Multilink Starfighter 4048D User manual

Recommended Installation Procedure
Doc. No 10-8381
Release 1.0, 1/14/2005
Page 1 of 1
Contents
1 Revision History
2 General
3 Specifications
4 Contents
5 Cable Preparation
6 Closure Preparation
7 Sheath and CSM Retention
8 Cable Seal and End Plate Assembly
9 Closure Re-assembly & Splicing
10 Closure Closing and Storage
1.0 Revision History
Release # Date Remarks
1.0 1/5/2005 Initial Release
2.0 General
2.1 Overview Refer to Figure 1
The Multilink Starfighter tm 4048D is a fully sealed
medium capacity dome style fiber optic splice closure
designed for traditional optical fiber splicing and
FTTH applications. The closure can be installed in
Aerial, Underground, Pedestal and Wall mount
applications supporting the various types of cable
designs and splicing methods. Incorporated into the
closure is a sealing system that requires no special
tooling, mastics, adhesives nor thermal sealing
products. All cabling is individually sealed allowing
for entry or re-entry to the closure without disturbing
existing cabling.
Figure 1
The 4048D consist of six (6) primary components.
Refer to Figure 2
2.2 Split End Plate
Split end plate allows for installing mid-accessed
cables. Split end plates are gasketed and secured to
one another with three hex head bolts. End plates
have two feeder or express ports, four branch or
lateral/drop ports, a bonding and grounding lug, and
an “F” pressure-testing valve. Additionally, the
endplate supports the installation of closure support
bracketing for aerial, wall, pedestal or below-grade
mounting.
2.3 Integrated Slack Storage Basket
The integrated slack storage basket is designed to
allow the storage and routing of all types of fiber
bundles. A hinged cover allows for ease in accessing
and managing stored slack.
2.4 Tray Stacking Module
The tray stacking module secures up to (4)* four
4048-SSTP type splice trays. The module has a tray-
locking feature that permits each of the splice trays to
be locked in a temporary position to allow access to
the individual fibers in trays beneath.
*The closure can be equipped with a passive coupler
cassette which utilizes one tray position reducing the
capacity to three trays.
2.5 “O” Ring
The “O” ring provides for a seal between the Dome
and Split End Plates.
2.6 “V” Band
An impact resistant plastic “V” band secures the
Dome to the Split End Plates. The “V” band has a
feature that supports a locking mechanism for field
security.

Recommended Installation Procedure
Doc. No 10-8381
Release 1.0, 1/14/2005
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2.7 Dome
Protects the internal components and allows for 360-
degree access to the splice.
Figure 2
3.0 Specifications
3.1 Cable Entry & Ordering Information Refer to
Figure 3 & Table 1
Maximum Cable entries: 6*
Feeder/Express (2) ports: .3” to .75” (7.6mm) to
(19.05mm).
Branch/Lateral/Drop (4) ports: .3”-. 63” (7.6mm)
to (16mm)
*Multiport grommets for supporting fiber drops for
FTTH are available
Figure 3
Table 1 - Dome Fittings & Inserts for Branch
Lateral/Drop Cables
Part
Number Description
10-8365 4048 Starfighter Fiber Optic Dome Splice Closure
10-8362 4000/4048D Starfighter Aerial Hangar Kit
10-8007 4048-SSTP Splice Tray, 24 Single/48 Mass Fusion
10-8181 4048D-CAK Cable Addition Kit
Individual Grommets
10-8084 4 port Insert .20” to .24” (5mm to 6mm)
10-8087 4 port Insert .16” to .20” (4mm to 5mm)
10-8085 3 port Insert .24” to .28” (6.1mm to 7.1mm)
10-8090 3 port Insert .16” to .20” (4mm to 5mm)
10-8092 3 port Flat Insert (Corning, Alcatel, Sumitomo) drop
cabling
10-8091 2 port Insert .25” to .29” (6.3mm to 7.4mm)
10-8088 1 port Insert .27” to .34” (6.8mm to 8.6mm) Included
in Basic Closure & 4048D-CAK
3.2 Closure Dimensions Refer to Figure 4
Figure 4
Length 19” (48.3cm)
Diameter 8.5” (21.6cm)
Weight 7.5 lbs. (3.4 kg)
“V” Band
(4) Branch
Lateral /Drop
Ports
(2) Feeder/Express
Ports
19.0”
(48.26cm)
8.5” (21.6cm)
2.2
2.3
2.4
2.5
2.6
2.7

