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Westell Boxer BXM2019-4HE3 User manual

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Equipment Issue A
030‐101446 Rev. B, November 2013
Section BXM‐204‐HE3‐20A
R
E2013 Westell, Inc. All rights reserved.
Westellris a registered trademark of and Westell Boxerris a trademark of Westell, Inc. Page 1 of 22
1311IARB
WestellrBoxerrBXM2019‐4HE3 & BXM2019‐4HE3G
Outdoor Cabinets with a 24VDC/‐48VDC 400W Heat Exchanger
CONTENTS PAGE #
1. GENERAL 1....................................
2. FEATURES 3...................................
3. INSTALLATION 7..............................
4. MAINTENANCE 15.............................
5. SERVICE & REPAIRS 15........................
6. CUSTOMER & TECHNICAL SERVICES 18........
7. WARRANTY & RETURNS 18.....................
8. SPECIFICATIONS 19...........................
9. APPENDIX A ‐ Product Views 21..................
1. GENERAL
1.1 Document Purpose
This document provides general, installation, and specifica
tion information for the WestellrBoxerrBXM2019‐4HE3 and
BXM2019‐4HE3G Outdoor Cabinets with Heat Exchangers
(‐4HE3 model shown in Figure 1). This product is designed to
provide Network equipment protection in outdoor environ
ments while providing a quick and easy customer hand‐off. The
intended audience for this document is engineering, opera
tions, and installation personnel of MSO, Telco, and utility
companies. See Table 4 for product ordering information and
available options, as well as information on the companion but
optional battery box or skirt that can be mounted under the
Boxer cabinet.
‐ NOTE ‐
Hereafter, either model may be referred to as the “Boxer‐20” or
“cabinet.” Where differences between models apply, “‐4HE3” or
“‐4HE3G” will be specified.
‐ NESC/OSHA NOTE ‐
All applicable NESC and OSHA requirements shall be followed
during installation of this product.
1.2 Document Status
Whenever this practice is updated, the reason will be stated in
this paragraph. Revision B adds the ‐4HE3G model to this doc
ument, adds several “G” models to Table 4, adds the
NESC/OSHA note above, adds the GR‐487 Issue 4 compliant
bullet list feature in Paragraph 1.5 (for the ‐4HE3G model),
and updatesFigure 4 and Figure 7 to show the pin‐in‐hex screw
locks for the ‐4HE3G model.
1.3 Product Purpose and Description
Boxer‐20 is a compact, actively‐cooled, NEMA 4 (and GR‐487
for the ‐4HE3G model) outdoor cabinet that can house and pro
tect a wide range of electronic equipment. Up to 20 vertical RUs
(35”) of 19‐inch wide internal rack space is available to house
Network equipment such as (but not limited to) multiplexers,
Figure 1. Isometric Closed View of Boxer‐20 Cabinet
copper bonding solutions, Ethernet switches and media convert
ers, xDSL boxes, and DS3 hand‐offs. Protectively mounted on
the Boxer front door, separate from the interior rack space, is a
heat exchanger and fan unit.
Boxer‐20 supports rapid equipment installation and wiring
through the use of adjustable and removable 19” rack channels.
An access panel is located at the rear of Boxer‐20 to allow easy
access to the rear of the installed equipment. To ensure easy ac
cess for input/output cables, Boxer‐20 includes ample room
below the rack space as well as various sized conduit knock‐outs.
1.4 Product Mounting
The Boxer‐20 cabinet is typically mounted outdoors, above
ground. Optional mounting kits are available to mount the cabi
net on an H‐frame, a wall, a round pole (from 8” to 20” in
diameter) or a square pedestal or post (minimum 8” wide). Con
crete pad mounting is supported when used with an optional
Boxer battery box or skirt. All mounting hardware must be capa
ble of supporting the weight of the Boxer‐20 cabinet plus the
weight of any equipment mounted in it. The Boxer‐20 cabinet is
typically located at the customer premises but can be located
anywhere a compact, weather‐tight, outdoor cabinet is required.
Section BXM‐204‐HE3‐20A 030‐101446 Rev. B R
21311IARB
Figure 2. Isometric Open View of Boxer‐20 Cabinet
Side lift ear with
2” hole
(not for permanent
mounting)
Door
sensor
switch
Door sealing gasket
ESD jack
Rack depth‐adjustment holes
Controller card*
(for fan, +24V / ‐48VDC
connections, see
Figure 12)
Fins of heat exchanger
Interior Fans
(Fan B connector)
Ground posts
Threaded holes
to mount
equipment in
rack channel
Convenience
outlet
Outside air fans
in heat exchanger
compartment
(uses Fan A
connector)
AC duplex
outlet (inside)
2‐point door latch
Wind
latch
* Factory pre‐wiring not shown
Paper bin/tray
Cable access hole for fan wiring
(liquid tight fitting)
1.5 Product Features
Each Boxer‐20 cabinet comes fully assembled, pre‐wired, tested,
and ready for field‐provided customer equipment installation,
and includes the following features and capabilities.
