4 Use Cases for Testing Long Haul Twisted Pair Cabling
Many cable install professionals are under the false impression that a cable tester only needs to verify twisted pair copper up to -- but not exceeding -- 100 meters (328 feet) in length. While it is true that most two- and four-pair 802.3 Ethernet standards do indeed have a maximum distance limitation at the 100-meter mark, there are plenty of other uses and standards that require a tester to verify proper cable operation well beyond 100 meters. This includes cabling projects for the Internet of Things (IoT), Industrial IoT (IIoT) and many surveillance camera deployments over twisted pair copper. In this article, we're going to point out four different real-world use cases where a cable test unit must be capable of validating copper runs up to 1000 meters.
1. Intelligent building control systems
A major part of the IoT movement is to make the buildings we work in smarter. Newly built constructions are receiving intelligent control systems right out of the gate. Older buildings are being retrofitted with similar systems that meter, monitor and automate many building functions. These technologies can be used to better control energy costs of electrical and mechanical systems while also automating previously manual processes. Ultimately, intelligent building controls provide the precise HVAC and lighting/power needs when and where occupants need them while conserving these resources everywhere else.
The problem is, many intelligent building control system components are dispersed throughout large building campuses. At the same time, they also require constant and fully connected communications. Many leverage the use of serial interfaces over twisted pair copper as a way to allow long haul connections to connect building control components located hundreds or thousands of feet away. Thus, once your business clients begin implementing these types of intelligent systems, expect the need to run and verify twisted-pair cabling well beyond 100 meters.
2. IoT sensors using single pair Ethernet (SPE)
Example 10Base-T1L 1000m (802.3cg) TestExample 10Base-T1L 1000m (802.3cg) TestThere are any number of new IoT sensors that are hitting the enterprise market in 2019 and beyond. Examples include sensors that measure temperature, humidity, smoke, pressure, acceleration and chemical levels. Sensors can be used to monitor areas that demand consistent temperature/humidity levels such as in a data center. Other uses are to identify objects/people in proximity to a sensor and send alerts when the object or person moves. Sensors can also be used to rapidly alert building occupants of a dangerous event such as a fire, gas/carbon monoxide/chemical leak or other dangerous environmental situation.
One interesting aspect of these types of sensors is that they typically don’t require even close to 1 Gbps or higher throughput rates that common 802.3 Ethernet data protocols provide. That said, IoT sensor deployments do often require cable runs that extend far beyond common 10/100/1000BASE-T distance limitations of 100 meters. That’s why many are looking at Single pair Ethernet (SPE) for future IoT deployments. SPE is a relatively new standard (IEEE 802.3cg) that allows for cable runs up to 1000 meters using only a single pair of Category 5e cabling or better. Runs can extend this far while also providing data speeds of 10Mbps.
Expect IoT sensor manufacturers to begin adopting the SPE standard in their hardware to further increase ease of deployment within large buildings, office campuses or even entire municipalities.
3. Manufacturing and warehouse automation
Manufacturing plants and warehouses are regularly being revamped with the latest in smart assembly lines and robotics. These technologies help to decrease process times, reduce outages, eliminate waste, and increase safety protections. This is often accomplished using intelligent monitoring, augmented reality and advanced analytics. The problem is, all these platforms, sensors and robots must be centrally connected. This often means that twisted pair cabling used to connect these types of systems will far exceed 100 meters. While this has been the case for manufacturing/warehouse environments for years, the need for long cable runs is only going to increase.
4. CCTV deployments
The demand for closed circuit television (CCTV) and other security control and surveillance systems is growing at a rapid rate. The reason for this is the fact that one can now deploy high-quality and high-definition surveillance cameras at a fraction of the cost compared to even a decade ago. Thus, to ensure the safety of employees, partners and guests within a building or campus – as well as to provide insurance policy protections against robberies, thefts and frauds – CCTV is a wise investment. That said, many CCTV cameras must be installed at considerable distances away from the central network. Cameras are often positioned at remote gates and entrances, building outposts and on rooftops. Thus, many manufacturers offer the ability to stream CCTV feeds over twisted pair cabling up to 1000 meters in length.
Is your test equipment capable of verifying operational status of cabling up to 1000 meters?
