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FieldSmart

FiberFlex 2000

__________________________________________________________

Installation Manual

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

Manual 021574 REV A - June 2020

Eltek FPS Rectifier Alarm Matrix

The Eltek FPS rectifier shelf detects multiple alarm conditions on the cabinet power system, but reports an umbrella Power

Major (Power MJ) alarm to the E7-2, B6-001, and E5-100. The following table lists potential alarm conditions on the Eltek

FPS shelf that report to the service units as Power MJ.

Summary of Contents for FieldSmart FiberFlex 2000

Page 1: ...FieldSmart FiberFlex 2000 Installation Manual _______________________________________________________ Manual 021574 Rev A May 2020...

Page 2: ...llation Process Overview 14 Installation Guidelines 15 Space Requirements 16 General Safety Recommendations 17 Installation Kit 18 User Supplied Items 19 Cabling Requirements 20 Chapter 3 Preparing th...

Page 3: ...tside Plant Cables 53 Bonding Cable Sheaths 54 Installing Fiber Cable 55 Installing Outside Plant Fiber Cable 55 Splicing Fibers 56 Connecting Fibers to the Equipment 56 Sealing Cable Entry Locations...

Page 4: ...aintenance 86 Replacing Parts and Equipment 88 Removing a Cabinet Door 88 Installing a Cabinet Door 89 Replacing the Cabinet Roof 91 Replacing AC Breakers 92 Replacing Rectifier Modules 93 Replacing B...

Page 5: ...nable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and u...

Page 6: ...provides a general description of the Clearfield FiberFlex 2000 outdoor cabinet including its standard features and options Topics Covered This chapter provides a general description of the Clearfiel...

Page 7: ...fice The FiberFlex 2000 cabinet has a single compartment that houses active electronic equipment together with various fiber terminations enabling deployment of multiple applications from one node The...

Page 8: ...om 40C to 46C per GR 487 specifications Equipment Support 19 inch equipment rack provides 4 RU of mounting space Mechanical support for fiber terminations 20 RU Door mounted 750W heat exchanger Power...

Page 9: ...template Foundation vault mounting third party supplied Fiber Management High density fiber management options 144 and 288 fiber distribution panels 1 32 PON splitters management accessories up to 57...

Page 10: ...h Clearfield 10 Cabinet Dimensions and Weights The external dimensions of the FiberFlex 2000 cabinet are shown below Dimension Measurement SAE Measurement Metric Height 54 inches 137 cm Width 24 inche...

Page 11: ...REV A June 2020 Cabinet Views Views of the FiberFlex 2000 cabinet follow Front Compartment The front compartment provides access to the electronics equipment cabinet power system and fiber management...

Page 12: ...y Information Not for use or disclosure except by written agreement with Clearfield 12 Battery Compartment Configured cabinets include a battery base compartment for housing one string of front access...

Page 13: ...ne 2020 Chapter 2 Installation Considerations This chapter provides general considerations for cabinet installation Review this information before starting the cabinet installation process Topics Cove...

Page 14: ...____________________________________________________ Proprietary Information Not for use or disclosure except by written agreement with Clearfield 14 Installation Process Overview The cabinet installa...

Page 15: ...tial sites for subsurface conditions Grounding properties Grounding properties The earth at the cabinet location should have a low ground impedance to provide an effective grounding system for lightni...

Page 16: ...ent with Clearfield 16 Space Requirements The illustration below shows the cabinet clearance and space requirements The minimum clearance area around the cabinet site must be free of permanent impedim...

Page 17: ...form the procedures described in this doc ument These procedures involve potentially hazardous activities including handling of heavy equipment and exposure to high electrical energy which could cause...

Page 18: ...llation Kit Clearfield supplies an installation kit with the cabinet that includes materials required for installation The installation kit contents are listed below Check to verify that your kit cont...

Page 19: ...ith universal socket and screwdriver bit sets Socket wrench nut driver set standard Box wrench set standard Screwdriver set standard Beam Level Insulated needle nose pliers Wire stripper Compression c...

Page 20: ...es 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 Facil...

Page 21: ...vault For pad mount applications you can construct a concrete pad using the Clearfield cast in place template or use a pre cast concrete pad A composite foundation vault available from a third party s...

