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Clearfield FieldSmart Fiber Active Cabinet 400 Installation Manual

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FieldSmart
Fiber Active Cabinet (FAC) 400
®
Installation Manual
______________________________________________________
Manual 020419 REV A - Feb 2019

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Summary of Contents for Clearfield FieldSmart Fiber Active Cabinet 400

  • Page 1 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual ______________________________________________________ Manual 020419 REV A - Feb 2019...

  • Page 2: Table Of Contents

    Preparing the Site Installing the Pole-Mount Kit Installing a Wall-Mount Kit: Local Power with 60 Ah Battery Base(s) Wall/H-Frame Mounting Guidelines Preparing the Site Installing the Wall-Mount Kit Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 3 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Installing a Foundation Vault Foundation Vault Requirements Preparing the Site Installing the Foundation Vault Chapter 4: Installing the Cabinet Unpacking the Cabinet Operating Cabinet Doors Preparing the Cabinet for Installation Installing the Cabinet on a Concrete Pad Installing the Cabinet on a Wall or H-Frame Installing the Cabinet on a Pole: Local Power with 60 Ah Battery...
  • Page 4 Replacing a Battery Heater Appendix A: Reference Information Specifications Optional Alpha Cordex HP Rectifier Alarms and Controller Set- tings Supported Batteries Wiring Diagrams Standard Warranty Proprietary Notice Technical Support Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 5: About This Guide

    __________________________________________________________ About This Guide This document provides a general installation practice for the Clearfield FAC 400 outdoor cabinet. This document also provides a general description of the cabinet and its subsystems, guidance for planning, site preparation, power installation, splicing to the outside plant, component installation and expansion, and cabinet maintenance.

  • Page 6: Chapter 1: Fiber Active Cabinet 400 Product Overview

    Installation Manual _________________________________________________________ Chapter 1: Fiber Active Cabinet 400 Product Overview This chapter provides a general description of the Clearfield FAC 400 outdoor cabinet, including its standard features and options. Topics Covered This chapter provides a general description of the Clearfield FAC 400 outdoor cabinet, including its standard features and options.

  • Page 7: Cabinet Description

    __________________________________________________________ Cabinet Description The Clearfield FAC 400 cabinet is an environmentally-controlled outdoor enclosure designed to house and protect network electronics equipment. Use the FAC 400 to provide services from a remote node location deep inside the customer serving area, beyond the direct reach of the carrier Central Office.

  • Page 8: Cabinet Features

    Low voltage DC disconnect (-42 VDC) • Battery backup in separate vented compartment • Up to 62 Ah battery reserve capacity (breaker-protected); up to 124 Ah capacity with second-string riser option Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 9: Cabinet Options

    Cabinet Options Common options for the FAC 400 cabinet include: Enclosure Mounting • Concrete pad mounting: pre-cast or site-cast pad (using Clearfield pad template) • Pole, wall, or frame mounting (using Clearfield mounting kits) • Foundation vault mounting (third-party supplied) Copper Protection &...

  • Page 10: Cabinet Dimensions And Weights

    The approximate weight of the FAC 400 cabinet is shown below. Configuration Weight (SAE) Weight (Metric) Local power (60 Ah batteries), 96 copper lines 222 lb 101 kg Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 11: Cabinet Views

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Cabinet Views Views of the FAC 400 cabinet follow. Front Compartment The front compartment provides access to the electronics equipment, cabinet power system, and fiber management or copper line protection. The cabinet power system consists of an AC load center. For fiber access, the fiber management accessories may vary greatly according to the ordered options.
  • Page 12 Note: Batteries fit compactly in the 60 Ah base. Use only approved batteries to meet seismic compliance and follow the installation instructions to ensure a proper fit in the compartment. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 13: Chapter 2: Installation Considerations

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ 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 •...

  • Page 14: Installation Process Overview

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual _________________________________________________________ Installation Process Overview The cabinet installation process involves the following high-level steps: Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 15: Installation Guidelines

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Installation Guidelines Review the following guidelines before starting installation activities. General Guidelines Follow these general guidelines and practices: • Read this document completely before starting any installation activities. • Only qualified personnel should perform the procedures described in this document. •...

