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TPG RAN Project - CPS Build Installation Guidelines v4.0 - 300323 - Final
TPG RAN Project - CPS Build Installation Guidelines v4.0 - 300323 - Final
v4.0
Do it correct at first time
Main Objective
• To create a consolidated document that can guide the field team during site build align to the client
standard documentations supporting TPG RAN Projects.
• To achieve “do right at first time” by highlighting the proper installation practice for those recently
identified common snags coming from previous build.
• To established a document that will be used by the Build Team and Quality Assurance Team as
common reference during site build, QA audit and HOP review.
This document will focus on the following TPG RAN Scope
❑ Internal Installation
• New BTS/ MER rack (Single Rack and Double Rack Solution)
• IDCDP Installation
• FMT, Fiber Distribution Frame and Alarm Patch Panel
• Baseband Unit (Nokia)
• Power System (Huawei and Eltek)
• Internal Earthing
• Cable Gland and Hybrid Cable
❑ External Installation
• External Earthing
• Steel Works, Cable Ladder and Tray lids
• Hybrid Cable, Breakout Box
• Antenna (5G and 4G) Installation
• GPS Installation
by MDS
Internal Recommended Installation – Single Rack Solution
CST QA Forum #3 01-11-2022 SET-S203 Tx and MER Racks : Item 6 (Q&A) Question 2 : The EBP is be the document to be followed and should always reflect the current STD-135 rack layout drawing. Should there be a discrepancy between the
two documents, contact Central Standards team to determine which rack layout should be complied with
New Single Rack Layout to be followed under STD D135 v1.0 Right side view Left side view Rear view
(Please contact CPS PE/PM in case EBP Layout and STD D135v1.0 has discrepancy)
IDCDP 2 : slot 31
(DBM0063 or RGL141/101)
FDF : slot 26
FSEE : slot 16
Reminder: This is the only portion that we recommend to install yellow split harness wrap support
(from FMT to FDF). The rest will only require Velcro to secure and groom the fiber cables - spiral
(Please note: In case we have 42RU Rack IDCDP 1 will start at slot 40) wrap is NOT allowed
TIP: Use the pre-installed flat bar in the rack to properly route and secure all cable running from left to right or vice
Note : In case we only have 1 BBU on site, BBU will be installed at BBU2 slot – slot 12. versa like earth cable and GPS cable). The are scenario that these items needs to move to fix the correct cable
Please refer to the STD D135 v1.0 documents of Rack layout specially if we have two (2) rack layout scenario. For any discrepancy, pls. send an routing (in red arrow)
email to your respective PE or to QA team.
Reminder : All Racks (MER, BTS and Tx racks) – must be bolted to the floor and wall using type 17, 2 – 25mm long Tek Screw (for
applicable shelter type) and All cable tie must be properly flushed.
Applicable for ODU, ICS Shelter and existing Shelter
Internal Recommended Installation – Cable Route (Single Rack Solution)
CST QA Forum #3 01-11-2022 SET-S203 Tx and MER Racks : IDCDP installation (page 44): Hybrid trunks should be run in the hybrid trunk sheath to the rack or cabinet, and be stripped back only at entry to the rack or cabinet
Earth cable run Alarm cable and CPRI run Hybrid cable run DC cable run
(Green) (Brown/Yellow) (Black) (Blue/Red)
Hybrid cable, DC cable and Earth cable
will enter the rack at the rear side.
Rack
front rail MER/BTS Rack
(Top view)
Rack
Note: This layout is before the STD D135 issuance rear rail
Patch panel should be between FMT and FSEE
Note:
(1) Earth Strip of the MER/BTS rack can be moved to
either side dependent on the location of the rack
inside the shelter. TIP: position the earth strip to the
most accessible location.
(2) Earth Strip / rack must be connected by 35mm earth
cable going to the Shelter SPC.
(3) Hybrid cable can be only stripped after entering the
rack.
(4) Tx Fibre, Fiber patch and alarm cable must be secured
using the from rail of the rack. For the alarm cable
terminated at the rear of the patch panel, this can be
secured on the back rail.
