TC 1

TELECOM
TELECOMCABLES
CABLES(COPPER)
(COPPER)

इरिसेट IRISET
 TC 1

TELECOM CABLES (COPPER)

The Material Presented in this IRISET Notes is for

guidance only. It does not over rule or alter any of the
Provisions contained in Manuals or Railway Board’s
directives

INDIAN RAILWAY INSTITUTE OF

SIGNAL ENGINEERING & TELECOMMUNICATION,
SECUNDERABAD - 500007

June 2022
 TC 1
TELECOM CABLES (COPPER)

INDEX

S.No. Chapter Page no.

1 Introduction of Telecom Cables 1
1.1 Introduction of Telecom Cables (copper)
1.2 Advantages of U/G cables over O/H lines
1.3 Comparison between U/G cables and O/H lines
1.4 Types of Telecom Cables
1.5 Special Features of Telecom Cables
1.6 Electrical characteristics of Telecom Cables
1.7 Important Terms
2 Paired Telephone Cables
2.1 Paired Cables 8
2.2 Types of Paired Cables
2.3 Telecommunication Switchboard Cables
2.4 Applications in Railways
2.5 Standard make of switch Board Cables
2.6 Technical Data
2.7 Double drop wire/Twin Flat wire
2.8 Field service (FS) Cable
2.9 Data Communication Cables
2.10 Coaxial Cable
2.11 RF Coaxial Cable
3 Underground PIJF Cables
3.1 Introduction 16
3.2 Brief Description
3.3 The colour code of conductors
3.4 Colour code scheme of 20 pair polythene insulated cables
3.5 Application
3.6 Technical Data
3.7 Advantages of Polythene Insulated Jelly Filled Cables
3.8 Marking on Cable
4 Effects of Railway Electrification on Telecom circuits
4.1 Effects of 25KV 50 Hz AC Traction on Telecommunications 21
4.2 Mechanism of Induction
4.3 Screening factor
4.4 I.T.U-T. Recommendations
4.5 Psophometric noise
4.6 Effects of 25 KVAC Traction on Telecom cable may be reduced
4.7 Precautions to be taken for the protection of staff and equipment
in 25 KV 50 Hz AC traction territory
5 Telecom Quad Cables
5.1 Introduction
5.2 Construction of PIJF Quad Cable
5.3 Colour Code scheme for PIJF Quad Cable 26
5.4 General specification of 4/6 PIJF Quad cable
5.5 Specifications of 6 Quad Cable
5.6 Present Status of 6 Quad System in Railways
5.7 Quad cable along with OFC and without OFC
5.8 Guidelines for the use of OFC system and 6 Quad cable in IR
5.9 Difference between PIJF u/g Paired and Quad Cables

6 Cable laying practices

6.1 Introduction 32
6.2 Important stages in Telecom Cable laying
6.3 Survey Work
6.4 Points to be covered under the survey for cable route
6.5 Information in Cable Route Plan
6.6 Detailed Cable Route Survey
6.7 Length of 6 Quad Cables
6.8 Typical cable requirement calculation
6.9 Telecom cable laying/arrangement in major yards and stations
6.10 Storage of Cable drums
6.11 Basic methods of laying underground cables
6.10 Methods of laying underground cables
6.12 Special cable laying practices
6.13 Cable Markers
6.14 Power Crossing 11KV and above

7 Jointing of Underground Telecom Cables

7.1 Introduction 43
7.2 Preparation of Cable for Jointing
7.3 Jointing procedure of Quad Cable conductors
7.4 Important stages of making a Cable Joint
7.5 Various Types of Joints in Quad Cables
7.6 Jointing Procedure of PIJF u/g cables
7.7 Termination of 6 quad cables

8 Testing of Cables
8.1 Types of tests 57
8.2 Acceptance tests for 6 Quad PIJF cables
8.3 Standard values of various tests
8.4 Mandatory Check & Tests to be done before commissioning of
BPAC/SSDAC/MSDAC applications on 4/6 Quad/PIJF cables
8.5 Causes for cable failures & precautions
8.6 Fault localisation tests

9 Quad Cable Maintenance

9.1 Typical 6 Quad cable failures & their causes 63
9.2 Important tools to protect u/g S&T Cables from damages
9.3 Quad Cable Maintenance Register
 10 Cable Route Locator and Fault localisation 73
10.1 Introduction
10.2 Cable Route tracing
10.3 Cable Route tracer CSCOPE
10.4 Important points for operation of locator
10.5 Usage of Generator mode
10.6 Depth measurement
10.7 Limitations of depth measurement
10.8 Cable fault localisation
10.9 APLAB Digital Cable Fault Locator (Model 3039-I)
11 Annexure 83
12 Question Bank 99
13 Abbreviations / Acronyms 107
14 Glossary 110

Prepared by : M.V.L.Narasimham, Instructor (Computer lab), ICP1

Reviewed by : D. Janardhana, Lecturer (IT)
Approved by : Susheel Namdeo, Senior Professor-Telecom.
DTP and Drawings : K. Srinivas, JE (D)
Version No. : 2.0 June 2022
No. of Pages : 111
No. of Sheets : 57

© IRISET
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and written permission of IRISET, Secunderabad, India”

http://www.iriset.indianrailways.gov.in
 CHAPTER-1

INTRODUCTION OF TELECOM CABLES

1.1 Introduction of Telecom Cables (Copper)
In Indian Railways different types of Telecom networks exist and play a vital role by providing
clear and distant voice and data services. Various types of telecommunication cables with
RDSO specification are being used depending upon the requirements of Telecom and safety
related Signalling circuits, which are under utilisation for functioning of administrative and train
operation activities.

For administrative purpose Telephone exchanges, Railnet (Intranet), UTS/PRS, FOIS (Freight
Operations Information System), MIS (Management Information System) MMIS (Material
management Information and IRPSM (Indian Railway Projects and Sanction Management) etc
are in use. Whereas for Train operation various safety circuits like Block, LC gate
communication, IB Phone (Intermediate Block), BPAC (Block Proving Axle Counter), EC
(Emergency Communication) and Train Traffic Control communication etc. are in use.

For all types of above Telecom networks, different types of Telecom links are established by
using Telecom trunk cables and tail cables.

The Telecom transmission media over Indian Railways is as follows:

1. Aerial Lines (Over Head Lines): GI wires & ACSR (Aluminium Conductor Steel Reinforced)
are in use for Section Control Communication, Block Communication and LC gate
Communication etc. These existing ACSR lines are under replacement with 6 Quad
Underground Cables.
2. Micro Wave System: Analog & Digital Systems were in use for Radio Patching for Control
Communication and long-distance administrative trunk circuits. Analog MW systems
became obsolete and closed down. However Digital MW systems are still in use. MW
system functionality is under replacement with OFC system.
3. RE Main Telecom Underground Cable: 0+12+2, 0+17+3, 0+18+2 etc. are in use in RE
areas for Section Control, TPC, RC, EC, Block etc circuits. Due to non availability and
foreign exchange currency involvement, these cables are under replacement with 6 Quad
with OFC cables.
4. Underground 4 Quad and 6 Quad Cables: These are in use as standalone or along with
OFC in many Zonal Railways.
5. OFC Cable: Laying optical fiber cable along the Railway track utilizing Railways‟ Right of
Way (ROW) and provide modern communication system to improve Railways operation
and safety through Memorandum of Understanding between the Ministry of Railways and
RailTel Corporation of India Limited vide Rail board letter number No. 2001/Tele/MW/3
RCIL- MoU New Delhi, 09.01.2002.
24 Fiber Underground OFC Cable is in use for high bit rate Telecom traffic with enormous
applications over Indian Railways. Railway is using only 4 fibers in which 2 fibers for
working and 2 fibers for standby and remaining 20 fibers handed over to RCIL (RailTel
Corporation of India Ltd.) as a policy between Railways and RCIL.
6. Leaky Coaxial Cable: leaky coaxial cable communication system is used inside tunnel in
Railways for seamless communication for Distributed Power Wireless Control System.
When the train enters the tunnel, communication ceases to exist between train crew due to
absence of signal. The system comprises “leaky” feeder cables that provide both
transmission and reception for the radio handsets in the tunnels and amplifiers for surface
communications.

IRISET 1 TC1 - Telecom Cables (Copper)

Introduction of Telecom Cables

1.2 Advantages of U/G cables over O/H lines

 Overhead lines may come in contact with trees, bushes, etc. and cause low insulation.
 Due to natural calamities and ravages of human beings, overhead lines are Prone to a
higher fault incidence. Hence, less liable to damage as well as faults.
 Due to headway considerations, the maximum number of pairs on a pole route in Over
Head Alignment is limited to 16.
 Due to induced voltage effects from the 25 KV OHE system, Over Head lines are not fit for
Telecommunication circuits in RE area.
 Low maintenance cost.
 General appearance is better.

1.3 Comparison between Underground Cables and Overhead Lines

Underground Cables Overhead Lines

Number of circuits is more. Number of circuits is limited.
No noise and no cross-talk Prone to noise and cross-talk
Less number of failures. More number of failures.
For long distance circuits-4wire For Long distance circuits- 2-wire
systems are required. system is required.
Maintenance cost is less. More maintenance cost .
Thefts are minimum. Thefts are maximum.
More secrecy. No secrecy.
Used in RE and- Non RE areas. Cannot be used in RE area

1.4 Types Telecom Cables:

1.5 Special Features of Telecom Cables

Telecom cables are:
a) PVC insulated d) Balanced cables
b) Twin Twisted paired / quad cables e) Loaded Cables and
c) Screened cables f) Colour coded

IRISET 2 TC1 - Telecom Cables (Copper)

Introduction of Telecom Cables

Unlike electrical noise, cross talk is the main criteria in telecom circuits. Cross talk arises mainly
from unbalanced electrostatic and electromagnetic couplings between the pairs of conductors
and sheath with respect to earth. These effects are respectively be measured in terms of
capacitance unbalance and mutual capacitance. At voice frequencies, capacitance unbalance is
the major source of cross talk. In order to reduce the cross talk in cables, insulated wires are
twisted together at regular intervals on their own axis helical throughout its length.
Different twist lengths are used to transpose the circuits continuously with respect to
one another pairs/quads. After laying the cable, if capacitance unbalance is persisting, it can
be reduced by introducing the external fixed capacitors. This process is called as “BALANCING
OF CABLES”.

In star quad cables diagonally opposite conductors are formed as one pair and two wires of the
pair are kept at an equal distance from the conductors of the remaining pair.

1.6 Electrical characteristics of Telecom Cables

1.6.1 The four primary elements

The four primary elements of cable should be taken into Consideration while designing
the circuits.

R = Series Resistance
L = Series self inductance
C = shunt capacitance
G = Shunt conductance [Leakage]
These four quantities per unit length of a pair of telephone lines are called primary elements of
the lines.

Dig: Schematic representation of the elementary components of a transmission Line.

Where R-is the resistance per unit length,
L- is the inductance per unit length,
G- is the conductance of the dielectric per unit length,
C-is the capacitance per unit length.

When alternating current flows through the lines, there will be voltage drop due to both
resistance and inductance and so they may be assumed to be present in series in the lines and
as capacitance and leakage are present between the lines, current is lost through them during
transmission.

Z0 = (L/C) are independent of frequency and as such all the frequency components are equally
attenuated during propagation through line. All the different types of distortions that are likely to
be introduced during transmission through long lines are thus eliminated when the condition GL
= RC is satisfied.

Telephone line is a balanced twisted pair transmission line and its characteristic impedance Z0
can be calculated from the data which was given by the manufacturer.

IRISET 3 TC1 - Telecom Cables (Copper)

Introduction of Telecom Cables

1.6.2 Defining the Impedance Vs Frequency.

The impedance, which describes the combined effect of resistance (R), inductive reactance (XL)
and capacitive reactance (XC) in an AC circuit, whether it occurs in a single component, or in a
whole circuit.

Because impedance is affected by reactance (X), as well as resistance (R), it is also affected by
frequency (ƒ) and the value of impedance will change at different frequencies.

The component or circuit will not have the same impedance at all frequencies. It is common for
inputs and outputs on many types of equipment to have their impedances quoted in Ohms and
to assume a common frequency for that particular type of equipment. For example, audio
commonly uses a frequency of 1 kHz as the standard for measuring impedance. This is
because 1 kHz is approximately the centre of an audio amplifier s bandwidth, measured on a
logarithmic scale, as shown in the above figure.

The wiring to the subscriber in telephone networks is generally done in twisted pair cable. It is
possible to manufacture this kind of cable to have a 600 Ω characteristic impedance but it will
only be this value at one specific frequency. This might be quoted as a nominal 600 Ω
impedance at 800 Hz or 1 kHz. Below this frequency the characteristic impedance rapidly rises
and becomes more and more dominated by the ohmic resistance of the cable as the frequency
falls. At the bottom of the audio band the impedance can be several tens of kilo-ohms. On the
other hand, at high frequency in the MHz region, the characteristic impedance flattens out to
something almost constant.

1.6.3 Loading of underground cable

The distortion less condition, GL=RC, is not satisfied in usual cables. In telephone cables as the
conductors are necessarily of thinner gauge and as the conductors are run side by side, both
the values R and C are large compared to values L and G. Usually the cables contain a
large number of conductors, and the dia. of the conductors are necessarily of smaller
dimensions and so the value of R is much high. From expression, GL=RC, the capacitance, C
value is much higher and inductance, L value is much lower. The L value has to be increased to
satisfy the equation GL = RC.

When the diameter of the conductors is increased, the value of R is reduced. This is not
possible considering its size and cost. If the value of G is increased, the transmission loss will
be increased which is not acceptable to a long-distance transmission line. Therefore, there is
one way to increase the value of GL by increasing the value of L. This is achieved by using the
coils of suitable inductance value wound on dust cores are placed in series with the lines at
suitable intervals. This is called coil loading or lump loading.
IRISET 4 TC1 - Telecom Cables (Copper)
Introduction of Telecom Cables

Effect of using 118 mH loading coil in 6 Quad Cable

The object of loading cables for voice frequencies is almost solely for the purpose of reducing
the attenuation constant per Km. For long distance cables and for trunk cables 118 mH coils are
used and spaced at regular intervalls of 2000 mtrs. Each (2000 mtrs) of such a cable then
appears as one section of a low pass filter in which L = 118 mH(59 mH in each limb of a pair)
and the shunt capacitance is C x S (C = Capacity per Km and S = spacing in Km)

Attenuation Vs Frequency of one Loading section

A cable has an appreciable amount of resistance, so that the attenuation characteristic of any
one loaded section, would be as shown in above figure.

Note: Unloaded cable has an attenuation of approx. 0.65 dB/ Km. This system of loading,
increases the Zo from 470 ohms to approximately 1,100 ohms and reduces attenuation to 1/3 of
its unloaded value i.e., 0.25dB/Km and this is the practice being followed in 6 Quad Cables.

Loading Section of 4/6 Quad Cable

Loading coil joint Condenser joint Loading coil joint

1. Loading section– 2000 Meters.

2. Condenser joint– 1000 Meters.
3. Normal Joint wherever requires.

(At present quad cables drum length of 1000 meters. are in use, hence number of Normal Joints
have been minimised)

1.6.4 V.F balancing of underground cable

V.F balancing of underground cable is done to reduce noise and crosstalk in cables. This is
necessary in 6 Quad Cables because the cables carry a number of important circuits.

The process of measuring the capacitance unbalances between various quads and earth, within
the quad and with adjacent quads and minimising the unbalances by connecting condensers is
called V.F. balancing.

Permissible limits of capacitance unbalance for full and half loading sections are 40 pF and 20
pF respectively.
IRISET 5 TC1 - Telecom Cables (Copper)
Introduction of Telecom Cables

The capacitance unbalance exists between,

a) Conductors of a quad and sheath (Earthed). This is called “Earth Coupling”.
b) Conductors of a quad and between adjacent quads. This is called “Crosstalk Coupling”.
Capacitive couplings cause cross-talk and Earth couplings cause „Noise‟ in VF circuits.

e1, e2, e3, e4 - earth couplings & c1, c2, c3, c4 - capacitive couplings

1.7 Important Terms

1. Core: Everything inside the sheath of the cable.

2. Pair: Two wires forming a single circuit, held together by twisting, binding, in Common
jacket.
3. Quad: A structured unit employed in cable. A quad consists of four separately insulated
conductors twisted together.
4. Unit: A Unit is made up of a number of pairs stranded together in layers.
5. Marker Pair/Quad: The conductors have different markings on their insulation to
distinguish them from other conductors. The counting and numbering of a pair/quad of a
layer commences from the marker pair/quad.
6. Paper-Insulated Cable: Cable in which the conductors are insulated with a paper ribbon.
Either spirally or longitudinally is applied.
7. Plastic-Insulated Cable: Cable in which the conductors are insulated with Plastics, such as
polyethylene and polypropylene.
Note: PVC insulated conductors are not referred to as Plastic-Insulated Cables.
8. Insulated: A non-conducting material that can offer a high and permanent resistance, for
separation from other conducting surfaces to the passage of current.
9. Interference: Any electrical or electromagnetic disturbance, man-made or natural, which
causes, or can cause, undesirable response.
10. Jacket: A covering over a cable. It is usually the outer component of a composite sheath.
11. Dielectric: Any material used in a cable that will insulate one conductor from another or
from shield.
12. Dielectric Strength: The maximum voltage that a dielectric can withstand without rupturing.
Also called “electric strength” or “break-down strength.
13. Phantom Circuit: A superimposed circuit derived from two suitably arranged pairs of wires
called side circuits. Each pair of wires is a circuit itself and, at the same time, acts as one
conductor of the phantom circuit.
IRISET 6 TC1 - Telecom Cables (Copper)
Introduction of Telecom Cables

14. Twisted Pair: A cable composed of two small-insulated conductors twisted together without
a common covering.
15. Cable: An assembly of one or more insulated conductors or optical fibers or combination
of both, within an enveloping jacket.
16. Underground Cable: A cable installed below the surface of the earth in conduit or ducts.
17. Unit-type Cable: A cable in which the pairs are first formed into bound units and then the
units are formed together to make the completed cable.
18. Moisture Barrier: In a cable, the material, usually in the form of an axially laid aluminium
foil/polyethylene laminated film, placed immediately inside the sheath. Generally called
Poly- Aluminium laminate moisture barrier.
19. Filling Compound (Jelly): It is a water resistance compound. The cable core shall be fully
filled with jelly and this will be used in joints also.
19. Sheath: A protective covering made of metals or plastics over the cable core.
20. Wire gauge: It is a measurement of wire diameter. This determines the amount of electric
current a wire can safely carry, as well as its electrical resistance. The following chart
gives above information on different copper wire gauges.

Copper wire gauge and conversion chart

IRISET 7 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

CHAPTER-2

PAIRED TELEPHONE CABLES

2.1 Paired Cables

Paired cables are balanced, by using two closely spaced conductors twisted together. The
purpose of twisting the wires is to reduce the electrical interference from neighbouring pairs.

A ground shield is used to prevent high frequency noise and balanced wires also reject noise
coming from ground loops.

How Cross Talk is being eliminated in Twisted Pair

The following representation shows potential difference between “Conductors without twist
(Fig.A) and Conductors with twist (Fig.B)”

Net induced voltages on L1 and L2 in twisted pair (figure B) are the same. Hence, no potential
difference, no current flow at destination then no cross-talk from adjacent pair or circuit.

IRISET 8 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

Twisting arrangement in twisted copper cables

2.2 Types of Paired Cables

Switchboard cables Underground PIJF cables

PVC Twin flat-2 core
10 pair-0.4/0.5/0.63mm (dia of conductor ) 10 pair-0.4/0.5/0.63mm (dia of conductor )
20 pair-0.4/0.5/0.63mm (dia of conductor ) 20 pair-0.4/0.5/0.63mm (dia of conductor )
50 pair-0.4/0.5/0.63mm (dia of conductor ) 50 pair-0.4/0.5/0.63mm (dia of conductor )
100 pair-0.4/0.5/0.63mm(dia of conductor) 100 pair-0.5/0.63mm (dia of conductor )
These cables are used for Indoor extension These cables are used for outdoor extension
TEC Spec.No: GR/WIR/06/03 of March 2002 RDSO Spec. No:IRS:TC 41/97 (Amd. 3)

2.3 Telecommunication Switch Board Cables

TEC Specification: GIR/WIR – 06/03 March 02

IRISET 9 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

2.4 Applications in Railways: These cables are used for indoor installation for the
interconnection of telephones & electronic equipment, Telephone switching exchanges, Switch
board & telephone wiring (MDF, SDH, DWDM, and DSLAM etc.) PDH/SDH systems, RS-232
Communication Systems and Digital Transmission networks.

2.5 Standard make of Switch Board Cables: Delton cables, Reliance cables, Finolex
cables, Havells cables etc.

2.6 Technical Data

Parameter Construction Technical Data

Solid Annealed Tinned Conductor dia (mm)
Conductor Copper in 0.4, 0.5 & 0.6mm 0.4 0.5 0.6
sizes.
Max. loop Resistance at (Ohms/Km.)
286 184 128
20°C
Insulation Polyethylene. Pairs are Min. Insulation
Colour coded as per Resistance at
specification. 50°C/Km. Mega 50 50 50
ohm/Km.
Capacitance For 200-meter length in pF (pair to pair)
Unbalance at 800/1000Hz 230 230 230
Assembly Pairs/units to laid up to form a round and compact cable.
Core Wrap Non-Hygroscopic (against moisture) polyester tape with min. 15% overlap
of width of the tape.
Screening If required, shall be of Aluminium tape. The Al. tape of min. 0.04mm
(Optional) thickness and a drain wire of solid tinned copper of 0.125 sq.mm shall be
laid parallel touching the Al.surface throughout the length.
PVC Sheathing Extruded PVC Type. It will be in Grey Colour.
Rip Cord A non-metallic suitable Nylon thread shall be longitudinally placed under
the sheath for the removal of sheath.
Length Standard lengths of packing: 100 mtrs / 500 mtrs. +/- 5%

2.6.1 Conductors

Each conductor shall consist of a solid wire of annealed high conductivity tinned copper circular
in cross section, uniform in physical, mechanical and electrical properties. The conductor is free
from spills, splits and defects of any other kind and shall conform to specification IS: 8130.The
conductor is uniformly coated with tin. Characteristic impedance of the conductor is 600 Ohms

2.6.2 Insulation

Each conductor is insulated with PVC. The PVC shall be applied by the extrusion process and
shall form a compact homogeneous uniform core. The PVC insulation shall have distinct single
colour for identification of each conductor.

For a hundred pairs cable, each unit consists of 20 pairs and there are all-together five units.
Mate colours of each unit is White, Red, Black and Yellow. The colour scheme of the 1st wire of
all other units is the same as shown above for the first unit.

