Clearfield FieldSmart Fiber Active Cabinet (FAC) 900 Installation Manual Download

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FieldSmart

Fiber Active Cabinet (FAC) 900

__________________________________________________________

Installation Manual

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

Manual 020420 REV B - April 2019

Chapter 1: Fiber Active Cabinet 900 Product Overview

This chapter provides a general description of the base Clearfield FAC 900 outdoor cabinet and Expansion Module (EXM),

including standard features and options.

Topics Covered

This chapter covers the following topics:

• A description of the FAC 900 cabinet

• A list of cabinet features

• A list of cabinet options

•

A description of the optional EXM

•

Views of the cabinet and EXM compartments

•

Views of the cabinet and EXM dimensions

Summary of Contents for FieldSmart Fiber Active Cabinet (FAC) 900

Page 1: ...FieldSmart Fiber Active Cabinet FAC 900 Installation Manual _______________________________________________________ Manual 020420 REV B April 2019 ...

Page 2: ...lation Considerations 21 Installation Process Overview 22 Installation Guidelines 23 Space Requirements 25 General Safety Recommendations 28 Installation Kits 29 User Supplied Items 30 Cabling Requirements 31 Chapter 3 Preparing the Installation Site 32 Installing a Ground Circuit 33 Constructing a Concrete Pad 36 Pad Construction Guidelines 36 Assembling the Cast In Place Template 42 Preparing th...

Page 3: ... 65 Installing an EXM and Riser on a Concrete Pad 67 Installing the Enclosure s on a Wall or H Frame 72 Removing the Lifting Details 75 Chapter 5 Installing Local AC Power 76 Installing the Cabinet and EXM Ground Connections 77 Installing AC Power 208 240 VAC 79 AC Load Center Installing Power 79 AC Junction Box Installing Power 80 Chapter 6 Installing and Splicing Outside Plant Cables 82 Bonding ...

Page 4: ...ing Frame 114 Installing a Protection Block 115 TE LSA Plus Cross Connect System 117 Installing an AC Meter 121 Installing a Battery Enclosure 122 Installing a Battery Heater 123 Installing a Generator Connector 127 Installing a Heat Exchanger Door 129 Installing Fiber Management Options 130 Installing a GPON Splitter Cage and Fiber Distribution Bulkhead Frame 132 Connecting PON Splitter Fibers to...

Page 5: ...rts and Equipment 153 Removing a Cabinet Door 153 Installing a Cabinet Door 154 Replacing AC Breakers 155 Replacing Rectifier Modules Alpha Cordex Rectifier Option 156 Replacing Batteries 157 Replacing a Battery Heater 158 Appendix A Reference Information 159 Specifications 160 Alpha Cordex HP Rectifier Alarms and Controller Settings 161 Supported Batteries 161 Wiring Diagrams 161 Standard Warrant...

Page 6: ...ence 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 software ...

Page 7: ... Active Cabinet 900 Product Overview This chapter provides a general description of the base Clearfield FAC 900 outdoor cabinet and Expansion Module EXM including standard features and options Topics Covered This chapter covers the following topics A description of the FAC 900 cabinet A list of cabinet features A list of cabinet options A description of the optional EXM Views of the cabinet and EX...

Page 8: ... to the premises FTTP focusing on the mixed deployment of a copper and fiber infrastructure The base FAC 900 cabinet has a single compartment that houses electronics equipment together with high density fiber and copper plant terminations enabling deployment of a broad suite of applications from a single node The electronics area is equipped with a vertically oriented 19 inch equipment rack that p...

Page 9: ...ON applications without an internal battery enclosure installed SC connectors up to 18 integrated PON splitters Mechanical support for copper 5 pin protection panel and fiber termination assemblies Modular scalable copper line protection 50 pair block increments 384 pairs maximum 768 copper pair protection or sixteen 50 pair pro panels blocks can be supported in the FAC 900 by deploying the intern...

Page 10: ...ors CAT5 interface cabling from the line protection blocks 12 24 48 or 96 position fiber splice or distribution panels 19 inch mount 6 and 12 position dual LGX fiber distribution panel 19 or 23 inch mount GPON and AE fiber management options supporting up to 384 subscriber fiber drops with an internal battery enclosure installed or up to 576 subscriber fiber drops for GPON applications without an ...

Page 11: ... Manual 020420 REV B April 2019 FAC 900 Battery Riser Description The Clearfield FAC 900 Battery Riser is an environmentally controlled outdoor enclosure that mounts under the base of the FAC 900 cabinet Clearfield provides an optional AC line operated 150W battery heater mat which turns on at 40 F to increase battery capaci ty in cold environments Battery mats are available in 120VAC and 240VAC v...

Page 12: ...of the base FAC 900 cabinet as shown below Rear Mount In line configuration Side Mount L configuration The field installable EXM provides the ability to grow the FAC 900 cabinet to support rack space for migration of copper loops to fiber drops additional subscriber fiber distribution endpoints additional copper line protection a secondary or alternative integrated battery enclosure The EXM offers...

Page 13: ...420 REV B April 2019 Cabinet and Expansion Module Views Views of the base FAC 900 cabinet and Expansion Module EXM follow Base Cabinet Front Compartment The base cabinet front compartment provides 19 inches of vertical rack space 9RU and houses the cabinet power system and electronics equipment The cabinet power system consists of an AC load center or AC junction box and DC rectifier shelf FAC 900...

Page 14: ...ment provides access to the cable entry locations main ground bar and fiber management or copper line protection For fiber access the fiber management accessories may vary greatly according to the ordered options For copper access the line protection may include up to eight 50 pair protection blocks The side compartment also houses an internal battery enclosure for local power configurations The b...

Page 15: ...es access to cable entry locations and rack space to support additional fiber management or copper line protection For fiber access the fiber management accessories may vary greatly according to the ordered op tions For copper access the line protection may include up to eight 50 pair protection blocks The EXM compartment also houses a secondary or alternative interior battery enclosure for local ...

Page 16: ...FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Cabinet Side and Expansion Module Compartments A view of an in line configuration follows with the EXM mounted on the rear of the FAC 900 cabinet In line Configuration local power ...

