409-5566
Customer Manual
Layout and Planning for
AMP NETCONNECT*
LOC B
1
of 35
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
19 JUN 08 Rev G
Undercarpet Cabling System
1. INTRODUCTION
3....................................................
2. LAYOUT RESPONSIBILITY AND PREPARATION
4............................
3. POWER SYSTEM
6...................................................
3.1. Component Description 7...........................................
3.2. Layout Planning 14................................................
3.3. Installation Instructions 19...........................................
3.4. Material Take-Off Procedure 23.......................................
4. COMMUNICATIONS SYSTEM
25.........................................
4.1. Component Description 26..........................................
4.2. Layout Planning 29................................................
4.3. Installation Instructions 32...........................................
4.4. Material Take-Off Procedure 34.......................................
5. REVISION SUMMARY
34...............................................
Document Part Number 1518331-1
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PRODUCT INFORMATION
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
PRODUCT INFORMATION offers a means of providing product and technical assistance.
To obtain information on AMP NETCONNECT products, call PRODUCT INFORMATION or visit the
AMP NETCONNECT website at www.ampnetconnect.com.
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Floor Plan Layout
Installation
Open Office Design
1. INTRODUCTION
The undercarpet cabling system is an alternative to conventional round cable for the wiring of retail and gaming
environments and commercial and industrial offices. It is a method of distributing power and communications
cables virtually anywhere on the floor without the limitations of underfloor ducts, walls, and utility poles. The
flat, low–profile configuration allows the cabling system to be installed directly on top of the floor (wood,
ceramic, composition, or concrete) and then covered with carpet squares. This undercarpet cabling system
provides an open office, retail, or gaming environment design which is modern, attractive, and reliable, and
which permits easy accessibility as cabling requirements change.
The undercarpet cabling system concepts can be used by architects, electrical designers, consulting
engineers, and building contractors in laying out working drawings for branch circuit wiring in the construction
and renovation of commercial buildings. Before actually attempting a layout, it is recommended that the
designer become familiar with the product, either through training with a qualified representative or by
participation in an actual installation.
This manual includes floor preparation procedures, precautions and suggestions for proper layout techniques,
considerations for economizing in material and labor requirements, physical and functional descriptions of all
components in each system, techniques for preparing material take–off lists, and encapsulated installation
instructions.
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When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
Denotes an imminent hazard which may result in moderate or severe injury.
Denotes a condition which may result in product or equipment damage.
Highlights special or important information.
Dimensions in this manual are in metric units [with U.S. customary units in brackets].
2. LAYOUT RESPONSIBILITY AND PREPARATION
The information and procedures provided are intended to assist professional engineers, contractors, and
electrical design personnel in making accurate layouts, working drawings, and material lists of the undercarpet
cabling system. Tyco Electronics Corporation cannot assume responsibility for knowledge of local codes and
construction practices that may affect publications of this type. Any electrical working drawing or layout must
be reviewed and approved by a licensed professional electrical engineer in accordance with appropriate
federal, state, and local laws governing such practices.
Any layouts or drawings must conform to appropriate National Electrical Codes (NEC
R
) as well as any state,
city, county, or local building code requirements and to service code requirements of the local operating
telephone company. Tyco Electronics Corporation cannot be responsible for any misuse or misapplication of
the product, or for any code violations resulting from such.
Tyco Electronics Corporation reserves the right to make product revisions and improvements at any time which
may affect layout methods as stated herein. If any question exists, contact Tyco Electronics Corporation prior
to performing any layout work.
Layout guidelines and economizing considerations are presented in the respective cabling system sections that
follow. Note that the floor plan layout for the power system should be considered first, and then the
communications system.
Before any of the undercarpet cabling systems are actually installed, an accurate and scaled floor plan which
shows the cable runs and the location and orientation of all floor fittings should be made. This plan will serve
several purposes:
1. It will define the number, type, and lengths of cables and the number and types of floor fitting kits.
2. It will coordinate the power and communications layout systems to avoid interference.
3. It will provide working drawings for the actual installation.
4. It will provide a permanent record that can be referenced for maintenance or for future relocations.
Refer to Figure 1 for a typical floor plan layout.
Undercarpet cabling systems is approved for installation in commercial and industrial offices and retail
environments on concrete, ceramic, composition, or wood floors. The undercarpet cabling system may not be
used outdoors or in wet locations; where it would be subject to corrosive vapors; in any hazardous (classified)
location; or in residential, school, and hospital buildings.
NEC is a registered trademark of the National Fire Protection Association
DANGER
CAUTION
!
NOTE
i
NOTE
i
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Figure 1
Typical Floor Plan Layout
Legend
Single Duplex Fitting (Power)
Communications Fitting (Voice, Data)
Combination Fitting (Power, Voice, Data)
5-Conductor Power Cable
3-Conductor Power Cable
Tap
Twisted Pair Communications Cable
Flush Wall Box - Power
Flush Wall Frame - Communications
Surface Wall Box - Power
Floor Box - Power and Communications
Proper floor preparation and electrical contractor training are the keys to successful installation of any
undercarpet cabling system. The floor layout plans may be accurately drawn and scaled, but problems may
arise if the condition of the floor is inadequate or if proper installation training is not provided.
It is recommended that the following floor conditions be examined and corrected.
— Uneven floors with irregularities must be leveled or patched (feathered).
— Concrete slabs must have all holes filled and projections removed to ensure a smooth surface.
— Porous floors must be sealed and free from grease, oil, and moisture.
— Clean floor thoroughly. Sweep and vacuum to remove all debris. Maintain clean area throughout
installation.
In addition to the above floor conditions, slab-on-grade applications require an additional floor preparation prior to
installing the cable. Floor preparation is recommended for all installations. Refer to Paragraph 3.1 for a description of
the floor preparation.
Tyco Electronics Corporation does not warrant proper functioning of the systems if recommended cleaning instructions
are not followed.