IRISET 10 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

Pair No. Lead A Lead B Pair No. Lead A Lead B

1 Blue White 11 Blue Black
2 Orange White 12 Orange Black
3 Green White 13 Green Black
4 Brown White 14 Brown Black
5 Slate White 15 Slate Black
6 Blue Red 16 Blue Yellow
7 Orange Red 17 Orange Yellow
8 Green Red 18 Green Yellow
9 Brown Red 19 Brown Yellow
10 Slate Red 20 Slate Yellow

Colour of PVC insulation for identification of 20 pairs cable.

2.6.3 Twining:

Two insulated conductors shall be uniformly twisted together with a right hand lay which shall
not exceed 100mm.Twisted pair shall be laid up to form a compact and symmetrical cable. The
lay of any two adjacent pairs shall be so chosen as to reduce the cross talk to the minimum
possible extent. The cable core consisting of the required number of twisted pairs shall be
stranded in concentric layers. The cable core shall be lapped with polythene tape.

2.6.4 Ripcord:
A non-metallic suitable ripcord shall be laid longitudinally under the PVC sheath. It shall
provide an effective means of ripping the PVC sheath longitudinally to facilitate the removal of
PVC sheath.

2.6.5 Sheath: The cable shall be sheathed with PVC.

2.6.6 Identification mark: The PVC sheath shall be prominently embossed on the outside with
IRS cable and the name/code of the manufacturer at intervals not exceeding 30cms to enable
identification of the cable.

The cables shall be supplied in standard lengths of 100/200/500 meters. A tolerance of + or -

5%of the standard real coil length is permissible.

The cable shall be wound on suitable wooden drums/rolls /coils and shall be strong enough to
withstand the stress and strain of transportation and handling.

2.7. Double Drop wire / Twin Flat Wire (IS 434-Part-1/1964)

This wire is used to extend one Telephone connection from outside the distribution box to inside
the house up to the Telephone instrument. It is available in copper conductors of 0.5mm and
0.9mmdia. The standard lengths of the cable‟s coil are of 100 meters, 200 meters and 500
meters. In this wire L1 and L2 are separated by PVC insulation to prevent short circuit.

2.8. Field Service (FS) Cable (IS-694-Part /1964)

This wire is used to extend telephone connection from outside DB to telephone instrument for
outdoor applications. During emergencies like Railway accidents, Floods, Cyclones, etc., this
cable is extensively used to provide temporary connections of the telephones as per
requirement. This is a single core twin twisted of size 7/0.375mm. Out of 7 strands three strands
are steel and four strands are copper with single PVC core called as L1. One more length has to
be taken as L2. This is available in length of 500Mtrs. and 1Km drum lengths. Steel strands will
provide additional mechanical strength. This FS cable is also called D8 Cable.
IRISET 11 TC1 - Telecom Cables (Copper)
Paired Telephone Cables

2.9. Data Communication Cables

For data communication, two types of cable are used for LAN network:
i. UTP: Unshielded twisted pair
ii. STP: Shielded twisted pair

2.9.1 UTP Cable

This type of cable is used in I.E.E.E (Institute of Electrical and Electronics Engineers) Ethernet
LANs. UTP wire offers an economical alternative for both Ethernet and Token ring networks.

This cable is less expensive than a shielded twisted pair, less bulky and is also easier to work
with. It is, limited to segments no longer than 100 meters and generally does not transmit as fast
as its shielded relative. Unshielded twisted pair cabling comes in different grades that are
assigned to six standard categories created by the Electronic Industry Alliance and the
Telecommunications Industry Association (EIA/TIA).

The Different UTP Categories and their specifications

Category 1/2/3/4/5/6/7 – a specification for the type of copper wire (most telephone and network
wire is copper) and jacks. The number (1, 3, 5, etc) refers to the revision of the specification and
in practical terms refers to the number of twists inside the wire (or the quality of connection in a
jack).

CAT1 is typically used for telephone wire. This type of wire is not capable of supporting
computer network traffic and is not twisted. CAT1 is also used by telco companies providing
ISDN and PSTN services. In such cases the wiring between the customer's site and the telco‟s
network is performed using CAT 1 type cable.

CAT2, CAT3, CAT4, CAT5/5e, CAT6 & CAT 7 are network wire specifications. This type of wire
can support computer network and telephone traffic. CAT2 is used mostly for token ring
networks, supporting speeds up to 4 Mbps. For higher network speeds (100 Mbps or higher)
CAT5e must be used, but for the almost extinct 10 Mbps speed requirements, CAT3 will suffice.
CAT3, CAT4 and CAT5 cables are actually 4 pairs of twisted copper wires and CAT5 has more
twists per inch than CAT3 therefore can run at higher speeds and greater lengths. The "twist"
effect of each pair in the cables ensures any interference presented/picked up on one cable is
cancelled out by the cable's partner which twists around the initial cable. CAT3 and CAT4 are
both used for Token Ring networks -- where CAT 3 can provide support of a maximum 10Mbps,
while CAT4 pushed the limit up to 16Mbps. Both categories have a limit of 100 meters.

The more popular CAT5 wire was later on replaced by the CAT5e specification which provides
improved crosstalk specification, allowing it to support speeds of up to 1Gbps. CAT5e is the
most widely used cabling specification world-wide and unlike the category cables that follow, is
very forgiving when the cable termination and deployment guidelines are not met.

IRISET 12 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

CAT6 wire was originally designed to support gigabit Ethernet, although there are standards
that will allow gigabit transmission over CAT5e wire. It is similar to CAT5e wire, but contains a
physical separator between the four pairs to further reduce electromagnetic interference. CAT6
is able to support speeds of 1Gbps for lengths of up to 100 meters, and 10Gbps is also
supported for lengths of up to 55 meters.

Today, most new cabling installations use CAT6 as a standard, however it is important to note
that all cabling components (jacks, patch panels, patch cords etc) must be CAT6 certified and
extra caution must be given to the proper termination of the cable ends.

In 2009, CAT6A was introduced as a higher specification cable, offering better immunization to
crosstalk and electromagnetic interference.

Organizations performing installations using CAT6 cabling should request a thorough test report
using a certified cable analyzer, to ensure the installation has been performed according to
CAT6 guidelines & standards.

CAT7 is a newer copper cable specification designed to support speeds of 10Gbps at lengths of
up to 100 meters. To achieve this, the cable features four individually shielded pairs plus an
additional cable shield to protect the signals from crosstalk and electromagnetic interference
(EMI).

Due to the extremely high data rates, all components used throughout the installation of a CAT7
cabling infrastructure must be CAT7 certified. This includes patch panels, patch cords, jacks
and RJ-45 connectors. Failing to use CAT7 certified components will result in the overall
performance degradation and failure of any CAT7 certification tests (e.g using a Cable
Analyzer) since CAT7 performance standards are most likely not to be met. Today, CAT7 is
usually used in Data Centres for backbone connections between servers, network switches and
storage devices.

Conductor: Each conductor is made up of annealed copper of dia. 0.5mm.and PVC insulated.
USE: UTP cable is connected with the connector known as RJ-45 and IO box. Eight no. of wires
are connected to these RJ 45 connector or IO box. Thick Ethernet cable is also used to connect
a 15-pin connector known as DB-15 or DIX.

Different types of UTP Cables and application

IRISET 13 TC1 - Telecom Cables (Copper)
Paired Telephone Cables

Category Speed Frequency

CAT 1 Carry only voice 1MHz
CAT 2 4Mbps 4MHz
CAT 3 10Mbps 16MHz
CAT 4 16Mbps 20MHz
CAT 5 100Mbps 100MHz
CAT 5e 1000Mbps 100MHz
CAT 6 1000Mbps 1000MHz
CAT 7 10Gbps 600MHz
CAT 7a 10Gbps 1000MHz
CAT 8 25Gbps 2000MHz

Different types of UTP Cables and it‟s speed and frequency

2.9.2 STP Cable

For high-speed data, the STP cables are used. The application of this cable is widely found in
SDH rack wiring. In this cable each twisted pair is shielded and an earth wire is drawn along
with it. The twisted pairs are to be bundled together and enclosed in a protective jacket to form a
thicker cable. Below the jacket a tape of aluminium foil is used as a screen. Each conductor is
made up of annealed copper of 0. 9mm.or 0.6mm dia. and PVC insulated.

2. 10. Coaxial Cable

Coaxial cable and parts

Different types of Coaxial cables

IRISET 14 TC1 - Telecom Cables (Copper)

Paired Telephone Cables

Coaxial cable often called coax is the round and flexible cable. Four separate elements are
identified, by the cross-sectional view. In the center there is a copper wire, carrying the signal.
Encasing this wire is a layer of non-conducting insulation made up of PVC or Teflon. Outside
the insulation, forming a protective sleeve around the conducting wire and its insulation, another
layer made up of a braided mesh of copper or Aluminium. This layer protects the transmitted
signal from the electromagnetic interference known as noise that can distort the transmitted
signal. Finally, outside the braided sleeve is an outer shield or jacket, made of either PVC or a
fire-resistant material such as Teflon. The coaxial cable comes in various forms for networking

a. Thin Ethernet or thin wire: Ethernet is based on the 3/8-inch coaxial cabling known as RG-
58. This Thinned cabling can carry a signal for about 185 meters. Above this the signal
begins to degrade.

Thin Ethernet LANs Coaxial cable is connected with the BNC (Bayonet Neill Concelman)
connector to make connection with the equipment.

b. Thick Ethernet: is based on less flexible coaxial cabling about ½ inch thick. Also known as
RG-8. Thick net cabling can carry signals farther than Thinned cabling about 500meters
and thus is often used as the backbone connecting.

2.11. RF Coaxial Cable

The coaxial cable radiates the least power and picks up interfering signals to the least degree.
the usual impedances are 40-50 ohms and 70-80 ohms, so the diameter remains reasonably
small. The optimum conductor diameter ratios for different transmission line properties will vary
from one to infinity, if the outer diameter “D” of the outer conductor is kept constant and inner
diameter “d‟' is varied.

Cross sectional view of RF co-axial cable

RF Coaxial cable and parts

A single compromise ratio is also desirable for certain fields of use because it simplifies
manufacturing and merchandising problems. These considerations have led to standardization,
in effect, of a single coaxial conductor diameter ratio for high frequency and microwave
application. This ratio (2.3) results in a nominal characteristic impedance of about 50 ohms. The
medium between conductors is assumed to be a gas.

IRISET 15 TC1 - Telecom Cables (Copper)

Underground PIJF Cables

CHAPTER-3

UNDERGROUND PIJF CABLES

POLYETHYLENE INSULATED, POLYETHYLENE SHEATHED, JELLY FILLED,
UNDERGROUND CABLES (ARMOURED or UNARMOURED)

3.1 Introduction

PIJF telephone cables are widely used in Railways for local loop and other networks due to
improved technology and simplicity in installation and maintenance.

Indian Railway Standard specification for Polythene insulated polythene sheathed jelly filled
telephone. cable with Poly-Al Moisture Barrier is IRS-TC: 41/97 (RDSO spec)

Cross section of PIJF Telephone Cable

IRISET 16 TC1 - Telecom Cables (Copper)

Underground PIJF Cables

B C D E F
A
A

A: Polythene Outer jacket B: Galvanised Steel Tape C: Polythene Tape

D: Polythene Inner sheath E: Poly-Al-Laminated Tape
F: Core wrapping (Polyester) tape G: Polythene Insulated Copper Conductor

Construction of PIJF Telephone Cable

3.2 Brief Description

Jelly filled cable is an underground cable having polythene as insulation on conductors and the
inter-spaces between the conductors is fully filled with petroleum jelly. Petroleum jelly prevents
ingress of moisture and water inside the core in the event of any damages to the cable. The
Cable is circular throughout its length and is free from any physical defects.

Jelly filled cable is wound on strong wooden drums. The length of cable on any drum is 500 /
1000 meter + 10% unless single longer lengths are specified by purchaser for specific
application. The diameter of the yoke of the drums is not less than 20 times of the overall
diameter of the cable. Both ends of the cable are kept inside the drum to get access to the cable
ends battens are painted by red colour arrow.

Number of pairs: The cable shall be of different sizes varying from 10 to 200 pairs and above
with nominal conductor diameter 0.5mm or 0.63mm or 0.9mm. The Standard cable sizes shall
be 10,20 50 100 and 200 pairs armoured / un-armoured.

Conductor: Each conductor shall consist of a solid round wire of annealed high conductivity
copper, smoothly drawn, normally circular in section, uniform in quality and free from defects.

Insulation: Conductor insulation shall be polythene insulating grade and 100% virgin material
as per ASTM (American Society for Testing and Materials) -D883.

Twining/Pairing: Two insulated conductors shall be twisted together with uniform lay to form a
pair. The length of the lay of any pair shall be different from the adjacent pairs. The lay of
various pairs shall be so chosen as to satisfy the capacitance unbalance.

Filling compound: (Petroleum Jelly): A cable core shall be fully filled with suitable water-
resistant compound like jelly, which is fully compatible with the polyethylene insulation, binders,
and tapes used in the cable.

Core wrapping: After application of water-resistant filling compound, a closed helical or

longitudinal lapping of a non hygroscopic and non wicking polyester tape or tape of any other
suitable materials shall be laid over the cable core.

IRISET 17 TC1 - Telecom Cables (Copper)

Underground PIJF Cables

Poly-Al Laminate moisture Barrier/Screen: Polythene coated aluminium tape shall be applied
longitudinally on the core with a minimum overlap of 6mm. Thickness of the aluminium tape
shall be 0.2mm + or –10% and that of polythene/ co-polymer coating on each side 0.05mm
nominal. Thickness of composite tape shall be 0.3mm + or - 15%.

Sheath: Cable shall be sheathed with polythene and containing a suitable anti oxidant system.
The material shall be virgin and meet required specification. The sheath shall be reasonably
circular and free from pin holes joints and other defects. The thickness depends on the size of
the cable.

Armour: The sheathed cable shall then be armoured with two applications of galvanized steel
tape conforming to IS: 3975 each applied helically in the same direction with gap in the first tape
of 25% + or – of the width of the tape, the second tape evenly covering the gap of the first tape.
Thickness of the galvanized steel tapes used in two applications including zinc coating on each
tape shall not be less than 0.5mm.

Jacket: The armoured cable shall be tightly jacketed with polythene conforming to the
requirements as specified for sheath.

3.3 The colour code of conductors:

In 5 pair,10 pair, 20 pair cable, colour code specified as below in para 3.4

Stranding: A 50 pair cable consists of 5 numbers of 10 pair units

A 100 pairs cable consists of 5 numbers of 20 pair units

3.4 Colour Code Scheme of 20 pair polythene insulated cables

Main↓ / Mate→ White Red Black Yellow

Blue 1 6 11 16
Orange 2 7 12 17
Green 3 8 13 18
Brown 4 9 14 19
Grey 5 10 15 20

Pair 1st wire 2nd wire Pair 1st wire 2nd wire
no. Main colour Mate colour no. Main colour Mate colour
1 Blue White 11 Blue Black
2 Orange White 12 Orange Black
3 Green White 13 Green Black
4 Brown White 14 Brown Black
5 Grey White 15 Grey Black
6 Blue Red 16 Blue Yellow
7 Orange Red 17 Orange Yellow
8 Green Red 18 Green Yellow
9 Brown Red 19 Brown Yellow
10 Grey Red 20 Grey Yellow

IRISET 18 TC1 - Telecom Cables (Copper)

Underground PIJF Cables

3.4 The colour code scheme of polythene insulated cables

Blue, Orange, Green, Brown & Grey are called the main colours. White, Red, Black and Yellow
are called mate colour. The five pairs make one unit. In this way there are four units in twenty
pair‟s cable. A cable of 50 pairs and 100 pairs, the twisted pairs shall be arranged in units of 10
pairs and 20 pairs respectively. 4 No of 50 pairs super unit shall be assembled to form a 200
pair cable.

Colour of binding tape: The different colours of the binding tape shall be used for identifying
each unit as given in Table 3.4

Unit number 1 2 3 4 5
Colour binder Blue Orange Green Brown Grey

Table 3.4 Colour of binding tape

3.5 Application: These cables are used for in transmission and distribution of networks
designed to be used underground, not inside the water. Cables having 0.5 mm conductor
diameter are used for short distance distribution networks, cables having 0.6 mm. conductor
diameter are used for long distance networks.

In Railways Polythene Sheathed Jelly Filled Cable with Ploy-Al moisture barrier is used for
providing telephone connections to the subscribers and local lead / last mile connectivity of
various circuits of both voice and data. These PIJF cables will be used in both RE and non RE
areas depending upon application.

Whereas in the RE area the usage of PIJF telephone cable may be limited to a maximum of 2
Km length due to induced voltage effects.

3.6 Technical Data

Parameter 0.51 mm dia conductor 0.63 mm dia conductor

Conductor resistance (20 C) 92 Ohms/Km 64 Ohms/Km
Loop Resistance of pair(20 C) 184 Ohms/L.Km 128 Ohms/L.Km
Insulation resistance
5000 M Ohms/Km 5000 M Ohms/Km
(500 V Megger)
Mutual Capacitance (800 Hz) 52 nF/Km 50 nF/Km
Operating Voltage 300 V 300 V
Attenuation at 800 KHz 1.379 dB/Km 1.107 dB/Km
Min. Bending radius 15 X Cable diameter 15 X Cable diameter
Weight 1.83 Kg/KM 2.81 Kg/KM
Application Up to 5 Km for sub. loop 5 to 10 Km for sub. loop

3.7 Advantages of Polythene Insulated Jelly Filled Cables.

1. Counting pairs is easy and human mistakes are avoided.
2. Jointing is easy and requires no additional place.
3. Failures are less.
4. Entry of moisture / water is prevented by Jelly in the core.
5. Cables can be directly terminated on MDF/CTB/Tag Block/Equipments, thus avoiding
additional joints decreasing the cost and time.
6. Handling of cable is easy not delicate like paper insulated cables.
7. Life of cable is more.
IRISET 19 TC1 - Telecom Cables (Copper)
Underground PIJF Cables

3.8 Marking on Cable

To enable proper identification of the cable, the following information is embossed, engraved or
printed on the polythene jacket in case of armoured cable, and on the sheath in case of un-
armoured cable. All the markings are white or yellow.

a) Name/Trade mark of the manufacturer

b) IRS Specification number
c) Year of manufacture
d) Length (Sequential marking)
e) Cable drum number
f) No. of pairs/conductor size (Example: 20 pairs/0.63mm)

This marking exists throughout the length at intervals of one metre.

IRISET 20 TC1 - Telecom Cables (Copper)

Effects of Railway Electrification on Telecom circuits

CHAPTER-4

EFFECTS OF RAILWAY ELECTRIFICATION ON TELECOM CIRCUITS

4.1 Effects of 25 KV 50 Hz AC Traction on Telecommunications

In the system of electric traction adopted by the Indian Railways, the catenary wire is fed at
25,000 V, 50 c/s, and single phase. The rails are being employed as the return conductor. Such
an arrangement while resulting in several advantages in respect of power transmission and
traction engineering, the power feed being inherently unbalanced, produces certain undesirable
effects on communication circuits in the neighbourhood of the tracks, rendering them unsafe
and unworkable.

4.2 Mechanism of Induction

The mechanism of induction from the 25 KV AC traction system is due to electrostatic coupling
and electromagnetic coupling.

4.2.1 Electrostatic Coupling (Capacitive coupling)

Electrostatic induction:- cable conductor insulated from earth and situated in this field will get
charged to certain potential with reference to the earth due to capacitance coupling. The
magnitude of this potential depends on the catenary current and distance between track and
conductor.

● With the catenaries maintained at 25,000 V an electric field is created in the vicinity of the
tracks.
● An electric conductor, such as a communication wire insulated from earth and situated
within this field will get „charged‟ to a certain potential with reference to earth due to
capacitance coupling.
● The magnitude of this potential depends on the voltage of the catenary and distance.

4.2.2 Electromagnetic Coupling

Electromagnetic induction:- Due to vicinity of AC Traction and length of parallelism, the

currents flowing in the catenaries return to the feeding point via rails, the rails are not specifically
insulated from the earth therefore some portion of currents field a path or induces emf in cable
sheath and conductors. It is dangerous to working people and equipment.

● The currents flowing in the catenary returns to the feeding point via the rails.
● The rails are not specifically insulated from the earth, therefore, provides an alternate path
for the currents.
● Some portion of this current penetrates deeply into the earth, to find a path in other rails,
cable sheaths, metal pipes and similar conductors parallel to the track.
● Near the feeder points the whole of the current must return to the secondary windings of
supply transformer.
● The current in the catenary is the source of an alternating magnetic field.
● This field cuts any conductors parallel to the track and induces e.m.f.‟s in them.
● The catenary system acts like a primary winding and each other parallel conductor acts like
the secondary winding of a transformer.

IRISET 21 TC1 - Telecom Cables (Copper)

Effects of Railway Electrification on Telecom circuits

Therefore, from the above, it should be evident that the inductive interference constitutes a
hazard to personnel using or working on the lines as also to the connected equipment. The
induced voltages also seriously interfere with the signalling arrangements on the
telecommunication circuits causing them to be unworkable. Apart from the induction at the
fundamental frequency 50 c/s another source of trouble is on account of the harmonic
components of the catenary currents.

4.3 Screening factor

Voltage induced in conductor in presence of metallic sheath

Screening factor, K = ----------------------------------------------------------------------------------------
Voltage induced in conductor in the absence of metallic sheath

The reduction in induced voltages that is affected by the various conductors parallel to the
catenary system is expressed by saying that each such conductor has a screening factor. This
is defined as follows: -

Screening factor, K is the ratio of Voltage induced into the conductors of the cable core in the
presence of the metallic sheath of the cable to which the screening factor refers to voltage that
would be induced to the conductor of the cable core if the metallic sheath of the cable to which
the screening factor refers, is absent.

● It follows from this definition that the screening factor is normally less than unity.
● Generally this value is as low as possible.
● The screening effect of current is the consequence of the magnetic field produced by
current in that conductor (sheath).
● This conductor (sheath) can only provide a screening factor when it is carrying current. To
achieve, it must be a part of a complete circuit.
● By considering the screening effect of a cable sheath, clear distinction should be made
between "the voltage of the core to the sheath," and “the voltage of the core to earth".
● If the sheath is insulated from earth, identical voltages are induced in sheath and core, the
voltage between them is zero.
● At the same time the sheath does nothing to reduce the voltage between core and earth.
● To do this the sheath must carry a return current, the field of which opposes the field
induced by the current in the catenary.
● To carry such a current the both ends of the sheath have to be earthed.
● According to the above mentioned phenomenon, it is very clear that an induced voltage
developed due to the difference of primary & secondary magnetic fluxes in the cable
conductors as shown in figure shown below.

