Horizontal Fiber Optic Splice Closure (FOSC) GJS-X

Detail

1. Scope of application

This Installation Manual suits for the Fiber Optic Splice Closure (Hereafter abbreviated as FOSC), as the guidance of proper installation.

The scope of application is: aerial and wall-mounting. The ambient temperature ranges from -40 to 60℃.

2. Basic structure and configuration

2.1 Dimension and capacity

Outside dimension (LengthxHeightxWidth)	205mm45mm210 mm
Weight (excluding outside box)	1000g
Number of inlet/outlet ports	4 pieces in general
Diameter of fiber cable	Φ6mm—Φ18 mm
Capacity of FOSC	Bunchy: 1—32 (Cores)

2.2 Main components

No.	Name of components	Quantity	Usage	Remarks
1	FOSC cover	1 piece	Protecting fiber cable splices in whole	LengthxHeightxWidth 205mm45mm210 mm
2	Fiber optic splice tray (FOST)	max. 1 pieces (bunchy)	Fixing heat shrinkable protective sleeve and holding fibers	Suitable for: Bunchy:4,6,8(cores)
3	Base	1 set	Fixing internal and external structure
4	Screw	4 set	Fixing between FOSC cover and FOSC base
5	Seal fitting	1 piece	Sealing between FOSC cover and FOSC base

2.3 Main accessories and special tools

No.	Name of accessories	Quantity	Usage	Remarks
1	Heat shrinkable protective sleeve	12 piece	Protecting fiber splices
2	Nylon tie		Fixing fiber with protective coat
3	Installation tape	1 roll	Enlarging diameter of fiber cable for easy fixing
4	Seal tape	1 roll	Enlarging diameter of fiber cable which fits in with seal fitting
5	Dry agent	1 bag	Put into FOSC before sealing for desiccating air
6	Special wrench	1 piece	Fixing octagonal nut
7	Labeling paper	1 piece	Labeling fibers

3. Necessary tools for installation

3.1 Supplementary materials (to be provided by operator)

Name of materials	Usage
Scotch tape	Labeling, temporarily fixing
Ethyl alcohol	Cleaning
Gauze	Cleaning

3.2 Special tools (to be provided by operator)

Name of tools	Usage
Fiber cutter	Cutting off fibers cable
Fiber stripper	Strip off protective coat of fiber cable
Combo tools	Assembling FOSC

3.3 Universal tools (to be provided by operator)

Name of tools	Usage and specification
Band tape	Measuring fiber cable
Pipe cutter	Cutting fiber cable
Electrical cutter	Take off protective coat of fiber cable
Combination pliers	Cutting off reinforced core
Screwdriver	Crossing/Paralleling screwdriver
Scissor	Cutting off reinforced yarns
Waterproof cover	Waterproof, dustproof
Metal wrench	Tightening nut of reinforced core

3.4 Splicing and testing instruments (to be provided by operator)

Name of instruments	Usage and specification
Fusion Splicing Machine	Fiber splicing
OT DR	Splicing testing
Provisional splicing tools	Provisional testing
Fire sprayer	Sealing heat shrinkable fixing sleeve

Notice: The above-mentioned tools and testing instruments should be provided by the operators themselves.

4. Installation flow chart

1. Open the closure

2. Determine length of fiber cable to be fixed and stripped inside FOSC

3. Strip off protective coats of fiber cable and fiber

4. Separate fiber cores and prepare work prior to fixing fiber cable

5. Fix reinforced core and fiber cable

6. Splice fibers

7. Install heat shrinkable protective sleeve and house fibers

8. Check up comprehensively

9. Assemble FOSC housing and fixing FOSC

5. The process of installing FOSC

5.1 Step One - Open the closure

5.1.1 Cleaning the locale and determine where to install the FOSC and then place

fiber cables required.

5.1.2 Check whether the main components and accessories have been well prepared

inside the package.

5.1.3 Open the closure

①Use the special wrench to demount all the locating bolts on the housing as well as fixing bolts at four corners and then succeed in opening closure.

② Pull the FOSC cover upwards out .installation could begin.

