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FieldSmart Fiber Crossover Distribution System (FxDS) Installation Manual FxDS Frame System Standard Frame System FxDS Patch Panels Standard Patch Panels Fiber Entrance Cabinet (FEC) High Density Ribbon Breakout Part #: 012010 Rev: D Updated: 11.2012 7050 Winnetka Ave N Minneapolis, MN 55428 Direct: 763.476.6866 National: 800.422.2537 www.ClearfieldConnection.com [email protected] Table of Contents Technical Support ................................................................................. 3 Introduction/Proprietary Notice............................................................... 3 FxDS Frame Solution ............................................................................. 5 Standard Floor Installation ....................................................... 7 Raised Floor Installation .......................................................... 9 FieldSmart Standard Frame Installation ............................................... 19 Standard Floor Installation ..................................................... 20 Raised Floor Installation ....................................................... 22 Patch Panel Installation in FxDS Frame .............................................. 27 Patch & Splice Patch Panel ................................................... 27 Mounting the Incoming Cable ................................................ 28 Patch Only Patch Panel ......................................................... 29 Tie Panel Installation ............................................................................ 30 FxDS PON Kit ..................................................................................... 33 Patch Panel Installation in Standard Frame ......................................... 35 Patch & Splice Patch Panel ................................................... 35 Patch Only Patch Panel ......................................................... 39 Optional Fiber Cable Mounting Methods ............................... 40 6 Drawer Splice Deck........................................................................... 41 Splice Deck – Cable Routing .............................................................. 42 Fiber Entrance Cabinet (FEC).............................................................. 45 High Density Ribbon Breakout ............................................................. 49 2 FxDS Part #: 012010 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: Phone: Fax: Customer Support: Technical Support: 3 800.422.2537 763.476.6866 763.475.8457 [email protected] [email protected] FxDS Part #: 012010 Introduction Proprietary Notice About FxDS 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. 4 FxDS Part #: 012010 Fiber Crossover Distribution System (FxDS) – Overview FxDS Frame Solution FxDS Frame Installation Part # 010802 5 FxDS Part #: 012010 Frame will come in a wood packaging crate (88” wide x 28” deep x 29” high). Open the crate by removing the 6 screws and removing the lid. The screws are called out by black circles. Carefully remove the contents. The contents should include: Frame contents include (1) frame and isolation pad, (4) doors, (2) interbay, (2) end guards, a trough kit usually containing (3) troughs, grounding bar and miscellaneous hardware for securing the hinges to the doors and end guards as well as for mounting the frame to the floor. IMPORTANT NOTE: The FxDS Frame system comes in a variety of configurations so the above bill of materials will vary. This is what the crate will look like while unpacking. Once you confirm all the parts and hardware are available, it is time to install the frame. 6 FxDS Part #: 012010 Standard Floor Installation The recommended tools / equipment are: Tools (required or recommended): 1. Hammer (or rotary) drill (with depth gauge recommended) 2. 5/8 masonry drill bit 3. Blowout air bulb or vacuum with small diameter tube. First determine where the frame is going to be installed. Using the isolation pad as a template mark the 4 holes where frame will be secured to the floor. Using a 5/8” masonry bit, drill the four required holes to a minimum depth of 50 mm (approx. 2”). Thoroughly clean the dust from each hole, using an air blowout or vacuum device. TIP: If for some reason you have trouble drill the 5/8” hole, we recommend first drilling a ¼” pilot hole before drilling out to 5/8”. IMPORTANT NOTE: To not degrade the anchor’s installed performance, any unused anchor holes (or other nearby holes) in the concrete, within 3” must be filled with an epoxy filler (pour stone) or equivalent. Filled holes must be fully cured before anchors are installed and torque. If not already in place, install the anchor brackets inside the frame base. Secure the anchor brackets (left hand and right hand respectively) to the frame’s uprights using two (2) grade 5 or better 1/2”-13 x 1-1/2” cap screws, lock washers and hex nuts in each anchor bracket. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. Place isolation pad in position over the predrilled holes and align as necessary. Lift frame onto isolation pad and line up with holes. Ensure that the anchor’s expansion shield is not expanded. Place the end of the anchor into the predrilled hole. Repeat for the other drilled holes. Make sure the anchor is fully embedded in the concrete. 7 FxDS Part #: 012010 Align the edges of the 2” square washer parallel with the slots in the frame base to obtain the maximum material overlap. Once aligned, tap each anchor/washer assembly until it is seated in the hole and firmly against the 2” square washer. Pre-tighten each anchor with a socket wrench or box-end wrench; do not use an open-end wrench (which could easily slip off and cause injury). Before final tightening, ensure that the frame is properly aligned (in the row and with any adjacent frames). IMPORTANT NOTE: Torque each anchor to 60 ft-lbs. When using the break off type anchor, a torque wrench is not required since the anchor’s (red) torque cap shears off at a predetermined torque value (approximately 60 ft-lbs.), leaving a green seal on the bolt head, indicating proper tightening. The anchoring line up should look as follows. 