Calix ODC-3000 User manual

Calix ODC-3000 Installation Guide
July 2008
#220-00183, Rev 10

Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Contents
About This Guide......................................................................7
Chapter 1: ODC-3000 Product Overview................................9
Cabinet Description.................................................................................................10
Cabinet Features .....................................................................................................11
Cabinet Options.......................................................................................................12
Cabinet Dimensions and Weights..........................................................................13
Cabinet Compartments ...........................................................................................14
Chapter 2: Installation Considerations ................................17
Installation Process Overview................................................................................18
Installation Guidelines ............................................................................................19
Space Requirements ...............................................................................................20
General Safety Recommendations ........................................................................21
Installation Kit..........................................................................................................22
User-Supplied Items................................................................................................23
Cabling Requirements ............................................................................................24

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Chapter 3: Preparing the Installation Site............................25
Installing a Ground Circuit......................................................................................26
Constructing a Concrete Pad .................................................................................28
Pad Construction Guidelines ..........................................................................28
Assembling the Cast-In-Place Template.........................................................31
Preparing the Site...........................................................................................33
Casting the Pad ..............................................................................................34
Installing a Pre-Cast Concrete Pad ........................................................................35
Pre-Cast Pad Requirements...........................................................................35
Preparing the Site...........................................................................................38
Installing a Pre-Cast Pad................................................................................39
Chapter 4: Installing the Cabinet ..........................................41
Unpacking the Cabinet............................................................................................42
Operating Cabinet Doors ........................................................................................43
Preparing the Cabinet for Installation....................................................................45
Installing the Cabinet on a Concrete Pad ..............................................................46
Replacing the Lifting Eyebolts ...............................................................................48
Chapter 5: Installing Power...................................................49
Installing the Cabinet Ground Connection............................................................50
Installing AC Power (220-240 VAC)........................................................................51
Chapter 6: Installing and Splicing Outside Plant Cables ...53
Installing Fiber Cable ..............................................................................................54
Installing Outside Plant Fiber Cable................................................................54
Splicing Fibers ................................................................................................56
Routing and Terminating Fibers......................................................................57

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© 2001-2008 Calix. All Rights Reserved.
Installing Metallic Cables ........................................................................................58
Installing Outside Plant Metallic Cables..........................................................58
Splicing Metallic Cables..................................................................................60
Applying T1 Labels to Protection Blocks.........................................................61
Installing 5-Pin Protection Modules.................................................................62
Sealing Cable Entry Locations ...............................................................................63
Chapter 7: Turning Up the Cabinet Power System .............65
Checking the Ground Connection .........................................................................66
Checking the AC Power Supply Voltage ...............................................................67
Installing Rectifier Modules into the Valere Power Shelf .....................................68
Installing Batteries ..................................................................................................70
Turning Up and Testing the DC Power System ....................................................73
Chapter 8: Installing Equipment and Adding Capacity ......75
Installing a C7 Expansion Shelf .............................................................................76
Installing a C7 Fan Tray ..........................................................................................80
Installing a Protection Mounting Frame ................................................................81
Installing a Protection Block ..................................................................................82
Installing a Battery Heater ......................................................................................84
Installing a Seismic Protection Kit.........................................................................85
Installing an AC Meter .............................................................................................88
Installing a Generator Connector...........................................................................89
Installing a Heat Exchanger Door ..........................................................................92
Installing a Fiber Splice Tray Holder......................................................................93
Installing a Fiber Distribution Panel ......................................................................95
Installing a Fiber Distribution Cassette Holder.....................................................96
Installing an xDSL Splitter Shelf ............................................................................98

