RFS HYBRIFLEX RRH Instruction sheet

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Direct Connection RRH HYBRIFLEX®
Guidelines and Instructions

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Table of Contents
Introduction to HYBRIFLEX® ........................................................................................................................... 3
HYBRIFLEX Feeder Configuration ................................................................................................................... 4
Hybrid riser kit model numbering structure................................................................................................... 6
Transporting, Shipping and Handling the Drum............................................................................................. 8
Handling HYBRIFLEX Cable.............................................................................................................................. 9
Protective Sleeve Removal/Packing .............................................................................................................10
Hoisting/Pulling HYBRIFLEX Cable ................................................................................................................11
HYBRIFLEX Bending.......................................................................................................................................13
Fixation/Mounting of the Cable ...................................................................................................................15
HYBRIFLEX Tower Accessories and Installation Tools .................................................................................. 16
Installation of the Grounding Kit.................................................................................................................. 17
Fiber Inspection............................................................................................................................................ 26
Fiber Cleaning Introduction..........................................................................................................................29
Cleaning ODC plug and socket connector ....................................................................................................34
RFS RRH jumper with FULLAXS COMPATIBLE connector installation guide................................................. 37
HYBRIFLEX Bulkhead Connector Fitting Installation..................................................................................... 40

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Introduction to HYBRIFLEX®
RFS’ HYBRIFLEX Remote Radio Head (RRH) hybrid feeder cabling solution combines multiple elements,
including optical fiber and DC power, for RRHs in a single lightweight cable, making it the world’s most
innovative solution for RRH deployments. It was developed to reduce installation complexity and cost at
macro sites. HYBRIFLEX allows mobile operators deploying RRH architecture to standardize the RRH
installation process. HYBRIFLEX combines optical fiber, power and alarm wire in a single jacketed cable and
can connect multiple RRHs with a single feeder. Standard RFS CELLFLEX® coaxial cable accessories may be used
with HYBRIFLEX cable. Both pre-terminated and on-site terminated options are available. The rugged jacket
facilitates easy transportation, handling, and installation.
These short instructions were written for qualified and experienced personnel. They describe, in few words,
the main points that MUST be noted during installation, without any claim of completeness.
Any liability or warranty for results of improper or unsafe use is disclaimed!
General remarks:
In principle, care must be taken to avoid all such strain that may cause permanent deformation on the cable,
e.g. going below admissible bending radii, kinking, applying too high tensile stress or forcible deformation (e.g.
pulling over sharp edges, over tightening of clamps etc.).

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HYBRIFLEX Feeder Configuration
This installation guideline supports HYBRIFLEX cable available in small, medium and large riser trunk
configurations, 6x12 and 6x24. The trunk cable assemblies comprise of 4, 6 or 10AWG DC wires, and twelve
(12) or twenty-four (24) pairs of single mode fiber terminated with ODC-LC connector.
This application eliminates the need of junction boxes, utilizing outdoor weather tight optical fiber connection
to armored, fiber only jumpers and direct DC connection to RRH from the riser trunk, for complete installation
from BBU to RRH.
HYBRIFLEX trunk cable assemblies are factory constructed specifically to suit this application, ensuring
trouble-free installation. Additional features that ease installation and ensure durability throughout service
life include:
▪Robust breakout design with identified optical fibers and power conductors
▪Stranded construction for easy bending and maximum fiber protection
▪Corrugated aluminum shield protects from crush and animal damage
▪Integrated rip cords for length management
▪Factory test certificate available for every cable assembly
▪Smartly packaged, easy fiber end face access for pre-testing
The installation instructions here within, apply to (but not limited to) the following HYBRIFLEX families:
Generic
Description
Type
DC
Pairs
DC gage
(AWG)
Cross
Section
(mm2)
DC Type
Fiber
Pairs
Fiber
type
Fiber
Termination
Top
Fiber
Termination
Bottom
Armor
Model Name Assembly
Model Name Assembly Kit
with predefined accessories
6x12 Hybrid Riser
Riser to
fiber
Jumper
610 5.3
Jacketed, braided pairs at
breakout; Unshielded
individually jacketed
wires in the bulk
12 SM ODC D-LC Al Corrugated
HB078-05U6S12-xxM-01
HB078-05U6S12-xxM-KIT-01
6x12 Hybrid Riser
Riser to
fiber
Jumper
6 6 13.4
Jacketed, braided pairs at
breakout; Unshielded
individually jacketed
wires in the bulk
12 SM ODC D-LC Al Corrugated
HB114-13U6S12-xxM-01
HB114-13U6S12-xxM-KIT-01
6x12 Hybrid Riser
Riser to
fiber
Jumper
6 4 21
Jacketed, braided pairs at
breakout; Unshielded
individually jacketed
wires in the bulk
12 SM ODC D-LC Al Corrugated
HB158-21U6S12-xxM-01
HB158-21U6S12-xxM-KIT-01
6x24 Hybrid Riser
Riser to
fiber
Jumper
6 4 21
Jacketed, braided pairs at
breakout; Unshielded
individually jacketed
wires in the bulk
24 SM ODC D-LC Al Corrugated
HB158-21U6S24-xxM
HB158-21U6S24-xxM-KIT
Typical
Application

