Flexcom Training Manual

Mine Radio Systems Inc.
Flexcom Training Manual

117 Ringwood Dr, Unit 5
Stouffville, Ontario
L4A 8C1
905-640-1839
3030 Hyw 69 North

Val Caron, Ontario
705-897-2440
Flexcom Operations Manual

117 Ringwood Dr, Unit 5
L4A 8C1
905-640-1839
TABLE OF CONTENTS
Flexcom Operations Manual

Section 1
1.0 INTRODUCTION
1.0 Introduction 1.0.1
1.1 Voice operation 1.1.1
1.2 Data operation 1.2.1
1.3 Video operation 1.3.1
1.4 Diagnostic operation 1.4.1
2.0 SYSTEM CONFIGURATION

2.0 System components 2.0.1
2.1 FHE/FCL4 Flexcom Head-End 2.1.1
2.2 FLFC Flexcom Leaky Feeder Cable
2.2.1
2.3 FLA Flexcom Line Amplifier 2.3.1
2.4 FLT Flexcom Line Termination 2.4.1
2.5 FBU1/FBU2 Flexcom Branch Units 1&2 2.5.1
2.6 FPS/PC Flexcom Underground Power Supply 2.6.1
2.7 FBSV/FBSD Flexcom Base Radio Voice/Data 2.7.1
2.8 FSB Flexcom Splice Box 2.8.1
2.9 FPAD Flexcom Attenuator 2.9.1
2.10 FVBU Flexcom Video Branch Unit 2.10.1
2.11 System Layout and Component Spacing 2.11.1
2.12 FLAD Flexcom Line Amplifier Diagnostic 2.13.1
2.12b FLAD FLAD Block Diagram 2.13.2
Flexcom Operation Manual Mine Radio Systems Inc
1.0 INTRODUCTION
Mine Radio Systems Inc. Flexcom underground radio communication system provides two way
radio voice communication, data communication and video signal transmission. A total of thirty-
two (32) voice/data and sixteen (16) video channels are available in the Flexcom system, for a
grand total of forty-eight (48) channels.
The following section provides a brief description of these different methods of operation.
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1.1 VOICE OPERATION

Two way voice communications are available to the following parties:
Portable and Mobile radios underground

Base radio controller surface and underground
Portable and Mobile radios above ground (with optional surface coverage)
Telephone access for radio/telephone calls (with optional telephone interconnect)
Each voice channel occupies one of the thirty-two voice/data channels.
VOICE OPERATION FIGURE 1.1
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1.2 DATA OPERATION
Two way data communication provides the means to monitor and control various configurations
of generic PLC and custom application RTU equipment.
The system can support Master Slave or Peer to Peer operation.
Data communication is available in underground and surface configurations and
can be extended with the use of Data regeneration equipment.
Data can be extracted or injected from other Networks into the Flexcom system
with additional Hardware ( ie Fibre Optic, Wire Line, etc.)
Each data channel occupies one of the thirty-two voice/data channels.
DATA OPERATION FIGURE 1.2
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1.3 VIDEO OPERATION
Video channels provide one way real time video transmission from a remote camera to a
video monitor.
To provide camera controls such as zoom, pan, tilt; one data channel is required. Each video
camera occupies one of the sixteen video channels while the camera control occupies one of
the thirty-two voice/data channels.
More than one camera can share a video channel with data control to turn on one camera at a time. In this case,
one data channel must be used for camera control.
When multiple video channels are used, all with camera control, only one data channel needs to be used as the
data speed in one channel is adequate for the control of cameras in multiple video channels.
VIDEO OPERATION FIGURE 1.3
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1.4 DIAGNOSTICS OPERATION
In order to monitor the health of the Flexcom System a self diagnostic sub-system can be installed.
The diagnostic sub-system does not occupy any of the voice/data or video channels. It allows continuous
monitoring of the system operation.
The system monitors Voltage, Current and RF signal levels and displays this information on a computer. The
system maintainer can use the information to isolate possible problems on the network.
Since the Diagnostic system is modular in its design it can easily be added to a system at any time.
MRSCOM Software
Optional Diagnostics Board

In FLA (FLAD) reports V,I and RF
Levels of Amplifier
DIAGNOSTICS OPERATION FIGURE 1.4
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2.0 SYSTEM COMPONENTS
The Flexcom Radio Communication System is designed for each mine individually to provide the required
radio coverage. As a result, each mine requires its own unique layout and design.
See Fig. 2.0
Based on the particular design requirements of the Mine, various types and quantities of Flexcom components
will be used
The following sections describe all the major components of the system and their interaction with each other
Surface coverage
antenna
Amplifiers are spaced

