FOSC-400B4-MC-X06-X-NV I N S T A L L A T I O N I N S T R U C T I O N Fiber Optic Splice Closure with integrated Organizer System for modular Cable Contents 1 Introduction 1.1 Product description 1.2 Port capacity 1.3 Tray capacity 2 General 2.1 Kit content 2.2 Tools 2.3 Accessories 3 Installation 3.1 Closure preparation 3.2 Installation of multiduct(s) into the port 3.3 Installation of microcable directly into the port A. Oval port B. Drop ports 3.4 Sealing of the oval port 3.5 Sealing of the round (drop) port A. Single multiducts entries B. Multiple multiducts entries 3.6 Microduct preparation 3.7 Termination and routing of the fibers A Oval port (10 mm microducts) B Drop ports (5 mm microducts) 3.8 Splicing and fiber storage 3.9 Closing the closure 4 Grounding/shielding 5 Re-entry 6 Inter tray jumping 7 General precautions 8 Mounting kit 1 Introduction 1.1 Product description This installation instruction describes the necessary installation steps to install the FOSC-400B4-MC product. The product has the capability to install microcable directly into the ports or multiducts. It can accommodate different types of trays. It has one oval entry port, which can handle 2 microcables or multiducts and 4-drop ports. It is recommended to install the cable seals with hot air (hot air should be at least 350 C). The FOSC-400 can be installed in: direct buried, manholes or aerial locations. Follow the local safety guidelines during installation.
1.2 Port capacity Capacity Multiduct Outside Oval port Drop port Diameter (D=19 mm) 1x5 mm 7.1 NA 2* 2x5 mm 13x8 NA 2* 4x5 mm 15.2 NA 1 7x5 mm 18.6 NA 1 12x5 mm 24 NA 0 19x5 mm 29.6 NA 0 2.2 Tools Marking pen FACC-TUBE-CUTTER-01 FACC-TUBE-CUTTER-MC-01 2.3 Accessories 1x10 mm 12.4 2 NA 2x10 mm 22x12 2 NA 4x10 mm 27 0 NA 7x10 mm 35 0 NA * sealing of multiples is done with the standard sealing kit and SCOP (see section 3.5B). 1.3 Tray capacity Fiber storage length X(Y) with X fibre storage length (mm) on both sides of smouv and (Y) maximum number of splices Tray type 250/250 250/900 900/900 FOSC-AS-TRAY-S6/A6* 1200(6) 1200(4) 1200(2) 2.3.1 Microduct connectors Tyco reference: FACC-MC-ECAP-10MM-10 FACC-MC-ECAP-5MM-10 FACC-MC-BCON-10MM-10 FACC-MC-BCON-5MM-10 FACC-MC-EBLOCK-5MM-10 2.3.2 Supplementary tray kit(s) can be ordered: see ordering guide * When A6 tray is used (use of ANT splice protectors). Only 250/250 column is applicable. 2 General 2.1 Kit content 2.3.3 SCOP to seal multiple cable entries in drop ports. Tyco reference: FACC-MC-SCOP-CS-10. 3 Installation 3.1 Closure preparation Dome Base with basket and organizer Velcro and wedge Clamp O-ring Silicagel Transportation tubes Strength member terminations Oval seal kit Loose buffer tubes storage bag 3.1.1 Loose the clamp. Push the lever down to release the locking tab. Open the clamp lever and release the clamp using the lever legs. Remove the clamp, dome and sealing ring and store carefully for later use. 2
3.1.2 Install the FOSC in the FOSC-STAND. 3.2.3 Position the jacket end halfway (± 30 mm) in the port and secure the microducts into the closure with tape. One can also secure the multiducts at the outside of the closure. Note: securing the microducts (multiducts) prevent the multiduct from moving out of the closure when installing the sleeve. Check the port capacity table (point 1.2) for the allowed configurations. 3.2.4 The above drawing shows the positioning of 2*2w10mm multiducts in the oval port. 3.2.5 Continue with section 3.4 or 3.5. 3.1.3 Open the appropriate port at the ridge; the cutting wire can be used. 3.2 Installation of multiduct(s) into the port 3.3 Installation of microcable directly into the port 3.3.1 Remove the microcable jacket over a distance of : - loop cable; 4 meter - cable ends; 2 meter. 3.3.2 Clean the loose buffer tubes and cut the strength members at : Oval port entry: 60 mm Drop port entry: 100 mm. A Oval port 3.2.1 Clean the multiduct jacket over a distance of 2 meters with a clean cloth.remove the outer-jacket over a distance of 300 mm. Note: in case of multiple multiducts in a round (drop) port, continue with section 3.5B. Make sure the microduct is not damaged. 3.2.2 Slide the cable seal over the multiduct(s). Note: make sure the arrow on the seal sleeve (uncoated zone) is pointing towards the base. 3.3.3 Slide the cable seal over the microcables. Insert the microcables thru the oval port. Note: make sure the un-coated zone (arrow on the cable seal) is pointing towards the base of the closure. 3
