MODULNET Carrierband Network

Siemens Energy & Automation, Inc. Installation and Service Instruction SD39MODULNET-1 Rev: 4 February 2003 MODULNET Carrierband Network

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SD39MODULNET-1 Contents Table of Contents Section Title Page 1.0 Introduction...1-1 1.1 Product Description...1-2 1.2 Specifications...1-7 1.2.1 Communications...1-7 1.2.2 MODULNET Hardware...1-7 1.2.3 Environmental...1-9 1.3 Glossary...1-10 1.4 Product Support...1-10 1.5 Related Literature...1-12 2.0 Installation...2-1 2.1 Installation Considerations...2-1 2.1.1 Trunk Cable...2-1 2.1.2 Trunk Tap...2-2 2.2 MODULNET Design...2-3 2.2.1 MODULNET Documentation...2-3 2.2.2 Safety Considerations...2-4 2.2.3 Procedure...2-4 2.2.4 MODULNET Length...2-7 2.2.4.1 Graphical Method...2-8 2.3 Tap and Cable Installation...2-11 2.3.1 Tools and Test Equipment...2-11 2.3.2 Tap Installation...2-12 2.3.3 Trunk Cable Installation...2-14 2.3.3.1 Trunk Cable Installation Procedure...2-15 2.3.3.2 Trunk Cable Fabrication Procedure...2-18 2.3.3.3 M-NET Cable Recommendations...2-23 2.3.4 Drop Cable Installation...2-24 2.3.4.1 Drop Cable Installation Procedure...2-24 2.3.4.2 Drop Cable Fabrication Procedure...2-25 2.3.4.3 M-NET Cable Recommendations...2-30 2.3.5 MODULNET Testing...2-31 2.3.5.1 Trunk Return Loss Measurement...2-31 2.3.5.2 Trunk Noise Level Measurement...2-32 2.3.5.3 Drop Cable-to-Tap Return Loss Measurement...2-33 2.3.5.4 Drop Cable Noise Level Measurement...2-33 2.3.5.5 Signal Level Measurement...2-33 2.3.5.6 Cable Sealing and Boots...2-36 3.0 Circuit Description...3-1 4.0 Maintenance...4-1 4.1 Tool and Equipment Requirements...4-1 4.2 Visual Inspection...4-1 4.3 MODULNET Troubleshooting...4-2 February 2003 i

Contents SD39MODULNET-1 4.3.1 Advance Diagnostics Techniques Beyond this checklist...4-5 4.4 MODULNET Testing...4-6 4.5 Tap or Cable Segment Replacement...4-7 4.6 Spare and Replacement Parts...4-7 4.7 Return of Shipment...4-7 List of Tables Table Title Page Table 1 1 MODULNET Hardware...1-1 Table 1 2 MODULNET Accessories...1-1 Table 1 3 TIC Contact Information...1-11 List of Illustrations Figure Title Page Figure 1 1 MODULNET Local Area Network...1-3 Figure 1 2 MODULBUS Expander Module and Transition Board...1-5 Figure 1 3 MODULNET Redundancy...1-6 Figure 2 1 MODULNET Taps...2-5 Figure 2 2 MODULNET Length vs. Number of 2-Port Taps...2-9 Figure 2 3 MODULNET Length vs. Number of 4-Port Taps...2-10 Figure 2 4 Tap Mounting within MODULPAC...2-13 Figure 2 5 F-Male Connectors for RG-6 and RG-11 Cables...2-17 Figure 2 6 Network Signal Level Analysis Example...2-35 Significant Changes for Revision 4 2.3 Tap and Cable Installation Addition of trunk cable and drop cable fabrication procedures. ii February 2003

SD39MODULNET-1 Introduction 1.0 Introduction This manual provides installation and service information for MODULNET hardware and accessories as listed in Table 1-1 and Table 1-2 below. Table 1 1 MODULNET Hardware Part Number Description 14753-1 Trunk Cable Tap, 2 Port 14753-3 Trunk Cable Tap, 4 Port 14753-2 F-Type 75 Ohm Terminator W2077 RG-6 Drop Cable (length specified by user) 16056-440 RG-11 Trunk Cable (200 meter reel) 16056-441 RG-11 Trunk Cable (400 meter reel) 16056-442 RG-11 Trunk Cable (800 meter reel) Table 1 2 MODULNET Accessories Part Number Description 14784-501 F-Type Connector, RG-11 (one connector) 14784-500 F-Type Connector, RG-6 (one connector) 15753-2 F-Type Precision Terminator, 75 Ohms (one terminator) 16137-68 MNET A Drop Cable with Dropsaver, 19.7 Ft (6 M) 16137-69 MNET B Drop Cable with Dropsaver, 19.7 Ft (6 M) 16056-411 Dropsaver F Connector Protector 16056-371 MNET 2-Port Tap Kit (with mounting brackets and terminators) 16056-372 MNET 4-Port Tap Kit (with mounting brackets and terminators) 16056-438 MNET RG-6 Drop Cable Kit (with connector sealing boots, dropsavers, 163 Ft/50 Meter RG-6 cable, and Instructions) 16056-374 MNET RG-11 Connector Kit (with connector sealing boots, dropsavers, cable markers, and Instructions) 16056-378 MNET Cable Preparation Tool Kit (with RG-6 and RG-11 connector crimping tools) 16056-377 Tap Support Bar (mounting base for tap mounting bracket) 16056-318 Tap Mounting Bracket (for mounting taps in a cabinet) 16056-660 25 in-lb Torque Wrench February 2003 1-1

