Fiber Optic Above-Ground) Cross-Connect Enclosure (ACE) Model ACE-200DS Installation Guide) 13536-A Figure 1. ACE-200DS Enclosure With OCM-HD Panels Content Page INTRODUCTION... 2 1 PRODUCT DESCRIPTION... 3 2 SPECIFICATIONS... 4 3 INSTALLATION... 6 3.1 Overview and Requirements... 6 3.2 Installing a Support Base... 6 3.3 Mounting the ACE-200DS on the Support Base... 9 4 INSTALLING PANELS...16 5 INSTALLING PATCH CORDS...18 6 CUSTOMER INFORMATION AND ASSISTANCE...19 1049545 Rev A Page 1
INTRODUCTION Revision History This guide describes the ADC Fiber Optic Above-Ground Cross-Connect Enclosure (ACE), Model ACE-200DS, and provides instructions for installing this product. The ACE-200DS may be installed on a mounting sleeve, concrete pad, or utility pole. Depending on how it was ordered, it may have been shipped empty, loaded with unterminated panels, or loaded with panels pre-terminated to Outside Plant (OSP) cable. This guide addresses all these various installation options, either by providing step-by-step instructions or by referring to related publications for kits used in installation. If any kit is on hand, the appropriate publication will be, also, packaged with the kit. ISSUE DATE REASON FOR CHANGE Issue 1 10/91 Original Issue 2 02/93 Revised to clarify the installation procedures for the cable rung assemblies and the equipment rack handles Issue 3 08/96 Updated to current graphics standards, non-technical changes. Issue 4 04/97 Updated to reflect discontinued use of metal mounting sleeve. Eliminated removable rack feature. Issue 5 11/99 Updated to streamline content and format. Trademark Information ADC and ADC Telecommunications are registered trademarks of ADC Telecommunications, Inc. Related Publications Title ADCP Number Outside Plant Fiberglass Mounting Sleeve (FMS) Installation Instructions ADCP-93-060 OSP Fiber Optic Above-Ground Cross-Connect Enclosure (ACE) Concrete Pad (with Pad Mounting Frame (PMF)) Installation Instructions ADCP-93-015 ACE-200DS Bottom Cover Kit Installation Instructions ADCP-93-017 ACE Pole Mount Frame Installation Instructions ADCP-93-024 Outside Plant Connector Panel (OCM) User Manual ADCP-93-032 Page 2
1 PRODUCT DESCRIPTION The ACE-200DS Enclosure is a secure, above-ground, double-entrance cabinet designed to hold ADC cross-connect panels. The enclosure provides service access, storage, and cable management for OSP cables and cross-connect patch cords at outdoor distribution points in a fiber optic network. OSP feeder and distribution cables are terminated on the rear side of the enclosure. Patch cords are installed on the front side. The enclosure is suitable for either single-mode or multi-mode fiber installations. The ACE-200DS Enclosure may be loaded with from one to three each of either of two types of cross-connect panels, the High Density OCM (OCM-HD) or the Outside Plant Connector Module (OCM). The OCM-HD configuration, shown in Figure 1 has 144 termination positions per panel, providing a maximum capacity of 432 terminations per enclosure. This configuration also has a lower storage trough providing storage for patch cord slack on the front side of the enclosure. REAR DOOR OCM-HD PANEL CABLE ASSIGNMENT LABEL 30 IN (76.2 CM) STEEL LIFTING EARS (2) 51 IN (129.5 CM) TAMPER- RESISTANT LATCH CABLE MANAGEMENT SPOOL CABLE MANAGEMENT PANEL FRONT DOOR CABLE TROUGH 22 IN (55.9 CM) 13537-A Figure 1. ACE-200DS Enclosure With OCM Panels Page 3
The OCM configuration, shown in Figure 2, is available with either 72-or 96-position panels, providing a maximum capacity, respectively, of either 216 or 288 terminations per enclosure. A lower storage trough provides storage for patch cord slack on the front side of the enclosure. OCM PANEL VERTICAL CABLE GUIDES CABLE MANAGEMENT PANEL CABLE MANAGEMENT SPOOL CABLE TROUGH FRONT VIEW 13538-A Figure 2. ACE-200DS Enclosure With OCM-HD Panels The enclosure is constructed of heavy duty aluminum coated with a sand or Telco green finish. It has stainless steel lifting ears for hoisting it into position. Front and rear doors, shown in both figures, provide convenient service access. Each door has a tamper-resistant latch, stainless steel hinges, a door prop to prevent accidental closing, and a padlock hasp for additional security. Access to the enclosure requires a keyed hex tool to operate the latches. Equipmentmounting rack-side flanges provide tie bars for cable management. Cable entry to the cabinet is from the rear. Figure 3 shows the cabinet rear with cable clamp bar and ground strip. These features are present in all configurations. 2 SPECIFICATIONS Table 1 lists specifications for the ACE-200DS and summarizes mounting and panel options. Page 4