  • Page 16: Space Requirements

    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 all times to provide adequate access for all installation and maintenance activities. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 17: General Safety Recommendations

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ General Safety Recommendations WARNING! Only trained, qualified technical personnel should perform 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 injury to untrained personnel.

  • Page 18: Installation Kit

    Installation Manual _________________________________________________________ Installation 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 contains all of the listed items.: Item Description Telco hex key, 5/16”...

  • Page 19: User-Supplied Items

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ User-Supplied Items Supply the following items for cabinet installation. Tools Bring the following tools to the installation site: • Power drill with universal socket and screwdriver bit sets • Socket wrench/nut driver set (standard) •...

  • Page 20: Cabling Requirements

    8–10 AWG stranded copper; Follow National Electric Code (NEC) and local codes (local power) Proprietary Information: Not for use or disclosure except by written agreement with Clearfield. Note: Local climatic conditions, site conditions, or local practices may require adjustments to cabling requirements.

  • Page 21: Chapter 3: Preparing The Installation Site

    A composite foundation vault, available from a third-party supplier, can provide easy under-cabinet access or serve as a 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: •...

  • Page 22: Installing A Ground Circuit

    Installing a Ground Circuit Clearfield requires installing an earth ground circuit (earth electrode) at the installation site to provide protection from electric shock for equipment and personnel. The ground circuit may consist of a simple copper rod driven into the earth or a com- plex system of buried rods and wires.
  • Page 23 FieldSmart Fiber Active Cabinet (FAC) 400 ® 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: Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • techsupport@clfd.net Manual 020419 REV A - Feb 2019...
  • Page 24 Wet soil provides low resistance ground, with resistance increasing as the soil dries. Rock, gravel, sand, loam and clay react differently to wet/dry conditions. Follow local code to satisfy additional requirements, if applicable. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 25: Constructing A Concrete Pad

    Construct a concrete foundation pad for the cabinet at the installation site. Pad construction requires excavating the site, trenching cable conduit, constructing a form, and casting concrete. Use the Clearfield -supplied cast-in-place template to provide exact locations for the mounting studs that anchor the cabinet to the pad and to provide the cable conduit locations.
  • Page 26 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual _________________________________________________________ Pad Drawings Use the following drawings for reference during pad construction. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 27 Conduit for outside plant cable (copper). b. Conduit for outside plant cable (fiber). c. Earth ground wire. d. Conduit for AC cable. Use the Clearfield cast-in-place template to provide precise conduit orientation. Conduit Locations Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • techsupport@clfd.net...

  • Page 28: Assembling The Cast-In-Place Template

    Step 4: Attach the short and long brackets together using seven supplied screws and nuts, as shown. Step 5: Tighten all screws to complete the template assembly. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 29: Preparing The Site

    Step 3: Place and tie rebar inside the form elevated above the gravel. Step 4: Place the Clearfield cast-in-place template into the form, guiding the cable conduits through the conduit entry ducts in the template. Step 5: Align the template mounting brackets flush with the top of the form, then nail the template to the form to secure it in place.

  • Page 30: Casting The Pad

    Backfill and grade the perimeter area around the pad with soil, as required. Step 8: Trim the cable conduits to a height no more than 4 inches above the pad. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 31: Installing A Pre-Cast Concrete Pad

    Pre-cast pads ship configured with conduit entry cutouts and mounting 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 suppliers.
  • Page 32 Pad Drawings Use the following drawings for reference during site preparation. Actual pad dimensions may vary by manufacturer. Refer to the manufacturer’s documentation for more information. Pad Size Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 33 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Pad Cross-Section (from left side) 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.

  • Page 34: Preparing The Site

    Note: When installed, the pad should stand at least one inch above grade. Adjust the compaction and gravel depth accordingly, based on the pad height. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 35: Installing A Pre-Cast Pad

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Installing a Pre-Cast Pad Install the pre-cast pad according to the manufacturer’s instructions (typically supplied with the pad). A general installation practice is described below for reference. Adapt the instructions as needed for local requirements, practices, or conditions.