Introduction SD39MODULNET-1 This Instruction is divided into four major sections: Section 1, Introduction Provides a list of hardware, cables, and accessories, a brief product description, specifications, and a glossary of terms. Section 2, Installation Furnishes hardware selection considerations, MODULNET design parameters, cable installation and test procedures, hardware identification and installation procedures. Section 3, Circuit Description Contains a brief description of the MODULNET. Section 4, Maintenance Consists of preventive maintenance and troubleshooting procedures, hardware removal and replacement references, and recommendations for spare and replacement parts. 1.1 Product Description A MODULNET is a carrierband network that permits plant-wide expansion of the APACS+ redundant MODULBUS, interconnecting Local Area Systems* (LAS) over short or long distances. A MODULBUS Expander Module (MBX) and an MBX transition board must be installed in a MODULRAC at each Local Area System. A MODULNET is installed when the local MODULBUS in a Local Area System is to be interconnected with the local MODULBUS in another Local Area System. This permits the exchange of process data and process control commands. Figure 1-1 is an illustration of a redundant MODULNET interconnecting three Local Area Systems in three separate plant areas. Each Local Area System is represented by an MBX and an MBX Extended Transition Board. MNET A is at the top of the figure, MNET B at the bottom. Each MNET (A or B) is independent and bi-directional. It consists of coaxial trunk and drop cables, taps, port terminations, end-of-trunk terminations, and the MODULBUS (A and B) in each LAS. The trunk cable connects to drop cables through nondirectional, passive, impedance-matching taps. A drop cable connects to an MBX transition board. 1-2 February 2003

SD39MODULNET-1 Introduction Figure 1 1 MODULNET Local Area Network February 2003 1-3

Introduction SD39MODULNET-1 Figure 1 2 shows an MBX and the MBX transition board. An MBX communicates with other MBXs on a MODULNET by sending and receiving MODULBUS communications across the redundant MNET. When an MBX and its transition board are installed in a MODULRAC, the transition board's Module Connector and the MBX's bottom connector (on its rear panel) are mated. Communication signals flow to and from the MODULNET through this mated pair. The MBX's top connector (also on its rear panel) mates with a connector on the MODULRAC backplane for access to the MODULBUS. The MBX has two independent channels to transfer information between the MODULBUS and the MODULNET. A System Node Address (SNA) must be assigned to each MBX so that communications can be addressed to it. Rotary switches in the MBX bezel compartment are set to assign an SNA. As shown in Figure 1 3, rack-to-rack and module-to-module redundancy are available. Rack-To-Rack Redundancy - Two MODULRACs are involved, each with an MBX. The racks must be identical with respect to module selection and slot location. Different System Node Addresses are assigned to the two MBXs. MNET A and MNET B are connected to both MBXs. Module-To-Module Redundancy - One MODULRAC is involved with two MBXs installed in adjacent slots. They are assigned the same System Node Address. One MBX will service MODULNET A and the other MODULNET B. The unused side of each MBX will not be connected to the MODULNET. *In this Instruction, the term Local Area System includes Unit Controllers. 1-4 February 2003

SD39MODULNET-1 Introduction Figure 1 2 MODULBUS Expander Module and Transition Board February 2003 1-5

Introduction SD39MODULNET-1 Figure 1 3 MODULNET Redundancy 1-6 February 2003

SD39MODULNET-1 Introduction 1.2 Specifications 1.2.1 Communications Local Area Network (MODULNET) IEEE 802.4 (Carrierband) Network Capacity 64 nodes (0 through 63) Signal Direct Encoded Data Signal Modulation Phase Coherent FSK Signal Protocol Deterministic Token Passing Data Rate 5 Mbps MBX to MODULNET Connection Non-Directional Tap 1.2.2 MODULNET Hardware W2077 Drop Cable Type RG-6 Carrierband Network Cable IEEE 802.4 Impedance 75 Ohms +/-2 Ohms Signal Attenuation (5 Mhz) 2.16 db/100 meters 0.66 db/100 feet Signal Attenuation (10 Mhz) 2.52 db/100 meters 0.77 db/100 feet Transfer Impedance 10 milliohm/meter Max. Conductor Size 18 AWG solid Shielding Quad (4) Shields Maximum Pulling Tension 45 lbs. (20.4 kg.) Bend Radii 3.0 inches Pulling Limit 45 lbs. (20.4 Kg) W2078 Standard Trunk Cable Type Impedance Signal Attenuation (5 Mhz) Signal Attenuation (10 Mhz) Transfer Impedance RG-11 Carrierband Network Cable IEEE 802.4 75 Ohms +\-2 Ohms 0.89 db/100 meters 0.27 db/100 feet 1.21 db/100 meters 0.37 db/100 feet 10 milli-ohm/meter Max. February 2003 1-7

Introduction SD39MODULNET-1 Conductor Size Shielding Structural Return Loss Cable Jacket Band Marks Maximum Pulling Tension Bend Radii Minimum Length Pulling Limit 14 AWG solid Quad (4) Shields 26 db (5 to 450 Mhz) Every 2.6 meters (8.5 ft.) 150 lbs. (68.1 kg) 7.0 inches 2.6 meters (8ft 6 in) 150 lbs. (68.1 Kg) Armored Trunk Cable Type Impedance Signal Attenuation (5 Mhz) Signal Attenuation (10 Mhz) Transfer Impedance Conductor Size Shielding Armor Structural Return Loss Cable Jacket Band Marks Bend Radii Armored RG-11 Carrierband Network Cable IEEE 802.4 75 Ohms +\-2 Ohms 1.14 db/100 meters 0.35 db/100 feet 1.48 db/100 meters 0.45 db/100 feet 0.8 milliohm/meter Max. 14 AWG solid Quad (4) Shields 1 (Steel or Aluminum) 26 db (5 to 450 Mhz) Every 2.6 meters (8.5 ft.) 10 times od (outside diameter) NOTE Avoid runs of multiple of 45 to 55 feet (1/4 wave = 49.2 ft.) Carrierband Tap Type (Hi-Rel) Drop Ports Drop-to-Trunk Port Attenuation Trunk-to-Drop Port Attenuation Drop-to-Drop Isolation Trunk Insertion Loss (2-port tap) Hi-Rel Industrial Grade IEEE 802.4 Standard & MAP Carrier- band Tap 2 or 4 Ports 20 db +\-0.5 db 20 db +\-0.5 db 30 db Min. 0.3 db Max. 1-8 February 2003

