TM Cable Requirement

Specification Lines WE 0303
Section 1 : General
SECTION 1- GENERAL
1. SCOPE 1.1 The specification covers complete installation of the following cable system : Main Cable System (Primary Cable) Cables from exchange to main distribution points, e.g. cabinets or subscribers distribution frame in multi-story buildings. 1.1.2 Distribution Cables System (Secondary Cable) Cables from main distribution point (e.g. cabinets) to subscriber distribution points e.g. DP boxes. 1.2 In general, the types of cables used in junction cable system shall be fibre optic cables to TM Specification as specified by FOKUS. In general, the type of cables used in main cable system shall be plastic cables of type Polyethylene Insulated, Polyethylene Sheath, Unit Twin Aircore (P.E.U.T.) to TM Specification CL 0522. Two types of cables are used in the distribution cable system. 1.4.1 Polyethylene insulated, polyethylene sheathed, unit twin type, integral bearer (P.E.U.T.I.B.) for aerial erection to TM Specification Lines AC 0001. Polyethylene insulated unit twin, fully-filled, polyethylene sheathed (P.E.U.T.F.F.) to TM Specification CL 0522. In general the aerial cable is not pressurised.
1.1.1
1.3
1.4
1.4.2
1.4.3
Issue, August 1993
Section II Definition
SECTION II - DEFINITION
The following words and expressions shall have the meanings hereby assigned to them valid for this specification only. 1. DUCT: Means a single or multi-way duct of 102 +/- 2 mm internal diameter, PVC, Galvanised Iron, or other materials, provided by TM. 2. JOINTING CHAMBER: Means any manhole, joint box or other underground vault or chamber and the subscriber distribution points. 3. LOCAL CABLE: Means any cables in the Local Exchange area between the exchange and the subscriber distribution points. 4. SURVEY MAP Means a survey plan showing the duct and cable route, position of cabinet and pillars, distribution and intermediate poles, locations of stays and struts. 5. DUCT PLAN Means a straight line diagram of the duct route showing the number of duct ways, types of manholes and joint boxes and their distance apart. 6. CABLE PLAN Means a straight line diagram of the cable network showing the termination, local as of joints, types of joints, location of gas pressure fittings and types of distribution boxes. 7. CABLE BEARER: Means galvanised U-channel iron fitted to the wall of jointing chamber for supporting brackets cable bearer. 8. TERMINATING CABLE: Means PVC insulated cable of unit-twin formation protected with PVC sheath. 9. JOINTING MATERIAL:
2 Issue, August 1993
Means all TM type approved materials such as mechanical connectors, heat shrink wraparound (HSW) closures and other accessories required to make a complete joint. 10. GAS PRESSURE FITTINGS: Means the necessary hardware and gas seals to be installed in a cable system for gas pressurisation. 11. JOINT: Means either a straight joint, multiple joint, numbered joint, termination joint, test selected joint or T-joint. 12. DISTRIBUTION FRAME: A connection frame where cable pairs are terminated and the cross-connection of the pairs are facilitated. 13. MAIN DISTRIBUTION FRAME (MDF): The distribution frame in a telephone exchange on which the local pairs and exchange multiple both terminate. 14. SUBSCRIBER DISTRIBUTION FRAME (SDF): The distribution frame in subscribers premises. 15. DISTRIBUTION, INTERMEDIATE AND TERMINAL POLE FITTINGS: Means the necessary hardware to be installed on pole for erection of aerial cable. 16. DISTRIBUTION BOX: Means a box for termination cable pairs from an exchange before distributing to subscribers premises such as:16.1 EXTERNAL DP: 16.1.1 Overhead Armed type with open wires on poles. 16.1.2 Overhead Ring type with insulated drop wire feeding radically from pole to subscribers premises.
16.2
EXTERNAL BLOCK CABLING:

A terminal block served by (usually) a cable and fixed to the exterior wall of a building. 16.3 INTERNAL BLOCK CABLING: In this form of distribution, the external cable (exchange cable) is lead directly into the building and is terminated on a distribution box, or distribution frame. From this point, the cables or wires run within the building possibly via subsidiary distribution cases or terminal blocks to serve the telephone requirements within the building. 17. CABINET: Means a terminal unit for terminating cables from a telephone exchange and distribution boxes and enables, by used of jumper wires or equivalent, and incoming pair to be connected to any of the outgoing pairs. 18. POLE: Means iron , wooden or concrete pole erected to support aerial cable or distribution box and fittings. 19. STAY: Means terminal stay, longitudinal stay, angle stay, transverse stay, overherad stay and stay crutch fitted to a pole route to counteract the pull of wires on poles. 20. STRUT: Means a rigid support in the form of a 50 mm G.I. pipe set obliquely in situations where there is no possibility of supporting a pole with stays. 21. DP EARTH: Means earth system consisting of a 7/1.04 mm tinned stranded copper earth wire with one end connected to the earth terminal of a DP box and the other end connected to an earth rod or trench earth or combination of both to obtain an earth resistance of 5 ohms or less. Unless otherwise specified the standard provision shall be two earth rods. 22. UP-STATION: Means the exchange or repeater station named under the tail of the arrow in the heading of the relative cable layout diagram. 23. SUPERINTENDING OFFICER: (OR THE INITIAL SO)
Means the Chief Executive Officer of Telekom Malaysia and his successors in office or any duly Authorised Officer acting on his behalf for the purpose of a Contract Work.
Issue, August 1993
Section III: Installation of Main Cable Network
SECTION III - INSTALLATION OF MAIN CABLE NETWORK

1. LAYING OF CABLES IN DUCT: 1.1. Preparation of worksite and manhole. 1.1.1 Place manhole guards around manholes and jointing pits before removing the covers. When working in manholes, erect road warning signs in positions where motorists will be warned in ample time. In built-up areas, the first warning notice at 70 to 100 metres from the hazard is usually adequate, but on high speed roads, it should be 100 to 200 metres ahead. Where one half of a high speed road is closed, the first warning sign should be 400 to 500 metres ahead. Position flagmen when necessary.
1.1.2
1.2
Rodding and cleaning ducts, all sizes. 1.2.1 Testing for the presence of explosive, asphyxiating and toxic gases in manholes and joint boxes. Rodding allotted ducts (avoid blocking the entry to other ducts) using Rod Sweep Cane, PVC rods or any approved equipment. Cleaning ducts using Mandrel Cutting, Brushes, Rod Cleaning Discs and removal of obstructions where encountered.
1.2.2
Drawing-in draw-rope in duct. 1.2.3 Testing duct with test cable piece 2 metre long of same size and type of cable to be drawn in.
1.3
Cable issued by TM 1.3.1 The cable for each project code which shall be supplied on wood or steel drums and accompanied by the manufactures test report shall be free from physical damage. The Contractor shall satisfy himself that the cable is in good condition physically and electrically before taking delivery of it. Contractor shall measure the pressure which should be between 20 and 70 kPag. The Contractor shall be held fully responsible for any damage or loss that may result subsequent to his taking delivery of the cable.
Issue, August 1993
1.3.2
The Contractor shall be responsible for transporting of cable to and from working site. The outside cable end shall be capped and marked CW for clockwise rotation of colour scheme as the case may be except for cable lengths less than 10 metres. Alternatively a band approximately 25 mm wide shall be painted on the outer surface of the cable (i.e. red band for CW and green band for ACW), 75 mm from cable end. The S.O. is to ensure that maximum usage of cables from each drum is practiced.
1.4
Drawing cable into ducts. 1.4.1 1.4.2 Placing barriers and road sign including flagmen. Testing for the presence of explosive, asphyxiating and toxic gases in manholes and joint boxes. Placing cable drum and Cable Feeder Tube at cable drum end.
1.4.3
All sectional cable lengths drawn-in with clockwise end towards the exchange. If this is not possible, redrummed and drawn-in with anti-clockwise ends away from exchange. See Appendix VI. Preparation of cable end for Cable Grip if pulling eye is not available. However, for cables of 800 pairs and above pulling eyes shall be fitted before laying into ducts. Placing drawing gear incorporated with slip clutch and dynamometer in position at other end. Unbattening drums, drawing-in and lubricating cables with diameter 35 mm and above or where sectional length 200 metres or pulling through bends. The lubricant used must be type-approved by Telekom Malaysia Berhad. Providing sufficient slack cable, bending into the positions they will finally occupy as directed by the S.O. (The minimum bending radius of the cable shall not less than 12 times its diameter). Cable Bender used. Cutting and sealing cable ends with heat-shrink end cap and attaching them on to cable bearer bracket as far away from the cable bearer as possible to give allowance for the installation of joint closure. Pressurize cable for air pressure of 70 kPag and record reading obtained after 24 hours. See section VIII, Preliminary Test para 1.1. Use Telescopic Scaffoldings, Cable Guide and Rollers as directed by S.O., and it is a must in pull-through manholes and tunnels. Worksite to be cleaned and left in condition acceptable to the S.O.
2.
MAKING A STRAIGHT JOINT 2.1 Preparation of manhole. 2.1.1 2.1.2 Placing barrier and road signs including flagmen. Test for the presence of explosive gases, asphyxiating gases and toxic gases in manhole and joint boxes. Pumping water out of manhole and cleaning. Taking precautions against dampness before opening cable sheath.
2.1.3 2.1.4 2.2
Setting up cables in manholes 2.2.1 Pressure in cable measured, recorded and compared with the previous reading. If the variation of pressure is within 3 kPag the cable is acceptable. Setting up cables around walls before opening for jointing. Bending cables into their final position using Cable Benders before releasing the gas from cables. Keeping the cables straight for about 150 mm after leaving the duct and on either side of the bracket cable bearers. Avoiding blocking the entry to other ducts. Avoiding damaging existing cables or joints in manholes.
2.2.2
2.2.3
2.2.4 2.2.5 2.3
Installing cable bearers 2.3.1 Installation of cable bearers with brackets on either side of the joint, just clear of the sleeve and at any other points where support is needed. Where the unsupported length of cable would exceed 1 metre, fitting an additional cable bearer with bracket at the centre point.
2.4
Preparation of cable ends 2.4.1 2.4.2 Preliminary testing (see Section VIII) Opening up cable sheath. Modular splicing connectors are used and they are normally arranged in two banks. The joint opening required shall be 500 mm for all sizes of primary cable.
2.4.3
Tying of unit identification tapes at the butt of each unit close to the cable sheath to preserve identification. Fanning, tying each unit and sub-unit separately for about 6 turns.
2.4.4 2.5
Jointing Wires 2.5.1 Making wire joints with connectors (25 pairs modular splicing connectors) type-approved by Telekom Malaysia. Where discrete connectors are used, measure the resistance of 5 samples of wire joints, record and check against Table 1 Appendix I. The readings shall be submitted together with the records of works to the SO. Wire joints and wires in cable joint shall be insulated from each other and from the cable sheath. The jointing of pairs shall be in colour rotation so that they appear in the same order throughout the cable. All connectors/modules shall be arranged in banks and tied. Insulating all stumped pairs which are terminated at the MDF so that they are securely protected. The stumped pairs left as long as possible and folded back so that they can be jointed through later if necessary. Bunching together and insulating all stumped pairs which terminated in the joint with PVC tape securely. The stumped pairs left as long as possible and folded back so that they can be jointed through later if necessary. Spare pairs jointed through only at straight joints between cables of similar type and size except for joint located in Exchange cable chamber and first manhole where the spares will be stumped. Where these pairs are stumped, their ends shall have their insulation removed, be bunched together and taped. Testing Screen Continuity.
2.5.2
2.5.3
2.5.4
2.5.5 2.6
Joint Closure. All material used for joint closure must be type-approved by Telekom Malaysia. Two types of sheath closures may be used in main cable system namely, Mechanical Closure and Heat Shrinkable Closure. 2.6.1 Mechanical Closure:- PSI-2 type. 2.6.1.1 This joint closure requires a cable sheath opening of at least 483 mm in the joint. Ends of sleeve dressed to fit snugly to sheathing, being careful not to damage cable sheath.
2.6.1.2 2.6.1.3
25-pair Modular Splicing Connector dry. Vinyl tape is used to fix collars on the cable before putting on the shield connector. Gasket tape is wound around the cable only after the cable surface has been cleaned to remove excess oil using solvent cleaning wipe which is supplied together with the closure. Then sand paper is used to scrub the surface of the cable to ensure the cable is completely clean before installing the closure. The type of washer and closure used is dependent on the size of cable as shown in Table 1, 2 and 3. The washer is to be cut using WCTIIK Washer Cutter Tool. The dimension from edge to edge of inner washer when it is placed on the joint shall be 590 mm. When fixing the outer washer the two slits shall not be parallel. Wrap muslin cloth at least 2 layers around joints. End plate is then installed at each end of the joint.