Page 17: ...ions and weights for the base FAC 900 cabinet and Expansion Module EXM follow Cabinet Dimensions and Weights The external dimensions of the base FAC 900 cabinet are shown below Dimension Measurement SAE Measurement Metric Height 36 inches 91 cm Width 24 inches 61 cm Depth 48 inches 122 cm Configuration Options Weight SAE Weight Metric Equipped with protection panels and internal battery enclosure ...

Page 18: ...______________________________________________ Expansion Module Dimensions and Weights The external dimensions of the EXM are shown below Dimension Measurement SAE Measurement Metric Height 36 inches 91 cm Width 24 inches 61 cm Depth 28 6 inches 74 cm Front Mating Side The approximate shipping weight of the empty EXM is shown below Weight SAE Weight Metric 50 lb 23 kg ...

Page 19: ...Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 In Line Configuration Dimensions The external dimensions of the in line configuration are shown below with the EXM mounted on the rear of the FAC 900 cabinet Front Side ...

Page 20: ..._________________________________________________________ L configuration Dimensions The external dimensions of the L configuration are shown below with the EXM mounted on the side of the FAC 900 cabinet Note For clearance and space requirements when mounting the EXM on the rear or side of the base FAC 900 cabinet refer to Space Requirements Front Rear Side ...

Page 21: ...REV B April 2019 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 contentsUser supplied ite...

Page 22: ...y written agreement with Clearfield 22 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Installation Process Overview The cabinet installation process involves the following high level steps ...

Page 23: ...nned in advance Consider the following factors when select ing an installation site 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 proper...

Page 24: ... 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 agree ment that includes right of access Avoid locations in public rights 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 Whe...

Page 25: ...uration Base FAC 900 cabinet In line configuration FAC 900 with an Expansion Module EXM mounted on the rear of the cabinet L configuration FAC 900 with an EXM mounted on the left side of the cabinet For each configuration the minimum clearance area around the cabinet site must be free of permanent impediments to allow full swing of the cabinet doors This area must be kept clear of obstructions at ...

Page 26: ...ment with Clearfield 26 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ In line configuration The illustration below shows the clearance and space requirements for an in line FAC 900 configuration FAC 900 ...

Page 27: ..._______________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 L configuration The illustration below shows the clearance and space requirements for an FAC 900 L configuration FAC 900 ...

Page 28: ...lectric shock Read and understand 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 PR...

Page 29: ...listed below Check to verify that your kit contains the listed items Qty Item Description 1 Telco hex key 5 16 for cabinet door 1 Hex security driver 5 32 for access panels 1 Isolation mat 1 Vent cover for side door included in installation kit when cabinet EXM includes an internal battery enclosure 4 Hex nuts for pad mounting 4 Flat washers for pad mounting 4 Split lock washers for pad mounting 4...

Page 30: ... Wire cutters Crimp tool Compression crimping tool Fiber cleaver Fiber splicer Modular MS2 or 710 splicing tool RB Razor Sharp Cutting Edge knife or another similar tool Wire brush to clean drill hole for a 1 2 13 inch hole concrete insert Materials Bring the following materials to the installation site Leveling shims Silicone sealant Two hole compression ground lug 2 6 AWG 3 4 inch spacing for ea...

Page 31: ...on Facility Requirements Power Ground Copper 6 AWG solid bare copper wire to earth ground circuit terminates to ground bar with screw lug AC local power Copper 8 10 AWG stranded copper Follow National Electric Code NEC and local codes Cabling Requirements Cables supplied to the cabinet must meet the following minimum requirements Note Local climatic conditions site conditions or local practices ma...

Page 32: ... mounting structure You can construct a concrete foundation pad using the Clearfield pour in place template and install an optional 6 inch or 12 inch riser For all mounting configurations Clearfield requires installation of an earth ground circuit at the installation site to provide lightning protection Topics Covered This chapter covers the following topics Installing a ground circuit at the inst...

Page 33: ...ocal codes or the NEC require ment of 25 ohms whichever is less 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 or enclosure ground via an earth ground wire bonded to the ground rod and bu...

Page 34: ... Clearfield 34 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Example of PANI compliant ground ring with main site ground buss Example of PANI compliant ground ring without a main site ground buss FAC 900 FAC 900 ...

Page 35: ...d bar to the initial ground electrode should be a 6 AWG or larger bare cop per ground wire The ground wire should enter the cabinet separated from power or copper transmission cables Never bundle the ground wire together with other copper cables Connect the ground wire to the main ground bar Follow the PANI organization for all connections made to the Clearfield equipment cabinet enclosure ground ...

Page 36: ...ct a pad for a stand alone FAC 900 cabinet configuration with minimum perimeter dimensions of 48 x 72 inch es Note Be sure to construct an adequate size pad if you may consider adding an EXM later as an expansion Construct a pad for an FAC 900 in line configuration with minimum dimensions of 48 x 101 inches Construct a pad for an FAC 900 L configuration with minimum dimensions of 77 5 x 99 inches ...

Page 37: ..._____________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 Pad Drawings Use the following drawings for reference during pad construction Pad Size FAC 900 Base Cabinet ...

Page 38: ...tion Not for use or disclosure except by written agreement with Clearfield 38 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Pad Size L Configuration ...

Page 39: ...inet FAC 900 __________________________________________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 Pad Size L Configuration ...

Page 40: ...e or disclosure except by written agreement with Clearfield 40 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Pad Cross Section FAC 900 Base Cabinet from left side ...

Page 41: ...m techsupport clfd net Manual 020420 REV B April 2019 FAC 900 For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cable copper b Conduit for outside plant cable fiber c Earth ground wire d Conduit for AC cable for local power configurations only Use the Clearfield cast in place template to provide precise conduit orientation ...

Page 42: ...assemble the template Step 1 Step 2 Unpack the template hardware from the shipping kit Place the four bracket members on the ground arranged as follows a Place the two long brackets parallel with each other flat side down b Place the two short brackets between and perpendicular to the long members flat side down with the conduit entry box bracket on the left Step 4 Step 3 Attach the short and long...

Page 43: ...nd wire through the conduit trench from the ground electrode Step 1 Step 2 Step 3 Step 4 Step 5 To construct a concrete form Using 2 x 6 boards and stakes construct a concrete form with minimum interior dimensions of 48 x 72 inches Make sure that the top edge of the form is level Refer to Space Requirements Place gravel into the foundation hole to create a level base The gravel layer should be at ...

