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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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 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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Proprietary Information: Not for use or disclosure except by written agreement with Calix.
© 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.