SNEMA 4 compliant (both models)
SGR‐487 Issue 4 compliant (BXM2019‐4HE3G model)
SActively‐cooled with heat exchanger
SDissipates up to 400 watts
SField‐replaceable door‐mounted fans
S‐48VDC or +24VDC powered
SLow noise level
STemperature‐controlled heat exchanger fans
SFan test button (on controller card)
SCompact size (24” W x 40” H x 28” D, approx.)
SWeather‐tight cabinet
SRemovable/adjustable rack channels
Section BXM‐204‐HE3‐20A
030‐101446 Rev. B
R
3
1311IARB
SRear‐access panel
SInterior area provides 20 RUs of 19” rack mounting space
SAmple space for tie‐downs and cable management
SNumerous ground/bond posts on interior ground plate
SKnock‐outs at cabinet bottom accept a variety of cable,
conduit, and connector sizes and types
SDoor security via:
S2‐point latch (top and bottom)
SCup‐washer screw (requires can wrench, ‐4HE3 model)
SPin‐in‐hex screw (pin‐in‐hex wrench provided, ‐4HE3G)
Sa hole/hasp for a padlock
SInterior sliding wind latch
SDoor open alarm/sensor switch
SFull‐width heavy‐duty mounting brackets allow H‐frame,
wall, or post mounting
SPole or pedestal mounting via optional pole‐mount kit
SPad mount using the optional battery box or skirt (optional
pad mount kit available)
SConvenient, heavy‐duty, side‐mounted, lift brackets
SOptional battery backup box available (knock‐out hole
patterns match in both units)
SOptional side‐mount customer demarcation cabinet
SAC GFI and AC duplex outlets
SBagged parts: AC cable, vent cap, cable ties
SLight‐weight aluminum construction (0.125” thick wall)
with powder‐coat finish
2. FEATURES
This section describes the exterior and interior features of the
WestellrBoxerroutdoor cabinet in more detail. Refer to
Figure 2 through Figure 10 as needed while reading this section.
2.1 Exterior Features
The features located outside the large main cabinet are de
scribed hereunder. See Paragraph 2.2 for the interior features.
2.1.1 Construction and Materials
The Boxer‐20 cabinet is designed to be weather‐tight for above‐
ground applications. As such, the powder‐coat painted alumi
num cabinet withstands many harsh weather conditions such as
rain, snow, and sleet.
2.1.2 Cabinet
The cabinet utilizes an “in‐the‐door” heat exchanger design.
Cabinet cooling is accomplished through the front‐door‐
mounted heat exchanger, fans, and vents. Security is provided
via a 2‐point latch, a tamper‐proof screw lock and a padlock
hasp. Side‐wall lift ears (Paragraph 2.1.2.6) are provided for
temporary installation lift‐assistance. The bottom floor of the
Figure 3. Boxer‐20 Depth, Door Open
43.5”
Rear‐Access
Panel
Temporary lift
ears (remove
then re‐insert
bolts when
attaching a
Boxer Side
Car cabinet)
Sealed
threaded
fasteners, to
attach
optional
Boxer Side
Car cabinet
Transportation
bracket (remove
after shipping)
main cabinet contains numerous, differently‐sized, intact
knock‐outs (Paragraph 2.1.2.7) to accommodate a variety of
cable, fitting, or conduit sizes and types.
2.1.2.1 Large Cabinet Door
A full‐size locking door provides ample technician and equip
ment access to the interior of the cabinet and also helps protect
the cabinet from tampering and vandalism. When the cabinet is
mounted and the door is open, the clearance or distance from
the back of the cabinet to the outer edge of the open door is
approximately 43.5” (as shown in Figure 3). The cabinet's cool
ing system is based in the door, with screened holes, a heat
exchanger and fans mounted in the door. At the inside bottom
of the door, near the hinge, a wind‐latch, shown in Figure 2, pro
tects the door (and technician) from possible wind damage. The
wind latch restricts the door's swing‐out angle to a safe but func
tional opening (95 degrees). In the closed position, the inside
perimeter of the door mates with a gasket installed around the
outer perimeter of the cabinet's door opening. When the door
is closed and tightened, the door and gasket provide a weather‐
tight seal to protect all equipment installed inside the cabinet.
The door sensor is described in Paragraph 2.2.2.
2.1.2.2 Door Handle, Door Locks and Panel Lock(s)
Built into the 2‐point latching door handle is a padlock hasp and
a tamper‐proof lock. The lock (Figure 4) is loosened and tight
ened with a can wrench or 216 tool (for the ‐4HE3 model) or a
pin‐in‐hex wrench (for the ‐4HE3G model, wrench provided). In
addition to providing security, when fully‐tightened, this cup‐
screw lock helps to seal the cabinet and protect the interior envi
ronment from outside elements or contaminants by
compressing the door and panel against their gasket(s). Addi
tional security is offered for the door via a hasp in the handle that
accepts a field‐provided lock or padlock. Once the locks are
open, lift the bottom of the handle and rotate the handle count
er‐clockwise to release the 2‐point latch. When closing and
locking the door, the door must be pushed fully closed before actuat
ing the swing handle, or damage to the locking mechanism may
result.