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6x12 / RRH Configuration for
demonstration purpose only
HYBRIFLEX feeder cable can be
ordered as 6x12 or 6x24
Hoisting grip attached no less
than 5 feet from breakout point
BBU Equipment cabinet or
shelter
Clamp spacing
0.9m (3ft) - 1.2m (4ft)
3
Breakout point for
separate fiber and power
conductors
Bulkhead fitting may be
included with main feeder
Single-Mode Jumper
without FULLAXS
Compatible Connector
Fiber jumper with ODC
to FullAXS Compatible
Connectors

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HYBRIFLEX® feeder assembly ODC (top) & LC (bottom) optical fiber connectors
Helpful tip - The following are just a few examples of hybrid riser cables kits for this application. Please
check with your local RFS representative for additional product variations and options.
Hybrid riser kit model numbering structure
HB078-05U6S12-xxM-KIT-01, HB114-13U6S12-xxM-KIT-01, HB158-21U6S12-xxM-KIT-01,
HB158-21U6S24-xxM-KIT
HB
078, 114,
158
05, 13,
21
U
6
S
12
xxxM
KIT
Hybrid
Over
Jacket
O.D.
Wire
Gauge
Unshielded
No. of
DC Pair
Single
Mode
No. of
Fiber Pair
Length
in
Meters
Includes
Ground kit,
Hoist grip
Hybrid
assembly
length
LC termination (enlarged to
show colors)
Color-coded power
wire conductors
End 2
Bottom BBU
Power
End 1
Top RRH
ODC
termination

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Quick reference
Cable type
HB078-05U6S12-
HB114-13U6S12-
HB158-21U6S12-
Cable brand
HYBRIFLEX®
HYBRIFLEX®
HYBRIFLEX®
Conductor gauge
10 AWG
6 AWG
4 AWG
Number of conductors
6 pairs
6 pairs
6 pairs
Number of fibers
12 pairs
12 pairs
12 pairs
Hybrid armor type
Corrugated aluminum
Corrugated aluminum
Corrugated aluminum
Hybrid fiber mode
Single-Mode
Single-Mode
Single-Mode
Hybrid termination
Top: ODC
Bottom: LC
Top: ODC
Bottom: LC
Top: ODC
Bottom: LC
Hybrid weight (kg/m (lb/ft))
1.03 | 0.7
2.24 |1.51
2.8 | 2
Max over jacket diameter
28.6mm | 1.13”
39mm | 1.54”
51mm | 2”
Breakout fiber length, top
0.5m | 20”
0.5m | 20”
0.5m | 20”
Breakout fiber length, bottom
1.3m | 53”
1.3m | 53”
1.3m | 53”
Breakout power length, top
4.0m | 157”
4.0m | 157”
5.0m | 197”
Breakout power length,
bottom
150mm | 6”
150mm | 6”
1.0m | 39”
Hybrid minimum bend radius
Multi
254mm | 10”
254mm | 10”
500mm | 20”
Hybrid minimum bend radius
Single
125mm | 5”
152mm | 6”
250mm | 10”
ODC
termination
Power
Power
LC
termination
Top

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Cable type
HB158-21U6S24-
Cable brand
HYBRIFLEX®
Conductor gauge
4 AWG
Number of conductors
6 pairs
Number of fibers
24 pairs
Hybrid armor type
Corrugated aluminum
Hybrid fiber mode
Single-Mode
Hybrid termination
Top: ODC
Bottom: LC
Hybrid weight (kg/m (lb/ft))
3.65 | 2.5
Max over jacket diameter
50.7mm | 1.9”
Breakout fiber length, top
700mm | 27”
Breakout fiber length, bottom
1610mm | 63”
Breakout power length, top
5m | 197”
Breakout power length,
bottom
1m | 39”
Hybrid minimum bend radius
Multi
500mm | 20”
Hybrid minimum bend radius
Single
250mm | 10”
LC
termination
ODC
termination
Power
Power
Top

