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FieldSmart

Fiber Active Cabinet (FAC) 3200

__________________________________________________________

Installation Manual

Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • [email protected]

Manual 020421 REV A - Jan 2019

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Step 6:

Installing Rectifier Modules

The FAC 3200 cabinet can be outfitted with an optional Valere compact power system to generate and distribute -48 VDC

bulk power. The Valere power system consists of a 23-inch C-series power shelf.

The Valere power shelf supports up to four rectifier modules (30A or 20A options). Normal operation for the FAC 3200

cabinet uses two rectifier modules, which includes N+1 rectifier redundancy. Use up to two additional rectifier modules to

support heavy loads, provide faster battery charging time, or powering for third-party equipment. The Valere shelf provides

integrated distribution, with two 30 Amp load breakers (A and B power feeds to the C7 shelf), two 40 Amp battery break-

ers (up to two strings), and 10 GMT fuse positions (heat exchanger and additional equipment). The Valere power shelf is

equipped with a controller module that monitors power functions and alarm information and regulates voltage in response to

battery temperature. The controller module features a 16-character front panel display for programming menu-driven system

controls. For a complete description, refer to the Valere product manual.

Install Valere modules into the power shelves as described below.

To install a controller module

Unpack the controller module.

If the face plate is attached to the controller module, disconnect its display cable from the controller module.

Insert the controller module halfway into the control slot on the Valere shelf.

Connect signal cables to the controller module as follows:

Connect the alarm (ALM), temperature probe (T3), and expansion (EXP) cables to the controller module.

Connect the face plate's display cable (Display) to the controller module. Allow the face plate to dangle.

Push firmly on the module to seat it in the slot, then tighten the set screw.

Attach the face plate to the controller module.

Summary of Contents for FieldSmart FAC 3200

Page 1: ...FieldSmart Fiber Active Cabinet FAC 3200 Installation Manual _______________________________________________________ Manual 020421 REV A Jan 2019 ...

Page 2: ...n Guidelines 16 Space Requirements 17 General Safety Recommendations 18 Installation Kit 19 User Supplied Items 20 Cabling Requirements 21 Chapter 3 Preparing the Installation Site 22 Installing a Ground Circuit 23 Constructing a Concrete Pad 25 Pad Construction Guidelines 25 Assembling the Cast In Place Template 28 Preparing the Site 30 Casting the Pad 31 Installing a Pre Cast Concrete Pad 32 Pre...

Page 3: ...r 110 120 VAC 66 Chapter 6 Installing and Splicing Outside Plant Cables 69 Installing Fiber Cables 70 Installing Outside Plant Fiber Cable 70 Splicing Fibers 72 Routing and Terminating Fibers 73 Installing Metallic Cables 74 Installing Outside Plant Metallic Cables 74 Splicing Metallic Cables 76 Installing 5 Pin Protection Modules 77 Sealing Cable Entry Locations 78 Chapter 7 Turning Up the Cabine...

Page 4: ... 110 Checking Cabinet Surfaces 110 Checking Cable Connections 111 Battery Maintenance 112 Replacing Parts and Equipment 114 Removing a Cabinet Door 114 Installing a Cabinet Door 115 Replacing AC Breakers 117 Replacing DC Breakers and Fuses 118 Replacing Rectifier Modules for optional Valere Rectifier 119 Replacing Batteries 121 Replacing a Battery Heater 122 Appendix A Reference Information 123 Sp...

Page 5: ...s the presence of a hazard that will cause severe personal injury or death if not avoided WARNING Warning indicates 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 avoided ALERT Alert indicates the presence of a hazard that can cause damage to equipment damage to...

Page 6: ..._________ Chapter 1 Fiber Active Cabinet 3200 Product Overview This chapter provides a general description of the Clearfield FAC 3200 outdoor cabinet including its standard features and options Topics Covered This chapter covers the following topics A description of the FAC 3200 cabinet A list of cabinet features A list of cabinet options A view of the cabinet dimensions Views of the cabinet compa...

Page 7: ... extending the service area beyond the reach of the carrier Central Office The FAC 3200 cabinet supports high density fiber and copper plant terminations 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 of 32 RU of mounting space The modular design of the F...

Page 8: ...0 spec Environmentally rated from 40C to 46C per GR 487 Equipment Support 23 inch front and rear equipment racks 32 RU total mounting space for equipment 16 RU per side Mechanical support for high density fiber and copper plant terminations Modular scalable up to 432 fiber distribution capacity Power Local 120 240 VAC load center UL listed 60 Amp capacity AC service disconnect breaker AC surge sup...

Page 9: ...A modules 20A only for 110 120 VAC input Support for AC meter mounting Low capacity 750W or high capacity 1850W heat exchanger door mounted Battery Support Battery heater kit Zone 4 seismic protection kit Battery compartment riser supports a second battery string Northstar OEM battery string and installation kit Copper Protection Splicing Copper line protection for up to 480 lines MS2 or 710 inter...

Page 10: ..._____________ Cabinet Dimensions and Weights Configuration Weight SAE Weight Metric 480 lines standard 650 lb 295 kg 480 lines cross connect 695 lb 315 kg The external dimensions of the FAC 3200 cabinet are shown below Dimension Measurement SAE Measurement Metric Height 54 inches 137 cm Width 38 inches 97 cm Depth 34 inches 86 cm The approximate shipping weights of the FAC 3200 cabinet are shown b...

