FieldSmart Fiber Scalability Center (FSC) Installation Manual 288/432/576/1152 PON Cabinets 432/864 Cross-Connect Cabinets Hub Collapse Cabinets (HCC) Vaults PenCell and Channell 288/432 Pole Mount and Underplate Kit Cable Accessories Part #: 009246 Rev: H Updated: 1.2018 7050 Winnetka Ave N. Minneapolis, MN 55428 Direct: 763.476.6866 National: 800.422.2537 www.clearfieldconnection.com techsupport@clfd.net
Table of Contents Technical Support... 3 Introduction... 4 Proprietary Notice... 5 Cabinet Packaging... 6 FieldSmart Cabinets Overview 288 PON... 7 432 PON... 9 576 PON... 11 1152 PON... 13 432 Cross-Connect... 15 864 Cross-Connect... 17 Hub Collapse Cabinet... 19 Cabinet Specifications... 21 PenCell Installation Base Installation (Grass, Dirt, Gravel)... 22 Base Installation (Concrete, Pavement)... 23 6 Inch Riser Installation... 24 CraftSmart Fiber Protection Vaults (FPV) CraftSmart FPV Overview... 26 CraftSmart FPV with Polymer Rings & Covers... 30 Locate & Prepare Base for Installation... 32 Grounding Enclosure... 34 Mounting the Clearfield FSC to the CraftSmart Vault... 35 Pad/Vault Mounting Hold Locations... 36 Vault Sizes... 40 Fiber Splitter Installation Pigtail Routing... 41 Jumper Routing... 43 Cable Installation (Patch & Splice Only) Cable Splicing... 44 288 PON Routing (Rear of Cabinet)... 47 576 PON Routing (Rear of Cabinet)... 48 Pole Mount Installation 288/432 PON & 432 Cross-Connect Installation... 49 FSC Pole Under Plate Kit Installation... 52 Optional Top Cable Entrance Ports... 53 Cabinet Accessories Mid-Span, Opening Feed-through Plate Kit... 54 Mid-Span Cable Preparation... 55 2
Technical Support Clearfield, Inc. can be contacted for any issues that arise with the supplied product. If you need to return the supplied product, you must contact the Clearfield, Inc. Customer Service Department to request a Returned Materials Authorization (RMA) number. Clearfield, Inc. 7050 Winnetka Ave N. Minneapolis, MN 55428 Toll Free: 800.422.2537 Phone: 763.476.6866 Fax: 763.475.8457 Customer Support: sales@clfd.net Technical Support: techsupport@clfd.net 3
Introduction Consistent with the entire FieldSmart product line, the FieldSmart Fiber Scalability Center (FSC) line of OSP cabinets is configured for both distributed splitter PON and cross-connect applications in three sizes of cabinets. In a small footprint, the FieldSmart FSC can support a 288 homes-served configuration for splitter configurations and a 432 port cross-connect application where feeder to distribution ratios are user defined further defining the flexibility that Clearview offers. In a larger footprint, a FieldSmart FSC can support 576 splitter PON application or an 864 cross-connect. For midsize applications, the 432 PON Cabinet is designed to maximize fiber terminations in a footprint similar to the 288 cabinet. All cabinets support cost-saving patch & splice configurations as well as traditional patch only. 4
Proprietary Notice About FieldSmart Product Line Application 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. However, no guarantee is given or implied that the document is error free or that it is accurate with regard to any specification. 5
Cabinet Packaging All cabinets are packaged for protection for shipment to our customers, depending on the application, packaging may vary. Patch and splice cabinets are typically bubble wrapped and put inside of a cardboard box. For patch only cabinets with pre-terminated fiber tails, they are bubble wrapped and attached to a pallet. Risers if ordered will typically ship separately (on the top of the cabinet). This is done for installation purposes. NOTE: There are multiple items and small parts packaged with every cabinet when unpackaging cabinets - make sure to inspect all packaging materials for these items. 6
FieldSmart Fiber Scalability Center (FSC) Overview PON Cabinets 288 Front View 6 3 1 4 2 5 7 1. Designation card 2. Distribution cassettes 3. Feeder cassettes 4. Fiber management rods and spools 5. Fiber splitter storage 6. Staging plate 7. Riser (available in 4 or 12 ) 7
PON Cabinet 288 Rear View 4 1 2 3 1. Distribution and feeder cassettes 2. Distribution and feed cable ports 3. Grounding bar 4. Fiber management rods and spools 4. Rods and Spools 8
PON Cabinets 432 - Front View 6 2 3 4 1 5 7 1. Designation cards 2. Feeder cassettes 3. Distribution cassettes 4. Fiber management rods and spools 5. Fiber splitter storage 6. Staging Plates 7. Riser (available in 4 and 12 ) 9
PON Cabinets 432 - Rear View 1 4 2 3 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 10
