Zhone 4300 User manual

4300 4U Outdoor Cabinet
Installation Instructions
Document Number 4300-A2-ZZ40-20
November 2005
Zhone Technologies
@Zhone Way
7001 Oakport Street
Oakland, CA 94621
USA
Copyright © 2005
Zhone Technologies, Inc.
4300-A2-ZZ40-20 November 2005 1
Contents
CONTENTS.................................................................................................................................................................................. 1
USING THIS INSTALLATION GUIDE ................................................................................................................................... 2
PRODUCT DOCUMENTATION ONLINE.............................................................................................................................. 2
CONTACTING GLOBAL SERVICE AND SUPPORT........................................................................................................... 3
TECHNICAL SUPPORT ............................................................................................................................................................ 3
SERVICE REQUIREMENTS..................................................................................................................................................... 3
INSPECTING SHIPMENT......................................................................................................................................................... 3
TRADEMARKS ........................................................................................................................................................................... 3
PRODUCT OVERVIEW............................................................................................................................................................. 4
CABINET CONFIGURATIONS ...................................................................................................................................... 7
EXPANSION,MOUNTING,AND MAINTENANCE KITS ................................................................................................. 8
PRODUCT SPECIFICATIONS ........................................................................................................................................ 9
QUARTER-TURN LOCKING DOOR LATCHES............................................................................................................ 10
INSTALLATION PROCEDURE ............................................................................................................................................. 11
CLEARANCE REQUIREMENTS .................................................................................................................................. 11
INSTALLATION PROCEDURE FOR POLE MOUNTING................................................................................................. 12
INSTALLATION PROCEDURE FOR WALL MOUNTING ............................................................................................... 14
CABINET GROUNDING INFORMATION ........................................................................................................................... 16
GROUND WIRE......................................................................................................................................................... 16
GROUNDING DIAGRAM AND PROCEDURE ............................................................................................................... 17
PROTECTION/CROSS CONNECTS...................................................................................................................................... 18
PROTECTION/CROSS CONNECT WIRING TABLES ...................................................................................................... 19
FAN/FILTER REPLACEMENT.............................................................................................................................................. 21
FILTER MAINTENANCE ............................................................................................................................................ 21
EXTERNAL WIRING............................................................................................................................................................... 22
LINE POWER ............................................................................................................................................................................ 22
SCHEMATIC WIRING DIAGRAMS ..................................................................................................................................... 22

4300 4U Outdoor Cabinet Installation Instructions
2 November 2005 4300-A2-ZZ40-20
Using This Installation Guide
This publication provides a description of the 4300 4U Outdoor Cabinet. Typical applications, mechanical
descriptions, installation instructions, safety guidelines, grounding instructions, and wiring diagrams are included.
Two types of messages appear throughout this manual, identified by the following icons:
Note - indicates special conditions.
Caution - indicates possibility of personal injury or equipment damage.
Product Documentation Online
Complete documentation for this product is available at www.zhone.com. Select the following documents:
GranDSLAM 4200 IP DSLAM Command Line Interface Reference
GranDSLAM 4200 IP DSLAM SNMP Reference
GranDSLAM 4200 IP DSLAM Training Guide
GranDSLAM 4200 ATM DSLAM User's Guide
GranDSLAM 4200 ATM DSLAM Installation Guide
GranDSLAM 4200 IP DSLAM Installation Guide
Field Upgrade Kit for the 4300 4U Outdoor Cabinet, Model PDN-4300-F1-100, Installation Instructions
Pole Mounting Kit for the 4300 4U Outdoor Cabinet, Model PDN-4300-F1-400, Installation Instructions
Wall Mounting Kit for the 4300 4U Outdoor Cabinet, Model PDN-4300-F1-401, Installation Instructions
Fan Replacement Kit for the 4300 4U and 6U Outdoor Cabinets, Model PDN-4300-F1-500, Installation
Instructions
Filter Replacement Kit for the 4300 4U and 6U Outdoor Cabinets, Model PDN-4300-F1-501, Installation
Instructions