  • Page 36: Installing A Pole-Mount Kit: Local Power With 60 Ah Battery Base(S)

    Use the Clearfield pole-mounting kit to provide the mounting fixture. The pole-mounting kit consists of a support frame that attaches directly to the pole, including a base platform that provides exact entry locations for the cable conduits. You can install the mounting kit onto an existing pole, or you can install a new pole at the installation site to support the cabinet.
  • Page 37 Conduit for outside plant cable (copper). b. Conduit for outside plant cable (fiber) and the earth ground wire. c. Conduit for AC cable. Use the Clearfield pole-mount kit to provide precise conduit orientation. Conduit Locations Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • techsupport@clfd.net...
  • Page 38 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual _________________________________________________________ FAC 400 (Front) FAC 400 (Front) Minimum Pole Height (single and dual 60 Ah battery base configurations) Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 39: Preparing The Site

    Step 5: Backfill the conduit trench with soil. Installing the Pole-Mount Kit Install the Clearfield pole-mount kit for local power configurations with a 60 Ah battery base(s) onto a pole or post, as described below. Adapt the instructions as needed for local requirements, practices, or conditions.
  • Page 40 Step 1: Attach the front mounting bracket to the pole as follows: Note: Clearfield recommends using two people to perform this task: One to hold the mounting bracket in position against the pole, and one to install the mounting hardware.
  • Page 41 Verify that the fixture is level, and then tighten all hardware to secure in place. Note: Clearfield recommends using cold-shrink tubing on the conduit entry ducts to seal the conduit entry. If any of the individual conduit entry ducts are not used, remove and replace the duct plates with blank plates from the installation kit.
  • Page 42 Pull the band tight (to 20 ft-lbs.) and tighten the nut on the bolt to secure it in place as shown below. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 43: Installing A Wall-Mount Kit: Local Power With 60 Ah Battery Base(S)

    Use the Clearfield wall-mount kit to provide the mounting fixture. The wall-mount kit consists of a support frame that at- taches directly to the wall or H-frame, including a base platform that provides exact entry locations for the cable conduits.
  • Page 44 • For H-frames, Clearfield recommends using (2) 4” x 4” x 4.0’ horizontal members on the top and (3) 4” x 4” x 4.0’ horizontal members on the bottom to support the fixture, positioned for the following mounting hardware locations:...
  • Page 45 Conduit for outside plant cable (copper). b. Conduit for outside plant cable (fiber) and the earth ground wire. c. Conduit for AC cable. Use the Clearfield pole-mount kit to provide precise conduit orientation. Conduit Locations Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • techsupport@clfd.net...
  • Page 46 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual _________________________________________________________ FAC 400 (Front) Wall-Mount Kit Dimensions Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 47: Preparing The Site

    H-frame. Backfill the conduit trench with soil. Installing the Wall-Mount Kit Install the Clearfield wall-mount kit onto a wall or H-frame as described below. Adapt the instructions as needed for local requirements, practices, or conditions.
  • Page 48 Attach the base platform to the wall or H-frame as follows: Note: Clearfield recommends using two people to perform this task: One to hold the base platform in position against the wall or H-frame, and one to install the mounting hardware.
  • Page 49 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install the top bracket Step 1: On the left side of the cabinet, remove the five plastic caps covering the bracket mounting holes. Step 2: Attach the top bracket to the cabinet as follows: a.

  • Page 50: Installing A Foundation Vault

    Use 1-inch conduit (maximum) for AC cable. See drawing below for entry location. • Include pull cords in all cable conduits. Refer to the vault manufacturer’s instructions for additional guidelines Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 51 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Vault Drawings Use the following drawings for reference during site preparation. Actual pad dimensions may vary by manufacturer. Refer to the manufacturer’s documentation for more information. Typical Foundation Vault Size For proper cable entry into the cabinet, place conduit into the following locations.
  • Page 52 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual _________________________________________________________ Vault Cross-Section (from left side) Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 53: Preparing The Site

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Preparing the Site Prepare the site for installation of a foundation vault. Some vaults may require custom preparations. Refer to the manufacturer’s instructions for more information. A general practice is described below for reference. Adapt the instructions as needed for local requirements, practices, or conditions.

  • Page 54: Installing The Foundation Vault

    Step 5: Backfill and grade around the vault perimeter with soil to secure it in place. Step 6: Verify that the vault remains level. Adjust as required. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 55: Chapter 4: Installing The Cabinet

    ® Installation Manual __________________________________________________________ Chapter 4: Installing the Cabinet This chapter describes how to install the Clearfield FAC 400 cabinet onto its permanent mounting location. Topics Covered This chapter covers the following topics: • Installing a ground circuit at the installation site •...

