DISAEC_310-195-2_QA_Installation.pdf

DEFENSE INFORMATION SYSTEMS AGENCY

EUROPEAN AREA

UNIT 30403

APO AE 09131

DISAEC 310-195-2 23 January 2003

Quality Assurance Installation Workmanship Standards for the

Defense Information System Network Europe (DISN-E) And Associated Systems and Site Inspection Checklist

1. Purpose. This document elucidates the general workmanship requirements for the installation of telecommunications equipment and associated items by the Defense Information System Agency (DISA) personnel or its contractors.

2. Applicability. These are minimum installation standards that are to be adhered to by the installer and are applicable to the installation of all DISA electrical or electronic equipment, systems, and subsystems. The guidelines herein complement other specified technical standards and requirements that are necessary for the installation of the equipment, subsystem or system.

2.1 If conditions arise that require deviations from the

requirements described herein, they are to be resolved by mutual agreement between the designated DISA engineering group and the installation team.

2.2 DISA reserves the right to revise this document for any

reason, including but not limited to, conformity with standards declared by various agencies, utilization of advances in the state of technical arts, or integration of new products.

3. References.

3.1 The following specifications, standards, and handbooks

form a part of this document to extent specified herein.

3.1.1 STANDARDS

OPR: EU71

Distribution: A B C D ii DISAEC 310-195-2 For Official Use Only

For Official Use Only

3.1.1.1 FEDERAL

3.1.1.1.1 FED-STD-368 Quality Control System Requirements

3.1.1.2 MILITARY

3.1.1.2.1 DISAC 300-85-1 Reporting of Facility and Link Data

for the Defense Communication Systems (DCS)

3.1.1.2.2 DOD-5200.22M Termination Standard for Multiconductor Cable Assembly

3.1.1.2.3 MIL-STD-100 Engineering Drawing Practices

3.1.1.2.4 MIL-STD-1276F Department of Defense Interface

Standard Leads for Electronic Component Parts

3.1.1.2.5 MIL-STD-1285C Department of Defense Standard

Practices, Marking of Electrical and Electronic Parts

3.1.1.2.6 MIL-STD-130 Identification Marking of U.S. Military property

3.1.1.2.7 MIL-STD-1568 Material and Processes for Corrosion

Prevention and Control in Aerospace Weapons Systems.

3.1.1.2.8 MIL-STD-188-124 Grounding, Bonding and Shielding for Common Long Haul/Tactical Communication Systems, Including Ground-Base Communication Electronic Facilities and Equipments

3.1.1.2.9 MIL-STD-348A Department of Defense Interface

Standard, Radio Frequency Connector Interface

3.1.1.2.10 MIL-STD-681D Military Standard Identification Coding and Application of Hookup and Lead Wire

3.1.2 HANDBOOKS

3.1.2.1 FEDERAL

3.1.2.1.1 DOE-HDBK-1092-98 DOE Handbook Electrical Safety

3.1.2.1.2 MIL-HDBK-411 Power and the Environment for Sensitive DoD Electronic Equipment

3.1.2.1.3 MIL-HDBK-419 Grounding Bonding, and Shielding for

Electronic Equipment and Facility

DISAEC 310-195-2 iii

3.1.2.1.4 MIL-HDBK-729 Corrosion and Corrosion Prevention

Metals

3.1.2.1.5 TM 5-683, NAVFAC MO-116, AFJMAN 32-1083 Facilities

Engineering Electrical Interior Facilities

3.1.2.1.6 TM-684, NAVFAC MO-200, AFJMAN 32-1082 Facilities

Engineering Electrical Exterior Facilities

3.1.2.1.7 MIL-HDBK-1004/4 Military Handbook Electrical

Utilization Systems

3.1.2.1.8 MIL-HDBK-1008C Military Handbook Fire protection for Facilities Engineering, Design, and Construction

3.1.2.1.9 MIL-HDBK-2051 Military Handbook, Fiber Optic Cable

Topology Guide

3.1.2.1.10 MIL-HDBK-454A Department of Defense General

Guidelines for Electronic Equipment

3.1.2.1.11 MIL-HDBK-2000 Military Handbook Soldering of

Electrical and Electronic Assemblies

3.1.2.1.12 MIL-HDBK-217 RED/BLACK Engineering: Installation

Guidelines

3.1.2.2 AMERICAN NATIONAL STANDARD INSTITUTE (ANSI)

3.1.2.2.1 ANSI/NFPA 70 National Electrical Code

3.1.2.2.2 ANSI/IEEE 142 Recommended Practice for Grounding of Industrial and Commercial Power Systems

3.1.2.2.3 ANSI/NEMA 250 Enclosure for Electrical Equipment

3.1.2.2.4 ANSI/IEEE C2 National Electrical Safety Code

3.1.2.3 COMMERICAL ENGINEERING HANDBOOK

3.1.2.3.1 Unistrut Engineering Catalog

iv DISAEC 310-195-2

For Official Use Only

Circular Table of Contents

1 Working Conditions

2. Ironwork:

2.1 Auxiliary Framing

2.2 Cable Racks

2.3 Frames, Bays and Cabinets

2.4 Unistrut

2.5 Conduit, Wireway, or Duct

3. Cable Penetrations:

3.1 General Requirements

4. Signal Cabling And Wire

4.1 General Requirements

4.2 Multiconductor Cable Terminations

4.3 Light Guide (Fiber Optic) Cabling

4.4 Nylon Cale Ties (Tye-Wraps)

5. Connectors

5.1 General Requirements

5.2 Soldering Connections

5.3 Coaxial Connections

5.4 Compression Connections General –(10 AWG and Smaller) 20

5.5 Solderless Wrapped Connections

6. Equipment Designations:

6.1 General Requirements

6.2 Character Colors

6.3 Requirements

7. DC Power:

7.1 General Requirements

7.2 DC Power Connectors and Connections

7.3 Bus Bars

7.4 Batteries

7.5 Fuses

8. Grounding Requirements

8.1 General requirements

8.2 Groung Conductorer Identification

8.3 Routing, Supporting and Securing Grounding Conductors.32

9. Waveguide, Ridge Coax, Semi-Ridge & Coax Grounding .. 33

9.1 General Requirements

10. Documentation:

10.1 General Requirements

10.1.5 Site Clean-up

DISAEC 310-195-2 v

Checklist Table of Contents

1. General:

2. Ironwork:

3. Cable Penetrations:

4. Cabling And Wire:

5. Connecting:

6. Equipment Designations:

7. DC Power:

8. Grounding Requirements:

9. Waveguide

10. Documentation:

vi DISAEC 310-195-2

INTENTIONALLY LEFT BLANK

DISAEC 310-195-2 1

1. Working Conditions

1.1 All equipment is to be protected against any material

falling onto or entering into the interior of the equipment during the installation.

