RF Cable - Installation Manual RFS HELIFLEX cables Edition 2014-2a

Technical manual
RF Coaxial Air dielectric Cable

Radio Frequency Systems
Edition 2014-2
www.rfsworld.com
© Radio Frequency Systems 2014 all rights reserved
Radio Frequency Systems GmbH

E-mail : techinfo.europe@rfsworld.com
Kabelkamp 20 Web : www.rfsworld.com
D-30179 Hannover, Germany
RFS HELIFLEX® Cables
Installation of HELIFLEX® cables - INSTALLATION Manual
Installation Manual
www.rfsworld.com Edition 2014-2
© Radio Frequency Systems 2014 All rights reserved

Edition 2014-2 1

Basics
Handle with care! Conserve the characteristic of the cable

In principle, care must be taken to avoid all such strain that may cause
remaining deformation on the cable, e.g. going below admissible bending
radius, kinking, applying too high tensile stress or forcible deforming of
the corrugated outer conductor.
Handle cable & accessories with
care during transportation, stocking
& installation.
Do not over tight clamps
Keep the accessories & cable clean,
prevent any particles, dust, dirt or
humidity from entering.
Install all accessories e.g.
connectors, grounding kits etc. in
according to the installation
instructions
Always note the safety aspects!
(not Topic of this presentation)
Edition 2014-2 4
1
Basics
Mechanical features of HELIFLEX® cables

Before commencing an installation
familiarize yourself with important
cable data:
- Minimum bending radius,
single bending
- Minimum bending radius,

repeated bending
- Maximum tensile force
- Recommended &
max. clamp spacing
Temperature considerations:
Always observe the manufacturers
Please Note also:
recommendations when handling The maximum hoisting
coaxial cables in extreme conditions. length per hoisting grip
Edition 2014-2 5

Drum handling
Shipment & Transportation
Cable drum trailer

for transportation
The drum must be carefully secured during transport! & installation
(unreeling) of the cable
When lifting, a special

hanger (spreader bar)
must be used to avoid
damage of the drum
flanges and cable

Edition 2014-2 8
2
Drum handling
Shipment & Transportation
If fork lifts are used, the forks must be

long enough to engage both flanges of
the drum to avoid cable damage!
Never lay the drum on its side!

Reels must be transported and handled
in its up – right position only!

Edition 2014-2 9

Cable installation
Preparation on site
Position the drum (cable trailer or drum stand)

where the full length of cable can be uncoiled.
This is important on sites where a relatively long
cable horizontal run is required.
Ensure that the cable unrolls from bottom of the

drum.
This is opposite to the direction shown by the
arrows on the drum flange.

Edition 2014-2 15
3
Connector installation
Premium Connectors
HELIFLEX® Lite Connectors

Premium -009 Series
All -009 series connectors for HELIFLEX®

cables are characterized by excellent gas
tightness and extremely low losses.
HELIFLEX ® connectors can be installed
with basic hand tools, but the use of
dedicated installation tools further
facilitates ease of assembly and improves
performance. HELIFLEX ® Lite premium
connectors have excellent electrical values
and provide outstanding performance for
the most demanding applications. The + Lightweight
+ Excellent gas tightness
connector design provides maximum + Robust Mechanical Design
sealing integrity and gas tightness. + Extremely low reflection factor
+ Totally Waterproof according to IP 66/68

Edition 2014-2 17

Tools – useful special tools
Gripper – with copper

covering (self made) Brass-Pins for flaring
[Water pump pliers
with reinforced head]
Poly Hook Spanner

Size depends on connector size
Stable trim
Metal shears
Stripping tool
Saw blades
straight line with
smooth saw tooth Very stable slasher
(for cutting of the cable in the
upright position)
Edition 2014-2 18
4
Preparation of the cable