Section BXM‐204‐HE3‐20A 030‐101446 Rev. B R
41311IARB
Lift handle, then turn
counter‐clockwise to
open door
Padlock
hasp
Note: When closing and locking the door, the door must be pushed fully closed
before actuating the swing handle, or damage to the locking mechanism may result.
Figure 4. Door Handle with Dual Locks
Pin‐in‐hex lock on
‐4HE3G model
(wrench provided)
Cup‐washer screw lock
on ‐4HE3 model Fans for circulating
external air
Nut
(remove to
replace fans)
Bottom vent for air intake
(Fan A connector)
To unlock the
compartment cover,
loosen the Phillips
head screw on the in
side of the door (see
Figure 6 for location)
Cover‐alignment posts
Compartment
cover
Figure 5. Heat Exchanger Compartment, Cover Off
2.1.2.3 Heat Exchanger Compartment
The cabinet's cooling system is based in the door, in a heat ex
changer compartment (see Figure 5). The compartment has a
secure cover, vents, a heat exchanger, and fans. To access the
heat exchanger compartment, loosen the Phillips screw that se
cures it, located near the center inside surface of the door
(under the internal fans, shown in Figure 6), then lift the com
partment cover up off the cover‐alignment posts at the top of
the compartment (see Figure 5).
2.1.2.4 Rear‐Access Panel (Detachable)
The rear‐access panel (Figure 7) can be removed for conve
nient access to the rear of equipment mounted inside Boxer‐20.
The purpose of the access panel is to facilitate equipment ac
cess, cabling, and servicing. The panel is secured with ten
tamper‐proof screws (hex‐nut‐in‐cup type for the ‐4HE3 mod
el and pin‐in‐hex type for the ‐4HE3G model). The panel can
be removed with a either a 216 tool or can wrench (for the
‐4HE3 model) or with a special hex wrench (provided with the
‐4HE3G model). With the panel removed, the access hole mea
sures approximately 17” wide by 23.5” high (see Figure 6).
2.1.2.5 Mounting Brackets
Full‐width mounting brackets are attached at the back of the
Boxer‐20 cabinet, one at the top and one at the bottom. The top
bracket has seven mounting holes in it (two of which are spaced
16” apart for stud wall mounting) and the bottom bracket has
five slots, for easy slide‐in installation. Use approved wall‐
mounting fasteners with a diameter of up to 3/8”. The vertical
distance between the top and bottom bracket mounting holes is
42.7”. The mounting hardware and the mounting surface must be of
Figure 6. Boxer‐20 Rear View, Rear Access Panel Removed
Inside of front door
visible through open
rear access hole
Fans
mounted
on front
door
Sealing
gasket for
rear access
panel
Figure 7. Rear Isometric View of Boxer‐20,
Showing Rear Access Panel Removed
Rear‐access
panel
Temporary
Lift Ear
Rail with holes
(adjusts rack
channel depth)
Rear View,
Panel On
Paper
bin/tray
Cup‐washer screw
on ‐4HE3 model
Screw which secures
heat exchanger com
partment cover
Pin‐in‐hex screw
on ‐4HE3G model
(wrench provided)
Section BXM‐204‐HE3‐20A
030‐101446 Rev. B
R
5
1311IARB
* Concentric knock‐outs: when removed from one side, a 1/2” hole is formed, when
removed from the opposite side, a 3/4” hole is formed.
5” in
12”
Customer
Knock-outs
2 Network
Knock-outs
Ground
rack
channel*
of rack
channel**
TOP VIEW
Door switch assembly
Rack channel
14.5”
plate
2”
2”
** Factory default position.
2”
(adjustable,
reversible)
*
*
2”
Channel is adjustable to multiple positions.
Knock‐out for cables from optional battery box or for Network
*
AC duplex outlets
GFI Duplex
behind
front
Outlet
(uses 1 knock‐out)
Figure 8. Bottom Isometric View of Cabinet
2” Knock‐outs
Factory‐installed fitting
(for 1/2” AC conduit, installed
through 1.125” hole)
Concentric knock‐out
(typically used as access for option
al battery cable,when used with a
battery box, or for Network cables)
Figure 9. “See‐Through” Top View of Cabinet, Door Off
Small knock‐out
(1 of 5, for attach
ing a battery box)
*
*
sufficient strength, quality and size to support the cabinet plus all
equipment to be mounted in it.
2.1.2.6 Side Lift Ears
The Boxer‐20 cabinet is equipped with two removable external
lift ears or brackets, one on each side, attached at the top of the
cabinet (see Figure 3). These lift ears can be used to lift the cabi
net using lift equipment, for mounting purposes. Each ear has a
hole with a 2” diameter, to accommodate various cable, strap, or
hook sizes. Always use two straps of equal lengths, one for each
lift ear, when using this method to lift the cabinet. Remove the
ears if mounting with a Boxer side car (use the same hardware).
Do not use these lift ears for permanent mounting.
2.1.2.7 Bottom Floor Knock‐outs
Multiple knock‐outs are provided on the floor of the cabinet.
