Scott VanDenBerg is Technical Sales Specialist with Optical Cable Corporation.
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SCOTT VANDENBERG
Optical Cable Corp.
Everyone has heard the saying: it&#;s the little things that make the biggest impact. This holds true especially when designing a data center. There are many important aspects to consider&#;from power and cooling requirements, to servers and hardware. Good cable pathway designers know that multiple products must work together to ensure a successful pathway from point A to point B. Let&#;s talk about a few of the key elements.
Pathways allow the placement of data center trunk cables and cross-connect cables between racks and cabinets. Both overhead and under floor pathways should be designed to support the weight of cables in the initial installation and it should also facilitate the addition of future cables. Planning for 90-degree bends, waterfall dropouts and other vertical support methods should be incorporated in the initial design and will allow routing of cable without damage. Pathway products come in a number of different styles:
A ladder rack is made of tubular steel and comes in sizes from 6&#; to 36&#; wide. The installation of a ladder rack is simple and requires little trade experience. Ladder rack come with many accessories such as 90-degree bends, waterfalls and cable retaining posts. These accessories allow the routing of cable without damage.
A cable tray is a ladder rack with sides and may be steel, aluminum or fiberglass. These sides allow for a greater amount of cable to be supported. The maximum loading depth recognized by the NEC is 6&#;. The cable tray is designed to support both electrical and data cables and is typically more robust than a ladder rack. It requires a pre-design effort because it is not flexible to work with in the field.
A basket tray is a cable tray designed for light duty applications. The basket tray is lightweight and easy to install; however a certain level of experience is needed to properly install. Many of the accessories that accompany ladder racks also accompany basket trays, to ensure proper bend radiuses are maintained a proper transition to the equipment rack.
An underfloor cable tray is a product used primarily in data centers. The concept is the same as the overhead support apparatus. However, when using under floor cable tray systems, the air space may be a plenum air space, so all cable and patch cables would need to be plenum for proper air flow.
In order to support existing infrastructure, and plan for future growth, there are a number of key considerations that should be made throughout the design process and installation. Some important things to keep in mind include:
Installation of overhead and underfloor supports should be done in a matrix type fashion that allows cables to be routed from point to point anywhere in the data center.
Grounding and bonding is very important when installing any cabling support product. Be sure that all racks, cabinets, and pathway support products are properly bonded and the system is grounded.
Allow room for future growth. All cable tray and ladder rack should be sized to accommodate at least 50% growth after the initial install.
Be very careful about stressing the cable. Be sure to use sweeping 90-degree bends always when transitioning from the pathway support and the racks or around corners.
Be sure the heaviest cable is on the bottom of the tray or separated from the lighter cables. This will prevent the heavier cable from stressing the lightweight cables.
Separate the copper cables from the fiber cables if possible.
Avoid mounting any cable components in locations that block access to other equipment inside and outside the racks.
Avoid routing pathways with copper cables near equipment that may generate high levels of electrometric interference. Avoid areas around power cords, florescent lights, building electrical cables and fire prevention components.
Care must be used in the engineering process when choosing Patch Cable and Pre-Terminated Fiber Cable lengths.
When utilizing Pre-Terminated cables, slack will always be a potential problem. If it is allowed it to build up it creates many problems such as, clogged up pathways, excessive weight overloading the supports, and reduced airflow./li
Now that we have considered everything we need to support our cabling above and below the equipment racks and cabinets, we need to consider our cabling pathways in and around the cabinet and or rack.
Horizontal wire managers allow the neat and proper routing of patch and equipment cords from the switch/server to a patch panel. Density is very important in data center cabinets and racks so keep in mind how many rack spaces are being utilized with horizontal wire managers. Horizontal wire managers are available in many sizes from 1U to 4U. 1U and 2U heights are the most prevalent. They also come in depths from 1.75&#; to 6&#; deep. Cable management can be accomplished in both the front and rear of the rack with double-sided organizers. Depending on how much you want to hide the cables, horizontal wire managers can also come with or without doors/covers. They come in metal and plastic.
A vertical wire manager provides a vertical pathway for cable within the rack or cabinet. It allows multiple horizontal wire managers to feed into a larger vertical pathway for the entire height of the rack. There can be as many as 20 horizontal wire managers feeding into one large vertical manager. Therefore, these vertical managers need to be large, with depth sizes from 4 to 10 inches deep and up to 10 inches wide. These managers can come with waterfalls and spools to help manage multiple cables and to help with maintaining proper bend radius on copper and fiber cables.
It&#;s important to make sure there is enough space to accommodate all the patch cords to avoid overfilling the wire managers. Overfilling wire managers will cause kinking in the patch cords make it very difficult for moves, adds or changes. You should allow a minimum 30 percent space in the wire manager for growth.