2.6.1.4
2.6.1.5
2.6.1.6 2.6.1.7 2.6.2
Heat Shrinkable Closure. 2.6.2.1 For Heat Shrinkable Closure, only those type-approved by Telekom Malaysia such as Xaga 1000 Heat-Shrink Closure shall be used, and the methods of installation shall follow the Suppliers installation procedures.
2.6.2.2 The use of this closure, however, is restricted and can only be installed in the situation where the use of mechanical closure is impractical e.g. where the joint is done at sharp corners, the cable is bent or the manhole is congested. In this circumstances the use of mechanical closure will result in its end plates not perpendicular to the cable. The S.O. must be consulted before any heat-shrinkable closure is used in primary cable system.
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Issue, August 1993
SIZES OF MECHANICAL CLOSURE (PSI) FOR PRIMARY CABLE

TABLE 1 - STRAIGHT JOINT STORE CODE 50002675 50002674 50006874 SIZE OF CLOSURE 2A2A -2 2B2A -2 2C2A -2 MAX. DIA OF CABLE 56 mm 86 mm 86 mm SIZES OF CABLE 200/0.4 - 200/0.63, 400/0.5, 400/0.63, 600/0.5 600/0.63, 800/0.5, 1000/0.5, 1000/0.63, 1200/0.5, 1400/0.4, 1600/0.4 2000/0.4, 2400/0.4
TABLE 2 - MULTIPLE JOINT (2 BRANCH) STORE CODE 50002677 50002676 50006875 50006874 SIZE OF CLOSURE 2A2A - 3 2B2A - 3 2C2A - 3 2D2A - 3 MAX. DIA OF CABLE 41+25 mm 56+56 mm 71+71 mm 86+86 mm SIZES OF CABLE 200/0.4 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5 600/0.63, 800/0.5, 800/0.63, 1000/0.5, 1200/0.5, 1400/0.4 1000/0.63, 1400/0.5, 1600/0.4, 2000/0.4, 2400/0.4
TABLE 3 - MULTIPLE JOINT (3 BRANCH) STORE CODE SIZE OF CLOSURE MAX. DIA OF CABLE SIZES OF CABLE
N/A
2B2A - 4
N/A
2C2A - 4
N/A
2D2A - 4
A 56+25+25 mm 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5 71+41+41 mm 400/0.63, 600/0.5, 600/0.63, 800/0.5, 800/0.63, 1000/0.5, 1200/0.5 86+56+56 mm 600/0.63, 800/0.5, 800/0.63, 1000/0.5, 1000/0.63, 1200/0.5, 1400/0.5, 1600/0.4, 2000/0.4
B 200/0.4
C 200/0.4
200/0.5, 200/0.63, 400/0.5 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5
200/0.5, 200/0.63, 400/0.5 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5
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2.6.3
All cables in manholes not being worked on are protected by heat insulating blankets e.g. glass fibre sheet etc. Other type of Sheath Closure may be used if approved by Telekom Malaysia Berhad. For such methods approved by Telekom Malaysia Berhad the method of installation shall follow suppliers Installation Instructions. Due attention should be paid to the following requirements:2.6.5.1 Screen continuity in the joint to be properly done according to instruction. Placing inside the joint dry silica gel made available in packets of approximately 100 grams each. The number and size of packets to be placed in each joint shall be as follows: Joint with 200 pairs - 4 packets. Joint with more than 400 pairs - 6 packets.
2.6.4
2.6.5
2.6.5.2
2.7
Labelling cables with codes. 2.7.1 All cables entering a joint are labelled with their code, size and wire gauge, Contractors name, and date of installation, on both sides of all cables joints. The label shall be fitted 80 mm away from the ends of the cable joint. The label must be of a permanent nature. A stamped aluminium or lead sheet 1.8 mm may be fitted around the cable in a secure manner. Pressure testing and continuity test as described in para 3.2.2 of this Section.
2.7.2
2.7.3
2.8 2.9
Remove all rubbish from the manhole after completion of work. Supporting the joint. 2.9.1 Supporting cable joint centrally between the cable bearers so that the cable ends sit squarely on the surface of bracket cable bearer to prevent sheath fatigue and fracture.
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Issue, August 1993
2.10
Cleaning manhole. 2.10.1 Manhole cleaned and left in condition acceptable to the S.O.
3.
MAKING A MULTIPLE (BRANCH) JOINT: As for Straight Joint except: 3.1 Setting up cables in manhole. 3.1.1 Branch cables enter the joint from the opposite end to the main cable entry. If mechanical closure is used the branch end is limited to a maximum of three cables. But if heat shrinkable closure is used, the branch end shall be limited to two cables only. Where necessary, an additional branch cable entering the joint on the same side as the main cable is allowed for both kinds of closure.
3.1.2
3.2
Jointing Wires. 3.2.1 Each branch cable is jointed to a group (sequence or range) of pairs in the main cable - these pairs being exclusive to each branch cable and strictly in accordance with the distribution cable pair diagram/ schedule. All pairs in the cable section must be identified by Continuity Test or by Automatic Pair Identifier. All split pairs, reversal of pairs/legs, short or open circuit condition or contact with shield shall be identified, recorded and rectified before commencement of splicing of the branch joint. This record shall be made available for inspection. The rectification shall be done at the point of defect. Where the pairs are to be taken out as a stumped cable, enough allowance on the cable length shall be given so that they can be jointed through at a later date. The end of the wires shall be insulated using PVC tape in a secure manner and fit an approved heat shrinkable end cap over it. Ensure that there is proper continuity for the electrostatic screen from the main cable to all the branch cables.
3.2.2
3.2.3
3.2.4
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3.3
Labelling cables with codes. 3.3.1 The branch cables if of the same type and size and appearing together in the same manhole shall be identified by an additional suffix serial number added to the original cable code. E.g. if original cable code is 400/0.4 the branch cables shall be A 200.0.4 and A-1 200/0.4. If HSW closure is used cables should be arranged such that they in perpendicular layer, whereby the larger cables are at the top layer while the smaller ones at the bottom layer.
3.3.2
4.
TERMINATION JOINT. As for a straight joint except: 4.1 Termination of Joint Closure. 4.1.1 4.1.2 Continuity Test on stub/tail cables. The primary cable shall be jointed to the 100-pair MDF stub/tail cables in a termination joint closure using Telekom Malaysia type-approved vault closures. The P.E.U.T. stub cables from the MDF shall be identified and labelled before commencement of splicing. For vertical mounting of vault closure, drill holes into cable chamber racking/ frame where necessary to fasten the top mounting bracket (for mounting closure to racking) and the lower cable clamp (for clamping main cable to racking) using bolts and nuts. Wherever possible, the vault closure shall be installed in a vertical position. In the event that there is insufficient space to install the vault closure vertically, then the joint may be placed in a horizontal position. In cases where the MDF blocks are not provided with stub cables, 100pair P.E.U.T. cables may be used as riser cables to be terminated directly to the block and the primary cable shall be jointed to the riser cables in a termination joint closure using vault closure.
4.1.3
4.1.4
4.1.5
4.1.6
4.2
Labelling Termination joint. 4.2.1 Termination joint shall be labelled with its cable code, type and size of cable, Contractors name, cable jointers name and date of installation.
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Issue, August 1993
4.2.2
Labels shall be stencilled with white paint with letters of height 50 mm on the body of the joint.
4.3
Screen Continuity and Earthing. 4.3.1 The screen or shield of the primary cable shall be extended to the Exchange earth from the vault closure using 7/1.04 mm stranded copper tinned earth wires. The screen of the MDF stub cables or riser cables, if any, shall be terminated at the MDF and connected to the Exchange earth system. This procedure is normally done during installation of the MDF blocks, pre-terminated with stub cables, to the MDF.
4.3.2
5.
DIRECT TERMINATION TO MDF. 5.1 Where Cable Chamber is Available. 5.1.1 If the MDF blocks are not provided with stub cables and a termination joint as para 4.1.6 is not desired the outdoor primary cable may be terminated directly to the MDF blocks. The cable end must be sealed for gas pressurisation either at the end of the cable sheath where the conductors are visible or in the mid section of the cable. The direct P.E.U.T. terminating cable shall be set up, formed and laced as follows:Bring the P.E.U.T. cable into the MDF room through MDF riser pipes or channel opening in the floor. The cable sheath shall be retained up to the first row of the termination blocks (MDF blocks) and removed beyond that. Form and lace the wires using waxed lacing twine. Lace the cable beginning with double turn near the butt of the cable, one turn around the cable made at the point where each group of wires is brought out. Where distance between these points exceeds 30 mm, additional lacing at approximately . 30 mm centres made between the normal lacing. The lacing shall always be evenly spaced and at every tie, the knot shall be self-binding. Secure the main vertical forms onto horizontal crossbar with lacing twine. At each horizontal bar of MDF frame take out. 100 pairs of wires from the terminating cable to be carried along the horizontal channel to the MDF block.
5.1.2
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Fasten the branch forms to the horizontal channel iron by at least three ties of lacing twine. Fan out branch of wires and thread the individual pairs/wires through its appropriate hole in the MDF block fanning strip and carefully solder/wrap/crimp and punch them to the connecting tags of the MDF block in the order of cable pairs. 5.2 Where There is NO Cable Chamber 5.2.1 The outdoor primary cable shall be terminated directly onto the MDF blocks if there is no cable chamber e.g. for mobile exchanges. The cable end must be sealed for gas pressurisation either at the end of the cable sheath where the conductors are visible or in the mid section of the cable. From the point of cable entry to the frame the cable should be fed direct from the trench via a rack . A rack must also be provided so that the cable is fed from the bottom of the frame upwards. Remove the cable sheath at the appropriate point and form and lace the wires according to the relevant para in 5.1.2 above. Screen of the primary cable should be connected to the Exchange Earthing system via Screen Continuity Kit.
5.2.2
5.2.3
6.
DIRECT TERMINATION TO SUBSCRIBER DISTRIBUTION FRAME/POINT 6.1 Direct feed cable shall be brought up to the SDF room in subscribers premises and directly terminated to the quick connect type SDF blocks provided. The cable core shall be laced accordingly and tied with lacing twine or plastics cable ties at 30 mm intervals, beginning with a tie near the butt of the cable, and then secured to tacking bars using plastic cable ties to the satisfaction of the SO. Where there is no SDF room and the termination blocks are provided in the ground floor, P.E.U.T. cables shall be terminated directly onto the blocks. In the event that termination blocks are not provided on the ground floor, the P.E.U.T. cables may be jointed direct to the individual floor DPs. The cable end must be sealed for gas pressurisation either at the end of the cable sheath where the conductors are visible or at the section nearest to the butt of the cable.
6.2
6.3
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7.
TERMINATION TO CABINET (KRONE OR POUYET STA/1800) The installation procedure for both of these cabinets are described in the later part of this Specification. When using this type of cabinet the cable has to terminated separately (the tails are not supplied pre-connected to the terminating blocks). However once the tail cables are terminated, it can be treated as ordinary tail (similar to the APO system). The joint between the primary cable and the primary side tail cable of the cabinet shall be similar to the branch joint except for the following: 7.1 Type of Terminal Block Tail Cable Since the terminal block consists of 10 pair strips, the tail cable shall be a 200 pairs cable and above in accordance to Telekom Malaysia Specification CL 0523. (N.B. This cabinet system allows for direct termination of the primary and secondary cable to the terminal units). 7.2 Closure The closure meant for this branch joint shall be capable of having one cable in and three cables out configuration (i.e. maximum 3x200 pairs). 7.3 Connectors The connectors to be used are similar to the one used for the normal joint (i.e. 25 pair modular connectors ). 7.4 Gas Seal (at cable butt in the cabinet) of the type approve by Telekom Malaysia. For pressurisation purposes, the cable butt in the cabinet must be sealed to keep the pressure inside the cable. A proper kit using a proper compound must be used to fabricate this. 7.5 Labelling Cables with Codes The tail cable shall be identified by the following codes : TE 1 for terminal unit E1, TE 2 for terminal unit E2, etc.
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8.
ANTI -CREEPAGE DEVICE 8.1 Anti-creepage device is to be provided to sections of cable affected by cable creepage when directed by SO. Cable creepage means the travel of cable in its duct or jointing chamber under the influence of vibration by road vehicles and road conditions. For any route where creepage occurs, anti-creepage device should be installed immediately. For any new cable installation in such condition, anti-creepage devise shall also be installed simultaneously. For conditions or situations where creepage is most likely to happen, such as :(i) (ii) (iii) Roads with soft ground and heavy traffic (coastal area) Roads parallel with deep trenches. Sloping roads.
8.2
8.3
8.4
In areas other than stated above the followings are necessary:(a) (b) (c) Mark the cable with white tape. Observe the cable over a period of six (6) months. If creepage is noticeable, anti creepage device is to be installed immediately.
