ADC PG-FlexPlus PG-CAB001 User manual

Section SCP-PGCAB001-010-01H
PG-FlexPlus Field Cabinet
Technical Practice
Model List CLEI Code
PG-CAB001 1 VABA1Z0N~~

July 19, 2004 SCP-PGCAB001-010-01H
ADC Telecommunications, Inc. i
REVISION HISTORY
Copyright © 2004 ADC Telecommunications, Inc. All Rights Reserved.
ADC is a registered trademark of ADC Telecommunications, Inc. PG-Plus, PG-Flex and PG-FlexPlus are registered
trademarks of ADC Telecommunications, Inc. No right, license, or interest to such trademarks is granted hereunder,
and you agree that you shall assert no such right, license, or interest with respect to such trademarks.
Other product names mentioned in this document are used for identification purposes only and may be trademarks
or registered trademarks of their respective companies.
Information contained in this document is company private to ADC Telecommunications, Inc., and shall not be
modified, used, copied, reproduced or disclosed in whole or in part without the written consent of ADC.
Contents herein are current as of the date of publication. ADC reserves the right to change specifications at any time
without notice. Information furnished by ADC is believed to be accurate and reliable. In no event shall ADC be liable
for any damages resulting from the loss of data, loss of use, or loss of profits and ADC further disclaims any and all
liability for indirect, incidental, special, consequential or other similar damages. This disclaimer of liability applies to
all products, publications and services during and after the warranty period.
Revision Release Date Revisions Made
01 July 19, 2004 Initial Release

SCP-PGCAB001-010-01H July 19, 2004
ii ADC Telecommunications, Inc.
USING THIS TECHNICAL PRACTICE
The following style conventions and terminology are used throughout this guide.
INSPECTING YOUR SHIPMENT
Upon receipt of the equipment:
• Unpack each container and visually inspect the contents for signs of damage. If the equipment has been dam-
aged in transit, immediately report the extent of damage to the transportation company and to ADC. Order
replacement equipment, if necessary.
• Check the packing list to ensure complete and accurate shipment of each listed item. If the shipment is short or
irregular, contact ADC as described in Product Support on page 55. If you must store the equipment for a pro-
longed period, store the equipment in its original container.
Reader Alert Meaning
Alerts you to supplementary information
!
IMPORTANT Alerts you to supplementary information that is essential to the completion of a task
ATTENTION
Alerts you to possible equipment damage from electrostatic discharge
CAUTION Alerts you to possible data loss, service-affecting procedures, or other similar type problems
WARNING Alerts you that failure to take or avoid a specific action might result in hardware damage or
loss of service
DANGER Alerts you that failure to take or avoid a specific action might result in personal harm

Table of Contents
July 19, 2004 SCP-PGCAB001-010-01H
ADC Telecommunications, Inc. iii
Revision History ...................................................................................................................... i
Using this Technical Practice ..................................................................................................ii
Inspecting Your Shipment .......................................................................................................ii
Field Cabinet Description ........................................................................................................ 1
Introduction ........................................................................................................................ 1
Features ............................................................................................................................ 1
Construction and Finish .................................................................................................... 1
Weight ............................................................................................................................... 2
Dimensions ....................................................................................................................... 2
Compartments ...................................................................................................................3
Electronics Compartment ............................................................................................ 3
Side Chamber .............................................................................................................. 4
Battery Compartment ................................................................................................... 4
Security ........................................................................................................................ 4
Environmental Control ....................................................................................................... 4
Cooling System ............................................................................................................ 4
6F-Fan Unit .................................................................................................................. 5
Heat Exchangers ......................................................................................................... 5
Battery Heating and Cooling ........................................................................................ 6
Battery Heaters ...................................................................................................... 6
Battery Cooling ....................................................................................................... 6
Site Planning ........................................................................................................................... 7
Overview ........................................................................................................................... 7
Site Selection .................................................................................................................... 7
Functional .................................................................................................................... 7
Easement Size ............................................................................................................. 7
Thermal Site Considerations ....................................................................................... 8
Electrical Considerations ............................................................................................. 8
Safety ........................................................................................................................... 8
Right-of-Way ................................................................................................................ 9
Field Cabinet Installation ........................................................................................................ 10
Overview ........................................................................................................................... 10
Handling ............................................................................................................................ 10
Storage .............................................................................................................................. 10
Field Cabinet Placement ................................................................................................... 12