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Outside diameter is the key to reducing cable fill in your cable tray and your cable management. Let&#;s look at the options available.
Copper cables are more difficult due to their weight and large OD compared to fiber optic cables. Copper cables are typically used for inter and intra rack communications.
Fiber optic cables offer options to reduce cable fill and can provide much greater bandwidth than copper.
There are many types of fiber optic cables designed for data centers that will dramatically reduce cable fill in cable trays.
Pre-Terminated fiber optic cables are also prevalent in data centers. They are used for many reasons including quality, dependability, and reduced installation time. Cable slack is hard to accommodate in data centers no matter where it is located&#;cable trays, vertical or horizontal cable managers. Every effort should be made to get the lengths right before they are installed.
Cable management in the racks is as important as in the pathways. Waterfalls from the overhead cable supports into the vertical wire managers provide necessary strain relief. Spools that can be attached in the vertical wire manager help maintain bend radius for both copper and fiber cable. Also, Velcro cable supports are reusable and a safe way to secure the cable without damaging it.
There are many things that need to be considered when it comes to cables and pathways in a data center. One thing is for sure: data centers will continue to grow as technology continues to advance the way we live.
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Electrical cable trays are an essential component of modern infrastructure, providing a safe, efficient, and organized means of managing cables and wires in various settings. From industrial facilities and commercial buildings to residential complexes, cable trays play a crucial role in ensuring the smooth operation of electrical systems while maintaining safety standards. In this comprehensive guide, we will delve deeper into the key factors to consider when choosing and installing electrical cable trays, along with best practices, industry insights, and real-world examples.
Electrical cable trays come in several types and materials, each with its unique features and advantages. The most common types include:
Ladder cable trays: These trays have an open design resembling a ladder, allowing for easy cable access, ventilation, and quick installation. Ladder trays are suitable for most environments and can accommodate a wide range of cable sizes, making them versatile and cost-effective.
Solid bottom cable trays: With a solid base, these trays provide additional support and protection for cables, particularly in harsh environments or applications where cables may be subject to damage or require extra insulation. Solid bottom trays also offer better cable retention and organization compared to open designs.
Wire mesh cable trays: Wire mesh trays offer excellent ventilation, flexibility, and adaptability. Their open structure allows for easy cable additions, removals, and reconfigurations, making them ideal for environments with frequent changes in cable layouts or high-temperature conditions.
Steel: Steel cable trays are durable, cost-effective, and suitable for most environments. They can be galvanized, powder-coated, or painted for added corrosion resistance and aesthetic appeal. Steel trays are available in different grades, including mild steel, carbon steel, and stainless steel.
Aluminum: Lightweight and resistant to corrosion, aluminum cable trays are ideal for installations where weight is a concern or in corrosive environments such as chemical plants or marine applications. Aluminum trays also offer good thermal conductivity, which can help dissipate heat generated by cables.
Stainless steel: Stainless steel cable trays offer superior corrosion resistance and are commonly used in food processing, pharmaceutical, and marine industries due to their hygienic properties and ability to withstand harsh chemicals and cleaning agents.
PVC (Polyvinyl Chloride): PVC cable trays are non-conductive, lightweight, and resistant to chemicals, making them suitable for environments where electrical insulation is critical, such as hospitals, data centers, or clean rooms. PVC trays are also fire-retardant and have low smoke emission properties.
To ensure the proper functioning and safety of your cable tray system, it&#;s essential to choose trays with sufficient load capacity to accommodate the weight of your cables and any additional accessories. Factors that influence load capacity include:
Tray material: Different materials have varying strength-to-weight ratios, affecting their load-bearing capabilities. Steel and stainless steel trays generally have higher load capacities than aluminum or PVC trays.
Tray design: Ladder trays generally have higher load capacities than solid bottom or wire mesh trays due to their open structure and reduced material usage.
Cable fill percentage: Cable trays have maximum recommended fill percentages to prevent overcrowding and ensure proper airflow. Overfilling a tray can lead to reduced cable life, increased heat buildup, and potential safety hazards such as electrical shorts or fires. Follow NEC guidelines or manufacturer recommendations for appropriate fill percentages based on cable size and type.
To determine the appropriate tray size, consider the number and size of cables you need to install, as well as any future expansion plans. It&#;s also important to factor in the required bend radius for your cables to prevent damage during installation and ensure optimal cable performance.
When selecting and installing electrical cable trays, it&#;s crucial to adhere to relevant electrical codes and standards, such as the National Electric Code (NEC) in the United States or IEC standards internationally. Key considerations include:
Proper grounding and bonding: Ensure that your cable tray system is properly grounded and bonded according to NEC requirements to protect against electrical faults and reduce the risk of fire or equipment damage. Use appropriate grounding straps, jumpers, or bonding conductors to create a continuous and low-impedance path for fault currents.
