3M 4220 Series User manual

1
December 2000
78-8130-1625-6-B
4220/4230 Series RH/XP Cabinets
for Rehab and Expansion
(AT&T/Lucent and HUB Cabinets with 76 type blocks)
Instructions

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TABLE OF CONTENTS
1.0 ENGINEERING AND CABINET SELECTION ................................................................................... 3
1.1 Engineering .................................................................................................................................................. 3
1.2 Cabinet Selection - “RH” Single Sided Cabinets ........................................................................................ 4
1.3 Cabinet Selection - “XP” Double Sided Cabinets....................................................................................... 6
1.4 Cabinet Clearances ...................................................................................................................................... 8
1.5 Mounting Pad .............................................................................................................................................. 8
1.6 Special Tools for Project.............................................................................................................................. 9
1.7 Check List .................................................................................................................................................... 9
2.0 REMOVAL OF THE OLD CABINET .................................................................................................. 10
2.1 Pivoting Frames ......................................................................................................................................... 10
2.2 Non-Pivoting Frames................................................................................................................................. 11
3.0 MOUNTING PAD AND NEW CABINET INSTALLATION ............................................................. 14
3.1 Using Existing Pad .................................................................................................................................... 14
3.2 Factory Built Pre-cast Split Pad ................................................................................................................ 14
3.3 Field Build a Concrete Pour-in-Place Pad................................................................................................. 15
3.4 Mounting New Cabinet on Slab ................................................................................................................ 16
4.0 MOUNTING EXISTING 76 BLOCK FRAMES .................................................................................... 17
4.1 4220 ET/RH or 4220 EET/XP Cabinets .................................................................................................... 17
4.2 F, G, KF or K series of RH and XP Cabinets ............................................................................................ 18
4.3 “Special Conversion Cabinets” ................................................................................................................. 22
5.0 FINISHING THE CABINET AND MOUNTING NEW FRAMES ...................................................... 24
5.1 Shield Bonding . ........................................................................................................................................ 24
5.2 Sealing Cable in the 4297 FPE Flexible Port Entry of the Cabinets......................................................... 24
5.3 Mounting New Expansion Frames on the Existing Frame Cabinet Side.................................................. 25
5.4 Adding New Expansion Frames to the back of the New Cabinet ............................................................. 25
5.5 Wire Management and Splicing ................................................................................................................ 26
5.6 Bind Post Label Installation ...................................................................................................................... 26
5.7 Jumper Wire Installation and Routing ....................................................................................................... 27
5.8 Accessories Installation ............................................................................................................................. 28

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1.0 Engineering and Cabinet Selection
The 4220 and 4230 Series of "RH" and "XP" Cabinets are used for the rehabilitation or expansion of existing
AT&T, Lucent or HUB cross connect cabinets. The new cabinets include brackets for the mounting of the
existing 76 terminal block frames and can be ordered to include new frames to add pair count to the cabinet
using the 3M™4320 Self-Strip System.
1.1 Engineering
a. To properly engineer a project using these cabinets, a "Pre-survey Trip" to the project site must be
made and four main questions have to be answered.
1) What specific size and type of old cabinet is on the project?
2) Are there any site "right-of-way" limitations?
(a) Does the new cabinet have to be single sided?
(1) -is there a fence or wall obstructions?
(2) -is there any community code height restrictions?
(b) Can the new cabinet be double sided?
3) Can the existing mounting pad be used?
(a) Is the pad level and not deteriorated?
(b) Where are the existing cable ducts?
(c) Are there spare ducts or room for new ducts for expansion?
(d) What are the dimensions of the pad?
(e) Can the pad be enlarged?
(f) If the existing mounting pad cannot be used, is a new "split" factory built pad or
a new "pour in place" concrete pad right for this project?
4) If this is an expansion, how many pairs are desired to be added, now or in the future?
(a) Are the number of pairs limited by the site or cabinet configuration?
(b) Should pairs be added to just the rear of a new double sided cabinet?