8 FxDS Part #: 012010 Raised Floor Installation Tools (required or recommended): 1. 2. 3. Hammer (or rotary) drill (with depth gauge recommended) 5/8 masonry drill bit Blowout air bulb or vacuum with small diameter tube. First determine where the frame is going to be installed. Using the isolation pad as a template mark the 4 holes where frame will be secured to the floor Also required is a raised floor mounting kit – Clearfield recommends part number 011236. Screw sequence for floor Screw sequence for frame TIP: Clearfield recommends installing the anchors directly into the concrete floor. Using the isolation pad as a guide, mark on the panel(s) of the raised floor where the frame is going to be mounted. 9 FxDS Part #: 012010 Replace the floor panels to their appropriate spots and, using a 5/8” drill bit, drill a hole through each of the oblong marks you made with the isolation pad. See examples below. Take the threaded roads from the raised floor mounting kit and slide through each one of the holes. Using a hammer and holding them perpendicular to the floor, tap on the end firmly. The goal is to make a “mark” on the concrete floor visible enough to see where the 4 holes should be drilled. Once the concrete floor is marked, remove the threaded rods and floor panels. Using a 5/8” masonry bit, drill the four required holes to a minimum depth of 2”. IMPORTANT NOTE: Thoroughly clean the dust from each hole, using a vacuum device. TIP: If for some reason you have trouble drill the 5/8” hole, we recommend first drilling a ¼” pilot hole before drilling out to 5/8”. To n ot degrade the anchor’s installed performance, any unused anchor holes (or other nearby holes) in the concrete, within 3” must be filled with an epoxy filler (pour stone) or equivalent. Filled holes must be fully cured before anchors are installed and torque. Install anchors into the floor. Replace raise floor panels and insert threaded rods through the four holes. IMPORTANT NOTE: You are not installing the rods at this point. We are measuring the rods to be cut to the appropriate length. 10 FxDS Part #: 012010 Measure the rods 2.5” above the floor and mark with an indelible marker. Remove the rods and cut each rod at the mark. Remove the floor panels Before installing rods into the floor back, place nut and then the washer on the threaded rods. Take rod and install into the anchor installed in the floor. Tighten the nut down to secure the rod into the floor. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. The anchor will expand and secure itself to the floor. TIP: Once all four rods are secure, thread another hex nut, then washer on each rod. Make sure the nut and washer are approximately ½” below the raised floor level. This hardware will be tightened down AFTER the frame is set into place but BEFORE the securely bolting the frame to the floor. Place the floor panels into position. Put isolation pad into place (Isolation pad may look different than example). Lift frame into place. Install the isolation bushing (packaged with the isolation pad) onto each rod. 11 FxDS Part #: 012010 Install the remaining hardware (washers, nuts, etc) from the raised floor installation kit. TIP: The square washer shown ships with the actual frame and is not part of the raised floor installation kit. If not already in place, install the anchor brackets inside the frame base. Secure the anchor brackets (left hand and right hand respectively) to the frame’s uprights using two (2) grade 5 or better 1/2”-13 x 1-1/2” cap screws, lock washers and hex nuts in each anchor bracket. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. IMPORTANT NOTE: Caution: Anchor brackets must be properly installed (bolted to the frame upright with bolts properly torque to 65 ft-lbs., +10, -0 ft-lbs.) and the frame must be properly secured to the concrete floor using the appropriate seismic floor mounting kit. Installing the frame in any other manner may reduce the load and/or seismic performance of the installation. Fastening to adjacent frames, securing the frame to overhead structure, etc., may also be added, but these do not replace proper installation of the seismic floor mounting kit. Once the frame is mounted to the floor, you can begin to install the interbay management and end guards. The interbay should be installed first. 12 FxDS Part #: 012010 TIP: The interbay has a “flanged” top to support itself during installation. This should help when building the frame by yourself. Hang the interbay from the top of the frame as shown below, and attach with the included hardware. Once the interbay has been installed, the end guards can be installed. TIP: The end guard has a “flanged” top to support itself during installation. This should help when building the frame by yourself. 