1

CHAPTER 1: INTRODUCTION

1.1 About Indian Railways:

Indian Railways is the state-owned railway company of India, which owns and
operates most of the country's rail tra.nsport. It is overseen by the Ministry of Railways of
the Government of India.

Indian Railways has more than 64,015 kilometers (39,777 mi) of track and 6,909
stations. It has the world's fourth largest railway network after that of the United States,
Russia and China. The railways traverse the length and breadth of the country and carry
over 20 million passengers and 2 million tons of freight daily. It is one of the world's
largest commercial or utility employers, with more than 1.6 million employees. As to
rolling stock, IR owns over 200,000 (freight) wagons, 50,000 coaches and 8,000
locomotives.

Railways were first introduced to India in 1853. By 1947, the year of India's
independence, there were forty-two rail systems. In 1951 the systems were nationalized
as one unit, becoming one of the largest networks in the world. IR operates both long
distance and suburban rail systems on a multi-gauge network of broad, meter and narrow
gauges. It also owns locomotive and coach production facilities.

Initially, the Indian railways were both designed and built by the British, during
their colonial rule of the subcontinent.

Indian Railways is a department owned and controlled by the Government of

India, via the Ministry of Railways. As of December 2010, the Railway Ministry is
headed by Mamata Banerjee, the Union Minister for Railways, and assisted by two
ministers of State for Railways. Indian Railways is administered by the Railway Board,
which has a financial commissioner, five members and a chairman.

1.2 Railway Zones:

Indian Railways is divided into zones, which are further sub-divided into divisions. The
number of zones in Indian Railways increased from six to eight in 1951, nine in 1952,
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and finally 17 in 2010. Each zonal railway is made up of a certain number of divisions,
each having a divisional headquarters. There are a total of sixty-seven divisions.

Each of the seventeen zones, Including Kolkata Metro, is headed by a General

Manager (GM) who reports directly to the Railway Board. The zones are further divided
into divisions under the control of Divisional Railway Managers (DRM). The divisional
officers of engineering, mechanical, electrical, signal and telecommunication, accounts,
personnel, operating, commercial and safety branches report to the respective Divisional
Manager and are in charge of operation and maintenance of assets. Further down the
hierarchy tree are the Station Masters who control individual stations and the train
movement through the track territory under their stations' administration.

1.3 Broad Construction of any Telecommunication Cable:

• Core:

All the insulated conductors compactly arranged in pairs, units and super units
constitute core of the cable

• Moisture Barrier:

As the presence of moisture deteriorate the quality of insulation of the telecom

cables, moisture barrier protects entry moisture into the core of the cable.

• Protection::

Telecom cables require Protection

o from probable mechanical damages

o from water and chemicals or soil conditions

o from Induction due to Electrical lines

o from diggings by different agencies and individuals

o from damages while handling

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1.4 The classification of underground cables with regard to design features:

• Place where it is used - Underground / overhead / submarine

• Insulation material used
• The filling compound
• Mechanical protection
• Place of utilization
• System for which used
• Type of conductor
• Gauge of the conductor
• Pressurization of core
- Paper / polythene cables
- Dry core / jelly filled cables
- Armoured / unarmoured cables
- Primary / Distribution / Junction cable.
- Co-axial / PCM
- Copper cable / Optical fibre cable
- 0.40 mm / 0.50 mm 0.63 mm / 0.90mm
- Pressurized / unpressurised cables

1.5 Design Features:

Before discussing the above classifications in a nutshell let us know what are the
purposes of the above Design features in a underground cables.
Sheath
LSDC / PVC
Insulating material
PVC / PAPER

C
2nd pair B Limb
O 1st pair A limb Annealed Copper
R
st
1 pair B Limb Conductors
3rd pair A Limb
E

Filling material Dry

air / Jelly

MECHANICAL PROTECTION
2 LAYERS OF GI STRIPS

Figure 1.1: Mechanical Protection

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1.6 Purpose of Insulation Underground Cables:

• The insulation is used to separate the conductors bunched in a unit to prevent

short circuit between two conductors in a pair or between conductor of one pair
with the conductor any other pair in the unit or core in the cable.

• The insulation is used as SHEATH to separate the insulated conductors from

being corroded or eroded in soil.

• The insulation is being used for marking / identifying the pair or conductor in the
unit and in the cable as a whole for that matter.

• The insulating material is used for preventing the grounding or earthing of the
conductors.

• The insulating material is used for preventing the corrosion of armouring

• Transmission characteristics of the cable

In the primitive stage paper insulation chosen as it has good di-electric properties and low
specific inductive capacity which is about 1.5. Its physical properties also enable large
proportion of air as dielectric. The ideal dielectric for telecom cable is air which has
specific inductive capacity of 1.0. The thickness, width and number of wraps per meter of
insulating paper is selected to achieve the required mutual capacitance of cables.

The Polythene insulation is easy to apply and have desired electrical characteristic such
as low dielectric constant, lo dissipation factor (loss) and high dielectric strength.
Mechanically it is tougher than paper and has abrasion resistant with ample tensile
strength and elongation.

The insulating resistance measurement shall be measured with a DC voltage of

magnitude not less than 500V after steady electrification for one minute. The insulation
resistance values between each conductor in the cable and all the other conductors
connected together and to the screen and earth shall not be less than 5000 Mega ohms /
km at Room temperature.
(Cable length in Km x observed insulation in Mega ohms).

1.7 Pairing and Overlay:

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 that of adjacent pairs. The lay of
various pairs shall be so chosen as to satisfy the capacitance unbalance requirements and
cross-task requirement.

1.8 Unit Formation:

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The pairs are then assembled into units with different length of unit twists assigned to
different units. These units are then assembled into a completed cable core.

1.9 Core:
Core wrappings are applied to the completed cable core to hold the units together and
provide high di-electric strength from core to shield and to protect the conductor
insulation from damage due to the heat of sheathing operation. In PIJF cables non-
hygroscopic and non-wicking polyester tape is used as core wrapping.

1.10 Filling compound:

The cable should be filled with suitable water resistant compound which shall be
compatible with the insulation, binders and tapes used in the cable. It shall be
homogenous and uniformly mixed material containing an anti-oxidant. It shall not
contain dirt, metallic particles or other foreign matter.
Paper insulated cables: Dry air only
Polythene insulated cables: Jelly compound.