  • Page 56: Unpacking The Cabinet

    Do not remove the cabinet from the pallet until after it has been delivered to the installation site. However, you can remove the cardboard crating to inspect the cabinet at the staging area, if required. Clearfield recommends keeping the protective packaging in place for transportation.

  • Page 57: Operating Cabinet Doors

    The cabinet has hinged front and side doors, each equipped with two telco hex-pin latches and a padlock hasp for security. Open and close doors using a Clearfield -supplied telco hex 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.
  • Page 58 Locally-powered cabinets have a battery compartment with a removable access door. The battery compartment door is secured at the top by a telco hex-pin latch, and it has a padlock hasp for security. Use a Clearfield -supplied telco hex key to open and close the door.

  • Page 59: Preparing The Cabinet For Installation

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Preparing the Cabinet for Installation Complete the following preparations before installing the cabinet. To prepare the cabinet for installation Step 1: Open the front and side cabinet doors. Step 2: From the side compartment, remove the isolation mat and the bag containing the installation hardware.

  • Page 60: Installing The Cabinet On A Concrete Pad

    Installing the Cabinet on a Concrete Pad The FAC 400 cabinet’s compact design allows you to install it without the use of heavy lifting machinery. Clearfield recom- mends using two people to install the cabinet (to lift, move, and lower the cabinet onto the pad).
  • Page 61 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install the cabinet (or riser) on a concrete pad Note: The following procedure also applies to installing the optional battery compartment riser onto a concrete pad). Step 1: Sweep the pad free of dirt and debris. Step 2: Install the isolation mat onto the concrete pad.
  • Page 62 Verify that the doors open and close freely. If necessary, use shims to level the cabinet or riser. Step 8: Apply silicone caulking to the bottom perimeter of the cabinet or riser. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 63: Installing The Cabinet On A Wall Or H-Frame

    Installing the Cabinet on a Wall or H-Frame The FAC 400 cabinet’s compact design allows you to install it without the use of heavy lifting machinery. Clearfield recommends using two people to install the cabinet (to lift, move, and lower the cabinet onto the pole-mount fixture).
  • Page 64 Note: To complete the installation, install the top bracket to secure the cabinet to the wall or H-frame. See Installing the Mounting Fixture on a Wall/H-Frame for instructions. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 65: Installing The Cabinet On A Pole: Local Power With 60 Ah Battery Base(S)

    Installing the Cabinet on a Pole: Local Power with 60 Ah Battery Base(s) The FAC 400 cabinet’s compact design allows you to install it without the use of heavy lifting machinery. Clearfield recommends using two people to install the cabinet (to lift, move, and lower the cabinet onto the pole-mount fixture).
  • Page 66 Apply silicone caulking to the bottom perimeter of the cabinet or riser. Note: To complete the installation, install the top bracket to secure the cabinet to the pole. See Installing the Mounting Fixture on a Pole for instructions. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 67: Installing The Cabinet On A Foundation Vault

    Installing the Cabinet on a Foundation Vault The FAC 400 cabinet’s compact design allows you to install it without the use of heavy lifting machinery. Clearfield recommends using two people to install the cabinet (to lift, move, and lower the cabinet onto the foundation vault).
  • Page 68 Verify that the doors open and close freely. If necessary, use shims to level the cabinet or riser. Step 8: Apply silicone caulking to the bottom perimeter of the cabinet or riser. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 69: Removing The Lifting Details

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Removing the Lifting Details After the cabinet is installed, remove the two lifting details from the cabinet. To remove the lifting details Step 1: Locate the two lifting details, attached to the upper left corners of the left and right sides of the cabinet. Step 2: Remove the three bolts securing the first lifting detail to the cabinet.