Every 350m (1150’)
Branches
provide a
means for
expansion
in multiple
directions.
Power supplies provide
additional DC approximately
every 10 amplifiers or as
required in design.
SYSTEM COMPONENTS FIGURE 2.0
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2.1 FHE/FCL4 FLEXCOM HEAD-END
Each Flexcom system requires 1 Head-End unit (FHE) consisting of 3 parts.
The FHE panel provides the interface between the base radios (FBS), Video monitor
and Data Radios. The main panel can support up to 8 channels (voice or data) and can
be expanded to 16, 24 or 32 channels with additional expansion chassis’.
The unit consists of filters and amplifiers designed to combine and divide the RF
signal and route them to the appropriate Receiver and Transmitter ports.
The addition of a Head-End Video Module FHEVM to the Main panel allows up to 16
channels of Video to be used.
The FCL4 unit interfaces between the FHE panel and up to 4 leaky coaxial cables. It
provides the interconnection for both the RF and DC power to the leaky feeder cable.
See Fig 2.1a
FHE/FCL4 FIGURE 2.1a
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The Head-End power supply system consists of a 13.6 VDC power supply and a
battery back-up unit powered from 120/220 VAC mains.
The system provides power to the Radio Base units (FBS) as well as the FHE
Main panel.
The Battery back-up system is designed to support 4 hrs of operation based on
standard voice duty cycle.
The DC power is routed to the FHE panel and feeds 4 independent power control
circuits for connection to the FCL4 unit as well as a Receiver amplifier
Each of the 4 outputs is limited to 1.3 Amps DC, thus protecting each other in the
event of a short circuit.
A DC Ammeter located on the front of the main panel is used to monitor the DC
current of each leaky coax.
See Fig 2.1b
SYSTEM COMPONENTS FIGURE 2.1b
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2.2 FLFC FLEXCOM LEAKY FEEDER CABLE
The Flexcom leaky coaxial cable acts as an antenna to carry RF signals between the Base radios
(FBS) and Portable/Mobile radios.
The 16 evenly spaced outer conductors form a very poor shield. The unique construction of the
cable allows the RF signals to enter and exit the cable all along its length
See Fig 2.2a
Evenly spaced outer

conductors
Center conductor RF Signal can

penetrate/exit cable
LEAKY FEEDER CABLE FIGURE 2.2a
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As well as carrying the Voice, Data, Video and Diagnostics signals the cable is utilized to
transport the DC current to power the Amplifiers (FLA)
The cable has an RF loss of 16dB per 350 M (160 MHZ) thus requiring an amplifier to be inserted
at every 350 M or as system requires to compensate for the loss.
See Fig 2.2b
Amplifiers
compensate for
cable losses
Amplifiers spaced 350m (1150’)

Line losses 16 db per 350m
LEAKY FEEDER CABLE FIGURE 2..2b
Leaky Feeder Cable is required to be installed in the radio coverage areas, and connected to the
FCL4 via FLA/FBU.
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2.3 FLA FLEXCOM LINE AMPLIFIER
The amplifiers (FLA) are installed at approximately 350 M intervals to compensate for the RF
signal losses in the leaky feeder cable (or shorter distance if branches are involved). The amplifier
has a nominal gain of 16 dBm at 160 Mhz.
The standard amplifier is equipped for voice/data channels with a connector for the addition of an
optional video amplifier module ( A2). In addition, the FLA can be equipped with a diagnostic
module (optional) for the monitoring of system performance. There are two cable connections in
the FLA, one for the cable coming from the Head-End the other for the cable going towards the
end of the system. Since the FLA amplifies signals in both directions simultaneously, the units
must be installed in the proper direction. An arrow on the FLA indicates the direction of the signal
towards the Head-End. The standard FLA has 2 amplifier modules A1 and A3. These modules are
plugged into the FLA motherboard with keyed connectors (ie: A1 module can only be plugged
into the A1 socket)
There are no electronic components exposed in the FLA, making it more robust against accidental
damage during installation.
A1 module amplifies the RF signal towards the FHE.
A3 module amplifies the RF signal from the FHE
A2 modules amplifies the Video RF signal.
See Fig 2.3
FLA FIGURE 2.3
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2.4 FLT FLEXCOM LINE TERMINATION
The Line Termination unit (FLT) is installed at the end of each leaky feeder cable.
It provides the proper 75 ohm impedance match for the system.
See Fig 2.4
FLT FIGURE 2.4
FLT FIGURE 2.4
2.4.1
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2.5 FBU1/FBU2
The Flexcom Branch Units (FBU1/FBU2) provide the means to “split” the signal
away from the main trunk line, such as a level or ramp. There are 2 versions, one
(FBU1) for a single and the other (FBU2) for a double branch configuration.
The branch is a passive device and incurs losses. Losses through the main line
ports are typically 3.5 dB. The branch port of the FBU1 has a loss of 3.5dB while
the 2 branch ports of the FBU2 are typically 7.0 dB.
These losses (3.5 dB=75 meters/ 7.0 dB=150 meters) must be compensated for by
decreasing the distance to the next FLA. (Refer to section 3 System Layout and
Component Spacing)
Since the branch is used to “split & combine” RF signals from both directions, it
must be installed in the proper direction
An arrow on the branch unit indicates the direction of the signal towards the FHE
FBU1 see fig 2.5a
FBU2 see fig 2.5b
Main In Main Out 3.5
FBU1 FIGURE 2.5a

Branch 1 3.5
Main In
Main Out 3.5
Branch 1 7.0
Branch 2 7.0
FBU2 FIGURE 2.5b
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2.6 FPS/PC Flexcom Power Supply/Power Coupler
The Flexcom Underground Power Supply system (FPS/PC) is required for

approximately every 10 Amplifiers in the system.
The system consists of three main components

