AT&T MERLIN LEGEND Release 3.1, MERLIN LEGEND 4.0 Installation Manual

AT&T 555-640-140
March 1996

MERLIN LEGEND
Communications
System
Releases 3.1
and 4.0

Installation

®

Customer Support Information,

Customer Support Information.

Copyright  1996, AT&T AT&T 555-640-140
All Rights Reserved Issue 1
Printed in U.S.A. March 1996

Notice

Every effort was made to ensure that the information in this book was complete and accurate at the time of printing. However,
information is subject to change.

See Appendix A, “
this binder.

” for important information. It follows

Maintenance and Troubleshooting

in

Your Responsibility for Your System’s Security

Toll fraud is the unauthorized use of your telecommunications system by an unauthorized party, for example, persons other
than your company’s employees, agents, subcontractors, or persons working on your company’s behalf. Note that there may
be a risk of toll fraud associated with your telecommunications system, and if toll fraud occurs, it can result in substantial
additional charges for your telecommunications services.

You and your System Manager are responsible for the security of your system, such as programming and configuring your
equipment to prevent unauthorized use. The System Manager is also responsible for reading all installation, instruction, and
system administration documents provided with this product in order to fully understand the features that can introduce risk of
toll fraud and the steps that can be taken to reduce that risk. AT&T does not warrant that this product is immune from or will
prevent unauthorized use of common-carrier telecommunication services or facilities accessed through or connected to it.
AT&T will not be responsible for any charges that result from such unauthorized use. For important information regarding your
system and toll fraud, see Appendix A, “

”

Federal Communications Commission Statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required
to correct the interference at his own expense. For further FCC information, see Appendix A, “Customer Support Information.”

Canadian Department of Communications (DOC)
Interference Information

This digital apparatus does not exceed the Class A limits for radio noise emissions set out in the radio interference regulations
of the Canadian Department of Communications.

Le Présent Appareil Numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils
numériques de la class A préscrites dans le reglement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.

Trademarks

5ESS, ACCUNET, ACCULINK, CONVERSANT, DEFINITY, Magic On Hold, Megacom, MERLIN, MERLIN II, MERLIN LEGEND,
MERLIN MAIL, MultiQuest, Music on Hold, and Systimax are registered trademarks and 4ESS, AT&T Attendant, AUDIX Voice
Power, FAX Attendant System, HackerTracker, MERLIN Identifier, MERLIN Identifier, MLX-10, MLX-10D, MLX-10DP,
MLX-16DP, MLX-20L, MLX-28D, Page Pac, and PassageWay are trademarks of AT&T in the U.S. and other countries.

Windows is a trademark and Microsoft
ProComm and ProComm Plus are registered trademarks of DataStorm Technologies, Inc.

Supra, StarSet, and Mirage are registered trademarks of Plantronics, Inc.
UNIX is a registered trademark of UNIX System Laboratories, Inc.
PagePac is a registered trademark of DRACON, a division of Harris Corporation.
Okidata is a registered trademark of Okidata Corporation.

® a registered trademark of Microsoft Corporation.

Ordering Information

in

Limited Warranty and Limitation of Liability

in Appendix A,
Customer Support Information,

Call: AT&T GBCS Publications Fulfillment Center

Write: AT&T GBCS Publications Fulfillment Center

Order: Document No. AT&T 555-640-140

For more information about AT&T documents, refer to the section entitled, “Related Documents”

Support Telephone Number

In the continental U.S., AT&T provides a toll-free customer helpline 24 hours a day. Call the AT&T Helpline at 1 800 628-2888
or your AT&T authorized dealer if you need assistance when installing, programming, or using your system. Outside the
continental U.S., contact your local AT&T authorized representative.

Voice 1 800 457-1235 International Voice 317 361-5353
Fax [phone] International Fax [phone]

P.O. Box 4100
Crawfordsville, IN 47933

Comcode: 107713737
Issue 1, March 1996

AT&T Corporate Security

Whether or not immediate support is required,
to AT&T Corporate Security at 1 800 821-8235. In addition to recording the incident, AT&T Corporate Security is available for
consultation on security issues, investigation support, referral to law enforcement agencies, and educational programs.

AT&T Fraud Intervention

If you

suspect you are being victimized

Service Assistance Center at 1 800 628-2888.

Warranty

AT&T provides a limited warranty on this product. Refer to “
“

“

About This Book

all

toll fraud incidents involving AT&T products or services

by toll fraud and you need technical support or assistance, call GBCS National

” which follows

Maintenance and Troubleshooting

in this binder.

.”

should be reported

”

Contents

About This Book

■

Intended Audience xix

■

How to Use This Book xix

■

Terms and Conventions Used xxi

■

Product Safety Labels xxii

■

Security xxiii

■

Related Documents xxiv

■

How to Comment on This Document xxv

1 Introduction

n

Installation Sequence 1–1

n

System Forms 1–2

n

Programming the System 1–4

n

Upgrading the System 1–5

2 Installing the Control Unit

n

Overview 2–1

n

AC Power and Grounding 2–5

n

Unit Loads 2–16

n

Installing the Basic Carrier 2–17

n

Installing the Power Supply 2–19

n

Installing the Auxiliary Power Unit 2–25

Installation

iii

Contents

Installing the Control Unit, Continued

n

Installing Expansion Carriers 2–27

n

Installing the Processor 2–29

n

Installing the Modules 2–32

n

Replacing a Module 2–40

n

Connecting the Control Unit to an AC Outlet 2–43

n

Powering Up the System 2–44

n

Powering Down the System 2–45

3 Installing Telephones and Adjuncts

n

Installing Multi-Function Modules 3–1

n

Installing Adjuncts 3–22

n

Installing Direct Station Selectors 3–43

n

Assembling MLX Telephones 3–48

n

Installing Cordless or Cordless/Wireless Telephones 3–57

n

Connecting Telephones to the Control Unit 3–58

4 Connecting the Control Unit to the Network Interface

n

Wiring 4–2

n

Testing Trunks 4–12

n

Labeling Trunks 4–14

n

Installing the Channel Service Unit 4–15

iv Installation

Contents

5 Installing the PC, CAT, or Printer

n

Connecting a PC to the Control Unit 5–1

n

Connecting a CAT to the Control Unit 5–7

n

Connecting a Printer to the Control Unit 5–7

6 Connecting Data Equipment

n

Data Stations 6–1

n

Analog Voice and Modem Data Stations 6–5

n

Modem Data-Only Stations 6–8

n

MLX Voice and Modem Data Stations 6–10

n

MLX Voice and Terminal Adapter Data Stations 6–12

n

Terminal Adapter Data-Only Stations 6–14

n

Video Conferencing Data Stations 6–17

7 Initializing and Testing the System

n

Initializing the System 7–1

n

Setting the Time and Date 7–3

n

Testing the System 7–3

n

Installing the Control Unit’s Housing 7–20

Installation

v

Contents

8 Installing Applications

n

Voice Messaging Systems and Touch-Tone
Receivers 8–2

n

Automated Document Delivery System 8–4

n

Call Accounting System 8–5

n

Call Accounting Terminal 8–8

n

Call Management System 8–9

n

CONVERSANT 8–12

n

Integrated Solution III 8–14

n

AT&T Attendant 8–17

n

MERLIN MAIL 8–18

n

MERLIN PFC 8–21

n

PassageWay Direct Connect Solution 8–23

n

System Programming and Maintenance (SPM) 8–25

9 Upgrading the System

n

Backing up System Programming 9–2

n

Removing the Control Unit Housing 9–3

n

Powering Down the System 9–5

n

Upgrading the Control Unit 9–7

n

Modifying the Processor for Key Mode 9–12

n

Completing the Upgrade 9–16

n

Upgrading from the MERLIN II
Communications System 9–16

n

Replacing the Control Unit Housing 9–18

vi Installation

Contents

2
4
5
6

2

A System Numbering Forms

Form 2a, System Numbering: Extension Jacks A–
Form 2b, System Numbering:Digital Adjuncts A–
Form 2c, System Numbering: Line/Trunk Jacks A–
Form 2d, System Numbering: Special Renumbers A–