1.2 The cutting, drilling, or filing of metallic material in

rooms housing operational DOD communication/computer electrical or electronic equipment is prohibited unless absolutely essential.

1.3 Close all cable penetrations opened for the installation

and/or removal of cabling temporarily at the end of each day during continuing work operations.

1.4 Opened cable penetrations require adequate protection for personnel and equipment where there is any danger of material falling to the floor below.

1.5 The installers are to maintain a clean environment. At the end of each shift they are to clean the work area, clear walkways of debris or installation materials, and remove any trash from the facilities.

1.6 At the end of their shifts, the installers are to store

their tools neatly in a secure area. Installer’s tools are their responsibility to maintain and track. DISA or any other government agency is not responsible for tools or materials that are lost or stolen.

1.7 The Installer is to protect existing equipment and cable

from damage during all work activities.

1.8 The tool used to crimp lugs is to have a ratchet mechanism that requires a full crimp before the tool can be removed from the connector. Only the correct size and type crimp die is to be used.

1.9 Wire wraps are to be made using the proper tool sized to

the wire gauge.

1.10 A hoist is to be used to lift battery cells, equipment

chassis or modules into place when total weight exceeds “two-man carry.”

1.11 When working under a raised floor the area where floor

tiles have been removed is to be quadrant off to prohibit the movement of all personnel not assigned to the installation team.

2 DISAEC 310-195-2

Stringers supporting floor tiles are not to be removed at any time without prior approval from an O&M Site Representative.

2. Ironwork

2.1 Auxiliary Framing

2.1.1 The location of auxiliary framing and other equipment is to conform to the particular floor plan and specifications for the installation as referred to in the installation drawings and engineering installation package (EIP).

2.1.2 All exposed, unfinished, or marred surfaces are to be

filed off and/or painted at the time of installation. The paint is to be of the color and type (enamel, oil base etc.)

consistent with the existing or adjacent surfaces.

2.1.3 All materials (bolts, screws, threaded rods, framework, etc.) are to be secure and have no sharp edges or burrs.

2.1.4 The threads of bolts, cap screws, machine screws, threaded rods and similar threaded parts are to extend at least two threads beyond the final thread of the fastening device, i.e. nut or threaded hole, except in the case of cap-nuts and self-locking nuts.

2.1.5 The threaded part is to protrude no more than an amount equal to the diameter of the bolt, screw or rod.

2.1.6 Threaded rods are to be screwed into floor or ceiling

inserts at least seven full turns.

2.1.7 All masonry or other anchor types hardware is to be of

the rating, size, material and type prescribed in the engineering drawings and EIP.

2.1.8 Holes that were drilled into concrete floors, walls, or ceilings but were not used are to be filled with a masonry patch.

2.1.9 Auxiliary framing bars used for support purposes are to be uniform, level, properly positioned, and properly supported.

2.1.10 All fastening details, piece parts, and other apparatus used in the assembly of auxiliary framing is to be assembled in accordance with manufacturer's specifications as specified in the engineering drawings and EIP.

DISAEC 310-195-2 3

2.1.11 Insulation or heat shrink tubing is to be placed on

threaded rods that may come in contact with wire or cable when used to support frames, rack, etc.

2.1.12 The ends of all auxiliary framing are to be finished

with the appropriate end caps.

2.1.13 Unless otherwise specified by the EIP, auxiliary framing is to be supported on approximately 5 feet (152 cm) to a maximum of 6 feet (183 cm) centers. Each length of auxiliary framing is to have at least two (2) support points.

2.1.14 Auxiliary framing is not to block or obstruct cable

paths and openings, light fixtures, conduits or other similar equipment units.

2.1.15 Auxiliary framing is not to extend more than 30 inches (76 cm) past last support.

2.1.16 Auxiliary framing splices are to be staggered whenever possible.

2.1.17 When splicing auxiliary framing, sections are to be a

minimum of 36 inches (91 cm) in length.

2.1.18 When an auxiliary framing member is cut, it is to be cut squarely. The cut is to be positioned to allow for future expansion, placement of a splice.

2.2 Cable Racks

2.2.1 The location of cable racks and other equipment is to

conform to the particular floor plan and specifications for the installation as referred to in the installation drawings and

EIP.

2.2.2 All exposed, unfinished, or marred surfaces are to be

filed off and/or painted at the time of installation. The paint is to be of the color and type (enamel, oil base etc.)

consistent with the existing or adjacent surface.

2.2.3 All materials (bolts, screws, threaded rods, framework, etc.) are to be secure and have no sharp edges or burrs.

2.2.4 The threads on bolts, cap screws, machine screws, rods

and similar threaded parts is to extend at least two threads beyond the final thread of the fastening device except in the case of cap nuts or self-locking nuts.

4 DISAEC 310-195-2

2.2.5 The threaded part of a fastener is to protrude no more

than an amount equal to the diameter of the bolt, screw or rod.

2.2.6 Threaded rods are to be screwed into floor or ceiling

inserts at least seven full turns.

2.2.7 All anchor type hardware is to be of the type size and

rating as specified in the engineering drawings and EIP.

2.2.8 Holes that were drilled into concrete floors, walls or

ceilings but were not used are to be filled with an acceptable masonry patch.