Pls. note rack back cable support was IDCDP 1 and 2 earth cable. Reminder to Earth and FSEE cable route from
Internal fiber tails and alarm cable should be run on moved to this location to properly have extra length to be able to open and right side going to left side of
the rail and not outside the rack. Properly groom guide the equipment earth and FSEE close the unit. Pls. note IDCDP 1 earth the rack. This was guided by the
using velcro tie. These cables will enter the rack in cable. connection is manually drilled hole. back support of the rack.
front side.
Hybrid Cables
Note : This is an ideal cable route but may differ in some site due to equipment layout.
Note: This is the correct CPRI cable routing for ODU inter bay connections. Propose DC cable grooming for ICS shelter
Note:
• For Optus using Nokia BBU, first BBU will
start at slot 14 and 2nd BBU if required
will start at slot 9.
• BBU Support shelf is required per BBU.
• These slot will be the same slot for Dual
rack solution.
• Other equipment (IDCDP, FMT,FDF and
DCDU) will have the same slot allocation
as Ericsson Rack Layout.
Legend sheet. Reminder to all check the correct model of the RRU installed.
Traffolyte Label. Reminder New labels identifying equipment in the Vodafone network
must identify devices as either “Vodafone” or “V” (SETB – 104)
All DC feeds must be run on the correct routes. All labels must
be installed on the correct location - clear and readable
DC cable route for DC cable route for
Feed A, B and C Feed D, E and F (1) Reminder to install the protective plastic cover properly.
(2) DC feeds and earth cable must have flat<> spring washer.
Marking is required to show the nut was tighten correctly
(3) Earth cable must be 16mm connected to rack earth strip.
Recommended : to install yellow split harness wrap support (from FMT to FDF – Single or Two rack solution).
The rest will only require Velcro to secure and groom the fiber cables - spiral wrap is NOT allowed
Excess Fiber Tray : All excess/extra fiber length (including Tx cable) must be
Reminder: groom properly on the tray (from BBU and from FDF). Recommended to have
• Maintain an enough separation between data cable and DC cable and earth cable. 3 meter CPRI cable for single rack solution.
• Alarm cable - Front and rear cable route must be routed using the front and back rail of the MER rack
respectively
• Alarm cable - Front termination is going to FSEE alarm box while rear termination is going to equipment side Refer to the sample wherein 5G only
• Alarm cable is CAT5 or better. have 1 connections (blue) while HB has
• All internal fiber be routed within the rack rail and must not run outside the MER rack. (2) connections (red)
• Legend sheet must reflect the actual connections per TU – (1) if we only 1 single connection and (1 and 2) if
we have dual connections.
(a) Strip the ends of the DC cable to 18mm using cable insulation
stripper. Do not attach bootlace ferrules to the end
(b) Strip the outer insulation by 6mm.
Same instruction can be found SET-S203 Tx and MER Racks – Slide 9
Sample Label installation
Note: DC Cable, Earth cable and GPS cable Label materials
Reminder:
✓ Material type: Nylon wrap around self-laminating label
• Actual port used on the BBU must be aligned on the EBP. In case there are discrepancies, email
✓ Label product supplier: Panduit S100X150VAC
approval from the designer must be secured.
✓ Label Location: 50mm from each cable termination end
• Fiber patch label should be same labels on the Fiber Distribution Frame.
• GPS cable should be cut to correct length going to the BBU – looping the excess GPS cable is not
Label material
permitted.