8.5
The anti creepage device should be installed in the direction opposing to the direction of creepage at the manholes where cable creepage is found. Select a suitable size of anti creepage device according to the diameter of the cable sheath as follows:CROSS SECTIONAL SHAPE
CIRCULAR
8.6
CABLE DIAMETER
65 MM- 80 MM 45 MM - 60 MM 20 MM - 40 MM 40 MM + 20 MM 20 MM + 20 MM
ORDER NO (MAHIRA ENG.)

7001 7002 7003 7004 7005
+ MULTI CABLES
Detail installation procedure is discussed in MTI Ref. 4390 ACD
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Issue, August 1993
Section IV: Installation of Distribution Cable Network
SECTION IV - INSTALLATION OF DISTRIBUTION CABLE NETWORK

1. LAYING OF PLASTIC FULLY-FILLED CABLE IN DUCTS As for installation of Main Cable except: 1.1 Testing duct with test cable piece 2 metre long of same size and type of cable to be drawn-in for cable diameter of 50 mm and above and unless exempted by SO. Cutting and sealing cables using type-approved End Caps.
1.2 2
MAKING A STRAIGHT JOINT 2.1 Preparation of manhole, setting cables in manholes, and installing brackets cable bearers as for straight joint of main cable except: Preparation of cable ends. 2.2.1 Joint openings and the corresponding type of Heat Shrink Wraparound and cable sizes to be used as shown in table 2 in Appendix III. Tying the unit binder for about 6 turns around each of the 10 pair units to preserve identification and easily seen. Fanning out and braiding pairs before jointing.
2.2.2
2.3
Jointing Wires As for straight joint of Main Cable except:2.3.1 Both pairs to be jointed are twisted together for 3 half turns without removing the insulation. Then separate the A and B legs and make 2 more half turns before fixing connectors. Making wire joints between the two A legs and B legs with appropriate sized discrete connectors or any other type approved by Telekom Malaysia Berhad. The wire joint position are spaced at 40 mm interval for discrete connectors. Spare Pairs in joint are left as long as possible and folded back so that they can be jointed through later. (For stub in joint a minimum of 1 metre length is recommended).
2.3.2
2.3.3
2.3.4
2.3.5
Electrostatic screen made continuous at the joint using screen continuity wire assembly.
2.4
Closing cable joint 2.4.1 Install the screen continuity, use tool to cut the cable jacket (over a length of 20 mm and width 10 mm). Paper insulating should be placed underneath the cable jacket strip. Install shield continuity clip with standard pair of pliers. Take the dessicant out of the aluminium bag(s) and place within the joint. Wrapping with 5 layers of paper insulating.
2.4.2 2.4.3 2.4.4
2.4.5 2.5
Joint Closure using Heat Shrink Wraparound Kit Sizes of Heat Shrink Wraparound closure and cables covered by each size Heat Shrink Wraparound Kit is as Appendix III Table 2. This table also shows sizes of Heat Shrink Wraparound used for repairing a straight joint. 2.5.1 Preshape the liner cylindrically by rolling. Wrap the liner tightly around the splice bundle and secure with tape. Tape the crowns, starting from the liner body (10 mm) down to the cable with 50 % overlap (use heat resistant tape). Tape maximum 5 mm onto the cable. Remove the solvent impregnated tissue from its package and clean the cables over distance of approximately 100 mm. Abrade the cable circumferentially over the same length as before. Use bondline gauge from the end of the liner and mark bondline length on all cables. Apply the aluminium foil to the cable , positioning the blue line at the mark of the bond length and smooth the aluminium foil. Flame brush the cable areas between aluminium foil and liner.
2.5.2
2.5.3
2.5.4 2.5.5
2.5.6
2.5.7
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2.5.8
Wrap the sleeve around the splice. Press the underclip (if applicable) over the rail at the centre of the sleeve. Position the Heat Shrink Wraparound sleeve such that the adhesive flap and sleeve rails are on the top.
2.5.9
2.5.10 Pull the flexible channels over the sleeve rails until they butt on the top of the underclip. Centre the sleeve over the joint such that the sleeve length matches the blue lines on the aluminium foil. 2.5.11 Regulate the flame to a total length of approximately 100 mm. During the shrinking process, move the flame continuously to avoid local overheating. Apply heat until the paint changes colour completely, except the area in the immediate vicinity of the clips and channels where a green area of approximately 2 mm may remain. 2.5.12 Start the shrinking at the centre of the sleeve and heat circumferentially the thermo-indicator paint changes colour from green to black. 2.5.13 When the temperature-sensitive paint has completely changed colour to black, gradually and progressively move towards the end of the sleeve. 2.5.14 Press the channel with a blunt tool to give the shape of the liner transition. Repeat para 2.5.12 and 2.5.13 starting at the centre toward the other end. Wait approximately 15 minutes (for cooling) before handling. 2.5.15 When all the temperature paint has changed colour on the first half of the closure, two separate white lines should be visible in the slots of the channel. If the lines are not visible, apply more heat at that point until the white lines appear. 2.6 Labelling cables with codes 2.6.1 All cables entering a joint are labelled with their code, size and wire gauge, Contractors name, Cable Jointers name and date of installation on both sides of all cable joints. Information stamped on collets made from 1.8 mm thick lead sheet.
2.6.2 2.7
Supporting the joint As for straight joint of Main Cable.

2.8
Cleaning worksite 2.8.1 Worksite to be cleaned and left in condition acceptable to the SO.
3.
MAKING A MULTIPLE (BRANCH) JOINT USING HEAT SHRINK WRAPAROUND KIT (XAGA 500) As for plastic cable straight joint except :3.1 Setting Up Cables in Jointing Chamber 3.1.1 The standard Xaga 500 Kit is designed for maximum of two cables branched at one end only. Branch joint for more than two cables requires the use of one additional branch-off kit (BOKT-5S or 5M) per added cable.
3.2
Preparation of cable ends 3.2.1 Length of joint opening, type of closures and the respective cable sizes are as shown in Table 1 Appendix III. Tying the unit binder for 6 turns around each of the 10 pairs units to preserve identification and be easily seen. Fanning out and braiding pairs before jointing.
3.2.2
3.3
Jointing Wires As for both main cable multiple joint and plastic cable straight joint, except:3.3.1 The electrostatic screen made continuous at the joint using TWO separate screen continuity wires and connectors for the branch cables.
3.4
Closing Cable Joint As for plastic cable straight joint except that the size of Heat Shrink Wraparound used for different sizes of cables are as that shown in Appendix III Table 1. 3.4.1 Position the Heat Shrink Wraparound sleeve such that the adhesive flap and sleeve rails are over the largest cables which are to be at the top of the vertical layer. Insert the Branch-Off Clip(s) completely between cables. Allow equal sleeve recovery space around cable.
3.4.2
3.4.3
Pull branched cables together with tie-wrap from BOKT-Kit.
Note: Do not place the Heat Shrink Wraparound sleeve over a wet cable. 3.5 All cables in manholes not being worked on are protected by asbestos blankets or heat insulating glass fibre sheet. Labelling cables with codes. Also as for branch joint on main cable. 4. TERMINATION FOR PLASTIC CABLE AT MDF: 4.1 In general the MDF termination block will be supplied complete with 100 pair plastic stub cable. In special circumstances, where the block is supplied without a stub cable, P.E.U.T. cable shall be used for termination. Opening up the cable, numbering the wires (as per Straight Joint) and terminating the wires to the MDF. Fully-filled Plastic Cable may be terminated directly onto the MDF provided it has first been thoroughly cleaned.
3.6
4.2
4.3
5.
MAKING A 10-PAIR BRANCH JOINT (ON ALL SIZES UP TO 200 PAIRS CABLE) Use Heat Shrink Wraparound Kit No. 1 (Table 1 in Appendix III). 5.1 Preparation of manholes, setting up cables in manholes, and installing bracket cable bearers are for Plastic Cable Straight Joint. Preparation of Cables. 5.2.1 5.2.2 The joint opening is 200 mm for all sizes of cables up to 200 pairs. The relevant 10 pair unit, which is identified by its binder colour, is cut at the end of the opening away from the exchange. The 10 pair DP cable tail is passed through the HSW and placed on the side of the main cable where the 10 pair unit has been cut away. The 10 pair DP cable is prepared for jointing. Testing Screen Continuity.
5.2
5.2.3
5.2.4 5.2.5
5.3
Jointing Wires. As for Plastic Cable Multiple (Branch) Joint.
5.4
Closing Cable Joint. As for Plastic Cable Multiple (Branch) Joint except: 5.4.1 The 10 pair tail cable is parallel to the main cable away from the incoming cable.
5.5
Labelling cables with code, supporting the finished joint, and cleaning jointing chambers.
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Section V: Installation of Aerial Cable
SECTION V - INSTALLATION OF AERIAL CABLE

1. ERECTING INTERMEDIATE POLE (IRON) 1.1 Pole Planting (Iron) 1.1.1 Digging hole 1.2 m to 1.8 m and 380 mm x 380 mm. (a) (b) (c) 1.1.2 Soil surface. Concrete surface. Bitumen surface.
Pole Planting. (a) (b) Tying rope to pole ring. Lifting and positioning (aligned without any incline).
1.1.3
Backfilling the hole with 150 mm layer of soil at a time and ramming each layer well for (a) (b) Soil surface. Concrete surface which includes making good with 80 mm thick of quality A (1:2:4) concrete where required. (Quality A concrete:- 1 part of cement : 2 parts of sand : 4 parts of aggregate). (c) Bitumen surface which includes making good with 80 mm thick of quality A (1:2:4) concrete.
1.1.4
If necessary, encasing pole with 1.2 m x 300 mm x 300 mm of quality A (1:2:4) concrete.
1.2
Dressing Pole (Iron) 1.2.1 Fitting surface plate. The top edge of surface plate shall be 150 mm below ground level and places on the same side of the pole as the pipe clamp/step.
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1.2.2
Fitting base plate. Its vertical face placed on the opposite side of the pole surface plate and parallel with it. Fitting galvanised iron pipe as cable riser for underground cable where required. The G.I. pipe shall be secured to the pole with steel clamps at two points. See Appendix VII.
1.2.3
1.3
Painting Pole (Iron) 1.3.1 Painting with one coat of I.C.I. paint bituminous black or other type approved by Telekom Malaysia. Aluminium paint may be used at road corners and on roads with heavy traffic or at places specified by the SO.
2.
ERECTING INTERMEDIATE POLE (WOOD) 2.1 Pole Planting (Wood) 2.1.1 As for planting Intermediate Pole (Iron) in para 1.1 (except painting):(a) (b) (c) (d) Soil Surface Concrete surface Bitumen surface Concreting with 1.2 metre X 300 mm X 300 mm of quality A concrete where necessary.
2.1.2
Where the ground is soft or directed by SO, the pole shall be reinforced by providing one or two tanalised ground braces/blocks 1.2 metre X 250 mm X 50 mm. The ground braces/blocks shall be placed as to present their full surface to the soil in the direction in which the pole would tend to overturn under severe loading. For position and direction of setting ground braces/blocks see Appendix IV.
3.
ERECTING INTERMEDIATE POLE (CONCRETE)

3.1
Pole planting (concrete) 3.1.1 Digging hole 1.8 metre and 500 mm X 500 mm (a) (b) (c) 3.1.2 Soil Surface Concrete surface Bitumen surface
Pole Planting. (a) (b) (c) Tying rope to pole ring. Lifting and positioning (aligned without any incline). Ensure through holes are at 90 degrees to the surface of the road.
3.1.3
Two methods of pole planting. (a) (b) 3.1.3.1 Manual method. Mechanical aids - (crane). Manual method. (a) (b) Requires 6 persons as shown in Fig. 1. Metal support with U-shaped end and platform wheeler may be used as aids.
3.1.3.2
Mechanical aids method. (a) (b) Requires 2 persons as shown in Fig. 2(b). Wire rope connected to the crane is tied to the pole not less than 300 mm from the centre of gravity. See Fig. 2(a).
3.1.3.3 3.2
Backfilling and ramming as in other types of pole.
Dressing pole (Concrete).
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Issue, August 1993
(a)
Fitting G.I. pipe as cable riser for underground cable where required. Then G.I. pipe shall be secured to the pole with steel clamps at 2 points. See Appendix VII. Where necessary the pole should be fitted with kicking block as directed by the S.O. Concrete pole accessories and their usage are listed in Table 1 and shown diagramatically in Fig. 3 and Fig. 4.
(b)
3.2.1
3.3
Concrete pole conversion. 3.3.1 Conversion of intermediate pole to distribution pole. (a) Remove some of the soil so that the pole can be moved and positioned to the appropriate direction. Tying the rope at pole and insert a piece of iron rod or wood. Turn the pole so that the through holes are at the appropriate direction. Backfilling with soil.
