General Cable Operation Guide
General Cable Operation Guide
Issue           01
Date            2020-05-20
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Purpose
                 This document describes the specifications for preparing, routing, and bundling
                 cables and attaching labels to these cables.
Intended Audience
                 This document is intended for upgrade personnel. Upgrade personnel must:
Symbol Conventions
                 The symbols that may be found in this document are defined as follows.
Symbol Description
Symbol Description
Change History
                 Updates between document issues are cumulative. Therefore, the latest document
                 issue contains all updates made in previous issues.
Issue 01 (2020-05-20)
                 This is the first official release.
Contents
                 This chapter describes the correct methods for routing cables (including ground
                 cables, power cables, network cables, disk enclosure expansion cables, and serial
                 cables) and optical fibers.
                 ●      Optical fibers are routed through the cable tray installed on the top of the
                        cabinet.
                 ●      If the cable tray is more than 0.8 m above the cabinet top, set up a ladder on
                        the cabinet.
                 Appropriate cable routing and bundling avoids unnecessary loss caused by cable
                 damage.
                 2.1 Cable Routing and Bundling
                 2.2 Optical Fiber/Optical Cables/AOC Routing and Bundling
Cable Routing
                 ●      In an equipment room containing brackets and an ESD floor, cables are
                        routed through the ground interlayer (the space between the concrete floor
                        and the ESD floor) or the cable tray.
                 ●      If the cables are led out from the top of the cabinet, a cable tray should be
                        built over the cabinet. Use cable ties to fix the PDU cables in the cabinet, to
                        prevent PDU connectors from loosening due to gravity of cables.
                 ●      The specifications, routing, section, and position for arranging the cables
                        should be predesigned. The cables should be lined up neatly, without
                        damaging the cover.
                 ●      The cable should be turned smoothly at the bends, with a minimum bending
                        radius of three times the diameter of the cable.
                             NOTE
                            Bend the mini SAS HD cables at a radius of at least 35 mm. The exposed length of the
                            mini SAS HD cables must be at least 70 mm.
                 ●      If cable trays are installed for a storage device, place all cables connected to
                        the device into the troughs of the cable trays.
                             NOTE
                            Evenly divide the cables connected to the storage device into two groups. Place the
                            left group of cables into the troughs of the left cable tray, and the right group in the
                            troughs of the right cable tray.
Cable Bundling
                 ●      Bind the cables when laying them on the passage. The cables should be
                        aligned snugly together. The spacing between the cable ties should be even
                        with a neat overall appearance.
                 ●      Cables running through a trough do not need to be bound but should be
                        arranged neatly and without crossover. The cables should not overflow the
                        trough. Bind or attach the cables with ties where they enter or exit the trough
                        and at turning points.
                 ●      The bundles should be tidy, clear, and elegant. The bundles can be classified
                        by type. A large number of cables can be further classified by column. Bind
                        each group of cables with ties.
                 ●      All cables must be bound properly to prevent cable loosening or damage.
                 ●      Do not connect two or more cable ties to bind cables, as this may decrease
                        the strength of the bundling.
                 ●      Bind the cables neatly and trim the excessive tie.
                 ●      The cable ties should be evenly spaced three to four times the diameter of the
                        cable bundle.
                 ●      Use as long a bending radius as possible to prevent internal cable stress and
                        breakage.
                 Figure 2-1 shows how to bind cables.
                  4: Cable tie not         5. Cable tie correctly   6: Cables are bundled at an even
                  trimmed                  trimmed                  interval, which is three or four
                                                                    times the diameter of the cable
                                                                    bundle
                        Evenly divide the cables connected to the storage device into two groups. Place the left
                        group of cables into the troughs of the left cable tray, and the right group into those the
                        right.
                 ●      The bending radius of optical fibers must be no less than 50 mm.
                 ●      Route optical fibers along the posts on the inner sides of the cabinet and
                        attach them when necessary.
                 ●      Corrugated pipes are required when running optical fibers outside the cabinet,
                        and should be extended into the cabinet by about 100 mm.
                 ●      When using corrugated pipes, optical fibers can be run through the cable tray
                        in an equipment room containing brackets and an ESD floor, or the ground
                        interlayer (the space between the concrete floor and the ESD floor).
                 ●      If the optical fibers are led out from the top of the cabinet, a cable tray
                        should be installed over the cabinet for cabling. If the cable tray is more than
                        0.8 m above the cabinet top, a cable ladder should be used.
WARNING
                 Before bundling optical fibers, read the instructions and precautions carefully to
                 prevent man-made accidents.
                        c.   Strain the optical fiber binding tape by the other end with the other
                             hand. Turn the fiber binding tape around the fiber bundle till the mat
                             side adheres to the hook side snugly, as shown in Figure 2-4.
