(Within a ceiling tile grid system) Zone Cabling Termination Cabinet
Model#: A1024-HR-B-AL-33
Instruction Index
Warning: Warning and Notes from the Manufacturer Parts: List of Parts Provided Tools: List of Tools and Supplies to be Provided by Installer Step 1: Preparation Step 2: Opening the Shipping Box and Removal of the ZCTC Enclosure Step 3: Equipment Mounting Plate Removal Step 4: Installing Equipment on the ZCTC Equipment Mounting Plate Step 5: Mounting Ceiling Tile to the ZCTC Enclosure Step 6: Installing the ZCTC Enclosure without the Equipment Mounting Plate Attached Step 7: Cabling the ZCTC Enclosure (Inlet and Outlet) Step 8: Installing the Equipment Mounting Plate to the Access Door Step 9: Inspection Options: Optional Kits Available Fire: Installation Instructions for Fire Penetration Kits Conduit: Installation Instructions for Conduit Penetration Applications Diagrams: Diagrams of ZCTC Enclosure and Chart of Materials CAD Drawings: CAD Drawings (.dwg files) for HR Unit.
Warning
1) This enclosure is a termination/distribution/consolidation access point. This enclosure is designed for low voltage communications applications only.
2) The ceiling tile grid system must be installed prior to the installation of this enclosure. This enclosure is designed to be hung from four (4) 3/8" threaded rods. The threaded rods, must be attached to the building structure, in accordance with local codes and regulations. The threaded wire must be attached to all four corners with a nut and washer above and below the support bracket, so the unit can not be pushed up through the ceiling when closing the door.
3) The load on the door is not to exceed 20 lbs. The overall load on the enclosure is not to exceed 70 lbs.
4) Do not bundle cables or tie them with wire ties. Use velcro straps only.
NotesModel Number A1024-HR-B-AL-33 is designed to accept INLET and/or OUTLET cables from either end. This allows for easy MAC's. The maximum number of cables per penetration should not exceed 16- 25 pair; 96- 4 pair copper; and/or 96 - 4 fiber cables. These units require fire rated cable penetration foam kits FP-C-33-25 for non-plenum environment and FP-B-33-25 for plenum environment. These kits are designed for simple (in the field), installation. Installation instructions are incorporated in these instructions.
Model Number A1024-HR-B-AL-00 is designed for conduit access only. MAC's are not easily done with this application. Installation instructions for these applications are incorporated in these instructions.
Parts List
- 1 ea. - ZCTC Enclosure.
- 2 ea. - Wing Knobs Assemblies
- 1 ea. - Knob recess plate
- 1 ea. - Equipment Mounting Plate (factory installed on the Access Door)
- 2 ea. -10/32 Equipment Mounting Plate Lock Nuts (installed at factory)
- 2ea. - FP-B33-25 Plenum rated foam kits
- 1ea. - 2U-DM-HR ASSEMBLY
- Installation Instructions
- Warranty registration card.
- NOTE: A Tile Template should be ordered for the HR-Unit
Installation Tools and Supplies to be Provided by Installer
- plum bob with string or pen laser
- adjustable wrenches
- screw drivers
- drill with assorted bits
- utility knife
- straight edge
- specialty tools as required by equipment manufacturer (Tile cutting Template)
- cable retaining apparatus as recommended by manufacturer (Velcro® cable straps)
- threaded rods with proper attaching apparatus as approved by local codes
- 10 ea. #6 x 1/2" sheet metal screws
Step 1 - Preparation
Prepare a location for the ZCTC enclosure to be positioned for inspection and equipment installation after removal from the shipping container. Ensure that this location will protect the ceiling tile receiving rails from denting. The ceiling tile receiving rails around the equipment ACCESS DOOR are designed to hold ceiling tile in place prior to and after installation. After removing the ZCTC enclosure from the shipping container, place the ZCTC enclosure on its side. This will protect the rails from damage.
Step 2 - Opening the Shipping Box and Removal of the ZCTC Enclosure
After the protective packing is removed, remove the ZCTC enclosure from the shipping container. NOTE : Parts # 6 & 7 are inside the enclosure.
CAUTION: The equipment ACCESS DOOR is located on the bottom of the ZCTC enclosure. It is attached to the ZCTC enclosure by a hinge and protective swing arms. The ACCESS DOOR is held in the closed position with tape affixed to the door and the body of the enclosure. The tape may come detached during shipping, which may allow the door to swing open when lifting the enclosure out of the box. To avoid damage to the door, lift carefully to ensure that the door does not swing open.
Step 3 - Equipment Mounting Plate Removal
With the ZCTC Enclosure on its side, (hinged side down), remove the tape holding the ACCESS DOOR closed. Hold the door closed while removing the tape. After the tape is removed, allow the ACCESS DOOR to open (downward). There are parts #6 & 7 inside the enclosure. Put them in a safe place until you can get to them.
