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TheprinciplesoffiberopticcableinstallationFebruary1,2012
FromtheFebruary,2012IssueofCablingInstallation&MaintenanceMagazine
Followingappropriatestepswillensureinstallersachievethefourgoalsofcableinstallation.
ByEricR.Pearson,PearsonTechnologiesInc.
Whenexaminingwhatmakesafiberopticnetworksuccessfulfromthestandpointsofinstallationandperformance,thecharacteristicscanbeorganizedintogroupsoffour.Asuccessfulfiberopticnetworkinstallationwillhavefourcharacteristics:1)lowopticalpowerloss,2)lowinstallationcost,3)lowtimeofinstallation,and4)highreliability.Likewise,therearefourgoalsoffiberopticcableinstallation:1)avoidbreakage,2)avoidreducedpoweratthereceiver,3)avoidreductionsinreliability,and4)proceedinasafemanner.Tomeetthesefourgoals,theinstallermustrecognizeandrespectcertainprinciples.Inthisarticle,Iorganizetheseprinciplesintofourgroups:1)environmentallimits,2)installationlimits,3)NationalElectricalCodecompliance,and4)endpreparation.
Environmentallimits
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Thenetworkdesignerisresponsibleforspecificationofacableproperfortheintendedenvironment.Withthisdefinitionofresponsibility,theinstallermightnotneedtobeconcernedwithenvironmentlimitations.However,networkdesignersmaynotrecognizeallrelevantenvironmentalconditions.Inorderthattheinstallerrecognizeandavoidcommonfieldproblems,weprovidethisfirstprinciple:Respectenvironmentallimits
Theinstallerinstallsthecableinenvironmentalconditionsthatarewithinthelimits.Shouldthecablebeexposedtoconditionsinexcessofitslimits,thecablecanfailtoprotectthefibers.Suchfailurecanleadtofiberbreakageandexcessiveattenuationrate.
Whilenotexhaustive,thislistoffiveenvironmentalconditionsrepresentsmostoftheconditionsthathaveresultedininstallationproblems:moisture,operatingtemperaturerange,bendradii,crushloadanduseloadalongwithverticalrisedistance.
Moisture.Aninstallercaninstallacablethatisnotmoistureresistantinanenvironmentthatcontainsmoisture.Insuchacase,thecablecanchannelmoistureintoelectronics,developincreasedattenuationrateandfiberbreakageduetofrozenwater,and/orexperiencereducedfiberstrengthandbreakageduetoattackfromthechemicalsingroundwater.
Operatingtemperaturerange.Ifaninstallerinstallscableinanenvironmentwithtemperaturesoutsideofthecablesoperatingrange,thecablecanexhibitincreasedattenuationand/ordegradationofcablematerials.Intheformercase,theremaybeinsufficientpoweratthereceiverforproperlinkoperation.Inthelattercase,thefibersmaybreak.
Bendradii.Duringinstallation,theinstallercanbendacabletolessthaneithertheshorttermbendradius(20xcablediameter)orthelongtermbendradius(10xcablediameter).Inthesecases,thecablecandevelopanincreasedattenuationrate,fiberbreakageorreductioninfiberstrength.Suchasituationcanoccurinanundergroundconduitpath,inwhichtheconduitsweep,orelbow,hasaradiuslessthaneitherbendradius(20xor10x)ofthecable.Inthissituationthecablepathitsenvironmentisforcingaviolationofthebendradius.
Crushloads.Ifaninstallerinstallsacableinanenvironmentthatimposeseitheralongorshorttermcrushloadinexcessofthecableslimit,thecablecanexperienceincreasedattenuationrateandfiberbreakage.Suchasituationcanoccurwhenanindoor,tighttubecableisdirectlyburied.
Useload.Aninstallercaninstallacablewithlongterm,oruse,loadonthecableinexcessofthecablesrating.Suchaconditioncanoccurwhenthecableisinstalledbetweenwidelyspacedbuildings,widelyspacedtelephonepoles,widelyspacedpowertransmission
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towers,andupalongverticalrise.Twoproblemscanoccurincreasedattenuationrateandfiberbreakage.
Aninstallershouldlimitthelongtermloadtoavaluelessthanorequaltothecablesrating.Todoso,theinstallerobtainstheuseloadfromthemanufacturer,typicallyfromadatasheetorfromthemanufacturerswebsite.