(b) (c)
(d)
FIG.1 CONRETE POLE PLANTING BY MANUAL METHOD
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CENTRE OF GRAVITY
FIG. 2(a)
FIG 2(b) CONCRETE POLE PLANTING BY MECHANICAL AID
EYEBOLT LUG
EYEBOLT POLE CLIP EYEBOLT
FIG 3 TO ERECT CABLE ON POLE
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Table 1 - Concrete Pole Accessories
NO. 1. 2. 3.
ACCESSORIES Strut Assembly Kicking Block Inlet/Outlet Plug Earth Assembly Eyebolt Pole Bracket Cable Clamp/Support Hook Earthing
FUNCTION Pole support
To support cable
4.
Bridle Ring Pole Head Ring Cable Tie
To support drop wire and DP cable To hold DP box on to pole Pole climbing Pole identification Cable riser Terminating
5. 6. 7. 8. 9.
Cable Tie Pole Step Bolt Paint and Stencil G.I. Pipe and Steel Band Preformed Grip Eyebolt with lug Thimble
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4.
ERECTING DISTRIBUTION POLE (IRON): 4.1 Pole Planting (Iron). As for planting Intermediate Pole (Iron) in para 1.1. (a) (b) (c) (d) 4.2 Soil surface. Concrete surface. Bitumen surface. Concreting with 1.2 m x 300 mm x 300 mm concrete.
Dressing Pole (Iron). As for dressing intermediate pole (iron) in para 1.2 plus: 4.2.1 Fitting 10 pair DP box 760 mm from top of pole and stencilling with 50 mm stencil using ICI white paint or equivalent. Fitting Bridle Ring Brackets - one approximately 80 mm below DP box and the other mid-way between Pole Head Ring and DP box. Fitting 25 mm diameter G.I. pipe with pipe couplings at ends. The length of the G.I. pipe shall be 6 metre or sufficient to cover the earth wire/feeder cable all the way from DP box down to at least 300 mm below ground level. The lower end should be fitted with a G.I. bend and buried as close to the pole as possible. Fitting of pole step pipe clamps - three for 6.7 metre poles at intervals of 500 mm and four for 7.6 metre poles at intervals of 600 mm. The first pole step/pipe clamp should be fitted approximately 2.6 metre above ground level. Fitting G.I. pipe of appropriate size as cable riser for underground cable where required. The G.I. pipe shall be secured to the pole with steel clamps at two points. It shall be at the distance of 600 mm from the pole.
4.2.2
4.2.3
4.2.4
4.2.5
4.3
Painting Pole (Iron) (This applies to intermediate pole)
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4.3.1
Painting with one coat of I.C.I. paint bituminous black or other type approved by Telekom Malaysia (paint supplied by Contractor ). Painting pole with a further coat of aluminium paint for a length of 600 mm at location directed by SO. The bend of painted portion shall be 460 mm above ground level.
4.3.2
4.4
Labelling pole with DP number at 1.5 metre above ground level in 50 mm letter using ICI white paint or equivalent approved by Telekom Malaysia.
5.
ERECTING DISTRIBUTION POLE (WOOD) 5.1 Pole Planting (Wood) As for planting Intermediate Pole (wood) in para 2.1 (a) (b) (c) (d) Soil surface. Concrete surface. Bitumen surface. Concreting with 1.2 metre x 300 mm x 300 mm of quality A (1:2:4) concrete.
5.2
Dressing Pole (wood) 5.2.1 As for Dressing Distribution Pole (Iron) in para 4.2 minus base and surface plates. Providing two ground braces/blocks as for Intermediate Pole (wood) para 2.1.2. Labelling pole with DP number at 1.5 metre above ground level in 50 mm letter using ICI white paint or equivalent approved by Telekom Malaysia.
5.2.2
5.2.3
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6.0
ERECTING DISTRIBUTION POLE (CONCRETE ) As for planting intermediate pole (concrete) in para 3.1 6.1 Pole Planting (concrete) (a) (b) (c) 6.2 Soil surface. Concrete surface. Bitumen surface.
Dressing Pole (Concrete) 6.2.1 Concrete pole are supplied with ragnuts for easy installation or attachment of accessories such as DPs, pole steps etc. Earthing Earth wire (7/1.04 mm) is pulled to the earth inlet through the pole core to the earth outlet using pulling wire which is supplied in the pole core for every pole. See Fig. 5. 6.2.3 Eye-bolt with lug/pole bracket 6.2.3.1 For every distribution pole, IB wire must be terminated at that pole. See Fig. 6. If pole bracket cannot used, eye-bolt with lug may be used instead. See Fig. 7.
6.2.2
6.2.3.2
6.2.4
Pole head ring The method is the same as that for wood and iron pole. See Fig. 8 (a) and (b).
6.2.5
Distribution box (DP box) Distribution box (Egerton Rocker Block DP) is installed on Concrete poles using two (2) cable tie No. 6, see Fig. 9. For further details refer to Section V para 16.3 of this Specification.
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6.2.6
Bridle ring 6.2.6.1 Ragnuts on the pole are also used for installation of bridle ring. Bridle rings come with thread and nut for easy tightening . See Fig. 10. Insert and turn the bolt at the end of bridle ring into the ragnut. Then continue turning the bolt until the required position achieved and the nut is tight enough.
6.2.6.2
6.2.7
Pole-step bolt 6.2.7.1 Pole step for this type of pole only need to be screwed into the ragnuts. Do not over-tighten the pole step during installation. (See Fig. 11).
6.2.7.2
6.2.8
Tying tail cable for distribution box with cable tie. 6.2.8.1 Use 2 cable tie No. 6
6.2.9
Pole identification mark 6.2.9.1 Using template or stencil for identification code on concrete pole at about 1.5 metre from the ground levels.
6.3
Pole Support 6.3.1 Stay The method and procedures are the same as that for wooden and iron pole. See Fig. 12 and 13. 6.3.2 Strut The method are the same as for wooden and iron pole. 6.3.3 Kicking block The kicking block is installed using a U-bolt attachment. It is installed 150 mm below ground level. See Fig. 15.
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6.3.4
Riser for cable G.I. pipes of sizes 25 mm, 50 mm, 100 mm are used for this purpose. These pipes are fixed to the pole by using steel band and buckle method. See Fig. 16.
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Issue, August 1993
7.
RECOVERY OF POLES AND FITTINGS 7.1 Digging, backfilling hole, reinstating if necessary and transport ALL recovered line plant items back to Telekom Malaysia Store.
8.
INSTALLATION EARTH ELECTRODE SYSTEM 8.1 Single Electrode System It comprises of two or more and up to a maximum of four earth rods coupled together and driven into the ground to achieve the normally desired resistance of 5 ohms of less. 8.2 Alternative Methods of Providing Additional Earth Electrode System to Initial Single Electrode System Where 5 ohms or less cannot be achieved by the single electrode system, the SO has the authority to accept a higher resistance value or to decide on alternative method of providing additional earth electrode system listed below. 8.2.1 Integral Bearer Wire Earth System As first alternative, connect the single electrode to the integral bearer wire earth of the aerial cable if it is available. Use openable wire jointing connectors to connect the 7/1.04 mm stranded copper wire (tinned) to the integral bearer wire.
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8.2.2
Multiple Electrode System Where the required resistance cannot be achieved by a single electrode system described in para 8.1 above, as a second alternative, install additional single electrode system and interconnect with the initial electrode system.
8.2.3
Buried Wire Electrode System A wire electrode, which consist of 7/1.04 mm stranded copper wire, is laid in a trench at least 600 mm deep and interconnected with the initial electrode system, as a third alternative. The length depends upon the soil conditions and the earth resistance required, and is normally not less than 30 metres.
8.2.4
Special Earthing System In some instances, it may be found that due to practical or economic consideration it is not possible to provide the Earthing system of sufficiently low resistance at the place of protective installation. In such cases, it may be necessary to install earthing electrodes in low soil resistivity locations distant from protective installations using the integral bearer wire of aerial cable for interconnections.
9.
FITTING GROUND STAY/ STRUT/STAY CRUTCH (i) Digging hole and recess of base plate 1.2 metre to 1.8 metre x 380 mm x 380 mm. Preparing groove for fitting of stay rod. Fitting, terminating and tightening stay wire on pole top and ground. Compacting soil at every 150 mm layers. Where required by SO reinstate surface with 80 mm thick concrete. All stays to have a base to height ration of 1 (on ground level). However, a base to height ratio of minimum of 1/2 is allowable (at ground level) for angle and transverse stays as specified by the SO.
(ii) (iii) (iv) (v) (vi)
10.
INSTALLING OVERHEAD STAY
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(i)
Planting Pole as for Pole Iron in para 1.1, Pole Wood as in para 2.1 and Pole Concrete in para 3.1. Fitting Ground Stay as in para 9 Fitting, terminating and tightening overhead stay wire on pole tops including stay swivel.
(ii) (iii)
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11.
ERECTION OF INTEGRAL BEARER AERIAL CABLE The minimum statutory clearance above ground level for aerial cables and the required separation from power lines shall be observed. The former is given in Appendix V. 11.1 Dead End Termination 11.1.1 Fitting Bracket Tubular/Eye bolt. 11.1.2 Separating bearer wire, stripping PVC insulation. 11.1.3 Terminating bearer wire with preformed grip. 11.1.4 Fixing pulley where necessary. 11.1.5 Terminating points for bearer wire shall be at :(i) (ii) Beginning and end of route (terminal poles). Angle poles where deviation of the route is greater that 45 degrees. Poles where two sections of cable are jointed e.g. change in cable size. Poles where DP box is required. Each end of isolated long spans greater than 200 metres. All river, railway and road crossings.
(iii)
(iv) (v) (vi) 11.2
Intermediate Support. 11.2.1 Fitting (a) (b) Terminating Bracket/Eyebolt/Pole Clamp. Appropriate size Support Hook.
11.2.2 Fix pulley at every intermediate pole and corner pole, pulley at angle pole (not exceeding 45 degrees route deviation).
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11.2.3 Securing cable to Support Hook using the appropriate size Cable Clamp after tensioning. 11.3 11.4 Laying out the cable on ground. Tensioning. 11.4.1 Fixing temporary anchorage stay or strut. 11.4.2 Fixing Cable Tensioning Winch, appropriate size Cable Grip and Dynamometer. 11.4.3 Hoisting I.B. Cable and placing in pulleys. 11.4.4 Tensioning I.B. Cable to correct value using Dynamometer. There should be no deflection or bending of pole during the process of tensioning. The maximum allowable sag is given in Table 1 in Appendix II. 11.5 11.6 Removing temporary stays, strut, pulleys etc. Earthing Bearer Wire of Aerial Cable. 11.6.1 Earthing of bearer wire of aerial cable at intervals of approximately 250 metres subject to a minimum of one earthing point in the whole section. Minimum earth resistance should be 5 ohms or less at each earthing point. Where 5 ohms or less cannot be achieved alternative methods as described in para 8.2 shall be considered. 11.6.2 Connecting one end of stranded copper earth wire (tinned) to bearer wire of aerial cable using openable wire jointing connectors and the other end to: (a) (b) existing DP Box earth terminal (if available) or, an earth electrode system specified in para 8.0 above.
11.6.3 Further to para 11.6.1 above where earthing is provided at 250 metre spacing, an additional earth shall be provided at the extremity of the end-section of the aerial cable if the end-section is greater than 125 metres.
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12.
MAKING A STRAIGHT JOINT: As for Plastic Cable Straight Joint except: 12.1 Setting up I.B. Aerial Cable on Pole Route. 12.1.1 All joints should be located close to poles and within easy reach to be worked out from a ladder. 12.1.2 If this is not possible, the bearer wire is jointed through by using interlocking thimbles and preformed grips/wire splices and a mobile platform or work basket is used to joint the cable. 12.2 Preparation of Cable Ends. 12.2.1 The slack cable is separated from the bearer wire by slitting the web preferably with a thin steel wire. The joint should be located at least 300 mm away from centre of the pole. 12.2.2 If it is necessary to used a sharp knife care shall be taken not to damage the sheathing over the cable beyond the joint opening. 12.2.3 The joint opening is as for Plastic Cable Fully Filled Straight Joint. 12.3 Supporting the Joint. 12.3.1 The joint is tied to the bearer wire with PVC tape at the ends of the cut in web and then a cable tie is applied over the PVC tape. 12.4 Cleaning the Worksite. 12.4.1 Worksite cleaned and left in condition acceptable to the S.O.
13.
MAKING A MULTIPLE JOINT: As for Plastic Cable Fully Filled Multiple Joint and Straight Joint and I.B. Aerial cable Straight Joint.
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14.