If possible, the upper connector should be installed before hoisting the cable.
To install the connector
• Straighten the end of the cable end (allow a minimum 1m). If the cable end
cannot be straightened a short length of cable should be discarded.
• Make a straight cut tilting the cable downwards to prevent copper particles,
pieces of jacket or other foreign material from entering the cable.
• Clean and prepare the cable end before fitting the connector.
Install the connector in accordance

with the installation instruction
Edition 2014-2 19

Preparation of the cable

When installing the connector keep the cable end pointing downwards.
If the connector must be installed in the upright position, use a cleaver for cutting
the cable. Final cutting can be made using metal shears.
It is strongly recommended to fill the end of the cable with cloth to prevent
particles from falling into the cable.
Especially when installing the connector

Knock carefully on the lower side of the
in the upright position a vacuum cleaner
connector to remove any particles which is very useful!
may be behind the top corrugation.

Edition 2014-2 20
5
Connector sealing – Sealing compounds

Sealing compound PACTAN for 009 series of Connectors for HELIFLEX® cables only.
Connectors for cable sizes HCA400 & smaller
For injection screw the 20 cm³

tube directly into the connector
P-5071-20
Connectors for cable sizes HCA495 & bigger
Injection of PACTAN 310
cm³ cartridge with
P-5071-310 DISP-001 dispenser (injection with
Adapter comes with all the 20 cm³ tubes is not
connectors for HCA495 possible!)
& all bigger ones
Alternative for the small sizes of Connectors

The injection of PACTAN into
DISP-A-001
small connectors can be done
with the 310 cm³ cartridge as
P-5071-310 DISP-001 well, but in this case the
adapter DISP-A-001 is needed
The adapter is not included in the package of the small in addition.
sizes of connectors – must be ordered in addition.
Edition 2014-2 21


Reliable Sealing Required Volume per connector
Cable type Content
(approximately)
HCA38-50
HCA58-50 5 cm³ (ccm)
HCA78-50
HCA118-50 10 cm³ (ccm)
HCA158-50 20 cm³ (ccm)
HCA295-50 40 cm³ (ccm)
HCA400-50 70 cm³ (ccm)
HCA495-50 120 cm³ (ccm)
HCA550-50 250 cm³ (ccm)

Please do not forget: The Sealing
HCA618-50 300 cm³ (ccm)
compounds has to be ordered
additionally to the connector HCA800-50 900 cm³ (ccm)

Edition 2014-2 24
6

Principle of Injection –Sample - First steps
1 2a 2b 2c
3 4 5

Edition 2014-2 25


Principle of Injection –Sample – second steps
6 7a 7b
10

Edition 2014-2 26
7

Principle of Injection –Sample – last steps
Close tube after using

immediately

Edition 2014-2 27

Cable installation
Hoisting grip types & varieties

Closed versions Open version
Open –
one loop type
Closed –
one loop type: can be used if the
connector is already
to be used only installed as well.
for cables without Max. hoisting length 60m,
mounted connectors. available for the cable sizes
up to HCA214
Max. hoisting length 60m,
available for the cable Open –
sizes up to HCA158 two loop type
For multi-use applications,
can be reused many times.
Usable for cables with already
installed connectors as well.
Max hoisting length see Table below.
Cable size HCA HCA HCA HCA HCA HCA HCA HCA HCA HCA HCA HCA HCA HCA
38-50 12-50 58-50 78-50 118-50 158-50 214-50 300-50 400-50 495-50 550-50 618-50 800-50 900.50
Max. pulling length

per hoisting grip 70 70 70 70 70 70 70 70 70 40 40 40 25 50
two loop type (m)