1.11 Screen:

An aluminum tape coated with polythene / copolymer on both sides shall be applied over
the cable core with a minimum overlap of 6 mm for all sizes of cables. The nominal
thickness of the aluminum tape shall be 0.2 mm and that of polythene / copolymer
coating on each side 0.05 mm.

The aluminum tape shall be sealed at the overlap and bonded to the inner surface of
polythene sheath extruded over it. The tape shall be electrically continuous throughout
the length of cable.

1.12 Sheath:

A moisture resistant, gas tight sheath must be applied to all the paper insulated cable
other wise relative humidity conditions throughout will increase and insulation resistance
will decrease. The sheath also protects the cable form damage during installation and
service.

The sheath shall be reasonably circular and free from pinholes and other defects. The
variation between maximum and the minimum diameter at any cross section shall not
exceed 5mm.

Paper insulated cables: Lead sheath or Polythene sheath

Polythene insulated cables: Polythene sheath only.

1.13 Conductor:
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Each conductor is a solid round wire made of annealed high conductivity copper of
diameter 0.32 mm, 0.40 mm, 0.50mm, 0.63mm and 0.90 mm.

1.14 Armouring:
In the armored cables bedding and amour are provided over the sheath to be followed by
jacket. Then the cables are called armored cables.
If this arrangement is not done then we call them as un armored cables.

1.14.1 Bedding:
Two close helical lapping of polythene or polypropylene tape is applied over the sheath
to provide sufficient mechanical protection during armouring. Each take is applied with a
minimum 5% overlap. The second tape will cover the overlap of the first tape evenly.

1.14.2 Nominal thickness of the Galvanised steel Tape armouring:

Diameter of cable
Thickness of Steel tape
over Polythene sheath
Upto 40 mm 0.5 mm
Above 40 mm 0.8 mm

Armouring is the application of two layers of galvanized steel tape both applied helically
in the same direction with a gap in the first tape of 25% +/- 10 % of the nominal width of
the tape, the second tape evenly covering the gap of the first tape. The overlap of the
second over the first shall not be les than 15% of the nominal width of the tape on either
side.

1.14.3 The standard armouring types are:

• Aerial tape armour

• Jute protection
• Burried tape armour
• Modified tape armour
• Steel armouring and polyjacketing
• Corrugated steel armouring and jacketing.

1.15 Jacket :
Most cables serve their lives with a basic sheath but after armouring the armouring is to
be protected from getting rusty and corrosion and jacket is the protection which
does the job. It should be reasonably circular, free from pinholes and other
defects.
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1.16 Nominal thickness of the Jacket:

Diameter of cable over Polythene

Thickness of Polythene Jacket
Jacket
Upto 46 mm 1.4 mm
Above 46 mm up to 64 mm 1.8 mm
Above 64 mm 2.2 mm

1.17 Identification and Length markings on a Cable:

To enable proper identification of Telecom cables the following markings shall be

embossed, engraved or printed on the polythene jacket in case of armoured cable and on
the sheath for unarmoured cables. These markings are at an interval of one meter
throughout the length and are distinct and visible to the naked eye from a distance of
about 1 meter.

• Telephone handset emblem

• Name of the Manufacturer
• Year of Manufacture
• Capacity of the cable in pairs
• Size of the conductor
• Length marking
1.18 Sealing of the Ends:

The cables will be sealed with thermo shrinkable end caps of adequate thickness after
completion of all tests in factory before dispatching to various stores and workplaces
directly.
 8

CHAPTER 2: POLYTHENE INSULATED JELLY FILLED CABLES

2.1 Introduction:
These are popularly known as PIJF cables and consist of twisted pairs of polyethylene
insulated copper conductors.

Paper insulated cables (LSDC, PCUT, PCQT, PCQL & PCQL ) are the primitive
underground cables that are used in the Telecommunications network. These cables are
available up to 1800 pairs. Later on due to various factors like escalation in the cost of
Lead and more incidence of faults due to paper insulation the Polythene insulated Jelly
filled cables ( Popularly known as PIJF ) are used extensively now a days in the
telecommunication networks. The PIJF cables are available up to 3600 pairs.

Some constructional features of Paper insulated cables are dealt in Job Aid – I, for
academic interest and as still a few number of these cables are still serving some of the
telecommunication networks.

The Pressurization of dry core paper insulated cables is now a avoidable feature as the
replacement of paper-insulated cables with PIJF cables is nearing completion. As the
PIJF cables are filled with Jelly as filling compound which takes care of prevention of
entry of moisture / water into the core of the cable.

2.2 Polythene insulated Jelly Filled Polythene Sheathed Under Ground Cable:

(a) Number of Pairs:

The cables shall be in sizes 5, 10, 20, 50, 100, 200, 400, 800, 2000, 2400, 2800, 3200 and
3600 pairs.

(d) Conductors:
Each conductor shall be insulated with polyethylene of insulating grade. Different gauges
of conductors 0.32mm, 0.40mm, 0.50mm, 0.63mm, and 0.90 mm are used in the cables.

Each conductor shall consist of a solid wire of annealed high conductivity copper
smoothly drawn & circular in section, uniform in quality, resistance and free from all
defects.

The average resistance of all the conductors in the cable shall not exceed the values
shown in Table given below.
 9

Nominal Resistance Tolerance Minimum Min %

diameter per km per on elongation conductor Attenuation at
of conductor conductor of Resistance 20 deg C
conductor at 20 0 C Resistance conductor unbalance

in mm ohms/km Ohms /km percentage Average Db/km

0.32 223 - 15 1.5 -
0.40 135 +/- 4 15 1.5 12.0
0.50 86 +/- 3 15 1.0 8.25
0.63 58 +/- 2 18 1.0 6.30
0.90 28 +/- 1 18 1.0 4.40

The Percentage of Resistance Unbalance of any individual pair tested shall be calculated
as follows::
( R1 - R2 )
x 100
R1 + R2
Percentage of Resistance Unbalance =

Where R1& R2 are the resistances of individual conductors of pair under test and R1 >
R2

2.2.1 The temperature correction for attenuation is:

Attenuation at t degrees C

Attenuation at 20 0 C = 1 + 0.0018 (t-20)

2.2.2 Correction Factor for Conductor Resistance:

Temperature in deg C at which

10 20 30 40 50
conductor Resistance is measured
Multiplier constant for conversion to 1.041 1.000 0.962 0.927
0.8945
20 deg C 9 0 2 1

(c) Insulation:
Each conductor shall be insulated with solid medium density polythene of density 0.926
to 0.94 to a thickness. The insulation should be uniform, smooth and free from all
defects. The insulation will have following color for identifying pairs /conductors under
normal lighting conditions.

