LONGXING GPJ83-H04 User manual

GPJ83-H04
Installation Manual

1
1. Scope of application
This Installation Manual is suit for the Fiber Optic Splice Closure (Hereafter abbreviated as FOSC), as
the guidance of proper installation.
The scope of application is: aerial, underground, pipeline, handhole. The ambient temperature ranges
from -40 to 65℃.
2. Basic structure and configuration
2.1 Dimension and capacity
Outside dimension (LxWxH)
450x220x110 (mm)
Weight (excluding outside box)
2750g-3200g
Number of inlet/outlet ports
3 (pieces) on each side (total 6 pieces)
Diameter of fiber cable
Φ5—Φ23 (mm)
Capacity of FOSC
Bunchy: 12—96 (Cores)
Ribbon: 72—288(Cores)
2.2 Main components
No.
Name of
components
Quantity
Usage
Remarks
1
Housing
1 set
Protecting fiber cable splices in
whole
Internal diameter:
378x136 (mm)
2
Insert plate
2 pairs
Fixing the housing
175x56x30(mm)
3
Fiber optic
splice tray
(FOST)
Max 4 pieces
(either bunchy
or ribbon)
Fixing heat shrinkable protective
sleeve and holding fibers
Suitable for:
Bunchy:6,12,24(cores)
Ribbon:3,6 (pieces)
4
Foundation
1 set
Fixing reinforced core of fiber-
cable and FOST
5
Seal fitting
1 set
Sealing between FOSC cover and
FOSC bottom
6
Port plug
6 pieces
Sealing empty ports
7
Pressure
testing valve
1 set
After injecting air, it is used for
pressure testing and sealing testing
Configuration as per
requirement
8
Earthing
deriving
device
1 set
Deriving metallic components of
fiber cable in FOSC for earthing
connection
Configuration as per
requirement
2.3 Main accessories and special tools

2
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
Insulation 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
Configuration as
per specification
5
Hanging hook
1 set
For aerial use
6
Earthing wire
1 piece
Putting through between earthing
devices
7
Abrasive cloth
1 piece
Scratching fiber cable
8
Labeling paper
1 piece
Labeling fiber
9
Special wrench
3 pieces
Fixing bolts, tightening nut of
reinforced core
10
Measuring paper
1 piece
To measure circle, of which its
diameter is enlarged with seal
tape
11
Buffer tube
To be decided
by customers
Hitched to fibers and fixed with
FOST, managing buffer
Configuration as
per requirement
12
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
3.2 Special tools (to be provided by operator)
Name of tools
Usage
Fiber cutter
Cutting off fibers
Fiber stripper
Strip off protective coat of fiber cable
Combo tools
Assembling FOSC

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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
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
10. Fix FOSC

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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
①Demount the fixing bolt of insert plate with a special wrench. Put out the fixing
bolt，Use the special wrench and stroke on the other side of the insert plate . The
insert plate will be unloading.
2Use the special wrench to demount all the locating bolts on the housing as well as
fixing bolts (it is also possible to install hanging hook depending on the installation
requirement) at four corners, then succeed in opening the closure.
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.
Earthing device
Drawing 1
Bolt for insert plate
Locating bolt
Fixing bolt
FOSC cover
FOST cover
Foundation
Fixing device for reinforced core
Single fiber cable pressboard
Insert plate
Shaft
FOSC bottom
Seal fitting
Double fiber cable pressboard
Port plug C
Port plug B
Locating bolt
Port plug A
Cover for seal fitting
Fixing bolt

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5.2 Step Two -Determine length of fiber cable to be fixed and stripped inside FOSC
5.2.1 ①. Fiber cable in 70mm length: the distance from seal fitting to fiber cable pressboard
②. Fiber cable in 2050mm length: it is used to be winded and spliced after stripping.
③. Fiber with protective coat in 450mm 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.
Drawing 2
④.1600mm length of protective coat
of fiber to be stripped
Fiber cable
③.450mm length of fiber
with protective coat
70mm
②.2050mm length of protective coat of
fiber cable to be stripped off
①. Fixing length of fiber cable inside FOSC
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 pull all the protective coat of fiber cable at one time, strip
it off section by section to avoid fiber breakage.
Temp locating mark
Fiber cable Cutter
Stripping terminal fiber cable
Drawing 3
5.4 Step Four – Separate fiber cores and prepares work prior to fixing fiber.
5.4.1 Wind 2 layers of insulation tape on protective coat of fiber core. Meanwhile, get rid of
the stuffing to separate fiber core and clean them. Form a ring with the diameter
of 100mm or so and fix it on the fiber temporarily by adhesive tape.