One near the center rear of the floor is for cable ingress and
egress for an optional battery cabinet that can be mounted below
the Boxer‐20 cabinet (or for Network cables). Provided on the
right side of the cabinet floor are multiple intact knock‐outs, for
easy Network and Customer cable access. The front‐most three
are typically for customer cable access, and the rear‐most knock‐
outs are typically for Network cable access. The knock‐out sizes
and quantities are shown in Table 1 and Figure 9. A “concentric”
knock‐out is provided for both Customer and Network access:
depending upon which direction the knock‐out is removed, ei
ther a 1/2” or 3/4” hole will be produced. Do not remove a
knock‐out unless it is absolutely necessary to do so for cable in
gress and egress, and use either tight‐fitting rubber grommets or
liquid‐tight fittings, or other proper and approved knock‐out
hole sealants, to assure the best internal air quality and weather‐
resistance. Always use proper and company‐approved tools to
remove knock‐outs. There are five, small, 0.575” diameter
knock‐outs in the floor of the Boxer‐20 cabinet where an option
al battery box attaches to the cabinet (hole patterns of both units
match).
‐ KNOCK‐OUT REMOVAL NOTE ‐
Always remove knock‐outs where holes are desired before
mounting the cabinet or the optional battery box, regardless of
the type of knock‐out and the order of the mounting steps.
Function Quantity Description
Customer
22.5” knock‐out for 2” conduit
31.125” concentric knock‐out, can be
used for 1/2” or 3/4” conduit.
Network
22.5” knock‐out for 2” conduit
11.125” concentric knock‐out, can be
used for 1/2” or 3/4” conduit.
Battery
Box 50.575” diameter knock‐outs, matches
hole pattern in optional battery box
Table 1. Knock‐out Sizes and Quantities
2.1.2.8 AC Conduit Fitting
A 1/2” AC conduit fitting is provided on the exterior bottom sur
face of the cabinet (see Figure 8) through a knock‐out hole near
the back right corner, to facilitate conduit attachment or power
cable access. The fitting is connected to an AC outlet box imme
diately above it inside the cabinet.
2.2 Interior Features
The interior cabinet features are described hereunder.
2.2.1 Internal 19” Rack Channels
Two removable/adjustable rack channels inside the cabinet pro
vide 20‐RU‐high 19” relay rack mounting for equipment that is
to be mounted in the cabinet. Each adjustable channel is factory‐
installed so approximately 5” of equipment space is available
from the inside of the closed front door to the channel (for up
to a 5” equipment projection), and approximately 12” of equip
ment space is available behind the channel to the rear cabinet
wall. The channels can be moved forward or backward the entire
depth of the cabinet, as needed, if more equipment depth is
needed at either the front or back of the channel. Multiple holes
are provided for multiple channel positions. Each rack channel
has predrilled holes, with standard hole spacings (either 1”,
1.75”, or 2” rack hole patterns), to mount customer‐supplied
equipment in the cabinet. Network equipment up to 20 Rack
Units (20 RUs = 35”) high can be mounted on the internal rack
inside the cabinet, either as a single piece or multiple pieces of
equipment.
Section BXM‐204‐HE3‐20A 030‐101446 Rev. B R
61311IARB
Figure 10. Door Sensor Switch & Internal Fan Locations
Door Switch
(prewired to
controller card)
Internal fan
(Fan B)
Pull out to deactivate
‐ LEFT CHANNEL NOTE ‐
Access to the controller card may be limited if one of the front‐
most channel mounting positions is chosen for the left channel.
2.2.2 Door Sensor Switch
A door sensor switch is located at the bottom right corner of the
cabinet door opening (Figure 10). This switch is factory‐pre
wired to the Controller Card for door alarm reporting purposes.
To temporarily disable the sensor, pull out the cylindrical door
switch actuator until it clicks. To re‐activate the sensor, either
gently push the actuator back in until a click is heard, or simply
close the cabinet door.
2.2.3 Cooling System
The Boxer‐20 cabinet features an active heat‐exchange system
that compensates for the effects of internal equipment heat and
external solar and temperature loading inside the cabinet. The
heat exchanger fans are temperature activated. The fans turn
on when the interior of the cabinet reaches 35° C (95° F) and
turn off when the internal cabinet temperature cools to 25° C
(77° F). At the core of the heat exchange system are numerous
aluminum fins (best seen in Figure 2) on each “side” of a sealed
divider wall within the heat exchanger. The dual air‐path ex
changer uses one set of fans (shown in Figure 11) to blow cool
outside air past the “exterior air side” fins of the heat exchanger
and to direct the heated air out the screened holes on the sides
Figure 11. Heat Exchanger Compartment, Cover Off
Fans for circulating
external air
Nut
(remove to
replace fans)
Bottom vent for air intake
(Fan A connector)
To unlock the
compartment cover,
loosen the Phillips
head screw on the in
side of the door (see
Figure 6 for location)
Figure 12. Controller Card (Showing Euro‐connectors)
Isometric
View
Side View
Manual fan
test switch
of the fan cover. Conversely, a second set of fans (shown in
Figure 2 and Figure 10) circulates warm inside air down past the
“interior air side” fins of the heat exchanger and blows cooled air
back through the main cabinet compartment. Both sets of fans
are field‐replaceable (see Table 4 for part numbers).
