Calix ODC-3000 Installation Manual Download

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.

Chapter 9

Cabinet Maintenance

This chapter describes how to perform cabinet maintenance, including routine maintenance
and corrective maintenance to replace worn or failed parts and equipment.

Topics Covered

This chapter covers the following topics:



Routine cabinet maintenance



Replacing parts and equipment

Summary of Contents for ODC-3000

Page 1: ...Calix ODC 3000 Installation Guide July 2008 220 00183 Rev 10...

Page 2: ......

Page 3: ...3000 Product Overview 9 Cabinet Description 10 Cabinet Features 11 Cabinet Options 12 Cabinet Dimensions and Weights 13 Cabinet Compartments 14 Chapter 2 Installation Considerations 17 Installation Pr...

Page 4: ...ad 35 Pre Cast Pad Requirements 35 Preparing the Site 38 Installing a Pre Cast Pad 39 Chapter 4 Installing the Cabinet 41 Unpacking the Cabinet 42 Operating Cabinet Doors 43 Preparing the Cabinet for...

Page 5: ...67 Installing Rectifier Modules into the Valere Power Shelf 68 Installing Batteries 70 Turning Up and Testing the DC Power System 73 Chapter 8 Installing Equipment and Adding Capacity 75 Installing a...

Page 6: ...08 Replacing a Cabinet Door 108 Installing a Cabinet Door 110 Replacing AC Breakers 112 Replacing DC Breakers and Fuses 113 Replacing Rectifier Modules 114 Replacing Batteries 116 Replacing a Battery...

Page 7: ...eld support personnel and craft personnel responsible for cabinet installation splicing equipment installation and maintenance Federal Communications Commission FCC Statement This equipment has been t...

Page 8: ...ndicates the presence of a hazard that can cause severe personal injury if not avoided CAUTION Caution indicates the presence of a hazard that can cause minor to moderate personal injury if not avoide...

Page 9: ...t Overview This chapter provides a general description of the Calix ODC 3000 outdoor cabinet including its standard features and options Topics Covered This chapter covers the following topics A descr...

Page 10: ...nations enabling deployment of a broad suite of applications from a single node The cabinet s main electronics compartment is equipped with 23 inch front and rear equipment racks that provide a total...

Page 11: ...ronmentally rated from 40C to 46C per GR 487 Equipment support Swing out 23 inch front and rear equipment racks 108 RU total mounting space for equipment 27 RU per bay Door mounted heat exchangers 4 p...

Page 12: ...it Zone 4 seismic protection kit Northstar OEM battery string and installation kit Copper Protection Splicing Copper line protection for up to 1920 lines MS2 or 710 interface connectors CAT3 or CAT5 i...

Page 13: ...ions and Weights The external dimensions of the ODC 3000 cabinet are shown below Dimension Measurement SAE Measurement Metric Height 73 50 inches 187 cm Width 98 00 inches 249 cm Depth 48 50 inches 12...

Page 14: ...Compartment The front compartment provides 94 inches of vertical rack space 54 RU The front compartment is split into two equipment bays 47 inches 27 RU per bay and typically houses two Valere power s...

Page 15: ...cabinet is equipped with two standard splice compartments a fiber splice chamber located on the right side of the cabinet when viewed from the front and a copper splice chamber located on the left si...

Page 16: ...Copper Splice Side Battery Compartment The battery compartment houses up to six strings of front access VRLA batteries three strings per side The battery compartment is equipped with two GFCI protect...

Page 17: ...s chapter provides general considerations for cabinet installation Review this information before starting the cabinet installation process Topics Covered This chapter covers the following topics Inst...

Page 18: ...Information Not for use or disclosure except by written agreement with Calix 2001 2008 Calix All Rights Reserved Installation Process Overview The cabinet installation process involves the following h...

Page 19: ...r possible the cabinet should be located in an area with a firm flat soil surface that does not require extensive earth work The location should not be constantly damp or prone to flooding Check soil...

Page 20: ...ts of way Electrical access Locally powered cabinets must have access to commercial AC power Verify the availability of AC service at potential cabinet locations Parking Whenever possible the cabinet...

Page 21: ...r procedures before performing tasks Take necessary precautions and use appropriate insulated tools when working with power This equipment must be installed operated and serviced by qualified technica...