  • Page 70: Chapter 5: Installing 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 power Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 71: Installing The Cabinet Ground Connection

    You must install the cabinet’s connection to the earth ground circuit before you connect commercial power to the cabinet. Guidelines Clearfield recommends adhering to PANI grounding methods to reduce ground current interaction: • The PANI system divides the ground bar into sections, with one type of conductor in each section: Producers, surge Absorbers, Non-isolated and Isolated (PANI).
  • Page 72 Attach the earth ground wire’s two-hole lug onto the 3/4-inch ground terminal studs per PANI guidelines. Step 6: Re-connect the nuts to the ground terminal studs and tighten to 26 inch-lbs. of torque. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 73: Installing Ac Power (220-240 Vac)

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Installing AC Power (220-240 VAC) Install 220-240 VAC power as described below. DANGER! High voltage may be present. Risk of electrical shock. Do not apply AC power to the cabinet until the installation process is complete.
  • Page 74 Tighten the coupling nut around the AC wires at the bottom of the load center housing. Step 8: Re-install the cover panel on the AC load center. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 75: Chapter 6: Installing And Splicing Outside Plant Cables

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Chapter 6: Installing and Splicing Outside Plant Cables This chapter describes how to install and splice outside plant cables into the cabinet, including fiber plant (fiber-optic cables for transport/uplink) and metallic plant (copper twisted pairs for subscriber drops and/or Ethernet-over-copper transport). Topics Covered This chapter covers the following topics: •...

  • Page 76: Bonding Cable Sheaths

    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 equipment cabinet/enclosure ground. The short run can then be bonded on either side (the Clearfield ground bar side or splice point side, but not both) per local practice.

  • Page 77: Installing Fiber Cable

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Installing Fiber Cable This section describes how to install fiber optic cable into the cabinet, including how to route and groom the outside plant cable and splice fibers for terminating to the equipment. Fiber management guidelines When installing, splicing, and routing fibers in the cabinet, follow these guidelines: •...
  • Page 78 Install a lug connector on the twisted end of the strength members. Note: Clearfield recommends using a two-hole lug connector, unless local practice indicates otherwise. c. Install a #6 AWG bond strap onto the lug connector together with the twisted strength members and tighten the lug connector.

  • Page 79: Splicing Fibers

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Splicing Fibers Note: If fiber splices will not reside in the cabinet, such as when using an external splice case or fiber hand-hole, skip this section. Splice fibers per local practice. Note: For additional fiber management options, see Installing Fiber Management Options.

  • Page 80: Installing Metallic Cables

    Attach a #6 AWG bond strap to the B-bond clamp. c. Terminate the other end of the bond strap to the main ground bar in a position below the AC load center ground. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 81: Splicing Metallic Cables

    You must install counterpart MS2 or 710 connectors on each 25-pair group of OSP cables before mating. Note: Clearfield equipment uses a ‘dead pair’ scheme, where the 25th pair in each 25-pair cable group is unterminated and not used (dead).

  • Page 82: Installing 5-Pin Protection Modules

    (circuit) that will be equipped for service. Refer to the cabinet pair assignment list for more information. Note: Clearfield equipment uses a ‘dead pair’ scheme, where the 25th pair in each 25-pair cable group is unterminated (dead). Therefore, on each protection block, positions 25 and 50 are not wired. Line identification labels cover the dead pair positions.

  • Page 83: Chapter 7: Turning Up The Cabinet Power System

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Chapter 7: 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.

  • Page 84: Turning Up The Power System

    Verify that the ohm meter reads 5 ohms or less. Step 3: If the reading is greater than 5 ohms, check the ground wire connection at the main ground bar, then retest. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 85: Checking The Ac Power Supply Voltage

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Checking the AC Power Supply Voltage The cabinet ships from the factory equipped to support 220-240 VAC service. Check the AC power supply voltage as follows. DANGER! High voltage may be present. Only a qualified electrician should perform these procedures. To check 220-240 VAC power supply voltage Step 1: Apply AC power to the cabinet at the local power transfer switch.

  • Page 86: Installing The Rectifier Modules (Alpha Cordex Rectifier Option)

    Install Alpha rectifier modules into the shelf as described below. Note: The controller module ships installed in the rectifier shelf. Push firmly on the controller module to verify that it is fully seated in the slot. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 87 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install a rectifier module Step 1: Unpack the rectifier module. Step 2: Insert the module in the first or second vacant slot, sliding the module into the rear connector (inside of the shelf).