4300 4U Outdoor Cabinet Installation Instructions
4300-A2-ZZ40-20 November 2005 3
Contacting Global Service and Support
Contact Global Service and Support (GSS) if you have any questions about this or other Zhone products. Before
contacting GSS, make sure you have the following information:
•Zhone product you are using
•System configuration
•Software version running on the system
•Description of the issue
Technical Support
If you require assistance with the installation or operation of your product, or if you want to return a product for
repair under warranty, contact GSS. The contact information is as follows:
E-mail [email protected]
Telephone (North America) 877-ZHONE20
Telephone (International) 510-777-7133
Internet www.zhone.com/support
If you purchased the product from an authorized dealer, distributor, Value Added Reseller (VAR), or third party,
contact that supplier for technical assistance and warranty support.
Service Requirements
If the product malfunctions, all repairs must be performed by the manufacturer or a Zhone-authorized agent. It is the
responsibility of users requiring service to report the need for service to GSS.
Inspecting Shipment
On receipt of the equipment, inspect the shipping container(s) and note any signs of damage. Then unpack the
container(s) and carefully inspect for damage to the contents. If the equipment has been damaged in transit,
immediately report the extent of damage to the transportation company and your sales representative.
Trademarks
All products and services mentioned herein are the trademarks, service marks, registered trademarks, or registered
service marks of their respective owners.

4300 4U Outdoor Cabinet Installation Instructions
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Product Overview
The 4300 4U Outdoor Cabinet is a pole-mounted or wall-mounted outdoor telecommunications equipment cabinet.
The cabinet has overall dimensions of 26 inches high x 19 inches deep x 22 inches wide. See the figures on the
following pages for details.
The cabinet is constructed of aluminum with a powder coat painted finish for reduced weight and superior corrosion
resistance. The front door is equipped with a quarter turn padlockable door latch. The top of the cabinet has a
double wall construction to reduce the effects of solar radiation and for structural integrity.
Cooling is provided by a –48 VDC fan ventilation system. The fan is mounted to the roof of the cabinet behind the
equipment. The fan pulls air through the front door of the cabinet and exhausts the air through the roof overhang
and the louvers in the sides of the roof.
The left front of the equipment-mounting bay has 6U (10.5 inches) of 19" rack space provided for mounting up to
three DSLAMs (1U each) and a rectifier or a DC-DC converter (2U each). An additional 1U is provided for future
expansion. Two swing-out 19” racks are provided on the right side of the equipment bay for mounting up to four 50
pair protection/cross connect assemblies (200 pair capacity). Each protection/cross connect swing-out rack has 4U
of 19” rack space (8U total).
Cable entry and exit from the cabinet passes through two sealing boots located in the bottom rear of the equipment
bay. The master grounding bus bar is located on the rear wall of the equipment bay on the left side. AC and DC
power centers are mounted to the rear wall on the right side.

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Figure A - Front view of cabinet with door open
Cabinet lifting eyelets
Protection/Cross
Connect Panels
Rectifier or DC-DC
Converter 1U DSLAMs
Swing out racks for
Protection/Cross
Connect Panels

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Figure B - Front view of cabinet without equipment
AC Input Panel for Model 2
DC Input Panel for Model 3
Air Filters
Cable Entry Ports DC Distribution Box
Cable Management
Brackets
Ground Bus Bar

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Cabinet Configurations
Three basic cabinet configurations are offered as explained below. Expansion kits are provided to increase the capacity of
each configuration to up to three 1U DSLAMs. Kits are also provided for fan and filter replacement and for pole or wall
mounting brackets.
The three basic cabinet configurations are:
Model 1 – Cabinet to be used at existing remote terminal sites, where the RT can supply 48 VDC power.
•PDN-43xx-P1-100 – This model is wired for one DSLAM assembly.
•PDN-43xx-P1-110 – This model has a battery pedestal and is wired for one DSLAM assembly.
Model 2 – Cabinet to be used where AC power is available.
•PDN-43xx-P1-200 – This model is wired for one DSLAM assembly and includes an AC load center and a 48
VDC rectifier.
•PDN-43xx-P1-210 – This model has a battery pedestal and is wired for one DSLAM assembly. It includes an
AC load center, a 48 VDC rectifier, and battery cables.
Model 3 – Cabinet to be used where AC power is not available.
•PDN-43xx-P1-300 – Power to the cabinet is provided by up to 25 common pairs. The tips and rings of the pairs
are bussed together and fed to a DC-DC converter, which provides the 48 VDC power to the DSLAM
assemblies. The input voltage to the DC-DC converter is 90 to 250 VDC. This model is wired for one DSLAM
assembly.
•PDN-43xx-P1-310 – Power to the cabinet is provided by up to 25 common pairs. The tips and rings of the pairs
are bussed together and fed to a DC-DC converter, which provides the 48 VDC power to the DSLAM
assemblies. The input voltage to the DC-DC converter is 90 to 250 VDC. This model has a battery pedestal and
is wired for one DSLAM assembly.