Page 11: ...7 www SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 Cabinet Views Views of the FAC 3200 cabinet follow Front Compartment The front compartment provides 32 inches of vertical rack space 18 RU The front compartment houses an optional Valere power system and one Calix C7 shelf leaving 12 RU of rack space for additional equipment FAC 3200 Front ...

Page 12: ...partment The rear compartment provides 32 inches of vertical rack space 18 RU The rear compartment houses no standard equipment leaving the full 18 RU of rack space available for optional or third party equipment When the cabinet is configured with an optional cross connect panel the rear compartment houses the copper line protection that otherwise resides in the splice compartment FAC 3200 Rear F...

Page 13: ...00 Splice Side cross connect Splice Compartment The splice compartment provides 48 inches of vertical rack space 27 RU The splice compartment houses the AC load center and main ground bar and provides the cable entry locations The splice compartment also typically houses the copper line protection which consists of up to two rack mounted protection frames each holding up to six modular 50 pair pro...

Page 14: ..._____ Chapter 2 Installation Considerations This chapter provides general considerations for cabinet installation Review this information before starting the cabinet installation process Topics Covered This chapter covers the following topics Installation process overview Installation guidelines Space requirements General safety recommendations Installation kit contents User supplied items Cabling...

Page 15: ..._________________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 Installation Process Overview The cabinet installation process involves the following high level steps ...

Page 16: ... 1 Functional requirements Suitable terrain Whenever 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 maps of potential sites for subsurface conditions Grounding properties The earth at the cabinet location should have a low ground impedance to provid...

Page 17: ...e adequate access for all installation and maintenance activities 2 Accessibility requirements Easement size Select a location with an easement that provides enough space to walk around the perimeter of the cabinet with its doors open Right of Way Secure a permanent location on private property whenever possible Obtain a firm right of way agreement that includes right of access Avoid locations in ...

Page 18: ...and all power 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 technical personnel only WARNING The cabinet and its components are heavy Handle with care to avoid personal injury or damage to the equipment DANGER CLASS 1 LASER PRODUCT INVISIBLE LASER RADIATIO...

Page 19: ...allation The installation kit contents are listed below Check to verify that your kit contains all of the listed items Qty Item Description 1 Telco hex key 5 16 1 Isolation mat for pad mounting 4 Hex nuts for pad mounting 4 Square washers for pad mounting 4 Split lock washers for pad mounting 4 Button head Allen bolts for replacing lifting eye bolts 12 12 24 hex mounting screws 1 T1 slot identific...

Page 20: ...ulated needle nose pliers Wire stripper Compression 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 earth ground wire Strain relief for 2 AWG earth ground wire Strain relief for 6 8 AWG AC supply wiring MS2 or 710 connectors for copper line splicing Silico...

Page 21: ...Cabling Requirements Cables supplied to the cabinet must meet the following minimum requirements Note Local climatic conditions site conditions or local practices may require adjustments to cabling requirements Function Facility Requirements Power Ground Copper 2 AWG solid bare copper wire to earth ground circuit terminates to ground bar with 2 hole compression lug AC Copper 6 to 8 AWG Follow Nati...

Page 22: ...face pole or wall H frame For pad mount applications you can construct a concrete pad using the Clearfield cast in place template or use a pre cast concrete pad To mount the cabinet on a vertical surface use the Clearfield pole mount or wall mount kits to provide the cabinet mounting fixture For all mounting configurations Clearfield requires installation of an earth ground circuit at the installa...

Page 23: ... Grounding options The cabinet main ground system must be bonded 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 ground via an earth ground wire 2 AWG solid bare copper bonded to the ground rod and buried at the site Multiple inter connected ground rod...

Page 24: ...rom the outside 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 is greater The wire connecting multiple electrodes should be connected with an exothermic weld or irreversible mechanical connector suitable for direct burial The wire connecting the c...

Page 25: ...binet to the pad and to provide the cable conduit locations Pad Construction Guidelines When constructing a concrete pad observe the following guidelines and refer to the pad drawings for guidance Guidelines Follow these guidelines to ensure proper pad construction Adjust for local conditions or practices as required Construct the pad with minimum perimeter dimensions of 72 x 88 inches Construct t...

Page 26: ...xcept by written agreement with Clearfield 26 FieldSmart Fiber Active Cabinet FAC 3200 Installation Manual __________________________________________________________ Pad Drawings Use the following drawings for reference during pad construction Pad Size ...

Page 27: ...rt clfd net Manual 020421 REV A Jan 2019 Pad Cross Section view from splice end For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cable b Earth ground wire preferred location for direct connection to cabinet ground bar c Earth ground wire Use the Clearfield cast in place template to provide precise conduit orientation Conduit Locations ...

Page 28: ...ound arranged as follows Place the two long brackets parallel with each other with the labels Front Rear up and the arrows pointing toward the outside Place the two short brackets between and perpendicular to the long members with the labels Left Splice up and the arrows pointing toward the outside Step 1 Step 2 Step 3 Step 4 Assemble the Clearfield cast in place template as follows Align the Left...

Page 29: ... 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 Step 5 Step 6 Install the eight supplied screws with washers into the threaded screw holes to connect the brackets together Use two screws at each junction point as shown Tighten all screws to complete the template assembly ...

Page 30: ...template mounting brackets flush with the top of the form then nail the template to the form to secure it in place Note The mounting studs should protrude approximately one inch above the form Step 1 Step 2 Step 3 Step 4 Step 5 Excavate the pad area Dig a foundation hole six inches deep with a perimeter measuring at least 72 x 88 inches Grade and compact the excavated surface until it is firm and ...

