RadioRouter® Base Station Outdoor Installation Guide Date: 03-31-2005 Version 1.3 Flarion Technologies, Inc. Bedminster One 135 Route 202/206 South Bedminster, NJ 07921 Web: www.flarion.com email: info@flarion.com Tel: (908) 947-7000 Fax: (908) 947-2050 Flarion Proprietary and Confidential © 2005 Flarion Technologies Inc.
Preface COPYRIGHT AND TRADEMARK STATEMENT Copyright © 2005 Flarion Technologies, Inc. All rights reserved. Flarion®, FLASH-OFDM®, RadioRouter®, Vector-LDPC® and FlashView™ are trademarks of Flarion Technologies, Inc. Other trademarks, trade names and brands contained herein are the property of their respective owners. Data subject to change without notice. Printed in USA.
Copyright and Trademark Statement Regulatory Compliance Information The Flarion® RadioRouter® base station complies with the following regulatory compliance requirements: • • • • Safety UL 60950 — Underwriters Laboratories, Inc. CAN/CSA-C22.2 No.
Preface Canadian Class A Statement This Class ‘A’ digital apparatus complies with Canadian ICES-003. Cet appareil numerique de la classe ‘A’ est conforme á la norme NMB-003 de Canada.
How to Use this Manual HOW TO USE THIS MANUAL ABOUT THIS DOCUMENT This guide is intended for use by qualified engineering personnel only. The RadioRouter® Base Station Outdoor Installation Guide covers the information required to install the hardware of an outdoor RadioRouter base station. INTENDED AUDIENCE This Guide is intended primarily for qualified engineering personnel who will use it to complete the base station installation process.
Preface WARNINGS, CAUTION STATEMENTS AND NOTES This document uses certain conventions to indicate supplementary information, of varying degrees of severity and importance. Material marked with a “warning” label is considered critical; failure to observe this information can result in death or serious injury. Information that refers to potential damage to equipment is marked with a “caution” label. Information that is considered additional but useful is marked with a “note” label.
Table of Contents TABLE OF CONTENTS Chapter 1. Overview ........................................................................................ 1 -1 1.1. Installation Equipment .......................................................................... 1 -2 Chapter 2. Verifying the Site Preparation ................................................................ 2 -1 2.1. Site Preparation Checklist — Outdoor Base Station........................................ 2 -1 2.2. Preparing the Floor ................
Preface Figure 4-2: Figure 4-3: Figure 4-4: Figure 4-5: Figure 4-6: Figure 4-7: Figure 5-1: Figure 5-2: Figure 5-3: Figure 5-4: Figure 5-5: Figure 6-1: Figure 6-2: Figure 6-3: Figure 6-4: Figure 7-1: Figure 7-2: Figure 7-3: Figure 7-4: Figure 7-5: Figure 7-6: Figure 7-7: Figure 7-8: Figure 7-9: Figure 8-1: Conduit for Power Cable — Rear View ................................................... 4 -2 Load Center Connections ....................................................................
Overview Chapter 1. Overview The RadioRouter® Base Station Outdoor Installation Guide covers all of the necessary information required to physically install the RadioRouter base station hardware. This guide assumes that a suitable site has already been prepared. A checklist is provided to assess the site prior to installation. Once the physical installation is complete, the base station can be configured and commissioned.
Chapter 1: Overview WARNING: THE RADIOROUTER BASE STATION OUTDOOR CABINET WEIGHS APPROXIMATELY 1150 LB AND IS TOP HEAVY. CARE MUST BE TAKEN TO HANDLE THE CABINET PROPERLY WITHOUT DANGER TO THE INSTALLATION PERSONNEL OR OTHER NEARBY EQUIPMENT. IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT ALL LOCAL, STATE, AND FEDERAL SAFETY REQUIREMENTS ARE FOLLOWED.
Verifying the Site Preparation Chapter 2. Verifying the Site Preparation Before you begin the physical installation of the base station, confirm that the site preparation is complete. The checklist that follows identifies the items that must be in place before the installation can begin. If any items are incomplete or missing, fill out the Punchlist in Appendix A - Outdoor Base Station Site Preparation Punchlist. 2.1.