Edition 2014-2 33
8
Cable installation
Cable hoisting
1. Place the hoisting grip around the cable ensuring the end with
the fitted connector is long enough to make the connection to the
antenna without opening the hoisting grip.
4
The two ends of the enclosed two flexible wire strands are
inserted in the two upper most net loops and then crosswise in
3
the lower net loops continuing to the end (similar to lacing a
shoe!).
The mesh of the cross wire strands shall not be smaller than the
existing mesh of the hoisting grip.
1
2. The two strand ends are to be knotted or clamped and to be secured
in the net loops.
The end of the hoisting grip can be fixed with tape.
3. Protect the cable area were the hoisting grip will be fixed to the rope
for example with rubber or clamp saddles.
4. Clamp the hoisting grip with clamps to the hoisting rope or hang in a
hook or shackles etc.
2
Note: The maximum hoisting length per hoisting grip!
Edition 2014-2 34

Cable installation
Cable hoisting
Before hoisting, the
connector has to be
protected e.g. by
wrapping cloth
around.
The connector and

all the cable to the
first hoisting grip
must be fixed onto
the hoisting rope e.g.
by using tear-proof
tape or hemp ropes.

Edition 2014-2 35
9
Cable installation
Cable hoisting
Connector with
1. Protect the connector end from safety cloth or
objects impending its way. wool
2. If the distance to the connector
(worker 1) is too long, he will
1
protect the hoisting grip from
objects blocking its way. Hoisting grip
3. If add. hoisting grips are Fixed to the
necessary they have to cable e.g. with
2
protect/observed also. hemp rope
4. Observe and maintain - decelerate
the drum turn. Protect the fixing
The cable is slack area e.g. with
5. Important Person ! above this hoisting grip clamp saddles !
Observe this place The rope is tensioned!
Second
3 hoisting grip
4
Protection on the ground, 5
e.g with pipe rollers or
wooden blanks Do not remove the hoisting grips before all clamps are closed !
Edition 2014-2 38

Cable installation
Cable hoisting & pulling procedure

Pulling in different direction –
with two winches
Hoisting grips
Winch
Winch (Electrical)
Pipe rollers (Manual or
Electrical) 39
Edition 2014-2
10
Cable installation
Cable hoisting & pulling procedure
Hoisting with special cable pipe roller construction made by the customer him self

Edition 2014-2 41

Cable installation
Fixation of the cable

Clamp the cable immediately after it is
lifted to avoid damage from wind, etc.
Do not leave the site before the cable

has been secured, even temporarily.
Start clamping as near as possible to the

top connector.
RFS recommends the first 3 clamps are

spaced at half of the published clamping
distance (refer data sheet).
Special, locally constructed, brackets may

be required to avoid obstructions, e.g.
tower/mast steelwork.

Edition 2014-2 50
11
Cable installation

Correct clamping is important and
installers must work with care when
handling air dielectric coaxial cables.
Work should start immediately below
the top connector continuing down
the structure until the complete cable
is secured.
Note: Air dielectric cables can be
likened to thin walled copper pipes.
They can easily be damaged by
incorrect handling or over tightening
the cable clamps.
Experience has shown that even the use of special torque spanners can not
avoid this (e.g. because cable ladders do not run really in straight line).
The treatment must be left to the feeling of skilled riggers.
There is no substitute for installer skill and experience when handling air
dielectric coaxial feeder cables.
Edition 2014-2 51

Cable installation
Always fix the cable starting at the top of the tower and
work contiguously downwards to avoid loops.
Note: Loops in the cable increase the risk of damage
caused by over-tightening clamps whilst trying to mate
the cable against tower steelwork.
Do not exceed the published clamp spacing (refer to the
relevant data sheet).
Only when the all clamps above the first (uppermost)

hoisting grip are secure should clamping continue down
to the next hoisting grip.
Working down the mast fix as many clamps as possible
until the slack (belly) in the cable above the hoisting grip
no longer allows the cable to be fixed in a straight line.

Edition 2014-2 52
12
Cable installation

Carefully lower the second hoisting grip to take out the
slack (belly) in the cable.
Lower the hoisting grip just enough to allow clamping to
continue in a straight line.
Important: The weight of the cable MUST remain on the

hoisting grips until the cable is securely clamped.
Continue working down the mast/tower using this

procedure until the cable is completely secured.
Remember a small number of clamps will not carry the

full weight of the cable or hold the cable in position.
Important: Do not remove the hoisting grips until the full

length of cable is fully secured.

