Physical Setup Guide

Connect cables and boot Pimeleon router

Physical Setup Guide

After flashing your SD card, it's time to assemble your Pimeleon router hardware and connect it to your network. This guide walks you through the physical setup process, from installing cooling solutions to connecting cables and powering on your router.

Before You Begin

What You'll Need

Essential:

  • Flashed SD card with Pimeleon router image
  • Raspberry Pi (3B+ or 4)
  • Power supply (2.5A for 3B+, 3A for Pi 4)
  • Ethernet cable (Cat5e or better)
  • Monitor and HDMI cable (for first boot only)
  • USB keyboard (for first boot only)

Recommended:

  • Heatsink or cooling solution
  • Case (optional but recommended)
  • USB Ethernet adapter (for dual-interface routing)
  • Cable ties for organization

Optional:

  • UPS for power backup
  • PoE HAT (for power-over-ethernet)
  • USB hub (if using multiple USB devices)

Preparation Checklist

  • SD card flashed and verified
  • Power supply tested and ready
  • Workspace clear and well-lit
  • Anti-static precautions taken
  • Network plan documented
  • Backup router available (in case of issues)

Step 1: Install Cooling Solution

Proper cooling is essential for reliable 24/7 router operation.

For Raspberry Pi 3B+ (Passive Cooling)

Heatsink Installation:

  1. Clean the chips:
    • Use isopropyl alcohol (70%+) and lint-free cloth
    • Remove any dust or residue from CPU, RAM, and regulator chips
    • Let dry completely (30 seconds)
  2. Apply heatsinks:
    • Remove adhesive backing from heatsink
    • CPU heatsink: Largest chip (center of board)
    • RAM heatsink: Square chip next to CPU
    • Regulator heatsink: Smaller chip near power connector
    • Press firmly for 10 seconds each
    • Ensure good contact
  3. Verify installation:
    • Heatsinks should be firmly attached
    • No air gaps between heatsink and chip
    • Heatsinks aligned properly (not crooked)

For Raspberry Pi 4 (Active Cooling)

Fan Installation:

  1. Install heatsinks first (same as Pi 3B+ above)
  2. Connect fan:
    • Locate GPIO pins (40-pin header)
    • Red wire to Pin 4 (5V power)
    • Black wire to Pin 6 (Ground)
    • Use pinout.xyz for pin reference
  3. Mount fan:
    • Position fan over heatsink
    • Airflow direction: toward or across heatsink
    • Secure with screws or adhesive (depending on fan type)
    • Ensure fan blades can spin freely
  4. Test fan:
    • Connect power briefly
    • Fan should spin immediately
    • No unusual noises or wobbling

Step 2: Install in Case (Optional)

Desktop Case Installation

  1. Prepare case:
    • Remove any protective film
    • Open case according to instructions
    • Identify mounting standoffs or clips
  2. Install Raspberry Pi:
    • Align GPIO header with case opening
    • Ensure SD card slot is accessible
    • Secure with screws (if provided)
    • Don't overtighten screws
  3. Route cables:
    • Plan cable routing before securing
    • Keep power and ethernet separate
    • Use cable channels if provided
    • Leave slack for movement
  4. Close case:
    • Ensure all cables clear the case edges
    • Verify fan can spin (if installed)
    • Check ventilation holes aren't blocked
    • Secure top cover

Professional Mounting

DIN Rail Installation:

  1. Snap DIN rail clips onto case
  2. Slide onto DIN rail in cabinet
  3. Secure with locking mechanism
  4. Verify firm attachment

Rack Mount Installation:

  1. Attach rack ears to case
  2. Slide into rack (typically 1U)
  3. Secure with rack screws
  4. Connect cable management

Step 3: Insert SD Card

  1. Power OFF the Raspberry Pi (if previously powered)
  2. Locate SD card slot:
    • Pi 3B+: On bottom, opposite GPIO header
    • Pi 4: On bottom, opposite GPIO header
  3. Insert SD card:
    • Metal contacts facing down
    • Push until it clicks
    • Card should sit flush with board
  4. Verify insertion:
    • Try gently pulling card (should not come out)
    • Card fully inserted, not protruding

Step 4: Connect Network Cables

Single-Interface Setup (Simplest)

For DNS/DHCP server mode:

Existing Router (LAN port)
    │
    └── Ethernet Cable ──> Raspberry Pi eth0
  1. Connect ethernet cable from existing router to Pi's ethernet port
  2. This will be your only network connection

For gateway mode with separate WAN/LAN:

Modem/ISP
    │
    └── Ethernet (WAN) ──> Raspberry Pi eth0
                              │
                              └── USB Ethernet Adapter (LAN)
                                    │
                                    └── Network Switch ──> Devices
  1. WAN Connection:
    • Connect modem/ISP to Raspberry Pi built-in ethernet port (eth0)
    • Use quality Cat5e or Cat6 cable
    • Ensure cable clicks into place
  2. USB Ethernet Adapter:
    • Insert USB Ethernet adapter into USB 3.0 port (blue port on Pi 4)
    • Adapter becomes eth1 (LAN interface)
    • Connect switch or devices to this adapter
  3. Cable Management:
    • Label cables ("WAN", "LAN") with tape or labels
    • Use different colored cables if possible
    • Secure with velcro ties (not zip ties)

Network Topology Reference

Standard Home Setup:

Internet
    │
Modem (bridge mode)
    │
[WAN] Pimeleon eth0 [LAN] ──> Wired devices
           │
         wlan0 ──> WiFi devices

Office Setup with Separation:

Internet
    │
Modem
    │
[WAN] Pimeleon eth0 [LAN eth1] ──> Trusted network
           │
         wlan0 ──> Guest WiFi

Step 5: Connect Display (First Boot Only)

For initial setup and configuration, connect a monitor temporarily.

  1. Pi 3B+:
    • Use standard HDMI cable
    • Connect to HDMI port on Pi
    • Connect other end to monitor
    • Select correct input on monitor
  2. Pi 4:
    • Pi 4 has two micro-HDMI ports
    • Use micro-HDMI to HDMI cable or adapter
    • Connect to HDMI 0 port (closest to power)
    • Select correct input on monitor
  3. Keyboard:
    • Connect USB keyboard to any USB port
    • Needed for initial configuration
    • Can disconnect after setup

Step 6: Power Connection

This is the final step - once connected, the Pi will boot immediately.

Pre-Power Checklist

  • SD card inserted and clicked in place
  • Cooling solution installed properly
  • Network cable(s) connected securely
  • Monitor and keyboard connected (first boot)
  • Case properly closed (if using)
  • Workspace clear of liquids

Power On Sequence

  1. Final visual check:
    • All cables properly seated
    • No loose components
    • Fan can spin freely
    • Nothing shorting the board
  2. Connect power:
    • Pi 3B+: Micro-USB power connector
    • Pi 4: USB-C power connector
    • Plug into power supply first, then wall outlet
    • Or connect to UPS if using
  3. Observe boot LEDs:
    • Red LED: Power indicator (should be solid)
    • Green LED: Activity indicator (should blink)
    • Normal boot: Green LED blinks irregularly for 20-30 seconds
  4. Watch monitor:
    • Boot messages should appear within 5 seconds
    • Colorful rainbow square (GPU test)
    • Then scrolling text (Linux boot)
    • Takes 60-90 seconds for first boot

Boot LED Patterns

LED PatternMeaningAction
Red solid, Green blinkingNormal bootWait for boot to complete
Red solid, Green offNo SD card or boot failurePower off, check SD card
Red offNo powerCheck power supply and cable
Red blinkingUnder-voltageUse better power supply
Green blinking pattern (4 times)Boot loader issueReflash SD card

Step 7: Initial Login

Default Credentials

Username: piPassword: raspberry (change immediately!)

Console Login

  1. Wait for login prompt: pimeleon-router login:
  2. Type username: pi
  3. Press Enter
  4. Type password: raspberry
  5. Press Enter

You should see the Pimeleon router welcome banner.

Change Default Password

Immediately change the default password:

passwd

# Enter current password: raspberry
# Enter new password: (your secure password)
# Confirm new password: (your secure password)

Verify Network Connectivity

# Check network interfaces
ip addr show

# Test internet connectivity
ping -c 3 8.8.8.8

# Test DNS
nslookup google.com

Step 8: Physical Placement

Ideal Placement

Desktop/Office Environment:

  • Well-ventilated area
  • Away from heat sources
  • Not in direct sunlight
  • On stable surface
  • Easy cable access
  • Visible status LEDs

Rack/Cabinet Environment:

  • Adequate airflow in rack
  • Not blocking other equipment vents
  • Cable management considered
  • Easy access for maintenance
  • Monitoring/alerting visible

Avoid These Locations:

  • Enclosed spaces without ventilation
  • Near heating vents or radiators
  • On top of other hot equipment
  • Where it could be knocked over
  • In dusty environments
  • Where cables will be stressed

Environmental Considerations

Temperature:

  • Ideal: 20-25°C (68-77°F)
  • Maximum: 30°C (86°F) ambient
  • Above 30°C: Upgrade cooling

