RFS HYBRIFLEX User manual

RFS HYBRIFLEX®
www.rfsworld.com Doc# HYB-GEN-001 rev. B
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RFS’ HYBRIFLEX®Remote Radio Head (RRH) hybrid feeder cabling solution combines optical fiber and
DC power for RRHs in a single lightweight aluminum corrugated cable, making it the world’s most
innovative solution for RRH deployments. It was developed to reduce installation complexity and
costs at Cellular sites. HYBRIFLEX®allows mobile operators deploying RRH architecture to
standardize the RRH installation process. HYBRIFLEX®combines optical fiber (multi-mode or single-
mode) and DC power wire in a single corrugated cable and can connect multiple RRHs with a single
feeder.
HYBRIFLEX®cables are manufactured, pre-terminated, with various types of termination and are cut
to specific lengths. The aluminium outer conductor facilitates easy transportation (because it is light-
weight) and handling. Moreover this cable is easier to bend than other optic / power solutions using
a steel outer conductor.
Click or scan to learn more
about RFS HYBRIFLEX®

RFS HYBRIFLEX®
www.rfsworld.com Doc# HYB-GEN-001 rev. B
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Table of contents
RFS HYBRIFLEX® introduction
1
Table of contents
2
Image of Non-OVP Hybriflex hybrid system
3
RFS Non-OVP HYBRIFLEX® feeder assembly
4
RFS Non-OVP HYBRIFLEX® configurations
5
RFS Non-OVP HYBRIFLEX® Generation 2 Design Enhancements
6
HYBRIFLEX® tower accessories and installation tools
8
IEC standard fiber inspection
9
Fiber interface zones per IEC template 613000-3-3
10
RFS suggested optical testing
13
HYBRIFLEX® handling and installation procedures
14
HYBRIFLEX® hoisting and pulling guidelines
17
Fixation/Mounting of the cable
19
RFS RRH jumper with IP-RC connector installation guide
20
HYBRIFLEX® bulkhead connector fitting installation
22
Additional installation guidelines for all HYBRIFLEX® products
28
Fiber cleaning introduction
29
General reminders and warnings
30
General inspection and cleaning procedures
31
HYBRIFLEX® jacket removal tools instruction
34
Armor cutting tool instructions for 1-1/4 and 1-5/8 inch cables
35
Armor cutting tool instructions for 5/8 and 7/8 inch cables
37

RFS HYBRIFLEX®
www.rfsworld.com Doc# HYB-GEN-001 rev. B
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RFS’ HYBRIFLEX®Remote Radio Head
(RRH) hybrid feeder cabling solution
combines optical fiber and DC power for
RRHs in a single lightweight aluminum
corrugated cable, making it the world’s
most innovative solution for RRH
deployments. It was developed to
reduce installation complexity and costs
at Cellular sites. HYBRIFLEX®allows
mobile operators deploying RRH
architecture to standardize the RRH
installation process. HYBRIFLEX®
combines optical fiber (multi-mode or
single-mode) and DC power wire in a
single corrugated cable and can connect
multiple RRHs with a single feeder.
HYBRIFLEX®cables are manufactured,
pre-terminated, with various type of
termination and are cut to specific
lengths.The aluminium outer conductor
facilitates easy transportation (because
of it is light weight) and handling.
Moreover this cable is easier to bend
than other Optic / power solutions using
a steel outer conductor.
RRH Configuration for
demonstration purpose only
HYBRIFLEX feeder cable can be
ordered as 3x6, 6x12, 9x18, in 2,
4, 6, and 10 gauge wires
Hoisting grip attached no less
than 5 feet from breakout point
BBU Equipment
cabinet/shelter
Clamp spacing
0.9m (3ft) - 1.2m (4ft)
3
Breakout point for
separate fiber and power
conductors
Fiber jumper with
ODC connector
Bulkhead fitting included
with main feeder

RFS HYBRIFLEX®
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Non-OVP HYBRIFLEX® feeder assembly (using ODC (top) & LC (bottom) connectors)
HYBRIFLEX® trunk cable assemblies are factory constructed specifically to suit modern RRH networks,
ensuring perfect compatibility and trouble-free installation. Additional features that ease installation and
ensure durability service include:
Robust breakout design with coloring 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 included with every cable assembly
Robust ODC connector with solid protective caps
Water-proofing seal for DC wire end caps
HB
078/114/158
05/13/21/33
U
6
S or M
12
XX
KIT
Hybrid
Over jacket Diameter
7/8”, 1-1/4”, 1-5/8”
10, 6, 4 and 2
gauge
unshielded
6 pairs DC
conductor
Single or
Multi-mode
(only single)
12
pairs
of
fiber
Assembly
Length (in
meters)
Include
Grounding kit and
Hoist grip
Model Structure
Hybrid
assembly
length
LC termination (enlarged to
show colors)
Color-coded, shielded
power wire conductors
End 2
Bottom BBU
Power
End 1
Top RRH
ODC
termination
on fully-
armored
fiber

