough. Note: If required by office cabling practices, the bottom spool may be removed by removing two screws from the rear of the bottom panel section. Filler trough may not be used with an end guard panel kit. 1. With the filler trough in a vertical position, slide it down between the frame trough and bottom spool, then rotate it into a horizontal position and drop it into place (as indicated by arrow in Figure 32). 2. Secure the filler trough using one Phillips screw installed in the lower center of the bottom panel section (located below the word BOTTOM in Figure 32). FRAME BOTTOM PANEL SECTION FRAME TROUGH FILLER TROUGH BOTTOM SECURE WITH PHILLIPS SCREW 11090-B FILLER ASSEMBLY Figure 32. Filler Trough Installation Page 34

3.8 Rear Fiber Storage Panel The Rear Fiber Storage Panel (RFSD) mounts flush on the rear side of an interbay fiber management panel using the same mounting hardware. The RFSD is shipped with an extra spool that is positioned differently depending on whether the RFSD is mounted on the left or right side of the frame (see Figure 33). Use the following procedure to install the RFSD: EQUIPMENT BAY UNEQUAL FLANGE FRAME (REAR VIEW) JUNCTION PLATES (6 PLACES) REAR FIBER STORAGE PANEL #12-24 X.31 SCREWS (6) INTERBAY FIBER MANAGEMENT PANEL #6-32 SCREWS (2) LOOSE SPOOL LEFT SIDE RIGHT SIDE WIDE FRONT FLANGE PANEL MOUNTING HOLES (6 PLACES) 3365-F Figure 33. Installing a Rear Fiber Storage Panel Page 35

1. Position yourself at the rear of the interbay fiber management panel with the RFSP in hand. 2. Stand up the RFSP in its correct location on either the left side or right side of the frame with the RFSP spools facing away from the frame. 3. Note that the RFSP has four upper spools and four lower spools with two spool-mounting positions between. Install the extra spool in the lowest mounting position using the two #6-32 screws provided in the kit. Note: If the RFSP is facing in the wrong left or right direction, the mounting positions will be reversed. Be sure to install the extra spool in the correct position before installing the junctions plates. 4. Observe that the interbay fiber management panel is fastened to the wide front flange of the rack with six junction plates, each secured with four 12-24 0.316 Phillips-head screws, as shown in Figure 33. 5. Remove the two innermost Phillips-head screws from the three junction plates (top to bottom) You will be using this same hardware to mount the RFSP and interbay fiber management panel together. 6. Align the rear fiber storage panel as shown, and secure it to the rear of the interbay fiber management panel using the six screws just removed above. 4 NON-NETWORK ACCESSORIES This section contains procedures for installing non-network rack accessories including guard box cover, second guard box, spacer box, rack spacer, and filler plate. 4.1 Guard Box Cover An optional cover may be installed on the integral guard box at the base of the non-network rack to provide a protective enclosure. To install the guard box cover, align it on top of the integral guard box as shown in Figure 30, and secure it using the two 12-24 0.25 inch Phillips-head mounting screws provided in the kit. Depending on the application, the integral guard box may be located on either the front or rear flange of the rack, as indicated in Figure 34. 4.2 Second Guard Box An optional second guard box may be installed on the non-network rack opposite from the integral guard box. Use the following procedure to install the second guard box (Figure 35). 1. Place the second guard box square against the flanges on the opposite side of the rack from the integral guard box. 2. Secure the second guard box by fastening it to the rack using the four 12-24 0.25 inch Phillips-head mounting screws provided in the kit. (To install an individual screw, place it on the tip of the screwdriver and then reach the screwdriver through the round hole on the front side of the second guard box. Install the screw in the corresponding hole on the rear side of the second guard box, in the position shown in Figure 31.) Page 36

FRONT OR REAR FLANGE COVER MOUNTING SCREW OPTIONAL AC OUTLET INTEGRAL MOUNTING SCREW 10032-A Figure 34. Installing a Guard Box Cover INTEGRAL MOUNTING SCREWS (4) SECOND 10044-B Figure 35. Installing a Second Guard Box Page 37

4.3 Rack Spacer Box The rack spacer box is mounted below a filler panel or below rack spacers, as shown in Figure 36. The rack spacer box must be ordered as a separate kit. The rack spacer box may be either open or closed, as shown. Fasten the rack spacer box to the concrete floor in the two mounting locations using the hardware provided in the kit (one 3/8 16 inch anchor bolt, one washer, and one nut per each mounting location, as shown in the detail bubble in the figure). ADJACENT S NUT WASHER SPACERS ANCHOR BOLT 3/8 x 16 MOUNTING LOCATIONS SPACER BOX (OPEN) SPACER BOX (CLOSED) 10047-A Figure 36. Installing a Rack Spacer Box 4.4 Rack Spacers Rack spacers may be used between adjacent racks to separate the racks from one another. The rack spacers mount above a rack spacer box, which should be installed first (refer to the previous procedure). Fasten the rack spacers to the rear side of the wide front flange using the hardware provided, as shown in Figure 37. Rack spacers are available in three spacing options, as shown in Figure 38. Page 38

ADJACENT S SPACERS SPACER BOX 10046-A Figure 37. Installing Rack Spacers SPACER (3 PLACES) SPACING 2.5 IN. (6.35 CM), 5.0 IN. (12.7 CM), OR 10.0 IN. (25.4 CM) 10031-A Figure 38. Rack Spacing Options Page 39

