CommScope Trunk Distribution Cable User Manual

Broadband Applications & Construction Manual

Trunk & Distribution Cable Products

Table of Contents 0.1 Trunk & Distribution Cable Applications and Construction Manual

Table of Contents

Section 1 ................Introduction

1.1 ACT

1.2 ACT

- Advanced Coring Technology

1.3 P3 Design Details and Advantages

1.4 QR Design Details and Advantages

1.5 MC

Design Details and Advantages

Section 2 ................Handling and Testing

2.1 Inspection

2.2 Unloading

2.3 Storing and Stacking Reels

2.4 Storing and Stacking Reels

2.5 Impedance/TDR Testing

Section 3 ................Aerial Installation

3.1 Overview

3.2 Pulling Tension

3.3 Bending Radii

3.4 Expansion Loops

3.5 Forming Expansion Loops

3.6 Styles of Expansion Loops

3.7 Styles of Expansion Loops

3.8 Back-Pull/Stationary Reel Set-Up

3.9 Back-Pull/Stationary Reel Block Placement

3.10 Back-Pull/Stationary Reel Passing the Pole

3.11 Back-Pull/Stationary Reel Expansion Loops an Lashing

3.12 Back-Pull/Stationary Reel Passing the Lasher

3.13 Drive-Off/Moving Reel Set-Up

3.14 Drive-Off/Moving Reel Expansion Loops

3.15 Overlashing

Section 4 ................Integrated Messenger Installation

4.1 Overview

4.2 Down Guys

4.3 Hardware and Block Placement

4.4 Moving Reel Method

4.5 Stationary Reel Method

4.6 Stationary Reel Method

4.7 Stationary Reel Method

4.8 Dead ending

4.9 Cable and Strand Separation

4.10 Pole Attachment

4.11 Splicing

4.12 Splicing

NOTE: Information in this manual is subject to change. Check the literature download area on on CommScope’s website for the most recent updates.

0.1 Table of Contents

Trunk & Distribution Cable Applications and Construction Manual

Section 5 ................Underground Installation

5.1 Overview

5.2 Pulling Tension

5.3 Bending Radii

5.4 Vibratory Plowing

5.5 Vibratory Plow Movement

5.6 Trenching

5.7 Boring and Ductwork

5.8 Conduit

Section 9 ................Connectorization

6.1 ACT

6.2 ACT

6.3 ACT

6.4 ACT

6.5 ACT

6.6 ACT

6.7 Overview of P3 Connectorization

6.8 Overview of QR Connectorization

6.9 Overview of MC2 Connectorization

Section 7 ................Plant Maintenance

7.1 Overview

Section 8 ................Appendix

8.1 Introduction

8.2 OSHA and NEC Standards

8.3 NEC and Other Ratings

8.4 NESC Standards and Construction Grades

8.5 Wire Clearance

8.6 Pole Lease Agreements and Other Codes

8.7 Equipment/Benders

8.8 Equipment/Blocks

8.9 Equipment/Blocks, Chutes and Brackets

8.10 Equipment/Lashers, Pullers, Positioners and Guides

8.11 Equipment/Lifting tools and Brakes

Section 9 ................Digital Broadband Resource Center™

- Advanced Coring Technology

Introduction 1.1 ACT

- Advanced Coring Technology

Advanced Coring Technology

Another CommScope Innovation...Setting a New Standard in Cable Technology!

• EnhancedMechanicalPerformance

• Meets/ExceedsANSI/SCTE,EN50117,IECandCenelec

• FullyBackwardCompatible

• IdenticalinElectricalPerformance

• PatentPending

Traditional coaxial trunk and distribution cables require considerable attention to the preparation of the cable end for proper connectorization. Critical to that end preparation is the proper removal of dielectric and bonding compound from the conductors.

The normal process for this requires the craftsman to first core the cable and then clean the center conductor in a second step. CommScope’s new P3 conductor cleaning step by enabling a clean coring process in which the center conductor is cleaned of dielectric and bonding compound during the coring process.

