Assembling the First-Generation Hybrid Cables
Context
The first-generation hybrid cable is composed of optical fibers and copper cores. It is mainly used to connect an S5732-H48XUM2CC switch to an AP or a remote unit for PoE power supply and data transmission.
The first-generation hybrid cables must be made onsite using the purchased bare wires, auxiliary material packages that contain RJ45 connectors, and auxiliary material packages used for mechanical or fusion splicing of optical fibers.
- The first-generation hybrid cables can only be used indoors and cannot be connected to outdoor APs.
- The first-generation hybrid cables cannot be connected through a cable distribution frame. Copper cores in a hybrid cable must be directly connected to a switch and an AP.
- Assembling cables onsite must be performed with no power supply connected.
Do not stretch, step on, or place heavy objects on hybrid cables. Keep the cables away from sharp objects.
At least three trained and qualified persons are required for laying out hybrid cables. Cabling is allowed only when communication facilities are available.
- Route cables according to the planned positions and mark the cables in advance to eliminate the need to differentiate cables on the switch side after the cables are routed. Reserve a sufficient length of cable at the end where the cable label is attached, avoiding cutting off the cable label during cable assembling.
- A maximum of 100 hybrid cables can be bundled when no pipe is used. When a pipe is used, ensure that one-third space inside the pipe is vacant.
- When routing hybrid cables, coil the excess optical fibers around dedicated devices, such as a fiber management tray. Even force needs to be applied when cables are coiled to ensure the cables are not overly bent.
- After hybrid cables are assembled onside, you are advised to use a red pointer and an optical fiber adapter to check whether optical fibers are broken or not.
- Optical fiber connectors not in use must be covered with dustproof caps. Ensure that the end face of optical fiber connectors is clean. When an optical fiber connector is installed or removed, you need to protect its end face from touching other objects, preventing contamination or damage. If any dirt is found, use alcohol or dust-free paper to clean it. If the end face is damaged, start from the very beginning to assemble the cable.
- Optical fiber connectors must be assembled by engineers experienced in optical fiber mechanical connection and equipped with professional optical fiber assembling and testing tools. When assembling optical fiber connectors, do not bend optical fibers or contaminate the end faces. Otherwise, services may be adversely affected.
- The bending radius of a hybrid cable is at least five times its diameter. The minimum bending radius of a branch optical fiber inside a hybrid cable is 15 mm.
- To facilitate cabling, it is recommended that hybrid cables connected to the first twelve multi-GE ports and 10GE optical ports (ports 1 to 12) of an S5732-H48XUM2CC switch be routed along the left side of the cabinet. In addition to this, those connected to the last twelve multi-GE ports and 10GE optical ports (ports 13 to 24) be routed along the right side of the cabinet.
- After hybrid cables are connected to switches and APs, you are advised to bind the optical fibers together using binding straps. Then bind the copper cores and optical fibers together using cable ties to prevent the cables from reaching the cabinet door.
- It is recommended that the exposed optical fibers and copper cores on the AP side be protected by corrugated pipes.
Hybrid cables must be led to target positions by slowly and evenly turning the cable drum. It is recommended that a 5 m to 15 m length be led every minute. Do not place the cable drum upside down and manually lead out the cables, as shown in Figure 3-45.
Do not circle or twist hybrid cables or bind them at the bend, as shown in Figure 3-46.
At corners and turns, hybrid cables must be laid out by an appointed person to ensure they are not blocked or stuck. The minimum bending radius must be guaranteed, as shown in Figure 3-47.