Page 22: ...hex key 5 16 1 Isolation mat for pad mounting 6 Hex nuts for mounting 6 Square washers for mounting 6 Split lock washers for mounting 4 Hex head bolts for replacing lifting eye bolts on the roof 24 1...

Page 23: ...ssion crimping tool Fiber cleaver Fiber splicer Modular MS2 or 710 splicing tool Materials Bring the following materials to the installation site Two hole compression lug 3 4 hole spacing for 2 AWG ea...

Page 24: ...er SMF 28 splices should not exceed 0 5 dB loss Jumpers single mode fiber LC SC ST or FC connectors from OSP splices distribution to LC connectors equipment DS3 Copper RG 735 mini coaxial cable 75 Ohm...

Page 25: ...Install the cabinet onto a concrete foundation pad You can construct a concrete pad using the Calix cast in place template or you can purchase a pre cast concrete pad from a third party supplier For...

Page 26: ...ed to a suitable earth ground circuit which may include any of the following Ground rod s A ground rod consists of a simple copper rod driven into the earth A ground rod connects to the main cabinet g...

Page 27: ...perimeter of the cabinet pad or pole The wire connecting multiple electrodes should be 2 AWG bare copper or larger and should be buried at least 24 inches deep or below the frost line whichever depth...

Page 28: ...d Construction Guidelines When constructing a concrete pad observe the following guidelines and refer to the pad drawings for additional guidance Guidelines Follow these guidelines to ensure proper pa...

Page 29: ...rietary Information Not for use or disclosure except by written agreement with Calix 2001 2008 Calix All Rights Reserved Pad Drawings Use the following drawings for reference during pad construction P...

Page 30: ...ion Conduit Locations For proper cable entry into the cabinet place conduit into the following locations a Conduit for copper plant b Conduit for fiber plant c Earth ground wire preferred locations fo...

Page 31: ...s Front pointing the same direction b Install two screws into the threaded screw holes at the junction point to attach the two Front brackets together c Place the two Rear brackets end to end with the...

Page 32: ...e left as shown c Align the screw holes on the Splice and Left brackets with the counterpart holes on the Front and Rear brackets d Install 12 supplied screws into the threaded screw holes to connect...

Page 33: ...s into the conduit trench Refer to the pad construction guidelines for conduit sizes and locations 5 Route the earth ground wire through the conduit trench from the ground electrode To construct a con...

Page 34: ...eeded for local requirements practices or conditions To cast the concrete pad 1 Prepare the concrete mix Be sure to mix enough concrete to cast the entire pad in a single pour Note To avoid structural...

Page 35: ...readed inserts for anchoring the cabinet to the pad Specific features and dimensions vary by manufacturer Contact your sales representative for a list of Calix certified suppliers Pre Cast Pad Require...

Page 36: ...tten agreement with Calix 2001 2008 Calix All Rights Reserved Pad Drawings Use the following drawings for reference during site preparation Actual pad dimensions may vary by manufacturer Refer to the...

Page 37: ...lix All Rights Reserved Pad Cross Section Conduit Locations For proper cable entry into the cabinet place conduit into the following locations a Conduit for copper plant b Conduit for fiber plant c Ea...

Page 38: ...if a person must reach underneath the lowered pad to feed cables through its entry cutout To prepare the site for pad installation 1 Excavate the pad area Dig a foundation hole at least six inches dee...

Page 39: ...oid personal injury or damage to the pad To install a pre cast pad 1 Transport the pre cast pad to installation site 2 Using a crane and slings lift the pad into position above the gravel base inside...

Page 41: ...This chapter describes how to install the Calix ODC 3000 cabinet onto a concrete foundation pad Topics Covered This chapter covers the following topics Unpacking the cabinet from its shipping crate Op...

Page 42: ...ng in place for transportation When transporting the cabinet to the installation site strap down the cabinet securely to the truck or trailer to prevent shifting or tipping Unpack the cabinet at the i...

Page 43: ...rough the equipment Pull the switch plunger to disable the alarm reporting while you are working on the cabinet The alarm switch is located at the upper corner of the door frame To open a cabinet door...