Cable test equipment manufactures only guarantee their test results up to a certain distance limitation. In many cases, this distance is far below what you might need given today’s demand for long haul twisted pair runs. In order to prepare for the increase in long haul runs, be sure to have test tool like the AEM CV100 which can verify twisted pair runs up to 1 KM in length. The CV100’s standard autotest supports testing twisted-pair cabling up to 600 meters. If you require testing beyond this length, there is a special test mode for cables that range between 500 and 1000 meters.
Long Cable Setting for 500m to 1km Testing 
Showing GamerChanger Cable Type inSetup
Many field test units on the market today aren’t capable of testing this far. Considering the growing need for building control systems IoT sensors, IIoT and CCTV long cable runs, long haul verification tests are definitely a function of the CV100 test tool that you’ll put to good use.
Superspreader for PoE Lighting
Powering light through the data IP network using Category cable, instead of hazardous 120V electrical systems is creating a superspreader of PoE technology throughout all buildings and outdoor applications. With the emergence of smart/intelligent buildings, PoE lighting is on forefront of driving converged building application advancements. LEDs are inherently DC, so installation is greatly simplified by eliminating separate power and control wiring. And because LEDs require little energy and are powered through Ethernet cables, they easily create a connected system providing many benefits over traditional independent ballast/lamp systems, but can also present new challenges when it comes to the design of the cabling topology.
Many IT players are designing and installing LED PoE-powered lighting systems as part of the intelligent building infrastructure to reap numerous benefits. From commercial office and data center employees to retail shoppers, from hotel guests to patients at a hospital, building occupants are demanding a more customized, comfortable, and smart building experience. Smart and connected LED-based lighting is a key part of the picture with associated control systems which account for HVAC systems, air quality, and more. Building owners and managers are realizing that the implementation of a PoE lighting system allows numerous energy efficient and sustainability benefits such as: installation savings through low-voltage cabling (vs. electrical products and installation); LED averages 70% more efficient cost savings than fluorescent or HID lamps; UL924 compliancy which eliminates a separate emergency lighting network; and can be monitored and scheduled through an integrated management system which also optimizes work space. In addition, without line-voltage connections, light fixtures and sensors can be more easily added, reconfigured and upgraded.
PoE lighting is gaining ground and providing growth opportunities for all IT designers and integrators. According to a report by Fortune Business Insights, the global PoE LED lighting market will rise from a value of 192.3 million units in 2018 to 544.8 million units by the end of 2026. The forecast period is set from 2019 to 2026 and the market for PoE LED lighting is anticipated to rise at a compound annual growth rate (CAGR) of 14.1%.
PoE Safety Ratings
With the ratification of IEEE P802.3bt which recognizes 60W (Type 3) and 90W (Type 4) of power (PoE) to run over twisted pair cabling, there is growing concern of excessive heat generation due to additional current (amperage) running through the cable. Bundled cable is especially vulnerable to heat build-up. As a result, UL created a certification called “LP” (Limited Power) which includes a test procedure for determining how many amps a conductor can safely accommodate. Some cable manufacturers have submitted their twisted-pair cables to be tested and earn that rating.
An alternative to LP cables is to refer to the ampacity chart, which was published by the National Electrical Code® (NEC) in Section 725 of the 2017 NFPA 70®. This chart is based on allowable amps for each conductor’s current carrying capacity at 60W or above, and is determined by the cable’s mechanical (operating) temperature, gauge size (AWG) of the conductors and bundle size. This table is solely based on an ambient temperature of 30° C (86° F). As expressed in the chart, the larger the AWG, the better performing the cable and the greater the bundles for higher wattage. Note that a 4-pair cable constructed with 22 AWG conductors, such as the GameChanger Cable™ from Paige Datacom would be recommended as the best choice to safely transmit over 60W and with a maximum bundle size of 192 cables without having to carry the LP rating .
System Architecture
There are different architecture designs for PoE LED lighting. PoE lighting systems contain multiple components connected through Ethernet cabling: the PoE switch — the power supply for the PoE lighting systems — provides the needed voltage for the lighting system ; LED luminaires (such as troffers); wall controllers and ceiling sensors. The wall controllers are wall switches and are usually directly connected to the sensors which sense occupancy, daylight harvesting or ambient temperature.
