Molex Connected Enterprise Solutions

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Molex ConnectedEnterprise SolutionsOnsite Installation and Testing Pocket GuideVersion 1.4 November 2020

Structured cabling architectures anddesign considerations4Recommended component placement 20Open office cabling6Maximum pair un-twist for twisted-paircable termination21EuroClasses6Modular Plug Terminated Link (MPTL) 21Installation best practices - copper 7ANSI/TIA 568.2-D and AS/NZS 11801.1link models - Modular Plug TerminatedLink21De-rating factors as per ANSI/TIA568.2-D74-pair color standard7Termination sequence - standard RJ458Cabling under false floor8Cabling in a suspended ceiling area8Basket or tray above suspended ceiling 9Cabling in floor void9Surface trunking10Containment types10Cable tray11Heat dissipation of pathways12Installation of patch panels12Patch panel presentation12Installing horizontal cables13Cabling support13Containment - loose cables13Installing in conduits13Pulling boxes for horizontal cables14Containment fill15Installing in pathways15Areas above ceilings15Access floor systems15Protection from damage16Protection from damage / painted cable16Power source separation16Recommended separation from powerwiring16Copper cable handling - bend radius &pull tension17Reels and boxes18Cable entry and exit19Cable installation19Fire stopping19Rack and cabinet layout20PowerCat 6 and PowerCat 6aterminations23PowerCat 6a - DataGate cable entryoptions244-Pair termination tool features25DataGate Jack terminations - toolpreparation - 110 type punch downtermination26DataGate Jack 4-pair termination tool 25UTP Category 6a cable preparation &jack termination - option #1 P/N KSJ00091-xx27U/UTP Category 6a cable preparation andjack termination: option #2A - KeystoneJack P/N KSJ-0008828U/UTP Category 6a cable preparation andjack termination: option #2B - DataGateJack P/N KSJ-00062-0x29U/FTP cable preparation30F/UTP cable preparation31U/UTP termination with 110 tool / punchdown wires32Termination with the Molex 4-pair tool lacing the IDC34Termination with the Molex 4-pair tool maintenance35Field testers and testing - copper36Copper testing - Modular PlugTerminated Link39How to test the new Modular PlugTerminated Link39Nominal Velocity of Propagation (NVP) 37

Installation best practices - fiberopticCable types4040Fiber optic termination - Pigtail splicing41Fiber optic termination - preconnectorized cables41Fiber optic termination - ModLink plugand play fiber optic solution42Fiber optic termination - direct fieldtermination42Fiber optic termination - direct fieldtermination: Xpress G2 OM3-LCconnector example43Cleaning a fiber optic45Field testers and testing - fiber optic48TSB-4979 / Encircled Flux (EF) conditionsfor multimode fiber testing49Comparing measured results against adesign Link Loss Budget52Standards approach against a MPO/MPTdesign Link Loss Budget52Molex custom approach against a MPO/MPT design Link Loss Budget53Standards approach53Fiber testing54Permanent Link test settings for fibertesting54Key take aways55Optical test- report checklist55Requirements for Warranties56Preface56Requirements per Warranty561) Warranty type: 25 Year SystemPerformance & Application AssuranceWarranty572) Warranty type: 25 Year Product OnlyWarranty59A note regarding Consolidation Point (CP)Testing61When processing Warranty Applications,Molex Connected Enterprise Solutionswill:62List of approved test equipment64Copper64Fiber optic64Important reminders66

Structured cabling architecturesand design considerationsThere are two basic architecturesfor structured cabling systems –Crossconnect and Interconnect.In a Crossconnect architecture, anadditional connection point is addedbetween the horizontal panel and theactive equipment, usually a switch.Often known as the equipment panel orequipment connection point. The switchis then hard wired to the equipmentpanel, then all moves and changes areperformed between the horizontal paneland the equipment panel.CrossconnectarchitectureEquipmentEquipment Patch PanelHorizontal CableCPInterconnectarchitectureHorizontal Patch PanelEquipmentModular Patch PanelHorizontal CableCPThe following illustration shows the same as the above, but using 110 connection blocks. PDSsolutions are usually wall mounted. Active equipment is housed in a freestanding cabinet/rack.Equipment cables from cabinet to wall mounted system side blocks deliver active services forCrossconnect to horizontal side blocks.CrossconnectarchitectureEquipmentEquipment Patch PanelHorizontal CableCPHorizontal Patch PanelInterconnectarchitectureEquipmentEquipment Patch PanelHorizontal CableHorizontal Patch Panel4Onsite installation and testing pocket guideCP