Chapter 2: Verifying the Site Preparation 2.2. Preparing the Floor A concrete slab at the outdoor base station location must be provided for mounting. Install concrete anchors in the slab for 3/8” size bolts, 1” minimum length. Use corrosion resistant anchors. Locate the anchors to match the mounting hole pattern of the outdoor cabinet assembly. There are a total of six (6) clearance holes in the base of the cabinet, one in each corner and two located centrally.
Preparing the Floor FRONT Ø0.56 [Ø14.2] 6 PLACES 3X23.250 [590.55] 3.38 [85.7] 3.75 [95.3] 2X20.000 [508.00] 2X40.000 [1016.00] Figure 2-2: Clearance Holes in Cabinet Base — Bottom View © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 2: Verifying the Site Preparation RadioRouter® Base Station Outdoor Installation Guide Page 2-4 © 2005 Flarion Flarion Proprietary and Confidential
Installing the Cabinet Chapter 3. Installing the Cabinet The RadioRouter base station cabinet is shipped assembled, shrouded in cardboard, and mounted on a shipping pallet. WARNING: THE RADIOROUTER BASE STATION OUTDOOR CABINET WEIGHS APPROXIMATELY 1150 LB AND IS TOP HEAVY. CARE MUST BE TAKEN TO HANDLE THE CABINET PROPERLY WITHOUT DANGER TO THE INSTALLATION PERSONNEL OR OTHER NEARBY EQUIPMENT. Equipment that can be used to move the base station is described in Section 1.1. Installation Equipment. 3.1.
Chapter 3: Installing the Cabinet Figure 3-1: Outdoor Cabinet Rear Screw Panels 4. Remove the side access screw panels using the tamper resistant insert hex bit. See Figure 3-2: Side Screw Panels.
Removing the Cabinet from the Pallet 5. Locate the battery tray on the front of the cabinet. See Figure 3-3: Battery Tray — Front View. Figure 3-3: Battery Tray — Front View 6. Unscrew the two screws in the front of the tray. Use a 7/16” socket for the hex head bolts. 7. Unlock the tray lock with a Southco Bellcore 216 key part number E3–12–1. © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 3: Installing the Cabinet 8. Slide the battery tray out as far as it will go. See Figure 3-4: Battery Tray Open. Figure 3-4: Battery Tray Open 9. Remove all four cabinet-to-pallet mounting bolts. You may have to access the front bolts from the rear access panels. 10. Close the battery tray. 11. Lock the tray and replace the two screws. The cabinet is now ready to be moved into place.
Lifting the Cabinet 3.2. Lifting the Cabinet The cabinet can be lifted by a hoist or crane using heavy duty structural straps or chains with 1500 lb load capability. Attach the straps or chains with hooks to the four eyebolts located at the top of the cabinet. Figure 3-5: Eyebolts for Lifting Cabinet shows the location of the eyebolts. Note: Before lifting the cabinet into place, make sure all necessary mounting holes have been drilled in the concrete slab. See Section 2.2. Preparing the Floor.
Chapter 3: Installing the Cabinet 3.3. Mounting the Cabinet to the Concrete Once the cabinet has been moved to its final location, it must be bolted to the concrete. 1. Align the clearance holes in the base of the cabinet to the threaded holes in the concrete. 2. Bolt the cabinet to the concrete using 3/8” diameter bolts, 1” minimum length, and flat washers. Use corrosion resistant screws and washers. 3. Tighten the bolts to 180 in-lb +/- 25 in-lb.
Connecting the Power System Chapter 4. Connecting the Power System The outdoor base station cabinet requires a connection to AC power. This chapter contains procedures for routing the power cable and connecting to power and ground. WARNING: WHEN PERFORMING ANY TASKS INVOLVING THE POWER SYSTEMS, MAKE SURE THAT THE POWER IS NOT LIVE. ALL POWER OPERATIONS SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY. 4.1.
Chapter 4: Connecting the Power System Figure 4-2: Conduit for Power Cable — Rear View 1. Open the rear door of the cabinet using the handle hex tool key. 2. Route the cable through the side conduit connector hole into the 1” flexible conduit provided. 3. Interface to the 1” bulkhead conduit fitting provided on the outside of the cabinet with a conduit pull box with hole diameter 1.375” to 1.50”. The interface must be leak tight. 4.