✓ Material type: Nylon flag type self-laminating label
• Fiber cable (CPRI) labelling standard - STD-D259 CPRI Fibre Nokia BBU-ODF Labelling Standards - v1.0
✓ Label product supplier: Panduit S100X150VAC
✓ Sample CPRI label : Vodafone BBU1 B4 RF4 Vodafone MER1 ODF1 CST2 RFF2 P1718S2 18/21 RRU5 ✓ Label Location: 50mm from each cable termination end
Alarm Cable must have clear and readable label (flag type)
✓ STD-D450 Alarm Wiring 5G Overview - Nokia BTS - v6.0
✓ SED-329 Nokia Airscale Installation at Vodafone Sites - v0.10 (page 58 to 64)
✓ STD-D446 Alarms Wiring - Combined Signals (for TPG with RAN and TX PSU)
Note:
For sites tagged as POC 4 and BBUT is zero – Test first the BBUT of the existing battery string. If this BBUT will last
5 mins or more, don’t remove the battery and report to your respective PE.
Procedure:
✓ During SLO – after the receiving a confirmation from ORCA (login completed) and RIC support (all TU were
For the battery installation, same process with the new properly locked and SLO can start, Turn off the PSU CB (at DB board) and observe how long the battery will work
battery installation for Huawei PSU on the other slide. without shutting down any equipment.
Pls. note that we need to remove the existing grease on ✓ Observe – if the battery back up time will last more than 5 minutes, report this to your respective PE/PM and
the battery terminal and retighten all battery terminals. retain all battery strings.
✓ In case BBUT is less than 5 mins, continue on the battery decommissioning and recovery for POC4 or based on
FC and EBP details.
Internal Recommended Installation – Internal Earthing
A label is required at each end of every earth cable internal to the shelter/ODU. Any enclosure houses active equipment (Power supplies, BTS racks, MERs and others) must have its chassis earthed and bolted independently to the main earth bar or strap (SED 322 page 31).
Earth Point connections - bolt and flat washer and flat washer, spring washer and nut (SED 322 page 27)
Correct Earth Termination / Installation (SED 322 pages 27 – 28) Earth Cable size per equipment
• Be terminated using single hole compression lugs ✓ 35mm – PSU (requires 2 earth connections) going the main earth.
• Be attached to an earth point using bolt and flat washer and flat washer, spring washer and nut. ✓ 35mm – Tx Rack, MER rack and BTS rack going to main earth
• Be free from heat shrink, electrical tape or other taping or adhesive materials note: if existing rack will be reused or retain, make sure that earth cable was installed.
• Have the correct size compression lug for the cable used.
• Copper strands must not be trimmed to fit into compression lugs. ✓ 16mm – Baseband Unit (BBU), IDCDP, APDP, FSEE and other active equipment going to the
• Maintain 1-2mm of exposed copper cable between the connector end and cable insulation rack/ODU earth strip. For ICS Zone cool shelter, equipment earth cable can be tapped directly
• Have a label at each end of the cable identifying the location of the other end’s termination point. to the ICS rack.
note: make sure that ICS racks were connected to the main earth strip by 35mm
• Labels must be high quality flag or wrap around types only, must be printed, and must be readable from
a standing position in the shelter where possible. When attaching a label to the cable, the first character All Earthing connections should be going towards direction of main earth.
of text must be at the end closest to the terminal.
• Connections must NEVER be piggybacked, doubled up, or connected on either side of an earth bar
• Earth nuts/washers on MERs must face inwards to avoid abrasions
• Earth nuts/washers on earth straps near walls or above racks/cabinets where nuts/washers can fall into
equipment must face outwards.
• Have a minimal amount of excess thread beyond the nut, to minimize any safety concerns: between
3mm and 10mm of thread is required beyond the nut.
• Conductive Gel or earth paste is NOT to be used on earth connections as it provides no benefit
• Marking must be applied after tightening.
Recommended type of Earth Bar in case Earth Bar can be still reused as long as the This type of earth bar is recommended
replacement is required criteria were met. All earth cable must to be replaced.
