LONGXING GPJ83-D04 User manual

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Dome Mechanical Seal Fiber Optic Splice Closure
(FOSC)
GPJ83-D04
Installation Manual

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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, underground, wall-mounting, duct-mounting, handhole-mounting.
The ambient temperature ranges from -40℃to +65℃.
2. Basic structure and configuration
2.1 Dimension and capacity
Outside dimension (Height*Diameter)
480mm*220mm
Weight (excluding outside box)
3500g-4100g
Number of inlet/out ports
6 pieces
Diameter of fiber cable
Φ5mm-Φ18mm
Capacity of FOSC
Bunchy: 12 cores - 288 cores; Ribbon: up to 432 cores
2.2 Main components
No.
Name of components
Quantity
Usage
Remarks
1
FOSC cover
1 piece
Protecting fiber cable
splices in whole
Height*Diameter
400mm*220mm
2
Fiber optic splice tray
(FOST)
Max. 6 trays
(either bunchy
or ribbon
Fixing heat shrinkable
protective sleeve and
holding fibers
Suitable for:
Bunchy: 24, 36, 48, 72
cores
Ribbon:12, 18 pieces
3
Base
1set
Fixing internal and
external structure
4
Fiber holding tray
1 pcs
Holding fiber with
protective coat
5
Plastic hoop
1 set
Fixing between FOSC
cover and base
6
Gasket ring
1 set
Big gasket ring is used to
seal FOSC cover and base.
Small gasket ring is used
to seal entry/exit tube
1 piece of big gasket ring,
6 pieces of small gasket
ring
7
Pressure testing valve
1 set
After inject air, it is used
for pressure testing and
sealing testing
Configuration as per
requirement
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Earthing deriving
device
1 set
Deriving metallic parts of
fiber cables in FOSC for
earthing connection
Configuration as per
requirement

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2.3 Main accessories and special tools
No.
Name of accessories
Quantity
Usage
Remarks
1
Heat shrinkable
protective sleeve
Protecting fiber splices
Configuration as
per capacity
2
Nylon tie
Fixing fiber with protective coat
Configuration as
per capacity
3
Earthing wire
1 piece
Putting through between earthing
devices
4
Abrasive cloth
1 piece
Scratching fiber cables
5
Labeling paper
1 piece
Labeling fibers
6
Special wrench
2 pieces
Installing and tightening nut of
reinforced core and nut (plastic) of
entry/exit tube
7
Measuring paper
1 piece
To measure perimeter of fiber
cable, of which the diameter is
enlarged with seal tape
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Seal tape
1 ring
Enlarging diameter of fiber cable
which fits in with gasket ring.
Configuration as
per specification
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Insulation tape
1 ring
Enlarging diameter of fiber cable
for easy fixing
10
Metal hoop
1 set
For wall mounting and pole
hugging
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Buffer tube
decided by
customers
Hitched to fibers and fixed with
FOST, managing buffer.
Configuration as
per requirement
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Desiccant
1 bag
Put into FOSC before sealing for
desiccating air
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

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3.2 Special tools (to be provided by operator)
Name of tools
Usage
Fiber cutter
Cutting off fiber 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
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
Notice: The above-mentioned tools and testing instruments should be provided by the operators
themselves.

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4. Installation flow chart
5. The process of installing FOSC.
5.1 Step One - Open the closure
Cleaning the locale and determine where to install the FOSC and then place
fiber cables required.
Check whether the main components and accessories have been well prepared
inside the package.
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
5. Fix fiber cable and reinforced core
4. Separate fiber cores and prepare work prior to fixing fiber cable
6. Splice fibers
7. Install heat shrinkable protective sleeve and house fibers
8. Check up comprehensively
9. Assemble FOSC housing and fix FOSC

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Open the closure
1Demount hoop fixing bolt and pull hoop locking system out, then proceed in
demounting the hoop.
2Pull the FOSC cover upwards out, installation could begin.
See Drawing 1
Important issues: If the weather condition is not good enough, then a tent must
be pitched for waterproof and dustproof.
Base
Fiber holding tray
Grommet
Fixing slot of heat
shrinkable
protective sleeve
FOST
90°
FOST
Fixing shelf for FOST
Entry/exit tube
Grommet
Big gasket ring
FOST Cover
Nut (plastic)
Fixing device for
reinforced core
FOSC cover
Hoop (left) Hoop (right)
Hoop connector
Hoop locking system
Hoop fixing bolt
Drawing 1
5.2 Step Two -Determine length of fiber cable to be fixed and stripped inside
FOSC
5.2.1 ①. Fiber cable in 120mm length: the distance from small gasket ring to fiber cable
pressboard
②. Fiber cable in 1740mm length: it is used to be winded and spliced after stripping.
③. Fiber with protective coat in 140mm length: the distance from the fixing point of
fiber cable to the fixing point of FOST (fiber optic splice tray).