B Unit Load Calculation Worksheet

Unit Load Worksheet B–

Index IN-1

Installation

vii

Figures

1. AC Grounding Requirements 2

2. Measuring the AC Outlet Voltages 2

3. Central Office and AC Grounds 2

4. Installing 146A and 147A Protectors 2

5. Marking the Basic Carrier Screw Holes 2

6. Installing a Copper Shield in the Power Supply 2

7. Installing the Ferrite Cores 2

8. Installing an Auxiliary Power Unit 2

9. Connecting the Carriers 2

10. Installing the Processor into the Carrier 2

11. 400EM Module Sample Dip Switch Settings for

12. Line/Trunk and Telephone Jack Locations on

13. Removing Modules from the Carrier 2

1. Multi-Function Module Packing List 3

2. Removing the User Card Tray and Line Cable 3

3. Releasing the Deskstand 3

4. Removing the Deskstand 3

5. Releasing the Module Cover Screw 3

6. Releasing the Module Cover 3

7. Removing the Module Cover 3

8. Removing an MFM Module 3

2 Installing the Control Unit

2–
2–
2–
2–
2–
2–
2–
2–
2–
2–
2–

Signaling Types 1C and 5 2–37

2–

Each Module 2–39

2–

–7
–9
–11
–15
–18
–22
–24
–26
–28
–31

–42

3 Installing Telephones and Adjuncts

3–

viii Installation

3–
3–
3–
3–
3–
3–
3–

–3
–4
–5
–6
–7
–8
–9
–10

Figures

9. Installing an MFM Module 3

10. Setting and Adjusting the MFM Jumpers 3

11. Removing the Jack Guard 3

12. Placing the Module Cover into the Locating Slot 3

13. Lowering and Locking the Module Cover 3

14. Replacing and Tightening the Module Cover Srew 3

15. Replacing the Deskstand 3

16. Lowering the Deskstand and Locking into Place 3

17. Replacing the User Card Tray and Line Cable 3

18. Adjusting the Deskstand Height 3

19. Powering Up the Telephone after Installing the

20. Routing the Cord(s) Through the Cord Channel 3

21. Manual and One-Touch Headset Operation 3

22. Single-Zone Paging with PagePac Plus 3

23. Single-Zone Paging with Customer-Supplied

24. Single-Zone Paging with UPAM 3

25. Single-Zone Paging with Background Music and

26. Multizone Paging with Background Music, Magic

27. Installing the Supplemental Alert Adapter 3

28. Connecting One or More DSSs 3

29. Wiring for Auxiliary Power 3

30. Adjusting or Removing the Deskstand 3

31. Connecting the Line Cords 3

32. Removing the Extension Label 3

Installing Telephones and Adjuncts, Continued

3–
3–
3–
3–
3–
3–
3–
3–
3–
3–
3–

MFM 3–21
3–
3–
3–
3–

Amplifier 3–32
3–
3–

Magic on Hold 3–36
3–

on Hold, and Bidirectional Paging (Talk-Back) 3–37
3–
3–
3–
3–
3–
3–

–11
–12
–13
–14
–15
–16
–17
–18
–19
–20

–23
–29
–31

–33

–39
–45
–46
–49
–50
–51

Installation

ix

Figures

33. Labeling the Extension 3

34. Removing the Handset Holder 3

35. Rotating the Handset Holder 3

36. Replacing the Extension Label 3

37. Mounting the Backplate 3

38. Routing the Cord Through the Backplate 3

39. Connecting Two Voice Pairs to a Telephone Using

40. Removing the Connecting Block 3

1. RJ21X Network Interface Connector 4

2. RJ21X Wiring Field Hardware 4

3. RJ21X Wiring Field Tools 4

4. Using the D-Impact Tool to Seat the Conductors 4

5. RJ11 and RJ14 Interfaces 4

6. 3150 Front Panel 4

7. 3150 Back Panel 4

Installing Telephones and Adjuncts, Continued

3–
3–
3–
3–
3–
3–
3–

a Bridging Adapter (BR-241-B1) 3–61

3–

4 Connecting the Control Unit to the Network Interface

4–
4–
4–
4–
4–
4–
4–

–52
–53
–53
–54
–55
–56

–63

–5
–6
–7
–8
–10
–17
–17

x Installation

Figures

1. Connecting a PC Within 50 ft. (15.2 m) 5

2. Connecting a PC More Than 50 ft. (15.2 m) Away 5

3. Connecting a CAT and Printer on the Same AC

4. Connecting a CAT and Printer on Different AC

5. Connecting a Printer Within 50 ft. (15.2 m) 5

6. Connecting a Printer More Than 50 ft. (15.2 m)

7. Connecting the 248B Adapter and the 2012D

1. Analog Voice and Modem Data Equipment

2. Modem Data-Only Equipment Configuration 6

3. Modem Data and MLX Voice Equipment

4. MLX Voice and Terminal Adapter Data Equipment

5. Terminal Adapter Data-Only Equipment

6. Video Conferencing Configuration 6

5 Installing the PC, CAT, or Printer

5–

6 Connecting Data Equipment

5–
5–

Outlet 5–10
5–

Outlets: Control Unit Connections 5–13
5–
5–

Away 5–19
5–

Transformer 5–20

6–

Configuration 6–7
6–
6–

Configuration 6–10
6–

Configuration 6–13
6–

Configuration 6–16
6–

–3
–6

–16

–9

–19

Installation

xi

Figures

1. Ground-Start Button 7

2. Installing the Control Unit Top Cover 7

3. Installing the Control Unit Front Cover 7

1. Removing the Control Unit Housing 9

2. Powering Down the System 9

3. Removing a Module from the Carrier 9

4. Replacing a Module in the Carrier 9

5. Removing the Processor Module Cover 9

6. Removing the Processor Module Circuit Board 9

7. Changing the Key Mode Switch Position to Closed 9

8. Installing the Control Unit Housing 9

2
4
5
6

7 Initializing and Testing the System

7–

9 Upgrading the System

7–
7–

9–
9–
9–
9–
9–
9–
9–
9–

–18
–21
–22

–4
–6
–9
–11
–13
–14
–15
–18

A System Numbering Forms

A–1. Form 2a, System Numbering: Extension Jacks A–

xii Installation

A–2. Form 2b, System Numbering:Digital Adjuncts A–
A–2. Form 2c, System Numbering: Line/Trunk Jacks A–
A–4. Form 2d, System Numbering: Special Renumbers A–

Tables

1. Environmental Requirements 2

2. AC Power Requirements 2

3. Heavy Lightning Protection 2

4. Setting the 400EM (Tie Trunk) Module DIP

5. Signaling Formats for the 400EM (Tie Trunk)

1. Unsupported Telephones and Adjuncts 3

2. Single-Line Telephones 3

3. Single-Line Telephones Supported by Release 3.0

1. Network Interfaces 4

2. Central Office Network Interface Codes 4

2 Installing the Control Unit

2–

3 Installing Telephones and Adjuncts

2–
2–
2–

Switches 2–35
2–

Module 2–36

3–
3–
3–

and Later 3–42

–2
–8
–14

–40
–41

4 Connecting the Control Unit to the Network Interface

4–
4–

–2
–3

Installation

xiii

Tables

1. AT&T 572 Printer Options 5

2. AT&T 475/476 Printer DIP Switch Settings 5

3. AT&T CAT Printer DIP Switch Settings 5

1. Data Station Configurations 6

2. Terminal Adapter Settings 6

1. TTRs Required by VMS 8

2. MERLIN MAIL Ports Required 8

5 Installing the PC, CAT, or Printer

5–

6 Connecting Data Equipment

8 Installing Applications

5–
5–

6–
6–

8–
8–

–22
–24
–25

–2
–21

–3
–19

xiv Installation

Safety

The exclamation point in an equilateral
triangle is intended to alert the user to the
presence of important operating and
maintenance (servicing) instructions in the
literature accompanying the product.

IMPORTANT SAFETY INSTRUCTIONS

When installing telephone equipment, always follow basic safety precautions
to reduce the risk of fire, electrical shock, and injury to persons, including:

■

Read and understand all instructions.

■

Follow all warnings and instructions marked on or packed with the
product.

■

Never install telephone wiring during a lightning storm.

■

Never install a telephone jack in a wet location unless the jack is
specifically designed for wet locations.

■

Never touch uninsulated telephone wires or terminals unless the
telephone wiring has been disconnected at the network interface.

■

Use caution when installing or modifying telephone lines.

■

Use only AT&T-manufactured MERLIN LEGEND Communications
System circuit modules, carrier assemblies, and power units in the
MERLIN LEGEND Communications System control unit.

■

Use only AT&T-recommended/approved MERLIN LEGEND
Communications System accessories.

■

If equipment connected to the analog extension modules (008, 408,
408 GS/LS) or to the MLX telephone modules (008 MLX, 408 GS/LS­MLX) is to be used for in-range out-of-building (IROB) applications,
IROB protectors are required.

Installation

xv

Safety

■

Do not install this product near water, for example, in a wet basement
location.

■

Do not overload wall outlets, as this can result in the risk of fire or
electrical shock.

■

The MERLIN LEGEND Communications System is equipped with a
3-wire grounding-type plug with a third (grounding) pin. This plug will
fit only into a grounding-type power outlet. This is a safety feature. If
you are unable to insert the plug into the outlet, contact an electrician
to replace the obsolete outlet. Do not defeat the safety purpose of the
grounding plug.

■

The MERLIN LEGEND Communications System requires a
supplementary ground.

■

Do not attach the power supply cord to building surfaces. Do not
allow anything to rest on the power cord. Do not locate this product
where the cord will be abused by persons walking on it.

■

Slots and openings in the module housings are provided for
ventilation. To protect this equipment from overheating, do not block
these openings.

■

Never push objects of any kind into this product through module
openings or expansion slots, as they may touch dangerous voltage
points or short out parts, which could result in a risk of fire or electrical
shock. Never spill liquid of any kind on this product.

■

Unplug the product from the wall outlet before cleaning. Use a damp
cloth for cleaning. Do not use cleaners or aerosol cleaners.

■

Auxiliary equipment includes answering machines, alerts, modems,
and fax machines. To connect one of these devices, you must first
have a Multi-Function Module (MFM).

■

Do not operate telephones if chemical gas leakage is suspected in
the area. Use telephones located in some other safe area to report the
trouble.

xvi Installation

Safety

!

WARNING:

■

For your personal safety, DO NOT install an MFM yourself.

■

ONLY an authorized technician or dealer representative shall install,
set options, or repair an MFM.

■

To eliminate the risk of personal injury due to electrical shock, DO
NOT attempt to install or remove an MFM from your MLX telephone.
Opening or removing the module cover of your telephone may expose
you to dangerous voltages.

SAVE THESE INSTRUCTIONS

Installation xvii

Safety

xviii Installation

About This Book

The MERLIN LEGEND Communications System is an advanced digital
switching system that integrates voice and data communications features.
Voice features include traditional telephone features, such as Transfer and
Hold, and advanced features, such as Group Coverage and Park. Data
features allow both voice and data to be transmitted over the same system
wiring.

Intended Audience

This book is intended for qualified field technicians who install and upgrade
the system.

How to Use This Book

Qualified technicians can use this book as a guide to installation and
upgrading procedures. The technician is given specific steps for installing all
units of the control unit, telephones, adjuncts and data equipment.

Installation

xix

How to Use This Book

later in this section, provides a complete list of system

Refer to the following documentation for additional information:

■

Equipment and Operations Reference

on system hardware, telephones, and other equipment.

■

Feature Reference

communications system.

■

System Planning

system for installation.

■

System Programming

system features.

■

Users’ guides and Operators’ Guides give procedural instructions for
programming and using telephone features.

“Related Documents,”
documentation together with ordering information.

In the U.S.A. only, AT&T provides a toll-free customer Helpline (1 800 628-

2888) 24 hours a day. Call the Helpline, or your AT&T representative, if you
need assistance when installing, programming, or using your system.

provides detailed information

provides details on the features of the

provides procedures and forms for planning a

gives procedural instructions for programming

xx Installation

Terms and Conventions Used

Terms and Conventions Used

In this document, the terms in the following list are used in preference to
other, equally acceptable terms for describing communications systems.

Lines, Trunks and Facilities

Facility

telephone system and the telephone company central office. Technically a

trunk

Communications System to the central office. Technically, a
start facility or a communications path that does not connect two switches
(for example, an intercom line or a Centrex line). However, in actual usage,
the terms
use
refer to
start trunk, Direct Inward Dialing (DID) trunk, and so on. When you talk to
your local telephone company central office, ask them what terms they use
for the specific facilities they connect to your system.

Some older terms have been replaced with newer terms. The following list
shows the old term on the left and the new term on the right:

is a general term that designates a communications path between a

connects a switch to a switch, for example the MERLIN LEGEND

line

is a loop-

line

and

trunk

are often applied interchangeably. In this book, we

line/trunk

and

lines/trunks

digital facilities

to refer to facilities in general. Specifically, we

. We also use terms such as personal line, ground-

trunk module line/trunk module
trunk jack line/trunk jack
station extension
station jack extension jack
analog data station modem data station
digital data station terminal adapter
7500B data station terminal adapter
analog voice and analog data station analog voice and modem data
digital voice and analog data station MLX voice and modem data
analog data only station modem data only station
digital data only station terminal adapter only station
7500B data only station terminal adapter only station
digital voice and digital data station MLX voice and terminal

adapter station

MLX voice and 7500B data station MLX voice and terminal

adapter station

Installation

xxi

Product Safety Labels

Typographical Conventions

Certain type fonts and styles act as visual cues to help you rapidly
understand the information presented:

Example Purpose

It is

very

important that you follow
these steps. You
wristband before touching the
connection.

The part of the headset that fits over
one or both ears is called a

headpiece.

If you press the Feature button on an
MLX display telephone, the display
lists telephone features you can
select. A programmed Auto Dial
button gives you instant access to an
inside or outside number.