have correct size of ferrule. Poor earthing techniques
Applicable for ODU, ICS Shelter and existing Shelter
Internal Recommended Installation – Cable Gland and Hybrid cable
All Feeders must enter the feeder entry window, enclosed in cable glands that are the correct size and design for the feeder being used. Silicon must not be used to band-aid untightened or faulty glands must be replaced and/or screwed up
firmly, however silicon may be used to seal the feeder entry window. Half-inch feeders must enter the window using the Enersys Split cable glands, which come pre-fitted in new enclosures or may be purchased separately. It is recommended
that the entire gland window be replaced when upgrading sites (SED 322 page 96)
Gland Plates
Sample of replaced/new
1. Cable gland must use correct size base on the cable used. gland plate during RAN
Refresh build
Recommended Gland size:
Hybrid Cable : M63
GPS Cable : M32 (using 25mm black conduit)
Hybrid Cable
1. All Hybrid cable must be run / secure on the shelter cable ladder.
2. Recommended to secure by black cable tie : every 1 - meter
separation
3. Hybrid cable can be only stripped after entering the rack. * Always check the updated version. These table was updated as of 28/03/2023.
4. Hybrid label must be installed upon right after entering the gland
plate and before entering the MER/BTS rack.
5. Recommended to have atl east 300mm straight cable run first
before starting the bend going to the cable ladder.
Instructions:
• All existing krone block either collocated to Tx rack or wall mounted should be recovered if no
active load / connections as a result of the following activities.
• Alarm migration from Krone Block to Patch Panel
• Recovery of old equipment.
• Old Transmission equipment on site must be recovered if the following criteria are met.
• Tx equipment is tag to be recovered in FC or CAT file.
• Tx equipment was already turned off and no other visible connections.
• Tx equipment running on a 24V
• MWR radio with no IF cable connections.
• Fiber Distribution Frame (FDF) Cable layout and Labelling • CPRI cable routing and labelling
• Fiber Management Tray (FMT) – Cable grooming. • DC cable, Earth cable and GPS cable installation.
Note: Follow the same cable routing and installation for ODU and two rack solution except fiber lead that will run
from one bay/rack to another bay/rack. Use as reference the cable route from slide 7 – Two rack solution
• Fiber Distribution Frame (FDF) Cable layout and Labelling • Patch Panel and FSEE labelling.
• Fiber Management Tray (FMT) – Cable grooming.
• FSEE Alarm routing and labelling
Note: Follow the same cable routing and installation for ODU and two rack solution except fiber lead that will run
from one bay/rack to another bay/rack. Use as reference the cable route from slide 7 – Two rack solution
Tower Top View Connectivity Correct Earth Termination / Installation (SED 322 pages 27 – 28)
Sector Earth Bar / Sector Assembly Earth Bar
• Requires 35mm earth cable connections going to the FEB Top. • Be terminated using single hole compression lugs
• Main earth connections of : (1) All RRU (2) Breakout Box (3) 5G • Be attached to an earth point using bolt and flat washer and flat washer, spring washer and nut.
antenna (4) Other active equipment Sector Earth Bar • Be free from heat shrink, electrical tape or other taping or adhesive materials
• For eJV build, Optus must have separate sector earth bar. • Have the correct size compression lug for the cable used.
• Copper strands must not be trimmed to fit into compression lugs.
Feeder Earth Bar (FEB - Tower Top) • Maintain 1-2mm of exposed copper cable between the connector end and cable insulation
• Hybrid and Feeder earth connections. • Have a label at each end of the cable identifying the location of the other end’s termination point.
• 1 meter before the vertical to horizontal transition.
• Connections must NEVER be piggybacked, doubled up, or connected on either side of an earth bar
• All Sector Assembly earth bar will be directly connected to FEB.
• Have a minimal amount of excess thread beyond the nut, to minimize any safety concerns: between
• Connected to FEB – Tower Bottom by 35mm earth cable.
FEB Top 3mm and 10mm of thread is required beyond the nut.
• Recommended to have 12 holes earth bar.
• Conductive Gel or earth paste is NOT to be used on earth connections as it provides no benefit
• 3 x for Sector Earth Bar
• External to the shelter/ODU, all earth cables connected to the SEB • Marking must be applied after tightening.