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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 customers according to
installation requirement
Temp locating mark
Fiber cable
Drawing 2
120mm fixing length of fiber cable inside FOSC
1740mm length of fiber cable to be stripped off
1600mm length of protective coat of fiber to be stripped off
140mm lenght of fiber with protective coat
5.3 Step Three –Strip off 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.
Entry terminal fiber cable
Drawing 3
Stripping terminal fiber cable
Cutter
Temp. locating mark
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

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the diameter of 100mm or so and fix it on the fiber cable temporarily by adhesive tape.
5.4.2 Reserve reinforced core in 50mm length and cut off the unnecessary ones.
5.4.3 See Drawing 4.
Important issues：Entry/exit tubes are to be selected accurately to make it easy for splicing
and sealing.
Adhesive tape
Fiber cable
Adhesive tape
Fiber
Fiber with protective coat
Fiber cable
Drawing 4
Reinforced core
50mm
5.5 Fix reinforced core, and pyrocondense, fix and seal fiber cable.
5.5.1 This FOSC is provided with 6 entry/exit tubes, among these tubes, 2 entry/exit tubes suit
for 1pc fiber cable with max. diameter ф 21mm, 4 entry/exit tubes suit for 1pc fiber
cables with max. diameter ф 16mm.

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5.5.2 After deciding number of fiber cable entry/exit, demount the nut, gasket and gasket
ring of the corresponding entry/exit tubes according to the diameters of fiber cables
actually to be installed, insert them into fiber cable in sequence, then insert fiber cables
into entry/exit cable , tighten the nut in order to seal properly.
5.5.3 Do not demount the nut of entry/exit tubes which fiber cables are not installed.
5.5.4 While diameter is not big enough, enlarge the diameter with seal tape at fixing position of
small gasket ring in order to improve sealing.
5.5.5 Fix fiber cable to the fixing seat, press it with the pressboard. While diameter is small,
enlarge the diameter with insulation tape at the fixing position of fixing seat.
5.5.6 Demount the nut of fixing device of reinforced core with special wrench (plastic one),
set reinforced core into fixing slot, tighten the nut, retighten it with metal wrench (metal
wrench to be provided by operator).
5.5.7 See Drawing 5
Important issue: Fixing nut of reinforced core should be tightened.
Fixing device for
reinforced core
Big gasket ring
Reinforced core
Fiber cable
Fiber cable
Fiber cable
Gasket (plastic)
Nut (plastic)
Seal tape
Small gasket ring
Pressure testing valve
Entry/exit tube
Base
Earthing
deriving device
Bracket
Fiber
Fiber with
protective coat
Fiber with protective coat
Drawing 5
Fiber
Grommet
FOST
Adhesive tape
Fiber with protective coat
Fiber
Adhesive tape
Fiber holding tray

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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.)
5.7.2 See Drawing 6
Important issue: pay attention to the twist and bend of fiber.
Drawing 6
Heat shrinkable
protective sleeve
(bunchy or ribbon)
Fiber (bunchy or
ribbon)
Fixing slot for heat
shrinkable protective
sleeve (bunchy or ribbon)
Fiber (bunchy or
ribbon)
FOST
Nylon tie
Fiber with
protective coat
Fiber with
protective coat
Nylon tie
5.8 Step Eight - Check up comprehensively
To ensure the technical requirements, the following instructions must be followed:
5.8.1 Fibers with protective coat are fixed with nylon tie at the entrance of FOST.

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5.8.2 Grommet should be pressed from inside to outside in order to properly install FOST.
5.8.3 Straight-through and reserved fibers with protective coat should be winded into fiber
holding tray.
5.8.4 Check whether the internal tighteners and reinforced core are well tightened.
5.8.5 Check whether gasket ring is installed neatly and smoothly without any breakage. If
not, level it up with seal tape.
5.8.6 See Drawing 7.
Important issues: If any problems occur, they should be solved right away.
Reinforced core
Fiber cable
Fiber cable
Drawing 7
Reinforced core
Big gasket ring
Bracket
Grommet
Fiber holding tray
FOST
Nylon tie
Fiber with
protective coat
Fixing device for
reinforced core
Base
Fiber with
protective coat
Fixing shelf for
FOST
Reserved fiber with
protective coat
FOST cover
Fixing seat
Fiber cable
Entry/exit tube
Nut (plastic)
Pressboard

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5.9 Step Nine – Assemble FOSC housing and fix FOSC
5.9.1 Put desiccant into FOSC.
5.9.2 Put FOSC cover on base directly.
5.9.3 Install plastic hoop between FOSC cover and the base, aim at center point of FOSC,
tighten hoop locking system, which is to be fixed by hoop fixing bolt then.
5.9.4 All nuts (plastic ones) of base need to be retightened once more.
5.9.5 FOSC installation
①Aerial application: fix metal hoop and transom to the pole. Please refer to Drawing 8
②Wall mounting application: fix the bracket on the wall with the bolt. (metal hoop is
not required.)
③Underground application: metal hoop is not required.
5.9.6 See drawing 8
Important issues: 1. Pay attention while installing plastic hoop.
2. The specification of the bolt for wall-mounting is M8.
FOSC cover
Transom (metal)
Hoop (metal)
Base
Hoop fixing bolt
Hoop locking system
Hoop (left)
Hoop (right)
Drawing 8
Fiber cable
Fiber cable
Nut (plastic)
Entry/exit tube
Fiber cable

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6. Fiber Optic Splice Closures (FOSC) inspecting and testing items
Inspecting
item
Technical Requirements
Inspecting type
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

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Bending
The spot between the FOSC and seal fitting can bear
bending tension of 150N at bending angle of ±450for 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±900,
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.