Clearfield FieldSmart FiberFlex 2000 User manual

FieldSmart®FiberFlex 2000
Installation Manual ______________________________________________________
Manual 021574 Rev A - May 2020

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
2
Table of Contents
About This Guide 5
Chapter 1: FiberFlex 2000 Product Overview 6
Cabinet Description 7
Cabinet Features 8
Cabinet Options 9
Cabinet Dimensions and Weights 10
Cabinet Views 11
Chapter 2: Installation Considerations 13
Installation Process Overview 14
Installation Guidelines 15
Space Requirements 16
General Safety Recommendations 17
Installation Kit 18
User-Supplied Items 19
Cabling Requirements 20
Chapter 3: Preparing the Installation Site 21
Installing a Ground Circuit 22
Constructing a Concrete Pad 25
Pad Construction Guidelines 25
Assembling the Cast-In-Place Template 28
Preparing the Site 29
Casting the Pad 30
Installing a Pre-Cast Concrete Pad 31
Pre-Cast Pad Requirements 31
Preparing the Site 34
Installing a Pre-Cast Pad 35
Installing a Foundation Vault 36
Foundation Vault Requirements 36
Preparing the Site 37
Installing the Foundation Vault 38

3
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
Chapter 4: Installing the Cabinet 39
Unpacking the Cabinet 40
Operating Cabinet Doors 41
Preparing the Cabinet for Installation 43
Installing the Cabinet on a Concrete Pad 44
Removing the Lifting Details 47
Chapter 5: Installing Local AC Power 48
Installing the Cabinet Ground Connection 49
Installing AC Power (220-240 VAC) 51
Chapter 6: Installing Outside Plant Cables 53
Bonding Cable Sheaths 54
Installing Fiber Cable 55
Installing Outside Plant Fiber Cable 55
Splicing Fibers 56
Connecting Fibers to the Equipment 56
Sealing Cable Entry Locations 57
Chapter 7: Turning Up the Cabinet Power System 58
Turning Up the Power System 59
Checking the Ground Connection 59
Checking the AC Power Supply Voltage 60
Installing Rectier Modules 61
Installing and Testing Batteries 62
Chapter 8: Installing Equipment, Options and Adding Capacity 70
Installing a Battery Compartment Riser 71
Installing a Battery Heater 72
Installing Fiber Splitters 78
Chapter 9: Cabinet Maintenance 81
Routine Maintenance 82
Checking Cabinet Surfaces 82
Checking Electrical Components 83
Checking Cable Connections 84
Checking the Heat Exchanger 85

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
4
Battery Maintenance 86
Replacing Parts and Equipment 88
Removing a Cabinet Door 88
Installing a Cabinet Door 89
Replacing the Cabinet Roof 91
Replacing AC Breakers 92
Replacing Rectier Modules 93
Replacing Batteries 99
Replacing a Battery Heater 100
Appendix A: Reference Information 101
Specications 102
Supported Batteries 103
Wiring Diagrams 103
Standard Warranty 104
Proprietary Notice 105
Technical Support 105

5
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
This document is intended for use by network planning engineers, outside plant engineers, eld support personnel, and craft
personnel responsible for cabinet installation, splicing, equipment installation, and maintenance.
Intended Audiences
This document provides a general installation practice for the Cleareld FiberFlex 2000 outdoor cabinet. This document also
provides a general description of the cabinet and its subsystems, guidance for planning, site preparation, power installation,
splicing to the outside plant, component installation and expansion, and cabinet maintenance.
About This Guide
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.
Federal Communications Commission (FCC) Statement
This document uses the following safety notice conventions.
Safety Notices
DANGER! Danger indicates the presence of a hazard that will cause severe personal injury or death
if not avoided.
WARNING! Danger indicates the presence of a hazard that will cause severe personal injury or death
if not avoided.
CAUTION! Danger indicates the presence of a hazard that will cause severe personal injury or death
if not avoided.
ALERT! Danger indicates the presence of a hazard that will cause severe personal injury or death
if not avoided.
DANGER! CLASS 1 LASER PRODUCT. INVISIBLE LASER RADIATION MAY BE PRESENT
Danger indicates the presence of a hazard that will cause severe personal injury or death
if not avoided.