Page 44: ...abinet door above it is open thus preventing unauthorized access To open a battery compartment door 1 Open the cabinet door above the battery compartment door 2 Using a 7 16 inch nut driver remove the...

Page 45: ...unting screws securing the duct cover panels to the fixture b Slide the upper panel sideways to align its two keyholes with the two mounting screws When aligned pull the panel away from the fixture c...

Page 46: ...ing anchors holes and the conduits entry boxes as the cabinet lowers DANGER The cabinet is very heavy If it falls during lifting it could cause serious injury or death to personnel Do not stand under...

Page 47: ...cabinet 7 Pull the earth ground wire into the splice compartment through the center cable entry box 8 After the cabinet rests on the pad disconnect the slings from the cabinet lifting eyebolts 9 Ancho...

Page 48: ...ts from the installation kit Note The four bolts on the cabinet roof secure the roof assembly to the cabinet When replacing the eyebolts remove and replace each bolt in sequence Do not remove all bolt...

Page 49: ...1 2008 Calix All Rights Reserved Chapter 5 Installing Power This chapter describes how to install a commercial AC power supply to the cabinet Topics Covered This chapter covers the following topics In...

Page 50: ...nt door 2 Route the earth ground wire to the main ground bar located at the bottom of the compartment and cut the wire to length 3 Using a crimp tool attach a two hole compression lug 2 AWG 3 4 inch h...

Page 51: ...nels to the fixture b Slide the upper panel sideways to align its two keyholes with the two mounting screws When aligned pull the panel away from the fixture c Slide the lower panel sideways to align...

Page 52: ...r disclosure except by written agreement with Calix 2001 2008 Calix All Rights Reserved 10 Dress and secure the AC cable providing adequate strain relief 11 Replace the AC duct cover two panels and th...

Page 53: ...is chapter describes how to install and splice outside plant cables into the cabinet including fiber plant fiber optic cables for transport and or PON subscriber drops and metallic plant copper twiste...

Page 54: ...nly Follow local practice wherever applicable To install outside plant fiber cable 1 Open the cabinet s splice compartment door 2 Route the OSP fiber cable from the feeder location through the conduit...

Page 55: ...e bond strap to the main ground bar 4 Mount and secure the OSP cable to the rack or tie bars with cable ties 5 For cabinets equipped with a fiber splice tray do the following a Route the core tubing t...

Page 56: ...mechanical splicing options Each splice tray can hold up to 12 fiber splices See Installing a Fiber Splice Tray Holder on page 93 for installation instructions DANGER CLASS 1 LASER PRODUCT INVISIBLE L...

Page 57: ...er optic radiation can cause severe eye damage or blindness Do not look into the open end of an optical fiber To route and terminate fibers to equipment 1 At the splice tray locate the fiber pigtails...

Page 58: ...r cable ties temporarily hang and secure the OSP cables inside the splice compartment 5 If splicing shall be performed at a later time do the following Using rope or cable ties temporarily hang and se...

Page 59: ...e the OSP cable to the rack or tie bars with cable ties 5 Remove the core wrap from around the bundled copper pairs then install binder group identification labels on each 25 pair group 6 Repeat Steps...

Page 60: ...y before splicing cables you can install additional protection blocks See Installing a Protection Mounting Frame and Installing a Protection Block for instructions To splice the metallic cables 1 Open...

Page 61: ...protected by that block For any C7 slots that will contain a T1 card apply a red T1 label over the factory label on the protection block The protection blocks are located in the splice compartment for...

Page 62: ...tection blocks The 5 pin modules serve as fuses to protect the equipment from electrical surges on the lines Each protection block protects two slots in the C7 shelf with each 5 pin position on the bl...

Page 63: ...le or pierce the sealant package To seal the cable entry locations 1 Get the package of sealant compound from the installation kit 2 Mix the sealant compound inside its package per the manufacturer in...

Page 65: ...cludes checking the AC power supply voltage installing rectifier modules into the Valere power shelf installing batteries for reserve power and turning up and testing the DC power system Topics Covere...

Page 66: ...arth ground circuit earth electrode which should have been installed and tested before the cabinet was installed To check the cabinet ground connection 1 Using an ohm meter test between the main groun...

Page 67: ...er to ON 3 Using a volt meter test between the L1 and neutral busses a Place one lead on the L1 buss b Place the other lead on the neutral buss c Verify that the volt meter reads between 110 and 120 V...