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Field Cabinet Grounding ................................................................................................... 12
Equipment and Materials Required for Field Cabinet Grounding ................................ 12
Field Cabinet Grounding Requirements ...................................................................... 13
Field Cabinet Grounding Procedures .......................................................................... 13
AC Service Installation ............................................................................................................ 16
Overview ........................................................................................................................... 16
Precautions ....................................................................................................................... 16
Utility Power Connections ................................................................................................. 16
Bulk Power System ................................................................................................................. 17
Overview ........................................................................................................................... 17
Description ........................................................................................................................ 17
Valere Power System ....................................................................................................... 18
Valere Plug-Ins - System Controller ............................................................................. 18
Distribution Module ................................................................................................. 18
Rectifiers ................................................................................................................ 18
Batteries ............................................................................................................................ 19
Alarm Interface Panel ........................................................................................................ 19
Metallic Cable Termination and Wiring ................................................................................... 20
Overview ........................................................................................................................... 20
Precautions ....................................................................................................................... 20
Weather ....................................................................................................................... 20
Preparation ........................................................................................................................ 20
AC Power ..................................................................................................................... 20
Field Cabinet and Hardware Preparation .................................................................... 21
Digital Cable Pair Splicing and Termination ...................................................................... 22
PG-FlexPlus HDSL (Tip/Ring) Pairs and Test Pair Splicing .............................................. 24
Splice Completion ........................................................................................................ 24
Intrashelf Connection ........................................................................................................ 26
Protector Installation .......................................................................................................... 26
Alarm Interface Panel ........................................................................................................ 27
Battery Installation .................................................................................................................. 28
Overview ........................................................................................................................... 28
Substitute Battery Types .................................................................................................... 28
Other DC Power Systems ................................................................................................. 28
Safety Precautions ............................................................................................................ 28
IR-30, IR-40, and TEL-12-45 SLC Battery Installation ...................................................... 29
Procedure .................................................................................................................... 29

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Tyco 12IR125 or C&D FA12-125 Battery Installation ....................................................... 31
Procedure .................................................................................................................... 31
Replacement and Repair Parts ............................................................................................... 33
Cabinet Power System Turn-up .............................................................................................. 35
Overview ........................................................................................................................... 35
Tools and Materials ........................................................................................................... 35
Installation of Valere Modules ........................................................................................... 35
Module Names ............................................................................................................. 35
Preparing to Install the Modules .................................................................................. 35
Installing the System Controller .................................................................................. 36
Installing the Rectifier Modules .................................................................................... 36
Controller Set Up ......................................................................................................... 36
Verify Plant Voltage and Current .................................................................................. 36
Post Test .....................................................................................................................36
Test Access and Alarms .........................................................................................................37
Overview ........................................................................................................................... 37
Test Access ....................................................................................................................... 37
DC Test Pair ................................................................................................................. 37
Digital Pairs ..................................................................................................................37
Alarms ............................................................................................................................... 39
Alarm Interface Panel .................................................................................................. 39
Troubleshooting ........................................................................................................... 42
Equipment Alarms ....................................................................................................... 42
Power System Alarms ................................................................................................. 42
Field Cabinet Environmental Alarms ........................................................................... 43
Intrusion Alarm ............................................................................................................. 44
Field Equipment Installation and Cabinet Maintenance ......................................................... 45
Overview ........................................................................................................................... 45
Field Equipment Installation .............................................................................................. 45
Tools ............................................................................................................................. 45
Generic Equipment Installation Procedure .................................................................. 45
Maintenance ...................................................................................................................... 46
Routine Inspection Procedure ..................................................................................... 46
Check Battery Compartment/HX Air Inlets ............................................................. 46
Check Surge Arrester ............................................................................................. 46
Check AC Circuit Breakers .................................................................................... 46
Check GFCI Outlet ................................................................................................. 46