Page 44: ...crete to cast the entire pad in a single pour Note To avoid structural weakening do not cast a pad from multiple concrete pours Pour the concrete into the form Do not allow the cast in place template to bend or twist out of shape during the pour Smooth and level the top surface of the concrete Leave the pad to cure Do not remove the form until the concrete has fully cured at least 72 hours Perform...

Page 45: ...ng to the manufacturer s instructions Some pads may require custom preparations A general practice is described below for reference Adapt the instructions as needed for local requirements practices or conditions DANGER Do not place outside plant cables into conduits at the pad site before installing the pre cast pad Attempting to install a pre cast pad over existing cables becomes hazardous if a p...

Page 46: ...der the pad during lifting Handle with care to avoid personal injury or damage to the pad To install a pre cast pad Transport the pre cast pad to installation site Using a suitable lifting device such as a backhoe equipped with lifting slings lift the pad into position above the gravel base inside the foundation hole Lower the pad onto the gravel base allowing the conduits to pass through the cuto...

Page 47: ...hru assembly which provides exact entry locations for cable conduits You can install the mounting kit onto an existing wall or you can construct an H frame at the installation site to support the cabinet Installing the wall H frame mount kit requires trenching cable conduit to the site and installing the mounting kit on the wall or H frame Wall H Frame Mounting Configurations and Drawings Clearfie...

Page 48: ...tion Not for use or disclosure except by written agreement with Clearfield 48 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ H Frame Mount Side View ...

Page 49: ...___________________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 Wall H Frame Mount Dimensions Low Profile Configurations No splice blister allowance on backside ...

Page 50: ... by written agreement with Clearfield 50 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ Wall H Frame Mount Dimensions High Profile Configurations Allowance for splice blister on backside ...

Page 51: ...per mounting support for the cabinet and EXM Adjust for local conditions or practices as required The wall H frame must be vertically plumb The wall H Frame must support a minimum load weight as follows FAC 900 only 730 lbs FAC 900 EXM 880 lbs Note These weights include fully loaded enclosures with a single battery string The top of the base platform must be a minimum of 15 25 inches above the gro...

Page 52: ...urations Two 6 x 6 x 9 4 vertical beams or two 8 x 8 x 9 4 vertical beams for seismically active areas FAC 900 EXM Both low and high profile configurations One 2 x 8 x 8 0 horizontal beams on the top and two 2 x 8 x 8 0 horizontal beams on the bottom to support the fixture Note To use the supplied hardware do not exceed the nominal size for the horizontal beams A nominal size of 2 x 8 x 8 0 correl...

Page 53: ...acing inward with mounting slots against the wall H frame and on the top Align the top of the mounting bracket flush to the top edge of the middle horizontal beam and center the mounting slots on the drilled holes in the beam Note You can offset the horizontal position of the brackets later if needed once the cabinet is roughly posi tioned d Install 1 1 2 13 x 3 00 hex screw 1 2 split lock washer ...

Page 54: ...tary Information Not for use or disclosure except by written agreement with Clearfield 54 FieldSmart Fiber Active Cabinet FAC 900 Installation Manual __________________________________________________________ ...

Page 55: ...throughs flush to the top edge of the middle horizontal beam with the right edge of the assembly mated to the left side of the mounting bracket as shown in the illustration below b Hold the conduit assembly in place with c clamps and drill 1 8 pilot holes into the beam through the assem bly mounting slots c Install 1 3 8 x 1 50 LAG screw 3 8 split lock washer and 3 8 flat washer to attach the asse...

Page 56: ...3 Step 4 Position the stabilizer bracket against the rear enclosure wall in the location where you removed the lifting detail aligning the 2 bracket holes with the counterpart holes in the cabinet For low profile configurations the 2 bracket holes are on top for high profile configurations the 2 bracket holes are on the bottom as shown in the illustration below Reinstall the hardware set aside fro...

Page 57: ...res threaded inserts for anchoring the cabinet to the top of the vault Specific features and dimensions vary by manufacturer and model Contact your sales representative for Clearfield certified supplier information to contact directly Preparing the Site Prepare the site for installation of a foundation vault according to the manufacturer s instructions Some vaults may require custom preparations A...

Page 58: ... The foundation vault may be very heavy Do not place any part of your body under the vault during lifting Handle with care to avoid personal injury or damage to the vault To install a foundation vault Transport the foundation vault to installation site Using a suitable lifting device lift the vault into position above the foundation hole Lower the pad onto the gravel base making sure the conduits ...

Page 59: ...dule This chapter describes how to install the Clearfield FAC 900 cabinet onto its permanent mounting location Topics Covered This chapter covers the following topics Unpacking the cabinet or Expansion Module EXM from its shipping crate Operating the cabinet or EXM doors Preparing the cabinet for installation Preparing the EXM for installation Installing the cabinet or riser onto a concrete pad In...

Page 60: ...t them at the staging area if required Clearfield recommends keeping the protective packag ing in place for transportation When transporting the cabinet EXM or risers to the installation site strap them down securely to the truck or trailer to pre vent shifting or tipping Unpack the cabinet EXM or risers at the installation site To unpack the cabinet EXM or risers After the cabinet EXM or risers h...

Page 61: ... alarm switch that monitors the position of the door When a door on an in service cabinet or EXM is opened an intrusion alarm reports through the equipment Pull the switch plunger to disable the alarm reporting while you are working on the cabinet or EXM The alarm switch is located at the upper right corner of the door frame To open a cabinet or EXM door Insert the telco hex key into the door s up...

Page 62: ..._____________________________________________________ Step 1 Step 2 Step 3 Step 4 Step 5 To close a cabinet or EXM door Push up on the wind brace to disengage it Swing the door closed Insert the telco hex key into the door s upper latch While holding the door firmly closed turn the key clockwise to engage the latch Repeat Steps 3 and 4 to engage the lower latch ...

Page 63: ... cabinet remove the isolation mat and the bag containing the installation hardware Set them aside for use during installation In the front of the cabinet remove the right AC cover panel as follows a Remove the 3 mounting screws securing the cover panel to the fixture b Push up on the 2 lifting tabs angle the panel away from the fixture and lift the panel from the 3 capture tabs on the bottom of th...