2.2.9 All fastening details, piece parts, and other apparatus used in the assembly of cable racks are to be assembled in accordance with manufacturer's specifications as specified in the engineering drawings and EIP.

2.2.10 Cable racks are to be rigid, level, properly supported, and properly aligned.

2.2.11 Heat shrink tubing or sheathing is to be placed on all threaded rods from the top of the relay racks to a height of 18 inches (46 cm) above the highest level of cable ladder or cable rack.

2.2.12 When placing cross aisle cable ladder, it is to be

positioned so as not to block the vertical cable ladder

2.2.13 Cable runway pan is to be installed on the 2nd tier cable ladder rack. THey are to have no visible seams showing when viewed from the floor.

2.2.14 Cable runway pan seams are to be taped with duct tape at all seams so that the cable does not snag on the seams.

2.2.15 Unless otherwise specified by the EIP, horizontal cable racks are to be supported on approximately 5 feet (152 cm)to a maximum of 6 feet (183 cm) centers.

2.2.16 Each length of cable rack is to have at least two (2)

support points.

2.2.17 There is to be no more than one (1) cable ladder splice between any two-support points on a horizontal run.

2.2.18 Exposed ends of all cable racks are to be finished with end caps.

DISAEC 310-195-2 5

2.2.19 Runway termination kits are required on all second tier cable ladder racks.

2.2.20 Exposed ends or sharp edges of cable rack stringers are to be covered with a protective material such as fiber paper or cable sheathing at cross-aisle locations, turns, offsets and points where the cable leaves the cable rack.

2.2.21 Cable racks are not to extend more than 36" past its

last support.

2.2.22 When splicing cable rack, sections are to be a minimum of 36” in length.

2.2.23 Cable rack sections are to be bonded together with a

ground strap no smaller than 12 AWG at every seam and interface.

They are to be bonded to the equipotential ground plane or signal ground not more than 24 inches (61 cm) from the end of each run and every 50 feet (15 meters) along the run.

2.2.24 When a cable rack is cut, it is to be cut squarely. The cut is to be positioned to allow for future expansion, placement of a closing bar, corner clamp, or splice.

2.3 Frames, Bays and Cabinets

2.3.1 The use of the word "frame" applies to distribution

frames, cabinets, bays, or other equipment that occupies floor space.

2.3.2 An equipment frame consists of structural framework and all equipment mounted on it.

2.3.3 There is to be at least three feet (91 cm) of free access space in the front, rear and sides of a continuous row of racks, unless the designated engineering authority of DISA-Europe has granted a written waiver approved by the Commander or his/her appointed representative.

2.3.4 All frames are to be secured to the floor using the

applicable bolts, lag-bolts, threaded-rod, masonry-anchors, flat washers, lock washers, and nuts.

2.3.5 All frames, bays, and cabinets are to be positioned, fastened, and supported per engineering drawings and EIP.

2.3.6 All exposed, unfinished, or marred surfaces are to be

filed off and/or painted at the time of installation. The paint

6 DISAEC 310-195-2

is to be of the color and type (enamel, oil base etc.)

consistent with the existing or adjacent surfaces.

2.3.7 All anchor type hardware is to be of the rating, type and size prescribed in the engineering drawings and EIP.

2.3.8 Holes that were drilled into concrete floors, walls, or ceilings but were not used are to be filled with acceptable masonry patch.

2.3.9 The threads on bolts, cap screws, machine screws, rods

and similar threaded parts are to extend at least two threads beyond the final thread of the fastening device except in the case of cap nuts or self-locking nuts.

2.3.10 Threaded rods are to be screwed into floor or ceiling

inserts at least seven full turns.

2.3.11 Threaded rods which anchor the base of a channel relay rack are to protrude no more than 5 threads above the nut.

2.3.12 Threaded rod, which anchors the base of an unequal

flange bay, is to protrude no more than 1-1/2 inches (38 mm) above the base.

2.3.13 The threaded part is to protrude no more than an amount equal to the diameter of the bolt, screw or rod, except as stated in. 2.3.10 and 2.3.11.

2.3.14 All threaded rods that go through a false floor are to be anchored in the sub-floor and are to have a flat washer and hex nut placed against the underside of the floor tile.

2.3.15 Floor masonry anchors are to be secured and not protrude above the concrete, tile or linoleum level.

2.3.16 Equipment frames are to be grounded to a nearby

equipotential plane or fault protection subsystem. The diameter of the ground cable is to be at least 2000 cmil (1X10-6 M2) per running foot. Refer to Table 8.2.11.B for listing of the maximum length of ground cable in respect the diameter of its conductor.

2.3.17 Equipment frames are to be individually grounded to the equipotential plane or fault protection subsystem, and not grounded in series or “daisy chain” with other equipment frames.

DISAEC 310-195-2 7

2.3.18 Frames are to be level and square. Adjacent frames may step up or down not more than 1/8 inch (3 mm) to conform to the contour of the floor.

2.3.19 The vertical alignment of the framework is to be plumb within the following allowable deviations.

Frame Height Maximum Allowable Deviation From

Vertical Plumb

4’ 6” to 7’ 0” (137 cm to 213 cm)

1/8” (3 mm)

7’ 0” to 9’ 0” (213 cm to 274 cm)

3/16” (5 mm)

> 9’ 0” (>274 cm)

1/4” (6 mm)

Table 2.3.20

2.3.20 All adjacent frames are to be bolted together except

where otherwise specified by engineering drawings and EIP.

2.3.21 Joined ends of frames are not to be out of alignment (in or out from a straight line extending the full length of the lineup) more than 1/16” (2 mm).

2.3.22 Enclosed cabinets or bays at the ends of a continuous

lineup are to be secured to the floor in the two outside corners and either of the inside corners. The intermediate cabinets or bays are to be secured in two corners diagonally opposite from each other and diagonally opposite from the anchor in the adjacent cabinets. Individually isolated cabinets or bays are to be secured on all four corners.

2.3.23 All doors are to open and close properly.

2.3.24 The designed thermal cooling, natural air convection or forced air convection from internal fans are not to be altered or blocked.