SD39MODULNET-1 Introduction Trunk Insertion Loss (4-port tap) Impedance, all ports Surge Protection, each port Pin Connector Finish Trunk Cable Isolation Operating Temperature 0.45 db Max. 75 Ohms Gas Discharge Surge Protector Gold Plated Trunk cable segments MUST be connected between the non-isolated (grounded) trunk port (T2) and the isolated port (T1) of 2 taps (e.g., T1 connect to T2). -40 C to +84 C (-58 F to +183 F) Connectors Type Contact Finish F-Series Industrial Grade, EIA FD Standard 550 Cable-end male Gold Plated Terminator Type Return Loss Nominal Impedance Contact Finish Precision F Type 40 db min. @ 10 Mhz. 75 Ohms Gold Plated 1.2.3 Environmental Operating Temperature Storage Temperature Humidity Range 0 to 60 C (32 to 140 F) 0 to 85 C (32 to 185 F) 5 to 95% Non-Condensing IMPORTANT The MODULNET is a high performance digital data link for which the cables and hardware listed in section 1 and described above are highly recommended. Any substitutes MUST BE ELECTRICALLY EQUIVALENT and meet the IEEE 802.4 specifications for carrierband service. Failure to use proper cables and hardware can result in erratic MODULNET performance. February 2003 1-9

Introduction SD39MODULNET-1 1.3 Glossary The following are definitions of terms used in this Instruction: Attenuation - The reduction of a signal's level as it travels along a cable. (Expressed as a relative value in db.) Baseband - A type of cable network that supports only one signal at a time. Carrierband - A type of baseband network used in the factory. The MODULNET is a carrierband network. Drop Cable - The cable connecting the tap to the MODULBUS Expander Module. Frequency Shift Keying (FSK) - The carrierband signaling method. Binary ones are one cycle of 5 Mhz; binary zeros are two cycles of 10 Mhz. Insertion Loss - The amount of loss of the signal passing through a tap on the trunk cable. (Expressed as a relative value in db.) Nondirectional - Signal from the drop cable splits equally in both directions from a tap onto the trunk cable. Return Loss - The amount of signal reflected from a cable impedance discontinuity. Tap - A passive non-directional impedance matching device for connecting the MBX to the MODULNET (trunk cable). Termination - A device which absorbs signals at the end of a trunk cable. 1.4 Product Support Product support can be obtained from a Technical Support Center (TSC). Each regional TSC is a customer service center that provides direct telephone support on technical issues related to the functionality, application, and integration of all products supplied by Siemens. Regional TSC contact information is provided in Table 1 3. Your regional TSC is the first place you should call when seeking product support information. When calling, it is helpful to have the following information ready: Caller name and company name Product part number or model number and version If there is a problem with product operation: - Whether the problem is intermittent - The steps performed before the problem occurred - Any error messages or LED indications displayed 1-10 February 2003

SD39MODULNET-1 Introduction - Installation environment Customers that have a service agreement (ServiceSuite or Field Service Agreement) are granted access to the secure area of our Web site (http://www.smpa.siemens.com/techservices/techlibrary.asp). This area contains a variety of product support information. To log on, you will be prompted to enter your username and password. Table 1 3 TSC Contact Information Tel: +1 215 646 7400, extension 4842 TSC NORTH AMERICA Fax: +1 215 283 6343 E-mail: TICGroupNA@sea.siemens.com Hours of Operation: Secure Web Site: 8 a.m. to 5 p.m. eastern time Monday Friday (except holidays) www.sea.siemens.com/process/product/papao.html Tel: +011 65 740 7818 TSC ASIA Fax: +011 65 740 7817 E-mail: TICGroupAP@sea.siemens.com Hours of Operation: Secure Web Site: 8:30 a.m. to 5:30 p.m. Singapore time Monday Friday (except holidays) www.siemens.com Tel: +44 (0) 1905 450930 TSC EUROPE Fax: +44 (0) 1905 450931 E-mail: TICGroupEurope@spa.siemens.co.uk Hours of Operation: Secure Web Site: 8:30 a.m. to 4:30 p.m. GMT/BST Monday Friday (except holidays) www.siemens.com February 2003 1-11

Introduction SD39MODULNET-1 1.5 Related Literature The following Instructions should be available for reference during a MODULNET installation. MODULBUS Expander Module Installation and Service Instruction (document number SD39MBX-1) MODULPAC Installation and Service Instruction (document number SD39MODULPAC-1) MODULRAC Installation and Service Instruction (document SD39MODULRAC-1) ANSI/IEEE 802.4, 1990, Token Passing Bus Access Method and Physical Layer Specifications; a copy can be obtained from the following addresses: U.S.A.: American National Standards Institute Attn: Customer Service 11 West 42nd Street New York, NY 10036 Phone Orders: 212-642-4900 Europe: ISO 1,Rue, De Varembe CH-1211 Geneva 20 Switzerland/Swiss Phone: 4122749011 " 1-12 February 2003

SD39MODULNET-1 Installation 2.0 Installation This section describes design and installation of a redundant MODULNET including taps, terminations, and trunk and drop coaxial cables. Read this entire section before beginning an installation. Refer to the MODULBUS Expander Module's Installation and Service Instruction (document number SD39MBX-1) as necessary during the installation. 2.1 Installation Considerations Before beginning to install MODULNET hardware, complete the following: 1. System Layout Design the MODULNET cable-system (see section 2.2) and select MODULNET hardware (refer to section 1.0, section 1.3, and section 2.1.1 in this Instruction and the MODULBUS Expander Module Instruction). Avoid areas containing environmental contaminants that could damage cables. If this is not possible, use installation techniques to control contamination. 2. Install taps (see sections 2.1.2 and 2.3.2). 3. Prepare and install trunk cables (see section 2.3.3). 4. Prepare and install drop cables (see section 2.3.4). 5. Test installed MODULNET (see section 2.3.5) 6. Refer to MODULBUS Expander Module Installation and Service Instruction to connect drop cables and set MNET A and B switches. 2.1.1 Trunk Cable Trunk cable specifications are listed in section 1.2. Cable is available in flexible and armored versions. Flexible cable is used in most installations, however, armored cable has advantages and disadvantages, as discussed later in this section. For a Superior Installation: Use a high quality cable designed for IEEE 802.4 carrier band service from one manufacturer for the entire trunk to maintain constant impedance between cable segments. Prior to shipment, have the manufacturer test the cable to ensure that it meets attenuation specifications and that concealed (internal) discontinuities that can cause reflections do not exist. - Structural Return Loss from both cable ends: Loss should be -26 db or better. February 2003 2-1