B Drop ports 3.3.8 Microcables directly installed thru the drop port are sealed with the kit: - FIST-GCO2-RSK-16-MC. Note: when multiple cables per port are required, the kit FIST-GCO2/16-MU-2/2-6 can be used together with FIST-GCO2-RSK-16-MC. 3.3.9 Make sure one has minimum 2 m of microcable inside the closure. 3.3.10 Remove the microcable jacket at 70 mm of the bottom of the base. 3.3.4 Secure the strength member connectors into the closure, secure the strength members into the strength member connector. Note: avoid crossings of loose buffer tubes and strength members, two strength members can be cut if necessary. 3.3.11 Continue with point 3.6.9. 3.4 Sealing of the oval port 3.3.5 Clean and abrade the port and the microcable. 3.4.1 Thoroughly clean oval port and multiducts with the cleaning tissue over a distance of 150 mm from the edge of the port. Note: in case the microcable was entered directly into the port, a SCOP is already installed around the microcable. Cleaning the microcable is not necessary anymore at this point. 3.3.6 Install a SCOP around each cable (FACC-MC-SCOP-CS-10). Position the SCOP directly underneath the oval port. 3.3.7 Continue with section 3.4 (sealing of the oval port). 3.4.2 Abrade oval port and multiducts circumferentially on the cleaned area with the abrasive strip. Note: in case the microcable was entered directly into the port, a SCOP is already installed around the microcable. Abrading the microcable is not necessary anymore at this point. 4
3.4.3 Place the oval seal over the oval port and the multiducts. When the seal butts against the base, mark the sleeve length onto the multiducts. 3.4.5 Slide the cable seal over the port. Install the branch-off clip. Check that the heat-shrinkable cable seal butts up against the base and the branch-off clip is completely inserted. Tape the two multiducts together. 3.4.6 Shrink the cable seal on the base side with the recommended hot air gun device with reflector. Shrink sleeve until the green thermoindicating paint is converted to black. (Make sure the hot-air temperature is at least 350 C). (If a FACC-HEAT-GUN-220V is used, set position on scale 10). 3.4.4 Match the blue line of the aluminum cable protection foil with the marks on the multiducts. Wrap aluminum cable protection foil around the multiducts. Note: in case of microcables directly into the port (section 3.3), disregard the blue line and place the aluminum protection foil only 15 mm to the inside of the mark (end of seal). 3.4.7 Shrink down the end of the cable seal on the multiduct side. Heat until the sleeve shrinks down on the multiducts and make sure that the green thermo-indicating paint is converted to black. Postheat the clip on both sides till the adhesive shows a proper flow on the clip. Do not move the closure or multiducts (microcables) during 20 mm. 5
3.5 Sealing of the round (drop) port A Single multiduct entries 3.5.1 Thoroughly clean the port and the multiducts with the cleaning tissue over a distance of 150 mm from the edge of the port. 3.5.4 Match the blue line of the aluminum cable protection foil with the mark on the multiduct. Wrap the aluminum cable protection foil around the multiduct. 3.5.2 Abrade the port and the multiducts circumferentially on the cleaned area with the abrasive strip. 3.5.5 Slide the seal over the port. Shrink the seal on the base side with the recommended hot air gun device. Use the reflector to ensure heat distribution around the outlet. Shrink the seal until the green thermo-indicating paint is converted to black. Note: setting of the thermogun. FACC-HEAT-GUN-220V in position 10. Minimum hot air temperature should be 350 C. 3.5.3 Place the seal over the drop outlet of the base. When the seal butts against the base, mark the sleeve length on the multiduct. 3.5.6 Shrink down the end of the seal on the multiduct side. Heat till the seal shrinks down onto the multiduct, the green thermo-indicating paint is converted to black and the hot melt is visible at the bottom. Do not move the closure or multiducts (microcables) during 20 mm. 6