In an Interconnect environment, thepatch cord between the equipment(usually a switch) and the patch panelwill be stranded cable and will match theperformance level of the infrastructure.The horizontal cable between the patchpanel and the work area outlet will havesolid conductors. The patch cord betweenthe work area outlet and the device at adesktop will have stranded conductors,and should also match the performancelevel of the infrastructure.In a Crossconnect environment, the linkbetween the equipment and the patchpanel will be solid core cable assemblies.The link between the equipment patchpanel and the horizontal patch panelwill have stranded patch cords. Thehorizontal cable between the patch paneland the work area outlet will have solidconductors and the patch cord betweenthe work area outlet and the device at adesktop will have stranded conductor.Switch/equipment to patch panel Use solid conductor in this cableassembly Use stranded conductor in patch/equipment cord for routing flexibilityPatch panel to work area outlet Use solid conductor cable in thepermanent linkWork area outlet to deviceSwitch/equipment to patch panelSwitch/equipment patch panel tohorizontal patch panel Use stranded conductor in patch/equipment cord for routing flexibility Use stranded conductor in patch cordfor routing flexibilityHorizontal patch panel to work areaoutlet Use solid conductor cable in thepermanent linkWork area outlet to device Use stranded conductor in patch cordfor routing edStrandedModular Patch PanelHorizontal CableSolidCPCross connectarchitectureEquipmentSolidEquipment Patch PanelStrandedStrandedHorizontal CableSolidCPHorizontal Patch PanelOnsite installation and testing pocket guide5

Open office cablingOpen office cabling was designed tosolve a practical problem rather than atechnical one. There are two solutionson open offices, a MUTO, Multi-UserTelecommunications Outlet (or MUTOA,Multi-User Telecommunications OutletAssembly), which can accommodate up to12 users in one central connection point.It is often used in locations core centerswhere teams are located together.The other is Consolidation Pointarchitecture. These are often used wherethe cabling infrastructure needs to bechanged a lot. This is a portion ofcabling from the TR to the CP that isEuroClasspermanent and never moved. The portionfrom the CP to the outlet is moved manytimes. This is often used in developmentlabs where the benches are often moveddepending on the location where theproject is being worked on.EuroClassesFrom 1st July 2017 all data andtelecommunications cable must beranked in terms of its reaction to fireperformance, by its EuroClass.There are seven EuroClasses for flamespread and heat release as shown in thetable below.Reaction to Fire StandardsAdditional ParametersSmokeproductionAcaB1caB2caCcaGross heat of combustion EN ISO 1716Heat Release EN 50399Flame spread EN 50399 andEN 60332-1-2DcaHeat Release EN 50399Flame spread EN 50399 and EN 60332-1-2EcaFlame spread EN 60332-1-2Fca6Onsite installation and testing pocket guideFlamingdropletsAcidityNones1a, s1b,d0, d1, d2a1, a2, a3s2, s3EN 50399EN 50399EN 50399EN 60754-2 EN 60754-2EN 61034-2NoneNone

Installations best practices - copperThe colors and associated pairs areshown below:De-rating factors as perANSI/TIA 568.2-DCopper cable performance is affecteddue to heat which changes the resistanceof the copper. ANSI/TIA-568.2-D hasprovided Table I.2 below outlining the derating requirements for both screen andunscreened cables. As can be seen,screened cables have a lower de-ratingfactor and will perform better in hotterenvironments. ISO/IEC 11801.1 alsolists de-rating requirements in Table 84 Backbone link length equations.4-Pair color standardThe wires within a cable are all colorcoded in pairs. These pairs were namedtip and ring with one predominatelycolored, whilst the other ispredominately white. Other combinationsof the color markings can include thewhite ring conductor having a coloredstrip to match the tip conductor color,or each the tip and ring conductorshave a color strip their paired cabled. Pairs are color-coded Each pair has a Tip conductor andRing conductor Pair 1 is designated T1 & R1, or A & B,or & Cables conform to the following colorstandard: T1 White Blue and R1 Blue T2 White Orange and R2 Orange T3 White Green and R3 Green T4 White Brown and R4 ntal Screened (Unscreened) (Screened)Length (M) Length (M)Cable Length (M)Temperature C ( F)MaximumHorizontal UnscreenedCable Length (M)20 (68) (77) (86) (95)85.587.74.52.340 (104) (113)81.786.58.33.550 (122)79.585.510.54.555 (131)77.284.712.85.360 (140) 568.2-D Table I.2 – Maximum horizontal screened cable length de-rating factor for different temperatures (ANSI/TIA 568.2-D). Note: This table assumes that the channel includes 10meters of Patch and Equipment cords at 20 C. .Onsite installation and testing pocket guide7