These cables meet and exceed all ANSI/SCTE, EN50117, IEC and Cenelec testing methods for trunk, feeder, and distribution cables.

with ACT® and QR® with ACT® cables virtually eliminate the center

Below is an example of a traditional P3

Cable:

Residual dielectric and bonding compound on conductor after coring

Below is an example of

with ACT®:

Conductor clean of dielectric and bonding compounds after coring

1.2 Introduction

P3 Design Details and Advantages

Advanced Coring Technology

P3® with ACT® and QR® with ACT

cables were developed to address a question that has been clearly

stated and often repeated by the craftsmen, engineers, and technical operations managers of the broadband industry.

Why must a hardline cable be so difficult and problematic to properly core and prep? Before the introduction of ACT cables, craftsmen struggled with the cleaning of the center conductor. To remove the remaining dielectric and bonding compound craftsmen have:

 •Usedametallicblade,resultinginlossofcopperandnegativelyimpactingtheskineffect.  •Usedatorchtoheatupandsoftenthematerial,resultingindielectricmeltdowninsidethecable.

This dielectric melt down causes changes in the electrical and mechanical performance characteristics of the cable.

 •Usedchemicalandpetroleumbasedsolventstoremovethematerial,exposingthemtoatoxichazard

unnecessarily and leaving inappropriate residues on the center conductor.

 •Usedacenterconductorcleaningtoolthatrequiresbladestobereplacedastheybecomewornordamaged.  •Usednothing,leavingthedielectricandbondingcompoundresidueandcausingpoorsignalperformance

and electrical anomalies.

ACT cables not only eliminate all of these issues, but also significantly reduce the time needed to core and prep the cable end and make connectorization easier. This is accomplished through the development of an advanced technology bonding agent coupled with CommScope’s consistent manufacturing capabilities. This patent pending formulation leverages the shearing action produced by every coring tool enabling most tools to produce a one pass coring operation leaving the conductors clean of dielectric and bonding compounds. Tools and craft skill may affect the clean coring capabilities.

P3 with ACT and QR with ACT cables are expected to provide system operators with a reduction in truck rolls and labor cost for trunk and distribution plant. This reduction of truck rolls and labor cost is achieved through consistent clean coring. Ensuring that this critical step in the connectorization process is done right the first time every time eliminating many of the issues associated with poor connectorization, thus reducing the need to return to troubled locations to make corrective changes.

Introduction 1.3

ACT® - Advanced Coring Technology

P3® - Traditional Reliability

P3 is the standard by which all coaxial cables are measured.

The P3 center conductor is copper-clad aluminum for superior RF transmission.

The P3 dielectric is a closed-cell polyethylene that is compressed during the swaging

process. Compression provides superior bending. The closed-cell nature of the dielectric permits an impressively high velocity of propagation of 87%.

The P3 shield, a solid and robust aluminum construction, provides 100% RF protection and solid mechanical performance.

Migra-Heal

before moisture can seep in and cause corrosion.

P3 and Service –

the two names

associated with

, CommScope’s special underjacket compound, helps fill in jacket damage

The P3 jacket is a tough medium-density polyethylene

compound designed to resist the effects of sun, moisture

most often

and temperature extremes. CableGuard resistant jacket, is also available.

CommScope

Steel armor is available for added protection.

, a unique crush

1.4 Introduction

QR Design Details and Advantages

QR® - Superior Design and Construction

QR’s patented design combines several elements to achieve its unparalleled combination of superior performance in a smaller, less expensive cable.

The QR center conductor is copper-clad aluminum for superior RF transmission and is generally larger than the conductors found in competitive cable of similar outer diameter.

The QR dielectric is a closed-cell polyethylene that is compressed during the swaging process. Compression allows the dielectric to actively press against the shield and help heal small dents. The closed-cell nature of the dielectric permits an impressively high velocity of propagation of 88%.