PON Cabinets 576 - Front View 2 6 3 1 4 7 5 1. Designation cards 2. Feeder cassettes 3. Distribution cassettes 4. Fiber management rods and spools 5. Fiber splitter storage 6. Staging Plates 7. Riser (available in 4 and 12 ) 11
PON Cabinets 576 - Rear View 1 4 3 2 5 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 5. Access panel (on 12 riser only) 12
PON Cabinets 1152 Front View 6 2 3 1 4 5 8 7 1. Designation cards (on doors) 2. Distribution cassettes 3. Feeder cassettes 4. Fiber management rods and spools 5. Fiber splitter storage 6. Staging Plates 7. Riser (available in 4 and 12 ) 8. Dual stacked cabinets 13
PON Cabinets 1152 - Rear View 1 4 6 5 3 2 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 5. Designation card holders 6. Dual stacked cabinets 14
432 Cross-Connect Cabinet - Front View 2 4 1 3 5 1. Designation cards 2. Distribution cassettes 3. Feeder cassettes 4. Fiber management rods and spools 5. Riser (available in 4 and 12 ) 15
432 Cross-Connect Cabinet - Rear View 4 6 1 3 2 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 5. Access panel (on 12 riser only) 6. Routing guide 16
864 Cross-Connect Cabinet - Front View 2 1 3 4 5 1. Designation cards 2. Distribution cassettes 3. Feeder cassettes 4. Fiber management rods and spools 5. Riser (available in 4 and 12 ) 17
864 Cross-Connect Cabinet - Rear View 1 6 4 3 5 2 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 5. Access panel (on 12 riser only) 6. Routing guide 18
Hub Collapse Cabinet (HCC) - Front View 4 1 3 2 5 1. Designation cards 2. Distribution and feeder cassettes 3. Fiber management rods and spools 4. LGX card areas 5. Riser (available in 4 and 12 ) HCC Bracket (013475) 19
Hub Collapse Cabinet (HCC) Rear View 6 4 1 2 3 5 1. Distribution and feeder cassettes 2. Distribution and feeder cable ports 3. Grounding bar 4. Fiber management rods and spools 5. Access panel (on 12 riser only) 6. LGX card areas 20
Cabinet Dimensions and Specifications 288 PON/432 Cross- Connect/HCC Cabinet 432 PON 576 PON/864 Cross-Connect 1152 PON/1728 Cross-Connect Size/Weight 32 H x 16 W x 16 D (51 lbs) 37 h x 21 W x 17 D (62 lbs) 32 H x 33:W x 16 D (92 lbs) 64 H x 33 W x 16 D (184 lbs) Standard Riser Base 4 (6 lbs) 4 (7 lbs) 4 (9 lbs) 4 (9 lbs) Optional Riser Base 12 (13 lbs) 12 (14 lbs) 12 (19 lbs) 12 (19 lbs) Pole Mount Yes Yes No No Pad/Vault Mount Yes Yes Yes Yes Splicing Yes - Within Clearview Cassettes Yes - Within Clearview Cassettes Yes - Within Clearview Cassettes Yes - Within Clearview Cassettes Feeder/Express ports 48 48 96 192 Standard Bottom Cable Entrance Ports Optional Top Cable entrance ports 1 x 32 Splitter capacity 6 6 12 12 6 6 12 12 9 14 18 36 21
PenCell Installation (Grass, Dirt or Gravel) NOTE: Boxes larger than 2 feet x 2 feet should be installed with an additional 8 inches to 10 inches of room in length, depth and width allowed. If using a 6 inch riser, excavation will need to be 6 inches deeper than standard installation. Install with cover and support beams in place. Prepare the excavation approximately 6 inches deeper than the overall height of the enclosure. The length and width of the excavation should be determined by adding 4 inches to 6 inches to the overall length and width of the hand hole or pull box. Place approximately 3 inches to 6 inches of compacted material such as sand or gravel in the bottom of the hole. Gravel is the recommended material because of its drainage characteristics. The compacted material should be leveled so the top of the hand hole or pull box is flush to the grade. Place selected backfill into the excavations at 1foot lift and compact either by manual compacting or flooding the excavation to achieve the desired relative compaction. Install with cover and support beams in place. Document adapted from original found at http://www.pencell.com 22
PenCell Installation (Concrete and Pavement)* NOTE: For installation in concrete and pavement (PenCell units with steel or polymer concrete lids). Plastic lids are NOT recommended in sidewalk applications. Boxes larger than 2 feet x 2 feet should be installed with an additional 8 inches to 10 inches of room. If using a 6 inch riser, excavation will need to be 6 inches deeper than standard installation. NOTE: Install with cover and support beams in place. Prepare the excavation approximately 6 inch deeper than the overall height of the enclosure. The length and width of the excavation should be determined by adding 4 inches to 6 inches to the overall length and width of the hand hole or pull box. Place approximately 3 inches to 6 inches of compacted material such as sand or gravel in the bottom of the hole. Gravel is the recommended material because of its drainage characteristics. The compacted