13 FxDS Part #: 012010 Now, install the male hinge section to the end guard as shown below. TIP: Install the hinge piece to the adjustment plate before attaching the adjustment plate to the end guard. IMPORTANT NOTE: If the frame is going to be mounted next to a wall or it is multiple frames in a line up you must install the interbay management and end guards BEFORE mounting the frame to the floor. Once the interbay, end guards and frame is mounted you can add the end guard supports bars. These may also be called crossover or stabilizing bars. 14 FxDS Part #: 012010 Now, you can add the doors. After the hinges are added the door simply hang into the mating hinge on the end guards. TIP: Install the hinge piece to the adjustment plate before attaching the adjustment plate to the end guard. IMPORTANT NOTE: 4 doors are included with each kit. Make sure the female hinges are installed with the right orientation so that you end up with 2 left hand and 2 right hand doors. The doors serve as your front protection. TIP: The panels that will be installed into this frame will not have the front smoke colored protection. Install the hinges in the door as follows: 15 FxDS Part #: 012010 Now, you can add the trough. The FxDS Frame system comes in multiple configurations. The troughs show below may differ from the version the customer purchased. Installation is essentially the same. IMPORTANT NOTE: Standard troughing can be easily installed at anytime. The SmartRoute Troughs MUST be installed before installing the patch panels. Install the ground bar. The ground bar enclosed in the crate can be installed at either the top or bottom of the frame. 16 FxDS Part #: 012010 Installation should be similar to drawings below front view on the left, rear view on the right. The below drawings reflect SmartRoute troughs. 17 FxDS Part #: 012010 Finished Frames 18 FxDS Part #: 012010 FieldSmart Standard Frame Installation Standard Telco frames are a packaged in regular cardboard. The standard Telco frames that Clearfield stocks are 7’, 8’ and 9’ heights in both 19” and 23” widths. IMPORTANT NOTE: Floor mounting hardware is NOT included with the frame. Hardware is sold as a separate line item. 19 FxDS Part #: 012010 Standard Floor Installation Tools (required or recommended): 1. 2. 3. Hammer (or rotary) drill (with depth gauge recommended) 5/8 masonry drill bit Blowout air bulb or vacuum with small diameter tube. First determine where the frame is going to be installed. Using the isolation pad as a template mark the 4 holes where frame will be secured to the floor. 19” FRAME Using a 5/8” masonry bit, drill the four required holes to a minimum depth of 100 mm (approx. 4”). Thoroughly clean the dust from each hole, using an air blowout or vacuum device. Verify that the anchor’s minimum embedment depth of 80 mm (approx. 3”) using the seismic anchors. This is marked by a ring on the sleeve of the anchor. TIP: If for some reason you have trouble drill the 5/8” hole, we recommend first drilling a ¼” pilot hole before drilling out to 5/8”. IMPORTANT NOTE: To not degrade the anchor’s installed performance, any unused anchor holes (or other nearby holes) in the concrete, within 3” must be filled with an epoxy filler (pour stone) or equivalent. Filled holes must be fully cured before anchors are installed and torque. 20 FxDS Part #: 012010 If not already in place, install the anchor brackets inside the frame base. Secure the anchor brackets (left hand and right hand respectively) to the frame’s uprights using two (2) grade 5 or better 1/2”-13 x 1-1/2” cap screws, lock washers and hex nuts in each anchor bracket. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. Place isolation pad in position over the predrilled holes and align as necessary. Lift frame onto isolation pad and line up with holes. Ensure that the anchor’s expansion shield is not expanded. Place the end of the anchor into the predrilled hole. Repeat for the other drilled holes. Align the edges of the 2” square washer parallel with the slots in the frame base to obtain the maximum material overlap. Once aligned, tap each anchor/washer assembly until it is seated in the hole and firmly against the 2” square washer. Pre-tighten each anchor with a socket wrench or box-end wrench; do not use an open-end wrench (which could easily slip off and cause injury). Before final tightening, ensure that the frame is properly aligned (in the row and with any adjacent frames). IMPORTANT NOTE: Torque each anchor to 60 ft-lbs. When using the break off type anchor, a torque wrench is not required since the anchor’s (red) torque cap shears off at a predetermined torque value (approximately 60 ft-lbs.), leaving a green seal on the bolt head, indicating proper tightening. The anchoring line up should look as follows. 21 FxDS Part #: 012010 Raised Floor Installation Tools (required or recommended): 1. 2. 3. Hammer (or rotary) drill (with depth gauge recommended) 5/8 masonry drill bit Blowout air bulb or vacuum with small diameter tube. First determine where the frame is going to be installed. Using the isolation pad as a template mark the 4 holes where frame will be secured to the floor. Also required is a raised floor mounting kit – Clearfield recommends part number 011236. Screw sequence for floor Screw sequence for frame TIP: Clearfield recommends installing the anchors directly into the concrete floor. 22 FxDS Part #: 012010 Using the isolation pad as a guide, mark on the panel(s) of the raised floor where the frame is going to be mounted. 19” FRAME Replace the floor panels to their appropriate spots and, using a 5/8” drill bit, drill a hole through each of the oblong marks you made with the isolation pad. See examples below. Take the threaded roads from the raised floor mounting kit and slide through each one of the holes. Using a hammer and holding them perpendicular to the floor, tap on the end firmly. The goal is to make a “mark” on the concrete floor visible enough to see where the 4 holes should be drilled. 