Theinstalleralsoshouldlimitverticalrisedistance.Theuseloadandtheverticalrisedistancearedifferentstatementsofthesamecharacteristic.Theverticalrisedistanceisthedistancetowhichthecablecanbeinstalledverticallywithoutsupport.Theinstallerlimitsthecabletoaverticaldistancelessthantheverticalriselimit.Todoso,theinstallerobtainstheverticalriselimitfromadatasheet.Theinstallercanachieveatotalverticalrisedistanceinexcessofthislimitbysupportingthecableataseparationnogreaterthanthislimit.
Indoorloosetubecablescanallowthefiberstoslideoutofthecable.Thustheinstallerinstallsserviceloopsinverticalloosetubecable.
Installationlimits
Therearetwotypesofcableinstallation:1)pullingthecableintoitspath,and2)placingthecableinitslocation.Theinstallerinstallsthecablewithconditionsthatarewithinthelimitsofthecable.Theoverallprincipleistorespectinstallationlimits.
Duringthecablepull,theinstallerrespectsfiveinstallationlimits:1)notwisting,2)installationload,3)installationbendradius,4)installationtemperaturerange,5)storagetemperaturerange.
Notwisting.Avoidanceoffiberbreakagerequiresthatfibercablesbeinstalledwithouttwisting.Inordertoavoidtwisting,theinstallerusesapullingswivelbetweenthepullingropeandthecable.Theinstallerattachesthepullropeandthecabletothepullingeye.
Inordertocomplywiththeinstallationloadlimit,theinstallermustknowtheloadlimitandhaveamethodforlimitingtheloadappliedtothecable.Theinstallerwilllearnthelimitfromthedatasheetforthecable,creatingtwoprinciples:1)Knowtheinstallationloadlimit2)Limittheinstallationload.
Therearethreemethodsbywhichaninstallercanlimittheshortterm,orinstallation,loadappliedtoacable.Inaddition,therearetwomethodsforreducingtheappliedinstallationload.
Thethreemethodshavetheadvantageofprovidingconcreteevidencethattheinstallationloadhasnotbeenexceeded.Thesemethodsaretheuseof1)apullingeyewithaswivelwithashearpin,2)apullingdevicewithaslipclutch,and3)apullingdevicewithaload
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gage.
Theeyehasashearpin,whichisratedataloadlessthanthemaximuminstallationloadofthecable.Forexample,acablewitharatingof600poundsforcewouldrequireashearpinrated500500poundsforce.Iftheinstallerexceedstherating,theshearpin(notthecable)breaks.
Theinstallercanuseapullingeyewithaswivelwithoutashearpiniftheinstallerhassomeothermethodoflimitingtheloadappliedtothecable.Pullershavetwomethodstoprovidesuchlimitation.Thesemethodsareaslipclutchandaloadgage.
Aninstallercansettheslipclutchofapullertoalevellessthantheinstallationloadofthecable.Shouldtheappliedloadexceedthelevelset,theclutchclips,eliminatingfiberdamage.
Aninstallercansettheloadgageofapullertoalevellessthantheinstallationloadofthecable.Shouldtheappliedloadexceedthelevelset,theloadgagestopsthepullingmotorwithoutfiberbreakageordamage.Theloadgagehasanadditionaladvantageitallowsattachmentofachartrecorder,whichprovidesproofthattheinstallerdidnotloadthecableinexcessofitsrating.
Reducingtheload
Thesethreemethodslimittheloadbutdonothingtoreducetheload.Therearetwomethodsforreducingtheloadappliedtothecable:lubricantandaFigure8installation.
Theinstallerusesacablelubricanttoreducefrictionandloadonthecable.Whilecoppercablelubricantsexist,theinstallerusesafibercablelubricant,assuchalubricantismatchedtothejacketofthecable.
Thesecondmethodforreducingtheloadispullingthecablebyhandinmultiple,reducedlengthpulls.Breakingalongpullintomultiplepullsofreducedlengthreducestheloadonthecable.Iftheinstallerinstallsthecableinmultiplepulls,heorshewillstorethecableatintermediatelocationsinaFigure8pattern.Theadvantageofthismethodisreducedload.Thedisadvantageisincreasedlaborcost.
