CABLING INSTALLATION GUIDE

Siemon Cabling Installation Guide

The purpose of this document is to provide for those not currently familiar with the structured cabling industry a set of general guidelines and tips for preparing and installing network communications cables. The information contained was developed from first hand experience of our technical staff, conversation with cabling contractors and review of available training content and other industry resources. They highlight typical issues and concerns faced on the job site and ways to make the most of the available resources. As with most installation related tasks, proper planning is the key to any successful implementation. Prior to beginning any cable installation, it is important to take time up front to review and identify the following elements: Pathway. Clearly identify the cable pathway that will be used if not already identified on the construction drawings. Doing this prior to having a full crew on site will greatly reduce lost time from the crew standing waiting for instructions. Communication. Even on a small 2-man job, having a form of communication such as two-way radios will greatly increase the overall efficiency of the team. Tools. Know your installation requirements upfront and make sure you have all the necessary tools on hand, such as: ladders, pull string, lubricant, tape, etc. Doing this prior to starting the installation will also reduce lost labor time. These requirements can easily be identified while planning the cable pathway on a pre-installation walk through. GENERAL CABLE INSTALLATION TECHNIQUES Utilize a pull string when making all pulls. Note: Periodically this pull string will have to be rerun, because it will entangle itself in the previously installed cable runs and will damage those cables if its used on new runs. A good rule of thumb is to install a new pull string after every 3rd pull. Make long runs first to take full advantage of the pull string on the shorter runs Never exceed the manufacturers maximum limits for pulling tension or the minimum bend radius of the cables. Violating either of these can have a significant impact on the overall performance of the installed infrastructure.

CONNECTING THE WORLD TO A HIGHER STANDARD

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Make a cut sheet showing a rough idea of what cable(s) are going to what room/drop location. Use this cut sheet to track your progress throughout the installation as well as any changes to the original design. This cut sheet will also be invaluable in creating the AsBuilt drawings at the end of the project.

TIP: A clean copy of the telecommunications floor plan is the best thing to use as a cut sheet. This insures that all required drops are installed and the print can be checked off as the cables are installed providing you with an accurate barometer of your progress throughout the installation.
When hand labeling the cables as theyre installed, mark both ends of the cable 2-3 times at 2 intervals. This insures that the cable can be easily identified after theyre all installed, even if a portion of the cable should be cut or one of the markings become unreadable. [Figure 1]
CABLE JACKET 2-3 2-3

CABLE LABEL #1

CABLE LABEL #2

CABLE LABEL #3

FIGURE 1

When writing the numbers on these cables, write them down in a vertical pattern along the length of the jacket. This will allow you to write the numbers larger making it easier for everyone to read. Underline these identifiers at least 3 times so everyone on the team can determine where the bottom of your identifier is, and will eliminate the confusion caused when identifiers have the numbers 6 or 9 in them as well as other characters that can be confused when read upside down. Its also important to label the reel/box with the same identifier as the jacket. This is how youll be able to correctly label the other end of the cable when the pull is complete. Note: It is critical that before a new pull is made from the same reel/box, the identifier from the last pull be crossed out as thoroughly as possible to avoid mislabeling on subsequent pulls. Crew size is determined not only by the number of cables being pulled, but also the number of direction changes that occur along the cable path. Typically one tech will be placed at each location of a direction change. However, at a minimum there should be at least 2 techs involved in any cable pull. One at the head end, this is the end of the cable that is being pulled to the desired location, and another at the reels/boxes. This persons job is to make sure that the cables are coming off the reels smoothly as well as take slack from the reels making the pull easier for the tech(s) at the head end of the cable.

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TIP: Pulling from the TR out to the Work Area/Consolidation Point typically is the best manner of installing a cabling plant. The TR is the location of highest concentration, which allows for a more consistent installation, reduced cable waste and also provides for an easier breakout of the cabling at the end of the installation by function within the TR.
Creating the head-end: When installing multiple cables in a single pull, staggering the ends of the cables creates the head end of the cable. This will provide you with a tapered/pointed end to pull with allowing the cable to work around and through any obstacles in the pathway. This also greatly assists in navigating 90-degree bends and other offsets located within a conduit system. [Figure 2]
PULL STRING WRAPPED & TIED ALONG LENGTH OF HEAD-END STAGGERED CABLE LAYOUT

CABLE HEAD-END

FIGURE 2

TIP: Pre-sort your cabling when setting up the pull. When doing large cable installations it can get very confusing in the TR when all the cables are finally pulled and can be time consuming to breakout all these cables by function and termination location within the TR. If you set up your cable reels by function, (Voice, Data #1, Data #2, Video, etc) this will go a long way to making the dress-in portion of the installation within the TR a more efficient and cleaner job.
When working with reeled cables, a properly designed cable reel stand should be used. This will not only make the job easier, it will also minimize potential damage to the cable from kinking by allowing the reel to spin more freely. [Figure 3]

TIP: When placing reels of cable on a reel stand avoid placing full reels of cable right along side partial reels. This is due to the fact that when both reels are pulled together, the lesser reel will spin at a higher rate than the full one. When placed next to each other they have a tendency to make contact. The slower reel will begin to spin at a rate faster than the cable being pulled off of it. This will cause the cable wraps to open up and then begin to snag and kink potential damaging the cable.