2.2.4 Internal‐Air Fans (“FAN B” Connector)
Two, factory‐installed, temperature‐controlled fans (see
Figure 10) to circulate warm interior air down through the heat
exchanger and back into the cabinet are are located on the inside
of the cabinet door. These fans are factory‐wired to the
“FAN‐B” connector on the controller card mounted on the left
side wall of the cabinet, and are powered from either a field‐pro
vided +24VDC power source or a ‐48VDC power source.
2.2.5 External‐Air Fans (“FAN A” Connector)
Two, factory‐installed, temperature‐controlled fans (shown in
Figure 11) to circulate cooler exterior air up through the heat ex
changer are located under the cover of the heat exchanger
compartment. These fans are factory‐wired to the “FAN‐A” con
nector on the controller card mounted on the left side wall of the
cabinet, and are powered from either a field‐provided +24VDC
power source or a ‐48VDC power source. To access or view the
fans, loosen the Phillips screw near the inside center of the door,
then lift off the cover off it's two posts.
2.2.6 Controller Card
This section and Table 2 describe the features of the controller
card. Internal wiring has been factory‐wired. See Paragraph 3.8
and 3.9 to perform external connections (installer power, tem
perature, and alarm wiring and connections) to the controller
card.
Boxer‐20 includes a factory‐wired controller card located on
the inside left wall of the cabinet (Figure 12). The card includes
connections for power and for the fans, temperature alarm,
door alarm, a fan test button and a 5A fan fuse. Internal wiring
has been factory‐wired. External wiring to the power source
and alarm monitoring equipment is done using “Euro‐connec
tor” snap‐in terminal blocks which can be disconnected from the
controller card, and later re‐inserted for quick and easy connec
tions. Table 2 lists all of the connectors and positions on the
controller card. The only installer connections needed are the
TEMP ALARM, DOOR ALARM, and power connections (‐V and
Section BXM‐204‐HE3‐20A
030‐101446 Rev. B
R
7
1311IARB
+V). To make these connections to the Euro‐connectors, pull‐
off the Euro‐connector, loosen the screws inside the set‐screw
holes, strip approximately 3/8” off the end of each wire, insert
wire(s) into hole(s), tighten screws, and push‐on the Euro‐con
nector (see Paragraph 3.8 and 3.9 for more installation details).
Connector
Name
# of
Positions
Position
Name Description
Left Side of Controller Card
TEMP ALARM 2
NO
Normally Open.
(Installer connects to field‐
provided equipment.)
COM
Common.
(Installer connects to field‐
provided equipment.)
DOOR ALARM 2
NO
Normally open.
(Installer connects to field‐
provided equipment.)
COM
Common.
(Installer connects to field‐
provided equipment.)
FAN −A*
(2 External Air Fans) 2
BLK −voltage. Factory
connected to Fan A.
RED + voltage. Factory
connected to Fan A.
FAN −B*
(2 Internal Air Fans) 2
BLK −voltage. Factory
connected to Fan B.
RED + voltage. Factory
connected to Fan B.
FAN TEST button FAN
TEST
Momentary push-button
to test fan operation
+24V Power
Operation
Only
Power
Connections
2
BLK -V
System Ground
(Installer connects to field‐
provided DC power.)
RED +V
Apply +24V
(Installer connects to field‐
provided DC power.)
−48V Power
Operation
Only
Power
Connections
2
BLK -V
Apply -48V
(Installer connects to field‐
provided DC power.)
RED +V
System Ground
(Installer connects to field‐
provided DC power.)
Right Side of Controller Card
DOOR
SWITCH 1 2DOOR Not used.
SWITCH-1
DOOR ALARM
SWITCH 2 2DOOR Door open alarm.
Factory wired.
SWITCH-2
*Two fans are wired to each set of terminals.
Shaded rows indicate installer connections (TEMP ALARM, DOOR ALARM, and Power)
Table 2. Controller Card Connectors - Front Access
Connectors and Features on the Controller Card
STEMP ALARM Euro‐Connector. A Normally Open Temper
ature Alarm thermostat contact closes when the internal
cabinet temperature exceeds 65° C and will remain on until
the temperature drops below 55° C. For temperature alarm
connections, connect alarm wiring from the field‐provided
alarm equipment to the 2‐position Euro‐connector at the
top left of the controller card.
SDOOR ALARM Euro‐Connector. A Normally Open (NO)
Door Alarm contact closes when the door is opened. For
door alarm connections, connect wiring from the field‐
provided alarm equipment to the 2‐position Euro‐connec
tor labelled DOOR ALARM at the top left of the
controller card.
SFan A and Fan B Euro‐Connectors. The internal temperat
ure‐controlled fans are factory‐wired to the controller
card at the FAN‐A and FAN‐B Euro‐connectors (FAN‐A
= external fans, Fan‐B = internal fans). The fans require a
‐48VDC, 1.75A or a +24V, 3.5A power source to be wired
to the power Euro‐connector of the controller card.