RFS HYBRIFLEX®
www.rfsworld.com Doc# HYB-GEN-001 rev. B
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Non-OVP HYBRIFLEX® Generation 2 Design Enhancements
Customers have requested several product enhancements to the HYBRIFLEX® trunk cable designs.
This was due to recent attacks from animals that would permanently damage the fiber optic break-outs at
the top of the assembly, and to shielding power wires to additional transient voltages from lightning
strikes. RFS was able to accommodate these requests by Engineering new features into the existing
models:
Shielded power cables
Each power conductor pair is wrapped with a tinned copper braid, layered with protective jackets
Braid can be “pony-tailed” to a common ground for additional EMI protection
Round profile allows water-tight seal to power connector
Fully-armored fiber optic cable breakouts
Helically-wrapped stainless steel prevents crushing, animal bite damage and over-bending
Armor is layered inside larger corrugation junctions to provide 100% mechanical coverage

RFS HYBRIFLEX®
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6x12 HYBRIFLEX® configurations
Cable type
HB078-05U6S12-
HB114-13U6S12-
HB158-21U6S12-
Cable brand
HYBRIFLEX®
HYBRIFLEX®
HYBRIFLEX®
Conductor gauge
10 AWG
6 AWG
4 AWG
Number of conductor
6 pairs, shielded
6 pairs, shielded
6 pairs, shielded
Number of fibers
12 pairs, armored
12 pairs, armored
12 pairs, armored
Hybrid armor type
Corrugated aluminum
Corrugated aluminum
Corrugated aluminum
Hybrid fiber mode
single
single
single
Hybrid termination
Top: ODC
Bottom: LC
Top: ODC
Bottom: LC
Top: ODC
Bottom: LC
Hybrid weight (kg/m (lb/ft))
1.39 | 0.93
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
1350mm | 53”
1350mm | 53”
1350mm | 53”
Breakout power length, top
4m | 157”
4m | 157”
4m | 157”
Breakout power length, bottom
150mm | 6”
150mm | 6”
150mm | 6”
Hybrid minimum bend radius
125mm | 5”
152mm | 6”
250mm | 10”
ODC
termination
Power
Power
LC
termination
Top

RFS HYBRIFLEX®
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9x18 HYBRIFLEX® configurations
Cable type
HB114-05U9S18-
Cable brand
HYBRIFLEX®
Conductor gauge
10 AWG
Number of conductor
9 pairs, shielded
Number of fibers
18 pairs, armored
Hybrid armor type
Corrugated aluminum
Hybrid fiber mode
single
Hybrid termination
Top: ODC
Bottom: LC
Hybrid weight (kg/m (lb/ft))
2.24 |1.51
Max over jacket diameter
39mm | 1.54”
Breakout fiber length, top
0.5m | 20”
Breakout fiber length, bottom
1350mm | 53”
Breakout power length, top
4m | 157”
Breakout power length, bottom
150mm | 6”
Hybrid minimum bend radius
152mm | 6”
Power
Power
ODC
termination
LC
termination
Top

RFS HYBRIFLEX®
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3x6 HYBRIFLEX® configurations
Cable type
HB078-13U3S6-
HB114-21U3S6-
Cable brand
HYBRIFLEX®
HYBRIFLEX®
Conductor gauge
6 AWG
4 AWG
Number of conductor
3 pairs, shielded
3 pairs, shielded
Number of fibers
6 pairs, armored
6 pairs, armored
Hybrid armor type
Corrugated Aluminum
Corrugated aluminum
Hybrid fiber mode
single
single
Hybrid termination
Top: ODC
Bottom: LC
Top: ODC
Bottom: LC
Hybrid weight (kg/m (lb/ft))
1.03 | 0.7
2.24 |1.51
Max over jacket diameter
28.6mm | 1.13”
39mm | 1.54”
Breakout fiber length, top
0.5m | 20”
0.5m | 20”
Breakout fiber length, bottom
1350mm | 53”
1350mm | 53”
Breakout power length, top
4m | 157”
4m | 157”
Breakout power length, bottom
150mm | 6”
150mm | 6”
Hybrid minimum bend radius
125mm | 5”
152mm | 6”
Top
Power
Power
ODC
termination
LC
termination

