Calix ODC-10 Installation Guide

Calix ODC-10 Installation Guide

July 2003Part #220-00015, Rev. 12

TABLE OF CONTENTS

Before You Begin Installing the ODC-10 Cabinet

Product Overview and Access....................................................... 3

Introduction to the ODC-10 cabinet ...........................................3Front access...........................................................................6Side splice access ...................................................................7Rear access............................................................................9Opening and closing compartment doors .................................. 10Battery access ...................................................................... 11Heat exchanger blower access ................................................ 13

Installation Prerequisites ........................................................... 15

Guidelines............................................................................ 15Site requirements ................................................................. 16What you need to bring ......................................................... 17What you get with the cabinet ................................................ 18

Placing the ODC-10 on a Pad

Pad Mounting the Cabinet........................................................... 21

Unpack the cabinet ............................................................... 21Prepare the cabinet for placement ........................................... 22Lower and bolt ..................................................................... 23Seal the cabinet.................................................................... 24

iv

Installing Power, Subscriber Cables, and Equipment

Cable Requirements.................................................................... 27

Minimum requirements for terminating cables ...........................27

Connecting Power and Ground.................................................... 29

Introduction..........................................................................29Ground the cabinet and test the ground....................................30Install and test the AC power ..................................................32Install and test rectifier modules..............................................37Install and test the batteries ...................................................39Install and test the fan tray ....................................................43

Install Outside Plant Cables........................................................ 45

Subscriber cables ..................................................................45Install the fiber holders ..........................................................50Install the fiber .....................................................................53

Installing Plug-in Cards .............................................................. 57

Install the AMP plug-in card ....................................................57Install the RAP-OC3/12/48 plug-in card ....................................59Install metallic plug-in cards ...................................................61Install optical plug-in cards .....................................................63

System and Network Configuration ............................................ 65

Introduction..........................................................................65Configure your computer to connect to the Calix C7 ...................66Start the Calix integrated Management System .........................68Define nodes in the network ...................................................70

Maintaining and Troubleshooting the ODC-10

Maintaining the Calix Outdoor Cabinet........................................ 75

Battery Maintenance ..............................................................75Maintain external cable connections .........................................76Maintain the cabinet surfaces ..................................................77


Proprietary Information: Not for use or disclosure except by written agreement with Calix. © 2001-2003 Calix. All Rights Reserved.

v

Environmental Alarms ................................................................ 79

AC fail alarm ........................................................................ 79Battery circuit breaker alarm .................................................. 80Auxiliary fuse fail alarm ......................................................... 81Cabinet over temperature alarm ............................................. 82Door alarm .......................................................................... 84GMT fuse fail alarm ............................................................... 85Low battery alarm................................................................. 86Low voltage disconnect alarm ................................................. 87Rectifier major alarm............................................................. 88Rectifier minor alarm............................................................. 89

Troubleshooting and Replacing Outdoor Cabinet Hardware........ 91

Failed heat exchanger module ................................................ 91Replace and test a rectifier module.......................................... 93Replace the batteries............................................................. 94Replace the circuit breakers ................................................... 96Replace the fuses.................................................................. 97Replace the battery heater ..................................................... 98Replace the generator connector ............................................. 99

Reference

Customer Service and Support ................................................. 103

The Calix Technical Assistance Center .................................... 103

Appendix: Specifications .......................................................... 105

ODC-10 specifications.......................................................... 105


Proprietary Information: Not for use or disclosure except by written agreement with Calix.© 2001-2003 Calix. All Rights Reserved.

1Chapter

Before You BeginInstalling the

ODC-10 Cabinet

3

Product Overview and Access

Introduction to the ODC-10 cabinetInformation on the ODC-10 cabinet description, features, options, access, and size follows.

General description of the ODC-10 cabinet

The ODC-10 cabinet is an environmentally controlled, aluminum and steel enclosure designed to deploy the Calix C7 in outdoor terminal locations. The cabinet can be configured for purely copper, fiber, or a combination of both with flexibility for field migration from copper to fiber.

The Calix ODC-10 cabinet consists of a main cabinet sitting on a battery compartment base. The main cabinet houses three compartments, an equipment compartment, splice compartment, and a copper protection and fiber compartment.

The Calix C7 ODC-10 cabinet is wired for delivery of copper or fiber-based services supporting up to 240 subscribers. The patent-pending integrated cooling system combines low power DC cooling blowers with advanced air-to-air tubular heat exchangers to dissipate large amounts of heat in very small spaces.

Door description of the outdoor cabinet

The cabinet has three doors - front, rear, and side - as well as battery compartment access panels in the front and rear. Accessories such as a document pocket, a fold-down laptop tray, or a cup holder are located on some of the doors.

All main compartment doors have 2-point position tamper-proof Telco hex-pin locks, each with provision for a padlock, if required by local site practice. Each battery compartment panel has two tamper-proof hex-pin locks, each with provision for a padlock.



4

View of the ODC-10 cabinet

Features of the ODC-10 cabinet

Following are some features of the Calix C7 ODC-10 optical access cabinet.

• integrated air-to-air tubular cooling system with DC blowers• wired capacity of up to 240 subscribers (copper and/or fiber)• environmentally rated -40C to +52C ambient temperature• standard 5-pin copper protection panels - up to 240 positions• 220-240 VAC single phase power feed• 30 Amp service with UL listed service disconnect• redundant AC feeds to rectifier, redundant DC feeds to Calix C7 shelf• low voltage DC disconnect• high power AC surge protection• extensive alarm functionality• UL-67 and GR-487 compliance



5

Options of the ODC-10 cabinet

Following are some options of the Calix C7 ODC-10 optical access cabinet.

• pad mount kit• 30 Amp Twist-Lock generator connector• splice tray fiber management options• fiber distribution cassette options• cross-connect panel• battery heater

Dimensions of the ODC-10 cabinet

Parameter Size - standard Size - metric

width 38 inches 96.5 centimeters

depth 33 inches 78.8 centimeters

height 45 inches 114.3 centimeters

weight ~500 pounds (700 pounds equipped with Dynasty batteries. Calix recommends and supports using Dynasty 80 AH batteries.)

227 kilograms (318 kilograms equipped with Dynasty 80 AH batteries)



6

Front accessThe front equipment compartment contains one Calix C7 shelf, a rectifier shelf, the AC load center and convenience outlets.

Front view of the ODC-10 cabinet



7

Side splice accessThe side splice compartment contains subscriber cable entry holes, an AC cable entry hole, and two peg boards for mounting all splice equipment and fiber distribution options.

Cable entry plates

Cable entry plates come in various configurations.

• The AC entry plate has one 1 1/2" feed (2" with knockout removed).• Field-configurable subscriber cable entry plates have two 2" or one 4" feeds

(for copper or fiber).• The ground plate has 4 field-configurable knockouts

(two 3/4", one 1", one 1 1/2").

Integrated cross-connect panel

Cabinets ordered with the integrated cross-connect option will have a hinged panel in the splice compartment that holds the connection blocks.

Features of the integrated cross-connect include:

• 2:1 configuration. (2 subscriber pairs for each equipment pair)• Marconi URLS 10 pair connection blocks• a hinged connection block panel to provide access to the cable entry and fiber

splice area• integrated test cable• jumper wire spool• room for one fiber splice tray holder supporting 120 fiber splices when cross-

connect panel is installed



8

Side view of the ODC-10 cabinet



9

Rear accessThe rear copper protection and fiber compartment houses the copper protection panel. The rear compartment also contains the DC distribution panel.

Copper protection panels

The rear panel holds five copper protection blocks. Each block corresponds to two slots on one of the Calix C7 shelves.

The panel is hinged to support easy maintenance and to provide access to the back of the Calix C7 shelf.

Each protection block provides protection for two copper plug-in cards. Protection blocks terminate with MS2 connectors for interface in the splice compartment.

Rear view of the ODC-10 cabinet



10

Opening and closing compartment doorsYou open and close the compartment doors on a cabinet using the provided hex-key.

Procedure to open the door

Procedure to close a cabinet door

Step Action

1. Insert and turn the key to release the door handle.

2. Pull the handle up to unlatch the door.

3. Swing the door open until the retainer latch engages to hold the door in place.

4. Pull out the door alarm switch in the top corner of the door opening to disarm the door alarm.

Step Action

1. Pull the retainer latch release tab to release the door.

2. Hold the door handle up, then push the door closed and press the handle against the cabinet.

If the handle does not lock in place, insert and turn the key until it clicks. Then, press the handle latch into place.