IRISET 22 TC1 - Telecom Cables (Copper)

Effects of Railway Electrification on Telecom circuits

Induced Voltage in Cable conductors

4.4 I.T.U-T. Recommendations

● Recommendations on permissible voltages, calculating method and protective measures

have been issued by the I.T.U-T.
● Accordingly the following voltages may not be exceeded in the circuit formed by cable
conductors and ground.
a) As regards electrostatic induction, the critical figure recommended by the I.T.U-T is 15
milli amperes current.
b) When a person is in contact with both the earth and with the conductor of a
telecommunication line. During the normal functioning of the power line, or electric
traction system, the longitudinally induced voltage in the telecommunication circuits
should not exceed 60V.
c) During the abnormal functioning of the traction power line, the longitudinal induced
voltage shall not exceed more than 150 Volts.
d) During traction power line short circuit condition, the induced should not exceed more
than 430V rms.
e) As regards interference to speech transmission, the psophometric voltage in the
communication circuits should not exceed 2mV.
● By the way of sectionalising all the communication circuits to break the metallic continuity of
the conductors to prevent cumulative build up of induced voltages with the introduction of
isolating transformers at every 17 Km on long distance communication networks and
adoption of special maintenance precautions.
● The cables to be laid along the tracks should have aluminium sheath and steel tape
armouring so as to have a screening factor of less than 0.1 in the anticipated range of
magnetic field intensity.
IRISET 23 TC1 - Telecom Cables (Copper)
Effects of Railway Electrification on Telecom circuits

4.5 Psophometric noise

• When cable is in close proximity to strong electromagnetic fields, unwanted current and
voltage may be induced on it. If the power level is high enough, the electrical "noise" can
interfere with voice and data applications running on the cabling. In data communication,
excessive electromagnetic interference (EMI) hinders the ability of remote receivers to
successfully detect data packets. The end result is increased errors, network traffic due to
packet retransmissions, and network congestion. For analog voice communication, EMI can
create psophometric noise, which degrades transmission quality. This will be measured
with a psophometric meter.

4.6 Effects of 25 KV 50 Hz AC Traction on Telecommunication cable may be reduced by

▪ Changing over Overhead system to Underground Cables is mandatory.
. Isolation Transformers: It is considered that a normal field strength of 87.5 V/Km exists in
the vicinity of a telecom cable. This induces a voltage of 8.75 V/Km in each conductor of
cable, because of its screening factor of 0.1. As cable length increases this voltage also
increases proportionately. If this longitudinally induced voltage exceeds 150V AC, the
safety of working personal and equipment becomes hazardous as per the
recommendations of ITU-T. It is essential to isolate all circuits from induced voltage, so that
its value will not raise above 150volts. For that divide 150V by per-kilometre induced value
i.e., 8.75V/Km of the cable, gives 17 Km of max. permissible length for cable circuits.
Hence, Isolating circuits are provided physically by Isolation Transformers at a distance of
17 Km on each circuit at cable Hut. By doing this accumulation of induced voltage on the
cable pairs is brought to Zero.
▪ Provision of Earthing and SPD`s for all telecom equipment as per RDSO guidelines.
▪ Using Aluminium Sheathed/Screened cables which are having good screening factor (0.1).
▪ Screening factor is the ratio of voltage induced in the conductor in presence of metallic
sheath and voltage induced in the absence of metallic sheath.

4.7 Precautions to be taken for protection of staff and equipment in 25 KV 50 Hz AC

traction territory.
Any Telecommunication circuits in the vicinity of AC Traction running parallel to 25 KV lines are
liable to be affected by AC induced voltage. Therefore, precautions should be taken to eliminate
the possibility of induced voltage affecting equipment and humans.
1. Crossing of track, if any, should be negotiated by underground cables running at right
angles to the track as far as practicable.

2. Special protective measures (viz. provision of G.D tubes, fuses and earthing etc) are
required to be taken for telecommunication lines entering equipment rooms/OFC huts.

3. For the human safety considerations, the safe working voltages should be 60 V under
normal conditions and 150 V with special precautions and 430 V under fault conditions as
discussed earlier.

4. Precautions are required to be taken on account of following,

i) Proximity of live conductor.
ii) Pressure of return current in Rails.
iii) Induction in all metallic bodies situated close to overhead equipment.
IRISET 24 TC1 - Telecom Cables (Copper)
Effects of Railway Electrification on Telecom circuits

5. Precautions to be taken by staff are

i) Use Insulated Tools.
ii) Use Rubber Gloves.
iii) Use Rubber Mats.
iv) Before cutting the armour or sheath of the cable an electrical connectivity is to be
established between two ends of the cable through an external wire.

IRISET 25 TC1 - Telecom Cables (Copper)

Telecom Quad Cables

CHAPTER-5

TELECOM QUAD CABLES

5.1 Introduction: At the time of conversion of Non-RE Area into RE (Railway Electrification)
Area of 25KVAC Traction Line, the Underground Quad Cables are utilized in place of Over-
Head transmission line of metallic wires to avoid the effect of induced EMF on Over Head
Alignment running parallel to the electrified traction lines. The existing PIJF cables are not fit for
long distance communication; hence underground quad cables have been introduced. These
underground Quad cables work excellently for good quality of speech. In non-RE areas the
Telecom circuits are working on Overhead ACSR wires and its overall dia of the line wire is 4.5
mm with 0.038 dB loss per Km. The long-distance Telecom networks on ACSR wire were
working on 2 wires since no amplifier is used upto the length of 350-400 Km of Telecom
network. Because of tremendous induced voltage effects in the Railway Electrification area the
Telecom networks are changed to screened underground quad cables. Here the dia of the
underground quad cable conductor is 0.9 mm with the loss of 0.63 dB per Km for unloaded
cable and 0.25 dB per Km for loaded cable, due to this high attenuation of the conductors in
cable, the amplification of the speech and signal became essential at every 40-50 Km length of
cable section. Hence, 2 wires for Trans and 2 wires for Receive are used for amplifiers, totally
four wires are used known as quad and circuit is modified as 4 wire circuit in RE area.

“STAR QUAD” is four conductors balanced cable, two pairs form a tighter, more consistent pack
will resist even more noise.

IRISET 26 TC1 - Telecom Cables (Copper)

Telecom Quad Cables

PIJF Quad Cables

4 Quad cables 6 Quad cables

0.9 mm dia conductor

1.4 mm dia conductor

RE cable and PIJF quad cable

These RE Main Cables were specially designed for long distance communication networks in
Railway Electrified areas. This cable is a combination of Paper and PVC insulated quads. Being
paper is a very good insulator, this paper insulated quads are used for long distance Telecom
circuits such as Section Control (CTO), Dy Control, Traction Power Control (TPC), Traction
Loco Control (TLC), Remote Control (RC) and Emergency Control (EC). PVC insulated quads
(PET) are used for signalling applications such Block, IB etc. In the present scenario the RE
cable is phased out due to its limited bandwidth with limited route diversity and introduction of
OFC with 4 quad /6 quad cable. All the long distance Voice Frequency (VF) circuits as
mentioned above are transferred into OFC network and existing signalling circuits, such as
Block, BPAC, IB, TAWS and Telecom circuits such as LC gate communication, EC sockets are
working in 4 quad/6 quad underground cable. In addition to this, data circuits such as UTS/PRS,
FOIS, Railnet, MIS, MMIS and Telephony trunking etc., are switched over to OFC network.

The 4/6 quads Jelly filled cable of IRS-Specification No- 30/2005 version-1 (0.9mm dia
conductor) affected from 1/1/2006 has been introduced (latest is amendment no. 5 for this
specification). In addition to this, 1.4 mm dia copper conductor underground Railway jelly filled 6
or 4 quad cables for Signalling & Telecom installations have been introduced by RDSO under
specification no: RDSO/SPN/TC/72/07 for long (more than 25 Km) distance Block sections.
(Latest specification is with amendment 2)

5.2 Construction of PIJF Quad cable

1. Conductor, 2. Petroleum jelly, 3. Dummy tube, 4. Binder, 5. Polyester tape

6. Poly aluminium tape, 7. PVC inner jacket, 8. Aluminium wire screen
9. Woven tape (yellow colour), 10. PVC intermediate jacket, 11. G.I. Steel armour
12 PVC outer jacket

IRISET 27 TC1 - Telecom Cables (Copper)

Telecom Quad Cables

5.2.1 Polythene Insulated conductor

The conductor is composed of plain annealed high conductivity copper wire. The conductor is
circular in cross-section, free from splits, cracks and corrosion. Each conductor is insulated with
solid polythene. The insulation is applied closely and homogeneously on the conductor. The
insulation resistance between each conductor shall not be less than 5000 Mega ohms per
kilometre at room temperature when tested with 500 V megger.

5.2.2 Jelly
The cable core is fully filled with a water resistant compound of jelly which is fully compatible
with the polythene insulation of the conductors.

5.2.3 Polyester Tape

After application of the filling compound a close helical or longitudinal lapping of a polyester tape
is applied over the cable core. The tape is impregnated or flooded with jelly.

5.2.4 Poly Aluminium Moisture Barrier

Polythene coated aluminium tape is applied longitudinally on the core with a minimum overlap of
6mm.

5.2.5 Inner Sheath

Cable is sheathed with polythene. Sheath is circular, free from pin holes, joints and other
defects.

5.2.6 Screen
The cores with inner sheath are surrounded by a reasonably close fitted screen of aluminium in
the form of wires/strips.

IRISET 28 TC1 - Telecom Cables (Copper)

Telecom Quad Cables

5.2.7 Woven Tape

The aluminium screen is wrapped with a single layer of woven tape impregnated with barium
chromate to protect the screen from oxidation.

5.2.8 Intermediate Sheath

Further protection for the screening is provided by extruded PVC circular sheath over screening.
The colour of this intermediate sheath is grey.

5.2.9 Armouring

The galvanised steel tape armouring is applied tightly over the intermediate sheath with two
layers. The direction of the lay of the armour is opposite to that of the outermost layer of
screening.

5.2.10 Outer Sheath

The outer sheath is applied over the armouring. The colour of this outer sheath shall be black.

5.3 Colour Code scheme for PIJF Quad Cable

5.3.1 4-Quad cable

The colour code scheme of 4 Quad polyethylene-insulated quads

Colour of insulation of conductor Colour scheme of the

Quad No
A-Wire B-Wire C-Wire D-Wire quad whipping
Quad 1 Orange White Red Grey Orange
Quad 2 Blue White Red Grey Blue
Quad 3 Brown White Red Grey Brown
Quad 4 Green White Red Grey Green

5.3.2 6-Quad cable

Colour code scheme of conductor insulation of 6-Quad cable

Colour of conductor insulation Colour scheme of

Quad No
A-Wire B-Wire C-Wire D-Wire the quad whipping
Quad 1 Orange White Red Grey Orange
Quad 2 Blue White Red Grey Blue
Quad 3 Brown White Red Grey Brown
Quad 4 Green White Red Grey Green
Quad 5 Yellow White Red Grey Yellow
Quad 6 Black White Red Grey Black

Wire A and B shall form a pair and similarly Wire C and D shall form another pair. Conductors
are diagonally opposite forming one pair and the remaining two diagonally opposite conductors
forming the second pair of the quad. The quad shall be held together firmly by means of an
open helical whipping of nylon yarn or coloured tape of suitable material of appropriate
thickness.

IRISET 29 TC1 - Telecom Cables (Copper)

Telecom Quad Cables

5.4 General specification of 4/6 PIJF Quad cable

1.4 mm dia
Sl.No. General Specifications 0.9 mm dia conductor
conductor
Characteristic impedance 470 Ohms (Unloaded) 310 Ohms (Unloaded)
1
at 800 Hz 1120 Ohms (Loaded)
2 Max. Loop Resistance 56 Ohms / Km 23.2 Ohms / Km
Insulation resistance of the >100 M Ohms / Km >100 M Ohms / Km
3 PET Quad measured with
100V DC. Megger
Transmission loss at 1 Kz 0.63dB/Km. (Unloaded) 0.3 dB/Km. (Unloaded)
4
0.25 dB/Km. (Loaded)
5 RDSO spec. IRS:TC: 30/2005 ver.2 RDSO/SPN/TC/72-07

Note: The value of attenuation shall not exceed 2 dB/km for any frequency in the frequency
range 300 Hz – 3400 Hz at 20C.

5.5 Specifications of 6 Quad Cable

RDSO spec. no: IRS-TC 30/2005 ver. 1, Amendment5. (w.e.f:4-10-2016)
1. Loop resistance: 56Ω/L.Km
2. Transmission loss: 0.25 dB/L.Km (loaded), 0.63 dB/ L.Km (unloaded)
3. Impedance: 470 Ω (unloaded) / 1120 Ω (loaded)
4. Insulation resistance: >100 MΩ /Km with100V Megger
5. Conductor diameter nominal: 0.9 mm
6. Minimum diameter of insulated conductor: 1.5 mm
7. Thickness of PVC outer sheath: 2 mm
8. Thickness of G.I. Armour tape: 0.8 mm
9. Thickness of PVC intermediate sheath (Grey colour): 1 mm
10. Thickness of inner PVC sheath: 2 mm
11. Thickness of Aluminium tape: 0.2mm±10%
12. Aluminium wires/strips used for screening: 36/12 no.
13. Mutual Capacitance of the pair: 50 pF/Km.
5.6 Present Status of 6 Quad Cable System used in various Railways
1. Conventional 6 quad cable system with loading, balancing and V.F repeaters at regular
intervals of 40-50 Km.
2. Equalizer Amplifier System at all stations with unloaded 6 quad cable, balancing of cable at
the stations.
3. 6 Quad cable with OFC.

5.7 Quad cable along with OFC and without OFC.

The Railways are presently following two schemes of laying 6 quad underground
Telecommunication Quad cables as under:

a) 6 Quad cable only b) 6 Quad cable along with OFC

Where the section is non-RE area only 6 quad cables was used for Train operational
communication arrangements. However, additional Signalling sub-systems like BPAC, TAWS,
IB Phone to improve safety and reliability are gradually being integrated into the Signalling
systems. Railway board have considered this emerging need and decided that 6 quad cables
shall be provided along with OFC in all future works on sections where communication based
Signalling schemes are being planned.
IRISET 30 TC1 - Telecom Cables (Copper)
Telecom Quad Cables

5.8 Guidelines for use of Optical Fiber System and 6 quad cable on various routes in
Indian Railways.

(a) New Railway Projects – Gauge Conversion/New lines/Doubling/Railway Electrification.

On A, B, C, D & D spl Routes, the following configuration should be used.
24 Fibers Optical Fiber Cable (as per RDSO Specification IRS.TC.55 with amendment 3)
with Six Quad cable (as per RDSO Spec. IRS.TC30/2005 or latest).

(b) Replacement of existing overhead /RE quad cable for control communication.
(i) Existing RE Telecom Cable, whenever it is due for replacement on age cum condition
basis, it should be replaced by Optical Fiber System with 6 quad cable
(ii) Existing Overhead alignment on A, B, C & D-special should be replaced with Optical
Fiber System with 6 quad cable.

Tentative Quad allocation of a 6 Quad Cable, when laid along with OFC or without OFC is as
under:
a) 6 quad cable with OFC b) 6 quad cable without OFC
Quad No Name of the circuit Quad No Name of the circuit
1 Block Circuit 1 Block Circuit
2 Spare 2 Section Control
3 Emergency Control 3 Emergency Control
4/1 LC gate telephone 4/1 BPAC
4/2 BPAC 4/2 LC gate telephone
5 BPAC 5 BPAC
6 TAWS 6 TAWS
Quad allocation of 6 quad cables
**Quad allocation will be done as per the section requirement duly following the latest Rly
Board letters if any and local circulars in the zone.
5.9 Difference between PIJF underground Paired and Quad Cables:

Sl.No PIJF Telephone Paired Cable PIJF Telecom Quad Cable

Conductors are available in the form of Pairs. Conductors are available in the form of Quads.
1
Twin Twisted. Twin Twisted pairs.
2 Available in 10/20/50/100 pairs Available in 4/6 quads
3 Dia of conductors: 0.51/0.63 mm Dia of conductors: 0.9/1.4 mm
Characteristic Impedance of the pair: 600 Characteristic Impedance of the pair in the quad:
4
Ohms 470 Ohms (0.9 mm dia) / 310 Ohms (1.4mm dia)
Induced Voltage reduction done in two stages Induced Voltage reduction done in three stages
5
by earthing Al foil & armour by earthing Al foil, Aluminium screen & armour.
Used for short distance Telephony/ Data
Used for long distance Signalling and Telecom
6 Circuits applications in the Railway station area
safety circuits between two Block stations.
as last mile connectivity.
Loop Resistance of the pair is an important Transmission loss in pairs of quad is an
7
criterion. important criterion.
8 RDSO spec. of Cable: IRS-TC: 41/97 RDSO spec. of Cable: IRS-TC: 30/2005
Jointing is in the form of Straight Through/
Jointing is in the form of Straight Through
9 Derivation/Transformer Joints (as required in the
Joints.
section).
Thermo Shrinkable Jointing Kits for different Thermo Shrinkable Jointing Kits for 4/6
10 sizes of cables used as per RDSO spec. no: underground Quad Cable as per RDSO spec.
RDS0/SPN/TC/57/2015 no: IRS:TC:77/2012
Terminated in Krone/Wago type modules and Terminated in 10 Pair/20 Pair CTBs and Wago
11
terminal strips. type modules
Generally used by all Telecom Service Exclusively designed for Signalling and Telecom
12
providers. applications of Indian Railways.
IRISET 31 TC1 - Telecom Cables (Copper)
Cable Laying Practices

CHAPTER-6

CABLE LAYING PRACTICES

6.1 Introduction: This Chapter deals with the Specifications under which the various works
for trenching and laying of underground telecommunication cables.
The OFC HDPE duct and 6quad underground communication cable are to be laid in the same
trench. Basically, the HDPE duct for OFC cable is to be laid into the ground in a depth of 1200
mm or at the bottom of the trench. 6 quad cable shall be laid after 200 mm backfilling i.e., at a
depth of 1000mm, followed by bricks protection wherever requires and also between station
area (home signal to home signal).

OFC and 6 quad cable with warning brick in a cable trench

6.2 Important stages in Telecom Cable laying

a. Cable route survey

b. Obtaining permission from Engineering department
c. Trial pits to identify soil condition
d. Trenching
e. Shifting of material and cable drum placement
f. Laying of various types of pipes in trenches wherever required
g. laying the Cable
h. Bedding and tiling to protect the cable
i. Backfilling of trench
j. Placing of Cable route markers

IRISET 32 TC1 - Telecom Cables (Copper)

Cable Laying Practices

6.3 Survey Work

a. Surveying of the route and submission of proposed cable route plan
b. Preparation of soil strata report and data collection.
c. Submission of Cable route plan.
6.3.1 Route Survey: Cable route surveys are two types

a) Preliminary Cable Route Survey b) Detailed Cable Route Survey

After allocation of work, foot inspection has to be carried out to arrive at the approximate and
exact route plan of the alignment of cable route. While carrying out the survey, Railway
boundaries, availability of other Signal, Electrical cables, water pipes etc. are shall be identified
and certified by the P. Way, Signal & Electrical authorities of Railways. In case of obstruction or
availability of other cables, alternative routes have to be selected. On approval of the same, the
detailed survey of the section has to be started.

6.3.2 Soil strata report: After getting the clearance, carry out the soil strata analysis. To
identify soil condition, at every 500mtrs the pits have to be excavated and soil condition has to
be analysed. The analysis readings are to be recorded and incorporated in the report as well as
in the drawings.

6.3.3 Submission of cable route plan: Based on the above survey the cable route plan
should be prepared.

6.4 Points to be covered under the survey for cable route

1. Avoiding underground structures, signalling cable, power cables and pipelines etc.
2. Avoid rodent/termite infested or infected side of the alignment.
3. Off set of the cable trench from the central line of the track such as having burrows.
4. Avoiding proximity to chemical, paper and such other industries, which discharge
Chemically active affluent.
5. Avoiding areas prone to water logging.
6. Avoiding large rock cutting thick jungles and areas difficult to approach etc.
7. Avoid the side of the alignment which is likely to be affected due to addition/alteration of
earth work, super structures such as doubling, shifting of alignment of the existing track
etc., For this, cable route should be discussed with construction and doubling
organization.
8. The orientation of the route i.e., left or right side of the track in the sections to be decided
on following: -
a. That side of the main line, which is away from other cables such as signalling and power.
b. Side which is likely to involve least track crossings and likely to be more convenient for
crossing the track, bridges culverts etc.
9. Figure out and scale crossing of roads, tracks etc.
10. Scale out proposed arrangements of crossing bridges, culverts etc. out of the many
alternatives available.
11. Assess special problems if any in the section such as undulating surfaces, long cuttings,
tunnels etc.
12. Scale out the cable entry or exit arrangement at the cable huts of drop insert locations.
Avoid built up areas including those areas where buildings etc. are likely to come up in
future.
IRISET 33 TC1 - Telecom Cables (Copper)
Cable Laying Practices

13. With engineering drawing already in hand, verify pathways/pedestrian crossing and other
lateral clearances.
14. Scale out the special work required if any and the manner of the cable route in approach of
the existing bridge‟s locations.
15. Identify, if any special lengths of cable is required to avoid joints on bridges/culverts etc.,
16. For the straight runs as far as possible a separation of 10 Meter should be kept from the
nearest track.
17. No OFC or Quad Cables shall be laid close to the existing track. It shall be laid
close to the Railway boundary on one side of the Railway track to the extent
possible to avoid any interference with the future works.
18. As a rule, a minimum distance of 5.75 M should be maintained between the OHE masts
and the cable. In Yards etc., where observance of this rule may be difficult, a minimum
distance of 3 Meter should be maintained. In exceptional cases where the cable trench
depth is less than 0.5 Meter the lateral distance may be reduced to 1Meter. In such
trenches, which are in close proximity to OHE masts, the cable should be laid in
PVC/RCC Pipe.
19. Location of traction substations / feeding posts and other OHE switching posts.

6.5 Information in Cable Route Plan

The cable route plan shall contain following information:
1. Whether the cable route is on the up or down side of the Railway Tracks.
2. Approximate location and length where the cable shall be laid in GI pipes and GI troughs
and under the bed on culverts.
3. Locations of sections where the cable shall be covered by burnt bricks positioned breadth
wise @ nine bricks/meter (average).
4. Location of track crossing and the number of tracks to be crossed.
5. Location of road crossing and the number of RCC pipes to be provided.
6. Locations and length for protection of cable in rocky area and platform cutting etc.
7. Approximate locations of derivation Joints for L.C. Gate or emergency socket posts will be
provided on 6-Quad cable. EC posts will be installed exactly at KM Zero markings.
8. The size, length and route of PIJF derivation cables from OFC cable hut to various
subscriber points.
9. Furnish the final cable route plan showing the distance of cable from the nearest track
centre at every 30 M and location of EC posts and joint locations.