De-RatingDe-RatingMaximumHorizontal Screened (Unscreened) (Screened)Length (M) Length (M)Cable Length (M)Temperature C ( F)MaximumHorizontal UnscreenedCable Length (M)20 (68) (77)87.588.72.21.330 (86)86.488.23.61.835 (95)84.687.35.42.740 (104)82.886.47.23.645 (113)76.585.513.54.550 (122)73.884.616.25.455 (131)71.183.718.96.360 (140)68.482.821.67.2Derating as per ISO/IEC 11801-1. Maximum horizontal screened cable length de-rating factor fordifferent temperatures. Note: This table assumes that the channel includes 10 meters of Patchand Equipment cords at 20 C. .Termination sequence –standard RJ45Shown on the next page are thetwo globally accepted terminationsequences 568A and 568B. Essentiallyboth sequences are the same with theexception being pairs 2 and 3 (orangeand green) are transposed. There is noperformance difference between the twosequences.Cabling under false floorRunning cables under a false floor hasbecome common place in new buildings,where the floor system has been designedas part of the building. This allows fora more flexible cabling system, accesspost installations are easier, and fewerservices run under the floor. It is oftena dedicated area for cabling. However,the disadvantages are that it is initiallymore expensive, the noise of people’smovement is increased, and is betterif installed and designed during thebuilding’s construction, as the floors canbe level.Advantages Clean Easy access (no ladder as with ceilinginstallation)8Onsite installation and testing pocket guide Available space is greaterDisadvantages Expensive (false floor) Ambient noise increases Needs to be considered at design stageto have floors levelCabling in suspendedceiling areaCables in trays and supported cablingon catenaries, should be laid in randomorder, but kept neat. This assists in themitigation of Alien Crosstalk. Cablesshould be secured to the containmentat every change of direction, andthe supported weight of the chosencontainment must be considered. Donot lay cables directly onto the ceilingsupport system, cabling should alwayshave a dedicated pathway. Most common and cost-effectivepathways for running cable Cable must be supported at everychange of direction Do not lay cables directly onto theceiling support system as cablingshould have a dedicated pathway Support cabling by using cable trays orcatenary cables

568BInternationalISDN standardMost widelyspecifiedPairs 1 and 2USOC compatibleAlso calledT258 or 258A Do not over-fill catenaries or supportstands Maximum of 24 cables per catenarystrandBasket or tray abovesuspended ceilingThe diagram below shows cables run ona basket, or tray. Do not overfill the cabletray, and ensure the cable is supported asit comes off the tray. Make sure there areno sharp edges, which could damage thecable sheath. Any cables with damagedsheaths should be replaced, as exposingthe pairs massively reduces the potentialperformance, and is more susceptible toexternal influences such as EMI or AlienCrosstalk (ANEXT).Cabling in floor voidThe diagram on the next page showscables run on a cable tray or basketunder a false floor. The cables should besecured at every change of direction. It isadvisable to protect the cables servicingspecific floor boxes from damage, andflexible conduit is an ideal solution forthis. If flexible conduit is not used, thecables should be secured to the floor.The cables are depicted on matting, andsit on a dedicated pathway, marked onthe concrete floor, the cables can beloose laid, but should be secured at everychange of direction.Using floor boxes or GOP boxes, it iscrucial to protect the cables enteringthe floor box from damage. It is notMain run of cables on tray, basket, or trunking(bundling not required)Cablingbetweenmain runand dropsupportSupportcablingbetweenmain runand dropTrunking dropto outletTrunkingdrop tooutletMain run cable bundles to cable tray, basketor trunking within suspended ceiling voidConduitdrop tooutletOnsite installation and testing pocket guide9