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Inspect Field Cabinet Mounting Bracket ................................................................ 46
Fan Replacement Procedures ..................................................................................... 47
6F-type Fan Unit Replacement Procedure ............................................................ 47
Heat Exchanger Fan Replacement Procedure ...................................................... 47
Batteries ....................................................................................................................... 48
Battery Heater Pads .................................................................................................... 48
Battery Heater Pad Inspection Procedure ............................................................. 48
Battery Heater Pad Replacement Procedure ......................................................... 49
........................................................................................................................................... 49
Glossary .................................................................................................................................. 51
Product Support ...................................................................................................................... 55
Technical Support ..............................................................................................................55
Limited Warranty ...............................................................................................................55
Returns .............................................................................................................................. 55
FCC Class A Compliance ....................................................................................................... 56
Modifications ..................................................................................................................... 56

List of Figures
July 19, 2004 SCP-PGCAB001-010-01H
ADC Telecommunications, Inc. vii
Figure 1. PG-FlexPlus Field Cabinet Dimensions (Shown With Heat Exchanger) .............. 2
Figure 2. PG-FlexPlus Field Cabinet Layout (Front View – Shown With Field Cabinet
Door Removed) ........................................................................................................ 3
Figure 3. PG-FlexPlus Field Cabinet Clearance Requirements ........................................... 9
Figure 4. Securing a Packed Field Cabinet for Shipping ...................................................... 11
Figure 5. Securing an Unpacked Field Cabinet for Shipping ................................................ 11
Figure 6. Grounding Requirements for PG-FlexPlus Field Cabinet
(Shown With Field Cabinet Door Removed) ...........................................................14
Figure 7. Grounding Requirements for Multi-Field Cabinet Installation ................................ 15
Figure 8. Bulk Power System Block Diagram ....................................................................... 17
Figure 9. Intrashelf Cable Assignments ................................................................................ 26
Figure 10. Securing the Thermal Probes to Tyco IR-30 or IR-40 Batteries ............................ 29
Figure 11. Tyco IR-30 or IR-40 Battery Installation Layout in PG-FlexPlus Field Cabinet ..... 30
Figure 12. 12IR125 Battery Installation Layout (PG-FlexPlus Field Cabinet Shown) ............ 32
Figure 13. Tyco 12IR125 or C&D FA12-125 Battery Installation and Interconnection ........... 32
Figure 14. W4DF Looping Test Cord ...................................................................................... 37
Figure 15. 6W3E Test Cord .................................................................................................... 38
Figure 16. Wiring of Miscellaneous Pairs ............................................................................... 38
Figure 17. Alarm Interface Panel ............................................................................................ 40
Figure 18. Front View Cabinet Alarms to Alarm Inputs .......................................................... 41
Figure 19. Door Switch ........................................................................................................... 44
Figure 20. Heat Exchanger Fan Installation ........................................................................... 48

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List of Tables
July 19, 2004 SCP-PGCAB001-010-01H
ADC Telecommunications, Inc. ix
Table 1. PG-FlexPlus Field Cabinet ..................................................................................... 2
Table 2. PG-FlexPlus Dimensions ....................................................................................... 2
Table 3. Thermostat Temperature Set Points ...................................................................... 5
Table 4. Standard Pad and Minimum Functional Easements .............................................. 7
Table 5. Maximum Current Consumption of Standard Field Cabinet Configurations .......... 16
Table 6. Battery Options ....................................................................................................... 19
Table 7. Sheath Identification and Function ......................................................................... 21
Table 8. Network T1/HDSL Cable Assignments .................................................................. 23
Table 9. PG-FlexPlus HDSL Cable Assignments ................................................................ 25
Table 10. Test Pair ................................................................................................................. 26
Table 11. Replacement and Repair Parts .............................................................................. 33
Table 12. Miscellaneous Supplemental Items ........................................................................ 34
Table 13. Standard Modules .................................................................................................. 35
Table 14. Power System Alarm Formats, Abbreviations, and Indicators (P221) ................... 43
Table 15. Environmental Alarm Formats, Abbreviations, and Indicators ............................... 43
Table 16. Battery Heater Pad Inspection Procedure Test Values .......................................... 49