Choose
screen.

To activate Call Waiting, dial

Ext Prog

must

attach the

from the display

*11

.

Italics indicate emphasis.

Italics also set off special terms.

The names of fixed-feature, factory­imprinted buttons appear in bold. The
names of programmed buttons are
printed as regular text.

Plain constant-width type indicates text
that appears on the telephone display
or personal computer (PC) screen.

Constant-width type in italics indicates
characters you dial at the telephone or
type at the PC.

Product Safety Labels

Throughout these documents, hazardous situations are indicated by an
exclamation point inside a triangle and the word

!

WARNING:

Warning indicates the presence of a hazard that could cause death or
severe personal injury if the hazard is not avoided.

xxii Installation

caution

or

warning

.

Security

on the inside front cover of this book and

Security
in Appendix A,

!

CAUTION:

Caution indicates the presence of a hazard that could cause minor
personal injury or property damage if the hazard is not avoided.

Security

Certain features of the system can be protected by passwords to prevent
unauthorized users from abusing the system. You should assign passwords
wherever you can and limit knowledge of such passwords to three or fewer
people.

Nondisplaying authorization codes and telephone numbers provide another
layer of security. For more information, see Appendix A, “Customer Support
Information” following

Throughout this document, toll fraud security hazards are indicated by an
exclamation point inside a triangle and the words Security Alert.

Maintenance and Troubleshooting

.

!

Security Alert:

Security Alert indicates the presence of toll fraud security hazard. Toll
fraud is the unauthorized use of your telecommunications system by an
unauthorized party (e.g., persons other than your company’s
employees, agents, subcontractors, or persons working on your
company’s behalf). Be sure to read “Your Responsibility for Your
System’s Security”
of Your System: Preventing Toll Fraud”
Support Information.”

“

“Customer

Installation xxiii

Related Documents

Related Documents

In addition to this book, the documents listed below are part of the
documentation set. Within the continental United States, these documents
can be ordered from the AT&T GBCS Publications Fulfillment Center by
calling 1 800 457-1235.

Document No. Title

System Documents

555-640-110
555-640-111
555-640-112
555-640-113
555-640-116
555-640-118

555-640-122

555-630-150
555-630-153
555-640-124
555-630-151
555-640-120
555-640-126
555-640-138

555-640-134
555-640-132
555-640-136

555-640-130
555-640-105

Feature Reference
System Programming
System Planning
System Planning Forms
Pocket Reference
System Manager’s Guide

Telephone User Support

MLX-10D, MLX-10DP, MLX-16DP
MLX-20L



Display Telephones User’s Guide

,

MLX-28D, and

MLX-10D Display Telephone Tray Cards (5 cards)
MLX-28D and MLX-20L Telephone Tray Cards (5 cards)
MLX-10 Nondisplay Telephone User’s Guide
MLX-10 Nondisplay Telephone Tray Cards (6 cards)
Analog Multiline Telephones User’s Guide
Single-Line Telephones User’s Guide
MDC 9000 and MDW 9000 Telephones User's Guide

System Operator Support

MLX Direct-Line Consoles Operator’s Guide
Analog Direct-Line Consoles Operator’s Guide
MLX Queued Call Console Operator’s Guide

Miscellaneous User Support

Calling Group Supervisor’s Guide
Data and Video Reference

xxiv Installation

How to Comment on This Document

Document No. Title

Documentation for Qualified Technicians

555-640-140

555-025-600

Installation, Programming & Maintenance (IP&M) Binder
[consists of Installation, System Programming & Maintenance
(SPM), Maintenance & Troubleshooting

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GBCS Products Security Handbook

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Installation

xxv

How to Comment on This Document

xxvi Installation

Introduction

1

1

Installation of the MERLIN LEGEND Communications System involves the
following:

■

Installing the control unit

■

Installing the telephones

■

Connecting system wiring

■

Installing optional equipment

This chapter provides an overview of the installation process, which varies
from customer to customer.

Installation Sequence

The following is a list of the components that the system can include and
shows the order in which you should install them. When installing your
customer’s system, try to adhere to this order as much as possible:

1. Install the control unit (required).

2. Connect power accessories to the control unit (optional).

3. Install the telephones (required) and adjuncts (optional).

4. Connect the telephones to the control unit (required).

Introduction

1–

System Forms

5. Connect the control unit to the network interface (required).

6. Connect the channel service unit (CSU) to the 100D module on the
control unit (required only with the 100D module).

7. Connect the printer and PC to the control unit (optional).

8. Connect data equipment to the control unit (optional).

9. Initialize and test the system (required).

10. Install the control unit housing (required).

11. Install applications (optional).

A list of required tools and equipment is given before each installation
procedure.

System Forms

Some of the installation procedures in this guide refer to system forms. These
forms indicate information that is specific to your customer’s system. The
forms you need should be included with the system programming disk or
memory card, which contains all of the programming specifically for your
customer’s system.

If you are upgrading an existing system and do not have the required forms
for your customer’s system, you can load System Programming and
Maintenance (SPM) and print out the required forms.

If you find that you do not have a completed set of system forms for your
customer’s system, contact your technical support organization or the
Customer Service Center (CSC). See the inside front cover for telephone
numbers.

The system forms that you need are specific for each system, and include
some or all of those described in the following sections.

1–2 Introduction

Installing

3

System Forms

Installing the Control Unit

■

Form 1, System Planning. Some procedures in Chapter 2, “
the Control Unit,” refer to the Control Unit Diagram, which is printed on
the reverse side of this form.

■

Form 3c, Incoming Trunks: Tie. If you install a 400EM module in the
control unit, use this form to determine the appropriate switch settings
prior to installation.

Installing Telephones (Required) and Adjuncts (Optional)

The following forms indicate the telephones and adjuncts that you must install:

■

Form 2a, System Numbering: Extension Jacks

■

Form 2b, System Numbering: Digital Adjuncts

■

Form 4b, Analog Multiline Telephone

■

Form 4d, MLX Telephone

■

Form 4e, MFM Adjunct: MLX Telephone

■

Form 4f, Tip/Ring Equipment

■

Form 5a, Direct-Line Console (DLC): Analog

■

Form 5b, Direct-Line Console (DLC): Digital

■

Form 5c, MFM Adjunct: DLC

■

Form 5d, Queued Call Console (QCC)

Introduction

1–

Programming the System

Connecting the Network Interface

The following forms indicate the trunks that you must connect to the control
unit. Information regarding the channel service unit (CSU) is included on
these forms.

■

Form 2c, System Numbering: Line/Trunk Jacks

■

Form 3a, Incoming Trunks: Remote Access

■

Form 3b, Incoming Trunks: DS1 Connectivity (100D Module)

■

Form 3d, Incoming Trunks: DID

Connecting Data Equipment

The following forms indicate the data equipment you will need to set up data
stations.

■

Data Form 1a, Modem Data Station

■

Data Form1b, 7500B Data Station

■

Data Form 2, Data Hunt Groups

Programming the System

If you have a system programming disk created with SPM or a Translation
memory card, you do not need to program the system. Instead, you can use
the disk or memory card to restore the system; see Chapter 7, “Initializing and
Testing the System,” for instructions. If you did not receive a disk or a memory
card and it is your responsibility to program the system, see

Programming

for instructions.

1–4 Introduction

System

Upgrading the System

then Chapter 7,

5

Upgrading the System

If you are upgrading to Release 4.0 from Release 3.1, 3.0, 2.1, 2.0, 1.0, 1.1, or
from the MERLIN
the System,”
instructions.

NOTE:

You cannot retain the programming from the MERLIN ll Communications
System. You must first upgrade the hardware, then reprogram the system.



II Communications System, refer to Chapter 9, “Upgrading

“Initializing and Testing the System,” for upgrade

Introduction

1–

Upgrading the System

1–6 Introduction

Installing the Control Unit

1

2

If you have not read Chapter 1, “Introduction,” do so before continuing with
this chapter.

Overview

Installing the control unit involves the following procedures:

■

Preparation requirements

■

Installing the backboard

■

Meeting the power and grounding requirements

■

Checking the total unit load

■

Installing the basic carrier

■

Installing any expansion carriers

■

Installing the power supply

■

Installing the processor

■

Installing the line/trunk and extension modules

■

Connecting the control unit to AC power

■

Powering up the system

■

Powering down the system

Installing the Control Unit

2–

Overview

The following sections provide detailed instructions for these installation
procedures. Follow the procedures in the order in which they are presented.

Environment

The control unit must be installed on a backboard. The placement of the
backboard, and the control unit on it, requires careful consideration. Make
sure you install the backboard in an area that meets all of the environmental
requirements listed in Table 2–1.

Table 2–1. Environmental Requirements

Operating
Temperatures

Humidity
Airborne

Contamination
Ventilation

Electrical Fields

Heat Dissipation

!

WARNING:

Do not install the control unit outdoors.

40o–104oF (4o–40oC)
Optimal temperature: 60oF (15.6oC)

20%–80%
Do not expose the control unit to moisture, corrosive gases, dust,

chemicals, spray paint, or similar material.
Allow at least 1 in. (2.54 cm) on the right and left sides of the control

unit and 12 in. (30.48 cm) minimum, above and below it, to prevent
overheating.

Do not place the control unit near extreme heat sources (for example:
furnaces, heaters, attics, or direct sunlight).

Do not expose the control unit to devices that generate electrical
currents causing interference (such as arc welders or motors).

Basic carrier: 500 Btu/hr
Basic carrier: with one expansion carrier 1000 Btu/hr
Basic carrier: with two expansion carriers 1500 Btu/hr

2–2 Installing the Control Unit

Overview

Basic carrier: 14 in. wide by 23 in. high by 12 in. deep
Basic carrier and one expansion carrier: 25 in. wide by 23 in. high

3

Electrical Noise/Radio-Frequency Interference

In most cases, electrical noise is introduced to the system through trunk or
telephone cables. However, electromagnetic fields near the control unit can
also cause noise in the system. Therefore, you should
unit and cable runs in areas where a high electromagnetic field strength
exists.

Radio transmitters (AM and FM), television stations, induction heaters, motors
(with commutators) of 0.25 horsepower (200 watts) or greater, and similar
equipment are leading causes of radio-frequency interference (RFI). Small
tools with universal motors are generally not a problem when they operate on
separate power lines. Motors without commutators generally do not cause
interference.

Field strengths below 1.0 volt per meter are unlikely to cause interference. To
estimate the field strength produced by radio transmitters, divide the square
root (√) of the emitted power, in kilowatts, (÷) by the distance from the antenna
in kilometers which equals (=) the field strength in volts per meter.

not

place the control

Example: √49,000 kw

This yields the approximate field strength in volts per meter and is relatively
accurate for distances greater than about half a wavelength (492 ft., or 150 m,
for a frequency of 1000 Hz). If the result exceeds 1.0 volt per meter, you may
have to install shielded cables and or Z200A filters. See Appendix A,
“Customer Support Information,” following
for FCC Part 15 radio frequency regulations.