The QR shield is formed through a unique, high efficiency process where a precision tape is continuously roll-formed around the core and is then welded by RF induction. This results in a contaminant-free seam which is stronger than the surrounding material. We verify seam integrity with a core and cone test, where a cored sample is flared to a diameter well beyond even the most extreme installed usage.

conductor combine

best performing

Thin shield, compressed

dielectric and

a larger center

to make QR the

coax available

Migra-Heal

helps fill in jacket damage before moisture can seep in and cause corrosion.

The QR jacket is a tough medium-density polyethylene compound designed to resist the effects of sun, moisture and temperature extremes.

Double jacketing, in which two independent jackets are separated by polypropylene tape, is also available.

Steel armor is available for added protection.

, CommScope’s special underjacket compound,

anywhere

Introduction 1.5

MC2 Design Details and Advantages

- Supporting Legacy Plant

MC2 is offered to sustain plants designed and built around this cable.

The MC

center conductor is copper clad aluminum

dielectric is an air disk structure, often referred to as bamboo cable, it provides for

low attenuation values.

The MC

Migra-Heal

shield is a roll formed aluminum tape welded by RF induction.

, CommScope’s special under jacket compound, helps fill in jacket damage

before moisture can seep in and cause corrosion.

The MC

jacket is a tough medium-density polyethylene compound.

Steel armor is available for added protection.

2.1 Handling and Testing

Inspection

Inspecting and Unloading CommScope Cables

Trouble-free unloading begins with letting your CommScope Customer Service Representative know of any special packaging or delivery requirements (no shipping dock available, call before delivery, etc.). CommScope will make every reasonable effort to comply with your shipping needs.

When the shipment arrives, inspect every reel and pallet of material for damage as it is unloaded. Suspect cable should be set aside for a more detailed inspection before the shipping documents are signed.

Damage can occur during the unloading process. Coaxial cable can be damaged by dropping the reels or pallets, or improper handling of reels with a forklift.

CommScope

makes every ef-

fort to assure

Stacked cable must be carefully unstacked to prevent cable damage and possible injury. CommScope drivers are experienced in handling and unstacking the cable without injury or damage. A Cargomaster crane is useful in unstacking and unloading cable with or without a dock.

Common carriers are only required to move the cable to the back of the truck for unloading. If a common carrier driver cannot unstack the cable, the driver should be instructed to return to the shipping terminal where equipment exists to unstack the cable. The cable can be reloaded onto the truck on rolling edge.

If any cable damage is visible or suspected and if it is decided to accept the shipment, note the damage and the reel number on ALL copies of the bill of lading.

If the damage is too extensive to accept the shipment, advise the carrier’s driver that the shipment is being refused because of the damage. Immediately notify CommScope’s Customer Service Department so that arrangements can be made for a replacement shipment.

that QR and P3 cables arrive in

the same 100%

ready-to-install

condition as

when they left

the factory.

Handling and Testing 2.2

Unloading

Unloading CommScope Cable

Unloading at a Dock

Use a pallet jack or forklift to remove all cable on pallets. Remove any blocking materials for the individual rows of cable and roll the reels onto the dock. If the back of the trailer and dock are not at the same height, use an appropriate loading ramp to compensate for the difference.

Unloading without a Dock

If you use a ramp, it should be strong enough to support the weight of the unloading personnel and the heaviest cable reels. The ramp should have raised sides to prevent the cable reels from rolling off the sides of the ramp.

The ramp should be long enough to allow control of the momentum of the cable as it rolls down the ramp. A pulley system connected to the sides of the truck and to a shaft passing through the center of the reels can help control the momentum of the rolling reels. With this method, two workers can usually control movement of the heaviest reel.

If you use a Cargomaster crane, unstack and move the cable to the ground at the rear of the truck.

DO NOT drop reels off the back of the truck onto a stack of tires, onto the ground or any other surface. The impact may injure personnel and

damage the cable. Always use ample personnel to safely unload shipments of cable.