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© 2001-2008 Calix. All Rights Reserved.
Installing a PON Splitter Kit ..................................................................................101
Removing the Rear Air Plenum Covers ...............................................................102
Chapter 9: Cabinet Maintenance.........................................103
Routine Maintenance ............................................................................................104
Battery Maintenance.....................................................................................104
Checking Electrical Components..................................................................106
Checking Cabinet Surfaces ..........................................................................106
Checking Cable Connections........................................................................107
Replacing Parts and Equipment...........................................................................108
Replacing a Cabinet Door.............................................................................108
Installing a Cabinet Door...............................................................................110
Replacing AC Breakers.................................................................................112
Replacing DC Breakers and Fuses...............................................................113
Replacing Rectifier Modules .........................................................................114
Replacing Batteries.......................................................................................116
Replacing a Battery Heater...........................................................................117
Appendix A: Reference Information...................................119
Specifications ........................................................................................................120
Supported Batteries ..............................................................................................121
Rack Space for Additional Equipment.................................................................121
Environmental Alarm Mapping (to C7).................................................................122
Valere Rectifier Alarm Matrix................................................................................123
Valere Rectifier Setpoints .....................................................................................124
Programming the Valere Shelf Controller ...........................................................126
Rectifier Module Usage Guidelines......................................................................128
Wiring Diagrams ....................................................................................................131
AC Wiring (220-240 VAC).............................................................................132
DC Wiring .....................................................................................................133
Ground Wiring...............................................................................................134
Alarm Wiring.................................................................................................135

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
About This Guide
Purpose
This document provides a general installation practice for the Calix ODC-3000 outdoor
cabinet. This document also provides a general description of the cabinet and its subsystems,
and guidance for planning, site preparation, power installation, splicing to the outside plant,
component installation and expansion, and cabinet maintenance.
Intended Audiences
This document is intended for use by network planning engineers, outside plant engineers,
field support personnel, and craft personnel responsible for cabinet installation, splicing,
equipment installation, and maintenance.
Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy, and, if
not installed and used in accordance with the instruction manual, may cause interference to
radio communications. Operation of this equipment in a residential area may cause harmful
interference; the user will be required to correct the interference at his expense.

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Safety Notices
This document uses the following safety notice conventions.
DANGER! Danger indicates the presence of a hazard that will cause death
or severe personal injury if not avoided.
WARNING! Warning indicates the presence of a hazard that can cause
severe personal injury if not avoided.
CAUTION! Caution indicates the presence of a hazard that can cause
minor to moderate personal injury if not avoided.
ALERT! Alert indicates the presence of a hazard that can cause damage to
equipment, damage to software, loss of data, or service interruption if not
avoided.
DANGER! CLASS 1 LASER PRODUCT. INVISIBLE LASER RADIATION
PRESENT. Fiber optic radiation can cause severe eye damage or
blindness. Do not look into the open end of an optical fiber.

Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Chapter 1
ODC-3000 Product Overview
This chapter provides a general description of the Calix ODC-3000 outdoor cabinet,
including its standard features and options.
Topics Covered
This chapter covers the following topics:
A description of the ODC-3000 cabinet.
A list of cabinet features.
A list of cabinet options.
A view of the cabinet dimensions.
Views of the cabinet compartments.

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Cabinet Description
The Calix ODC-3000 cabinet is an environmentally-controlled outdoor enclosure designed
to house and protect network electronics equipment, including the Calix C-Series, E-Series,
and F-Series access platforms. Use the ODC-3000 to provide network services from a
remote node location, extending the service area beyond the reach of the carrier Central
Office.
The ODC-3000 cabinet supports high density fiber and copper plant terminations, enabling
deployment of a broad suite of applications from a single node. The cabinet's main
electronics compartment is equipped with 23-inch front and rear equipment racks that
provide a total of 108 RU of mounting space. The hinged racks swing outward up to 90
degrees, providing easy rear access to the mounted equipment. The ODC-3000 houses up to
four Calix C7 shelves, serving up to 1920 copper access lines or up to 8192 PON subscribers
(32x split).
The modular design of the ODC-3000 enables incremental field expansion of system
capacity, lowering initial deployment costs while maintaining the capacity for future growth.
Modular components designed for expansion include copper line protection, fiber splicing
and distribution, thermal management, and battery support.