= 7,000 ÷ 10 km (6.2 miles) = 0.7 volts per meter

Control Unit Requirements

■

Dimensions
—
—

by 12 in. deep

Maintenance and Troubleshooting

Installing the Control Unit

2–

,

Overview

Basic carrier and two expansion carriers: 37 in. wide by 23 in. high

Within 5 ft. (152 cm) of an AC power outlet that is

not

switch-

Within 25 ft. (762 cm) of the network interface, or use an Off-

Within 1000 cable ft. (305 m) of telephones, or use an OPRE (for

¾-inch plywood
Check with the local building code enforcement agency to see

—

■

Location

by 12 in. deep

—

controlled

—

Premises Range Extender (OPRE)

—

!

basic telephones)

CAUTION:

The AC outlet for the control unit cannot be switch-controlled. Plugging
the control unit into such an outlet invites accidental disconnection of
the system.

Hardware Preassembly Process

If an installation is to be preassembled, wired, programmed, and tested on
the new lightweight plastic backboard, see “Installing the Backboard.”

Backboard Requirements

The backboard should be wide enough to accommodate the carrier and up to
two additional carriers, assuming that system growth is anticipated. There
should be enough room on each side of the control unit for the necessary
wiring fields.

To accommodate the maximum control unit size, make sure the backboard
meets the following requirements:

■

Material
—
—

whether fire-retardant material is required.

2–4 Installing the Control Unit

AC Power and Grounding

Make sure that the material meets local building codes.

With Systimax wiring: 7 ft. wide by 4 ft. high
Without Systimax wiring: 6 ft. wide by 3 ft. high

5

—

■

Dimensions
—
—

Installing the Backboard

When you are certain that the backboard meets the requirements indicated
above, or is the new lightweight plastic material backboard with
preassembled equipment in place, attach the backboard to the wall.

Use the following mounting hardware:

■

For a wood mounting surface, use wood screws.

■

For brick, cinderblock, or concrete, use masonry anchors.

■

For plaster or plasterboard, use toggle bolts.

■

For sheet metal, use sheet-metal screws and attach them to the
structural members.

NOTE:

The mounting hardware should resist a combined pullout force of at least 650
pounds (295 kilograms).

AC Power and Grounding

Proper power and grounding are essential for the system to run correctly and
safely.

!

CAUTION:

If any of the following requirements are not met, the customer must
contact a licensed electrician. Do not install the system until all
requirements are met.

Installing the Control Unit 2–

Approved Grounds,

later in

1).

includes complete installation instructions.
below,

AC Power and Grounding

Verify that all of the following power and grounding requirements are met:

■

The load center of appropriate current rating must be equipped with
circuit breaker(s) labeled

■

Each breaker must protect one dedicated quad AC outlet or two

120 V AC, 15 amps

.

dedicated duplex AC outlets.

■

All AC outlets must connect to the same load center and the ground
wire must connect to the single-point ground bar on the first AC outlet
(see Figure 2–1).

■

One outlet must have an attached ground bar connected by a #6 AWG
copper wire to an approved ground (see “
this chapter, for a description of approved grounds). This ground bar
is the system’s single-point ground (see Figure 2–

■

To prevent someone from accidentally shutting off the power,
connect the control unit to a switch-controlled outlet.

■ The AC outlet should be within 5 ft. (152 cm) of the control unit.

■

Each carrier requires one AC outlet receptacle.

■

Auxiliary equipment requires additional AC outlets.

■

If a printer or PC is installed on the system, it must be plugged into the
same AC branch as the power supply of the basic carrier.

”

do not

If the printer or PC is 50 ft. (15 m) or more from the control unit, or is
plugged into a different AC circuit, Asynchronous Data Units (ADUs)
must be installed as well. Chapter 5, “Installing the PC, CAT, or
Printer,”

■

The AC power requirements indicated in “AC Outlet Tests,”
must be met.

2–6 Installing the Control Unit

AC Power and Grounding

1. AC Grounding Requirements

7

From AC

Load Center

(2 separately

fused 15 A

circuits)

HUBBELL

Receptacles

(5262 15 A

or equivalent)

Ground Wire
#14 AWG

4" Box (RACO 230
or equivalent)

Figure 2–

Single-Point

!

CAUTION:

Ground

Ground Bar Mounted
on a 4" Box (Square
"D" PK9GTA or

approved equivalent)

Approved
Building Ground

#12 or #14 AWG Copper
Wire to Each Power Supply
Grounding Screw

4" Cover 
(RACO 807
or equivalent)

Ground Wire
#6 AWG Copper

The AC outlet for the control unit cannot be switch-controlled. Plugging
the control unit into such an outlet invites accidental disconnection of
the system. The AC outlet must be properly wired as described in “AC
Outlet Tests.”

Installing the Control Unit 2–

AC Power and Grounding

Table 2–2. AC Power Requirements

Parameter Value

Nominal voltage 117 V AC
Voltage range 110–125 V AC
Frequency 60 Hz +/– 5%
Maximum current 3 amps per power supply
Power consumption 225 watts per power supply

AC Outlet Tests

If the AC outlet tests indicate that any of the power requirements in Table 2–2
are not met, your customer must contact a licensed electrician.
the system until all requirements are met.

If the AC outlet tests reveal any of the following conditions, they must be
corrected before you install the system:

■

Open ground

■

Hot and neutral reversed

■

Open hot

■

Open neutral

■

Hot and ground reversed

Do not

install

!

WARNING:

Hazardous voltages are present during the following tests. Follow all
instructions carefully when working with AC power line voltages.

2–8 Installing the Control Unit

AC Power and Grounding

2. Measuring the AC Outlet Voltages

9

Using an Ideal 61-035 Circuit Tester (or Equivalent)

1 Plug the circuit tester into the outlet that you want to test.

If the circuit is properly grounded, the yellow and white lights on the tester
turn on.

2 Unplug the circuit tester.

Using a Volt-Ohm Milliammeter (VOM)

1 Set the VOM to the lowest scale on which you can read 130 V AC.
2 Measure the AC outlet voltages. See Figure 2–2.

■

Phase to ground should be 110 to 125 V AC.

■

Neutral to ground should be less than 1 V AC.

■

Phase to neutral should be 110 to 125 V AC.

110 - 125

Volts AC

Figure 2–

!

Neutral

Less than

1.0 Volt AC

Phase
(HOT)

Ground

110 - 125
Volts AC

WARNING:

If the voltage readings do not measure the values required, the AC
outlet is improperly wired—do not install the system. Advise the
customer to have a licensed electrician correct the problem.

Installing the Control Unit 2–

1 and 2

3 show this connection.

AC Power and Grounding

Grounding Requirements

Proper grounding of the installation site safeguards the system by protecting it
from the following:

■

Lightning

■

Power surges

■

Power crosses on central office trunks

■

Electrostatic discharge (ESD)

When installing the control unit, make sure you meet the following grounding
requirements:

■

The control unit, the central office trunk protector, and the AC power
service panel should be as close to each other as possible.

■

Because equipment can be located throughout a building, the
National Electrical Code requires that the ground point for the central
office trunk protector be bonded to the AC power ground as shown in
Figure 2–3.

■

The AC outlet and the single-point ground bar must be properly
grounded as shown in Figure 2–1 and Figure 2–3.

■

Each power supply in the control unit must be connected to the single­point ground bar by a #12 AWG or a #14 AWG solid copper wire.
Figures 2–

This wire run should be as short as possible, preferably within 5 ft.
(152 cm), not to exceed 10 ft. (305 cm). See “Approved Grounds,”
later in this chapter, for more information.

■

The AC outlet must be connected to the 147A protector with #12 AWG
or a #14 AWG solid copper wire.

–

2–10 Installing the Control Unit

AC Power and Grounding

3. Central Office and AC Grounds

To Central

Office or

Serving

Facility

CO

Lines

#12 or #14

AWG

Ground

Wire

CO

Line

Protector

Earth

Ground

Network

Interface

Coupled Bonding
Conductor (optional)

Power

)

(

Supply

CAUTION

TURN OFF

POWER BEFORE

INSERTING OR

REMOVING
MODULES

Plug

#6 AWG

Ground

Wire

Power

Ground

Bond

Wire

Processor

Outlet

Rod

DIW or

25-Pair Cable

AC

Single -
Point
Ground
Bar

Shield

Ground

CO

Wiring

Field

B
W

GND (Green)

Commercial 

Power

Power 

Service

D2R
Cords

Figure 2–

Installing the Control Unit 2–11

AC Power and Grounding

Other local metal underground systems or structures, such as

Rod and pipe electrodes, a 5/8-in. (1.58-cm) solid rod or ¼-in.

Plate electrode, a minimum of 2 square ft. (61 square cm) of

!

WARNING:

Improper ground can cause equipment failures, service outages, and
electrical shock. Verify that the AC power uses an approved ground for
its primary ground, that all voltage-limiting devices are grounded to an
approved ground, and that the ground is one of the approved grounds
listed below.

Approved Grounds

Approved grounds are listed below, in order of preference:

■

Building Steel. The most preferred ground.

■

Acceptable Water Pipe. Must be a metal,
underground water pipe at least ½ in. (1.27 cm) in diameter, and in
direct contact with the earth for at least 10 ft. (3 m).

It must be electrically continuous so that the protector ground is
uninterrupted. (Check for insulated joints, plastic pipe, and plastic
water meters that might interrupt electrical continuity.)

A metallic underground water pipe must be supplemented by the
metal frame of the building, a concrete-encased ground, or a ground
ring. If these grounds are not available, the water pipe ground can be
supplemented by one of the following types of grounds:

not plastic or vinyl

,

—

tanks and piping systems,

—

(0.63-cm) conduit or pipe electrode driven to a minimum depth of
8 ft. (244 cm)

—

metallic surface exposed to the exterior soil

2–12 Installing the Control Unit

but not gas pipes

AC Power and Grounding

At least 20 ft. (6.1 m) of one or more steel reinforcing rods, each at

20 ft. (6.1 m) of bare copper conductor not smaller than #4 AWG,

This electrode must be located within and near the bottom of a

Ground ring, consisting of at least 20 ft. (6.1 m) of bare copper

this is a safety

■

Concrete-Encased Ground. Must be an electrode, consisting of one
of the following:

—

least ½ in. (1.27 cm) in diameter

—

encased in 2 in. (5 cm) of concrete

—

concrete foundation or footing that is in direct contact with the
earth.

—

conductor (not smaller than #2 AWG) encircling the building. The
ground ring must be in direct contact with the earth and buried at
least 2.5 ft. (77 cm) below the earth’s surface.

!

WARNING:

Do not use a metal underground gas piping system—

risk.

Central Office Trunk Protection

The telephone company is responsible for providing the following protection
of central office (co) trunks at the entrance to the site:

■

Carbon blocks or gas discharge tubes connected to an approved
ground

■

Adequate bonding of the central office trunk protector ground and the
power company ground

!

CAUTION:

Check these requirements with a simple, visual inspection. If you cannot
verify that the central office grounding requirements are met, contact the
central office. Do not connect the control unit to the central office trunks
until you are certain that these requirements are met.