There are two industry standards that provide well-defined guidelines for the design, planning and installation of PoE LED lighting systems as an integral part of an intelligent building infrastructure — TIA-862-B-2016 Structured Cabling Infrastructure Standard for Intelligent Building Systems and ANSI/BICSI-007-2020 standard, Information Communication Technology Design and Implementation Practices for Intelligent Buildings and Premises. These two documents complement each other in the IP cable installation planning of intelligent building applications. Specific content in the TIA standard provides guidelines for cabling types, topology, design and installation best practices and test procedures for any size building or premise. The BICSI standard leverages the TIA requirements but gets more granular with best practices for planning spaces, topology and media selection for the specific building applications, including a detailed chapter on LED lighting. In addition, the BICSI standard recognizes that in many instances, the cabling infrastructure and cabling selection of the horizontal cabling may vary as it should be planned to incorporate the deployment of numerous building systems that may utilize an IP network. In addition, BICSI-007 recognizes that some building systems may require cabling other than balanced twisted-pair or optical fiber because of system and application architecture or manufacturer requirements. In fact, primary decisions for cabling type are often based on manufacturer requirements, signal type, distance and location, power requirement, and longevity of building occupancy.
Depending on the cabling requirements of the lighting manufacturer, the horizontal cable can run in a star topology from the telecommunications room (TR) directly to the lighting (also known as point-to-point). However, some lighting manufacturers incorporate a node (or a gateway device) where the Ethernet cable runs from the switch (either an endspan in the TR or a midspan within the horizontal run or housed in a zone enclosure) to the node to maximize the usage of each port. (For more information on zone cabling design, see https://paigedatacom.com/news-article/in-the-zone-cabling-design-for-todays-intelligent-buildings) From the node, the cable can either be a twisted pair construction or even a multi-conductor cable such as an 18 gauge, 2 conductor cable (18/2) which can be daisy-chained. This is known as a tree topology.
(Courtesy of ANSI/BICSI-007-2020)
Spreading the Light
One of the biggest challenges in the cabling design for PoE LED lighting for both Star and Tree topologies are distance considerations from the TR or node to the actual components. Because these are running on Ethernet cables, the TIA and IEEE standards limit the Category cable runs to 100 meters. But in many instances the cable runs will need to exceed that distance, such as:
The solution to this constant challenge is installing the GameChanger Cable™ from Paige Datacom, which doubles the distance of a typical Category 6 or 6A cable. PoE LED lights use very low bandwidth and power which means that the patented GameChanger cable is UL verified to deliver 10 Mb/s up to 850 feet from the switch in the TR to the device or the node. If using a Star topology, the distance is determined by the voltage drop. (See the GameChanger voltage drop chart). If the lighting components are daisy chained from a node employing a multi-conductor cable the total cable length is determined by the number of devices, wattage required, voltage drop and, of course, gauge (AWG) size (usually, 12, 16 or 18 AWG).
The GameChanger is available in different constructions to suit the specific installation environment including indoor unshielded riser or plenum, outdoor direct burial or shielded OSP. For those industrial locations, GameChanger is also available in an ITC-HL Class 1 Division Armored style specifically designed for hazardous locations. See the complete GameChanger cable specifications here. Many integrators have already seen the light as GameChanger has all scenarios covered and is becoming the recognized superspreader for delivering power and data to smart lighting systems.
Electrical equipment can and does cause explosions in some atmospheres. As cameras and senor capabilities increase, these cameras are being used in more areas than ever. In the past, one of the limiting factors was placing a camera in a critical area defined as hazardous. Hazardous areas are environments in which the atmosphere contains, or may possibly contain, flammable or explosive gases and, in the right conditions, may cause a fire or explosion. The frequency of occurrence determines the level of hazard for a location. The longer the material is present, the greater the risk. These areas present many challenges in terms of where you can place, maintain, and use a sensor. Explosion-protected cameras address some of these concerns and regulations.
To help define hazardous areas, a rating system was devised for definition of what can be used in a Hazardous Area. In short, areas that produce a certain level of gas, vapor or liquid that are present in normal operation conditions. Class/Division/Zone is the classification system set up in the US. For this discussion we will use the Class I Division I hazardous areas.
Class I, Division 1: There are three different situations that could exist to classify an area as a Class I, Division 1 location:
1. Ignitable concentrations of flammable gases or vapors may exist under normal operating conditions.
2. Ignitable concentrations of such gases or vapors may exist frequently because of repair or maintenance operations or because of leakage.
3. Breakdown or faulty operation of equipment or processes might release ignitable concentrations of flammable gases or vapors and might also cause simultaneous failure of electric equipment.