Page 64: ...re installing the Expansion Module EXM To prepare the EXM for installation Open the EXM door Remove the isolation mat and the bag containing the installation hardware from the EXM compartment Set them aside for use during installation Remove the four bolts flat washers and lock washers securing the EXM to the pallet The bolts are located at the bottom corners of the EXM and can be accessed by remo...

Page 65: ...le of lifting at least a 200 lb working load When using a lifting device to place the cabinet follow these guidelines Check the two lifting details on top of the cabinet to ensure that they are securely attached Attach the lifting slings to the lifting device attach the other sling ends to the cabinet lifting details with connecting links or hooks Do not disconnect the slings from the cabinet unti...

Page 66: ...ne flat washer lock washer and hex nut onto each of the four anchor studs c Tighten the hex nuts to secure the cabinet or riser to the pad Pre cast pads with threaded inserts a Get four anchor bolts four flat washers and four lock washers from the installation kit b Install one flat washer lock washer and anchor bolt into each of the four threaded mounting inserts c Tighten the bolts to secure the...

Page 67: ...g a lifting device to place the EXM follow these guidelines Check the two lifting details on top of the EXM to ensure that they are securely attached Attach the lifting slings to the lifting device attach the other sling ends to the EXM lifting details with connecting links or hooks Do not disconnect the slings from the EXM until after it rests securely on the pad ALERT Isolation mat usage is mand...

Page 68: ...n the base of the module and mark each one on the pad d Remove the EXM from the pad Install each concrete insert into a marked location on the pad as follows a Use a hammer drill to drill the appropriate diameter hold for a 1 2 13 inch hole concrete insert b Clear all dirt and debris from the hole using a wire brush or vacuum c Install an insert into the hole making sure that it is level with the ...

Page 69: ...nstalling the Cabinet and EXM Ground Connections Verify that the door opens and closes freely If necessary use shims to level the EXM Note If you removed the door previously re install it to check door swing alignment See Installing a Cabinet Door for instructions Clearfield recommends applying silicone caulking to the bottom perimeter of the EXM once the installation is complete To install a rise...

Page 70: ...to a marked location on the pad as follows a Use a hammer drill to drill the appropriate diameter hole for a 1 2 13 inch concrete insert b Clear all dirt and debris from the hole using a wire brush or vacuum c Install an insert into the hole making sure that it is level with the pad Install the isolation mat onto the concrete pad Place the riser on the pad and position it against the FAC 900 align...

Page 71: ...with the counterpart threaded nuts on the FAC 900 Attach the EXM to the FAC 900 cabinet as follows a Get the six shoulder screws six flat washers and six lock washers from the installation kit b From inside the EXM install one screw lock washer and flat washer in the mounting holes on the EXM wall and into corresponding threaded nut on the FAC 900 compartment wall c Tighten the screws to secure th...

Page 72: ...g heavy loads Before installing the cabinet and EXM verify that the door s has been removed or locked in the open position wind brace engaged To install the enclosure s on a wall mount or H frame Check the two lifting details on top of the FAC 900 to ensure that they are securely attached Attach the lifting slings to the lifting device attach the other sling ends to the enclosure lifting details w...

Page 73: ...ntry box d Before removing the lifting device from inside the EXM loosely install 2 1 2 13 x 1 25 hex screws through holes at each end of the EXM base and the counterpart holes in the mounting brackets to prevent the enclosure from slipping off the brackets e Remove the lifting device from the EXM Attach the EXM to the FAC 900 cabinet as follows a Get the six shoulder screws six flat washers and s...

Page 74: ... 8 1 2 flat washers 8 1 2 split lock washers and 4 1 2 13 hex nuts d Install one hex screw one flat washer and one split lock washer into each of the four mounting holes e Tighten the screws to secure the enclosure to the mounting brackets To secure the EXM to the mounting brackets remove the 1 2 13 x 1 25 hex screws loosely installed in Step 8d and then repeat steps 12b 12e If you removed the doo...

Page 75: ...e the two lifting details from the enclosure To remove the lifting details Locate the two lifting details FAC 900 Attached to the upper left corners of the left and right sides of the cabinet EXM Attached to the upper left corner of the left side and the upper right corner of the rear compartment wall Remove the three bolts securing the first lifting detail to the enclosure Remove and discard the ...

Page 76: ..._______________ Chapter 5 Installing Local AC Power This chapter describes how to install power to the cabinet This process includes installing the cabinet earth ground connection and installing and wiring local AC power Install power according to your cabinet configuration type Topics Covered This chapter covers the following topics Installing the cabinet ground connection Installing local AC pow...

Page 77: ...to sections with one type of conductor in each section Producers surge Absorbers Non isolated and Isolated PANI The middle position on the ground bar bisects separate ground connections for surge producers from surge absorbers active electronics The earth ground connection on the cabinet ground bar serves as the primary surge absorber to isolate the equipment grounds from the surge producing groun...

Page 78: ...round bar for the EXM and cut the wire to length Using a ratcheting crimp tool with embossing dies attach a two hole compression lug 2 6 AWG 3 4 inch hole spacing to the earth ground wire Ensure that the correct lug is used to match the earth ground wire At the middle of the ground bar locate a ground position with 3 4 inch stud spacing Remove the nuts from the identified terminal studs Attach the...

Page 79: ... until the installation process is complete WARNING Electrical hazard Only a qualified electrician should perform this procedure Before proceeding verify that AC service to the cabinet site is OFF at the local power transfer switch To install AC power 208 240 VAC Note Refer to the AC Load Center wiring diagram on Clearfield s website seeclearfield com for guidance An AC wiring label is attached be...

Page 80: ...ip and tin the wire as needed Connect the white neutral lead to the neutral bar Connect the black L1 lead to the left side of the Main breaker Connect the red L2 lead to the right side of the Main breaker Dress and secure the AC cable providing adequate strain relief Replace the right cover panel on the AC load center AC Junction Box Installing Power Cabinets factory equipped with the AC junction ...