5.1.4 See Drawing 1

Important issues: If the weather condition is not good enough, then a tent must be pitched

for waterproof and dustproof.

5.2 Step Two -Determine length of fiber cable to be fixed and stripped inside FOSC

5.2.1 Please refer to Drawing 2 for stripping length.

①. Fiber cable in 60mm length: the distance from seal fitting to fiber cable pressboard

②. Fiber cable in 1950mm length: it is used to be winded and spliced after stripping.

③. Fiber with protective coat in 1350mm length: the distance from the fixing point of fiber cable to the fixing point of FOST (fiber optic splice tray).

④. Fiber in 1600mm length: after stripping off the protective coat, it is to be winded inside the FOST after splicing with other fibers

5.2.2 See Drawing 2

Important issues:

1. Reserve enough length of fiber cable to be spliced.

2. Stripping length also could be decided by customer according to installation requirement.

5.3 Step Three – Strip off fiber protective coat of fiber cable and fiber

5.3.1 Strip off protective coat of fiber cable from the temp. locating mark with the cutter and the

stripper, please refer to Drawing 2 for stripping length. Stripping length also could be

decided according to installation requirement

5.3.2 See Drawing 3.

Important issues: If it is difficult to strip off all the protective coat of fiber cable at one time,

strip it off section by section to avoid fiber breakage.

5.4 Step Four – Separate fiber cores and prepare work prior to fixing fiber cable.

5.4.1 Wind 2 layers of insulation tape on protective coat of fiber core for protection. Meanwhile, get rid of the stuffing to separate fiber and clean them. Form a ring with the diameter of 100mm or so and fix it on the fiber temporarily by adhesive tape.

5.4.2 FOSC-X is provided with 4 inlet/outlet ports ,the inlet/outlet ports cloud be decided to according to diameter of fiber cables to be actully installed .then the corresponding number of ports plugs should be take out.

5.4.3 This FOSC is stuitable for the following diameters of fiber cables respectivly

Port A :stuitable for fiber cable with max :diameter 18MM

Port B :stuitable for fiber cable with max :diameter 6MM

5.4.4 The corresponding inlet/outlet ports are to be selected according to fiber cables actully installed .when the diameter of fiber cable is smaller then that of the inlet/outlet ports .then the seal tape shuold be used enlarge the diameter of fiber cable.of which the perimeter could be measured by the corresponding measuring paper.

5.4.5 Reserve reinforced core in 35mm length and cut off the unnecessary ones.

5.4.6 See Drawing 4

Important Issues: 1.Before the seal tape is used for enlarging the fiber cable diameter,it shuold be scratched and to be cleaned with abrasive cloth ethyl alcohol.

2.Cut off reinforced core with a special cutting plier.

5.5 Step Five - Fix reinforced core and fiber cable

5.5.1 UP finishing the above steps ,then demount port plugs,pressboard and fixing out of reinforced core.Make sure whether the fiber cable stripped fits in with the fixing ports or not.if not adjustment should be done in time .Otherwise it will affect installation quality.

5.5.2 tighten fiber cable pressboart.diameter of fiber cable is small.then enlarge it with insulation tape.

5.5.3 tighten out of reinforced core with the special wrench (plastic) and then retighten it with metal wrench(the metal wrench shuold be provided operator)

5.5.4 See Drawing 5

Important Issues: 1.fixing out of einforced core should be tightened

2.while heating.heat shrinkable fix tube shuold shrik evenly .and there should be no bubbles .pores and other defects inside the tube.

5.6 Step Six - Splice fibers

5.6.1 Follow user manual of fusion splicing machine to splice fiber.

Important issue: pay attention to the twist and bend of fiber.

5.7 Step Seven -Install heat shrinkable protective sleeve and house fibers

5.7.1 When having completed splicing the fibers, the first fiber ring should be housed on the farthest side of FOST, the remaining fiber should be winded, forming a ring with diameter not less than 80mm. then put it into FOST (Fiber Optic Splice Tray) together with heat shrinkable protective sleeve.( Firstly fix heat shrinkable protective sleeve into the slot, then enlarge the diameter of fiber ring properly.)