INSTALLATION OF CABLE PLASTIC INTEGRAL BEARER ON WALL/CEILING. 14.1 Fixing 10 mm thick semi-hard, tanalised batten wood using three (3) 38 mm steel nails per metre. Running I.B. cable and nailing it on batten wood with three (3) 38 mm steel nails per metre.
14.2
15.
INSTALLATION OF CABLE PLASTIC FULLY-FILLED ON WALL/CEILING: 15.1 Fixing 10 mm thick semi-hard, tanalised batten wood using three (3) 38 mm steel nails per metre. Running cable and fixing aluminium cleats at 150 mm intervals. Aluminium cleats shall be cut from aluminium sheet of appropriate thickness.
15.2
16.
INSTALLATION AND MOUNTING OF 10 PAIR AND 20 PAIR EGERTON ROCKER BLOCK PROTECTED DP TERMINAL. 16.1 For Wooden Poles. 16.1.1 Materials required. (a) (b) Three No. 10 Wood Screws at least 50 mm long. A suitable screwdriver.
16.1.2 After hoisting the Rocker Block DP terminal safely with a sash line, proceed as follows: (a) Position the Rocker Block DP terminal so that the top is 600 mm below the pole head ring. Remove the DP lid. Insert one screw in the hole at the top of the block and fasten lightly to take the weight of the DP block and descending cable. Ensure the block hangs vertically and fits snugly against the pole.
(b) (c)
(d)
(e)
Insert the second and third screws into the bottom left and right holes and then fasten all the three screws firmly and fasten the lid to the DP Rocker Block terminal.
16.2
For iron pole. 16.2.1 Material Required. (a) One Jubilee Clip No. 3 to be used for the upper DP aperture and one Cable Tie No. 3 at the bottom aperture.
16.2.2 After hoisting the DP block up safely with a sash line, proceed as follows: (a) Position the Rocker Block DP terminal so that the top is 600 mm below the pole head ring. Remove the lid. Pass one cable tie through the break-out apertures or slot at the top of the DP terminal and around the pole. Tighten the jubilee clip until the block does not move or slip and check to see that the terminal is vertical and fitting snugly against the pole. Pass the second cable tie through the bottom left and right apertures and then tighten until the DP terminal is fixed firmly to the iron pole. Figure 17 shows the complete installation and the mounting of DP box on the iron pole.
(b) (c)
(d)
(e)
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FIG. 17 INSTALLATION AND MOUNTING DP ON IRON POLE
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16.3
For Concrete Poles. Same procedure and materials apply as for iron poles except that instead of using cable tie No. 3 to fasten the Rocker Block terminal, black Cable Ties No. 6 are used. However, if Cable Tie No. 6 is not available in stock, use two Cable Tie No. 3 joint together. (i.e. slot one cable tie into the buckle of the other cable tie to make up the required length as shown in Figure 18) for both top and bottom apertures. Note: The terminal block should be positioned so that the top of the DP terminal block is 600 mm below the pole head ring for all the three types of aerial pole.
FIG. 18 JOINTING TWO CABLE TIE NO. 3
16.4
Fitting the Pipe to DP Pole. 16.4.1 Clamp the 25 mm diameter G.I. pipe to the pole commencing at a distance of about 1 metre from the bottom edge of the DP box (or at the highest point before the second step in pole) using the pole step/pipe clamp fitting. 16.4.2 Ensure that the top end of the G.I. pipe is placed 300 mm below the bottom edge of the DP box. 16.4.3 Fit three more pole steps (two for a 6.7 metre pole) below this point at equal interval of 600 mm (500 mm for 6.7 metre pole). A minimum spacing of 2.6 metre from the ground is necessary to ensure public safety and to prevent misuse. The use of ladder is thus necessary to climb to the first pole step. 16.4.4 The pole is erected such that the pole steps/pipe clamps are at right angles to the road surface or building line. The DP box will be at right angle to the road surface. Fit the necessary earth electrode systems to obtain the desired earth resistance of 5 ohms and crimp these to the earth wire which is then connected to the earthing terminal in the DP box
Note: In housing area where the position of the DP poles is less than 1.5 metre away from the roof of a house, the pole steps/pipe clamps are not required to be installed on the pole except the one at the uppermost position. This pole step/pipe clamp is required for maintenance purposes. 16.5 Connection of Dropwire to DP Box Terminals from Pole Head Ring. 16.5.1 Run the Dropwire from the pole head ring to the DP box leaving adequate length for securing to the DP pole and terminating the DP box. 16.5.2 Remove the bearer wire carefully, taking great care to avoid damaging the conductor insulation. The termination of bearer wire is according to Lines AC 3100. 16.5.3 Pass the Dropwire along the pole through the bridle rings fitted approximately mid-way between the DP box and the pole head ring and those fitted below the DP box. 16.5.4 Separate the two conductors of the Dropwire outside the DP box, to a length such that it is long enough to reach the desired Rocker DP terminal inside the box. 16.5.5 Insert each of the conductors from below into the appropriate Rocker terminal. Then insert the two-wire Dropwire one into A-leg and the other to B-leg without stripping the insulation. Note: The accessories needed for installing this new DP are the same as the accessories used for the old DPs.
17.
INSTALLATION OF 10 PAIR DP BOX ON WALL; 17.1 17.2 Mounting DP Box on to wall using rawl plug and Wood Screw 50 mm. Drawing 10 metre tail through conduit or cleating the tail along the wall as in para 15 above.
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18.
EARTHING REQUIREMENT 18.1 External DP. 18.1.1 The DP box has an internal earthing on the bottom of the earth bar near the cable entry. At this stage, an earth wire 7/1.04 mm stranded tinned copper will be used to connect the DP earth terminal to earth. The wire is inserted through the bottom hole. A fork cable lug is then crimped to the earth wire and terminated to the DP earth terminal. 18.1.2 The lower end of the earth wire is to be connected to the earth rod or buried in trench or a combination of both. Where it is necessary to earth the bearer wire at the DP pole, connect a length of 7/1.04 mm stranded tinned copper to the bearer wire using a line connector and terminate the other end to the DP earth bar. 18.1.3 Details of earthing procedures given in MTI Lines P 0020 will be followed for installing earth wires and to ensure they are effective and a value of 5 ohms or less is achieved.
19.
TEST OF DP TERMINATION AND INSPECTION 19.1 Testing of DP Termination. The DP contacts can be accessed either by terminating two short lengths of wire put into the white holes in order to connect to the test gears or such access can be done by using an Egerton Test Adapter 48A. Egerton Test Adapter 48A can be obtained from the supplier. Note: When testing a Protected Rocker Block, remember that when the protecting arrester is removed, both the A and B legs will be short circuited to earth. 19.2 Inspection. As for preventive maintenance, DP boxes should be inspected at least once a year to ascertain the following:(a) (b) The distribution box is correctly mounted on a pole. The distribution lines are properly connected to the respective terminals.
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(c)
The arrestors are serviceable and correctly installed and the earth wire connected. The earthing resistance is less than 5 ohms. The DP or pole identification are up to date and legible. The cover is always properly closed to provide sealing between the cover and the back plate thus preventing dust and water from getting into the box. Check Labelling.
(d) (e) (f)
(g) 20.
YELLOW PLASTIC INSULATOR CAP The purpose of the Yellow Plastic Insulator is to insulate the 3-pole gas-filled protection arresters which have a rating of 230V from the 500V voltage which will be generated through the cable pairs during the course of Insulation Resistance testing for cable commissioning. However, the Yellow Plastic Insulator MUST BE REMOVED once the DP is put into service, otherwise the arrestor is not effective as the earth path is not in contact. Note : It is advisable whenever a new subscriber is installed at the DP, the arrestor housing should be inspected to ensure the arrestor is in place and the Yellow Plastic Insulator is removed.
21.
TERMINAL BOX IDENTIFICATION The terminal box should be marked according to Telekom Malaysia normal practice. 21.1 DP Number Stenciling Stencil the terminal box identification (e.g. 5/1, using the 50 mm stencil) on the pole if it is not possible to stencil on the terminal box because of its curved surface (not flat). Details of guide line and specifications of Egerton Rocker Block DPs are discussed in MTI ref. No. 4350 EBOX.
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22.
INSTALLATION OF DROPWIRE 22.1 Dropwire lead-in from Ring Pole Head At the pole a stay thimble small is fitted to the ring pole head. Fig. 19 and 20 show the typical terminating at ring pole head. 22.1.1 Terminating the Bearer Wire at the DP Pole (a) While holding the dropwire firmly over the ring pole head with the required tension, cut the bearer wire approximately 460 mm beyond the thimble separate it from the conductor for approximately 530 mm i.e. to a point approximately 80 mm past the thimble. Bend the insulated bearer wire around the groove of the thimble approximately 80 mm from where the bearer wire is parted from the conductor. Make three tight turns as shown in Fig. 21 (step 1), then make a further three turns as shown in step 2 close to the thimble. Finally make two loose turns around the bearer wire and conductors and cut off the surplus wire.
(b)
(c)
22.2
Terminating and Fitting at Subscriber Premises At the subscriber premises a thimble is fitted to a Bracket BPO No. 22 as shown in Fig. 26. Two type of fittings being considered as shown in Fig. 27. However, the normal fitting will be Bracket BPO No. 22 which should be placed at least 2.7 metre above the ground such that it provides the necessary vertical and horizontal clearance from power lines, trees and other obstructions. Special Fittings : When the required ground clearance cannot be obtained, the use of the special fitting as shown in Fig. No. 28 (a) or (c) may be required.
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FIG. 19 DP POLE SERVED BY UNDERGROUND CABLE
FIG. 20 DP POLE SERVED BY AERIAL CABLE
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23.
INSTALLATION OF DIGITAL PAIR GAIN EQUIPMENT 23.1 Pair-gain equipment Type 1+1 23.1.1 This type of pair-gain equipment is to be mounted on the DP pole, adjacent to the DP box. It can also be wall-mounted at the customers premises. 23.1.2 If there are one or two waiters at the DP this 1+1 type of pair-gain equipment can be used to give service. Typical installation is as shown in Fig. 29. One DP should not have more than two 1+1 type of Remote Terminal (RT) units on the DP pole. 23.2 Pair-gain equipment 1+3 23.2.1 This is high capacity type of pair-gain equipment and is recommended for DPs with 3 or 6 waiters. 23.2.2 The RT unit must be wall mounted at the customers premises or along the corridor. 23.2.3 Full utilisation of the three additional circuits of this type of pair-gain equipment must be made immediately after it is installed at the customers premises. 23.2.4 Pair-gain equipment type 1+3 is to be installed when there are 3 or 6 waiters existing on the DP. 23.3 23.4 If there are 5 waiters on the DP, one 1+3 and two 1+1 type must be used. If there are already (existing) two 1+1 type on a given DP and if service is to be given to another waiter, then the two 1+1 type must be recovered and replaced by a 1+3 type. The installation of 1+1 type together with 1+3 type is as shown in Fig. No. 30. Fig 31 and Fig 32 shows how Remote Terminal equipment is installed on the pole.
23.5
23.6
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Section VI: Installation of Cabinet
SECTION VI - INSTALLATION OF CABINET

1. INSTALLATION OF CABINET TYPE KRONE 59M 1.1 Conduit and Manhole 1.1.1 The cabinet is connected to the manhole via two 152 mm PVC duct bends. To avoid the usage of extra length of the 152 mm PVC duct the cabinet should be placed as far as possible within 1 metre from manhole wall. The PVC bends are firmly plastered with cement to prevent any entry of soil or water. The PVC bends may or may not be encased in concrete depending on the nature of the soil.
1.1.2
1.1.3
1.2
Concrete Foundation (Plinth). 1.2.1 The recommended plan for plinth is as shown in Fig. 1.
1.3
Cabinet Installation. 1.3.1 Take the key which is placed at the side of the cabinet and insert it into the lock (DO NOT TURN THE KEY). Turn the handle clockwise. Open the door to get access to the cabinet. Locate the cabinet fixing bolt (near the door hinge) and unscrew to release the cabinet from the framework. Lift the cabinet to remove it from the framework. Plan and select the required cable entry at the base of the framework and break the appropriate entry holes using a hammer. Put the framework on the plinth and align the rag bolt to fit through the holes provided on the framework. Fix the base plate to the plinth by tightening the nuts on the four rag bolts.
1.3.2 1.3.3 1.3.4
1.3.5 1.3.6
1.3.7
1.3.8
1.3.9
Pull the cable through the base plate via the cable entry (rubber grommet) which is cut according to cable size.