Page 81: ...om the fixture and lift the panel from the 3 capture tabs on the bottom of the fixture From inside the AC junction box push the plug out from the AC input hole and then install the supplied cord grip and locknut Install a user supplied AC conduit between the outside entry duct in the cabinet floor and the junction box entry location Install the conduit per local practice Make sure the conduit is r...

Page 82: ...stalling and Splicing Outside Plant Cables This chapter describes how to install and splice outside plant cables into the cabinet or EXM including fiber plant fiber optic cables for transport and or 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 metallic cables ...

Page 83: ...o a grounding rod or system at regular intervals along the entire run external to the cabinet enclosure site per RUS guidelines Clearfield recommends that you bond optical fiber cable sheaths at the first entrance to the cabinet enclosure site only the splice case or similar and then isolate the sheaths in the short run between splice point and the Clearfield equip ment cabinet enclosure ground Th...

Page 84: ...e Install outside plant OSP fiber cable into the cabinet and or EXM and prepare it for splicing The following steps are gener al guidelines only Follow local practice wherever applicable To install outside plant fiber cable Open the side cabinet or front EXM door Route the OSP fiber cable from the feeder location through the conduit and up into the compartment Pull the fiber cable up into the comp...

Page 85: ...herwise 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 ground bar in an open position below the AC load center or junction box lug Refer to Installing the Cabinet Ground Connection for more information Route fiber to the splice location a Insert the core tubing into the ...

Page 86: ...cally use a fiber splice tray to hold the individual splices Clearfield offers splice tray options with fusion heat shrink and mechanical splicing options Each splice tray can hold up to 12 fiber splices DANGER CLASS 1 LASER PRODUCT INVISIBLE LASER RADIATION MAY BE PRESENT Fiber optic radiation can cause severe eye damage or blindness Do not look into the open end of an optical fiber CAUTION Only ...

Page 87: ...6 position fiber splice or distribution panels Adapters are available with SC or LC con nector options DANGER CLASS 1 LASER PRODUCT INVISIBLE LASER RADIATION MAY BE 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 te...

Page 88: ...r more pluggable transceiver modules into the optical Ethernet port sockets If the laser at the far end is enabled you can use an optical power meter to test the signal strength on the fibers before connecting to the equipment Defer to local practice wherever applicable DANGER CLASS 1 LASER PRODUCT INVISIBLE LASER RADIATION MAY BE PRESENT Optical radiation can cause severe eye damage or blindness ...

Page 89: ...compartment when installing or splicing outside plant metallic cables remove the battery enclosure as described below To remove the battery enclosure Open the side cabinet or front EXM door Open the latch on each side of the terminal cover and remove the cover Remove the seismic retaining bracket from the battery enclosure as follows a Remove the temperature probe cable from the right upper hole i...

Page 90: ...es remove the Battery Enclosure if present To install outside plant metallic cables Open the side cabinet or front EXM door To keep the cabinet or EXM compartment clear of environmental gel drape plastic sheeting over the door protection panels and the bottom of the splice area Route the OSP metallic cables from the feeder location through the conduit and up into the compartment Pull approximately...

Page 91: ...ble enters the compartment Take care to expose but not penetrate the core wrap surrounding the bundled copper pairs Ground the OSP cable sheath to the cabinet s main ground bar or EXM s subground 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 ...

Page 92: ...earfield equipment uses a dead pair scheme where the 25th pair in each 25 pair cable group is unterminated and not used dead Refer to the pair assignment list shipped with the cabinet Open the side cabinet or front EXM door Turn the 2 knobs on the left side of the protection mounting frame counter clockwise and swing the frame forward Segregate the bundled pairs from the OSP cable into 25 pair gro...

Page 93: ...AC 900 or EXM pull the battery enclosure forward and then re tighten the screws Replace the retaining bracket and terminal cover Close the door and check to be sure that the battery housing properly seals against the door gasket For the FAC 900 this can be viewed through the front equipment compartment for the EXM this can be viewed through the rear access panel using a flashlight Installing 5 Pin...

Page 94: ...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 location Remove the cabinet or EXM rear access panel to access the cable entry location if needed From outside the compartment use a 5 32 hex security driver to remove the eight tamper resistant screws anchoring each panel to...

Page 95: ...Turning Up the Cabinet Power System This chapter describes how to turn up and test the cabinet power system This process includes checking the cabinet ground connection checking the AC power supply voltage installing rectifier modules into the rectifier shelf installing batteries for reserve power and turning up and testing the DC power system Topics Covered This chapter covers the following topic...

Page 96: ...tion Checking the AC power supply voltage Installing rectifier modules into the rectifier shelf Installing batteries for reserve power Turning up and testing the DC power system Checking the Ground Connection Check the impedance of the cabinet ground connection before turning up the cabinet power system Note The following procedure does not test the quality of the earth ground circuit earth electr...

Page 97: ...enter b Switch the 30A 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 the neutral buss c Verify that the volt meter read...

Page 98: ...ons and alarm infor mation and regulates voltage in response to battery temperature The controller module ships pre programmed for operation in the FAC 900 Power Hub For a complete description of the controller module refer to the Cordex Controller Software Manual Install Alpha modules into the power shelf as described below Note The controller module ships installed in the rectifier shelf Push fi...

Page 99: ... Follow the manufacturer guidelines and local safety practices CAUTION Electrical chemical fire and heat hazard Handle batteries with care to avoid personal injury or damage to the equipment WARNING Electrical hazard Batteries contain a stored charge Only a qualified technician should perform this procedure To prepare batteries for installation Unpack the batteries from the shipping packaging Remo...

Page 100: ... the solar shield At the front of the seismic retaining bracket disconnect the 8 AWG battery power cables from the power supply leads if connected Open the latch on each side of the terminal cover and remove the cover Remove the seismic retaining bracket from the internal battery enclosure as follows a Remove the 2 hex head screws and washers from each side of the retaining bracket b Rotate the re...

Page 101: ...be cable lug onto the string s negative terminal post at the left end of the string e Tighten the hardware on the terminal posts to the torque specified by the manufacturer f If available install protective covers manufacturer supplied over the battery terminals Replace the retaining bracket and terminal cover Connect the Anderson power connectors together To connect a temperature probe cable to t...