The control and monitoring of equipment to ensure sustained processing activity is essential in refineries and industrial plants to control production and operational cost. Companies are always looking to increase production, drive down the cost of production and improve environmental performance in refineries. In the past, most of the monitoring relied on individual people walking an area to be the eyes and ears for any problems. Sensors were introduced and embedded in processing areas to monitor vibration, heat, and the like. Verification once a sensor alarmed was confirmed by still having to send in a person to validate the alarm. Cameras today can be the eyes and ears of a human to validate remotely without disruption to process operation or production thus reducing production costs.
As we investigate a typical oil and processing area, we see the hazardous area and the CID1 with ignitable concentrations present as defined. We also see many process monitoring applications present. Such applications include:
· Rotating equipment – equipment that could come out of balance triggering a vibration sensor
· A thermal couple area – areas that could heat up too fast or exceed processing limitations. Many products are developed by mixing and adding chemical at a precise temperature for the chemical reaction to occur properly. I.e. antifreeze
· Valves and seals – junction points controlling volume tend to leak and fail.
· Settling tanks – used for separations during process. Monitored by thermal couples
· Pumps and pumping stations – looking for seal failure and early leaks
· Piping – miles and miles of pipes can be monitored for leaks and wear or damage
Using sensors such as visible and thermal cameras can help in monitoring and verify problems in some of these applications, remotely without shutdown or the risk of sending a person in that area.
Challenges in remote monitoring in hazardous areas
Some challenges in remote monitoring in hazardous areas involve access to equipment for maintenance and reducing failure points. Shut down for maintenance is costly in lost production. Unscheduled shutdowns are very costly. Easy quick installations with reduced crews because of lighter camera systems and no additional equipment needed to boost or extend network signals help reduce production downtime. New cabling solutions like the GameChanger CableTM from Paige, deliver 1Gb/s Ethernet and PoE+ up to 656 feet or 10Mbs/s up to 850 feet reducing costs, simplifying installs and saving money. By extending the distance limitation with cable alone, installers are also avoiding the need to install (and later service) equipment in remote and hazardous areas, saving money and keeping workers safe.
Preventive maintenance
Remote monitoring of these applications listed could help establish trend analysis and facilitate predictive maintenance thus allowing intelligent scheduling for preventive maintenance. Explosion-protected cameras are IP cameras that can be configured remotely, health monitored remotely and rebooted remotely reducing the need for human interaction in the hazardous areas.
Processing applications
Process capabilities of these cameras have increased significantly in the past several years. The ability to take an unacceptable image and process to get an acceptable usable image has never been more available than today. These sensors are now a computer with a lens. Users are seeing more in challenging conditions using this technology to verify and confirm before costly intervention.
On the edge analytics
The ability to run multiple event-driven edge analytics reduces bandwidth use lowering costs and automates our monitoring process for implementation of AI (Artificial Intelligence) and ML (Machine Learning). Edge based analytics can not only tell you if a person is entering an area that is restricted (safety, security) but can also notify if it see a rise in temperature of a failing component or detect a leaking pipe or emissions.
New markets and applications
As we see the cost of explosion-protected cameras go down, we see other verticals opening such as agriculture (processing plants, storage facilities, transportation lines, fuel distribution terminals), chemical (fertilizer plants, chemical facilities) transportation and water treatment facilities all having hazardous areas associated. These verticals also have common applications within their own plants requiring explosion-protected cameras and sensors. Automating critical monitoring not only reduces overall production costs but positions companies for the new digital age to come.
In the Zone
Intelligent Buildings have changed the landscape of low-voltage infrastructure layout. One of the biggest changes is selecting the proper cable and topology to deliver network data and power (PoE) to devices, which had previously run on many different disparate cabling types and automation systems. These include security cameras, access control, wireless access points, HVAC, lighting and many more. Location of these devices vary greatly since they do not attach to typical telecommunications outlets installed 15” above the floor. These applications are fixed in ceilings, on walls, by doors, as well as outdoors in garages and parking lots. Gaining attention to connecting IP cabling to these devices is to employ a flexible zone cabling layout.
A CB Series of zone enclosures from FSR Inc. are designed to house both active and passive equipment for intelligent building applications. Zone cabling was originally introduced to provide flexibility for open office space. But with the growth of PoE and converged applications onto the data network, zone cabling expanded its widespread use. A zone cabling design consists of an intermediate connection point, referred to as a Horizontal Connection/Consolidation Point (HCP) between the Telecommunications Room (TR) and the end devices. Cables are pulled and terminated into the HCP, also called a zone enclosure, or ceiling box. From the cross connection in the zone enclosure, additional horizontal cables are pulled to the outlets or connected directly to the device through a modular plug terminated link (MPTL).