6.6 Detailed Cable Route Survey

The purpose of the detailed survey is to undertake the closer study of the various existing
telecommunication facilities, to work out the exact requirement of the 6 Quad and Derivation
/PIJF Cables and materials required for different items of work, finalise all the drawings and site
plans required for the execution of work as also to examine the details collected during
preliminary survey and to effect necessary changes/modification if any.

6.7 Length of 6 Quad Cables

The Quad cable length is to be worked out on the following basis to arrive at the location of the
straight joints.

IRISET 34 TC1 - Telecom Cables (Copper)

Cable Laying Practices

Cable location Cable reserve / loop required

Route length distance between two stations

Contour allowance 2.5% of route length

Track crossing / Road crossing 2.5 meters on each side

Major bridges 10 meters on each side

Minor bridges 5 meters

Cable joint 10 meters from both ends

LC gates / other derivation locations 3 meters

Station / OFC hut 10 meters

6.8 A typical cable requirement calculation for a block section having length of 10 km
with 3 LC gates, one major bridge and two minor bridges/culverts

Sl.no. Cable requirement length in Km.

1 Block section route length 10.00

2 Contour allowance length @ 2.5% x 10 km 00.25

3 Cable loop at 3 LC gates: 3x3 mtrs 00.01

4 Cable approach towards either side of bridge: 10+10 mtrs 00.02

5 Cable loop at either side of major bridge: 10+10 mtrs 00.02

6 Cable loop at 2 minor bridges/culvers: 5+5 mtrs 00.01

7 Cable loop at joints (joints in the section are 10):10x 20 mtrs 00.20

8 Cable approach towards station buildings: 10+10 mtrs 00.02

9 Cable loop at both the station ends: 10+10 mtrs 00.02

10 Total length of cable 10.55 = 10.6

6.9 Telecom cable laying / arrangement in major yards and stations

In big yards and major stations involving large numbers of Cabins/Depot/Tapping points, it may
not be practicable to lay independent derivation cables for various locations. Therefore, one
main cable shall be laid to transverse in a zigzag way through the yard involving frequent
tapping points. 6 Quad and/or higher size PIJF paired cable may be laid for this purpose. The
circuits shall be preferably be tapped through V.F. Transformers. If the depth of the trench is not
feasible to standard depth of one meter in yards and station areas, the lesser depth of cable
trench shall be protected with warning bricks.

IRISET 35 TC1 - Telecom Cables (Copper)

Cable Laying Practices

6.10 Storage of Cable drums

a. The cable drums shall be stored on a well drained, hard surface, so that the drums do not
sink in the ground causing rot and damage to the cable drums. Paved surface is preferred,
particularly for long term storage.
b. The drums shall always be stored on their flanges, and not on their flat sides.
c. Both ends of the cables should be properly sealed to prevent ingress/ absorption of
moisture by the insulation during storage.
d. Protection from rain and sun is preferable for long term storage for all types of cables.
There should also be ventilation between cable drums.
e. Damaged battens of drums etc. should be replaced as may be necessary

6.11 Basic methods of laying underground cables

a) Laying direct in the ground
b) Drawing through ducts
c) Laying solid
6.11.1 Laying direct in the ground
This method of laying cables is comparatively simple and cheap, and is the one that is widely
used. It involves digging a trench in the ground and directly laying the cable on a bedding of soft
earth free from corrosive elements at the bottom of the trench, covering the cable with a layer of
soft earth, placing warning bricks centrally over the soft earth covering and finally filling up the
trench. When the soil contains appreciable quantities of stones or pieces of rock 1.25 mm layer
of sand may be used for the bedding and covering below the layer of bricks.

6.11.2 Drawing through ducts

In this system, also known as the draw in system, one or more ducts are laid together,
according to anticipated requirements and a single or more cables according to size are drawn
through each pipe or duct. Manholes are provided at definite intervals. The initial cost of laying
ducts is high. The system is generally used only in difficult locations such as crossings, railway
bridges, culverts and in such situations where subsequent excavation of a trench is both very
expensive and inconvenient.

6.11.3 Laying solid

This method involves laying a cable in trough made in the excavated trench, filling the trough
completely with molten bituminous compound/ cement concrete, providing warning bricks on top
and then back filling with earth. Laying solid is higher cost than laying direct.

6.12 Special cable laying practices

6.12.1 Track Crossings

a. All cable crossings across the Railway track in station yards shall be done in DWC pipes,
threading the cable through these pipes. The Contractor shall do the trenching to the
required depth wherever necessary, such as approaches to track crossing and the length in
between the adjacent tracks. Two G.I Wires of 10SWG size shall be threaded through DWC
pipes, one to pull the cable and one for future use. The arrangement of cable and DWC
pipe trunking under track crossings has been shown in Drg. No. RDSO/TCDO/COP/19.
b. At locations other than specified above, as directed by site engineer, Track crossing shall
be done by horizontal boring for DWC pipe provision.
IRISET 36 TC1 - Telecom Cables (Copper)
Cable Laying Practices

6.12.2 Road Crossings

a. Metalled, macadamised, concrete and stone paved roads shall also be cut to a depth of 1
metre. The cable shall be laid through RCC or DWC or GI pipes as applicable as per
Drawing No. RDSO/TCDO/COP/20. The road surface shall be restored to original.
b. When crossing Roadways, it is necessary to lay the cable in such a manner as to avoid the
necessity of handling the cable sharply and minimize the excavation of road surface as far
as possible. Where cable is laid on the surface, trunking, trunking aligning should be curved
down to the pipes and proper brick or concrete joint should be made between trunking and
pipe.
c. The crossing of main roads often involves difficulties especially if traffic is heavy.
Precautions to avoid accidents to workmen, pedestrians and the vehicles should be taken.
On minor roads, which can be temporarily closed to traffic, it is possible to open up and
cross the entire width of the road. Pipes should be installed quickly in the cutting, which is
then filled in thereby reducing to a minimum time for which the road is closed.
d. Some roadways, which are broad, may be opened for half the width first allowing the other
half for use by Road traffic. Pipes are laid in the opened half. After the backfilling the
opened portion, the other half is opened and the first half will be used by the road traffic.
After the pipes have been laid in the second half, they must be linked with those laid in the
first half. DWC pipes shall be used for road crossings. In all cases, pipes shall be laid at a
depth of one meter below the formation level or lower as may be required.
e. Wherever a cable is laid across an important road particularly one with a special surface it
is good investment to provide for future expansion. The following methods may be adopted.
f. The size of the pipe shall be so chosen that other cables may be drawn subsequently. Two
lengths of G.I. wire 10 SWG shall be used as lead wire. Two such lengths of G.I. wire shall
be laid through the pipe. One wire shall be used for leading in the cable and the other shall
be kept with suitable overlay to enable cable pulled out at later stages if required. At road
crossings, RCC or DWC pipes of specified dia shall be used.

6.12.3 Culverts and Bridges

a. Wherever possible, the cable shall be laid under the bed of the culvert through RCC pipes
as applicable at site. Similar arrangement shall be provided for taking the cable in water
logged areas and drains.
b. In case of wet culverts or unfriendly terrains where it is not possible to lay cables under the
bed of culverts, the cable may be laid over the culverts and GI pipes as per the Drawing No.
RDSO/TCDO/COP/13 &14.
c. When laying cable on long bridges, the question of longitudinal expansion caused by
temperature differences should be taken into consideration and suitable cable loops should
be provided at the pillars of the Bridges. The cable should also be laid sinuously inside the
GI pipe.
d. The laying of the cable on the bridges is to be done with much care and planning. It is
necessary that the cable drum to be laid on the bridge is inspected and tested thoroughly
so that damaged cable cannot be installed.
e. As laying involves movement of a large number of staff over the bridge, the line should be
blocked if necessary and flagman posted on the other side.

IRISET 37 TC1 - Telecom Cables (Copper)

Cable Laying Practices

6.12.4 Laying of Cable in Solid & Rocky soils and Residential & Marshy areas
a. If the terrain is rocky normal dimensions of the trench cannot be ensured. In such cases
trenching to be done as per Railtel diagrams enclosed.
b. In marshy areas, where it is not possible to divert the cable route, the cable should be
suitably laid and protected as per the decision of the Railway
c. Representative depending on site condition, like laying cables in RCC pipes of suitable dia
concreted at every Meter.
d. The cable will have to be led inside any masonry buildings such as ASM‟s Room at a depth
of 0.75 m by cutting the Masonry structure of the wall. After the cable has been led inside
the masonry wall, the floor inside shall be duly repaired and plastered.
e. Laying of Cable near Power cable: When the contractor comes across any other cable
already laid, he shall first report the fact to the engineer. Should the cable be identified by
the Engineer as a Power cable (LT / HT), the trench shall be dug as far away from the route
of the power cable as practicable.
f. Crossing of Telecommunication cable with another cable shall be avoided wherever
possible. Where, however, this is not possible the telecommunication cable shall be laid in
RCC pipe. The length of the RCC Pipe to be provided on either side of the crossing shall be
at least one meter.
g. The cable shall be laid through GI pipes at the location marked on the tapping and route
plan and as required by SSE/JE.
h. Laying the cable through pipes, galvanized steel wires of a cross section not less than 10
SWG shall be used as a lead wire. Two such lengths of wires shall be laid through the
pipes so that after the cable is threaded through the pipe one led wire is permanently left in
the pipe with a suitable overlay at two ends to enable the cable to be pulled out at a later
stage if required to do so.
i. On arch bridges and culvert bridges, the cables will be threaded through the GI pipes etc.
j. Damages to cables is likely if care is not taken in laying cables where the bed changes from
solid support such as the foundation pipe or bridge to soft support such as soft soil. The
cable must not press against the edge of the solid support.
The soft soil near the edge must be tamped and the cable raised slightly.
k. Special Soil Condition: Cable should not be run through high acidic or alkaline soil or
through sewage. If this is unavoidable, special measures should be taken against
Corrosion.
l. Laying of 6 quad Cable near Feeding Posts/TSS: In the vicinity of feeding posts as far as
possible the cable shall laid be on the side of the track opposite to the feeding post. Further
the cable shall be at least one meter away from any metallic part of the OHE and other
equipments at the substation, which is fixed on the ground and at least one meter away
from substation earthing. In addition, the cable shall be laid in RCC pipes for a length of 300
meters on either side of the feeding point.

6.13 Cable Markers

RCC cable markers shall normally be provided at a distance of every 50 meters on the cable
route, at derivations and also to be provided at all types of cable joints. They should be of
standard RCC with letters “IR / 6 QUAD CABLE “and logo engraved and painted. They shall be
painted with Green when placed at joint locations and painted with Red/ Orange for normal
indication.

IRISET 38 TC1 - Telecom Cables (Copper)

Cable Laying Practices

Joint Inspection shall be carried out by SSE/JEs of Open Line and SSE/JEs of Concerned
Organisation (Ex: Projects/Con.) after completion of cable laying works.

6.14 Power Crossing 11KV and above

Power and telecom cables should have the shortest length of parallelism. When high
voltage power cable 11 KV and above, has a parallelism exceeding 0.8 Km, appropriate
safety measures have to be taken.

Whenever laying of new telecom cables across or parallel to the existing 11KV and above
power crossing, PTTC (Power Telecom Co-ordination Committee) approval is mandatory to
protect Railway Telecom network from induced voltage effects from power lines and vice versa.
As per the PTTC guideline the protection devices such as surge protection devices shall be
provided.

As per PTTC, it is advisable to take the telecom cable with maximum horizontal clearance as far
as practicable but not less than 0.6 meters, so that the intensity of inductive interference can be
minimized. Absence of sheath continuity and armour continuity in Telecom cable and it‟s
improper earthing in the vicinity of power cable will result in AC induction and consequent
impairment of the telecom circuits. When the power parallelism is more than 0.8 kms the cable
route should be referred to PTCC for recommendation of protection measures. In case of
crossings, care should be taken to see that telecom cable crosses at right angles and at a
vertical clearance preferably of 0.6 meters but not less than 0.3 meters at any point. When the
specified clearances cannot be maintained, it is preferable to lay the telecom cable through
cement concrete pipes and seal the mouths at both ends.

In the vicinity of the switching stations, the cable shall be laid at least one meter away from any
metallic body of the station which is fixed in the ground and at least 5 meters away from the

IRISET 39 TC1 - Telecom Cables (Copper)

Cable Laying Practices

station earthing. The distance of 5 meters can be reduced to one meter provided the cables are
laid in concrete pipes or ducts.

IRISET 40 TC1 - Telecom Cables (Copper)

Cable Laying Practices

IRISET 41 TC1 - Telecom Cables (Copper)

Cable Laying Practices

IRISET 42 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

CHAPTER-7

JOINTING OF UNDERGROUND TELECOM CABLES

7.1 Introduction

Underground Telecommunication cables are manufactured in the lengths of 1000 Metres or 500
Metres. To increase the length of the communication media to the required length, the available
cable lengths are to be jointed compulsorily. Therefore, cable jointing is unavoidable to meet the
need. But cable jointing is a highly skilled job and should be done with all precautions. Any
defect in the joint may lead to the total failure of all the circuits. Joints are very vulnerable points
in a cable network, so efforts should be made to do the perfect joint strictly as per the
specifications.

7.2 Preparation of Cable for Jointing

a) During the installation, a minimum of 10 meter of cable of each end is coiled in the jointing
pit to provide for jointing to be carried out at convenient location as well as spare length to
be available for future use in case of failures.
b) The pit size must be chosen carefully to ensure that the length of the wall on which joint is
mounted is greater than closure length plus twice the minimum bending radius of the cable.
A pit length of 1 meter is sufficient for most of the cable and joint closures.
Bending radius of underground telecom cable shall be minimum of 20 times of its dia
c) The cable is then coiled on to the pit wall in the same position as required after the joint is
complete. The marking is done on all the loops so that it will be easier to install it later.
d) The distance from the latest center to the end of the cable must be at least 1.8meter. This is
being the minimum to be stripped for preparation of the joint.

7.3 Jointing procedure of Quad Cable conductors

The method of conductor joints are:

The conductors are twisted and soldered. The twisted portion is covered with PVC sleeve so
that the entire twisted portion up to the PET insulation is well covered by the sleeve.

7.4 Important Stages of making a Cable Joint

1. Testing of Cable ends
2. Arrange pairs/quads
3. Twisting of conductors
4. Soldering Conductors
5. Sheath Continuity (Poly Al, Al Screen and GI armour)
6. Filling the splice filling compound
7. Provision of Al Canister
8. Shrinking of RTSF sleeve

7.5 Various Types of Joints in Quad Cables

The 6 Quad Telecommunication cable is received in lengths of 1000 metres. So, there will be a
cable joint at regular intervals. These joints are systematically arranged as
(i) Straight / Normal joints
(ii) Derivation Joints
(iii) Straight cum Derivation joints

IRISET 43 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

i) Normal joints are straight through joints connecting two ends of a cable.

ii) Derivation Joints: These are transformer joints for tapping various railway control circuits,
to the various utilisation points. According to the requirements of the tapping points the
requisite number of transformers are kept inside of a joint. The derivation side of the
transformer windings are connected to the derivation cable and the main side of the
transformer windings are connected to the main cable.

iii) Straight cum Derivation joints: A normal joint for joining two ends of cable associated
with transformers for a derivation cable. In general, this type of joint will be carried out for
EC sockets, placed at regular intervals of 1 Km.

A typical transformer joint connection is shown in the following figure.

The type of transformer used will depend upon the type of circuit. The following table shows the
transformers of different ratios.

The impedance ratio of matching transformer

Name of the circuit where it is used
in Ohms
When 6 quad cable When 6 quad cable
is loaded is not loaded
1120: 1120 470:1120 For V.F. circuits (Control etc)
1120: 600 470:600 For terminations of 2 wire circuits (LC)
For Block circuits (irrespective of
470 :1120 470:1120
loading)
As per IRS-TC 60-2007, 0.6dB
Insertion loss of VF transformer
maximum
IRISET 44 TC1 - Telecom Cables (Copper)
Jointing of Underground Telecom Cables

7.6 Jointing Procedure of PIJF Underground Cables

7.6.1 Jointing of polythene insulated jelly filled paired cables
The Underground PIJF telephone cables are as per RDSO spec. IRS/TC/41/97
To make cable joints for PIJF Underground telephone cable, universal TSF kit under RDSO
Specification IRS-TC-57/2015 revision1 is used.

The cable drum length, of 10, 20, 50 and 100 pairs, is generally of 500/1000 mtrs. When two
cable lengths are joined together with the Thermo shrink filled closure type jointing kit, the
following sizes of jointing kits are selected. The jointing procedure of polythene insulated paired
cables is the same as the polythene insulated quad cables.

Dia of the Size of Maximum

Heat
conductor Aluminium sheath
Type shrink
in mm canister opening
of kit sleeve size
length/ dia length
(mm)
0.51 0.63 (mm) L (mm)

TSF-1 10 P 10 P 525 +/-15

155/42 225
20 P 20 P 42/8

700 +/ –15
TSF-2 50P 50P 305/42 350
42/15

700+/-15
TSF-3 100P 100P 305/62 350
62/22

200P 200P 910+/-15

TSF-4 405/92 500
400P 92/30

Underground PIJF Paired cables jointing kits selection table

7.6.2 Jointing of 6 Quad PIJF underground Telecom Cables

Thermo shrink joint closure for various types of joints in 6-quad Telecom cables is used as per
RDSO specification no. IRS.TC.77-2012 (rev.3). For EC sockets, L.C. gates, Pump Houses etc.,
the straight through joints with the 2T (for 1 quad) transformer assembly as per RDSO spec.
IRS TC-76/2021 (effective from 29-04-2021) shall be provided for deriving the circuits using 10
pair PIJF paired cable (as derivation cable).

 Jointing Kit

Thermo Shrink Jointing kits, specification no: IRS-TC: 77/2012 (rev.3), for underground 4/6
Quad Jelly Filled Cables of conductor dia. 0.9 mm and 1.4 mm are in use. This Jointing Kit is
meant for straight through / normal, Y/derivation, transformer Joints.

 General Jointing Procedure

a. For jointing of cables pit of 1Mx1Mx1.5M shall be made. The pit surface is to be levelled by
ramming the earth. In case of loose soil or mud, bricks or ballast may be used if necessary.
A tent may be placed over the pit to protect adverse weather/ dust.

IRISET 45 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

b. Bend the two cables ends slowly into an „S‟ shape taking care that the cables are not
strained excessively and minimum overlap of 350 mm is available.
c. Prepare the cable ends as per the detailed installation instructions for making heat
shrinkable joints for 6 quad cables.
d. Preliminary checks may be carried out using Multimeter for continuity of conductors and
breaks/crosses etc., if any. The insulation is measured between all conductors bunched
together and screen/armour by 500 V megger. The equivalent average insulation
resistance/conductance/Km is obtained by multiplying the megger reading with the number
of conductors and the length of the cable in Kilometres.
e. Slip the quad rings on a PE insulated quad of the cable end. Similarly slip another quad ring
on the corresponding PE insulated quad of other cable ends. Select a conductor and slip a
PE sleeve over it. Take this corresponding conductor of the corresponding PE quad of the
other cable end. Peel off the PE insulation from these conductors for a length of 50mm.
f. Bring the two conductors together perpendicular to the cable. Twist the two conductors by
rotating, giving approximately 10 turns for a length of 25mm. Cut off the surplus wire. Solder
half the length of twisted conductors using solder resin core. Solder bit flat and blowlamp.
Fold the twisted conductors along the main cable conductors and allow it to cool. Draw a
PE sleeve over twisted joint in such a way that former projects equally on the two sides of
the latter and equally covers the polythene insulation of the two conductors. It should be
ensured that the PVC sleeve fits properly over the twisted joint and does not move easily
over it.
g. For tapping joint, select the quad from which the circuit is to be tapped. Cut the quad, slip
numbered group ring over both ends as also on the lead wire bunch of required
transformers. Select a conductor in one quad and slip a P.E. sleeve over it and its other
end. Select a conductor, a short lead wire and transformer lead wire and make twisted joint.
With the other end of the short lead and other cut end of same conductor, make another
twisted joint.
h. The conductors of the remaining PE quads should also be joined accordingly.
i. Complete the joint as per the detailed installation instructions given in the jointing kit for
making heat shrinkable joints for 6- Quad telecom Cable

 Quad Cable Jointing Procedure

Cable Preparation

A. Lay cables with overlap of 505mm for Straight through joint or Transformer joint
(Derivation).
B. Expose various sheaths/armour as per details given below:
- Outer Sheath : 505 mm
- GI double tape armour : 20 mm
- Intermediate sheath : 160 mm
- Aluminium Wine Screen : 50 mm
- Inner sheath + poly al : 275 mm
(Splice length)
C. Cut section of 40D/4QJ/6QJ cable for Thermoshrink joint.

IRISET 46 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

1. Mark M1 on both the cables at a distance of 505mm from the end. Cut and remove the
outermost sheath up to M1.

2. Cut and remove the armour up to a distance of 20 mm less than M1.

3. Mark M2 at a distance of 180 mm from M1, towards the cable end, on the middle sheath.
Cut and remove the middle sheath up to M2.

4. Mark 50 mm from M2 towards the cable end, on the Aluminium shield wires. Cut and
remove Aluminium shield wires up to this mark.

IRISET 47 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

5. Slide the split Al. ring over the A1. Shield wires and bend back the wires over the ring.
Repeat steps 2 to 5 on the other cable also.

6. Lay cables with an overlap equal to exposed inner sheath (275mm). This will be the splice
length.

7. Mark 275mm on the inner sheath from the cable end. Cut and remove inner sheath up to
this mark. In case of Jelly filled cable, clean the jelly using the cleaning liquid. This will
expose 25mm of inner sheath of the cable. By making two 10mm wide parallel cuts on the
inner sheath, lift this portion by 45º (inner sheath together with polyAl sheath) for crimping
sheath connector assembly.

8. In case of Derivation / Transformer Joints, Connect Sheath Connector Assembly to the

inner sheath of quad cable and Jelly filled cable. For Straight Through Joints connect the
sheath connector assembly between inner sheath of Quad Cables. Insert PVC Sleeve over
all the wires to be connected, twist the conductors, solder them. After soldering, pull back
IRISET 48 TC1 - Telecom Cables (Copper)
Jointing of Underground Telecom Cables

the PVC sleeves over the soldered conductors. The conductor joints should be staggered to
ensure even splice bundle.

(i) In case of Transformer Joints, the lead wires of transformer and derivation cable also
need to be twisted along with the quad cable conductors and soldered.

(ii) For derivation joints, the wires of derivation cable should be twisted along with the
required wires of quad cables.