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Table I - Single Sided Applications
Existing Hub, AT&T Maximum Pairs Other Materials
Drawing or Lucent Frame added on Front Side Cabinet Required Used
1 1200 0 4220-ET/RH Empty None
Requires Order:
2 1200 600 4220-F Empty (1) 4230-RH/XP Hardware kit
SS6 frame
Requires Order:
4230-F/RH Empty SS300 frame
3 1800 Low Profile 300
(3 rows of 600 pairs) Requires Order:
4220-F Empty (1) 4230-RH/XP Hardware kit
SS300 frame
Includes:
4 1800 Low Profile 900 4220-KF/R -1800/2700 3 ea. SS2 frames
(3 rows of 600 pairs) Special Conversion 1 ea. SS300 frame
Cabinet (not standard frames)
Requires Order:
4230-KF/RH Empty SS9K frame
5 1800 Standard Height 900
(2 rows of 900 pairs) Requires Order:
4220-KF/R Empty (2) 4230-RH/XP Hardware kit
SS9K frame
Requires Order:
4230-KF/RH Empty SS450 frame
6 2700 450 Requires Order:
4220-KF/R Empty (2) 4230-RH/XP Hardware kit
SS450 frame
4230-LF/RH- Includes:
7 2700 900 on a 1350 frame 2700/3600 1 ea SS1350-9
Special Conversion
Cabinet
1.2 Cabinet Selection - "RH" Single Sided Cabinets
a. The "RH" single sided cabinet provides a new cover over the existing 76 block frames and
INCLUDES BRACKETS to hold the frames. Pair capactity can be increased on the same side of the
new cabinet from 300 to 1350 pairs by mounting new 4230 Self-Strip block frames. See Table I for
the options available.
b. The 4220-F Empty (1), and the 4220-KF/R Empty (2) are narrow cabinets and can be used when the
cabinet site has obstructions (fence or wall) or limited space for the use of the 4230 series cabinet.
The 4230-RH/XP Hardware Kit IS NOT included with the 4220 Cabinets and must be ordered
separately.
c. The Self-Strip block frames can be ordered with 3M 710 Connectors (T) or 3M 4005 CBM Modules
(CBM) for the field terminations. Using the SS6 in Drawing 2 that requires an order as an example,
this frame contains SS (Self-Strip blocks), 6 (600 pair) and add a T for the 710 connectors.

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Frame Layout for “RH” Cabinets
1
Existing 1200 Pair
2
Existing1200Pair
3
New 300 Pair Frame
Existing1800Pair
4
New 300 Pair Frame
Existing1800Pair
5
New 900 Pair Frame
Existing1800Pair
6
New 450 Pair Frame
Existing2700Pair
7
Existing2700Pair
New 1350 Pair Frame
New 600 Pair Frame
New 200
Pair
New 200
Pair
New 200
Pair
(not standard frames)

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Table II - Double Sided Applications
Existing Hub, AT&T Maximum Pairs Other Materials
Drawing or Lucent Frame added on Rear Side Cabinet Required Used
Requires Order:
8 1200 1350 4220-EET/XP Empty SS1350 frame (Opt.)
SS1350-6 frame (Opt.)
SS1350-9 frame (Opt.)
Requires Order:
4230-G/XP Empty SS6 frame(s)
4246 chamber cover(s)
9 1800 Low Profile 1800
(3 rows of 600 pairs) Includes:
4230-G/XP/900SST 1 ea. SS6 frame
1 ea. SS6-3 frame
1 ea. 4246 chamber cover
Requires Order:
4230-K/XP Empty SS9K frame(s)
4246K chamber cover(s)
10 1800 Standard Height 2700
(2 rows of 900 pairs) Includes:
4230-K/XP/900SST 1 ea. SS9K frame
2 ea. 4246-K chamber covers
Requires Order:
4230-K/XP Empty SS9K frame(s)
4246K chamber cover(s)
11 2700 2700 Includes:
4230-K/XP/900SST 1 ea. SS9K frame
2 ea. 4246-K chamber covers
Includes:
12 3600 1800 4230-K/XP-3600/5400 6 ea. SS2 frames
Special Conversion 2 ea. SS300T frames
Cabinet (not standard frames)
1.3 Cabinet Selection - "XP" Double Sided Cabinets
a. The "XP" double sided cabinet provides a new cover over the existing 76 block frames and
INCLUDES BRACKETS to hold the frames. Pair capacity can be increased on both sides of the
new cabinet by mounting new 4230 Self-Strip block frames. See Table II for the options available.
b. The "XP Cabinet comes with and without additional 4230 Self-Strip Block frames.
c. The Self-Strip block frames can be ordered with 3M 710 Connectors (T) or 3M 4005 CBM Modules
(CBM) for the field terminations. Using the SS6 in Drawing 9 that requires an order as an example,
this frame contains SS (Self-Strip blocks), 6 (600 pair) and add a T for the 710 connectors.