material should be leveled so the top of the hand hole or pull box is flush to the grade. Install with cover in place with shims on all sides and ends to prevent deflection. Place selected backfill into the excavation at 1 foot lifts and compact either by manual compaction or by flooding the excavation. The backfill should be discontinued approximately 8 inches below the finished grade. The final 8 inches of the excavation should be finished with concrete. This should be accomplished by providing a form around the enclosure that would produce a 6 inch wide collar. Small shims should be placed between the cover and wall until concrete is set. Document adapted from original found at http://www.pencell.com 23
6 Inch Riser Installation NOTE: Excavation will need to be 6 inches deeper than standard installation. Remove the bolts securing the lid to the hand hole enclosure and remove both sides of the lid (Fig. 3 and Fig.4). Figure 3 Retain the bolts for re-installation of the lid. Figure 4 24
Place the riser on top of the enclosure where the lid previously was positioned (Fig. 5). Figure 5 Using the pre-existing holes in the spacer as a guide, drill clearance holes through the hand hole enclosure to accept the mounting bolts (included with the riser) (Fig. 6). Figure 6 Insert bolts with the flat washer into the mounting holes. Add remaining flat washer, split ring lock washer and nut. Tighten until secure (Fig. 7). Figure 7 Replace the lid and fasten with original bolts and washers. Bury hand hole using appropriate method. 25
CraftSmart Fiber Protection Vaults (FPV) Installation FPV 2436-24 Series Solid Lid w/ L Bolts FPV 1730-24 Series Split Lid w/ Plug and L Bolts (FPV 3048-36 Series Not Shown) NOTE: All CraftSmart Vaults come standard with ¼ turn L-Bolt locks and 3 step racks on the inside of the vault. Step racks can be repositioned by customer by simply removing the 2 wing nuts, washers and bolts, then drilling 2 - ¼ holes and re-installing the step racks where required. For maximum clearance and cable bend radius, measure 23 from the inside sidewall of vault for step rack placement. 26
Scope Installation instructions provide general information useful for parkway placement in grass surround. This guide cannot anticipate all situations that could develop in the field. Rather, it represents information applicable to common installation conditions. Installation Location Location alone should not dictate product selection. Pedestrian loading, sometimes referred to as Greenbelt, defines our HDPE thermoplastic body and covers vaults intended for installation in landscape or grass surround areas where they will not be exposed to vehicular traffic. Exceptions to this rule include residential or light commercial mowers but do now include tractor/mowers in highway easements. Procedure WARNING: Buried Telecommunications Cables...Call Before Digging. Site Preparation Ensure that national local electrical and building codes, OSHA and company safety work rules are observed and provisions made for street flags, barricades and cones. Secure permits as required by city and company. Excavation Plan excavation approximately twelve to sixteen inches (12-16 ) longer and wider than actual dimensions of the vault to be installed. Similarly, excavate six to eight inches (6-8 ) deeper than the overall dimensions of the vault with cover in place. NOTE: Vault size is generally defined by the approximate cover dimensions. The vault actual measurements will differ. The dimensions above for determining the size of excavation provide sufficient volume for accommodating the maximum recommended select backfill. The volume of excavation would be reduced if a lesser volume of backfill material were chosen. Excavate hole to appropriate dimension with mechanical excavator or hand dig as appropriate. Confirm the excavation floor is level. Installation While it is common practice to install Pedestrian Rated vaults in grass surround without select backfill, it is recommended to use a minimum three to five (3-5 ) crushed rock to prevent subsidence over time. Subsidence is a familiar example of neglecting this step. NOTE: Base material shall be crushed rock 3/4 and smaller, and not river rock or round stone. Desired compaction and equivalent resistance to lateral loading will not be achieved with round stone. The rock should be free of soil and organic material. ALTERNATE: A dry lean mix may be prepared for backfill using Portland cement and crushed rock in a ratio of 1:10. This higher strength alternative is useful where severe surcharge loading (lateral live load) is anticipated and the more flexible HDPE body is chosen. 27