Connecting the Power Cable 4.2. Connecting the Power Cable 1. Locate the AC power connection points in the Load Center. See Figure 4-3: Load Center Connections. Figure 4-3: Load Center Connections 2. Insert the ground wire into the ground connector and tighten the screw. Use #12 AWG wire or heavier. 3. Connect the power cable to the screw terminals for Neutral, Line 1, and Line 2. Use #12 AWG wire or heavier. 4. Connect the other end of the cable to the AC power source in the Service Entrance.
Chapter 4: Connecting the Power System 4.3. Connecting the Ground Cable The cabinet must be connected to earth ground at the installation site. CAUTION: Failure to properly connect the cabinet to ground could result in permanent damage to the equipment. 1. Locate the main ground connection. It is located inside the lower side panel next to the antenna connections. See Figure 4-4: Main Ground — Side View.
Connecting the Ground Cable 2. Locate the Roxtec® assembly on the bottom rear of the cabinet. See Figure 4-5: Roxtec Assembly. Figure 4-5: Roxtec Assembly 3. Remove the outer panel and seal inserts of the Roxtec assembly. Additional information and instructions for the assembly are available on line from Roxtec. 4. Route the ground cable into the lower compartment through the rectangular opening. © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 4: Connecting the Power System 5. Connect the ground cable to the connectors shown in Figure 4-6: Main Ground Connection Point. Use a #6 to #2 AWG wire with a 2–hole lug for a 1/4” diameter stud.
Connecting the Ground Cable 6. Fasten the lug onto the stud with the nuts provided. Tighten the nuts to 40–50 in-lb torque.Figure 4-7: Main Ground with Cable shows the ground cable attached to the studs. Figure 4-7: Main Ground with Cable 7. Connect the other end of the cable to the Master Ground Bar or other suitable ground source available at the installation site. Note: Reinstall the Roxtec seal inserts and outer panel after all of the system cables have been routed.
Chapter 4: Connecting the Power System RadioRouter® Base Station Outdoor Installation Guide Page 4-8 © 2005 Flarion Flarion Proprietary and Confidential
Connecting the Core Network Cables Chapter 5. Connecting the Core Network Cables The RadioRouter base station accesses the core network through a T1 connection. 5.1. Routing the T1 Cables 1. Remove the rear access panel above the Roxtec cable entry ports. See Figure 5-1: Access to T1 Connections — Rear View. Use a 7/8” socket for the hex head bolts. Figure 5-1: Access to T1 Connections — Rear View 2. If they have not been removed already, remove the outer panel and seal inserts of the Roxtec assembly.
Chapter 5: Connecting the Core Network Cables 3. Insert the cables through the rectangular opening into the lower compartment of the cabinet. 4. Route the cables through the internal cable clearance holes into the electronics compartment. Figure 5-2: Cable Clearance Holes shows the clearance holes. Figure 5-2: Cable Clearance Holes Note: Reinstall the Roxtec seal inserts and outer panel after all of the system cables have been routed.
Connecting the T1 Cables 5.2. Connecting the T1 Cables T1 connections are made using a 66–punch down block or using cables terminated in RJ-48 connectors. Both connectors are located in the T1 termination box shown in Figure 5-3: T1 Termination Box — Rear View. Figure 5-3: T1 Termination Box — Rear View 1. Loosen the two latch screws on the right of the T1 termination box. Open the box. © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 5: Connecting the Core Network Cables 2. Route the cable through the existing cable grip in the T1 termination box as shown in Figure 5-4: T1 Termination Box Open. Seal by tightening the cable grip seal nut. Figure 5-4: T1 Termination Box Open 3. Choose an installation method. To install using RJ-48 plugs, go to Step 4. To install using the 66–block, go to Step 5. 4. To install T1 using RJ-48 plugs: 4.a. Remove the jumper cables from the 66–block. 4.b.