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8
Existing1200Pair
FRONT REAR
New1350PairFrame
REAR
9
Filler Panel
Filler Panel
Existing1800Pair
FRONT
10
Existing1800Pair
FRONT REAR
11
Existing2700Pair
FRONT REAR
12
New 300 Pair Frame
Existing1800Pair
FRONT
New 300 Pair Frame
Existing1800Pair
REAR
New 200
Pair
New 200
Pair New 200
Pair
New 200
Pair
New 200
Pair New 200
Pair
New 900 Pair Frame
New 900 Pair Frame
New 900 Pair Frame
New 900 Pair Frame
New 900 Pair Frame
New 900 Pair Frame
New 900 Pair Frame
New 600 Pair Frame
New 600 Pair Frame
New 600 Pair Frame
Frame Layout for “XP”Cabinets
(not standard frames)

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4220ET/EET 4220F/G/KF/K 4230F/G/KF/K 4230LF
A 36 1/2" 57 1/2" 57 1/2" 77”
B 18" 18" 26" 26”
C 33 1/2" 27 3/8" 27 3/8" 40”
D* 85" 72 3/4" 80 3/4" --
*Double sided cabinets only
D
C
B
Cabinet Clearance
A
1.4 Cabinet Clearances
Use the chart and drawing to help select the appropriate new cabinet. On your “Presurvey”trip, be aware of
any barriers or obstructions around the existing cabinet that would restrict the size of the new cabinet.
Cabinet Clearance Chart and Drawing
1.5 Mounting Pad
a. Existing Mounting Pad
1) It is recommended to use the existing pad or add concrete around it with new anchors and bolts
whenever possible. Make sure that it is level and not deteriorating.
2) Many existing pads are constructed with the old cabinet and cable ports located near the rear
edge of the pad. Using the dimensions from the clearance chart, verify that the pad will
accommodate the new cabinet. The existing pad must exceed the “A”and “B”dimensions as
follows:
- “A”dimension by 2 1/2"
- “B”dimension by 11" on both side of the cable hole for the 4230 series
- “B”dimension by 7" on both side of the cable hole for the 4220 series
3) It is recommended that the pad extend to cover the full door swing for both sides of the cabinet.
b. Split Composite Pads (factory built)
See your companies manufacturers for pad dimension. This method does require the removal of the
old pad.

