MultiCOM Installation Manual Rev 2 0 2010-Feb-12

MULTICOM
INSTALLATION AND APPLICATION

MANUAL
Rev 2.0 Feb 2010

February 12, 2010 MultiCOM Installation and Application Manual 2.0
1. INTRODUCTION.................................................................................................................... 4
1.1 LEAKY FEEDER SYSTEMS .................................................................................................... 4
1.1.1 System Planning ........................................................................................................ 4
1.2 BASIC THEORIES OF OPERATION ......................................................................................... 5
1.3 LOSS AND GAIN .................................................................................................................. 5
2. LAYOUT ................................................................................................................................ 6
2.1 BASE STATION PLANNING .................................................................................................... 6
2.1.1 Leaky Feeder Cable ................................................................................................... 7
2.2 PASSIVE SPLITTING ............................................................................................................. 8
2.2.1 Amplified Splitting..................................................................................................... 10
2.2.2 Amplifiers.................................................................................................................. 11
2.3 VIDEO AMPLIFIERS ............................................................................................................ 11
2.3.1 Power Supply ........................................................................................................... 12
2.3.2 Pilot Generators ....................................................................................................... 12
2.4 CABLE TERMINATION......................................................................................................... 13
3. INSTALLATION................................................................................................................... 15
3.1 INSTALLATION OF LEAKY FEEDER CABLE ........................................................................... 15
3.1.1 Introduction............................................................................................................... 15
3.2 INSTALLATION PLANNING ................................................................................................... 15
3.2.1 Installation Procedures............................................................................................. 16
3.2.2 Leaky Feeder Cable in the Shaft.............................................................................. 16
3.3 LEAKY FEEDER CABLE ON A LEVEL OR DECLINE ................................................................. 17
3.3.1 Installation of Components....................................................................................... 17
3.3.2 Introduction............................................................................................................... 17
3.4 INSTALLATION PLANNING ................................................................................................... 18
Page 2 of 22 © 2009 Mine Radio Systems

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3.4.1 MultiCOM Base Station - BSVx................................................................................ 18

3.4.2 Installation Procedures - MultiCOM Line Components ............................................ 18
3.5 REQUIRED TOOLS ............................................................................................................. 18
3.5.1 Cable Preparation .................................................................................................... 19
3.5.2 Component Orientation ............................................................................................ 20
3.6 CABLE TERMINATION......................................................................................................... 20
3.6.1 Waterproofing........................................................................................................... 20
3.6.2 Enclosure Mounting.................................................................................................. 21
3.7 INSTALLATION PROCEDURES - POWER SUPPLY.............................................................. 21
3.8 INSTALLATION PROCEDURES-MULTICOM SYSTEM SPLITTER ............................................. 22

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1. Introduction
1.1. Leaky Feeder Systems

Leaky Feeder is a technology used to provide communication services in underground mines.
The basic technology, invented in the 1950’s relies on the use of a special coaxial cable, Leaky
Feeder. Leaky Feeder cable, unlike conventional coaxial cable, has a partially covered shield.
This allows radio signals propagating (travelling) inside the cable to leak out and radiate into the
immediate vicinity. These “leaked” radio signals may be received by conventional VHF two-way
radio equipment. This concept is ideal for mining applications and tunnels since the leaked
signals effectively covers mine drifts.
Since radio signals in the cable leak out along its length, the signals become weaker as they
travel further down the cable. Periodic signal boosting is required, and this is accomplished by
using special amplifiers.
1.1.1. System Planning

The MultiCOM system succeeds because it is easy to install, operate and maintain. Once mine
personnel understand the basic theories of operation, they are able to design the installation
layout and subsequent expansions. During the planning stages the following questions must be
answered:
• Is communication required in the shaft?
• Is slack rope detection required in the shaft?
• Where is communication and automation required presently?
• In which locations will automation and communication be a future requirement?

