Installation Instruction

This document provides a comprehensive overview of all necessary

installation tasks for the HYBRIFLEX™ Solution

HYBRIFLEX™ solution for Qtel Group Installation Instructions

HYBRIFLEX™ Solution For Qtel Group

© RADIO FREQUENCY SYSTEMS 2012. ALL RIGHTS RESERVED

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Installation Instructions 5100005-A

About this document

This document provides a comprehensive overview of all necessary installation tasks for the HYBRIFLEX™ Solution. It includes a step-by-step-guide that explains how to handle and assemble all necessary HYBRIFLEX solution piece parts.

A typical HYBRIFLEX solution per site (max. configuration) contains:

3 HYBRIFLEX riser cable

12 HYBRIFLEX jumper cables

3 distribution boxes

1 patch panel

24 patch cords

2 loop back connectors

Note:

These instructions are written for

qualified and experienced

installation personnel.

Please read this document

carefully before starting any work.

Any liability or responsibility for

the results of improper or unsafe

installation is disclaimed.

Please respect valid

environmental regulations for

assembly and waste disposal.

Always use appropriate personal

protection and observe all work

safety and security precautions in

accordance with local regulations

during installation.

Contents 1. Mounting the HYBRIFLEX

jumper in the box 3

1.

2. Mounting the box to

the pole 5

3. Mounting a HYBRIFLEX riser

cable in the box 7

4. Hoisting and mounting the

riser cable 9

5. Grounding of riser cable 10

6. Over length management 11

6. Mounting the patch panel in

a 19 inch rack 12 12

7. Changing jumper cables in

the field 13

Tools Required Philips (cross) screwdriver

Flat head screwdriver

13 mm open-ended spanner

19 mm open-ended spanner

5 mm Allen key

Standard pipe cutter

Rip Tool HTRT-1-000

JSTRIP-78-2



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1. Mounting the HYBRIFLEX jumper in

the box

Loosen the compression nuts of the cable glands to allow the jumper to be fed through the gland.

Caution:

Do not lose the

compression nuts!

Open the jumper grounding bars by loosening the corresponding screws.

Tools required: Phillips (cross) screwdriver

Starting with the bottom left gland (grounding bar marked in green) feed the fiber optic cable from the jumper through the cable gland and the grounding bar.

Caution: To minimize the risk of

increased fiber attenuation,

do not kink or bend the

cable too sharply.

Temporarily affix the fiber optic cable to the over length holder.

Feed DC cable and armor of the jumper through the cable gland and the grounding bar.

Fix grounding bar to the armor and tighten until the screw reaches its mechanical stop.

Connect the DC cables to the screw terminal. Match each cable to its corresponding color-coded terminal.

Tools required: Flat head screwdriver



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Repeat this process with the

Bottom right gland (grounding bar marked magenta)

Top left gland (grounding bar marked yellow)

Top right gland (grounding bar marked white)

Lay the fiber optic cables clockwise into the over length holders and terminate each cable at the fiber optic adapters.

Make sure that the fiber optic connectors with a red boot are connected to the bottom adapter (marked red), and that the connectors with a blue boot are connected to the top adapters (marked blue).

Caution: Clean the fiber optic

connectors before

connecting them.

Use only approved fiber optic

connector cleaning kits.

Tighten the glands to seal the cables – hand tight only.



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I-N

G-H B

C-F A

2. Mounting the box to the pole

Check the mounting hardware to make sure all parts are included. A complete kit includes:

2 pole mounting devices 2 fixing brackets 4 M6x20 hexagon socket screws including nuts and washers 4 fiberglass reinforced plastic latches with securing screws (in a plastic bag) 4 M8x150 machine screws including nuts and washers

Click the plastic latches into the back of the box.

Fix the latches with securing screws.


When installed, the latches should point to the top and to the bottom (not to the left or to the right).

Attach the pole mounting devices to the latches using the four M6 x 20 hexagon socket screws.

Tools required: Allen key and 13 mm open-ended spanner

C-F

B

G-H

I-N

A



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Mounting to the pole is achieved with the two fixing brackets. One is mounted at the top and the other at the bottom of the box.

Secure each bracket to the pole with two M8 x 150 machine screws and their corresponding nuts and washers per bracket.

Tools required: 19 mm open-ended spanner

The Box´s outer grounding terminal

can be terminated by means of

A: using a cable lug installed directly

on the grounding stud

1. Remove nut from grounding stud 2. Feed cable lug over stud 3. Replace and tighten nut

B: Using a bare wire and the transverse

hole of the grounding terminal

1. Loose nut on grounding stud 2. Feed cable through transverse hole

of stud 3. Tighten nut



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3. Mounting a HYBRIFLEX riser cable

in the box

Use a standard cable clamp to temporarily attach the riser to the infrastructure. This will simplify the assembly process.

Open the riser grounding bar by loosening the corresponding screws.


Feed fiber optic cable from the riser cable through the cable gland and the grounding bar. Start with the bottom left gland (grounding bar marked in green).

Caution: Do not remove the

protective bubble wrap foil

because it will make the

insertion process easier.

To minimize the risk of



cable too sharply.

Temporarily attach the fiber optic cable to the over length holder.

Feed the DC cable and armor of the jumper through the cable gland and the grounding bar.