4300 4U Outdoor Cabinet Installation Instructions
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Expansion, Mounting, and Maintenance Kits
See Table 1 for expansion kit part numbers. The Ordering Procedure section of this document contains instructions
for ordering the kits.
Table 1 - Expansion, Mounting and Maintenance Kits
Model Number Description
PDN-4300-F1-100 Field upgrade for adding one protected 1U DSLAM to Model 1, 2 or 3.
Includes one 50 pair protection/100 pair cross connect block and associated
cabling.
PDN-4300-F1-400 Pole mounting kit. Includes mounting brackets and hardware for pole
mounting the cabinet.
PDN-4300-F1-401 Wall mounting kit. Includes mounting brackets and hardware for wall
mounting the cabinet.
PDN-4300-F1-402 Pad mounting collar for installing a 4300 4U cabinet on a concrete pad. Adds
6 inches to the overall cabinet height.
PDN-4300-F1-500 Fan field replacement kit. Includes one –48 VDC fan assembly.
PDN-4300-F1-501 Filter field replacement kit. Includes the filters required for one cabinet.

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Product Specifications
Cabinet outer physical dimensions:
Height – 26 inches (66 cm)
Width – 22 inches (56 cm) — does not include heat exchanger
Depth – 19 inches (48 cm) internal
Approx. Weight – 60 pounds (27 kg)
Figure C – Cabinet overall dimensions
Side View
Top View
Front View

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Quarter-Turn Locking Door Latches
The cabinet door is equipped with 2 quarter-turn padlockable latches. The latches are secured by turning the 7/16” hex
security bolt one quarter turn clockwise until the stop is reached. Convenient security locking hasps are factory installed
to allow for a #1 Master Lock padlock (or equivalent) to be installed. With a padlock on the latch, the door cannot be
opened, deterring vandalism.
Figure D – Quarter turn locking door latches

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Installation Procedure
The 4300 4U Outdoor Cabinet can be mounted on a pole or wall. See figures below.
Lifting eyelets are provided to facilitate hoisting if desired.
During cabinet mounting, fix the cabinet securely to avoid personal injury or cabinet
damage.
Clearance Requirements
When selecting a location to mount the cabinet, ensure that proper clearance is available to allow adequate
ventilation and to allow the cabinet door to open fully. See figure E below for the top view of the cabinet footprint.
Figure E - Cabinet Footprint

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Installation Procedure for Pole Mounting
Use this procedure to mount the cabinet on a 6-inch to 8-inch diameter pole. See Figure F below for a cabinet
mounting illustration.
Figure F - Pole Mounting Diagram

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Have the following equipment ready before beginning this procedure:
•One drill
•One 3/4” x 12” drill bit
•One 9/16” wrench
•Two 15/16” wrenches
•One 7/16” wrench
•A pencil
•Optional pole mounting kit
Follow this procedure for pole mounting:
1. Pre-assemble the upper and lower horizontal brackets to the vertical bracket as shown in the above figure.
2. Select a convenient mounting location on the pole.
3. Position the mounting bracket assembly against the pole and mark on the pole the location of the two (2) 5/8 “
bolts (item 18).
4. Place the mounting bracket assembly out of the way.
5. Drill two (2) 3/4” (19 mm) diameter holes completely through the pole at the locations marked in step 2.
6. Insert machine bolt (item 18) through mounting bracket and into the top mounting hole and press bolt and
bracket flush against the pole.
7. Place round-cupped washer (item 21), with the concave side in, on bolt and finger tighten nut.
8. Repeat step 6 for remaining bolt.
9. Secure the mounting bracket assembly to the pole by securely tightening the machine bolts to 40 ft-lbs for
wooden posts and 100 ft-lbs for metal posts.
10. Using proper lifting and safety equipment, place cabinet on mounting bracket assembly using supplied 3/8”
hardware and tighten to 45 ft-lbs. Lifting eyelets are provided on the cabinet for hoisting it in place.
11. If the cable stubs connect to an underground cable, dress the cable down the pole. If the cable stubs connect to an
aerial cable, form a drip loop in the cable and dress it up the pole to the splice case.
For mounting heights less than 7’ above grade, excess bolt length may need to cut off in order to prevent a
hazardous protrusion.
Lifting eyelets are provided to facilitate hoisting if desired.