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1.2. Basic Theories of Operation

• Radiating cable (Leaky Feeder) requires periodic amplification of its signals since it is losing
energy through radiation.
• A single cable can carry many different signals, each signal on a different frequency.
Direction Frequency Application

Towards Base Station 20 - 115 MHz Video (NTSC or PAL)
Towards Base Station 172 - 174 MHz Voice/Data
Away From Base Station 155 - 159 MHz Voice/Data
Table 1-1 - MultiCOM System Frequency Allocations
• Portable radios and data transceivers transmit in the 172-174 MHz band and receive in the
155-159 MHz band.
• The 172-174 MHz transmission from the portable is transferred up the Leaky Feeder to a
repeater. The repeater re-transmits the signal in the 155-159 MHz band. This 155-159
MHz signal travels throughout the mine to all portables.
1.3. Loss and Gain

In this document, a loss means the reduction in signal strength from one point to another. A
gain is the increase in signal strength from one point to another. All components in the
MultiCOM system have a net loss, except for the amplifiers, which have a net gain.
When the MultiCOM system is installed correctly, the net gain from all of the amplifiers in the
system will equal the net loss of all of the passive components such as cable and splitters. The
Automatic Gain Control (AGC) of the MultiCOM amplifiers acts to maintain “unity” gain.

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2. Layout
When laying out the system, always use accurate and up-to-date mine plans to identify regions
of the mine where communications/control is required.
2.1. Base Station Planning

Generally, the base station is located on surface because this location allows the option to
broadcast on surface with the addition of multicoupling and surface antennas. Diagnostics
information from the amplifiers in the system can also be linked directly to a surface computer.
These surface frequencies may require approval and licensing from the proper authorities. It is
recommended to use as many of the four available ports from the MultiCOM FCL4 as possible.
Each port has its own DC power source and current limiting circuit. If a problem in the cable
occurs which is connected to port # 1 it would only affect the section of the system, which is
connected to port # 1. The rest of the system would continue to operate normally.

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2.1.1. Leaky Feeder Cable

Mine Radio Systems Leaky Feeder cable has a yellow jacket for easier visibility and is shipped
on 350-meter (1150 feet) rolls. It meets the P-177-16-MSHA requirement for flame retardancy.
The loss of the cable changes due to several factors but can be approximated at 16 dB per 350
meters at 157 MHz.

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Layout the Leaky Feeder cable from the MultiCOM base station, keeping in mind that line of
sight communications is required with the cable.
Never run two or more Leaky Feeder cables in the same drift. If more than one cable in a drift is
requirements then make one a Leaky Feeder cable and all others shielded cable (e.g. RG
11/U).
Figure 1-1 Leaky Feeder Cable
2.2. Passive Splitting

Locate the appropriate splitter devices at the points where cable has to be run into different
locations of the mine. Each splitter device has a specific equivalent loss associated with it in
terms of meters or feet of cable (see Table 2-1). This loss, in terms of cable length, must be
subtracted from the recommended amplifier spacing to determine the length of cable that can
extend between two amplifiers with the splitting device in line.

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For example:
If an MSS is inserted between two MultiCOM amplifiers, the distance that the amplifiers can be
separated is:
350 meters - 130 meters = 220 meters
Component Application Insertion Cable Equivalent EL-3529

Loss (dB) Meters Feet
MSS - Input to port 1 System Splitter 6 dB 130 m 425 feet
- Input to port 2 6 dB 130 m 425 feet
- Input to port 3 6 dB 130 m 425 feet
MSB Splice Box 1 dB 22 m 75 feet
MPC Power Coupler 1 dB 22 m 75 feet
MBU1 Branch Unit 1 dB 22 m 75 feet
Table 2-1 - MultiCOM Passive Component Insertion Loss
Figure 1-2 MSS Board

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2.2.1. Amplified Splitting

An amplified splitter (MSA) combines splitting and amplification within one component. Amplifier
spacing with MSA components is 250 meters.
Figure 1-3 MSA

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2.2.2. Amplifiers
The recommended amplifier spacing for MultiCOM components is 350 meters (1150 feet). This
recommended distance is made up of the actual length of Leaky Feeder cable and any
equivalent length because of splitter devices in the line (see Table 2-1).
Figure 1-4 MLAD
2.3. Video Amplifiers

The path where video is to be transmitted by Leaky Feeder requires the addition of the
MultiCOM video amplifier board (MLAV). The video amplifiers transmit video one-way, from the
bottom to the top of the mine or towards the base station.
Figure 1-5 MLAVU