Installing the Control Unit 2–13

AC Power and Grounding

Heavy Lightning Protection

For most surges, adequate protection is provided by meeting the previously
listed requirements. Additional protection is required when the customer is
located in a heavy lightning area.

Connect a 147A protector to the system to limit surges from the AC lines and
up to four CO trunks.

For systems with more than four CO trunks, do the following:

■

Connect a 146A protector to the 147A protector, providing protection
for an additional four trunks.

■ Connect up to three (maximum) 146A protectors to a 147A protector,

allowing a maximum of 16 trunks on one 147A protector.

■

For more than 16 trunks, add another 147A protector and continue
adding 146A protectors as needed. See Table 2–3 for various
configurations and Figure 2–4 for a typical 147A protector installation.

Table 2–3. Heavy Lightning Protection

Number of CO Trunks Required Protectors

1–4 147A
5–8 147A and a 146A
9–12 147A and two 146As
13–16 147A and three 146As
17–20 Second 147A
21–24 Second 147A and one 146A

NOTES:

1. When you use the second 147A, you can connect the 146As in any
combination, up to a maximum of three 146As per 147A.

2. For detailed installation instructions, see the documentation packaged with
the protectors.

2–14 Installing the Control Unit

AC Power and Grounding

4. Installing 146A and 147A Protectors

CONTROL UNIT

TEL CO LINE

CONTROL UNIT

TEL CO LINE

CONTROL UNIT

TEL CO LINE

CONTROL UNIT

TEL CO LINE

To Central

Office

Cross-Connect

Field

Status

Indicator

Ground

Connection

AC Surge/Suppressor

Protector

AC

Outlet

To 
Control
Unit

147A Protector

Light

Strap

AC

146A

Protector

Ground
Strap

8 MLX (Digital) Telephones

008 MLX

408

PROCESSOR

POWER

CAUTION

ON



OFF

Turn off
power before
inserting or
removing
modules

AG INPUT

FR
GND

#12 or #14
AWG Ground Wire

To Power Supply
Module

44GS or LS Outside Lines/

408 GS/LS

012

8 Analog Telephones (ATL)

Control Unit

Figure 2–

Connect telecommunications
equipment only to these outlets.
Maximum load 12.5A

Installing the Control Unit 2–15

Unit Loads

Unit Load Calculation Worksheet.

Unit Loads

A unit load is a measure of power (1.9 watts) that you use to determine the
electrical load that the components listed below place on the control unit’s
power supply.

Only the telephones and adjuncts that connect to the analog and digital
extension jacks (ports) on the control unit require unit load calculation. When
calculating unit load, do not include any equipment with its own power supply.

Checking Unit Loads

In the event of maintenance or equipment changes, recalculate the unit loads
for each carrier where there is a new configuration. Use the worksheet in
Appendix B, “

As a general rule, if you can distribute the 800 DID modules and telephone
modules equally across the carriers, you prevent unnecessary drain on any
one carrier. However, the rule varies depending on the system’s mode. The
next two sections provide the rules for calculating unit loads in various modes.

■

Telephones and adjuncts

■

800 DID modules

”

Unit Loads for Hybrid/PBX Mode

Older power supplies (models 391A1 or 391A2) generally supports six
modules of any type in Hybrid/PBX mode, without requiring an upgrade to a
newer power suppy (model 391A3). If the following conditions are true,
however, the unit loads on a carrier can exceed the 54-unit maximum and,
therefore, require a newer power suppy (model 391A3):

■

All six carrier slots are occupied by MLX telephone or analog multiline
telephone modules.

■

The carrier has a total of more than 45 MLX-20L telephones or
34-button analog multiline telephones installed.

2–16 Installing the Control Unit

Installing the Basic Carrier

Unit Loads for Key or Behind Switch Mode

In a Key or Behind Switch system with four or fewer modules, no calculation is
needed. The older power supplies (models 391A1 or 391A2) generally
supports four modules of any type. With more than four modules, a newer
power suppy (model 391A3) may be needed.

Installing the Basic Carrier

Continue with this procedure only if you have met all of the requirements
discussed earlier in this chapter.

NOTE:

When you mount the basic carrier onto the backboard, leave 29 in. (73.66 cm)
of backboard to the right. This allows you to easily install and remove the
control unit cover, and also allows enough room for system expansion to the
right for the total length of up to three carriers.

Installing the Control Unit

2–17

Installing the Basic Carrier

5. Marking the Basic Carrier Screw Holes

To install the basic carrier, follow the steps below:

1 Mark the screw-hole locations on the backboard, using the basic carrier

or the template supplied with the plastic preassembled backboard as a
guide. See Figure 2–5.

Make sure the carrier is level before marking the holes.

2 Drill a pilot hole in the center of each of the four screw-hole marks.
3 Anchor the screws approximately halfway into the backboard.
4 Position the carrier on the screws and slide the carrier to the left.
5 Tighten the screws.

Mounting Surface

Figure 2–

2–18 Installing the Control Unit

Mounting
Screw

Backboard

Basic 
Carrier

Installing the Power Supply

later in this chapter. Failure to comply with this procedure

Installing a Copper Shield,

later

Installing the Power Supply

!

WARNING:

Do not attach any cables or power cords to the power supply until it is
installed in the carrier.

Do not power up the control unit until all of the modules and power
equipment are installed. Once they are installed, refer to “Powering Up
the System,”
can result in shock hazard and or damage to the equipment.

If you are upgrading an older system and a ring generator is specified in
the system forms (Control Unit Diagram), install it in the power supply
before putting the power supply in the carrier. The procedure is detailed
in

Maintenance and Troubleshooting.

For expansion carriers with older power supply modules only, a copper
shield must be installed on the power supply before installing it in the
carrier. The procedure is explained in “
in this chapter.

”

Before touching leads, connectors, pins, and other components, use a
properly grounded wrist strap, to prevent damage from electrostatic
discharge (ESD).

Remove the protective cover from the gold-finger connector (on the
back of the power supply) before inserting it into the carrier.

Installing the Control Unit 2–19

Installing the Power Supply

Installing the power supply can involve as many as four procedures,
depending on the system configuration. The procedures are:

■

Turning off all power to the control unit

■

Installing a copper shield [for older power supply modules (391A1,
391A2, 391B1) only]

■

Installing the ferrite cores

NOTE:

It is not necessary to install ring generators in a new system with new 012
(apparatus code 517G13 or later) modules or new 008 (apparatus code
517D28 or later letter). If you are upgrading or using older modules, see

Maintenance and Troubleshooting

.

Turning Off the Power

1 Turn off
2 Disconnect

each

power supply.

all

power cords and auxiliary units.

Installing a Copper Shield

The added power supply in each expansion carrier can cause excessive
noise in the module occupying the next slot. To eliminate this noise, a copper
foil shield is installed over the power supply. These shields and their labels
are packaged in the power unit shielding kit included with the expansion
carrier.

NOTE:

The 391A3 and 391B2 power supply modules do not require copper
shielding. Perform this procedure for older power supply modules (391A1,
391A2, and 391B1) only.

2–20 Installing the Control Unit

Installing the Power Supply

To install a copper shield, follow the steps below. Refer to Figure 2–6
throughout the procedure.

1 Make sure all power is off.
2 Place the power supply on a flat surface with the right side up (as viewed

from the front edge).
3 Wipe the module free of any dust or dirt.
4 Peel the backing paper from the smaller copper-foil shield to expose the

adhesive.

Check the positioning of the foil shields before sticking them to the side of the

module. Once in place, the foil is difficult to remove.

5 Position the foil on the upper part of the module and work out any air

bubbles as you press the foil firmly in place.
6 Peel the backing paper from the larger copper-foil shield to expose its

adhesive.
7 Position the foil on the lower part of the module.

a The shields

b They should

must

meet.

not

overlap or have

any space

between them.

Installing the Control Unit

2–21

Installing the Power Supply

6. Installing a Copper Shield in the Power Supply

CAUTION

TURN OFF

POWER BEFORE

INSERTING OR
REMOVING

MODULES

Upper Copper
Foil Shield

Lower Copper
Foil Shield

Power Unit 
Information
Label

UL Label
or
CSA Label

Figure 2–

8 Tuck the foil shield tightly along the ledge (or crease) of the housing and

work out any air bubbles as you press the foil firmly in place.

9 With the copper-foil shield in place, put the power unit information label

on the lower piece of foil.

10 Attach the UL or CSA label on the power supply below the copper-foil

shield.

2–22 Installing the Control Unit

Installing the Power Supply

Installing the Power Supply Module in the Carrier

1 Lower the power supply module hook onto the rod on top of the carrier.
2 Make sure the connector on the module mates properly with the

connector on the carrier.
3 Push the module into the carrier until it locks into place.

Installing the Ferrite Cores

At this point, the power supply should have been installed in the carrier, but

there should be no cables or power cords attached to the power supply

module.

NOTE:

If you are upgrading a system, unplug the AC power cord and remove the

ground wire attached to the grounding screw on the front of the power supply.

Follow these steps to install the ferrite cores:

1 Feed the AC power and ground wire through the wire manager (refer to

Figure 2–7).
2 Open the ferrite cores by unsnapping the plastic case.
3 Attach a ferrite core around the AC power cord and the ground wire by

snapping the plastic case shut.
4 Attach the second ferrite core adjacent to the first ferrite core by

repeating Steps 2 and 3.
5 Slide the ferrite cores between the wire manager and the power supply

module (refer to Figure 2–7).
6 Attach the ground wire to the grounding screw on the power supply

module.
7 Check that the other end of the ground wire is connected to the terminals

of the single-point ground bar on the AC outlet box.

Installing the Control Unit

2–23

Installing the Power Supply

7. Installing the Ferrite Cores

!

CAUTION:

Do not connect the power cord until the entire control unit is assembled.

AC Power Cord

POWER SUPPLY MODULE

Figure 2–

2–24 Installing the Control Unit

Ground Wire

Attach

Ferrite Cores

(Open Position)

CAUTION

TURN OFF

POWER BEFORE

INSERTING OR

REMOVING
MODULES

On/Off Power Indicator (Green LED)

-48 VDC Auxiliary Power Input Jack
On/Off Switch
AC Power Input
Grounding Screw

Wire Manager

Feed AC Power Cord and
Ground Wire through
Wire Manager

Installing the Auxiliary Power Unit

Powering Up the System

Installing the Auxiliary Power Unit

The Control Unit Diagram on the back of Form 1, System Planning, indicates

whether an auxiliary power unit is required for the carrier that you are

installing.

NOTE:

Use the 9024 auxiliary power unit for new installations. You can continue to

use a previously installed 335A auxiliary power unit, as long as no new

telephones or modules are added to the carrier.

To install an auxiliary power unit, follow the steps below. Refer to Figure 2–8

throughout this procedure.

1 Turn off the switch on the power supply.
2 Mount the auxiliary power unit on a surface (preferably the backboard)

within 2 ft. (61 cm) of the control unit.
3 Plug the power unit line cord into the AUX POWER INPUT jack on the

power supply.
4 Plug the other end of the line cord into the AUX POWER jack on the

auxiliary power unit.