Tools and Accessories
Tool |
Appearance |
Description |
|---|---|---|
Cable stripper |
Used to peel off the outer sheath of hybrid cables. This item does not come with the device and needs to be purchased separately. |
|
Flat drop cable stripper |
Used to remove the jacket of optical fibers in hybrid cables. This item does not come with the device and needs to be purchased separately. |
|
Fiber cleaver |
Used to cut optical fibers. This item does not come with the device and needs to be purchased separately. |
|
Duckbilled wire stripper |
Used to remove the jacket of copper cores in hybrid cables. This item does not come with the device and needs to be purchased separately. |
|
Fiber cleaning paper |
- |
Used to clean bare fibers. This item does not come with the device and needs to be purchased separately. |
Alcohol (concentration: 99.5%) |
- |
Used to clean bare fibers. This item does not come with the device and needs to be purchased separately. |
RJ45 connector |
Included in the 02233FKX auxiliary material package, which needs to be purchased. |
|
LC connector and wedge unit |
Included in the 02233FKY and 02233FLA auxiliary material packages, which need to be purchased. |
|
Fiber clamp |
Included in the 02233FKY and 02233FLA auxiliary material packages, which need to be purchased. |
|
Fiber holder |
Included in the 02233FKY and 02233FLA auxiliary material packages, which need to be purchased. |
|
Fiber coating stripper |
Included in the 02233FKY and 02233FLA auxiliary material packages, which need to be purchased. |
|
Fiber clamp release tool |
Included in the 02233FKY and 02233FLA auxiliary material packages, which need to be purchased. |
|
Fiber stripper pliers |
Used to strip a pigtail. This item is used only in the fusion splicing scenario and needs to be purchased separately. |
|
Single-core fiber fusion splicer |
Used to fusion splice the optical fiber and pigtail. This item is used only in the fusion splicing scenario and needs to be purchased separately. |
|
Heat shrink tubing |
Used only in the fusion splicing scenario. It is included in the 02233FLA and 02233FLB auxiliary material packages, which need to be purchased. |
|
Fiber pigtail |
Used only in the fusion splicing scenario. It is included in the 02233FLA and 02233FLB auxiliary material packages, which need to be purchased. |
|
Fusion splice protection sleeve |
Used only in the fusion splicing scenario. It is included in the 02233FLA and 02233FLB auxiliary material packages, which need to be purchased. |
|
Red pointer |
Used to test the connectivity of optical cables. This item does not come with the device and needs to be purchased separately. |
|
Laser source |
Used to test the insertion loss of optical fibers. This item does not come with the device and needs to be purchased separately. |
|
Optical power meter |
Used to test the insertion loss of optical fibers. This item does not come with the device and needs to be purchased separately. |
Procedure
- Peel off at least a 400 mm long section of the outer sheath from one end, for connecting to a switch of a hybrid cable. Peel off at least 300 mm from the other end, for connecting to an AP. All figures in this section assume that the left end of the cable is connected to a switch and the right end is connected to an AP.Figure 3-48 Peeling off the outer sheath
You are advised to peel off the outer sheath in two or three sections, allowing the outer sheath to be easily peeled off and preventing optical fibers from being broken.
Do not damage the copper cores or optical fibers.
Do not overly bend the cable at the stripping positions.
- Cut the cable according to the cabling direction in a cabinet.
Cut the copper cores or optical fibers connected to a switch depending on the side of the cabinet along which hybrid cables connect to the switch:
- Left side: The optical fibers must be 100 mm longer than the copper cores. In this case, cut the copper cores.
- Right side: The copper cores must be 100 mm longer than the optical fibers. In this case, cut the optical fibers.
The copper cores and optical fibers connected to an AP do not need to be cut.
Figure 3-49 Cutting 100 mm of the copper cores (switch cabling along the left side of the cabinet)Figure 3-50 Cutting 100 mm of the optical fibers (switch cabling along the right side of the cabinet) - Assemble optical fibers by referring to Assembling Optical Fibers in the First-Generation Hybrid Cable in Mechanical Splicing Mode or Assembling Optical Fibers in the First-Generation Hybrid Cable in Fusion Splicing Mode.
- Assemble RJ45 connectors by referring to Assembling Copper Cores in the First-Generation Hybrid Cables.Figure 3-51 Hybrid cable with connectors assembled (switch cabling along the left side of the cabinet)Figure 3-52 Hybrid cable with connectors assembled (switch cabling along the right side of the cabinet)
- Use a red pointer and an optical power meter to test the connectivity and insertion loss of optical fibers in the finished hybrid cable. The insertion loss of optical fibers must be less than 1.2 dB.
