Cisco CGR 1240 User manual

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Cisco Systems, Inc. www.cisco.com
Mounting the Router
This section describes the safety information, equipment, and procedures required to mount the
Cisco 1240 Connected Grid Router (CGR 1240 or router) on a vertical pole or streetlight.
These topics are discussed:
Mounting Kits Overview, page 49
General Safety Information for Mounting, page 50
Contents of the Mounting Kits, page 50
Materials and Tools You Supply, page 54
Mounting Instructions, page 54
Grounding Instructions, page 69
Bracket Dimensions, page 71
Mounting Kits Overview
You will need some or all of the kits described in this section to install the router on a pole. Your installation environment
and requirements determine the kits you need.
For a detailed description of each kit, see Contents of the Mounting Kits, page 50.
:
Cisco Product ID (PID) Name Description
–Mounting Bracket Kit,
page 51
Use this kit if your installation requires a Cisco mounting
bracket to mount the router. This kit is included with in the
router accessory kit, and is used with the pole kit and
includes the hardware required to attach the mounting
bracket to the mounting plate.
CGR-PMK1000 Pole Mount Kit, page 50 This kit is required for all pole or streetlight installations and
includes a mounting plate and the hardware required to
attach the mounting plate to a pole.
CGR-PMK-BAND Band Strap Kit, page 52 This kit includes two steel straps for mounting the router on
poles larger than 4.5 inches (11.4 cm) in diameter. This kit
is used together with the Pole Mount Kit, page 50. A
BAND-IT Tool is required to install the steel straps on a pole.
AIR-BAND-INST-TL= Strap Tool Kit, page 53 This kit includes a BAND-IT tool that is required when using
steel straps to install the router on poles larger than
4.5 inches (11.4 cm) in diameter.

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General Safety Information for Mounting
Read the safety warnings in this section and in Installation Safety and Site Preparation, page 7.
One person is required to properly and safely mount the router.
Caution: All mounting methods at any location are subject to the acceptance of local jurisdiction.
Caution: The mounting surface, attaching screws, and optional wall anchors must be able to support a 50 pound (22.7
kg) static weight.
Caution: Personnel mounting the router must understand grounding methods.
Warning: Do not locate the antenna near overhead power lines or other electric light or power circuits, or where it
can come into contact with such circuits. When installing the antenna, take extreme care not to come into contact
with such circuits, as they may cause serious injury or death. For proper installation and grounding of the antenna,
please refer to national and local codes (for example, U.S.:NFPA 70, National Electrical Code, Article 810, Canada:
Canadian Electrical Code, Section 54). Statement 1052
Contents of the Mounting Kits
This section describes the contents of the mounting kits available for the router and when you should use each kit.
Pole Mount Kit
Use the Cisco pole mount kit to install the mounting plate on any pole or streetlight. The kit supports poles that meet the
following criteria:
Size—2 to 16 inch diameter poles
Material—Metal, wood, or fiberglass poles