It is recommended that Tyco Electronics Corporation become involved as early as possible with the
responsible engineering firm in providing input and guidance based on our experience with the layout and
installation of the many undercarpet cabling system sites. Early involvement does not stop when the layout is
completed. Resources are available to maintenance personnel for assistance in making future relocations and
additions. Information can be obtained by calling PRODUCT INFORMATION at the number at the bottom of
page 1.
NOTE
i
NOTE
i
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3. POWER SYSTEM
The undercarpet power system is a branch circuit wiring method per Rule 12–800 of the 2006 CEC and Article
324 of the 2008 NEC
R
. The cable is Listed by Underwriters Laboratories Inc. (UL) in File E73212. The
connector fittings and assembly components are Listed by UL in File E73213. The cable, connector fittings,
and assembly components are Certified by CSA International in File LR 7189.
The wiring system consists of a flat, flexible cable with separable conductor legs, a protective vinyl shield
bonded to both sides of the cable, and a grounded, protective, plated–steel top shield. Special cable tapping
and splicing connectors, along with insulators, are available to provide flexibility in wiring. The connectors are
terminated with a Tyco Electronics Corporation undercarpet hand crimping tool.
The transition from flat conductor cable to round wire is made using unique insulation–piercing transition blocks
that require only a screwdriver for termination. Fittings are provided for protecting the power source
connections to the circuit and for floor mounting of single and double duplex receptacles.
Refer to Figure 2 for a typical undercarpet power system.
Figure 2
Typical Undercarpet Power System
(3-Conductor Ref)
Round Wire Cable to Panel Board
or Selected Power Source
Wall Box (Flush or Surface
Mounted Transition Fitting)
Power Cable (Flat Conductor Cable, Type FCC)
Top Shield
Top Shield Splice
Cable
Bend
Hold-Down
Tape
Tap Connector
Insulator Splice
Connector
Cable Dead End
Top Shield
Dual Duplex
Direct Connecting
Receptacle
Slab-On-Grade
Floor Preparation
Floor Fitting
(Transition Fitting)
Direct Connecting
Receptacle
Top Shield
Bonding Clips
Round Wire Cable to
Panel Board or
Selected Power Source
NEC is a registered trademark of the National Fire Protection Association
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3.1. Component Description
A thorough understanding of what the components look like and how they work is necessary before planning
the layout of any undercarpet cabling system. The following physical and functional descriptions, illustrations,
and part numbers will aid in the identification and selection of components when they are referenced in the
layout planning and in the product ordering lists.
A. Cable
The flat conductor cable (Type FCC) is available in sizes corresponding to 10 AWG (30 A) or 12 AWG
(20 A) round wire. The number of conductors may be 3 or 5 depending on the load circuit to be serviced.
An isolated ground is available on 5–conductor cables to provide a means of supplying a separate ground
to sensitive equipment. This isolated ground circuit is channeled directly to the power source and prevents
surges and noise from entering the circuit from other equipment.
The flat copper conductors are placed side–by–side and then laminated with plastic strips to separate and
enclose the conductors for insulating purposes. The polyester material is flame–retardant, has excellent
dielectric properties, and resists moisture and object penetration. All conductors are marked (part number,
AWG size, etc.) and color coded (lettering and/or solid line) on the insulation for ease of identification and
to maintain proper polarity during installation. The insulation between adjacent conductors is perforated so
that the conductors may be separated without exposing bare copper conductors.
The tough vinyl shield is bonded to both sides of the cable. The shield cushions and protects the cable
from abrasion. See Figure 3.
For additional installation instruction, refer to 408–3154.
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
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B. Floor Preparation
(Required for Slab-On-Grade Application)
The floor preparation is a yellow–colored, polyvinyl material that is designed to protect the cable from floor
moisture, chemical reaction, and abrasion in slab–on–grade level applications. This shield is placed over
the circuit path on the concrete surface and the cable is centered on top of the floor preparation. See
Figure 4.
Figure 4
Floor Preparation 554123-1
(203.2-m [8-in.] by 76.2-m [250-ft] Roll)
0.25 mm
[.010 in.]
C. Top Shield
The top shield is made from a corrosion–resistant steel material. The shield is a fully–grounded
component covering the entire system and providing physical protection for the cable. It is electrically
connected to the ground to provide fault protection and minimize hazards. The penetration–resistant steel
is designed to protect the cable against hazards such as thumbtacks and chair legs. A spray adhesive and
tape are used to attach the top shield to the floor surface. See Figure 5.
The top shield bonding clip is a device that is used to electrically and mechanically connect the top shields
at taps, splices, and re–direction points. The copper alloy clip slips over the top shields.
PART NUMBER LENGTH (m [ft])
553536-1 76.2 [250]
553536-3 15.24 [50]
553536-4 30.48 [100]
Top Shield 553536-[ ]
168.15-mm [6.62-in.] Wide Roll
(3- or 5-Conductor, Size 10 or 12 AWG)
Hold-Down Tape 553481-1
50.8 mm [2.0 in.] by 54.86 m [180 ft] Roll
Top Shield Bonding Clip 553534-1
Qty: 50 Per Box
(2 Required at Each Tap, Splice, and Redirection Point)
0.25 mm
[.010 in.]
Figure 5
Spray Adhesive
6-553453-1
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D. Transition Fittings
(Wall/Floor Box, 3- or 5-Conductor)
Transition fittings are made from zinc–plated steel material shaped into a box–type configuration. The
transition fitting houses the transition block and is designed to provide protection in the area where the
round (supply) cable connects to the flat conductor cable. Various fittings are available for wall or floor
mounting with special covers for each fitting. See Figure 6.