Page 102: ...wer up and operation You can modify the settings for system voltages battery configuration temperature compensation and so forth if required For programming instructions refer to the Alpha Cordex Controller Software Manual Verify that the rectifier shelf controller has acquired the rectifier modules as follows a Connect a laptop to the CXCM1 Ethernet port using a standard network cable b Laptop IP...

Page 103: ...n the System screen System View Live Status check that the installed rectifiers have been acquired by the controller by verifying the number associated with Acquired Rectifiers Note Alarm conditions may be present and will not clear due to no load conditions Step 5 At the 20 position fuse panel do the following Install a 2A GMT fuse in position 20 and verify that the heat exchanger fans start runn...

Page 104: ...tery 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 Measure the voltage difference between the power system and the battery string The voltage difference should be less than 3V If the voltage difference is greater than 3V check for connection integ...

Page 105: ...er Battery Configuration Settings and Alarm Values Note Assumption is that the controller s IP address is defaulted to the factory IP address of 10 10 10 201 Also we highly recommend that the controller s software version is the latest released version The latest software released can be down loaded here http www alpha ca support support main menu software firmware downloads Connecting to the CXCM...

Page 106: ...sername Your initials or other unique identifier Password 1234 Changing the battery configuration parameters a Navigate to Batteries Configure Batteries b In the Battery Properties section enter the battery string capacity into the Capacity Rating box Battery Type Capacity Value Ah for One String Northstar NSB60FT Red 68 Enersys SBS B14 68 Northstar NSB100FT Red 106 Northstar NSB170FT Red 180 Ener...

Page 107: ...V B April 2019 Battery Type Temperature Compensation Slope Northstar NSB60FT Red 2mV deg C Cell 1 1mV deg F Cell Enersys SBS B14 4mV deg C Cell 2 2mV deg F Cell Northstar NSB100FT Red 2mV deg C Cell 1 1mV deg F Cell Northstar NSB170FT Red 2mV deg C Cell 1 1mV deg F Cell Enersys SBS 190F 4mV deg C Cell 2 2mV deg F Cell c In the Temperature Compensation section enter temperature compensation slope i...

Page 108: ...Installation Manual __________________________________________________________ Battery Type Peukert Value Northstar NSB60FT Red 1 156 Enersys SBS B14 1 130 Northstar NSB100FT Red 1 131 Northstar NSB170FT Red 1 128 Enersys SBS 190F 1 113 d In the Battery State of Charge Estimation section enter the peukert number in the Peukert Number box ...

Page 109: ...pensation section enter the upper lower temperature breakpoint temperature and voltage in the respective boxes Battery Type Upper Temperature Breakpoint Lower Temperature Breakpoint Temperature in C in F Voltage Temperature in C in F Voltage Northstar NSB60FT Red 50 122 53 28 10 50 55 2 Enersys SBS B14 50 122 52 08 10 50 55 92 Northstar NSB100FT Red 50 122 53 28 10 50 55 2 Northstar NSB170FT Red 5...

Page 110: ...900 Installation Manual __________________________________________________________ f In the Charge Current Control section the charge rate can be entered either in terms of Charge Rate Amps or the C X charge rate Enter the desired charge rate in either format into the respective box g Ensure the Enable Primary CCC check box is checked ...

Page 111: ...ng the alarm setting a Navigate to Alarms Configure Alarms b In the Alarm Configuration drop down box select Voltage Alarms c Enter the High Voltage 1 and High Voltage 2 in the Activation Value box Alarm Name Activation Value High Voltage 1 56 5 High Voltage 2 56 6 Rectifier Setting Name Value Float Voltage 54 48 Equalize Voltage 56 3 OVP 57 7 LVA 46 0 HVA 56 5 d Navigate to Rectifiers Configure R...

Page 112: ...tion Manual __________________________________________________________ Step 4 Submitting and saving the changes a At the top left side of the page click the Submit Changes button A pop up window will be displayed compar ing the old settings and the new settings b Select all the changes and click the Accept button to save all the necessary changes ...

Page 113: ...Topics Covered This chapter covers the following topics Installing a protection mounting frame Installing a protection block Installing a cross connect panel Installing an external splice compartment Installing an battery enclosure Installing a battery heater Installing a power buffer capacitor Installing a generator connector Installing a heat exchanger door Installing fiber management options In...

Page 114: ...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 2 knobs on the frame counter clockwise to the latch s disengaged position b Position the frame against the rack oriented with the hinge on the right side Note To correctly align the frame for mounting the hinge must align with mounting holes on the right...

Page 115: ...fica tion labels cover the dead pair positions 25 and 50 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 interface cables two with MS2 or 710 connectors two with RJ 21 connectors In the cabinet or EXM locate the next open position on the protection mounting frame then feed the block s i...

Page 116: ...s provide a critical ground path to the cabinet s main ground bar or EXM s subground bar Terminate the protection block interface cables as follows a Route the two RJ 21 equipment interface cables into the main compartment and connect to the Clearfield service unit s RJ 21 connectors b Mate the two MS2 or 710 subscriber interface cables to the counterpart OSP interface cables c Dress and secure th...

Page 117: ...net s copper line protection and the OSP subscriber side cables Clearfield recommends performing the installation during a maintenance window to minimize the service impact CAUTION Installing a cross connect panel requires safe handling to ensure that no injury to personnel or damage to equipment occurs To install a cross connect mounting frame Unpack the cross connect mounting frame from the ship...

Page 118: ... panel Unpack the cross connect panel from the shipping package and open the EXM door Mount the test tool holder on the 4 studs located on the interior door and secure using 4 Keps nuts Note One test tool holder ships with each cross connect panel only one test tool holder is required per enclo sure At the right side of the cross connect frame partially insert 4 self tapping screws leaving a 25 in...

Page 119: ...the equipment cables The cables are labeled Subscriber and Equip ment Note To ease installation it may be advantageous to remove some of the cable bundle tie wraps in some applications b Orient the panel face down with the bottom of the panel toward the rear of the enclosure and then route the cables under the cross connect frame c Lay the cross connect panel on the pad Terminate the cables as fol...

Page 120: ...with tie wraps against the rear wall Install the cross connect panel as follows a Lift the panel up toward the frame and slide the panel keyholes over the 4 screws that were pre installed in step 3 b Use a long extension power drill to tighten the screws Remove the pad from the base of the enclosure Repeat steps 2 8 to install a second cross connect panel adjusting the steps as necessary to instal...