Recommended Installation Procedure
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3.3 Tray & Splice Capacity Refer to Figure5
(4) 4048-SSTP Splice Trays
*(24) Single Fused Fibers
(192) Mass Fused fibers
*NOTE: All single fusion splice organizers allow for
double stacking splice sleeves.
Figure 5
4.0 Contents
4.01 The basic closure is equipped with the
following;
(1) Complete closure (Dome, O Ring, V Band,
End Plates, and Slack Storage Module)
(2) Multicentric Cable seals (Feeder/Express
ports)
(1) 4048D-CAK, Cable Addition Kit for
securing a branch/lateral cable
(3) Grounding/Bonding kits (RUS Compliant)
(2) CSM/Strain relief brackets for feeder/express
cabling
(2) Silicon Gel packages (1 oz each)
(1) 4048-SSTP Splice Tray
4.02 Additional Material Required
- Cable Cleaner or wipes
- Cable identification markers
- Pressure testing solution or equivalent
- Splice sleeves or other splicing specific
material.
4.03 Tools Required
- Splicing Shears
- Splicing Equipment
- Cable Stripper
-7/16” Nut Driver
-3/8” Nut Driver
- #2 Phillips Head Screwdriver
- Air Pressurization source
5.0 Cable Preparation
The closure is designed for mid-accessed and full cut
cable entries. The following information serves as a
guideline for sheath opening lengths.
5.1 Mid-Accessed or Full Cut Cables –remove up
to 96” (243.8cm) of sheath exposing the underlying
kevlar, cable loose tubes, core tube or other fiber
protective tubing. If armored, remove armor leaving
1” (25.4mm) of armor for bonding/grounding.
5.1.1 Cut central or outer strength members’ 5.0”
(127mm) from the sheath end (will be trimmed later)
5.1.2 Clean the optical bundles or outer buffer tubes
with an approved cable cleaner.
5.1.3 Do not expose any fibers at this time.
5.2 Bundle Preparation Refer to figure 6
For loose tube bundles, depending on the cable
manufacturer, the loose tubes may be routed directly
to the appropriate splice tray and can be opened and
trimmed after installation within the closure. Core
tube cables’, remove the core tube to within 7.0”
(177.8mm) from the end of the cable sheath or armor.
This tube will be routed and secured into the slack
storage basket and all bundles managed within the
basket later.
Figure 6

Recommended Installation Procedure
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6.0 Closure Preparation Refer to Figure 7
The closure must be disassembled for installing the
feeder/express cables into the multicentric grommets.
6.01 Back off the two spring loaded bolts securing
the “V” band and remove.
6.02 Slide the Dome and “O” ring off and protect the
“O” ring from contamination
6.03 Remove the two Phillip Head screws securing
the Slack Storage Basket and set all aside.
6.04 Back off the three hex head bolts using a 7/16”
Nut Driver securing the End plate sections and
expose the two multicentric grommets.
6.05 Remove the two Multicentric grommets.
Figure 7
7.0 Sheath and CSM Retention
The following information provides installation
information regarding the different types of cable
sheath and bundling designs. Note that the CSM
clamp provides both cable strain relief and CSM
termination. If Core Tube cabling is being installed
the CSM extension of the combination clamp will be
removed.
Armored cable preparation requires the completion of
sections 7.01 through 7.04.
7.01 Armored Cable; Slit a 1” long slit under the
armor and polyethylene sheath on the opposite side
of where the bond connector is to be installed and 90
degrees away from the top and bottom. See Figure 8
7.02 Slide the supplied Mini Bonding Connector’s
bottom up to the sheath’s end ensuring that it is under
the armor between the optical bundles or core tube
and the armor.
7.03 Attach the connector top plate and nut to the
bond clamp and tighten
7.04 Attach the perforated bond wire to the stud of
the clamp and gently tighten the second nut.
NOTE: The opposite end of the bond wire will be
attached to the closure’s end plate in a later step. Figure 8