The Power Supply (FPS) is a 13.6 VDC power supply and battery back up unit
powered from 120/220 VAC mains. The 13.6 VDC output of the power supply is
routed through the Underground Power Control Module (FUPCM) to provide 2
independent outputs for connection to the Power Coupler (FPC). Each output is
limited to 1.3 Amps DC, thus protecting each other in the event of a short circuit.
See Fig. 2.6
POWER + POW
CONTR
+ BATTE
- MODU - 7.2
AC 13.6
110/220 FUPCM-
VAC
+ + -
13.6
-
+ +
LEAKY
Common
FPC
FPS/PC FIGURE 2.6
The battery is connected via the FUPCM and provides up to 4 hrs of operation
during AC failure. ( based on typical 1.2Ahr current consumption)
The power supply ,battery and control board are all housed in a NEMA 4
enclosure
0040-0001-00 2.6.1
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The Power Coupler (FPC) is installed in the leaky coaxial cable. It couples the
two 13.6 VDC outputs of the FUPCM to the leaky coaxial cable. A three
conductor cable is required between the FPC and the FUPCM.
The FPC provides DC isolation between both sections of the leaky cable and
works in conjunction with the control module to protect the cable system in the
event of a short circuit.
An optional Diagnostic Module (FPS/SDS) can be added to the FPS to monitor

the Voltage and Current of both outputs as well as the AC Mains.
0040-0001-00 2.6.2
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2.7 FBSV/FBSD Flexcom Base Radio Voice/Data
The Flexcom Base Station Voice/Data (FBSV/FBSD) consist of three

components, receiver, transmitter and controller. These components are set up in
various configurations of duplex, half duplex and simplex operation depending on
the application.
The Flexcom system can be configured from one to thirty two RF Channels. Each
channel may transport voice or data information. The base radio (FBS) is co-
located with the Head-end (FHE) in the Flexcom upright Cabinet FUC.
The FBS operates on 13.6VDC supplied by the Head-end power supply system.
Additional power supplies are added based on the number of FBS units, RF power
settings and duty cycle requirements.
Operating frequencies of the FBS radios are 150-159 MHz for the Transmit unit
and 165-174 MHz for the Receive unit.
For most voice applications the FBSV is configured as a repeater.

See Fig. 2.7
This provides portable/mobile to portable/mobile communication throughout the

system.
Half-duplex operation is also possible using a central control station tied to the
FBS.
For one way paging applications only a Transmit unit is required.
A telephone interconnect unit attached to a FBSV allows the Flexcom Radio

System to access a public or private telephone network.
The FBSD (data) operates in the same way as the voice but requires higher
performance transmitters and receivers in order to achieve high data speeds with
low Bit Error Rates.
The channel can be configured for half or full duplex operation. Special
controllers are used if regenerated data (repeater) is required.
Both low speed (up to 2400 baud) and high-speed (4800-9600 baud) serial data is
available.
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FBSV/FBSD FIGURE 2.7
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2.8 FSB Flexcom Splice Box
The Flexcom Splice Box (FSB) provides a proper cable splice to repair damaged
cable. The FSB can be installed in either direction and has an insertion loss of 1
dB.
A cable that has 4 or more units installed in one length due to damage should be
replaced.
See Fig. 2.8
FSB FIGURE 2.8
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2.9 FPAD Flexcom Attenuator
The Flexcom Attenuator (FPAD) provides a means to insert signal loss in the
cable system. In cases were the geography or modifications to the system layout
does not allow for proper spacing between the amplifiers, the FPAD is installed. It
provides the choice of 0dB, 6dB or 9dB attenuation.
The unit can be installed in either direction.
See Fig. 2.9
FPAD FIGURE 2.9
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2.10 FVBU Flexcom Video Branch Unit
The Flexcom Video Branch Unit (FVBU) provides a means to insert an RF video
signal onto the leaky coaxial cable. The unit can also be used to extract the signal
from the cable system. The unit must be installed in the proper direction
depending on the application.
The unit has an insertion loss of 3dB.
The unit also provides DC isolation between the video port and the main cable
ports.
The video port is coupled via a BNC female connector
See Fig. 2.10
FVBU FIGURE 2.10
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2.11 FHED Flexcom Head-End Diagnostics Interface
The Flexcom Head-End Diagnostic Interface (FHEDI) works in conjunction with

the MRSCOM software to form one part of the Flexcom Self-Diagnostic System.
Together they monitor the operation of the Head-End, diagnostic amplifiers
(FLAD) and diagnostic underground power supply system (FPSD/PC).
The FHEDI chassis is comprised of 4 main components.

The Interface Board (SDS/IF) acts as a modem to convert the RS-232 serial data
from the computer to a Bell 103 FSK format.
The Head-end SDS board monitors voltage and current at the FHE.
The RF detector measures the RF signal produced by the FLAD at the head-end.
The Diagnostic transmitter injects a signal on the cable network that is measured
by the FLAD
The MRSCOM software is used to display information gathered by the FHED.
See Fig. 2.11a

See Fig. 2.11b
FHEDI FIGURE 2.11a
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2.12 FLAD Flexcom Line Amplifier Diagnostic
The Flexcom Line Amplifier, Diagnostic (FLAD) is comprised of a standard FLA

and a Self-Diagnostic System (SDS) board. The factory-installed board monitors
the DC voltage and current consumption of the FLA. The board can also measure
the RF level produced by the FHEDI and generate a fixed RF level that is
monitored by the FHEDI.
Each FLAD has it own distinct identification, and the MRSCOM software uses
this method to poll each individual FLAD.
The FLAD has a higher current consumption than the standard FLA and must be
taken into account in the DC power system design requirements
Typical FLA current 100 ma dc

Typical FLAD current 160-180 ma dc
See Fig. 2.12a

See Fig. 2.12b
FLAD FIGURE 2.13a
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FLAD FIGURE 2.12b
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Flexcom Operations-Spec Manual
MINE RADIO SYSTEMS INC.