!

CAUTION:

Do not plug the power supply or the auxiliary power unit into the AC
outlet until you are ready to turn on the system, as described in
“

If the system is backed up by an Uninterruptible Power Supply (UPS),
connect the auxiliary power to the UPS.

Do not attach the power cord(s) to any building surfaces.

Use only the power unit line cord supplied with the auxiliary power unit.
An incorrect cord will damage the power supply and may damage
modules.

” later in this chapter.

Installing the Control Unit 2–25

Installing the Auxiliary Power Unit

8. Installing an Auxiliary Power Unit

Auxiliary

Power 

Unit

AC

INPUT

AUX Power Unit
AC Power Cord

AUX

POWER

AC 

Outlet

-48 VDC
Auxiliary

-48 VDC

Power Cord

Power

Input

AC

Input

Ground
Wire

Processor

Ferrite
Cores

Control Unit
AC Power Cord

Figure 2–

2–26 Installing the Control Unit

Installing Expansion Carriers

Upgrading
in Chapter 9 before continuing.

Installing Expansion Carriers

1 Locate the breakaway plastic tab on the right side of the previously

2 Align the connector of the expansion carrier with the card extender on

3 Mark the screw-hole locations on the backboard, using the expansion

4 Disconnect the expansion carrier connector from the previously mounted

5 Drill a pilot hole in the center of each of the four screw-hole marks.

If you are adding an expansion carrier to an existing system, see “

the Control Unit”

If you are to install one or more expansion carriers, follow the steps below to

mount each one. Refer to Figure 2–9 and Figure 2–5 throughout the procedure.

mounted carrier. Using a flat-blade screwdriver, gently pry the tab open

to expose the card extender.

the previously mounted carrier and slide the connector onto the

extender.

carrier or the template that comes with the preassembled plastic

backboard as a guide.

Make sure the carrier is level before marking the holes.

carrier and put the expansion carrier aside.

6 Anchor the screws approximately halfway into the backboard.
7 If housing clips are to be installed on the housing and this is the last

carrier in the control unit, place the housing clips around the right-hand

molding for the screws on the back of the carrier.

If not, go to Step 8.

8 Position the expansion carrier on the screws and slide it to the left, to

reconnect the expansion carrier card extender to the previous carrier’s

connector.
9 Make sure the connection is secure.
10 Make sure the carrier is level and that the housing clips extend as far as

possible from the right side of the carrier.
11 Tighten the screws.

Installing the Control Unit

2–27

Installing Expansion Carriers

9. Connecting the Carriers

BASIC CARRIER EXPANSION CARRIER

BASIC CARRIER EXPANSION CARRIER

CONNECTOR

CARD
EXTENDER
(under the 
breakaway tab)

BACKBOARD

BACKBOARD

Figure 2–

2–28 Installing the Control Unit

Installing the Processor

Form 1, System Planning, indicates Permanent Key mode.
Form 2c, System Numbering: Line/Trunk Jacks, indicates no GS

Installing the Processor

Installing the processor includes the following procedures:

■

If

both

of the following conditions are true, follow the procedures in

Chapter 9, “Modifying the Processor for Key Mode.”
—

NOTES:

—

(ground-start) trunks in the Incoming Trunk Type column.

■

Insert the processor into the carrier as indicated in “Installing the
Processor in the Carrier,” later in this chapter.

1. If the system is programmed for Permanent Key mode, check the switch
setting. Refer to Chapter 9, “Modifying the Processor for Key Mode” for
detailed procedures. If the switch is set to Permanent Key-only operation,
all trunks revert to loop-start. If the switch is not set, any programmed
designation for ground-start trunks is retained.

The ground-start pool never has trunks assigned to it automatically, but
must be programmed after the ground-start ports are designated. Ground­start trunks are assigned to the ground-start pool on initialization, except in
a system switched for Permanent Key mode operation. (In Release 1.0,
ground-start and loop-start trunks automatically defaulted to loop-start.)

2. Beginning with Release 3.0, the feature module required for Release 2.1
and earlier is no longer needed. The Release 3.0 processor module
contains a PCMCIA memory card interface capable of accommodating a
4-MB memory card. This card is used to install or upgrade system
software and perform firmware upgrades on circuit modules. It can be
used to backup and restore system programming,

Installing the Control Unit

2–29

Installing the Processor

!

CAUTION:

Before touching leads, connectors, pins, and other components when
handling the circuit board, use a properly grounded wrist strap to
prevent damage from electrostatic discharge (ESD).

Installing the Processor in the Carrier

To install the processor in the carrier, follow the steps below. Refer to Figure
2–10.

1 Remove the protective cover from the gold-finger connector on the back

of the processor.

2 Lower the hook on top of the processor module onto the rod on top of

the carrier in Slot 0, the first slot next to the power supply.

3 Make sure that the connector on the module mates properly with the

connector on the carrier as you swing the processor down into place.

!

CAUTION:

To avoid damage, do not force the module. If the module does not insert
easily, press the bottom rear locking tab, remove the module, and
inspect the module and carrier for damage or obstruction. The bottom­rear locking tab is shown in Figure 2–10. This tab is used on all
modules.

If there is no damage and no obstruction, reinsert the module.

A damaged carrier or module must be replaced.

4 Push firmly until the processor snaps into place.

The processor should be securely attached to the carrier and locked in place
by the locking tab on the bottom rear of the processor.

2–30 Installing the Control Unit

Installing the Processor

10. Installing the Processor into the Carrier

2

1

3

Figure 2–

Installing the Control Unit 2–31

Installing the Modules

Installing the Modules

!

CAUTION:

Use a properly grounded wrist strap to prevent damage from
electrostatic discharge (ESD) when installing the modules, and avoid
touching leads, connectors pins, and other components.

Guidelines

Follow these guidelines when you install modules, as indicated on the Control
Unit Diagram of Form 1, System Planning:

■

Do not leave empty slots between modules. The system ignores
modules installed beyond any empty slot.

■

If a phantom module (a programmed empty slot) is indicated on the
Control Unit Diagram, make sure the slot remains empty and do not
install any modules to the right of it. The system ignores any modules
installed to the right of a programmed empty slot.

■

Make sure you install each module in its assigned slot. If you install a
module in the wrong slot, the system will not function properly.

■

Be sure to place all 012 modules and all 008 OPT modules without

built-in ring generators in carriers with modules that have ring
generators so that the modules without ring generators can be
supported.

NOTE:

All 016 modules and some 012 modules (apparatus code 517G13
or later) have built-in ring generators.

■

Once you have installed the power supply and the processor in the
basic carrier, use the remaining slots for the modules as follows:

— Basic carrier: slots 1 through 5
— First expansion carrier: slots 6 through 11

2–32 Installing the Control Unit

5 and shown in Figure 2

Installing the Modules

— Second expansion carrier: slots 12 through 17

Installing Modules

To install modules starting from slot 1 (the first open slot next to the
processor), follow the steps below:

1 For each 400EM tie line/trunk module, for jacks numbered 1 through 4 in

Figure 2–11, check Form 3c, Incoming Trunks: Tie, for E&M signaling
type.

Set the dual in-line packaging (DIP) switches on the front of the 400EM Tie
Trunk module according to the E&M signaling type settings listed in Table 2–4
and Table 2–
require any adjustments in the DIP switches.

2 Remove the protective cover from each module’s gold-finger connector.
3 Lower the hook on top of the module onto the rod on the top of the

carrier in the appropriate slot. See Figure 2–10.

4 Make sure the connector on the module mates properly with the

connector on the carrier.

5 Swing the module into the slot and firmly push the module into the

carrier until it locks into place.

–11. The default E&M signal does not

!

CAUTION:

To avoid damage, do not force the module. If the module does not insert
easily, press the bottom rear locking tab, remove the module, and
inspect the module and carrier for damage or obstruction.

If there is no damage and no obstruction, reinsert the module. A
damaged carrier or module must be replaced.

6 Repeat Steps 1 through 5 for each module you want to install.

Installing the Control Unit

2–33

Installing the Modules

Tie Trunks

Tie trunks connect two separate PBX communications systems either directly
or through one or more central offices, as if they were one system at the same
location. In the MERLIN LEGEND Communications System, the 400EM
module is the originating and terminating unit for tie trunk operation.

Tie Trunk Signaling

The 400EM (tie trunk) module can transmit signals in three different formats.
Each format is made up of a specific signaling mode and a specific signaling
type. The DIP switches on the 400EM module allow you to select the signaling
mode for tie trunk transmission. The signaling type is selected through system
programming.

Signaling Modes

There are two signaling modes:

■

E&M. This is a standard interface. The E&M signaling leads are
separate from the transmission leads, requiring a 3-pair wire interface.

■

Simplex. In Simplex, the two signaling leads are superimposed onto
the analog transmission leads, providing a 2-pair wire interface for
connecting two local systems at minimal cost.

Protected or Unprotected

Depending on the type of tie trunk installation, protective resistance may be
installed to protect the circuit from outside interference from high-voltage
transients or voltage fluctuations. In Simplex mode, the circuit always requires
protective resistance. The E&M mode can be either protected or unprotected,
depending upon the location of the distant PBX.

Signaling Types

Three different signaling types combine with the signaling modes. Together
these create the proper signaling format for each system. Signaling types in
each mode are as follows:

2–34 Installing the Control Unit

4 and
5, and to Figure 2

Installing the Modules

■

E&M Mode

Type 1 Standard (default factory setting). This setting is used to

connect two systems through telephone company facilities.

Type 1 Compatible. This setting connects two systems directly

(without using telephone company facilities).

■

Simplex Mode
Type 5. This setting is used on 4-wire (2-pair) circuits.

400EM (Tie Trunk) Module DIP Switches

During installation of 400EM (Tie Trunk) modules, refer to Table 2–
Table 2–
signaling protocols.

Table 2–4. Setting the 400EM (Tie Trunk) Module DIP Switches

Ports DIP Signaling Type

–11 for the correct DIP switch settings for varying

(as numbered in

Figure 2–11)

Switch

Position

1S (Default)

and 1C

Unprotected

E&M Mode

1C and 1S

Protected

E&M Mode

5

Simplex

Mode

1 ON OFF OFF or ON
2 ON OFF OFF or ON

24 3 OFF OFF ON

4 OFF OFF ON
5 OFF OFF ON
6
7 ON OFF OFF or ON

1 3 8 OFF OFF ON

9 OFF OFF ON

10 OFF OFF ON

ON OFF OFF or ON

Installing the Control Unit 2–35

5 below.