9. Slip the heat shrink tube centrally over the tinned copper braid and shrink the tube on the
braid. Ends will be exposed. Fix the bare end of copper braid to shield wire and apply one
turn of spring roll, bend the copper braid end towards inner sheath and complete full turns
of spring roll.

10. Affix Transparent PE Sheet on to the sealant tape and secure the ends of the pouch
after filling the splice filling compound. Filling Compound should be used in all quad
cables including dry core cables.

11. Wrap the PVC tape over the splice bundle with a 50% overlap. Start from one end and
proceed to the other.

IRISET 49 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

12. Remove the insulation of the armour continuity wire to the required length and wrap three
rounds of the bare wire over the armour. Solder the wire to the armour and cover the
soldered area with sealant tape followed by PVC tape. The excess length of the wire can
be secured to the middle of the splice bundle, with PVC tape.

13. Install the Aluminium Cannister centrally over the splice bundle. Apply one round of PVC
tape in the center to hold the half-shells. Cover the parting lines with PVC tape. Wrap two
layers of PVC tape tightly, with 50% overlap, on the canister fingers to form the transition.
Start from the crown end and proceed to the finger end.

14. Place the reinforced H.S. Sleeve centrally on the splice and mark the sleeve ends on the
cable. The area between this mark and the end of the canister is the Bonding Surface.
Clean the bonding surface of grease and dirt with the cleaning tissue and abrade the
surface circumferentially with emery strip. DO NOT TOUCH THE BONDING SURFACE
AFTER CLEANING OR ABRADING.

15. Wrap the Adhesive Aluminium Foil around the Outer Cable Sheath by keeping 25mm of
foil inside the bonding surface.

IRISET 50 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

16. Flame brush the bonding surface TILL IT BECOMES GLOSSY. DO NOT OVERHEAT AS
IT COULD DAMAGE THE CABLE SHEATH.

17. Remove the protective film from the Heat shrink Sleeve.

18. Wrap around the reinforced H.S. Sleeve and position the under clip on the rails at the
center. Slide the S.S. Channels over the rails in such a way that they meet at the center of
the sleeve and are held by the under clip. The S.S. Channel and the canister parting lines
should not come over one another.

19. Insert branch off clip between the cables on to the thermo shrink sleeve. The thermo shrink
sleeve shall be evenly distributed over all the cables. Use cable tie provided in the kit for
securing derivation cable and main cable together.

20. Preheat the channel for about 30 seconds to a minute and then start shrinking the sleeve.
Begin from the center and proceed circumferentially to either end. Tap the channel portion
gently at the transition points adjacent to the canister crown. The shrinking is complete
when the Thermo chromic paint changes colour and white lines appear below the
channels.

IRISET 51 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

21. Concentrate the flame on the metal part of the BOC till the adhesive on the clip melts and
oozes out. Post heat the channels with a moving flame for 15 seconds. Press the channel
with a blunt tool to follow the form of the canister at the transition area and post heat the
transition area.

22. After shrinking, allow the joint to cool for at least 30 minutes, before handling.

 Description of contents in a quad cable jointing kit

(Spec. IRS: TC-77/2012 rev.3, w.e.f: 01.11.2012)

The material (Kit Contents) for Universal Jointing Kit to be used for straight through joint, Y-
(Derivation) joint, Transformer Joint.

0.9 mm cond. Dia 1.4 mm cond. Dia

S. Description of of 4/6 Quad cable of 4/6 Quad cable
No. Materials
Size Qty Size Qty

Heat Shrink Sleeve Size:75/15mm Length: Size:92/25mm

1 1 1
(Reinforced) 850m Length:910mm

Length–450mm Length–470mm
Thickness 0.7mm & Thickness 0.7mm &
Stainless Steel
2 Under clip (Length = Under clip Length = 1
Channels x 2
35mm) & Thickness 1 35mm) & Thickness
0.2mm 0.2mm
Aluminium Canister Size = 75mm x Size = 92mm x
3 1 1
Finger Coated length 507mm length 507mm
Width (25mm ±1mm) x Width (25mm±1mm) x
Adhesive P.V.C. length (10 meter/roll length (10meter/roll
4 2 2
Tape Minimum) x Thickness Minimum) x Thickness
(0.1 to 0.13mm) (0.1 to 0.13mm)
Length(400mm±4mm) x Length(400mm±4mm) x
Adhesive width (100mm±2mm) x width (100mm±2mm) x
5 1 1
Aluminium Foil thickness (0.06 thickness (0.06
±0.01mm) ±0.01mm)
Cleaning Tissue
Tissue paper size- Tissue paper size-Length
( Soaked with 5ml
6 Length (190mm min.) 3 (190mm min.) Width- 3
min Iso Propyl
Width- (140mm min.) (140mm min.)
Alcohol )
Length (600mm±5mm) x Length (600mm± 5mm) x
7 Emery Strip width (25mm± 1mm) x 2 width (25mm± 1mm) x 2
60 mesh) 60 mesh)
length (500mm±5mm) x
length (500mm±5mm) x
width (7mm±1mm) with
Tinned Copper width (7mm±1mm) with
8 heat shrink tubing size 1 1
braid heat shrink tubing size
12/4mm (length
12/4mm (length 450mm).
450mm).

IRISET 52 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

Length 400mm ±10, Length 400mm ±10,

9 Sealant Tape width 35mm ±3 x 2 width 35mm ±3 x 2
thickness 3mm ±0.5 thickness 3mm ±0.5
Size: – Dia 22mm x Size: – Dia 22mm x
Protective split
10 width 20mm x thickness 2 width 20mm x thickness 2
Aluminium Ring
0.9mm 0.9mm
OD-21mm ±1mmWidth OD-21mm ±1mmWidth –
– 16mm ±1mm, No. of 16mm ±1mm, No. of rolls
11 Spring Steel Roll rolls Minimum 8, 4 Minimum 8, thickness of 4
thickness of the steel the steel sheet
sheet 0.2mm±0.02mm 0.2mm±0.02mm
i) dia –(7mm±0.5mm) x
dia –(5mm±0.5mm) x length (50mm±3mm)
12 PVC Sleeves 30 30
length (50mm±3mm) ii) dia – (10mm±0.5mm)
10
x length (65mm±3mm)
Length 1 Meter min. x Length 1 Meter min. X
13 Cleaning Cloth 1 1
Width 0.75-meter min. Width 0.75-meter min.
2 2
14 Cotton Waste 50 grams (min.) 50 grams (min.)
bags bags
Multi strand tinned Length 2000 mm±10 Length 2000 mm±10
copper conductors mm, Nominal Cross mm, Nominal Cross
15 1 1
insulated cable sectional area4 sq. mm, sectional area 4 sq. mm,
(single core) for armour continuity for armour continuity
length (500mm Min) x
length (500mm Min) x
Transparent width (300mmMin),
16 1 width (300mmMin), 1
polythene sheet: thickness (0.07 to
thickness (0.07 to 0.1mm
0.1mm
Jelly filling 2 2
17 (300 gm. min.) (300 gm. min.)
Compound pack pack
Installation
18 1 1
Instructions
size length 900mm x size length 950mm x
140mm height x 120mm 140mm height x140mm
19 Kit Packing Box 1 1
width (Tolerance + width (Tolerance +
10mm, -5mm) 10mm, -5mm)
20 Packing Slip 1 1
1 1
21 Cleaning Liquid 200 gm. (min.) 200 gm. (min.)
pack pack
(1+1+1) indicates (1+1+1) indicates
1 1
a) 2 Clips Sheath a) 2 Clips Sheath
Connector, length Connector, length
1 1
Sheath Connector 700mm ± 7mm 700mm ± 7mm
22
(1+1+1) Assembly b) 1 Clip Sheath b) 1 Clip Sheath
Connector, length Connector, length
1 1
300mm ± 3mm 300mm ± 3mm
c) Bridge connector c) Bridge connector
Branch Off Clip For Y (Derivation) Joint For Y (Derivation) Joint &
23 1 1
(Medium) & Transformer Joint Transformer Joint
Length (254mm±3mm),
Length (315mm±3mm),
Width
Width 4.75mm±0.5mm),
24 Cable tie (4.75mm±0.5mm), 1 1
thickness
Thickness(1.43mm±0.1
(1.56mm±0.1mm)
mm)
25 IDC type Jelly filled IDC type jelly filled butt 30 -
IRISET 53 TC1 - Telecom Cables (Copper)
Jointing of Underground Telecom Cables

discreet wire connector modules Nos. Not applicable

connectors made of polypropylene
for 3 wires (0.4mm to
0.9mm dia. conductors)
IDC type jelly filled
connector modules
IDC type Jelly filled
made of polypropylene 6
26 discreet wire -
for 2 wires bridging type Nos. Not applicable
Connector
(0.4mm to 0.9 mm dia.
conductors)
Parallel jaw plier for
crimping the discrete
wire connectors. The
dimension of the plier
shall be compatible with
27 Parallel jaw plier Not applicable -
the crimping tool and
shall be supplied by the
manufacturer of the
discrete wire
connectors.

Note: - Supply of either item at SN.12 or items under SN 25, 26 and 27 shall be specific to
purchaser‟s requirement as per clause 12 of the specification. Item No. 25, 26 and 27 shall only
be supplied if IDC type discrete wire connectors are required by purchaser and in that case item
number 12 shall not be supplied.

 Precautions for Thermo Shrink Joints of Quad Cables

RDSO guidelines vide lr no: STT/RE/CJ/368 dated 06.03.2013
It has been noted that the failure of the joint is often caused due to incorrect jointing method.
The detailed method of jointing is explained in the installation instructions which are supplied
along with every jointing kit. The performance of Thermo Shrink Joints depends to a large extent
on the correct method of jointing. Thus, the jointing must be carried out by trained jointers only.

Certain important points are highlighted in Annexure -1 which if taken care shall ensure correct
joint in the field.

Precautions to be taken while jointing the cables

1. The mud around the tent should protect the pit from entry of water.
2. The joint should be kept at the same horizontal level.
3. A heap of mud is to be placed over the buried joint so that the water flows away from the
joint.

 6 Quad Cable joint located in half location box

Instead of putting the joints into the jointing pits, the joints are kept in a half location box in the
middle of the sections. In this case, these quad cable conductors shall be terminated on Wago
terminals. (Do not use Krone modules for quad cable termination)
.
7.7 Termination of 6 QUAD CABLE at Stations/SSP/SP/IB Hut

The 6 Quad cable terminated in 20 pair cast iron termination box is 20 pair CTB. The CT box
after termination of quads shall be sealed by pouring paraffin wax. These 20 pair CTB will be
used at ASM rooms, LC gate lodges, IBS huts etc.
IRISET 54 TC1 - Telecom Cables (Copper)
Jointing of Underground Telecom Cables

The 6 quad cables will have to be led inside the masonry building in the ASM‟s room / SSP/IB
Hut at a depth of 0.75 meter by cutting the masonry structure of the wall. After the cable has
been lead inside the masonry wall, the floor inside shall be duly repaired and plastered. The 6
Quad cables shall be taken through GI pipe and dressed upon wood plank mounted at one-
meter height from the floor level and terminal box duly fixed on the wall with suitable bolts and
nuts.

The Six quad cables shall be terminated in the following order in a CTB

Quad 1: I Pair a) Orange b) White

II Pair c) Red d) Grey
Quad 2: I Pair a) Blue b) White
II Pair c) Red d) Grey
Quad 3: I Pair a) Brown b) White
II Pair c) Red d) Grey
Quad 4: I Pair a) Green b) White
II Pair c) Red d) Grey
Quad 5: I Pair a) Yellow b) White
II Pair c) Red d) Grey
Quad 6: I Pair a)Black b) White
II Pair c) Red d) Grey

The cable termination box shall consist of the following components.

a. Case b. Front cover c. Back plate d. Terminal plate

e. Terminal stud f. Hinge pin.

20 pair CTB

The case front cover and back plate shall be made from alloy aluminium casting. Brass used for
terminals. The terminals block shall form one face of the C.T. Box. It shall have requisite pairs of
brass terminals so that the connections of the underground cable can be soldered on the inner
side of the block and external wires can be connected with nuts on the outer side. For outdoor
cable termination the Cast Iron C.T. Box or Alloy aluminium casting C.T. Box is used for R.E or
non-R. E area.

IRISET 55 TC1 - Telecom Cables (Copper)

Jointing of Underground Telecom Cables

7.7.1 Termination of 10p/20p/50p/100p PIJF Telephone Cables

Termination Box with Krone / Wago type modules are in use for terminating PIJF telephone
cables. Cable terminal boxes are supplied in different variants viz., 20 pairs, 50 pairs and 100
pairs. They are used for terminating the switchboard cables or jelly filled cables entering the
CTB.

KRONE LSA-PLUS® Connection Module

KRONE LSA-PLUS® Connection Module, for 10 pairs with parallel test facility or provision for
over voltage protection using 10 pair protection magazine. Conductor diameters of connectable
wires are 0.40 to 0.63 mm

a b a b a b a b - - - - a1
1 2 3 4
1 1 2 2 3 3 4 4 a10 0

a b a b a b a b - - - -
1 2 3 4 a1
1 1 2 2 3 3 4 4 a10

100 Pair Krone modules assembly

At present the pairs of polythene-insulated jelly filled cables are terminated in Krone. Generally
one block of Krone can be used for termination of 10 pairs of cable. Such type of crone can be
used in CTB / Location Box for termination of primary, secondary or distribution cable. Each
block of Krone is assembled in a frame, which may hold 10 such blocks (100 pairs termination).

7.7.2 Wago terminal

Wago terminal block

A 0.2mm square conductor (left) and nominal diameter 16mm square (right) in one 16mm
square terminal block. CAGE CLAMPR and CAGE CLAMPRS connections clamp Copper
conductors from 0.08mm square to 35mm square (95mm square), or from 0.25mm square to
25mm square, respectively. Splice protection is not required–but can be used. The conductor is
pressed against the current bar in the predefined contact area, without damaging it. The
clamping force automatically adjusts to the wire size. Possible conductor deformation is
balanced and an accidental loosening is safely prevented.
IRISET 56 TC1 - Telecom Cables (Copper)
Testing of Cables

CHAPTER-8

TESTING OF CABLES

8.1 Types of tests: Cable testing can be classified into:

1. Testing before laying of cable
2. Testing after laying of cable
3. Fault localization tests
4. Testing of cable before commissioning of BPAC
5. Routine Testing (as per Telecom Manual)

8.1.1 Tests before cable laying

a) Test the cable for proper end sealing.
b) Check for any physical/Mechanical damages during transportation, and during
manufacturing etc.,
c) Continuity and Insulation Test

8.1.2 Tests after completion of cable laying

a) Continuity test – Ohm-meter
b) Insulation test – Insulation Tester/ Megger

8.1.3 Fault localisation tests

a) Conventional methods
b) Using Cable fault locator
At the time of commissioning of the cables, the insulation values of the cable should again be
checked and the value obtained shall not be below 100 Mega Ohms per KM with 100V Megger.
If there is wide disparity between insulation of different conductors, the conditions of the cable
should be thoroughly checked before permitting its use. The readings shall be recorded in the
register for all cables.

8.1.4 Testing of cable before commissioning of BPAC application

Mandatory Check & Tests to be done before commissioning of BPAC/SSDAC/MSDAC
applications on Quad/PIJF cables as per RDSO letter No. STS/E/SSDAC/ SPN/177
dt. 28/30-08-2006. (Refer Para 8.4)

8.1.5 Routine tests

a) Conduction test : Monthly
b) Transmission loss test : Monthly
c) Crosstalk (near end and far end) test : Quarterly
d) Psophometric Noise test : Quarterly
e) Insulation test : Yearly

8.2 Acceptance tests for 6 Quad PIJF cables

8.2.1 Conduction Test (loop resistance and continuity)
To measure the loop resistance of the pair and resistance of each conductor. Measuring
instrument used for this measurement is Multimeter or Ohm meter or Null balance Bridge
Megger
IRISET 57 TC1 - Telecom Cables (Copper)
Testing of Cables

8.2.2 Transmission loss test (Frequency attenuation measurement)

To measure the Transmission loss of the system (cable). It also indicates the insertion loss of
way station equipment. Instruments used are Transmission measuring sets

8.2.3 Insulation Resistance test

To measure the Insulation Resistance of a transmission line (conductors) Instrument used for
measurement of insulation resistance is Insulation Tester (Megger)

IRISET 58 TC1 - Telecom Cables (Copper)

Testing of Cables

8.2.4 Crosstalk Test:

The signals of one pair of the cable produce unwanted signals in other pairs due to electrostatic
and electromagnetic induction effects. These unwanted signals are called „Cross Talk‟. The first
pair is called the DISTURBING PAIR and the other pair is called the DISTURBED PAIR.

The instrument used is Cross Talk measuring sets. The cross talk is of two types:
1. Near end crosstalk (NEXT) 2. Far end crosstalk (FEXT)

1. Measurement of Near End Cross Talk (NEXT):

Meter Characteristic
DISTURBING PAIR
Output Impedance
N Far
Near end
end of
of the the
pairs Pairs

Meter Characteristic
DISTURBED PAIR
Input Impedance

2. Measurement of Far End Crosstalk (FEXT):

Characteristic
Meter
DISTURBING PAIR Impedance
Output

Characteristic
DISTURBED Meter
Impedance
PAIR Input

8.2.5 Psophometric noise level test

Psophometer is basically used to measure the interfering effect of noise in telephone equipment
caused by amplifier noise, fundamental and harmonic frequencies of AC line supply as well as
by intelligible or unintelligible crosstalk from neighbouring lines. Instrument used for measuring
this noise is a Psophometer.

IRISET 59 TC1 - Telecom Cables (Copper)

Testing of Cables

8.3 Standard values of various tests

S. No Description Value
1 Loop Resistance in Ω
Cable conductor of dia 0.51 mm 184 Ω / L.Km
Cable conductor of dia 0.63 mm 128 Ω / L.Km
Cable conductor of dia 0.9 mm 56 Ω / L.Km

2 Psophometric Noise ≤ 2 milli Volts

3 Insulation Resistance in MΩ
a) With 100V Megger >100 MΩ / Km
b) With 500V Megger >1000 MΩ / KM
4 Transmission loss in dB
a) Cable conductor of dia 0.51 mm 1.379
b) Cable conductor of dia 0.63 mm 1.107
c) Cable conductor of dia 0.9 mm 0.65 (unloaded)
0.25 (when loaded}

8.4 Mandatory Check &Tests to be done before commissioning of

BPAC/SSDAC/MSDAC applications on 4/6 Quad/ PIJF cables.
a) Conduction test :
56 ohms/loop km
b) Insulation Resistance :
> 10 M Ohms.
c) Transmission loss test. :
At 2 KHz/600ohms Transmission loss will be 1.2
dB/Km and it shall not be more than 30 db for full
length Section.
d) Near end Crosstalk at 155 KHz : Should be better than -55 dB
e) Far End Crosstalk at 155 KHz : Should be better than -55 dB
f) Psophometric Noise : Should not be more than 2 mV.
g) Continuity of Armour : Should be Ensured
h) Earth Resistance at Armour : Less than 1 Ohm
i) Position of one quad in quad cable x(A)
x (C) x (D) 1st pair - AB
x (B) 2nd pair CD
j) Each Quad is bounded by respective quad colour binder

Precautions to be taken while using quad cable:

• Designated pair of wire of the same quad should be used.
• Do not use one wire of one quad and another wire from another quad.
• If any wire of a pair of the quad is broken then a fresh pair of wire should be used.
• No wire should be paralleled for reducing the conductor resistance.

8.5 Causes for cable failures & precautions

• Manufacturing defects – Test the cable before laying
• Laying of cable at lower depth–Check the depth of the trench before closing the cable
trench
• Joint failure due to use of substandard / expired jointing kit or jointing done by un skilled
jointer- use RDSO approved jointing kit and ensure a skilled person for jointing.
• Cable joint burnt due to lightning- Ensure the proper continuity of amour before closing the
joint and armour shall be connected to an earth at cable terminations. Earth Resistance
shall be less than 1 ohm at both ends of cable termination.

IRISET 60 TC1 - Telecom Cables (Copper)

Testing of Cables

• Using a Quad cable without jelly – Water enters into the joint along with cable core when
there is any cable damage (crowbar hit) in between two joints. Use the PIJF 6 quad cable
as per RDSO spec no. IRS: TC30-2005.
• Exposing of cables on Bridges/ Culverts/Rocky areas- Regular Cable route inspection shall
be done by section Technician (TCM)/JE and strengthening of cable route shall be carried
out as per Railway Board Telecom Action plan.
• Cable cuts and thefts- Ensure the cable laid within Railway boundary, avoid the exposing of
cable implement the Railway Board JPO for Earth digging works by Engg. Dept., update the
cable route diagrams and upload to the web page for easy access to concerned dept.
• Codal life of Cable- Plan for replacement of cable within its codal life (20 / 25 years).

8.6 Fault localisation Tests

8.6.1 Conventional methods

Inspection of cable route to identify the spots of recent digging:

Foot inspect the entire cable path in the section. If there is any sign indicating any recent
digging the same can be suspected to contain the fault. Excavate the trench and expose the
cable. Extend the trench for about 10 ft. length or up to the length covered by the recent digging.
Expose the cable. Inspect for any damage on the cable. If there is any damage, operate the
cable.

Operating the joint nearest to the point of localization

a) Find out from the cable diagram the joint nearest to the point of localisation. Locate it (Joint
J1 in figure). Expose the joint. Inspect for any damage. If the joint is damaged, verify if this
was the fault. If so, repair and close the case.
b) If the fault is not found in this joint, expose the joint on the other side of point of localisation.
Call it joint J2 and repeat the above operation of testing.

Spot localizations
1. Test from joint J1 to determine if the fault is towards the point of localisation or on the other
side i.e., towards joint J3.

J1 --- L -----J2----- L---------J3-----L-----J4

2. If the fault is towards joint J2 take the test from J2 If the fault is towards J1 from here,
proceed for spot localisation and determine the length of the overlap between joints J1 and
J2.
3. If fault is towards J3, tested from J2, operate J3 and repeat the spot localisation and
determine the length of overlap between J2 and J3.
4. If you find fault on either side of a joint, it indicates multiple faults. Clear faults one by one.

8.6.2 Using Cable fault locator

Fault localizations by using Digital Cable Fault locator

Cable repair work, localisation of faults must be simple and accurate. In most of the techniques
adopted for cable fault localisation, the procedure adopted is very much laborious. A loop test
for example, is time consuming. It is essentially a D.C. test whose accuracy can be altered with
the presence of a foreign potential in the cable pair under test.
IRISET 61 TC1 - Telecom Cables (Copper)
Testing of Cables

All the types of faults in the cable as mentioned below can be identified
1. Break/Open Circuit and Short Circuit fault.
2. Low Insulation faults.
3. Induced Voltage
For accurate and speedy fault localisation, the techniques using pulse reflection method is
found to be quite useful. It is essentially a high frequency AC test signal generator and useful for
localizing those faults that do not upset any DC condition but affect the propagation of the A.C.
high frequency energy. The nature of faults that include open circuits, open sheaths, high
resistance joints, and water logged cable section etc.