Edition 2014-2 53

Cable installation
HCH clamps (Premium Clamp for HELIFLEX ® cables)
Do not over tighten!
For anchor bar Angle irons in different Flat

Type C lengths constructions
Type L (e.g. L4 for 40mm) Type R

Edition 2014-2 54
13
Cable installation
HCH clamps (Premium Clamp for HELIFLEX ® cables)
Reminder: When installing RF feeder cables you are handling

sensitive electrical equipment.
Therefore…
Proper care, and attention to detail, is required at all times.
Why? because incorrect installation and
clamping can damage a cable.
Be aware…..
• That cable ladders do not always run in a straight
line.
• Always check that the clamp screw is free
running.
• Always ensure the cable is correctly formed
and seated to ensure an even force
distribution on the cable.
The skill and experience of the installer is critical to this

operation and should not be under estimated.
Edition 2014-2 55

Cable installation
Special fixing solutions

Wall and ceiling bracket
Different types of brackets are

available on the market. E.g. consist
of two anchor bars welded together
with a welded plate for fixing.
The anchor bar construction

allows a number of cables to
be installed on both sides of
the bracket.
Edition 2014-2 60
14
Cable installation

Wall and ceiling bracket - Installation example
In critical areas, e.g. bends,

standard clamps may not
provide the solution.
Clamping in these areas
often requires special local
arrangements.
Standard accessories, e.g.
wall & ceiling bracket may
be used with locally made
brackets to provide the
solution.

Edition 2014-2 61

Cable installation

Specially constructed cable support – fabricated by the customer

Edition 2014-2 62
15
Cable installation
Bending of the cable
Pull carefully
bit by bit While pressing
slide your hand
Always observe
r
the minimum Do not only press in the
bending radius !
middle of the bow, but work
(refer data sheet)
along the complete bow with
the same pressure applied.
Edition 2014-2 74

Cable installation

Large diameter cables are less easy to bend than
smaller diameter cables.
Bending by hand
is possible without
the use of special
bending tools.

Edition 2014-2 75
16
Cable installation
The min. bending radius must be strictly

observed at all times!
Example of bending:
Whilst bending by hand a manual
winch is used to carefully pull the
cable.

Edition 2014-2 76

Cable installation
Cutting of the cable

Keep the cutting area down, in order to avoid dirt or copper
shavings falling into the cable !
For provisionally cutting of small

When the top connector must be installed cable sizes we recommend using a
after hoisting, RFS recommends using a cable trim. It produces nearly
slasher or fly cutter to cut the cable and no copper chips during cutting.
then the final cut made by trimming.
Place cloth in the cable prevent dirt from
entering.
Edition 2014-2 77
17
Cable installation
Cutting of the cable
Do not cut the lower end of

the cable before the
connector on top is
installed, because otherwise
the inner conductor can slip
downwards – out of the
cable.
To prevent moisture from

entering the cable, we
recommend not to open
both cable ends at the
same time.

Edition 2014-2 78

Cable installation
Sealing of the cable end

Keep the cable sealed
Seal the ends of the cable !

We recommend to use heat
shrink caps for sealing.
Rough up the cable jacket with

emery cloth (280 grain).
Remove all dust & dirt particles
with a clean cloth and clean this
area of shrinking with cable
cleaner (e.g. with CA-CLEAN-500)
Shrink the sleeve with a soft
yellow flame by evenly applying a
constant flame with a circular
motion, beginning at the closed
end of the cap.