23 FxDS Part #: 012010 Once the concrete floor is marked, remove the threaded rods and floor panels. Using a 5/8” masonry bit, drill the four required holes to a minimum depth of 2”). IMPORTANT NOTE: Thoroughly clean the dust from each hole, using a vacuum device. TIP: If for some reason you have trouble drill the 5/8” hole, we recommend first drilling a ¼” pilot hole before drilling out to 5/8” IMPORTANT NOTE: To not degrade the anchor’s installed performance, any unused anchor holes (or other nearby holes) in the concrete, within 3” must be filled with an epoxy filler (pour stone) or equivalent. Filled holes must be fully cured before anchors are installed and torque. Install anchors into the floor. Replace raise floor panels and insert threaded rods through the four holes. IMPORTANT NOTE: You are not installing the rods at this point. We are measuring the rods to be cut to the appropriate length. Measure the rods 2.5” above the floor and mark with an indelible marker. Remove the rods and cut each rod at the mark. Remove the floor panels. 24 FxDS Part #: 012010 Before installing rods into the floor back, place nut, then washer, on the threaded rods. Take rod and install into the anchor installed in the floor. Tighten the nut down to secure the rod into the floor. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. The anchor will expand and secure itself to the floor TIP: Once all four rods are secure, thread another hex nut, then washer on each rod. Make sure the nut and washer are approximately ½” below the raised floor level. This hardware will be tightened down AFTER the frame is set into place but BEFORE the securely bolting the frame to the floor. Place the floor panels into position. Put isolation pad into place (Isolation pad may look different than example). Lift frame into place. Install the isolation bushing (packaged with the isolation pad) onto each rod. Install the remaining hardware (washers, nuts, etc) from the raised floor installation kit. TIP: The square washer shown ships with the actual frame and is not part of the raised floor installation kit. 25 FxDS Part #: 012010 If not already in place, install the anchor brackets inside the frame base. Secure the anchor brackets (left hand and right hand respectively) to the frame’s uprights using two (2) grade 5 or better 1/2”-13 x 1-1/2” cap screws, lock washers and hex nuts in each anchor bracket. Tighten each bolt to 65 ft-lbs., +10, -0 ft-lbs. IMPORTANT NOTE: Caution: Anchor brackets must be properly installed (bolted to the frame upright with bolts properly torque to 65 ft-lbs., +10, -0 ft-lbs.) and the frame must be properly secured to the concrete floor using the appropriate seismic floor mounting kit. Installing the frame in any other manner may reduce the load and/or seismic performance of the installation. Fastening to adjacent frames, securing the frame to overhead structure, etc., may also be added, but these do not replace proper installation of the seismic floor mounting kit. Once the frame is mounted to the floor, you can begin to install the interbay management and end guards. The interbay should be installed first. Attach the interbay and end guards from the top of the frame as shown below, and attach with the included hardware. IMPORTANT NOTE: The 9 foot interbay is shipped in two pieces per side. End guards are only needed on frames at the end of the frame line-up. Once the interbay has been installed, the end guards can be installed. You can now ground per your local NEC practices. The frame is now ready for patch panels, troughs, etc. 26 FxDS Part #: 012010 Patch Panels Installation in the FxDS Frame System Now that the frames are mounted securely to the floor, they are ready for patch panels. IMPORTANT NOTE: All FieldSmart panels & troughs (Patch & Splice panels, patch only panels, tie panels, optical component chassis, crossover panels, crossover troughs, slack management troughs, etc) are all mounted and secure to the frame in the same manner. Patch & Splice Patch Panel The patch panels come boxed individually with the appropriate mounting hardware and technical documentation for each Clearview Cassette. Patch and Splice panel bulkheads are designed for a 19” frame. Since the FxDS frame is a 19” frame installation is quick and easy. Simply unpack the panel and, while supporting the panels in the desire location, screw in the 4 mounting screws (2 per side) to secure the panel to the frame. The panel is mounted into the frame by using the provided 12-24 x ½” thread cutting screws. It is recommended that two screws are used on each side. In order to help align the panel, it is also recommended that vertical and horizontal holes are used on each side for mounting. IMPORTANT NOTE: All FieldSmart panels & troughs (Patch & Splice panels, patch only panels, tie panels) mounted and secured to the frame in the same manner. Before splicing remove the patch and splice cassettes. Feed the buffer tubes for all ports on the left side of the panel, through the front of the panel, to the right side of the bulkhead (when looking from the rear of the panel.) SEE SPLICING MANUAL FOR SPLICING IN THE CLEARVIEW CASSETTE. After splicing the fibers into the cassettes, feed the buffer tubes back through the bulkhead and install the cassette into the bulkhead in the appropriate port location. After splicing and mounting the cassettes back in the panel it is time to store the buffer tube slack. 27 FxDS Part #: 012010 Mounting the Incoming Cable Choose a green clamp shell that is close to the same size but slightly bigger than the cable you plan to mount. The difference in size can be made up by either wrapping the cable with some of the provided grommet tape, or laying a small strip of tape in the bottom of the side of the clamp shell. The bracket and clamp are mounted as shown below. IMPORTANT NOTE: The angle of cable mounting can be adjusted by pivoting the bracket on one of the mounting holes and securing it down with the other. A greater range of angles can be achieved by flipping the bracket over. When bringing fiber to a patch & splice panel, to store the required buffer tube slack, you need to use part number 010600 in pairs. This part number is ordered and shipped separately from the frame kit or panels. 