Important issue :pay attention to the twist and bend of fiber.

5.8 Step Eight - Check up comprehensively

To ensure the technical requirements, the following instructions must be followed:

5.8.1 The fibers in the FOST are spliced and installed orderly. The curved diameter of fiber meets with the technical requirements.

5.8.2 The inlet/outlet ports without fiber cables installed must be blocked up with the port plugs.

5.8.3 Fibers with protective coat are fixed with nylon ta the entrance of FOST.

5.8.4 The inlet/outlet ports without fiber cables installed must be blocked up with the port plugs.

5.8.5Control the amount of seal tape within a proper range.

5.8.6 Seal fitting is installed neatly and smoothly. If not, level it up with seal tape.

Important issue : If any problems occur, they should be solved right away

5.9 Step Nine – Assemble FOSC housing

5.9.1 Put the FOSC cover on the FOSC bottom directly.

5.9.2 Insert locating bolt of FOSC and tighten it with the special wrench.

Important issues: cleaning the housing and pay attention to the above sequence.

6. Fiber Optic Splice Closures (FOSC) inspecting and testing items

Inspecting item	Technical Requirements	Inspecting type
Inspecting item	Technical Requirements	Routine test (Before leaving factory)	Type test
Package	Each small package contains one fiber optic splice closure, together with its accessories, tools, installation manual and packing list.	full	At least 3 sets sampled each time
Appearance	Intact in shape, no burrs, bubbles, chaps, pores, warps, impurities and other defects, all background colors should be even and continual.
Sign	There is a clear sign on the housing, such as name and model of the product, etc.
Fiber storage device	The fibers reserved are to be winded in fiber optic splice tray (FOST), the length of fibers housed in FOST is >1.6m, the curved radius is >30mm. During the installation and maintenance, there should be no attenuation on fibers.	At least 3 sets sampled each time
Electrical jointing device	Inside FOSC: metallic components of fiber cables has the functions of electrical putting through, earthing connection and disconnecting. It is possible to install earthing deriving device outside the housing
Sealing performance	After sealing according to the stipulated operation procedures, the injected air pressure is 100KPa±5Kpa, when immersed in clean water of normal temperature for 15 minutes, there should be no air bubbles, then observed for 24 hours, there should be no change of air pressure.
Re-sealing performance	After reopening and resealing according to the stipulated operation procedures, the injected air pressure is 100KPa±5Kpa, when immersed in clean water of normal temperature for 15 minutes, there should be no air bubbles, then observed for 24 hours, there should be no change of air pressure.
Pull	Bearing pull is ≧ 800N at axle orientation, there should be no breakage on the housing.
Punching	Bearing pressure of 2000N/10cm for 1 minutes, there should be no breakage on the housing
Impact	Bearing impact energy of 16N•m, 3 times of impacts there should be not breakage on the housing
Bending	The spot between the FOSC and seal fitting can bear bending tension of 150N at bending angle of ±45⁰ for 10 circles, there should be no breakage on the housing	At least 3 sets sampled each time	At least 3 sets sampled each time
Torsion	Bearing torsion 50N•m, 10 circle at torsion angle±90^0, There should be no breakage on the housing.
Temperature circle	Injected air pressure of 60KPa±5 KPa, the temperature circle ranging from -40℃~+65℃, 10 times of the circular tests (one circular consists of high temperature for 2 hours + indoor temperature for 2 hours + low temperature for 2 hours + indoor temperature for 2 hours ) when the pressure declines, the amplitude is ≦5Kpa, immerse the swatch in clean water of normal temperature for 15 minutes, there should be no air bubbles.
Voltage resistance strength	After sealing the FOSC according to the stipulated operation procedures, immerse it in clean water of normal temperature in 1.5m depth for 24 hours, there should be no breakdown or arc over between the metallic components of the FOSC, between metallic components and the ground at DC 15KV for 1 minutes.
Isolating resistance	After sealing the FOSC according to stipulated operation procedure, immerse it in clean water in 1.5m depth for 24h, the isolating resistance between the metallic components of the FOSC, between the metallic components and the ground should be ≧ 2×10⁴MΩ.

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