Testing Procedure
There is no need for a good pair or limb for conducting the tests of break, open, insulation and
induced voltage. However, if a good pair is required as a reference pair to identify low insulation
faults. It is advisable that the cable pair to be tested is free from voltage. The reflection of pulse
will depend on the impedance irregularity of the pair under test.

In the case of open or break fault the reflection pulse will be indicated by upward kink or positive
reflection. For short or low resistance faults the reflection pulse will be indicated by downward
kink or negative reflection. Whatever energy reaches the dead short is totally reflected back
because the dead short appears as a mere impedance irregularity and we can see a big
reflected pulse corresponding to the dead short. Poorer the insulation at the fault greater is the
magnitude of the impedance irregularity and bigger the reflected pulse. The presence of
moisture in a particular section alters transmission characteristics of that section. It is essential
to connect the instrument to one end of the circuit under test and shift it to the other end and
carryout the same test so as to find out the length of overlap.

The accuracy of distance to fault depends upon the accuracy of V/2 values.
D = V/2 X T
Where T is the time taken for the reflected pulse energy to arrive back at the instrument, V is the
velocity of propagation in a circuit and D is the distance to fault.

For Knowing V/2 value, connect the cable pair to the instrument the reflected pulse should be
aligned accurately with the incident pulse and the switch should be set such that the display on
the digital readout corresponds to the V/2 value for that pair.

It should be remembered that alignment of incident and reflected pulses should be done with
reference to the commencement of their leading edges (align the foot of the reflected pulse with
the foot of incident pulse).

Types of Faults and their respective Reflection Pulses

1. Conductor break fault (one limb or both): A positive reflection will be shown at the point of
break.
2. Contact Fault (Limb to Limb). A negative reflection will be shown at the point of contact.
3. Earth Fault (Limb to Sheath). It is a very low resistance fault. When pulse is applied
between the conductor (limb) and sheath a negative reflection similar in the above case is
observed.

IRISET 62 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

CHAPTER-9

QUAD CABLE MAINTENANCE

9.1 Typical 6 Quad cable failures & their causes

1. Cable burnt at joint due to lightning and all circuits failed- armour connectivity in joint was
given up.
2. Cable is noisy while train passing in the section and BPAC circuit is frequently failing-
improper earthing of cable armour.
3. Abnormal delay (48 hrs) in restoring of 6 quad cable fault: Cable was not traceable
because cable was laid outside Railway Boundary one year back and the colony people
constructed culvert on the cable route at about 10mts. The drainage water was overflowing
and spread over the area and got covered with thick bushes. Staff were not able to walk on
the cable route with cable route locator and missed the fault. Cable was found damaged in
the culvert.

Integrated Cable path diagram showing all S&T Cable path positions shall be prepared
and made available with all S&T staff to protect the underground S&T Cables.

9.2 Important tools to protect underground S&T Cables from damages

1. Integrated Cable Path diagram
2. Cable route tracer
3. Cable Fault Locator (Digital)

9.3 QUAD CABLE MAINTENANCE REGISTER

General Instructions
Do's
Quad cable testing of Block, BPAC and IB applications should be done with
1.
disconnection and jointly with ESM/ JE-Sig.
To avoid train detention, ensure proper planning before work and test the circuit
2.
after the work is completed in consultation with signal staff.
3. Before testing the cable, ensure suitable staff availability at both ends
4. Before testing, check your meters for correct calibration.
5. Isolate the working circuit from the end point and test the cable end to end.
Before insulation testing check earth resistance at test point. Test results will be
6.
misleading in absence of proper earth.
7. Ensure the watering of the earth pit on every visit.
After testing and reconnecting the cable, ensure functioning of all circuits with SMR
8.
/ Test room.
Don’ts
Don‟t disconnect Block, BPAC and IB circuits without issuing disconnection memo
1
for testing of Quad cable

IRISET 63 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

Measuring Instruments & Tools Required for Maintenance of

PIJF underground Telecom quad cables

(i) Multimeter 1 no.

(ii) T.M.S. Kit 2 sets

(iii) Psophometer 1 no.

(iv) Cross Talk Measurement Set 2 sets

(v) Megger (100 Volts) 1 no.

(vi) Earth Tester 1 no.

(vii) Cable fault locator (Digital) 1 no.

(viii) Cable Route Locator 1 no.

(ix) Emergency Control Telephone 1 no.

(x) Pick axe 2 nos.

(xi) Crow Bars 2 nos.

(xii) Shovels 2 nos.

(xii) Search Light 1 no.

Schedule of Testing & Measurements

1 Checking Attenuation Monthly

2 Loop Resistance Test Monthly
3 Checking Crosstalk Level Quarterly
4 Checking Noise Level Quarterly
5 Insulation Resistance Test Yearly

Inspections

1 Monthly schedules JE / SSE - Telcom

2 Quarterly & Yearly schedules SSE / T/ Section Incharge

3 Annual inspection ADSTE/ DSTE/ Sr. DSTE

IRISET 64 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

Quad Cable Allocation in the Section

Quad No. Circuit working

Quad 1

Quad 2

Quad 3

Quad 4 / 1

Quad 4 / 2

Quad 5

Quad 6 / 1

Quad 6 / 2

INDEX SHEET
SSE / JE Section: ________________________________________
Page Sl. Page
Sl. No. Name of the Block Section Name of the Block Section
No. No. No.
1 21
2 22
3 23
4 24
5 25
6 26
7 27
8 28
9 29
10 30
11 31
12 32
13 33
14 34
15 35
16 36
17 37
18 38
19 39
20 40

IRISET 65 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

6 QUAD CABLE TEST REPORT (for 1st Quarter)

Control Section : ____________________________

Section Under Testing: ____________________________

1 st Month ____________ 2 nd Month ____________ 3 rd Month _____________

Date of Testing _________ Date of Testing _________ Date of Testing __________

Transmission Transmission Transmission

Quad Loss @ 800HZ Loss @ 800HZ Conduction Loss @ 800HZ
Conduction Conduction
No (0.28 db/KM for (0.28 db/KM Test (0.28 db/KM
Test Test
loaded for loaded (56 Ω for loaded
(56 Ω /KM) (56 Ω /KM)
0.8db/Km 0.8db/Km /KM) 0.8db/Km
unloaded) unloaded) unloaded)

Pair Pair
Pair-1 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2
-1 -1

6
1) Earth Resistance
at cable Armour
( To ensure integrity of
________ Ω. ________ Ω. ________ Ω.
Earth)
2) Armour continuity
with respect to Earth
( To ensure Armour
________ Ω. ________ Ω. ________ Ω.
continuity)

Remarks:

Signature
Name
Designation

IRISET 66 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

6 QUAD CABLE TEST REPORT (for 2nd Quarter)

Control Section : ____________________________

Section Under Testing : ____________________________

1 st Month ____________ 2 nd Month ____________ 3 rd Month _____________

Date of Testing _________ Date of Testing _________ Date of Testing __________

Transmission Transmission Transmission

Quad Loss @ 800HZ Conduction Loss @ 800HZ Conduction Loss @ 800HZ
Conduction
No (0.28 db/KM for Test (0.28 db/KM Test (0.28 db/KM
Test
loaded (56 Ω for loaded (56 Ω for loaded
(56 Ω /KM)
0.8db/Km /KM) 0.8db/Km /KM) 0.8db/Km
unloaded) unloaded) unloaded)

Pai Pair
Pair-1 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2
r-1 -1

6
1) Earth Resistance
at cable Armour
( To ensure integrity of
________ Ω. ________ Ω. ________ Ω.
Earth)
2) Armour continuity
with respect to Earth
( To ensure Armour
________ Ω. ________ Ω. ________ Ω.
continuity)

Remarks:

Signature
Name
Designation

IRISET 67 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

6 QUAD CABLE TEST REPORT (for 3rd Quarter)

Control Section : ____________________________

Section Under Testing : ____________________________

1 st Month ____________ 2 nd Month ____________ 3 rd Month _____________

Date of Testing _________ Date of Testing _________ Date of Testing __________

Transmission Transmission Transmission

Quad Loss @ 800HZ Conduction Loss @ 800HZ Conduction Loss @ 800HZ
Conduction
No (0.28 db/KM for Test (0.28 db/KM Test (0.28 db/KM
Test
loaded (56 Ω for loaded (56 Ω for loaded
(56 Ω /KM)
0.8db/Km /KM) 0.8db/Km /KM) 0.8db/Km
unloaded) unloaded) unloaded)

Pai Pair
Pair-1 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2
r-1 -1

6
1) Earth Resistance
at cable Armour
( To ensure integrity of
________ Ω. ________ Ω. ________ Ω.
Earth)
2) Armour continuity
with respect to Earth
( To ensure Armour
________ Ω. ________ Ω. ________ Ω.
continuity)

Remarks:

Signature
Name
Designation

IRISET 68 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

6 QUAD CABLE TEST REPORT (for 4th Quarter)

Control Section : ____________________________

Section Under Testing : ____________________________

2 nd Month
1 st Month ____________ 3 rd Month _____________
____________
Date of Testing _________ Date of Testing __________
Date of Testing _________

Transmission
Transmission Transmission
Loss @
Quad Loss @ 800HZ Conduction Loss @ 800HZ
Conduction 800HZ (0.28 Conduction
No (0.28 db/KM for Test (0.28 db/KM
Test db/KM for Test
loaded (56 Ω for loaded
(56 Ω /KM) loaded (56 Ω /KM)
0.8db/Km /KM) 0.8db/Km
0.8db/Km
unloaded) unloaded)
unloaded)

Pai
Pair-1 Pair-2 Pair-1 Pair-2 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2
r-1

6
1) Earth Resistance
at cable Armour
( To ensure integrity of
________ Ω. ________ Ω. ________ Ω.
Earth)
2) Armour continuity
with respect to Earth
( To ensure Armour
________ Ω. ________ Ω. ________ Ω.
continuity)

Remarks:

Signature
Name
Designation

IRISET 69 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

Length of the cable : ______________ KMs

Test Location : _______________________
st
1 Quarter
Date of Testing _________________________
Near End Crosstalk @ Far End Crosstalk
Psophometric Noise Induced Voltage w.r.t earth
800 Hz @ 800 Hz
(< 2 m V) (<5V)
(better than -61db) (better than -65db)
Pair-1 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2 a b c d

Length of the cable : ______________ KMs

Test Location : _______________________
2nd Quarter
Date of Testing _________________________
Near End Crosstalk @ Far End Crosstalk
Psophometric Noise Induced Voltage w.r.t earth
800 Hz @ 800 Hz
(< 2 m V) (<5V)
(better than -61db) (better than -65db)
Pair-1 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2 a b c d

IRISET 70 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

Length of the cable : ______________ KMs

Test Location : _______________________
rd
3 Quarter
Date of Testing _________________________
Near End Crosstalk @ Far End Crosstalk
Psophometric Noise Induced Voltage w.r.t earth
800 Hz @ 800 Hz
(< 2 m V) (<5V)
(better than -61db) (better than -65db)
Pair-1 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2 a b c d

Length of the cable : ______________ KMs

Test Location : _______________________
4th Quarter
Date of Testing _________________________
Near End Crosstalk @ Far End Crosstalk
Psophometric Noise Induced Voltage w.r.t earth
800 Hz @ 800 Hz
(< 2 m V) (<5V)
(better than -61db) (better than -65db)
Pair-1 Pair-2 Pair-1 Pair-2 Pair-1 Pair-2 a b c d

IRISET 71 TC1 - Telecom Cables (Copper)

Quad Cable Maintenance

6 QUAD CABLE INSULATION TEST REPORT (YEARLY)

Control Section : ____________________________
Section Under Testing : ____________________________
Insulation test
Insulation test with Adj. conductor in the quad
w.r.t Earth
(>20 M Ω)
Quad No (10 M Ω/KM)
a b c d ab ac ad bc bd cd
1
2
3
4
5
6

Remarks:

Signature
Name
Designation

Length of the cable : ______________ KMs

Test Location : _______________________

Insulation test with adjacent Quad

(>20 M Ω.)
Q1- Q1- Q1- Q1- Q1- Q2- Q2- Q2- Q2- Q3- Q3- Q3- Q4- Q4- Q5-
Q2 Q3 Q4 Q5 Q6 Q3 Q4 Q5 Q6 Q4 Q5 Q6 Q5 Q6 Q6

IRISET 72 TC1 - Telecom Cables (Copper)

Annexure

CHAPTER -10

CABLE ROUTE TRACING AND FAULT LOCALISATION

10.1 Introduction
In the Telecom Cable maintenance, the cable route tracing and fault localisation
activities are very important on different occasions.

10.2 Cable Route Tracing

Cable Route tracing is required in the following occasions:
1. During Cable fault localisation activity
2. During joint inspection for new cable laying path survey to decide the path which is not
affecting the existing cable in use.
3. During the joint inspection with Engg. Department for various Civil engineering works
pertaining to new constructions etc.,
4. During the joint inspection with Engg. Department for other civil engineering works
involved with JCB working which will affect the existing cable path
5. During the joint inspection with Electrical department for the electrical cable laying for
maintaining the separation of the cable paths
6. During the joint inspection with other Govt. Enterprises like GAIL, RWS for giving
clearance to their runway existing cable path to be traced and marked
7. For preparing updated cable path diagrams Cable route tracing is required
8. During the joint inspection with other private agencies crossing Railway boundary in
underground, cable path location is to be made available.

10.3 Cable Route Tracer CSCOPE

Cable Route Tracer of C Scope is a precision instrument which facilitates the
identification of underground utilities such as Telecom Cables, Power cables,
underground pipes and any underground metallic structures along with its depth.
It consists of two units: 1. Transmitter or Signal Generator 2. Receiver or Cable
Avoidance tool

10.3.1 Transmitter or Signal Generator

The function of the Transmitter is given below :
I. Automatic Self-Test.
II. Data Logging of all Signal Generator activity.
III. Automatic Back-light
IV. Four Power Output settings.
V. Pulsed or Continuous output signal.
VI. Loud, Muted or Silent audible output settings.
VII .Combined Frequency (CF) signal output (33 kHz and 131 kHz)

10.3.2 Receiver or Cable Avoidance Tool

The receiver works in three different modes as per the prevailing condition of the
underground structures, i.e. detection of Telecom Cables, Power cables,
underground pipes and any underground metallic structures.
A) POWER MODE
B) RADIO MODE
C) GENERATOR MODE

IRISET 73 TC1 - Telecom Cables (Copper)

Annexure

10.3.2.1 POWER MODE

In Power Mode, the Locator detects power signals. These power signals are
present in all current carrying electric cables, though all are not detectable.
Power signals may also flow along other conductors such as metallic gas and
water pipes, telecom cables, metallic fences and railway tracks.
Limitations of Power Mode: Not all electric cables can be found using the Power
Mode. For example, when there is no power for Street light or building, the
power cable may not be detectable using Power mode i.e. when power is not
available in the conductors and in the case the cable is located more than 3m
(9‟9”) deep
Note: Locators can only detect services radiating detectable electromagnetic
signals. There may be some services that do not radiate these signals which
cannot be located. Absence of Power signal doesn‟t mean service is not live

10.3.2.2 Radio Mode

In Radio Mode, the Locator detects signals from various radio transmitters.
These signals flow through the ground and will tend to follow the line of least
resistance such as a buried metallic service. When this happens, the service can
often be detected by using the Locator in Radio Mode
Limitations of Radio Mode: Not all services will be detectable in Radio Mode. A
strong radio signal present on one service may be masking a weaker radio signal
present on an adjacent service. Radio signals do not favour one utility (objects
such as metallic pipes) over the other. The depth of the buried service cannot be
judged by the strength of the radio signal alone. Normally it is only possible to
detect radio signals present on services up to 2 m (6‟6”) depth. A short service
may not have enough signals to be detected

10.3.2.3 Generator Mode

In Generator Mode the Locator detects conductors radiating a signal applied by
the Signal Generator. The Signal Generator sends a known signal along buried
metallic services which can then be detected by using the Locator. By detecting
this signal, it is possible to locate, trace and identify the pipes or cables that may
be carrying it.
There are TWO basic methods by which the generator signal can be applied to
buried services:
a) Direct Connection method - The Signal Generator is attached directly to the
service using either the Direct Connection Leads or one of the accessories
available for use with the Signal Generator such as the Signal Clamp or Signal
Injector.
b) Induction method - The Signal Generator can induce a signal onto a buried
metallic service remotely from the surface without the need to physically connect
to that service.

IRISET 74 TC1 - Telecom Cables (Copper)

Annexure

10.4 Important points for operation of Locator

1. Batteries: Before using the locator battery backup to be checked from the
battery level indicator in the bottom left hand corner of the display If there is only
one segment or no segments of the indicator, then the batteries need to be
replaced as this may give erroneous result.
2. Holding the Locator: It should be held up right. It should never swing.
3. Locating the Cables: There are three stages to locate, i.e., Searching,
Pinpointing and Tracing.

10.4.1 Searching
1. Mode Switch to the appropriate mode is to be selected first
2. Holding the On/Off trigger. The Locator should emit the audible battery test
tone and the digital display should come on. Battery level indicator to be checked
for confirming the batteries are usable.
3. Sensitivity Control to be rotated clockwise for the required maximum setting
and it will be indicated by the arrow on the control.
4. Carrying out the search using a grid pattern. Walking slowly and keeping the
Locator upright at all times and stationary to get the better result.
5. On approaching the area in which there is a signal, the Locator will respond
and shows a visual response on the display. Walk to be continued till the visual
responses disappear in the display to pinpoint the cable.

IRISET 75 TC1 - Telecom Cables (Copper)

Annexure

10.4.2 Pinpointing
After getting a signal the next step is to pinpoint the source. The closer the
Locator is to the signal source, the stronger the response. This can be done by:
1. By keeping the Locator vertical, to be moved through the area of the
signal response for any changes in the signal. If the visual response is observed
moving out of the scale, then walking to be stopped and the sensitivity of the
Locator to be reduced slightly before continuing.
2. The width of the signal response will shrink as the sensitivity is
reduced. Once it is reduced enough then a clear peak response will be seen on
the display, as the Locator traverses the service. The Locator is to be positioned
directly above the buried service. When the display is at its highest (peak)
reading, then the Locator to be rotated over the peak reading until the visual
response falls to a minimum. The Locator is now roughly IN LINE with the
direction of the buried service (cable). Now the position can be marked.

10.4.3 Tracing
After pinpointing a service (cable/ pipe) it will be possible to trace its route.
1. The direction of the signal holding the Locator at right angles to the line of the
signal is to be followed carefully. It is necessary to constantly „slice‟ the Locator
from side to side in order to be sure of still being over the peak signal response.
2. The position of the signal at regular intervals is to be marked. If more marks
are recorded, the precise direction of the service will become more apparent.

10.5 Usage of Generator Mode

The signal Generator/ Transmitter mode is used when a particular cable is to be
detected and traced, out of many cables. This can be done in the following four
ways:
Direct Connection - Physically connecting the Signal Generator to the cable is
the most effective way to transfer the signal and the best way to trace the route.
Signal Clamp - The Signal Clamp is an accessory that allows the Signal
Generator to be applied to a specific cable without having an electrical contact
with that cable.
Signal Injector - The Signal Injector is an accessory that allows the signal of the
Signal Generator to be safely applied to an electrical system via a conventional
3-pin power socket.
Induction - Induction is a method of applying a signal to a cable where there is
no direct access.
**Warning: The instrument should not be directly connected to an electrical
service Permission of the service holder to be taken before connecting it to cable.
The Leads and Earth Stake that are supplied with the Signal Generator can be
used for applying the signal to any metal pipe or cable.

10.5.1 Direct Connection method

1. Direct Connection Leads will be plugged directly into the Signal Generator
Connection Socket.
2. Red lead to be attached to the cable at the point of access using the
Crocodile Clip. Secure and clean grip with the Crocodile Clip to be ensured
3. Signal Generator will be turned to ON.

IRISET 76 TC1 - Telecom Cables (Copper)

Annexure

4. Earth Stake to be placed in the ground. The ideal position for the Earth Stake
is at right angles to the assumed line of the cable.
5. Black Earth Lead will be connected to the Earth Stake. If the earth point is too
far away from the pipe access point for the black Earth Lead to reach then 10
metre yellow Auxiliary Earth Lead can be used
6. As the Earth Lead is connected to the Earth Stake, the audible signal from
the Signal Generator should change in pitch. Lower the pitch, the better the
signal. If there is no change in the pitch, it indicates there may be some dirt,
rust or paint on the pipe.
7. Output Power Level to be adjusted to suit the system.

10.5.2 Signal Clamp method

1. Signal Clamp will be plugged into the Connection Socket on the Signal
Generator.
2. Signal Generator to be turned ON.
3. The jaws of the Signal Clamp to be checked for cleanliness. Signal Clamp to
be placed around the cable making sure that the jaws are able to fully close. The
audible signal from the Signal Generator should drop in pitch indicating that the
jaws have closed correctly.

10.5.3 Signal Injector method

1. Signal Injector is to be plugged into the Connection Socket on the Signal
Generator/ Transmitter and an electric outlet.
2. Signal Generator and the socked are to be turned on. The audible tone from
the Signal Generator will drop in pitch to indicate a successful connection.

10.5.4 Induction method

This is the standard method for inducing signals onto buried metallic services. It
produces a strong signal directly below the Signal Generator but the signal
strength drops off quite quickly either side of the Signal Generator.
1. It should be checked that there are no accessories plugged into the
Connection Socket. The Signal Generator switches automatically to Induction
Mode when the socket is unused.
2. Signal Generator is to be placed upright on the ground where the suspect of
the services (Cables) is buried. Make sure the Signal Generator is in line with the
expected route of these services.
3. Signal Generator is to be turned ON and the batteries condition to be checked.
4. The signal will be radiated into the ground immediately below and for
approximately 3 m (10‟) either side of the Signal Generator.

Limitations of Induction Method - There are limitations concerning what can be

achieved when using a Signal Generator on the Induction Mode compared to the
Connected Mode. It is not normally possible to identify what the service is that
has been detected with an induced signal. Cables with a very small cross section
may not have enough signals induced onto them to make them detectable. It is
often not possible to apply an induced signal onto just ONE specific buried
service, in order to trace it alone, when other services are positioned in a close
proximity.