Set vault into excavation on top of backfill material and adjust height to grade. Tamp base material to level with a mechanical tamper or hand tamper. When a vault must be installed on a hill, a retaining wall provision shall be made. The cover of the enclosure shall be at or to final grade as specified by the Owner/Operator. Soil in the immediate vicinity shall be tamped and sloped away from the enclosure. Center the vault in the excavation parallel with sidewalk or curb. Mark the vault for duct entry locations. The HDPE vault may be cut with a hole saw and drill motor. Provide adequate clearance for ovality in ducts. Small clearance between duct and vault may be sealed with expanding polyurethane foam. Replace cover on the FPB body before backfilling. Bolting the cover in place is recommended, but not required during backfill. It is important when using the FPV thermoplastic covers outfitted with the L bolt cover that you replace the cover as follows: Place the cover on the base at an angle as shown in Figure 2. Figure 2 The end of the cover with the two black hooks (opposite the end of the stainless steel L bolt) MUST be slid into the sidewall of the FPV base (see Figure 3). Once the cover meets the upper sidewall of the base, it can be secured by turning the L bolt a 1/4-turn to the right. Figure 3 Backfill material can vary based on product and installation location (refer to Figure 4). It is customary and acceptable in landscape installations where vehicles are prevented from traffic on or around a Pedestal Rated vault to use the spoils removed during excavation for backfill. Remove stones three inches (3 ) and larger. Excess backfill material should be removed from the site. 28
For all product categories, begin the backfilling operation by adding soil, crushed rock or dry lean mix in eight inch (8 ) lifts or layers. A mechanical tamper may be used with the CraftSmart Fiber Protection Vaults bodies. Figure 4 - Light Duty Product - Typical grass surround installation Crushed rock backfill is shown as specified in the CraftSmart Fiber Protection Vaults (FPV). The tamped crushed rock supports the vault, preventing subsidence and providing for drainage. The excavated spoils have been used for backfill. NOTE: The soil is free of rocks larger than three inches. NOTES: 1. The cover should be installed and secured into the FPV body prior to backfilling. This prevents debris from entering the vault or interfering with the cover fasteners, and ensures cover fit on completion of installation. 2. No internal bracing should be required during mechanical tamping if proper installation procedures are followed. 29
CraftSmart Fiber Protection Vault (FPV) with Polymer Rings and Covers FPV 2436-24 Series FPV 1730-24 Series FPV 3048-36 Series Not Shown Scope Installation instructions provide general information useful for installing the Shutter Box in sidewalk and driveway placement with concrete surround. This guide cannot anticipate all situations that could develop in the field. Rather, it represents information applicable to common installation conditions. Sidewalk and Driveway Sidewalk described as a walk for pedestrians at the side of a street. It is usually, but not always, an area between curb and parkway surrounded with concrete. Sidewalks are intended for pedestrian traffic with a safety factor for non-deliberate vehicular traffic. Driveway described as an access way from public road to a building or resident. Driveway is subject to occasional non-deliberate heavy vehicular traffic. Procedure WARNING: Buried Telecommunications Cables... call before digging. Ensure that national - local electrical and building codes, OSHA and company safety work rules are observed and provisions made for street flags, barricades and cones. 30
Excavations Plan excavation approximately twelve to sixteen inches (12-16 ) longer and wider than the actual outside dimensions of the vault to be installed. Similarly, excavate six to eight inches (6-8 ) deeper than the overall dimensions of the vault with the PC Ring and Cover in place. Excavate hole to approximate dimension with mechanical excavator or hand dig as appropriate. Confirm the excavated floor is level. Installation While it is common practice to install vaults in a concrete surround without the select backfill, it is recommended to use three to five inches (3-5 ) of crushed rock to prevent subsidence over time. Subsidence is a common example of neglecting this important step. Install the PC Ring on to vault as shown. Fasten the PC Ring to the FPV with hardware provided with vault. Set vault into excavation on top of the backfill material