4.5 Filler Panel A filler panel may be used between adjacent racks to separate the racks from one another. The panel mounts above a rack spacer box, which should be already installed (if not, refer to subsection 4.3). Fasten the panel to the rear side of the wide front flange using the junction plates and mounting screws, as shown in Figure 39. FILLER PANEL ADJACENT S JUNCTION PLATES SPACER BOX 10048-A Figure 39. Installing a Filler Panel 4.6 Interbay Fiber Management Panel If installing an interbay fiber management panel on a non-network rack, refer to the network rack procedure (subsection 3.6). 5 COMMON ACCESSORIES The common rack accessories documented here can be used with either type of unequal flange rack (network or non-network). 5.1 End Guard Panel An end guard panel can be used with any ADC unequal flange rack of either type, network or non-network. It can be attached directly to a rack or to a filler panel or interbay fiber management panel. Three heights are available corresponding to the three heights of racks. Use the following procedure to install an end guard panel (Figure 40). Page 40

FILLER BET 8 FT. AND ABOVE FIBER BAY ONLY ADJACENT END GUARD INNER SUPPORT PANEL 7 FT. FIBER BAY ONLY COVER PANEL ALARM LIGHT COVER AC COVERS AC COVERS ANGLE MOUNTING BETS (3 PLACES) COVER 10043-B ANCHOR HOLES Figure 40. Installing an End Guard Panel Directly to Network Rack 1. If the rack or filler panel to which the end guard panel will be joined does not have angle mounting brackets already installed in the positions shown in Figure 36, fasten the angle mounting brackets to the rear side of the rack or filler panel using the four 12-24 0.25 inch Phillips-head mounting screws provided in the kit. Page 41

5.2 Rack Extenders 2. Place the end guard inner support panel in its approximate position, and temporarily support it by loosely securing it to the angle mounting brackets using the 12-24 0.25 inch Phillips-head screws provided in the kit. 3. For additional temporary support, temporarily install the filler bracket shown in Figure 34. Loosely attach the filler bracket using two 12-24 0.50 inch Phillips-head screws. 4. Align the end guard inner support panel and mark the anchors holes on the floor. 5. Unfasten the end guard inner support panel from the brackets and set it aside. 6. Drill anchor holes and install the floor anchors. 7. Set the end guard inner support panel in position again and loosely attach it to the floor anchors. 8. Re-attach the inner support panel to the angle mounting brackets and filler brackets using the same screws as used above. Note that the longer screws are used for the filler bracket. 9. Tighten the floor anchors, then tighten the screws in the brackets. 10. Mount the cover panel to the end guard inner support panel using 12-24 0.5 inch selftapping screws. 11. Mount the blank alarm light cover using 8-32 0.31 inch Phillips-head screws. 12. Mount the four blank AC covers to the cover panels using 8-32 0.31 inch screws. Rack extenders for non-network type racks are available from 6.0 to 54 inches (15.2 to 137 cm). Rack extenders for network type racks are available from 18.0 to 54.0 inches (45.7 to 137 cm). Figure 41 shows a rack extender. Install by fastening the two bolts shown. Note: Earthquake zone racks do not accommodate extenders on racks 8.5 feet (2.4 m) or over. Extenders are not recommended for use in earthquake zones three and four. 5899-B Figure 41. Installing a Rack Extender Page 42

6 CUSTOMER INFORMATION AND ASSISTANCE For customers wanting information on ADC products or help in using them, ADC offers the services listed below. To obtain any of these services by telephone, first dial the central ADC telephone number, then dial the extension provided below. The central number for calls originating in the U.S.A. or Canada is 1-800-366-3891. For calls originating outside the U.S.A. or Canada, dial country code 1 then dial 952-946-3000. Sales Assistance Extension 63000 Systems Integration Extension 63000 BCG Technical Assistance Center Extension 63475 E-Mail: bcg_tac@adc.com Product Return Department Extension 63748 E-Mail: repair&return@adc.com Quotation Proposals Ordering and Delivery General Product Information Complete Solutions (from Concept to Installation) Network Design and Integration Testing System Turn-Up and Testing Network Monitoring (Upstream or Downstream) Power Monitoring and Remote Surveillance Service/Maintenance Agreements Systems Operation Technical Information System/Network Configuration Product Specification and Application Training (Product-Specific) Installation and Operation Assistance Troubleshooting and Repair ADC Return Authorization number and instructions must be obtained before returning products. Product information may also be obtained using the ADC web site at www.adc.com or by writing ADC Telecommunications, Inc., P.O. Box 1101, Minneapolis, MN 55440-1101, U.S.A. Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice. In no event shall ADC be liable for any damages resulting from loss of data, loss of use, or loss of profits and ADC further disclaims any and all liability for indirect, incidental, special, consequential or other similar damages. This disclaimer of liability applies to all products, publications and services during and after the warranty period. This publication may be verified at any time by contacting ADC s Technical Assistance Center at 1-800-366-3891, extension 63475 (in U.S.A. or Canada) or 952-946-3475 (outside U.S.A. and Canada), or by e-mail to bcg_tac@adc.com. All Rights Reserved Printed in U.S.A Page 43