FRONT DOOR CONNECTOR PANELS (OCM-HDs SHOWN HERE) GROUND STRIP CABLE CLAMP MOUNTING BAR REAR DOOR 13539-A Figure 3. Ace 200DS Rear (OCM-HD Configuration Shown) Table 1. ACE-200DS Enclosure and Related Products ITEM DESCRIPTION ACE-200DS Enclosure Dimensions (H W D) Weight Mounting Options Fiberglass Mounting Sleeve (FMS) Pad Mounting Frame (PMF) Pole Mounting Brackets Panel Options 51.0 in. (129.5 cm) 30 in. (78.2 cm) 22 in. (55.9 cm) 250 lbs. (550 kg) ADC Kit FMS-10000 or FMS-20000 ADC Kit ACE-200PMF ADC Kit ACE-202PMK or ACE-203 PMK OCM (72 or 96) Maximum number of panels per enclosure: 3 Capacity per panel: 72 or 96 Total capacity per enclosure: 216-288 OCM-HD Maximum number of panels per enclosure: 3 Capacity per panel: 144 Total capacity per enclosure: 432 Page 5
3 INSTALLATION 3.1 Overview and Requirements Installation of the ACE-200DS involves the following main tasks. 1. Installing a Support Base The ACE-200DS must be mounted on suitable support base. If such a support base has not been already installed, you must first select the support base and install it. There are three options for a support base: Underground Mounting Sleeve provides a water-tight storage space for cable slack. This is the ADC-recommended support base. The ADC Fiberglass Mounting Sleeve (FMS), Model 20000, is the product used. Poured Concrete Pad may be constructed using an ADC frame or a frame of customer design. Use of the ADC Pad Mounting Frame (PMF) Kit is the preferable method. It provides a steel-reinforced form and ensures that the mounting bolts will be placed in the correct locations. If using a customer design, ensure that the form is constructed using the dimensions provided in this guide. Pole Mount involves use of support brackets installed on a utility pole. The ACE- 200DS is mounted on the support brackets. The ADC ACE Pole-Mounting Kit contains the brackets and other hardware used for pole-mounting. Two kits are available: ACE-202PMK or ACE-203PMK. The ACE-202PMK kit mounts the cabinet with the rear side flat against the pole (rear door cannot be opened). The ACE-203PMK kit mounts the cabinet with the side against the pole giving access to both front and rear doors. 2. Mounting the ACE-200DS After ensuring that a suitable support base is available, you can proceed to this task. If the enclosure was shipped with a spool, you should first uncoil the spool, pull through the cable to the splicing location, and then store any slack at the splicing location or at the ACE-200DS, as determined by local practice. You can then mount the ACE-200DS on the support base. 3. Installing Panels If the ACE-200DS was shipped empty with panels shipped separately for installation at the site, you can now mount the panels within the enclosure. This usually also includes installing an OSP cable shipped on a spool and pre-terminated on the rear of the panel. 4. Installing Patch Cords Last step in installation is installing patch cords to establish circuits between OSP fibers terminated on the rear of the enclosure. This involves identifying the circuits to be turned up and installing patch cords to turn up the circuits. 3.2 Installing a Support Base As indicated in the previous section, the enclosure may be mounted on an underground fiberglass sleeve, poured concrete pad, or on pole-mount brackets. For each option, refer to the following guidelines or instructions. Page 6
3.2.1 Fiberglass Mounting Sleeve (FMS) If the enclosure is being mounted on an FMS and the FMS is not already installed, install the FMS before proceeding. The FMS is provided as a separate product and is shipped with its own installation instructions. Locate those instructions and refer to them to install the FMS, then return to this guide to the section on mounting the enclosure. 3.2.2 Concrete Pad Using a Pad Mounting Frame (PMF) Kit If the enclosure is being mounted on a poured concrete pad using the ADC PMF kit, unpack the kit and refer to the instructions within the kit to install it, then return to this guide to the section on mounting the enclosure. 