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FieldSmart

FiberFlex 2000

Installation Manual

_________________________________________________________

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

Table of Contents

About This Guide

Chapter 1: FiberFlex 2000 Product Overview

Cabinet Description

Cabinet Features

Cabinet Options

Cabinet Dimensions and Weights

Cabinet Views

Chapter 2: Installation Considerations

Installation Process Overview

Installation Guidelines

Space Requirements

General Safety Recommendations

Installation Kit

User-Supplied Items

Cabling Requirements

Chapter 3: Preparing the Installation Site

Installing a Ground Circuit

Constructing a Concrete Pad

Pad Construction Guidelines

Assembling the Cast-In-Place Template

Preparing the Site

Casting the Pad

Installing a Pre-Cast Concrete Pad

Pre-Cast Pad Requirements

Preparing the Site

Installing a Pre-Cast Pad

Installing a Foundation Vault

Foundation Vault Requirements

Preparing the Site

Installing the Foundation Vault

Содержание FieldSmart FiberFlex 2000

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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