Figure 6
Floor Duct Fitting
553286-1
Floor Duct Fitting Cover
553287-1 (Black)
553287-3 (Gray)
Flush Floor Service Box
555039-1
Flush Fitting Wall Box
554805-1 Surface Fitting Wall Box
553288-1
Surface Fitting Wall Box Cover
553289-1
Flush Fitting Wall Box Cover
553292-1
Partition Kit
555040-1
Blank Cover
Activation Kit
555038-1
Bridge Kit
555041-1
Not Shown
Flush Floor Service Box with Blank Cover
Activation Kit 9-1933131-9
Flush Floor Service Box with Single Gang
Activation Kit 1933131-1
Flush Floor Service Box with Dual Gang
Activation Kit 1933131-2
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E. Comprehensive Kits
The comprehensive kit provides everything that is needed to install or retrofit a single room with service for
power and communications (4 ports of any combination of voice or data and 2 duplex power receptacles).
See Figure 7.
PART NUMBER DESCRIPTION
1479050-1 Conference Room Kit (Category 5e)
1933466-1 Conference Room Kit (Category 6)
Figure 7
F. Power Transition Block
The transition block features a plastic block, copper–alloy terminals, a zinc–plated steel baseplate, and
screws. The block is designed to make the transition from round conductors to flat conductors at the
transition fitting and from flat conductors to round conductors at the floor fitting. See Figure 8.
A common screwdriver is used to terminate the flat conductors. When the silver pan–head screws are
tightened, the baseplate is drawn up, pulling the cable against the insulation–piercing contact points that
make the electrical connection. The color coded pan–head screws on the top of the terminals make
standard electrical connections to round conductors.
For additional installation instruction, refer to 408–3176.
Figure 8
Power Transition Block 554862-1
(3- and 5-Conductor, Sizes 10 and 12 AWG)
G. Direct Connecting Receptacle (DCR)
Each DCR kit includes a galvanized–steel mounting plate, a thermoplastic receptacle assembly, a plastic
cover, copper–alloy terminals, stainless steel bonding clips, and attaching hardware. The low–profile
receptacle is terminated directly to the flat cable. Tightening the screws allows the terminal tines to pierce
the cable insulation and engage the conductors. The spring–loaded receptacle covers are closed (to
protect the contacts) until a plug is inserted. See Figure 9.
The adapter housing assembly is required to complete termination for the 5–conductor DCR kit.
For additional installation instruction, refer to 408–3129.
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5-CONDUCTOR ADAPTER HOUSING ASSEMBLY
PART NUMBER DESCRIPTION
553908-1 Isolated GroundĊRed Phase Circuit
553909-1 Isolated GroundĊBlack Phase Circuit
553910-1 Standard GroundĊBlack Phase Circuit
554188-1 Standard GroundĊBlue Phase Circuit
554189-1 Standard GroundĊRed Phase Circuit
DCR KIT
NUMBER OF PART NUMBER
D
DESCRIPTION
CONDUCTORS 20 A 15 A (Canadian Version)
DESCRIPTION
553947-[ ] 554128-[ ] Single Duplex
3554192-[ ] 554321-[ ] Dual Duplex
554142-[ ] 554319-[ ] Combination (Duplex Receptacle and Blank)
5
554186-[ ] 554136-[ ] Single Duplex Ċ Standard Ground
5
558650-[ ] 554592-[ ] Single Duplex Ċ Isolated Ground
Figure 9
D
Dash Number Indicates Color: -1 is Black, -3 is Gray
Adapter Housing
Assembly
(Required for
5-Conductor
DCR Kit)
DCR Kit
Single Duplex
Adapter Bracket
Accommodates
12.7-mm [.50-in.]
Trade Size Conduit
and Fittings
Stainless Steel Bonding Clip
554178-1
(Qty: 50 per Box)
DCR Kit
Dual Duplex
DCR Kit
Combination
(Duplex Receptacle and Blank)
Power Whip Kit
554181-1 (Black)
554181-3 (Gray)
(3- and 5-Conductor)
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H. Tap and Splice Connectors
These connectors are made from a copper–alloy material with insulation–piercing lances. With the use of
the hand crimping tool, they are designed to electrically connect two flat conductor cables. Five–conductor
to three–conductor taps allow more efficient cable runs with a minimum of power transition fittings. Splice
connectors allow electrical connections between the end of one roll of cable and the beginning of another
roll of cable, and also permits the extension of existing cable runs. See Figure 10.
For additional installation instruction, refer to 408–3128.
Figure 10
Tap 553455-2
(Sizes 10 and 12 AWG)
Splice 553454-1
(Sizes 10 and 12 AWG)
Undercarpet PRO-CRIMPER* III
Hand Tool Assembly 91384-1
I. Insulator Kit
This kit includes two identical insulator assemblies which are required whenever the cable is spliced,
tapped, dead–ended, or has had a fitting removed. Each insulator assembly has vinyl on one side and
adhesive–faced foam (covered by paper backing) on the other side. The two assemblies are placed
together around the cable to form the insulator. The insulator is designed to protect and insulate the tap
and splice connectors and protect exposed conductor ends or areas. See Figure 11.
For additional installation instruction, refer to 408–3218.
Figure 11
Insulator Kit 556411-1
(Includes 2 Insulator Assemblies)
J. Floor Fitting Patch Kit
Floor Fitting Patch Kit 1479151–1 is required for taps, splices, cable ending, cable repair, and DCR
abandonment. The kit consists of a pair of adhesive cable insulator assemblies, a length of top shield, a
roll of hold–down tape, and four bonding clips.
For installation installation instruction, refer to 408–8635.
*Trademark
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3.2. Layout Planning
The undercarpet power cabling system flat conductors have the same current–carrying capacity ratings as
conventional round wire conductors of the same size (AWG) designation. Use the appropriate articles in the
NEC
R
for round wire applications as a guideline for making voltage drop calculations for the flat conductor
cable applications. Include all round cable as well as flat cable applications in a system when making
calculations. Appropriate articles are as follow:
— For number of outlets required, the total load, and the location of electrical outlets, NEC Article 210 applies.
— For number of branch circuits required, NEC Article 220–3 applies.
— For specifics on flat conductor cable, NEC Article 324 applies.
Refer to Paragraph 3.1 for description of components referenced in these layout procedures.