Installation SD39MODULNET-1 - Cable attenuation: Refer to the manufacturer's specification for the length of cable on the reel. The attenuation is measured at 10 Mhz. The cable manufacturer should provide a test document with each reel of cable listing the following: - Manufacturer's Lot Number - Cable Attenuation @ 5 and 10 MHz. - Structural Return Loss - Tilt per Distance - Cable Impedance - Group Delay Distortion - Maximum Cable Length The maximum cable length is an important cable parameter. It specifies the maximum length the cable can be and remain within the IEEE Standard 802.4 specification. Pretested RG-11 trunk cable can be ordered from Siemens. See Table 1 1. All segments of trunk cable for MNET A, or for MNET B, should come from one reel. If more than one reel is required to fabricate the entire A or B trunk, use a reel from the same lot (same extruder at the same time of manufacture). It is the extruder-to-extruder differences that create slightly different characteristic impedances which cause unwanted signal reflections. Splicing a trunk cable segment is not recommended for a new installation. Armored Cable Advantages and Disadvantages: Superior protection from factory electrical noise. Its higher transfer impedance is indicative of its ability to reject unwanted shield currents. Can be buried without installation in conduit. Can be hung between poles separated by up to 150 feet (46 meters) without the need for messenger wire support. Protected against moisture and physical damage. More complex installation. For example, it must be formed to make bends and turns. Requires grounding of the armor for lightning protection and additional noise immunity. 2.1.2 Trunk Tap This section discusses tap mounting locations and methods. Figure 2 1 shows 2-port and 4-port taps. 2-2 February 2003

SD39MODULNET-1 Installation NOTE Taps are known as 2-port and 4-port taps. This refers to the number of drop ports. Both taps also have two trunk ports. Each tap will have connected to it one or two trunk cables and one to four drop cables. The taps at each end of an MNET must have a 75 ohm termination installed in the trunk port that is not connected to a trunk cable. Unused drop ports must also be terminated. NOTE All Taps must be grounded by connecting the tap s ground lug to a ground point. Do not float tap. Two taps are needed for a Local Area System to connect to a redundant MODULNET. They can be mounted either inside a cabinet housing an MBX or external to the cabinet. External Tap: At each Local Area System (LAS), mount the taps as close as possible to the cabinet housing the MBX to minimize drop cable length. Mount the taps with user supplied hardware. When the trunk cable is aerially suspended and a tap is suspended in mid-air, provide a messenger cable for support and cable strain relief to prevent axial cable loads at the tap connections. Internal Tap: MNET 2-Port and 4-Port Tap Kits (seetable 1 2) include a tap mounting bracket for the rail mounting of taps in a MODULPAC cabinet. A mounting instruction is included in each kit. Mounting a tap internally yields the shortest drop cable which can permit additional taps or a longer trunk. This may be offset by the additional trunk cable often needed to reach the internally mounted tap. 2.2 MODULNET Design The design of the MODULNET (MNET) requires consideration of a number of parameters, including safety, environment, number of taps, and trunk and drop cable lengths. The following sections discuss these and other topics. 2.2.1 MODULNET Documentation Network documentation should be created during the design phase. The documentation can be used by cable system installers to route the cable, install and mark taps, and compare calculated signal values with measured values. It will also assist in visualizing the installation during the design phase and provide a reference for servicing the network and for future additions to the network. A permanent record of the network's physical structure and performance characteristic should include the following: February 2003 2-3

Installation SD39MODULNET-1 - Trunk and drop cable routes - Length of each trunk and drop cable segment - Trunk cable segment identifier (ID) and drop cable ID (including cabinet ID and MODULRAC slot number of the MBX to which it connects) - Each tap type and ID - Calculated trunk port SIGNAL IN/OUT level at each tap - Calculated drop port SIGNAL IN (to MBX) level at each tap - Measured return loss value of finished trunk 2.2.2 Safety Considerations The installation should include the following safety considerations: IMPORTANT The installation must comply with the National Electrical Code and all other applicable construction and electrical codes. 1. Physically isolate MODULNET components from all power or lighting circuits. 2. Properly ground all MODULNET taps to provide for: The dissipation of static charges in MODULNET cables. The shunting to ground of high-energy transients (surge protection) 3. Ensure that safety grounds to which various MODULNET components are connected are at the same electrical potential. 2.2.3 Procedure This section contains a series of steps for designing a MODULNET that will meet IEEE 802.4 specifications. IMPORTANT MNET A and B must have the same number of taps and MBXs, although trunk lengths can be different if they are within the limits of the IEEE 802.4 specifications 2-4 February 2003

SD39MODULNET-1 Installation Figure 2 1 MODULNET Taps 1. Refer to the user documentation listed in section 1.5, Related Literature, for information regarding proposed MODULNET requirements. Note the location of each Local Area System (LAS) and the location of each cabinet that will house an MBX. February 2003 2-5

Installation SD39MODULNET-1 An MBX and transition board (or redundant MBXs and transition boards) must be installed at each LAS. Note module-to-module and rack-to-rack redundancy requirements. See Figure 1 3. Module-to-Module Redundancy - One MBX will service MNET A and the other MNET B. The unused A or B side of each MBX is turned off. Rack-to-Rack Redundancy - Completely duplicates the MBX, control, and I/O module subsystem for maximum availability. Both MBXs are connected to MNET A and B. 2. Determine the location of each 2-port and 4-port tap and record the number of taps required and the estimated length of each drop cable. If the plant already exists, determine the tap locations and estimate and record the length of the associated drop cables. If the plant is being designed, tap locations and estimated drop cable lengths should be specified as an installation drawing. Include extra taps for future Local Area Systems additions. Provide ports for test points at critical locations on the network, for example, at each end of the trunk cable, where the trunk cable enters an inaccessible area, and where a trunk cable enters or leaves a building. Select a cable routing medium (e.g., conduit, raceway, trough) for trunk and drop cables. 3. Determine the maximum allowable end-to-end trunk length. Refer to section 2.2.4 for a the graphical and calculation methods. Then return to step 4 below. 4. Estimate the length of each between-taps trunk cable segment. Estimate as accurately as possible the length of each trunk cable segment. Refer to plant drawings. The sum of all cable segments must be equal to or less than the total allowable end-to-end trunk cable length. Each trunk cable segment must be installed in increments of 8 ft. 6 in. (2.6 meters) which are clearly marked by bands on the cable's outer sheath. Note the following: - Minimum trunk cable segment: 8 ft. 6 in. (2.6 meters) - Maximum trunk cable segment: The maximum trunk cable segment length is a function of the end-to-end trunk length and number of taps between cable segments. 5. Determine secure routes for MNET A and MNET B cables from tap to tap. 2-6 February 2003