11

Battery accessThe battery compartment has one sliding battery tray. The tray holds one battery string. Each string has four batteries.

You can access the battery compartment from the front or rear of the cabinet. The front allows access to the batteries in their sliding tray. The rear allows cable access and battery heater installation access.

Procedure to remove a battery compartment panel

Step Action

1. Insert the key into a latch and turn it counterclockwise until it stops to release the panel latch.

Repeat for all other latches on the panel.

2. Lift the panel slightly to free the tabs at the bottom of the panel from the cabinet, then lay the panel down in front of the compartment.

3. On the panel, remove the ground strap from the panel.

4. Set the battery compartment panel out of your way.



12

Procedure to replace a battery compartment panel

Step Action

1. Reattach the grounding strap to the panel.

2. Align the tabs at the bottom of the panel with the cutouts in the bottom of the battery compartment and tilt the panel into place.

3. Insert the key into a latch and turn it clockwise until the inner keyhole notch aligns with the outer keyhole notch.

Repeat for all latches on the panel.



13

Heat exchanger blower accessLift the roof of the cabinet to access the cooling fans.

View of the heat exchanger blowers

Procedure to open the roof of the cabinet

Step Action

1. Open the front and side cabinet doors to access the underside of the roof overhang.

2. Locate the retaining bolts in the front of the roof overhang and remove them using a 5/16" allen wrench.

An allen wrench is provided with the cabinet.

3. Push the front edge of the roof up until the support arm locks into place.



14

Procedure to close the roof of the cabinet

Step Action

1. Hold the front edge of the roof and press the release button on the support arm, then lower the roof.

2. Open the front and side cabinet doors to access the underside of the roof overhang.

3. Locate the retaining bolt holes in the front of the roof overhang, then insert the bolts and tighten them using a 5/16" allen wrench.

An allen wrench is provided with the cabinet.



15

Installation Prerequisites

GuidelinesInstallation Prerequisites gives instructions to prepare for installation on a concrete pad. The concrete pad can be poured insight using a pour-in-place template.

Pad recommendation and alterations

Calix recommends a reinforced 5 1/2-inch thick concrete pad. Your pad may vary depending on site and environmental conditions.

Recommended minimum cable requirements

• For ground cable, use AWG #2 cable (AWG #6 minimum). Leave approximately 4 feet of cable above the top of the pad.

• For ground cable, use the appropriate 2-hole compression lug for vertical grounding to the main ground bar (hole spacing options are 5/8", 1", or 1 1/4"; bolt size is 1/4").

• For AC power cables, use AWG #6, minimum. Leave approximately 6 feet of cable above the top of the pad. Follow National Electric Code (NEC) and local codes when installing AC power at your site.

• For subscriber cables, leave approximately 8-10 feet of cable above the top of the pad.

• For subscriber cables, have the appropriate termination equipment and tools available.

• For fiber cabling, if you are using fiber, use single-mode fiber only.• For fiber cabling, use a fiber splice value of no greater than.5 dB loss.

Note

Modify for local conditionsLocal climatic conditions, site conditions, or local practices may require modifications to cable termination. The following are minimum requirements.



16

Site requirementsCabinet pad footprint

The Calix C7 ODC-10 cabinet pad footprint measures 74" wide x 80" deep - the minimum dimension for the concrete pad. The drawing below shows the proper placement of the cabinet on a concrete pad.

Click to view a larger image.



17

What you need to bringCustomer-supplied tools for cabling

You need to bring the following tools for cabling.

• compression connector crimper• screwdriver set (standard)• socket wrench set (standard)• box wrench set (standard)• fiber cleaver• fusion splicer• Modular MS2 splice tool

Customer-supplied materials for cabling

You need to bring the following materials to install cabling.

• copper pigtail with MS2 terminators, long enough to get to your cross-connect box• #2 AWG 2-hole compression lug (options are 5/8", 1", or 1 1/4")• fiber optic cable for splicing into cabinet• #2 AWG strain relief for ground wire• #2 AWG strain relief for AC cabling

Test equipment

Depending on the system configuration, the following test equipment may be needed:

• Digital Volt/Ohm meter• Bit Error Rate tester• Analog test set (for testing POTS lines)• DS1 test set• DS3 test set• ADSL test set• Optical power meter



18

What you get with the cabinetItems in the installation kit

The following items are shipped inside the battery tray of the ODC-10 as an installation kit:

• Calix coffee cup with lid (quantity 1)• 2-inch cold shrink tubing (quantity 2)• 4-inch cold shrink tubing (quantity 4)• cable management posts for use in the cable splice compartment (quantity 6)• allen wrench for cable management post installation, T-handle (quantity 1)• cable entry plate, 4-inch (quantity 2)• cable entry plate containing two 2-inch feed tubes (quantity 1)• security hex key for door access, 8mm (quantity 2)• allen wrench for roof access, T-handle, 5/16-inch ball end (quantity 1)• hole plugs 0.325-inch for threaded lift mounts (quantity 8)• brackets for holding third-party rack mount fiber and cable management

accessories (quantity 1)• seismic battery kit• pad mount hardware kit• fiber strain relief

Items in the optional battery string kit with batteries

• string of 4 Dynasty 12 Volt 80AH batteries• battery wiring kit for Dynasty batteries (white wire jumpers, pre-terminated)• No-Ox grease for use on battery terminals• set of four battery lifting straps

Items in the optional battery string kit without batteries

• battery wiring kit for Dynasty batteries (white wire jumpers, pre-terminated)• No-Ox grease for use on battery terminals



2Chapter

Placing the ODC-10on a Pad

21

Pad Mounting the Cabinet

Unpack the cabinetThe cabinet ships bolted to a shipping pallet and enclosed in a cardboard box.

Procedure to unpack the cabinet

Step Action

1. Remove the cardboard shipping box.

2. Remove the front and rear battery compartment panels and the panel ground straps to reach the shipping bolts at each corner of the cabinet.

See the procedure to remove battery compartment panels.

3. Remove the four shipping bolts at each corner of the cabinet that hold the cabinet to the pallet.

4. Open the battery tray and remove the installation kit and related items.



22

Prepare the cabinet for placement

Procedure to prepare the cabinet for permanent placement

Step Action

1. In the splice compartment, remove the AC, ground, and subscriber cable entry blank plates.

2. Pop out the AC conduit tray under the AC access blank plate. If you are using AC conduit between 1" and 2", use channel locks to remove the extra conduit knockout on the tray.

3. Close and latch the front, rear, and splice compartment doors. See the door close procedure.

4. Ensure the bolts for all lifting details are securely fastened.

5. Sweep the pad.

6. Suspend the cabinet approximately 2 feet (61 cm) above the pad.

SAFETY: Minimum working load of each lifting strap must be 1000 lbs. (454 kg).

7. Recycle the pallet.



23

Lower and boltProcedure to lower and bolt the cabinet

Step Action

1. While suspended, align the holes in the cabinet base with the four bolts protruding from the pad.

2. Open the splice compartment door and align the AC conduit with the splice compartment AC entry hole.

3. Lower the cabinet onto the pad, ensuring the bolts in the pad fit into the holes in the base of the cabinet and the AC conduit fits through its corresponding hole in the splice compartment.

4. Install one square washer, lock washer, and nut from the installation kit on each of the four bolts (two in front, two in rear).

5. Securely tighten the nuts to secure the cabinet to the pad.

6. Close the rear battery compartment panel. See the battery access procedure.



24

Seal the cabinetProcedure to seal the cabinet

Step Action

1. Remove the lifting details from the sides of the cabinets.

2. Cap the lift mount holes with the hole plugs shipped in the bag attached to the lift detail.

3. Cover any unused cable entry ports with the blank plates provided.



3Chapter

Installing Power,Subscriber Cables, and

Equipment

27

Cable Requirements

Minimum requirements for terminating cables

Recommended minimum cable requirements

• For ground cable, use AWG #2 cable (AWG #6 minimum). Leave approximately 4 feet of cable above the top of the pad.

• For ground cable, use the appropriate 2-hole compression lug for vertical grounding to the main ground bar (hole spacing options are 5/8", 1", or 1 1/4"; bolt size is 1/4").