2.3.25 Separation of adjacent equipment within a frame is to be in accordance with engineering drawings and EIP. Top and bottom interval spacing of at least 1.75 inches (44 mm) is to be provided for equipment that is cooled through conventional means, unless otherwise specified by the EIP.

8 DISAEC 310-195-2

2.3.26 Open relay racks or unequal flange bays are to be

anchored to the floor with all four-anchor holes unless otherwise specified by the EIP.

2.4 Unistrut

2.4.1 All fastening details, piece parts and other apparatus

used in the installation of Unistrut are to be assembled in accordance with manufacturer's specifications, as specified by the engineering drawings and EIP.

2.4.2 The location of Unistrut and other equipment is to

conform to the particular floor plan and specifications for the installation in accordance with engineering drawings and EIP.

2.4.3 All materials (bolts, screws, threaded rods, framework, etc.) are to be secure and have no sharp edges or burrs.

2.4.4 The Unistrut is anchored directly to the flooring using fasteners spaced no greater that 2 ft. 6 in. (76 cm) apart.

2.4.5 Unistrut may be cut as needed to fit around obstructions.

It is to be cut squarely. Ends are to be finished with an end cap if specified by the EIP.

2.4.6 The threads on bolts, cap screws, machine screws, rods

and similar threaded parts are to be engaged through to the final thread of the Unistrut (spring) nut.

2.4.7 The threaded rods are to be fastened to the Unistrut

using flat plate washers, lock washers and nuts.

2.4.8 All bolts, nuts, and screws used to secure any part or

unit are to be tight.

2.5 Conduit, Wireway, or Duct

2.5.1 All conduits are to be installed in accordance with

engineering specifications and drawings called out in the EIP.

2.5.2 All unused knockouts of wireways, electrical boxes and

cabinets are to be closed or covered to prevent the entry of foreign objects into their interior.

2.5.3 Conduits are to be placed so as not to block future

cabling and equipment installations.

2.5.4 All conduits are to be grounded at their far ends. In

cases where a conduit run exceeds 133 feet (40 meters) the

DISAEC 310-195-2 9

conduit is to be grounded at least every 100 feet (30 meters) with 2 AWG stranded copper wire.

2.5.5 The total bond resistance between the conduit and the

equipotential plane or fault protection subsystem is not to exceed 5 milli-ohms.

2.5.6 The number wires or cables in a conduit are not to exceed 40 percent of the cross-sectional capacity of the conduit.

2.5.7 Rigid conduit or EMT is to be supported at least every 6 feet (183 cm) and within 3 feet (91 cm)of each end.

2.5.8 In the effort of shielding electrical and magnetic fields from emanating from power lines, only ferrous metallic conduits, raceways, or ducts are to be used as raceways for the distribution of AC or DC power lines in a computer or communication facilities. Aluminum, copper or non-metallic conduits, raceways or ducts are not to be used in conveying power-lines.

2.5.9 Flexible ferrous metallic conduit must be supported at

least every 4 ft. 6 in.(137 cm) and within 12 inches (30 cm) of any box or fitting.

2.5.10 Conduit is to be deburred after cutting.

2.5.11 All conduit fittings, connectors, boxes, coupling, etc.

are to be of the proper type and material for the conduit used and are to be properly assembled in accordance with the engineering drawings and EIP.

2.5.12 All conduit supports are to be of the proper size, type and material for the application, and are to be applied correctly in accordance with engineering drawings and as specified by the EIP. Conduit is to be bent to conform to the supporting structure. Supports are only for shoring the conduit; they are not to be used to force the conduit to conform to the supporting structure.

2.5.13 All conduits are to be installed plumb or level.

2.5.14 Wire is to exit conduit only through a connector or

bushing. Wire is not to exit through the unprotected end of the conduit.

2.5.15 Ducts and wireways are to be supported at least every 5 feet (1.5 meters) and within 2 feet (61 cm) of each end.

10 DISAEC 310-195-2

2.5.16 All ducts and wireways are to be installed plumb or

level, except when changing elevations with 45-degree elbows.

2.5.17 All duct and wireway fittings are to be assembled

properly, IAW manufacturer’s instructions as specified by the engineering drawings and EIP.

2.5.18 The edges of wire access cutouts in ducts and wireways are to be covered with plastic grommet or other suitable protective material.

2.5.19 Ducting and wireways are to be made electrically

continuous by bonding together all sections and covers.

Associated brackets or hanger is to be electrically bonded to the ducting or wireway. Ducting and wireway are to be electrical bonded to the equipment frames that they feed through physically mating or by wide, flexible solid metallic bond straps.

2.5.20 Ducting and wireways are to be bonded to facility ground system with copper cable conforming to the 2000cmil per foot (1X10-6 M2 per 30 cm) criteria. Refer to Table 8.2.11.B. The bonding resistance between the ducting/wireway and the facility ground system is not to exceed 5 milliohms and is to be grounded not more than 2 feet (61 centimeters) from each end and every 50 feet (15 meters) along the length of the run. Duct containing AC power wiring is to be connected to the protective ground in the AC distribution panel.

2.5.21 Duct or wireway is to be squarely cut and deburred. The cut is to be positioned to allow for future expansion, installation of a coupling fitting. Wire is not to exit through the end cap of a duct or wireway unless the duct cannot be physically extended further in that direction.

2.5.22 Fiber duct is to be supported at least every 5 feet (1.5 meters) and within 2 feet (61 cm) of each end. The end of a fiber duct is to be secured where it enters a cabinet or extends to a rack.

2.5.23 All fiber duct is to be installed plumb or level, except when changing elevations with 45 degree elbows.

2.5.24 All fiber duct fittings and supports is to be assembled properly, IAW manufacturer’s instructions as specified by the

EIP.

2.5.25 Fiber carrying secure (RED) communication is to be

incased in metallic conduit or ducting.

DISAEC 310-195-2 11

3. Cable Penetrations (Cable Holes and Sleeves)

3.1 General Requirements

3.1.1 All cable holes penetrating a fire zone boundary are to be permanently fire stopped in accordance DOD fire regulations.