  • Page 88: Installing And Testing Batteries

    Note: If the batteries are not fully charged, perform these procedures after charging the batteries. WARNING! In -48V telecom systems, red leads connect to the negative terminal and black leads connect to the positive terminal. Do not reverse the wiring polarities. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 89 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install a single string of 60 Ah or 62 Ah batteries Note: If you plan to install a second battery string in the riser compartment, go to the next procedure. If you do not plan to install a second battery string, locate the Anderson connector for the second battery string and disconnect if required.
  • Page 90 3V. 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. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 91 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 10: Install the protective covers (manufacturer-supplied) over the battery terminals. Step 11: Connect the string of batteries to the power system by plugging the battery string and the rectifier system out- put Anderson connectors together.
  • Page 92 Note: You will slide the batteries into the battery trays after installing the cables and protective covers. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 93 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 5: Connect the second-string battery power cables to the string in the riser compartment as follows: a. Attach the black power jumper cable to the positive (+) terminal post at the positive end of the string. b.
  • Page 94 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 will slide the batteries into the battery tray after installing the cables and protective covers. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 95 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 11: Connect the battery power cables in the upper battery compartment as follows: a. Remove the protective caps from the cable ring lugs. b. Attach the black cable to the positive (+) terminal post at the positive end of the string. c.
  • Page 96 Note: If you are using the optional seismic protection kit, install the front seismic bracket and stiffener above the lower retainer. Step 20: Replace the battery compartment doors. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 97: Chapter 8: Installing Equipment, Options And Adding Capacity

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Chapter 8: Installing Equipment, Options 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 modular growth of line capacity and supports field installation of all factory options.

  • Page 98: Installing A Protection Mounting Frame

    Locate the mounting holes on the equipment mounting rail. b. Position the mounting plate against the rail, aligning mounting plate mounting holes with the counterpart holes in the rail. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 99 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ c. Secure the mounting plate to the rail using (2) 10-32 X .38 screws. Step 4: From the front of the cabinet, install the mounting frame as follows. a. Locate the four threaded studs. Note: The two studs on the left are attached to the mounting plate.

  • Page 100: Installing A Protection Block

    Note: All Clearfield protection blocks use dead pair wiring, with a dead pair at the 25th position on both the equipment side (RJ-21) and subscriber side (MS2 or 710) interface cables. On the protection blocks, line identification labels cover the dead pair positions (25 and 50).
  • Page 101 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 3: Terminate the protection block interface cables as follows: a. Route the two RJ-21 equipment interface cables from the back of the block to the active service unit and connect to the appropriate equipment interfaces (RJ-21 connectors).

  • Page 102: Installing A Cross-Connect Panel

    OSP (‘Subscriber’ side) cables. Clearfield recommends performing the installation during a maintenance window to minimize the service impact. Note: All Clearfield equipment uses a ‘dead pair’ scheme, where the 25th pair in each 25-pair cable group is unterminated and not used (dead).
  • Page 103 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install a cross-connect panel Step 1: Unpack the cross-connect panel from the shipping packaging. Step 2: Open the cabinet’s side door. Step 3: Position the cross-connect panel against the mounting fixture, with the cables toward the back. Align the eight mounting holes in the cross-connect panel with the counterpart holes in the mounting fixture.

  • Page 104: Installing A Battery Compartment Riser

    Installing a Battery Compartment Riser Clearfield offers an optional battery compartment riser to support a second 60 Ah battery string. The battery compartment riser ships detached from the cabinet, even when ordered as a factory option. Install the battery compartment riser onto a concrete pad, foundation vault, or pole/wall mount pedestal, and then mount the cabinet assembly (with battery compartment) onto the riser.

  • Page 105: Installing A Battery Heater

    __________________________________________________________ Installing a Battery Heater For colder climates, Clearfield recommends using an optional battery heater to prevent batteries from freezing and to pro- long battery life. The battery heater is controlled by a thermostat set for the following operation: •...
  • Page 106 Route the jumper cable’s lower power connector into the riser compartment through the left rear hole of the upper battery compartment, and insert the connector into the panel mount bracket on the left inside wall. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 107 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ d. Plug the power cord from the riser’s battery heater into the jumper cable’s lower connector (inserted into the panel mount bracket in step 4c). Step 4: Mount the thermostat to the side of the battery tray as follows: a.