SD39MODULNET-1 Installation To improve system reliability, MNET A and MNET B should follow separate routes between taps so that a single accident will be unlikely to damage both cables. A secure route is one that also eliminates or minimizes induced noise which can degrade system reliability. Use a direct route whenever possible to minimize trunk cable length. Estimate and record the length of each segment (i.e., each length between two taps). Select a suitable passage medium (conduit, flexible armor, cable trays, aerial post-to-post, etc.) to accommodate the trunk cables. 6. Compare the estimated sum of trunk cable segment lengths from step 4 with the maximum allowable end-to-end trunk length determined from step 3. The estimated end-to-end trunk lengths of MNET A and MNET B must be less than or equal to the maximum allowable trunk length. IMPORTANT If the estimated trunk length exceeds the maximum allowable trunk length, consult a Siemens engineer for options to extend trunk length. 2.2.4 MODULNET Length The MODULNET must be within the length determined in this section to ensure reliable communications. MODULNET maximum length is affected by: Trunk and drop cable signal attenuation The number of 2-port and 4-port taps and the signal attenuation caused by these taps The MODULNET maximum length for the needed number of taps can be determined by either of two methods: Graphical Method: Estimated from the graphs in Figure 2 2 and Figure 2 3. Calculation Method: Calculated by a formula provided in Appendix A. The formula describes the relationship between trunk cable length, the number and type of taps, and the length of drop cables. The formula must be used when the MODULNET consists of a mixture of 2-port and 4-port taps excluding the end-of-trunk taps. Section 2.2.4.1 describes the use of the graphs to determine the number of allowable taps versus a given MODULNET length or vice versa. February 2003 2-7

Installation SD39MODULNET-1 2.2.4.1 Graphical Method The graphs in Figure 2 2 and Figure 2 3 are applicable to MODULNETs consisting of only 2-port or 4- port taps. The graphs were generated using the formula in Appendix A and the cable and tap specifications in section 1.2. The number of allowable taps per MODULNET length shown in the graphs EXCLUDES both end-oftrunk taps and represents the number of taps allowed between the end-of-trunk taps. IMPORTANT End-of-trunk taps can be of the same type or one of each type. The type of end-of-trunk taps used is independent of the composition of the intervening taps. Several examples show use of the graphs. While the examples refer to Figure 2 2, the 4-port graph in Figure 2 3 is used identically. Read the graphs carefully to avoid errors which could result in a poorly performing MODULNET. Example 1: Find the maximum allowable MODULNET trunk length. Known: Longest (estimated) Drop Cable = 120 Ft. Total Taps = 14 Tap Type = 2-port 1. Figure 2 2 (2-port tap graph) is applicable to this example. 2. Since the graph excludes the two end of trunk taps, subtract 2 from the total number of taps (14). 3. Find curve E for the 130 ft. drop cable. 4. Locate on the horizontal NUMBER OF 2-PORT TAPS scale the point for 12 taps. Follow the vertical line to curve E. 5. From the above point on curve E, move horizontally to the MODULNET LENGTH scale to read the allowable MODULNET length. For this example, the MODULNET length is an estimated 1725 feet. 2-8 February 2003

SD39MODULNET-1 Installation Figure 2 2 MODULNET Length vs. Number of 2-Port Taps February 2003 2-9

Installation SD39MODULNET-1 Figure 2 3 MODULNET Length vs. Number of 4-Port Taps 2-10 February 2003

SD39MODULNET-1 Installation Example 2: Find the maximum allowable number of 2-port taps. Known: MODULNET length (estimated) = 1900 Ft. Longest (estimated) drop cable = 60 Ft. 1. Figure 2 2 (2-port tap graph) is applicable to this example. 2. Locate on the graph the intersection of the horizontal 1900 ft. line and curve C. 3. Move down vertically and read the number of allowable taps from the horizontal tap scale. Note that the value of the tap number falls between 13 and 14 taps. Fractional numbers are rounded down to the lowest whole number, which is in this case, 13 taps. Adding the two end-of-trunk taps (any type) gives a total of 15 taps across the MODULNET. Example 3: Find the allowable drop cable length. Known: MODULNET length = 1300 ft. Number of taps (excluding end-of-trunk taps) = 20, 2-port taps 1. Figure 2-2 (2-port tap graph) is applicable to this example. 2. Locate on the graph the intersection of the 1300 ft. horizontal line and 20 tap vertical line - between the C and D curves. 3. Note that the span between the C and D curves is 40 ft. 4. Estimate from the intersection of the 1300 ft. and 20 tap lines that the allowable longest drop cable length is 75 ft. 2.3 Tap and Cable Installation The procedures in the following subsections are for installing taps, trunk cables and drop cables. It may be necessary to modify these procedure to accommodate the installation site, available tools and test equipment, or local ordinances. 2.3.1 Tools and Test Equipment Typical tools and test equipment are listed below. They are supplied by the installer. Cable preparation and installation tools for RG-6 and RG-11 cable; see accessory list in Table 1 2 25 lb-in Torque Wrench (PN 16056-660) Carrierband Network Tester Some manufacturers of carrierband hardware offer a network tester and signal generator for field testing to the IEEE 802.4 standard. February 2003 2-11