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2.3.1. MultiCOM Power Supply

Each branch of Leaky Feeder coming from the MultiCOM base station provides DC power to the
amplifiers. In most systems however, the MultiCOM Power Supply (MPS) is required
periodically in the system in order to maintain an adequate voltage at each amplifier. The
positioning of these units is also dependent on the availability of 120/240 VAC which the MPS’s
use as their primary voltage source. The MPS unit uses a device called the MultiCOM Power
Coupler (MPC) to couple the DC voltage to the Leaky Feeder cable.
Figure 1-6 MPS
2.3.2. Pilot Generators

The MultiCOM system utilizes a pilot tone to set the Automatic Gain Control (AGC) of each
amplifier. This 175 MHz tone is generated at the end-of-line units. Generally a MTUR is used.
Short branches with 5 or fewer amplifiers do not require a pilot tone.

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2.4. Cable Termination

At the end of each branch, a MultiCOM Termination Unit (MTU) is required to optimize system
performance.
Figure 1-7 MTU

Base Station Equipment
Name Component Description
MHE MultiCOM Headend
MBSV MultiCOM Base Station Voice
MDBE MultiCOM Diagnostics Base Equipment
Amplifiers
MLA MultiCOM Line Amplifier
MLAD MultiCOM Line Amplifier with Diagnostics
MLAV MultiCOM Line Amplifier with Video
MLAVD MultiCOM Line Amplifier with Video and Diagnostics
Splitters
MSS MultiCOM 3 Way Splitter
MSA MultiCOM Splitter Amplifier
MSAV MultiCOM Splitter Amplifier with Video
MPC MultiCOM Power Coupler

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Miscellaneous
MPS MultiCOM Power Supply
MTU MultiCOM Termination Unit
MSB MultiCOM Splice Box
MLFC MultiCOM Leaky Feeder Cable
Table 2-2- MultiCOM System Component List
Fig ure 2-1- Sample MultiCOM Installation Layout

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3. Installation
3.1. Installation of Leaky Feeder Cable
3.1.1. Introduction
To maximize MultiCOM system performance the cable must be installed:
• so that it can radiate freely
• without damage due to mechanical stresses
Please see Introduction for a more detailed explanation.
3.2. Installation Planning

1. Read the MultiCOM Manual sections System Planning and Layout.
2. Review mine plans to determine the location of the cable and components.
3. Determine method of securing the Leaky Feeder cable. We recommends the following:
• rock bolt hangers (see Appendix N, Recommended Tools and Test Equipment)
• screen hangers (see Appendix N, Recommended Tools and Test Equipment)
• messenger cable
• fastened to outside of existing cable hangers with cable ties
• fastened to screening with cable ties
Do not place Leaky Feeder in cable trays alongside or under heavy cables.
4. Ensure all installation personnel have adequate training, equipment and documentation.
5. An on-site visit by MRS before installation will help the mine determine the proper layout for
the geometry of each particular mine MRS will perform on-site training during this pre-
installation service call.

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3.2.1. Installation Procedures
General Rules
1. Each end of the Leaky Feeder cable is wrapped with tape to prevent water and dirt from
entering cable. This protection should be left in place until the components are installed.
2. Special attention should be made so that the cable is not damaged by:
- excessive force from pulling or securing devices
- sharp bends (90°) with a radius of less than 30 cm (1 foot)
3. If possible, the Leaky Feeder cable should be a minimum of 10-cm (6 inches) away from any
metal structure. Avoid securing the cable to large metal objects for any distance, this
causes excessive loss of radio signals in the cable.
4. Leave at least 3 meters (10 feet) of excess cable at each point where a component will be
installed.
3.2.2. Leaky Feeder Cable in the Shaft

1. Place the reel of cable on stands or jacks in order that the cable can be unreeled with
minimal tension. Place cable stand on top of conveyance.
2. Secure the cable in place, as it is unreeled. The cable should be secured every 2-3 meters
(6-10 feet) in the shaft. The cable should be secured immediately to the shaft wall as
installed. Do not suspend the cable unsupported down the shaft without the use of a
messenger cable to relieve the strain.
3. No components should be installed in the shaft compartment. The cable should be
extended onto a level to a dry area about 5 meters from the shaft. If a component has to be
installed in the shaft it should be sealed as well as possible with silicone grease and rubber
tape.