3.2.3 Concrete Pad Using a Customer-Designed Frame If using a customer-designed frame, prepare the site, install ground rods, and construct the forms following the instructions provided immediately below, in the next three topics. Preparing the Site Prepare a base for the concrete pad meeting local code requirements. The base should consist of 4 to 6 inches (10.2 to 15.2 cm) of sand or gravel on firmly compacted soil. The conduit, ground rod(s), and ground wire must be placed before the concrete is poured. Keep the inside area of the mounting frame clear to allow future conduit and cable additions if desired. Installing Conduits and Ground Rods Install conduits and ground rod using the following procedure (refer to Figure 4). 1. Place 90-degree-bend conduits so that the upward bend will meet the cable entrance area in the ACE-200DS when it is put into position. 2. Extend the conduits upward so they will be flush with the finished pad, as shown. 3. The ACE-200DS requires a grounding system (not provided) that meets local electrical codes. Take care not to damage the conduits when installing the grounding system. Install the grounding system as follows: Note: (1.) Seal external openings of the unused ducts with plugs or sealant to prevent moisture and foreign objects from entering the ACE-200DS. (2.) For ground wire connections, consult local electrical codes for use of clamps, wire size, or any other grounding requirements. A typical ground wire is No. 6 AWG copper. a. Install one or more ground rods in the locations shown in the figure. b. Prepare and install a ground wire for connection from the ground rod(s) to ACE- 200DS ground bar. (Only the ground rod end of the connection can be made at this time. Coil and wrap the loose end and place out of the way for the concrete pouring operation.) Page 7
46.0 IN. (116.8 CM) 27.25 IN. (69.2 CM) 25.5 IN. (64.8 CM) 10.0 IN. (25.4 CM) 5.0 IN. (12.7 CM) 9.38 IN. (23.8 CM) 12.25 IN. (26.0 CM) 78.0 IN. (198.1 CM) 31.75 IN. (80.7 CM) FRONT 33.0 IN. (83.8 CM) 14.5 IN. (36.8 CM) 12.0 IN. (30.5 CM) 3.0 IN. (7.62 CM) GROUND ROD (REFERENCE) CENTER DIMENSIONS NOT TO SCALE REAR 1 IN. (2.54 CM) FLEXIBLE INNERDUCT 4-IN. (10.2 CM) (90* BEND CONDUIT 6 IN. MIN. (15.2 CM) SAND OR GRAVEL 4 IN. MIN. (10.2 CM) TO 6 IN. (15.2 CM) COMPACTED SOIL 12917-B Figure 4. Concrete Pad Page 8
Constructing the Concrete Pad Using Figure 4 for dimensions, construct the concrete pad as follows: 1. Construct an outside form for the pad. Recommended pad size is 46 inches (116.8 cm) long, 34 inches (76.2 cm) wide, and 6 inches (15.2 cm) deep. 2. Construct an inside form 25.5 inches (64.8 cm) long, 12 inches (30.5 cm) wide, and 6 inches (15.2 cm) deep. 3. Place reinforcing material (if used) between the inside and outside forms. Do not pour cement in the center area of the pad. 4. Ensure that the forms are level and the top surface of the pad will be approximately 3 inches (7.6 cm) above the final grade. 5. Pour the concrete to form the pad. 6. Insert anchors (not provided) in the concrete pad in the locations shown. After the concrete pad has cured proceed to section 5, Installing the ACE-200DS. 3.2.4 Installing a Pole-Mounting Kit If the ACE-200DS is being mounted on a utility pole, use ADC kit ACE-202PMK or ACE- 203PMK. Follow the instructions provided in the kit to install the pole mount frame. 3.3 Mounting the ACE-200DS on the Support Base After a suitable support base has been provided, continue to this procedure to install the ACE- 200DS on the FMS sleeve, concrete pad, or pole-mount frame. The hardware necessary to install the ACE-200DS onto the support base is contained in the hardware kit. The kit contents are listed in Table 2. Table 2. ACE-200DS Mounting Hardware ITEM QTY 0.375 in. (9.5 mm) 1.0 in. (25.4 mm) aluminum bolt 4 0.375 in. (9.5 mm) flat washer 8 0.375 in. (9.5 mm) lock washer 8 0.375 in. (9.5 mm) 0.75 in. (19.0 mm) carriage bolt 4 0.375 in. (9.5 mm) hex nut 4 Bottom Cover Kit 1 Page 9
3.3.1 FMS Use the following procedures to install the ACE-200DS on a Fiberglass Mounting Sleeve (FMS) Model 20000. Refer to Figure 5. FRONT ACE-200 CABINET REAR FMS COVER II (FCVR-200CVR) MOUNTING BOLTS (4) BOTTOM COVER (2 PIECES) FMS COVER I (FCVR-200ACE2000) FMS-20000 13121-B Figure 5. FMS 20000 Installation Page 10