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Recommended Pad Size
A
F
B
4"
(4256 F/G
mounting ring shown)
E
C
cable entry
area
D
c. Concrete "Pour-in-Place" Mounting Pad
1. If you are to pour a new concrete pad, it should be built before the old cabinet is removed.
2. The 3M 4256-E/EE or 4256-F/G/K Mounting Rings will be used to position the cables and
attach the anchors.
3. The drawing and chart are the recommended measurements for the pad, but if the site has
limitations, a smaller pad can be used with an increase in pad depth (more than 4").
1.6 Special tools required for the expansion and rehab projects
a. Normal hand tools needed for a mechanical job, ie. socket set, open end wrenches etc.
b. Reciprocating saw with a fast cutting metal blade
c. Heavy duty grinder
d. Power drill/hammer drill (if using existing pad)
e. Concrete saw/jackhammer (to remove existing pad)
f. "A" Frame or Boom Truck (if using a pour in place pad)
g. Power screw driver
h. Electrical Generator
i. 4411 Pedestal Base Sealant or equivalent expanding form
1.7 Check List of Things Done Before the Start of the Project
a. Completed the "Pre survey" trip.
b. Ordered correct sized cabinet from Tables I or II.
c. Ordered additional frames and all accessories for the project, if required from Tables I or II.
d. Ordered composite pad or 4256 Series Mounting Ring, if required.
E/EE F/G/KF/K LF
A53”74”88”
B75”75”75”
C15”32”32”
D19”21”28”
E7”7”7”
F34”34”34”
Cabinets

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2.0 Removal of the Old Cabinet
Note: If a new concrete "pour-in-place" pad is to be used, it should be poured before the old cabinet is
removed. See Section 3.3.
Note: “Double sided” old cabinet removal is covered in Section 4.3.b.
Note: The following tools are required for the rehab or expansion project:
a) Normal hand tools needed for a mechanical job, i.e. socket set, open end wrenches etc.
b) Reciprocating saw with a fast cutting metal blade
c) Heavy duty grinder
d) Power drill/hammer drill (if using existing pad)
e) Concrete saw/jackhammer (to remove existing pad)
f) "A" Frame or Boom Truck (if using a pour in place pad)
g) Power screw driver
h) Electrical Generator
i) 4411 Pedestal Base Sealant or equivalent expanding form
2.1 Procedures for Removing Old Cabinets with Pivoting Frames
The Top Drop-Down Bracket from the new cabinet can be installed during this procedure.
a. Open cabinet door(s) and remove the base access
plate(s). Clean away the gravel and remove the
bolts holding the cabinet to the pad.
b. Disconnect all bond wires from the cabinet bond
bar. Temporarily connect them together.
Hub Cabinets
c. Unbolt and remove top and bottom pieces from the base access window of the cabinet.
AT&T Cabinets
d. Cut off and remove the top and bottom portion of the base access window with a reciprocating saw.
Make four cuts, one in each corner of the window. Tilt the cabinet backward to cut the bottom. Do
not cut into the frame.
Remove
Bolts
Cut
Locations

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e. Unlatch the frame top from the cabinet and tilt it forward.
f. Install the Top Drop-Down Bracket with the AT&T or HUB position to the frame. Position this
bracket on the two row frames so the frame will be on the left side of the cabinet. Reuse the 1/4"
bolts from the Hub Cabinet and use the #10 self-drilling screws for the AT&T frame.
g. Lower the frame and cut off anything securing
the cable and 76 block wires to the cabinet.
Lift the frame out of the front side of the
cabinet. Protect the wirework and support it,
block face down, off the ground with a
splicer's box.
h. Slide the old cabinet away from the cables and
frame.
i. Remove and save any test clips, binder post
logs and jumper information from the old
cabinet for the new cabinet.
2.2 Procedures for Removing Old Cabinets with
NON-Pivoting Frames
All non-pivot frames will be changed to a pivoting
frame with the Top Drop-Down Bracket and Pivot
Conversion Bracket from the new cabinet.
a. Open cabinet door(s) and remove the base access
plate(s). Clean away the gravel and remove the
bolts holding the cabinet to the pad.
b. Disconnect all bond wires from the cabinet
bond bar. Temporarily connect them together.
Hub AT&T
Hub
Side
AT&T
Side
Top Drop-Down Bracket

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c. Some old cabinet frames and jumper runs are
held together by a panel that is riveted to the
cabinet or a bracket riveted to the cabinet. This
assembly must be removed as one piece by
grinding off the rivet heads holding the panel to
the end walls and drilling or punching out the
rivet shafts.
d. Loosen the bolts at the top of the frame. Remove
the bolts from the bottom of the frames and
jumper runs. Pull the frame out from the cabinet.
e. Screw the Pivot Conversion Bracket to the bottom of the frame and jumper runs with the #10 self
drilling screws provided.
f. Cut off and remove the top and bottom position
of the access window with a reciprocating saw.
Make four cuts, one in each corner of the
window. Tilt the cabinet backward to cut the
bottom. Do not cut into the frame or the
Pivot Conversion Bracket.