                 ●      Expected result
                        The optical fibers are bundled successfully, as shown in Figure 2-5.
                 ●      Precautions
                        –   When using a fiber binding tape, keep the mat side inside and the hook
                            side outside. It is only the mat side of the fiber binding tape that contacts
                            the optical fiber.
                        –   Arrange the optical fibers tidily into a bundle before bundling.
                        –   Bundle the optical fibers with appropriate force. Never bundle them too
                            tight.
                        –   The interval between two pieces of optical fiber binding tape should not
                            exceed 40 cm.
                        –   A bundle can contain a maximum of 100 optical fibers (each with a
                            diameter of 2 mm) or 60 optical fibers (each with a diameter of 3 mm).
                            If more optical fibers need to be bundled, separate them into different
                            bundles.
                 This chapter describes how to prepare power cables, ground cables, and network
                 cables.
                 3.1 Preparing Ordinary Network Cables
                 3.2 Preparing Shielded Twisted Pair Cables
                 3.3 Preparing External Power Cables and Ground Cables with OT Terminals
                 ●      Ensure that the materials, including the RJ-45 connectors, category 5 UTP
                        cable, and the boots, are available.
                 ●      Check whether the protective cover is damaged and whether the cable has
                        any defect or is uneven in thickness. If any damage or defect exists, replace
                        the protective cover or cut the part of the cable that has defects.
Procedure
         Step 1 Use the diagonal pliers to cut the cable according to the required length.
         Step 2 Put the cable through the boot, and reserve at least 100 mm of the cable for
                installing the connector. Ensure that the boot is installed in the correct direction,
                as shown in Figure 3-2.
         Step 3 Use a blade or knife to peel off 20 mm of the sheath, as shown in Figure 3-3. Do
                not damage the insulation of the wires.
         Step 4 Arrange the four pairs of wires according to the color codes followed by pins of
                the RJ-45 connector shown in Table 3-1, and Figure 3-4 illustrates pins of the
                RJ-45 connector (pay attention to the pin colors).
NOTE
In Table 3-1, end A and end B refer to both ends of a network cable.
5 White and blue White and blue White and blue White and blue
         Step 5 Ensure that the wires are 13 to 15 mm long. Cut off the excess if the wires are
                longer than required, arrange them in the correct order, and then insert them into
                the RJ-45 connector, as shown in Figure 3-5.
         Step 6 Use the RJ-45 crimping tool to crimp the connector. Ensure that the connector is
                put in the right position in the RJ-45 crimping tool. After crimping, the metal cover
                on the connector must be lower than other area on the connector.
         Step 7 Use a network cable tester or a multimeter to test all the wires, and ensure that
                they are connected properly.
Step 8 Push the boot to cover the RJ-45 connector, as shown in Figure 3-6.
----End
Procedure
         Step 1 Install the boot of the RJ-45 connector.
                 1.     Select a cable of proper length and install the boot on the RJ-45 connector of
                        the cable, as shown in Figure 3-9.
                 2.     Use a blade or knife to peel off 30 mm of the sheath and use a blade to slit
                        up to 5 mm on the sheath, as shown in Figure 3-10.
                 3.     Install a shielded iron cover on the cable shield, and then insert the shielded
                        iron cover into the sheath along the crack. Install the shielded iron cover
                        correctly, as shown in Figure 3-11.
WARNING
                 When peeling off the cable sheath, do not damage the cable shield or the
                 insulated wires.
                 1.     Use the diagonal pliers to peel the cable shield, grounding wire, aluminum
                        foil, and polyester band off the first 20 mm of the cable, leaving only the
                        insulated conductors.
                 2.     Arrange the four twisted pairs properly and insert them into the wire
                        fastening slot, as shown in Figure 3-12 and Figure 3-13. Maintain the
                        original twist pitch of the twisted pairs.
                 3.     Arrange the pairs smoothly and straightly at the aperture of the wire
                        fastening slot. Arrange the wires properly and cut off the extra part of the
                        wires along the edge of the wire fastening slot. Table 3-2 shows the wires
                        order, and Figure 3-14 shows the pins of the RJ-45 connector (pay attention
                        to the colors of pins).
                 4.     Install the plastic cover on the wire fastening slot, and then fasten the slot. To
                        ensure that the cover is fitted properly, push it into the slot until you hear a
                        click, as shown in Figure 3-15.
----End
Tools:
Materials:
                 ●      Power cables
                 ●      Insulation tape
                 ●      OT terminals
                 ●      Heat shrink tube
Procedure
         Step 1 Peel off a section of the insulation layer C from the power cable based on the
                cross-sectional area of the power cable conductors. A section of power cable
                conductor D with a length of L1 is exposed, as shown in Figure 3-17. Table 3-3
                lists the recommended lengths of the insulation layer to be peeled off (L1).