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Figure 23 Pole Mount Kit Contents
Mounting Bracket Kit
Use the mounting bracket kit if you require a Cisco mounting bracket. The mounting bracket attaches to the mounting
plate, and then the router is installed on the mounting bracket.
Note: You can optionally use any compatible mounting bracket with the Cisco pole mount kit. Check with your authorized
Cisco reseller for compatible mounting brackets. See Pole Mount Kit, page 50
Item Name Qty. Description
1Mounting plate 1 Install mounting plate on pole. Mounting bracket attaches to
mounting plate.
2Clamp brackets 2 Use the clamp brackets to install the mounting plate on a pole.
Included Hardware
3Washer (3/8 inch) 4 Use the included hardware to attach the mounting plate to the pole,
as described in Install the Mounting Plate onto a Pole, page 54.
4Split lock washer (3/8 inch) 4
5Nut (3/8-16) 4
6Carriage bolt (3/8-16 x 7 inches) 4
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Included Hardware
Qty 4
3
Qty 4
4
Qty 4
6
Qty 4
5
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Figure 24 Mounting Bracket Kit Contents—Required Parts
Band Strap Kit
Use the straps in the Band Strap Kit when you mount the router on a pole larger than 4.5 inches (11.4 cm) in diameter.
This installation also requires the pole mount kit and strap tool kit. See Pole Mount Kit, page 50 and Strap Tool Kit,
page 53.
Item Name Qty. Description
1Mounting bracket 1 Mounts router to mounting plate, which is installed on pole.
2Mounting bracket security panel
(optional)
1 Optional bracket feature, which prevents the unauthorized users
from removing the router from the mounting bracket.
Included Hardware
3Washer (M8) 12 Use this hardware to attach the mounting bracket to the mounting
plate, and the router to the mounting bracket. Assemble the
washer, split lock washer, and bolt as described in Assemble
Bracket Hardware, page 59.
4Split lock washer (M8) 12
5Bolt (M8 x 1.25) 12
6Serrated nut (M8 x 1.25) 1
7Security panel screws (8-32) 3 Use these screws to attach the security panel to the mounting
bracket.
Included Hardware
Qty 12
3
Qty 12
4
Qty 4
6
Qty 12
5
Qty 4
7
21
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Figure 25 Band Strap Kit Contents
Strap Tool Kit
Use the tool in the Strap Tool Kit to attach the steel straps included in the band strap kit. Steel straps are required to
install the mounting plate on poles larger than 4.5 inches (11.4 cm) in diameter. See Band Strap Kit, page 52.
Note: The tool in the Strap Tool Kit is manufactured and supported by BAND-IT. For more information about the tool, see
www.band-it-idex.com.
Figure 26 Strap Tool Kit Contents
Item Description
1Steel straps (2)
1
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300604
Item Description
1Strap tool
2Strap tool documentation (not shown)
1
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Materials and Tools You Supply
You must supply some or all of these items to mount the router on a pole. The items you supply depends on the
installation procedure that you use.
Mounting Instructions
This section includes all the procedures required to mount the router on any supported pole type.
This section covers the following procedures:
Router Orientation, page 54
Install the Mounting Plate onto a Pole, page 54
Attach the Mounting Bracket to the Mounting Plate, page 59
Install the Router onto the Mounting Bracket, page 62
Mounting the Router onto a Wall, page 66
Router Orientation
When mounting the router on a pole, ensure that:
The router is oriented with the chassis cabling openings pointing down so the router cables can be correctly
connected through the openings and so the router door opens correctly, as shown in Figure 35 on page 62.
The router is mounted with the hinged access cover facing out.
Install the Mounting Plate onto a Pole
This section describes three different procedures for installing the mounting plate on a pole. Follow the instructions for
the pole type used in your installation.
The instructions in these section refer to the mounting plate features shown in Figure 27 on page 55.
Install the Mounting Plate—Poles Up to 4.5 Inches in Diameter, page 55
Install the Mounting Plate—Poles Larger than 4.5 Inches in Diameter, page 57
Item Required for These Procedures
13-mm box-end wrench or socket set Install the Mounting Plate—Poles Up to 4.5 Inches in Diameter, page 55
Install the Mounting Plate—Through-Pole Mounting (Optional), page 58
Attach the Mounting Bracket to the Mounting Plate, page 59
Bolt, standard washer, fender washer, and nut,
5/8 inch (2 sets)—Bolt length depends on the size
of the pole used in the installation.
Install the Mounting Plate—Through-Pole Mounting (Optional), page 58
Drill and drill bit Install the Mounting Plate—Through-Pole Mounting (Optional), page 58
Phillips screwdriver, or other screwdriver for
cross-recessed screws
Ground the Router, page 70
Install the Optional Security Panel, page 63
Crimping tool or pliers Ground the Router, page 70

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Install the Mounting Plate—Through-Pole Mounting (Optional), page 58
Figure 27 Mounting Plate Details
Install the Mounting Plate—Poles Up to 4.5 Inches in Diameter
Required Materials
Mounting plate, carriage bolts, and clamp brackets included in Pole Mount Kit, page 50.
13-mm box-end socket wrench
To install the mounting plate on a vertical pole up to 4.5 inches (11.4 cm) in diameter (refer to Figure 28 on page 56 and
Figure 29 on page 57:
1. Select a mounting location on the pole and place the top and bottom pole clamp bracket (1) notches against the
pole.
2. Place one of the clamp brackets on the opposite side of the pole, aligning the clamp bracket holes with the top two
carriage bolt holes on the mounting plate.
3. Insert a carriage bolt (5) through each of the top two carriage bolt holes on the mounting plate and through the holes
in the clamp brackets.
4. Position the each bolt in the clamp so that the bolt is next to the pole, as shown in Figure 28 on page 56.
5. To place the bracket hardware on each carriage bolt (see Figure 28 on page 56):
Item Description Qty.
1Carriage bolt holes 4
2Bracket mount holes 8
3Clearance holes, 3/4 in. 2
4Pole clamp notches 2
5Steel band strap slots 4
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1
5
4
4
2
3
Reverse angle