1.3.10 Install the cable and seal the cable entry with the sealing putty provided. 1.3.11 Assemble the back-mount frame and terminate the cables and earthings as described in para 1.4.2. 1.3.12 Fix the cabinet back into the framework and tighten the fixing bolt. 1.3.13 Close the door and turn handle anti-clockwise to lock the cabinet. 1.4 Primary Cable Installation. 1.4.1 Pressure block (gas seal). (i) For pressurisation purpose the primary cable must be sealed (or pressure block). This should be done at the cable core coming out of the seal. (See details in Fig. 2). Detailed installation is discussed in Appendix X. If necessary another seal can be fabricated on the mid-cable inside the manhole. (ii) This pressure blocks can be fabricated on site or tail cables with pre-fabricated blocks may be supplied by the central store.
1.4.2
Cable Termination. 1.4.2.1 The conductors will be terminated on the connection modules which is then mounted onto the back-mount frame. This back-mount frame will then be bolted onto the mounting rail of the framework. Cable termination can be done both on site or in a local workshop. If it is done in a local workshop the termination should be done on the back-mount frame after which the whole frame can be transferred to the site for installation. In other words the back-mount frame with the cable terminated can be considered as a terminal block of 200 pairs.
1.4.2.2
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1.4.2.3
The procedures to fabricate the terminal block (primary side) are as follow: (a) If the cable is not sealed for pressurisation, fabricate the seal using the approved kit leaving about 1 metre of unsheathed cable. By means of the cable tie, fasten the pressure block on the wall of the back-mount frame. Lace the cable accordingly so that the top most module is numbered 1 to 10 and so on. The connection modules are to be installed from the bottom to top (for primary termination the last module is on the 20th row). Push the 10 pair unit through the centre lug from below (See Fig. 3). The modules with the fanning fingers on top are slipped and locked on the bracket of the back-mount frame in such a way that a surplus of conductor will remain (see Fig. 3). Each wire is laid around the fanning fingers to the contact slots. The slots are numbered 1 to 10 from left to the right (see Fig. 4 and 6). After placing all the 20 conductors on the slots they are to be pressed into the contact slots using the LSAPLUS insertion tools. The cutter of the tool will slot into the centre of the module as shown in Fig. 5. The tool has a built-in stop at which point the spare end of the conductor will be cut off. In other works in one pushing action the insulation will be displaced, connection will be made and the remaining conductor will be cut off. (g) The connecting modules are numbered to facilitate easy tracing of cable pairs. Four plug recesses are available and the modules are numbered as shown in Fig. 3. The numbers are for 100 pair only and it repeats itself for the next 100 pair. The cable pairs on the vertical must be clearly labelled on the label holder and must be placed underneath the last module as shown in Fig. 3.
(b) (c) (d)
(e)
(f)
(h)
1.4.2.4
After the cable has been installed, secure it by clamping the screw-type clamps provided.
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1.4.2.5
Joint the tail cable to the appropriate cable end, close it using the appropriate joint closure. (The RXS Universal closure, UCN 6-20). The installation procedure is according to the Manufacturer Installation Instructions provided in the closure kit.
1.5
Secondary Cable Installation . 1.5.1 Two sizes of cable can be used for the secondary termination i.e. 100 pair or 200 pair fully-filled cables with gauges up to 0.63 mm. The jelly must be cleaned off first using the approved solvents. The cable termination procedures for secondary side is exactly the same as the procedures for the primary termination described in para 1.4.2 except that the secondary side does not require any pressure blocking. In order to reduce excessive jelly from flowing out of the cable during the normal environment the end of the cable must be properly taped according to the following instruction. (a) Measure a suitable length and remove the cable sheath. Wind four rounds of adhesive tape around the cable core (See Fig. 7a). Clean the jelly properly using the approved solvents. Cut the cable sheath (approximately 20 mm) and bend upwards. Punch the hole through the sheath flap and install the earthing tag. Wrap the adhesive plastic tape around the cable and the remaining cable sheath (see Fig. 7b). Then press the flap down and wrap adhesive plastic tape around the end of the cable (see Fig. 7c). Complete the earth terminal installation.
1.5.2
1.5.3
(b)
(c)
1.6
Jumpering. 1.6.1 The lower row of the LSA-PLUS connection modules are for jumper termination. These are numbered from 1 to 10 (or 0) Termination are done using the same LSA-PLUS insertion tool. To ensure a good and easy connection of jumper wire an extra 50 mm of wire should be available in the jumpering.
1.6.2 1.6.3
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1.6.4
The jumper wire must run through the jumper of the module. Direct jumpering is not recommended in order to maintain a systematic and easy tracing of jumper wires. Run pairs 1 - 5 to the left hand side of the module and pairs 6 - 10 to the right hand side. The jumpering wires that run to the left of the modules should go through the upper jumper rings and the wires that run to the right should go through the lower jumper rings (the rings are above the modules). This applies to E-side only. For D-side, the wires shall go through the wire guide for direct termination. It is possible to connect 2 wires of the same gauge to one contact.
1.6.5
1.6.6 1.7
Maintenance and Repair. 1.7.1 In general the management and maintenance of Krone cabinet is similar to the APO system as given in detail in MTI K3010. The only technical differences are as follow: Access to the Cabinet. (i) The cabinet can be access by opening the door using the key as described in para 1.3. It is important to note that the key must not be turned to open the door. Instead the handle should be turned when the key has been pushed into place. During the initial installation work and when there is a major work to be carried out on the cabinet the casing can be removed from the framework by loosening the two screws as described in para 1.3. For ordinary jumpering work, opening the door should be suffice.
(ii)
Test Pair. The test pair for the cabinet is the last pair of the E-side terminal unit (e.g. E 200, E 400 and E 600). 1.8 Routine Inspection. Routine inspection is to be carried out on all cabinets every six months to detect any deterioration. The suggested format for reporting is given in the Appendix IX
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In this inspection, check particularly for: (a) (b) (c) Wire joints in jumper wires. Jumper wires running outside the jumper guides. Proper running of the jumper wire (i.e. pair 1 - 5 to the left and 6 - 10 to the right of the module). Evidence of cracking in the sealing putty. Evidence of faulty sealing rubber for the door. Effectiveness of the locking system (i.e. the 3 point locking). Corrosion in the framework or connection module. Sign of condensation of moisture. Any unplugged cable entry hole. Any missing terminating modules. Any rubbish (especially pieces of jumper wires) at the bottom of the cabinet.
(d) (e) (f) (g) (h) (i) (j) (k)
1.9
Steps taken during maintenance. 1.9.1 Use the correct size and colour of jumper wires (i.e. a maximum of 0.63 mm and orange/red jumper for important circuits). Use the proper terminating tool for termination and removal of jumper wires from the modules. Leave some slack in the jumper (at least 50 mm) in order to facilitate tracing of jumper wire and rectify any possible mistake. Do not leave disconnected jumper wire in the jumper space. Do not interfere with other circuit while searching for a spare or faulty cable pair in the cabinet.
1.9.2
1.9.3
1.9.4 1.9.5
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1.9.6
Pairs in the cabinet should only be accessed only by means of a test cords. It is forbidden to cut through the wire insulation with a pen knife or needle for pair identification. Do not leave the cabinet open or unlocked as entry of moisture, dirt, dust etc. will cause low insulation resistance and corrosion problem.
1.9.7
2.
INSTALLATION OF CABINET TYPE POUYET STA/1800 2.1 Conduit and Manhole. As for Krone cabinet in para 1.1. 2.2 Concrete Foundation (Plinth). The recommended plan for the plinth is as shown in Fig. 1 2.3 Cabinet Installation. The following descriptions illustrates the procedure for the installation of the cabinet. 2.3.1 2.3.2 Before inserting the key, place the sliding lock cover upwards. Then the key is inserted all the way into the keyhole to unlock the safety catch. Note: The key cannot be removed when the door is opened thus making key loss impossible.
2.3.3
Use the handle to open and close the door. (Never use the key itself as it could break). Open the door to get access into the cabinet. Locate the cabinet lashing bars (see Fig. 8) and pull out to release the cabinet doors (if necessary). Plan and select the required cable entry at the base of the framework and cut the rubber grommet to appropriate cable size. Put the framework on the plinth and align the rag bolt to fit through the holes provided on the framework.
2.3.4 2.3.5
2.3.6
2.3.7
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2.3.8
Fix the base-plate to the plinth by tightening the nuts on the four rag bolts. Install the cable and seal the cable entry with the sealing putty provided.
2.3.9
2.3.10 Assemble the modules on the back-mount frame and terminate the cables as described in para 2.4. Each terminating cable should have an earth wire connection to the aluminium moisture barrier sheath. These leads should then be bolted onto the mounting rail which is connected to the framework. 2.3.11 Fix the cabinet door by slotting the lashing bars into its proper slot. 2.3.12 Close the door, remove the key and push the sliding lock cover downwards. 2.4 Primary Cable Installation and Termination. 2.4.1 As being described before, the conductors will be terminated on the connection modules which is then mounted onto the back-mount frame. After the cable has been installed, secure it by using cable ties to the back-mount frame. Lace the cable accordingly so that the top most module is numbered 1 to 10 and so on. The connection modules are first installed from the top pair 1 to 200 on E1 rack using the first 200 pairs cable tail. The other 200 pairs cable tail is used for the next 200 pairs starting from pair 201 to 300 on E1 and pair 301 to 400 on E2. Select the 10 pairs corresponding to the module to be installed and pass them through the guide in the rear of the module. Place the pairs in order, passing each conductor through the appropriate wire retainers. The retainers are in the upper rear portion of the modules. Then thread them through the connection channels, where two small pins hold the wire in place to allow insertion. Place the module in the special slots and press into place by applying even pressure with thumbs as shown in Fig. 12 (c).
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
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2.4.7
After installing all the conductors in the modules, these are inserted individually using the POUYET Termination Tool. For connection, place the tool so that the pressure elements located in its head are inserted in connection channel as shown in Fig. 13. Press the tool firmly until you hear a click signalling correct installation. After making all the insertions for one module, remove all excess wire which has been cut automatically. The connecting modules are numbered to facilitate easy tracing of cable pairs. The numbers are for 100 pairs and it repeat itself for the next 100 pairs.
2.4.8
2.4.9
2.4.10 The cable pairs on the vertical must be clearly labelled on the label holder and must be placed underneath the last module as shown in Fig. 14. 2.4.11 After the cable has been installed, secure it by using cable ties. 2.5 Secondary Cable Installation. 2.5.1 Two sizes of cable can be used for the secondary termination i.e. 100 pairs or 200 pairs fully-filled cables with gauges up to 0.63 mm. The jelly must be cleaned off by using the approved solvents (Guideline 18 RT 4310 CSOL) The cable termination procedures for the secondary side is exactly the same as the procedures for the primary termination described in para 2.4 except that the secondary side does not require any pressure blocking. In order to reduce excessive jelly from flowing out of the cable during normal environment, the end of the cable must be properly taped according to the following instruction: 2.5.3.1 Measure a suitable length and remove the cable sheath. Wind four rounds of adhesive tape around the cable core (see Fig. 7a). Clean the jelly properly using the approved solvents. Cut the cable sheath (approximately 20 mm width) and bend upwards. Punch a hole through the cable flap and install screen continuity wire and terminate on the earthing bar. Wrap adhesive plastic tape around the cable and the remaining cable sheath (as shown in Fig. 7b).
2.5.2
2.5.3
2.5.3.2
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2.5.3.3
Then press the flap down and wrap adhesive plastic tape around the end of the cable (see Fig. 7c). Complete the Earth termination installation.
2.6
Jumpering. 2.6.1 The lower row of POUYET connection termination. 2.6.2 modules are for jumper
To ensure a good and easy connection of jumper wire, an extra 50 mm of wire should be available in the jumpering. The jumper wire must run through the jumper ring of the module. Direct jumpering is not recommended in order to maintain a systematic and easy tracing of jumper wires. Run pairs 1 - 5 to the left hand side of the module and pairs 6 - 10 to the right hand side. The jumpering wires should go through the jumper rings. Use the blue/white jumper wire for normal circuit and orange/red for important circuit.
2.6.3
2.6.4
2.6.5
3.
MANAGEMENT AND SERVICE ASPECT. In general, the management and maintenance of this kind of cabinet is similar to the APO and Krone system and the details are given in MTI K 3010 and MTI K 3020. 3.1 Routine Inspection. Routine Inspection is to be carried out on all cabinets every six months to detect any deterioration. The suggested format for reporting is as for Krone Cabinet in Appendix IX. In this inspection, check particularly for: (a) (b) (c) To ensure there is no joints in jumper wires. Jumper wires running outside the jumper guides Proper running of the jumper wire (i.e. Pair 1-5 to the left and pair 610 to the right of the module. Evidence of cracking in the sealing putty.
(d)
(e) (f) (g) (h) (i) (j)
Effectiveness of locking system. Corrosion in the framework or connection modules. Sign of condensation of moisture. Any unplugged cable entry hole. Any missing terminating modules. Any rubbish (especially the pieces of jumper wires) at the bottom of the cabinet.