Page 31: ...t least 72 hours Remove and discard the form Backfill the cable conduit trenches with soil or gravel as required Backfill and grade the perimeter area around the pad with soil as required Trim the cable conduits to a height no more than 4 inches above the pad Perform the remaining steps only after the concrete has cured Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Cast the concrete foun...

Page 32: ...ts and mounting fixtures anchor studs or countersunk threaded inserts for anchoring the cabinet to the pad Specific features and dimensions vary by manufacturer Contact your sales representative for a list of Clearfield certified suppliers Pre Cast Pad Requirements When preparing for and installing a pre cast concrete pad observe the following guidelines Refer to the pad drawings for guidance Guid...

Page 33: ...al Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 Pad Drawings Use the following drawings for reference during site preparation Actual pad dimensions may vary by manufacturer Refer to the manufacturer s documentation for more information Typical Pad Size ...

Page 34: ...ion Manual __________________________________________________________ Pad Cross Section from left splice end For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cable b Earth ground wire preferred location for direct connection to cabinet ground bar c Conduit for AC cable Conduit Locations ...

Page 35: ...it sizes and locations Route the earth ground wire through the conduit trench from the ground electrode Place gravel into the foundation hole to create a level base The gravel layer should be at least two inches deep compacted and leveled Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Prepare the site for installation of a pre cast pad Some pads may require custom preparations Refer to the manufacturer...

Page 36: ...ravel base until it is stable and level Pull the earth ground wire through the cutout in the pad allowing at least four feet of wire to extend above the top of the pad Backfill and grade around the pad perimeter with soil to secure the pad in place Verify that the pad remains level Adjust as required Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Install the pre cast pad according to the manufac...

Page 37: ... Guidelines When installing the pole mount kit observe the following guidelines Refer to the pole mount drawings for guidance Guidelines Follow these guidelines to ensure proper mounting support for the cabinet Adjust for local conditions or practices as required The pole must be vertically plumb and must support a minimum load weight of 1800 lbs The pole diameter must be 8 inches minimum to 14 in...

Page 38: ...Assembly For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cable b Earth ground wire preferred location for direct connection to ground bar c Conduit for AC cable Use the Clearfield pole mount kit to provide precise conduit orientation Conduit Locations Use the following drawings for reference during site preparation Actual pole dimensio...

Page 39: ...____________________________________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 Minimum Pole Height front view of cabinet position FAC 3200 Front ...

Page 40: ... pole mounting guidelines for conduit sizes and locations Note The minimum height of 76 inches has the bottom of the mounting assembly standing flush with the ground elevates the cabinet approximately 16 inches above the ground To elevate the cabinet higher than 16 inches above ground use a pole with sufficient additional height Route the earth ground wire through the conduit trench from the groun...

Page 41: ...eeded for local requirements practices or conditions The primary components of the kit are identified at right To install the pole mounting fixture Assemble the base platform as follows a Attach the left and right support brackets to the cable entry bracket using 4 1 4 inch hex head screws 4 flat washers 4 lock washers and 4 nuts two sets per side b Attach the left and right support brackets to th...

Page 42: ...top edge at the marked height If necessary arrange the cable conduits underneath the platform into the appropriate entry ducts c Verify that the base platform is level d While holding the platform in position drill 3 3 8 inch pilot holes into the pole through the holes in the center of the mounting bracket e Install 3 1 2 x 3 inch lag screws into the pilot holes to attach the bracket to the pole T...

Page 43: ...to secure it in place Step 1 Step 2 Step 3 To install the top bracket Attach the rear mounting bracket to the base assembly as follows a Position the rear mounting bracket against the opposite side of the pole fitting the 4 threaded rods through the counterpart holes in the rear bracket b Loosely install a 1 2 inch flat washer lock washer and nut onto each rod c Verify that the bracket is level an...

Page 44: ... stand at least 76 inches above ground Note The minimum height of 76 inches has the bottom of the mounting assembly standing flush with the ground elevates the cabinet approximately 16 inches above the ground To elevate the cabinet higher than 16 inches above ground use a pole with sufficient additional height Use the Clearfield wall mount kit to provide the mounting fixture and conduit entry loca...

Page 45: ...ew of Mounted Assembly For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cable b Earth ground wire preferred location for direct connection to ground bar c Conduit for AC cable Use the Clearfield wall mount kit to provide precise conduit orientation Conduit Locations Use the following drawings for reference during site preparation Wall d...

Page 46: ...for use or disclosure except by written agreement with Clearfield 46 FieldSmart Fiber Active Cabinet FAC 3200 Installation Manual __________________________________________________________ Wall Mount Kit Dimensions FAC 3200 Front ...

Page 47: ...e cable conduits into the conduit trench At the wall or H frame allow the conduit to extend above ground to the approximate height of the base platform Refer to the wall mounting guidelines for conduit sizes and locations Route the earth ground wire through the conduit trench from the ground electrode Pull six feet of wire above ground and position it adjacent to the wall or H frame Backfill the c...

Page 48: ...s per side b Attach the left and right support brackets to the mounting bracket using 6 1 2 inch hex head screws 12 flat washers 6 lock washers and 6 nuts three sets per side c Attach two mounting ears to the mounting bracket using 4 1 2 inch hex head screws 8 flat washers 4 lock washers and 4 nuts two sets per side Step 1 To install the wall mounting fixture Installing the Wall Mount Kit Install ...