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July 19, 2004 SCP-PGCAB001-010-01H
ADC Telecommunications, Inc. 1
FIELD CABINET DESCRIPTION
INTRODUCTION
The PG-FlexPlus field cabinet is for North American applications. The field cabinet houses telephony equipment
along with batteries to supply backup power.
In a typical application, the PG-FlexPlus field cabinet houses an extension of the central office allowing telephony to
be served efficiently to remote business and residential communities. The PG-FlexPlus field cabinet is tested for
compliance to Telcordia GR-487.
This section describes the PG-FlexPlus field cabinet system configurations including design highlights, features, and
physical specifications.
FEATURES
The field cabinet design includes several attractive features such as:
• Side access splicing
– Eases installation by separating splicing from the electronics
– Provides more splicing area
• Field cabinet designed for slide-in placement
• Separate under-cabinet battery compartment
– Keeps battery temperatures lower for longer battery life
– Does not occupy valuable equipment space
• Patented enhanced cooling system
– Allows greater equipment heat dissipation for more equipment or higher traffic rates
– Eliminates possibility of hydrogen accumulation in battery compartment
– Cools batteries
• Pad, pole, H-frame, floor or wall mounting options
– Flexibility for site selection.
CONSTRUCTION AND FINISH
The PG-FlexPlus field cabinet’s features are:
• Rugged heavy-gauge aluminum construction
• Weather, fire, vandal, and corrosion-resistant
• Durable baked-on polyester powder paint in an ultra-light gray color
• High-gloss finish to minimize accumulation of dirt and soot
• Aesthetically pleasing to enhance public acceptance
• Security
– Special hex key with padlock hasp used to open all doors (standard)

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WEIGHT
The approximate weights of the PG-FlexPlus field cabinet are listed in Table 1.
Table 1. PG-FlexPlus Field Cabinet
DIMENSIONS
The dimensions of the PG-FlexPlus field cabinet are listed in Table 2 and illustrated in Figure 1.
Table 2. PG-FlexPlus Dimensions
Figure 1. PG-FlexPlus Field Cabinet Dimensions (Shown With Heat Exchanger)
Shipping Weight
Weight Without Plug-Ins
or Batteries
Weight With Plug-Ins
and Batteries
300 lb (136 kg) 220 lb (100 kg) 700 lb (318 kg)
External Dimensions Internal Dimensions
Height 48 inches (1220 mm) 29 inches (737 mm) usable (1 bay)
Width 36 inches (914 mm) 23 inches (584 mm) nominal
Depth 30 inches (762 mm) 22 inches (559 mm) usable
36
”
(914 mm) 30”
(762 mm)
48”
(1219 mm)
860
1
3
1
9
4
5
-
0
1.
cd
r

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COMPARTMENTS
The PG-FlexPlus field cabinet is divided into two compartments (Figure 2):
• Upper Electronics Compartment
• Lower Battery Compartment
The upper Electronics Compartment houses the Bulk Power System and all of the active electronic gear. The
Battery Compartment is below the Electronics Compartment and is designed to accommodate various types of
batteries for back-up power. All copper, fiber, and AC power cables enter the field cabinet at the bottom left-side of
the field cabinet. The outside plant copper cable(s) are spliced to the field cabinet cables in the splice chamber.
Figure 2. PG-FlexPlus Field Cabinet Layout (Front View – Shown With Field Cabinet Door Removed)
Electronics Compartment
The PG-FlexPlus field cabinet has a one-sided electronics compartment that includes one 23-inch rack, which
provides 29 inches (737 mm) of vertical mounting space below the 6F-fan unit. Access to the electronics
compartment is obtained by using a special hex key to open the front door of the cabinet (Figure 2).
The electronics compartment also contains the Alarm Interface Panel (AIP) and 307 protector block, located to the
left of the rack. The AIP provides an alarm interface and fusing for the field cabinet’s fans. The standard layouts of
electronic equipment in each field cabinet are shown in Figure 2.
Fan Unit
Alarm
interface
panel
Splice area
AC
Junction
box
Ground bus
Cable entry
compartment
Battery
Compartment
23.0”
(
584 mm
)
29.0”
(737 mm
)