FLEXCOM COMMUNICATION SYSTEM
SPECIFICATIONS
Confidential Page 15 08/09/00

1.0 INTRODUCTION The Flexcom radio system is flexible and is designed for
each mine individually to provide the required radio
This document provides the technical specifications of coverage. As a result, each mine requires its own unique
Mine Radio Systems Inc.'s Flexcom underground radio layout and design. Described herein is a general system
communication system. operation. Please refer to drawing MRS95505 for a typical
Flexcom System layout.
Mine Radio Systems Inc.'s Flexcom underground radio
communication system provides two way radio voice 3.1 System Components
communications, data communications and video signal
transmission. A total of thirty-two (32) voice/data and To provide radio coverage in a mine, the following major
sixteen (16) video channels are available on the Flexcom system components are required:
system, for a grand total of forty-eight (48) channels. • Flexcom headend unit (FHE). It provides the interface
between the base radios/video monitors with four
2.0 RADIO CHANNEL UTILIZATION leaky cables. These four leaky cable ports allow 4 runs
of cable to different parts of the mine from the
Two way voice communications provide communication headend. It also provides the interface between the
amongst the following parties: base radios and the above ground antenna and DC
- portable radios underground power with battery backup.
- mobile radios underground • Leaky coaxial cable. It acts as an antenna to carry RF
- base radio controller above ground signals between the base radios and remote/portable
- portable and mobile radios above ground radios. Leaky cable is required to be installed in the
(optional, available with above ground radio radio coverage areas, and connected to the headend
coverage equipment) via FLA/FBU.
- telephone access for radio/telephone calls • Amplifier (FLA). It compensates for the RF signal
(optional, available with telephone losses in the leaky cable. An amplifier is required for
interconnection equipment) every 350 meters of cable (or shorter distance if
Each voice channel occupies one of the thirty-two branches are involved). The standard amplifier is
voice/data channels. equipped for voice/data channels with a connector for
the addition of an optional video amplifier module In
Two way data communications enable communication addition, the FLA can be equipped with a diagnostic
between the following equipment: module (optional) for the monitoring of system
- remote data terminals (RTU) and master data performance.
terminal • FLA-2000. This is a single PCB amplifier with the
- remote data terminal and remote data terminal voice/data and video channel amplifiers installed.
(optional, available with data repeater and • Termination unit (FLT). It is installed at the end of
regenerator base) each leaky cable for proper system impedance
Each data channel occupies one of the thirty-two voice/data matching.
channels. • Branch unit (FBU1/FBU2). Where the mine coverage
includes branches away from the main line, such as a
Video channels provide one way video transmission from a level or ramp off the main line, an FBU is used to
remote camera to surface video monitor. To provide connect the leaky cable in the branch to the main line.
camera controls such as zoom, pan, tilt, one data channel is
required. Each video camera occupies one of the sixteen
video channels while the camera control occupies one of
the thirty-two voice/data channels.
More than one camera can share a video channel with data
control to turn on one camera at a time. In this case, one
data channel must be used for camera control.
When multiple video channels are used, all with camera

control, only one data channel needs to be used as the data
speed in one channel is adequate for the control of cameras
in multiple video channels.
A self diagnostic sub-system can be installed. This sub-

system does not occupy any of the voice/data or video
channels. It allows continuous monitoring of the system
operation and reports failed system components.
3.0 SYSTEM CONFIGURATION
Flexcom Specifications, April, 2000

