COMMSQDesignGuideAtch5.doc

355 Communications Squadron

Design Criteria For Pre-Wiring and Other Telecommunications

Systems

1. Purpose:

This guide will be used by all Air Force Agencies at Davis-Monthan AFB to plan, design, review and evaluate telecommunications cabling and distribution systems for pre-wiring new and remodeled facilities and for rewiring existing facilities at the time of remodeling or requested upgrades. Per AF Engineering Technical Letter (ETL) 87-9, pre-wiring shall be included in all facility construction, addition and alternation projects accomplished with 3300 Series funding and all Military Construction Projects (MCP).

2. General Scope:

a. The facility design will provide concealment of the wiring/cabling systems, adequate space for installation and maintenance of C-CS equipment and wiring, proper separation if specialized systems and cable, flexibility of office layout in administrative areas and standardization and commonality of common user requirements. The base CSO will be the approving authority in ensuring that the most efficient cable/wiring distribution system is selected, consistent with facility size and function, current and projected C-CS requirements and the need for flexibility to accommodate future additions or changes.

b. The installation shall be consistent with all known base installation criteria and shall support the current base blueprint document prepared by the 38 EIW, Tinker AFB, OK as approved by HQ ACC/SCX and 355 Communications Squadron.

3. Personnel Certification Requirements:

a. Contract personnel involved in the design , planning and construction of these systems shall have expertise in the design, engineering and installation of telecommunications, cabling and distribution systems. Whenever determined necessary by the CSO, contract personnel shall provide adequate proof of their individual skills, upon request, in writing, to be reviewed and recorded by the CSO. National certifications or collegiate credentials may be required to ensure the training adequacy of personnel performing the work.

b. AF engineers, designers, operators and maintainers shall be involved in all phases of the project including preliminary planning and technical requirement definition phases.

4. Local Minimum Standards:

To minimize the long-term cost of the infrastructure, local standards are established as follows and may only be changed when approved in writing by the CSO. These standards are intended to promote common skills among maintenance personnel and to minimize the necessity for excessive on hand spare parts and varying equipment.

1. For Base Fiber Optic Back-Bone Connections:

ATM Technology Connections - 36 Strand SM Fiber 8.3/125 micron

2. For Base Fiber Optic Satellite Connections:

Switched Ethernet Connections - 12 Strand SM Fiber 8.3/125 micron

3. Minimum of 25 pair copper cable for new installations.

4. All cables used for telecommunications outlets shall be four pair, 24 AWG, solid copper conductor, Category 6, UL tested and certified.

5. Whenever exposed in air circulation areas, only plenum cable may be used.

6. Each cable shall be dedicated to one device or outlet only

7. All telecommunications jacks shall provide dual RJ45 type jacks utilizing TIA 568A wiring configuration. (Reference figures 1 and 2)

8. Information outlet spacing in office areas shall be based upon one jack for each 12LF of perimeter wall space or one for each 50 square foot of floor space whichever provides a higher outlet density. All other locations will be provided with outlet density as determined by the CSO.

9. Administrative telephone wiring will be based on the single-line instrument concept with individual cable running from the wall outlet to the Communications Equipment Room (CER) or Telecommunications Closet (TC) via the cross connect cabinet, if required.

10. All wall mounted wall phone jacks shall be 630B type receptacles.

11. All outside metallic Twisted Pair (TP) Cable will be filled core type, and meet Rural Utility Service (RUS)PE-39 or PE-89 specifications.

12. Comprehensive Requirements: Comprehensive requirements include those requirements that apply to all telecommunications systems.

a. Building Communications Distribution System - Entrance Conduit, Duct Banks and Manhole (MH) System

1. All primary backbone conduits shall be installed in locations as determined by the 355CS CSO, and shall provide adequate size and quantity to meet current requirements, plus 100% growth for future use, to preclude digging at a later date to meet emerging requirements.

2. Whenever new construction or remodeling takes place, the design, installation and all related cost necessary to extend the conduit and manhole system to the new location shall be included in the project cost. Multiple service entrance locations will be required for all facilities housing command and control systems to provide redundant, survivable service.

3. A manhole with a minimum of two four inch conduit/duct bank lateral system with tracer and pull rope will be used for required cables plus 100% spare ducts (not less than 2 spares) for expansion and maintenance on all primary duct banks.

4. Manholes shall be installed for all connections to the existing cable plant as required to maintain a maximum manhole spacing of 475 feet. Additional manholes may be required to provide adequate control of connection and distribution of cable plant. See attached detail sheet (Figure 4) for specific manhole construction criteria.

