Installing the T640 Router Using a Mechanical Lift

1. Remove the T640 Power Supplies
2. Attaching the T640 Router Installation Handle
3. Mounting the T640 Chassis Using a Mechanical Lift
4. Removing the T640 Router Installation Handle and Reinstalling the Power Supplies

Remove the T640 Power Supplies

The power supplies are located at the rear of the chassis below the SIBs. Each two-input 160-A DC power supply weighs approximately 23 lb (10.5 kg). Each three-input 240-A DC power supply weighs approximately 25 lb (11.3 kg). Each four-input 240-A DC power supply weighs approximately 26.6 lb (12.0 kg). Each AC power supply weighs 31.0 lb (14.06 kg).

To remove the power supplies, starting with the upper power supply:

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to an approved site ESD grounding point. See the instructions for your site.
2. Switch the circuit breakers on the DC power supply faceplates to the off position (O) or the power switches on the AC power supply faceplates to the standby position. We recommend this even though the power supplies are not connected to power sources.
3. Loosen the captive screws on the lower corners of the power supply faceplate completely.
4. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
5. Grasp the handle on the power supply faceplate and pull firmly to start removing the power supply. Slide it halfway out of the chassis (see Figure 1).

   Caution: Be prepared to support the full weight of the power supply as you remove it from the router.

6. Place one hand underneath the power supply to support it and slide it completely out of the chassis.
7. Repeat the procedure for the other power supply.

Note: Figure 1 shows the two-input 160-A DC power supply, but the procedure also applies to the three-input 240-A DC power supply.

Figure 1: Removing a Power Supply Before Installing the Router

Attaching the T640 Router Installation Handle

To assist you with the installation of the T640 router, attach the installation handle over the power supply slots of the chassis. To remove the power supplies and attach the handle, starting with the upper power supply:

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to an approved site ESD grounding point. See the instructions for your site.
2. Switch the circuit breakers on the power supply faceplate to the off position (O). We recommend this even though the power supplies are not connected to power sources.
3. Loosen the captive screws on the lower corners of the power supply faceplate completely. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
4. Twist the ejector handles on the upper corners of the faceplate counterclockwise to unseat the power supply.
5. Grasp the handle on the power supply faceplate and pull firmly to start removing the power supply. Slide it halfway out of the chassis (see Figure 2).

   Caution: Be prepared to support the full weight of the power supply as you remove it from the router.

6. Place one hand underneath the power supply to support it and slide it completely out of the chassis.
7. Repeat the procedure for the other power supply.
8. Attach the installation handle by tightening the captive screws of the handle into the holes previously occupied by the captive screws of the power supplies (see Figure 3).

Figure 2: Removing a Power Supply Before Installing the Installation Handle

Figure 3: Attaching the Installation Handle

Mounting the T640 Chassis Using a Mechanical Lift

Caution: Before front-mounting the router in a rack, have a qualified technician verify that the rack is strong enough to support the router's weight and is adequately supported at the installation site.

1. If you are installing the router in an open-frame rack, ensure that the rack is in its permanent location and is secured to the building. Ensure that the installation site allows adequate clearance for both airflow and maintenance. For details, see T640 Clearance Requirements for Airflow and Hardware Maintenance .
2. Load the router onto the lift, making sure it rests securely on the lift platform (see Figure 4).

   Caution: Do not lift the router using the installation handle, or the handles on the sides of the chassis. Use these handles only to help position the router.

3. Using the lift, position the router in front of the rack or cabinet, centering it in front of the mounting shelves.
4. Lift the chassis approximately 0.75 in. above the surface of the mounting shelves and position it as close as possible to the shelves.
5. Carefully slide the router onto the mounting shelves so that the bottom of the chassis and the mounting shelves overlap by approximately 2 inches.
6. With one person pulling on the installation handle from the rear of the rack or cabinet while two people push on the front-mounting flanges, slide the router onto the mounting shelves until the mounting brackets or front-mounting flanges contact the rack rails or spacer bars (depending on your type of installation). The shelves ensure that the holes in the mounting brackets and the front-mounting flanges of the chassis align with the holes in the rack rails.

   If you center-mount the chassis, you use the center-mounting brackets attached to the chassis; if you front-mount the chassis, you use the front-mounting flanges.

7. Move the lift away from the rack.
8. If you are installing the router in a four-post rack or cabinet, install a mounting screw and a cage nut into each of the holes aligned with the threaded holes in the spacer bars. If you are installing the router in an open-frame rack, install a mounting screw into each of the open mounting holes aligned with the rack, starting from the bottom.
9. Visually inspect the alignment of the router. If the router is installed properly in the rack, all the mounting screws on one side of the rack should be aligned with the mounting screws on the opposite side and the router should be level.

Figure 4: Loading the Router onto the Lift

Figure 5: Installing the Router in the Rack

Note: This illustration depicts the router being installed in a four-post rack. For an illustration of the mounting hardware required for an open-frame rack, see Install the Mounting Hardware for an Open-Frame Rack.

Removing the T640 Router Installation Handle and Reinstalling the Power Supplies

After you have installed the T640 router, remove the installation handle and reinstall the two power supplies in the chassis, starting with the lower power supply (see Reinstalling a Power Supply):

1. Attach an electrostatic discharge (ESD) grounding strap to your bare wrist, and connect the strap to an approved site ESD grounding point. See the instructions for your site.
2. Loosen the captive screws on the installation handle completely, and remove the handle from the chassis.
3. Switch the circuit breakers on the power supply faceplate to the off position (O).
4. Using both hands, slide the power supply into the chassis until you feel resistance.
5. Twist the ejector handles at the upper corners of the power supply faceplate clockwise until they stop.
6. Tighten the captive screws at the lower corners of the power supply faceplate to secure the power supply in the chassis.
7. Repeat the procedure for the upper power supply.

Figure 6: Reinstalling a Power Supply