The EQUIPMENT MOUNTING PLATE is located on the ACCESS DOOR. Remove the plate retention lock nuts at the top of the EQUIPMENT MOUNTING PLATE, located at the top of the inside of the ACCESS DOOR.
Lift the top of the plate sufficient enough so it will clear the plate retention screws. Remove the EQUIPMENT MOUNTING PLATE from the ACCESS DOOR plate retention groove.
NOTE: If rails require painting - prepare surface and prime rails as required by paint manufacturer.
Step 4 - Installing Equipment on the ZCTC-HR Equipment Mounting Plate
SWITCH TYPE : CISCO, BAY NETWORKS, and 3COM - ALL CAN NOT EXCEED 12" DEEP AND 3.5" TALL. All brackets must be ordered to be with this shipment.
Place the EQUIPMENT MOUNTING PLATE on a flat surface. Notice the slotted holes and where they are positioned. Position the equipment to be mounted on the surface of the EQUIPMENT MOUNTING PLATE, centered from the top of the plate downward. With a pen or pencil locate and mark the correct positioning of the mounting holes to be drilled. Drill the holes where marked. Drill the holes the proper size for mounting screws.
NOTE: Total weight of apparatus mounted on plate not to exceed 20 lbs.
CAUTION: screws used to mount the equipment should not protrude through the mounting plate by more than 1/8 inch. Do not mount any equipment that exceeds 3" tall any closer than 3 1/2" from the bottom of the Equipment Mounting Plate or the door will not close properly.
Step 5 - Mount Ceiling Tile to the ZCTC Enclosure
Cut the ceiling tile to fit the ZCTC enclosure. Install the ceiling tile to the ZCTC enclosure before mounting the enclosure to the building structure. Measure your cut dimensions approximately 1/8" longer or wider than required. Ensure that the tile cut lines are clean and smooth. The only tile cuts visible should be located at the end of the ACCESS DOOR ceiling tile retention rails near the side of the ZCTC enclosure. A template can be ordered from the factory and be used as a guide in cutting large amounts of tiles.
Mark and cut two square holes into the ACCESS DOOR portion of the cut ceiling tile. These holes are positioned directly in alignment with the (RECESSED DOOR CLOSURE LATCH KNOB HOLES).
Locate the two WING KNOBS and two CAM ASSEMBLIES as identified in the parts list. Insert the threaded end of the WING KNOBS into the cut holes of the RECESS PLATE and through the door. Carefully push the threaded end of the WING KNOB through the two holes so the can slots are pointing to the downward end and the edge of the door. This will allow for movement of the cam to open and close the door.
From the back side of the ZCTC bottom surface, insert the ceiling tile retention screws (10 - # 6 X 1/2") through the holes that are pre-drilled. This will hold the tiles in place until the ZCTC enclosure is hung from the building structure.
Step 6 - Installing the ZCTC Enclosure Without the Equipment Mounting Plate Attached
Install four (4) threaded rods to the building structure in accordance with standard practices and local codes. Level the enclosure, with the rods so the weight of the ZCTC enclosure is not born by the ceiling tile grid system. Allow approximately 1/32" space between the grid system and the surface of the ceiling tile mounted on the ZCTC enclosure.
Step 7 - Cabling the ZCTC Enclosure (Inlet and Outlet)
With the ZCTC enclosure in place and supported, install the cables. Install the cables against the back wall of the ZCTC enclosure. Secure cables with Velcro® cable straps. (SEE WARNING #2)
Place the EQUIPMENT MOUNTING PLATE equipped with installed termination apparatus on a flat work surface directly below the ZCTC enclosure. Prepare all cable ends and terminate according to equipment manufacturing specifications.
Note: Total weight of cables and apparatus inside enclosure not to exceed 70 lbs. The maximum number of cables per penetration should not exceed 96 - 4 pair, 16 - 25 pair copper or 96 - 4 fiber cables.
Step 8 - Installing the Equipment Mounting Plate to the Access Door
Store the cable slack inside the cabinet by forming a "Figure 8" by using the cable retention brackets as a pattern. Secure "slack cables only" in place by using plastic ties or Velcro® cable straps. The slack cable may also be stored in the ceiling, if allowed by local codes.
Re-install the EQUIPMENT MOUNTING PLATE to the ZCTC enclosure ACCESS DOOR. Ensure the lip of the EQUIPMENT MOUNTING PLATE firmly seats into the plate retention groove and the two holes at the top of the plate are firmly seated over and onto the plate retention screws. Reinstall the two (2) previously removed EQUIPMENT MOUNTING PLATE retention lock nuts. Do not over tighten lock nuts.
Step 9 - Inspection
- Ensure that the ZCTC enclosure is hung from the building structure using approved threaded rods or approved hanging wires and is installed according to local code and regulations.
- Ensure that the facing of the ZCTC enclosure does not bare its weight directly onto the ceiling tiles grid system.