• For AC power cables, use AWG #6, minimum. Leave approximately 6 feet of cable above the top of the pad. Follow National Electric Code (NEC) and local codes when installing AC power at your site.

• For subscriber cables, leave approximately 8-10 feet of cable above the top of the pad.

• For subscriber cables, have the appropriate termination equipment and tools available.

• For fiber cabling, if you are using fiber, use single-mode fiber only.• For fiber cabling, use a fiber splice value of no greater than.5 dB loss.

Note

Modify for local conditionsLocal climatic conditions, site conditions, or local practices may require modifications to cable termination. The following are minimum requirements.



29

Connecting Power and Ground

IntroductionConnecting Power describes procedures for connecting cables and batteries for the cabinet. The cabinet requires a 240-220 VAC power feed with 60 Amp service.

Ground, AC, and DC wiring diagrams are located in the Diagrams and Worksheets binder that ships with the cabinet.

DANGER! High voltage may be present. Only a qualified electrician should install and connect power cables. Install the power cables only after you have securely mounted the cabinet and routed all cables inside. Follow NEC and local codes when installing AC power.

Do not turn on the main power to the cabinet until the power installation is complete.



30

Ground the cabinet and test the groundGround the cabinet to a grounding device with a maximum resistance to ground of 20 Ohms, then test the ground connection.

A ground wiring diagram is included in the Diagrams and Worksheets binder that ships with the cabinet.

Procedure to ground the cabinet

Step Action

1. Route the main ground cable to the splice compartment and cut the cable to sufficient length to reach the ground bar at the right side of the cabinet.

2. Remove a knockout from the ground cable entry plate and install a matching strain relief fitting into the hole.

3. Slide the ground cable entry plate down the ground cable and attach the plate to the bottom of the splice compartment.

4. Strip the ground cable 1/2 inch (1.27 cm) and attach a 2-hole compression lug with an appropriate crimp tool (hole spacing options are 5/8", 1", or 1 1/4"; bolt size is 1/4").

5. Secure the terminal lug of the ground cable to the ground bar stud.

6. Tighten the strain relief fitting to secure the ground cable.



31

Procedure to test the cabinet ground

Step Action

1. In the splice compartment, attach one lead from an Ohm meter to the terminal lug of the ground cable.

2. Attach the second lead from the Ohm meter to the ground bar.

3. Verify that the Ohm meter reads 1 Ohm or less.



32

Install and test the AC powerRoute and connect AC power to the cabinet, then test the AC voltage.

You have two options for routing AC power based on the flexibility of the power cable and whether you have installed subscriber cable first. Calix recommends that you install AC power before installing subscriber cable.

An AC power wiring diagram is included in the Diagrams and Worksheets binder that ships with the cabinet.

Requirements for AC power input.

The Calix outdoor cabinet requires a 240-220 VAC power feed with 60 Amp service.

DANGER! High voltage may be present. Do not turn on the main power to the cabinet until the installation is complete.

Procedure to route AC power cable into the splice compartment

Step Action

1. In the right-side splice compartment, do the following if you have not already done so:

a. remove the AC cover plateb. remove the AC entry tray

2. In the right-side splice compartment, place the AC entry tray over the male adapter on the AC conduit and attach the conduit locking nut. Remove the tray knockout, if necessary.

3. Pull the AC cables through the AC conduit and into the AC entry tray.



33

Choose an AC power routing method

Choose one of the following methods to route AC power from the splice compartment to the AC Load Center.

Procedure to remove pegboard and route AC power cables to the AC Load Center

Use this procedure for clear access to the AC access feed and if you have not installed subscriber cable in the splice compartment yet.

Step Action

1. At the AC Load Center in the front equipment compartment, switch all breakers to the off position.

2. Remove the metal AC Load Center front panel. Note: Do not remove the plastic cover.

3. In the right-side splice compartment, locate the left pegboard then do the following:

a. On the right edge of the pegboard, remove the retaining screws.

b. On the left edge of the pegboard, loosen the locking nuts.

c. Slide the pegboard to the right and remove it from the splice compartment.

Note: ODC-10 and ODC-20 pegboards have 3 screws per side.

4. Remove the wall plate located above the AC entry tray.



34

Procedure pull AC power cables to the AC Load Center using fish tape

Use this procedure if you have flexible power cables or if you have already installed subscriber cable.

5. Push the AC power cable through the AC access feed in the splice compartment wall to reach the AC Load Center.

6. Reinstall the wall plate and pegboard.

Step Action

Step Action

1. At the AC Load Center in the front of the cabinet, switch all breakers to the off position.

2. In the front equipment compartment, remove the metal AC Load Center front panel. Note: Do not remove the plastic cover.

3. At the AC Load Center: a. drop a fish tape through the wall AC access feed to reach the AC entry

tray in the splice compartmentb. attach the fish tape to the AC cables in the AC entry trayc. pull the cables through to the AC Load Center.



35

Complete AC power installation and test

After routing AC power, complete the following procedures to connect and test AC power.

Procedure to connect AC power cables

Step Action

1. At the AC Load Center in the front of the cabinet, switch all breakers to the off position.

2. If the cabinet Main breaker is used as the primary AC disconnect, install a bonding strap between neutral and ground. Follow NEC and site code.

3. Run the green lead to the ground bus bar.

4. Run the white lead to the neutral bar.

5. Run the black hot lead to the L1 side of the breaker.

6. Run the red hot lead to the L2 side of the breaker.



36

Procedure to test AC power levels

Procedure to replace AC power cover plates

Step Action

1. Set main power to the cabinet to ON.

2. At the AC Load Center, set the Main breaker to ON.

3. Using a volt meter test between L1 and neutral. a. place one lead on L1b. place the other lead on neutralc. verify that the volt meter reads between 110 and 120 VAC

4. Using a volt meter test between L2 and neutral. a. place one lead on L2b. place the other lead on the neutralc. verify that the volt meter reads between 110 and 120 VAC

5. Using a volt meter test between L1 and L2. a. place one lead on L1b. place the other lead on L2c. verify that the volt meter reads between 220 and 240 VAC

6. At the AC Load Center, set all breakers, except the rectifier breakers, to ON.

Step Action

1. In the front equipment compartment, re-attach the AC load center front panel.

2. In the side splice compartment, re-attach the AC cover plate over the AC entry tray.



37

Install and test rectifier modulesDescription of the rectifier shelf

The Calix rectifier shelf contains an alarm control unit on the left and space for three rectifier modules on the right. Each rectifier module has its own alarm and status indicators.

A full rectifier shelf, with three rectifier modules, provides a -48VDC power source (30 Amps). Normal operation for the ODC-10 cabinet uses two rectifier modules (20 Amps). The optional third rectifier module provides faster battery recharge. The modular design makes the rectifier simple to install and maintain. Each hot-swapable module slides in and plugs into place.

Location of the rectifier and components

Procedure to install or replace a rectifier module

Step Action

1. Unbolt and remove the cover plate (or module to be replaced).

2. Slide the new module into the slot.

3. Tighten the front bolt to secure the module in place.

Alarm control unit

Rectifier modules 1-2 Rectifier module 3(optional)



38

Procedure to test voltage at the rectifier shelf

Step Action

1. Check that main power to the cabinet is ON, then at the AC load center, set the Rectifier (A), Rectifier (B), and Main breakers to ON.

2. Using a volt meter test between the V- and V+ receptacles on the front of the alarm control unit.

a. place the red lead of the voltmeter into V-b. place the black lead of the voltmeter into V+c. verify that the volt meter reads -54.5 +/-.5 VDC

3. At the AC Load center, set all the breakers to OFF.



39

Install and test the batteriesSupported battery types

Calix recommends and supports using Dynasty 80 AH batteries. One string fits into the ODC-10 cabinet.

Procedure to prepare for battery installation

Note

Install battery heater firstIf you have ordered a battery heater for field installation, you should install it before installing batteries. See the procedure to install the battery heater.

Step Action

1. Open the front battery compartment. See the procedure to remove battery compartment panels.

2. Slide out the battery drawer.

3. On the battery temperature compensation sensor, remove the protective cap to expose the lug.

4. Remove the protective caps from the remaining battery terminal lugs.



40

Procedure to install the batteries

Step Action

1. Set the battery breaker switch next to the drawer to OFF.

2. Place the batteries into the battery drawer.

3. Clean the battery terminals and apply No-Ox anti-corrosion grease to each.

4. For each end of the 3 white battery cables, thread the following onto a terminal bolt:

a. lock washerb. flat washerc. battery cable lug

5. Attach the white battery cables to connect the batteries in series according to the wiring diagram printed on the inside of the battery compartment panel.