Installation SD39MODULNET-1 Frequently, a carrierband network tester can be used by cable installation personnel having no specific electronics training. An auxiliary signal generator is used as a signal source at one end of the trunk cable and the tester measures the signal strength and return loss along the trunk cable. This equipment is used for the following network activities: - Component qualification - Installation verification - Servicing The manufacturer of the CB Tester and Auxiliary Signal Generator (standard accessory) is: RELCOM Inc. Rt. 1, 244H Forrest Grove, OR 97116, USA Cable pulling grips Conduit cutting and bending tools Heat gun for heat-shrink tubing Standard hand tools 2.3.2 Tap Installation Mount each tap either within the cabinet housing the MBX or external to the cabinet. 1. Refer to system documentation for the quantity of each type of tap (2-port or 4-port) to be installed and for mounting locations. Taps, Installation Instructions, and mounting hardware are provided in each Tap Mounting Kit. External Mounting - Refer to Figure 2 1 for tap mounting dimensions and fabricate mounting brackets. Internal Mounting - Refer to Figure 2 4 and the Tap Mounting Kit Instructions to mount the taps. 2. Install taps in pairs at their selected locations, one each for MNET A and B. Typically, begin at an end-of-trunk tap and proceed along the trunk to the opposite end-of-trunk tap. Tag every tap with its number and MNET A or B ID. 2-12 February 2003

SD39MODULNET-1 Installation Figure 2 4 Tap Mounting within MODULPAC 3. External Mounting - Install a 14 gauge (AWG) wire between the tap's ground stud and building safety ground. Do not rely on building structure, conduit, or messenger cable to complete the ground path. 4. At each tap, install a 75 ohm Terminator on each port that will not receive either a trunk or tap cable, to maintain proper network impedance. 5. At each tap's trunk ports, provide cable strain relief so the trunk cable does not put a stress on the tap trunk port. February 2003 2-13

Installation SD39MODULNET-1 2.3.3 Trunk Cable Installation Trunk cable installation consists of routing and installing cable segments between successive taps until all cable segments comprising the cable-system are installed. Pull each cable through conduit or lay it in cable trays at an appropriate point in the installation procedure provided below. The following is applicable to both MNET A and B trunks: Refer to user's MODULNET documentation and the results of the MODULNET design in section 2.2 for trunk and tap cable routing, cable lengths, tap locations, MBX slot locations and other needed information. Do not exceed the manufacturer's trunk cable pulling force during installation, especially when pulling cable through conduit. W2078 cable has a pulling limit of 150 lbs (68.1 kg). Do not bend a cable around sharp corners. A trunk cable has a minimum bend radius of 17.75 cm (7.0 inches). For aerial suspension, the maximum unsupported cable length for standard RG-11 cable is 100 feet (30.5 m) and for armored RG-11 cable 150 feet (45.7 m). If longer distances are required, use messenger wires. Trunk cable can be laid in a cable tray or trough, or secured to polls, walls, or building structural members. Do not crush the trunk cable with attachment devices. Route trunk and drop cables away from plant areas with electromagnetic/electrical fields that might interfere with MODULNET communications. Such areas may contain electric arcs, high current electrical equipment which emit strong electromagnetic fields and switching transients, welding operations, or electrical motors turning on and off. Armored RG-11 trunk cable requires grounding of the armor for lightning protection and additional noise immunity. Ground the armor in as many places (two places minimum) between taps as possible with a 14 AWG conductor to safety ground. Do not ground the armor to the taps or to the cable's inner shields. Use ground clamps designed for armor cable to make these connections. Make sure that all MNET taps are cabled from T1 on the first tap to T2 on the next tap (not T1 to T1 or T2 to T2). Mnet uses a segmented ground for the coaxial cable. The trunk port labeled T2 is grounded. The T1 port is isolated from ground. Connecting both ends of a cable segment to T! ports fails to ground the cable. Connecting both ends to T2 ports creates a ground loop. Strain-relieve all MNET/MBUS cables. Replace any cables with signs of connector damage. (See MNET Kit Instructions 15900-553 and -554). Excess force on the cables can result in cable or connector failure Verify that the entire APACS+ system is properly grounded (See Installation and Service Instruction SD39GND-1). Improper grounding can cause ground loops, which can cause noise. Avoid runs in multiple of 45 to 55 ft. (1/4 wave = 49.2 ft.) 2-14 February 2003

SD39MODULNET-1 Installation 2.3.3.1 Trunk Cable Installation Procedure 1. Refer to MODULNET documentation and the results of the MODULNET design in section 2.2 for cable length between the first and second taps on MNET A. Include some extra cable for connector installation and future servicing. 2. Route the trunk cable between selected taps. 3. Cut cable to desired length. 4. Refer to Figure 2 5 and the section, Trunk Cable Fabrication Procedure, to attach F-male connectors to both ends of the cut trunk cable. Use a crimping tool recommended by the connector manufacturer. Tag each end of the trunk cable segment with its segment number and its MNET A or B ID. 5. Remove the rubber gasket from all MNET terminators (Service Note SN39MNET-1). 6. Completely remove any MNET terminator and chain from the T1 side of the taps before installing the cable. If the dangling terminator touches any grounded object, it can cause a ground loop by grounding the isolated tap trunk port, T1. NOTE Lubricate all MBUS/MNET connections of all connectors (Kit Instruction 15900-394, included with the lubricant kit, P/N 14850-121). Lubrication protects the contacts from harsh environments and fretting corrosion. 7. Use a proper torque wrench to tighten coaxial connectors (cables and terminators) Use P/N 16056-660, 25 in.-lb. torque wrench for cables, included in Tool Kits 16056-652 and 16056-653) If a proper torque wrench is not immediately available, approximate 25 in.-lb. by finger tightening, plus 1/8 turn for connectors and terminator without gaskets. Be sure to relieve any strain the cable may exert on the connector while tightening. Insufficient torque can result in a poor connection; excessive force can result in damage to hardware. IMPORTANT Each trunk cable MUST connect to an isolated trunk port (T1) on one tap and a grounded, non-isolated trunk port (T2) on a second tap. See Figure 2-1 to identify the ports. A white dot often marks the isolated port. Be careful not to cross-connect MNET A and MNET B. 8. Install the next MNET A trunk cable segment. Repeat the preceding steps for each cable segment until all MNET A segments are installed, then proceed to step 9. 9. Install each MNET B trunk cable segment by repeating the above steps. February 2003 2-15

Installation SD39MODULNET-1 IMPORTANT Terminate the ends of the MODULNET with 75 ohm terminators. See Figure 1 1. Do not connect the network ends together. 2-16 February 2003

SD39MODULNET-1 Installation Figure 2 5 F-Male Connectors for RG-6 and RG-11 Cables February 2003 2-17