Warning: The ACE-200DS cabinet, unloaded, weighs approximately 250 pounds (550 kg). Use hoisting equipment or enlist the aid of other persons to move the cabinet. 1. If the sleeve is presently covered with a temporary cover, remove the temporary cover to expose the inner area of the sleeve. 2. With suitable lifting equipment, place FMS Cover 1 (FCVR-200ACE200) onto the mounting sleeve. 3. With suitable lifting equipment, place the ACE-200DS onto the mounting base and align it with the mounting holes of the support base. 4. Place a 0.375 inch (1.59 cm) aluminum bolt, with a stainless steel washer through each of the four mounting holes of the adapter plate. Loosely secure each bolt in place with a flat washer, lock washer, and nut. 5. Ensure that the ACE-200DS is centered on the support base and tighten all four bolts. 6. Remove the lift eyes and replace with four 0.75 inch (19 mm) carriage bolts provided in the hardware kit. 7. Pull the ground wire (which was attached to the ground rod in the mounting base installation procedures) up into the enclosure. Attach the wire to the ground strip located in the lower right corner of cabinet as viewed from rear. See Figure 6. Tighten the lug screw securely. CABLE GROUND CABINET GROUND 13540-A Figure 6. ACE-200DS Ground Strip (Rear View) 8. Install the bottom cover kit using the instructions provided with it. Ensure that the ground wire has sufficient slack to route through the cable cutouts in the bottom cover. 9. With suitable lifting equipment, place FMS Cover 2 (FCVR-200CVR) onto the mounting sleeve. Page 11
3.3.2 Concrete Pad Use the following procedure to install the ACE-200DS cabinet onto a concrete pad (with or without PMF frame). Refer to Figure 7. ACE-200 CABINET (FRONT) NO BOTTOM COVER CABLE CONDUIT CONCRETE PAD 13123-B PAD MOUNTING FRAME (PMR) IF PRESENT Figure 7. Concrete Pad Installation 1. With suitable lifting equipment, place the ACE-200DS onto the mounting base and align it with the mounting holes of the support base. 2. Place a 0.375 inch (1.59 cm) aluminum bolt, with a stainless steel washer through each of the four mounting holes of the adapter plate. Loosely secure each bolt in place with a flat washer, lock washer, and nut. 3. Ensure that the ACE-200DS is centered on the support base and tighten all four bolts. 4. Remove the lift eyes and replace with four 0.75 inch (19 mm) carriage bolts provided in the hardware kit. Page 12
3.3.3 Pole Mount Using PMK 202 Use the following procedure to install the ACE-200DS cabinet onto a pole using ADC PMF kit PMK 202. The pole mounting bracket kit should be already installed. Refer to Figure 8. REMOVE LIFTING EYES (2) ACE-200 CABINET NO BOTTOM COVER POLE 13122-B Figure 8. PMK 202 Installation Page 13
1. With suitable lifting equipment, place the ACE-200DS onto the frame base and align it with the mounting holes of the frame base. 2. Using four each of the bolts, flat washers, and lock washers provided in the kit, loosely fasten the cabinet to the four mounting holes in the frame base. 3. Using four each of the bolts, flat washers, and lock washers provided in the kit, fasten the cabinet to the horizontal arms as shown in Figure 8. 4. Ensure that the ACE-200DS is centered on the support base and tighten all four bolts. 5. Install a ground wire from the pole to the cabinet ground strip. Follow local code for ground wire size. Connect the ground wire to the ground lug located in the lower left corner of ACE-100. Tighten the lug screw securely. 6. Remove the lift eyes and replace with four 0.75 inch (19 mm) carriage bolts provided in the hardware kit. 3.3.4 Pole Mount Using PMK 203 Use the following procedure to install the ACE-200DS cabinet onto a pole mount frame base using ADC PMF kit PMK 202. The pole mount frame base should be already installed. Refer to Figure 9. 1. With suitable lifting equipment, place the ACE-200DS onto the frame mount base and align it with the mounting holes of the base. 2. Using four each of the bolts, flat washers, and lock washers provided in the kit, loosely fasten the cabinet to the four mounting holes in the frame base. 3. Using four each of the bolts, flat washers, and lock washers provided in the kit, fasten the cabinet to the horizontal arms as shown in Figure 9. 4. Ensure that the ACE-200DS is centered on the support base and tighten all four bolts. 5. Install a ground wire from the pole to the cabinet ground strip. Follow local code for ground wire size. Connect the ground wire to the ground lug located in the lower left corner of ACE-100. Tighten the lug screw securely. 6. Remove the temporary lift eye. Page 14
REMOVE TEMPORARY LIFT EYE ACE-200 CABINET NO BOTTOM COVER POLE 13124-B Figure 9. PMK 203 Installation Page 15