Page 49: ...s underneath the platform into the appropriate entry ducts c Verify that the base platform is level d While holding the platform in position drill up to 6 3 8 inch pilot holes into the wall or frame through the holes in the mounting ears three holes per side for walls or two holes per side for H frames e Install the appropriate user supplied mounting hardware into the pilot holes to attach the bra...

Page 50: ...n the roof aligned with the two vacant eyebolt holes b Insert 2 1 2 inch hex screws with flat and lock washers into the threaded holes c Tighten the screws completely to secure the bracket in place Secure the top bracket to the wall or H frame as follows a Drill 2 3 8 inch pilot holes into the wall or frame through the holes in the top bracket b Get the two cylindrical spacers from the installatio...

Page 51: ...ing the Cabinet This chapter describes how to install the Clearfield FAC 3200 cabinet onto its permanent mounting location Topics Covered This chapter covers the following topics Unpacking the cabinet from its shipping crate Operating the cabinet doors Preparing the cabinet for installation Installing the cabinet onto a concrete pad Installing the cabinet onto a pole Installing the cabinet onto a ...

Page 52: ...nd is enclosed in cardboard crating for protection The cabinet is secured to the pallet by four bolts Do not remove the cabinet from the pallet until after it has been delivered to the installation site However you can remove the cardboard crating to inspect the cabinet at the staging area if required Clearfield recommends keeping the protective packaging in place for transportation When transport...

Page 53: ...f the intrusion alarm Note Do not rotate the switch plunger Rotating the plunger may damage the switch Step 1 Step 2 Step 3 Step 4 Step 5 To open a cabinet door Operating Cabinet Doors The cabinet has hinged front rear and side doors each equipped with two telco hex pin latches and a padlock hasp for security Open and close the doors using a Clearfield supplied telco hex key Each door is equipped ...

Page 54: ...and pull the door panel forward away from the cabinet To completely remove the door disconnect the ground strap using a 3 8 inch hex nut driver Step 1 Step 2 Step 3 Step 4 To open a battery compartment door The cabinet s battery compartment is equipped with a removable access door The battery compartment door is secured at the top by two 7 16 inch hex bolts that are accessible only when the cabine...

Page 55: ...l the panel away from the fixture c Slide the lower panel sideways to align its two keyholes with the two mounting screws When aligned pull the panel away from the fixture From the battery compartment remove the box containing the installation kit and set it aside for use during installation From the rear compartment remove the isolation mat and set it aside for use with pad mount installations No...

Page 56: ...box 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 the load or place any part of your body under the load during lifting Follow local safety practices for lifting and moving heavy loads CAUTION Installing the cabinet requires safe handling to ensure that no injury to personnel or damage to the...

Page 57: ...t the slings from the cabinet lifting eyebolts Anchor the cabinet to the pad as follows Pads with anchor studs a Get the four hex nuts four square washers and four lock washers from the installation kit b Install one square washer lock washer and hex nut onto each of the four anchor studs two in the splice compartment two in the battery compartment c Tighten the hex nuts to secure the cabinet to t...

Page 58: ...sling junction to the boom line Use appropriately rated connecting links or lifting hooks Clearfield recommends using at least three people to install the cabinet one to operate the crane or derrick one to guide the cabinet laterally as it lowers and one to spot check alignment of the mounting studs holes and conduits entry box as the cabinet lowers Before installing the cabinet verify that the sp...

Page 59: ...ry reach down through the entry box to grasp and align the conduit to guide it through the entry box Do not reach under the cabinet Step 1 Step 2 Step 3 Step 4 Step 5 Pull the earth ground wire into the splice compartment through the cable entry box Anchor the cabinet to the mounting platform as follows a Get 4 square washers 4 lock washers and 4 hex nuts from the installation kit b Install one sq...

Page 60: ... the sling junction to the boom line Use appropriately rated connecting links or lifting hooks Clearfield recommends using at least three people to install the cabinet one to operate the crane or derrick one to guide the cabinet laterally as it lowers and one to spot check alignment of the mounting studs holes and conduits entry box as the cabinet lowers DANGER The cabinet is very heavy If it fall...

Page 61: ... as the cabinet lowers If necessary reach down through the entry box to grasp and align the conduit to guide it through the entry box Do not reach under the cabinet Pull the earth ground wire into the splice compartment through the cable entry box Anchor the cabinet to the mounting platform as follows a Get 4 square washers 4 lock washers and 4 hex nuts from the installation kit b Install one squa...

Page 62: ... cabinet roof secure the roof assembly to the cabinet When replacing the eyebolts remove and replace each bolt in sequence Do not remove all bolts at the same time CAUTION Replace the eyebolts one at a time to ensure that the roof is securely attached to the cabinet at all times To replace the lifting eyebolts Step 1 Using a screwdriver unscrew and remove a lifting eyebolt from the top of the cabi...

Page 63: ...eClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 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 Installing the cabinet ground connection Installing the AC power supply 220 240 VAC standard Installing the AC power supply 110 120 VAC option ...

Page 64: ...s 4 mounting screws and moving it up or down as required To install the cabinet ground connection Open the splice compartment door Route the earth ground wire to the main ground bar and cut the wire to length Using a crimp tool attach a two hole compression lug 2 AWG 3 4 inch hole spacing to the earth ground wire At the middle of the ground bar locate a ground position with 3 4 inch stud spacing R...