Recommended Installation Procedure
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Release 1.0, 1/14/2005
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7.1 Strain Relief Installation Refer to Figure 9
Loose tube cables typically have a Central Strength
Member that must be terminated to inhibit any
movement. Trim the strength member to 2.5” from
the sheath’s end.
7.1.2 Slide the Cable Retention and CSM clamp over
the CSM’s end and secure the assembly to the cable
sheath using one of the supplied Hose Clamps.
Tighten the clamp but do not overtighten.
7.1.3 Using a standard pair of pliers, crimp the CSM
clamp end to secure it to the CSM.
7.1.4 For Central core cables, break-off the CSM
extension of the CSM clamp leaving the strain relief
intact.
NOTE: For Outer Strength member cables, cut the
strength member’s flush to the sheath end.
Figure 9
8.0 Cable Seal and End Plate Assembly
8.0.1 Multicentric Cable Seals Refer to Figures 10
thru 13
Using the measuring gauge provided in the closure
kitting, follow the directions on the gauge and
determine the diameter of the feeder/express cable(s)
and number of layers to be removed.
Figure 10

Recommended Installation Procedure
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Release 1.0, 1/14/2005
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8.0.2 Use caution when removing layers. Splicing
shears or a cable knife may be used to start the
removal by placing a small knick at the point where
the layer joins the grommet.
Figure 11
8.0.3 Pull on the layer at the location of the nick.
Figure 12
8.0.4 Any differential between the OD of the cable
and the adjusted ID of the grommet can be made up
with a layer of sealing tape included in each closure
kit.
8.0.5 Place a layer of silicone grease around the
inside diameter of the grommet where the cable will
seat.
8.0.6 Install the grommets on the cable with the
Square end flush up against the strain relief placed
earlier and face the grommet slit up.
Figure 13
NOTE: Squeeze the two strain relief clamps tight to
the grommet flange
8.0.7 Apply a thin layer of Silicone Grease to the
gaskets entire surface of the lower and upper end
plates of the closure. See Figure 14
Figure 14
8.0.8 Apply a liberal layer of Silicone Grease on the
exterior surface of the grommet and lower the
assembly down into the lower end plate of the
closure. Refer to Figure 15
Figure 15