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3.3. Leaky Feeder Cable on a Level or Decline

1. Place the reel of cable on stands or jacks in order that the cable can be unreeled with
minimum tension. Place cable stand on back of truck or tractor.
2. Install cable off to one side of the “back” in full view from all directions.
3. Secure the cable in place, as it is unreeled. The cable should be secured at least every 5
meters (15 feet).
Figure 3-1 - Leaky Feeder Cable Installation
3.3.1. Installation of Components
3.3.2. Introduction
The installation of the MultiCOM components can be done at the same time or after the Leaky
Feeder cable installation. The components may be installed with the Leaky Feeder “live” or
unpowered.

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3.4. Installation Planning
3.4.1. MultiCOM Base Station - BSV

1. For planning purposes, the BSV is a stand-alone, fully enclosed 19” cabinet, 2 meters tall.
The Base Station requires 60 cm of clearance in both the front and rear to allow the access
doors to open.
2. Typically the BSV is located on surface, however some mines may benefit from a more
central location underground. Check the system layout plan for the proper base station
location.
3. The BSV should be located in a dry, dust free, heated area.
4. The BSV requires 120/220 VAC input.
5. For the telephone interfacing option a dedicated telephone line to the BSV is required.
6. The assembly of components (repeaters, power supply, MHE, etc.) in the base station will be
completed by a Mine Radio Systems Technician during commissioning.
3.4.2. Installation Procedures - MultiCOM Line Components
3.5. Required Tools

MultiCOM components are designed to be installed with a minimum of tools, namely:
• Utility knife
• Standard “slot” screwdriver 3/32” blade
• Standard “slot” screwdriver 3/8” blade
• Linemen’s pliers or side cutters
• Standard cable ties (50 pounds)

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3.5.1. Cable Preparation

1. Remove or trim off the protective tape on the cable ends. Verify that the cable end is dry and
clean.
2. Prepare the Leaky Feeder cable as shown in Figure 3-2.
a) Cut back 12 cm (5 inches) of the outer yellow jacket being careful not to cut into the inner
black jacket
b) Cut back 5 cm (2 inches) of the black jacket, being careful not to cut into any of the 16
copper strands (outer conductor).
c) Separate the 16 copper strands into 2 groups of 8 strands each and then twist each group
together tightly with pliers, making sure no strands are broken.
d) Cut off about 2.5 cm (1 inch) of the center plastic tube being careful not to cut into the center
conductor.
e) Trim the three conductors to the same length, extending approximately 1.5 cm (1/2 inch)
past center tube.
Place the cable grip nut, clamp ring and gasket on the prepared cable end as shown in Figure
3-2.
Figure 3-2 - Leaky Feeder Cable Preparation

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3.5.2. Component Orientation

1. Ensure each component is put into the system in the proper direction. “To base” which is
printed on the circuit board next to the connector for the cable coming from the base station.
3.6. Cable Termination

1. Ensure the three termination screws are fully CCW.
2. Insert the three conductors into the appropriate terminal block connector, being careful not to
bend back any of the copper strands.
3. Tighten down the center terminal screw first. Verify connection of center conductor by
attempting to pull cable out. Complete termination by tightening the two ground screws. See
Figure 3-3.
3.6.1. Waterproofing
1. Tighten the cable grip by hand.
2. Once the cables are connected, the component enclosure cover should be firmly fastened.
3. Make a “drip loop” on each cable as shown in Figure 3-4. The recommended diameter of a
drip loop is 50 cm (18”).
If a component has to be located in the shaft compartment it should be sealed with silicone
grease and rubber tape.
Figure 3-3 - Cable Termination to an Amplifier

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Figure 3-4 - Enclosure Mounting
3.6.2. Enclosure Mounting

1 Use cable ties to secure the component in place horizontally (see Figure 3-4). The cable
grips should be pointing down on all components when applicable.
3.7. Installation Procedures – MPS/MPC