Page 68: ...ide module redundancy faster battery charging time or powering for third party equipment Each Valere power shelf is equipped with a controller module that monitors power functions and alarm informatio...

Page 69: ...ce plate s display cable Display to the controller module Allow the face plate to dangle 5 Push firmly on the module to seat it in the slot then tighten the set screw 6 Attach the face plate to the co...

Page 70: ...and apply No Ox anti corrosion grease to each battery terminal 4 Locate the bagged kit containing the string jumper straps and other materials Set the kit aside for use during installation Note If you...

Page 71: ...ts of the batteries in each string per the manufacturer instructions 6 For each battery string connect the battery power cables as follows a Remove the protective rubber caps from the cable ring lugs...

Page 72: ...lug onto the negative terminal post of String 1 8 Reconnect the six pairs of battery power cables Anderson connectors to the power supply leads 9 Optional If you are using the Zone 4 seismic protectio...

Page 73: ...e present refer to the Valere Compact DC Power System Installation and Maintenance manual for troubleshooting assistance 4 On each Valere shelf controller face plate press the UP button once to displa...

Page 74: ...re not fully charged perform this procedure after charging the batteries WARNING Electrical hazard Only a qualified technician should perform these procedures To test the batteries 1 At the DC distrib...

Page 75: ...topics Installing a C7 expansion shelf Installing a C7 fan tray Installing a protection mounting frame Installing a protection block Installing a battery heater Installing a seismic protection kit In...

Page 76: ...es on page 128 for details ODC 3000 For supported operation the C7 expansion shelf must be equipped with a fan tray Install the fan tray included in the kit before turning up the shelf See Installing...

Page 77: ...fied carefully set the C7 shelf aside c Install two mounting screws to half depth at the identified hole locations on the rack d Lift the C7 shelf so that the bracket keyholes fit over the screws prot...

Page 78: ...cable ties to secure the cables to the rack 7 Install the C7 fan tray into the expansion shelf See Installing a C7 Fan Tray on page 80 for instructions 8 To apply power to the C7 expansion shelf switc...

Page 79: ...on Mounting Frame and Installing a Protection Block for installation instructions a Route the 25 pair interface cables from the protection panel location typically in the splice compartment to the C7...

Page 80: ...ism 3 Gently slide the fan tray into the slot beneath the C7 shelf 4 Push the handle down to lock the fan tray into position Note In the locked position the handle should sit flush with the bottom lip...

Page 81: ...install protection mounting frames to expand system capacity To install a protection mounting frame 1 Unpack the protection mounting frame from the shipping packaging 2 Verify that two ground wires a...

Page 82: ...otection block from the shipping packaging 2 On the back of the protection block remove any cable ties that coil up the two pairs of interface cables two with MS2 connectors two with RJ 21 connectors...

Page 83: ...ock s dead pair positions 25 and 50 6 On the mounting frame turn the two knobs counter clockwise to the open position then pull the frame forward to access the area behind the protection blocks 7 Rout...

Page 84: ...pack the battery heater from the shipping packaging 2 Remove the front battery compartment door See Operating Cabinet Doors on page 43 for instructions 3 Facing the front battery compartment orient th...

Page 85: ...ic protection kit 1 Unpack the seismic protection kit from the shipping packaging 2 Remove the front and rear battery compartment doors See Operating Cabinet Doors on page 43 for instructions 3 Instal...

Page 86: ...ll Rights Reserved 5 Install batteries into the battery compartment See Installing Batteries for instructions 6 Install the front bracket as follows a Position the front bracket against the front moun...

Page 87: ...l Rights Reserved 7 Install the top bracket as follows a Position the top bracket against the front mounting rack directly above the batteries as shown b Attach the bracket to the rack using two self...

Page 88: ...the cabinet wall For cabinets not equipped with a generator connector you can remove the plate covering the connector housing and install the AC meter in that location After installing an AC power met...

Page 89: ...rvice The equipment automatically switches to battery reserve power 2 Open the splice compartment door 3 At the AC load center switch the Main Service Disconnect and Main main circuit breakers to OFF...