2.2.3 Code for Wire Identification:

Primary colors Secondary colors

For 2nd wire in a pair and binder tape of
For 1st wire in a pair
unit in 50pr/100pr unit
 10

White Blue
Red Orange
Black Green
Yellow Brown
Slate / Gray

d) Unit:
A number of twisted pairs laid up to form a group shall constitute the unit. The color
scheme of pairs and wires in a unit shall be read as below.

3.2.4 Code for Tape or Binder for Unit Identification:

Unit number 1 2 3 4 5
Color of Binder Blue Orange Green Brown Slate / Gray

2.2.5 Code for Conductor Insulation:

Pair No Color
First Wire Second Wire
1 White Blue
2 White Orange A
3 White Green
4 White Brown
5 White Slate / gray
6 Red Blue
7 Red Orange
B
8 Red Green
9 Red Brown
10 Red Slate / gray
11 Black Blue
12 Black Orange
13 Black Green
14 Black Brown
15 Black Slate / gray
16 Yellow Blue C
17 Yellow Orange
18 yellow Green
19 Yellow Brown
20 Yellow Slate / gray
21 Natural Blue
22 Natural Orange
Note:
(a) In 5 pair cable, color code specified for pairs 1 to 5 above is used.
(b) In 10 pairs cables and 10 pairs units of 50 pair cables, color code specified for
pairs 1 to 10 is used.
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(c) In 20 pair cables and 20 pairs units of 100 pair cables, color code specified for
pairs 1 to 20 shall be used.

(d) The number of the pairs with respect to the color scheme is only for the purpose
of identification of pairs, the actual numerical sequence of the pairs varies as the size
increase.

The different colors of the binder shall be readily distinguishable under normal lighting
conditions.

(e) Stranding:
A 50 pair cable consists of 5 number of 10 pair units
A 100 pairs cable consists of 10 number of 20 pair units.

These units shall be stranded into a compact and symmetrical cable. the sequence of the
units in the cable shall be same throughout the length of the cable.

An open lapping of 0.02 mm miler tape of any other suitable material of appropriate
thickness shall be applied for each unit.

The tapes shall be so colored and have lay not exceeding 200 mm. This tape is not
necessary on the 5 pairs, 10 pairs and 20 pairs cables.

In case of 5, 10, 20 and 50 pair cables, one spare pair will be stranded as the last pair.
The color of the spare pair shall be in accordance with pair No. 21 of above table .

In the case of 100 pair cable, 2 spare pairs shall be provided. the color of the pair shall be
as specified for pair No. 21 & 22 of above table. The spare pairs in the case of 50 pairs
and 100 pairs cables shall be provided within the cable core, but shall not be within any
unit.

The 200pair and 400 pair cables ( cables above 100 pr and unto 400 pairs) will be
formed by super units of 50 pairs. and the units stranded in the form of layers

The cable over 400 pairs is formed be the super units of 100 pairs and the units stranded
in the form of layers.
 12

CHAPTER 3: COMMUNICATION EQUIPMENT

3.1 Four Wire Station Control Telephone

3.1.1 APPLICATION:

The 4 Wire Station Control Telephone to use with 4 Wire Way Station, which is installed
on the way side stations.

3.1.2 DESCRIPTION:

The 4 wire station control telephone consists of dynamic type Transmitter and Receiver
Insets (RT 200). It has an Led to indicate that the station is called, a buzzer for hooting
while the station is called. It has a pre-amplifier circuit in the Trans side to give an output
voltage of 250mv across the line with 1120 ohms load impedance, for an input of 5mv
across the dynamic type transmitter (220 ohms load impedance). The 4 wire control
telephone consists of ABS body, Hand Micro Telephone, with press to talk Micro Switch,
Cradle Switch, Coil cord & straight Cord, 6 way Rosette Box, Buzzer & LED.

3.1.3 CONSTRUCTION:

The body, handset and other plastic parts are of ABS plastic. It consists of 1.5 meter long
coiled cord and a straight cord terminated in a rosette box.

3.1.4 SPECIFICATIONS:

Power supply : 12V + 20% - 10%

Dielectric strength
Insulation Resistance@500VDC
DC Resistance of the cord
Send level across, mic & ground
& 3 & 4 terminals. 5mv at 1kHz
(Handset terminals)
: 1KVAC 50Hz 1 minute
: 10MΩ between all wires in the terminal strip
and body.
: 1.15 ohms/meter at 20.
: 250mv adjustable across 1120 ohms load mic
ground.
 13

Receive Efficiency : clear tone heard in the receiver Tone of

Micro switch Mechanism
Cradle switch Mechanism
Working of buzzer
1KCat -10dB fed to 5 & 2 terminals across
1120 load.
: When PTT pressed continuity between 2 & 7
terminals.
: Continuity between 1 & 2 terminals when
handset off the hook.
: 12VDC at 2 & 4 terminals. Short 4 & 6 and
Buzzer should Buzz.

3.2 Two Wire Way station Control Telephone:

3.2.1 APPLICATION:

The 2 Wire Station Control Telephone used for 2W way station equipment which is
installed on the way side stations.

3.2.2 DESCRIPTION:

The 2 wire station control telephone consists of dynamic type Transmitter and Receiver
Insets. It has an Led to indicate that the station is called, a buzzer for hooting while the
station is called. It has a pre-amplifier circuit to give output voltage of 775mv across the
line with 600E load impedance at the input of 5mv across dynamic type transmitter. The
2W control telephone consists of ABS body, Hand Micro Telephone, with press to talk
Micro Switch, Cradle Switch, Coil cord & straight Cord, 6 way Rosette Box, Buzzer &
LED.

3.2.3 CONSTRUCTION:

The body, handset and other plastic parts are of ABS plastic. It consists of 1.5 meter long
coiled cord and a straight cord terminated in a Rosette box.