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Hub
Side
AT&T
Side
AT&T
g. Unbolt the top of the frames and jumper
runs from the cabinet and pull them away
from the cabinet.
i. Lower the frame and cut off anything
securing the cable and 76 block wires to
the cabinet. Lift the frame out of the
cabinet. Protect the wirework and support
it block face down, off the ground with a
splicer's box.
j. Slide the old cabinet away from the cables
and frame.
k. Remove any test clips and copy all binding
post logs and jumper information from the
old cabinet for the new cabinet.
h. Install the Top Drop-Down Bracket with the AT&T position to the top of the frame using the #10
self-drilling screws. Position this bracket on the two row frames so the frame will be on the left side
of the cabinet.

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3.0 Mounting Pad and New Cabinet Installation
Note: There are three options to use for the mounting pad of the new cabinet.
3.1 Using the Existing Pad
If the existing pad is level, in good condition and meets the minimum size requirements in section 1.5a,
it can be used to mount the new cabinet. Concrete can be added to it to meet these size requirements
before the old cabinet is removed.
a. Mark the location of the 4 anchor bolts, either internal or external mounting positions, on the pad by
using a cabinet Mounting Ring or the new cabinet. Drill the holes and install 1/2" threaded concrete
inserts into the pad.
3.2 Factory Built Pre-cast Split Pad
Use this method when the site pad is in bad
condition and needs to be replaced.
a. Break up and remove the old pad. Place
addition cable duct sweeps for future additions.
Spread 1"-2" of sand to level the new pad site.
b. Remove side segment of the split pad. Place
the pad around the cable area. Level the pad
and reinstall the segment.

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3.3 Field Build a Concrete Pour-in-Place Pad
Use this method when the site pad is in bad condition and needs to be replaced. The new pad should be
installed before the old cabinet is removed. Use a 3M™4256-E/EE or 4256-F/G/K Mounting Ring with
this application.
a. Open the cabinet door(s) and remove the base access plate(s).
Clear out the gravel and remove the bolts holding the cabinet to
the pad.
b. Check the cables and bond wires for enough slack for cabinet
movement, cut cable ties if necessary. Lift the old cabinet 4"-5"
above the old pad with a boom truck or "A" frame.
c. Break up and remove the old pad.
d. Build the forms to the recommended size. Place addition cable
duct sweeps for future additions. and box the cable ducts to block
the concrete flow. If the size of the site is limited, build a smaller
pad to the minimum dimensions in section 1.5a, with the concrete
thickness increased for stability.
e. Cut out the removable section of the mounting ring and attach the anchors and bolts to the internal or
external location, 4256 F/G/K is shown.
Opening Opening
Cable duct location markers
Internal Mount
Removable section for rehab
External Mount
62"
19"
Recommended Pad Size
(4256 F/G mounting ring shown)
A
F
B
4"
E
C
cable entry
area
D
f. Pour and level the concrete in the forms and place the mounting ring around cables and ducts. Press
the mounting ring into the SOFT concrete and level. Allow the concrete to dry for 24 hours.
E/EE F/G/KF/K LF
A53”74”88”
B75”75”75”
C15”32”32”
D19”21”28”
E7”7”7”
F34”34”34”
Cabinets

