A hybrid copper-fiber cable is a cable that integrates optical fibers and conductive copper wires. Figure9-1 shows the structure of a hybrid copper-fiber cable.

Figure9-1 Cross section of a hybrid copper-fiber cable

Application scenarios

A hybrid copper-fiber cable connects a switch and a powered device (for example, a switch or AP) for DC power supply and optical fiber communication, which reduces cabling costs.

A complete hybrid copper-fiber cable contains the pigtail cord at the switch, the main cable, and the pigtail cord at the powered device side. You must fusion splice the main cable and the pigtail cords on site.

CAUTION:

The two optical fibers of the main cable must be spliced crosswise with the optical fibers of the pigtail cords. As a best practice, fusion splice the optical fibers of the same color at the hybrid copper-fiber switch side, and fusion splice the optical fibers of different colors at the powered device side.

Differences among the main cable, pigtail cord, and jumper of a hybrid copper-fiber cable

Main cable

A main cable is used for long-distance cabling from the switch to a powered device. There are no connectors at both ends of the cable. You can select main cables as needed.

Figure9-2 Main cable

Pigtail cord

A pigtail cord is used for connecting a powered device. The two optical fibers and two copper wires are connected to the corresponding optical fibers and copper wires in the main cable, respectively. The pigtail cord has an optical-electric hybrid connector at one end.

Figure9-3 Pigtail cord

Jumper

For standard and neat cabling in the equipment room, you can use jumpers. A jumper has an optical-electric hybrid connector at each end.

Figure9-4 Jumper

Fusion splicing an optical fiber

Fusion splicing tools

The following tools are required for optical fiber fusion splicing. Prepare the tools yourself.

Tool list: Hybrid copper-fiber cable, alcohol cotton swab, fiber cleaver, multifunctional stripping pliers, insulating tape, cable stripping pliers, fiber stripping pliers, utility knife, scissors, fusion splicer, pigtail cord, and alcohol lamp.

Figure9-5 Fusion splicing tools

Fusion splicing accessories

The following accessories are required for optical fiber fusion splicing. Prepare the accessories yourself.

Fusion splicing accessories: Fiber protection sleeve (optional) and heat shrinkable tube.

Figure9-6 Fusion splicing accessories

Fusion splicing an optical fiber

Stripping a hybrid copper-fiber cable

1. Strip the rubber protective cover to an appropriate length based on the current installation scenario.

2. Separate the optical fibers and power wires from the hybrid copper-fiber cable.

3. To prevent the outer jacket of the cable from cracking, use insulating tape to protect the other side of the hybrid copper-fiber cable.

Figure9-7 Stripping a hybrid copper-fiber cable

Stripping an optical fiber

1. Take out the two optical fibers from the stripped hybrid copper-fiber cable.

2. Thread an optical fiber into a cap of the optical fiber protective sleeve.

3. Use wire stripping pliers to peel off the outer sheath of the optical fiber and cut off the excess aramid yarn.

4. Use wire stripping pliers to peel off the inner sheath and insulation layer of the optical fiber.

5. Use alcohol cotton swabs to clean and erase the insulation residue from the fiber core.

CAUTION:

To avoid twisting the optical fiber core, peel off the inner sheath and insulation layer of the optical fiber in small sections.

Figure9-8 Stripping an optical fiber

Cleaving optical fibers

Cut the optical fiber end after cleaning the fiber core to ensure smooth fusion process.

To cleave an optical fiber:

1. Open the clamp cover and fiber holder lid.

2. Place the prepared fiber in the fiber holder groove, and close the clamp cover and fiber holder lid.

3. Push the blade carriage sliding block forward firmly.

4. Open the cover on the left side of the fusion splicer and put the fibers into the fiber holders in the fusion splicer. Close the cover.

NOTE:

If the fiber end is not flat, perform the previous steps again.

Figure9-9 Cleaving optical fibers

Stripping a pigtail cord

1. Separate two optical fibers from the stripped pigtail cord.

2. Thread an optical fiber into a cap of the protective sleeve and a heat shrink tube in turn.

3. Use wire stripping pliers to peel off the outer sheath of the optical fiber, cut off the excess aramid yarn, and then peel off the inner sheath and insulation layer of the optical fiber.

4. Use alcohol cotton swabs to clean and erase the insulation residue from the fiber core.

Figure9-10 Stripping a pigtail cord

Cleaving the pigtail cord

The procedure is the same as cleaving the optical fibers of the main cable. For more information, see "Cleaving optical fibers."

Fusion splicing an optical fiber

1. Open the clamp cover on the right side of the fusion splicer and put the pigtail cords into the fiber holders in the fusion splicer. Close the clamp cover.

2. Close the fusion splicer cover, and the fusion splicer starts to work.

3. Observe the monitor on the fusion splicer. The monitor is as shown in Figure9-11 when fusion splicing succeeds.

4. After the optical fiber is fusion spliced successfully, open the clamp cover and remove the spliced fiber.

5. Open the heater clamp, slide the heat shrink tube over the spliced fiber, place the spliced fiber in the heater, and close the heater clamp. When the HEAT LED turns off, heat shrinking has finished.

Figure9-11 Fusion splicing an optical fiber

(Optional) Installing the fusion splice protection sleeve

After fusion splicing is complete, put the heat shrinking tube in the fusion splice protection sleeve. If other protections are available, for example, a low voltage box or fiber patch panel, no fusion splice protection sleeve is required.

