The Principles of Fiber-optic Cable Installation - Cabling Install

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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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