Edition 2014-2 79
18
Cable installation
Wall gland – WFS Series for small cable diameters

Wall - plate
O - ring
Inner part hot shrink part
with thread
Art./Mod.No Required Shrinking

Part No. drilling Ø zone Ø
WFS-1 25,5 mm 14,0 – 3,0 mm
WFS-2 25,5 mm 19,0 – 6,0 mm
WFS-3 35,0 mm 28,0 – 13,0 mm
WFS-4 51,0 mm 40,0 – 19,0 mm
WFS-5 85,0 mm 70,0 – 36,0 mm
5 different sizes available
Edition 2014-2 80

Cable installation
Wall gland – WF Series for small cable diameters
Can be installed after installation of the cable
Useful for existing wall plates

and for wall entry of long cable lengths
where a large hole is required for the
installation
Edition 2014-2 81
19
Cable installation
Wall gland – WF Series for larger cable diameters
The Wall Gland can be installed before

or after the HELIFLEX® cable is fed
through the entry hole.

Edition 2014-2 82

Cable installation
Grounding philosophy – Recommended grounding points

Local building codes should be followed
Antennas has to be grounded !

(e.g. through the mast/tower)
In the first straight section

Or connector grounding
Grounding kit Before changing directions

Model name:
EAR-*** Before entering buildings

Approximately
Before penetrating
higher LPZ Every 20m

Edition 2014-2 83
20
Cable installation
Fittings for Grounding cables/Copper bands

RFS recommends:
Do not connect copper
to galvanized steel
Bi-metal connection
Grounding terminal Not RFS supply
model no. CEAR-AC
for stainless steel anchor bar
Fitting for fixing

to flat galvanized
iron with long
stainless steel
Fitting for fixing to flat screw
galvanized steel Not RFS supply
Not RFS supply

Edition 2014-2 84

Cable installation
Connection of grounding cables/copper bands
In this
Solution with: Solution with: Solution with:
bi metal connection
position
long stainless CEAR-AC
steel screw only!

Edition 2014-2 85
21

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Technical manual

RF Coaxial Air dielectric Cable

© Radio Frequency Systems 2014 all rights reserved

Radio Frequency Systems GmbH

www.rfsworld.com Edition 2014-2

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

Handle with care! Conserve the characteristic of the cable

Mechanical features of HELIFLEX® cables

- Minimum bending radius,

- Maximum tensile force

Installation of HELIFLEX® cables - INSTALLATION Manual

Shipment & Transportation

Cable drum trailer

When lifting, a special

© Radio Frequency Systems 2014 All rights reserved

Shipment & Transportation

If fork lifts are used, the forks must be

Never lay the drum on its side!

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

Position the drum (cable trailer or drum stand)

Ensure that the cable unrolls from bottom of the

© Radio Frequency Systems 2014 All rights reserved

HELIFLEX® Lite Connectors

All -009 series connectors for HELIFLEX®

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

Tools – useful special tools

Gripper – with copper

Poly Hook Spanner

Preparation of the cable

Install the connector in accordance

Installation of HELIFLEX® cables - INSTALLATION Manual

Preparation of the cable

Especially when installing the connector

© Radio Frequency Systems 2014 All rights reserved

Connector sealing – Sealing compounds

For injection screw the 20 cm³

Alternative for the small sizes of Connectors

Installation of HELIFLEX® cables - INSTALLATION Manual

Connector sealing – Sealing compounds

HCA118-50 10 cm³ (ccm)

HCA158-50 20 cm³ (ccm)

HCA295-50 40 cm³ (ccm)

HCA400-50 70 cm³ (ccm)

HCA495-50 120 cm³ (ccm)

HCA550-50 250 cm³ (ccm)

© Radio Frequency Systems 2014 All rights reserved

Connector sealing – Sealing compounds

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

Connector sealing – Sealing compounds

© Radio Frequency Systems 2014 All rights reserved

Connector sealing – Sealing compounds

Close tube after using

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

Hoisting grip types & varieties

Max. pulling length

© Radio Frequency Systems 2014 All rights reserved

Installation of HELIFLEX® cables - INSTALLATION Manual

The connector and

© Radio Frequency Systems 2014 All rights reserved