4 INSTALLING PANELS If the cabinet was shipped empty with panels shipped separately for installation at the site, install the panels after mounting the ADC-200DS on the support base and before installing the bottom cover kit (as indicated in the previous procedure). Use the instructions below to install the panel if attached to a pre-terminated cable. If the panel is not attached to a pre-terminated cable, refer to the instructions that came with the panel. 1. Cut the bindings on the spool and uncoil the spool completely, being careful not to bend the cable sharply. Leave the panel in place on its shipping platform. 2. Route the fiber into the conduit and pull it through to the splicing location. Refer to Figures 10 and 11 for concrete pad mounting and FMS mounting, respectively. 3. Unpack the panel and mount it following the instructions provided in the manual shipped with the panel. Route the cable to the cable clamp bar and clamp it as shown in Figure 12. Follow the instructions provided in the cable clamp kit. 4. Ground the cable to any cable ground terminal on the grounding strip in the bottom right of the rear side of the enclosure. Refer to Figure 6 in the previous procedure to identify the cable ground terminal. 5. Rearrange cable storage as needed. 6. Install the bottom cover kit following the instructions provided in the kit. FRONT DOOR OPEN ACE-200DS NEARBY MANHOLE GRADE SPLICE MODULE STORED OSP FIBER CABLE CONDUIT 13393-A Figure 10. OSP Cable Routing for Concrete Pad and Manhole Page 16
FRONT DOOR OPEN ACE-200DS GRADE MOUNTING SLEEVE STORED OSP FIBER CABLE SPLICE MODULE CONDUIT 13394-B Figure 11. OSP Cable Routing for FMS 20000 (Bottom) CABLE CLAMP DETAIL OSP CABLE CABLE CLAMP BAR 13541-A REAR VIEW Figure 12. OSP Cable Clamping in Rear of Cabinet Page 17
5 INSTALLING PATCH CORDS After installing the enclosure and storing the OSP cable, you can proceed to install patch cords to complete the optics circuits. ADC recommends using 2.5-3.0 meter (8.2-9.8 feet) patch cords. In general, route all patch cords from the center of the panel toward the outside as shown in Figure 13. Loop patch cord slack around the cable management spools from left side to right spool, from right side to left spool, as shown. For specific instructions for each specific type of panel, refer to the user manual for that type of panel. A user manual is shipped with each panel. 13400-A Figure 13. Correct Patch Cord Routing Page 18
6 CUSTOMER INFORMATION AND ASSISTANCE For customers wanting information on ADC products or help in using them, ADC offers the services listed below. To obtain any of these services by telephone, first dial the central ADC telephone number, then dial the extension provided below. The central number for calls originating in the U.S.A. or Canada is 1-800-366-3891. For calls originating outside the U.S.A. or Canada, dial country code 1 then dial 612-946-3000. Sales Assistance Extension 3000 Systems Integration Extension 3000 BCG Technical Assistance Center Extension 3475 E-Mail: technical@adc.com Product Return Department Extension 3748 E-Mail: repair&return@adc.com Quotation Proposals Ordering and Delivery General Product Information Complete Solutions (from Concept to Installation) Network Design and Integration Testing System Turn-Up and Testing Network Monitoring (Upstream or Downstream) Power Monitoring and Remote Surveillance Service/Maintenance Agreements Systems Operation Technical Information System/Network Configuration Product Specification and Application Training (Product-Specific) Installation and Operation Assistance Troubleshooting and Repair ADC Return Authorization number and instructions must be obtained before returning products. Product information may also be obtained using the ADC web site at www.adc.com or by writing ADC Telecommunications, Inc., P.O. Box 1101, Minneapolis, MN 55440-1101, U.S.A. Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice. In no event shall ADC be liable for any damages resulting from 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. This publication may be verified at any time by contacting ADC s Technical Assistance Center at 1-800-366-3891, extension 3475 (in U.S.A. or Canada) or 612-946-3000 (outside U.S.A. and Canada), or by writing to ADC Telecommunications, Inc., Attn: Technical Assistance Center, Mail Station #71, P.O. Box 1101, Minneapolis, MN 55440-1101, U.S.A. All Rights Reserved Printed in U.S.A. Page 19