The major benefit of a zone cabling design is that it provides easy-to-manage cabling between the TR and the devices, without having to homerun cable from all the way back to the TR. A zone layout also reduces labor and material costs during reconfiguration because the cabling from the TR to the HCP stays intact, especially when adding future devices that will only require cable or patch cords from the HCP.
Zone Cabling Guidelines
There are two standards that provide well-defined guidelines for the design, planning and installation of a zone cabling layout as an integral part of an intelligent building infrastructure — TIA-862-B-2016 Structured Cabling Infrastructure Standard for Intelligent Building Systems and ANSI/BICSI-007-2020 standard, Information Communication Technology Design and Implementation Practices for Intelligent Buildings and Premises. Together these two documents complement each other to provide cabling installation planning but may vary in some of the recommendations.
For twisted-pair copper cabling, both TIA and BICSI recommend Category 6A for new installations or Category 6 at minimum in an existing building or as a retrofit. In addition, BICSI also recognizes that in existing installations of intelligent building systems, the use of non-recognized horizontal cabling shall be allowed if the following conditions are met: use of non-recognized cabling does not violate current Code or AHJ requirements; the need for cabling is a result from the movement, expansion, or other alterations to an existing system; or the non-recognized cabling meets or exceeds the performance of the existing cabling in use by the specific system.
TIA provides guidelines for cabling types, pathways, terminations and installation best practices. A zone enclosure or HCP is defined by TIA to house one or more of the following: a) a consolidation ; b) a horizontal connection point; or, c) intelligent building system outlet. For twisted-pair cabling, in order to reduce the effect of multiple connections in close proximity on NEXT loss and return loss, the HCP should be located at least 15 m (49 ft) from the TR (or “Distributor”) that houses the active equipment. When cross-connections are used at the HCP, an equipment outlet shall not be installed as part of Cabling Subsystem 1 to ensure that the cabling channel contains no more than four connections. The zone enclosure should be sized to accommodate immediate requirements and long-term growth but not more than 96 connections.
The BICSI standard leverages the requirements by TIA but delves more granular into the best practices for planning spaces, topology and media selection for the additional building applications. The revised BICSI-007-2020 has expanded the section on design considerations for zone enclosures to include more options and topologies for horizontal cabling and contains diagrams and layouts that depict examples of a star topology (point-to-point), different coverage area patterns, and tree topology.
Although TIA recognizes zone enclosures as only housing passive cross connections (or interconnections) for data or building devices, BICSI’s 007-2020 version states, “Unlike a consolidation point, an HCP may be either active or passive.” Allowing active equipment, such as PoE extenders, midspan injectors, AC outlets, fans or switches within the HCP expands the design of the zone boxes. Spare capacity for future expansion is considered when determining the size of the HCP. Manufacturers of ceiling boxes are now offering different configurations, sizes and features. (See photo for a ceiling box with electrical connections and accommodation for both patching fields and active components)
Zoning Out
A zone cabling horizontal channel distance is limited by TIA to 100m for twisted pair cabling from the equipment in the TR to the device itself, including patch cords. This means that if the HCP is located at least 15m from the TR, that the end device can not run further than 85m from the zone enclosure (including the patching field) (See Figure 1). Since most of building devices are beyond 100m, there are options – add PoE extenders, which would require AC power for the active components, or use a hybrid fiber/copper cable which would include employing media converters and PoE extenders and AC power, which greatly increases the material and installation costs, or simply specify the long-distance GameChanger Cable™. The patented 22 AWG GameChanger cable more than doubles the distance of a Category 6 or 6A cable (unshielded or shielded) out to 260m (850 ft.) from the TR to the device if the zone box only houses a cross connection. If active PoE midspans or digital building PoE switches are installed in the HCP, then the GameChanger cable can run out to 260m from that point which drastically extends the total horizontal cable run. (See Figure 2).
Figure 1: TIA-862B-2016 - Example of a Cabling Subsystem 1 using a star topology to coverage areas
Figure 2: GameChanger Cable extends the cable channel distance to 260m/850 ft. without zone cabling or at least 275m/899 ft with an HCP containing active equipment.