Page 65: ...transfer switch To install the cabinet ground connection Open the splice compartment door At the cabinet AC load center switch all breakers to the OFF position Remove the left cover panel from the AC load center Remove the AC duct cover two panels as follows a Loosen but do not remove the mounting screws securing the duct cover panels to the fixture b Slide the upper panel sideways to align its tw...

Page 66: ...d center Step 8 Step 9 Step 10 Step 11 Installing AC Power 110 120 VAC The cabinet ships from the factory equipped to support 220 240 VAC service but can be reconfigured to support 110 120 VAC service if required Converting the AC load center to support 110 120 VAC input requires modification to existing wiring The 110 120 VAC input power option is only supported in conjunction with use of 20 Amp ...

Page 67: ...ce Disconnect breaker Install a 12 AWG wire jumper 3 5 inch length between the two terminal screws L1 L2 of the Main Service Disconnect breaker For cabinets equipped with a generator connector perform these additional steps a Remove the right cover panel from the AC load center b Disconnect the L2 wire from the Gen Conn breaker Remove the other end of the L2 wire red from the back of the generator...

Page 68: ...ays to align its two keyholes with the two mounting screws When aligned pull the panel away from the fixture Pull the AC cable into the cabinet through the entry hole in the base of the compartment Route the AC cable up through the duct and feed it into a hole on the left side of the AC load center Remove the Main Service Disconnect breaker from the load center housing to ease wire termination Pul...

Page 69: ...Chapter 6 Installing and Splicing Outside Plant Cables This 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 twisted pairs for subscriber drops and or transport Topics Covered This chapter covers the following topics Installing fiber cable Installing metalli...

Page 70: ...ions Installing Outside Plant Fiber Cable Install outside plant OSP fiber cable into the cabinet and prepare it for splicing The following steps are general guidelines only Follow local practice wherever applicable To install outside plant fiber cable Open the cabinet s splice compartment door Route the OSP fiber cable from the feeder location through the conduit and up into the cabinet Pull the f...

Page 71: ...rength members c Install a 6 AWG bond strap onto the lug connector together with the twisted strength members and tighten the lug connector d Terminate the other end of the bond strap to the main ground bar Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Mount and secure the OSP cable to the rack or tie bars with cable ties For cabinets equipped with a fiber splice tray do the following a Route the core...

Page 72: ...tions with fusion heat shrink and mechanical splicing options Each splice tray can hold up to 12 fiber splices See Installing a Fiber Splice Tray Holder for installation instructions DANGER CLASS 1 LASER PRODUCT INVISIBLE LASER RADIATION PRESENT Fiber optic radiation can cause severe eye damage or blindness Do not look into the open end of an optical fiber CAUTION Only a qualified technician shoul...

Page 73: ...SIBLE LASER RADIATION PRESENT Fiber 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 At the splice tray locate the fiber pigtails or jumpers to route and terminate Route the fibers to the termination point as follows If the splice tray is located in the splice compartment insert the pigtails or jum...

Page 74: ...local practice where applicable To install outside plant metallic cables Open the cabinet s splice compartment door Route the OSP metallic cables from the feeder location through the conduit and up into the cabinet Pull approximately six feet of each cable up into the splice compartment through the entry duct Using ropes or cable ties temporarily hang and secure the OSP cables inside the splice co...

Page 75: ...P cable sheath to the cabinet ground bar as follows a Install a B bond clamp onto the cut end of the OSP cable s outer sheath Wrap the connection with electrical tape b Attach a 6 AWG bond strap to the B bond clamp c Terminate the other end of the bond strap to the main ground bar Secure the OSP cable to the rack or tie bars with cable ties Remove the core wrap from around the bundled copper pairs...

Page 76: ... from the OSP cables If you require additional copper line protection capacity 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 Open the cabinet s splice compartment door Segregate the bundled pairs from the OSP cable into 25 pair groups Terminate MS2 or 71...

Page 77: ...nt cables you must install 5 pin protection modules into the protection blocks The 5 pin modules serve as fuses to protect the equipment from electrical surges on the lines Each protection block protects 48 pairs with each 5 pin position on the block protecting one wire pair one 2 wire circuit or half of a 4 wire circuit Install a 5 pin protection module into each position on the protection block ...

Page 78: ...regions Failure to take these precautions will void cabinet warranty ALERT The sealant package does not require tools to open or mix the compound Do not insert tools into the plastic nozzle or pierce the sealant package To seal the cable entry locations Get the package of sealant compound from the installation kit Mix the sealant compound inside its package per the manufacturer instructions printe...

Page 79: ...nd test the cabinet power system This process includes checking the AC power supply voltage installing rectifier modules into the optional Valere power shelf installing batteries for reserve power and turning up and testing the DC power system Topics Covered This chapter covers the following topics Checking the cabinet ground connection Checking the AC power supply voltage Installing rectifier mod...

Page 80: ... The following procedure does not test the quality of the earth ground circuit earth electrode which should have been installed and tested before the cabinet was installed To check the cabinet ground connection Using an ohm meter test between the main ground bar and the earth ground wire a Place one lead on the main cabinet ground bar located in the splice compartment b Place the other lead on the...

Page 81: ... b Switch the 60A Main Service Disconnect breaker to ON c Switch the 60A Main breaker to ON 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 VAC Using a volt meter test between the L2 and neutral busses a Place one lead on the L2 buss b Place the other lead on ...

Page 82: ...wing a Remove the left and right cover panels from the AC load center b Switch the 60A Main Service Disconnect breaker to ON c Switch the 60A Main breaker to ON 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 VAC Using a volt meter test between the L2 and neut...