Page 1
• Underground power supply unit (FPS/FPC). One an IBM compatible computer and self-diagnostic
FPS/FPC with battery backup is required for software are also required.
approximately 10 amplifiers. The DC power
required by the amplifiers and the RF signals are 3.2 Voice Operation
carried in the same leaky cable. Power supply for
the first 20 amplifiers (5 amplifiers per leaky Portable radio users can initiated a voice transmission
cable port) is included in the headend. An by pressing the Push to Talk (PTT) switch on the side
optional diagnostic module can be added for of the portable radio and speak into the front
system performance monitoring. microphone.
• Voice/data base radio (FBS). It is located at the
headend and provides radio communication The voice transmission is coupled to the leaky
among portable radio, mobile radio, and RTU coaxial cable and routed to the headend unit via
underground (and above ground if so equipped). FLA/FBU. At the headend unit, the radio
• Portable/mobile radio. Used by personnel for transmission is demodulated by the base radio
voice communication underground (and above receiver.
ground if so equipped).
• (Optional) Base controller. A voice channel This voice signal is then re-transmitted by the base
control unit connects to the base voice radio to radio transmitter. The re-transmitted signal is fed to
provide the above ground operator access to a all the leaky cable through the FHE/FLA/FBU. Other
radio channel. One controller is required to portable radios will receive this re-transmitted signal
access each voice radio channel. It can be located from the transmitting portable.
anywhere in the mine complex.
• (Optional) Above ground coverage antenna The portable to portable transmission is simplex, i.e.
extends the radio coverage to include the area PTT to talk, release to listen.
around the headend. One set is required for each
voice/data channel with above ground coverage. 3.3 Telephone Calls
Typical radio coverage available is about 3 Km
radius, exact coverage depends on the To access the telephone system from a portable radio,
geographic terrain. the portable radio must have a touch tone pad.
• (Optional) Telephone interconnect. It provides
an interface between the base radio and the For details on the telephone call operations, please
mine’s telephone switch for communication refer the operations manual provided with the
between telephone sets and the radios. For telephone interconnect unit.
portable radio access to the telephone system, the
portable radio must be equipped with a touch- 3.4 Data Transmission
tone pad.
• (Optional) Remote data terminal (RTU). Data Data transmission operates similar to the voice
operation. A standard data channel has a MTU at the
equipment located underground to send and
headend which receives and decodes the RTU
receive data through a radio channel.
transmitted data. The MTU also transmits down-link
• (Optional) Master data terminal (MTU). Data
data to the RTU. Connected to the MTU is a mine
equipment located at the headend to send and
supplied host computer or annunciation panel for data
receive data to/from RTUs.
analysis and display.
• (Optional) Video equipment. Video equipment
including camera, modulators, video transmitter,
With a data repeater base radio, the RTU transmitted
FVBU (video branch unit), video amplifier
data is decoded and re-transmitted by the MTU at the
module, demodulators, monitors, camera control
base radio to other RTUs.
and video switcher provides video monitoring
capability. With this set of equipment, an
Data transmission protocol over a Flexcom channel
underground camera can be monitored at the
can use one of the following:
headend.
• digital and/or analog data points
• (Optional) Self-diagnostic headend. It
• RS232 serial data
continuously polls the self diagnostic modules in
• other format to be reviewed and confirmed by
the FLA, PS/PC units to monitor the system
performance. For the self-diagnostic sub-system, MRS

Page 2
Each data channel is configured as a data network 4.0 SYSTEM SPECIFICATIONS
and can be configured as a polled system or a
contention system. Frequency
Voice/Data Base 1 Mhz bandwidth
3.5 Video Transmission transmit 150 to 159 Mhz
Voice/Data Base 1 Mhz bandwidth
Video transmission from a camera unit is coupled to receive 165 to 174 Mhz
the leaky coaxial cable. This signal is boosted by Video 10 to 110 Mhz
amplifiers to maintain proper signal level en route to Modulation
the headend unit. At the headend unit, the video Voice/Data narrow band FM, AM
signal is separated from the voice/data signals and and/or PM
sent to the video monitor for display.
Video NTSC or PAL
Number of Channels
For camera control functions, the control signal is
transmitted on a data channel, occupying one of the Voice/Data 32
thirty-two voice/data channels. This camera control Video 16 (NTSC format)
channel operates like a data channel. Channel bandwidth
Voice/Data 25, 12.5 or 6.25 Khz
Video NTSC or PAL standard
Power supply voltage 12 VDC
Underground power Through the RF leaky
distribution coaxial cable, no
separate power cable
required
System impedance 75 ohm
RF radiating medium Leaky coaxial cable
RF power radiated 15 mW maximum
Radial RF coverage 10 meters (32.8 ft.) min.
from the cable
Above ground coverage Typically 3 Km radius
from antenna, dependent
on terrain and antenna
height.
Inside building coverage Provided by leaky
coaxial cable run through
the building
System size Total of main line and
branches, 100 Km (62
miles) linear cable length
minimum.
Branch size No specific limitation,
except limited by system
size
Headend location On surface for above
ground coverage,
otherwise can be located
anywhere
Headend/Base radio -30 to +50 degree
operating Celsius
temperature

Page 3
5.0 FLEXCOM COMPONENT
SPECIFICATIONS Frequency range 165 to 174 Mhz
Frequency response +/- 0.5 dB
5.1 FTC Base Transmitter Coupler Number of outputs 32 max.
Impedance 50 ohm
Frequency range 150 to 159 Mhz Connectors BNC female
Impedance 50 ohm Output to output isolation 20 dB min. 25 dB
Connectors BNC female typical
Insertion loss . VSWR 1.5:1
Transmitter to 0.7 dB max. Insertion loss
Antenna 8 voice/data channel 19 dB +/- 2.0 dB
Transmitter to 10 to 20 dB adjustable 16 voice/data 22.5 dB +/- 2.0 dB
Flexcom channel
VSWR 32 voice/data 26 dB +/- 2.0 dB
Transmitter to 1.2:1 max. channel
Antenna Above ground antenna 17 +/- 2.0 dB
Transmitter to 1.4:1 max. port insertion loss
Flexcom
Power Consumption None, passive device 5.2.4 Video Section
5.2 FHE, Headend Unit Frequency range 10 to 110 Mhz