Installation SD39MODULNET-1 2.3.3.2 Trunk Cable Fabrication Procedure Follow steps 1 through 9 to fabricate the cables. Detailed procedures for each step are provided. 1. Initial Cable Preparation: Slip heat shrink over cable end. For M-NET A, use white; for M-NET B, use black. 2. Preparing the Cable End RG-11 QUAD SHIELD TRUNK CABLE CommScope P/N 5950 COPPER-COATED STEEL CENTER CONDUCTOR F-CONNECTOR END HEAT SHRINK Figure 1 - Initial Cable Preparation a. Remove 1/2 inch of the cable jacket (see Figure 2). Be careful not to cut the braid. 1 2 " Figure 2 - Remove Cable Jacket b. Carefully fold back the outer braid over the jacket (see Figure 3). Figure 3 - Folding Back the Outer Braid 2-18 February 2003

SD39MODULNET-1 Installation c. Carefully peel off the outer foil after first making a small cut at the base of the foil at the end of the foil wrap (see Figure 4). PEEL OUTER FOIL SMALL CUT Figure 4 - Removing the Outer Foil d. Carefully fold back the inner braid over the outer braid (see Figure 5). Do not remove the inner foil. Figure 5 - Folding Back the Inner Braid e. Trim the dielectric so that there is 1/8 inch protruding from the jacket (see Figure 6). Use a wirestripping tool that is notched or can be adjusted so that the center conductor does not get nicked. Adjust the stripping tool to match the center conductor s dimension of 14 AWG. 1 8 " Figure 6 - Trimming the Dielectric f. Trim the center conductor, which is 14 AWG copper-coated steel wire, so that there is only 1/8 inch protruding from the dielectric (see Figure 7). 1 8 " Figure 7 - Trimming the Center Conductor February 2003 2-19

Installation SD39MODULNET-1 3. Crimping the Pin to the Center Conductor: a. Insert the pin over the center connector so that the end of the pin is flush with the end of the dielectric (see Figure 8). PIN Figure 8 - Inserting the Pin over the Center Conductor b. Using the 0.100 hex of the Siemens Crimping Tool P/N 16056-414 (reference also Gilbert P/N G- CRT-211), crimp pin to center conductor (see Figure 9). CROSS-SECTION OF CRIMPER JAW 4. Inserting Cable into Connector: Figure 9 - Crimping the Pin to the Center Conductor Perform the following procedure to insert the cable into the connector: a. Insert the cable into the F-connector (Siemens F-connector, P/N 14784-501 (reference also Gilbert P/N 44344) (see Figure 10). 3 32 " GILBERT F-STYLE CONNECTOR P/N 44344 Siemens P/N 14784-501 Figure 10 - Inserting the Cable into the Connector 2-20 February 2003

SD39MODULNET-1 Installation b. Check to see that cable insertion is complete by determining that the pin protrudes a minimum of 3/32 in. past the end of the connector (see Figure 11). Use the F-connector pin gauge provided. CHECK WITH 3 32 " F-CONNECTOR PIN GAUGE Siemens P/N 16056-648 5. Crimping the Connector onto the Cable: Figure 11 - Checking Cable Insertion Crimp the connector onto the cable using the 0.475 hex on the Siemens Crimping Tool, P/N 16056-414 (reference also Gilbert P/N G-CRT-211) (see Figure 12). CRIMP WITH 0.475 HEX Figure 12 - Crimping the Connector onto the Cable NOTE The jaws of the crimping tool must close fully to effect a good crimp. As the jaws close, the handles can be felt to toggle over center. Make sure that you use the entire width of the crimping tool. February 2003 2-21

Installation SD39MODULNET-1 6. Sliding the Heat Shrink over the Connector a. Slide heat shrink tubing over back of connector (see Figure 13). b. Using heat gun, shrink tubing on connector. HEAT SHRINK 7. Applying the Cable Label Figure 13 - Sliding the Heat Shrink over the Connector Apply the cable label to the approximate position shown in Figure 14. LABEL A OR B 8. Installing the Protective Cap Figure 14 - Applying the Cable Label Install the protective caps onto cable ends to protect the pin during storage and handling. 2-22 February 2003

SD39MODULNET-1 Installation 2.3.3.3 M-NET Cable Recommendations Cable Strain Relief It is recommended that all M-NET cables be strain-relieved to minimize the stress on the F connector. This can be accomplished by ensuring that a short length of cable extending from the connector is straight. Figure 15 illustrates acceptable and unacceptable cable stress conditions. Cable Bend Radius Excessive cable bending or kinks in cables have an effect on dielectric strength, possibly causing communication problems. The bend radius on the RG-11 cable should be equal to or greater than 7 inches. If it is impossible to meet the minimum cable bend radius because of limited space, it is recommended that a right-angle, F-style adapter be employed. For maximum reliability, the adapter should have a gold-plated pin. Adapters are available from Siemens (P/N 16056-663) or Gilbert Engineering Co., Inc (P/N 46288). STRAIGHT 16056-663 GOOD GOOD BAD Figure 15 - Sample Cable Stress Conditions Connector Tightening Torque The proper tightening torque for an F-style connector is 20 to 30 in.-lbs. A 25in.-lb. torque wrench (P/N 16056-660) is available in Siemens Kit P/N 16056-653. If a torque wrench is not available, first make the connector finger-tight; then turn the connector an additional 1/8 turn clockwise with a wrench to approximate the torque. February 2003 2-23

