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Installation of RFS FLEXWELL速 waveguides

Installation of Waveguides Part 1 of 3

P1-1 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Introduction Fredy Ahlenstorf

Technical Consulting European Sales & Customer Service Radio Frequency Systems GmbH Kabelkamp 20, 30179 Hannover (Germany) Phone: +49 (0)511 676 2418 Fax: +49 (0)511 676 2471 E-mail: Fredy.Ahlenstorf@RFSWorld.com

Do you need support?

Sales:

Your Sales Partner are pleased to help you. P1-2

The Technical Consulting Group of RFS will support him RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Information of RFS products Visit us via internet

www.rfsworld.com

P1-3 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Contents

P1-4

-

Construction & Mechanical features of RFS waveguides

-

Clamps & Fixing accessories Handling & shipment of drums Cutting & bending of waveguides Hoisting procedure Installation of connectors Accessories Earthing measures Wall glands Dehydration concepts Installation examples RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Construction & Properties of RFS FLEXWELL® waveguides • Construction - elliptical corrugated copper tube - black polyethylene jacket • Properties - excellent bending characteristics even at –20°C low weight

- high transversal stability P1-5 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Mechanical features of RFS FLEXWELL® waveguides Before starting installation note the datasheets

-

Minimum bending radius without rebending E plane H plane and with rebending

P1-6

-

Maximum pulling length per hoisting grip

-

Recommend clamp spacing at normal areas and critical areas

& the recommended minimum lengths of Overmoded waveguides RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Mechanical features of RFS FLEXWELL® waveguides Size of waveguide E 20 E 30 E 38 E 46 ES 46 EP 58 Minimum Bending Radius without rebending (single bending)

E 60

E 65 EP 70

E 78 EP 100 E 105 E 130 E 150 E 185 E 220 E 250 E 380

E Plane mm (in)

600 (24)

550 (22)

300 (12)

280 (11)

150 (6)

250 (10)

200 (8)

200 (8)

200 (8)

200 (8)

150 (6)

130 (5)

130 (5)

130 (5)

130 (5)

110 (4)

90 (4)

80 (3)

H Plane mm (in)

1800 (71)

1500 (59)

800 (31)

700 (28)

500 (20)

600 (24)

550 (22)

500 (20)

500 (20)

500 (20)

350 (14)

280 (11)

280 (11)

280 (11)

280 (11)

230 (9)

150 (6)

140 (6)

Minimum Bending Radius with rebending (multible bending)

P1-7

E Plane mm (in)

800 (31)

700 (28)

400 (16)

380 (15)

150 (6)

350 (14)

300 (12)

300 (12)

300 (12)

250 (10)

200 (8)

150 (6)

150 (6)

150 (6)

130 (5)

130 (5)

100 (4)

90 (3)

H Plane mm (in)

2400 (94)

2000 (79)

1000 (39)

850 (33)

600 (24)

800 (31)

800 (32)

600 (24)

600 (24)

600 (24)

400 (16)

300 (12)

300 (12)

300 (12)

300 (12)

250 (10)

180 (7)

150 (6)

50 (164)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

50 (164)

50 (164)

2,0 (6,7)

2,0 (6,7)

1,2 (4,0)

1,2 (4,0)

1,2 (4,0)

0,9 (3,0)

0,9 (3,0)

0,9 3,0

0,9 (3,0)

0,9 (3,0)

0,6 (2,0)

0,6 (2,0)

0,6 (2,0)

0,6 (2,0)

0,6 (2,0)

0,6 (2,0)

0,5 (1,8)

0,3 (1,0)

1,0 (3,3)

1,0 (3,3)

0,8 (2,7)

0,8 (2,7)

0,8 (2,7)

0,5 (1,8)

0,5 (1,8)

0,5 (1,8)

0,5 (1,8)

0,5 (1,8)

0,4 (1,4)

0,4 (1,4)

0,4 (1,4)

0,4 (1,4)

0,4 (1,4)

0,4 (1,4)

0,3 (1,0)

0,2 (0,8)

Max. Pulling lenght per hoisting grip, m (ft) Recommended clamp spacing normal areas m (ft) Recommended clamp spacing critical areas m (ft)

RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Mechanical features of RFS FLEXWELL® waveguides Size of waveguide EO 11 EO 15 EO 19 EO 22 Minimum Bending Radius without rebending (single bending)

Features of overmoded waveguides

P1-8

EO 38

E Plane mm (in)

400 (16)

300 (12)

200 (8)

200 (8)

lower freq. range 80 (3) upper freq. range 150 (6)

H Plane mm (in)

900 (35)

600 (24)

400 (16)

400 (16)

lower freq. range 150 (6) upper freq. range 300 (12)

Minimum Bending Radius with rebending (multible bending) E Plane mm (in)

400 (16)

300 (12)

200 (8)

200 (8)

lower freq. range 80 (3) upper freq. range 150 (6)

H Plane mm (in)

900 (35)

600 (24)

400 (16)

400 (16)

lower freq. range 150 (6) upper freq. range 300 (12)