- Ensure that the cuts and holes on the ceiling tiles are clean and smooth.
- Ensure that the ACCESS DOOR opens and closes without binding or pinching cables.
- Ensure that the cable bending radius is within manufacturer specifications.
- Ensure that the EQUIPMENT MOUNTING PLATE is properly seated and secured to the ACCESS DOOR.
Optional Kits Available
- Foam Kit "C" - P/N FP-C-33-25: Cable Penetration Foam Kit consisting of non-plenum rated foam pads for each cable penetration access. (2 kits per enclosure)
- Foam Kit "B" - P/N FP-B-33-25: Cable Penetration Foam Kit consisting of plenum-rated foam pads for each cable penetration access. (2 kits required per enclosure)
- 2U-DM-HR Assembly: This is a bracket assembly that will give you rack space for 2-48 port patch panels and a wire management assembly all in one piece that bolts directly to the Equipment Mounting Plate.
Installation Instructions for Installing Fire Penetration Kits
Stock Numbers: FP-B33-25 and FP-C33-25
Drawing 1
These kits are used to seal the unit with Fire Penetration Foam around installed access cables into the Zone Cabling Termination Cabinet.Note: If you are using the plenum-rated foam (Stock Number FP-B33-25) you must remove the blue plastic sheeting from the patterned side. The foam will seal to itself. For non-plenum applications follow the same instructions.
- Remove the top plate (Drawing 1, item 11) by removing the four (4) top screws. (See Drawing 1, item 24)
- Sort and comb your cables for smooth and straight access through the penetration.
- Lift the cables and place two layers of foam underneath the cables.
- Place cables and space so you can insert strips of foam between them firmly to create a seal. Cut foam strips at least 3/8" width to be placed between the cables.
- Put down a layer of foam and repeat the process until all cables are beaded between layers of foam.
- Take the remainder of the foam and fill the void to the top of the penetration and compress down with the top plate and put the screws back. Be careful not to bind cables in excess of cable manufacturer's specifications. Cables are installed.
Installation hint: We suggest that you stagger the cables in their layers to give a better seal. (Example: 1st row - 4 cables, 2nd row - 5 cables, 3rd row - 6 cables, 4th row - 5 cables, 5th row - 6 cables and so on...)
Installed Foam Layers
Installation Instructions for Conduit Penetration Applications
Drawing 2Conduit penetration must start at the top rear of the panel. The first conduit penetration should be 1 1/2 inches from the rear of the panel.
Conduit penetrations may be staggered in an area 1 1/2 inches from the top, 1 1/2 inches from the rear and 1 1/2 inches from the bottom, and extend 4 inches to the front of the panel. See Drawing 2 above.
All conduit penetrations must conform to UL Type 12.
Diagrams of ZCTC Enclosure
CAD drawings of ZCTC-HR Enclosure (.dwg files requires CAD 12 or newer)
Drawing 3
Drawing 4
Drawing 5Materials List
Item Quantity Part # Sheet # Description 1 1 CAL-01 5 Door 2 2 CAL-02 6 Rails 3 1 CAL-03 7 Flat Bottom Panel 4 1 CAL-04-33-L 8 Left End Panel 5 1 CAL-04-33-R 9 Right End Panel 6 1 CAL-05 10 Equipment Mounting Plate 7 1 CAL-06 11 Body Wrapper Panel 8 2 CAL-07-L 12 Left Mounting Bracket 9 2 CAL-07-R 13 Right Mounting Bracket 10 2 CAL-08 14 Cable Access Bracket 11 2 CAL-09 15 Cable Access Cover Plate 12 2 CAL-10 --- PT-CL-FL-50-ST Door Knobs, Black Texture Clamp, Custom Stud with 1/2" Dia. and 1/4-20 Treading 13 2 CAL-11 --- 82-32-201-20, Retainer S. S. 14 1L 1R CAL-12 --- Catalog#CD441, Brace, 441/2 Right Hand Left Hand Steel-Bright Zinc-Plated (us2c), w/o crews 15 --- --- --- --- 16 --- --- --- --- 17 9 CAL-15 --- THFL3, Footman Loop, Steel, Zinc 1-5/8" x 1/4" x 2-5/8" 18 --- CAL-16 --- AD44H, Rivets Close Dome Head, .125 Grip Range .188 to .250 19 --- CAL-17 --- AD43H, Rivets Close Dome Head, .125 Grip Range .127 to .187 20 1 CAL-18 18 Piano Hinge 1 1/2" Open x .500" Knuckle .250" Dia. 21 --- CAL-19 --- Silicone Sealer, must meet MIL-A46106A, ASTM-6-920-79 and COM-NBS 22 1 CAL-20 16 Door Stop, Front 23 2 CAL-21 17 Stay Bracket 24 8 --- --- Screw B.H. Phill SST 632 x 3/8" Long
These files will be coming soon.
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