A technical manual from the experts
in Business-Critical Continuity™
Aerial Ultracab Cross-Connect Enclosures
Description and Installation
631-201-009 (Version D, October 11, 2011)
Business-Critical Continuity™, Emerson Network Power, and the Emerson Network
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NETSURE™, NetSpan™, NetReach™, NetXtend™, and NetPerform™
are trademarks of Emerson Network Power, Energy Systems, North America, Inc.
All other trademarks are the property of their respective owners.
The products covered by this instruction manual are manufactured and/or
sold by Emerson Network Power, Energy Systems, North America, Inc.
The information contained in this document is subject to change without notice and may not be
suitable for all applications. While every precaution has been taken to ensure the accuracy and
completeness of this document, Emerson Network Power, Energy Systems, North America, Inc.
assumes no responsibility and disclaims all liability for damages resulting from use of this information
or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct
methods, tools, and materials to be used in performing procedures not specifically described in this document.
This document is the property of Emerson Network Power, Energy Systems, North America, Inc.
and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use or disclosure of it without the written permission
of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Copyright © 2011, Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved throughout the world.
Emerson Network Power
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631-201-009
Version D, October 11, 2011
TABLE OF CONTENTS
1. ABOUT THIS DOCUMENT
1
1.1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.2
Reason for Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.3
Information Not Provided in This Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2. DESCRIPTION
2
2.1
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2.2
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2.3
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2.4
Wire Pair Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2.5
Feeder Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3. INSTALLATION
5
3.1
Choosing and Preparing a Location for the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3.2
Installing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
4. JUMPER WIRING
7
4.1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4.2
Terminating Jumper Wires on CQF Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4.3
Terminating Jumper Wires on RLS Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
4.4
Routing Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
5. ACCESSORIES
10
5.2
Spool Shafts for Cross-Connect Jumper Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
5.3
One-Pair Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
5.4
Special Service Protective Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
5.5
Label Kits for the Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
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Version D, October 11, 2011
Part No. P71350
AERIAL ULTRACAB
CROSS-CONNECT ENCLOSURES
DESCRIPTION AND INSTALLATION
1. ABOUT THIS DOCUMENT
1.1 Purpose
This practice provides instruction for installing the Aerial Ultracab
Cross-Connect Enclosures.
1.2 Reason for Reissue
Whenever this practice is reissued, the reason for reissue will be stated in this
paragraph.
•
Update the installation instructions and illustrations.
1.3 Information Not Provided in This Practice
Refer to other local practices or building codes as applicable for the correct
methods, tools and materials to be used in performing procedures not specifically
described in this document.
If your enclosure is equipped with RLS terminal blocks, then refer to the following
documents for specific information on wire termination on RLS50 blocks:
•
•
641-202-002, RLS50 Self-Strip Block Description and Installation and
641-202-009, RLS50 Self-Strip Block Feed-Thru Half-Tap Activator Kit
Description and Installation
Note: The information contained in this practice is subject to change
without notice and may not be suitable for all applications.
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Emerson Network Power
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2. DESCRIPTION
2.1 Application
The Aerial Ultracab Cross-Connect Enclosures (Fig. 1 and Fig. 2) are
pole-mounted, center-feed cross-connect/interface system equipped with quiet
front CFQ terminal blocks or RLS self-strip terminal blocks.
Fig. 1 : 400 Pair Aerial Ultracab Cross-Connect
Enclosure
Fig. 2 : 1800 Pair Aerial Ultracab
Cross-Connect Enclosure
2.2 Construction
Enclosures are manufactured of aluminum and mill-galvanized steel. All
enclosures are powder coat painted with green or off-white finish. Enclosure
dimensions are given in Table A. All enclosures are equipped with filtered vents
for proper ventilation. Enclosure doors are secured by a three-point locking system
and have closed-cell and bulb seal neoprene gasketing.
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TABLE A - ENCLOSURE DIMENSIONS
Enclosure Dimensions (inches)
Pair Count
Height
Width
Depth
100-400
33
16
14
500-900
45
24
14
1000-1200
45
32
14
1300-1800
62
33
14
1900-2700
62
46
14
2.3 Terminal Blocks
The terminal block field is drop-down style and secured with hex head bolts. All
blocks are hard-wired to a cable stub or harness behind the block face and are
encapsulated for moisture resistance.
Enclosures are equipped either with 50-pair CQF quiet-front screw-type binding
post terminal blocks or with 50-pair RLS self-strip terminal blocks both shown in
Fig. 3. The CQF terminal lugs are tin-plated for corrosion resistance and are
captivated in the block to eliminate accidental detachment from the block housing.
For information on RLS terminal blocks, see document 641-202-002, RLS50
Self-Strip Block Description and Installation.