Shipping weights lbs/kft (kg/km)

QR 320 JCA, JCASS 63 (94)

QR 540 JCA, JCASS 120 (179)

QR 715 JCA, JCASS 205 (305)

QR 860 JCA, JCASS 291 (433)

P3 500 CA 97 (143)

P3 500 JCA 120 (179)

P3 500 JCASS 123 (183)

P3 625 CA 158 (235)

P3 625 JCA 182 (271)

P3 625 JCASS 185 (275)

P3 750 CA 237 (353)

P3 750 JCA 272 (405)

P3 750 JCASS 275 (409)

P3 875 CA 295 (439)

P3 875 JCA 336 (500)

P3 875 JCASS 342 (509)

MO500CB 78 (116)

MO500CU 106 (158)

MO500CJ 111 (165)

MO650CB 112 (167)

MO650CU 147 (219)

MO650CJ 153 (228)

MO750CB 164 (244)

MO750CU 206 (307)

MO750CJ 213 (317)

2.3 Handling and Testing

Storing and Stacking Reels

Storage and Stacking CommScope Reels

CommScope cable can be stored indoors or outdoors, and the cable may be stacked on flange or stored upright on the rolling edge. Use a forklift or some type of overhead hoist to stack cable.

When cable is stored outside, the ground should be somewhat level and have good drainage to reduce the possibility of deterioration of the reel flanges. CommScope’s reel recycling program only accepts reels in good condition.

Reels which are stored on the rolling edge should be aligned flange to flange to prevent possible damage to the cable once the protective cover has been removed.

Stacking CommScope Cable

When CommScope cable is moved, shipped, or stored, use this table to ensure that maximum stacking heights are not exceeded. Consideration must be given to the maximum height as well as the total weight of the stack. To allow the use of a pallet jack or forklift, place boards between each layer and a pallet on the ground under the bottom reel. Exceeding the recommended storage and loading heights may damage the cable due to flange deflection.

QR Cable

Storage Height Loading Height

QR 540 5 Reels 3 Reels

QR 715 5 Reels 3 Reels

QR 860 5 Reels 3 Reels

P3 Cable

Storage Height Loading Height

P3 500 6 Reels 4 Reels

P3 625 6 Reels 4 Reels

P3 750 5 Reels 3 Reels

P3 875 5 Reels 3 Reels

Storage Height Loading Height

MO500 6 Reels 4 Reels

MO650 6 Reels 4 Reels

MO750 5 Reels 3 Reels

Maximum Maximum

Cable

Handling and Testing 2.4

Storing and Stacking Reels

Testing CommScope Cables

While testing reels of CommScope cables after delivery is not required, testing prior to, during and after construction will identify any degradation in the performance of the cable caused during installation.

There are three phases in CommScope cable testing:

1) Visual inspection for shipping damage

2) Pre-installation testing, which occurs immediately after delivery of the cable, and

3) Post-installation/final acceptance testing, which occurs just prior to activation. Post-installation testing is accomplished as part of system activation and as proof of performance. Broadband frequency response (sweep) testing is included as a part of the activation process.

Pre-Installation Testing

Pre-installation testing of CommScope cable typically consists of SRL and impedance/TDR (Time Domain Reflectometer) tests, with the TDR test being the quickest way to discover cable damage. These pre-installation checks can be jointly conducted by the system operator and the construction group in order to preclude future difficulties if a cable is damaged during construction.

CommScope cable is

extensively tested

Every reel of

prior to shipment

for attenuation,

Structural Return

Attenuation (insertion loss) tests are seldom conducted after shipment, but can be easily performed during pre-installation testing. Testing for attenuation by conventional methods is extremely difficult after installation due to the physical placement of the cable over substantial distances.

Loss (SRL) and

impedance with

certified test

reports available

at your request

Post Installation - Final Acceptance Testing

SRL and TDR tests can be performed after installation if required. The results should be compared to the pre-installation test.

2.5 Handling and Testing

Impedance/TDR Testing

Impedance/TDR (Time Domain Reflectometer) Testing

Impedance testing using a TDR is a quick and straightforward method for finding the distance from the test point to any fault (shown as an impedance mismatch) in the cable.

Impedance tests should be made from both ends of the cable to ensure finding the correct distance to fault. The correct velocity of propagation (Vp) for the test is essential - an incorrect Vp will cause a proportional measurement error in the distance to the fault. The Vp for QR cable is 88%. The Vp for P3 cable is 87%.