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NO SPACER

PARTIAL REEL

FULL REEL

PARTIAL REEL

FULL REEL

TAPE ROLL SPACER

FIGURE 3

Another tip to help in the above situation is to place rolls of electrical tape between the reels to act as spacers and maintain a workable gap between the reels. [Figure 3] When working with boxed cables they should be placed on the floor. No additional apparatus is required. These boxes can be stacked as well, but it is recommended that they not be stacked more than two (2) high. Any higher than this you run the risk of the stack tipping over from the tension of the pull. This will damage the box and potentially the reel in side. If the box is the type that has no reel within, issues can still arise from any deformation of the box. [Figure 4]

NO MORE THAN 2 BOXES HIGH

FIGURE 4

Always pull the cable in a slow and steady manner. This will not only minimize any reel issues, but will also greatly reduce damage to the cables should they get snagged on an obstacle along the cable path. For long runs it is recommended that there be at least 3 members of the pulling team even if the run is straight. The reason for this is to reduce pulling tensions on the cable. For long, straight pulls the 3rd team member should be placed in the center of the run to create an intermediate pulling point (service loop). This, in a sense, turns the long straight run into two short ones, greatly reducing the overall stress on the cable.

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When completed with any cable pull, clearly mark all cable reels/boxes with the exact footage of the remaining cable. Even small amounts of cable can be re-used for short pulls, such as those that are within the TR or Main Equipment Room.

TIP: When a reel/box gets to point where there is no usable length of cable remaining, remove all the excess cable and then breakdown the box or wooden spool for easy recycling or disposal. As for the cable itself, most municipalities have reclamation centers where you can take the cable to and receive cash for each pound of copper. Stripping of the jacket and insulation is not required. Its an excellent way to offset fuel costs associated with a project.
FIBER The process for installing fiber cable is very much the same as with copper. However, more consideration needs to be taken into account when handling the cable. Never exceed the minimum bend radius or maximum pulling tension of the cable as specified by the cable manufacturer. When creating a head-end for the start of the pull, it is recommended to strip back the jacket and fiber strands leaving a length of Kevlar exposed. This material is placed into the fiber because of its ability to resist stretching. Pulling from here minimizes any deformation of the cable jacket that could be caused by placing the pulling stresses on the outside jacket of the fiber. As with copper, the head-end should be tapered to assist in the pulling process. [Figures 2 & 5]

DO NOT PULL FROM FIBER OR JACKET

PULL FIBER FROM ARAMID YARN (KEVLAR) STRENGTH MEMBER

FIGURE 5

For long runs it is recommended that there be at least 3 members of the pulling team even if the run is straight. The reason for this is to reduce pulling tensions on the cable. For long, straight pulls the 3rd team member should be placed in the center of the run to create an intermediate pulling point (create a figure 8 service loop at this location). This, in a sense, turns the long straight run into two short ones, greatly reducing the overall stress on the cable.

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TIP: After the pull is complete, cut off the first 5 10 of cable to remove any portion of the cable that may have been stretched or damaged during the pull.
TRUNK CABLES Trunk cables are pre-terminated copper or fiber cable assemblies ordered to specific lengths, ideal for data center applications where cable distances are more predictable. Shorter length trunk cables will typically be shipped, coiled flat within a box. In these instances its best to remove the cable completely from the box before installing. This will eliminate any potential kinking of the outer jacket. The process of installing these cables are the very much the same as those described above. However, special care has to be taken not to damage the connectors on the ends of the cable. If not so equipped from the manufacturer, a special head end assembly (pulling grip) should be applied over the end of the cable. These are products specifically designed to place the pulling tension to a portion of the cable beyond the terminated ends. It also offers a level of protection to the pre-terminated ends.

CAUTION: Be careful when removing this pulling grip so as not to damage the cables/connectors contained within it.
When these pulling grips are installed, whether at the factory or in the field, the head end of the cable can get quite large in diameter and length. Take this into account when planning your cable pathway to insure there is sufficient space for the end to pass without damaging the cable or any other preexisting building infrastructure. Its a good idea to perform a link test of the assembly prior to installation. Although these cables are typically factory tested and certified, it is worth taking the time to verify this up front before taking the time and effort to install it.

Note: After this link test is performed it is important to re-install the dust caps or any other protective product installed by the manufacturer before installing the trunk cable.

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BASIC CABLING ERRORS TO AVOID Never cut or pull an unlabeled cable Never label cable with a persons name. People move and names change. Never pinch or kink the cable. Never exceed the manufacturers rated pull tension of the cable. This will distort, not only the jacket of the cable, but also the conductors and their geometry within the jacket. Both aspects of the cable construction play a very important role in the overall performance of the network infrastructure. Once a cable is severely distorted, it cannot be corrected to a point where it will perform to its designed standard. Avoid twisting, stretching and exceeding the rated bend radius of the cable. All of these will have a detrimental effect on the overall performance of the network. Unlike copper cables, do not install fiber cables using the outside jacket. The aramid yarn (kevlar) strength member should be used to avoid stretching the jacket which in turn can affect fiber performance. Cable storage: Avoid storing reeled cable vertically. Storing it this way will cause the cable wraps to loosen and drop to one side of the reel. The next time this reel is used significant snagging and kinking of the cabling will occur.

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2008 Siemon

TB_Cabling Installation Guide, Rev. A 2/08