3.2.4 SPECIFICATIONS:

Power supply : 12V, 6V and 3V DC + 20% - 10%

Dielectric strength : Between all wires in the terminal strip and
metal
@1KV, 50Hz AC parts(Chassis).
Insulation Resistance@500VDC : >10MΩ between all wires in the terminal
strip and
metal parts (Chassis).
DC Resistance of the cord : ≤1.15 ohms/meter at 20C.
 14

Send level across L1 & L2 : ≥775mV.

Side tone : <100mV.
Receive efficiency at 193mv : ≥100mV.
Insertion loss : ≤0.2dB Listen condition.
≤0.8dB Talk condition.
DIMENTIONS : 220×180×75mm.
WEIGHT : <1Kg.

Figure 3.1: 2 Wire Control Telephone

3.3 Universal Way Side DTMF control telephone:

Universal Way Side DTMF control telephone is used for control communication
on 4 wire/2 wire control telephone as well as way station equipment for both 4 wire & 2
wire control communication systems. The telephone is assembled in Siemens type ABS
plastic body. The telephone is capable of work on both 4 wire & 2 wire omnibus circuits
by using a changeover switch provided inside the telephone and the telephone works on
• Over head 2 wire system.
• Underground cable 4 wire system.
• OFC or Digital Microwave system.
 15

The telephone instrument consists of the following parts:

a. Telephone housing, HMT, Dynamic Insets, Rosettee Box
b. Speech circuits
c. Decoder circuit
d. RBT circuit etc

Electro Dynamic Transducers (RT200) are used perform functions of transmitters

and receivers. One charge over switch is provided at PCB of the telephone. It will work
one side with 4 wire control line and opposite side with 2 wire control line. The telephone
will work on 12V DC with ± 20% supply voltage.

Specification : RDSO/SPN/TC/36/00
Power supply : 12V DC with ± 20%
Current consumption (max) : 30mA in idle condition
75mA during conversation
125mA during ringing period
Decoder : The decoder circuit is designated to
work the Signaling system of DTMF
control office Equipment.
Ringer : On receipt of the valid code piezo
electric buzzer will be activated even
if the handset (HMT) is OFF cradle.
Ring back tone : After the buzzer the telephone is
activated, a ring back tone is
automatically transmitted to the
control office in acknowledgement of
the receipt of the ring. The level of
the ring back tone across Trans
terminal of the telephone is adjustable
between -6dBm to -10dBm.

4 WIRE SEND EFFICIENCY:

The receiver replaced by a non-inductive : The level across1120Ω is greater than

resistance of 200Ω. 0dBm.
The oscillator level to be adjusted such
that it is -44dBm at1000Hz. The Trans
terminals of rosette box terminated by
resistance of 1120Ω.
Total harmonic distortion : Not more than 3%
 16

Frequency response : +/- 3dB in the frequency range 300 to

3400Hz.

2 WIRE SEND EFFICIENCY:

The receiver replaced by a non-inductive : The level across L1, L2 (600Ω) is

resistance of 200Ω. greater than 0dBm.
The oscillator level to be adjusted such
that it is -44dBm at1000Hz. L1 & L2
terminals of rosette box terminated by
resistance of 600Ω.
Total harmonic distortion : Not more than 3%
Frequency response : +/- 3dB in the frequency range 300 to

SIDE TONES (2 WIRE):

Oscillator level -44dBm at 1000Hz : The level across R1 & R2 not more
across Trans terminals L1 & L2 than -18dBm.
terminals of rosette box terminated
by resistance of 600Ω.

4 WIRE EFFICIENCY:

The line simulated by non inductive : the level across R1 &R2 greater than
resistance of 560+560Ω the level and -26dB.
frequency -20dBm at 1000Hz.
Total harmonic distortion : Not more than 3%
Frequency response : +/- 3dB in the frequency range 300 to
3400Hz.

2 WIRE EFFICIENCY:

The line shall be simulated by non inductive : The level measured across R1
resistance of 300+300Ω. Oscillator level to be & R2 not be less than -18dB.
adjusted across L1 & L2 -12dBm at 1000Hz.
Total harmonic distortion : Not more than 3%
Frequency response : +/- 3dB in the frequency range 300 to
3400Hz.
 17

INSERTION LOSS:

4 wire ON hook condition : Not be greater than 0.5dBm

4 wire OFF hook condition : Not be greater than 1.0dBm
2 wire ON hook condition : Not be greater than 0.5dBm

2 wire OFF hook condition : Not be greater than 0.8dBm

Figure 3.2: Universal Way Side DTMF Control Telephone

3.4 Six Pin Emergeny Plug and Socket:

Six pin plug and socket used for communication on 4 wire basis on emergency
control circuits from the points provided for this purpose along the side of the track in AC
electrified areas. These are made of glass filled ABS plastic (unbreakable).

The transmitter, receiver of the 4 wire emergency portable telephone shall be

connected to the six pin plug by means of 6 way cord provided in the 4 wire emergency
portable telephone.
 18

Socket shall be fixed in the socket box. The socket be connected to trans, receive
of the emergency control circuit, derived from the main cable through transformer joint.

Six pin plug & socket consists of the following components:

a. Six pin plug shall consists of plug top cover, plug base and plug pin.
b. Six pin socket shall consists of socket base, socket fixing clamps, contact spring,
rivet and buffer pin.

Six numbers of plug pins are embedded in the plug base. The wires are connected on
the screw terminals of the plug base as per the pin configuration.

SPECIFICATION:
High voltage test : plugs and sockets outlets shall satisfactorily
withstand a voltage of 2KV r.m.s for 1min without
breakdown when applied between
i. All terminals looped and body.
ii. Between terminals.
Insulation Resistance : Insulation Resistance when measured at a voltage of
500V DC between all terminals looped to together
and the body, and in between terminals shall not be
less than 100MΩ.
Contact Resistance : The contact resistance of each pin shall not exceed
20 milli Ohms.
Contact pressure : The contact pressure when measure with a pressure
gauge applied on the contact spring front of the
socket shall not be less than 500gms.
Dimensions : The outline dimensions are given in the drawing.
 19

Figure 3.3: 6 Pin Emergency Plug and Socket

3.5 4W/2W Portable Emergency Control Telephone for Use in Electric Field
Sections:

3.5.1 SCOPE:

The Portable Emergency Control Telephone is a part of the 4Wire/2 Wire

emergency train traffic control system. This telephone provides inter communication
between any way side point along the train route and controller. This can be connected
through 6 Pin Socket located along the railway track in 4W side and 2 Wire lines in 2
wire side. The telephone has ‘Trans’ and ‘Receive’ speech circuits. The telephone works
on 3 VDC with the aid of 2 Nos. of 1.5V dry cells. The entire circuit, HMT and the
battery container are housed inside the M.S body provided with shoulder strap to carry
easily. With the aid of switch, this telephone can be selected for 2W or 4W operation.