Page 90: ...oved previously onto the four studs Tighten the nuts to secure the adapter plate in place 3 Attach the generator connector to the cabinet mounting fixture as follows a From the exterior front of the c...

Page 91: ...ole on the rear panel Note If any slack wires hang below the bottom edge of the load center use cable ties to secure the wires to the back of the rack beneath the load center c Terminate the generator...

Page 92: ...heat exchanger door on bay 2 is required when the cabinet is configured with a fourth C7 shelf and or third party equipment Installing a heat exchanger door may become necessary if The cabinet coolin...

Page 93: ...using two supplied screws per comb 3 Determine the mounting location for the fiber splice tray holder Note The splice tray holder requires 3 RU of vertical space on a 23 inch rack Select a location wi...

Page 94: ...acks when opened or closed To install a splice tray 1 Unpack the splice tray from the shipping packaging 2 After splicing fibers place the splices into the splice tray as follows a Open the plastic co...

Page 95: ...n for the fiber distribution panel Note The fiber distribution panel requires 1 RU of vertical space on a 23 inch rack Select a location with sufficient room to route fiber pigtails and jumpers to and...

Page 96: ...C or SC UPC or APC connector options To install a fiber distribution cassette holder 1 Unpack the cassette holder assembly from the shipping packaging 2 Assemble the distribution cassette holder as fo...

Page 97: ...side of the cassette b Remove the dust caps from the rear of the optical adapters c Install each pigtail into the distribution cassette entering from the back end as shown Neatly arrange any slack fib...

Page 98: ...ts up to six 24 port splitter cards Install the splitter shelf into any available rack space in the cabinet The procedures below apply to both the 48 port and 144 port splitter shelves To install an x...

Page 99: ...RJ 21 and MS2 connectors Connect the cable s RJ 21 end labeled PSTN to the first PSTN RJ 21 connector on the rear of splitter shelf c Connect the subscriber interface cable On the back of the C7 shel...

Page 100: ...e equipment rack with cable ties every 6 to 8 inches To install the ADSL POTS splitter cards 1 Unscrew the two captive screws on the front cover panel of the splitter shelf Remove the cover and set it...

Page 101: ...8 Calix All Rights Reserved Installing a PON Splitter Kit To support passive fiber splitting within the enclosure the ODC 3000 can house up to twelve 96 line 3 x 1 32 PON splitter kits arranged as sho...

Page 102: ...sted on the rear rack However if any powered equipment is to be installed on the rear rack you must first remove the air plenum cover to enable proper air circulation and cooling to the rear rack Remo...

Page 103: ...Reserved Chapter 9 Cabinet Maintenance This chapter describes how to perform cabinet maintenance including routine maintenance and corrective maintenance to replace worn or failed parts and equipment...

Page 104: ...ed technician should perform this procedure CAUTION Electrical chemical fire and heat hazard Handle batteries with care to avoid personal injury or damage to the equipment ALERT To ensure service cont...

Page 105: ...provides 13 5 VDC plus or minus 2 VDC c Clean each battery to remove dust dirt or corrosion from the battery surface Note Only use water for cleaning the battery surface Do not use any chemicals d Cle...

Page 106: ...eat exchangers Verify that the air intake locations are unobstructed and that the fans are running Check the GFCI convenience outlets located in the front and battery compartments Test the outlets per...

Page 107: ...e battery compartment with a dry soft brush to ensure optimal airflow Checking Cable Connections Check external cable connections at least once a year External cables are any cable that enters the cab...

Page 108: ...ty must be increased to support the addition of a C7 shelf or third party equipment where a factory installed blank door is replaced by a heat exchanger door You can replace a cabinet door in the fiel...

Page 109: ...ges Lift the pin lever up and rotate it away from the cradle b Bottom hinge Press the pin lever down and rotate it away from the cradle 5 Release the hinge pins from the hinge pin channels as follows...

Page 110: ...the pin lever up and rotate it away from the cradle Press down on the pin lever until the pin slides free from the channel b Bottom hinge Press the pin lever down and rotate it away from the cradle L...

Page 111: ...ws a Pull the heat exchanger power and alarm cables from the recess inside the door b Connect the heat exchanger cables to the cabinet wiring system as follows Note If the previous door was equipped w...