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Transporting, Shipping and Handling the Drum
Drums must be handled carefully to avoid any damage to the drum and/or the hybrid cable.
•If the drum will be shipped by van or truck the drum must be secured against rolling. Pay special
attention to careful loading and unloading. Do not roll the drum from high levels (load floor) of the
vehicle without protective measures, e.g. roll the drum from the vehicle by using planks as a ramp. Do
not drop the drum!
•If forklifts are used, the forks must be long enough to engage both flanges of the drum at the same
time to avoid cable damage.
•If a crane is used, a special hanger is necessary to ensure vertical application of forces and thus
avoiding damage of the drum flanges and the cable.
•Do not lay the drum on its side, reels must be transported and handled in their up-right position only
(the cable could be deformed due to its own weight).
•Make sure that the cable end is always properly sealed and fixed as close as possible to the drum core.
•Note the recommended rotation direction of the drum, which is shown by an arrow on the drum
flange (during installation/pulling of the cable the drum will be on drum stands and will then be
turned in the opposite direction to unwind the cable).
•If the drum is completely protected by wooden planks, these should not be removed before the drum
is placed (transported) to the final position.
Handling HYBRIFLEX Cable
Upon receiving the HYBRIFLEX shipment it is highly
recommended that the drum be inspected for any
physical damage and all fiber connection points be
tested.
Do not drag the cable over sharp edges. If, it can’t be
avoided to drag the cable over sharp edges, protective
measures must be taken, if necessary by positioning an
additional rigging at those critical places.
To protect the cable against any damage, protective
measures must be taken. This is also applicable if cables
must be pulled in horizontal runs (example: using pipe
rollers, wooden planks or similar).
Prevent any pinches to the DC wires, which may cause
electrical spikes and shorten circuitry.

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Protective Sleeve Removal/Packing
It is recommended that all assemblies are
inspected and pre-tested before hanging, to do
so no need to unreel the assembly. Both optical
end faces are easily accessible. Use this quick
instruction to unwrap and test the fiber.
▪Each hybrid termination is protected by
a robust protective sleeve (as shown
below) and ESD plastic bags to prevent
damage to the fiber end face.
▪Use caution when removing the sleeve.
▪Unwrap the packaging reel
▪Remove tape and tie wraps
▪Slowly pull off protected sleeve
▪Untapped and remove ESD plastic bag (only remove the
section that is been work on)
Protective sleeve
Tape & tie wraps

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Hoisting/Pulling HYBRIFLEX Cable
•Note: when hoisting and pulling HYBRIFLEX always use caution.
•Do not remove the protective sleeve. If it is removed during pre-testing, re-attach securely before
hoisting the cable.
•Do not attach the hoisting grip over the protective sock.
•Hoisting grips should be attached no less than 5 feet from the breakout point.
Breakout point
No less than 5 feet

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HYBRIFLEX cable is supplied in specific cut lengths with fully terminated and polished factory connectors.
Short lengths of small HYBRIFLEX can be hoisted manually, otherwise
a winch is recommended. Provide a pulley high enough on the tower
to enable the HYBRIFLEX line to be raised sufficiently.
Attach a hoisting grip (do not use a closed lacing style) using tie back
rope or additional electrical tape if needed to prevent any stress or
force to fiber and electrical wire. When using pre-installed hoisting
grips, simply adjust it to the desired section of the cable and clamp it
or use heavy duty tape to secure it.
For every long vertical run of cable, additional hoisting grips should be
attached at 50-60m intervals.
Add the hoist line to the hoisting grip or rope sling; protect the
HYBRIFLEX against shackles.
Keep slack in the cable between the hoisting grips in case more than
one is needed. Ensure that the slack is maintained during hoisting.
Hoist the cable slowly.
Rotation of the reel must be slow to prevent buckling of the cable.
When unspooling, keep the reel secure so that it does not accidentally
roll over the unprotected components.
If it is necessary to drag the cable over sharp edges of buildings or
tower members, protective measures must be taken.
Careless handling can damage the cable jacket eventually causing
damage to fiber end face which may render the entire HYBRIFLEX line
length useless.
If the cable is hoisted inside the tower, feed it into the tower base and
keep its top off the tower steel work. Please refer to the Monopole
installation section of this document.
Caution! The protective sleeve should not be removed until
installation is complete.
Hoisting Grips: 1 for every 100ft of vertical run. For heavier runs, such
as 1-5/8” 4AWG, use 2 hoisting grips for every 200ft vertical run.
Hoisting Grip
Always secured
with electrical
tape or tie wrap
before applying
tension
Protective
sock
Do not Hoist
without Sock
Minimum
18.12 FT