A major safety concern defined in "hazardous locations" is the occurrence of fires and explosions due to presence of flammable gases, vapors, dusts or fibers. Hazardous locations (HL) are usually found in industrial facilities where explosive liquids, gases or dusts are present. No other aspect of industrial safety receives more attention in the form of codes, standards, technical papers, and engineering design.
Regulatory bodies like the Occupational Safety and Health Administration (OSHA), National Electrical Code (NEC) and the NFPA 70 have established classification systems for locations which exhibit potentially dangerous conditions and hazards. They define the types of hazardous substances that are, or may be, present in the air in quantities sufficient to produce explosive or ignitable mixtures. Hazardous location requirements exist not only to prevent a fire or explosion, but also to contain the fire or explosion should it occur. OSHA provides guidelines for specially designed equipment and special installation techniques must be used to protect against the explosive and flammable potential of these substances.
Hazardous locations are broken into different categories called “Classes” and “Divisions” in NEC’s Article 500 Hazardous (Classified) Locations – Classes I, II, and III, Divisions 1 and 2. The NEC imposes strict requirements for cabling methods in these locations which are permissible by the code-making bodies, also known in the ICT industry as the Authority Having Jurisdiction (AHJ), with safety being the most critical consideration. The “Classes” define the type of explosive or ignitable substances which are present in the atmosphere or could be present. The “Groups” define substances within the Classes and are rated by their flammable nature in relation to other known substances. The “Divisions” apply to the specific conditions and the likelihood of the specific substances in the Groups to exist in the areas.
Class | Groups | Divisions | |
Division 1 | Division 2 | ||
I Gases, Vapors and Liquids |
| Explosive or ignitable gases or vapors are present under normal operating conditions | Explosive or ignitable gases or vapors are NOT normally present (but may accidentally exist) under normal operating conditions |
II Dusts
|
| Combustible dust is in the air under normal operating conditions | Dust is not normally in the air in ignitable concentrations (but may accidentally exist) |
III Fibers and Flyings | Textiles, wood chips, etc. (ignitable but NOT explosive) | Easily ignitable fibers and flyings are handled, manufactured or used | Easily ignitable fibers are stored or handled |
The process of classifying an area is often complex, so it is generally determined by the facility’s engineering staff. Buildings are not classified, but areas within the building are. “Class I, Division 1” is the most hazardous classification. Notice that the ignitables get bigger as the class number increases. Unfortunately, there isn’t always a clear boundary. Often there are areas that have a mix of particle sizes.
Some examples of Class 1 areas are:
Selecting Proper Cable and Following Best Installation Practices
Each type of hazardous location requires specific types of cable and installation methods. Approved wiring methods range from a rigid, highly impenetrable type of cable, such as Type MI (mineral insulated cable), to a raceway system such as metallic conduit. Cable glands (cable entry devices) used in hazardous locations are intended to provide the safe connection of suitable cables to enclosures, maintaining the explosion protection and ingress properties of equipment. Cable glands provide a degree of environmental and ingress protection required for the equipment they are being connected to and the hazardous location for which they are being installed in. NEC prescribe the requirements for both cable glands and cables.
The NEC defines the types of cables that can be used in hazardous locations, and UL provides the means to approve cables for the US. The various cable types, in conjunction with the appropriate terminations, must provide a system that significantly limits or completely eliminates the possibility of an electrical arc or spark igniting the surrounding flammable gases, vapors, dusts or fibers. The approved cable types range from extremely rigid and impermeable mineral-insulated, metal-sheathed Type MI cables and MC-HL and ITC-HL cables with gas/vapor-tight continuous corrugated metallic sheaths to unarmored, highly flexible Type TC-ER-HL cables and flexible cords.
Cable allowed for use in Class I Division 1 are limited, with a few exceptions, to type MC-HL, ITC-HL, and TCER-HL under special conditions. NEC provides requirements for equipment (including cables) installed in HL areas which includes:
In jurisdictions following IEC requirements, there are product standards for hazardous location cable glands. However, unlike NEC, IEC does not identify specific product standards for hazardous location cables, but provides installation cable requirements according to the IEC 60079-14. And although this standard provides guidance for the minimum requirements for cable installation, it does not define specific tests or construction specifically for hazardous location cable. IEC recommends certain cable properties, such as jacketing materials not to be an “easy tear” type (i.e. with low tensile strength sheaths) unless installed in conduit, jacketing to be extruded and constructed of thermoplastic, thermosetting or elastomeric materials and any fillers need to be water blocking.