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a. Place the washer (2) and then the split lock washer (3) on the back of each carriage bolt (5).
b. Thread the hex nut (4) on each carriage bolt. Place the split-lock washer between the washer and the nut.
Figure 28 Carriage Bolt Hardware Assembly Details
6. Hand tighten the hex nuts (do not overtighten).
7. Repeat Step 3 through Step 6, installing the two bottom carriage bolts and the second clamp bracket at the bottom
of the mounting plate.
8. Position the mounting plate and clamp brackets on the pole as needed before further tightening the carriage bolts.
9. Use a socket wrench to evenly tighten all four carriage bolts to finish installing the mounting plate on the pole.
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4
5
3
1

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Figure 29 Mounting Plate Installed on Pole with Clamp Brackets
Install the Mounting Plate—Poles Larger than 4.5 Inches in Diameter
Required Materials
Mounting plate and steel straps included in Pole Mount Kit, page 50.
BAND-IT tool included in Strap Tool Kit, page 53
Torque wrench
To install the mounting plate on a vertical pole that is larger than 4.5 inches (11.4 cm) in diameter (refer to Figure 30 on
page 58):
1. Assemble the straps and the mounting plate by threading the two steel straps through the band strap slots on the
mounting plate.
2. Select a mounting location on the pole.
3. Position the mounting plate on the pole as needed and tighten the straps around the pole.
Item Description
1Pole clamp notch
2Carriage bolts (4)
3Pole clamps (2)
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2
3

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4. Use the BAND-IT strap tool to tighten the metal bands around the pole, following the instructions in the box with the
tool. Ensure the metal bands are as tight as possible (approximately 7 ft-lbs).
Note: When the metal bands are tightened to the full tension, the mounting plate cannot be adjusted unless the metal
bands are disassembled or cut.
Figure 30 Mounting Plate Installed on Pole with Steel Straps
Install the Mounting Plate—Through-Pole Mounting (Optional)
If the pole used in your installation is made of wood, you can optionally install the mounting plate using the procedure
described in this section. This is an alternate mounting method to the following two mounting methods, which can also
be used when mounting the router on a wood pole:
Install the Mounting Plate—Poles Up to 4.5 Inches in Diameter, page 55
Install the Mounting Plate—Poles Larger than 4.5 Inches in Diameter, page 57
Required Materials
Mounting plate included in Pole Mount Kit, page 50.
Hardware that you supply: 5/8-in. carriage bolt (length depends on the pole size in your installation), standard
washer, fender washer, nut (2 sets)
Tools that you supply: Drill, drill bit (for 5/8-in. through bolts), and 13-mm box-end socket wrench
To mount the router on a wood pole:
1. Place the mounting plate on the selected mounting location on the pole.
2. Mark the drilling locations on the pole through the clearance holes and remove the mounting plate.
3. Drill holes completely through the pole at the points you marked in Step 2.
4. Position the mounting plate over the drilled holes. Align the clearance holes on the mounting plate with the drilled
holes.
5. Place a standard washer against one of the clearance holes on the mounting plate, then feed the bolt through the
washer, clearance hole, and drilled hole. Push the bolt all the way through the pole. See Figure 27 on page 55.
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6. Follow these steps on the opposite side of the pole:
a. Place a fender washer on the end of the bolt, and then a nut.
b. Hand tighten the nut.
7. Repeat Step 5 and Step 6 for the second bolt.
8. Use a socket wrench to evenly tighten both bolts to finish installing the mounting plate on the wooden pole.
Figure 31 Mounting Plate Installed on Wooden Pole with Through Bolts
Attach the Mounting Bracket to the Mounting Plate
This section describes how to attach the mounting bracket to the mounting plate.
Assemble Bracket Hardware
Several of the procedures in this section require you to assemble the bracket hardware before installing the bracket. A
bracket hardware set consists of one bolt, one washer, one split lock washer, and one nut.
To assemble the bracket hardware:
1. Slide the split lock washer (2) on the bolt (1).
2. Slide the regular washer (3) on the bolt (1).
Place the split-lock washer between the regular washer and the bolt as shown in Figure 32 on page 60.
Item Description
1Wood pole
25/8-in. through bolts (2)
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Figure 32 Assemble Bracket Hardware Sets
The instructions for the procedures in this section refer to the mounting plate features shown in Figure 33 on page 60.
Figure 33 Mounting Bracket Details
Note: The mounting plate must be installed as described in Install the Mounting Plate onto a Pole, page 54.
To attach the mounting bracket to the mounting plate (refer to Figure 34 on page 61):
Required Materials
Mounting bracket and hardware included in the Mounting Bracket Kit, page 51
13-mm box-end socket wrench
1. Assemble four sets of bracket hardware (washer, split lock washer, and bolt) as shown in Assemble Bracket
Hardware, page 59.
2. Place the mounting bracket against the mounting plate by inserting the bracket quick hang notch over the mounting
plate quick hang stud (4).
Item Description
1Pivot grooves (4)
2Quick hang notch
3Quick hang slots (2)
4Optional wall-mount holes (4)
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2
3
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3
2