S5A Fan Fuse. A field‐replaceable 5A fuse for proper fan op
eration is provided and accessible near the left bottom
corner of the controller card. Remove this fuse whenever
performing fan maintenance or replacing the fans.
S-V and +V power Euro‐Connector. The Euro connector la
belled ‐V and +V is prewired to a 48” red and black cable
wire stub. For +24V power applications, connect the red
wire to the +24V source and connect the black wire to
ground. For ‐48V power applications, connect the black
wire to the ‐48V source and the red wire to ground.
SFan Test Button. A momentary fan test button is provided in
the lower left corner of the controller card. Use this button
for fan testing purposes.
SDoor Switch 1 Euro‐Connector. A door switch connector la
belled DOOR SWITCH ‐ 1 is not used.
SDoor Switch 2 Euro‐Connector. A door switch connector la
belled DOOR SWITCH ‐ 2 is provided at the right side of
the controller card. This connector is factory‐prewired to
the door alarm/sensor switch for door open alarming. The
door switch is field‐replaceable.
2.2.7 AC Duplex & GFI Outlets for Installed Equipment
In the bottom‐right rear corner of the cabinet are two AC duplex
outlets (with a 1/2” fitting below one on the cabinet exterior sur
face), for powering any customer‐supplied AC‐powered
equipment mounted in the cabinet. When an external AC power
source is connected to these outlets, AC power also can be pro
vided to the GFI convenience outlet in the lower‐left front corner
of the cabinet (to facilitate the installer's test equipment power
ing), by installing the provided AC 3‐wire cable (see Figure 21).
2.2.8 Grounding and Bonding Center
Boxer‐20's grounding and bonding center is located on the bot
tom interior surface of the cabinet (Figure 13), close to the front
door. A ground plate is provided that contains eight sets of ground
posts and one copper ground lug, for cable, equipment and chas
sis/earth ground. Bond equipment/cables to the ground posts per
company practice, and connect a #6 AWG chassis or earth
ground wire to the ground lug. An Electro‐Static Discharge
(ESD) wrist‐strap jack is also located on the ground plate.
Ground lug hardware should be tightened to 20 inch‐pounds.
3. INSTALLATION
Use and follow local codes and company practices to install the
WestellrBoxerrcabinet. If none exist, use the instructions con
tained herein. Installation consists of:
Section BXM‐204‐HE3‐20A 030‐101446 Rev. B R
81311IARB
Sinspecting the unit for damages that may have incurred dur
ing shipping,
Sfollowing proper safety precautions,
Sreviewing pre‐mounting considerations, such as selecting
the mounting type and location, and preparing the mount
ing site,
Sgathering all tools, materials, and equipment,
Sremoving any knock‐outs where access holes are required,
Smounting the cabinet,
Smaking ground and all power connections,
Spowering up the cabinet (system power‐up),
Smounting any customer‐supplied equipment inside the cab
inet,
Smaking communication cable connections,
Smaking any desired alarm connections,
Soptioning the installed equipment and placing it in service,
and
Sperforming cabinet housekeeping, and closing and locking
the cabinet.
The following paragraphs provide detailed instructions for
performing these procedures.
3.1 Inspecting the Equipment
‐ INSPECTION NOTE ‐
Visually inspect the unit for damages prior to installation. If the
equipment has been damaged in transit, immediately report the
extent of the damage to the transportation company and to West
ell (see Part 6 for telephone number).
‐ DESICCANT NOTE ‐
To prevent condensation during shipment and storage, Westell
includes a desiccant pack within the Boxer‐20 cabinet. Once the
electronic equipment is installed and turned‐up, the internal
power dissipation reduces the likelihood of condensation within
the cabinet. However, follow company practices for desiccant
maintenance procedures to prevent internal condensation.
Figure 13. Ground Plate & AC Duplex Outlet Locations
Ground Plate
AC duplex
outlets
GFI outlet
(see Figure 21)
3.2 Following Proper Safety Precautions
The cabinet should be installed only by authorized and trained
personnel. Always exercise caution and follow all safety precau
tions.
Important Safety Instructions (Please Save)
When using your telephone/telecommunications equipment,
follow basic safety instructions to reduce the risk of fire, electric
shock, and injury to person(s), including the following:
A. Read and understand all instructions.
B. Follow all warnings and instructions marked on product.
C. Do not place this product on an unstable cart, stand or table:
the product may fall, causing serious damage to product.
D. Slots and openings in the cabinet are provided for ventilation.
To protect it from overheating, these openings must not be
blocked or covered. This product should never be placed near
or over a radiator or heat register. This product should not be
placed in a built‐in installation unless proper ventilation is pro
vided.
E. This product should be operated only from the type of power
source indicated on the marking label.
F. Never push objects of any kind into this product through cabi
net slots as they may touch dangerous voltage points or short
out parts that could result in the risk of fire or electrical shock.
Never spill liquids of any kind on the product.
CAUTION ‐ STATIC‐SENSITIVE
This product contains static‐sensitive components! Proper
electrostatic discharge procedures must be followed to
maintain personal and equipment safety. Do not store units
near magnetic, electromagnetic or electrostatic fields. Always
store or ship units in the original static‐protective packaging
from Westell. Use anti‐static mats when working on units.