Assembling Optical Fibers in the First-Generation Hybrid Cable in Mechanical Splicing Mode
Context
Optical fibers in the first-generation hybrid cable can be assembled in either of the two modes: mechanical splicing and fusion splicing.
- In mechanical splicing mode, LC connectors in the purchased 02233FKY or 02233FLA auxiliary material package are used to terminate optical fibers.
- In fusion splicing mode, optical fibers are fusion spliced with fiber pigtails in the purchased 02233FLA or 02233FLB auxiliary material package, without the need of LC connectors.
Procedure
- Assemble an optical fiber.
- Use a flat drop cable stripper to remove the unwanted fiber jacket. Note that using fiber stripper pliers may damage the optical fiber and is therefore not recommended.
The bare fiber must be at least 50 mm long, without any damages.
Replace the flat drop cable stripper if it is not sharp enough to cut off the steel wire or damages the optical fiber.
Ensure that the cut surfaces are neat and even, the optical fiber is not damaged, and the steel wire in the jacket is not bent.
- Bend the bare fiber to an angle greater than 60º in the upward and downward directions, three times in each direction.
If the optical fiber is broken during the bending, start from the very beginning to assemble the optical fiber.
- Use a flat drop cable stripper to remove the unwanted fiber jacket. Note that using fiber stripper pliers may damage the optical fiber and is therefore not recommended.
- Clamp the optical fiber.
- Open the fiber clamp and insert the optical fiber.
Vertically place the optical fiber inside the fiber clamp, with the narrow side facing the notch.
Ensure that there is no gap between the fiber clamp and the cut surfaces. (See the red dotted line.)
- Close the fiber clamp and press it tight.
- Open the fiber clamp and insert the optical fiber.
- Strip the optical fiber.
- Place the assembly inside the fiber holder and close the buckles.
- Place the fiber holder (with the assembly) inside the fiber coating stripper.
Ensure that there is no gap between the fiber holder and the fiber coating stripper. (See the red dotted line.)
- Press the fiber coating stripper and pull out the fiber holder at an even speed to remove the fiber coating.
Be sure not to tilt the fiber holder when pulling it out. Otherwise, the optical fiber will break.
- Place the assembly inside the fiber holder and close the buckles.
- Cut the optical fiber.
- Bend the bare fiber to an angle greater than 60º in the upward and downward directions, three times in each direction.
If the optical fiber is broken during the bending, start from the very beginning to assemble the optical fiber.
- Clean the bare fiber using fiber cleaning papers with absolute alcohol.
Do not break the optical fiber during the cleaning.
- Place the fiber holder on the fiber cleaver, ensuring there is no gap between them.
If the cutting is not completed at a time, start from the very beginning to assemble the optical fiber.
If the cutter blade is worn out, replace it immediately.
- Cut the optical fiber.
- Take out the assembly from the fiber holder.
- Use the fiber holder to check the fiber length. If the lengths of the bare fiber without coating and the bare fiber with coating exceed the scale on the fiber holder, start from the very beginning to assemble the optical fiber.
- Bend the bare fiber to an angle greater than 60º in the upward and downward directions, three times in each direction.
- Assemble the optical fiber.
- Press the wedge unit and ensure that the wedge unit is firmly seated on the LC connector. Press the wedge unit first at part 1 and then at part 2. Then follow directions indicated by numbers 1 and 2 on the wedge unit.
- Insert the optical fiber until the fiber clamp is entirely within the LC connector (you will hear a click).
Do not squeeze the wedge unit during the assembly.
- Inspect the bare wire on the LC connector. The bare fiber should be slightly bent and should not protrude from the LC connector.
- Press the wedge unit and ensure that the wedge unit is firmly seated on the LC connector. Press the wedge unit first at part 1 and then at part 2. Then follow directions indicated by numbers 1 and 2 on the wedge unit.
- Remove the protection cover of the wedge unit, and release the wedge unit by squeezing it.
Do not overly bend the optical fiber near the LC connector.