• 3 x for Hybrid cables
• 2 x 35mm earth cable connections must be labelled close to the SEB
• 1 x for the mounting to the tower • Labels were preferred to be white vinyl with black text, or paper
• Remaining 2 holes (for S4 if required) with black text and clear heat shrink over label to prevent
deterioration, it is also OK to use Stainless Steel labels. Transport bracing
must be removed
Feeder Earth Bar (FEB - Tower Bottom)
Same requirement on FEB tower top
GPS Cable Earth
Cable ladder
earth Feeder
Earth Bar
Hybrid cable
Flexible conduit (typically white) is not required for external earthing. Applicable for all types of Towers (Lattice and Monopole)
External Recommended Installation – Steel Works, Cable Ladder and Tray lids
The earth kits are installed 1 meter before the transition from vertical to horizontal at top and bottom of the tower. If the distance from the pole or lattice tower/guyed mast is greater than 3 meters, an earth kit is installed prior to the feeder entry gland plate. See SED-313 –
this clearly identifies the need to earth 1 meter before bends (SET-S204 Question 9 page 72)
Marking on the Grade 8.8 Structural bolt, nut and washer TPG Standard lock nut
Steel works and Head frame installation
• Steelworks - Grade specific bolts nuts and washers tightened to AS1252.
Identified by the 3 radial lines, the
• TPG Standard lock nut installation – Flat washer <> Lock nut <> Full nut
manufacturer’s markings, and an 8.8
with (3) three full exposed threads after the nut on any bolted connection
numeral stamp
but maximum of 10 full threads (SET-S201 page 11 and 23) Key Point to Remember
• The Hobson thin nut (deforms and performs as a locknut) is always Identified by the 3 grooves in the
installed on top of the structural washer with the structural nut being face of the nut, each spaced 120° • TPG use the Hobson thin nut as the standard for
placed on last lock nut assemblies
• When using a Hobson thin nut, a structural grade flat washer is installed Identified by the 3 raised nodules • Other operators use different standards: Telstra and
between the surface of the bolted assembly and the Hobson thin nut each spaced 120°apart Optus use a single structural nut and spring washer
• A split washer is not used to secure the nut and bolt assembly, while NBN
apply the same standard as TPG using Hobson thin
• No earth lug between lock nuts (not allowed) Cable Ladder (SED 322 page 86 to 87) nuts
• Only Structural bolt, nut and washer with grade 8.8 must be used.
• For slotted hole used in the assembly of a connection, plate washer must • All cable tray lids, whether horizontal or vertical, new, or existing, are to be • When hardware is supplied by Site Pro 1, all nuts,
be installed to ensure the spring or structural washer was fully supported installed using 20mm M6 316 stainless steel hex-head bolts, with Nyloc nuts washers and spring washers are supplied in the
over the hole UNLESS stated otherwise in the structural drawings. and two flat washers fitted (Tek Screw is NOT allowed) pack to allow the installation to be undertaken on
• Marker must be applied after properly tightening all nuts • J-Bolts are only allowed where no other method to secure cable tray lids any operator’s site, the constructor MUST select
specially on the tray bends. the correct components and discard the unused
• All tray works must be bonder together. components in accordance with the operator’s
standards
• New Cable trays/ladders must be installed as per the FC drawings.
• When a slotted assembly is used a flat plate
• Black plastic cable ties, steel ties and Band-It or similar securing products
washer of the correct grade must be used on the
must be cut flush using flat edged side-cutters or a professionally
Hybrid cable slotted side
manufactured cutting tool
• When installing extra strengthening or structural
• Reference for the cable ladder installation (if not provided in the FC)
members the drawings supplied by the design
• STD S515 – Cable ladder cover details
house and certified by the structural assessor must
• STD S501 – Cable ladder support details
be adhered.
• STD S503 – Cable ladder fixing details
Note:
• For steel works design by third party like Axicom, Structel, Stillmark and others, install as per the approved design (SET-S201 page 22)
• No need to install lock nuts on the multiple bolted connections UNLESS stated otherwise in the structural drawings.
• Structural steel main reference – STD N003.
• For those scenario that Hybrid was run inside the pole – make sure that cable entry and exit must be properly covered by Mesh.