Refer to MIL-Handbook 1008 for guidance for fire protection.

4. Signal Cabling and Wire

4.1 General Requirements

4.1.1 Cables and wires selected are rated for carrying twice

the planned applied RMS current. The breakdown voltage of the insulation of the cables and wires used is to be at least 150 percent more than the planned applied peak voltage.

4.1.2 All cables and wire are to be of the specified type, color, and gauge as outlined in the EIP or engineering drawings.

4.1.3 All cables and wire are to be positioned, placed and

supported according to the EIP specifications. They are to be supported and secured at least every 18 inches (46 cm).

4.1.4 Cables are to not be dropped between rungs of the cable ladder rack unless specified by the EIP.

4.1.5 All wires are to be dressed in such a manner as to avoid stress on terminations, congestion, to ensure accessibility, and to maintain proper clearance between terminals.

4.1.6 Cables are not to be routed to obstruct access to

terminals.

4.1.7 Care is to be taken when stripping wire so that the wire is not nicked or scraped.

4.1.8 Wires are to be stripped to the proper length for

accommodating the connection being made in accordance with manufacturer’s instructions or applicable standard.

4.1.9 All spare and unused wires for planned future

installation are to be long enough to reach any required termination point of that cable. Coil and store all cabling designated "future" so that they can be accessed when required.

12 DISAEC 310-195-2

4.1.10 All spare and unused cable pairs are to be terminated to ground and properly treated (dressed in heat shrink, cable sheath, or fiber tubing and properly secured to the cable, fan, or form).

4.1.11 All signal cables are to be tested end to end in

accordance with the test procedures or standards reference in the EIP or Test Plan.

4.1.12 When possible, cables are to lay side by side on racks, without crossing. Cables leaving the rack are to retain their respective positions. Cable runs are to be planned as much as possible so that cables leaving the rack are on the top layer and do not have to cross.

4.1.13 Power cable external to racks that are not shielded by a ferrous metallic conduit or ducting requires at least a three feet separation from control and signal lines that are also not contained in a metallic conduit or ducting. A ferrous metallic conduit or ducting that is plated with a non-ferrous metal, such as galvanized steel will provide sufficient electrical and magnetic shielding against offending electromagnetic interference and transients traveling on power lines.

4.1.14 A minimum of four inches (10 cm) of separation between power lines and control/signal lines is to be maintained in cabinet/racks.

4.1.15 All power cables are to be routed along the side of the equipment frame that is opposite to the control and signal cables. Generally, ground, control and signal lines are routed down the right side of an equipment cabinet/rack, and power lines are routed along the left side of an equipment cabinet/rack.

4.1.16 Cables are to leave the rack directly above or below the cabinet, rack, or frame that they terminates to. Cables are to leave the rack, flowing over the edge creating a “waterfall effect”, with no excessive slack and not pulled tight.

4.1.17 All cables are to enter a distribution frame on the

vertical side. Cables serving the vertical side are to be routed to the left of the transverse arm near the terminal strip and kept forward of the spacer bar to avoid interference with cross connects. For other than connecting cables, the cable butt is to be located level with the first fanning hole of the terminal block, 1 inch (25 mm) behind the terminal block-fanning strip. Cables serving the horizontal side of the frame are to be routed to the flat side of the transverse arm and secured

DISAEC 310-195-2 13

near the vertical upright. Cables then cross over the arm, make a half turn, and are secured in the channel of the transverse arm. For other than connecting cables, the cable butt is to be located 3 inches (76 mm) behind the terminal block-fanning strip.

4.1.18 Minimum bending radius is to be maintained for all

cables as specified by the manufacturer. When the minimum bending radius is not specified the following criteria are to be followed: 5 X diameter for paired cables, and 10 X diameter for coax, triax, twinax, helix and fiber optic.

4.1.19 No cabling or wiring is to be routed directly from one cabinet or rack to another. All cabling between cabinets is to be routed over the cable ladder or under the raised floor.

4.2 Multiconductor Cable Terminations

4.2.1 In cases where cable butts are covered with heat

shrinkable tubing, the shrinkable tubing is to extend from 1 inch (2.5 cm) above to 1 inch (2.5 cm) below the butt. Heat shrink is not to be used on cable butts within connector backshells unless specified by the EIP.

4.2.2 Cable sheaths are to be butted where the conductors break off to be terminated to the equipment, using heat shrink tubing or crimp-type butt.

4.2.3 There are to be no changes or modifications made to the DSX panel or any other equipment.

4.2.4 Cables that enter a 66, 89, or 110-type block are to be butted where they enter the block.

4.2.5 Only minimum amount of slack in the length of a cable is to be permitted in a cable rack. The excess length of the cable is to accommodate changing of cable’s terminating connectors five times and to relieve the stresses associated with movement of objects to which the cable is terminated to or fastened to.

4.2.6 All shielded cables and wires carrying signals of

frequencies less than 30 kilohertz or of data rates of less than 30 KBPS are to be ground bonded at one end only, unless directed otherwise by the equipment manufacture, installation drawing or the designated the DISA engineer. Typically shielded cables and wires are to be grounded at the distribution frame or block termination.

14 DISAEC 310-195-2

4.2.7 All shielded cables and wires carrying signals of

frequencies greater than 30 kilohertz or of data rates of greater than 30 KBPS are to be ground bonded at both ends unless directed otherwise by the equipment manufacturer, installation drawing or the designated the DISA engineer.

4.2.8 Twisted pair cables carrying signals greater than 1 MHz or 1 MBPS are to be terminated to Type-110 distribution blocks, or termination blocks having stray capacitance and high conductive characteristics that similar or better than the Type- 110 block. Note that the Type-66 block’s electrical characteristics are substandard to those of the Type-110 block.

4.2.9 The insulation of cables and wires that are to pass

through areas used for the circulation of air in a building, such as ducting, raised-floors and suspended ceilings, are to be plenum rated. This guideline is to not be waived due to the high toxicity of the gases emitted by some burning plastics that are used in electrical insulation.