Page 112: ...ace an AC circuit breaker 1 At the local power transfer switch disconnect AC power to the cabinet Note If the cabinet is equipped with charged batteries this action does not affect service The equipme...

Page 113: ...avoid an interruption of service you can replace breakers while the distribution system is hot The bullet style breakers can be removed with no wiring disconnections Refer to the Valere DC Distributi...

Page 114: ...nd the cause of the failure Replacing Rectifier Modules If a Valere rectifier module experiences a failure in the field or if you are converting from 20A to 30A rectifier modules or vice versa you can...

Page 115: ...n the set screw and slide the controller module halfway out of the slot c Disconnect the face plate s display cable from the controller module and set the face plate aside d Disconnect the temperature...

Page 116: ...uity in the event of an AC outage connect an external generator to the cabinet while performing battery maintenance To replace batteries 1 At the DC distribution panel switch the breaker s for the bat...

Page 117: ...ear battery compartment doors See Operating Cabinet Doors on page 43 for instructions 2 Remove the batteries from the battery compartment if present See Replacing Batteries on page 116 for battery rem...

Page 119: ...about the ODC 3000 cabinet Topics Covered This appendix covers the following topics Cabinet specifications Supported batteries Rack space available for additional equipment Environmental alarm mapping...

Page 120: ...3000 RPM High temp alarm at 75C low temp alarm at 0C Cooling capacity 3700 Watts Thermal operating range 40C to 46C Environmental alarming 8 environmental and intrusion alarms Electrical AC power sys...

Page 121: ...rthstar NSB 100FT 100 Ah 6 PowerSafe SBS C11 92 Ah 6 Rack Space for Additional Equipment In addition to its standard factory installed equipment the ODC 3000 can also house third party equipment The t...

Page 122: ...cription Default Severity 1 BATTERY Breaker Open DC breaker open or fuse failure Major 2 OPENDR Open Door Door security Minor 3 RECT Rectifier Rectifier minor Minor 4 RECT Rect Failed Rectifier major...

Page 123: ...MJ and Rectifier Minor RECT MN The following table lists the Valere alarms that may be reported by the C7 as Rectifier Major or Rectifier Minor Alarm Condition Display Severity Major Minor AC Fail X...

Page 124: ...me seconds that the plant voltage must exceed the LVD reconnect setpoint prior to reconnecting the LVD contactor 20 20 20 LVD 2 Open The system LVD contactor will open if the plant voltage falls below...

Page 125: ...ned voltage in the event of a controller failure or removal If disabled rectifiers will stay at last voltage setting Disabled Disabled Disabled Controller Fail Fallback Voltage The voltage to which th...

Page 126: ...ed menu level Scroll to and select Log In to access the Administrator level The default username is Admin case sensitive and the default password is 5001 The Administrator level allows you to modify a...

Page 127: ...utton once to display CHOOSE EXIT 6 Press the MENU button to return to the basic menu Changing rectifier settings You can verify or change the rectifier settings from the SETPOINT submenu To modify re...

Page 128: ...any rectifier modules to use for your application based on the total load Expected Max Power Output per Rectifier Module Load per Rectifier Shelf Power Supplied Rectifier Modules Required 1 20A 30A 20...

Page 129: ...d 2 RPOTS ADSL2 COMBO2 OLTG HDSL2 4 20A 30A ODC 2000 1 20 0 0 0 0 730W 1 1 0 20 0 0 0 1230W 2 1 0 0 20 0 0 1330W 2 1 4 0 0 16 0 1150W 1 1 0 0 0 0 20 1850W 3 2 2 2 40 0 0 0 0 1460W 2 1 0 40 0 0 0 2460...

Page 130: ...0 60 0 0 0 3690 W 5 3 0 0 60 0 0 3990 W 5 3 12 0 0 48 0 3450 W 3 3 0 0 0 0 60 5550 W 3 6 5 4 80 0 0 0 0 2920 W 4 2 0 80 0 0 0 4920 W 6 4 0 0 80 0 0 5320 W 6 4 16 0 0 64 0 4600 W 4 4 0 0 0 0 80 7400 W...

Page 131: ...2008 Calix All Rights Reserved Wiring Diagrams This section contains wiring diagrams of the ODC 3000 cabinet power ground and alarm systems Wiring diagrams are shown for reference only For better deta...

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