3.5.2 FEATURES:

• Glass epoxy boards are used for better environmental performance.

 20

• Ferrite Core Transformer is used for miniaturization and better quality

performance.
• High reliability press to talk and press to call switches are used.
• Sealing arrangement is provided for preventing pilferage of battery.
• Rugged construction of box to ensure rough handling.
• HMT is of Siemens type or type 677 of ITI, made with ABS moulding which is
unbreakable.

3.5.3 TECHNICAL DESCRIPTION:

• The indication transformers are made of high permeability. Ferrite cores meet
acceptable specification of grade 3, category 3 to IS:6297, Part1/Part3.
• The windings are terminated on glass epoxy PCB.
• The transformers are duly marked Trans and Rec.
• The windings used comply with IS:4800, Part1.
• The transformers are duly impregnated/Potted.
• The handset is of Siemens type or type 677 of ITI make with ABS plastic which is
unbreakable and has 1 meter long five core coil cord terminated to the PCB using
two pin connectors.
• The press to call and press to talk switches are of LCSO approved make.
• Terminals are provided to connect Battery and Handset internally.
• The outgoing four cable is connected to 6 pin plug using 2 meter long standard
cord and 2 lines are connected to the terminals marked L1&L2.
• The internal wiring is done using 0.5mm over all dia 7 strand PVC insulated wire
as per IS:5608.
• The supply is 3V DC with the aid of 2 Nos. of 1.5V dry batteries, type R20 of
IS:8144. The batteries are housed in a battery box which is fitted on a MS plate.

High voltage test and 2KVRMS, 50Hz for 1 min. 4W SIDE 2W SIDE
i. Between Primary/Secondary : No breakdown N.A
ii. Between Primary/Earth : No breakdown N.A
iii. Between Primary/ Earth : No breakdown N.A

Insulation Resistance at 500 VDC/Ambient Temp. 4W SIDE 2W SIDE

i. Between Primary/Secondary : >100M >10MΩ
ii. Between Primary/Earth : >100M >10MΩ
iii. Between Primary/ Earth : >100M >10MΩ

3.5.4 CONSTRUCTION:
 21

The box is made of M.S Sheet with spot welded brackets and has a middle plate.
Under this middle plate, battery container is fixed and the battery can be replaced easily
from the top. The PCB made of epoxy glass is fitted with the trans and receive circuitry.
The cables are taken from the bottom through grommets for 4 Wire. Two terminals
marked L1 & L2 are provided on the top of the plate, using which the telephone can be
selected for 2 Wire/$ Wire operation. The complete box can be closed after taking out the
coil cord, straight cord and connection from L1,L2 terminals through special outlet
shrouds provided.

Dimensions : 260×135×160mm
Weight : 2.5KGS(Approx.)

Figure 3.4a: 2/4 Wire Portable Emergency Control Telephone

Figure 3.4b: 2/4 Wire Portable Emergency Control Telephone (Inside View)
 22

3.6 Block Bell Equipment:

3.6.1 APPLICATION:

The Block Bell Equipment is a part of the block instrument which is provided at the end
of the block sections of cabins /ASMS. DC impulses cannot be sent in AC electrified area
since block circuit is converted from overhead alignment to under ground cable
terminated transformer at both of the ends. This equipment is used in AC electrified area
to convert the DC impulses to AC at the sending end and AC impulses to DC all the
receiving end.

3.6.2 TECHNICAL DESCRIPTION:

The Equipment is a single transistor oscillator to give 45V AC across 1120ohms. This
also has a full wave rectifier circuit to rectify the received AC voltage and to energize a
relay.

The plunger is connected to terminals TS9 and TS10 of terminal strip (Refer circuit
diagram enclosed). Hen the plunger is pressed 12 V.DC supply is fed simultaneously to
the Transistor Oscillator and the Relay So/2. The output of the oscillator, Viz, 45volts at
150Hz, is thus made available at terminals. TS3 and TS11 through the energized contacts
of Relay So/2. This is fed to the line. At the distant station, this voltage from the line is
fed to terminals TS3 and TS11 at the Block Bell Equipment installed at the station.
Though the normally closed contacts of Relay So/2, this voltage is fed to the bridge
rectifier. This rectified voltage is available, as desired from terminal TS4 and any of the
other terminals, namely, TS5, TS6, TS7, TS12, TS13, TS14 and TS15 for ringing the
bell.

3.6.3 CIRCUIT DESCRIPTION:

When the plunger is operated, the single transistor is energized of the oscillator gives an
output 60V (open circuit) @ 150Hz and 45V (across 1120 Ohms.) at 50Hz., sinusoidal at
TS3 and TS11.

3.6.4 SPECIFICATION:

a) Input Voltage : 12V.DC ± 20%, -10%

b) Output Voltage : < 1 Amp

c) Output Voltage across 1120 Ohms : 45V.AC± 5%

d) Output Frequency : 150HZ ± 5HZ

e) Wave- Shape : Sinusoidal

 23

f) Dielectric Strength

(Between all current carrying points and above) : No Breakdown

g) Insulation resistance at 500VDC : More than 10M Ohms

3.6.5 CONSTRUCTION:

The box is made of aluminum alloy and it has a hinged front door, with a knurled screw
and sealing arrangement. The cables can be wired through the grommet hole provided in
the rear, to the terminal plate.

The terminal plate is marked for wiring purpose. A wiring diagram is also pasted on the
rear of the door.