IRISET 77 TC1 - Telecom Cables (Copper)

Annexure

10.6 Depth Measurement

Depth measurement should be carried out in Generator mode it should not be
carried out in Power or Radio mode.
Procedure:
1. The Signal Generator must be set to „Continuous‟ signal output, not
„Pulsed‟ output.
2. It is important that the signal being measured is a good quality signal.
This is best achieved by using the Signal Generator in Connected Mode rather
than Induced Mode.
3. The Locator to be set to Generator Mode and pinpoint the position of
the buried Cable. Make sure that the Locator is directly over and at right angles
to the route of the buried cable. Locator is to be rested on the ground with the
body in vertical position.
4. By Pressing and holding down the depth button, the depth will be
shown on the display.
5. The depth can be verified by lifting up the Locator whilst keeping the
depth button pressed. The depth indication should increase by the same amount
that the Locator has been raised.
10.7 Limitations of Depth Measurement
1. There are some situations where it is not possible to gain accurate depth
information:
2. A curve or bend in the route of the service.
3. Close to where the depth of the cable changes sharply.
4. Near to a „T‟ junction in the service.
5. at the very end point of a service.
6. at any point where the signal has coupled onto an adjacent service.
7. Close to any large metallic objects such as metal fences or vehicles.
8. under reinforced concrete.
9. The signal is of poor quality.
10. Too close to the Signal Generator or leads if used in Connected Mode.

10.8 Cable Fault Localisation

During failures in the cable, the location of cable fault to be identified first to start
the restoration process. After identifying the location the faulty portion is to be
isolated, removed and replaced with new healthy cable length. The cable will be
restored by completing the new joints.
The identification/ localisation is a tedious task. It needs lot of manpower and
time to localise the faulty portion/joint in the section. Previously the entire section
is localising by testing from the ends and from in between termination point in the
section. Then the localised small portion will be again tested by opening the
joints available in that portion. The development of Cable fault locator made it a
better way of fault localisation by which the time and the manpower are saved.

10.9 APLAB DIGITAL CABLE FAULT LOCATOR (MODEL 3039-I)

This meter can be used to locate the faults in 6 Quad cables such as
1) SHORT Circuit faults
2) SHEATH faults
3) OPEN Circuit faults
4) LOW INSULATION faults.

IRISET 78 TC1 - Telecom Cables (Copper)

Annexure

10.9.1 Principle of Operation

The cable fault locator employs the Pulse Echo Reflection Technique. It applies a
high energy pulse of very short duration to the circuit under test. The pulse travels
along the circuit at a velocity “V” which depends primarily on the mutual capacitance
of the circuit. The irregularity in which circuit reflects some portion of the pulse
energy, the reflected energy reflects back to the instruments and can be seen as
reflected pulse. The instrument measures a time T as it takes full incident pulse to
reach joint of the irregularity and for the reflected pulse to arrive back on the
instrument.

10.9.2 Function of Controls and Indicators

1. CRT INTENSITY CONTROL Controls intensity or brightness of oscilloscope
display screen.
2. CRT FOCUS CONTROL Controls focus of sharpness of oscilloscope display
screen.
3. CRT SCREEN Displays both the transmitted pulse and the reflection from the
fault
4. HORIZONTAL POSITION Controls left and right movement of display on
oscilloscope screen
5. VERTICAL POSITION Controls up and down movement of display on
oscilloscope screen.
6. HORIZONTAL EXPANSION Controls horizontal expansion of the reflection in
order to obtain the most accurate display of the reflected pulse
7. VERTICAL GAIN Controls vertical amplification of the pulse reflection on the
oscilloscope screen.
8. VELOCITY SELECTOR Switches used to enter one-half the velocity of
propagation value for the cable under test.
9. L1 CONNECTION Jacks for connection of cable or pair to be tested.
10. L2 CONNECTION Jacks for connection of reference cable or pair.
11. BATTERY CHARGE LEVEL: LOW-BATT Indicator shows sufficient charge level
when LED indicator is off. LED is lit when recharging is required.
12. DISTANCE READOUT 4½ Seven Segment LED type digits to display distance in
feet/metres to the reflected pulse.

IRISET 79 TC1 - Telecom Cables (Copper)

Annexure

13. POWER ON/OFF Switch turns power on when depressed. Release or alternate
action of switch turns power off.
14. RANGE SELECTOR 50m, 100m & 300m position provides a short duration
transmitted pulse for ranges 50m, 100m & 300m. The 1KM, 3KM, 10KM
positions provides progressively wide pulses required for 0 - 1 KM, 0 - 3 KM, 0 -
10 KM ranges respectively
15. ALTERNATE TRACE SELECTOR when pressed, the CRT shows the complete
trace of the cable under test and allows the reflection to be shifted towards the
transmitted pulse as controlled by Trace Shift Control 18. When not pressed,
only one trace is displayed.
16. SHIFT / MEASURE SELECTOR In the SET position, the Trace Shift Control 18
can be used to pinpoint a reflection. When READ is pressed, it allows digital
readout of the distance to the selected pulse reflection.
17. SWITHC L1-L1/L2 in pressed position it will be used to compare two traces of the
cable pairs
18. ALIGNMENT CONTROL is used to pinpoint a reflection
19. EXTPWR is used to connect external 12 V- 15 V DC power supply
20. GROUND is used to connect the earth to L1 and L2 jacks
21. Chg. ON LED used to indicate the unit is in charging condition
22. SELFTEST is used to self-test the fault locator
23. HVON LED Red LED indication shows when HV is available on the cable lead

10.9.3 Front panel diagram of the meter

IRISET 80 TC1 - Telecom Cables (Copper)

Annexure

10.9.4 Operating Procedures

The following steps describe how to make a fault location test. Refer to front panel of
meter diagram for control identification.
1. Battery-charge level is to be adequate, or can be operated from an external DC power
source.
2. It should be ensured that there is no voltage available on the cable or pair being
tested.
3. The V/2 value is to be set by using the velocity selector switches (8) for the cable type
under test. (For 6 Quad cables V/2 set to be 95 meters/µs).
4. The vertical gain sensitivity control (7) is to be adjusted to obtain a pulse height of
approx. 2 divisions high.
5. The horizontal position control (4) is to be adjusted such that the foot of the transmit
pulse is aligned with the vertical reticule line.
6. The horizontal expansion control (6) is to be adjusted to show the reflected pulse on
the right side of the screen
7. The alternate trace selector switch (15) is to be depressed. The trace shift control
(18) is to be adjusted such that the foot of the transmitted pulse is clearly displayed on
the screen.
8. The SET/READ switch (16) to be depressed. The distance can be read in feet/ meters
to the fault on the distance readout (12). The length of the test leads to be subtracted to
obtain the actual distance

10.9.5 Indication of Typical Faults

10.9.5.1 Open Circuit
It gives a positive reflection at the point of break. If both conductors are open, reflection
amplitude is greater and reflection at open far end of cable is not seen

10.9.5.2 Short Circuit

A short gives a negative reflection and far end reflection is not seen. If a low resistance
is across pair, a smaller negative reflection is seen and smaller positive reflection may
show open far end

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Annexure

10.9.5.3 Sheath
A short or low resistance between one or both conductors shows a negative reflection,
which is smaller as resistances increases. A small reflection is seen at the far end.
Connect the model 3039-I between the sheath and one or both conductors. Sheath
should not be grounded when making this test.

10.9.5.4 Resistive Splice

Cable splice shows positive reflection, which is higher as resistance increases

Good Splices: Even good splices show a reflection because of capacitance change. This
shows as a small positive reflection followed by a negative one

10.9.5.5 Water in cables

Water in section of cable affects dielectric. A negative reflection shows where water
begins and positive where water ends. Amount of reflection shown by degree of
saturation. To better pinpoint watered section, make tests from each end of cable.

IRISET 82 TC1 - Telecom Cables (Copper)

Annexure

ANNEXURE-1

JPO issued by Railway Board to prevent cable cuts

IRISET 83 TC1 - Telecom Cables (Copper)

Annexure

IRISET 84 TC1 - Telecom Cables (Copper)

Annexure

IRISET 85 TC1 - Telecom Cables (Copper)

Annexure

IRISET 86 TC1 - Telecom Cables (Copper)

Annexure

IRISET 87 TC1 - Telecom Cables (Copper)

Annexure

IRISET 88 TC1 - Telecom Cables (Copper)

Annexure

ANNEXURE-2

Precautions for Thermoshrink Joints of Quad Cables issued by RDSO

IRISET 89 TC1 - Telecom Cables (Copper)

Annexure

IRISET 90 TC1 - Telecom Cables (Copper)

Annexure

IRISET 91 TC1 - Telecom Cables (Copper)

Annexure

IRISET 92 TC1 - Telecom Cables (Copper)

Annexure

IRISET 93 TC1 - Telecom Cables (Copper)

Annexure

IRISET 94 TC1 - Telecom Cables (Copper)

Annexure

IRISET 95 TC1 - Telecom Cables (Copper)

Annexure

IRISET 96 TC1 - Telecom Cables (Copper)

Annexure

ANNEXURE-3

RDSO Specifications pertaining to Telecom Cables (Copper)

Sl. No. Description of Telecommunication Item Specification / Drawing No.

Telecom Cables
PIJF Telephone Cable (Polythene Insulated
1 polythene sheathed Jelly Filled Telephone IRS TC 41/97(Amd.3)
Cable with poly –Al moisture barrier)
Underground Railway Jelly Filled Quad Cables
2 for Signalling and Telecom Installations (0.9 mm IRS TC 30/2005 (Ver.-1) Amd.5
dia conductor)
RDSO/SPN/TC/72/2007, Rev.0,
3 1.4 mm dia copper conductor 4/6 quad cable
Amd.2
Composite Underground Armoured Cable
4 **RDSO/SPN/TC/50/2007 (Rev 5)
Consisting of 6 Copper Quads And 8/24 Fibers
TECSpecification:
5 Telecommunication Switch Board Cables
GIR/WIR – 06/03 March 02
Jointing Kits
Thermo Shrink Jointing Kit for Jointing RDSO/SPN/TC/57/2015
1
Underground PIJF Cable (TSF: 1-5) (Rev.1) Amd-1
Thermo Shrink Jointing Kit for Jointing
Underground Quad Cable (RTSF for
0.9mm/1.4mm conductor dia 4/6 quad cable IRS TC 77/2012(Rev.3)
2
Derivation Joint/transformer Joint/Straight amendment 3
through Joint/Condenser Joint/Loading Coil
Joint)
Joint Closure for Composite (Optical & Quad) **RDSO/SPN/TC/56/2007(Rev.-2)
3
Underground Armoured Cable. (Amdt-1)
RDSO/SPN/TC/101/2012
4 Silicone Gel based cable jointing kit
amendment1
Termination boxes
1 Cable Termination Boxes (indoor) IRS TC 18/75
Telecom Cable Termination Box (non-metallic)
2 RDSO/SPN/TC/97-2012 Rev.1
for indoor use
TEC: CT Block spec. GR/CTN-
4 KRONE LSA-PLUS Connection Module
03/03 March 04
TEC spec. GR/CTN-01/04 May
5 KRONE LSA-PLUS Insertion Tool
2005
Passive Devices
V.F. Tapping Transformer; 1120: 1120, 1120:
1 IRS TC: 22/2021 ver 1.1
600 & 470: 1120
V.F. Transformers (2T/3T) Suitable for
2 IRS TC: 76/2021 ver 1.0
underground telecom. Cable circuits.
3 Balancing Condensers. IRS TC 11/73
Polystyrene Condenser for Balancing and
4 **IRS TC 49/93
Building out Network.
5 Loading Coil joints. IRS TC 29/81

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Annexure

Earthing System
1 Conventional Earthing arrangement RDSO drg no: TCA 565(ADV)
Code of practice for earthing and bonding
2 system for signalling equipment (The acceptable RDSO/SPN/197/2014 ver.1
Earth Resistance shall not be more than 1 ohm).
Control Communication
4 Wire / 2 Wire Train Traffic Control Equipment
IRS TC: 60/2007 amendment 1
1 with Dual Tone Multi Frequency (DTMF)
Signalling
2 Repeater Station Equipment IRS TC 50/90
Voice Frequency Communication System for RDSO/SPN/TC/34/2002 (Ver. 4)
3
Underground Quad cable amendment1
Junction Equipment and speech Conversion
4 IRS TC 46-88
Equipment used in AC Electrified Area.
5 Desk Type 2 Wire, 12 Way DTMF Telephone IRS TC 80/2000 (Amd. 3)
6 Universal Wayside DTMF Control Telephone IRS TC 82/ 2005 (Amd.3)
Integrated Way Station Control Communication **RDSO/SPN/TC/70/2007
7
Equipment With Amendment- 1
8 Emergency Control Room Equipment IRS TC:61/93 (Amd.2)
9 Light Weight Portable Control Telephone IRS TC: 78/20 version 1
10 4-Wire Way Station Control Telephone IRS TC: 38/97 (Amd.2)
11 2 –Wire Way Station Control Telephone IRS TC 37/97 (Amd.2)
4-Wire/2 Wire Combined Portable Control
12 IRS TC: 75/99 (Amd.4)
Telephone
13 Magneto Telephone Desk Type IRS TC: 36/97 (Amd.2)
14 Desk Type Electronic Magneto Telephone IRS TC: 79/2000(Amd.4)
LC Gate Control Equipment Using Wired &
15 RDSO/SPN/TC/49/202- Ver. 1
Wireless Data Communication.
16 Electronic L.C Gate Telephone System RDSO/SPN/TC/51/2021 rev 1.0
Auto Dialling System from Emergency Socket in
17 IRS: S-83/2007 Amd-1
RE Area
18 Six Pin Emergency Plug and Socket IRS TC: 42/20 ver1.0
19 Emergency Socket Box of FRP Material RDSO/SPN/TC/44/2002 Ver.3.0
Power Supply Unit for Telecom Installations at
20 IRS TC: 72/97 (Amd.1)
Way Side Stations In 25 KV Electrified Area
Measuring Instruments
1 Digital Capacitance Unbalance Measuring set. IRS TC 48/90
2 Transmission Measuring Sets. IRS TC 43/87
3 Cross Talk Measuring Sets. IRS TC 45-88
TEC Spec: GR/TIE-05/03 July
4 Digital Cable Fault Locator
2006
OFC Cable
1 24 Fiber Armoured Optic Fiber Cable IRS TC: 55/2006 Rev-1 Amd.3
2 Fiber Distribution Management System RDSO/SPN/TC/037/2020 Rev.4.0
Fiber Distribution Management System for
**RDSO/SPN/TC/071/2008
3 Composite (Optical and Quad) Underground
(Rev. 1.0) Amdt. -1
Armoured Cable
** RDSO site presently not showing the reference for these specifications.

IRISET 98 TC1 - Telecom Cables (Copper)

Question Bank

QUESTION BANK

OBJECTIVE

Chapter 1

1. The maximum number of pairs on a pole route in Over Head Alignment is limited to ____.
a) 8 b) 12 c) 16 d) 20
2. Distortion less condition in a cable can be achieved by satisfying the condition of______.
a) LR=CG b) GL=CR c) RG=CL d) CG=LR
3. Length of Loading section in the 4/6 quad cable system is _______________________.
a) 500 meters b) 1000 meters c) 1500 meters d) 2000 meters
4. Commonly used frequency for standard audio measurements is__________________.
a) 10 KHz b) 3.4 KHz c) 1 KHz d) 0.3 KHz
5. Loading of cable in underground cable is done to reduce cross-talk. (T/F)
6. Overhead lines are not fit for Telecom circuits in the RE area because of induced voltage.
(T/F)
7. Phantom circuit is a super imposed circuit derived from side circuits. (T/F)
8. Cross-talk couplings causes‟ noise and Earth couplings cause side tone in VF circuits.
(T/F)
9. The purpose of twisted pairs in telecom cables is to reduce cross talk. (T/F)
10. Capacitance unbalance can be reduced by adding118 mH external capacitors. (T/F)

Chapter 2

1. The Characteristic impedance of the pair in a switch board cable is ________Ohms.

a) 470 b) 600 c) 1120 d) 1180
2. RG 58 cable can be used up to the length of _____________ meters.
a) 125 b) 165 c) 185 d) 210
3. 0.51 mm dia copper conductor is denoted as _________________ AWG.
a) 22 b) 24 c) 26 d) 28
4. The co-axial cable usual impedance shall be _______ or ______ Ohms.
a) 40-50 and 70-80 b) 50-60 and 80-90 c) 60-70 and 80-90 d) 70-80 and 100-120
5. In STP cables, _______________ is used as a screen
a) Copper mesh b) Steel mesh c) Aluminium foil d) Copper foil
6. Purpose of Rip Cord in SB cable is to facilitate the removal of PVC sheath. (T/F)
7. UTP is Uniform shielded Twisted Pair. (T/F)
8. D8 Cable and Field Service cable are same and consists of 7 strands. (T/F)
9. The material used as conductor in telecom cables is high conductivity annealed tinned
aluminium. (T/F)
10. In general, CAT cables will be terminated with DB15 or RJ45 type connecters. (T/F)
11. Specification of Switch Board cable is IRS TC 41/97. (T/F)

Chapter 3
1. Expand PIJF: ___________________________________________________________
2. RDSO spec. for PIJF telephone Cable is ____________________________________
3. In 20 pair PIJF cable, colour code of pair number 18 is __________________________.
a) Green-Black b) Green-Yellow c) Brown-Black d) Brown-Yellow

IRISET 99 TC1 - Telecom Cables (Copper)

Question Bank

4. In 20 pair PIJF cable, number of main conductor insulation colours are ___________ and
mate colours are ________.
a) 5 and 5 b) 4 and 5 c) 5 and 4 d) 4 and 4
5. The number of conductors in 20 pair cable are ______________________.
a) 10 b) 20 c) 30 d) 40
6. The number of units in 50 pair cable are ___________________________.
a) 2 b) 3 c) 5 d) 10
7. The number of pairs in each unit in 100 pair cable are ___________________.
a) 5 b) 10 c) 20 d) 50
8. The number of units in 20 pair cable are ______________________.
a) 1 b) 2 c) 4 d) 5
9. The colour of the binding tape used for identifying 4 th unit in 50 pair cable is__________.
a) White b) Blue c) Red d) Brown
10. 0.51 mm dia conductor pair may be used upto _____ mtrs for subscriber loop application.
a) 100 b) 500 c) 1000 d) 5000
11. Entry of moisture / water is prevented by __________________in the core of PIJF cable.
a) Sheath b) PVC Jacket c) Jelly d) Armour
12. Loop Resistance of a pair of 0.63 mm dia conductor is ____________Ohms.
a) 184 b) 128 c) 86 d) 56
13. Min. bending radius of underground PIJF Telecom cable is _____time of cable diameter
a) 3 b) 5 c) 10 d) 15
14. How many number of super units shall be assembled to form a 200 pair cable?
a) 2 b) 4 c) 5 d) 10
15. The basic purpose of Amour in UG cable is to reduce induced voltage. (T/F)
16. Loop Resistance of pair of 0-51 mm dia conductor is 184 Ohms. (T/F)
17. PVC Jacket is the sheathing arrangement made over armoured cable to protect the
armour against oxidation. (T/F)
18. Information of the cable exists throughout the length of cable at regular intervals of ten
meters. (T/F)
19. 0 .63 mm dia conductor pair may be used upto 10 Km for subscriber loop application (T/F)
20. A 50 pair cable consists of 10 numbers of 5 pair units (T/F)

Chapter 4

1. Psophometric voltage in the communication circuits should not exceed ___________.

a) 2 V b) 20 V c) 2 mV d) 20 mV
2. The screening factor of Aluminium sheath/screen is always less than ______________.
a) 10 b) 1 c) 0.1 d) 0.01
3. Under normal conditions of the traction power system the longitudinally induced voltage in
the telecommunication cable should not exceed __________V AC.
a) 60 b) 150 c) 430 d) 600
4. Cumulative build up of induced voltages in a circuit in RE can be prevented by introducing
isolation transformers at a regular interval of ___________Km.
a) 10 b) 17 c) 20 d) 2
5. Isolation transformers are used to reduce the ______ in cable conductors.
a) Transmission loss b) induced voltage c) loop resistance d) impedance
6. The currents flowing in the catenary returns to the feeding point via the rails. (T/F)

IRISET 100 TC1 - Telecom Cables (Copper)

Question Bank

7. Electrostatic induction occurs due to capacitance coupling between conductor and earth.
(T/F)
8. Before cutting the armour or sheath/screen of cables an electrical connectivity is to be
established between two ends of the cable through an external wire. (T/F)
9. Screening factor is the ratio of voltage induced in the conductor in absence of metallic
sheath and voltage induced in the presence of metallic sheath. (T/F)
10. In RE area normal field strength of 87.5 V/Km exists in telecom cable (T/F)
11. The 25KV AC catenary system acts like a primary winding and each other parallel
conductor acts like the secondary winding of a transformer. (T/F)
12. Usage of “Insulated Tools and Rubber Gloves” are mandatory precautions for protection
of staff who are working in 25 KV 50 Hz AC traction territory. (T/F)
13. The induction by A.C traction system in Telecom circuits is due to electrostatic coupling
and electromagnetic coupling. (T/F)
14. Sectionalisation of the Telecom circuits prevents cumulative build-up of induced voltage
(T/F)
15. The magnitude of potential due to electrostatic induction depends on the voltage of the
catenary and distance. (T/F)

Chapter 5

1. The Transmission loss in 4.5 mm dia ACSR line is 0.038 dB and 0.9 mm dia copper pair
in quad cable is 0.63 dB. (T/F)
2. 4 Wire system in U/G cable is because of usage of amplifiers. (T/F)
3 RDSO specification of 4/6 PIJF quad cable of 0.9 mm dia conductor is IRS:TC 30/2005.
(T/F)
4. RDSO specification of 4/6 PIJF quad cable of 1.4 mm dia conductor is RDSO SPN TC
RDSO/SPN/TC/72-07. (T/F)
5. A 1.4 mm dia conductor 4/6 quad cable is used in longer (more than 25 Km) distance
Block sections. (T/F)
6. The insulation resistance between each conductor of a quad shall not be less than 5000
Mega ohms per kilometre when measured with 500V megger under factory acceptance
test. (T/F)
7. Purpose of the Poly Aluminium Moisture Barrier in a quad cable is to prevent ingress of
moisture. (T/F)
8. The colour code of quad no 5 in 6 quad cable is Yellow-White & Red-Grey (T/F)
9. Present Status of 6 Quad Cable System used in various Railways is, 6 quad cable with
Equalizer Amplifier OFC and 6 quad cable with OFC (T/F)
10. The Colour of the 4th quad whipping is Green (T/F)