3.2
Maintenance and Repair This cabinet is made of reinforced hot-pressed plastic materials which provide a high degree of mechanical and weather resistance as such not much maintenance is required. Painting is not necessary. However, to ensure a clean and long-lasting cabinet, the following steps must be taken every time work is carried out in the cabinet. (a) Use the proper terminating tool for termination and removal of jumper wires from the modules. Leave some slack in the jumper (at least 50 mm) in order to facilitate tracing of jumper wire and rectifying any possible mistake. Do not leave disconnected jumper wire in the jumper space. Do not interfere with other circuit while searching for a spare or faulty pair in the cabinet. Pairs in the cabinet should only be accessed by means of test cords. It is forbidden to cut through the wire insulation with a knife or needle for pair identification. Do not leave the cabinet open or unlocked as entry of moisture, dirt, dust etc. will cause low insulation resistance and corrosion problem. Illegal tampering can also be avoided if the cabinets are always locked.
(b)
(c) (d)
(e)
(f)
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Section VII: Gas Pressurisation
SECTION VII : GAS PRESSURISATION

The following specifications describe two types of pressurisation systems namely, the conventional GPA system and the new computer based GPA system (CGPA). 1. CONVENTIONAL GPA SYSTEM 1.1 Hard-wares All hard-wares used for cable pressurisation must be type approved by Telekom Malaysia Berhad. 1.2 Test Valve 1.2.1 Fitting test valves at 350 - 450 metre intervals, or as instructed by the SO. Fitting the first test point at least 2 metre down straight from the seal or at least 600 mm further down stream from the air inlet elbow.
1.2.2
1.3
Contactor Alarm 1.3.1 1.3.2 1.3.3 Wiring and connecting polythene tubing to contactor alarm. Fitting contactor alarm at 1830 metre intervals or as instructed by SO. Locating contactor alarm on manhole wall position that is dry, is readily accessible for maintenance, where danger of mechanical damage is unlikely, and acceptable to SO. Round head brass metal thread screws used.
1.4
Contactor Gauge ( at terminal station) 1.4.1 1.4.2 Wiring and connecting polythene tube to contactor gauge. Fitting contactor gauge on station wall/polish backboard in a manner acceptable to the SO. Connecting to station alarm.
1.4.3
1.5
Labelling
1.5.1
Labelling the cable with yellow tape (warning - GAS DO NOT OPEN) on either side of the joint in every manhole to indicate cable under pressure.
1.6
Connection to Compressor Dryer 1.6.1 Fixing air-inlet elbow at the terminal joint closure. Use a branching air inlet valve to enable the pressure to be tested. Otherwise use the wraparound air-inlet. Running and cleating tube connection between flowmeter and air-inlet elbow.
1.6.2
1.7
Alarm Pair to Alarm Panel 1.7.1 1.7.2 1.7.3 Identifying alarm pair allocated by SO and checking for continuity. Fitting alarm pair to alarm panel. Fitting terminating-resistor of suitable value at the last contactor alarm to balance the alarm pair to 3000 ohms Fitting identifying resistor in contactor alarms (where applicable) in branch cables.
1.7.4
1.8
Charging Cable with Air 1.8.1 Charging the cable with dry air at 70 kPag. Continue charging until pressure at all test points to reach their stabilised readings. The minimum charging period prior to commencement of pressure reading shall be 3 days and the minimum stabilised pressure at the distant end shall be 35 kPag unless otherwise specified by SO. Single gas cylinders shall not be discharged below 700 kPag if used.
1.8.2 1.9
Calibrating Contactor Alarm and Contactor Gauges: 1.9.1 Calibrating and adjusting contactor alarms and contactor gauge (where applicable) to their normal operating pressure. The minimum pressure at any point of the pressurised cable shall be 35 kPag unless otherwise specified by S.O. Checking contractor on failing pressure by bleeding air at nearest test point.
1.9.2
1.10
Pressure reading. 1.10.1 Recording and submitting pressure readings taken at every test point and flow meter reading using From No. 3. 1.10.2 Providing a chart for the cable showing the meter readings obtained for each of the contactors in an operated condition using Form No. 4.
2.
COMPUTER-BASED GAS PRESSURISATION (CGPA) Clauses 1.1, 1.5, 1.6 and 1.8 are applicable to Computer-based GPA System. 2.1 Transducer Preparation. 2.1.1 Make sure Worksheet No. 8 is prepared and request the S.O. to program the transducer addresses into the Master Unit. Set addresses on transducers accordingly. Bundle these transducers and terminate them on the intermediate MDF block for CGPA system. Confirm the operation of the port and transducers by reading the report from the relevant PC terminal. Remove the transducers from the MDF after test.
2.1.2 2.1.3
2.1.4
2.1.5 2.2
Alarm Pair Preparation. 2.2.1 2.2.2 Select an alarm pair which is approved by the S.O. Measure and ensure that the alarm pair in every cable section is in good condition for the following tests: (i) (ii) (iii) Insulation resistance [A-B, A-E, B-E (minimum 100 Mohm)]. Copper resistance (< 10 Kohm). No noise or crosstalk shall be detected by the VF Monitor.
2.3
Transducer Installation .
2.3.1
The jointing of the new cable is carried out according to standard procedure. When it comes to the joint location where a transducer was planned, identify the alarm pair with battery or multimeter or pair identifier. After the jointing of all wires in that location, connect the transducer by bridging it across the alarm pair (non-polarity). Hand twist the transducer wire to the alarm pair without cutting the cabinet side of the alarm pair. Solder and insulate the wire joint. Place the transducer in the joint away from the seam or heating spot and close the joint closure according to standard procedure. Put two rounds of identification tape (TRANSDUCER IN JOINT) on both ends of the closure. If the last transducer is more than 3 km from the exchange, install a terminator together with the last transducer. (Wire code: green and white for unloaded pair, green and red for loaded pair). Only one terminator at the last transducer position is needed. After the installation of the cable and transducers have been completed, jumper the alarm pair in the MDF to the CGPA intermediate block. Test the installation with VF Monitor and multimeter connected to the alarm pair at the cabinet. VF Monitor response with a noisy tone for every transducer connected. Multimeter reading should be > 30V DC. Put red marking on alarm pair in cabinet and MDF. WARNING: Care must be taken not to: (i) (ii) (iii) blow air into the transducer with mouth, drop the transducer in the water, megger the alarm pair (A to B) with the transducer installed (Measurement using multimeter is allowed).
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8 2.3.9
2.3.10 Collect pressure report from the PC terminal after the installation is completed
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Section VIII: Testing
SECTION VIII - TESTING

1. PRELIMINARY TEST FOR INDIVIDUAL CABLE SECTION BEFORE JOINTING WORK 1.1 Insulation Resistance Test and Shield Continuity Test 1.1.1 Insulation Resistance Test This test shall be carried out in accordance with para 2.2 for 2 pairs per unit for cables of unit construction or 2 pairs per layer formatting. In all cases the minimum number of pairs to be tested shall be 10 pairs. 1.1.2 Shield Continuity Test This test shall be carried out on individual lengths of cable prior to jointing work. The measurement of shield resistance shall be made with a Wheatstone bridge or an accurate ohmmeter. Measurement of Shield Resistance (i) The far ends of the A and B legs of any pair are connected to the shield and the loop resistance of the pair is measured and recorded as RL. With the far ends of the pair as in (i) above, the near ends of the A and B legs are connected together on one terminal of the bridge or Ohmmeter. The resistance of this circuit is measured and recorded as RT The Shied Resistance RS is computed from RS = RT - RL 4 A close approximation of shield resistance for longitudinally applied 200 mm aluminium is 1.0 ohm per 1000 metre or one centimetre diameter cable. Shield resistance for cables with diameters other than one centimetre may be converted to a per centimetre value using the following expression. R1 = RS D/L
(ii)
(iii)
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where, R1 is the equivalent 1 centimeter value of shield resistance in ohms per 1000 metre. is the measured value of shield resistance in ohms per length. is the outer diameter of the cable in centimetre. is the cable length in Kilometre.
RS D L
If the calculated shield resistance R1 is close to 1.0 ohm per 1000 metre the shield is assumed to be continuous. 2. COMMISSIONING TESTS ON COMPLETED CABLE SYSTEM: All test described below shall be carried out in the presence of S.O., or his appointed representative. If the cable is rejected or the results prove unsatisfactory the Contractor will be required to repeat these tests after the faults have been cleared without additional payment. 2.1 Main Cable System. All pairs having a split, reversal of pairs/legs, short or open circuit condition or contact with shield shall be rectified. In the event that these faulty pairs still cannot be rectified after all reasonable attempts have been made, the penalty for faulty pairs shall be imposed. However, a completed cable system with faulty pairs, other than those due to manufacturing defects, falling under any of the following circumstances shall be rejected. (i) If the total number of pairs having either a ground, split, reversal of pairs, reversal of legs, short or open circuit condition, exceeds 1% of the total number of pairs in the cable or 10 pairs whichever is lower. If the total number of pairs other than those in (i) above not complying with the electrical parameters of para 2.1.2 and 2.1.3 exceeds 1% of the total number of pairs in the cable or 10 pairs, whichever is lower.
(ii)
Collet or label the faulty pairs at the MDF end and at the other termination end with sleeves marked with the pair number and details of the fault, e.g. Pair No. 601 Dis A.
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2.1.1
Pair identification Test (from MDF to any termination). Individual pair shall be identified by means of Continuity Test or Automatic Pair Identifier. For stumped pairs, this test should be done before closing the joint, i.e. prior to final commissioning tests. All split pairs and reversed pairs shall be identified, recorded and rectified. This record shall be submitted to the S.O. Reversals (A and B legs of the same pair) shall be identified and recorded. The total number of leg reversals shall not exceed 1% of the total number of pairs in the cable or 10 pairs, whichever is lower.
2.1.2
Insulation Resistance Test on Cable End. The insulation Resistance Test shall be measured with a 500 Volt DC Test Meter. The insulation resistance of each wire (including stumped pairs) in the cable shall be measured with all other wires, and screen connected to earth and the measurements recorded. The Guard facility of the I.R. Test Meter shall be used in order to avoid the effects of leakage current during measurement. For this test all equipments connected to the cable at the MDF and the field mounted carrier frequency equipment must be disconnected. The pairs used to feed power remote from the exchange must have the power disconnected. All wires at the far end must be opened. After steady electrification for one minute the insulation resistance of each conductor in the cable measured with all other conductors and screen connected to earth shall not be less than 1500 megohm kilometre at ambient temperature. The measurement to be made to the nearest megohm wherever possible. If the conductor fails to meet the minimum requirement, then that pair is classified as a faulty pair unless the defect is rectified or proved to be due to any associated equipment.
2.1.3
Conductor Resistance Test All conductor should be tested for continuity and the loop resistance of each pair should be recorded. The measured value of all pairs should be within 10% of the calculated value. The calculated value is based on the cable length as determined from the length installed, standard conductor resistance and adjusted to the temperature at the time of measurement. For stumped pairs, conductor resistance test should preferably be done prior to closing the joint, i.e. before final commissioning tests for
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Issue, August 1993
completed cable system. Readings shall be recorded and submitted formally to the S.O. as soon as possible. For calculation purposes, the standard resistance for single copper conductors at 20 0 C shall be as given in the table below:
CONDUCTOR DIAMETER (MM) 0.4 0.5 0.63 0.9 1.27
RESISTANCE (IN OHMS) PER KM OF CABLE AT 200 C . (SINGLE WIRE) 143 91 58 28 14
The temperature co-efficient of resistance (copper conductor) is 0.0039 per degree centigrade. 2.1.4 Shield Continuity Test. This test shall be carried out on the whole cable length from the MDF to the cabinet/SDF. The measurement shall be made with a Wheatstone Bridge or an accurate Ohmmeter as follows: (i) The far ends of the A and B legs of any pair are connected to the shield. In the case of cabinets, the shield is already connected to the earth tag of the cabinet. So the desired looping can be obtained by connecting the appropriate tags together using a piece of wire. With the far ends of the pair of conductors as in (i) above the near ends of the A and B legs are connected together to one terminal and the shield to the other terminal of the Bridge or Ohmmeter. The resistance of this circuit, i.e. a pair of conductors and the shield in series, is measured and recorded as RT. The grounding of the shield at the MDF end, e.g. through the mounting bracket of the vault closure, need not be removed during this measurement.