Page 121: ...sconnect boxes to customer supplied Unistrut metal framing installed on the exterior of the cabinet Use the 6 mounting studs located on the left side wall to the right of the access panel to install the Unistrut For AC wiring information refer to the AC wiring diagram on the inside cabinet wall DANGER High voltage may be present Only a qualified electrician should install an AC meter Follow NEC an...

Page 122: ...net battery riser or the EXM Place the battery enclosure in base of the FAC 900 battery riser or EXM aligning the mounting bracket holes against the counterpart holes on the equipment rack Install the eight mounting screws 4 per side to secure the enclosure to the rack Tighten the screws to 45 in lbs of torque enclosure for VRLA battery string shown below Ensure that the front bottom edge of the e...

Page 123: ...sure Unpack the battery heater from the shipping packaging Open the side cabinet door Install the mounting bracket for the battery heater jumper cable as follows a Position the bracket against the left equipment rack aligning the bottom bracket hole with the counterpart hole on the rack immediately above the internal battery enclosure b Install 2 mounting screws to secure the bracket to the rack R...

Page 124: ... the black wire and then connect the terminated black wire to the load terminal of the 5A Battery Heater breaker d Connect the white lead to the Batt Htr position on the panel board Neutral bar Note An AC wiring label is attached behind the load center front panel for reference e Tighten the cord grip around the jumper cable at the rear of the load center AC junction box Install the battery heater...

Page 125: ...osure b Install 2 mounting screws to secure the bracket to the rack Install the second string battery heater jumper cable as follows a Locate the battery heater power cable installed in the primary FAC 900 battery enclosure b Disconnect the primary battery heater power cable connector from the panel mounted connector located on the mounting bracket above the FAC 900 battery enclosure c Connect the...

Page 126: ...om face down and the power and ground wires on the left side b Route the heater power and ground wires through the left rear hole of the battery enclosure c Drop the heater into place over the plastic insulator Connect the heater power and ground wires as follows a Route the ground and power wires from the rear of the battery enclosure to the mounting bracket installed in step 3 b Attach the groun...

Page 127: ...tch disconnect AC power to the 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 front cabinet door Install a circuit breaker for the Gen Conn circuit into the load center as follows a Remove the right panel from the AC load center b At the AC load center switch the Gen Conn if p...

Page 128: ...xture c Install the 4 tamper resistant screws removed previously to attach the generator connector Connect the generator connector wires to the AC load center as follows a Route the generator connector wires through the access hole in the right side of the AC load center b Terminate the generator connector wires to the load center as follows Connect the green wire to the ground bar Connect the whi...

Page 129: ...front door is equipped with an integrated heat exchanger to cool equipment inside the cabinet Installing a heat exchanger door in the field may become necessary if the existing door becomes damaged or the heat exchanger fails or becomes damaged To install a heat exchanger door on an FAC 900 cabinet Remove the existing door that is to be replaced See Removing a Cabinet Door for instructions Install...

Page 130: ...thout internal bat tery enclosure installed The EXM supports equal fiber distribution configurations Fiber management solutions include 96 and 192 position fiber distribution frames each supporting two 48 fiber or two 96 fiber termination assemblies respectively with pre terminated 100 foot OSP fiber cable for high density point to point Ethernet and GPON applica tions Up to eighteen integrated 1 ...

Page 131: ...assemblies are offered as field installed options only Fiber distribution frames and fiber management accessories are offered as factory integrated and field installed options You can order and install individual components to scale support as required Additionally the field installable EXM provides the ability to grow the FAC 900 cabinet to support rack space for additional fiber distribution end...

Page 132: ...ng items fiber staging area conduit mounting bracket conduit 2 conduit fittings and twine Open the cabinet s side door or EXM door Install the splitter cage assembly as follows a Orient the assembly with the fiber tray in the front b Position the assembly against the rear inside of the equipment rail and the top of the assembly flush against the roof of the enclosure c Align the assembly mounting ...

Page 133: ... Manual 020420 REV B April 2019 d While holding the bulkhead against the rack install up to six mounting screws 3 per side to secure the bulkhead to the rack Tighten the screws to 45 in lbs of torque e To install an additional bulkhead frame s Orient the bulkhead with the fiber spool on the left Position the bulkhead flush under the installed bulkhead and against the front equipment rail Repeat st...

Page 134: ...al power meter to identify active fibers Never assume laser power 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...

Page 135: ...feed approximately 20 feet of twine through the conduit b Secure the twine to the inside of each conduit fitting with tape Skip this step if your cabinet was shipped with the splitter integration kit installed Install the conduit mounting bracket in the cabinet as follows a Locate the conduit mounting bracket set aside previously b Position the bracket against the back of the front equipment rail ...

Page 136: ...e conduit in the enclosure as follows a Orient a conduit fitting toward the mounting bracket in the FAC 900 b Feed the twine through the mounting bracket c Insert the conduit fitting into the mounting bracket until it snaps in place d Route the other end of the conduit to the mounting flange located behind the bulkhead frame in the FAC 900 or through the access panel on the rear cabinet wall and t...

Page 137: ...nduit b Route one end of the twine along the outside of the conduit until the end c Tie the ends of the twine together with a looped knot similar to a bowline knot or fisherman s knot Feed the fiber jumpers through the conduit as follows Note You may feed the first few fiber jumpers through the conduit without using the fiber pull a Secure a fiber jumper to the fiber pull for example tie the loop ...

Page 138: ...h in place from the opposite side of the conduit Connect the fiber jumper to the SC adapter plate as follows a At the SC adapter plate locate the OLT side fiber red SC connector b Route the fiber jumper from the conduit through the SC adapter plate mounting fixture in the bulkhead frame c Connect the fiber jumper to the corresponding SC connector on rear of the adapter plate Connect the fiber jump...

Page 139: ...ation requires simply mounting the termination assembly on the bulkhead frame and then routing the OSP cable to the fiber routing duct and then outside of the cabinet to interface to the outside plant fiber facilities such as in a fiber hand hole To install a fiber termination assembly Unpack the bundled fiber termination assembly from the shipping packaging Locate the machine screws to install th...