Figure9-12 Installing the fusion splice protection sleeve

Splicing copper wires

Splicing copper wires by using bare crimp terminals

Splicing tools

The following tools are required for splicing copper wires. Prepare the tools yourself.

Tool list: Hybrid copper-fiber cable, wire crimping pliers, bare crimping terminals, wire stripping pliers, utility knife, and pigtail cord.

Figure9-13 Splicing tools

Stripping copper wires

1. Strip the pigtail to separate the two wires from the cable.

2. Peel off the insulation coating from the wires. Make sure you peel off 9 to 10 mm (0.35 to 0.39 in) of insulation coating.

3. Separate two power wires from the hybrid copper-fiber cable.

4. Peel off the insulation coating from the wires. Make sure you peel off 9 to 10 mm (0.35 to 0.39 in) of insulation coating.

NOTE:

The procedure is the same for stripping the copper wires of the hybrid copper-fiber cable and pigtail cord.

Figure9-14 Stripping copper wires

Splicing copper wires

1. Insert copper wires in the main cable into the left part on the bare crimp terminal.

2. Use a crimping tool to crimp the wires.

3. Insert copper wires in the pigtail into the right part on the bare crimp terminal.

4. Use a crimping tool to crimp the wires.

5. Gently pull both ends of the crimped copper wires to ensure firm splicing.

IMPORTANT:

Make sure you splice copper wires of the same color in the main cable and the pigtail.

Figure9-15 Splicing copper wires

Splicing copper wires by using common DC wire terminals

Splicing tools

The following tools are required for splicing copper wires by using common DC wire terminals. Prepare the tools yourself.

Tool list: Hybrid copper-fiber cable, common DC wire terminals, wire stripping pliers, utility knife, and pigtail cord.

Figure9-16 Splicing tools

Stripping copper wires

1. Strip the pigtail to separate the two wires from the cable.

2. Peel off the insulation coating from the wires. Make sure you peel off 9 to 10 mm (0.35 to 0.39 in) of insulation coating.

3. Separate two power wires from the hybrid copper-fiber cable.

4. Peel off the insulation coating from the wires. Make sure you peel off 9 to 10 mm (0.35 to 0.39 in) of insulation coating.

NOTE:

The procedure is the same for stripping the copper wires of the hybrid copper-fiber cable and pigtail cord.

Figure9-17 Stripping copper wires

Splicing copper wires

1. Lift up the four levers.

2. Insert copper wires in the main cable and the pigtail into the wire terminal.

3. Close the levers.

4. Gently pull both ends of the crimped copper wires to ensure firm splicing.

IMPORTANT:

Make sure you splice copper wires of the same color in the main cable and the pigtail.

Figure9-18 Splicing copper wires

Connecting copper wires to a terminal block

IMPORTANT:

Bare parts of the positive and negative copper wires cannot be exposed to air and must be fully inserted into the terminal block.

Connecting copper wires to a terminal block commonly used by a switch (FS5100-8T2RS-EI)

1. Peel off the insulation coating from the wires. Make sure you peel off about 5 mm (0.20 in) of insulation coating.

2. Press down the orange button on the terminal block, and then insert the bare copper wires into the terminal block.

3. Identify the positive and negative feed positions based on the "+" and "–" marks on the target PoE port of the endpoint-side device. "+" corresponds to the positive wire and "–" corresponds to the negative wire.

Figure9-19 Connecting copper wires to a terminal block (1)

Connecting copper wires to a terminal block commonly used by an AP (WA6520H-FIT(H20))

IMPORTANT:

The terminal block is only applicable to copper wires with 0.5 mm2 (0.0008 in2) cross sectional area. If the cross-sectional area of the copper wires exceeds 0.5 mm2 (0.0008 in2), use an RJ-45 power terminal as a best practice.

1. Peel off the insulation coating from the wires. Make sure you peel off about 5 mm (0.20 in) of insulation coating.

2. Press down the orange button on the terminal block, and then insert the bare copper wires into the terminal block.

3. Identify the positive and negative feed positions based on the "+" and "–" marks on the target PoE port of the endpoint-side device. "+” corresponds to the positive wire and "–" corresponds to the negative wire.

Figure9-20 Connecting copper wires to a terminal block (2)

Connecting copper wires to a terminal block commonly used by an AP (WA7538-FIT)

1. Peel off the insulation coating from the wires. Make sure you peel off about 5 mm (0.20 in) of insulation coating.

2. Use a screwdriver to loosen the screws on the terminal block.

3. Insert the positive and negative copper wires into the terminals marked "+" and "–" on the terminal block, respectively, and then fasten the screws.

Figure9-21 Connecting copper wires to a terminal block (3)

Connecting copper wires to an RJ-45 power terminal

IMPORTANT:

Bare parts of the positive and negative copper wires cannot be exposed to air and must be fully inserted into the RJ-45 power terminal.

1. Peel off the insulation coating from the wires. Make sure you peel off about 5 mm (0.20 in) of insulation coating.

2. Use a screwdriver to loosen the screws on the RJ-45 power terminal.

3. The RJ-45 power terminal has the "A" and "B" marks. Insert the positive copper wire into the terminal marked with "A" and the negative copper wire into the terminal marked with "B".

Figure9-22 Connecting copper wires to an RJ-45 power terminal

H3C S7500X-G Switch Series Installation Guide-6W101

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