Spur cabling to floorbox bundledand tied at 500mm centersFloorbox with cableaccess grommetedSpur cabling securedto slab at main runFloorbox withcable accessgrommetMain run cablebundles laid directly toclean slab and securedSpur cablingto floorboxbundled andsecuredMain run cablebundles laiddirectly to slabDisadvantages Space is at a premium Shared with power cablesacceptable to have the bare metal fromthe knockout exposed. There shouldalways be a rubber grommet or a gland.Where an outlet is to be located inthe ceiling space or under a floor forconnection to building devices, likeWAPs, the outlets need to be securelyfixed in position.Surface trunkingSurface trunking offers some keyadvantages over the other two options.Less pre-design thought needs to go intothe building, outlets can be anywherearound the perimeter of a room, outletscan be at desk level for easy access,and there are many shapes and sizesavailable. The disadvantages are thatspace is at a premium, and the samecontainment is often used for power.So, the length of cable that can be runin unshielded conduit is limited.Advantages Easier to retrofit into a building Outlets can be at desk level Less pre-design required Many options available Reasonably cost effective10Onsite installation and testing pocket guideTwo compartment trunking is better than3 compartments, but 3 compartmentsare still more common. This is becauseof legacy designs. It is important wheninstalling surface trunking to consider thebend radii limitations of the cable beinginstalled and use the correct hardwareto limit how tight the cables can bebent inside the trunking. You must usecontainment that is deep enough to limitdamage and crimping. This is especiallyimportant when installing Cat 6a cables.Containment typesThere are many options for containingcables on a cable run. The purpose ofthe containment is to give cabling adedicated marked pathway, which can bedocumented.Cable pathways should always runparallel or perpendicular to walls.Baskets are a commonly used form ofcontainment in both ceiling voids, andunder floors, to mark a pathway fromcabling and offers a level of protection.Cable trays are similar to baskets interms of the way they are installed, andwhere it can be used, however it can offermore protection especially when a lid isused.It is important to consult themanufacturer for weight limits of basketsystems. Metal cable baskets should

always be grounded. When installing in aceiling void allow 200mm (8in) clearanceabove the tray, as per ANSI/TIA-569-Estandard. Under raised floors allow50mm (2in) clearance above the side ofthe basket. When using basket as a pathway,always consult manufacturer’sspecifications for installationrequirements and load capacity Metal support systems must alwaysbe bonded together and grounded When installing metal basket trays inthe ceiling void, allow 200mm (8in)*clearance above the tray. In the USthere should be 18 inches of clearancebelow a sprinkler head Under raised flooring, allow 50mm (2in)clearance above the basket/tray siderails Allow additional space if tray has a lidfor removal and re-installation Note: Metallic pathways under 1m(3 ft.) in length (e.g., wall and floorsleeves, J-hooks) are not required to bebonded* As per the latest ANSI/TIA-569-E,the minimum access headroom abovecable trays is reduced from 300 mm(12 in) to 200 mm (8 in).The photo above shows infrastructurecabling that is supported at the changeof direction, and there is protectionwhen the cables go from horizontal tovertical. There are no sharp edges. Thecables once installed will be supportedvertically.The cables supported vertically should besecured every 500mm (20in) on basket ortray, and every 1,500mm (60in) in closedcontainment. The cables should alwaysbe free from any tension.Cable trayLaying cables in a tray or basket is agreat way of defining cable routes andprotecting cables in ceiling voids, orunder false floors. The cables should berun in bundles and secured to the tray orbasket. The height of the bundles as laidin the containment should not exceed theheight of the container, and should not beOnsite installation and testing pocket guide11

stacked higher than the cable tray or thebasket’s side rail. It is better if you canseparate fiber cables from copper cables. Contact area between cables andpathways Start laying cables to the side ofthe tray Installation factors Ability to control number of cables Design factors Separate fiber from copperAs per Standards, the followingexamples are mandated by Molexfor Type 3/ Class 5 & above PoEapplications. Tie fiber to underside of tray if practicalAs per international cablingStandards, cable bundles mustnot contain more than 24cables. This is a requirementfor the Molex 25-Year SystemPerformance and ApplicationAssurance warranty, ifIEEE802.3bt Type 3 and above isto be supported.Installation of patchpanelsWhen terminating on patch panels, youmust support the cables onto the cablesupport bars (cable managers) providedwith every Molex patch panel and dressthe cables to the sides of the cabinet.Heat dissipationof pathwaysHeat dissipation of cables carryingpower is influenced by many pathwaycharacteristics. The table below showsthe relative heat dissipation effectivenessof various pathway types, depending oncable quantity and bundling state.The cables must be supported on thesides of the cabinet. Using cable basket isideal for this. Vertical cable managementrules apply.According to ANSI/TIA-569-E, pathwayscan be characterized for thermalperformance based on several attributes,such as: Shape Material Coatings Thickness Channels providing cable separation Contact area between pathway andambient airPathway TypeCable RoutingNon-continuousConduit (metallic and non-metallic)Sealed conduit12Table: ANSI/TIA-569-E: Heat dissipationeffectiveness of pathways (excludingcable trays).Onsite installation and testing pocket guideCable Quantity1-3738-6162-91 wLowLowLowUnbundledLowLowLowLow

Patch panel presentation

Fiber optic termination - ModLink plug and play fiber optic solution 42 Fiber optic termination - direct field termination 42 Fiber optic termination - direct field termination: Xpress G2 OM3-LC connector example 43 Cleaning a fiber optic 45 Field testers and testing - fiber optic 48 TSB-4979 / Encircled Flux (EF) conditions for multimode fiber .

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