5. All manhole designed and constructed to meet the requirement of T.O. 31-W-3-10-22, and provide a clear floor space of 8’ x 10’ measured inside the manhole. An alternate size of 6’x 8’ may be approved only when no primary backbone cable passes through the manhole (lateral or dead end service only). All manholes shall provide a clear height of not less than 7’-0”. Mandatory appurtenances include grounding bus bar and rod and related conductors and wiring, a ladder or steps, cable rack supports, a 50 cubit foot sump (French drain), pull in irons, frame and manhole cover cast with the word “Communications” exposed to the surface. Conduits shall enter the MH’s 4 50 5 feet from floor on the end and be perpendicular to the wall in approximate location as shown on attached sketch (figure 4).

6. IAW T.O. 31-W-3-10-12, power and communications cables will be separated by 12 inches (30.48cm) of well tamped, fine earth protection. The cable at the top of the crossing, whether power or communications cable, will receive the same additional protection (see item 8 below). Gas and water mains will be separated and protected by 3” of concrete or 12” of fine earth. In addition, if the cable crosses over the main, extend additional cable protection 3 feet from each side of the crossing. Where highway, railroad and runway crossings occur, cable at crossing must be placed in underground metallic conduit. PVC conduit may be direct buried. If steel pipe conduit is used, boring procedures will be followed that ensures protection of existing resources. Where PVC conduit are installed, a metallic tracer wire will be installed within the conduit or 6” above the duct bank to assist in future location efforts, with bonding to occur inside each manhole and at CER grounding frame.

7. Stub up 2 each 4” lateral conduits 6” above finished floor in the corner of the CER, adjacent to the telephone back board, continuous from the nearest manhole. Provide one lateral (entrance) conduit with four each 1.25 inch interduct from CER to the inter-connect manhole location within the existing backbone conduit system for fiber optic cable connection and for future requirements.

8. Provide 36” minimum cover for all conduit duct banks and 36” minimum cover for laterals measured to top of conduit. 355CS Telephone O&M contractor will provide termination in the manhole and perform any necessary cross-connection in the CER.

9. When determined necessary to simplify installations, conduit will be curved to provide gentle sweeps, with a minimum radius of 25 feet, for a total bending radius not to exceed 180 degrees between manholes.

10. All conduits shall be sloped toward each opposing manhole at a slope of 3” per 100’ of run to promote drainage of any accumulated liquids.

11. Handholes, when specified, will be nominally 4’ x 4’ x 4’ inner dimensions and is provided with a grounding rod, cable rack supports sump drain and pulling irons.

b. Telephone Entrance Cable

The contractor will provide base cable, gel filled, IAW Rural Electrical Association (REA) standard from main communications panel to the nearest manhole with sufficient vacant airs to provide each facility with required circuits plus 100% spare pairs, as determined by the CSO.

c. Communications Equipment Rooms (CER)

1. A CER will be provided for C-CS switching and transmission equipment, private branch exchanges (PBXs, gateways, power supplies, etc.) main distribution frame(s), Local Area Networks (LAN) equipment racks, fiber optic cable termination and patch panels and other equipment needed for termination of the building’s interior wiring systems and to interface the local service equipment with the exterior base cable system. Adequate installation and maintenance space (See figure 5), environmental control and power, typical to an office environment, shall be included to support this equipment and any necessary cable entry requirements. No other building support equipment, including mechanical equipment, plumbing equipment and electrical panels, will be placed in the CER. Maintenance space and access space will not be utilized for any other purpose and will be free and clear of all obstructions to a height of 8’-0” to allow for adequate cooling and servicing of equipment. Storage is prohibited in the CER and Telecommunications Closet (TC). Special attention will be given to the space allocation required for placement of classified systems IAW AFSSI 7010 and AFSSM 7011 to ensure security countermeasures are met.

2. TC’s will be provided with space required for CER rooms (See figure 5) and will be located that the distance, measured along the routing path of the cable, will not exceed 300’, including vertical distance to wall telecommunications outlets, to maintain the intergrity of the digital data signal as stipulated by Category 6 wiring requirements. Where multiple TC rooms are required, attention must be given to their strategic placement to support interconnection via two 4” conduits between each room as well as to the primary CER in which the cable head/fiber connections are to be located. Where it is necessary to interconnect more than one remote TC to the primary CER, Multimode fiber optical cable will be used. A 1.25” innerduct will be provided inside the 4” conduit or conduit raceway, with pull chord, as a dedicated, direct path between each TC and the primary CER. For telephone interconnection, provide not less than 300 pair copper 24AWG wire cable between the TC and the CER.