Impedance tests should be done per the standards set forth in SCTE-TP-006. Impedance testing will require a time domain reflectometer (TDR). Methods of operation will vary for each TDR; however, these are general guidelines for using one:

1) Set the velocity of propagation for 88% for QR or 87% for P3,and the impedance reference for 75 ohms.

2) Adjust the display for a sharp, clear baseline, and position the leading edge to a convenient starting point or graticule.

3) Set the pulse width as recommended by the TDR manufacturer.

4) Attach the test lead (coaxial cable test leads are preferred) to the cable under test. Connectors should match the impedance of the tested cable.

5) Adjust the display and control settings to show the entire length of the cable. The control settings can be adjusted to allow precise measurement of the distance to any impedance mismatch. Operator proficiency and equipment capability are critical factors in making consistent and precise measurements.

End-to-end impedance tests are very beneficial in an evaluation of post-installation plant performance. The TDR traces should be kept with the as-built drawings along with the reel numbers of the installed cable.

Aerial Installation 3.1

Overview

Aerial Installation of CommScope Cable

There are two cable types built specifically for aerial installation:

QR/P3 JCA the standard construction, available in five sizes for trunk and feeder installation, to be lashed to a strand or support wire, and

QR/P3 JCAM standard construction with a messenger extruded in place in a figure-8 design.

The two preferred methods for installation are the back-pull/stationary reel method and the drive-off/moving reel method. Circumstances at the construction site and equipment/manpower availability will dictate which placement method will be used.

The back-pull/stationary reel method is the usual method of cable placement. The cable is run from the reel up to the strand, pulled by a block that only travels forward and is held aloft by cable blocks. Cable is then cut and expansion loops formed - lashing takes place after the cable is pulled.

are particularly

deformation in

QR cables

resistant to

cable geometry

The drive-off/moving reel method may realize some manpower and time savings in cable placement and lash-up. In it, the cable is attached to the strand and payed-off a reel moving away from it. The cable is lashed as it is being pulled - cuts and expansion loops are made during lashing.

due to their

highly flexible

during

installation

construction

Regardless of the installation method, mechanical stress is of great concern during cable placement. Like other coaxial cables, QR can be damaged by exceeding the maximum allowable pulling tension or the minimum allowable bending radii. Fortunately, QR’s highly flexible construction permits lower than normal pull tensions and tighter bends, almost completely eliminating the chance of cable installation deformation.

Make sure all down guys at corners and dead ends are installed and tensioned prior to cable placement.

3.2 Aerial Installation

Pulling Tension

Pulling tension for CommScope cables are shown in this chart. JCAM cables should be pulled by the messenger, where the maximum pulling tension is limited by its minimum breaking strength. Cables are available with a .109 in (3mm) messenger rated at 1800 lbs (818 kgf), .188 in (5 mm) messenger rated at 3900 lbs (1769 kgf) .250 in (6 mm) messenger rated at 6650 lbs (3022 kgf).

Cable Max. Pulling Tension lbs / kgf

QR 320 120 (54.5)

QR 540 220 (100)

QR 715 340 (154)

QR 860 450 (204)

P3 500 300 (136)

P3 625 475 (216)

P3 750 675 (306)

P3 875 875 (397)

MO500 270 (123)

MO650 360 (164)

MO750 500 (227)

NEVER EXCEED THE MAXIMUM PULLING TENSION.

Excessive forces applied to the cable will cause the cable to permanently elongate. Good construction techniques and proper tension monitoring equipment are essential. The highly flexible nature of QR cable makes it very difficult to exceed the maximum pulling tension.

During cable placement, attention should be given to the number and placement of cable blocks. The amount of sag between the blocks and the amount of bending at the block affects the pulling tension.

Tail loading is the tension in the cable caused by the mass of the cable on the reel and reel brakes. Tail loading is controlled by two methods. It can be minimized by using minimal braking during the pay-off of the cable from the reel - at times, no braking is preferred. Tail loading can also be minimized by rotating the reel in the direction of pay-off.