100 (305)

100 (305)

100 (305)

100 (305)

100 (305)

0,9 (3,0)

0,9 (3,0)

0,6 (2,0)

0,6 (2,0)

0,6 (2,0)

0,5 (1,8)

0,5 (1,8)

0,4 (1,4)

0,4 (1,4)

0,4 (1,4)

35 (115)

20 (66)

15 (50)

10 (33)

5 (16)

Max. Pulling lenght per hoisting grip, m (ft) Recommended clamp spacing normal areas m (ft) Recommended clamp spacing critical areas m (ft) Recommended minimum lenght, m (ft)

RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Universal – clamp for E 20 & E 30

Model Number of Clamps inclusive fixing hardware & clamp lining

P1-9

E 20

E 30

Fixing Hardware (Kit of 10)

on angle iron 50mm

5000 60 41

5000 60 45

on angle iron 80mm

5000 60 42

5000 60 46

on flat iron 15mm

5000 60 44

5000 60 48

on anchor bar

5000 60 43

5000 60 47

Dimension in mm

length

215

185

80

80

height

180

150

diameter

150

120

wide

lengt h

RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Universal clamp with lining for E 38 up to 220

P1-10

Model Numbers: CLAMP-R-

***

RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Dimension of Universal clamp

für Hohlleiter for waveguide

P1-11

Abmessungen / Dimension in a b c

E 38 - ES 46

100

50

125

E 58 - E 70

62

50

80

EO 15 - EO 19

50

50

75

E 130 - E 220

37

50

60 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - fixing hardware for Universal clamp

for 18 to 22 mm slot anchor bar Art. No. 153 200 13

P1-12

Cleat with screw M 8x10 for fixing on flat, angle & U-iron Model number MKD-001, Art. No. 153 904 04 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - fixing hardware for Universal - clamp

for angle iron up to 50 mm

for angle iron up to 80 mm

for flat iron up to 15 mm

P1-13 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - RSB - Clip with lining

Available for: P1-14

EP 100, E 105, E 130, E 150, E 185, E 220, E 250, E 380, EO 19 (old name 108/19), EO 22 (old name 125/22) RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - RSB - clip / components

Direct Wall installation

Round member

Angle or flat member

C - rail

Tube

P1-15 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - RSB - Clip / Rucksack option For E 100 – E 150

For E 185 – E 380

P1-16 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Fix waveguides in critical areas

Fix the waveguides and Twist Flex especially in critical areas !

Installation clamp with long screw and RSB - clip

Straptite with long screw and RSB - clip

P1-17

Attachment with round member adapter kit RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Connecting Hardware for Flex/Twist

Available for R 70 to R 320

Possible fixing options P1-18 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Pipe components

6 1. 2. 3. 4. 5. 6. 7. P1-19

fixing clamp for pipe 1“ 158 910 76 fixing plate for pipe 1“ 158 910 91 support pipe 1“ 158 910 80 cross connection 158 910 81 fixing support for clamp 158 910 78 angle for support 158 910 77 cap for pipe 158 910 79

5

3

7 4 2

1 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Fixing with 1” pipes

P1-20

High stability fixing components with a lot of variety to be fixed on different places

RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - Wall & ceiling bracket

Cap for bracket bracket (hot dip galvanized / L = 1,0m) P1-21 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - special solutions – wall & ceiling bracket on cable trays

P1-22 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - special solutions – second cable way on towers

P1-23 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Fixing accessories - special solutions – clamps taken down

P1-24

In this position only! RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - special solutions – cable way on round tower constructions

C-rail (anchor bar) on round tower construction fixed with clamps or U-bolds

P1-25

If several clamps have to be install, the installation of anchor bar (or angle iron) saves both time and money. RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Fixing accessories - special solutions – hardware for round tower constructions 8 – 25 mm

P1-26

20 – 40 mm

Hardware for installation in vertical and horizontal runs, usable for different clamps RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Cable handling - Shipping of the waveguide

Drums packed on pallets with only reduced protection Drums packed on pallets protected by wooden lagging

P1-27

Short lengths of waveguides are shipped in crates or cartons RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Cable handling - Shipment of drums

P1-28

The drum has to be secured carefully during transport ! RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Cable handling - Lift up the drum

P1-29

If fork lifts are used, the forks must be long enough to engage both flanges of the drum to avoid waveguide damage!

If a crane is used a special hanger is necessary to avoid damage of the drum flanges RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Cable handling - Transport of the drum on site

Do not lay the drum on its side! P1-30

Reels must be transported and handled in its up – right position only!

We recommend to use a cable drum trailer.

RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELLÂŽ waveguides

• Cable handling

Turning direction

- Handling of the drum

Do not remove the wooden planks before the drum is in position

After carefully unlagging secure the drum.

P1-31

Note the safety aspects ! RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Cable handling - Cut the waveguide

For provisionally cuttings we recommend to use a cable trim to cut the cable. It produces nearly no copper chips during cutting.