Tighten the terminal bolts to the torque specified by the battery manufacturer. Dynasty recommends 110 in.-lbs. or (12.4 n-m).

6. On the end of the black battery terminal cable, thread the following onto a terminal bolt:

a. lock washerb. flat washerc. the battery temperature compensation sensord. the terminal lug of the black battery terminal cable



41

7. Attach the bolt from the previous step, with the black battery terminal cable, to the rear positive (+) battery terminal.


8. On the end of the red battery terminal cable, thread the following onto a terminal bolt:

a. lock washerb. flat washerc. the terminal lug of the red battery terminal cable

Attach the bolt to the rear negative (-) battery terminal.


9. Using a volt meter test the battery connection between the negative and positive battery leads.

a. place the red voltmeter lead on the red negative battery leadb. place the black voltmeter lead on the black positive battery leadc. verify that the volt meter reads between -46 and -54 VDC

10. Set the battery breaker switch next to the drawer to ON.

Step Action



42

Procedure to test the batteries and recharging system

Procedure to finish the battery installation

Step Action

1. In the battery compartment, set the battery breaker to ON.

2. At the AC Load center, set the Main breaker to ON.

3. Using a volt meter, test the rectifier output to the batteries. a. place the red volt meter lead on the red negative battery leadb. place the black volt meter lead on the black positive battery leadc. verify that the volt meter reads -54.5 +/-.5 VDC

4. At the AC load center, set the Main breaker to OFF to check that the batteries supply power to the Calix C7 fan trays. The fan trays should continue to run with no warnings on the fan tray display.

5. At the AC load center, set the Main breaker to ON.

Step Action

1. Place the battery cover over the batteries and close the battery drawer.

2. Close the front battery compartment. See the procedure to close battery compartment.



43

Install and test the fan trayInstalling a fan tray into a Calix C7 shelf in the front compartment of the cabinet provides cooling for the Calix C7 shelf.

The front panel of the fan tray also shows the results of a power test at start-up, and provides status displays and interfaces for testing.

Install and test the fan tray

Step Action

1. Check that main power to the cabinet and AC load center breakers are ON.

2. Verify that the optional Metallic Services Protection modules have been installed, if ordered, prior to installing the fan tray.

3. Remove the fan tray from its packaging.

4. Hold the fan tray from beneath with one hand so that you are looking at the display panel, and with the other hand pull the fan tray handle up to disengage the locking mechanism.

5. Gently slide the fan tray into the slot beneath the Calix C7 plug-in card shelf.

6. Push the handle down to lock the fan tray into position. (Note: In the locked position, the handle should be flush with the bottom lip of the shelf.)

7. Check that the fan tray fans are running and that the System Alarm Status display reads:

INPUT VOLTAGE OK

8. At the AC Load center, set the Rectifier (A), Rectifier (B), and Main breakers to OFF.



44

Outdoor cabinet fan tray filter description

Install the filter after the fan tray has been installed. The filter used in outdoor cabinets contains no filter element but is required to provide EMI suppression.

Procedure to install the shelf filter

Step Action

1. If you have not already done so, remove the filter from its packaging.

2. Lift the fan tray handle up to disengage its locking mechanism, and rotate it out to its upright and locked position. Do not remove the fan tray.

3. Insert the filter into its slot below the fan tray with the "Airflow" label text on the front edge of the filter in the upright position facing you. Push the filter into place.

4. Push in on the fan tray handle and rotate down to lock the fan tray into position. (Note: In the locked position, the handle should be flush with the bottom lip of the shelf.)



45

Install Outside Plant Cables

Subscriber cablesEntry location for subscriber cables

You can route subscriber cable through any of the cable entry locations in the splice compartment. For best results:

• with a high copper count configuration, route the cable to the right.• with an integrated cross-connect, route the cable to the right and towards the back

of the compartment to clear the cross-connect panel.

Procedure to install the subscriber cabling

Step Action

1. Route the subscriber cable up through a cable entry hole in the bottom of the side splice compartment. Leave 8-10 feet of cabling hanging out of the cabinet.

2. Slide a 4" cable entry plate down the subscriber cable and fasten the plate to the bottom of the side splice compartment.

3. Slide a 4" cold shrink tube down the subscriber cable with the loose pull tab of the cold shrink removable core feeding from the bottom of the tube through to the top.

4. Wrap mastic tape (from the installation kit) around the subscriber cables at the location where the cables will meet the cold shrink tubing.



46

Terminating subscriber cables

The procedure for terminating subscriber cables is the same whether you have ordered the integrated cross-connect option or not. The only difference is the source of the equipment cables.

• Equipment cables come directly through the ports from the copper protection compartment in cabinets without the integrated cross-connect option.

• Equipment cables come from the back of the cross-connect panel in cabinets with the integrated cross-connect option.

5. Hold the cold shrink tubing tight against the cable entry plate as you pull the loose tab to remove the cold shrink core. Continue to push down on the cold shrink tubing until the bottom of the tubing seals against the cable entry plate.

6. While holding the cold shrink tubing firmly, pull the loose tab to completely remove the core and the cold shrink tubing seals against the subscriber cable.

Step Action



47

Procedure to terminate the subscriber cables

Route subscriber cable over the pegs

The above configuration is one possible routing suggestion. Your cable routing configuration may differ. Additional cable routing posts are included in the cabinet installation kit.

Step Action

1. Terminate the sheath ground to the main ground bar.

2. On the factory installed subscriber cable, remove the cover from one cable binder.

3. On the outside plant cable, remove the opposite cover from the matching cable binder.

4. Use the appropriate tool to squeeze the two connectors together for a tight fit.

5. Repeat steps 2 through 4 for all binders in the outside plant cable.

After the subscriber cable is installed and sealed, route the cable over the cable management pegs as shown.

The blue cables are the outside plant cables and the gray are the factory installed cables.



48

Cross connections between equipment and subscriber pairs

Cabinets ordered with the integrated cross-connect option ship with the equipment cabling terminated to the center column of connection blocks in the cross-connect panel.

The 2 outside columns of connection blocks are wired and terminated to the subscriber cables for a 2:1 configuration. (2 subscriber pairs for each equipment pair)

Install jumper wires from the center column of equipment connection blocks to subscriber connection blocks in either outside column.

View of the integrated cross-connect panel

Install copper protection modules

In the rear compartment, install copper protection modules for all slots corresponding to your configuration.

The sample image shows 240 modules installed in the copper protection panel. Your configuration may differ.



49

Install T1 labels

Calix outdoor cabinets ship with labels to indicate which slots on the copper protection blocks are connected to a T1 card. Use these labels to alert field technicians to the possible presence of powered T1 lines at a protection block.

The figure shows the labels for slot 1 and where you would apply them to the copper protection block.



50

Install the fiber holdersThe fiber holders are fiber distribution cassettes, fiber splice trays, and the jumpers between them.

Fiber options in cabinets with an integrated cross-connect panel

If an integrated cross-connect panel is present:

• There is room for only 1 fiber splice tray holder supporting 120 fiber splices.• No fiber distribution cassette holders can be installed.

Available fiber distribution cassette options

Fiber distribution cassettes are available for fibers with SC or LC connectors. Each cassette can hold up to 12 fiber connections.

Fiber cassette holder capacity

A fiber cassette holder can accept up to 6 fiber distribution cassettes. At 12 connections per cassette, one cassette holder supports a total of 72 fiber connections.

Procedure to install the fiber distribution cassette holder and cassettes

Step Action

1. Choose where you want the fiber distribution cassette holder to attach to the pegboard.

2. Hold the fiber distribution cassette holder to the pegboard, then insert and tighten 2 mounting bolts.

3. Slide each cassette into the holder (hook-side down) to prepare for connecting fibers. See the photo above.

4. Fold the cassette holder back until it is flush against the pegboard.



51

Available fiber splice tray options

Fiber splice trays are available for three splice types. The splice options are mechanical, fusion, and heat shrink. Each fiber splice tray can hold 12 fiber splices.