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3.4 Mount the New Cabinet on the Pad
a. Reposition the cabinet's two lifting straps up, attach a sling to them and handle the cabinet with a
boom truck. If a boom truck is not available, remove all frames from the cabinet to minimize weight.
b. Remove the back panel(s) and open the door(s).
Remove frames on the base cover plate side and
Pivot Support Bracket. Larger cabinets have
factory mounted Filler Panels that may be
removed for easier cabinet handling.
c. Remove the base cover plate, Flexible Port Entry Plate and bottom frame support, if present.
d. Lift the cabinet and align it to the anchors, the cabinet has external and internal mounting holes. Use
the clips and 1/2" bolts from the parts bag, and loosely bolt the cabinet to the pad. If needed, align
the doors by leveling the cabinet using the shims and then tighten the bolts.
e. Replace the bottom frame support, base cover plate, and Flexible Port Entry Plate. Remove the
cabinet lifting straps and reinstall the bolts with the carriage head to the outside.
f. Address label the cabinet, install the old test clips and record all binding post and jumper information
from the old cabinet according to your company practice.
g. The new cabinet is ready for the existing frame and expansion frames to be installed.
Plate

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4.0 Mounting Existing 76 Block
Frames in the New Cabinets
4.1 4220-ET/RH or 4220-EET/XP Cabinets
These cabinets include the Top Mount Bracket
and Pivot Support Bracket.
a. Loosen the bolts of the Top Mount Bracket
in the cabinet, so it can be adjusted with
the top of the frame. If needed, reposition
it to the Hub side of the bracket facing the
existing frame.
Top Mount
Bracket
Pivot Support
Bracket
Screws, nuts
& sleeves
for Hub pivot
Top Mount Bracket
(shown AT&T side
outward)
b. Reinstall the Pivot Support Bracket into the cabinet. The cable and frame wires must be on top of the
bracket. When needed, install the bolts, sleeves, washers and nuts to the bracket for a Hub frame.
Hub Frame

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4.2 F, G, KF or K series of RH and XP Cabinets
All non-pivot frames will be converted to pivot by the "Pivot Conversion Bracket".
c. Set the frame's pivots onto the Pivot Support
Bracket and swing the frame up to the top
bracket. Adjust the top bracket to align it with
the top of the frame. Secure the AT&T frame
to the Top Mounting Bracket using the #10
self-drilling screws. The Hub frame uses the
1/4" bolts and nuts from the old cabinet frame
mounting.
1
2
3
4
5
6
6
5. 2 Bottom Frame Support Assemblies
for 300/450 and 600/900 pair frames
6. 2 Filler Panels (short or tall)
(Factory Installed)
The new cabinet includes:
1. Top Mounting Bracket (Factory Installed)
2. Top Drop-Down Bracket
3. Pivot Support Bracket with Hub hardware
4. Pivot Conversion Bracket

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a. Assemble the Pivot Support Bracket parts as required for the specific type of frame.
2700 pair-3 row
1800 pair-2 row
Optional-Cut off
when using for
1800 pair
1200 pair-2 row
1800 pair-3 row
Optional-Cut off
when using for
1200 pair
AT&T
1800-2 row
2700-3 row
AT&T
1200-2 row
1800-3 row
HUB
2700-3 row
HUB
1800-3 row
HUB
1200-2 row
Optional-Cut off
when using for
1200 pair

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c. Loosen the Top Mount Bracket in the cabinet
so it can be adjusted to the Top Drop-Down
Bracket attached to the top of the frame.
d. Place the Pivot Support Bracket onto the
cabinet base but don't secure it. Lay the frame
onto the bracket and carefully swing the frame
up to the Top Mounting Bracket. The top of the
HUB 2700 pair frame is tall and may need to
have a slot cut into it to clear the cabinet's door
latch retainer.
e. There are two attachment positions on the Top
Mounting Bracket for the Top Drop-Down
Bracket, in the center and left of center.
Hub AT&T
Hub
Side
AT&T
Side
Top Drop-Down Bracket
b. If the Top Drop-Down Bracket was not attached to the frame during frame removal from the old
cabinet, install it with the AT&T or HUB position to the frame. Position this bracket on the two row
frames so the frame will be on the left side of the cabinet. Reuse the 1/4" bolts from the Hub Cabinet
and use the #10 Self drilling screws for the AT&T frame.
Top Mount Bracket