28 FxDS Part #: 012010 Patch Only Panels Patch only panels are mounted in the same way EXCEPT the patch only tail may need to be “fed” through the panel and routed into the appropriate ladder racks for securing the panel to the frame. IMPORTANT NOTE: The cable for the patch only panel is clamped off on the back of the frame using the provided bracket, clamps and screws. IMPORTANT NOTE: For the panel just below the middle SmartRoute Trough, we recommend you use the offset bracket (part number 012270). Mounting the cable would be the same. Once the panels are mounted and cables clamped off, route the fiber cable to the appopriate ladder racking. Below is a picture of patch and splcie panels moutned in the top half of the frame and patch only panels mounted in the bottom part of the frame. 29 FxDS Part #: 012010 Tie Panel Installation Simply unpack the panel, and while supporting the panels in the desire location, screw in the four mounting screws (2 per side) to secure the panel to the frame. The panel is mounted into the frame by using the provided 12-24 x ½” thread cutting screws. It is recommended that two screws are used on each side. In order to help align the panel, it is also recommended that vertical and horizontal holes are used on each side for mounting. TIP: FxDS frame are only 19” so the 23” extenders would not be needed. For mounting panels to a 23” frame attached the provided “extender” brackets, they are secured to the ends of the panels using (2) 12-24 x ½” screws on each end. This will allow the panel to be mounted onto a 23” frame using the same method described above for a 19” frame. Below is an example of a 23” extender bracket for a 6” chassis, how it is mounted to the panel and the panel mounted to the frame. 30 FxDS Part #: 012010 For the incoming multi-fiber slack storage is performed in the rear protection of the panel. Before bringing in the fiber install the included self-adhesive foam separators and cable management clips. Trim the foam separators to the correct height for the panel that is being installed. IMPORTANT NOTE: The 1RU panel will NOT have the separator and the 288 panel will have (4) separators. (2) will be stacked on top of each other. Remove the protective tape of the adhesive and install the separators on the edges of the panel approximately half way from the front of the panel to the back. TIP: The adhesive is fairly aggressive so make sure you know where to place the pieces before removing the protective tape of the adhesive. Once installed let sit for a few minutes. Do not worry if they are not in the exact location as long as they are not too close to the tie plate adapters to not allow for a proper bed radius. Install the cable management clips in the locations indicated. IMPORTANT NOTE: Top cover is removed to show install. 31 FxDS Part #: 012010 Once the cable management is set you can install and route the fiber into the panel. Clamping off the incoming multi-fiber is the same method as our standard panels. Use the included mounting screws to fasten the green clam shells and cable to the rear cable bracket. The cable should be mounted so that the breakout is slightly beyond the end of the clamp. If bringing all the jumpers into the tie panels the cables can either be bundled and wrapped in foam tape to clamp to the back of the panel, or tied to the provided bridge lances. TIP: If bring in jumpers periodically it is recommended you use zip ties and bridge lance to secure the jumpers. This will make it easier to unsecure and re-secure the jumpers when fiber is added. 32 FxDS Part #: 012010 FxDS PON Kit The FxDS PON Kit allows the user to have the ability to install up to (36) 1x32 PON circuits onto an FxDS frame system. It is comprised of 2 576-port bulkhead panels that are self contained with specialized fiber management for the 1x 32 ruggedized splitters. IMPORTANT NOTE: The PON insert is designed to only be used in a FxDS frame system. There is a FxDS frame system configuration specially designed for the PON insert. Because of the PON insert width the configuration does not have interbay management spool. If you have a standard FxDS Fame you will need to remove the interbay spools on the frame that would interfere with the bulkhead (the right picture). The bulkhead panel can now be installed using the provided hardware. The bulk head is very large and should be installed without any cassette or fiber installed. Due to its size, load the insert without any cassette in it. TIP: The top 24 ports on both sides are the feeder ports for their respective sides. They are tie plates with adapters to allow for plugging in the back, jumpers from the active gear. 33 FxDS Part #: 012010 Optical splitters can then be installed by first inserting the splitter into the provided splitter cage, and routing around the outside of the panel to the top parking block bracket. In the bottom left and right corner of the panel, you will find a routing guide to help determine the proper spool to route the splitter legs over when deploying. You will notice that the provided desi-card has corresponding color coded squares. Simply route the cable over the spool associated with the color of the port you intend to activate and the slack will be properly addressed. IMPORTANT NOTE: Splitters can only be routed and deployed on their respective side of the insert. Each half of the PON Insert holds (9) splitters. There are more feeder ports than (9) allowing for pass through ports if needed. 