- (Optional) Disassemble the optical fiber.
If the optical fiber fails the performance test, disassemble and re-assemble it.
- Seat the wedge unit on the LC connector.
- Press the wedge unit first at part 1 and then at part 2 until you hear a click.
- Place the fiber clamp release tool at the hole on the connector and slide it to withdraw the fiber clamp.
- Pull out the optical fiber.
If the length of the bare fiber without coating is less than 10 mm, it can be determined that the fiber is broken inside the connector. In this case, the connector can no longer be used.
- Seat the wedge unit on the LC connector.
Assembling Optical Fibers in the First-Generation Hybrid Cable in Fusion Splicing Mode
Context
Optical fibers in the first-generation hybrid cable can be assembled in either of the two modes: mechanical splicing and fusion splicing.
- In mechanical splicing mode, LC connectors in the purchased 02233FKY or 02233FLA auxiliary material package are used to terminate optical fibers.
- In fusion splicing mode, optical fibers are fusion spliced with fiber pigtails in the purchased 02233FLA or 02233FLB auxiliary material package, without the need of LC connectors.
Procedure
- Feed one end of an optical fiber and one end of a pigtail through the caps of a fusion splice protection sleeve.
- Assemble the optical fiber. Remove the fiber jacket and fiber coating in the same way as in the mechanical splicing scenario.
If no 02233FKY or 02233FLA auxiliary material package is purchased, you can use fiber stripper pliers.
- Process the pigtail. Use fiber stripper pliers to strip a pigtail, cut off the unwanted aramid yarn, strip the fiber coating, and route the pigtail into the heat shrink tubing.
- Clean bare fibers in the optical fibers and pigtails with pure alcohol using fiber cleaning papers.
- Cut the optical fiber and pigtail. Place the fiber holder on the fiber cleaver and use the trough matching the optical fiber and pigtail.
- Use a 0.9 mm trough for the pigtail.
- Use a 0.25 mm trough for the optical fiber.
- Use a 0.9 mm trough for the pigtail.
- Fusion splice the optical fiber and pigtail. Place the optical fiber and pigtail on the fiber fusion splicer, while ensuring that they do not outreach the electrodes.
Test the insertion loss of the spliced optical fiber. If the value is greater than 0.05 dB, repeat the preceding fusion splicing operations. (The fiber fusion splicer will display the cause, such as uneven end face, bubbles, or fiber core damage.)
- Heat the heat shrink tubing. Cover the splicing point with the heat shrink tubing, secure the heat shrink tubing to the heat shrink trough, and start heating.
Check whether the heat shrink tubing is tightly wrapped around the jacket of the optical fiber. If not, continue to heat it.
- Assemble the fusion splice protection sleeve. Place the spliced optical fiber into the fusion splice protection sleeve, and tighten the caps at both ends.
Ensure that the heat shrink tubing has cooled down before you assemble the fusion splice protection sleeve.
- Repeat steps 1 to 8 to fusion splice the other optical fiber.
Assembling Copper Cores in the First-Generation Hybrid Cables
Context
Copper cores in a hybrid cable need to be terminated by RJ45 connectors before being connected to devices.
No screw is required to assemble RJ45 connectors. Figure 3-53 shows the appearance of a screw-free RJ45 connector.
1. Lever |
2. Cable inlet |
(3) Observation window |
Procedure
- Strip 8 mm of the insulation layer off each copper core.
- Raise the levers of an RJ45 connector.
- Insert the copper cores all the way into the cable inlets. Ensure that no copper conductors are bent or exposed.
Connect the copper cores of the corresponding colors to the positive (+) and negative (-) terminals on a connector by following the routing requirements for specific colors of cables in the local country or region. Ensure that both ends of a single copper core are connected to the same type of terminals (positive or negative).
- Lower the levers and look through the observation windows to verify that the springs do not overlap with the insulation layers.
- Pull each copper core with a force of about 10 N and ensure that each copper core is properly connected. Bind the copper cores with cable ties in the same direction and cut off the excess cable ties.