and adjust height to final grade. Tamp base material, the PC Ring and cover of the enclosure should be at or to final grade as specified by the Owner/Operator. Soil in the immediate area shall be tamped and sloped away beginning 1 below the bottom of the PC Ring. The top of the vault with PC Ring and Cover attached should be parallel with the top of the sidewalk or curb final grade level. Backfill material can vary based on product and installation location. Be sure to remove stones three inches (3 ) and larger from excavated area. Excess backfill material should be removed from the site to insure proper concrete thickness in surround. For all product categories, begin the backfill operation by adding soil, crushed rock in eight inch (8 ) even layers around exposed excavation. A mechanical tamper can be used during backfill operation. NOTE: The PC Ring and Cover should be installed and secured to the FPV during the backfill operation. This will eliminate debris from entering into the vault and interfering with the cover fasteners, and will insure the cover fits properly upon completion of installation. Crushed rocked backfill is shown as specified in the CraftSmart Installation Manual. The tamped crushed rock supports the vault, preventing subsidence and providing for drainage. The excavated spoils have been used for backfill. NOTE: The soil is free of rocks larger than three inches. 31
Locate and Prepare the Enclosure Base for Installation Locate the enclosure base and remove any packaging materials. They are typically assembled and packaged on top of FieldSmart Cabinets. There are both a 4 and 12 riser kit available to each style cabinet. All have pre-cut vent holes and the 12 has an access door. 288 PON, 432 Cross-Connect, Hub Collapse Cabinet 4 12 432 PON Cabinets U-mounted Install Access door should be placed so it s in the rear of cabinet 4 12 U-mounted Install U-mounted install access door facing front and rear 576 PON, 864 Cross-Connect, 1152 PON 4 12 U-mounted Install U-mounted install access door facing front and rear 32
If the base is installed on the enclosure, remove the base by removing the (4) bolts from the bottom of the inside of the cabinet. Position the enclosure base onto the pad (typically concrete). Assure that the (4) anchor locations in the enclosure base align with the anchor locations in the pad. After verification of the anchor alignment, remove the enclosure base from the pad (Fig. 8). Figure 8 Apply continuous beads of caulk / sealant (such as a polycarbonate based product) to the bottom outer periphery of the enclosure base and around the anchor locations. Return the enclosure base to the previously determined position on the concrete pad before the caulk "skims" over. Place the rectangular washer plates (found in the hardware package) onto the enclosure base, aligning the holes with the anchor locations in the pad (or placing over cast-in-studs) (Fig. 9). Figure 9 NOTE: 288/4 base shown in picture Orient the plates to provide the most contact with the base flange. Install the chosen fasteners and tighten firmly. 33
Mount the Enclosure on the Base Locate the hardware package shipped with the enclosure. Locate the (4) bolts, washers and lock washers. Assure the enclosure is oriented properly to the base and then insert the bolts through holes in the corners of the enclosure. Insert all four bolts before tightening them with a wrench. Check for and remove all tape, cardboard and foam supports used during shipping. Grounding the Enclosure A grounding plate and lug is located in the lower left corner of the rear of the cabinet (Fig. 10). The cabinet can be grounded via the large lug attached to the plate using a 6 gauge or larger wire. Individual cables can be grounded using the remaining studs on the ground plate. *All Pencell Vaults (if ordered with FieldSmart FSC Cabinets) come with mounting hardware. Figure 10 34
Mounting the Clearfield FSC to the CraftSmart Vault See following pages for specific cabinet templates and bolt kits. *All CraftSmart Vaults (if ordered with a FieldSmart FSC Cabinet) are shipped with mounting templates for drilling the holes in the cover and a bolt kit to secure cabinet to cover. Cut out and place the drilling template over the side of the vault cover with the cable entrance holes. Next, tape the template into place to prevent moving during the drilling process. Now, using a small drill bit (3/16 ), drill a pilot hole through the paper and into the base at the 4 required locations. Remove the paper and enlarge the hole with a ½ drill bit. To install the base on the vault, use the included 3/8 x 2 bolt and washer to secure the base to the vault. The large rectangle washer included with the cabinet should be used below the 3/8 washer. The bolt is secured on the bottom of the vault lid using a washer and Nylock nut. The cabinet can then be bolted to the base using standard practices. 35