4.2.10 Connectors are to be installed in accordance with the

engineering drawings or as specified by the EIP. There is to be no excess slack of terminated conductors inside of connector backshells. Conductors are to be fanned inside the backshell to minimize crossing. Spare conductors are to be trimmed to reach the furthest pin and neatly folded or coiled inside the backshell. The connector is to be properly assembled, with the strain relief engaging the cable sheath. If conductors are stripped, they are not to be nicked (solid) or have strands cut off (stranded). They are to be terminated to the respective contact.

4.2.11 Modular connectors are to be the proper size and type

for the cable being terminated (solid/stranded, gauge, diameter, oval/flat). Cables are to be the proper type for a modular connector. The connector is to be applied properly. The strain relief is to engage the cable sheath. The conductors are to be pushed completely into the connector so that the contacts fully engage the conductors.

4.3 Light Guide (Fiber Optic) Cabling

4.3.1 Light guide cables are to be segregated from other types of cables and are to be either installed in separate cable raceway or in a fiber management systems such as fiber ducting.

DISAEC 310-195-2 15

4.3.2 Light guide cables conveying secure (RED) information or data are to be encased in a metallic conduit or ducting.

4.3.3 Light guide cables are to be routed loose without

restraints. Velcro cable straps may be used to secure this type of cable.

4.3.4 When it is necessary to secure a light guide cable the

cable is not to be fastened so tightly as to cause damage or deform the cable. Nylon cable ties are not to be used for banding or securing fiber optic cables. It is recommended that light guide cabling be routed in plastic flex-tubing.

4.3.5 The minimum bending radius of a light guide cable is to be greater than the manufactures specified bending radius.

4.3.6 Light guided cables are to be installed with no kinks, surface damage or any other deformity.

4.3.7 Slack in light guide cables is not to be stored

unprotected in a rack. The excess cable is to be coiled into a light guide cable storage device.

4.3.8 Light guide cables are to be labeled as any other cables in accordance with this standard or as specified in the EIP.

Refer to Paragraph 6.3.9.

4.3.9 When running cables equipped with optical connectors, the connectors are to be protected with a cover to prevent damage and contamination to the connector.

4.3.10 Light guide cables that pass through areas used for the circulation of air in a building, such as ducting, raised-floors and suspended ceilings, are to be plenum rated. This guideline is not to be waived due to the high toxicity of the gases emitted by some burning plastics that are used in the fabrication of light guide cables.

4.4 Nylon Cable Ties (Tye-wraps)

4.4.1 Nylon cable ties are not to be used for banding or

securing fiber optic cables.

4.4.2 Nylon cable ties may be used to secure cable and wire

above and below raised access floors. They are to be free of sharp edges. The tail or exposed end is to be flush or extend no more than 1/64 inch (0.5 mm) beyond the tail head.

16 DISAEC 310-195-2

4.4.3 Specific tools (flush cut) designed to cut tails off

nylon cable ties are to be used. Tension of tie wrap gun is to be set correctly for each application.

4.4.4 Nylon cable ties are to be tensioned tightly enough to

hold the wires securely together and/or properly positioned, but not so tightly or at such angles as to cause possible damage to the insulation of the wire or cable.

4.4.5 The nylon cable ties banded around wire and cable are to be capable of being rotated with slight to moderate pressure applied with the thumb to the head of the tie. The wires or cables under and/or adjacent to the tie are not be twist when rotating the tie.

4.4.6 The permanent use of nylon cable ties are permissible

above or below raised access floors in installations.

4.4.7 Welding cables are to be protected when secured with

nylon cable ties.

5. Connectors

5.1 General Requirements

5.1.1 Cables and wires are to be of a sufficient length at the area of a connector’s termination to allow replacement of the connector at least five times.

5.2 Soldered Connections

5.2.1 Solder connections are to have concave fillets around the complete connection. The solder connection is to have good wetting characteristic, evidenced by smooth feathering of the fillet onto the connection elements, and the formation of a small angle of contact between the solder fillet and the elements being joined.

5.2.2 63/37 rosin-core solder or 60/40 rosin-core solder is to be used for making soldered connections.

5.2.3 Only rosin based fluxes conforming to types R or RMA of MIL-F-14256 is to be used for making a soldered connection. The flux used in solder (wicking) braid is to be type R or RMA.

Rosin base flux conforming to Type RA of MIL-F-14256 may be used for tinning component leads of sealed devices, solid bus wire, and terminals.

DISAEC 310-195-2 17

5.2.4 Solder connections are to be free of the following

defects:

5.2.4.1 Non-soldered connection,

5.2.4.2 Solder bridging,

5.2.4.3 Rosin flux connection,

5.2.4.4 Cold solder joints,

5.2.4.5 Solder connections with stress lines,

5.2.4.6 Connections of insufficient solder,

5.2.4.7 Connections of excessive solder,

5.2.4.8 Solder splatter, Pin-holes in the solder,

5.2.4.9 Pits in the connection exposing inner surface of

connection,

5.2.4.10 Contaminated connections,

5.2.4.11 Non-wetting wherein basis metal is exposed,

5.2.4.12 Solder connection dull grainy and gray in appearance,

5.2.4.13 Solder silvers,

5.2.4.14 Overheated connections where solder is dull and

chalking in appearance,

5.2.4.15 Measling of the solder,

5.2.4.16 Improperly cut wires,

5.2.4.17 Excessive wicking where the solder extends to the

wire’s insulation.

5.2.5 Soldering procedure for cup type terminals found in

connectors is to be the following:

5.2.5.1 Place the connector in a holding fixture at

approximately a 45 degree angle with open side sup facing up.

18 DISAEC 310-195-2

5.2.5.2 Apply heat to the side of the cup until the flow

temperature of the solder is reached.

5.2.5.3 Slowly feed the solder into the cup until the required amount is present.

5.2.5.4 If required, place insulation tubing on the wire and

slide it back out of the way.