WEIGHT: 2.7KGS (App)

 24

Figure 3.5: Block Bell Equipment

 25

CHAPTER 4: FLEXIMUX

4.1 General Description:

The Flexilv LJX is a programmable add/drop multiplex equipment which combines

variety of voice and data traffic of public or private network into a 2.048 Mbps stream in
CCITT-ITLJ-T G.73 1/G.732 format. For voice transmission the equipment
accommodates different types of interfaces ranging from 2W/4W E&M interface to
subscriber, exchange and junction line interfaces. The digital interface units consists of
both high speed and low speed accesses to accommodate variety of data communication
applications. Multiple low speed data are combined into one 64 Kb/s channel for efficient
utilisation of information bandwidth. The add/drop feature of the F1ex1MUX is realised
through the use of a high performance time/space non-blocking cross-connect switch
with four independently controlled serial time division multiplexed buses. Conferencing
of voice is done through a separate Digital Signal Processing circuit in digital format
conforming to CCITT-ITU-T G.7 11 A- law format. All the signalling information are
handled by a microcontroller which can also optionally take care of some signalling
protocol conversion if required. The system can be programmed for its channel
assignments locally through a portable laptop computer or remotely from a Central
Supervisory Terminal through a polled data channel derived through unused National bits
or the overhead bit-stream of the transmission equipment. The same channel is also used
for Network Monitoring and Control operations. Polled mode of operation allows it to be
used in tandem, loop or star to suit the network structure of the user. Various diagnostics
features are built-in the system which eases the maintenancc of the network. -

4.2 System Architecture

The F1exiMUX is .a compact unit based on the 19 inch mechanical construction

measuring 10.5” H (6U) x 19” W x 19” D (267mm x 483mm x 457mm). This 6U sub
rack is a common mechanical housing with a bussed backplane which accepts all the
modules with vertical mounting making a modular equipment concept possible. LEDs on
the front panel indicate the status of all the individual modules. The 2 Mbps streams are
accessed from the rear side either through coaxial connectors for 752 interface or through
wire wrap posts for 1202 balanced connection. All the voice, signalling and data
information are accessed from wire wrap connectors mounted at the back. The NMS can
be accessed through a 9 pin D-shell connector, mounted in the backplane or from RJ1 1
jack mounted in the facia of Network Interface Module. The basic system consists of the
Network Interface Module, Tributary Module, Power Supply and the sub rack with the
backplane. Analog and digital services are realised with interface specific access units
connected to an internal 2 Mbps bus. The realisation concept of the FlexiMUX is
presented in Figure 1. Each, of the access units accommodates one to four channels
depending on the complexity of the interface. Each individual service channel consumes
one time slot (e.g. voice and high speed data up to 64 Kbps) and fractional time slots (e.g.
low speed data unto 19.2 Kbps) of the 30 time slots available for use with the 2 Mbps
stream. For voice channels various interface options are available to suit the customers
requirement. The interface units are small adaptor cards which can be plugged into any
 26

one of the four adaptor sockets available on a voice access module. Flexibility of these
plug-in modules allows free inter-mixing of interface units on a particular voice access
module. The various interface options available at present are

a. 4W/2W E&M
b. Subscriber Interface
c. Exchange Interface
d. Hot Line Interface

Figure 4.1: System Architecture

The sub rack has altogether 13 slots for housing the various modules. Out of these slot 1
& 2 are dedicated for PSU Modules (in case of redundant power supply) and slot 2 & 3
are dedicated for the Network Interface • Module (MM) & Tributary Module (TM). Slot
3 to slot 13 is meant for housing various access modules for both voice and data
interface. Each of these slots supports access to 4 Time Slots of the 2 Mbit/s stream. Thus
slot 5 to slot 11 supports altogether 28 Time Slots of the 2 Mb/s bus. Slot 12 and slot 13
has equal and parallel access to time slots 30 and 31. This has been done for efficient
utilisation of the bit stream during sub multiplexing of a time slot for low speed data. The
structure of the sub rack and its arrangement of time slot allocation is shown in Fig4.2.
 27

Figure 4.2: Sub rack

Access to the 2 Mb ports is available from the backplane from the rear side. Separate
connectors are available for 75 2 and 120 2 impedance matching. For 75 Q, spinner type
threaded connector has been provided for firm contact. For 120 2 , three pin 1mm square
post has been provided for either wire wrap termination or termination through self lock
header socket. A separate port is also available for driving the system using external
clock. Extension of voice and data has been provided on Euro type wire wrap connectors.
This has enough space for wrapping 0.5mm or 0.6mm telephone cable normally used for
telecommunication. Separate connector has been provided feeding input -48V DC power
supply to F1exiMUX. The backplane. also provided a D-Shell 9pm connector for
interfacing the V24 / RS232C serial link of the Network Monitoring System. NMS can
also be accessed from RJ1 1 jack located at the front of NIM.

4.3 Power Supply Module:

The power supply unit operates from 48V supply. The input power is fed through a surge
protector and filter section to protect the system from high voltage spikes and lightning
strikes coming along the. power line. The first stage is a Gas Arrestor which can absorb
high energy pulses. This is followed by LC filter which then faces a transient protector to
bring down the spikes within acceptable limit. The primary supply is connected to earth
through high voltage capacitors to bypass AC noises but ensuring DC isolation.
Each PSU has three separate switching power supply modules, one for +5V, one for ±1
OV and another for +80V. They are also mutually isolated with each other. +5V is used
to operate all the digital devices of the system. The ±1OV is post regulated in different
card to ±5V and is used to drive the analog devices. The card also has under-voltage and
over-voltage alarm for both input and output. The capacity of the PSUs are overrated
adequately so that each of the PSUs individually can support the whole system.

LED Display Status:

PSU OK It is a green LED. When the power supply is frmnctioning properly it glows.
PSU ERR It is a yellow LED. When there is output undervoltage alarm it glows.
SHUT DN It is a red LED. When the power supply goes into shutdown it glows.
 28

SW1 It is the power ON switch.

SW2 It is the switch for resetting the power supply card.