Pad/Vault Mounting Hole Locations 288 PON and 432 Cross-Connect on 24 x 36 Channell Vault 36
432 PON on 24 x 36 Channell Vault 37
576 PON, 864 Cross-Connect, 1152 PON on 30 x 48 Channell Vault 38
288 PON, 432 PON, 432 Cross-Connect, Hub Collapse Cabinet on 30 x 48 Channell Vault with adapter bracket 39
Configured Part Numbers and Accessories Pencell Vaults Slack Storage SCD Mounting Options Cabinet Mounting Options Bolt and Template Kit Vault Description Part Numbers Empty Vault Universal Vault Step Racks 288 PON, 432 CC, HCC 432 PON 576 and 1156 PON, 864 CC Electronics Cabinet Below-grade, 17 W x 30 L x 24 D, Solid Lid, Hex-Bolt, Green, Telecommunications V5A-AZP V5A-AZP VAP-UMP VAP-STEP N/A N/A N/A N/A Below-grade, 17 W x 30 L x 24 D, Split Lid, Hex-Bolt, Green, Telecommunications Below-grade, 17 W x 30 L x 24 D, Solid Polymer Concrete Lid, Bolt Lid, Green, Telecommunications V5A-BZP V5A-BZP VAP-UMP VAP-STEP N/A N/A N/A N/A V5A-DZP V5A-DZP VAP-UMP VAP-STEP N/A N/A N/A N/A 3 Spacer for 17 W x 30 L Vault VA-1730-3 Order Separately N/A N/A Order Separately Order Separately Order Separately N/A Below-grade, 24 W x 36 L x 24 D, Solid Lid, Hex-Bolt, Green, Telecommunications Below-grade, 24 W x 36 L x 24 D, Split Lid, Hex-Bolt, Green, Telecommunications, No Knock Out Below-grade, 24 W x 36 L x 24 D, Split Lid, Hex-Bolt, Green, Telecommunications, With Knock Outs for Clearfield Cabinets Below-grade, 24 W x 36 L x 24 D, Solid Polymer Concrete Lid, Bolt Lid, Green, Telecommunications V6A-AZP V6A-AZP VAP-UMP VAP-STEP N/A N/A N/A N/A V6A-BZP V6A-BZP VAP-UMP VAP-STEP N/A N/A N/A N/A V6A-CZP V6A-CZP N/A N/A 009092 009092 N/A N/A V6A-DZP V6A-DZP VAP-UMP VAP-STEP N/A N/A N/A N/A 6 Spacer for 24 W x 36 L Vault VA-2436-6 Order Separately N/A N/A Order Separately Order Separately Order Separately N/A Below-grade, 30 W x 48 L x 24 D, Solid Lid, Hex-Bolt, Green, Telecommunications Below-grade, 30 W x 48 L x 24 D, Split Lid, Hex-Bolt, Green, Telecommunications, No Knock Out Below-grade, 30 W x 48 L x 24 D, Split Lid, Hex-Bolt, Green, Telecommunications, With Knock Outs for Clearfield Cabinets Below-grade, 30 W x 48 L x 24 D, Solid Polymer Concrete Lid, Bolt Lid, Green, Telecommunications Below-grade, 30 W x 48 L x 36 D, Solid Lid, Hex-Bolt, Green, Telecommunications Below-grade, 30 W x 48 L x 36 D, Split Lid, Hex-Bolt, Green, Telecommunications, No Knock Out Below-grade, 30 W x 48 L x 36 D, Split Lid, Hex-Bolt, Green, Telecommunications, With Knock Outs for Clearfield Cabinets Below-grade, 30 W x 48 L x 36 D, Solid Polymer Concrete Lid, Bolt Lid, Green, Telecommunications V7A-AZP V7A-AZP VAP-UMP VAP-STEP N/A N/A N/A N/A V7A-BZP V7A-BZP VAP-UMP VAP-STEP N/A N/A N/A N/A V7A-CZP V7A-CZP N/A N/A 009092 009092 N/A N/A V7A-EZP V7A-EZP VAP-UMP VAP-STEP N/A N/A N/A N/A V7B-AZP V7B-AZP VAP-UMP VAP-STEP N/A N/A N/A N/A V7B-BZP V7B-BZP VAP-UMP VAP-STEP N/A N/A N/A N/A V7B-CZP V7B-CZP N/A N/A 009092 009092 N/A N/A V7B-EZP V7B-EZP VAP-UMP VAP-STEP N/A N/A N/A N/A 6 Spacer for 30 W x 48 L Vault VA-3048-6 Order Separately N/A N/A Order Separately Order Separately Order Separately N/A Pad, HDPE for Electronics Cabinet, 44 W x 44 L x 4 H, 12 x 27 Knock Out for Cable Entrance VAP-4444-P N/A N/A N/A N/A N/A N/A 009092 40
Fiber Splitter Pigtail Routing Record the fiber splitter number and port designations in the space provided on a designation card. Additional designation cards can be ordered from Clearfield. Install the splitter into the top-most usable slot in the fiber storage bracket and lock into place using the splitter retainer pin. Route the fibers from the splitter over to and around the right side of the D-spool in the lower right side of the cabinet. Then route the fibers to the top-most radius spool in the upper right side of the cabinet, loop the fibers over the radius limiter and across the two support fingers. Install the staging plate into staging plate brackets located in the top corners of the cabinet. Slide any excess slack in the fibers back to the bottom of the cabinet, if installed correctly the fiber will hang from the splitter module and not rest on the floor of the cabinet. The input and output pigtails for the fiber splitter are stored and accessed in the staging plate located in the top corners of the cabinet. Route the input pigtail to the feeder port (Fig. 11). The input pigtail is identified by the red booted connector. Route the output pigtails to the distribution ports (Fig. 11). Figure 11 NOTE: The splitters should be installed starting at the top of the storage bracket to the bottom so that fiber crossing is minimized. 41
