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SIGNAL CABLE

SIGNAL CABLE

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Published by Vikas Srivastav

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Published by: Vikas Srivastav on Sep 13, 2008
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01/04/2013

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SIGNALLING CABLE
1. INTRODUCTION
A Cable can be defined as a number of insulated electrical conductors bunched in to acompact form by providing mechanical protection and electrical insulation.Cable can be classified as Underground Cable (laid under ground), Submarine cable ( laidunder water), Aerial cable (laid over head) and Indoor cable ( laid along the walls of  building. However, in Railways only Underground and Indoor Signalling Cables are used.This handbook covers Construction. Laying, Jointing, Testing, and Maintenance of Signalling Cables as per Indian Railway Standard Specifications No. S:63-89, S-35/93,S:76-89 and IS:1554. These Specifications cover the requirements and tests for armouredand unarmoured single core and multicore copper conductor, PVC insulated sheathed andunsheathed cables for Indoor and Outdoor Railway Signalling.
2. BRIEF DESCRIPTION
The Cable is circular throughout its length and is free from any physical defects. Themeasured length of cable on any drum should not vary by more than + 0.2% of drum length(CL.4.2 of S/63-89) Single core cables may be supplied in coils of 100 +
 
0.5 metres (CL.6.1of S/63-89) .Unless otherwise specified, the multicore cable is supplied in length of 500 metres each.With the prior approval of cosignee, cable upto 9 cores may be supplied in length of 1000metres each. Non-standard lengths each not less than 100 metres shall be acceptable upto4% of the total quantity ordered (CL.6.4 of S/63-89).The cable ends are sealed to prevent moisture entry. The length of the cable is marked in asequential manner over the outer sheath at intervals of one metre with an accuracy of +0.2%. The Cable drum number shall be legibly embossed at every one metre or less on thePVC outer sheath throughout the length of cable (CL.4.4 of S/63-89).The following information shall be stencilled on the drum in black paint over yellow painted background (CL.4.3 of S/63-89):a) Manufacturer’s name, brand name or trade mark. b) IRS Specification number.c) Type of cable and voltage grade.d) Number of cores.e) Nominal cross-sectional area of conductor.f) Colour of cores (In case of single core cable).g) Number of lengths on drums/in coils ( if more than 1)h) Length of the cable on the drum/coil.i) Initial and final sequential marking for the length. j) Direction of rotation of drum (by means of arrow).k) Approximate gross weight.l) Country of manufacture.m) Month and year of manufacture.
 
CAMTECH/99/S/SIG-CAB/1.0 2SIGNALLING CABLE JUNE1999
2.1Advantages of Underground Cable1.
Overhead lines may come in contact with trees, bushes, etc. and cause lowinsulation.
2.
Due to natural causes and ravages of humans beings, overhead lines are prone to ahigher fault incidence.
3.
Due to headway considerations the maximum number of pairs on a pole route islimited to 16.By using underground cable all these disadvantages can be minimised.
3. TYPES AND USE
3.1 Outdoor Signalling Cable
 Signalling cables for outdoor circuits should be laid underground. Following types of underground cables are normally used in Railway Signalling.
A) Main Cable
These cables are used for extending signalling circuits from cabins to location boxes and between location boxes. Normally 2, 4, 6, 9, 12, 18, 24, 30 and 37 cores, armoured cablesare recommended for use as main cable. 
B)Tail Cable
Tail Cables are used for extending signalling circuits from location boxes to signallinggears. Cables of 5 core to 12 core are normally used as tail cables.
C) Power Cable
These cables are used for extending 230/110 Volt AC supply. Normally aluminium cables2/16 Sq.mm, 2/25 Sq.mm, 2/35 Sq.mm, 3/16 Sq.mm, 3/25 Sq.mm, 3/35 Sq.mm sizes areused. In addition, 2/10 Sq.mm. copper cable is also used.
3.2 Indoor Signalling Cable
Indoor Signalling Cable is used for indoor wiring of signalling circuits. Following cablesare normally being used for indoor signalling applications :
TABLE 3.1 : ‘TYPES OF INDOOR CABLES & USES’
Sr.No.Type of CableUse
116/0.2 mmWiring of Q series and Shelf type Relays23/0.75 mmWiring of shelf type Relays31/1.4 mm Wiring of lever lock, Circuit Controlle
 
CAMTECH/99/S/SIG-CAB/1.0 3SIGNALLING CABLE JUNE1999
47/1.4 mmPower Supply i.e Battery Room toCharger and Busbar 51/ 2.5 mmWiring of Boot leg (Track Circuit)640/0.6 mm60/0.6 mmRack to Rack wiring in metal to metaltype relay installations.724/1.0 mm40/1.0 mm60/1.0 mmFor wiring from control or Relay rack upto Cable termination rack for outdoor circuits i.e signal and point.81/0.6 mmFrom tagblock to tagbloc(except Signal and Point)91/1.0 mmFrom tagblock to tagblocFor Signal and Point)1036/0.3 mmFor wiring of track relays from MDF
Note :
Busbar conductors shall be so chosen that voltage drop is not more than 0.5% of  busbar voltage between battery terminals & busbar in equipment room.
4. CONSTRUCTION
Construction of a typical 30 core, un-screened, armoured cable is shown below:
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