4.4 Circuit Description:

The input -48V supply is fed through a surge protection section Li & SA. Diode CR1
protects the system from reversal of input voltage. C48, Cl & C6 are input filter
capacitors. Qi along with CR2 & CR4 provides crowbar protection for the input going
beyond 58V. Q2 is a series regulator which gives the initial power to the switching
regulators Ui, U3 & U5 for its operation Switching regulator Ui and its associated
hardware generates +5V power, U3 generates ±1OV and U5 generates +80V supply.
Primary and secondary of the power supplies are fully isolated through the transformer
Ti, T2 & T3 and feedback opt isolators U2, U4 & U6. The +5V, ±1OV and +80V at the
secondary side is also mutually isolated. Use of entirely separate hardware for +5V,
±1OV and +80V helps to maintain much better regulation of the derived power supplies
compared to that with a single switching regulator.
R8, R9 and C8 fixes the oscillation frequency of the switching regulator of Ui to 80KHz
approx. Reference voltage from Ui :16 is fed to non- inverting input of the error amplifier
Ui :2 through a filter R44, R7 & C7. Opt isolator U2 provides a feedback signals of the
+5V output through the resistance combination R6 & R4. R5 & C9 provides frequency
compensation for the error amplifier. The output switching pulses from Ui is fed to the
switching transistor Q3 which in turn drives the switching transformer Ti. Snubber circuit
consists of R16, C13, CR7 & R15, C12 & CR14. R13 & R14 gives feedback of the
overload condition to Ui. Operation of ±1OV and +80V power supply is same as that of
the +5V power supply except the difference in the winding ratio of the switching
transformer T2 and T3. U8:A & U8:B senses the alarm for input over-voltage (-58V) and
under- voltage (-40V). U8:A & U8:B senses input for out of limit (-58V & -40V) beyond
which the power supply unit is shut off by disabling the switching regulators Ui, U2 &
U5 through diodes CR29, CR30 and CR28 for safety of the equipment.
U7:A & U7:B senses over-voltage and under-voltage condition for the ±5V power
supply. If the output voltage exceeds 6.4V Ki relay is initiated through transistor Q7 to
isolate the power supply from the system backplane. The situation is also displayed by
DS2 LED. For under- voltage, however, only DS3 LED glows, DS 1 indicates the OK
condition of the power supply. U7:C & U7:D similarly senses over-voltage and under-
voltage condition for the +1OV supply. If the output voltage exceeds 14V Ki relay is
initiated through transistor Q7 to isolate the power supply from the system backplane.
The situation is also displayed by DS2 LED. For under- voltage, however, only DS3 LED
glows. DS1 indicates the OK condition of the power supply.
U9:A & U9:B similarly senses over-voltage and under-voltage condition for the +80V
supply. If the output voltage exceeds 100V 1(1 relay is initiated through transistor Q7 to
isolate the power supply from the system backplane. The situation is also displayed by
DS2 LED. For under- voltage, however, only DS3 LED glows. DS 1 indicates the OK
condition of the power supply. Under voltage alarms of +5V, ±10 & +80V are
extended to the processor module to the backplane. The power supply is rated

as follows:
 29

+5V - 3 Amp
±i0v - 0.75Amp
+80V - 0.2 Amp

4.5 Network Interface Module

The Network Interface Module primarily takes care of the alarm acquisition function
from various internal and external sources and responds to the queries and commands
issued by the Network Manager through the “Super-Net” Network Management System.
The module runs on a high performance Intel 80C196 microcontroller with associated
communication and alarm interfaces for its operation. The block diagram of the Network
Interface Module is presented in Figure2. The Network Interface module is used for
exchange of information among the Network Manager, the Tributary Module and the
various access modules interconnected via the backplane. It has altogether four
communication interfaces for information exchange. The network management system is
realised through, two serial interfaces, one for external NMS for interfacing the central
supervisory computer while the other is used for realising the NMS through the unused
National bits of the -2 Mb stream. Other than these, the tributary unit is interconnected
through a serial link while the access modules are interfaced through another serial bus.
Communication for Network Supervision and Parameter uploading! Downloading is
done through a standard 1EC65 frame format whose structure is as shown below.

The structure has been adapted for all transmission equipment of WEBFIL make so that
the same NMS system may be used to access all types of transmission equipment
manufactured by WEBFIL. The baud rate of this link is 1200 bps and is operated as
digital omnibus link is semiduplex master/slave mode.
 30

CHAPTER 5: ADVANTAGES AND DISADVANTAGES

5.1 Advantages of Polythene Insulated jelly Cables:

• Counting of pairs is easy and human mistakes are avoided.

• Jointing is easy and require no chamber or additional place.
• Failure of joints is less.
• Entry of moisture / water is prevented by Jelly in the core.
• Cables can be directly terminated on MDF / Cabinet / Pillar and DPs, thus
avoiding additional joints decreasing the cost and time.
• Handling of cable is easy not delicate like paper insulated cables.
• Life of cable is more.

5.2 Disadvantages of Paper Insulated Cables:

• Numbering of pairs is in coded form. Require more skill. Color markings also
fade with due course of time.

• Jointing of cables require skill and perfection is required while plumbing as even
a slight pinhole will cause entry of moisture / water and damage all the pairs.

• Extra care is required for handling like coiling, uncoiling to avoid damage.

• Water / moisture entry will affect the complete cable at once instantaneously.

• Termination in cabinet / pillars / DPs and at MDF is very expensive and time
consuming & increases number of joints.
 31

Figure 5.1: PIJF Cable

 32

Figure 5.2: Layers of Units in PIJF cable

 33

CHAPTER 6: OPTICAL FIBRE CABLE

6.1 Introduction to Optical Fiber:

Optical fiber is the latest underground cable that is being used extensively in all
the networks including long distance trunks, junction circuits and even the local
subscriber loops to enhance the data transmission.

The OF cables are detailed extensively in the other modules of the basic course.
How ever for academic interest the advantages of OF cables over copper cables are
discussed here under

• Optical Fibers are non conductive, hence does not require ground and surge
suppression
• Optical Fibers are immune to electromagnetic interference
• Un authorized tapping is not feasible.
• Easily upgradeable to higher bandwidth.
• Low loss ( 5db per km to < 0.25 db per km on a typical fiber)
• Long and unrepeated links , hence inexpensive
• Small light, and hence cost is less and easy for installation.
• It does not attract lightning, It does not carry electricity hence not hazardous

The Application of the Fiber Optical cable in communications are:

• Is the common carrier nation wide networks

• Inter connecting all Trunk automatic exchanges
• Inter connecting all the Exchanges.
• Under sea cable
• Control systems
• Customer premises communication networks.
• SDH systems
• 8 MB MUX for 120 channels
• 34 MB for 480 channels
• 140 MB for 1920 channels

6.2 Construction:
Optical fiber has two layers:
• Core made of material with high refractive index.
• Outer layer with low refractive index.
• The OFC has glass structure, with small size, it transmits light to a greater
distance with small amount of loss which makes it use in transmitting data.
 34

• A core which carries most of light, surrounded by cladding. The core is

usually made of pure glass or plastic.
• Cladding which bonds the light, confine it to core surrounded by it.
• A substance layer of glass which doesn’t carry light, but adds to the diameter
& strength of fiber covered by primary layer.
• A primary buffer containing which provides the first layer of mechanical
protection covered by secondary buffer.
• Secondary buffer coating this protects the relatively fragile primary coating &
underlying fiber.