5.2.1 Common Equipment Number of outputs 1
Impedance 75 ohm
Transmit to receive 55 dB min. Connectors BNC female
rejection
VSWR 1.5:1
Transmit to video rejection 60 dB min. 70 dB
Insertion loss 3 dB max. 2 dB typical
typical
Receive to video rejection 25 dB min. 30 dB
5.3 FCL4, Headend Splitter
typical
Flexcom port to receive 20 dB min.
Frequency range 10 to 175 Mhz
antenna port isolation
Impedance 50 ohm FHE port
Power requirement None, passive devices
75 ohm leaky cables
only
Insertion loss 8 dB max. 6.5 dB
typical
VSWR
5.2.2 Transmit Section
FHE port 1.22:1, 10 to 120 Mhz
1.4:1, 148 to 175 Mhz
Leaky cable ports 1.22:1, 10 to 120 Mhz
1.4:1, 148 to 175 Mhz
Number of inputs 32 max.
Power requirement None
Impedance 50 ohm
Power for Flexcom 14 VDC max.
Connectors BNC female
amplifiers 1.0 A max. for each
Input level 27 dBm leaky cable port
Input to Input isolation 20 dB min. 25 dB Connector, FHE BNC female
typical
Connectors, leaky cable MRS proprietary,
VSWR 1.5:1 Nickel plated brass
Insertion loss
8 voice/data channel 18 dB +/- 2.0 dB
16 voice/data 21.5 dB +/- 2.0 dB
channel
32 voice/data 25 dB +/- 2.0 dB
channels
5.2.3 Receive Section

Page 4
5.4 FLA, Amplifier 5.7 FLT, Termination Unit
Frequency range Frequency range 10 to 175 Mhz

Base to portable 150 to 159 Mhz Impedance 75 ohm
Portable to base 165 to 175 Mhz VSWR 1.55:1 max.
Video 10 to 110 Mhz Connectors, leaky cable MRS proprietary,
Gain Nickel plated brass
Base to portable 16 dB min. 16.5 dB
typical, -10 dBm input 5.8 FPS, Power Supply
Portable to base 16.5 +/- 0.5 dB
Video 10 +/- 0.5 dB Input power 105 to 125 VAC,
at 110 Mhz 1A max.
Base to portable AGC 5 dB gain with 5 dBm 210 to 250 VAC,
input power 0.5 A max.
Frequency response +/- 0.5 dB for all signals Output power Two outputs, each output
Intermodulation is 13.6 VDC, 1.25 A
Base to portable -48 dBc min. min.
Portable to base -50 dBc min. Line regulation 0.05%
Video -50 dBc min. Load regulation 0.1%, no to full load
Power requirement 100 mA max. no video Output ripple and noise 1 mV RMS typical
130 mA max. with Isolation 500 VDC to ground
video Operating temperature 0 to 50 deg. Celsius
100 mA max. for SDS Overload protection Current limited, self
Through current capacity 1.0 A max. restoring
Connectors, leaky cable MRS proprietary, 5.9 FPC, Power Coupler
Nickel plated brass
5.5 FBU1, Branch Unit, One Branch Impedance 75 ohm
Insertion loss 1 dB max.
Frequency range 10 to 175 Mhz Connectors, leaky cable MRS proprietary,
Impedance 75 ohm Nickel plated brass
Insertion loss 4.5 dB max. Current capacity 2.5 A min.
Isolation, Branch to down 20 dB min. DC voltage drop 0.2 VDC max.
VSWR
148 to 175 Mhz 1.4:1 max. 5.10 Other Equipment
10 to 120 Mhz 1.22:1 max.
Through current capacity 1.0 A max. Base radio Per Motorola data sheet
Power requirement None Portable radio Per Motorola data sheet
Connectors, leaky cable MRS proprietary, Mobile radio Per Motorola data sheet
Nickel plated brass Data radio Per Manufacturer data
sheet
5.6 FBU2, Branch Unit, Two Branches Remote Data Terminal Per Manufacturer data
sheet
Same As FBU1 Master Data Terminal Per Manufacturer data
Specifications sheet
Except: Video Camera Unit Per Manufacturer data
Insertion loss sheet
Main line 4.5 dB max. Above ground antenna Per Manufacturer data
Branches 7.5 dB max. equipment sheet
Telephone interconnect Per Manufacturer data
equipment sheet

Page 5
Mine Radio Systems
Flexcom
Leaky Feeder Installation Guide

117 Ringwood Drive, Unit 5
Canada L4A 8C1
Phone (905) 640 1839 Fax (905) 640 1649
Flexcom Leaky Feeder Installation Guide
Table of contents
Introduction 1
1.0 System Layout and component Spacing 2

Figure 1.0 3
Figure 1.1 4
1.1 Flexcom Device Mounting 5

Figure 1.2 6
Figure 1.3 7
1.2 Cable Installation 8

Figure 1.4 9
Figure 1.5 10
1.3 Mechanical Protection 11
1.3.1 Low Backs 12

1.3.2 Cathedral Decline (Ramp) 13
1.3.3 Loading Bays and Stock Piles 14
1.3.4 Ventilation Bags/Duct 15
1.4 Termination of Flexcom Leaky Feeder Products 16 -18