3. Circuit connectivity from the telecommunications outlet jacks to the TC closet or the CER will be provided through ¾” (min) conduit stubbed to 12” above the finished ceiling, using the most direct route available, complete with pull chords. A 12” wide by 4” deep above the ceiling cable trough/raceway may be used to connect rooms provided plenum type cable is used or provided. Where cable trays are provided, conduits will be extended to the cable tray and be terminated. The trough/raceway will run above the ceiling, on the top of proper support structures, using the most direct route between TC and the CER. Conduit fill will not exceed the 40% rule as stipulated in the National Electrical Code (NFPA 70).

4. 630B type wall jacks will be provided for wall mounted telephones in the CER, electrical/mechanical rooms and communications closets mounted 60” above the finished floor.

5. Secure interior and exterior access to CER workspace should be provided to allow 24-hour access.

6. Environmentally controlled temperatures will be provided in the CER and TC areas, equal throughout the building with a constant temperature of not less than 40 degrees (F) or greater than 85 degrees (F).

7. LAN wiring will be terminated in a standard 19” rack mounted category 6 patch panel located in the primary communications room (CER) situated in a central location within the building (See figure 6), unless the cable distance exceeds 300’. In such cases, the LAN cable will be terminated in a TC patch panel and provisions will be made to interconnect each TC to the primary via two 4” conduits or innerduct.

8. Fourplex 110 VAC power outlets on a separate 20 AMP circuit with isolated ground will be provided on each wall for use in powering telecommunications devices only. An additional duplex convenience outlet will be located away from the telecommunications outlets to provide power to operate service and maintenance equipment. Switched lighting will be provided in all CER areas, adequate to promote work with small fiber items and miniature lettering devices.

9. Ground facility for cable sheaths, protectors and other equipment in accordance with T.O. 31-W-3-10-22. No 6 ground wire or larger must be used and the grounding point should be 10 ohms or less. A ground bus bar should be 6" (H) X 24" (L).

10. 355CS telephone O&M contractor will be terminating entrance cable inside the CER to Building Entrance Terminals (BET).

11. All BETs will be provided with 3-element plug in gas tube protective modules and will provide equal protection to REA-PE-80 specifications.

12. BETs used for the termination of outside Twisted Pair (TP) cables, 300 pair or less in size, will have a built in splice chamber with 710 type splice modules. Equipment side of BET will use AT&T 110 type connection to station.

d. Wiring and Termination

1. Administrative telephone and data lines will be terminated on CAT 6 type 110 blocks with CAPs provided. Blocks will be mounted on the fire retardant coated, ¾ inch 4’ x 8’ ACX plywood backboard mounted with smooth side out in the TC and CER. Termination will be numbered according to room and jack number. Pairing and color-coding will be accordance with EIA 568A standards (See figures 1 & 2).

PIN NO. COLOR PIN NO. COLOR

White/Green 5 White/Blue

2 Green

6 Orange

3 White/Orange 7 White/Brown

4 Blue 8 Brown

Distribution frame and interior conduits shall be of sufficient size to allow for 100% growth and not exceed the 40% fill rule stipulated in the National Electrical Code (NFPA 70).

3. Wiring:

a. The contractor will perform all interior pre-wiring to include the CER, TC, with termination to CER.

b. Wiring administrative telephones and office automation equipment will be unshielded twisted pair (UTP), category 6 cable, 24 AWG, will be Integrated Services Digital Network (ISDN) compatible and be installed by a category 6 certified installation team. All installations require compliance with the Institute of Electrical and Electronic Engineers (IEEE) standards 802.3 for baseband systems.

c. 355CS Telephone O&M contractor will cross connect the interior blocks and splice the cable in the manholes when required.

4. Modular/Movable Equipment and Construction Items: Areas with equipment or construction items which can be easily moved, such as pre-wired work stations, system furniture and modular walls/offices, will be pre-wired by the contractor and will provide sufficient flexibility and connectivity to enable rearrangement without modifications to the permanent TC or CER wiring system in the facility. Adequate quantities or suitable connectors and extension cables will be provided; permanent splices/connections will not be made.