‐ PRECAUTIONARY STATEMENT ‐
Never install telephone wiring during a lightning storm.
Never install telephone jacks in wet locations unless the jack
is specifically designed for wet locations.
Never touch uninsulated telephone wires or terminals unless
the telephone line has been disconnected at the network
interface.
Use caution when installing or modifying telephone lines.
3.3 Selecting and Preparing the Mounting Type
and Site (Pre‐Mounting Considerations)
Mount the cabinet in a location with an adequate earth ground
and power access, with unobstructed cabinet access, and which
insures the best lighting, ventilation, heat dissipation, and equip
ment access. Verify sufficient space exists to allow the opening
of the left‐hinged large door, to access and mount the cabinet,
to mount and access the optional battery box if it will be mounted
below it, and to adequately access, prepare, and dress all cables.
Adequate horizontal and vertical space should be be left be
tween any multiple installations to allow for cabinet opening,
equipment access, and cable routings and preparations. Follow
company practice for the proper distance from the cable entry
point or from upstream or downstream equipment.
3.4 Gathering all Tools and Equipment
The following tools and supplies (not provided) are required to
mount the Boxer‐20 cabinet.
Section BXM‐204‐HE3‐20A
030‐101446 Rev. B
R
9
1311IARB
Door Opening/Locking Tools
 V7/16” can wrench or 216 tool (‐4HE3) or provided pin‐in‐hex
wrench (‐4HE3G)
 VPadlock (optional)
Knock‐Out Removal Tools
 VHammer
 VPunch
 VPliers
Cabinet Mounting Tools, Equipment, and Hardware
 VTape measure
 VMarking utensil (to mark mounting hole locations)
 VLevel (optional)
 VPower or hand drill with assorted bits, plus long bits or drill
bit extensions if pole mounting
 VSocket driver and sockets, or wrenches
 VWall‐ or pole‐mounting hardware, such as 3/8” diameter
wood‐type lag screws or bolts
 VH‐frame mounting hardware (for H‐frame mounting)
 VOptional pole‐mount kit (for pole mounting)
 VOutdoor site preparation tools
 VSafety gloves and glasses (optional)
 VPower hoist or lifting equipment and cables (optional)
 VAssorted screwdrivers
 VAppropriate ground wire and equipment
Cable Preparation Tools and Equipment
 VCable opening and preparation tools
 VProper lengths and types of communications cables
 VProper lengths and types of power cables and fittings
 VCable management supplies (ties, clips, markers, etc.)
 VPower installation and testing equipment
 VESD protection
3.5 Removing the Knock‐outs
Knock‐outs should be removed prior to mounting the cabinet.
See Figure 9 or Table 1 for knock‐out sizes, quantities, and loca
tions, and follow the steps below to remove the knock‐outs.
1. Open the cabinet door. If knock‐outs will need to be re
moved, using a 216 tool or can wrench (‐4HE3), or the
provided pin‐in‐hex wrench (provided with the ‐4HE3G),
open the large front door of the Boxer‐20 cabinet to access
the knock‐outs.
2. Remove knock‐out(s). Prior to mounting the cabinet, per
company practice, remove as many appropriately‐sized
knock‐outs at the bottom of the cabinet as needed for the
specific application (consider ground, power, and com
munication cable access needs, venting, and whether
optionally mounting a battery box with the cabinet).
3. Install rubber grommets or conduit fittings. Install either
a heavy‐duty rubber grommet or the conduit fitting of
choice (liquid‐tight recommended) in each selected
knock‐out hole. If an optional vent is desired, the provided
vent cap can be installed in one of the smaller knock‐outs.
Figure 14. Open Boxer‐20 Front View (and Side Car,
Mounted On Battery Box)
Open Door of Optional
Boxer Side Car
Open Door
of
Boxer‐20
Optional Battery Box
Rack channels
(20 RUs)
Isometric View,
Conjoined Units
4. Close the cabinet door. Once the knock‐outs are removed,
lock the door using the 216 tool, can wrench or pin‐in‐hex
wrench, to minimize possible product damage and person
al injury.
3.6 Mounting the Cabinet
The Boxer‐20 cabinet is typically mounted outdoors, above
ground, on an H‐frame, a wall, a concrete pad, or a pole. Option
al mounting kits are available to support pole (from 8” to 20” in
diameter), wall, and H‐frame mounting. Concrete pad mount
ing is typically performed in conjunction with the optional Boxer
battery box. An optional pad mount template kit is available for
easy and convenient cement anchor placement. All mounting
hardware (not provided) must be capable of supporting the
weight of the Boxer‐20 cabinet plus the weight of any equipment
mounted in it. For convenience, lift hooks or ears are provided
for temporary lifting purposes (do not use lift ears from which
to hang the cabinet in permanent installations). Run all cables
to the mounting location, perform any trenching, trench cable
placements, and backfilling prior to the cabinet mounting, and
clear the installation area of any debris, vegetation, and unneed
ed equipment or obstacles.
‐ KNOCK‐OUT REMOVAL NOTE ‐
Always remove knock‐outs where holes are desired before
mounting cabinet or securing the battery box, regardless of the
knock‐out type and regardless of the order of the mounting steps.