Installation SD39MODULNET-1 2.3.4 Drop Cable Installation 2.3.4.1 Drop Cable Installation Procedure Install MNET A and B drop cables as follows. Drop cable does not have the band marks that appear on trunk cable and may be cut to the needed length. 1. Refer to MODULNET documentation and the results of the MODULNET design in section 2.2 for the length of each drop cable. Each cable connects to a tap drop port on MNET A or MNET B and to a connector on an MBX transition board. Also note or confirm the following: Tap ID and location (external or internal) Number of MBXs to be connected to the taps including: - The ID of all cabinets housing the MBXs and their locations. - The MODULRAC slot location of each MBX and its associated transition board that is assigned to the tap's drop port "number" Route of each drop cable and needed length 2. Route the first drop cable between the assigned tap and MBX transition board. Allow extra cable for connector installation and future servicing. Do not exceed the manufacturer's drop cable pulling force (45 lbs./20.4 kg.) during installation, especially when pulling cable through conduit. IMPORTANT Do not bend a cable around sharp corners. A drop cable has a minimum bend radius of 3 inches (8 cm). 3. Attach F-male connectors to both ends of each cut drop cable as shown in Figure 2 5 and in the section, Drop Cable Fabrication Procedure. Use the crimping tool recommended by the connector manufacturer. Tag each drop cable connector with the following: Tap end of cable: Tap ID, drop port number, and MNET A or B ID. Transition Board end of cable: Tap ID, MBX MODULRAC slot number, and MNET A or B ID. Connector kits listed in Table 1 2 contain connector and cable preparation instructions which are duplicated in section, Drop Cable Fabrication Procedure. 2-24 February 2003

SD39MODULNET-1 Installation 4. At the tap, thread the connector onto the drop port and hand tighten. Stress relieve the cable at the drop port and use a proper torque wrench to tighten coaxial connectors (cables and terminators). Use P/N 16056-660, 25 in.-lb. torque wrench for cables, included in Tool Kits 16056-652 and 16056-653). If a proper torque wrench is not immediately available, approximate 25 in.-lb. by finger tightening, plus 1/8 turn for connectors and terminator without gaskets. 5. Terminate the free end of the drop cable as follows: If an MBX transition board is installed, refer to the MBX Installation and Service Instruction (see section 1.5 for Instruction identifier) to connect the drop cable to the MBX transition board connector. If an MBX transition board is not installed, terminate the drop cable in a 75 ohm terminator. 6. Repeat the preceding steps for each MNET A and B drop cable. IMPORTANT Be careful to connect the MBX transition board's MNET A connector to MNET A and the board's MNET B connector to MNET B. 2.3.4.2 Drop Cable Fabrication Procedure Follow steps 1 through 9 to fabricate the cables. Detailed procedures for each step are provided. 1. Initial Cable Preparation a. Slip ferrite bead over cable end (see Figure 1). b. Slip heat shrink tubing (gray) over ferrite bead. c. Use heat gun to shrink tubing over bead. d. Slip smaller heat shrink over cable end. For M-NET A, use white; for M-NET B, use black. HEAT SHRINK RG-6 QUAD SHIELD DROP CABLE CommScope P/N 5750 FERRITE BEAD WITH HEAT SHRINK COPPER-COATED STEEL CENTER CONDUCTOR F-CONNECTOR END Figure 1 - Initial Cable Preparation February 2003 2-25

Installation SD39MODULNET-1 2. Preparing the Cable End: a. Remove 5/16 inch of the cable jacket (see Figure 2). Be careful not to cut the braid. 5 16 " Figure 2 - Removing the Cable Jacket b. Carefully fold back the outer braid over the jacket (see Figure 3). Figure 3 - Folding Back the Outer Braid c. Carefully peel off the outer foil after first making a small cut at the base of the foil at the end of the foil wrap (see Figure 4). PEEL OUTER FOIL SMALL CUT Figure 4 - Removing the Outer Foil d. Carefully fold back the inner braid over the outer braid (see Figure 5). Do not remove the inner foil. Figure 5 - Folding Back the Inner Braid e. Trim the dielectric and inner foil so that there is 3/32 inch protruding from the jacket (see Figure 6). Use a wire-stripping tool that is notched or can be adjusted so that the center conductor does not get nicked. The center conductor is 18 AWG; adjust the stripping tool to suit. 2-26 February 2003

SD39MODULNET-1 Installation 3 32 " Figure 6 - Trimming the Dielectric f. Trim the center conductor (18 AWG copper-coated steel wire) so that there is only 1/16 inch protruding from the dielectric (see Figure 7). 1 16 " 3. Crimping the Pin to the Center Conductor Figure 7 - Trimming the Center Conductor a. Insert the pin over the center connector so that the end of the pin is flush with the end of the dielectric (see Figure 8). PIN Figure 8 - Inserting the Pin over the Center Conductor b. Using the 0.054 hex of the Siemens Crimping Tool P/N 16056-413 (also reference: Gilbert P/N G-CRT-188), crimp the pin to the center conductor (see Figure 9). CROSS-SECTION OF CRIMPER JAW Figure 9 - Crimping the Pin to the Center Conductor February 2003 2-27

Installation SD39MODULNET-1 4. Inserting Cable into Connector: a. Insert the cable into the Siemens F-connector, P/N 14784-500 (also reference Gilbert F-Style Connector P/N 70070) (see Figure 10). 3 32 " MIN GILBERT F-STYLE CONNECTOR P/N 70070 Siemens P/N 14784-500 Figure 10 - Inserting Cable into Connector b. Check to see that cable insertion is complete by determining that the pin protrudes a minimum of 3/32 in. past the end of the connector (see Figure 11). Use the F-connector pin gauge provided. CHECK WITH 3 32 " F-CONNECTOR PIN GAUGE Siemens P/N 16056-648 5. Crimping the Connector onto the Cable: Figure 11 - Checking Cable Insertion Crimp the connector onto the cable using the 0.324 hex on the Siemens Crimping Tool P/N 16056-413 (reference also Gilbert P/N G-CRT-188) (see Figure 12). CRIMP WITH 0.324 HEX Figure 12 - Crimping the Connector onto the Cable NOTE The jaws of the crimping tool must close fully to effect a good crimp. As the jaws close, the handles can be felt to toggle over center. 2-28 February 2003

SD39MODULNET-1 Installation 6. Sliding Heat Shrink over Connector: a. Slide heat shrink tubing over back of connector (see Figure 13). b. Using heat gun, shrink tubing on connector. HEAT SHRINK 7. Applying the Cable Label: Figure 13 - Sliding the Heat Shrink Tubing over the Connector Apply the cable label to the approximate position shown in Figure 14. LABEL A OR B Figure 14 - Applying the Cable Label 8. Positioning the Ferrite Bead: Slide the ferrite bead along the cable so that it is as close to the cable end as possible (see Figure 14). 9. Installing the Protective Cap: Install the protective caps onto cable ends to protect the pin during storage and handling. February 2003 2-29