34 FxDS Part #: 012010 Patch Panels Installation in the Standard Frame Now that the frames are mounted securely to the floor, they are ready for patch panels. Patch & Splice Patch Panel The patch panels come boxed individually with the appropriate mounting hardware and technical documentation for each Clearview Cassette. Patch and Splice panel bulkheads are designed for a 19” frame. Since the FxDS Frame is a 19” frame, installation is quick and easy. Simply unpack the panel, and while supporting the panels in the desire location, screw in the four mounting screws (2 per side) to secure the panel to the frame. The panel is mounted into the frame by using the provided 1224 x ½” thread cutting screws. It is recommended that two screws are used on each side. In order to help align the panel, it is also recommended that vertical and horizontal holes are used on each side for mounting. For mounting panels to a 23” frame attached the provided “extender” brackets, they are secured to the ends of the panels using (2) 12-24 x ½” screws on each end. This will allow the panel to be mounted onto a 23” frame using the same method described above for a 19” frame 35 FxDS Part #: 012010 Below is an example of a 23” extender bracket for a 6” chassis, how it is mounted to the panel and the panel mounted to the frame. For patch and splice panels, (all sizes other than 1RU) buffer tube slack storage is performed in the slack basket which is part of the panels rear protection. See the 1RU directions below. SEE THE SPLICING MANUAL FOR PREPPING THE FIBER AND SPLICING IN THE CLEARVIEW CASSETTE. Use the included mounting screws to fasten the clamp shells and cable to the rear cable bracket. The cable should be mounted so that the breakout is slightly beyond the end of the clamp. 36 FxDS Part #: 012010 Feed the buffer tubes for all ports on the left side of the panel, through the front of the panel, to the right side of the bulkhead (when looking from the rear of the panel). After splicing the fibers into the cassettes, feed the buffer tubes back through the bulkhead and install the cassette into the bulkhead in the appropriate port location. Feed the right side buffer tubes in order, through the front of the panel, starting at the top and alternating every other tube with the existing buffer tubes on the right. Note: Buffer tubes from the right and left sides should be interwoven as shown. Splice and install the cassettes for the right side of the panel, in the same fashion as the right side, until the panel is fully spliced in. Coil the buffer tube slack in loops that will fit into the slack storage basket and be retained by the tabs as shown. After the buffer tubes are coiled, use the included Velcro to secure the buffer tubes in the locations shown. 37 FxDS Part #: 012010 Carefully close and latch the slack storage basket, paying attention to not damage the buffer tubes. When using the 1 RU panel, please use the following steps to store the buffer tube slack in the panel after splicing. After splicing the cassettes and reinserting them into the bulkhead, start by coiling up the buffer tubes from each cassette into a coil around 6-8" in diameter. The coil can be secured with the provided Velcro. TIP: If the buffer tube used in spicing a 2 RU panel is too stiff to coil in the slack basket, the slack can be stored in the same fashion as the 1RU panel. The buffer tubes can then be inserted—one above and one below the cassettes—in the panel. 38 FxDS Part #: 012010 Patch Only Panels Patch only panels are mounted in the same way EXCEPT the patch only tail may need to be “fed” through the panel and routed into the appropriate ladder racks for securing the panel to the frame. For patch only panels the fiber cable is factory clamped to the back of the panel before the product is shipped to the customer. IMPORTANT NOTE: All FieldSmart panels & troughs (Patch & Splice panels, patch only panels, tie panels, optical component chassis, crossover panels, crossover troughs, slack management troughs, etc) are all mounted and secure to the frame in the same manner. For mounting panels to a 23” frame attached the provided “extender” brackets, they are secured to the ends of the panels using (2) 12-24 x ½” screws on each end. This will allow the panel to be mounted onto a 23” frame using the same method described above for a 19” frame Below is an example of a 23” extender bracket for a 6” chassis, how it is mounted to the panel and the panel mounted to the frame. 39 FxDS Part #: 012010 Optional Fiber Cable Mounting Methods Each panel comes with two types of cable mounting brackets. One is used for applications where you have access to pre-drilled and tapped holes in the back of the frame, and one is for instances where these holes are not available. TIP: The standard frame Clearfield offers already has rear mounting holes so these clamps are not needed This bracket is for frames with no rear mounting holes. This bracket is for frames equipped with rear mounting holes. If no rear mounting holes are available, the other bracket can be used. You will need to hold the bracket up to the frame and drill a #10 size hole into the frame as shown. Then, you can mount the bracket using the self-tapping screw included with the panel. The angle of the cable can be adjusted by using different sets of threaded holes in the bracket. Drill here 40 FxDS Part #: 012010 6-drawer Splice Deck Installation IMPORTANT NOTE: The splice deck can only be mounted to 23” standard Telco frame. The splice deck is 6” tall and comes with open brackets. The splice deck is installed by inserting the panel from the front of the frame and securing with the enclosed #12-24 screws. IMPORTANT NOTE: In order to assure the panel is centered in the frame, install at least one screw in a vertical slot on the bracket. To assure the panel is installed level in the frame, be sure to insert a screw in like horizontal slots of both brackets. Once the splice deck is mounted, to access the splicing drawers, pull out the push / pulls at the top of the door and lift the door from the hinges and set aside. Once the door is removed, open a splicing drawer by pushing both black locks toward the center of the drawer and pulling the drawer straight out. TIP: The drawer will NOT come completely out of the panel. 