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Attach the grounding bar to the armor and tighten to mechanical stop.


Connect the DC cables to the screw terminal. Match each cable to its corresponding color-coded terminal.

Tools required: Flat head screwdriver

Lay the fiber optic cables counter-clockwise into the over length holders and terminate each cable at the fiber optic adapters.

Make sure that the fiber optic connectors with a red boot are connected to the bottom adapter (marked red), and that the connectors with a blue boot are connected to the top adapters (marked blue).


connectors before

connecting them.

Use only approved

fiber optic connector

cleaning kits.

Tighten the glands to seal the cables – hand tight only (Gland P 3,5 – 5Nm / Gland Q 9 -11 Nm).

Close the box door and tighten the locking screws hand tight to achieve proper sealing.




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4. Hoisting & Mounting the riser cable

Check materials to make sure all parts

are available. The following are required

to mount and adjust the riser cable:

Pre-connectorized HYBRIFLEX Riser Cable assembly

GKSPEED Earthing Kits (if applicable)

Clamps (if applicable)

Rip tool (HTRT-1-000), electrical screwdriver, pipe cutter

Unpack the HYBRIFLEX cable and

prepare it for hoisting:

Attach the hoisting grip to the armored part of the cable.

Attach individual DC and fiber optic cables to the hoisting rope (this can be done with insulation tape).

Ensure that the fiber optic connectors distribution parts of the riser cable should not be unpacked before connecting it to the Distribution Box (DB) or Baseband Unit (BBU).

Hoist the HYBRIFLEX cable:

Based on cable length and site conditions, this can be accomplished manually or by means of a winch. The maximum pulling length per hoisting grip should not exceed 50m. If a second hoisting grip is needed, make sure the cable between the hoisting grips hangs with a bit of slack.

Extend the required cable length up to the entrance of the distribution box. Then attach the main part of the cable temporarily as near as possible to the box.

Before removing the hoisting grip, install a minimum of three cable clamps to the top of the horizontal run to prevent the cable from slipping. Use MBHS78-1-F (single layer) or MBHS78-3-F (triple layer) cable clamps.

Complete all the connection work described in Section 3.



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Clamping

Install the remaining clamps, starting at the top and moving down along the structure.

Pre-install the clamps to the structure.

Clamp the cable into the clamps.

Remove the hoisting grip when the clamping process is completed.

Tools required: 13 mm open-ended spanner

5. Grounding of riser cable

For this project three grounding points are foreseen:

On the top near to the distribution box

Before transition from vertical to horizontal cable run

Before entering the building / outdoor cabinet for BBU

Clean the jacket at the desired grounding point and cut out a strip of 20mm (0.8 in) with the stripping tool JSTRIP-78-2 (do not damage the outer conductor!)

Remove covering paper from Butyl carefully in direction of the arrow and pre-bend the grounding body. Align the grounding kit body to the slot (grounding wire on the bottom side) and wrap it around the cable. Make sure wire mesh keeps in place in the body and is placed in the dismantled area. Do not turn or move the body after wrapping around the cable, otherwise butyl sealing could be damaged.



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Tighten the two screws alternating (6-10 Nm)

Straighten the grounding wire in the direction to the grounding point (shortest way possible). The fixation of the wire is recommended. Note the standard & local rules.

Tools required: JSTRIP-78-2, Flat head screw driver, 5mm Allen key

6. Over length management

Typically, an excess length of the main cable is not stored. If installation results in an over length of HYBRIFLEX cable, the excess cable can be cut easily by removing the armor and the jacket from the excess length.

Start by determining the new break point and cut the armor and jacket using a standard pipe cutter.

The HYBRIFLEX cable is constructed with a built-in Kevlar rip cord, which allows cutting longitudinally through the armor and jacket. To simplify the cutting process, use the RFS rip tool (HTRT-1-000) with an electric screwdriver.

Remove the armor and jacket.

Tools required: Standard pipe cutter Rip Tool HTRT-1-000

Caution: Wear protective gloves

during this process!

Remove the protective foil from the inner core.

Note that DC cables can be cut to the desired length, while pre-connectorized fiber optic cables can be coiled to a handy ring that can be stored in the 19” patch panel.



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7. Mounting the patch panel in a 19

inch rack

Typically, the fiber optic distribution and patch panel is mounted using a cage nut.

Hold the patch panel in position…

… and mount it using rack-screws with plastic washers. Note that these screws are not part of the patch panel package. They should be part of the 19” rack.


The drawer can be opened by raising the front panel.



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Feed the fiber optic cables through one of the four cable entries in the back of the drawer. The single excess cables can be secured in multiple positions using cable ties.

Caution: To minimize the risk of



cable too sharply.

Connect the fiber optic connectors to the adapters.

The dust caps on the connectors and adapters can be stored in the drawer for later use. But dust caps should be stored in dust protective packaging before storage.


connectors before

connecting them.

Use only approved

fiber optic connector

cleaning kits.

8. Changing jumper cables in the field

Remove the old jumper:

Disconnect the fiber optic connectors from the adapters and unwind the fiber optic cable from the over length holder.

Disconnect the DC cables from the screw terminal.

Open the jumper grounding bar and loosen the compression nut on the cable gland.

Carefully pull out the jumper.

Re-attach the new jumper:

Follow the detailed instructions in Section 1.



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