Cable tray spacing and support: Follow NEC guidelines for minimum tray spacing and support intervals to maintain structural integrity and prevent sagging or collapse. Support brackets should be securely attached to building structures or independently installed supports, and the tray should be level and aligned throughout the installation.
Cable tray routing and accessibility: Plan your cable tray layout to avoid obstacles, maintain adequate clearance from combustible materials, and provide easy access for maintenance and inspections. Consider factors such as cable tray elevation, tray transitions, and tray penetrations through walls or floors.
Fire-rated cable trays: In certain environments or applications, fire-rated cable trays may be required to slow down the spread of flames and limit the release of toxic gases in case of a fire. Choose cable trays with appropriate fire-resistant coatings or materials, and follow local building codes and regulations for installation.
Proper installation techniques are vital for the longevity and safety of your electrical cable tray system. Some key best practices include:
Using appropriate mounting hardware: Choose the right type and size of screws, bolts, or other fasteners to securely attach cable trays to walls, ceilings, or supports. Ensure that the mounting hardware is compatible with the tray material and meets the required load-bearing specifications.
Ensuring proper alignment and leveling: Accurately position cable trays to maintain consistent elevation and minimize stress on cables and connections. Use laser levels or plumb bobs to check tray alignment and adjust supports as needed.
Protecting cables during installation: Use cable supports, ties, or saddles to secure cables within the tray and prevent damage or chafing. Follow manufacturer recommendations or industry best practices for cable separation, bundling, and strain relief.
Labeling and documenting the cable tray system: Clearly label cables and document the tray layout to facilitate troubleshooting, maintenance, and future upgrades. Use standardized labeling systems, such as the Electronic Industries Alliance (EIA) 568-B standard, to ensure consistency and clarity.
Minimizing electromagnetic interference (EMI): In sensitive environments or applications, consider using shielded cable trays or EMI-compliant cable management solutions to reduce the risk of signal interference or data corruption.
Accommodating cable growth and expansion: Plan your cable tray system to allow for easy addition, removal, or reconfiguration of cables as your facility or infrastructure evolves. Incorporate modular or adjustable tray components, and enough space for future cable runs.
Real-world example: In a large manufacturing facility, engineers designed a cable tray system that incorporated ladder trays for general-purpose wiring and solid bottom trays for high-voltage power cables. The team carefully calculated cable fill percentages, adhered to NEC guidelines for spacing and support, and used fire-rated cable trays in areas with increased fire risks. The installation process involved precise alignment, proper cable support, and clear labeling, resulting in a safe, organized, and easily maintainable cable management solution.
Regular maintenance and inspections are essential to ensure the continued performance and safety of your electrical cable tray system. Key maintenance tasks include:
Cleaning and debris removal: Periodically clean cable trays to remove dust, dirt, and other contaminants that can impede airflow, contribute to overheating, or cause premature cable degradation. Use appropriate cleaning methods and tools that do not damage the tray or cables.
Inspecting cables and connections: Check cables for signs of wear, damage, or corrosion, and verify that connections are secure and free from loose or frayed wires. Replace or repair damaged cables promptly to prevent system failures or safety hazards.
Assessing tray integrity: Examine cable trays for signs of rust, cracks, or other structural issues that could compromise their load-bearing capacity or safety. Repair or replace damaged trays as needed, and reinforce supports if necessary.
Updating documentation: Update cable tray layouts, cable labels, and inspection records as needed to reflect changes or additions to the system. Maintain accurate and up-to-date information to facilitate maintenance, repairs, and compliance audits.
Training and education: Provide training and education to facility personnel on proper cable tray installation, maintenance, and safety procedures. Ensure that workers understand the importance of adhering to codes, standards, and best practices to minimize risks and optimize system performance.
Real-world example: A data center implemented a rigorous cable tray maintenance program to ensure the reliability and security of their electrical infrastructure. The program included regular visual inspections, scheduled cleaning and debris removal, and periodic testing of grounding and bonding connections. The data center also provided ongoing training for technicians and updated documentation whenever changes were made to the cable tray system. As a result, the facility experienced fewer cable-related incidents, improved energy efficiency, and enhanced overall system performance.
By following these guidelines and best practices, you can confidently choose and install electrical cable trays that meet your specific needs, comply with industry standards, and promote a safe and efficient electrical infrastructure. Investing in high-quality cable trays, diligent maintenance, and ongoing education will ultimately help safeguard your facility, equipment, and personnel while optimizing your operational efficiency and reducing downtime. This ultimate guide serves as a comprehensive resource to guide you through the process of selecting and installing electrical cable trays, ensuring that your project is a success and your electrical systems operate smoothly and safely.
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