DuringaFigure8pull,theinstallerpullsthecableintothefirstmanholeandoutofasubsequentmanhole.Thesubsequentmanholemaybethenextmanholealongthecablepath,ortheNthmanholealongthecablepath.Theinstallerdeterminesthismanholebytheloadtheinstalleriswillingtoimposeonthecable.
Astheinstallerpullsthecablefromthemanhole,heorsheplacesthecableonthegroundinaFigure8pattern.Thispatterncanbe12feetlongand4to6feetwide.Forpractical
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reasons,thepatternisrarelystackedmorethan24incheshigh.
Whentheinstallerhaspulledthecableoutofthemanhole,theinstallerandseveralhelperspickuptheFigure8andflipitoversothecableendisontop.Theinstallerputsthecablebackintothesamemanholealongthecablepath.Atthismanhole,theinstallerrepeatstheFigure8patternontheground.Theinstallercanrepeatthisprocessasmanytimesasdesired,untilthecableisinstalledalongtheentirepath.
TheinstallercanusetheFigure8methodforbothunidirectionalpulls,andmidpulls.Inamidpull,theinstallerpullsthecableinonedirection.TheinstallerplacestheremainingcableinaFigure8patternontheground.Finally,theinstallerpullsthecablefromtheFigure8patternintheoppositedirection.
Someprofessionalinstallersuseafourthmethodforlimitingtheloadtheyapplyduringinstallation.Thismethodrequirespullinga600poundforcecablebyhand.Theassumptionisthatitisessentiallyimpossibletocreatea600poundloadbyhandpullinginahorizontalaxis.Thismethoddoesnothavetheadvantageofprovidingconcreteevidencethattheinstallershavenotexceededtheinstallationload.
Allfourmethodsrequireattachmentofapullropetothecable.Theinstallerattachesapullropetoacablesothatthecablestrengthmemberssupporttheloadandnoloadisimposedonthefibers.
Theinstallerhasatleastthefollowingfiveattachmentpossibilities.
AttachmentofthepullropearoundtheoutsideofthecablejacketAttachmentofthepullropetoaKellemsgripthatgripsthecablethroughthejacketAttachmentofthepullropetocentralstrengthmembersAttachmentofthepullropetostrengthmembersoutsidetheloosebuffertubesAttachmentofthepullropetostrengthmembersbetweenmultiplejackets
Withallthesepossibilities,theinstallerneedsanotherprinciple.Thebestmethodofattachmentisthemethodrecommendedbythecablemanufacturer.
Themanufacturerhasdesignedthecablesothatitcanbeinstalledwithoutdamage,andhasdonesobyassumingthattheinstallerwillattachthepullropetospecificstrengthmembers.Attachmentofapullropetoanycablestructuralelementotherthanthesestrengthmembersmayresultinaloadimposedonthefibers.Suchaloadcanresultinfiberbreakage.
Thereisonefinalmethodthatsomeinstallersfollow.Theinstallerusesaloosetubecable
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designforinstallationsinwhichtheinstallationloadwillbehigh.Theexcessfiberinthistypeofcableallowsthefibertomovetoreducethestressonit.Thismovementcanbeforhundredsoffeetfromthehighstressarea.
Bendradius.Inordertoavoidbreakage,theinstallerlimitsthebendradiusofthecabletoabovetheminimumvalue.Thislimitationmeansthateachdeviationfromastraightpathrequiressomeformofcontrol.Apulleyorsheaveprovidessuchcontrol.Toensurecompliancewiththeselimits,theinstallerobtainsthevaluesfromthecabledatasheet.AcablethatcomplieswithTIA/EIA568Cmeetstherequirementtolimitashorttermbendradiusto20xthecablediameter.Somecableswillwithstandbendradiitighterthan20x.
Supplyreel.Theinstallermonitorsthesupplyreeltoavoidbendradiusviolationsduetoimproperwindingofcableonthereel,looseningofcable,cablewrappingaroundtheshaftthatsupportsthereel,orbackwrappingwhenthepullstops.Ifthecableisimproperlywoundonthereel,thecablewillattempttopullalowerlayerfromunderanupperlayer.Thissituationresultsinthecablemakingarightangleasitleavesthereelanobviousbendradiusviolation.
Ifthecableloosensduringthepullingprocess,itcanrideoverthetopoftheflangeofthereelandwraparoundtheshaftthatsupportsthereel.Thissituationisanotherexampleofabendradiusviolation.