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HYBRIFLEX Bending
•The minimum-bending radius should be strictly observed. [See product spec sheet].
HYBRIFLEX cable should be bent manually with a force applied in a distributed manner, pressing
carefully while the hand slides along the cable [see diagram 1]. Avoid rapid, sharp motions.
•Avoid any tight micro bends near the fiber end face as micro bends can cause broken fiber and
increase insertion loss. [See diagram 2&3].
Helpful Tip: Hybrid cables that utilize aluminum outer shield, are easy to bend, but must be handled
carefully to avoid damage to internal elements.
•Do not twist the cable, e.g. if changing from vertical to horizontal runs [See diagram 4]
•Do not leave the Hybrid cable hanging in a long free space, e.g. during the installation under a
platform. In adverse conditions, additional protective measures may have to be taken [for example
see picture 1].
Pull carefully
bit by bit
While pressing, slide your hand
Diagram 1
Diagram 3
Diagram 2
Protective measures:
temporary fixation of the cable
As shown from side (upper) and
top (lower) view, do not swing
the cable horizontally creating a
twist in the vertical run
As shown from side view, rather
form a large bow and pull and
guide the cable horizontally
without creating any twist

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HYBRIFLEX Bending
Minimum Bending Radius
•Minimum bend radius is the tightest bend an installer can bend a section of the cable without causing
performance degradation and/or damage. Refer to product data sheet for specific hybrid cable bend
radius.
RFS specifies two types of minimum bending radius for a cable.
•Single bend –irreversible minimum bend section of the cable
•Repeated bend –reversible minimum bend section of the cable
Repeated bend radius, can be
reversed without damage or cable loss.
For single bend radius, DO NOT reverse.
Doing so will damage and increase cable loss

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Fixation/Mounting of the Cable
Crush resistance may vary for different outer materials. This should be considered when tightening the clamps
(especially if these clamps have not been approved by RFS).
Several different clamps may be used, we recommend using the SNAP-IN type. The SNAP-IN is suitable for all
fixing situations while at the same time it is a safer clamp (less chance of failure) offering many advantages.
The recommended and maximum clamp spacing shown in table 1 must always be considered. The small
spacing applies to severe site conditions (wind load, icing, etc.); whereas the greater/recommended spacing
can be used for less exposed cable runs (e.g. indoor applications).
Table 1
HYBRIFLEXSize
Spacing
HBF058 [5/8”]
0.7m (28in)
HBF078 [7/8”]
0.9m (3ft)
HB114 [1-1/4”]
1.3m (4.25ft)
HB158 [1-5/8”]
1.5m (5ft)

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HYBRIFLEX Tower Accessories and Installation Tools
Helpful Tip: Accessories may be kitted with the hybrid assembly upon request. RFS recommends its
accessories be used to avoid any incompatibly issues that may arise during the installation process.
Caution! Only use approved accessories and tools. Also note: RFS HYBRIFLEX® does not require the use of
grommets.
Note: Hangers are sold in kits of 10 with hardware included (three options available)
Cable size
Model number
Short description
HB058
HB078
HB114
HB158
GKFROM60-58
GKFORM60-78
GKFORM60-114
GKFORM60-158
60-inch grounding kit
HB058
HB078
HB114
HB158
CLAMP-58 or SNAP-58 or SNAP-ST-58
CLAMP-105 or SNAP-58 or SNAP-ST-78
CLAMP-114 or SNAP-114 or SNAP-ST-114
CLAMP-158 or SNAP-158 or SNAP-ST-158
Standard clamp bolt-
on hanger; Snap-in
hanger; Stackable
snap-in hanger
HB058
HB078
HB114
HB158
HOIST1-58L
HOIST1-78L
HOSIT1-114-L
HOSIT1-158L
Hoisting grip, lace up
Any size
ANGLE-UI
ANGLE-CLPI
Universal angle
adapter, snap-in or
3/8" (kit of 10)
Angle member
adapter kit 3/8" (SS)
(Kit of 10)
HB078
HB114
HB158
JSTRIP-78
JSTRIP-114
JSTRIP-158
Manual jacket
stripping tool

