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Unit Rack Assembly, Wiring, and Commissioning Preparation

Harshal
  • Updated

1.0 Overview

This section provides the complete installation procedure for the Unit Rack, including the Bill of Materials (BOM), power requirements, rack assembly, cable routing, labeling standards, and final verification steps. All procedures are standardized to ensure consistent installation across all units.

Note: The number of switches may vary from unit to unit.

 The rack supports up to three (3) PoE switches.

 Installation steps remain the same regardless of switch count.

 

1.1 Bill of Materials (BOM)

1.1.1 Rack Hardware

  • A rack enclosure (as shown in the image below)
  • 24‑port Cat6 patch panel
  • Power Distribution Unit (PDU)
  • Rack screws, cage nuts, wall anchors

 

Inline Image — Rack Overview

 

1.1.2 Network Devices

  • Up to 3 × 8‑Port PoE Switches
    • Labeled by physical position:
      • Top Switch
      • Middle Switch
      • Bottom Switch
  • 6 × SFP Modules (for switch uplinks)
  • 1 × Router (Comcast or project‑specific)
  • 1 × NUC (Mini‑PC)

1.1.3 Patch Cords (Pre‑terminated Cat6)

Total: 28 patch cords

Length Quantity Purpose Amazon Link
1 ft 8 Switch → patch panel

https://www.amazon.com/dp/B00K2E4X2U?th=1

 
1.5 ft 8 Switch → patch panel (mid‑length)

https://www.amazon.com/dp/B0CY22XNMJ?th=1

 
2 ft 8 Switch → patch panel (longer reach)

https://www.amazon.com/dp/B0CQXFZCL5?th=1

 
0.5 ft 4 SFP uplink jumpers https://www.amazon.com/dp/B07MVS5NRT?th=1

 

1.1.4 Additional Materials (not supplied)

  • Cat6 riser cable (for in‑unit drops)
  • RJ45 connectors + boots
  • Velcro straps (preferred)
  • Zip ties (limited use)
  • Heat‑shrink labels + label printer

 

1.2 Power Requirements

The rack requires stable AC power to support switches, router, and NUC.

Power Options (Min requirement)

  • Option 1 — Dual‑Circuit Power
    • 2 × 15‑amp circuits
  • Option 2 — Single‑Circuit Power
    • 1 × 30‑amp circuit

 

Power Notes

  • All devices must connect to the PDU
  • Avoid daisy‑chaining power strips
  • Circuits must be clearly labeled

Inline Image — PDU

 

1.3 Installation Procedure

1.3.1 Pre‑Installation Checklist

Technician must verify:

  • All BOM components are present
  • Power outlet is available
  • Router location confirmed in the closet
  • Cable run to eg. 2025 closet (server) is accessible
  • Label printer is available

 

1.3.2 Rack Mounting

  1. Install PDU at the top.
  2. Install patch panel directly below PDU.
  3. Install switches in the following order:
    • Top Switch
    • Middle Switch
    • Bottom Switch
  4. Install  router inside the rack on the back side.

 

1.3.3 Device Installation

  1. Mount the Top Switch and connect power to PDU.
  2. Mount the Middle Switch and connect power.
  3. Mount the Bottom Switch and connect power.
  4. Install SFP modules in uplink ports.
  5. Mount router and NUC (if applicable).

 

1.4 Cable Routing

1.4.1 Patch Cord Length Assignments

  • 1 ft → Shortest runs (top switch to top patch panel ports)
  • 1.5 ft → Bottom switch to patch panel
  • 2 ft → Middle switch to patch panel
  • 0.5 ft → SFP uplinks between switches

 

Inline Image — Patch Panel Wiring

(Marking indicates which patch cord should land to which ports on the patch panel so that it looks neat and clean)

 

1.4.2 Backside Cable Labeling Requirement

To simplify installation and ensure consistency across all units, every cable that exits the backside of the rack must be labeled before routing.

Labeling Requirements

  • All cables must follow the device plan labeling scheme.
  • If a node is labeled:

 

UN-1-A-001

 

  • Then the PoE cable that connects to that node must carry the exact same label at the device's end.

 

Buy the Cable label printer from here:  Amazon.com : VolenGo E1000 Heat Shrink Label Maker, Wire Label Maker Waterproof-Labels, Labeler Mac…

Purpose

This requirement ensures:

  • Installers can quickly identify where each cable is going
  • Reduces installation time and errors
  • Prevents misrouting during commissioning
  • Ensures future maintenance teams can trace cables without guesswork

 

Installer Note

No cable should be routed to the node through the back of the rack unless it is labeled first. This is a mandatory step for all units.

 

1.5 Final Verification Checklist

Technician must confirm:

  • Rack is securely mounted
  • All devices powered
  • All cables labeled
  • SFP uplinks connected
  • Patch panel ports mapped
  • Router uplink to server is active
  • Cable routing is clean and consistent

 

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