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Cabinet Features
Standard features of the ODC-3000 cabinet include:
Enclosure Design
Environmentally sealed design protects from dust and water intrusion
Compartmentalized for safety, including separate vented battery compartment
Separate splice chambers for copper and fiber entry (with AC on the fiber side)
Environmental and intrusion alarm systems
GR-487 compliant and UL-60950/UL-50 spec
Environmentally rated from -40C to +46C (per GR-487)
Equipment support
Swing out 23-inch front and rear equipment racks
108 RU total mounting space for equipment (27 RU per bay)
Door-mounted heat exchangers (4) provide 7400W of cooling capacity
Mechanical support for high density fiber and copper plant terminations
Modular, scalable copper line protection (50-pair block increments)
Power
220 VAC load center (UL-listed); 60 Amp capacity
AC service disconnect breaker
AC surge suppressor
Redundant AC supplies to DC power system
Convenience outlets (GFCI protected)
Valere compact DC power systems (2) with distribution
Redundant DC supplies to equipment (A and B)
Low voltage DC disconnect (-42V)
Up to 1020 Ah battery reserve capacity (NSB 170FT)

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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Cabinet Options
Common options for the ODC-3000 cabinet include:
Enclosure Mounting
Pre-cast concrete pad mounting
Site-cast concrete pad mounting using Calix template
Calix Platform Equipment
Calix C7 (up to 4)
Calix E5 and F5 (adjunct/subtended configurations)
Power
220/240 VAC input
Generator connector (Hubbell); 30A, 60A, and 100A options
N+1 rectifier redundancy; 30A or 20A modules
Support for AC meter mounting
Battery Support
Battery heater kit
Zone 4 seismic protection kit
Northstar (OEM) battery string and installation kit
Copper Protection & Splicing
Copper line protection for up to 1920 lines; MS2or 710 interface connectors
CAT3 or CAT5 interface cabling to the line protection blocks
Fiber Management
Fiber splice tray holder (3 RU), holds up to 10 splice trays; each tray holds up to 12 fiber
splices (fusion, mechanical, heat shrink options)
Fiber distribution panel (1 RU); 12 or 24 positions (SC, LC, ST, FC connector options)
Fiber distribution cassette holder (6 RU), holds up to six cassettes; each cassette has 12
fiber positions (SC or LC connector options)
Third Party Equipment Support
Test head installation kits
CWDM EDFA mounting kit (for FTTP RF video applications)
Splitter shelves (1:32 PON or xDSL/POTS splitters)

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© 2001-2008 Calix. All Rights Reserved.
Cabinet Dimensions and Weights
The external dimensions of the ODC-3000 cabinet are shown below.
Dimension
Measurement (SAE)
Measurement (Metric)
Height
73.50 inches
187 cm
Width
98.00 inches
249 cm
Depth
48.50 inches
123 cm
The approximate shipping weight of the ODC-3000 cabinet is shown below.
Configuration
Weight (SAE)
Weight (Metric)
1920 lines
2350 lb
1066 kg

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© 2001-2008 Calix. All Rights Reserved.
Cabinet Compartments
Views of the ODC-3000 cabinet compartments follow.
Front Compartment
The front compartment provides 94 inches of vertical rack space (54 RU). The front
compartment is split into two equipment bays (47 inches/27 RU per bay) and typically
houses two Valere power systems and up to four Calix C7 shelves, leaving 5 RU per bay of
rack space for additional equipment. The swing frame rack design allows for easy access to
the backside of the mounted equipment.
ODC-3000 Front

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© 2001-2008 Calix. All Rights Reserved.
Rear Compartment
The rear compartment provides 94 inches of vertical rack space (54 RU). The rear
compartment is split into two equipment bays (47 inches/27 RU per bay) and houses no
standard equipment, leaving the full 54 RU of rack space available for optional or third-party
equipment. The swing frame rack design allows for easy access to the backside of mounted
equipment.
ODC-3000 Rear
Splice Compartments
The ODC-3000 cabinet is equipped with two standard splice compartments: a fiber splice
chamber (located on the right side of the cabinet when viewed from the front) and a copper
splice chamber (located on the left side of the cabinet when viewed from the front). The
fiber splice compartment is equipped with a standard 23-inch rack and houses the AC load
center, main ground bar, and provides cable entry locations for fiber plant.
The copper splice compartment provides cable entry locations for copper plant and houses
the copper line protection, which consists of up to four rack-mounted protection frames,
each holding up to 10 modular 50-pair protection blocks. The modular design of the copper
line protection system allows for incremental expansion if required.