The following considerations should be kept in mind when planning the floor layout:
1. Maximum cable run is calculated using a cable resistance of 1.64 ohms per 305 m [1,000 ft] for size
12 AWG and 1.02 ohms per 305 m [1,000 ft] for size 10 AWG.
2. Conduit and round wire are used as distribution circuits through columns and interior walls, or even to
floor duct fittings. Then, flat cable is used for actual service to the work area.
3. Circuits should be loaded with outlet quantities that are less than the design capacity, thereby allowing
for reserve capacity for future planning.
4. Five–conductor cable can be used as a main run with outlets tapped as required, permitting additional
circuits to be run from each transition box.
5. Cable taps, although designed to be fast and economical, still involve additional material and labor.
Therefore, when laying the power system, minimize taps by making additional bends with the cable.
6. Planning communication outlet locations can minimize bends and manipulation of the power layout.
Use of a combination fitting can economize both systems on a floor plan. This planning will assure
proper cable approach to a combination fitting.
7. Refer to Figure 12 for unique cable routing recommendations and dimensions.
Figure 12 (Cont’d)
90
_
Turns are made at any angle up to 90
_
.
(It is recommended that all turns be 90
_
).
Floor
Baseboard Height
Allow Space
for Cover
Flush Wall Box
(Transition Fitting)
Recommended distance from floor for mounting a surface
or flush wall box is approximately baseboard height.
203.2 mm [8 in.]
Minimum distance from a cable bend (90
_
) to another
cable bend is 203.2 mm [8 in.] (centerline to centerline). Taps must be made at 90
_
to the main cable run.
Unique Cable Routing Recommendations and Dimensions
NEC is a registered trademark of the National Fire Protection Association
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Figure 12 (End)
Exit at transition fitting shall NOT be
at angle other than 90
_
.Cable shall extend a minimum of 0.3 m [1 ft]
beyond wall before angle.
0.3 m [1 ft]
Column Column
Cables shall NOT curve around obstacles. 90
_
bends will allow cable to avoid obstacles.
Cables shall NOT run on top of another cable. Cables should extend past another cable.
0.3 m [1 ft]
Two taps require a minimum of 0.3 m [1 ft]
between junction points. Cables shall NOT cross at
floor fitting. A tap and a 90
_
bend offer
a similar layout.
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The layout of an undercarpet power system begins with a review of the floor layout plans with the location of
the walls, desks, partitions, and fixtures indicated. The following must be determined and then checked for
compliance with the requirements of the federal, state, and local electrical codes.
1. Determine which outlets are to be grouped into a branch circuit and the total number of branch
circuits required. On the floor layout plan, note the location and number of 120–Volt outlets which are to
be part of the 20–Ampere branch circuits. Note the outlets and circuits that are different from the
120–Volt, 20–Ampere branch circuits. Identify the circuits that require size 12 or 10 AWG conductors for
20–Ampere or 30–Ampere capacity. See Figure 13.
Figure 13
Circuit 4
3-Conductor
Size 12 AWG, 20 A
Circuit 3
3-Conductor
Size 12 AWG, 20 A
Circuit 2
3-Conductor
Size 12 AWG, 20 A
Circuit 1
3-Conductor
Size 12 AWG, 20 A
Outlets Grouped into Branch Circuits
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2. Determine the location of the transition fittings and the routing of the cable. Transition fittings should
be located near each group of branch circuits and may be installed in walls, columns, or floors. Round
wire in conduit should be fed to each transition fitting from the distribution panel. Flat conductor cable
may run anywhere under the carpet squares; down a corridor or aisle; under
temporary
partitions; and
under chairs, desks, and cabinets. The cable may run parallel or diagonally with the carpet–square
sides. See Figure 14.
Figure 14 (Cont’d)
Transition Fittings and Cable Routing (4-Branch Circuits Using 3-Conductor Cable)
Surface Wall Box
Round Wire Feed from Circuit Breaker Panel
Floor Box
Flush Wall Box
Flush Wall Box
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A 5-conductor cable can be used as a main run with three separate circuits (having identical outlet voltages) tapped
into it.
Figure 14 (End)
Transition Fittings and Cable Routing (5-Conductor Main Run)
Circuit 2
3-Conductor Cable
Tapped to Blue
Conductor
5-Conductor Cable
(Main Run)
Three Circuits from
Circuit Breaker Panel
Circuit 3
3-Conductor Cable
Tapped to Red
Conductor
Circuit 1
3-Conductor Cable
Tapped to Black
Conductor
NOTE
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3.3. Installation Instructions
This encapsulated installation procedure serves as an aid in identifying system components, indicating where
they are used, and showing how they are installed. The outline of the sequence of installation may be helpful
for layout planning. Refer to Figure 15. For specific instructions, refer to the instruction sheets packaged with
the components.
Figure 15 (Cont’d)
1Locate and mount power supply transition fittings on walls and floor.
Surface Wall Mount
Flush Floor Mount
Flush Wall Mount
101.6 mm
[4 in.] Min
Lay out circuit centerlines on floor with chalk line.
Chalk Line
Using mounting plates as patterns, mark screw hole locations.
2 3
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Figure 15 (Cont’d)
Drill holes and install outlet anchors.
Chalk Line
Patching
Compound
Scrape, patch, clean, and vacuum floor on cable path.
Clean entire floor.
Step 1 Remove screws
Step 2 Loosen remaining screws
Step 3 Install cable
Step 4 Tap screws through cable
Step 5 Tighten screws
Connect cable to transition blocks at power supply transition fittings.
Edge Tape
Cable
Lay cable.
Direction
of Run
Establish direction for 0.91 m [3 ft] or 1.22 m [4 ft] then
crease. Fold cable at corners. Tape as required.
Cable
4 5
7
8 9
Lay floor preparation (for slab-on-grade installation).
6
Floor
Preparation Fitting
Location
Circuit
Chalk Line
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Figure 15 (Cont’d)
10a
Cable Tap
Install cable to tap at branch circuits.
Connect cables with tap or splice connectors as required. Seal splices and taps with insulator kit.
Note:
See 408-3128 for recommended method to
interface with another existing cabling system.