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Side Chamber
The side chamber contains:
• AC Power Panel or Junction Box
• 307 Protector Block
• Main Ground Bus for the Cabinet
Rubber cable boots are used to seal the outside plant cables to the entrance ports at the bottom of the side
chamber. The grounding of the outside plant cable shields to the field cabinet ground bus also occurs here.
AC service to the field cabinet enters through the bottom of the side chamber and is fed via conduit to the AC power
panel. An optional bracket is available for mounting an AC power meter to the outside of the field cabinet.
Battery Compartment
The PG-FlexPlus field cabinet battery compartment houses:
• Multiple 48 V DC strings of batteries for backup power
• Thermostatically-controlled, AC-powered battery heaters that protect the batteries from reduced capacity due to
cold temperatures
• Battery temperature probes for monitoring battery temperature
• Heat exchanger and battery cooling fans.
Refer to Table 6 on page 19 for battery options and capacities.
Security
The field cabinet door is accessed using the special hex key and can be padlocked, if required. As an option, a key
entry lock may be ordered and installed to secure the door. The battery panel and cable entrance panel can only be
removed by first opening the field cabinet door.
ENVIRONMENTAL CONTROL
Cooling System
The PG-FlexPlus field cabinet was designed with new enhanced cooling features. The field cabinet uses a patent-
pending enhanced cooling system, which includes:
•6F-fanunits
• Door ducts
• Door-mounted heat exchanger
No outside air is introduced into the electronics portion of the field cabinet for cooling purposes.

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6F-Fan Unit
A 6F-fan unit is mounted at the top of the electronics compartment to circulate air through the equipment to minimize
critical component temperatures. The motors of the fan units remain on at all times, which improves the life of the
electronics by minimizing stress due to thermal cycling. This also ensures good thermal coupling between the field
cabinet air and the circuit packs, preventing the occurrence of hot spots. Moving the heat from the equipment to the
field cabinet air allows the field cabinet to dissipate it to the outside environment.
In the PG-FlexPlus field cabinet, the 6F-fan unit pulls internal field cabinet air upward through the electronic
equipment and exhausts the air into the top plenum. This air then enters and travels down the front duct, exiting at
the bottom. The cooled air exiting at the bottom of the duct re-enters the equipment stack at the bottom of the rack.
This field cabinet is equipped with a door-mounted heat exchanger. Heat exchanger fans draw outside air through
the battery compartment and blows it through the outside heat exchanger plenum, exhausting the warm air through
louvers at the top of the door. The high velocity air in the heat exchanger plenum considerably increases the amount
of heat eliminated from the field cabinet.
Heat Exchangers
A convoluted-core heat exchanger (highest performing heat exchanger offered by CommScope) is provided with the
PG-FlexPlus field cabinet.
The heat exchanger is located on the PG-FlexPlus field cabinet’s front door. Two environmentally protected fans are
included with this heat exchanger. These fans are environmentally protected to provide long life in corrosive
environments.
The fans draw outside air through louvers at the bottom of the front door and exhaust the air into the heat exchanger
plenum. The warmed air then exits through vents at the top of the door on the outside of the field cabinet. A small
amount of air from the HX intake is vented into the battery compartment which exits through the vents on the left-
side of the battery compartment. Equipment heat is brought into the heat exchanger for cooling by the 6F-fan unit
mounted at the top the equipment rack.
The two heat exchanger fans on each door are controlled by two separate thermostats. The low-temperature
thermostat ensures that heat exchanger fans are off at very cold ambient temperatures, which maximizes the night-
time cooling of batteries. The high-temperature thermostat operates the fans only when the equipment compartment
is hot which allows the field cabinet to run quieter at night, though night-time battery cooling is sacrificed.
Thermostat set points are listed in Table 3.
Table 3. Thermostat Temperature Set Points
Thermostat
Type
Monitored
Temperature
Turn ON
(±5°F) (±3°C)
Turn OFF
(±5°F) (±3°C)
Low Battery
Compartment
55°F (13°C) 37°F (3°C)
High Equipment
Compartment
131°F (55°C) 117°F (47°C)