The MultiCOM Power Supply is required in order to maintain voltage levels on the Leaky Feeder
system. The voltage level must remain above 8 VDC in order for the MultiCOM amplifiers to
operate properly. The Power Supply requires 120 or 240 VAC as its primary power source. It
may be mounted in substation, lunchroom, garage, or directly into the drift as long as there is an
AC power source available.
The Supply comes with a Power Coupler (MPC), which is used to couple the DC power
generated by the power supply into the Leaky Feeder cable.
1. Check the system layout in order to determine the location of the power supply.
2. Mount the Power Supply on the wall. This is usually accomplished through the use of Hilti
bolts.
3. Install the Power Coupler into the MultiCOM system in a convenient location.
4. Wire the AC supply to the DC power supply.

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Figure 3-5 – Power Supply
3.8. Installation Procedures-MultiCOM 3 Way Splitter

The MultiCOM 3 Way Splitter (MSS) and the Amplified System Splitters (MSA) and (MSAV) are
used in order to provide communications to secondary branches off of the main trunk. The
component is installed using the same rules as the rest of the components except that special
attention needs to be made in selecting the jumpers inside. A table is provided in the
component specification section of this manual under MultiCOM System Splitters, Table 3. The
amplifier board(s) for Voice/Data and Video can be installed or removed at any time just as long
as the jumpers are reset to reflect the change.

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MULTICOM

INSTALLATION AND APPLICATION

Rev 2.0 Feb 2010

Page 2 of 22 © 2009 Mine Radio Systems

3.4.1 MultiCOM Base Station - BSVx................................................................................ 18

Page 3 of 22 © 2009 Mine Radio Systems

1.1. Leaky Feeder Systems

1.1.1. System Planning

Page 4 of 22 © 2009 Mine Radio Systems

1.2. Basic Theories of Operation

Direction Frequency Application

1.3. Loss and Gain

Page 5 of 22 © 2009 Mine Radio Systems

2.1. Base Station Planning

Page 6 of 22 © 2009 Mine Radio Systems

2.1.1. Leaky Feeder Cable

Page 7 of 22 © 2009 Mine Radio Systems

Figure 1-1 Leaky Feeder Cable

2.2. Passive Splitting

Page 8 of 22 © 2009 Mine Radio Systems

350 meters - 130 meters = 220 meters

Component Application Insertion Cable Equivalent EL-3529

Table 2-1 - MultiCOM Passive Component Insertion Loss

Figure 1-2 MSS Board

Page 9 of 22 © 2009 Mine Radio Systems

2.2.1. Amplified Splitting

Figure 1-3 MSA

Page 10 of 22 © 2009 Mine Radio Systems

Figure 1-4 MLAD

2.3. Video Amplifiers

Figure 1-5 MLAVU

Page 11 of 22 © 2009 Mine Radio Systems

2.3.1. MultiCOM Power Supply

Figure 1-6 MPS

2.3.2. Pilot Generators

Page 12 of 22 © 2009 Mine Radio Systems

2.4. Cable Termination

Figure 1-7 MTU

Page 13 of 22 © 2009 Mine Radio Systems

Fig ure 2-1- Sample MultiCOM Installation Layout

Page 14 of 22 © 2009 Mine Radio Systems

3.1. Installation of Leaky Feeder Cable

3.2. Installation Planning

Page 15 of 22 © 2009 Mine Radio Systems

3.2.1. Installation Procedures

3.2.2. Leaky Feeder Cable in the Shaft

Page 16 of 22 © 2009 Mine Radio Systems

3.3. Leaky Feeder Cable on a Level or Decline

Figure 3-1 - Leaky Feeder Cable Installation

3.3.1. Installation of Components

Page 17 of 22 © 2009 Mine Radio Systems

3.4. Installation Planning

3.4.1. MultiCOM Base Station - BSV

3.4.2. Installation Procedures - MultiCOM Line Components

3.5. Required Tools

Page 18 of 22 © 2009 Mine Radio Systems

3.5.1. Cable Preparation

Figure 3-2 - Leaky Feeder Cable Preparation

Page 19 of 22 © 2009 Mine Radio Systems