Tough Cable Challenges and an Easy Solution
In addition to the cable’s robust construction needed to perform in severe environments, one of the biggest challenges for Ethernet cable is the 100m distance limitations. In harsh environment locations, such as the Class I areas mentioned above, the distances from the telecommunications room (TR) to the devices often exceeds 100m. Adding an additional termination point, whether a telecom enclosure or an additional TR is just not feasible or cost effective.
The GameChanger™ Cable, which was designed to deliver both data and power (PoE) far beyond the Ethernet distance limitations for Category cable, is now available in a version specifically developed for harsh locations. This cable is classified as ITC-HL (instrumentation tray cable for hazardous locations), meeting UL2250 and UL2225 listings for 300V copper conductors for use in Class 1, Division 1 (CI/DI) hazardous locations.
This GameChanger cable consists of 22 AWG copper conductors with FEP insulation and manufactured with an inner jacket covered by a continuously corrugated welded (CCW) armoring and then sheathed with an outer PVC jacket. This cable is ROHS-2 compliant, sunlight resistant and can be direct buried. The operating temperature has a wide range of -50°C to +90°C which assures reliable performance in all severe environments. With the CI/D1 rating this armored cable allows installers to skip the expensive and time-consuming installation of rigid pipe or conduit, and with a reach that goes well over two times traditional cable, saving a significant amount of time and money.
All GameChanger cables deliver 1Gb/s Ethernet and PoE+ up to 656 feet (200 meters) and 10Mb/s Ethernet and PoE+ up to 850 feet making it an ideal pairing for explosion proof cameras, WAPs and other edge devices. This cable eliminates intermediate IDF requirements and the need to install repeaters, power supplies and other equipment, which are costly and introduce additional points of failure.
A Creative Solution to Warehouse Wi-Fi Connectivity
When installing a Multigigabit Wi-Fi system in a large facility like a warehouse, how can you run the Ethernet cabling long enough to provide proper connectivity and PoE to the Wireless Access Points (WAP), without additional IDFs, boosters or extenders? In this video, you will see how Creative Security Solutions of Piscataway, NJ simplified the design of this 802.11ac Wave 2 Wi-Fi deployment.
These days, wireless and mobile technologies like Wi-Fi 6 and 802.11ac Wave 2 have revolutionized how warehouse’s function. Their efficiency and productivity now often hinge on having a robust and reliable wireless infrastructure. The installation needs to satisfy the expectation, today and in the future - of multigigabit speed – without dead zones and constant disconnections of the multitude of wireless devices that keep a modern warehouse operation going strong.
It remains a fact that the wireless Internet in a facility like a large warehouse depends on extended cable runs to provide the power and the connectivity to the network backbone. In situations like these, installers and end users have normally had to make compromises like:
On this video, you will see how Creative Security Solutions very much lived up to its name and found a solution to this challenge – running cable an extended distance from “Point A to Point B” to implement Multi-Gig Wi-Fi across a massive warehouse space - with “no extra equipment” and “no extra costs.”
Hint: It is a GameChanger!
For more information on how the explosion in wireless technology and Wi-Fi is driving the future of network connectivity and infrastructure, be sure to read this previous blog post by Carol Oliver.
When COVID-19 emerged, the entire country learned the true meaning of “essential work.” “Healthcare” instantly rose to the top as the most essential business in the world. Through this pandemic, it became essential that healthcare facilities have the right medical equipment for treatment, but also a robust communications system. From real-time telemedicine, medical testing, extensive research and the ability to access universal medical records, the network infrastructure became the fundamental vehicle to transport the data faster and more efficiently than ever before, whether within the confines of one hospital or out to a multitude of facilities worldwide. As a result, the network has become the heartbeat of any healthcare facility.
Healthcare networks are expanding exponentially to face the challenges of managing diverse information such as patient records and bandwidth intensive scans and virtual diagnostic information. The amount of data that must be created, transmitted, managed and stored continues to increase dramatically. In addition, the broad adoption of standards-based electronic health record (EHR) system, which was implemented over a decade ago, created a global health information exchange. The use of this technology for clinical decision support improves patient care and ultimately can lower healthcare costs by facilitating communication, coordination, and collaboration among healthcare providers.