Break-away swivels should be placed on each cable to ensure that the maximum allowable tension for that specific cable type is not exceeded. The swivel is placed between the cable puller and pulling grip. A break-away swivel is required for each cable.

QR’s flexible

Dynamometers are used to measure the dynamic tension in the cable. These devices allow continuous review of the tension and accordingly a realization can be made of any sudden increase in pulling tension. Sudden increases in pulling tension can be caused by many factors such as a cable falling from a block or a cable binding against pole-line hardware.

construction

means less

pulling effort

is required

Aerial Installation 3.3

Bending Radii

Cables are often routed around corners during cable placement and pulling tension must be increased to apply adequate force to the cable to bend the cable around the corner. Tension is directly related to the flexibility of cable - and flexibility is QR’s greatest strength.

Minimum Cable Bending Radii

in/cm

QR 320 3 (7.6)

QR 540 4 (10.2)

QR 540 armored 6.5 (16.5)

QR 715 5 (12.7)

QR 715 armored 7.5 (19.1)

QR 860 7 (17.8)

QR 860 armored 9.5 (24.1)

P3 500 standard (jacketed) 6.0 (15.2)

P3 500 bonded (jacketed) 3.5 (8.9)

P3 625 standard (jacketed) 7.0 (17.8)

P3 625 bonded (jacketed) 4.5 (11.4)

P3 750 standard (jacketed) 8.0 (20.3)

P3 750 bonded (jacketed) 6.0 (15.2)

P3 875 standard (jacketed) 9.0 (22.9)

P3 875 bonded (jacketed) 7.0 (17.8)

MO500 6.0 (15.2)

MO650 7.0 (17.8)

MO750 8 (20.3)

CommScope’s specified minimum bending radius is the static (unloaded) bending radius of the cable. This is the minimum radius to which the cable can be bent without electrically or mechanically degrading the performance of the cable. Bending the cable in this manner is usually only done during splicing or final forming. This is also the radius allowed for storage purposes.

Always review the specifications for the appropriate bend radii. If you do not exceed the minimum bend radius nor exceed the maximum pulling tension, you should have a successful installation.

The bending radii of cables during the construction process are controlled by construction techniques and equipment. Corner blocks and set-up chutes have large radii and low friction surfaces that minimally contribute to the overall increase in pulling tension.

QR cable’s

shield

construction

permits the

tightest bend

radius in the

industry

3.4 Aerial Installation

Espansion Loops

Expansion Loops

As temperature rises and falls, coaxial cable will expand/contract at almost twice the rate of strand. Expansion loops allow the cable to move to allow for stress caused by thermal changes and strand creep. They are critical to cable life. A typical loop will use no more than an extra 2 - 3 inches (5 - 8 cm) of cable.

Loops are formed using mechanical benders or bender boards. CommScope strongly recommends the

use of mechanical benders for consistently-formed loops.

When to place expansion loops

Loops are formed prior to lashing in the back-pull method and during lashing in the drive-off method. In either case, it is recommended that you keep the bender in place as the cable is being lashed. Remove the bender only after the cable has been lashed to the strand.

QR expansion loops will last

2 - 3 times

longer than

those of

conventional

Where to place expansion loops

Form one expansion loop at each pole, on the input/output of every active device and at every tap. Form two loops at a pole where the span length exceeds 150 feet (45 meters), on street/RR crossings and in spans with little to no midspan sag.

If you are running multiple cables, do not bind them together in the same loop.

An expansion loop is supported on the strand by a strap fitted with a spacer that separates the cable from the strand. The strap should be no more than hand-tightened.

The cable must be permitted to move within the loop or the cable may buckle and fail.

Place the bug nut 4” from the end of the loop and place the spacer and strap on the span side of the loop behind the bug nut. (See diagram.) Note: the end of the loop is at the end of the loop forming tool.

Pole Side

coaxial cable

Span Side

Aerial Installation 3.5

Forming Expansion Loops

Expansion Loops - Forming

Two different sizes of expansion loops are currently used.