Page 83: ... two 40 Amp battery break ers up to two strings and 10 GMT fuse positions heat exchanger and additional equipment The Valere power shelf is equipped with a controller module that monitors power functions and alarm information and regulates voltage in response to battery temperature The controller module features a 16 character front panel display for programming menu driven system controls For a c...

Page 84: ...k the rectifier module On the lower left of the module face plate press the tab to release the ejector lever Insert the rectifier module into an empty slot in the Valere shelf Slots are typically populated from left to right Push firmly on the module to seat it in the slot Push the ejector lever closed to secure the module in place Repeat Steps 1 5 to install additional rectifier modules Note Refe...

Page 85: ...qualified 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 Read the battery manufacturer s instructions before installing batteries Follow the manufacturer guidelines and local safety practices To prepare batteries for installation Unpack the batteries from the shipping pac...

Page 86: ...tall the jumper straps between the battery terminal posts per the manufacturer instructions Connect the battery power cables as follows a Remove the protective caps from the cable ring lugs b Attach the black cable to the positive terminal post at the right end of the string c Attach the red cable to the negative terminal post at the left end of the string ALERT Check all connections carefully to ...

Page 87: ... controller face plate press the UP button once to display plant voltage and current de faults Note The Valere shelf controller is programmed at the factory with default settings that enable safe power up and operation You can modify the settings for plant voltage battery profile temperature compensation etc from the defaults if required See Programming the Valere Shelf Controller for details or r...

Page 88: ...ectifier fuse panel verify that the battery breakers are ON Using a digital volt meter test the battery connection between the negative and positive battery leads a Place the red volt meter lead on the red negative battery lead b Place the black volt meter lead on the black positive battery lead c Verify that the volt meter reads between 46 and 54 VDC d If the reading is outside of these limits ch...

Page 89: ...uipment to increase system capacity The modular design allows for incremental growth of line capacity and supports field installation of factory options Topics Covered Installing a protection mounting frame Installing a protection block Installing a battery compartment riser Installing a battery heater Installing an AC power meter Installing a generator connector Installing fiber termination assem...

Page 90: ... protection mounting frame from its packaging Verify that two ground wires are connected to the mounting frame Install the ground wires if necessary Install the protection mounting frame on the rack as follows a Turn the knob on the frame counter clockwise to the latch s disengaged position b Position the frame against the rack oriented with the hinge on the left side Note To correctly align the f...

Page 91: ...in the rear compartment for cross connect configurations To install a protection block Unpack the protection block from the shipping packaging On the back of the protection block remove any cable ties that coil up the two pairs of interface cables two with MS2 or 710 connectors two with RJ 21 connectors if present Locate an open position on the protection mounting frame then feed the protection bl...

Page 92: ... protection block to the mounting frame using two supplied screws Note The screws provide a critical ground path through the mounting frame to the cabinet s main ground bar Apply the appropriately numbered slot identification labels over the protection block s dead pair positions 25 and 50 On the mounting frame turn the two knobs counter clockwise to the open position then pull the frame for ward ...

Page 93: ... Use the riser with concrete pad mount applications only Do not use the riser with pole or wall mount applications due to weight concerns Clearfield recommends using two people to install the riser one to operate the cabinet lifting device and another to guide the cabinet onto the riser as it lowers and align the anchor holes DANGER The cabinet is very heavy If it falls during lifting it could cau...

Page 94: ...abinet base to the riser using 4 anchor bolts 8 square washers 4 lock washers and 4 nuts one set per each of the four anchor holes Tighten all hardware to secure the cabinet to the riser If you are using the battery compartment riser to house a second string of batteries perform the additional steps below to connect the second string battery cables to the cabinet power system If you are only using...

Page 95: ...e following operation 0 C Battery heater turns On 12 C Battery heater turns Off Note The battery heater sits directly underneath the battery string You must install the heater into the battery compartment before installing batteries To install a battery heater Unpack the battery heater from the shipping packaging Remove the battery compartment door See Operating Cabinet Doors for instructions Orie...

Page 96: ...meter in this location you must cut a hole in 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 meter be sure to thoroughly seal the opening For AC wiring information refer to the AC wiring diagram on the inside door of the splice compartment DANGER Hig...

Page 97: ...e cabinet Note If the cabinet is equipped with charged batteries this action does not affect service The equipment automatically switches to battery reserve power Open the splice compartment door At the AC load center switch the Main Service Disconnect and Main main circuit breakers to OFF Remove the cover panel from the AC load center Remove the AC duct cover two panels as follows a Loosen but do...

Page 98: ...s to secure the adapter plate in place Attach the generator connector to the mounting fixture as follows a From the exterior front of the cabinet feed the generator connector wires through the mounting fixture open ing into the splice compartment b Insert the generator connector into the mounting fixture aligning the four studs with the counterpart holes in the adapter plate 30 Amp model c From in...

Page 99: ... Jan 2019 c Terminate the generator connector wires to the load center as follows Connect the green wire to the ground bar Connect the white wire to the neutral bar Connect the black and red wires to the Gen Conn breaker Replace the AC duct cover two panels and the AC load center cover panel At the AC load center switch all breakers to ON At the local power transfer switch restore AC power to the ...