  • Page 108: Installing A Generator Connector

    Note: Do not discard the four mounting nuts. The nuts will be reused to install the generator connector. d. Pull the blank plate away from the wall to expose the connector mounting location. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 109 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install a generator connector Step 1: Unpack the generator connector assembly from the shipping package. Note: The connector ships pre-assembled in a mounting housing. Step 2: Attach the generator connector assembly to the mounting fixture as follows: a.

  • Page 110: Installing Fiber Management Options

    The distribution panels and PON splitters are always user-installed. You can order and install individual components to scale support as required. For more information and detailed installation instructions, refer to the Clearfield Installation Guide: Fiber Management Solutions for FAC 400.

  • Page 111: Installing A 48-Position Fiber Distribution Panel

    Clearfield also offers a 96-position distribution panel, which is comprised of (8) 12-position cassettes, also pre-terminated to a 100-foot OSP fiber cable. For 96-position panels, simply repeat the procedure for the 48-position panel below to install the second set of (4) cassettes into the adjacent space using a second mounting bracket.
  • Page 112 Note: For a 96-position fiber distribution panel, repeat the procedure above to install the second set of (4) cassettes into the adjacent space on the mounting frame. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 113 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 5: From the back of the distribution panel, carefully feed the OSP cable down through the cabinet's cable-entry duct. Route the OSP cable out to the splicing location. Direct: 763.476.6866 • National: 800.422.2537 • www.SeeClearfield.com • techsupport@clfd.net Manual 020419 REV A - Feb 2019...

  • Page 114: Installing The Fiber Management Accessories

    Position the comb bracket on the mounting frame as shown, aligning with the (2) holes in the frame. b. Secure the comb bracket in place reusing the (2) screws and nuts removed in Step 1. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 115 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Step 3: Install the spool bracket on the mounting frame. a. Position the spool bracket on the mounting frame as shown, aligning with the (2) holes in the frame. b. Secure the spool bracket in place using (2) supplied screws. IMPORTANT! When routing optic fibers, be careful to avoid bending fibers beyond the manufacturer recom- mended 1 inch (2.54 cm) bend radius.

  • Page 116: Installing A 1:32 Splitter And Integration Kit

    Hold the retaining pin lanyard against the vertical rail, above the splitter cage. b. Attach the lanyard to the vertical rail using (1) supplied screw. Tighten the screw to secure the lanyard in place. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 117 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ To install a 1:32 fiber splitter assembly Step 1: Insert a 1:32 fiber splitter into any vacant position in the mounting cage. Step 2: Insert the retaining pin through the bracket (and corner of the splitter) to secure the splitter in place. IMPORTANT! When routing optic fibers, be careful to avoid bending fibers beyond the manufacturer recom- mended 1 inch (2.54 cm) bend radius.
  • Page 118 Hang the staging plate on a stud on the inside corner wall. Step 5: Organize and dress the fibers with enough slack to accommodate the staging area position. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 119 Installation Manual __________________________________________________________ If a patch and splice or pigtail fiber splice solution is required, Clearfield offers a field installed Clearview xPAK fiber assembly. This module supports low count fiber distribution with Light Guide Cross Connect (LGX) 6- or 12-position cassettes.

  • Page 120: 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 Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 121: Routine Maintenance

    Clearfield support for assistance with a resolution. • Repair damage to the paint using touch-up paint available from Clearfield after cleaning the surface and removing rust. • Inspect all gaskets around the doors and the roof to ensure a tight secure fit.

  • Page 122: Checking Electrical Components

    Check the heat exchanger. Verify that the air intake locations are unobstructed and that the fans are running. If any of the inspected items requires replacement due to failure or damage, replace the item as described in Replacing Parts and Equipment. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 123: Checking Cable Connections

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Checking Cable Connections Check external cable connections at least once a year. External cables are any cable that enters the cabinet from the outside plant. • Visually inspect all cables for signs of physical damage. If damage is present, cables should be repaired or replaced per local practice.

  • Page 124: Checking The Heat Exchanger

    CAUTION! Always disconnect power to the heat exchanger prior 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: •...