RFS HYBRIFLEX®
www.rfsworld.com Doc# HYB-GEN-001 rev. B
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HYBRIFLEX® tower accessories and installation tools
Although RFS suggests that hangers and hoisting grips be part of the hybrid kits, which includes the main
trunk assembly, RFS can offer these items to be ordered separately if need be.
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

RFS HYBRIFLEX®
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IEC standard fiber inspection
Non-OVP Hybriflex optical interface connectors
In addition to the LC and ODC connectors on the main
trunk, jumpers with ODC plug and socket connectors
attach the RRH to the main trunk.
Tools and test equipment
Use only approved test equipment recommended by RFS.
Note: It is recommended that the main feeder be tested
using ODC to LC test adapters and not the actual
HYBRIFLEX® jumper.
Safety Caution!
Operator should always assume fiber optic cables are live;
laser radiation can cause irreversible damage or injury to
the human eyes.
Optical end-face Inspection
It is industry standard as per the IEC document 61300-3-25
1.0 that all optical fiber end-face are inspected and cleaned
before mating. Please refer to the cleaning procedure
within this document if need be.
LUCENT
Connector (LC)
ODC Plug
ODC Socket

RFS HYBRIFLEX®
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Zone
Description
Diameter
Allowable defect
diameter
Allowable size
scratches
A
Core zone
25μm
None @200x
None @200x
B
Cladding
zone
25-120μm
Less than 2-5μm,
none > 10μm
No greater than 3μm
C
Adhesive
zone
120-130μm
None >10μm
Any scratch ok
D
Contact
zone
130-250μm
None> 10μm
Any scratches ok
Fiber interface zones, per IEC Template 613000-3-3 (for single-mode fiber)
A. Critical zone
B. Cladding zone
C. Adhesive zone
D. Contact zone

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LC connector inspection
1. Inspect the LC fiber end-face using approved test equipment probe and the appropriate
LC fiber tips. If the test fails due to too much debris, clean end-face accordingly and re-
test.
ODC connector inspection
2. Inspect the ODC fiber end-face using the approved test equipment probe and the
appropriated ODC plug and ODC socket fiber tips. If the test fails due to too much dirt
clean end-face accordingly and re-test.
a. Unscrew the ODC cap (Caution! Protect cap against dust during the testing process).
b. Insert ODC plug or socket tips into the ODC plug or socket connector as shown in figure A,
Band inspect each connector (Caution! Make sure that tip is inserting fully into the
connector to prevent any false image or damage).
c. Adjust inspection probe zoom until image can be viewed clearly.
LC end-face inspection
Fail
Pass
ODC plug, Figure A
ODC socket, Figure B

RFS HYBRIFLEX®
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Important Note: In the event of failure, clean connectors as shown below, refer to optical fiber cleaning
section within this document for additional cleaning suggestions.
Cleaning ODC plug and socket connector
If the ODC plug or socket end-face shows any particles or debris, clean the end-face using the following
1.25mm one click cleaning or swab stick.
Swab stick
(Use as recommended)
One-click cleaner
used on the appropriate tip for plug and socket
Clean the ODC socket using the Swab stick, gently moisten the cleaning swab tip with a
alcohol or Electro-Wash pen wet solution and gently clean each connector
Cleaning ODC plug using the
one-click cleaner
Cleaning ODC socket using the
1.25mm one-click cleaner

RFS HYBRIFLEX®
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Non-OVP optical testing
Note: OTDR uni-directional measurements lead to inaccuracies when fibers with different Mode Field
Diameters (MFD) are connected. The inaccuracies usually are in the form of “gainers” or “exaggerated
losses”. At MFD mismatched connection OTDR backscattered light is greater or smaller, depending on the
direction. Specifically, the capture fraction in an optical fiber is inversely proportional to the mode-field
diameter squared. Thus, when two fibers of dissimilar mode field diameter are connected together,
measurable differences in back reflected signal will occur that will add additional 0.1 to 0.5dB per IL
connection. This is an OTDR testing issue only and does not affect cable performance and actual optical
loss. In order to avoid this issue OTDR testing must be done bi-directionally per FOTP-61
RFS suggests that all Hybriflex cables be tested using Loopback loss method -
Use only RFS-approved test equipment and loopback patch cords
Perform only recommended tests
Keep all cleaners, adapters and calibration items clean & free of any contamination
Replace any old, worn adapters and test cables
Test all individual components before mating
Used only single-mode fiber accessories. Do not mix-match adapter or loopback devices.
Typical system insertion loss table (using power meter only to measure insertion loss)
Fiber characteristic
Single-mode
Light propagation mode
1310 and 1550 nm
IL per connector one way
0.25 dB
Reflectance
Min 50 dB
Max system fiber loss allowed
4 dB (2 dB up and 2 dB down)
Field Jumpers testing
Connect the HYBRIFLEX® jumper cable to the ODC plug test lead as shown below, and follow test
equipment instructions. Refer to the system insertion loss table for pass/fail criteria when recording
results.
Note: ODC plug and socket can be mated securely by hand but if need be use, approved torque wrench
with the applicable torque of 1 N-m to firmly secure the connection. Test equipment and reference cables
should be reset prior to each measurement.