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Battery Heating and Cooling
Battery Heaters
The provided battery heater is located beneath the plate on which the batteries rest. It is designed to prevent the
loss of battery reserve capacity that occurs when batteries are exposed to cold temperatures. The heater is
connected to a thermostat that is set to operate the heater pad when it senses battery temperatures below 32°F
±5°F (0°C ±3°C) and shut them off when it senses above 50°C ±5°F (10°C ±3°C).
Battery Cooling
Battery cooling is provided by the heat exchanger door. The heat exchanger pushes air through vents in the door of
the field cabinet and exhausts the air through vents on the left side of the battery compartment. Outside air, drawn
past the batteries by the heat exchanger, reduces the heating of the batteries that otherwise occurs as a result of
solar heating of the battery compartment sides, by the equipment heat in the field cabinet, and self-heating due to
charging.
This resulting reduction in battery temperature extends the life of batteries.

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SITE PLANNING
OVERVIEW
This section describes the selection of PG-FlexPlus field cabinet sites based on existing plant configurations,
economics, and functional requirements such as zoning restrictions. The impact of site selection on field cabinet
and electronic equipment performance is also discussed. Plan the location of the PG-FlexPlus field cabinet site
ahead of time, taking into consideration the requirements described in this section.
SITE SELECTION
The field cabinet site should be selected based on existing plant configurations, economics, permanency, public
acceptance, and functional requirements. The final physical location of the field cabinet is determined by a field
inspection. Some of the factors in evaluating a possible site are discussed in the following paragraphs.
Functional
Unless a field cabinet is pole-mounted, it should not be located in an area that is prone to flooding or is constantly
damp. Soil maps for the area should be checked for subsurface conditions. Whenever possible, a field cabinet
should be located in an area that does not require extensive earthwork. Local zoning restrictions should be checked
to verify that the field cabinet can be used. Consideration should be given to specific requirements such as
easements, minimum lot sizes, and type of landscaping.
Sufficient parking and turnaround space should be allowed for the installation and maintenance vehicles, including
trailer-mounted motor-generator sets, if required.
Easement Size
When selecting an installation site, choose a location that has a minimum functional easement large enough to walk
around the field cabinet with its doors in their fully open and locked position. Table 4 shows the area required for the
field cabinets when the doors are opened to their locked positions. The PG-FlexPlus field cabinet doors extend
beyond the standard pad size.
Table 4. Standard Pad and Minimum Functional Easements
Figure 3 on page 9 shows the clearance areas required by the PG-FlexPlus field cabinet. See Field Cabinet
Installation and the field cabinet foundation pad drawing, ED-1T339-01, for additional information.
Standard Pad Size Minimal Functional Easement
84 in x 74.5 inches
(2133 mm x 1892 mm)
108 in x 102 inches
(2740 mm x 2590 mm)

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Thermal Site Considerations
In all but the coldest of climates, proper site selection can improve the life of the electronics and batteries in the field
cabinet. This can be done by:
•Reducing the field cabinet’s exposure to the afternoon sun
Peak daily ambient temperature is generally attained between 2 p.m. and 3 p.m. The afternoon sun in combina-
tion with the high afternoon ambient temperature results in the maximum temperature rise inside of the field cab-
inet. Situating the field cabinet such that it is only exposed to the early morning and/or evening sun will reduce
the maximum temperature of the equipment and batteries inside of the field cabinet, thus extending their life.
•Increasing the field cabinet’s exposure to wind
The greater the exposure to wind, the cooler the equipment inside will run, again extending equipment life. Solid
fences around the field cabinet are not desirable since they can block wind but not the overhead sun.
•Placing the field cabinet away from blacktop surfaces
Blacktop surfaces will collect and radiate heat onto the field cabinet. Grass or dirt provides a much cooler, more
favorable environment for the field cabinet.
Electrical Considerations
The availability of AC service, need for power meter, transfer switch, or generator inlet needs to be factored into the
site requirements. Refer to AC Service Installation on page 16 for the field cabinet's requirements for electrical
service.
If a power pedestal is required, the size of the concrete pad may need to be larger to accommodate both the field
cabinet and the pedestal. As a result, the easement for the field cabinet may also need to be larger.
Safety
Whenever possible, a field cabinet should be located in vacant, unused, and out-of-sight portions of private, public,
or commercial property with easy access and adequate parking. If a field cabinet must be located near a street or
highway, it should be located away from curves and busy intersections.