Keep the cutting area down, in order to avoid dirt or copper shavings P1-32

falling into the waveguide !

In this case the deformed cable is doesn't matter RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Cable handling - Cut and clean the waveguide Deburr inner conductor

Keep the cutting area down

Remove all particles & dirt

Knocking

- from the button side

Clean

P1-33

Remove all copper chips

Metallic Metallic particle particle RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Cable handling - Sealing of waveguide ends Seal the ends of the waveguide ! We recommend to use heat shrink caps for sealing. Rough up the cable jacket with emery cloth (280 grain). Remove emery remnants with clean cloth and clean this area of shrinking with cable cleaner.

P1-34

Shrink the sleeve with a soft yellow flame by evenly applying a constant flame with a circular motion, beginning on the end. RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Cable handling - Bending the waveguide

Pull carefully bit by bit

While pressing slide your hand

r

Note the minimum bending radius ! P1-35 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Cable handling - Bending the waveguide with bending tool kit

P1-36 RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL® waveguides

• Waveguide handling - Change the plane

P1-37

Do not twist the waveguide ! Changing of plane is possible by bending only two bows . RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Waveguide handling - Connection to the antenna

P1-38

We do not recommend to connect the waveguide directly to the antenna. A longer waveguide run with bows allows easier alignment. RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Cable handling - Devices for hoisting the waveguide

Pipe rollers

Hoisting grip

P1-39

Cable angle roller

Cable drum trailer

Cable drum hydraulic jacks RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELLÂŽ waveguides

• Hoisting of waveguides - Hoisting grip types

Hoisting grip closed type This hoisting grip are to be used only for waveguides without mounted connector.

Hoisting grip open type This type can be used as well for waveguides with mounted connector.

P1-40 RFS /HSR/ ah / 2003-4


Per ulteriori Info: SITEL s.r.l. Via Della Chimica, 12 20867 Caponago (MB) Tel. +39 02 95743609 Fax +39 02 95740631 info@sitel.it

Installation of RFS FLEXWELL® waveguides

• Hoisting of waveguides

4

- Installation of hoisting grip – open type

P1-41

1.

Place the hoisting around the waveguide, whereby the end with the connector shall be long enough to make the connection to the antenna without opening the hoisting grip. Both ends with the two enclosed flexible wire strands are to be inserted in the two topmost net loops and then crosswise in the lower net loops and so up to the end (shoe close style) The meshes of the crossed wire strands shall not be smaller than the existing meshes of the hoisting stocking

2.

The two strand ends are to be knotted or clamped and to be secured in the net loops. It is recommended to fix the end of the hoisting grip with tape.

3.

Protect the waveguide area were the hoisting rope will be fixed to the hoisting grip for example with the safety cloth, wool etc.

4.

Clamp the hoisting rope with clamps to the hoisting grip or hang in a hook.

3

1

2

Note: The maximum hoisting length per hoisting grip! RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELLÂŽ waveguides

• Hoisting the waveguide

Connector with safety cloth, wool or clamp lining

- Hoisting procedure 1.

Protect the connector end from objects impending its way.

2.

If the distance to the connector (worker 1) is to long, he will protect the hoisting grip from objects blocking its way.

3.

If add. hoisting grips are necessary they have to protect also.

4.

Observe and maintain - declare 4 the drum turn.

5.

P1-42

Important Person ! Observe this place - pull the cable and bend this bow manually.

1 Hoisting grip Fixed by tape

2 Protect the fixing area with safety cloth, wool or clamp linings !

The waveguide is slack above this hoisting grip The rope is tensioned!

3

Additional hoisting grip

5

Do not remove the hoisting grip before all clamps are closed !

RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELLÂŽ waveguides

• Waveguide laying - Horizontal runs Horizontal runs must be protected against the weight of accumulated ice and damage through falling ice or other objects. If the waveguide will be pulled on the ground, we recommend to use pipe rollers to avoid any damaged of cable jacket.

P1-43

Even if it is necessary to drag the cable over sharp edges of buildings and tower members, protective measures must be taken (e.g. with wooden planks or observed by an installer). RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELLÂŽ waveguides

• Waveguide laying - Pulling the waveguide in horizontal hollow tubes The diameter of the hollow tube (or underground cable duct) shall be at least twice the waveguide diameter (e.g. min. 100mm for E 70). The bending radii for tubes installation shall be at least twice the minimum bending radius (for multiple bending) of the respective waveguide (see data sheet). Inter- connections of several tubes must not damage the cable during pulling/pushing the cable. - Avoid any risk of blocking. Avoid sharp edges during pulling the waveguide. Pulling of waveguide can be supported by an additional layer of grease on the waveguide jacket.

P1-44

If the waveguide will be pulled with a winch, we recommend to use a measuring device to make sure the max. tensile force (see data sheet) will not be exceeded. RFS /HSR/ ah / 2003-4


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Installation of RFS FLEXWELL速 waveguides

P1-45 RFS /HSR/ ah / 2003-4


Installation of waveguide 2003 - 4 JPart 1