Mount floor fitting base plate.
Note:
Perform a continuity check
before
installing
the top shield.
Top Shield
Floor Fitting
Base Plate
Trim
Stainless Steel Top
Shield Bonding Clips
Trim and connect top shield at floor fittings. Use top
shield bonding clips to join top shield at splices, taps,
and corners.
Tape
11
13
12
14
Cable Ends Trimmed with
3.18-mm [1/8-in.] Gap
Install cable to splice as required.
Splice Wire Sizes
10 and 12 AWG
10b
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Figure 15 (End)
15
Tape
Top Shield
Primer Width
Spray primer along edge of top shield and on floor.
Apply tape to both edges of top shield. Assemble skirt to fitting.
Install carpet squares.
16
17
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Tyco Electronics Corporation
3.4. Material Take-Off Procedure
The following procedure will aid in calculating the materials needed for the undercarpet power cabling system.
After the floor layout plans have been completed, number each branch circuit, and proceed as follows:
1. Refer to Figure 16 for the components needed for each fitting type, connector, and cable. Each
component must be ordered separately.
Refer to Paragraph 3.1 for physical and functional description of components.
REQUIRED MATERIAL LIST
FITTING TYPE CONNECTOR CABLE
Transition Floor Tap Splice Bend Dead End
1 Base
1 Cover
1 Transition Block
1 DCR Kit
0(3-Conductor or
05-Conductor)
1 Adapter Block
0(5-Conductor)
1 Tap Connector
0for Each Conductor
1 Insulator Kit
2 Top Shield
0Bonding Clips
1 Splice Connector
0for Each Conductor
1 Insulator Kit
2 Top Shield
0Bonding Clips
2 Top Shield
0Bonding Clips (Outside of
Transition Block)
1 Insulator Kit
Figure 16
2. Start at the power supply transition fittings, and survey each circuit for the components needed. List
the quantity of each component under the specific circuit number. Use the floor plan layout scale to get
the approximate cable footage.
3. Reading across the list, combine the totals of each component in each circuit, and list the total
quantity in the last column.
4. Calculate the necessary scrap factor on items such as cable, top shield, tape, and spray adhesive.
Also provide for final variations that may occur on site.
Suggested guidelines are:
— Equal amounts of cable and top shield should be ordered.
— For each roll of cable, order a set of cable splices.
— For every 0.3 m [1 ft] of cable, order 0.8 m [2.5 ft] of hold–down tape.
— For every 3 rolls of hold–down tape, order 1 can of spray adhesive.
5. Adjust final figures wherever possible to accommodate standard packaging of the product (available
from the distributor).
NOTE
i
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
*9
G24
3+ "<(3 0*(7532.(6 35435&7.32
POWER SYSTEM MATERIAL TAKE-OFF LIST
CATEGORY
DESCRIPTION
PART NUMBER
CIRCUIT NUMBER
TOTAL QTY
CATEGORY
DESCRIPTION
PART NUMBER
1 2 3 4
TOTAL QTY
Cable
32)8(7356 # > 0&(/ $ %
Y
32)8(7356 # > 0&(/ $ %
Y
32)8(7356 # $ %
Y
32)8(7356 # $ %
Y
32)8(7356 # $ %
Y
Transition Fittings
086- .77.2, #&00 3;
086- .77.2, #&00 3; 39*5
!85+&(* .77.2, #&00 3;
!85+&(* .77.2, #&00 3; 39*5
086- 0335 !*59.(* 3;
086- 0335 !*59.(* 3; 0&2/ 39*5 (7.9&7.32 .7
086- 0335 !*59.(* 3; &57.7.32 .7
086- 0335 !*59.(* 3; 5.),* .7
0335 8(7 .77.2,
0335 .77.2, 39*5 $ %
D
086- 0335 !*59.(* 3; :.7- 0&2/ 39*5 (7.9&7.32 .7
086- 0335 !*59.(* 3; :.7- !.2,0* &2, (7.9&7.32 .7
086- 0335 !*59.(* 3; :.7- 8&0 &2, (7.9&7.32 .7
Comprehensive Kits
32+*5*2(* 331 .7 &7*,35< *
32+*5*2(* 331 .7 &7*,35<
Transition Block
"5&26.7.32 03(/
Floor Fittings
.7 32)8(735 !.2,0* 840*; $ %
D
.7 32)8(735 !.2,0* 840*; $ %
D
.7 32)8(735 8&0 840*; $ %
D
.7 32)8(735 8&0 840*; $ %
D
.7 32)8(735 31'.2&7.32 $ %
D
.7 32)8(735 31'.2&7.32 $ %
D
.7 32)8(735 !.2,0* 840*; $ %
D
.7 32)8(735 !.2,0* 840*; $ %
D
.7 32)8(735 !.2,0* 840*; $ %
D
.7 32)8(735 !.2,0* 840*; $ %
D
)&47*5 386.2, 66*1'0< 32)8(735 > *) .5(8.7
)&47*5 386.2, 66*1'0< 32)8(735 > 0&(/ .5(8.7
)&47*5 386.2, 66*1'0< 32)8(735 ! > 0&(/ .5(8.7
)&47*5 386.2, 66*1'0< ! > 08* .5(8.7
)&47*5 386.2, 66*1'0< ! > *) .5(8.7
3:*5 #-.4 .7 $ %
D
Accessories
"34 !-.*0) # $ %
Y
"34 !-.*0) 32).2, 0.4 4*5 3;
!7&.20*66 !7**0 32).2, 0.4 4*5 3;
"&4 322*(735 #
!40.(* 322*(735 #
2680&735 .7 #
0335 5*4&5&7.32 1 $+7% 300
30)3:2 "&4* 1 $+7% 300
!45&< )-*6.9*
&2) "330 66*1'0<
0335 .77.2, &7(- .7
D
&6- 81'*5 2).(&7*6 3035 .6 0&(/ .6 5&<
Y
&6- 81'*5 2).(&7*6 &'0* 35 !-.*0) 4*5 300 *2,7- .6 1 $ +7% .6 1 $ +7% .6 1 $ +7%
630&7*) 5382)
!7&2)&5) 5382) !