Introduction
Leaky Feeder cable is the backbone of the FLEXCOM leaky feeder communications
system providing radio coverage in underground tunnels and mines where
conventional radio methods may not operate effectively.
It is important to ensure that the leaky feeder cable is installed in a proper manner to
ensure maximum coverage of the working areas while providing a degree of physical
protection from mechanical hazards.
1 System Layout and component Spacing
Since each mine has its own unique layout, each Flexcom system is custom designed
to meet the coverage area required. Based on scaled drawings supplied by the
customer Mine Radio Systems Engineering Department produces a system layout
indicating cable lengths and component spacing.
It is important for the mine personal to install the cable and Flexcom components as
per the system layout drawing in order to achieve maximum system performance.
(See Fig. 1)
In the event that the system layout does not match the actual physical layout, the
installer must ensure that cable lengths and component spacing are within +/- 35
meters of the system layout drawing for optimal performance. Variations beyond
these limits may result in poor system performance.
If there is a need to expand or alter the system design, the installer should consult
Mine Radio Systems Engineering.
Component spacing Requirements
Leaky Feeder Cable Reel 350 M

FLA/FLAD spacing 350 M apart
FBU1 decrease distance to next FLA by 75 M

FBU2 Main port decreases distance to next FLA by 75 M
Branch port 1 and 2 decreases distance to next FLA by 150 M
FSB decreases distance to FLA by 20 M

FPC decreases distance to FLA by 20 M
FVBU1 decreases distance to FLA by 75 M
(See Fig. 1.1)

Figure 1.0
3
Figure 1.1
4
1.1 Flexcom Device Mounting
Flexcom devices should be mounted in a manner which allows ease of access for
maintenance purposes while providing mechanical protection of the enclosure and
cable.
Mounting devices at a readily accessible height enables maintenance personnel to

perform faultfinding functions with relative ease reducing system downtime
When terminating Flexcom devices ensure that the arrow is pointed towards the
Head-end unit to ensure correct amplification in both directions. (See Fig. 1.2)
Improperly installed devices will result in poor system performance.
It is recommended that each leg of leaky feeder cable terminated at a Flexcom device
have sufficient excess cable to allow for the provision of a drip loop directly below
the enclosure entry gland.
This loop will ensure that any water running along the length of the cable will not
reach the device enclosure, as it will drip from the bottom of the loop onto the ground.
Drip loops also provide enough excess cable should the joint or connections to the
device need to be reworked in the future. (See Fig. 1.2 & 1.3)
Arrow indcates directon of
Head- n
Drip Loops
FIG 1.2
6
insuf c e t drip
lops
Drip Loop
ok
Fig 1.3
7
1.2 Cable Installation
Leaky Feeder cable is considerably smaller than most service cables installed in
modern mines and as such is easily handled and installed.
Cable reels are provided in 350-meter lengths and are marked with meters along the
fire retardant sheath. (See Fig. 1.4) When installing cable, a loop of 2 meters should
be left every 100 meters to allow for any future splicing or cable repairs.
The following points should be considered when installing leaky feeder cables.
• Leaky Feeder cable has a bend radius of 15cm or 6 inches. The cable
should not be bent to a lesser radius than this at any time. A minimum
radius of 25 cm or 12 inches should be observed for drip loops etc.
• Nylon cable ties should be used to secure the leaky feeder cable to a
supporting structure at intervals of no more than 3 meters or 10 feet apart.
(See Figure 1.5)
• When pulling the cable in raises or shafts, use pull ropes/wire at 30 meter
or 100 foot intervals to support the weight of the cable.
The cable is not self supporting . Stretching the cable will affect the
RF radiating characteristics of the cable
• Should the leaky feeder cable be kinked or stretched as result of incorrect

installation, the effected section of cable should be replaced. The altered
electrical characteristic of the cable can impair overall system
performance.
cable length
indcator
Fig 1.4
9
Figure 1.5
10
1.3 Mechanical Protection
The majority of faults associated with the Flexcom system are due to mechanical
damage caused by the daily operations of mining equipment.
Seldom does a Flexcom device fail other than when effected water entering the
cable or a short circuit due to a cable being damaged.
It is recommended that the leaky feeder cable be installed in a manner that maximizes
physical protection of the cable.
Leaky feeder cable should be run above major services such as water and air and
always over these services when the two cross. While it is easier to simply loop the
cable under other services when crossing paths, experience has proven this to be an
area of repeated damage to the cable.
Leaky feeder cable should not be bundled with other services. Shielding of the cable
may result in degraded system performance due to less radiated signal to the coverage
areas.
When crossing services such as firing line and High Voltage cables, the cables should
intersect at 90 degrees to minimize potential interference sources.
The following examples illustrate recommended installation methods for maximum

mechanical protection and system performance.
1.3.1 Low Backs
The leaky feeder cable should be installed above existing services where possible.
Care should be taken to ensure that the cable is not run in the center of the drive in an
area where the vehicle load may damage the cable.
1.3.2 Cathedral Decline.
Increased height of Cathedral Declines (ramp), provides a higher degree of

mechanical protection for the leaky feeder cable
As a precaution the leaky feeder cable should be mounted as high as possible above
existing services as in the previous example.
1.3.3 Loading Bays and Stock Piles
The leaky feeder cable should be installed on the opposite wall to the stockpile in the
loading bay to prevent damage from vehicle loading operations.
If the cable is installed on the stockpile side of the drive when approaching the
loading bay, an attempt to relocate the cable to the preferred side of the drive should
be made. Any crossover of this type should be made at least 10 meters before the
loading bay and it should be ensured that there is sufficient height to prevent cable
damage.
A loop of cable should be allowed for either side of the loading bay to allow for
splicing of the cable should any damage occur.
1.4 Ventilation Bags/Duct
Care should be taken when installing leaky feeder cable in areas where a ventilation
bag or duct is installed.
Utilizing the vent bag or metal duct as mechanical protection for the cable may act as
shield reducing signal to the coverage area.
Note: In some instances cable located directly above ventilation bags has worn
through on the shotcrete or rock surface due to the motion of the inflated bag.
Flexcom Leaky Feeder Installation Guide.
1.4 Termination of Flexcom Leaky Feeder Products.
AIM: This document is inted to instruc a competn elctria trade