Fiber splice tray capacity

Fiber splice tray holders can accept up to 10 fiber splice trays. At 12 splices per tray, one splice tray holder supports a total of 120 fiber splices. All the trays install and stack in the same way.

If you don't install any fiber distribution holders, you can install 2 splice tray holders to support 240 fiber splices.

Fiber jumper and pigtail options

• From the front of a Calix C7 optical plug-in card, you can run a fiber jumper to a fiber distribution cassette.

• From the front of a Calix C7 optical plug-in card, you can run a fiber pigtail to a fiber splice tray.

• You can run a pigtail between a fiber splice tray and a fiber distribution cassette.

Fiber holder locations

The above configuration is a sample placement suggestion. Your configuration may differ.

The fiber splice tray holder and fiber distribution cassette holder are mounted on the left near the center of the splice tray compartment.

The fiber splice tray holder is above the fiber distribution cassette holder.



52

Procedure to install the fiber splice tray holder and trays

Step Action

1. Choose where you want the fiber splice tray holder to attach to the pegboard.

2. Hold the fiber splice tray to the pegboard, then insert and tighten 2 mounting bolts.

3. Slide the fiber trays into the holder.

4. Secure the fiber trays to the holder with the supplied velcro strap.



53

Install the fiberTo install the fiber, you will need to install and route the cabling, splice and terminate the fiber, then seal and support the fiber cables within the splice compartment.

Entry location for fiber cables

You can route fiber cable through any of the cable entry locations in the splice compartment. For best results:

• for most situations, route the fiber cable to the left.• with an integrated cross-connect, route the fiber cable to the right.

Procedure to install the fiber cabling

Example of fiber cable routing

The above configuration is a sample placement suggestion. Your configuration may differ.

Step Action

1. Route the fiber cable up through a cable entry hole in the bottom of the side splice compartment. Leave 8-10 feet of cable hanging out of the cabinet.

2. Slide a 2" fiber cable entry plate down the fiber cable and fasten the plate to the bottom of the side splice compartment.

3. Slide a 2" cold shrink tube down the subscriber cable with the loose pull tab of the cold shrink removable core feeding from the bottom of the tube through to the top.

The fiber cable is routed up the left side of the compartment and supported by the fiber strain relief bracket.

Pigtails are spliced to the fiber with the splices placed in the fiber splice trays.



54

Procedure to splice the fiber cables

Procedure to route fiber jumpers to the fiber distribution cassette

Procedure to terminate the fiber cables

Step Action

1. Pull the loose fiber cable from the splice compartment to your fiber splicing equipment.

2. Splice fibers from the cable to fiber jumpers following the instructions for your splice equipment.

3. Place the spliced fiber in a fiber splice tray, routing the fiber as shown.

4. Place the fiber splice tray into the fiber splice tray holder and secure the tray with the supplied velcro strap.

Step Action

1. Remove a fiber distribution cassette from the holder.

2. Route fiber jumpers through the back of the holder.

3. Route each fiber jumper from the back of the fiber distribution cassette to the front connectors as shown.

4. Insert the fiber distribution cassette into the holder.



55

Step Action

1. Install the splice tray holder(s) and splice trays. See the splice tray holder procedure.

2. Terminate the outside plant fibers to the fiber splice trays.

3. Install the fiber distribution cassette holder(s). See the fiber distribution cassette holder procedure.

4. When optical plug-in cards are installed, terminate the fibers using jumpers from the front of the plug-in cards onto the fiber distribution cassette(s). You can also terminate fibers using pigtails from the front of the plug-in cards to the fiber splice tray(s).

5. If desired, run fiber pigtails from the fiber distribution cassette(s) to the corresponding fiber splice tray.

6. Use velcro around the splice tray ends to simplify cable management.



56

Procedure to seal and support the fiber cable

Step Action

1. Attach the fiber strain relief bracket (from the installation kit) to the desired position on the pegboard. Align the bracket with the center of the cable entry plate through which the fibers are routed.

2. Route the strength member from the fiber cable through the strain relief clamp and tighten the clamp to support the fiber.

3. Wrap mastic tape (from the installation kit) around the fiber cable at the location where the cable will meet the cold shrink tubing.

4. Hold the cold shrink tubing tight against the cable entry plate as you pull the loose tab to remove the cold shrink core. Continue to push cold shrink tubing down until the bottom of the tubing seals against the cable entry plate.

5. While holding the cold shrink tubing firmly, pull the loose tab to completely remove the core and the cold shrink tubing seals against the fiber cable.



57

Installing Plug-in Cards

Install the AMP plug-in card

ELECTRO-STATIC DISCHARGE ALERT! When installing or removing the plug-in cards, always wear the electro-static discharge (ESD) wristband provided. Plug the wristband cable into the ESD jack located on the inside of the Calix C7 door on the lower left corner.

Procedure to install the AMP card

Step Action

1. If you have not already done so, remove the AMP card from its packaging and remove the plug cover at the rear of the card.

2. Pull the card ejector down to the unlocked position.

3. Slide the AMP card along the guide rails into the management interface slot labeled MS in the center of the shelf. Important: To avoid causing damage to the card or the shelf, make certain the card is aligned correctly with the guide rails prior to inserting it.

4. Push the card ejector up into the locked position.



58

AMP installation view



59

Install the RAP-OC3/12/48 plug-in card


FIBER OPTIC DANGER! Never look into the end of a fiber optic cable! Light output from a fiber optic cable is invisible to the human eye. However, it can destroy the retina of the eye.

Procedure to install a RAP card

Step Action

1. If you have not already done so, remove the optical RAP card from its packaging and remove the plug cover at the rear of the card.

2. Open the card ejectors at the top and bottom of the card.

3. Slide the RAP card along the guide rails into the appropriate control slot (CS-A or CS-B). Important: To avoid causing damage to the card or the shelf, make certain the card is aligned correctly with the guide rails prior to inserting it.

4. Lock the card ejectors at the top and bottom of the card.



60

RAP installation view



61

Install metallic plug-in cards


Procedure to install a Calix C7 metallic plug-in card

Step Action

1. If you have not already done so, remove the card from its packaging and remove the plug cover at the rear of the card.

2. On the card, pull the card ejector down to the unlocked position.

3. In any universal slot, slide the card in along the guide rails. Important: To avoid causing damage to the card or the shelf, align the card correctly with the guide rails prior to inserting it.

4. On the card, push the card ejector up into the locked position.



62

Metallic plug-in card installation view



63

Install optical plug-in cards


FIBER OPTIC DANGER! Never look into the end of a fiber optic cable! Light output from a fiber optic cable is invisible to the human eye. However, it can destroy the retina of the eye.

Procedure to install an optical plug-in card

Step Action

1. If you have not already done so, remove the optical card from its packaging and remove the plug cover at the rear of the card.

2. Pull the card ejector down to the unlocked position.

3. Slide the card along the guide rails into any universal slot. Important: To avoid causing damage to the card or the shelf, align the card correctly with the guide rails prior to inserting it.

4. Push the card ejector up into the locked position.

5. Remove the fiber protector cover from the top front of the card.



64

Optical plug-in card installation view

6. Identify the appropriate fiber cable assignments for each optical card (from the labels applied when you dressed the fiber cables earlier in the installation process).

7. Beginning with port 1 at the top of each card, insert the appropriate LC connector with the key turned to the right into the face of the card. (Note: the Calix optical card ports are located on the face of each card and are numbered from the top of the card down -1, 2, 3, etc. - with the RX connector in the front and the TX connector immediately behind it.)

8. After terminating all the appropriate LC connector ends into the optical card, replace the card's fiber protector cover.

9. Repeat steps 1 through 7 for each optical card.

Step Action



65

System and NetworkConfiguration

IntroductionCalix iMS features

The Calix integrated Management Software (iMS) is a graphical user interface that you use to configure and monitor all of the Calix C7 nodes on a network. With the Calix iMS, you can:

• view a diagram of your network topology• configure all aspects of a Calix C7 network• manage timing and synchronization• view current alarms• view and clear performance monitoring registers

You start the Calix iMS by using Internet Explorer (version 5.0 or higher with the Java 1.3 plug-in) to connect to any Calix C7 node in the network. See "Configure your computer to connect to the Calix C7".



66

Configure your computer to connect to the Calix C7

You must configure the Ethernet port of your computer before making the first connection to your Calix C7 network.