B Multiple multiducts entries 3.5.7 Clean and abrade the appropriate port and cables (over a distance of 200 mm). 3.5.8 Position the SCOP at 30 mm from the multiduct jacket and wrap the SCOP around the multiduct (FACC-MC-SCOP-CS-10). 3.5.11 Place the seal over the drop outlet of the base. When the seal butts against the base, mark the sleeve length on the SCOP. 3.5.9 Slide the cable seal over the multiduct(s). Note: make sure the arrow on the seal sleeve (uncoated zone) is pointing towards the base. 3.5.12 Position the aluminum cable protection foil 15 mm to the inside of the mark on the SCOP. Wrap the aluminum cable protection foil around the SCOP and smoothen. Note: disregard the blue line on the aluminum cable protection foil. 3.5.10 Push the multiducts into the port till the SCOP butts against the port edge. Secure the microducts into the closure with tape. One can also secure the multiduct on the outside of the closure. Note: securing the microducts(multiducts) prevent the multiduct from moving out of the closure when installing the sleeve. Check the port capacity table (point 1.2) for the allowed configurations. 3.5.13 Slide the seal over the port. Shrink the seal on the base side with the recommended hot air gun device. Use the reflector to ensure heat distribution around the outlet. Shrink the seal until the green thermo-indicating paint is converted to black. Note: setting of the thermogun. FACC-HEAT-GUN-220V in position 10. Minimum hot air temperature should be 350 C. 7
3.5.14 Shrink down the end of the seal on the multiducts side. Heat till the seal shrinks down onto the multiducts, the green thermoindicating paint is converted to black and the hot melt is visible at the bottom. Do not move the closure or multiducts (microcables) during 20 mm. 3.6.2 All the not used microducts are sealed with the specific ENDCAP connector (5 or 10 mm). On the used 10 mm microducts a blocking connector is installed. The rubber blocking on the 5 mm microduct is installed after the microcable is blown. Note: make sure the blocking connector (10 mm) is installed before the microcable is blown in case of a looped cable. 3.6 Microduct preparation 3.6.3 The microcable length needed inside the closure is : - Loop microcable: 4 meter - Drop microcable: 2 meter. 3.6.4 Tighten the blocking connector by turning the gland clockwise. Hold the body when turning. Note: when the connector is being re-opened (for example:change of microcable), the connector has to be replaced. 3.6.1 After the cable seal has cooled down, mark and cut the microducts (with the tube cutter) at 70 mm from the bottom of the base. Note: make sure that the tube is not damaged at this spot. When necessary, re-cut the tube. 3.6.5 Remove the microcable jacket at 15 mm above the blocking connector (10mm microduct) or the microduct (5 mm). Note: make sure the microcable jacket is not being cut with the ripcord (or damaged) within the 15 mm distance from the microduct (5 mm). 8
A Oval port (10 mm microducts) B Drop ports (5mm microducts) 3.6.6 Secure the strength member connectors. 3.6.9 Cut the strength members at 100 mm leaving from the microcable jacket. Note: make sure the strength members and fibers are not entangled. Strength Strength members members Rubber blocking 60 mm Rubber blocking 60m Microcable jacket 900 900 micron fibers fibers 60 15 15 Microduct 5 mm Microduct 5mm 3.6.7 Measure the distance to the strength member connector, mark and cut the strength members to length. 3.6.8 Secure the strength members in the strength member connectors. Note: avoid crossings of loose buffer tubes and strength members; one can cut two strength members if necessary. 3.6.10 Mark the 5 mm microduct(s) at 15 mm from the edge and the strength members of the microcable at 60 mm from this mark (is the length of the rubber blocking) Note: make sure the microcable jacket was 15 mm out of the microduct (microcable can move in the microduct). When a microcable is directly inserted through the port (3.3.8) the rubber blocking is positioned 30 mm onto the microcable (no microduct available). 3.6.11 Slide over and position the rubber blocking equal with the mark on the microduct. Make sure the mark on the strength members of the microcable is equal with the other side of the rubber blocking. Move the microcable if necessary. 9