Page 22: ...EC 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 gr...

Page 23: ...lation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 021574 REV A June 2020 Example of PANI compliant ground ring with main site ground buss Exampl...

Page 24: ...nitial 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 to...

Page 25: ...ocations Pad Construction Guidelines When constructing a concrete pad observe the following guidelines and refer to the pad drawings for guidance Follow these guidelines to ensure proper pad construct...

Page 26: ...anual __________________________________________________________ Proprietary Information Not for use or disclosure except by written agreement with Clearfield 26 Pad Drawings Use the following drawing...

Page 27: ...techsupport clfd net Manual 021574 REV A June 2020 Pad Cross Section from left side For proper cable entry into the cabinet place conduit into the following locations a Conduit for outside plant cabl...

Page 28: ...ipping kit Place the four bracket members on the ground arranged as follows Place the two long brackets parallel with each other flat side down Place the two short brackets between and perpendicular t...

Page 29: ...above the form Verify that the form remains level across the entire surface Adjust as required Pull the earth ground wire from the conduit trench through the entry duct in the template allowing at lea...

Page 30: ...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 the remaining steps...

Page 31: ...ounting fixtures 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 suppli...

Page 32: ..._____ Proprietary Information Not for use or disclosure except by written agreement with Clearfield 32 Pad Drawings Use the following drawings for reference during site preparation Actual pad dimensio...

Page 33: ...ional 800 422 2537 www SeeClearfield com techsupport clfd net Manual 021574 REV A June 2020 Pad Cross Section from left side For proper cable entry into the cabinet place conduit into the following lo...

Page 34: ...lace 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 ins...

Page 35: ...l 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...

Page 36: ...nting fixtures 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 certi...

Page 37: ...location Place the cable conduits into the conduit trench Refer to the vault guidelines for conduit sizes and locations Route the earth ground wire through the conduit trench from the ground electrod...

Page 38: ...vault positioning on the gravel base until it is stable and level Backfill and grade around the vault perimeter with soil to secure it in place Verify that the vault remains level Adjust as required...

Page 39: ...ing the Cabinet This chapter describes how to install the Clearfield FiberFlex 2000 cabinet onto its permanent mounting location Topics Covered This chapter covers the following topics Installing a gr...

Page 40: ...losed 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 Howeve...

Page 41: ...key Each door is equipped with an alarm switch that monitors the position of the door When a door on an in service cabinet is opened an intrusion alarm reports through the equipment Pull the switch p...

Page 42: ...telco hex key into the door s hex pin latch Turn the key counter clockwise to disengage the latch Tilt and pull the door panel forward away from the cabinet Step 1 Step 2 Step 3 To open a battery comp...

Page 43: ...nter s front breaker panel and then remove the panel from the load center housing Retain the hardware for re installation b Loosen the coupling nut at the bottom of the housing to allow AC wires to pa...

Page 44: ...r hooks Do not disconnect the slings from the cabinet until after it rests securely on the pad CAUTION Installing the cabinet requires safe handling to ensure that no injury to personnel or damage to...

Page 45: ...irectly above its mounting position on the pad Step 1 Step 2 Step 3 To install the cabinet or riser on a concrete pad Note The following procedure also applies to installing the optional battery compa...

Page 46: ...tallation kit b Install one 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...

Page 47: ...etails attached to the upper left corners of the left and right sides of the cabinet Remove the three bolts securing the first lifting detail to the cabinet Remove and discard the lifting detail Inser...

Page 48: ...48 Chapter 5 Installing Local AC Power This chapter describes how to install AC local power to the cabinet This process includes installing the cabinet earth ground connection and installing and wirin...

Page 49: ...ain earth ground that connects to the ground field should bisect the main ground bar effectively separating ground termination positions into two zones as follows Isolated Ground Zone IGZ equipment gr...

Page 50: ...tach 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 groun...

Page 51: ...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...

Page 52: ...r supplied AC conduit into the load center Install the conduit per local practice Make sure the conduit is rated for AC cabling Pull the AC wires 8 10 AWG into the AC load center Connect the AC wires...