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5.4.2 This FOSC is provided with six inlet/outlet ports. Number of fiber cables is determined
by the customers according to their actual requirements and the corresponding number
of port plugs should be taken out. The max number of fiber cables to be installed is six.
5.4.3 This FOSC is suitable for the following diameters of fiber cables respectively:
Port A: suitable for fiber cable with max. external diameter ф23mm
Port B: suitable for fiber cable with max. external diameter ф20mm
Port C: suitable for fiber cable with max. external diameter ф16mm
5.4.4 The corresponding inlet/outlet ports are to be selected according to fiber cables
actually installed. When the diameter of fiber cable is smaller than that of the
inlet/outlet port, then the sealing tape should be used to enlarge the external diameter of
fiber cable, of which the perimeter could be measured by measuring paper marked by
Hole A, Hole B, Hole C, coming as accessories.
5.4.5 Reserve reinforced core in 40mm 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
should be scratched and to be cleaned with abrasive cloth and ethyl
alcohol.
2. Cut off reinforced core with special cutting pliers.
15
2025
10 40mm
5~10mm
Adhesive tape
Fiber Bunchy/ribbon fiber
(with protective coat)
Seal tape
Insulation tape
Reinforced core
Drawing 4
5.5 Step Five - Fix reinforced core and fiber cable
5.5.1 Upon finishing the above steps, then demount port plugs, pressboard and fixing nut of
reinforced core. Make sure to check whether the fiber cable stripped fits in with the
fixing ports or not. If not, the adjustment should be done in time. Otherwise it will affect
installation quality.
5.5.2 Tighten fiber cable pressboard. If the diameter of fiber cable is not long enough, then
enlarge it with insulation tape.
5.5.3 Tighten nut of reinforced core with the special wrench (plastic) and then retighten it with
the metal wrench.(the metal wrench should be provided by operator).
5.5.4 See Drawing 5

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D raw ing 5
Fiber
Fixing device for reinforced core
N ut for
reinforced
core
Fixing bolt for fiber cable
Fixing device for fiber cable
H ou sing
Seal fitting
Fiber cable
Pressboard
5.6 Step six - Splice fibers
5.6.1 Follow user manual of fusion splicing machine to splice fiber cores.
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 sleeve for splice protection.
( 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.
Heat shrinkable
protective sleeve
Fixing slot of heat shrinkable
protective sleeve (bunchy)
Drawing 6
Left terminal fiber
with protective coat
Right terminal fiber with
protective coat
FOST
Fiber
Nylon tie
Fixing slot of heat
shrinkable protective
sleeve (Ribbon)
Grommet

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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 internal tighteners are tightened.
5.8.3 The inlet/outlet ports without fiber cables must be blocked up with the port plugs.
5.8.4 Control the amount of seal tape within a proper range.
5.8.5 Seal fitting is installed neatly and smoothly.
5.8.6 Seal the cover of seal fitting
5.8.7 See Drawing 7
Grommet
Port plug C
Terminal A
fiber cable
Seal tape
Insulation tape
Port plug B
FOST Nylon tie Grommet Earthing device
Drawing 7
Port plug B
Seal fitting
Terminal B fiber cable
Seal tape
Seal fitting
Single fiber cable pressbard
Heat shrinkable protective sleeve
Fixing slot of heat shrinkable protective sleeve
Terminal A fiber with protective coat
Nylon tie
FOST
FOST cover
Terminal B fiber with protective coat
Fiber
Fiber with protective coat
Fixing device for reinforced core
Reinforced
core of fiber cable
Double fiber
cable pressbard

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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 .
5.9.3 Put the insert plates into the slot and with special wrench knocked tight (one pair on each
side, one piece with a hole with screw thread in the middle, the other with a hole without
screw thread in the middle). Tighten bolts of insert plate with the wrench .
5.9.4 If the FOSC is for aerial application, then put the hanging hook on one side of the closure
and then tighten fixing bolts on both sides. Otherwise tighten the four fixing bolts on
four corners respectively.
5.9.5 See drawing 8
Important issues: cleaning the housing and pay attention to the above sequence.
Fixing slot for
hanging hook
Earthing
deriving device
Pressure testing valve Fixing bolt
(at 4 corners)
FOSC bottom
Insert plate
Locating bolt
Bolt of insert plate
FOSC cover
Port C Port B
Port A
Locking hole with
female thread on
insert plate
Fixing bolt
Cover of seal fitting
Port plug A
Locating bolt
Port plug B
Double fiber
cable pressboard
Seal fitting
FOSC bottom Panel
Single Fiber
cable pressboard
Fixing device for
reinforced core Foundation
FOSC cover
Fixing bolt Locating bolt
Bolt for insert plate
Insert plate
FOST cover
Port plug C
Earthing device
Drawing 8
The location to dismantle percussion
Fixing bolt

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5.10 Step Ten - Fix FOSC.
5.10.1 Fixing the FOSC and tighten bolts in sequence as per drawing 9.
Important issues: Retighten in five minutes
Tighten properly to avoid the closure to be out of shape.
12.
Port A
2.
10.
5. 7. 3.
9.
Port C Port B
1.
Port A
11.
6.
8.
4.
Drawing 9

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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 have
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
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.