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
6
Chapter 1: FiberFlex 2000 Product Overview
This chapter provides a general description of the Cleareld FiberFlex 2000 outdoor cabinet, including its standard features
and options.
Topics Covered
This chapter provides a general description of the Cleareld FiberFlex 2000 outdoor cabinet, including its standard features
and options.
• A description of the FiberFlex 2000 cabinet.
• A list of standard cabinet features.
• A list of cabinet options.
• Listed cabinet dimensions and weights
• A Views of the cabinet compartment.

7
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
Cabinet Description
The Cleareld FiberFlex 2000 cabinet is an environmentally-controlled outdoor enclosure designed to house and protect
network electronics equipment. Use the FiberFlex 2000 to provide services from a remote node location deep inside the
customer serving area, beyond the direct reach of the carrier Central Ofce.
The FiberFlex 2000 cabinet has a single compartment that houses active electronic equipment together with various ber
terminations, enabling deployment of multiple applications from one node. The electronics area is equipped with a 20 RU,
19-inch equipment rack providing exible mounting space.
The FF2K supports local AC power congurations. The local power conguration includes an additional base compartment
to support battery reserve power.
The modular design of the FF2K enables incremental expansion of system capacity, lowering initial deployment costs while
maintaining the capacity for future growth. Modular components designed for expansion include compact service units, ber
management capacity, DC power modules, and cooling elements.

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
8
Cabinet Features
Standard features of the FiberFlex 2000 cabinet include:
Enclosure Design
• Environmentally sealed design protects from dust and water intrusion
• Designed to GR-487
• Environmentally rated from -40C to +46C (per GR-487 specications)
Equipment Support
• 19-inch equipment rack provides 4 RU of mounting space
• Mechanical support for ber terminations
• 20 RU
• Door-mounted 750W heat exchanger
Power (Local)
Standard features for the local power conguration include:
• 240 VAC load center (ETL-listed); 60 Amp capacity
• AC main/service disconnect breaker
• AC surge suppressor
• Duplex convenience outlet (GFCI protected)
• Fuse-protected DC supply to equipment
• Battery backup in separate vented compartment
• Up to 155 Ah battery reserve capacity (breaker-protected); up to 310 Ah capacity with second-string riser option

9
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
Cabinet Options
Common options for the FiberFlex 2000 cabinet include:
Enclosure Mounting
• Concrete pad mounting: pre-cast or site-cast pad (using Cleareld pad template)
• Foundation vault mounting (third-party supplied)
Fiber Management
• High density ber management options (144 and 288 ber distribution panels, 1:32 PON splitters,
management accessories), up to 576 ports of internal distribution
Power
Local power support (commercial AC power supply); additional options include:
• 110/120 and 220/240 VAC input
• Generator connector (Hubbell); 30A NEMA twist lock with breaker
Battery Support (local power congurations)
• Northstar battery string and installation kit (OEM)
• Battery heater kit
• Battery compartment riser (supports second 155 Ah battery string)

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
10
Cabinet Dimensions and Weights
The external dimensions of the FiberFlex 2000 cabinet are shown below.
Dimension Measurement (SAE) Measurement (Metric)
Height 54 inches 137 cm
Width 24 inches 61 cm
Depth 35 inches 89 cm
The approximate weight of the FiberFlex 2000 cabinet is shown below.
Conguration Weight (SAE) Weight (Metric)
FF2K (single string 155 Ah batteries) 222 lb 101 kg

11
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
Cabinet Views
Views of the FiberFlex 2000 cabinet follow.
Front Compartment
The front compartment provides access to the electronics equipment, cabinet power system, and ber management. The
cabinet power system consists of a side mounted AC load center option. For ber access, the ber management accesso-
ries may vary greatly according to the ordered options.
FiberFlex 2000 Front
(local power)

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
12
Battery Compartment
Congured cabinets include a battery base compartment for housing one string of front-access VRLA batteries.
Battery compartment interior dimensions (for batteries): 11.3” (H) x 20.2” (W) x 21.5” (D)
FiberFlex 2000
Back