  • Page 125: Battery Maintenance

    Battery maintenance does not impact cabinet service, provided that an AC power failure does not occur during the main- tenance process. Clearfield recommends connecting an external generator to the cabinet while performing battery mainte- nance to ensure service continuity in the event of an AC outage.
  • Page 126 Step 7: Re-install the batteries into the battery compartment. See Installing Batteries for instructions. Step 8: Re-install the seismic protection bracket, if present. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 127: Replacing Parts And Equipment

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Replacing Parts and Equipment This section describes how to replace worn or failed parts and equipment in the cabinet. Removing a Cabinet Door You can remove the cabinet doors for convenience during cabinet installation or maintenance activities, or to replace a door. Replacing a cabinet door may become necessary if: •...

  • Page 128: Installing A Cabinet Door

    On the new door hinges, disengage the hinge pin lever from its cradle: a. Top hinge: Lift the pin lever up and rotate it away from the cradle. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.
  • Page 129 FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ b. Bottom hinge: Press the pin lever down and rotate it away from the Step 2: cradle. Release the hinge pins from the hinge pin channels: Step 3: a. Top hinge: Press down on the pin lever until the pin slides free from the channel. b.

  • Page 130: Replacing The Cabinet Roof

    Lift and remove the damaged roof from the cabinet. Step 7: Place the replacement roof on the cabinet. Step 8: Secure the roof in place using the screws removed in step 5. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 131: Replacing Ac Breakers

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Replacing AC Breakers On cabinets configured for local power, if a circuit breaker in the AC load center fails or becomes damaged, you can replace the breaker in the field as described below. If the cabinet is equipped with charged batteries, this procedure does not affect service.

  • Page 132: Replacing Rectifier Modules (Alpha Cordex Rectifier Option)

    Step 4: Apply pressure to the module front panel to engage the rear connector in the shelf receptacle. The locking clip automatically secures the rectifier to the shelf. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 133: Replacing Batteries

    Replacing batteries does not impact cabinet service, provided that an AC power failure does not occur during the replacement process. Clearfield recommends connecting an external generator to the cabinet while performing battery maintenance to ensure service continuity in the event of an AC outage.

  • Page 134: Replacing A Battery Heater

    Step 8: At the AC load center, switch the Battery Heater breaker to ON. Step 9: Replace the battery compartment door and switch the battery breaker to ON. Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 135: Appendix A: Reference Information

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Appendix A: Reference Information This appendix provides general reference information about the FAC 400 cabinet. Topics Covered This chapter covers the following topics: • Cabinet specifications • Optional Alpha Cordex HP rectifier alarms and controller settings •...

  • Page 136: Specifications

    (2) 2.5-inch diameter entry ports AC service entry (local power only) (1) 1-inch diameter entry port Compliance Safety UL 67 FCC Part 15, Class A Telcordia GR-487-CORE, Issue 2 Proprietary Information: Not for use or disclosure except by written agreement with Clearfield.

  • Page 137: Optional Alpha Cordex Hp Rectifier Alarms And Controller Settings

    FieldSmart Fiber Active Cabinet (FAC) 400 ® Installation Manual __________________________________________________________ Optional Alpha Cordex HP Rectifier Alarms and Controller Settings The Alpha rectifier shelf detects and reports multiple alarm conditions in the cabinet, but only two umbrella alarms are re- ported through the active equipment: Minor (MN) and Major (MJ). For a list of the alarms reported through the active equip- ment as well as parameters and default settings for the Alpha rectifier shelf controller, refer to the Alpha Cordex Controller Default Configuration document or for more detailed information refer to the Alpha Cordex Controller Software Manual—...

  • Page 138: Standard Warranty

    Clearfield shall repair or replace the defective Product at its sole option and discretion, and return the repaired or replacement Product to Cus- tomer’s site, freight prepaid Note: If the Product is not found to be defective by Clearfield, the product will be returned to the Customer and the customer billed for freight in both directions.

  • Page 139: Proprietary Notice

    __________________________________________________________ Proprietary Notice Information contained in this document is copyrighted by Clearfield, Inc. and may not be duplicated in full or part by any person without prior written approval of Clearfield, Inc. Its purpose is to provide the user with adequately detailed documentation to efficiently install the equipment 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.

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