Page 53: ...eClearfield com techsupport clfd net Manual 021574 REV A June 2020 Chapter 6 Installing Outside Plant Cables This chapter describes how to install outside plant cables into the cabinet including fiber...

Page 54: ...et enclosure grounding system bond to the same point on the main site ground bar SPGP or equivalent that the cross connect bonds to Bond the metallic sheaths of all optical cables to a grounding rod o...

Page 55: ...r management guidelines When installing splicing and routing fibers in the cabinet follow these guidelines Avoid tight bend radii for fibers and provide adequate strain relief Dress and secure fiber j...

Page 56: ...finished splices and slack fiber in the splice tray Replace the splice tray into position on the cabinet wall Dress any slack fiber from the pigtails or jumpers around the dressing assembly below the...

Page 57: ...tment riser door Adjust or trim the rubber cone gaskets on the cable entry ducts to create a tight seal around the cables as required If required prepare the sealant for application per the manufactur...

Page 58: ...net 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 re...

Page 59: ...er 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 imped...

Page 60: ...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 reads between 110 and 120 VAC Using a volt meter test between...

Page 61: ...itions for equipment and one 40 Amp circuit breaker for batteries The Eltek shelf is equipped with a Smartpack S controller module that monitors power functions and alarm information and regulates vol...

Page 62: ...ed charge Only a 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 Unpa...

Page 63: ...ries into the battery tray after installing the cables and protective covers Connect the battery power cables as follows a Remove the protective caps from the cable ring lugs b Attach the black cable...

Page 64: ...If the voltage difference is greater than 3V check for connection integrity replace bad battery cell as applicable and retest the voltage Reconnect the battery power cables to the power supply leads...

Page 65: ...er compartment In the riser compartment route the battery supply leads along the sides of the battery tray and then arrange a string of four batteries with the terminals accessible in front Note You w...

Page 66: ...nnection integrity replace bad battery cell as applicable and retest the voltage Reconnect the battery power cables to the power supply leads Install the protective covers manufacturer supplied over e...

Page 67: ...on the terminal posts to the torque specified by the manufacturer Install three jumper cables between the battery terminal posts using the supplied flat washers split lock washers and bolts Check for...

Page 68: ...so forth if required For programming instructions refer to the Eltek Smartpack S Controllers User Guide At the rectifier shelf open the fuse panel door and do the following a To apply power to the fir...

Page 69: ...attery 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...

Page 70: ...ns and Adding Capacity This chapter describes how to install optional equipment and components into the cabinet including expansion components to increase system capacity The cabinet allows for modula...

Page 71: ...Install the FiberFlex 2000 cabinet onto the riser compartment as follows a Lift the cabinet onto the riser keeping the 4 anchor holes in the cabinet base aligned with the counterpart holes in the ris...

Page 72: ...controlled by a thermostat set for the following operation 4 C Battery heater turns On 16 C Battery heater turns Off Note The battery heater sits directly underneath the battery string so you must in...

Page 73: ...Manual 021574 REV A June 2020 b Adhere the battery warmer to the inside of the battery warmer mount plate c Attach the battery warmer ground wire to the battery warmer mount plate ground stud using wa...

Page 74: ...ly to the white black and green cables of the provided AC power cords using 3x wire nuts f Install the battery warmer assembly in the battery base on top of the plastic pad with the assembly towards t...

Page 75: ...e AC Load Center ACLC as follows a Remove the ACLC face plate Remove the knockout from the ACLC face plate Location 8 for the 1st battery warmer breaker and Location 10 for the 2nd battery warmer brea...

Page 76: ...back along the cable out of the way c Run the AC power cords through the cabinet and into the ACLC The thick jacket of the cable should extend into the ACLC by 1 2 d Push the grommet down the cable t...

Page 77: ..._____________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 021574 REV A June 2020 f Attach the black wire to the 15A...

Page 78: ...slack trays pre installed Install splitters and route the splitter legs as shown Pictured is the interior of the FiberFlex 2000 loaded with two 288 panels and both slack trays installed Step 1 Instal...

Page 79: ...the slots on the splitter tray with the splitter legs facing towards the back of the cabinet Use velcro to hold the splitter body s in place c Using velcro or curly locks installed into the interior...