5.2.5.5 Place the iron on the side of the cup near the bottom and heat until the solder is molten. Place the stripped and tinned wire in the cup, bottoming the wire in the cup. Maintain heat until it forms a good fillet to the cup and wire. Do not heat longer than necessary to form an acceptable connection since excessive heat can cause excessive wicking under insulation. Ensure wire does not move while solder is solidifying.

5.2.6 Soldering procedure for turret-terminals is to be the

following:

5.2.6.1 Tin the conductor of the wire with solder.

5.2.6.2 The bend in the wire is to maintain contact with post.

The curvature of the wrap is to extend not less than 180 degrees and not more than 270 degrees.

5.2.6.3 There are to be no more than three conductors for each section a turret terminal.

5.2.6.4 Apply the tinned iron tip to the connection at a point near the midpoint of the mechanical wrap, and heat to the flow temperature of the solder.

5.2.6.5 Feed a sufficient amount of solder to form a heat

bridge to the other side of the connection.

5.2.6.6 First remove the solder source, then the iron.

5.2.7 Soldering procedure for bifurcated-terminals is to be the following:

5.2.7.1 Tin the conductor of the wire with solder.

5.2.7.2 The wire or component lead is to be dressed through the slot and wrapped to either post of the terminal. The wire or lead is to be wrapped to the terminal post a minimum of 180 degrees and a maximum of 270 degrees (1/2 to 3/4 turn). The wire or lead is to be wrapped on the terminal post to assure positive

DISAEC 310-195-2 19

contact of the wire with at least two corners of the post. The wire or lead is to also be in firm contact with the base of the terminal or the previously installed wire.

5.2.7.3 The number of attachments is to be limited to three per terminal post and is to be maintained such that:

5.2.7.3.1 There is no overlapping of wraps and wires.

5.2.7.3.2 Spacing between wires, and spacing between the wires and the terminal board or panel is a minimum consistent with the thickness of the wire insulation.

5.2.7.3.3 The wraps are dressed in alternate directions.

5.2.7.4 Apply the tinned iron tip to the connection at a point near the midpoint of the mechanical wrap, and heat to the flow temperature of the solder.

5.2.7.5 Feed a sufficient amount of solder to form a heat

bridge to the other side of the connection.

5.2.7.6 First remove the solder source, then the iron.

5.2.8 Soldering procedure for pierced or perforated terminals is to be the following:

5.2.8.1 Tin the conductor of the wire with solder.

5.2.8.2 For wiring to a single terminal, the wire is to pass

through the eye and be wrapped around the terminal between 180 to 270 degrees (1/2 to 3/4 turn).

5.2.8.3 If wires are to be attached to a group of terminals

such as on transformers, certain relays, and rotary switches, the wire are to be neatly arranged around the terminals in such a manner that they do not cross one another.

5.2.8.4 Apply the tinned iron tip to the connection at a point near the midpoint of the mechanical wrap, and heat to the flow temperature of the solder.

5.2.8.5 Feed a sufficient amount of solder to form a heat

bridge to the other side of the connection.

5.2.8.6 First remove the solder source, then the iron.

20 DISAEC 310-195-2

5.2.9 There is to be no burned insulation. Maximum length

exposed conductor is 1/16 inch (2 mm) when soldering to any pin or lug.

5.3 Coaxial Connections

5.3.1 Connector must be the proper size and type for the cable.

5.3.2 Ferrules are to be crimped using the manufactures

recommended tool as specified by the EIP.

5.3.3 The ferrule are to be butted against the BNC connector

body. Only one crimp is to be made.

5.3.4 The crimp is to be hexagonal with no burrs, flanges or

excessive rounding of the corners.

5.3.5 The coax-braided shield is not to extend beyond the point where the ferrule and connector body meets.

5.3.6 The outer jacket of the coax cable must be under the

ferrule.

5.3.7 Crimped center pins on BNC connectors are to be done

using only the manufacturer’s recommended tools as specified by the EIP. The center pin is to be soldered to a solid center conductor.

5.3.8 Miniature coaxial/twinax cable is to be routed and

supported as to eliminate any strain on the terminated end of the miniature coaxial cable.

5.3.9 The connector is to be of the proper size and type for

the cable. It is to be assembled properly, using the proper tool(s). The strain relief (nut or ferrule) is to engage with the cable sheath.

5.4 Compression Connections General -(#10 AWG 5.3mm2) and

Smaller)

5.4.1 All crimps or compression connections using the various types of commercial connectors are to be properly made with the number of crimps being determined by the supplying manufacturer's requirements pertaining to wire gauge, type of lug, and the crimp or compression tool used.

DISAEC 310-195-2 21

5.4.2 Only connectors and splices with electrical rating that exceeds the predicted current and voltage of a termination are to be used.

5.4.3 Connectors are to be made of tin-plated copper with an

insulated barrel unless otherwise specified by the EIP.

5.4.4 Wires are to be inserted so that they extend 1/16 inch (2

mm) past the barrel of the lug.

5.4.5 Space between wire insulation and the body of solderless connectors and power lugs are to be kept to a maximum of 1/16 inch (2 mm). Solid wire is to not be nicked. Stranded wire is to not have any strands cut off.

5.4.6 Crimps are to not extend onto the tang area.

5.4.7 The number and sequence of crimps are to be appropriate for the connector used.

5.4.8 The connector is to agree with the wire size as follows for #10-22 AWG (5.27 - 0.63 mm2):

Red Terminal #22 - #18 AWG (0.63 - 0.82 mm2) Blue Terminal #16 - #14 AWG (1.31 - 2.08 mm2) Yellow Terminal #12 - #10 AWG (3.31 - 5.27 mm2)

5.4.9 Lugs are to be crimped with the proper tool in accordance with manufacture instructions or recommendations.

5.5 Solderless Wrapped Connections

5.5.1 All connections not meeting the requirements of this

section are to be soldered.

5.5.2 When one connection on a terminal is soldered then all

connections on that terminal are to be soldered.

5.5.3 There are to be no separations between turns of wire on the terminal. Wraps are to begin at the bottom of the terminal.

5.5.4 Insulation is to be within 1/32 inch (1 mm) of the

terminal, or a modified wrap.