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Additional installation tools
Model Number
Description
HTPT-1-058-CT
5/8” Armor cutter
HTPT-1-078-CT
7/8” Armor cutter
HTPT-1-114-158
1-1/4” Armor cutter
HTPT-1-158-CT
1-5/8” Armor cutter
HTPT-1-058
5/8” Jacket removal
HTPT-1-078
7/8” Jacket removal
HTPT-1-158
1-5/8” Jacket removal
HTPT-1-114
1-1/4” Jacket removal
HTRT-1-001-KIT
Ripcord removal kit (mandrel,
stop collars)
Installation of the Grounding Kit
RFS recommended that hybrid cable be grounded regardless of size. Recommended 3 Kits per run up to 200ft
plus 1 for every additional 200ft. Although the HYBRIFLEX jacket
removal tool (HTPT’s series) can be used, to avoid ripping off too
much jacket the J-Strip is recommended.
To avoid any corrosion problems, the contact element of the
grounding kit is tin plated copper. The tin plating allows
compatibility with both aluminum and copper conductors.
Because of electrochemical potential differences between
copper and aluminum do not use the grounding kits, which are
designed only for copper cables!
Do not used copper grounding on cable with aluminum outer.

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Please follow the included installation instruction carefully. For removal of the jacket we also strongly
recommend the use of a manual jacket stripping tool, examples model JSTRIP-114-2 or JSTRIP-114 for 1-1/4”
size. Check with you local RFS representative for other cable sizes.
▪Set the JSTRIP onto a straight part of cable. (a)
▪Insert a screwdriver into the two support holes and begin turning, maintaining a straight line –do not
push in any lateral directions and do not twist or leave the right-angle line. Continue turning by hand
(the screwdriver is needed for the start only) until the jacket is cut completely around, still maintaining
a straight line. (b)
▪Make a mark onto the cable jacket in 70mm (2.75in) from the beginning of the first cut (that’s 50mm
(2.0in) which is needed for the grounding kit installation and for the part of the tool from the end of
the cutting edge to the end of the tool. (f)
Put the tool onto the cable again, whereby the cutting edge should be in the already jacket stripped area.
Start again, while pushing the tool slowly in direction of the marking. The jacket will be cut in a spiral. Turn
further by pushing the tool very slowly until reaching the marking. If the tool is on the mark, turn further, but
now push a little bit in the reverse direction to finish the cut in straight line.

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Note: If the tool has been started to cut in a spiral, the tool will move continuously by itself in the same
direction. If the marked area is reached, this movement must be stopped by pushing carefully in the opposite
direction. To develop the proper technique, we recommend testing on a part of cable, which is not needed for
the installation. If this process is not easy enough or not acceptable, a clamp (e.g. RSB-Clip) may be placed on
the mark. This clamp will then stop the movement of the tool in the final position [see pictures 2-4].
Put the body of the grounding kit very carefully around the cable, to prevent damaging the outer conductor,
and then carefully tighten the nuts.
Finally use the supplied sealing materials as described in the grounding kits
installation instruction to perform a proper sealing of the complete kit.
For example, GKFORM series, place the remaining third 50 mm (2”) piece of
butyl mastic carefully over the ground wire. (as shown in Diagram 5)
We recommend bending it with overlapping on both sides when placing over
the ground wire. Afterwards mold it in a straight line to the coaxial cable to avoid holes where water could
enter [see Diagram 5].
Special care must also be taken to form
tile-like overlaps when wrapping the tape
layers, i.e. start from the bottom and end
at the top.

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1-1/4 |1-5/8 inch Armor cutting tool instruction
The following instructions can be use for 1-5/8” HYBRIFLEX cable. The cutting tool is a special design. An “off
the shelf” pipe cutter from local hardware store should not be used. Note: This is not a combo tool; size must
be purchased as either 1-5/8” or 1-1/4”,
To use the HTPT’s cutting tool to cut the outer armor,
1) Using the jacket striping tool remove the jacket off the cutting section
2) Turn the turning knob counter clockwise all the way until the tool is completely open (Figure 2).
Warning! Do not try to release the latch, it
is locked in place. The blade can only be
moved in and out by tuning the knob.
3) Insert the cable between roller 1 and
2 as shown in figure: 2.
4) Grasp cable and tool together with
one hand as shown in figure: 2a
5) Slowly spin tool around the cable
while rotating the knob continue until the
aluminum armor cut through. As shown in
figure: 3, 3a