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© 2001-2008 Calix. All Rights Reserved.
ODC-3000 Fiber Splice Side
ODC-3000 Copper Splice Side
Battery Compartment
The battery compartment houses up to six strings of front-access VRLA batteries (three
strings per side). The battery compartment is equipped with two GFCI-protected duplex
outlets to support optional battery heaters, and can support an optional Zone 4 seismic
protection kit.
Battery Compartment (front)
Battery Compartment (rear)

Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 2001-2008 Calix. All Rights Reserved.
Chapter 2
Installation Considerations
This chapter provides general considerations for cabinet installation. Review this information
before starting the cabinet installation process.
Topics Covered
This chapter covers the following topics:
Installation process overview
Installation guidelines
Space requirements
General safety recommendations
Installation kit contents
User-supplied items
Cabling requirements

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© 2001-2008 Calix. All Rights Reserved.
Installation Process Overview
The cabinet installation process involves the following high-level steps:

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© 2001-2008 Calix. All Rights Reserved.
Installation Guidelines
Review the following guidelines before starting installation activities.
General Guidelines
Follow these general guidelines and practices:
Read this document completely before starting any installation activities.
Only qualified personnel should perform the procedures described in this document.
Follow standard safety precautions when performing installation and maintenance tasks.
Always wear standard safety gear when performing installation and maintenance tasks
(hardhats/safety headgear, eye protection, insulated gloves).
For safety, keep bystanders and other unauthorized personnel away from work
operations at all times.
Do not perform installation activities during thunderstorms or when the threat of
lightning is present.
Site Selection
The location of a cabinet installation site should be carefully planned in advance. Consider
the following factors when selecting an installation site:
1. Functional requirements:
Suitable terrain. Whenever possible, the cabinet should be located in an area with a
firm flat soil surface that does not require extensive earth work. The location should
not be constantly damp or prone to flooding. Check soil maps of potential sites for
subsurface conditions.
Grounding properties. The earth at the cabinet location should have a low ground
impedance to provide an effective grounding system for lightning protection and
safety. Perform ground testing to determine the grounding requirements (on page 26).
Safety. Whenever possible, the cabinet should be located on vacant property away
from motor traffic to reduce injury risks to maintenance personnel or damage to
equipment. On streets and highways, avoid locations near busy intersections or
curves in the road. Erecting guard rails or concrete pillars can provide additional
safety barriers against motor traffic.
Solar exposure. Whenever possible in hot or warm climates, avoid locations with
heavy exposure to direct afternoon sun, so as to maximize the life of electronics
equipment in the cabinet. High outdoor temperatures and heavy solar exposure raise
temperatures inside cabinets, a condition that can reduce the life span of equipment.
Conversely, wind exposure improves thermal conditions in a cabinet, so locations
that do not block wind are desirable.

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© 2001-2008 Calix. All Rights Reserved.
2. Accessibility requirements:
Easement size. Select a location with an easement that provides enough space to
walk around the perimeter of the cabinet with its doors open.
Right-of-Way. Secure a permanent location on private property, whenever possible.
Obtain a firm right-of-way agreement that includes right of access. Avoid locations in
public rights-of-way.
Electrical access. Locally-powered cabinets must have access to commercial AC
power. Verify the availability of AC service at potential cabinet locations.
Parking. Whenever possible, the cabinet should be located in an area that provides
sufficient parking space for installation and maintenance vehicles.
Space Requirements
The illustration below shows the typical cabinet clearance and space requirements.
The minimum clearance area around the cabinet site must be free of permanent impediments
to allow full swing of the cabinet doors. This area must be kept clear of obstructions at all
times to provide adequate access for all installation and maintenance activities.