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3. Thread the serrated nut onto the quick mount stud (4) and hand tighten (do not overtighten).
4. Align the pivot grooves (2) on the bracket with four of the bracket mount holes (1) on the mounting plate. Follow these
guidelines:
—Each of the four pivot grooves on the bracket must be attached to at least one bracket mount hole on the
mounting plate.
—The final desired orientation of the mounting plate and router determine which bracket mount holes are used.
—Mount the router as described in Router Orientation, page 54.
5. Insert one bolt assembly (3) through one of the pivot grooves (2) on the bracket and then through the corresponding
bracket mount hole on the mounting plate.
6. Repeat Step 5 for the remaining bolt assemblies.
7. Position the mounting bracket onto the mounting plate as needed before further tightening the bolts.
8. Use a socket wrench to evenly tighten all four bolts and the serrated nut to finish installing the bracket on the plate.
Use a torque of 6-7 foot-pounds when tightening the bolts and nut.
Figure 34 Mounting Bracket Attached to Mounting Plate
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5
4
6

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Install the Router onto the Mounting Bracket
This section describes how to attach the router to the mounting bracket. The mounting bracket is installed on the
mounting plate (included in the Cisco pole mount kit), which is installed on a supported pole type. See Pole Mount Kit,
page 50.
The instructions for the procedures in this section refer to the mounting bracket kit contents shown in Figure 24 on
page 52 and the bracket features described in Figure 33 on page 60.
Note: Refer to Install the Optional Security Panel, page 63 for how to install the optional security panel on the bracket.
Figure 35 Router Installed in Mounting Bracket
Required Materials
Mounting bracket and hardware included in Mounting Bracket Kit, page 51.
Socket wrench that you supply.
To mount the router on the bracket (refer to Figure 36 on page 63 and Figure 37 on page 63:
1. Assemble eight sets of bracket hardware (washer, split lock washer, and bolt) as shown in Assemble Bracket
Hardware, page 59.
2. Attach one set of hinge bolt hardware to the mounting bracket connector shown in Figure 37 on page 63 (1).
Do not tighten the hardware until Step 6. There must be enough space between the washer and the router to slide
the router onto the bracket.
3. Repeat Step 2 on the other side of the router.
4. Slide the router onto the bracket by inserting the hinge bolts you attached in Step 2 into the bracket quick hang slots
(2).
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Figure 36 Attach One Hinge Bolt to Each Side of the Router
5. Attach the six remaining sets of hardware to each side of the bracket and router (3 sets on each side), as shown in
Figure 37 on page 63.
6. Use a socket wrench to evenly tighten all four bolts, using 6-7 foot-pounds of torque.
Figure 37 Attach Remaining Bolts to Bracket and Router
Install the Optional Security Panel
The Cisco includes an optional security panel. See Mounting Bracket Kit, page 51. The security panel prevents
unauthorized users from removing the router from the mounting bracket, and also prevents unauthorized access to the
SD Card Slot (see SD Card Slot Access for Bracket-Mounted Routers, page 68).
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2
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Required Materials
Security panel and the hardware (three 8-32 PNH screws) included in the mounting bracket kit.
Phillips screwdriver
Figure 38 Security Panel Details
To install and secure the security panel to the bracket and router:
1. Loosen the captive bolt that is located inside router door lock post. For lock post location, see Figure 57 on page 82.
2. Install the security panel on the bracket by inserting the security panel tabs into the corresponding slots on the
bracket as shown in Figure 39 on page 65.
Note: For clarity, the router is not shown here. During this procedure, the router is mounted in the bracket.
Item Description
1Insert the security panel tabs into the corresponding notches on the mounting bracket.
2Secure the security panel to the bracket at these locations, using the screws included in the Mounting Bracket
Kit, page 51.
3Insert the captive screw located in the router door lock block through this hole when closing the router door.
1
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Figure 39 Assemble Bracket and Security Panel