Figure 6.1: Cross section of Optical fiber

6.2.1 Buffer Tube:
• It is the first shield protecting fiber from damage.
• It can have one fiber or more.
• It can be tight buffer or loose buffer.
• It is color coded for identification.
 35

6.2.2 Features of Tight Buffer Tube:

• Tight buffer’s inner diameter is same as fiber’s outer buffer.
• Each buffer can hold one fiber only.
• It can keep the fiber operational despite break, as the fiber is held in position
firmly.
• Easy to prepare for and provide connectors/splicing.
• Can be installed vertically.
• Normal tight buffer tube cables are used in in-door.

6.2.3 Features of Strength Member:

• Purpose is to release fiber from mechanical stress during installation/operation.
• Following materials are used as strength member:
Flexible aramid yarn
Flexible fiber glass roving
Metal wire
Metal rope made from twisted steel wires

6.2.4 Features of Outer Jacket:

• Surrounds the entire assembly of buffer tube or tubes and strength member.
• To provide environmental protection to fibers.
• Made of PE.
• Steel armor is provided for armored cable.

6.3 Strength of Optical Fiber Cable:

• While traditional bulk glass is brittle, the ultra-pure glass of optical fibers exhibits
both high tensile strength and extreme durability.
• Tensile strength is of the order of 44000 to 60000 kg/sq.cm.
(For copper it is only 7500 kg per square cm.)
 36

6.3.1 Cladding Diameter:

• The cladding diameter tolerance controls the outer diameter of the fiber, with
tighter tolerances ensuring that fibers are almost exactly the same size.
• During splicing, inconsistent cladding diameters can cause cores to misalign
where the fibers join, leading to higher splice losses.

6.3.2 Core/Clad Concentricity:

• This reduces the chance of cores that do not match up precisely when two fibers
are splicing together.
• Tighter core/clad concentricity tolerances help to ensure that the fiber core is
centered in relation to the cladding.
• Core/clad concentricity is determined during the first stages of the manufacturing
process.

6.3.3 Fiber Curl:

• It is the inherent curvature along a specific length of optical fiber that is exhibited
to some degree by all fibers.
• It is a result of that occurs during the manufacturing process.

6.4 Optical Transmission and Reception:

• Optical transmission of data requires a source, which convert signal into light
signals, which convert signal into light signals, which is transmitted then the
receiver is present which causes the light signals to be converted into data signals.
• Basically fiber technology is based on use of light energy to transmit data.
• The encoded data is converted from electrical signals to optical light pulses and
then transmitted through medium to its destination, when they converted back.
• In any fiber link there are mainly 3 parts:
 Transmitter
 Optical fiber
 Receiver
 37

CHAPTER7: JOINT AND TERMINATION OF OPTIC FIBER CABLE

7.1 Methods Of Joining Fiber Optic Cable:

There are two methods:
1. Splicing
2. Connectors
7.1.1 Splicing:

It is a process of connecting two bare fibers directly without any connections.

These are of two types. They are:

• Mechanical Splicing:
This aligns the axis of the two fibers to be jointed and physically hold them
together. It is used for temporary splicing of fibers.
 38

Figure 7.1: Mechanical splicing

• Fusion Splicing:

It provides a fast, reliable, low-loss, fiber to fiber connection by creating a

homogeneous joint between the two fibers. The fibers are melted or fused together by
heating the fiber ends typically using an electric arc. Fusion splices provide a high-quality
joint with the lowest loss (in the range of 0.01 db to 0.1 db) and are practically non-
reflective.

Figure 7.2: Fusion splicing

 39

CHAPTER 8: CONCLUSION

With The Introduction of state of the art technology into the switching and
Transmission equipments the faults due to indoor equipment have been reduced
drastically increasing in the satisfaction of the customer. But the rate of faults occurring
in the external plant is causing worry to the Managers of the plant.

By adopting two methods of

• Implementing Pole less External plant

• Replacement of obsolete / fault prone telephone instruments

These methods have to detected during inspection and implemented by the way of
rehabilitation of the external plant, which results in reduction of heavy fault rate in the
outdoor network thereby increasing the satisfaction of customers and managers.

By implementing the pole less external plant the overhead section in the outdoor
network including poles, AI wire and drop wires will be replaced by a 5 pair underground
cable which is proposed to be laid from the nearest Distribution cable to the Guard’s
room and terminated at the LJU.

An average of 50 meters of 5 pair cable perhaps have to be laid in the premises of

Guard. With in the Guard’s room it may not require digging of trench to a depth of 1
meter and a easy method of laying in cost free earthen or PVC pipes can be laid under the
flooring which it self is a mechanical protection. This also reduced cost and easy
replacement in future.

Implementation of pole less scheme should be done in phased manner. In order to

get quick results in reducing fault rate with minimum expenditure and time, the following
points should be kept in mind while identifying the priority area where:

• Maximum Over head lines exist

• Maximum faults are booked and noticed
• Many overhead bridge with railway track and power crossing exist.
 40

• DPs are in bad condition due to traffic congestion.

• Different gauge drop wires exist.
• Many DPs for which the Phone Mechanic is Removing the pair from DP
termination and twisting the UG cable pair to Drop wire directly.
• Non feasible areas exist.
• High telephone density exists

BIBILOGRAPHY

India Telecom By Information Gatekeepers, Inc.

• Electrical Cables for Power and Signal Transmission by Oswald I. Gilbetson.

• Underground CABLE FAULT Location by Barry Clegg.

• Power and Communication Cables: Theory and Application by R. Bartnikas

(editor) and K. D. Srivastava (editor).

• High Speed Signal Propagation: Advanced Black Magic by Howard W. Johnson

and Martin Graham.

• Plastic Optical Fibers: Principles, Components, Installation by Andreas Weinert.

• http://www.cablemasterinc.com/

• http://www.cablemasterinc.com/