N/A

N/A

N/A

Unprotected

Protected

Unprotected

Unprotected

N/A

Installing the Modules

NOTE:

DIP switches 1, 2, 6 and 7 determine whether the tie trunks are protected or
unprotected. DIP switches 3, 4, 5, 8, 9, and 10 determine the mode. Simplex
mode is

always

protected. Therefore the Protected/Unprotected settings for

DIP switches 1, 2, 6 and 7 have no effect.
The successful implementation of a tie trunk format is dependent upon

matching the characteristics of both the PBX systems it connects. The
preferred signaling formats for a tie trunk originating in the system are shown
in Table 2–

Table 2–5. Signaling Formats for the 400EM (Tie Trunk) Module

Installation Situation Preferred Signaling Format

From System System Distant Location

Distant

To

MERLIN II Same site

System
25/75/85
or DEFINITY
System
25/75/85
or DEFINITY
Dimension PBX Same site

Dimension PBX Inter-office E&M Type 1C

Other Systems Same site

Other Systems Inter-office E&M Type 1C

MERLIN
LEGEND

Location

co-located
Same site
co-located

Inter-office Type 5 Simplex

co-located

co-located

Same site
co-located
or inter-office

Signaling
Mode/Type

Type 5 Simplex

Type 5 Simplex

E&M Type 1C
(Compatible)

(Compatible)
E&M Type 1C
(Compatible)

(Compatible)
Type 5 Simplex

Protected or
Unprotected

Signaling
Mode/Type

Type 5 Simplex N/A

Type 5 Simplex N/A

Type 5 Simplex N/A

E&M Type 1S
(Standard)
E&M Type 1S
(Standard)
E&M Type 1S
(Standard)
E&M Type 1S
(Standard)
Type 5 Simplex N/A

Protected or
Unprotected

Unprotected

Protected

Unprotected

Requires a
protection unit

2–36 Installing the Control Unit

Installing the Modules

11. 400EM Module Sample Dip Switch Settings for Signaling Types

400 EM
Module

4

3

2
1

N

N

O

1
2

34

5

6

7
8

9
10

O

1
2

34

5

6

7
8

9
10

Switches
1 through 5
control
Port 4
(1C. E&M
unprotected)

Switches
6 through 10
control
Port 3
(1C. E&M
protected)

Switches
1 through 5
control
Port 2
(5 simplex)

Switches
6 through 10
control
Port1
(1C. E&M
protected)

Figure 2–

1C and 5

Installing the Control Unit

2–37

Installing the Modules

Labeling

1 After all modules have been installed, label all jacks with the numbered

labels provided with the feature module.

■

Line/trunk labels have green numbers on off-white background.

■

Telephone labels have blue numbers on off-white background.

See Figure 2–12 for the locations of line/trunk jacks and telephone jacks on
each module, and label them as described next.

2 Label each line/trunk jack on the modules sequentially, 1 through 80.

Begin with the module in slot 1, numbering from bottom to top on each
module and working from left to right across the carrier(s).

The 100D module has 24 numbers assigned to the line/trunk jack.

3 Label each telephone jack sequentially, 1 through 144. Begin with the

module in slot 1, numbering from bottom to top on each module and
working from left to right across the carrier(s).

!

CAUTION:

The 008 OPT module is assigned 12 logical IDs, and the last four
numbers are not assigned to jacks. For example, if the previous module
(on the left) is labeled with logical IDs 1 through 8, label the 008 OPT
jacks with logical IDs 9 through 16. Skip numbers 17 through 20. When
you label the next module (on the right), label the first jack as logical ID

21.

2–38 Installing the Control Unit

Installing the Modules

12. Line/Trunk and Telephone Jack Locations on Each Module

800 GS/LS

8 GS/LS Outside Lines

PFT Jack

8

*

5

4

1

8

Line/Trunk 
Jacks

PFT

Extension
Telephone 
Jacks (Analog or Digital)

or

Off-Premise
Telephone Jacks on
008 OPT Module

1

Figure 2–

These four jacks are

*

used for extension
telephones on the 012 Module.

Installing the Control Unit 2–39

Replacing a Module

Replacing a Module

!

CAUTION:

This section does not apply to the processor or power supply.

Although the system allows you to remove and replace modules without
affecting call processing, partially inserting and removing a module can
cause a cold start.

To add a 100D module or change any of its DS1 parameters, the system
must be idle.

When you replace a module, use the same module type. For example,
do not put a 008 MLX module in place of a 400 GS/LS/TTR module. If a
module is replaced with another type of module, or if a module is added
to the system without powering down the system first, a cold start
(System Reset) occurs.

If you move any module to a different slot, be sure to renumber the
modules by selecting

System Programming

Board Renumber

for information about board renumbering.

from system programming. See

NOTE:

You can remove and replace line/trunk and extension modules with the
system power on, without affecting normal call processing.

2–40 Installing the Control Unit

Checking Unlabeled Wiring

Replacing a Module

To remove and replace a module, follow the steps below. Refer to
Figure 2-13.

1 Busy-out or reset the module. (Busy-out is recommended.)
2 Label all cords (if they are not labeled already) and then unplug them

from the module.

For information about labeling trunk and extension cords, see Chapter 3,
“Installing Telephones and Adjuncts” and Chapter 4, “Connecting the Control
Unit to the Network Interface.” For instructions on checking unlabeled wiring,
see “

Troubleshooting

guide.

” in Chapter 3 of the

Maintenance and

3 Run a demand test by entering the test mode.
4 Power down the system, if required. See “Powering Down the System,”

later in this chapter, for instructions.

5 Remove the module by pushing up firmly on the tab at the bottom rear of

the module.

6 While holding up the tab, swing the bottom of the module towards you

and away from the carrier.
7 Lift up the module to disengage it from the rod on the top of the carrier.
8 Inspect the module for visible damage.
9 Insert the new module. See Figure 2–10.
10 Restore the module. Refer to Chapter 7, “Initializing and Testing the

System,” for instructions.
11 Connect the trunk and extension cords.
12 Attach a tag, error printout, and any information that will help identify any

visible problems or failure symptoms.

Installing the Control Unit

2–41

Replacing a Module

13. Removing Modules from the Carrier

3

Figure 2–

2–42 Installing the Control Unit

1

2

Connecting the Control Unit to an AC Outlet

AC Outlet Tests,

earlier in this chapter, for instructions.

Connecting the Control Unit to
an AC Outlet

!

CAUTION:

Make sure the AC outlet has been tested for proper grounding. The
outlet should be 117-V AC, 60-Hz, 3-wire (phase, neutral, ground). See
“

1 Turn the basic carrier’s power supply switch to the OFF position.
2 Turn off the power supply switches on the expansion carriers.
3 Unplug the power cords from any auxiliary power units.
4 Plug one end of the power cord into the AC INPUT connector just below

To prevent someone from accidentally shutting off the power, do not
connect the control unit to a switch-controlled outlet. The AC outlet
should be within 5 ft. (152 cm) of the control unit.

To connect the control unit to a dedicated AC outlet, follow the steps below.

the power switch on the front of the basic carrier’s power supply.

”

5 Plug the other end of the power cord into the AC outlet, allowing at least

1 ft. (30.4 cm) of slack in the cord.
6 Repeat Steps 4 and 5 for each expansion carrier.

!

CAUTION:

Do not attach the power cord(s) to any building surfaces.

Installing the Control Unit 2–43

Powering Up the System

Powering Up the System

!

CAUTION:

Follow the procedure below to power up the system only if the system is
completely installed. Failure to comply with this procedure can result in
shock hazard or damage to the equipment.

1 Turn on the power switch for each expansion carrier: start with the power

supply in the

The green power lights on each expansion carrier power supply should turn
on.

2 Turn on the power switch on the basic carrier power supply.

■

The dot on the one-character display LED flashes.

■

The green light on the power supply should turn on.

■

The red light on the processor should turn on for 15 to 45 seconds and
then turn off.

■

All indicators on the 100D and 400EM line/trunk modules (if present)
should turn on and then off. They remain off when the modules are
idle.

3 If any of these conditions are not met, refer to

Troubleshooting

rightmost

.

carrier.

Maintenance and

2–44 Installing the Control Unit

Powering Down the System

Powering Down the System

You may need to power down the system for troubleshooting during

installation, or to add new equipment to the carrier.

!

CAUTION:

Follow these steps in the exact sequence.

To power down the system, follow the steps below.

1 Turn off the power supply on the basic carrier.
2 Turn off the power supplies on the expansion carriers.
3 Unplug any auxiliary power units.

Because the power supplies are already off, the sequence for removing

auxiliary power cords is not important.

4 Unplug the system from the AC outlet.

Installing the Control Unit

2–45

Installing Telephones and

To connect the MERLIN PFC, see Chapter 8,

1

Adjuncts

3

The control unit supports the MLX-10, MLX-10D, MLX-10DP, MLX-20L, and

MLX-28D telephones, with or without Direct Station Selectors (DSSs), as well

as analog multiline and single-line telephones. It also supports various

adjuncts, which may require Multi-Function Modules (MFMs) or other adapters

for installation.

This chapter provides installation instructions for the following procedures:

■

Installing Multi-Function Modules

■

Installing adjuncts

■

Installing Direct Station Selectors

■

Assembling MLX telephones

■

Connecting telephones to the control unit

To connect data equipment to the system, see Chapter 6, “Connecting Data

Equipment.”

Applications.”

Installing Multi-Function Modules

The Multi-Function Module (MFM) is an optional adapter that provides a

modular jack connection to MLX telephones for the two classes of adjuncts

listed below:

“Installing

Installing Telephones and Adjuncts

3–

Installing Multi-Function Modules

KS22911 power supply
400B or 400B2 adapter
D6AP cord

■

Tip/ring (T/R) devices such as single-line telephones, fax machines,
modems, and credit card verification terminals. Once connected, the
MLX telephone and adjunct work independently of each other. This
means they can send and receive calls at the same time. The MFM is
the only T/R adapter you can use with MLX telephones.

■

Supplemental alerts such as bells, chimes, horns, and strobes. These
alerts notify people in noisy areas of incoming calls.

Considerations

Review the following items before you begin the procedure.

■

If you install an MFM, do so

■

You

must

connect the KS 22911 power supply to an electrical outlet

within 50 ft. (15 m) of cord length of the MLX telephone.

■

If you connect an MFM and two DSSs to a telephone, you
a 406743419 power unit.

■

If a wall jack is more than 7 ft. (213 cm) from an MLX telephone, you
must use a longer D8W cord.

■

The MFM uses one of the two channels when it is active. This means
that when an adjunct, such as a fax machine, and the MLX telephone
are in use at the same time, Voice Announce to Busy is not possible.
(Voice Announce to Busy is a feature that allows users to be paged on
the speakerphone even if they are on a call.)

■

The MFM has two jumper blocks that are factory-set for T/R operation.
The MFM is packaged with the following items, shown in Figure 3–1:

before

you assemble the MLX telephone.

must

install

—
—
—

3–2 Installing Telephones and Adjuncts

Installing Multi-Function Modules

1. Multi-Function Module Packing List

3

400B Adapter or 400B2 Adapter

..

..

..

.

.

.

...

.

.

.

.

.

.

..

.

..

.

.

.

.

.

.

..

.

Power Supply 

(KS22911)

.

..

Figure 3–

RISK OF ELECTRICAL SHOCK: Follow all warnings and cautions.

!

WARNING:

Only a qualified technician should install, repair, or set options for an
MFM.