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Installation Procedure for Wall Mounting
Use this procedure to mount the cabinet on a flat wall. See Figure G below for a cabinet mounting illustration.
Figure G - Wall Mounting Diagram

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Have the following equipment ready before beginning this procedure:
•One drill
•One 3/8” drill bit
•One 7/16” wrench or socket
•One ½” wrench or socket
•A pencil
•Optional wall mounting kit
Follow this procedure for wall mounting:
1. Pre-assemble the upper and lower wall mounting brackets to the cabinet as shown above.
2. Position the cabinet with mounting brackets against the wall and mark on the location of the mounting holes
on the wall.
3. Drill six (6) 3/8” diameter holes completely through the wall at the locations marked in step 2.
4. Lift the cabinet with mounting brackets into position against the wall.
5. Insert 5/16” diameter bolts through the upper mounting bracket.
6. Secure the cabinet to the wall by installing 5/16” flat washers, lock washers and nuts to the bolts inserted in
step 5.
7. Repeat steps 5 and 6 for the lower mounting bracket.
Lifting eyelets are provided to facilitate hoisting if desired.

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Cabinet Grounding Information
Bonding and grounding should be done in accordance with the operating telephone company’s
standard procedures and comply with local electrical codes.
Ground Wire
The ground wire protects the electronics from voltage surges. A #6 ground wire must be properly grounded to
provide lightning surge protection for the cabinet. Please follow this practice for attaching the ground unless local
policies dictate otherwise.
For safety and performance reasons it is imperative that a cabinet be properly grounded. The following guidelines
should be used to ground the cabinet unless local practices, rules, or regulations dictate otherwise.
Each door and equipment rack is grounded to the cabinet frame. The cabinet frame is connected to the internal
grounding bus by a stranded wire. A similar ground wire must be used to connect the ground bus to each equipment
ground lug. These ground wires may need to be removed temporarily to troubleshoot ground faults. The wire may
be removed by unscrewing the screws that secure the green wire to the ground bus. Be sure to reattach these wires
after troubleshooting and resolving any ground conflicts.
Be sure to ground the cabinet before connecting power to the cabinet. This grounding must be in effect at all times
to safeguard personnel.

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Grounding Diagram and Procedure
Figure H - Grounding Diagram
To ground the cabinet, see Figure H above.
1. Drive the ground rods into the ground near the cabinet location.
2. Use a Megger-type ohmmeter to measure the resistance between cabinet ground and the ground rod. The
resistance must be 25 ohms or less.
3. If the resistance requirement in Step 2 is met, proceed to step 4. Otherwise, follow local practices to lower
the resistance to ground.
4. Connect a #6 ground wire to the ground rod.
Internal Grounding bus
Ground Rods
Front view of cabinet with
door open

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Protection/Cross Connects
Figure I – Protection/Cross Connect Panel, top view (50 pair)
Figure J –Cross Connect Panel, front view
Protection prewired to
cross connect panel
OSP side, 5 ft
unterminated
cable
Equipment side,
wire wrap posts
Cross connects,
prewired at factory (100 pair
terminations)
Protection modules,
5-pin gas tube, 230 Volt
(50 pair)
Pair numbers