Once connected, you can change Ethernet log-on parameters on the Calix C7 to support connections following your company standards. For details on configuring Ethernet log-on parameters, see the full documentation in the Calix C7 iMS Guide.

Calix factory settings for the front Ethernet port

The Calix C7 ships with the front Ethernet port on the AMP (E1) active and set to the following configuration:

IP: 192.168.1.1Subnet: 255.255.255.0Gateway: 0.0.0.0

Configuration needed on your PC

To connect to the front Ethernet port of the AMP, you must configure the Ethernet port on your computer to the following settings:

IP: 192.168.1.2 (The last number can be 2 to 255. Calix recommends 2.)Subnet: 255.255.255.0Gateway: 0.0.0.0Cable: Use a straight-through cable to connect your computer to the Calix C7.



67

Procedure to configure your computer to connect to the Calix C7

This procedure is for computers using Microsoft Windows 2000.

Connect your computer to the front Ethernet port

Use a straight-through Ethernet cable to connect the Ethernet port on your computer to the Ethernet port on the front of the AMP in the Calix C7 shelf.

Step Action

1. On the Start menu, click Settings, then click Network And Dial-up Connections, then right-click Local Area Connection, and click Properties.

2. On the Local Area Connection Properties dialog box, do the following:a. Click Internet Protocol (TCP/IP).b. Make sure the check box to the left of Internet Protocol (TCP/IP) is

selected.c. Click Properties.

3. On the Internet Protocol (TCP/IP) Properties dialog box, do the following:a. Click Use The Following IP Address to select it.b. In the IP Address box, type 192.168.1.2.c. In the Subnet Mask box, type 255.255.255.0.d. In the Default Gateway box, type 0.0.0.0.e. Leave the DNS Server addresses blank.

4. On all open dialog boxes, click OK to save your network connection settings.



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Start the Calix integrated Management System

You start the iMS by entering the IP address of the Calix C7 shelf into your browser.

One-time install of the Java Runtime Environment

The first time you start the Calix iMS, you may be prompted to:

• Install the latest version of the Java Runtime Environment (JRE). Follow the instructions on the screen to complete the install.

• Review a Java Plug-in Security message. Click Grant Always after reviewing the security message.

Procedure to start the Calix iMS from the front Ethernet (E1) port

Step Action

1. Start Internet Explorer, then in the Address box enter 192.168.1.1 for the front Ethernet port (E1) IP address of the Calix C7.

Note: You can enter other IP addresses assigned to the Calix C7 shelf after you configure the Ethernet port to your standards.

2. On the initial screen, click Calix iMS.

3. When the dialog box displays Do you want to close this window?, click Yes.

4. On the Login to iMS dialog box: a. In the User box,

type sysadmin.b. In the Password box,

type sysadmin.c. Click OK.

NOTE: To ensure system security, Calix recommends changing the default sysadmin user name and password after logging in for the first time.



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Start up view of your network

The first time you log in to a new Calix C7 network, you will see the following:

• An empty Work Area with no network topology. • One entry in the Navigation Tree named Unassigned Shelves.

You must use the Network Wizard to group shelves into nodes.



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Define nodes in the networkTo define a network node, you will complete 4 steps:

• Assign the node a name and number (i.e., its address within the network)• Identify what type of node it is (e.g., indoor rack mount or outdoor cabinet)• Designate a primary AMP for the node• Assign shelves to the node

The purpose of the primary AMP

The primary AMP collects and reports alarms for all shelves within a node. The primary AMP must reside in the Management/Maintenance slot of a shelf within the node.

Procedure to define nodes in the network

Step Action

1. On the Tools menu, click Network Wizard to start the wizard.

2. In the Unassigned Shelves area, press the CRTL key, and click all the shelves to be assigned to the new node, then click Add.

3. In the node information area on the right, do the following:a. In the System ID box, type a node name.b. In the Node # list, click a number for the node.c. In the Node AMP list, click the Shelf ID that contains the primary

AMP for the node.d. In the Node Type list, click either Rack Mount for an indoor node, or

an ODC cabinet type.e. In the Alarm Setting list, click either Node to display alarms only for

this node, or Network to display all alarms.



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4. Click Assign to create the node and display it in the Current Nodes area.

5. Repeat steps 2 - 4 to create additional nodes.

6. In the lower left corner of the Current Nodes area, click from the list of shelves to select an Admin Master for the network.

7. Click Next to save all node definitions and the Admin Master designation, and to exit the Network Wizard.

Step Action



4Chapter

Maintaining andTroubleshooting the

ODC-10

75

Maintaining the Calix OutdoorCabinet

Battery MaintenanceAt a minimum follow the battery manufacturers recommended maintenance. Additionally Calix recommends that all batteries be removed from the cabinet, tested and maintained at least once a year. Perform the following task:

• Visually inspect each battery for physical damage, leakage, or bulging. Replace any battery displaying any defect before the batteries are placed back in service.

• Load Test each battery to verify that ample current is available to maintain the system.

• Ensure that each battery is providing 13.5 VDC +/-.2 VDC• Clean the batteries so there is no dust dirt or corrosion present on the battery

surface.• Clean and visually inspect the area for any signs of damage. Damage to painted

areas should be fixed by removing all rust and dirt from the affected area then apply touch-up paint to the area to prevent future corrosion.

• Before reconnecting the batteries, ensure that there is an oxide inhibiting grease applied to all terminals.



76

Maintain external cable connectionsCheck external cable connections at least once a year. External cable is defined as any cable or wire that enters the cabinet from an external source.

• Visually inspect all cables for signs of physical damage. If damage is present cables should be repaired or replaced, if possible, per local site practices.

• Check all outside plant copper connections for complete and secure connection.• Ensure that all cable management accessories provide a clean appearance. Replace

any fastening devices (i.e. tie wraps) so that they include all cables being secured.• Check all fiber optic connectors to ensure that they are securely fastened.• Check all connections on the cabinet ground bar for a tight and secure fit.• Check all protector modules and fiber modules to ensure that all devices are

securely seated.• Check all conduits to ensure that any material used to seal between the cable and

the conduit is still present and providing a complete seal.



77

Maintain the cabinet surfacesInspect inside surfaces

Clean and inspect the inside of the cabinet for damage and wear once a year. Items to check include the following:

• Visually inspect the inside of the cabinet for signs of visible damage to the metal or paint.

• Repair damage to the paint using touch-up paint available from Calix after cleaning the surface and removing rust.

• Note any damage to the metal work. If the damaged metal work interferes with the operation of the Calix C7 cabinet or electronics contact Calix support for assistance with a resolution.

• Inspect all gaskets around the doors and the roof to ensure a tight secure fit.

Inspect outside surfaces

Clean and inspect the outside of the cabinet for damage and wear once a year. Items to check include the following:

• Inspect the outside of the cabinet for signs of damage to the metal work or paint.• Repair damage to the paint using approved type touch-up paint after cleaning the

surface and removing rust.• Note damage to the metal work. If the damaged metal work interferes with any

operation of the Calix C7 cabinet or electronics contact Calix support for assistance with a resolution.

• Clean all surfaces so that they are free of dirt, dust, and foreign material.• Remove all material from air intake screens and louvers (i.e. spider webs, leaves,

etc.).• Clean base and roof vents with a dry, soft brush to ensure optimal airflow.



79

Environmental Alarms

AC fail alarm

Alarm output

When the alarm occurs, the following message displays:

TID-000 01-09-10 08-15-00 ** 001 REPT ALM ENV "N2-1:MJ,POWER,NSA,9-10,8-15-00,NEND;"

Clearing output

You will see this message once the alarm has been cleared from the system.

TID-000 01-09-10 08-15-00 A 001 REPT EVT ENV "N2-1:POWER,CL,9-10,8-15-00;"

Description Severity

The AC fail (POWER) alarm indicates that commercial power has failed or is absent.

Calix outdoor cabinets are designed to provide eight hours of battery backup. If the POWER alarm persist for longer than eight hours service may be lost. Connect a backup power generator to the outdoor cabinet to prolong the battery backup capabilities.