50-pair CQF Block
50-pair RLS Block
Fig. 3 : Terminal Blocks
2.4 Wire Pair Identification
The feeder (in) and distribution (out) pairs are identified separately on the face of
the enclosure blocks by color code. The binding posts or IDC clips are given
terminal pair identification, starting with one and proceeding to the last pair
number for that particular type of pair. Therefore, each has a feeder (in-green) pair
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Version D, October 11, 2011
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number one and a distribution (out-blue) pair number one, etc. Terminal blocks
are numbered horizontally (EXAMPLE: Row 1, pairs 1-5; row 2, pairs 6-10; on
RLS: Row 1, pairs 1-10; etc.).
2.5 Feeder Pairs
100 - 400 pair
enclosure
600 - 900 pair
enclosure
1200 - 1800 pair
enclosure
distribution
distribution
feeder
feeder
distribution
distribution
distribution
feeder
feeder
distribution
distribution
feeder
distribution
distribution
feeder
All standard pole-mounted cross-connect enclosures of 600 pairs and larger are
configured for a feeder to distribution ratio of 1 to 2. Engineering design may
dictate different counts. Feeder pairs are located in the left column for 100-pair to
400-pair enclosures; in the center column for 600-pair to 900-pair enclosures and
in the two center columns for 1200-pair to 2700-pair enclosures. Refer to Fig. 4.
1900 - 2700 pair
enclosure
Fig. 4 : Layout of Terminal Blocks
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3. INSTALLATION
3.1 Choosing and Preparing a Location for the Enclosure
The pole-mounted cross-connect enclosures can be installed at any height. For
ease of access, install the enclosure at working level per local practices.
SAFETY
SAFETY: In areas where damage could occur to enclosures mounted at ground
level, such as alleys, mount the enclosure below aerial cables, with adequate
clearance for bending the stub at a 90o angle to prepare the splice. A balcony
may be installed for ease of access and to provide a safe working position for
field technicians.
3.2 Installing the Enclosure
DANGER
Be sure the area above the hoisting operation is clear of power lines or obstructions. Also be sure to follow all local and company safety practices during lifting.
Perform the following steps to install an Aerial Ultracab Cross-Connect
Enclosure:
Step 1: Drill a 11/16-inch hole through the pole for the top bracket (see Fig. 5).
Fig. 5 : Top Pole-Mounting Bracket
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Step 2: Secure the top bracket to the pole with a 5/8-inch through bolt. Level the
bracket before tightening the bolt.
Step 3: Raise the unit using a block and tackle or winch line passed through a
snatch block attached to the top of the sling. Guide the unit during the
hoisting operation with a hand line fastened to the bottom
pole-mounting bracket.
Step 4: Place the enclosure on top of the pole-mounted bracket and verify that
both brackets on the enclosure are properly engaged and sitting levelled
on the pole bracket (see Fig. 6).
Step 5: Secure the bottom pole mounting by drilling a 11/16-inch hole through
the pole and using a 5/8-inch through bolt (see Fig. 7).
Step 6: Attach the supplied stabilizer bars to the bottom of the enclosure using
the supplied "U" clamps, do not tighten (see Fig. 7).
Note: DOES NOT APPLY FOR 400 PAIR SIZE UNITS.
Step 7: Attach the other end of the stabilizer bars to the pole using two 3/8-inch
bolts per bar (see Fig. 7).
Note: DOES NOT APPLY FOR 400 PAIR SIZE UNITS.
Step 8: Tighten all mounting hardware.
LIFTING
BRACKETS
POLE
STABILIZER
STABILIZER
BARS
BARS
Fig. 6 : Lifting Brackets and Stabilizer Bars
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Fig. 7 : Bottom Pole-Mounting Bracket
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4. JUMPER WIRING
4.1 Before You Begin
Before running cross-connect jumper wire, craft personnel should become familiar
with the numbering sequence used in the terminal as described in Paragraph 2.4
and Paragraph 2.5.
Feeder and distribution fields are color-coded. Feeder cables are terminated in the
green field and distribution cables are terminated in the blue field.
Begin by terminating each 22 AWG "G" or 24 AWG "F" cross-connecting jumper
wire pair as described in Section 4.2, Terminating Jumper Wires on CQF Blocks
or Section 4.3, Terminating Jumper Wires on RLS Blocks.
4.2 Terminating Jumper Wires on CQF Blocks
Perform the following steps to terminate a jumper wire pair on a CQF terminal
block in the feeder field:
Step 1: Pull enough jumper wire from the spool mounted on the housing door to
reach the assigned feeder cable terminal binding post (see Fig. 8).
Fig. 8 : Pulling Jumper Wire
Step 2: Terminate the jumper wire on the terminal binding post as shown below
(see Fig. 9).
• Strip approximately 1/2-inch of insulation from the end of the jumper
wire. Do not nick the conductor.