Page 140: ...________________________ Step 4 Step 5 d Install machine screws to secure the assembly in place e To install additional fiber termination assemblies repeat steps 2a 2d Feed the OSP fiber cable down into one of the cabinet s cable entry conduits and out of the cabinet to the external splicing location Repeat the steps above to install additional bundled fiber termination assemblies as needed ...

Page 141: ...eld CAUTION A Class 1 laser product with an internal Class IIIb hazard is used in this equipment Use an optical power meter to identify active fibers Never assume laser power 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 avoi...

Page 142: ...e bracket against the rack install the mounting screw to secure the staging area to the rack Tighten the screws to 45 in lbs of torque e Place the foam staging plate in the bracket Pull on the 2 push pins on each side of the SC adapter plate and remove the plate from the mounting fixture Identify the next available position in sequence on the adapter plate and remove the dust cover Place the adapt...

Page 143: ...iber Route and terminate the 2 16 or 32 PON side fibers from the splitter to the fiber staging plate EXM shown below Route each PON side fiber from the staging plate to the appropriate position on the fiber assembly and ter minate the fiber Begin with the lower right assembly and then proceed to the lower left assembly populating each assembly in sequence with the top left assembly populated last ...

Page 144: ... terminating all PON side fibers install the first splitter terminated to the top left fiber termination assembly as follows a Dress the fibers from the termination assembly to the left and through the dressing spools as desired allow ing adequate slack b Route the fibers and splitter from the dressing spools to the fiber ramp above the fiber distribution bulk head c Insert the splitter into the n...

Page 145: ...___________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 020420 REV B April 2019 d Repeat steps 9a 9c to install the remaining splitters from left to right until you reach the top left assembly ...

Page 146: ... Step 11 Reinstall the SC adapter plate as follows a Feed the fibers on the rear of the adapter plate through the mounting fixture into the area behind it b Position the adapter plate against the mounting fixture c Align the two push pins on the adapter plate with the holes on the mounting bracket d Push the push pins to secure the adapter plate in place e Neatly dress any slack OLT side fiber alo...

Page 147: ...the Clearfield Clearview xPAK Installation Note LGX option Metal LGX cases 6 position SC or LC connector options or 12 position LC connectors Clearview assemblies with pre terminated 100 foot OSP fiber cable To install a dual LGX fiber distribution panel into an FAC 900 cabinet Unpack the fiber distribution panel from the shipping packaging Mount the LGX case s in the fiber distribution panel as f...

Page 148: ...________________________________________________________ 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 149: ...fter cleaning the surface and removing rust Note damage to the metal work If the damaged area interferes with operation of the cabinet or electronics contact Clearfield support for assistance with a resolution Clean all surfaces so that they are free of dirt dust and foreign material Remove all material from air intake screens and louvers i e spider webs leaves etc Clean the air vents on the heat ...

Page 150: ...ior to servicing Check the heat exchanger for proper functioning at least once a year Verify that no fan failure ENV alarms are present on the Clearfield equipment Verify fan operation including visual inspection the following Verify that all fans are spinning with no obstructions or odd noises Verify that the heat exchanger is secured to the cabinet and all gasket material is intact and adhered t...

Page 151: ...chnician 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 continuity in the event of an AC outage connect an external generator to the cabinet while performing battery maintenance Open the side cabinet door Open the latch on each side of the terminal cover and remove...

Page 152: ...s 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 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 housing for any signs of d...

Page 153: ...acing a cabinet door may become necessary if A door becomes damaged The heat exchanger fails or becomes damaged You can replace cabinet doors in the field without impacting service CAUTION Handle detached cabinet doors with care to avoid personal injury or damage to the door To remove a cabinet door For a door equipped with a heat exchanger disconnect the heat exchanger cable Disconnect the ground...

Page 154: ... away from the cabinet Installing a Cabinet Door Unpack the new door from its shipping packaging Remove the pins from the new door s hinges a Top hinge Lift 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 Lift up on the pin lever until the pin slides...

Page 155: ...ow If the cabinet is equipped with charged batteries this procedure does not affect service DANGER High voltage may be present Only a qualified electrician should perform this task Follow NEC and local 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 th...

Page 156: ...tifier is plug and play When a rectifier module is added to the system the Controller will detect and update the in ventory automatically However replacing an installed rectifier requires a manual Inventory Update at the controller to clear the removed rectifier from its current list of rectifiers To remove a module push up on the locking clip release and slide the module out of the shelf At the c...

Page 157: ...at 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 cabinet while performing battery maintenance To replace batteries Open the side FAC 900 cabinet or EXM front door Open the latch on each side of the terminal cover and remove the cover Remove the seismic retain...

Page 158: ...mic retaining bracket from the internal battery enclosure as follows a Remove the 2 hex head screws and washers from each side of the retaining bracket b Rotate the retaining bracket forward and lift the bracket from the groove at the base of the battery enclo sure If batteries are present remove the batteries from the battery enclosure See Replacing Batteries for removal instructions Unplug the h...

Page 159: ...B April 2019 Appendix A Reference Information This appendix provides general reference information about the FAC 900 cabinet Topics Covered This appendix covers the following topics Cabinet specifications Support matrix for Clearfield service units Optional Alpha Cordex HP rectifier alarms and controller settings Optional Emerson rectifier alarm matrix Optional Emerson rectifier setpoints Supporte...

Page 160: ...nits or third party equipment Rack attributes 19 inch EIA standard oriented for vertical mounting Environmental Heat exchanger Door mounted Internal fan Tmin 30C 50 RPM and Thigh 45C 100 RPM External fan Tstop 30C Tmin 40C 50 RPM and Thigh 55C 100 RPM Cooling capacity 47 Watts C Thermal operating range 40C to 46C Environmental alarming Environmental Electrical Local Power AC load center 208 240 VA...

Page 161: ...uipment shelf as well as parameters and default settings for the Alpha rectifier shelf controller refer to the Cordex HP Rectifier Controller Default Configuration document or for more detailed information refer to the Alpha Cordex Controller Software Manual both available from My Clearfield online seeclearfield com Supported Batteries The FAC 900 supports the following batteries For a list of bat...

Page 162: ... 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 an...

Page 163: ...quipment 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 nee...

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