3.6.12 Secure a tie wrap around the rubber blocking in the microcable jacket area. Note: make sure that the jacket of the microcable was positioned correctly. 3.7 Termination and routing of the fibers 3.7.4 Slide the transportation tube over the loose buffer tube. Slide the SECO onto the transportation tube. A Oval port (10 mm microducts) 3.7.1 In case of loops, cut the to be spliced loose buffer tubes in the middle of the loop. 3.7.5 Divide the fibers into circuits and place each circuit in an outgoing port of the SECO. Note: Do not Secure the SECO into the SECO holder yet. 3.7.2 Remove the loose buffer tubes leaving 70 mm (X) from the microcable jacket end. 3.7.6 Slide the small transportation tubes(fopt-sf) over the fiber circuits and insert them into the SECO outlets. 3.7.3 Insert the biggest transportation tube into the appropriate SECO entrance. Route it towards the microcable, mark and cut the transportation tube at 15 mm (X) from the microcable jacket. 10
3.7.7 Secure the SECO into the SECO holder. 3.7.10 Secure them to the back of the basket. Note: The loop is secured to avoid kinking of the tubes when the closure is turned. 3.7.8 Route the transportation tubes at the back of the basket as shown. Secure the transportation tubes at the back of the basket. Note: make sure the transportation tubes make smooth(as big as possible) bends. 3.7.9 Store the uncut loose buffer tubes in the plastic bag. 3.7.11 Each splice tray accommodates 6 fiber splices maximum, and each side of the tray holds a maximum of 4 transportation tubes. Start with the bottem tray and push the tube in the tray. Use the tray-wedge to support the trays, or remove the upper trays. 11
B Drop ports (5 mm microducts) 3.7.16 Take the transportation (FOPT-CS) tube and slide it over the fibers. 3.7.12 When the trays have been removed, insert the first tray in the fifth hole from the bottom. 3.7.13 Route the transportation tubes around the tray tower to the appropriate tray. Note: Do not route the transportation tube tight around the tray tower. Give them some slack. 3.7.17 Mark the transportation tube at 15 mm from the end at rubber blocking side. 3.7.18 Slide the transportation tube into the rubber blocking till the mark (15mm). Make sure the strength members are on the outside of the transportation tube. 3.7.19 Secure a tie wrap onto the rubber blocking in the transportation tube area. 3.7.14 Mark the transportation tube at the end of the tray entrance as shown. Carefully cut the transportation tube at the mark. 3.7.20 Cut the strength members next to the rubber blocking. 3.7.15 Insert the transportation tube till it butts against the end of the tray entrance. Note: The first tube on a tray should be placed in the inner groove. Make sure the transportation tubes are not routed tight around the tray tower. 12
3.7.21 Secure the tray(s) in upwards position by means the tray wedge 3.7.25 Insert the transportation tube till it butts against the end of the biggest cavity (middle of the tray entrance). Note: The first tube on a tray should be placed in the inner groove. Make sure the transportation tubes are not routed tight around the tray tower. 3.7.26 Repeat above steps for each drop. 3.8 Splicing and fiber storage 3.8.1 Position the FOSC by the splicing machine in a convenient location and secure the closure. 3.7.22 Route the transportation tubes into the basket as shown. Note: when all tubes are routed, tubes can be secured with tie wraps. 3.7.23 Route the transportation tubes around the tray tower to the appropriate tray Note: do not route the transportation tubes tight around the tray tower. 3.8. 2 Slide the heat-shrinkable splice protection over one fiber and fuse fibers according to local recommendations and procedures. After the fusion splice is made, install the heat-shrinkable splice protection (e.g. SMOUV) with appropriate heating source. Allow the splice protection to cool down to ambient temperature. 3.8.3 After each splice is made, the splice should be stored in the splice holder. Do not deform the splice protector during insertion. The fiber slack should be coiled into the tray. The incoming fibers should be routed at the right side of the little pin (arrow). 3.7.24 Mark the transportation tube at the end of the tray entrance as shown. Carefully cut the transportation tube at the mark. 13