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G 25
of 35
Tyco Electronics Corporation
4. COMMUNICATIONS SYSTEM
The undercarpet communications system is designed for interconnection of voice and data devices to a
telecom closet by way of undercarpet cabling. This wiring layout provides flexibility in open office environments
and eliminates access problems associated with underfloor ducts and poles. The wiring system consists of
three types of components:
1. Transition fittings are used in walls, floors, or columns to house connectors that make the transition
from round cable to flat conductor cable.
2. The 4–pair undercarpet cable is supplied in 76.2–m [250–ft] reel lengths available for field termination.
3. Floor fittings house connections that make the transition from flat conductor cable to round cable and
interconnect with communications devices.
See Figure 17 for a typical undercarpet communications system.
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Typical Undercarpet Communications System
Combination DCR Kit
(Power and Data/Communications Outlets)
Multimedia Floor Fitting Kit
(Data/Communications Outlets)
2-Port Low-Profile Floor Fitting Kit
(Data/Communications Outlets)
Figure 17
Flush Wall Box
(Transition Fitting)
4-Pair UTP Data Cable
Type CMUC (UL Listed Undercarpet Communications Wire and Cable)
Type CMH (Complies with CSA FT-1 Flame Test)
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G26
of 35 Tyco Electronics Corporation
4.1. Component Description
A thorough understanding of what the components look like and how they work is necessary before planning
the layout of any undercarpet cabling system. The following physical and functional descriptions, illustrations,
and part numbers will aid in the identification and selection of components when they are referenced in the
layout planning and in the product ordering lists.
A. Cable
Four–pair, unshielded, twisted pair undercarpet communications cables are available in Category 5e and
Category 6 performance levels. The cable features ramped side wings which eliminate the need for top
and bottom taping. The cables meet all Telecommunications Industry Association (TIA) transmission for
system testing requirements and may be designed in with no special consideration. See Figure 18.
Figure 18
Communications Cable
1499119-1 (Category 5e, 76.2 m [250 ft])
1499539-1 (Category 6, 76.2 m [250 ft])
20.32 mm
[.80 in.]
Internal Dia
Spray Adhesive
6-553453-1
Hold-Down Tape 553481-1
(50.8-mm [2.0-in.] by 54.8-m [180-ft] Roll)
Undercarpet Cable Notcher Tool
1725698-1
B. Comprehensive Kits
The comprehensive kit provides everything that is needed to install or retrofit a single room with service for
power and communications (4 ports of any combination of voice or data and 2 duplex power receptacles).
See Figure 19.
PART NUMBER DESCRIPTION
1479050-1 Conference Room Kit (Category 5e)
1933466-1 Conference Room Kit (Category 6)
Figure 19
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G 27
of 35
Tyco Electronics Corporation
C. Transition Fittings
(Wall/Floor Box)
Transition fittings are made from zinc–plated steel. The transition fitting houses and protects the mating
connectors in the area where ground (supply) cable connects to the undercarpet cable. The floor service
box functions as a distribution point for power and communication cabling systems. See Figure 20.
Figure 20
Flush Fitting Wall Frame
553739-2
Flush Fitting Wall Frame Cover
553095-1
Not Shown
Flush Floor Service Box with Blank Cover
Activation Kit 9-1933131-9
Flush Floor Service Box with Single Gang
Activation Kit 1933131-1
Flush Floor Service Box with Dual Gang
Activation Kit 1933131-2
Flush Floor Service Box
555039-1
Partition Kit
555040-1
Blank Cover
Activation Kit
555038-1
Bridge Kit
555041-1
Flush Fitting Wall Box
554805-1
Flush Fitting Wall Box Cover
553292-1
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G28
of 35 Tyco Electronics Corporation
D. Communications Floor Fitting Kits
Floor fitting kits include a galvanized steel mounting plate and a plastic cover. The 2–port and direct
connecting receptacle (DCR) combination fittings can each house two 4–pair mated cables, and two
surface jacks or two Category 5 or Category 6 110Connect modular jacks. The 4–port fitting can
accommodate twice as many cables and jacks as the 2–port fitting. See Figure 21.
The low–profile multimedia floor fitting kit can accommodate up to four modular jacks. This kit also has
four knockouts in the cover which will accept the communications outlet single–port installation kits.
Low-Profile Floor Fitting Kit (2-Port)
554206-[ ]
(Cover Color: -1 Black, -3 Gray)
Low-Profile Floor Fitting Kit (4-Port)
555287-[ ]
(Cover Color: -1 Black, -3 Gray)
Low-Profile Multimedia Floor Fitting Kit
1479542-1
(Cover Color: Black)
Combination Direct-Connecting Receptacle (DCR) Kit
554142-[ ]
(Cover Color: -1 Black, -3 Gray)
Accepts Super Graphic
Video Array (SVGA)
Connector
Ċ Voice
Ċ Data
Ċ Video
Figure 21
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G 29
of 35
Tyco Electronics Corporation
E. Transition Blocks
Transition blocks are designed to make the transition from round conductors to flat conductors. The blocks
are intended for use with wall boxes and the floor service box. The transition block kit for Category 6 is
backwardly compatible. See Figure 22.
Figure 22
Transition Block Kit (Category 5e)
1479384-1 Transition Block Kit (Category 6)
1479985-1
F. Modular Jack Data Kits
The Category 5e and Category 6 modular jack kits are intended for use with the communications floor
fittings. Refer to Figure 23.
Refer to Paragraph 4.4 (Material Take–Off Form) for additional modular jacks and inserts.