person in the coret method of terminag leaky fedr RF cable to a Flexcom
devic .
E
M THO:D A simple step by step procedu describ gn eht s ecorp ot wol a ysae
ident f ca o of comp ne ts and visual aids to il ustra e pref d methods.
Step 1: Prepar equipmnt and locate

requi d to ls ie: remov lid from devic to be
termina d and lo sen al locking nuts and screw .
Tools Required:
Medium Size Flat Blade Screwd iv .
Size 7 Nutspiner.
Wire Cuters.
Sharp Knife.
Step 2 : Using a sharp knife, strip the outer

fire reta d n sheat (yel ow) to expos
aproximtely 10 centimrs of the black iner
sheat .
Step 3 : gnisU a prahs ,efink pirts kcab

ap roxim tely 8 centim r s of the black in er
sheat to expos the 16 strand of outer
condu t r.
16
Step 4: Separ t outer condu t rs into

two groups of 8 strand each. Twist thes
strand toge h r to form two condu t r groups
for earth termina o .
Step 5: Measur cable ag inst

noita mre skcolb dna mirt evis cx ertn c
condu t r.
Step 6: Place Gland locking nut and

rube seal over leaky fedr cable. Positon
cable throug gland into termina g blocks,
gnirus e eht erif tnadr e htae s )wol ey( si
expos d at the in er lip of the gland.
Step 7: Wrap the outer condutr twised

pairs around the earth terminal stud , ensuri g
eht pmalc liw erutpac eht .srotcudn Trmi
evis cx rotcudn morf htrae pmalc dna
tigh en with nut spin er.
17
Step 8: Tighten locking nuts on centr

condu t r termina o block. Do not
overtigh n as this may hinder removal of
cable if requi d in fut re operati ns.
Step 9: Intceps imret natio for cor e t

clamping of al condu t rs and measur to
ensur the pres nc of DC voltage.
( Nominal 12 Vdc.)
18
DO AND DON’T’S OF LEAKY FEEDER SYSTEM
1). CABLE
a). Support cable every 0,5m with cable ties and NOT binding wires, with 2m slack every 100m..
b). No bends and or kinks with radius smaller than 100mm in cable, because that could cause RF
reflections. Where possible cable should not be tied to HT cables. And no coils to be formed on
cable as no comms will be possible after the coils.
c). Cable should not be pulled into position by pulling the whole length at one go. The cable
should be moved into position by starting at the end and move the cable to the desired position in
100m sections because the cable could stretch.
d). When removing cable the cable ties should be cut to remove cable and not be yanked till the
cable ties snap because the cable will be damaged.
e). Cable should be terminated correctly with a FLT.
f). Cable should not be boxed in or buried by other cables and should always be in sight and on
the bottom of the cables.
g) When connecting cables, test cable before connecting for short circuits, then connect cable and
test for D.C. voltages for correct value. This should be done before and after each connection.
2). DISTANCES
a). The distance between 2 amplifiers with nothing connected in between should be 350M that is a
whole roll of cable.
b). The distance between 2 amplifiers with a FBU1 in between should be 270M that is between
the amplifier at the FHE side and the outgoing side of the FBU1 as well as the branch side.
c). The distance between 2 amplifiers with a FBU2 in between should be 270M between the
amplifier at the FHE side and the outgoing side of the FBU2 but between the amplifier and the
first branch amplifier should be 150M and the same with the second branch.
d) The distance between 2 amplifiers with two FBU1 in between should be 150M with a
maximum of three devices between two amplifiers.
3). MOUNTING OF FLA’S , ETC.

a). FLA: The FLA’s are direction sensitive and care should be taken when connecting the units.
The incoming side is marked with a arrow showing the direction of the FHE.
The glands should always face downwards in a vertical direction.
The slack at the FLA should be done that if any water run along the cable it should drip
off before reaching the connecting gland.
b). FBU: The FBU are also direction sensitive and the same rule are used as with the FLA.
c) PC: The PC are not direction sensitive except for IS PC. Normal PC transmit DC in both
direction but IS PC only transmit DC in the down ward leg. The input side and output are DC
isolated.
d) SB: The SB’s are not direction sensitive and normal connections can be done.
e) POWER SUPPLIES: All wiring in the power supplies should be terminated with forked lugs.
When mounting any hardware care should be taken that the unit is not mounted direct under
any dripping or running water. If possible , move unit away at least one meter.
As a golden rule all leaky cables should be lower than the entry point of the devices as to prevent
any running water along the cable to enter the device.
The minimum voltage needed for a FLA to operate reliable is 5V and for a FLAD it is 7V.
Usually a PC should be connected after every 10 FLA’s and if only FLAD’s are used every 8.
The voltage at the unit will usually determine whether additional PC should be connected.

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