Iftheinstallerdoesnotstopthereelfromrotatingattheendofthepull,thecablecanwrapbackwardsaroundthereel.Backwrappingprovidesathirdexampleofabendradiusviolation.
Communicationduringthepullingprocessisessential.Theinstallercommunicatesandcoordinatesthepullingactions.Inadvanceofastop,theinstallerinchargeofthepullingequipmentinformstheinstalleratthesupplyreelofhisorherintent.Withthisadvancenotice,theinstalleratthesupplyreelcandontheheavyworkglovesneededtoavoidsplinterswhilegrabbingtherapidlyspinningsupplyreelflangeinordertostopthereel.
Theinstallerinchargeofthepullingequipmentmayforgettoalerttheinstalleratthecablesupplyreel.Becauseofthispossibility,eachinstallationrequiresatleastthreeinstallers.Thethirdinstallercoordinatestheactivityoftheothertwo.
Aninstallermonitorseachpulleylocation.Thismonitorensuresthatthecabledoesnotcablejumpfromthepulley.Shouldthecablejump,theinstallercanhavetwoproblems:fiberdamageandstrengthmemberdamage.Shouldthecablejumpfromapulley,thebendradiusisnolongerundercontrol.Inaddition,thecablemayscrapeagainstasharpedgeattheentranceoftheconduit.Shouldthissharpedgecutthroughthejacket,itmaydamagestrengthmembersunderthejacket.Suchdamagewillreducetheinstallationloadcapability
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ofthecable,increasingthelikelihoodoffiberdamage.
Duringinstallation,theinstallerpulls,doesnotpush,thecable.Pushingcancauseaviolationofthebendradius.
Theinstallerinstallsthecableatatemperaturewithintherangespecifiedonthedatasheet.Atexcessivelylowtemperatures,thecablematerialsmaybebrittleenoughtocrack.Atexcessivelyhightemperatures,thecablematerialsmaystretchexcessively,resultinginnumerousproblems.
Theinstallerstoresthecableatatemperaturewithinthestoragetemperaturerangespecifiedonthedatasheet.Storageofacableatatemperatureoutsideofitsstoragerangewillcausethematerialproblems.
Cableplacement
Thetermcableplacement,asusedinthisarticle,meanscableinstallationwithoutpulling.Suchplacementoccursincabletrays,troughsandraceways.Onceagain,bendradiuscomesintoplay.Onceapulliscompleted,theinstallerlimitsthelongtermbendradiustoatorabovetheminimumvalueof10xthecablediameter.
Theinstallerbundlescablesthatrunalongthesamepath.Bundlingreducestheriskofbendradiusviolation.Additionally,bundlingsimplifiescircuittracing.
Cableties,iftheyareused,aretightenedbyhand,notwithacabletietool.Excessivelytightcabletiescandeformthecablejacket,resultinginalocalizedbendradiusviolationandexcesspowerloss.Theuseofhookandloopbandstobundlecablesminimizestheriskofbendradiusviolation.
Segregatefibercables.Whenevercopperandfibercablesresideinthesametray,theinstallerplacesthefibercablesininnerduct.Bysegregatingthetwotypesofcables,theinstallerreducestheriskofbendradiusandcrushloadviolationsofthefibercables.
Suchsegregationavoidsabendradiusviolationduringinstallationofadditionalcablesinthetray.Ifaninstallerisnotawareofbendradiusconcerns,heorshemayusecablestiestoattachnewcablestothoseinplace.Inthissituation,aviolationofbendradiusmayresult.
Segregationavoidsacrushloadviolationthatcanoccurwhenheavycoppercablesareinstalledontopoffibercablesinladdertrays.Inthissituation,thefibercablescanexperiencelocalizedbendradiusviolations.
Serviceloops.Theinstallerleavesserviceloopsthroughoutthelink.Serviceloopsarelengthsofexcesscablethatcanbepulledintoproblemareas.Serviceloopsare
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inexpensiveinsurancetheycertainlyarelessexpensivethanreplacingtheentiresegment.
Forindoorlinks,acommonpracticeisa10to12footserviceloopnearbothendsofeachlink.Thisserviceloopcoilmaybeinthebackofanenclosure,onacabletray,oraboveasuspendedceiling.