Chapter 6

1. The normal depth of the trench for Telecom Quad Cable is ______cm.
a) 150 b) 120 c) 100 d) 80
2. The standard drum length of 4/6 quad cable is ________ meters.
a) 500 b) 1000 c) 1500 d) 2000
3. OFC and 6 quad U/G cables are to be laid in same trench in a depth ___ & ____cm
a) 100 & 80 b) 100 & 100 c) 120 & 100 d) 120 &120

IRISET 101 TC1 - Telecom Cables (Copper)

Question Bank

4. In general, minimum distance of _________ meters should be maintained between the

OHE masts and the telecom cable.
a) 4.75 b) 5.75 c) 6.75 d) 8.75
5. The derivation cable used in the 4/6 quad cable system is ___________________.
a) 4 quad b) 6 quad c) 10 pair d) 20 pair
6. At what intervals of proposed cable route “Soil strata report” have to be prepared.
a) 100 meters b) 250 meters c) 500 meters d) 1000 meters
7. Telecom cable shall be laid in ___ pipes for a length of ___ meters on either side of TSS.
a) GI and 300 b) RCC and 300 c) GI and 200 d) RCC and 200
8. RCC Telecom cable route markers shall be painted with _________ colour when placed
at joint locations.
a) Blue b) Orange c) Green d) White
9. The cable route indicators are to be placed at every__________ meters on normal path.
a) 10 b) 25 c) 50 d) 75
10. On each side of the major girder bridge, cable reserve of ____ meters shall be provided.
a) 5 b) 10 c) 20 d) 25
11. EC posts shall be installed exactly at KM Zero markings along the track. (T/F)
12. The cable drums shall always be stored on their flat sides, and not on their flanges. (T/F)
13. Minimum horizontal clearance between Power & Telecom cable shall not be less
than 60 cm. (T/F)
14. If the depth of the trench is not feasible to standard depth, then the lesser depth of cable
trench shall be protected with warning bricks. (T/F)
15. All new Telecom cables shall be laid close to existing Railway track. (T/F)

Chapter 7

1. The impedance ratio of the transformer used for EC socket in an unloaded quad cable
system is _____________Ohms.
a) 1120:1120 b) 470:470 c) 1120:470 d) 470:1120
2. Value of loading coil used for 6Q cable is ____________________ mH.
a) 88 b) 98 c) 118 d) 128
3. Length of loading section in 6Quad cable is ____________________ meters.
a) 500 b) 1000 c) 1500 d) 2000
4. Shelf life of U/G quad cable jointing kit is_______________________ months.
a) 12 b) 24 c) 36 d) 48
5. Minimum of ______ meter of cable of each end is coiled in the jointing pit while laying.
a) 3 b) 5 c) 8 d) 10
6. “Branch off clip” is used for derivation joint. (T/F)
7. RTSF is Reinforce Thermo Shrink Jointing Filled (T/F)
8. RDSO specification for RTSF jointing kit is RDSO / SPN / TC: 77 / 2012 (T/F)
9. The transformer used in unloaded quad cable for termination of 2 wire circuit is 470:1120
Ohms. (T/F)
10. Aluminium foil in TSF kit is to prevent the damaging of conductors during the shrinking
process. (T/F)
11. TSF 4 kit is used for jointing of 6 quad cable. (T/F)
12. In 6 quad cable the splice is to be filled with petroleum jelly. (T/F)
13. In a Quad cable jointing, the aluminium screen of the cable is made through by using
“Sheath Connector Assembly´. (T/F)
IRISET 102 TC1 - Telecom Cables (Copper)
Question Bank

14. The KRONE module can be used for termination of quad cable conductors. (T/F)
15. Wago terminals can be used for termination of different telecom cable conductors. (T/F)

Chapter 8

1. Insulation resistance of quad cable conductors shall be tested with 100 V Megger, at the
time of commissioning of quad cables. (T/F)
2. Transmission loss test shall be carried out with TMS kit. (T/F)
3. Cross Talk in quad cable has to be measured once in 6 months. (T/F)
4. Quad cable armour shall be connected to earth which is having resistance of 10 Ohms.
(T/F)
5. Working principle of Digital Cable Fault locator is reflection of pulses. (T/F)
6. Periodicity of Psophpmetric Noise test in a quad cable is once in a year. (T/F)
7. The insulation resistance of quad cable conductors shall not be less than
100 Mega Ohms/Km. (T/F)
8. Quad cable conductors can be paralleled for reducing the conductor resistance for BPAC
circuit. (T/F)
9. Transmission loss at 2 KHz will be 1.2 dB/Km. (T/F)
10. The instrument used for measuring all types of noise together is Psophometer. (T/F)

Chapter 9

1. Before disconnecting Block, BPAC and IB circuits in quad cable for testing, disconnection
memo has to be issued to Station Master. (T/F)
2. The Integrated Cable path diagram will show all S&T Cable path positions of particular
section in one sheet of paper. (T/F)
3. The important tools to protect S&T Cables from damages are Integrated Cable Path
diagram, Cable route tracer and Cable Fault Locator. (T/F)
4 BPAC circuit in quad cable shall be tested from Entry location to Exit locaton. (T/F)
5. Quad cable has to be tested periodically by JE/SSE/T once in three months.
(T/F)
6. Quad cable has to be inspected by officers once in a year. (T/F)
7. Insulation Resistance Test will be carried out one in three months under Schedule of
Testing. (T/F)
8. SSE / T/ Section In-charge has to test the quad cable one in six months. (T/F)
9. Induced Voltage in quad cable conductor with respect to earth shall be below 5V AC.
(T/F)
10. Near End Crosstalk @ 800 Hz in quad cable pairs shall be better than -65db. (T/F)

Key to Objective

Chapter 1: 1) c 2) b 3) d 4) c 5) False
6) True 7) True 8) False 9) True 10) False

Chapter 2: 1) b 2) c 3) b 4) a 5) c
6) True 7) False 8) True 9) False 10) True 11) False

Chapter 3:
1) Polythene Insulated Jelly Filled 2) IRS-TC: 41/97

IRISET 103 TC1 - Telecom Cables (Copper)

Question Bank

3) b 4) c 5) d 6) c 7) c 8) c 9) d 10) d
11) c 12) b 13) d 14) b 15) False 16) True 17) True 18) False
19) True 20) False

Chapter 4: 1) c 2) c 3) a 4) b 5) b 6) True 7) True 8) True

9) False 10) True 11) True 12) True 13) True 14) True 15) True

Chapter 5: 1) True 2) True 3) True 4) True 5) True 6) True 7) True

8) True 9) True 10) True

Chapter 6: 1) c 2) b 3) c 4) b 5) c 6) c 7) b 8) c 9) c 10) b
11) True 12) False 13) True 14) True 15) False

Chapter 7: 1) b 2) c 3) d 4) b 5) d 6) True 7) True 8) False

9) False 10) False 11) False 12) True 13) False 14) False 15) True

Chapter 8: 1) True 2) True 3) False 4) False 5) True 6) False 7) True

8) False 9) True 10) True

Chapter 9: 1) True 2) True 3) True 4) True 5) False 6) True 7) False

8) False 9) True 10) False

SUBJECTIVE:

Chapter 1

1. What are the different types of transmission media used in Indian Railways
Telecommunication?
2. Compare Underground cables with O/H lines.
3. Give the Classification of Telecommunication cables.
4. What are the “Primary elements” in telecom cable? What is their effect? How are they taken
care while manufacturing the cable?
5. Explain the relation between Impedance and Frequency in Telecom transmission lines.
6. What is the importance of V.F Balancing and Loading in Telecom cable?
7. What are the different types of capacitive and Earth couplings in Telecom quad cable?

Chapter 2

1. What are different types of Switch Board Cables and its specifications?
2. What are the different types of schemes of colour codes of 20 pair SB cable?
3. Explain briefly about Twin Flat and FS cable.
4. Write short notes on UTP and STP cables.
5. Mention different types of cables and its applications in Railways.

Chapter 3

1. Describe PIJF cable and its formation.

2. What are the advantages of Polythene Insulated Jelly filled cables?
3. Compare the specifications of 0.5 mm and 0.6 mm dia conductors of paired cables.

IRISET 104 TC1 - Telecom Cables (Copper)

Question Bank

Chapter 4

1. Explain the types of induction develops in Telecom circuits in the RE area.

2. Define Screening factor and explain how screening of voltage is done in Telecom Cables.
3. What are the ITU-T recommendations, on permissible induced voltages?
4. Define Psophometric noise and how it degrades transmission quality in Telecom circuits?
5. What are remedial measures to be taken to minimise the effects of 25KV 50 Hz AC traction
system in Telecom cables?
6. What are the Precautions to be taken for protection of staff and equipment in 25 KV 50 Hz
AC traction territory?

Chapter 5

1. Explain the importance of Quad Cable over ACSR overhead lines in RE area.
2. What are different types of Quad Cables?
3. Explain about RE Main Cables.
4. Explain the construction of 6 quad cables with a neat figure.
5. Explain the importance of metallic protection systems available in quad cable.
6. What is the colour code scheme of 6 quad cable?
7. What are the general specifications of 4/6 quad cable of 0.9 mm & 1.4 mm dia conductor?
8. Write the Specifications of 6 quad cable.
9. Write the quad allocation of 6 quad cables with OFC and without OFC.
10. What is the difference between PIJF underground Paired and Quad Cables

Chapter 6

1. What are the important objectives to be considered in the preliminary cable route survey?
2. What are guidelines for finalizing the route and preparation of the cable route plans?
3. What are the methods of laying underground cable? Explain each in detail.
4. What is the procedure of laying U/G cable while crossing Roadways, Railway tracks?
5. How underground cables shall be protected on culverts and bridges?
6. What precautions to be taken while laying underground cables at TSS/FP locations?
7. How are underground telecom cables protected in the 11KV electric cables area?

Chapter 7

1. What are the important stages of making a cable joint?

2. What are the various types of joints in 4/6 quad cable and explain them briefly?
3. What are the requirements of a loading coil and explain the effect of using loading coil in
quad cable?
4. Explain jointing of PIJF paired cables and PIJF quad cables.
5. Explain the procedure of Quad Cable Jointing by using RTSF kit.
6. What are the contents in a RTSF Jointing kit used for quad cable jointing?
7. What are the precautions followed for RTSF joints of quad cable?
8. Write short notes on the following:
a) Termination of Quad Cables b) Termination of Paired Cables

IRISET 105 TC1 - Telecom Cables (Copper)

Question Bank

Chapter 8

1. What are the tests to be carried out before laying the cable and after laying the cable?
2. What are mandatory checks and tests to be carried out before commissioning of a BPAC
application in quad cable?
3. What are causes for cable failures and how to prevent them?
4. How to localize the cable faults and explain its procedure?
5. What cable faults can be identified by using a Digital Cable fault locator?

Chapter 9

1. What are typical 6 quad cable failures and their causes?

2. What are Dos and Don‟ts while carrying out quad cable testing?
3. What are schedules of testing and measurements to be carried out in quad cables?
4. Practice how to fill up / maintain the “Quad Cable Maintenance Register”.

Chapter 10

1. What is the role of JE/SSE (Tele) to prevent cable cuts?

2. What are the departments signed on the Railway Board JPO to prevent cable cuts.
3. Under which clause the penalty on cable damage shall not be levied on the contractor who
is executing the work?
4. What are the different modes of working in Cable route tracer receiver?
5. What are the different faults that can be traced by Cable fault locator?

IRISET 106 TC1 - Telecom Cables (Copper)

Abbreviations/Acronyms

ABBREVIATIONS / ACRONYMS

ACSR- Aluminium conductor, steel reinforced. Aluminium wires stranded around a steel core.
AERIAL CABLE- A cable suspended in the air on poles or other overhead structures.
AWG: AMERICAN WIRE GAUGE
ANNEALED WIRE- Wire which has been softened by heating and gradually cooling.
ARMOUR - An outer braid of metal or spiral steel tapes, primarily for the purpose of mechanical
protection.
ATTENUATION - The loss of power or signal in a circuit, generally expressed in decibels (dB)
per unit length, usually one thousand (1,000) feet. In optical fiber cables, attenuation is the ratio
of input power vs. output power, measured in decibels per unit length, usually dB/km.
Abbreviated as attn.
AUDIO FREQUENCY - The range of frequencies audible to the human ear, approximately 20 to
20,000 Hz.
AWG - Abbreviation for American Wire Gauge. The system most commonly used in the United
States for describing the size of copper wire.

BARE CONDUCTOR - A conductor not covered with any insulating material.

BREAKDOWN OF INSULATION - Failure of an insulation resulting in a flow of current through
the insulation. It may be caused by the application of too high a voltage or defects or decay in
the insulation.
BREAKDOWN VOLTAGE- The voltage at which the insulation between two conductors breaks
down.
BUS(BUSBAR) - A conductor, often a heavy strap or bar, used to make a common connection
between several circuits.

CABLE- A cable may be a small number of large conductors or a large number of small
conductors, cabled together, usually colour coded and with a pro-tective jacket overall.
CABLE ASSEMBLY - A cable assembly is a cable with plugs or connectors on each end for a
specific pur-pose. It may be formed in various configurations.
CABLE CORE- The portion of an insulated cable lying under the protective covering or jacket.
CAPACITANCE, MUTUAL- The capacitance be-tween two conductors with all other
conductors, including shield, short-circuited to ground.
CAPACITANCE, UNBALANCED - An inequality of capacitance between the wires of two or
more pairs which results in a transfer of unwanted signal from one pair to others.
CAPACITANCE, UNBALANCED to GROUND - An inequality of capacitance between the
ground ca-pacitance of the conductors of a pair which results in a pickup of external source
energy, usually from power transmission lines.
CAPACITIVE COUPLING - Electrical interaction between two conductors caused by the
capacitance between them.
CHARACTERISTIC IMPEDANCE- a) The imped-ance that when connected to the output
terminals of a transmission line of any length, makes the line appear infinitely long. b) The ratio
of voltage to cur-rent at every point along a transmission line on which there are no standing
waves.
COAXIALCABLE- A cable in which one conductor completely surrounds the other, the two
being coaxial and separated by a continuous solid dielectric or by dielectric spacers. When the
outside conductor is grounded, the inside conductor is not susceptible to external fields from
outside sources.
IRISET 107 TC1 - Telecom Cables (Copper)
Abbreviations/Acronyms

COIL- A coiled conductor, wound on a form or core which uses electromagnetic induction to
cause changes in a current.
COLOR CODE- Colour code is the use of different coloured insulated wires for purposes of
identification in a multi-conductor cable.
COMPOSITE CABLE- A cable consisting of two or more different types or sizes of wire and/or
cable.
CONDUCTIVITY - The capability of a material to carry electrical current, usually expressed as a
percentage of copper conductivity (copper being 100%). The reciprocal of resistivity.
CONDUCTOR - A material that offers a low resistance to the passage of electric current. When
a potential difference is applied across it, a relatively large current flow. A conductor usually
consists of copper, aluminium, steel, silver, or other materials.
CONDUIT - A tube or trough for protecting electrical wires or cables.
CONTINUITY CHECK - A test performed on a length of finished wire or cable to determine if the
electrical current flows continuously throughout the length. Each conductor may also be
checked against each other to ascertain that no shorts exist between conductors.

db LOSS- The loss of signal over a path or conduc-tor, expressed in decibels.

EARTH FAULT - A fault that occurs when a conductor is accidentally connected to earth or
when the resistance to earth of an insulator falls below a specific value.

FAULT CURRENT - A current that may flow through a circuit or device as a result of a fault,
such as a defect in the insulation.

GROUND FAULT - A failure of transmission involving insulation to shield or ground.

HEAT SHRINK - A material that shrinks when heated. Heat shrink tubing is used for insulation,
sealing, and protecting wire connections, terminations, and splices.
HOOK-UP WIRE- A wire used for low current, low voltage (under 1,000 volts) applications
within en-closed electronic equipment, usually 12 AWG and smaller.

IMPEDANCE- A measure of the response of an electric circuit to an alternating current.

Measured in ohms (volts per ampere). Symbol Z. The current is opposed by the capacitance
and inductance of the circuit in addition to the resistance. The total opposition to current flow is
the impedance.
INDUCED CURRENT - An electric current that flows in a conductor as a result of a changing
magnetic flux density, in which lines of magnetic flux intersect with the conductor.
INDUCTION - The phenomenon of a voltage, mag-netic field, or electrostatic charge being
produced in an object by lines of force from the source of such fields.

LOOP RESISTANCE-The total resistance of two conductors measured round-trip from one end.

PAIR - Two insulated wires of a single circuit associ-ated together.

PATCH CORD - Usually braid covered, with plugs or terminals on each end. Used to connect
jacks or blocks in switchboards or analog programming systems. Called a patch cord because it
is used to “patch” a circuit.
POWER RATIO - The ratio of power appearing at the load to the input power. Expressed in db,
it is equal to 10 log 10 (P1/P2) where P1 is input power and P2 is the power at the load.

IRISET 108 TC1 - Telecom Cables (Copper)

Abbreviations/Acronyms

QUAD - Two twisted pairs on its own axis (four conductor).

RIP CORD - A parallel construction of two or more insulated conductors which may be easily
separated leaving the insulation of the conductors undisturbed.

SHIELD - In cables, a metallic layer placed around a conductor or group of conductors to

prevent elec-trostatic or electromagnetic interference between the enclosed wires and external
fields.
SHIELDED CONDUCTOR - An insulated conductor which has been shielded by a copper braid
or tape, aluminium foil, copper foil, or a semi-conductive vinyl. The purpose is to confine the
electrical field.
STP - Shielded twisted pair. UTP - Unshielded twisted pair.

TINNED COPPER - Tin coating added to a copper conductor or braid to aid in soldering and
inhibit corrosion.

VSWR - Abbreviation for Voltage Standing Wave Ratio. The ratio of the voltage maximum to
voltage minimum which exists in a transmission line. Caused when there is reflection of the
incident wave, due to a discontinuity or improper match to the transmission line.

IRISET 109 TC1 - Telecom Cables (Copper)

Abbreviations/Acronyms

GLOSSARY
A F
aerial, 1 failure, 13, 43, 54, 60,
alignment, 2, 26, 31, 33, 62 fiber, 1,
allocation, 31, 33, 65 flux,
annealed, 10, 13, 14, 17, 28 foil, 7, 14, 31, 50,
attenuation, 5, 19, 26, 30, 58, 64 foreign, 1, 61
availability, 1, 33, 63 frequency, 3, 4, 8, 14, 15, 22, 30, 62,
axis, 3 G
B galvanised, 29,
backbone, 13, 15 gauge, 4, 7,
balancing, 5, 30 glossy,
bandwidth, 3, 27 gloves,
bending, 43 ground, 8, 23, 32, 36, 38, 39, 97, 98,
C H
harmonic, 22, 59,
canister, 45, 50, 51, 52 hazardous, 24,
capacitance, 3, 4, 5, 6, 17, 21 homogeneous, 10,
capacitive, 4, 6 I
catenary, 21, 22 impairment, 39,
channel, 51, 52 impedance, 3, 4, 10, 15, 30, 44, 62,
characteristic, 3, 4, 5, 15 impregnated, 28, 29,
clamp, 56 improper, 39, 63,
coaxial, 1, 15 induction, 21, 22, 23, 39, 59,
codal, 61 inductive, 4, 22, 39,
condenser, integrity, 66, 67, 68, 69
conductance, 3, 46 introduced, 3, 13, 26, 27
conduit, 7, 100 introduction, 23, 27
connector, 13, 15, 48, 53, 54 isolation,
control, 31, 44 J
corrosive, 36, jacket, 6, 7, 14, 15, 17, 20, 27
couplings, 3, 6, jelly, 7, 16, 17, 27, 28, 45, 48, 53, 54, 56,
crimping, 48, 54, 61,
crosstalk, 5, 12, 13, 59, joint, 5, 34, 35, 37, 38, 43, 44, 45, 46, 52,
culvert, 37, 38, 63, 54, 60, 61, 63
D K
db, 60, 66, 67, 68, 69, kink, 62
dbm, kit, 45, 46, 51, 52, 54, 60
derivation, 34, 35, 44, 45, 49, 51, krone,
disconnection, 63, L
discrete, 54, layer, 6, 15, 29, 36
disparity, 57, laying, 4, 3, 30, 32, 35, 36, 37, 38, 39, 57,
duct, 32, 36, 60,
dummy, leakage, 3,
dwc, lightning, 60, 63,
E loading, 4, 5, 30, 44,
earthing, 25, 31, 38, 39, 63, localization, 57, 61,
effect, 4, 12, 15, 22, 26, 34, 59, longitudinal, 17, 23, 28, 37,
electrification, loop, 10, 16, 19, 35, 57, 60, 61,
electrified, 26, M
electromagnetic, 3, 6, 13, 15, 21, 24, 59 magnetic, 4, 21, 22, 23,
electrostatic, 3, 21, 23, 59, magnitude, 21, 62,
embossed, 11, 20 matching, 44,
emf, 21, megger, 28, 46,
excavation, 36, 37 metallic, 10, 11, 22, 23, 24, 25, 26, 38, 39
extend, 11,
IRISET 110 TC1 - Telecom Cables (Copper)
Glossary

N shrink, 45, 49, 51, 52,

next, sleeve, 15, 43, 45, 46, 50, 51
noisy, 63, soldered, 43, 49, 50, 55
nylon, 29, soldering, 48
O superimposed, 6,
ohm, 10, 60, switchboard, 56,
oxidation, 29, switchboards,
P switched, 27
parallel, 10, 21, 22, 24, 26, 39, 48, 56, switches, 13
picked, 12, switching, 10, 34, 39
polyethylene, 6, 7, 17, 29, symbol,
potential, 8, 21, 61, T
protective, 7, 14, 15, 23, 25, 51, tapping, 35, 38, 44, 46
protects, 15, teflon,
proximity, 24, 33, 34, tent, 45, 54,
psophometer, thermoshrink,
psophometric, 23, 24, transformer, 21, 44, 45, 46, 49,
R trench, 32, 33, 34, 35, 36, 38, 60, 61,
rapidly, 4, tss,
reinforced, 50, 51, twining,
ripcord, 11, twist, 3, 8, 12, 48
rms, 23, twisted, 3, 4, 6, 7, 8, 9, 11, 12, 14, 17, 19,
S 43, 46, 49
schematic, U
screen, 14, 27, 28, 29, 31, 46, unarmoured,
screened, 26, unbalance, 3, 5, 6, 17, 89,
screening, 22, 23, 24, 29, 30, underground, 4, 5, 17, 19, 25, 26, 27, 30,
sheath, 3, 6, 7, 10, 11, 17, 18, 20, 21, 22, 31, 32, 33, 36, 43, 45, 55, 63, 64
23, 24, 25, 28, 29, 30, 39, 45, 46, 47, 48, uniform, 10, 17
49, 62 W
sheathed, 11, 16, 18, 28 wrapped, 29

IRISET 111 TC1 - Telecom Cables (Copper)

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