432 Cabinets 42
Jumper Routing Fiber routing in the 576- port cabinet is done in the same fashion as the 288-port, with the exception that splitter outputs from either side of the cabinet can reach distribution and feeder ports on either side of the cabinet. 576 Cabinets 432 Cross-Connect Cabinet 864 Cross-Connect Cabinet 43
Cable Installation (Patch & Splice Versions Only) Cable Splicing Determine which feed-through hole will be used to install the feeder cable. If the corresponding feed-through plate already has a cable installed, you will need to loosen the compression fitting securing the cable to the plate. This will allow the plate to slide along the preinstalled cable (Fig 12). Figure 12 Remove the six mounting screws that are holding the plate to the floor of the rear of the cabinet, saving the mounting screws. Select the compression fitting that most nearly fits the cable to be installed. The fittings are included in the ship-along hardware. Loosen, or if needed, remove the dome nut on the compression fitting to allow the cable to fit through the internal sealing ring (Fig. 13). Figure 13 44
NOTE: The sealing ring inserts come in different sizes and colors, and can be interchanged to meet the cable size. Make sure compression fittings are tight and secure. Locate the end of the cable to be spliced into the cabinet. Feed this end through the locknut, the feedthrough plate, the compression fitting and finally the dome nut. Thread the locknut onto the fitting, being careful to avoid crossing the threads and tighten firmly against the feed-through plate. Reinstall the feed-through plate by securing it to the floor of the cabinet using the original six mounting screws. Determine the correct amount of outer jacket to remove from the cable by referencing the splicing section of this manual. Pull enough of the cable through the compression fitting to allow access to the splicing area. Install the distribution cable as described in the cable installation section. Remove 15 feet of the outer jacket. Group the buffer tubes to be spliced and fully insert them into one of the mesh sleeves enclosed in the ship along hardware. This will help to control the bundle while routing and storing. Start marking the buffer tubes 10 feet from the outer jacket and staggering the marks 1" longer for each buffer tube. Remove all Clearview Cassettes from panel that are to be spliced (if required). SEE THE SPLICING MANUAL FOR SPLICING IN THE CLEARVIEW CASSETTE. After splicing is complete, stack the cassettes and tie them together using cable ties for easy installation (Fig. 34). Figure 34 45
Route the grouped buffer tubes first over the top radius limiter. Continue routing the grouped buffer tubes down and around the bottom radius limiter. Finish routing the grouped buffer tubes back up and around the top radius limiter. After routing the buffer tubes, install the cassette into the bulkhead in the appropriate port locations from the rear of the cabinet and tighten fastener screws (Fig. 37). NOTE: Re-tighten the seal-con fitting nut, being sure not to damage the threads. 46
288 PON Routing (Rear of Cabinet) The suggested cable routing for feeder and distribution cables is in the rear of the cabinet. NOTE: Cables should enter cassettes on side closest to cable management not crossed over. 47
576 PON Routing (Rear of Cabinet) Suggested cable routing for feeder and distribution cables in the rear of the cabinet. NOTE: Cables should enter cassettes on side closest to cable management not crossed over. 48
288/432 PON and 432 Cross-Connect Installation of Pole Mount 1. Locate and install using the included hardware, a Hoist Plate to the top of the cabinet. 2. Place the plate on the side of the cabinet that will be closest to the pole. NOTE: A second hoist plate is included for use if the cabinet will be raised with a hoist. Hoist Plate 3. Locate the toothed bracket that has mounting holes in the flange and mount it to the base (below the previously installed Hoist Plate) using the included hardware. Toothed Bracket 4. Determine the top height of the cabinet. Drill a 5/8 hole 8 inches below the anticipated height of the cabinet, all the way through the pole. 49