Foroutdoorlinks,acommonservicelooppracticehasthefollowingthreeparts.
1. A100footserviceloopforeach1000feetofcable2. A100footserviceloopforeachstreetcrossing3. Nomorethan200feetofserviceloopper1000feetofcable
Finally,therewillbeaserviceloopofatleast10to12feetateachcableend.Oftenthisserviceloopis50feet,andisinadditiontothelengthofcablethatwillbestrippedfortermination.Foraerialcablesystems,serviceloopholdersholdtheserviceloop.
Inanylocationinwhichthecablecanbeaccess,theinstallermarksitasFiberOpticCable.Therearetworeasonsforsuchmarking.First,whenthecablesaresomarked,electricianswillnotbetemptedtocut,rerouteandsplicethemwithblacktape.Second,installerswillnotbetemptedtousesuchmarkedcablesinamanholeasaladder.
Installersinstalloutdoorcableswithsagtoallowforthermalexpansionandcontraction.A2.5footsagfor150footspanisacommonpractice.
NECcompliance.IndoorcablesmustcomplywiththeNationalElectricalCode(NEC)andlocalelectricalcodes.HorizontalcablerunsrequireOFNorOFCratedcables.CablerunsbetweenfloorsrequireOFNRorOFNCratedcables.CablerunsinairhandlingplenumsrequireOFNPorOFCPratedcables.Inaddition,firewallpenetrationsmustmeettherequirementsoftheapplicablefirecode.Todeterminecompliance,theinstallerreadstheprintedinformationonthecable,becausetheNECrequiresthatallcablesbeprintedwiththeirratingandtestnumber.
Endpreparation
Afterpullingandplacingthecable,theinstallerpreparesthecableendsforsplicingorconnectorinstallation.Theinstallerprotectsbuffertubesandfibers.Thisprinciplemeansthatthejacketendsinsidetheenclosure,notoutsidetheenclosure.Thebuffertubesandfibersarenotdesignedtowithstandexposuretotheworkingenvironment.
Theinstallersealstheendsofgreasefilled,gelblockedcableswithafiberopticcablesealant.Waterblockingcompoundscanandwillflowfromevenasmallverticaldrop.Suchflowwillcausemaintenanceproblems.Animpropersealantcanattackprimarycoatingof
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thefiber.
Itisthisauthorsunderstandingthatsomesiliconesealantscuretoproduceaceticacidwhileotherscuretoproducewater.Aceticacidcanattacktheprimarycoatingofthefiber.Thus,theinstallershoulduseafiberopticcablesealant.
Someinstallersputheatshrinktubingovertheendofthejacket.Thisconcealsanyunevenjacketpreparation,sealant,andcablematerialsnottrimmedflushwiththejacket.
EricR.Pearson,CFOSisprincipalofPearsonTechnologiesInc.(www.ptnowire.com).ThisarticleisexcerptedfromPearsonsrecentlypublishedbookentitledProfessionalFiberOpticInstallationTheEssentialsForSuccess,Version8.0.ThearticleisaderivationofthebooksChapter11,CableInstallationPrinciples.Thebookcontainsatotalof26chaptersplusappendices.Eachchapterconcludeswithasetofreviewquestions.ThebookcanbeorderedfromthePearsonwebsite.
Textbookgoesintogreatdetailonfiberopticinstallation
ThisarticleisderivedfromChapter11ofEricR.PearsonsbookentitledProfessionalFiberOpticInstallationTheEssentialsforSuccess,Version8.0.ThechapterisentitledCableInstallationPrinciples.
Eachchapterofthebookendswithasetofreviewquestions.Chapter11includes9suchquestions.Thefirstquestionreadsasfollows:Aninstallationteamisplanningtopullacablethroughanundergroundconduitsystem.Thesystemconsistsofconduitsbetweenmanholes.Therearenosweepsatlocationsatwhichthecablepathchangesdirectionsoratwhichtheconduitchangeselevation.Whatmusttheinstallerdoatthesechangesofdirection?Anotherquestionis:Priortopreparingtheendofafilledandblockedcable,aninstallerstopsatHomeDepotforsiliconesealant.Whatshouldyousaytohim?
Thebookincludesatotalof26chaptersplusappendices.AmongchaptertitlesareInsertionLossPrinciplesandMethods,ConnectorInspection,andCableEndPreparation.
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