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System loss measurement (sector jumper connected to main assembly)
Verify that all end-faces are clean and free of any debris.
Connect loopback and test equipment as shown Follow
test equipment instructions to record test result, referring
to the system insertion loss table for pass/fail criteria.
Note: When using OTDR, the longer the loopback the
better the test result. RFS recommends a loopback of 30m
(min) be used. Lookback modules may be used with
power meters but not recommended for OTDR.
HYBRIFLEX handling and installation procedures
HYBRIFLEX® cable should be handled and installed according to the same rules, instructions and
regulations as typical coaxial cables.
Test diagram using ODM
power meter or similar
device
Breakout
termination
HYBRIFLEX cable
HYBRIFLEX®
Jumper
Fiber
breakout
Loopback
recommenm
Loopback
Module
Test diagram
using OTDR
device

RFS HYBRIFLEX®
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These short instructions were written for qualified and experienced installers. They describe, in short, the
main points that have to be noted during the 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 any strain that may cause permanent deformation on the armor
and exposed fiber end-face, like exceeding bending radii, kinking, applying too high tensile stress or
forcible deformation of the corrugated outer conductor (e.g. pulling over sharp edges, over tightening of
clamps, etc.).
Transport/shipment & handling of the drum
Drums have to be handled carefully, in order to avoid any damage to the drum and/or the cable.
Do NOT remove protective wooden covering until ready to install cable at final location.
If the drum will be shipped by van or truck, the drum has to 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. Roll the drum from the vehicle by using planks or 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 proper dispersion of weight 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 secured and fixed as close as possible to the drum core.
Note the required rotation direction of the drum, which is shown by an arrow on the drum flange.

RFS HYBRIFLEX®
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Handling of 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, protective measures must be
taken, such as positioning additional rigging at
those critical places.
If cables have to be pulled in horizontal runs, use
pipe rollers, wooden planks or similar devices.
Prevent any pinches to the DC wires, which may
cause electrical spikes and short-circuits.
HYBRIFLEX®cable, with aluminium outer conductor, is easy to bend, but must be handled carefully.
Do not twist the cable, e.g. if changing from vertical to horizontal run. The minimum bend
radius should be strictly observed (see product spec sheet for details).
HYBRIFLEX®cable should be bent manually with a force evenly distributed. While applying,
carefully slide your hand slides along the cable [see Diagram 1 below]. Avoid sharp motions.
While pressing, slide your hand
Diagram 1

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HYBRIFLEX® hoisting and pulling
Note: when hoisting and pulling HYBRIFLEX® always uses caution.
Do not remove the protective sock. If removed during pre-test, re-attach securely before
hoisting
Do not attach hosting grip over protective sock
Hoisting grips should be attached no less than 5 feet from breakout point
Breakout point
No less than 5 feet

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HYBRIFLEX® Cable is supplied in specific cut length, with fully terminated 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 the approved supplied hoisting grip, use tie back rope or
additional electrical tape if needed to prevent any stress or force to the
fiber and protective sock.
Only use the approved lace up hoist grip included with the main trunk
HYBRIFLEX® cable. Do not use closed lacing hoisting grips!
For very long vertical runs of cable, additional hoisting grips should be
attached at 50 –60m (150 –180 ft) intervals.
Add the hoist line to the hoisting grip or ropes sling; protect the
HYBRIFLEX® against shackles.
Make certain to allow slack in the cable between the hoisting grips in
case more than one is used, so each one can carry weight, and ensure
the slack is maintained during hoisting. Hoist the cable slowly.
Caution! Pay-out must be resistive to prevent buckling of the cable.
When unspooling, keep reel secure so it does not accidentally come
loose.
If it is necessary to drag the cable over sharp edges of buildings and
tower members, protective measures must be taken.
Careless handling can damage the protective layers and eventually
causing damage to fiber strands or end-faces 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 it from hitting any tower steel work.
Caution! Protective sock should not be removed until installation is
complete.
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 guidelines and parameters
Avoid any tight bends near the fiber connector boot as micro-bends can cause broken fibers or
increase insertion loss (see diagram 2 & 3 below).
Do not leave the 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, like
temporarily anchoring 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
Diagram
2
Diagram
3