Major



80

Battery circuit breaker alarm

Alarm output


TID-000 01-09-10 09-15-00 * 001 REPT ALM ENV "N2-1:MN,BATTCB,NSA,9-10,9-15-00,NEND;"

Clearing output


TID-000 01-09-10 09-20-00 A 001 REPT EVT ENV "N2-1:BATTCB,CL,9-10,8-15-00;"


The battery circuit breaker (BATTCB) alarm indicates that the circuit breaker in the battery compartment has failed.

The BATTCB alarm will occur as a result of a either battery or rectifier malfunction. A circuit breaker failure is caused by an over amperage condition.

Minor



81

Auxiliary fuse fail alarm

Alarm output


TID-000 01-09-10 10-15-00 * 001 REPT ALM ENV "N2-1:MN,FUSE,NSA,9-10,10-15-00,NEND;"

Clearing output


TID-000 01-09-10 10-45-00 A 001 REPT EVT ENV "N2-1:FUSE,CL,9-10,10-45-00;"


The auxiliary fuse fail (FUSE) alarm indicates that one of the GMT fuses for the auxiliary has failed.

The FUSE alarm will occur as a result of a either an over amperage condition on the shelf or a defective fuse.

Minor



82

Cabinet over temperature alarm

Alarm output


TID-000 01-09-10 11-15-00 ** 001 REPT ALM ENV "N2-1:MJ,HITEMP,SA,9-10,11-15-00,NEND;"

Clearing output

You will see this message once the alarm has been cleared from the system:

TID-000 01-09-10 11-55-00 A 001 REPT EVT ENV "N2-1:HITEMP,CL,9-10,11-55-00;"


The over temperature (HITEMP) alarm indicates that the outdoor cabinet has exceeded the allowable temperature for the Calix C7 equipment to operate. The outdoor cabinet will generate an over temperature alarm at 158F (70C).

There are two heat exchangers located in the sidewalls of the main equipment area: one internal and one external. The internal heat exchanger fans activate at 77F (25C), and the external heat exchanger fans activate at 86F (30C).

Major



83

Troubleshooting steps for HITEMP alarm

Step Action

1. Open all cabinet doors and remove the lower battery compartment panels.

2. Verify that the heat exchanger fans are operating by lifting the roof, feeling for airflow manually, or placing a paper next to the fans to check for airflow.

• If the fans are not operating, go to step 6.• If the fans are operating, proceed to the next step.

3. Verify that the equipment is not exceeding the maximum heat budget for equipment in the cabinet. (Refer to the appropriate cabinet guide for this number.)

• If the equipment is producing less heat than what is budgeted for equipment in the cabinet, go to step 7.

• If the equipment is producing more heat than what is budgeted for equipment in the cabinet, proceed to the next step.

4. Access the Calix C7 equipment with a computer and verify the heat setting for the shelf or shelves in the cabinet.

• If the heat settings do not exceed the budget for the cabinet, go to step 7.

• If the heat settings do exceed the budget for the cabinet, proceed to the next step.

5. Modify the heat setting so that it is within the heat budget for the cabinet, then proceed to step 7.

6. Replace the heat exchanger fans. See heat exchanger module procedure.

7. Leave the cabinet doors and panels open for approximately 1 hour, or until the cabinet has cooled to the point that the heat exchanger fans shut off, whichever comes first.



84

Door alarm

Alarm output


TID-000 01-09-10 17-15-00 * 001 REPT ALM ENV "N2-1:MN,OPENDR,NSA,9-10,17-15-00,NEND;"

Clearing output


TID-000 01-09-10 17-15-00 A 001 REPT EVT ENV "N2-1:OPENDR,CL,9-10,17-15-00;"


The door (OPENDR) alarm indicates one of the five cabinet doors is open.

To disable the door alarm while maintenance personnel are accessing the outdoor cabinet the door alarm switch should be pulled out while the door is open.

Minor



85

GMT fuse fail alarm

Alarm output


TID-000 01-09-10 12-15-00 * 001 REPT ALM ENV "N2-1:MN,FUSE,NSA,9-10,12-15-00,NEND;"

Clearing output


TID-000 01-09-10 12-15-00 A 001 REPT EVT ENV "N2-1:FUSE,CL,9-10,12-15-00;"


The GMT fuse fail (FUSE) alarm indicates that a GMT fuse in the DC distribution center, other than the Calix C7 fuse, has failed.

Minor



86

Low battery alarm

Alarm output


TID-000 01-09-10 13-15-00 * 001 REPT ALM ENV "N2-1:MN,BATTERY,NSA,9-10,13-15-00,NEND;"

Clearing output


TID-000 01-09-10 13-15-00 A 001 REPT EVT ENV "N2-1:BATTERY,CL,9-10,13-15-00;"


The low battery (BATTERY) alarm indicates that the battery voltage in the outdoor cabinet has dropped below -46 VDC.

Once the low battery alarm has been initiated the system has a limited amount of time before the low voltage disconnect for the outdoor cabinet will engage. Reestablish commercial power to the cabinet or connect a backup generator to prevent a service disruption.

Major



87

Low voltage disconnect alarm

Alarm output


TID-000 01-09-10 14-15-00 ** 001 REPT ALM ENV "N2-1:MJ,LVD,NSA,9-10,14-15-00,NEND;"

Clearing output


TID-000 01-09-10 14-15-00 A 001 REPT EVT ENV "N2-1:LVD,CL,9-10,14-15-00;"


The low voltage disconnect (LVD) alarm indicates that the outdoor cabinet battery voltage has reached -42 VDC and the cabinet will be shut down soon.

The low voltage disconnect will be activated when the battery voltage in the cabinet reaches -44 VDC. Once the low voltage disconnect has been activated the Calix C7 equipment will shut down and customer will be out of service.

Major



88

Rectifier major alarm

Alarm output


TID-000 01-09-10 15-15-00 ** 001 REPT ALM ENV "N2-1:MJ,RECT,NSA,9-10,15-15-00,NEND;"

Clearing output


TID-000 01-09-10 15-15-00 A 001 REPT EVT ENV "N2-1:RECT,CL,9-10,15-15-00;"


The rectifier major (RECT) alarm indicates that the outdoor cabinet rectifier shelf has a major alarm.

The Calix rectifier will report a major alarm for high voltage shut down, AC fail, Fuse Alarm, and low voltage disconnect.

Major



89

Rectifier minor alarm

Alarm output


TID-000 01-09-10 16-15-00 * 001 REPT ALM ENV "N2-1:MN,RECT,NSA,9-10,15-15-00,NEND;"

Clearing output


TID-000 01-09-10 16-15-00 A 001 REPT EVT ENV "N2-1:RECT,CL,9-10,16-15-00;"


The rectifier minor (RECT) alarm indicates that the outdoor cabinet rectifier shelf has a minor alarm. The RECT alarm is always reported as a minor alarm.

Minor



91

Troubleshooting and ReplacingOutdoor Cabinet Hardware

Failed heat exchanger moduleDescription of cooling fans

The cooling fans circulate air within the patented cabinet cooling system. The cooling fan module is located under the cabinet roof.

Heat exchanger blower module view

Procedure to test cooling fan operation

Verify cooling fan operation as part of regular cabinet maintenance.

An over temperature condition will occur as the result of a failed cooling fan.

Step Action

1. Locate the HX Fan Test near the temperature sensor grille on the DC Distribution panel.

2. Insert a small wire into the INT test hole to press the start button for the internal cooling fans. The fans will automatically shut off after running for 30 seconds. If the fans do not start, replace the fans.

3. Insert a small wire into the EXT test hole to press the start button for the external cooling fans. The fans will automatically shut off after running for 30 seconds. If the fans do not start, replace the fans.



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Procedure to replace the cooling fan module

Step Action

1. Open the cabinet roof. See the roof access procedure.

2. Remove the cartridge screws around the perimeter of the cooling fan module.

3. Lift the back end of the cooling fan module and slide it backward, then up to remove.

4. Disconnect the two power cables by pressing both sides of the cable plug toward the center then pulling the plug out.

5. Replace the old cooling fan module with the new one.

6. Re-connect the two power cables to the new cooling fan module.

7. Slide the new cooling fan module into place. You may need to push excess cabling back into the cabinet before lowering the new cooling fan module into place flush against the cabinet.