Page 100: ...er bundle installation requires simply mounting the termination assembly on the bulkhead panel and then routing the OSP cable to splice compartment and then outside of the cabinet to interface to the outside plant fiber facilities such as in a fiber hand hole Note For detailed instructions on splicing in a fiber termination 12 port distribution cassette without a pre terminated OSP fiber refer to ...

Page 101: ...n the panel position Secure the assembly in place by tightening the two captive screws using a 2 Phillips screwdriver Route the OSP fiber cable into the splice compartment through one of the cutout locations in the compartment wall preferably through one with a pass through fitting in place installed previously Feed the OSP cable down into one of the cabinet s cable entry conduits and out of the c...

Page 102: ...e delivery to the ONTs The SC adapter plate for terminating OLT feeder fibers splitter mounting cage and fiber staging plate are installed in the GPON fiber distribution bulkhead at the factory The mounting cage can house up to 14 1 16 or 1 32 splitters The splitter assembly is ordered and packaged separately and installed in the field To install a 1 16 or 1 32 fiber splitter assembly Insert a 1 1...

Page 103: ...plate Step 4 IMPORTANT When routing optic fibers be careful to avoid bending fibers beyond the manufacturer recommended 1 inch 2 54 cm bend radius Exceeding the bend radius can cause excess attenuation and possibly break the fiber Route and terminate the 16 or 32 PON side fibers from the splitter to the fiber staging area as follows a Dress the fibers from the splitter to the right and through the...

Page 104: ... is turned off or that the fiber is disconnected at the other end A protective cap or hood must be placed over any radiating bulkhead receptacle or optical fiber connector IMPORTANT When routing optic fibers be careful to avoid bending fibers beyond the manufacturer recommended 1 inch 2 54 cm bend radius Exceeding the bend radius can cause excess attenuation and possibly break the fiber To connect...

Page 105: ...ve cap or hood must be placed over any radiating bulkhead receptacle or optical fiber connector IMPORTANT When routing optic fibers be careful to avoid bending fibers beyond the manufacturer recommended 1 inch 2 54 cm bend radius Exceeding the bend radius can cause excess attenuation and possibly break the fiber To connect the AE fibers to OSP termination and equipment 1 Insert a fiber jumper into...

Page 106: ...r that the fiber is disconnected at the other end A protective cap or hood must be placed over any radiating bulkhead receptacle or optical fiber connector IMPORTANT When routing optic fibers be careful to avoid bending fibers beyond the manufacturer recommended 1 inch 2 54 cm bend radius Exceeding the bend radius can cause excess attenuation and possibly break the fiber To connect the transport f...

Page 107: ...bly panel and connect a fiber jumper Route the fiber jumper to the service unit as follows For AE fiber distribution bulkheads route the fibers to the dressing spool on the right and then over the top of the bulkhead and along the relay ramp to the service unit For GPON fiber distribution bulkheads route the fiber over the top of the bulkhead and along relay ramp to the service unit Neatly dress a...

Page 108: ...Cords Factory installed FAC 3200E GPON AE fiber distribution bulkheads include a fiber relay ramp among the routing dressing elements The relay ramp is installed between the front and rear racks enabling you to pass fiber jumpers terminated to bulkhead positions on the rear rack through the compartment to the OLT equipment located on the front rack Neatly dress any slack fiber within the comb duct...

Page 109: ...SeeClearfield com techsupport clfd net Manual 020421 REV A Jan 2019 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 ...

Page 110: ...l applicable breakers are in the ON position and that no fuses are blown Check the door mounted heat 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 local code If any of the inspected items requires replacement due to failure or damage replace the ite...

Page 111: ...ves etc Clean the air vents on the heat exchangers and the 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 cabinet from the out side plant Visually inspect all cables for signs of physical damage If damage is present cables should be repaired or replace...

Page 112: ...ure CAUTION Electrical chemical fire and heat hazard Handle batteries with care to avoid personal injury or damage to the equipment ALERT To ensure service continuity in the event of an AC outage connect an external generator to the cabi net while performing battery maintenance To perform battery maintenance At the rectifier DC feed Switch the battery breaker s to OFF Remove the battery compartmen...

Page 113: ... 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 Clean the battery terminals and apply No Ox anti corrosion grease to each e Record the inspection and maintenance details in the cabinet records per local practice Inspect the battery compartment for any signs of damage Clean the compartment ...

Page 114: ...e necessary if A door becomes damaged A heat exchanger fails or becomes damaged Cooling capacity must be increased to support additional lines or equipment replacing a 750W heat exchanger door with an 1850W heat exchanger door You can replace cabinet doors in the field without impacting service CAUTION Handle cabinet doors with care to avoid personal injury or damage to the door Clearfield recom m...

Page 115: ...le b Bottom hinge Press the pin lever down and rotate it away from the cradle Release the hinge pins from the hinge pin channels as follows a Top hinge Press down on the pin lever until the pin slides free from the channel b Bottom hinge Lift up on the pin lever until the pin slides free from the channel Lift the door away from the cabinet Installing a Cabinet Door You can quickly install a cabine...

Page 116: ...n lever until the pin slides free from the channel Insert the new door into the vacant door frame Align the door hinge knuckles with the counterpart hinge knuck les on the door frame Engage the hinge pins to secure the door in place as follows a Top hinge Lift up on the pin lever until the pin slides completely into the pin channel b Bottom hinge Press down on the pin lever until the pin slides co...

Page 117: ...cal codes when handling power systems Do not restore AC power until the task is complete To replace an AC circuit breaker 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 equipment auto matically switches to battery reserve power At the AC load center switch the Main Service Disconne...