For sizes < 625, use a mechanical bender to form a 12-inch flat bottom loop.

This bender produces a minimum 6” (15 cm) deep

43 in (1.1 m)

11 in (28 cm) radii

6 in (15 cm)

loop with a 12” (30 cm) flat bottom.

12 in (30 cm)

For sizes > 700, use a mechanical bender to form a 15-inch flat bottom loop.

This bender produces a minimum 6” (15 cm) deep loop with a 15” (38 cm) flat bottom.

If you are installing smaller cables with the larger sizes, it is recommended that you use the larger loop on all cables.

50 in (1.27 m)

14.8 in (38 cm) radii 6 in (15 cm)

15 in (38 cm)

Forming the Loop

Attach the mechanical bender to the strand at the appropriate location. Place the cable in the bender and form the loop according to the manufacturer’s directions. Carefully inspect the cable for any damage due to misalignment of the bender.

DO NOT REMOVE THE BENDER until after the cable has been lashed at least 50’ (15 meters) or to the next pole, as tensions imposed during lashing may deform the loop. Once the cable is lashed and the lash wire tied off, you may remove the bender. Double lashing is recommended for two or more cables.

Attach straps and spacers. Do not overtighten the straps.

3.6 Aerial Installation

Styles of Expansion Loops

Expansion Loops - Various Configurations

These are several examples of common expansion loop configurations.

Straight pole

Mid-span crossover

Angled pole

Aerial Installation 3.7

Styles of Expansion Loops

Expansion Loops - Various Configurations

These are several examples of common expansion loop configurations.

Double dead-end

Line pole dead-end

3.8 Aerial Installation

Back-Pull/Stationary Reel Set-Up

Installation - Back-Pull/Stationery Reel Set-Up

Set-Up Chute Placement

The set-up chute should be positioned on the first pole of the cable route or attached to the strand at the first pole. Placement of the set-up chute should keep the cable from rubbing on the reel or pole. Either a 45° or 90° corner block may be used as a set-up chute.

Trailer Set-Up

The trailer should be positioned in-line with the strand and twice the distance of the set-up chute to the ground from the chute. This prevents the cable from rubbing on the pole or reel or binding on the chute. If the trailer cannot be positioned there, move the set-up chute and cable trailer to an adjacent pole.

The cable should pay-off the top of the cable reel. The pay-off of the cable from the reel should cause a downward force at the hitch of the trailer.

Chock the trailer wheels. Adjust the reel brakes as needed. Place protective barriers and cones as needed to protect pedestrians.

2 x height of chute

height

of chute

set-up chute

cable blocks are

lifted into place

as the puller

passes

Aerial Installation 3.9

Back-Pull/Stationary Reel Block Placement

Back-Pull/Stationery Reel - Puller Set-Up and Block Placement

Cable Puller Set-Up

Place an appropriate cable grip on each cable. Secure the grip to the cable with tape to keep the cable from backing out of the grip should the pulling tension be relaxed.

Place a breakaway swivel between the pulling grip and the cable puller. An in-line dynamometer may be placed there instead or along with the breakaway swivel.

Place the cable puller on the strand and close the puller gates to secure the puller to the strand.

Attach a pulling line to the cable puller. Pull the cable puller along the strand by hand or by winch (see next page for winching notes). Place cable blocks to support the cable as it is pulled. The cable puller has an internal brake which prevents the cable puller from moving backward on the strand when the pulling tension is released.

Do not overspin the reel - keep the cable wraps tight.

Cable Block/Corner Block Placement

Use a cable block lifter/lay-up stick to place cable blocks on the strand every 30 - 50 feet (9 - 15 meters).

Place corner blocks at all corners greater than 30° in the pole line. NEVER pull cable over the end rollers of corner blocks as they will flatten and deform the cable.

At corners less than 30°, cable blocks can be placed on the strand several feet from and on each side of the pole/line hardware. The cable blocks should allow the cable to move through the corner without undue bending or drag.

+ 51 hidden pages