5. Mount the loose toothed bracket to the pole using threaded rod, washers and nuts on either side of the pole. Rod length will depend on the diameter of the pole. It is suggested to add 3 to the diameter of pole for rod length. NOTE: Clearfield does not recommend using lag bolts to mount cabinet to pole. Clearfield recommends using hardware with a minimum of 5/8" diameter. Care should be taken to avoid over-tightening and deforming the hoist plate. Lock tight (red) should be used on nuts to prevent loosening of nuts. Make sure the thread rod/nut does not exceed the top bend in bracket or it will interfere with cabinet. Threaded rod Pole Mounting 6. Lower the cabinet onto the pole mounted toothed bracket until the Hoist Plate is over the flange of the toothed bracket. Hoist Plate 50
7. Level cabinet and drill 5/8 hole through lower bracket and pole, and install 5/8 rod, washers and nuts. Toothed Bracket NOTE: Care should be taken to avoid over-tightening and deforming the hoist plate. 8. Cabinet fully mounted. Pole Mounting 51
FieldSmart FSC Pole Mount Under Plate Kit 1. After cabinet has been mounted on pole, the optional Pole Mount Under Plate Kit may be installed. 2. The kit comes with two plates with stenciled templates for multiple sizes of conduit. The standard knock out is for a 2 conduit. If larger conduit is being used, cut the plates to the appropriate size. 3. After plates have been prepared for correct conduit, install one side of the plate onto the bottom of the cabinet. 4. Install conduit and cable. Secure conduit with cable clamp provided in kit on inside/top of the installed plate. 5. Install remaining plate locking the conduit in place. 6. RTV or other silicone type sealing may be used if needed to seal opening. 52
Optional Top Cable Entrance Ports If this option is used the CABINET is typically drilled at the factory and sent to the customer with watertight plugs installed to maintain cabinet s environmental integrity. If additional cables need to be added to the top entrance holes: 1. Remove wing nut and washer from inside of cabinet 2. Carefully remove the grey sealing plug from hole 3. Install 1 NPT sealing plug and correct size cable grommet tighten to cabinet 4. Install cable through grommet/plug and into cabinet 5. NOTE MIDSPANNING of cable cannot be done using the top entry ports If the cabinet does not have factory drilled holes, the following can be done to field install to the cable entrance ports: 1. Locate the dimples on the top of the cabinet (there are 6 on the 288 PON, 432 PON and 432 Cross-Connect Cabinets - these are the cabinets that can be pole mounted). 2. Draw arrows showing the 3 dimples 3. Carefully drill a 1.365 inch hole using the dimple as a centering point 4. Debur hole, being careful not to scratch/damage painted surface 5. Install 1 NPT sealing plug into hole and tighten 6. Install cable as mentioned above 7. NOTE: MIDSPANNING of cable cannot be done using the top entry ports 53
Accessories Mid-Span, Opening Feed-through Plate Kit 1. Grommet Tape (003042) 2. Bottom Plate B (009598) 3. Clamping Bracket (009599) 4. Feed through Plate A (009597) 5. Foam Sealing Plug (XXXXXX) 6. Foam Gasket (009157) 7. Cable Clamp Shells a. 1" (003716) b. 3/4" (003717) c. 1/2" (003711) 8. Clamp Mounting Screw (001527) 9. Kit Mounting Bolts (009098) 1. 4. 10. 2. 11. 3. 12. 5. 6. 7. 8. 9. 54
Mid-Span Cable Prepping Prep the cable according to the instructions provided with the cabinet. NOTE: This kit will enable the cable to be prepped using either a midspan opening or the end of the cable. Locate the green clamp shells and corresponding 1/4-20 mounting screws from the ship-along hardware. The clamp shells are used in same-size pairs. Avoid using a clamp that is too small and does not easily close around the cable. Use the next larger clamp and grommet tape. Grommet tape should be applied to the green clamp shell prior to installation. Locate the height that is required to install the cable and mark the cable jacket where the cable passes through the floor of the cabinet. Be sure to leave at least 3" to 4" above the cabinet floor. Wrap grommet tape around the cable at the mark, until you have an overall outside diameter of 1 3/4". 55
Now the cable can be slid into the slot required, in feed through plate A. Feed through plate B can then be slid onto the cable followed by the cable clamp bracket. All four pieces can now be pinned together in the air by using 4 of the kit mounting bolts. Attach the kit to the base of the cabinet using the 6 kit mounting bolts and tightening them evenly to avoid warping the plates. Attach the cable clamps to the bracket using the clamp mounting screws. The unused holes can be plugged with the included foam plugs. The plugs can be installed by squeezing and compressing the foam until they are able to fit into the hole. The foam will then expand to seal the hole. 56