41 FxDS Part #: 012010 Cable Routing The 12-fiber distribution pigtails that will be spliced into the splice deck should be routed in the rear of the frame. IMPORTANT NOTE: Ensure that the pigtails are NOT TIGHT around the radius spool when tying off. Tie the pairs of pigtails as shown – piggy backed vertically. Pigtails are inserted into the drawers at the time of installation, not tied into the drawers. Tie pigtails to the back of the panel using the enclosed grommet tape and wax coated string. Route pairs of 12-fiber pigtails smoothly around the radius spool without crossing. Tie off points with extra string are located in the drawer and back of panel. If panel and splice tray are purchased separately, leave extra string when tying down IFC tails. This string will be used later for tying down OSP sub-units. When routing the fiber into the drawer, assure the pigtails stay uncrossed as they pass through the slack take-up slide and enter the panel. IMPORTANT NOTE: Depending on your cable entry, the slack take-up slide can be reversed by disconnecting the spring and reconnecting it to the alternative anchor point on the opposite side of the drawer. TIP: Orient the slack take-up slide BEFORE routing cable through it. 42 FxDS Part #: 012010 Once you have the fiber routed through form the back and the splice drawer completely open tie the two pigtails to the splice drawer. Pull the pigtails toward you and outward against the slack take-up-slide until the rivet in the slack take-up-slide aligns with the arrow on the slack take-up label. Maintaining the tension on the pigtails, mark them where they intersect the tie-off point. Cut and apply the supplied grommet tape to the pigtails at the mark. Apply tension to the pigtails and tie them to the drawer. This will allow the spring to take up the slack in the drawer when it is closed. Leave approximately 6” of extra wax string for later tying of the OSP sub-units. The incoming OSP cable can be clamped either directly to the splice deck… For either method, remove the desired amount of outer jacket. Locate the green clamp shells and corresponding mounting screws from the ship-along hardware. Determine which clamp best fits the cable to be installed. The clamp shells are used in the same size pairs. TIP: Avoid using a clamp that is too small and does not easily closer around the cable. Use the next larger clamp and grommet tape. Adhere a strip of foam tape (included in the ship-along hardware) to at least one side of the clamp. 43 FxDS Part #: 012010 Use the included mounting screws to fasten the clamp shells and cable to the appropriate cable bracket. The cable should be mounted so that the breakout is slightly beyond the clamp. The OSP buffer tubes are then routed on top of the IFC tails and secured with the remaining wax string and grommet tape. IFC and loose tube slack should be routed in the same direction as seen in. IMPORTANT NOTE: All fiber should enter a splice deck and drawers from the same side to allow proper drawer operation The splice deck is now ready. Strip the jacket off of both the IFC and OSP fibers. Clean and splice. 44 FxDS Part #: 012010 Fiber Entrance Cabinet (FEC) Cabinet The FieldSmart FEC is built on a modular platform scaling 288 HSF or 864 mass fusion (ribbon) fiber splices at a time. Lockable cupboard style doors allow for easy access with minimal swing clearance required for tight aisle clearances. The fiber entrance cabinet comes with 1 clamp kit and the hardware to attach to a wall. IMPORTANT NOTE: The base cabinet does NOT come with any splice trays. They are sold separately. The FEC does NOT come with hardware to mount to the wall. Depending on the type or style of the wall the end user should obtain the appropriate hardware from their local hardware store. TIP: There are (4) mounting holes. The mounting holes are .350” in diameter. The FEC Cabinet is 17.5” high x 34.5” wide and 8.25’ deep. Optional locking kit available (part number 010503) and is installed by two screw at the top and two on the bottom. Lock is not provided. Locking tab should be positioned to the right when installed. The parts below are shipped along with the FEC. The parts include the clamp kit and the plates to cover the numerous cable entry / exit points. Item Number Item Description Quantity 001527 002127 SCREW,ROUND HEAD,PHILLIPS,1/4-20 X 1 1/2" PLUG,BUTTON,BLACK POLYETHYLENE,FITS 1-5/16in HOLE X .01in-.10in THICK PANEL 8 14 003042 TAPE,GROMMETING,1",STRIPPING=1/8" X 1", COMES IN 5' STRIPS,SELL AS FEET IN 5' INCREMENTS STRAP,VELCRO,BLACK,1/2" WIDE,COMES IN 75' ROLLS,SELL IN FEET SADDLE,CLAMPING,1/2" DIAMETER, GREEN POLYPROPYLENE,GRP3 SADDLE,CLAMPING,1" DIAMETER, GREEN POLYPROPYLENE,GRP3 SCREW,PAN HEAD,PHILLIPS,10-32 X 1/4",18-8 SST BRACKET,FEC ENCLOSURE PLATE, COVER, FEC, ENCLOSURE 5 003083 003711 003716 009217 009902 009909 45 2 4 4 32 4 15 FxDS Part #: 012010 Once the FEC is mounted to the wall, you are now ready to route fiber into the cabinet. Multiple entry/exit points allow for multiple distribution and OSP fiber sheaths to enter into the FEC from top, bottom, or sidewalls transitioning from conduit, overhead fiber tray or raised flooring. Cable entry / exit points are locate around the perimeter if the cabinet. See picture below. TIP: Each cable entrance plate will support cable diameters up to 1 inch. The cabinet comes with 4 sheet metal brackets for cable mounting and 16 blank plastic plates. The cables can be installed with either the clamps on the outside of the cabinet or on with the clamps on the inside of the cabinet for extra security. Plugs are also included in the kit to fill the unused holes. NOTE: Grommet tape included in the kit may need to be used to build up the cable size to get a better grip with the provided clamps. A removable splice block, holding twelve 24-fiber splice trays, allows the user access and prep away from the cabinet. IMPORTANT NOTE: Splice trays are sold separately. 