Figure 3-17 Peeling off the insulation layer of the power cable
NOTICE
                 ● When peeling off the insulation layer of the power cable, take care not to
                   scratch the conductor of the power cable.
                 ● You can adjust L1 according to the length of the OT terminal. L1 = L + (1 to 2)
                   mm.
                 Table 3-3 Mapping between the cross-sectional area and the length of the
                 insulation layer to be peeled off (L1)
1 7
1.5 7
2.5 7
4 8
6 9
10 11
16 13
25 14
35 16
50 16
NOTE
                        Engineers can determine the length of insulation layer to be peeled off by comparing the
                        cable with the connector to be crimped.
         Step 2 Insert the power cable into the heat shrink tube A, as shown in Figure 3-18.
         Step 3 Insert the bare conductor of the power cable into the OT terminal B, and then
                press the OT terminal close to the insulation layer C, as shown in Figure 3-18.
NOTICE
                 After the OT terminal is installed, the length of the bare conductor outside the OT
                 terminal (L2) must not be larger than 2 mm. If L2 is larger than 2 mm, cut the
                 excess by using the diagonal pliers or wire clipper, as shown in Figure 3-18.
         Step 4 Use the power cable crimping tool to clamp the tail of the OT terminal and the
                contact part of the conductor, as shown in Figure 3-19.
                 Figure 3-19 Clamping the tail of the OT terminal with the contact part of the
                 conductor
NOTE
         Step 5 Push the heat shrink tube A towards the OT terminal, and cover the crimping area
                of the OT terminal and the conductor. Use a heat gun to heat the heat shrink
                tube, as shown in Figure 3-20.
NOTICE
                 Stop heating the heat shrinking tube once the cable is wrapped by it tightly.
                 Excessive heat may damage the insulation layer of the cable.
----End
                 This chapter describes how to make, fill in, and attach the cable labels, which
                 facilitate cable connection and maintenance.
                 Labels are affixed to the cables to identify the physical positions of the cables on
                 different devices. There are two types of cable labels: labels for the power cables
                 and labels for the signal cables.
NOTE
                        If the customers require label consistency in their equipment rooms, fill in and arrange the
                        labels according to requirements.
Material Specifications
                 The material features of the labels are as follows:
Types
                 There are two types of cable labels: one is for power cables and the other is for
                 signal cables.
                 The dividing lines on the label make the position of a cable clearer. For example,
                 there is a dividing line between the cabinet number and the enclosure number,
                 and another between the enclosure number and the slot number. The size of the
                 dividing line is 1.5 mm x 0.6 mm, and its color is PANTONE 656c (light blue).
                 The dotted lines mark the position for folding the label when you attach it to the
                 cable.
                 There is a mark "TO:" (upside down in the figure) at the lower right corner of the
                 label. Write information about the peer end of the cable, to which the label is
                 affixed, after the mark.
Contents on Labels
                 The contents on a label for a signal cable are different from the contents on a
                 label for a power cable.
                 ●      Area 1 carries the location information about the cable end to which the label
                        is to be affixed.
                 ●      Area 2 (with the "TO:" mark) carries the location information about the other
                        end of the cable.
                 ●      Area 3 is folded between areas 1 and 2.
                 If the label is viewed from the cable leading-out area, it appears on the right side
                 of the cable. The side with "TO:" that faces outward indicates the location of one
                 end of the cable; the other side indicates the location of the other end.
                 ●      When you print or write information on the labels or attach the labels, ensure
                        that the labels are clean.
                 ●      Do not use ink-jet printers or ink pens to print or write on the labels because
                        the label paper is made up of moisture-proof and waterproof material.
                 ●      Affix labels neatly. The new label is of striped type. The appearance of the
                        product is affected if the affixing position or direction is incorrect.
                 ●      Bundle the cable ties at the same height, and place all identification plates in
                        the same direction.
                 ●      The positions of "up", "down", "right", and "left" in this section (excluding the
                        description of printer setting) are from the perspective of facing the labels.
Writing Tool
                 To keep the labels legible and neat, use a black oil marker to fill in the labels. An
                 oil marker is more effective than a ballpoint pen. When you use a marker to fill in
                 the labels, ensure that the surface of the labels is not oily. Oil can smudge the
                 letters.
NOTE
The delivered marker has two nibs. Use the smaller nib to fill in the labels.
Writing Font
                 The handwritten font must be similar to the standard typeface "Times New
                 Roman" so that it is clear and legible. Table 4-1 lists the standard typeface.
0 1 2 3 4 5 6 7 8
9 A B C D E F G H
I J K L M N O P Q
R S T U V W X Y Z
The typeface for handwriting should be of a proper size, identifiable, and neat.