Connecting the T1 Cables T 1 2 3 4 5 6 R T R J1P1 J1P2 J1P3 J1P4 J1P1 J1P2 J1P3 J1P4 J2P1 J2P2 J2P3 J2P4 J2P1 J2P2 J2P3 J2P4 J3P1 J3P2 J3P3 J3P4 J4P1 J4P2 J3P1 J3P2 J3P3 J3P4 J4P1 J4P2 J4P3 J4P4 J4P3 J4P4 J5P1 J5P2 J5P3 J5P1 J5P2 J5P3 J5P4 J6P1 J6P2 J6P3 J6P4 J5P4 J6P1 J6P2 J6P3 J6P4 1 2 3 4 5 6 Figure 5-5: T1 Connections on 66–Block © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 5: Connecting the Core Network Cables 5. To install T1 using the 66–block: 5.a. Make sure that a jumper cable is in place for each connection you plan to make. 5.b. Expose an appropriate length of wire. 5.c. Attach to the punch-down insulation displacing terminals according to Table 5.1 Network Connection Pin Placement.
Connecting the Antennas Chapter 6. Connecting the Antennas CAUTION: Antenna cables may be prepared for installation, but do not connect the cables to the cabinet until the completion of RF Commissioning. Instructions for RF Commissioning can be found in the RadioRouter® Base Station Commissioning Guide. All antenna operations should be performed by qualified personnel only. Installers must meet the requirements of FCC Bulletin OET 65 and coax terminations and have expertise working with RF coaxial cable.
Chapter 6: Connecting the Antennas Figure 6-1: Antenna Connectors — Side View ANTENNA ENTRY SEAL REMOVEABLE SIDE PANEL ALPHA BETA GAMMA ALPHA TX/RX TX/RX TX/RX RX BETA GAMMA RX RX ANTENNA CONNECTION THIS SIDE FRONT Figure 6-2: Antenna Connectors Schematic — Top View RadioRouter® Base Station Outdoor Installation Guide Page 6-2 © 2005 Flarion Flarion Proprietary and Confidential
Connecting the Antenna Cables 6.1. Connecting the Antenna Cables 1. If they have not been removed already, remove the side access screw panels using a tamper resistant insert hex bit. See Figure 3-2: Side Screw Panels. 2. If they have not been removed already, remove the outer panel and seal inserts of the Roxtec assembly on the rear of the cabinet. See Figure 4-5: Roxtec Assembly. 3. Route the antenna cable through the rectangular opening in the rear of the cabinet. 4.
Chapter 6: Connecting the Antennas 7. Reinstall the Roxtec seal inserts and outer panel after all of the system cables have been routed. The seal inserts are installed tight against each cable and are held in place when the outer panel is installed as shown in Figure 6-4: Cables Installed in Cabinet.
Powering Up the Cabinet Chapter 7. Powering Up the Cabinet The cabinet requires AC power to operate. Before attempting to power up the cabinet, verify that AC power is available. It may be necessary to wait for a maintenance window to connect the cabinet to AC power and perform this procedure. WARNING: ALL POWER OPERATIONS SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY. BEFORE ATTEMPTING TO POWER UP THE SYSTEM, CONFIRM THAT ALL POWER CONNECTIONS HAVE BEEN MADE PROPERLY.
Chapter 7: Powering Up the Cabinet Figure 7-2: DC Power Distribution Panel — Front View 7.1. Powering Up the Cabinet The cabinet is powered up using the AC circuit breakers in the Load Center at the rear of the cabinet and the DC circuit breakers on the distribution panel on the front of the cabinet. For this procedure you will need a volt meter. 1. Before turning on the power, confirm the AC voltage: 1.a.
Powering Up the Cabinet 1.c. Connect the leads of the volt meter across the screws as shown in Figure 7-5: Load Center 120 VAC Test Points — Test 2. The voltage across should be 120 VAC. Figure 7-3: Load Center 240 VAC Test Points Figure 7-4: Load Center 120 VAC Test Points — Test 1 © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 7: Powering Up the Cabinet Figure 7-5: Load Center 120 VAC Test Points — Test 2 2. Turn all of the DC circuit breakers to the Off position. Make sure that the Low Voltage Disconnect switch is set to AUTOMATIC. 3. Turn on the AC circuit breakers in the following order. Begin with the top, left breaker, go down the column, and then continue with the top right breaker. See Figure 7-6: Turning AC Breakers On.