Many healthcare facilities have been re-evaluating their capability to deliver the technology needed in the healthcare environment today. Many significant life-changing advancements in patient care, diagnostic and research are supported by both wired and wireless technologies attached to the network infrastructure, which are constantly evolving.
Addressing Healthcare Infrastructure Challenges
System designers, consultants and I.T. managers who have faced the challenges of incorporating all of the growing healthcare applications, attest that there are many differences compared to planning an enterprise network for an office facility. These differences include a broader scope of applications which lead to increased outlet and device densities with their diverse termination locations, higher bandwidths and in more challenging installation environments.
To aid in the design and installation are two industry cabling standards, TIA-1179-A Healthcare Facility Telecommunications Infrastructure Standard, first published in 2010, revised in 2017; and ANSI/BICSI-004 Information Communication Technology Systems Design and Implementation Best Practices for Healthcare Institutions and Facilities, first published in 2012 and revised in 2018. The TIA standard addresses specific structured cable types for the backbone and horizontal, pathway and telecom room planning and recognizes the difference of outlet densities, depending on the different applications required for the specific facility areas (such as a waiting room versus and operating room). The BICSI standard builds upon the TIA document but hones in on providing guidance on the cabling layouts to address the diverse IP applications and system integration methods. Some of these applications include clinical and non-clinical IP-based systems such as building automation systems, nurse and code calls, paging, wayfinding, emergency radio, medical imaging, patient monitoring, television and A/V, and security and safety.
Each healthcare environment is unique and creates its own set of challenges and network priorities. Some of the major infrastructure concerns when planning network expansion, as addressed in the standards, include:
• Protected pathways – separating data cable from other services, such as gasses and liquids that may share the same above-ceiling spaces. In addition, pathways must be firestopped to eliminate the spread of fire as well as protect clean air within the facility.
• Bandwidth and data storage – MRI files and other advanced medical imaging files, such as Picture Archiving and Communications Systems (PACS), are bandwidth intensive. In addition to transmitting these files, networks also need to provide long-range storage which can vary from as little as seven years up to a lifetime, will translate to constant additions of servers and SANs to these facilities.
• Telecom Rooms (TRs) – as more and more IP devices are being added to the network, telecom rooms must be sized by number of applications, not necessarily by the number of users or floor size that it is serving.
• Outlet densities – the number of outlets and cables per area will also depend on the amount of applications needed to that workstation area.
Unique Cabling Solution
Staying on top of the IP application boom in healthcare means revamping and updating the existing infrastructure to meet the application bandwidth demands and device densities. This includes substantially increasing the cabling runs. In healthcare facilities, the TR should be dependent on the densities of applications on each floor and for each area, which may include custom designs and solutions.
One of the biggest growth areas is employing wireless for more than just voice and text communications. Mobile applications allow patients and medical professionals to access medical records and provide online diagnostics, but within the facilities, the healthcare professionals rely on wireless communications for patient monitoring systems (such as physical activity, heart rate and other biometric functions), patient tracking and wayfinding. More wireless applications require more wiring to the access points or sensors that enable these applications.
The biggest challenges to deploy increased IP applications, includes adding more connectivity to the equipment in the TRs and within the horizontal pathways to service the devices. Many of the older hospitals are struggling to find room for additional TRs and cabling. And a major roadblock of installing cable on premises are the regulations that apply to infection control requirements (ICR). ICR limits the time allowed for installers to be onsite, as well as requiring the proper equipment such as HEPA carts and protective gear.
System designers are looking at unique cabling solutions that would limit the installation disturbance by increasing the run lengths from the TR. One solution is the GameChanger Cable™ which can provide both data and power to many devices that are well beyond that 100-meter limit. Paige’s patented GameChanger cable, which is UL-verified, delivers 1Gb/s Ethernet and PoE+ up to 656 feet (200 meters) and 10Mb/s Ethernet and PoE+ up to 850 feet making it an ideal for cameras, WAPs and other edge devices. This cable eliminates intermediate IDF or telecom enclosure requirements and the need to install repeaters, power supplies and other equipment, which are costly and introduce additional points of failure in the network.
To meet increasing demands placed upon them, modern healthcare institutions must retool and rebuild. This includes looking at solutions that fit their environment. There is not a “one-size-fits-all” as each application’s requirement and the location of the device will generate opportunities for creative solutions, such as the GameChanger.
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