8. Replace and tighten all cartridge screws around the perimeter.

9. Close the cabinet roof. See the roof closure procedure.



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Replace and test a rectifier moduleProcedure to install or replace a rectifier module

Procedure to test voltage at the rectifier shelf

Step Action

1. Unbolt and remove the cover plate (or module to be replaced).

2. Slide the new module into the slot.

3. Tighten the front bolt to secure the module in place.

Step Action

1. Check that main power to the cabinet is ON, then at the AC load center, set the Rectifier (A), Rectifier (B), and Main breakers to ON.

2. Using a volt meter test between the V- and V+ receptacles on the front of the alarm control unit.

a. place the red lead of the voltmeter into V-b. place the black lead of the voltmeter into V+c. verify that the volt meter reads -54.5 +/-.5 VDC

3. At the AC Load center, set all the breakers to OFF.



94

Replace the batteriesSupported battery types

Calix recommends and supports using Dynasty 80 AH batteries. One string fits into the ODC-10 cabinet.

DANGER! Handle batteries with care. Batteries contain a stored charge.

Procedure to replace the batteries

Step Action

1. Set the battery breaker switch above the drawer to OFF.

2. Open the battery drawer, disconnect the battery wiring, and remove the batteries to be replaced.

3. Place the batteries into the battery drawer.

4. Remove the battery terminal bolts and apply No-Ox anti-corrosion grease to each battery terminal.

5. Thread a lock washer, a flat washer, the battery temperature compensation sensor, and a battery wire terminal lug onto a terminal bolt.



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6. Attach the bolt from step 4 to the positive (black) battery terminal bolt at the rear of the battery drawer.

Ensure that the battery wire terminal lug is in direct contact with the greased terminal when you insert the bolt.

7. Thread a lock washer, a flat washer, and a battery wire terminal lug onto all other battery terminal bolts. Attach and ensure that each lug is in direct contact with the greased terminal when you insert the bolt.

8. Use an insulated wrench to connect the battery leads according to the wiring diagram on the inside of the battery compartment door panel.

Click the diagram to the right to see the wiring diagram for one battery tray.

DANGER! The black battery lead is positive and the red battery lead is negative.

9. Using a volt meter test the battery charge between the negative and positive battery leads.

a. place the red voltmeter lead on the red negative battery leadb. place the black voltmeter lead on the black positive battery leadc. verify that the volt meter reads between -48 and -54 VDC

10. Set the battery breaker switch above the drawer to ON.

Step Action



96

Replace the circuit breakers

DANGER! High voltage may be present. Only a qualified electrician should install and connect circuit breakers. Follow NEC and local codes when installing AC power.

Do not turn on the main power to the cabinet until the power installation is complete.

Procedure to replace a circuit breaker

Step Action

1. Set the main circuit breakers for the cabinet to OFF.

2. Remove the access panel on the AC load center.

3. Remove any wires from the defective circuit breaker.

4. Replace the circuit breaker with one of the same type and rating.

5. Reconnect all wiring to the circuit breaker.

6. Replace the cover to the AC load center.

7. Set the main AC breaker, and the breaker that you just replaced, to ON.



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Replace the fusesFuses for the Calix C7 shelves and other equipment in the cabinet are located on the DC Distribution panel.

Fuse ratings in the DC Distribution panel

Procedure to replace a fuse

Fuse Type Fuse Rating

Calix C7 shelves 20 Amp

Heat exchanger fans and other equipment 5 Amp

Step Action

1. Remove the defective fuse from the fuse position with out causing damage to surrounding fuses.

Note: Calix recommends using a GMT fuse removal tool.

2. Replace the fuse with a fuse of the same rating and type.

3. If the fuse fails again do not replace it. Troubleshoot to find the cause of the failure.



98

Replace the battery heaterIf the battery heater fails or if there is damage to the batteries due to the cold, you will need to replace or install battery heaters in your cabinet.

Procedure to install a battery heater

Install the battery heater prior to initial battery installation.

View of the battery heater

The battery heater is highlighted in the image below.

Step Action

1. If not already removed, disconnect and remove all batteries. To open the front and rear battery compartment panels, see the procedure to remove battery compartment panels.

2. From the front, lay the heater into the base of the battery drawer with the power cord at the rear.

3. At the rear of the battery compartment, route and tie wrap the battery heater power cord to the cable routing arms.

4. Route and tie wrap the power cord along the top of the battery compartment and plug it into the outlet in the compartment.

5. Reload and reconnect batteries. See the battery installation procedure.



99

Replace the generator connectorEmergency generator connection

In the event of external AC power failure, an optional generator connection is available. The generator connector is located on the front exterior of the cabinet. A 30 Amp Hubbell twist lock connector with a weatherproof seal is available to order. A circuit breaker services the generator connector.

Description of emergency generator connector types

The 30 Amp generator connector is a Twist-Lock, NEMA L14-30R, 3 pole 4-wire grounding, 250 VAC. A weatherproof Seal-Tite Seal Boot is optional but strongly recommended.

View of the 30 Amp generator connector

Generator connector part numbers

The Hubbell part numbers for the generator connector and its mate are:

Generator connector

Inlet Weatherproofing Connector

30 Amp HBL2715 (NEMA L14-30R)

Seal boot HBL6035 HBL2713 (NEMA L14-30P)



5Chapter

Reference

103

Customer Service and Support

The Calix Technical Assistance CenterThe Calix Technical Assistance Center (TAC) provides 24-hour-a-day, 7-day-a-week coverage by our staff of experienced System Engineers.

During normal business hours: Use phone, FAX, or web for immediate assistance from the TAC. Normal business hours are 7:00 am to 7:00 pm PST, Monday through Friday.After hours and on holidays: Contact the Calix TAC by phone and receive an immediate response from a Service Engineer for Severity 1 and 2 issues.

Contact the TAC

Use the following methods to contact the TAC:

Voice: 877-766-3500 (Press 3)* or 707-766-3500 (Press 3)*FAX: 707-283-3500Email: [email protected](mailto:[email protected])Calix Customer Center: www.calix.com(http://www.calix.com)

* Please contact Calix via phone for after hours support.



mailto:[email protected]

http://www.calix.com

http://www.calix.com

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Appendix: Specifications

ODC-10 specificationsSpecifications

Wired Capacity Copper: up to 240 lines Fiber: up to 240 lines Any copper/fiber combination up to 240 lines

Dimensions 38"W X 33"D X 45"H

Weight 500 lbs. (Equipped with Dynasty 80 Ah batteries: 700 lbs.)

Environmental Ambient Temperature: -40 C to +52 C (per GR-487)

Cooling Integrated air-to-air tubular cooling system with DC blowers

Power 220-240 VAC single phase: 30 Amp service with UL listed service disconnect Redundant AC feeds to rectifier Redundant DC feeds to Calix C7 shelf Low voltage DC disconnect (-42 V) High power AC surge protection (Joslyn)

DC Rectifiers Standard DC rectifier: Calix (Delta)

Battery Back-Up Preferred batteries: Dynasty 80 AH battery One string per cabinet Option for extended battery tray configuration



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Alarms Calix C7 Fuse Fail A+B All doors (front, back, side, battery) Over temperature Rectifier Major Rectifier Minor AC Fail AUX/GMT Fuse Fail Battery Breaker Fail Low voltage Disconnect

Copper Protection Panels Standard 5-pin protection panels, up to 240 positions

Cable Management Copper plant OSP connectors: MS2

Fiber Management Options Fiber splice trays Fusion - 12 positions per tray Heat Shrink - 12 positions per tray Mechanical - 12 positions per tray

Fiber Distribution Cassette Options SC connectors - 12 positions per cassette LC connectors - 12 positions per cassette

cross-connect Options Marconi URLS (mini RLS) tool less punch down block Provides equipment to subscriber ratio of 1:2 Cross connect option excludes fiber distribution capability and 19" rack space in cabinet

Optional 3rd Party Cable Management Options RU of 19" rack space available in splice chamber for 3rd party passive equipment such as fiber management or DSX panels.

Generator Connector Options 30 Amp NEMA twist lock connector 60 Amp pin and sleeve

Mounting Options Pad, pole, H-frame, Wall



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Test Head Options 19" test head installed on back door Contact Calix for supported test head products

Color Warm gray

Compliance UL-67 Telcordia, GR-63-CORE, Network Equipment-Building System (NEBS) Requirements, Issue 1, October 1995. Telcordia, GR-487, Generic Requirements for Electronic Equipment Cabinets, Issue 2, March 2000.



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Calix ODC-10 Installation Guide

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