Powering Up the Cabinet Figure 7-6: Turning AC Breakers On 4. On the DC power distribution panel, make sure that the Low Voltage Disconnect switch is set to AUTOMATIC. See Figure 7-7: Low Voltage Disconnect. Figure 7-7: Low Voltage Disconnect © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 7: Powering Up the Cabinet 5. Turn on the Battery Disconnect breaker. The Battery Disconnect breaker is on the left as you face the front of the cabinet. See Figure 7-8: DC Battery Breakers. Figure 7-8: DC Battery Breakers 6. Turn on the RRC breaker. The RRC breaker is to the right of the Battery Disconnect breaker. See Figure 7-9: DC Circuit Breakers. Figure 7-9: DC Circuit Breakers 7. Turn on both LNA breakers which are located next to the RRC breaker. 8. Turn on all three PA breakers.
Powering Up the Cabinet 9. Verify that the LEDs on the front of the cabinet match Table 7.1 Power On Expected LEDs. If the LEDs do not match the table, power the system down and check the wiring. Table 7-1: Power On Expected LEDs Unit LED Name Condition PDU FAULT Green PDU Service Green PDU Fan Tray FAN Green RRC FAN STATUS Green RRC FAN STATUS Green PCU1 ON (GREEN) FAIL (RED) Green PCU2 ON (GREEN) FAIL (RED) Green 10.
Chapter 7: Powering Up the Cabinet RadioRouter® Base Station Outdoor Installation Guide Page 7-8 © 2005 Flarion Flarion Proprietary and Confidential
Powering Down the Cabinet Chapter 8. Powering Down the Cabinet The base station is powered down using a PC or terminal connected to the COM1 port on the Master Control Unit (MCU) board. This helps ensure that all system files are closed before the power is shut off. Attach the PC or terminal using a serial cable with a null-modem adapter. The PC should be running a terminal emulation such as Microsoft® Windows® HyperTerminal.
Chapter 8: Powering Down the Cabinet 8.1. Powering Down the Cabinet 1. Connect a PC to the serial port of the MCU. See Figure 8-1: COM Port on the MCU. Figure 8-1: COM Port on the MCU 2. Run a terminal emulator such as Microsoft Windows HyperTerminal. 3. At the Login: prompt, type root and press Enter. 4. At the Password: prompt, type the root login password and press Enter. 5. At the BS_Name#> prompt, type halt and press Enter.
Powering Down the Cabinet 7. Turn off the AC breakers beginning with the bottom right breaker. Go up the right column and then up the left column as follows. See Figure 7-6: Turning AC Breakers On. • Rectifier #3 • Rectifier #2 • Rectifier #1 • Battery Heater • Heat Exchanger • Heater • Surge Suppressor • Utility Outlet © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Chapter 8: Powering Down the Cabinet RadioRouter® Base Station Outdoor Installation Guide Page 8-4 © 2005 Flarion Flarion Proprietary and Confidential
Verifying the Installation Chapter 9. Verifying the Installation Verifying the proper installation of the cabinet must be done before the installation can be considered complete. Verify that all of the following requirements are met: • • • • • Clearance requirements are met — at least 24” front, 12” side, and 24” rear. There must be room to open the cabinet doors for service. The base station is powered up. All the LEDs in Table 7.1 Power On Expected LEDs must reflect the states listed in the table.
Chapter 9: Verifying the Installation RadioRouter® Base Station Outdoor Installation Guide Page 9-2 © 2005 Flarion Flarion Proprietary and Confidential
Outdoor Base Station Site Preparation Punchlist APPENDIX A.
Appendix A RadioRouter® Base Station Outdoor Installation Guide Page A-2 © 2005 Flarion Flarion Proprietary and Confidential
Outdoor Base Station Installation Punchlist APPENDIX B. Outdoor Base Station Installation Punchlist Installation Items If Okay or Describe Outage Cabinet is physically intact RadioRouter Base Station Chassis MCU BHU PCU BBU TXU RXU AIU LNA/Duplexers Power Subsystem T1 Antenna Connections Battery Other Signatures: (Name, Title) Company Date Witness: (Name, Title) Company Date © 2005 Flarion Flarion Proprietary and Confidential Version 1.
Appendix B RadioRouter® Base Station Outdoor Installation Guide Page B-2 © 2005 Flarion Flarion Proprietary and Confidential
List of Abbreviations APPENDIX C. List of Abbreviations AA ........................................................................ Authentication and Authorization ADC ............................................................................ Analog-to-Digital Converter BBU ............................................................................................. Baseband Unit BHU ............................................................................................. Backhaul Unit DAC .........