All knock‐outs should be knocked out from the inside of the
cabinet, except for the small 0.575” knock‐outs (which are to be
knocked out from the outside of the cabinet) and except for the
concentric knock‐out (from either direction, per hole size).
Section BXM‐204‐HE3‐20A 030‐101446 Rev. B R
10 1311IARB
Figure 15. H‐Frame Mounting
H‐frame
Sliding Nut
(compress spring, slide
nut into ends of rail)
Bolt
Washer
Pole or post
H‐frame Rail
or Channel
DETAIL A
H‐frame
Sliding Nut
(slide nut into
end of rail, see
DETAIL A)
43.7”
‐ WEIGHT NOTE ‐
The Boxer‐20 cabinet weighs 110 pounds. The weight of the inter
nal equipment installed in the Boxer‐20 should not exceed 130
pounds. The mounting surface, structure, and hardware must be
able to support the combined weight (240 pounds).
3.6.1 Mounting on an H‐Frame
Follow company practice or the steps below to mount the Box
er‐20 cabinet on an H‐frame. See Figure 15 for an H‐frame
mounting drawing. If the installation includes the battery box,
attach the battery box and the H‐Frame mounting kit to the cabi
net prior to mounting to the H‐Frame.
1. Determine exact mounting location in H‐frame. Select and
mark the exact horizontal and vertical final mounting loca
tion within the H‐frame. The spacing between the top and
bottom H‐frame horizontal‐rail mounting holes should be
42.7” (on centers). Westell recommends a height of 30”
from the ground. In addition to leaving a comfortable in
staller working height, leave adequate space under
Boxer‐20 for cable access, as well as in front of the cabinet
to allow the door to open, and at the sides in the event of
any multiple installations.
2. Remove knock‐outs. See the steps in Paragraph 3.5 (Re
moving the Knock‐outs) to remove the knock‐outs where
any cable access holes (or holes for mounting the optional
battery box) are desired. Note that if a Boxer “Side Car”
cabinet is being installed with the Boxer‐20, remove the
small, blind, threaded receptacles on the Boxer‐20's right
side wall to accommodate the side car's mounting bolts..
3. Prepare the H‐frame mounting hardware. Bring the ap
propriate rail nuts (to secure the cabinet to the H‐frame)
to the installation site. The mounting hardware must be
able to support the weight of the cabinet plus the weight of
the added internal equipment. Insert at least three rail
nuts into each rail (compress the spring on the nuts as
needed) and place them at the desired locations.
4. Lift cabinet. Lift the cabinet to the mounting height. If us
ing lift equipment, use two cables or straps of equal length,
one connected to each lift ear, for a balanced symmetrical
lift. The lift ears are provided at the top of the cabinet, one
at each side wall, and each lift ear has a 2” hole in it.
5. Attach cabinet to H‐frame rails. Align the holes in the cabi
net's top mounting bracket with the holes in the inserted
rail nuts in the H‐frame rails, then insert and install an ap
propriate bolt through each set of aligned holes. Westell
recommends a minimum of 3 mounting bolts per mount
ing flange (top and bottom). Tighten hardware appro‐
priately. Repeat for the bottom mounting bracket and H‐
frame rail. Verify the cabinet is in the proper horizontal
position, make any needed adjustments, then securely
tighten all mounting hardware.
6. Test installation firmness. Test the installation by attempt
ing to move the cabinet. Correct any looseness, if
detected. Tighten all bolts again.
7. Determine next step. If ground, power, and communica
tions cables and internal equipment will not be connected
and mounted at this time, proceed to the next step to final
ize the cabinet installation. If ground, power, and
communications cables and internal equipment will be
connected, mounted, and powered‐up at this time, skip
the next step and proceed to Paragraphs 3.7 through Para
graph 3.16 for those procedures.
8. Close up cabinet and clean the site. Close the Boxer‐20
door, and lock it using a can wrench or 216 tool (‐4HE3)
or the provided pin‐in‐hex wrench (‐4HE3G) and an op
tional padlock. Pick up any tools and materials at the
installation site, and clean the site of any trash or debris.
3.6.2 Mounting on a Wall
Follow company practices or the steps below to mount the Box
er‐20 cabinet to an approved wall (Figure 16). The approved
wall and hardware used must be able to support the combined
weight of the cabinet and the equipment mounted inside the
cabinet. Westell recommends a minimum cabinet installation
height of 30” from the ground.
1. Find best wall position. Locate the best mounting position
for the cabinet on the wall. Verify this location meets all
cabinet spacing requirements and company practices.
2. Remove knock‐outs. See the steps in Paragraph 3.5 (Re
moving the Knock‐outs) to remove the knock‐outs where
any cable access holes (or holes for mounting the optional
battery box) are desired. Note th at if a Boxer Side Car also
will be mounted with the Boxer‐20 cabinet, the knock‐outs
on the right side wall of the Boxer‐20 should be removed,
as well.
3. Prepare the mounting hardware. Bring the appropriate
wall‐mounting hardware to the installation site. The hard