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Protection/Cross Connect Wiring Tables
Table 2 - Protection Cross Connect Cable Wiring
Connector (DSL) Connector (POTS)
R T R T R T R T
Pair #1
BLUE / WHITE
Pair #14
BROWN / BLACK
Pair #26
BLUE / WHITE
Pair #39
BROWN / BLACK
Pair #2
ORANGE / WHITE
Pair #15
SLATE / BLACK
Pair #27
ORANGE / WHITE
Pair #40
SLATE / BLACK
Pair #3
GREEN / WHITE
Pair #16
BLUE / YELLOW
Pair #28
GREEN / WHITE
Pair #41
BLUE / YELLOW
Pair #4
BROWN / WHITE
Pair #17
ORANGE / YELLOW
Pair #29
BROWN / WHITE
Pair #42
ORANGE / YELLOW
Pair #5
SLATE / WHITE
Pair #18
GREEN / YELLOW
Pair #30
SLATE / WHITE
Pair #43
GREEN / YELLOW
Pair #6
BLUE / RED
Pair #19
BROWN / YELLOW
Pair #31
BLUE / RED
Pair #44
BROWN / YELLOW
Pair #7
ORANGE / RED
Pair #20
SLATE / YELLOW
Pair #32
ORANGE / RED
Pair #45
SLATE / YELLOW
Pair #8
GREEN / RED
Pair #21
BLUE / VIOLET
Pair #33
GREEN / RED
Pair #46
BLUE / VIOLET
Pair #9
BROWN / RED
Pair #22
ORANGE / VIOLET
Pair #34
BROWN / RED
Pair #47
ORANGE / VIOLET
Pair #10
SLATE / RED
Pair #23
GREEN / VIOLET
Pair #35
SLATE / RED
Pair #48
GREEN / VIOLET
Pair #11
BLUE / BLACK
Pair #24
BROWN / VIOLET
Pair #36
BLUE / BLACK
Pair #49
BROWN / VIOLET
Pair #12
ORANGE/ BLACK
Pair #25
SLATE / VIOLET
Pair #37
ORANGE/ BLACK
Pair #50
SLATE / VIOLET
Pair #13
GREEN / BLACK Pair #38
GREEN / BLACK

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Table 3 - Cross Connect Panel Wiring
WHITE / ORANGE
BINDER
WHITE / BLUE
BINDER
WHITE / BROWN
BINDER
WHITE / GREEN
BINDER
R T R T R T R T
Pair #1
BLUE / WHITE
Pair #2
BLUE / WHITE
Pair #3
BLUE / WHITE
Pair #4
BLUE / WHITE
Pair #5
ORANGE / WHITE
Pair #6
ORANGE / WHITE
Pair #7
ORANGE / WHITE
Pair #8
ORANGE / WHITE
Pair #9
GREEN / WHITE
Pair #10
GREEN / WHITE
Pair #11
GREEN / WHITE
Pair #12
GREEN / WHITE
Pair #13
BROWN / WHITE
Pair #14
BROWN / WHITE
Pair #15
BROWN / WHITE
Pair #16
BROWN / WHITE
Pair #17
SLATE / WHITE
Pair #18
SLATE / WHITE
Pair #19
SLATE / WHITE
Pair #20
SLATE / WHITE
Pair #21
BLUE / RED
Pair #22
BLUE / RED
Pair #23
BLUE / RED
Pair #24
BLUE / RED
Pair #25
ORANGE / RED
Pair #26
ORANGE / RED
Pair #27
ORANGE / RED
Pair #28
ORANGE / RED
Pair #29
GREEN / RED
Pair #30
GREEN / RED
Pair #31
GREEN / RED
Pair #32
GREEN / RED
Pair #33
BROWN / RED
Pair #34
BROWN / RED
Pair #35
BROWN / RED
Pair #36
BROWN / RED
Pair #37
SLATE / RED
Pair #38
SLATE / RED
Pair #39
SLATE / RED
Pair #40
SLATE / RED
Pair #41
BLUE / BLACK
Pair #42
BLUE / BLACK
Pair #43
BLUE / BLACK
Pair #44
BLUE / BLACK
Pair #45
ORANGE/ BLACK
Pair #46
ORANGE/ BLACK
Pair #47
ORANGE/ BLACK
Pair #48
ORANGE/ BLACK
Pair #49
GREEN / BLACK
Pair #50
GREEN / BLACK