5. Wiring Identification Standard: To clearly identify cables and their usage, each cable will be marked with an adhesive type strip marker at both ends, as noted in figure 6, which clearly identify their room and outlet number. Each outlet cover plate will also carry the outlet designation, as shall the termination jack on the patch panel or termination block. A permanent type label affixed to the cable or outlet jack cover to preclude damage due to age or other mechanical means will identify all cable and termination. Hand written or manual embossing labels is NOT permitted. Automated embossed labels are preferred, such as Brothers P-Touch systems utilizing ¼” labels with 1/8” lettering.

e. Cross Connect Closets

1. Cross-connect closets will be provided as required to serve approximately every 10,000 square feet of usable floor space. The closets will serve as a secondary interconnection point between the telephone modular jack outlets and the main communications frame in the CER. Wall and floor space will be provided for installation and maintenance of C-CS equipment such as frames or backboards. Such equipment will be concealed and secured as required for primary CERs and will not be installed in common use areas and must be fully accessible and maintainable as outlined for CERs.

2. All cables in the TC, cross connect closet and room and jack number to indicate its associated jack number and location will tag CER. (See figure 5). Cross-connect closets will not be used for LAN wiring. All LAN runs must be continuous from wall outlets to TC or CER.

f. Telecommunications Outlets

1. In general office areas, a dual modular Telecommunications outlet plate, with two each RJ45 type inserts, one for voice and one for LAN, will be provided approximately every 12’ around the room perimeter or one for each 50 square feet of net floor area, whichever provides greater density. All wall outlets components will be certified, as Category 6 and jacks will be RJ45 type wall jacks with a removable outer bezel that is color coded and labeled to identify the outlet usage. (See figure 1) Where modular furniture is to be installed, modular dual outlet jacks will be installed in each workstation.

2. Telecommunication outlets will be mounted at 18” above the floor, to the centerline of the cover plate, unless noted otherwise.

g. Periodic, Final Inspections, Testing and Documentation

1. All telecommunication cables will be certified and tested in accordance with EIA/TIA standards with written results to be provided to the 355CS/SCX. Where deficiencies of any type are discovered upon testing, the installation contractor will make all necessary repairs, including replacement if necessary, at no cost to the government.

2. Revised drawings which reflect the actual “as built” conditions will be maintained throughout the construction phases and will be submitted to the 355CS/SCX with the cable certification records upon completion of the work, but prior to final acceptance of the work, to allow representatives of the 355CS to perform a final review of drawings and inspect installations.

3. Communications-Computer System Installation Records: Design drawings and schedules which will form the basis of “as built” cable records, will be provided to the 355CS/SCX upon final project acceptance. The drawings will show cross-connect and termination points for each cable pair, locations and identification number for each modular outlet and the location and value of each line amplifier and multi-port device throughout the cable system. Approximate cable routing will also be shown. Five copies of these drawings will be updated to final “as built” conditions by the construction contractor and turned over to the 355CS, along with one digital as built drawing prepared in the most current version of AutoCAD, prior to the time of facility turn-over.

4. During construction, in-progress inspections by 355CS personnel are required. For example, trenches will not e covered without an in-progress inspection to verify conduit size and quantity, cable type, earth cover compliance with installation requirements and accuracy of “red line” base cable drawings. The installation activity/contractor is solely responsible for requesting in progress inspections before backfill, installation of sheet-rock, during cable certification, etc.

5. All installed cable (fiber and copper) will be tested in the presence of 355CS personnel and baseline test records provided to the CSO in printed and digital format. All category 5E cable will be tested and certified to 155 Mbps (100 MHz) to ensure it is usable at higher data transmission speeds. UL testing standard for new cable, including fiber optic testing of single-mode cable will be followed. (UL standards for Category 6 cable are attached)

6. All contractor cable installations will be inspected and all defects discovered will be repaired at no cost to the government.

h. Tempest/EMP and Classified Cabling Consideration: Classified requirements may vary and will be taken on a case by case basis. If any unit identifies classified message traffic or telephone requirements, coordinate all requirements with the 355CS/SCBS (228-3023) to ensure proper compliance measures are attained. Note: Red/Classified cable drop must be placed in rigid conduit and the conduit must be exposed.

i. Related Documents

The following documents are recognized within this document or are hereby recognized as a standard of good practice to be followed during the performance of the work.

National Fire Protection Association

NFPA 70 National Electrical Code

Underwriter's Laboratories

UL Standards for CAT 6 UTP Wire

Rural Utility Service

PE-39 Specifications for Filled Telephone

PE-80 Specifications for Gas Tube

PE-89 Specifications for Filled Telephone

Cable with Expanded Insulation

EIA/TIA Standards

EIA/TIA 568 Commercial Building Wire

AF Documents

ETL 02-12 Pre-wiring

TO 31-W-3-10-22 Telecom Engineering

TO 31-W-3-10-12 Outside Plant Cable

AFSSI 7010 Emission Security Assessment

AFSSM 7011 Emission Security Counter-Measures