Page 118: ...ed in the OFF position Note To avoid an interruption of service you can replace breakers while the distribution system is hot The bullet style breakers used with optional Valere rectifier can be removed with no wiring disconnections Refer to the rectifier product manual for more information If you elect to replace a breaker with the power off wait until a maintenance window to mini mize service im...

Page 119: ...lace it Troubleshoot to find the cause of the failure Replacing Rectifier Modules for optional Valere Rectifier 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 replace the module s in the field Rectifier modules are hot swappable and can be replaced without disconnecting power to the Valere shelf Note ...

Page 120: ...ce plate down and forward to disconnect it from the controller module Allow the face plate to dangle b Loosen 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 probe alarm and expansion cables from the controller module e Pull the controller module co...

Page 121: ...re CAUTION Electrical chemical fire and heat hazard Handle batteries with care to avoid personal injury or damage to the equipment ALERT To ensure service continuity in the event of an AC outage connect an external generator to the cabi net while performing battery maintenance To replace batteries At the rectifier shelf open the fuse panel door optional Valere rectifier or DC distribution panel Sw...

Page 122: ... batteries from the battery compartment To replace a battery heater Remove the battery compartment door See Operating Cabinet Doors for instructions If batteries are present remove the batteries from the battery compartment See Replacing Batteries for re moval instructions Unplug the heater power cord from the AC outlet located on the compartment wall Remove the battery heater from the compartment...

Page 123: ... Information This appendix provides general reference information about the FAC 3200 cabinet Topics Covered This chapter covers the following topics Cabinet specifications Supported batteries Rack space available for additional equipment Optional Valere rectifier alarm matrix Optional Valere rectifier settings battery profiles Programming instructions for the optional Valere shelf controller modul...

Page 124: ...hanger 1 door mounted 750 or 1850 Watt options Fans turn on at 30C 1500 RPM 40C 3000 RPM High temp alarm at 75C low temp alarm at 0C Cooling capacity Up to 1850 Watts Thermal operating range 40C to 46C Environmental alarming 8 environmental and intrusion alarms Electrical AC power system 220 240 VAC load center 110 120 VAC option Dual feeds to DC power shelf 2 duplex convenience outlets GFCI prote...

Page 125: ...hon M12V155FT 155 Ah 1 C D Dynasty TEL 150F 150 Ah 1 Northstar NSB 100FT 100 Ah 1 PowerSafe SBS C11 92 Ah 1 2 strings are supported when cabinet is equipped with the optional battery riser compartment Rack Space for Additional Equipment In addition to its standard factory installed equipment the FAC 3200 can also house third party equipment The total stor age capacity for third party equipment var...

Page 126: ...to the equipment shelf Rectifier Major RECT MJ and Rectifier Minor RECT MN The following table lists the Valere alarms that may be reported by the equipment shelf as Rectifier Major or Rectifier Minor Alarm Condition Display Severity Major Minor AC Fail X High Voltage Warning X High Voltage Shut Down X Battery on Discharge X Any LVD Warning X Any LVD Open X Distribution Open X Redundant Capacity X...

Page 127: ... 0 50 0 LVD 2 Reconnect Delay Time The amount of time seconds that the plant voltage must exceed the LVD recon nect setpoint prior to reconnecting the LVD contactor 20 20 20 Ringer AC Output Voltage The RMS value of the ringing AC sine wave output 86 86 86 Ringer Output DC Offset Voltage The DC offset value applied to the output AC sine wave Vfloat Vfloat Vfloat Ringer Output Frequency The frequen...

Page 128: ...abled Battery Recharge Current Limit The maximum amount of current that the controller will allow to flow to the battery during recharge 30 30 30 Rectifier Current Limit Enable Enables rectifier current limit feature Enabled Enabled Enabled Rectifier Current Limit The maximum amount of current that each installed rectifier will produce 35 35 35 Battery Discharge Test Enable Enables the battery dis...

Page 129: ...splay reads System OK the controller is at the Basic menu level Use the UP DOWN buttons to sequentially view basic parameters Press and hold the MENU button for 5 seconds to access the Advanced 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 all the pl...

Page 130: ...he UP button until the appropriate battery profile LMP NiCAD or VRLA displays Once the appropriate battery profile is selected press MENU for 5 seconds until the menu jumps back to CHOOSE CONFIG Press the UP button once to display CHOOSE EXIT 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 mo...

Page 131: ...r Module Load per Rectifier Shelf Power Supplied Rectifier Modules Required1 20A 30A 20A 22A 54V 1188W 1W to 1188W 1 1 1188W to 1782W 2 1 30A 33A 54V 1782W 1782W to 2364W 2 2 2364W to 3564W 3 2 1 Clearfield recommends using an N 1 rectifier module scheme for redundancy The quantity shown represents N only with no redundant module Note When using 20A rectifier modules loads greater than 3564W per p...

Page 132: ...n of Clearfield Inc shall constitute the exclusive sole remedy for a breach of this limited warranty Clearfield shall not be liable under any circumstances for any special consequential incidental punitive or exemplary damages arising out of or in any way connected with the product or with agreement to sell product to buyer including but not limited to damages for lost profits loss of use or for a...

Page 133: ...uipment supplied Every effort has been made to keep the information contained in this document current and accurate as of the date of publication or revision However no guarantee is given or implied that the document is error free or that it is accurate with regard to any specification Technical Support Clearfield Inc can be contacted for any issues that arise with the supplied product If you need...

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