Applicable for all types of Towers (Lattice and Monopole) Sample Lock nut installation Sample Cable Tray lid fixing
External Recommended Installation – Hybrid Cable, Breakout Box
Break out Box (BoB) Break out Box (BoB)
• All hybrid feeders entering the junction box must be labelled. • Correct DC termination
• STD-D254 RF Fibre Labelling Standards Nokia- v2.0 • Properly crimped
• STD-D256 RF Fibre Labelling Standards Ericsson - v1.0 • Fully inserted with both legs of the fork between the link plate and square
clamping plate
• Glands - all unused port must be properly sealed and gland must be correctly tightened (A)
• Terminal screw must be torqued to 5Nm
• Break out Box was IP66 rated and require glands to be tightened correctly in order to achieve • Entering the gland straight as
• Pull-test after installation to ensure correctly terminated
manufacturer IP performance. much as possible (A)
• Plastic cover must be re-installed correctly after all completing all
• Cable entry (Hybrid cable and tails) must enter the Breakout Box as straight / perpendicular • All unused port were properly
terminations.
to the glands as possible to achieved properly sealing and avoid stressing the cable (B) sealed (B)
• Correct fibre routing (D)
• Trunk cables must be installed with enough unstripped cable sheath to ensure that the
• All fibres are secured within plastic guides
internal clamp was secured over the un-stripped section of the trunk cable. The sheath
• Fibres are not crossed on entry to cassette
should extend a minimum 10mm above the cable clamp (C)
• Fibres are contained within BoB when door is open
• Always followed the standard port assignment based on the EBP and correct STD port
allocations. • Correct fibre termination block - all unused port must have dust cap cover.
• DC connection on the terminal block must be torqued to 5Nm as per SEQA-014. When • Legend sheet must be correct in terms of RRU type and port assignment used.
torqued, mark the connection to indicate that the correct torque has been met. • Legend sheet template - SED-044 Break-out Box Label Template
• The breakout box itself must have a label identifying its sector attached to the outside
Note: Breakout box must be rubbish free and all fibers are running on the correct route of its door, the 114mm pole must also have a label wrapped around it.
Hybrid Cable
• Correct Earth kit must be installed (as per manufacturer instruction)
• Hybrid must have 3 earth point connections on a typical scenario.
• Top (connected on the FEB tower top) – 1 meter before vertical to horizontal transition.
• Bottom (connected on the FEB tower bottom) - 1 meter before vertical to horizontal transition.
• Near the gland plate (FEB) – This is only required if distance from the FEB tower bottom is more than 3m.
• Hybrid must have cable hoisting sock, chain and shackles to remain fixed in place at the top of the pole . All rated
shackles must have a colour band applied or have a stamped rating.
• It must be installed securely using clip-in hangers or plastic-backed stainless-steel ties, and meet minimum bend radii • Proper Fiber tails routing (D)
• Hybrid trunks should be run in the hybrid trunk sheath to the rack or cabinet, and be stripped back only at entry to the • All fibers were running instead the cable holder
rack or cabinet - CST QA Forum #3 01-11-2022 SET-S203 Tx and MER Racks : IDCDP installation (page 44): • All unused port were covered by a plastic caps.
Sample Hybrid Cable Support
Note:
• Any marking on the antennas (by permanent marker) is not allowed • Plastic WPS cover must be line up correctly to the edges – not too high
• Labelling format: (1) STD D250 for RF tails or low.
• (2) STD D254 and STD D256 for Hybrid tails. • Stainless steel Panduit must be installed – refer to the photo (black
plastic cable tie is not allowed.
• Sample Antenna labels and correct label location. • Unused port with SS cap
Reminders : Marking on External Component is NOT Allowed
No Required Markings
• Breakout box (BoB)
• Mechanical tilt for both 4G and 5G c
• RRU
• Combiner and TMA
• Mounts and Pole
• RRU Bracket
Approved By
Reviewed and Approved Ned Tepsic National Field Services Manager 30/03/2023 Ned Tepsic