Do not touch the circuitry on the MFM. Touching the circuitry may result
in component damage from electrostatic discharge.

.

Multi-Function Module

.

.

D6AP Cord (7 feet long)

Installing Telephones and Adjuncts 3–

Installing Multi-Function Modules

2. Removing the User Card Tray and Line Cable

Before installing an MFM, disconnect all trunk and/or power cords that
are attached to the MLX telephone. This is to ensure that no hazardous
voltages are present during installation. Ringing voltage from the MFM
attached to the MLX telephone can cause electrical shock if
adjustments are made while the cords are connected.

Deskstand

Telephone

Base

HIGH

2

STAND ADJUSTMENT

Line
Cable

4
& LIFT
PRESS 

1

3

LOW

Card
Tray

Figure 3–

To install or replace an MFM and change its pin settings, follow these steps.

NOTE:

If you are installing or replacing an MFM in a wall-mounted MLX-10, MLX-10D,
or an MLX-10DP telephone, start at Step 3.

1 Place the telephone face down on a flat surface; remove the user card

tray and line cable from the bottom of the deskstand. See Figure 3–2.

3–4 Installing Telephones and Adjuncts

3. Releasing the Deskstand

5

Installing Multi-Function Modules

Pull Up
and
Away

Press
Center Tab

Figure 3–

2 Release and remove the deskstand from the telephone. See Figure 3–3

and Figure 3–4.

a Press on the top rear center of the deskstand to release the tab.
b Pull the deskstand up toward you and swing away from the telephone.

Installing Telephones and Adjuncts

3–

Installing Multi-Function Modules

4. Removing the Deskstand

Lift
Out of
Center
Slot

Figure 3–

c Lift the deskstand out of the locating slot in the telephone base and place

to one side.

3–6 Installing Telephones and Adjuncts

Installing Multi-Function Modules

5. Releasing the Module Cover Screw

7

Figure 3–

3 Release and remove the module cover. See Figure 3–5, Figure 3–6, and

Figure 3–7.

a Use a screwdriver to remove the screw in the lower righthand corner of the

module cover.

Installing Telephones and Adjuncts

3–

Installing Multi-Function Modules

6. Releasing the Module Cover

Figure 3–

Pull Up and Away

Press
Center Tab
to Release

MFM

Module

Cover

Locating

Slot

b Press the center of the right side of the module cover with one hand to

release the locking tab.

c Swing open the module cover to release it from the left side locating slot.

3–8 Installing Telephones and Adjuncts

Installing Multi-Function Modules

7. Removing the Module Cover

9

Lift
Out of Locating Slot

Figure 3–

d Lift module cover out of locating slot and place to one side.

Installing Telephones and Adjuncts

3–

Installing Multi-Function Modules

8. Removing an MFM Module

Locking Tab

Figure 3–

4 To install a new MFM, go to Step 5. To reset jumpers on an existing MFM,

Line Jack

Socket

Connector
Pins

..

...

.

.

Locking Tab

.

...

.

..

.

.

..

.

..

.

..

.

.

.

..

.

.

.

.

.

.

.

.

..

.

..

.

..

.

.

..

.

.

.

.

..

.

.

..

.

.

.
.

.

.

.

.

Handset Jack

.

.

..

.

..

.

.

Locking Tab

go to Step 6. To remove an existing MFM, continue (see Figure 3–8).

a Disconnect any cords attached to the phone and note the connections so

that you can reconnect the cords to the appropriate jacks later.

b Locate the MFM locking tabs on the top and bottom of the telephone base,

then spread the tabs apart to release the MFM.

c Grasp the MFM by the edges and pull it up to free the connector pins.

not touch the connector pins

.

Do

d Set the MFM aside on a clean surface.

3–10 Installing Telephones and Adjuncts

Installing Multi-Function Modules

9. Installing an MFM Module

Locking Tab

Socket

Connector
Pins

Locking Tab

..

...

.

.

.

.

..

.

..

.

..

.

.

..

.

.

.

.

.
.

.

..

.

.

.

.

.

..

.

Figure 3–

5 Install the new MFM. See Figure 3–9.

Line Jack

..

...

.

.

.

.

.

..

..

.

..

.

.

..

.

.

.

.

.

.

.

..

.

.

.

.

.

..

Handset Jack

.

Locking Tab

a Hold the MFM circuit board by the edges with the long connector pins

facing the socket. Take care not to touch the connector pins.
b Lower the MFM to insert the pins into the socket in the telephone base.
c Press firmly on the MFM board to snap the locking tabs into place.

The

connector pins and tabs must be secure.

Installing Telephones and Adjuncts 3–11

Installing Multi-Function Modules

10. Setting and Adjusting the MFM Jumpers

Multi-Function Module

..

..

...

.

.

.

.

.

.

..

.

..

.

.

..

.
.

.

.

.

.

..

.

.

.

..

W

X

Y

Z

T/R Operation Setting

Figure 3–

6 Set or adjust the MFM jumpers for either a T/R device or a supplemental

alert device. See Figure 3–10.

a Pull the four connectors off of the MFM module.
b Place the connectors over the appropriate pins for the required operation,

and push down to secure into place.

A, B, W and Y

A

B

Jumper

Placement

C

Pins
and

.

W

X

Y

Z

.

.

SAA Setting

A, C, X and Z

A
B

C

3–12 Installing Telephones and Adjuncts

Installing Multi-Function Modules

11. Removing the Jack Guard

MFM Jack Guard Cover

TEL/OTHER

TEL/OTHER

Figure 3–

7 To remove the jack guard, see Figure 3–11.

a If the module cover has a square jack guard that protects the TEL/OTHER

jack area, grasp and twist the guard to remove it.

Save the jack guard if you are wall-mounting an MLX-10 or MLX-10D

telephone.

Installing Telephones and Adjuncts

3–13

Installing Multi-Function Modules

12. Placing the Module Cover into the Locating Slot

Lower
Cover
Into Locating Slot

Figure 3–

8 To replace the module cover, see Figure 3–12, Figure 3–13, and

Figure 3–14.

a Place the locking tab on the module cover into the slot on the left side of

the telephone.

3–14 Installing Telephones and Adjuncts

Installing Multi-Function Modules

13. Lowering and Locking the Module Cover

Figure 3–

b Lower the cover to the right and press firmly into the center slot to lock the

tab in place.

Lower and
Press Into
Center Slot
to Secure


The tab must be secure.

Installing Telephones and Adjuncts 3–15

Installing Multi-Function Modules

14. Replacing and Tightening the Module Cover Screw

Figure 3–

c Replace and tighten the module cover screw that you removed in Step 3.

3–16 Installing Telephones and Adjuncts

Installing Multi-Function Modules

15. Replacing the Deskstand

Lower
Into Inner
Center Slot

Figure 3–

9 Replace the deskstand. See Figure 3–15. If you are wall-mounting an

MLX-10, MLX 10D, or MLX-10DP telephone, go to Step 11; otherwise,
continue with Step 9a.

a Place the tab on the narrow edge of the deskstand, into the locating slot

on the telephone base.

Installing Telephones and Adjuncts

3–17

Installing Multi-Function Modules

16. Lowering the Deskstand and Locking into Place

Figure 3–

b Lower the deskstand and lock into place.

Lower
and
Press Into
Center
Slot

3–18 Installing Telephones and Adjuncts

Installing Multi-Function Modules

17. Replacing the User Card Tray and Line Cable

Deskstand

Telephone

Base

Figure 3–

10 Replace the user card tray and line cable. See Figure 3–17.

a Insert the user card tray at an angle, then lower and slide into the

deskstand.
b Replace the line cable into the line jack in the deskstand.

HIGH

2

STAND ADJUSTMENT

Line
Cable

4

& LIFT

PRESS 

1

3

LOW

Card
Tray

Installing Telephones and Adjuncts

3–19

Installing Multi-Function Modules

18. Adjusting the Deskstand Height

Pull Up


Press
Center Tab

Deskstand

Telephone

Base

HIGH

2

STAND ADJUSTMENT

4

& LIFT

PRESS 

1

3

LOW

Card
Tray

Line
Cable

Figure 3–

11 Adjust the deskstand height. See Figure 3–18.

a To change the deskstand’s height from low to high, press the top rear

center of the deskstand to release the tab.
b Pull the deskstand up and insert the tab into the slot in the module cover.
c To readjust the stand, see the instructions on the bottom of the card tray.

12 Power up the telephone. See Figure 3–19.

a Plug the D8W cord from the telephone into the 8-conductor (large)

modular jack of the 400B or 400B2 adapter.

3–20 Installing Telephones and Adjuncts

Installing Multi-Function Modules

19. Powering Up the Telephone after Installing the MFM

AC Power

Wall Jack

400B2 Adapter

Outlet

D6AP

Power
Supply

D8W

Home

Menu

v

Volume

Feature

Transfer

HFAI

Conf

Mute

Drop

Speaker

Hold

Figure 3–

b Connect one end of the D6AP cord to the 2-conductor (small) modular jack

on the 400B or 400B2 adapter, and plug the other end into the modular
jack of the 406943837 power supply.

connecting the power supply to the MLX telephone must be less than or
equal to 50 ft. (15 m).

!

CAUTION:

Do not plug the D6AP cord into the 8-conductor (large) modular jack on
the 400B or 400B2 adapter; doing so can cause electrical damage to
the control unit and to the telephone.

MLX-20L

ABC DEF

123

GHI JKL

456

PQRS TUV WXYZ

789

OPER

0

*

MNO

#

More

Inspct

Message

DSS DSS

The total length of the cords

Installing Telephones and Adjuncts 3–21

Installing Adjuncts

20.

c Plug the power supply into a 117-V AC outlet that is not controlled by a

wall switch.
d Insert the plug end of the 400B or 400B2 adapter into the wall jack.

13 Test the MFM for T/R operation.

See “Testing MLX Telephones with MFMs” in Chapter 7.

14 Attach the adjunct to the MFM. See “Installing Adjuncts.”

Installing Adjuncts

This section provides general instructions for connecting most adjuncts.

NOTE:

If you need to connect the adjuncts differently from the instructions on the
system forms, record each jack and adjunct change on the appropriate
system numbering form. See Appendix A, “System Numbering Forms.”

1 Connect one end of the cord packaged with the adjunct (usually a D4BU

cord) to the adjunct.

See the documentation packaged with the adjunct for instructions.

2 Check the system form for the adjunct you want to connect. Then refer to

the appropriate step below.

■

To connect an adjunct to an MLX telephone, go to Step 3.

■

To connect an adjunct to a single-line telephone, go to Step 4.

■

To connect an adjunct to an analog multiline telephone, go to Step 5.

■

To connect an adjunct to a 012 0r 016 module, go to Step 6.

When you connect adjuncts to telephones, make sure you route the adjunct
and D8W telephone cords through the cord channel. See Figure 3–

3 Insert the other end of the adjunct cord into the TEL/OTHER jack on the

back of the MLX telephone. Go to Step 7.

3–22 Installing Telephones and Adjuncts