Not Shown
Standard Impact Tool 1583608-1
Modular Plug Hand Tool 1-231666-0
SL Series Modular Jack Termination Tool 1725150-1
110Connect Modular Jack Kit SL Series Module Jack Kit
PART NUMBER DESCRIPTION
0558054-1 110Connect Modular Jack Kit, Category 5e (T568A/B Wiring Pattern and Bracket)
0569996-1 Bracket Only
1933377-1 SL Series Modular Jack Kit, Category 6 (T568A/B Wiring Pattern and Bracket)
Figure 23
4.2. Layout Planning
The undercarpet communications cabling system conductors have similar electrical properties as conventional
round–wire communications cable. Consult the local installer for information involving building code
requirements and service codes to be used with the planned systems within your particular building.
Refer to Paragraph 4.1 for description of components referenced in these layout procedures.
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G30
of 35 Tyco Electronics Corporation
The following considerations should be kept in mind when planning the floor layout:
1. Consult the local building codes for information concerning code requirements.
2. The communications system, typically, is installed after the power system and may cross the top
shield, but should not run on top of the shield for any distance. The cross should not occur at a tap,
splice, or cable bend.
3. The preferred method for communications and power system layout is the “fingers” approach, where
a given area is fed in one direction with power circuits and is fed in the other direction by
communications circuits. Refer to Figure 24.
4. Select access points for the transition fittings that allow minimum cable runs to all floor fittings.
5. Leave extra station capacity at most transition fittings to allow for future expansion.
Figure 24
Finger" Layout Method
Power Circuits
Communications Circuits
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
Communications cable shall NOT
run on top of power cable. Communications cable may cross power cable but NOT
at a tap, splice, or cable bend.
When using combination fittings, the communications
cable shall NOT feed through to the next floor fitting. The power cable may feed through, but all communications
cable shall home run" to the transition fitting.
Column
Column
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
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Tyco Electronics Corporation
Unique cable–routing recommendations and dimensions are as follows (refer to Figure 25):
The layout of an undercarpet communications system begins with a review of the floor layout plans with the
location of the walls, desks, partitions, and power cable layouts indicated. The interconnect needs of the
communications equipment at each work station must be determined.
After determining the work station requirements, begin the layout by locating the access points (walls, columns,
or floor) for the transition fittings. The transition fittings will be receiving round cables from the equipment
closet. Allow for service accessibility, future expansion, and relocation needs by planning enough access points
and size of transition fittings. In some geographical areas, cable runs may be restricted to a maximum length,
so allow for minimum cable runs to all floor fittings.
The interface (if any) already located at the access point should be identified. The access point interface
partially determines the type of cable for each run, but a check should be made to determine if extra cable
pairs are needed for any other auxiliary devices at the work station.
The cable length is the distance between the transition fitting and the applicable floor fitting. This length may be
influenced by interior wall locations and anticipated furniture placement. One factor that may affect cable length
is the cable routing method. The runs may be made in “radial” fashion directly to the floor fitting from the
transition fitting, or the cable may be laid out in right–angle bends to follow the carpet–square pattern. The
length of the cable run should be marked on the print.
The appropriate floor fitting is selected according to the communications equipment requirements at the work
station. The floor fittings may be secured to the floor with screws or foam tape.
Figure 25
Transition Fittings and Cable Routing
Single Duplex
DCR
Floor Box
(Power and
Data/Communications)
Power Cable
Combination
DCR
Flush Wall Box
(Power)
Flush Wall Frame
(Data/Communications)
Data Cable Voice Cable
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G32
of 35 Tyco Electronics Corporation
4.3. Installation Instructions
This encapsulated installation procedure serves as an aid in identifying system components, indicating where
they are used, and showing how they are installed. This outline of the sequence of installation may be helpful
for layout planning. Refer to Figure 26. For specific instruction, refer to the instruction sheet packaged with the
components.
Figure 26 (Cont’d)
Patching
Compound
Scrape, patch, clean, and vacuum floor on cable path.
Clean entire floor.
Flush Fitting
Wall Frame
Floor Service Box
Locate and mount transition fittings.
Use mounting plates as patterns, mark screw hole
locations.
Note:
Floor fitting may be attached to floor by adhesive-
backed foam tape or by screws into outlet anchors. If outlet
anchors are used, drill holes and thoroughly clean floor.
The twisted-pair cable does not require a top or
bottom shield. Cross-tape as required along the cable
run, placing the cable bow pointed up while stretching
to remove any slack.
1
2
4
101.6 mm
[4 in.] Min
Lay out circuit centerlines on floor with chalk line.
Chalk Line
3
5
Chalk Line
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
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Tyco Electronics Corporation
Figure 26 (End)
3 or More Runs
Hold-Down Tape
553481-1 Each Run
152.4 mm
[6.00 in.]
(Typ)
7.87 mm
[.312 in.]
(Typ)
Hold-Down Tape
553481-1
406.4 mm
[16.00 in.]
Min
254 mm [10.0 in.]
Min Radius
Mate cable connectors and fasten cable at floor fitting.
Flex the cable wings while removing cable from the reel.
Start laying the cable from the distribution point (wall box
or floor fitting). Where more than two cable runs must exit
the distribution point, remove the inner wings" and place
the cables side by side. Then place tape over the area.
To Remove Wings, Cut to Groove, Flex, and
Tear Wing Back Slowly By Hand
Directional changes are made by notching the wings
and bending the cable to form a gradual turn.
Cable Notcher Tool
1725698-1
6 7
8
Cable Notcher Tool
1725698-1
9Mount floor fittings, and install carpet squares.
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G34
of 35 Tyco Electronics Corporation
4.4. Material Take-Off Procedure
The following procedure will aid in calculating the materials needed for the undercarpet communications
cabling system. After the floor layout plans have been completed, assign identification numbers or letters to the
transition fittings and assign numbers to each cable run exiting from each transition fitting. Proceed as follows:
Refer to Paragraph 4.1 for physical and functional description of components.
1. Start at the transition fittings and survey each circuit for the components needed. List the cable type,
terminations, cable length, and floor fitting type under the specific circuit number. Use the floor plan
layout scale to get the approximate cable footage.
All floor fittings include a base and a cover. Hardware (jacks, modular jack coupler, etc.) must be ordered separately.