3. Swing the panel shut over the bracket, aligning the three screw holes on the panel with the corresponding holes on
the bracket.
4. Insert the three security panel screws (included in the mounting bracket kit) and tighten using the Phillips screw
driver (see Figure 40 on page 65).
The router door captive bolt inside the door lock post is aligned over the bracket hole as shown in Figure 41 on
page 66.
Note: For clarity, the router is not shown here. During this procedure, the router is mounted in the bracket.
Figure 40 Security Panel Attached to Bracket with Included Screws
5. Tighten the captive bolt (using 6-7 ft-lbs of torque) located inside the router door lock post (2in Figure 41 on
page 66), ensuring the bolt extends into the security bracket (3in Figure 41 on page 66).
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Figure 41 Router Door Closed with Security Panel Installed
6. Insert a lock that you provide through the router door lock post (Item 1in Figure 41 on page 66).
The SD card can be accessed only by users who have access to the router door lock. The router can be removed from
the mounting bracket only by users who have access to the router door lock.
Mounting the Router onto a Wall
The mounting bracket has wall-mount holes that you can use to mount the router directly onto a wall.
To mount the router on a wall, you must provide the hardware and anchors that can be used with the wall material in the
installation environment.
Caution: The wall material and hardware that you use to mount the router must be able to support the weight of the router
with two modules installed: approximately 23.0 pounds (10.4 Kg). The bolts must support a minimum of 150 in-lbs of
pull out moment (FoS not included).
Router Orientation When Mounting
When mounting the router onto a wall, ensure that the router is oriented with the chassis cabling openings pointing
downward so the router cable hangs down.
Caution: Never mount the router with the bottom (facing up) or to the side.
Wall-Mount Location
Identify an area on a wall that meets the safety, space, and environmental requirements described in Site Requirements,
page 9.
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Wall-Mount Height
Mount the router at a height where you can view the top of the module-side panel, and at which the cables can be
managed without adding stress to the router ports.
Wall-Mount Hardware Distance
Mount any reinforcement hardware that you provide to the wall the correct distance apart so that when the bolts are
installed through the mounting bracket wall mount holes (Item 1, Figure 42 on page 67), they align with the holes in the
wall.
Figure 42 Distance for Wall-Mounting Hardware
Required Materials
Mounting bracket. For bracket dimensions, see Figure 42 on page 67 and Figure 43 on page 68.
Socket wrench that you supply
5/16th-in. or M8 bolts or equivalent (5) (customer supplied)
Bolt reinforcement hardware (for example, wall shoe anchor bolts) (5) (customer supplied)
1. Place the mounting bracket onto the location on the wall. Mark the locations of the four mounting holes and the one
center hole.
2. (If Required) Install the bolt reinforcement hardware onto the wall at the five hole locations.
3. Install the bolt into the center hole location. Do not fully thread in; leave bolt extended about 1/4”.

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4. Align the center hole of the mounting bracket over the previously installed bolt so that the bracket rests on the bolt.
Figure 43 Securing the Wall-mount Bracket to the Wall
5. Install the four mounting bolts through the bracket and into the wall.
Secure properly by hand-tightening in a star pattern order, beginning with the first bolt, tighten using the wrench.
Torque based on hardware and wall material. Torque center bolt last.
6. Install the router onto the mounting bracket. See Install the Router onto the Mounting Bracket, page 62.
7. Install the optional security panel. See Install the Optional Security Panel, page 63.
SD Card Slot Access for Bracket-Mounted Routers
When the Cisco mounting bracket is attached the router according to the instructions in this section, the bracket blocks
access to the SD card port slot the router exterior.
Note: You must open or remove the mounting bracket security panel to see or access the SD card port.
Item Description
1Bracket: bolt holes (4)
2Customer-supplied hardware: 5/16th-in. or M8 bolts or equivalent (1)
3Mounting bracket (1)
4Center mounting hole (1)
5Customer-supplied hardware: 5/16th-in. or M8 bolds or equivalent (4) (same as #2 above)
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