Page 80: ...under over the horizontal radius finger attached to the side of the slack tray before traveling upwards downwards between the two vertical rows of radius fingers c Route the splitter leg through the g...

Page 81: ...eld com techsupport clfd net Manual 021574 REV A June 2020 Chapter 9 Cabinet Maintenance This chapter describes how to perform cabinet maintenance including routine maintenance and corrective maintena...

Page 82: ...ine Maintenance This section describes how to perform routine maintenance on the cabinet Checking Cabinet Surfaces Clean and inspect the cabinet for contaminants damage and wear once a year Items to c...

Page 83: ...load center Verify that the operational indicators are lit Check the GFCI convenience outlet Test the outlet per local code Check the controller module on the rectifier shelf Verify that the controlle...

Page 84: ...be repaired or replaced per local practice Check all outside plant copper connections for complete and secure connection Ensure that all cable management accessories provide a clean appearance Replac...

Page 85: ...leaning based on the environmental conditions typically once a year Verify that no debris is blocking the inlet and outlet vent screens Place a piece of paper against the inlet vent and verify that th...

Page 86: ...while performing battery mainte nance to ensure service continuity in the event of an AC outage CAUTION Electrical chemical fire and heat hazard Handle batteries with care to avoid personal injury or...

Page 87: ...b Ensure that each battery provides 13 5 VDC plus or minus 2 VDC c Clean each battery to remove dust dirt or corrosion from the battery surface Note Only use water for cleaning the battery surface Do...

Page 88: ...ree nuts securing the wind brace bracket to the door Save the nuts to re attach the bracket to the new door b Detach the wind brace bracket from the three studs on the door Step 1 Step 2 Step 3 To rem...

Page 89: ...inge 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 fr...

Page 90: ...n 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...

Page 91: ...ard the front of the cabinet as far as it will go Using an offset screwdriver remove the screw in the interior roof above the mounting frame Remove the 3 remaining screws in each corner of the interio...

Page 92: ...tore 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 t...

Page 93: ...r module into the vacated slot b Push firmly on the module to seat it in the slot Repeat Steps 1 and 2 to replace an additional rectifier module Step 1 Step 2 Step 3 As each rectifier module is instal...

Page 94: ...the orange tab in and then insert the alarm wire in the connector Holding the wire in place release the orange tab c Connect the temperature probe cable as follows Connect the red alarm wire to P1 PI...

Page 95: ...hsupport clfd net Manual 021574 REV A June 2020 Eltek FPS Rectifier Alarm Matrix The Eltek FPS rectifier shelf detects multiple alarm conditions on the cabinet power system but reports an umbrella Pow...

Page 96: ..._______________________________________________ Proprietary Information Not for use or disclosure except by written agreement with Clearfield 96 Eltek FPS Rectifier Controller Settings The default set...

Page 97: ...rt FiberFlex 2000 __________________________________________________________ Installation Manual Direct 763 476 6866 National 800 422 2537 www SeeClearfield com techsupport clfd net Manual 021574 REV...

Page 98: ...ieldSmart FiberFlex 2000 Installation Manual __________________________________________________________ Proprietary Information Not for use or disclosure except by written agreement with Clearfield 98...

Page 99: ...ove an old 155 Ah battery string a Disconnect the battery power cables from the power supply terminals b Slide the batteries out of the battery compartment c Remove the protective covers from the batt...

Page 100: ...Operating Cabinet Doors for instructions If present remove the batteries from the battery compartment See Replacing Batteries for battery removal instructions Remove the battery heater from the batter...

Page 101: ...rfield com techsupport clfd net Manual 021574 REV A June 2020 Appendix A Reference Information This appendix provides general reference information about the FiberFlex 2000 cabinet Topics Covered This...

Page 102: ...rent 40 Amps 2 modules or 20 Amps 2 modules N 1 Battery Capacity Designed to accommodate 2 strings of Northstar NSB 155FT RED batteries One string support in the standard battery compartment Dual batt...

Page 103: ...Batteries The FiberFlex 2000 supports the following battery string with the 60 Ah battery base 2 strings are supported when the cabinet is equipped with an optional battery compartment riser Wiring D...

Page 104: ...rfield 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...

Page 105: ...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...

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