Humidity:

  • Ideal: 30-60% relative humidity
  • Avoid: Condensation or moisture
  • Basements: Watch for dampness

Dust:

  • Minimal dust accumulation
  • Clean every 3-6 months
  • Use compressed air for cleaning

Step 9: Cable Management

Professional Cable Management

  1. Label everything:
    • Use label maker or tape
    • Mark "WAN", "LAN", "Power", "Mgmt"
    • Include date of installation
  2. Bundle cables:
    • Group similar cables together
    • Use velcro ties (reusable)
    • Leave 10-15cm service loop
    • Don't create tension
  3. Documentation:
    • Take photos of final setup
    • Note all cable connections
    • Document IP addresses
    • Save in safe location

Safety Considerations

Electrical Safety:

  • Don't daisy-chain power strips
  • Ensure adequate power capacity
  • Consider UPS for backup power
  • Check outlet voltage matches device

Physical Safety:

  • Secure cables to prevent tripping
  • Don't overload network ports
  • Ensure adequate ventilation
  • Keep liquids away from equipment

Network Safety:

  • Change default passwords immediately
  • Document network configuration
  • Keep backup router available
  • Test rollback procedure

Troubleshooting Physical Setup

Pi Won't Power On

No LEDs lit:

  1. Check power supply is plugged in
  2. Try different power outlet
  3. Test with known-good power supply
  4. Check for physical damage

Red LED only, no Green:

  1. Power off immediately
  2. Reseat SD card
  3. Try different SD card
  4. Check for bent pins on GPIO

Overheating During Boot

Temperature > 70°C during boot:

  1. Verify heatsink contact (reseat if needed)
  2. Check fan is spinning (if installed)
  3. Improve case ventilation
  4. Move to cooler location

No Display Output

Blank screen:

  1. Check HDMI cable is firmly connected
  2. Try different HDMI port (Pi 4)
  3. Verify monitor input selection
  4. Try different monitor/TV
  5. Pi may be booting fine - check via SSH

No Network Connectivity

Can't get IP address:

  1. Check ethernet cable (try different cable)
  2. Verify cable plugged into correct port
  3. Check link lights on ethernet port
  4. Test cable with another device
  5. Reboot modem/router

USB Ethernet Adapter Not Detected

Adapter not showing as eth1:

  1. Try different USB port (USB 3.0 preferred)
  2. Check adapter has good Linux support
  3. Try booting with adapter connected
  4. Check dmesg | tail for errors
  5. Try different adapter brand

Post-Setup Verification

Hardware Checklist

  • All LEDs showing expected behavior
  • Fan spinning (if installed)
  • Temperature in normal range (< 60°C)
  • All network cables secure
  • Power supply stable (no voltage warnings)
  • SD card fully seated
  • Case properly assembled
  • Labels applied to cables

Network Checklist

  • eth0 has IP address
  • eth1 configured (if using)
  • Can ping gateway
  • Can ping internet (8.8.8.8)
  • DNS resolution working
  • Services starting properly

Security Checklist

  • Default password changed
  • SSH keys configured (recommended)
  • Firewall rules verified
  • Only necessary ports open
  • System fully updated

Next Steps

Now that your hardware is physically set up:

  1. Network Integration - Configure network mode
  2. First Boot Setup - Initial configuration
  3. Deployment Scenarios - Follow specific use case guide

Quick Reference

Power Supply Requirements

ModelVoltageCurrentConnector
Pi 3B+5V2.5A minMicro-USB
Pi 45V3A minUSB-C

GPIO Pin Reference

Common pins for accessories:

  • Pin 1: 3.3V power
  • Pin 2, 4: 5V power
  • Pin 6, 9, 14, 20: Ground
  • Pin 4 + Pin 6: Fan connection (5V + GND)

Visit pinout.xyz for complete GPIO pinout.

Temperature Monitoring

Check temperature anytime:

vcgencmd measure_temp

Target ranges:

  • Idle: 40-50°C
  • Load: 50-65°C
  • Warning: 70°C+
  • Throttle: 80°C+

Congratulations! Your Pimeleon router hardware is now physically set up and ready for network configuration.

ON THIS PAGE
Before You Begin
Step 1: Install Cooling Solution
Step 2: Install in Case (Optional)
Step 3: Insert SD Card
Step 4: Connect Network Cables
Step 5: Connect Display (First Boot Only)
Step 6: Power Connection
Step 7: Initial Login
Step 8: Physical Placement
Step 9: Cable Management
Troubleshooting Physical Setup
Post-Setup Verification
Next Steps
Related Documentation
Quick Reference