Recommended Installation Procedure
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8.0.9 Complete the second cable following the same
procedure.
8.1 End Plate Assembly
8.1.1 Align the top end plate to the bottom and gently
ease the two multicentric grommets into their storage
position.
8.1.2 Install the three Bolts and Nuts and gently start
all three.
8.1.3 Starting with the center bolt tighten the bolt
until it is snug.
8.1.3 Tighten the remaining two end plate bolts.
NOTE: If adding a Branch/Lateral cable or optical
drop cables refer to the following.
8.2 Installation of Branch/Lateral Cables
8.2.1 These cables are sealed using a compression
style grommet with a number of sized openings for
the different OD or Multiple cable entries.
8.2.2 Determine the OD and number of cables to be
installed using Table 1 in an earlier section.
8.2.3 Open up and remove up to 96” of sheath from
cables
8.2.4 Select the proper grommet and install the
grommet into the cable port by first backing off and
removing the blank port plug and domed nut. All
ports are equipped with the cable port feed through
and blank port plug at the factory. The feed through
has a insert that accommodates cables with an OD of
.35” to .65” which will be removed for cables under
.35” and replaced with a insert which will fit cables
.28” to .34”. Refer to figures 16 and 17
Figure 16
Figure 17
8.2.5 Slide the dome nut up and over the end of the
cable(s). Refer to Figure 18 (Exploded view of
assembly)
Figure 18
NOTE: The Strain relief clamp designed for the
Branch/Lateral cable installation is installed over the
exposed thread of the dome feed thru connector and
secured using the metal nut supplied with the kit.
Orient the strain relief clamp with the back facing the
Multicentric (figure 19), the interior of the closure
(figure 20) or sideways out towards the “o” ring
groove (figure 21) but NOT DOWN since it may
interfere with the installation of the dome. Refer to
Figures 19 thru 21
Figure 19
Figure 20
Figure 21
8.2.6 Secure the cable to the strain relief clamp by
installing the hose clamp supplied in the kit around
the cable and strain relief clamp.
8.2.7 Trim and secure the CSM to the clamp by
sliding the CSM between the nut plate and strain

Recommended Installation Procedure
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relief clamp. (If central Core Tube cable or Drop
cable, Remove the Bolt and CSM plate)
8.2.8 Slide the dome nut up and carefully thread the
nut onto the feed through.
8.2.9 Tighten the dome nut fully by hand. Torque the
dome nut to 44 in. lbs by hand.
After all Branch/Lateral/Drop cables are installed the
remainder of the closure can be assembled.
9.0 Closure Re-assembly & Splicing
9.1.1 Align the Slack Basket back onto the assembled
end plates and re-install the two #2 Phillip Head
screws removed earlier.
NOTE: Hand start the two screws to prevent cross
threading.
9.1.2 Open up the hinge tray storage plate and route
all fiber bundles in a counter clockwise direction
securing the bundles as you go using the twist loks
supplied. Refer to Figure 22
Figure 22
9.1.3 Secure any un-cut or bundles that will not be
used in the slack storage basket.
9.1.4 Close the hinged plate and secure using the
quarter turn latch. Refer to Figure 23
Figure 23
9.1.5 Install the required trays one at a time and
secure all fiber bundles using the tie wraps supplied.
The trays can be temporarily stood upright using the
locking design of the Tray Stacking Module. Refer to
Figure 24
Figure 24
9.1.6 Splice all optical fibers following standard
procedures. Rout all fibers within splice trays as
referenced in the tray instructions. Refer to Figure 25
Figure 25
9.1.7 Secure all trays using the Velcro straps
supplied. Refer to Figure 26
Figure 26

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10.0 Closure Closing and Storage
10.0.1 Route all bond/ground wires to the brass stud
on the bottom endplate, and secure with the nut and
washer pre-installed on the stud.
10.0.2 Locate and install the “O” ring and ensure that
it is fully seated around the joined end plates.
10.0.3 Apply a thin film of silicone grease to the
entire surface of the “O” ring.
10.0.4 Slide the Dome up and over the splice tray
stack and Slack Storage Module.
10.0.5 Align the dome’s front hangar support with
the end plate support.
10.0.6 Inspect the “O” ring to ensure it is in proper
position. Then assemble the “V” band over the
Dome and End Plates. Hand start one bolt of the “V”
band first and then start the other.
10.0.7 Inspect the “V” band for proper positioning.
If all is OK then using a 3/8” nut driver or ratchet and
socket tighten both bolts alternating as you tighten
until the plastic “V” band halves are fully closed.
10.0.8 Apply 5 PSIs to the End Plate “F” valve.
10.0.9 Apply “E” pressure testing solution or
equivalent around the circumference of the “V” band,
around all cable ports, and to the End Plate seam. If
no leaks are detected, install the appropriate
mounting bracket if required. If any leaks are
detected re-install or tighten components as required.
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