13
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
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

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
14
Installation Process Overview
The cabinet installation process involves the following high-level steps:

15
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
General Guidelines
Follow these general guidelines and practices:
• Read this document completely before starting any installation activities.
• Only qualied 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 (hard hats/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 when the threat of lightning is present.
• Warning! - Seal all cable entry locations immediately after the cabinet is installed to prevent ground moisture from
condensing inside the cabinet and damaging equipment.
Installation Guidelines
Review the following guidelines before starting installation activities.
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 rm at soil surface that does
not require extensive earth work. The location should not be constantly damp or prone to ooding. Check soil maps of
potential sites for subsurface conditions.
• Grounding properties. 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.
• Safety. Whenever possible, the cabinet should be located on vacant property away from motor trafc 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 trafc.
• 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.
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 rm right-of-way agree-
ment 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 sufcient parking space for
• installation and maintenance vehicles.

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
16
Space Requirements
The illustration below shows the 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.

17
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
DANGER! Risk of high power current surge and electric shock. Read and understand all power procedures
before performing tasks. Take necessary precautions and use appropriate insulated tools when working with
power. This equipment must be installed, operated, and serviced by qualied technical personnel only.
WARNING! Only trained, qualied technical personnel should perform the procedures described in this doc-
ument. These procedures involve potentially hazardous activities, including handling of heavy equipment and
exposure to high electrical energy, which could cause injury to untrained personnel.
WARNING! The cabinet and its components are heavy. Handle with care to avoid personal injury or damage
to the equipment.
DANGER! CLASS 1 LASER PRODUCT. INVISIBLE LASER RADIATION MAY BE PRESENT.
Fiber optic radiation can cause severe eye damage or blindness. Do not look into the open end of an
optical ber.
General Safety Recommendations
ESD ALERT! Beware of electrostatic discharge. Follow standard ESD precautions. Always wear a grounded
ESD wristband to avoid damaging the electronic equipment.
CAUTION! Batteries contain a stored charge. Handle batteries with care.

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
18
Installation Kit
Cleareld supplies an installation kit with the cabinet that includes materials required for installation. The installation kit
contents are listed below. Check to verify that your kit contains all of the listed items.:
Qty Item Description
1Telco hex key, 5/16”
1Isolation mat
4Hex nuts (for mounting)
8Flat washers (for mounting)
4Split lock washers (for mounting)
41/2” hex head bolts (for mounting)

19
FieldSmart®FiberFlex 2000
__________________________________________________________ Installation Manual
Direct: 763.476.6866 • National: 800.422.2537 • www.SeeCleareld.com • [email protected]
Manual 021574 REV A - June 2020
User-Supplied Items
Supply the following items for cabinet installation.
Tools
Bring the following tools to the installation site:
• Power drill with universal socket and screwdriver bit sets
• Socket wrench/nut driver set (standard)
• Box wrench set (standard)
• Screwdriver set (standard)
• Beam Level
• Insulated needle-nose pliers
• Wire stripper
• Compression crimping tool
• Fiber cleaver
• Fiber splicer
• RB Razor-Sharp Cutting Edge knife, or another similar tool
Materials
Bring the following materials to the installation site:
• Leveling shims
• Silicone sealant
• Strain relief for #6-8 AWG wiring.
Equipment
Bring the following equipment to the installation site:
• Digital multi-meter
• Optical power meter
• Digital multi-function test set

FieldSmart®FiberFlex 2000
Installation Manual _________________________________________________________
Proprietary Information: Not for use or disclosure except by written agreement with Cleareld.
20
Cabling Requirements
Cables supplied to the cabinet must meet the following minimum requirements.
Note: Local climatic conditions, site conditions, or local practices may require adjustments to cabling requirements.
Function Facility Requirements
Power
Ground Copper 6 AWG solid bare copper wire (to earth ground circuit);
terminates to ground bar with screw lug
AC
(local power) Copper 8–10 AWG stranded copper; Follow National Electric Code (NEC) and local codes