• Loosen the screw on the binding post until the first washer rides out
in front of the terminal silo.
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Emerson Network Power
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Step 3: Place the wire between the washers on the terminal binding post.
Tighten securely, but do not over tighten (see Fig. 10).
Fig. 9 : Jumper Wire Termination
Fig. 10 : Placing Wire Between Washers on
Binding Post
Step 4: Continue on to Section 4.4, Routing Wire to route the wires.
4.3 Terminating Jumper Wires on RLS Blocks
For specific information on terminating wire pairs on RLS blocks, see document
641-202-002, RLS50 Self-Strip Block Description and Installation. For
information on dual wire termination to a pair, see document 641-202-009, RLS50
Self-Strip Block Feed-Thru Half-Tap Activator Kit Description and Installation.
Once you have terminated a wire pair, continue on to Section 4.4, Routing Wire to
route the wires.
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4.4 Routing Wire
Perform the following steps to route a jumper wire pair:
Step 1: Route the wires horizontally between the activator rows to the wiring
trough (see Fig. 11).
Fig. 11 : Routing Wire
Step 2: Place the wire behind the wire retainers at the sides or bottom of the
terminal field, and make a finger loop in the wire to provide enough slack
to trace the wires when necessary.
Step 3: Route the cross-connecting jumper wire to the assigned distribution post
or activator and cut to required length.
Step 4: Terminate the jumper wire pair on the distribution field as you did on
the feeder field.
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Emerson Network Power
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5. ACCESSORIES
5.1 Table B lists ordering information for available accessories.
TABLE B - ACCESSORIES
Catalog Number
Description
P29869
spools shaft for cross-connect wire
P33392
one-pair tester - CQF
P69681
one-pair tester - RLS
P38220
special service caps - CQF (package of 80)
P53828
special service caps - RLS (package of 80)
P44195
green (feeder) CQF block numbers 1-1500
P49940
green (feeder) CQF block numbers 1500-2700
P49941
blue (distribution) CQF block numbers 2701-3600
P44196
blue (distribution) CQF block numbers 1-2700
P64541
green (feeder) RLS block numbers 1-2100
P53350
blue (distribution) RLS block numbers 1-3600
P90370E
off-white touch-up paint, 0.6 ounce bottle
5.2 Spool Shafts for Cross-Connect Jumper Wire
G cross-connect spool holds 300 feet; F cross-connect spool holds 400 feet.
Terminals have a spool shaft and retainer provided on the inside of the door (see
Fig. 12).
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5.3 One-Pair Tester
Terminals have a one-pair tester secured to a mounting dish on the door of each
terminal (see Fig. 13).
Fig. 12 : Jumper Wire Spool
Shaft
Fig. 13 : One-Pair Tester, CQF
Fig. 14 : Special Services
Protective Cap
5.4 Special Service Protective Cap
These are red plastic caps that fit over the silos surrounding the binding posts or
activators (see Fig. 14). A package with eighty pairs of caps is furnished with each
terminal.
5.5 Label Kits for the Terminal Blocks
These are available in green or blue colored labels. The green label kits are used
for pair counts in the feeder fields. The blue label kits are for pair counts in the
distribution field. Specify numbers required.
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NOTES
Emerson Network Power / 4350 Weaver Parkway / Warrenville, Illinois 60555 / (630) 579-5000 / FAX (630) 579-5050
©
2011 Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved. Any unauthorized reproduction or transmission
without the prior consent of Emerson Network Power is prohibited.
www.EmersonNetworkPower.com/EnergySystems
Specifications subject to change without notice. Emerson Network Power, Energy Systems,
North America, Inc. disclaims any responsibility or liability for the use of the information contained
in this practice.
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your business and your bottom line. That is why we offer a wide array of services to meet all of your
network infrastructure needs.
Technical Support
Email
Phone
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1.800.800.5260
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questions; determines status of warranties and
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Email
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Phone
1.800.800.1280, option 7
FreedomCare Secure.EmersonNetworkPower.com
Provides quotes and bid responses, order
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Download service & maintenance reports
online.
Spare Parts
Email
Phone
DCpower.Spares@Emerson.com
OSP.Spares@Emerson.com
1.800.800.1280, option 5
Pricing and PO processing of spare parts,
including but not limited to breakers, cables,
fuses, rectifier fans, misc. breaker and fuse
panels, enclosure fans, doors & switches, etc.
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Email
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Phone
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Creates and processes RMAs, determines lead
times and pricing, provides repair shipping
information and status.
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scheduling.
1.800.800.1280, option 8
For More Information
To learn more about service offerings from Emerson Network Power, please contact your sales
representative, call 1-800-800-1280 option 7, email ES.Services@Emerson.com or visit
www.EmersonNetworkPower.com/EnergySystems.
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.
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