46 FxDS Part #: 012010 Intuitive buffer tube and subunit slack routing prevents cable tie-in’s with a clockwise routing scheme to allowing quick and easy re-entry after initial deployment or to add additional capacity. If the cables are to be carried from one cabinet into the next, then the supports blank plates and bracket plates will not need to be used between the two cabinets. There is a removable bracket on all of the top and bottom entrances that will allow you to lay cables in without having to cut them. After choosing the entrance that will be used for your cables you will need to plan your cable route within the cabinet. All cables should eventually route in a clockwise direction. Depending on where you enter the box you may have to use the redirect spool in order to achieve a clockwise rotation. No redirect used Redirect used TIP: After all cables are routing the correct direction and there is an adequate amount of slack in the cabinet, the cables tie down locations can be marked with a permanent marker. Each splice tray can hold either 24 single splices or 6 ribbon splices. 47 FxDS Part #: 012010 The entire block of splice trays can be removed for splicing by loosening the thumb screw in the top left corner and lifting the block of splice trays. After splicing the splice trays can be secured into place using the included Velcro strap. Thumbscrew Velcro FEC Cabinets are easily grounded using the integrated ground bar. The FEC can be ganged together, in modular fashion, allowing scalability up to 864 fiber splices and beyond if vertical real estate is available. Below is an example of multiple FEC’s ganged together. 48 FxDS Part #: 012010 High Density Ribbon Break Out Installation Instructions These instructions detail the installation of the High Density (864 fibers max) Ribbon Break Out kit. This kit will allow the user to breakout a high fiber count cable into manageable 144 fiber groups that can then be further broken out with the use of the 144 Ribbon Fan Out kit FMA‐MZZ. Components Each High Density Ribbon Breakout kit contains the following components: 1. Large Liquid tight fittings and nut a. For cable sizes .51‐.79” #005397 b. For cable sizes .71‐.98” #005441 c. Hex nut for fitting #004117 2. Housing with cover and screws #010334 3. Small liquid tight fitting and nut a. Fitting for conduit #010407 4. Hex nut for fitting #010549 Tools The following tools will be needed: A. Phillips screw driver B. Cable jacket stripper C. Central tube cutter D. Indelible marker E. Gel Cleaner F. Knife or razor blade G. FMA‐MZZ (144 fiber ribbon breakout kit) Determine the Strip Length To calculate the total strip length of the cable adds the following measurable distances together: A. The longest distance from the mounting location of the housing to the panel or ribbon breakout location. B. The amount of fiber to extend past the individual ribbon breakout (amount of exposed ribbon in the splice tray). C. 85 inches (length of ribbon furcation tubes in FMA‐MZZ. Measure backward from the end of the cable the total distance calculated and mark the cable. This is the outer jacket strip point for the cable. 49 FxDS Part #: 012010 Measuring and Cutting Conduit Measure the distance needed to go from the mounting location of the housing to the individual breakout locations and cut the conduit to that length using a sharp knife or razor blade. Avoid using scissors or a side cutting tool as this may crush the conduit. Liquid Tight Fittings and Housing Preparation Choose the appropriate large fitting based on the cable diameter and remove the hex nut from the fitting (if installed). Install the fitting from the outside of the housing and secure with the hex nut. Install the required number of smaller fittings (1 per 144 fiber breakout kit to be installed) on the other end of the housing in the same fashion. Plug the extra holes with the provided dust plugs. Loosen the dome nut on the smaller fittings and insert the conduit until it bottoms out in the fitting and then tighten the dome nut. Cable End Preparation Loosen the dome nut on the large fitting and slide the housing assembly onto the end of the cable past the mark created. Strip the jacket back to the mark created. Remove any strength member materials. Central Tube Preparation Mark the central tube ½ inch from the end of the outer jacket. Score and remove 6 to 10 inches of the tube at a time until you have removed all the tube back the mark. Be careful not to break any fibers. Carefully separate the fiber ribbons from each other. Wipe all of the gel from the exposed ribbon using a gel cleaner or isopropyl alcohol. Clean the outside of the remaining central tube. Securing the Cable and Feeding the Ribbon Stacks Slide the cable back until there is approximately 1 to 2 inches beyond the liquid tight fitting inside the housing and tighten the dome nut to secure it in place. Group the ribbon stacks into groups of 144 fibers (or smaller if desired) and use a piece of tape to hold the ends together. NOTE: A small pull string can be attached at this same time if desired. Feed or pull the ribbon stacks through the small fittings and the associated conduit. 50 FxDS Part #: 012010 Installing the Ribbon Fan Out Kit The ribbon fan-out kits FMA‐MZZ are then installed to the end of the conduit per the instructions included in the kit. NOTE: Treat the conduit as if it were a separate piece of cable when installing the kit. You may need to pad the conduit with some of the included foam tape before installing the screw type hose clamp. 51 FxDS Part #: 012010