2. Reading across the list, combine the totals of each component in each circuit, and list the total
quantity in the last column.
3. Calculate the necessary scrap factor on items such as tape and spray adhesive. Also provide for final
variations that may occur on site.
4. Adjust final figures wherever possible to accommodate standard packaging of the product (available
from the distributor). Check part numbers of items, such as, transition fittings and floor fittings, with
identical items on the Power System Material Take–Off List. Combine such items for the final figure.
5. REVISION SUMMARY
Revisions to this customer manual include:
S
Updated customer manual to corporate requirements
S
Replaced page 2
S
Modified first paragraph of Sections 1 and 3
S
Added “type” to FCC in Figure 2 and Paragraph 3.1A
S
Removed cable part numbers for use in China
S
Changed part number for spray adhesive
S
Modified name of components and illustration of blank cover activation kit in Figures 6 and new 20
S
Added Paragraphs 3.1E and 4.1B and Figures 7 and 19
S
Added reference to instruction sheet to Paragraph 3.1A, and new F, G, H, I, and J
S
Removed indication of break off tabs from Figure 7
S
Added “5–conductor” to adapter housing assembly in Figure 8
S
Changed name of hand tool in new Figure 10
S
Added “3–conductor” to 4–branch circuit view of new Figure 14
S
Added bubble 6 and 10b and modified new bubble 11 of new Figure 15
S
Modified Power Systems Material Take–Off List to reflect changes made in Section 3
S
Modified new Figure 17
S
Added illustration of notcher tool to new Figure 18
S
Added text to Paragraph 4.1E and removed “universal category” from new Figure 22
S
Modified Paragraph 4.1F and name of components in new Figure 23, replaced modular jack kit, and
added illustration of new modular jack kit
S
Added detail to name of components in new Figure 25
S
Replaced scissors with notcher tool in bubble 6 of new Figure 26
S
Modified Communications System Material Take–Off List to reflect changes made in Section 4; in
addition, removed and added modular jacks
NOTE
i
NOTE
i
409-5566
Layout and Planning for AMP NETCONNECT Undercarpet Cabling System
Rev
G 35
of 35
Tyco Electronics Corporation
COMMUNICATIONS SYSTEM MATERIAL TAKE-OFF LIST
CATEGORY DESCRIPTION PART NUMBER TOTAL QTY
Cable
4-Pair, Unshielded Twisted Pair, Category 5e 1499119-1
4-Pair, Unshielded Twisted Pair, Category 6 1499539-1
Transition
Fitti
Flush Fitting Wall Box 0554805-1
Fi
tt
i
ngs
Flush Fitting Wall Box Cover 0553292-1
Flush Fitting Wall Frame (PC Board Mounting) 0553739-2
Flush Fitting Wall Frame Cover 0553095-1
Flush Floor Service Box 0555039-1
Flush Floor Service Box, Blank Cover Activation Kit 0555038-1
Flush Floor Service Box, Partition Kit 0555040-1
Flush Floor Service Box, Bridge Kit 0555041-1
Flush Floor Service Box with Blank Cover Activation Kit 9-1933131-9
Flush Floor Service Box with Single Gang Activation Kit 1933131-1
Flush Floor Service Box with Dual Gang Activation Kit 1933131-2
Comprehensive Kits
Conference Room Kit (Category 5e) 01479050-1
Conference Room Kit (Category 6) 01933466-1
Floor Fittings
Low-Profile Floor Fitting Kit (2-Port) 0-0554206-[ ]
D
Low-Profile Floor Fitting Kit (4-Port) 0-0555287-[ ]
D
Low-Profile Multimedia Floor Fitting Kit 0-1479542-1
DCR Kit (3-Conductor, Combination, 20 A) 0-0554142-[ ]
D
Transition Blocks
Transition Block Kit (6 In/6 Out) Category 5e 1479384-1
Universal Category Transition Block Kit, Category 6 1479985-1
Modular Jacks
dA i
110Connect Modular Jack Kit, With Bracket, 4-Pair T568A/B, Category 5e 0558054-1
an
dA
ccessor
i
es
Modular Jack Bracket Only 0569996-1
SL Series 8-Position Modular Jack, With Dust Cover, Category 5e 0-1375190-[ ]
DD
SL Series 8-Position Modular Jack, Category 5e 1375191-[ ]
DD
SL Series Tool-less, 8-Position Modular Jack With Dust Cover, Category 5e 1339189-[ ]
DD
SL Series Tool-less, 8-Position Modular Jack, Category 5e 1116604-[ ]
DD
SL Series Blank Multimedia Insert 1116412-[ ]
DDD
SL Series Modular Jack Kit, With Bracket, 4-Pair T568A/B, Category 6 1933377-1
SL Series Multimedia Jack, Red Dielectric 1479230-[ ]
DDD
SL Series Multimedia Jack, White Dielectric 1479231-[ ]
DDD
SL Series Multimedia Jack, Yellow Dielectric 1479232-[ ]
DDD
SL Series S-Video Multimedia Jack 1375149-[ ]
DDD
SVGA, 110Connect Modular Jack 1479287-2
SVGA, Screw Terminal 1933424-2
Modular Plug Hand Tool 01-231666-0
SL Series Modular Jack Termination Tool 1725150-1
Standard Impact Tool 1583608-1
Accessories
Hold-Down Tape (54.86-m [180-ft] Roll) 0553481-1
Spray Adhesive 06-553453-1
Undercarpet Communication Cable Notcher Tool 1725698-1
DDD
Dash Number Indicates Color: -1 is Black, -3 is Gray
DDD
Dash Number Indicates Color: -1 is Almond, -2 is Black, -3 is White, -4 is Gray, -5 is Orange, -6 is Blue, -7 is Red, -8 is Yellow, -9 is Green,
DDD
Dash Number Indicates Color: 1- -1 is Electrical Ivory
DDD
Dash Number Indicates Color: -1 is Almond, -2 is Black, -3 is White, -4 is Gray, 1- -1 is Electrical Ivory