3.9 Closing the closure 3.8.4 Upon completion of splicing, install the clear protective cover on the TOP tray. 3.9.1 Secure the trays with the Velcro. Open and remove the desiccant bag from the package and place the desiccant in the closure. Note: The tray wedge is secured on the Velcro. 3.8.5 Transportation tubes are inserted in the tray starting from the inside. Do not route the fibers tight around the island. Make sure all fibers are underneath the containment lips. The cross in the island can be used to make an S in a controlled manner. Example: when the tubes are coming at the same side onto the tray, one side (fibers) have to make the S to be able to splice the fibers together. 3.8.6 Repeat for all trays and continue with point 3.9) 3.9.2 Ensure sealing areas and sealing ring are clean and put sealing ring in place at the base. 3.9.3 Place the dome carefully over the trays onto the base (arrows should point to each other). Put the clamp around the base/dome interface. 3.9.4 Close the clamp. 14
4 Grounding/shielding Grounding or shielding might in some cases reduce the port capacity. For details, contact the local sales person. 4.4 In case of shielding, connect the wires to the multiducts (point 4.1 to 4.2) and connect the wires to each other with the connector as shown. 4.1 Connect the grounding wire to the multiduct shield. 4.5 Cut the excessive length of the wires. 5 Re-entry 5.1 Remove the clamp. Remove carefully the dome. Remove gently the sealing ring. Keep the sealing ring and seal area of the closure free of dirt (if needed rinse with clear water). 4.2 Put PVC tape underneath and on top. 5.2 Continue with the appropriate points of the instruction. Note: replace the dissicant before closing the closure. 4.3 Put the eyelet (other side of the wire) underneath the washer and nut (grounding). Make a connection with the earth at the bottom side of the closure. 15
6 Inter tray jumping 6.1 When it is necessary to splice fibers that are placed on different splice organizer trays an intertray jumper may be used to route one or more fibers to the desired tray. The 1,8 mm tubing must be used. 7 General precautions 7.1 Do not use damaged sleeve nor trim heat-shrinkable sleeve before installation. 7.2 The FOSC-400 closures can be installed at temperatures between -1 C and +45 C. 7.3 Generators used should have enough capacity for the hot air gun utilization. 7.4 The use of Isopropylalcohol is recommended to clean the cable and fibers. 8 Mounting kit 6.2 Push one end of intertray jumper tube into the splice tray,and thru the opening in the bracket. 6.3 Define the length of intertray jumper tube and cut to length. 6.4 Route the fibers in the jumper tube. 8.1 Position the two dome mounting brackets on the dome of FOSC-A/B-POLE-MOUNT. Clamp the brackets into the pole mounting brackets and secure it with the locking pin. 5.5 Carefully bring the intertray jumper tube to the appropriate tray 5.6 The fibers may now be spliced or stored. Tyco Electronics Raychem NV Telecom Outside Plant Diestsesteenweg 692 B-3010 Kessel-Lo, Belgium Tel.: 32-16-351 011 Fax: 32-16-351 697 www.te.com Velcro is a trademark of Velcro Industries B.V. The information given herein, including drawings, illustrations and schematics which are intended for illustration purposes only, is believed to be reliable. However, Tyco Electronics makes no warranties as to its accuracy or completeness and disclaims any liability in connection with its use. Tyco Electronics obligations shall only be as set forth in Tyco Electronics Standard Terms and Conditions of Sale for this product and in no case will Tyco Electronics be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use or misuse of the product. Users of Tyco Electronics products should make their own evaluation to determine the suitability of each such product for the specific application. TC 716/MC/IP/2 05/03