5.5.5 20 & 22 AWG wires are to have minimum-of-5 non-overlapping turns.

22 DISAEC 310-195-2

5.5.6 24-AWG wires are to have a minimum of 5 non-overlapping turns.

5.5.7 26-AWG wires are to have a minimum of 7 non-overlapping turns.

5.5.8 28 & 30 AWG (0.08 - 0.05 mm2)wires are to have a minimum of 7 non-overlapping turns plus a full turn of insulation.

5.5.9 The size of the wire is to not exceed the capabilities of the terminals.

5.5.10 There is to be no wire-end projections.

5.5.11 No turns of any connection are to overlap the turns of any existing connection on the same terminal. There is to be no gap between multiple connections on the same terminal.

5.5.12 The end of a wire is not to be over-wrapped.

5.5.13 All wraps are to be made in the clockwise direction.

6. Equipment Designations

6.1 General Requirements

6.1.1 It is to be the installer's responsibility to apply all equipment designations.

6.1.2 Labeling machines (such as P-Touch) may be used in place of rubber stamps and ink, as long as proper character size and color are adhered to.

6.1.3 The top front of equipment frame is to be labeled with

the following information:

6.1.3.1 The number of the row that frame is in.

6.1.3.2 The sequential number of the frame in respect with the adjacent equipment frame.

6.1.3.3 The number of the circuit breaker and breaker panel

that frame’s power cable is terminated to.

6.1.3.4 Letter is to be ¾ or 1 inch (19 or 25 mm) in size.

6.2 Character Colors

DISAEC 310-195-2 23

6.2.1 White label backgrounds or individual white lettering are required on dark surfaces, conversely dark-color label backgrounds or individual black lettering are required on a on light surfaces.

6.2.2 Caution notices are to be in white or black on a red

background. Fuse ratings are to be in black on a yellow background.

6.2.3 Outlets that supply AC power are to be designated with

the voltage in black on a white background on the front or side of the outlet.

6.3 Requirements

6.3.1 All equipment bays and relay racks are to be numbered on their front and rear sides using ¾ inch (19 mm) characters positioned on the top center of the horizontal rail or guard rail cover. The front label is to be placed on the center of the top horizontal guardrail so it can be easily viewed from the front of the rack. The rear label is to be positioned on the center of the top horizontal guardrail and is easily viewed from the rear of the rack.

6.3.2 All distributing frames are to have the verticals

numbered and shelves lettered with ¾ inch or 1 inch (19 or 25

mm) characters. Verticals side of the frame is to be labeled at the top of each vertical terminal blocks. The horizontals are to be labeled on the horizontal side of the frame adjacent to the shelves on the end guards. Verticals are to be labeled on the horizontal side of the frame between blocks E and F, above the jump rings.

6.3.3 All distributing frame connecting blocks and covers are to be marked as required, thereby designating the group, subgroup, equipment, frame, bay, etc.

6.3.4 Ensure that all fuse/breaker assignment book/cards are

complete and are placed on the inside of the front cover of the fuse/breaker panel. The load served by each circuit breaker or fuse is to be identified regardless of whether assignment books/cards are provided. Make the applicable changes to the facilities “one-line” power diagram or system power diagram to accurately reflect the installation.

6.3.5 Label all equipment shelves with the position in the rack or bay.

24 DISAEC 310-195-2

6.3.6 Mark all wall outlets and rack/cabinets with the source circuit breaker number and the power panel number.

6.3.7 Label all inner and outer power service distribution

frames or panels, top center, ¾ inch (19 mm) characters, with the name and number, the highest voltage provided, VAC or VDC, frequency, and phase.

6.3.8 Label all fuse panels and low voltages disconnect panels.

6.3.9 All signal cables are to have labels on each end, a “TO” label and a “FROM” label and are to correspond with the applicable Cable/Wire Run List of the EIP. The “TO” label is to be placed on the cable not more than 3 inch (76 mm) from the butt or connector, the “FROM” label is to be placed no more then one inch behind the “TO” label. The labels are to be legible when the cable is connected. The “TO” and “FROM” labels are to have at a minimum the Bay/type or Frame (LINE 1), the equipment nomenclature (LINE 2), and the Jack/Connector, or Row that the cable terminates to or where it originates from such that the termination location is uniquely identified. For example, a cable from a D4 channel bank to the distribution frame:

Total of 4 labels

D-4 END FRAME END

To Bay 13.01 From MDF From Bay 1301 To MDF D-4 #5 V14F D-4 #5 V14F

CS-1 C1 CS-1 C1

7. DC POWER

7.1 General Requirements

7.1.1 Fiber paper, U-shaped fiber insulators, plastic grommet, sheathing, or other suitable material are to be used to protect wire and cable that is being distributed off cable racks. The insulator or paper is to be secured in place with cable ties or other methods that ensures that it remains in place.

7.1.2 Power wires are to be protected with fiber paper or

acceptable plastic insulators where they passes through or come in contact with metal edged openings.

7.1.3 Fiber paper, U-shaped fiber insulators or plastic

grommets are required around any sharp edges of framework, racking, etc.

DISAEC 310-195-2 25

7.1.4 Power cables are to be marked with their voltage or

polarity near their termination points; therefore ‘-48’ and ‘+48’or ‘-‘ and ‘+’.

7.1.5 It is recommended that power cables used for supply (-48 VDC) are Black and White for return (+48 VDC). If other colors are used, the power cables are to be marked with a suitable material (tape, heat shrink, etc.) minimally as close as possible to the ends of the insulation and at not more than 48” intervals where accessible. Exposed ends of power cables are to be insulated with tape and heat shrink caps.

7.1.6 Power racks and bays are to be installed plumb and level with the same allowable deviations listed in Table 2.3.20 of this standard.

7.1.7 DC power cables are to be run and secured on cable racks, power brackets, duct, raceway, or conduit dedicated for their distribution.

7.1.8 AC and DC power cabling are not to be run on the same

cable ladder or in the same duct.

7.1.9 Power cables leaving cable…