(ii)
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The measured value of RT may be converted to a per kilometre value by simply dividing the measured value by the relevant length of cable to the cabinet SDF. If the per kilometre value of RT is less than 80 ohms, then the shield is assumed to be continuous. 2.2 Distribution Cable System. 2.2.1 Pair Identification Test. This test shall normally be carried out from the cabinet to all the distribution points of the network such as DP for which the test shall be carried out and recorded. All reversals, split pairs, reversed pairs shall be identified, rectified and recorded. 2.2.2 Insulation Resistance Test. As in paragraph 2.1.2 except the insulation resistance shall be not less than 500 megohms kilometre. However, for cable pairs of 0.1 kilometre or less and connected to DP, an insulation resistance (direct reading) of not less than 5000 megohms is acceptable. 2.2.3 Conductor Resistance Test. As in paragraph 2.1.3. 2.2.4 DP Earth Resistance. The measured earth resistance shall not exceed 5 ohms subject to the provision of clause 8.2 Section V. 2.3 Pressurised Cable Network. Where specified by Telekom Malaysia Berhad, the Contractor shall gas pressurise the cable system at a pressure of 70 kPag after completing the termination joint and tests, described in above. The contactor alarms and contactor gauge shall be adjusted so that the supervisory alarms for gas pressurisation shall operate when pressure falls below 35 kPag or any other pressure specified by S.O.
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After initial pressurisation, pressure at various test points shall be measured daily for one week and the results shall be submitted to the S.O. for acceptance. 2.4 Test Results and Certificate of Quality. 2.4.1 On completion of all tests, the full results shall be submitted in triplicate for the approval of the S.O. The tests for the different cable systems and the associated standard forms to be used are listed in Table below:
2.4.2
TEST Pair Identification and Continuity Insulation Resistance Screen Continuity Conductor Resistance Gas Pressure
REQUIREMENT MAIN CABLE All pairs All pairs Moisture Bearer All pairs X X X X X
DISTRIBUTION FORM CABLE X X X X NO. 1 2 2 2 3 and 4
3.
PAIR SELECTION FOR ISDN INSTALLATION . For ISDN installation pair selection has to be made. The GO. and RETURN bearers should be in separate units if possible. If this is not possible, then the maximum possible physical separation in the cable should be sought by careful examination of cable construction as shown Fig. 1. No bridge taps or multiples are permitted, and if any exist, then either transfers are required to enable multiple-free allocation to be made or the multiple must be cut away. Additionally, outgoing PABX exchange lines should be separated from 2 Mbit/s Go pairs and incoming PABX exchange lines separated from 2 Mbit/s Return pairs. At the very least, the separation should be greater than 10 pairs.
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3.1
Insertion Loss (Cable Transmission Loss). The purpose of this test is to measure the cable transmission losses by transmitting 40 kHz sine wave signal in the range of 20 kHz - 100 kHz at 0 dbm and 135 ohms impedance. The cable transmission loss shall at 40 kHz shall be less than 30 db and the cable transmission loss per unit distance is approximate to the Standard Transmission Loss. The results are recorded in Form No. 5.
3.2
Crosstalk. The purpose of this test is to investigate and measure the extent of noise induction from other signal lines that has an impact on specific signal line intended for communication by using sine wave signal for crosstalk coupling between signal line. The crosstalk loss should be at 40 kHz and the fluctuation of the crosstalk losses by cable is noted. The results of the test are recorded in Form No. 6.
3.3
BER Test. BER test is the ultimate measure that can determine the suitability of the cable network for ISDN services. This test is to ensure the Bit Error Rate is within operating limit of 1 in 10-6 while providing a sufficient signal to noise ratio. Sufficient BER margin with respect to the application limit should be verified. The readings are recorded in Form No. 7.
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FORM NO. 5 CABLE TRANSMISSION LOSS
EXCHANGE: .................................... CABLE GAUGE (mm): .................... CABLE LENGTH: ........................... DP NO. : ............................................
CABLE CODE: ................................................. CABLE TYPE/SIZE: ........................................ CABINET NO.: ..................................................
PAIR NO.
DC - OHM
TRANSMISSION LOSS (dB) 20 KHz 40KHz 60 KHz 80 KHz 100 KHz
NOTE
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FORM NO. 6 CABLE TRANSMISSION LOSS
DISTURBING PAIR
DISTURBED PAIR 40KHz
CROSS-TALK (dB) 80 KHz 500 KHz 1 MHz
NOTE
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FORM NO. 7
IMPULSE NOISE
PAIR NUMBER dBrn 15 Min. 15 Min. 15 Min. 15 Min 15 Min. 15 Min. 15 Min. 15 Min.
THRESHOLD/COUNT dBrn dBrn dBrn dBrn dBrn
NOTE
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Section IX: Cabinet Transfer
SECTION IX - CABINET TRANSFER

1. LOCATION AND RECORDS. 1.1 1.2 Install the new cabinet in a suitable location in respect to the cabinet manhole. Obtain the necessary cable pair records from the Exchange Test Desk and prepare the Transfer sheet (See Appendix VIII)
2.
ESTABLISHMENT OF COMMUNICATION ON E-SIDE. 2.1 Establish communication between the cabinet and Test Desk Clerk using the Test Pair in the cabinet. The test pair can be connected to the circuits for testing new subscribers line.
3.
CONFIRMATION OF RECORDS. 3.1 Identify each pair between MDF and Cabinet and check against the cable record using battery and ohmmeter method. Identify each pair between Cabinet (D-side) and DP against the record. One method of confirming the jumpering of any E-side to D-side in the Transfer Sheet is to connect the field telephone to the relevant D-side of the cabinet and dial the same subscribers number (according to the records from the cabinet). The engaged tone obtained would identify the correct pair at both the D-side and E-side of the cabinet. Any changes shall be noted and rectified during the time of transfer.
3.2 3.3
3.4 4.
TEE-IN E-SIDE. 4.1 Carry out pair by pair identification of all terminal units for use with the new cabinet to avoid any working circuits being connected to a faulty pair in the new terminal unit upon replacement. Open the joint in the cabinet manhole where tee-in is to be done. If it is possible to tee-in the new cabinet cable tail inside the cabinet manhole, then tee-in at a joint at one or two manholes away from the cabinet by pulling new sectional lengths of cable.
4.2 4.3
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5.
RECONFIRMATION OF CONNECTION ON THE E-SIDE. 5.1 Identify (number out) sequentially the first 25 pairs of the working cable from the E-side terminal of the existing cabinet and as well as from the MDF to the tee-joint. Proof of the number of a cable pair can only be obtained by checking the pair from the terminal points e.g. the terminals at the MDF and cabinet to the position the pair occupies at the joint where tee-in is to be done. Any pair not in sequence should be noted in the remarks column and corrected. Continue to find the missing counter-party say a split pair etc. which shall be noted and rectified upon transferring.
5.2
5.3
6.
CUT-OVER E-SIDE. 6.1 Then tee-in the 25 identified pairs sequentially from the new cabinet cable tail to the existing wire joint by using the appropriate module connector.
7.
ESTABLISH COMMUNICATION ON THE D-SIDE. 7.1 Establish communication between DP and existing cabinet using the test pair in the DP.
8.
PRE-JUMPER NEW CABINET: 8.1 Pre-jumper the new cabinet in accordance with the confirmed record.
9.
CONFIRMATION OF RECORDS IN D-SIDE. 9.1 9.2 Use battery and ohmmeter method to identify the pairs. Identify (number out) sequentially the pair of the working cable from the DP and as well as the D-side to the tee-joint. Proof of the number of a cable pair can only be obtained by checking the pair form the terminal points e.g. the terminals at the DP and cabinet to the position the pair occupies at the joint where tee-in is to be done. Any pair not in sequence shall be noted in the remarks column and corrected. Continue to find the missing counter-part, say a split pair etc. which shall be noted and rectified upon transferring.
9.3 9.4
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10.
CUT-OVER D-SIDE. 10.1 Tee-in the pairs of the D-side tail of the new cabinet to the corresponding pairs of the D-side tail of the existing cabinet. If it is not possible to tee-in the D-side tail in the cabinet manhole, then tee-in as in para 4 above. The tee-in of wires shall be performed by the use of the following types of discrete connectors to prevent service interruption. (i) Scotchlok UB connectors (with grease) for conductor sizes 0.4 mm to 0.63 mm. Scotchlok UGE connectors (with grease) for conductor sizes 0.9 mm to 1.27 mm.
10.2
10.3
(ii)
10.4
Recover the jumper wire cross connecting E-side to D-side terminal in the existing cabinet as soon as the associated pair is teed in the joint. Confirm by dialling the subscribers number from the exchange. When all circuits have been correctly teed to the new cabinet, cut off neatly all wires from the old cabinet in the tee-joint.
10.5 10.6
END OF SPECIFICATION
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Appendix I
1.
CONDUCTOR JOINT RESISTANCE: Connector Joint Resistance measuring set shall be used to make periodic test to ensure that wire joints are being crimped effectively by the present range of connector applicators. The permissible connection resistance of sample joints measured between two points on the jointed conductors separated by distance of 40 mm and symmetrical about the connector centre line shall be as in Table 1
TABLE 1: MAXIMUM RESISTANCE (Diameter in mm) 0.32 0.4 0.5 0.63 0.9 (mili-ohms) 10 8 7 5 4
2.
SILICA GEL IN PACKETS: TABLE 2: CABLE SIZES Cables up to and including 75 pairs. Cables from 100 to 200 pairs Cables from 300 pairs and over 400 grams 600 grams 4 6 APPROXIMATE WEIGHT REQUIRED 100 grams MINIMUM NUMBER OF SILICA GEL PACKETS 1
Note: Packets should be packed with Gel so that they are form 12 mm to 20 mm thick.
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Appendix II
TABLE 2 - MAXIMUM PERMISSIBLE SAGGING WHEN ERECTING OF IB CABLE BEARER CABLE SIZES WIRE SIZE
5, 10, 20, 30, 50/0.4 mm 5, 10,20/0.5 & 0.63 mm 5, 10/0.9 mm 5/1.27 mm 100/0.4 mm 30, 50/0.5 & 0.63 mm 20, 30/0.9 mm 10/1.27 mm 200/0.4 mm 100/0.5 mm 100/0.63 mm 50/0.9 mm 20/1.27 mm 200, 400/0.4 & 0.5 mm 200/0.63 mm 100/0.9 mm 30/1.27 mm
SPAN IN METRES 20 25 30 35 40 45 50 55 60 65 70 75 80 85
SAG IN METRES 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
1/2.5 mm
7/1.2 mm
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
7/1.6 mm
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
7/2.0 mm
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
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Appendix II
TABLE 2 - MAXIMUM HAULING TENSION ON CABLES
Cable Size 0.32 mm 10 20 30 38 50 54 60 100 104 200 216 254 300 308 400 500 504 600 620 800 1000 1040 1200 1400 1600 2000 2400 3200 4000
Maximum Tensions in Kilo Newton 0.4 mm 0.5 mm 0.63 mm 0.9 mm 0.10 0.20 0.30 0.50 0.20 0.30 0.50 1.10 0.30 0.50 0.80 1.59 1.0 1.99 0.50 0.80 1.30 2.59 1.39 2.89 1.59 3.19 1.0 1.59 2.59 5.28 2.69 5.48 2.09 3.29 5.18 5.58 11.36 6.58 13.35 3.09 4.88 7.77 7.97 16.24 4.18 6.48 10.36 5.18 8.17 12.85 26.50 6.28 9.76 15.44 16.04 8.37 12.95 20.63 10.36 16.24 25.81 26.80 12.46 19.53 14.55 22.82 16.64 20.82 25.01
1.27 mm 1.10 2.09 3.19 3.99 5.28 5.68 6.28 10.46 10.86 22.62 26.60
21.32 26.60 Note: 1 Kn = 0.100 ton force.
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Appendix III
TABLE 1 - RAYCHEM HEAT SHRINK WRAPAROUND FOR NEW AND REPLACEMENT FOR MULTIPLE CABLES
Item Descriptions
Max. Joint Diameter (mm)
Min. Joint Diameter (mm)
Maxi. Joint Opening (mm)
Stock Code
Cable Size
Closure HSW Kit No. 1 without Branch Off Kit (Xaga 500 - 3/8200) + Branch Off Kit BOKT 5S Closure HSW Kit No. 2 without Branch Off Kit (Xaga 500 - 75/15 320) + Branch Off Kit BOKT 5S Closure HSW Kit No. 3 without Branch Off Kit (Xaga 500 - 100/25 500) + Branch Off Kit BOKT 5M Closure HSW Kit No. 4 without Branch Off Kit (Xaga 500 - 125/30 500) + Branch Off Kit BOKT 5M
43
200
50006985 5 -30/0.4 - 0.9 5 - 30/0.4A - 0.9A + 5/1.27 50006989 Specially for Tee: 20 - 100/0.4 - 0.63
75
15
320
50006986 10 - 30/1.27 50 - 100/0.5 - 0.9 + 50 - 100/0.5A - 0.9A 50006989
100
25
500
50006987 100/0.9 - 1.27 200/0.5 - 0.63 + 200/0.5A - 0.63A 50006990
125
30
500
50006988 200 - 400/0.9 - 1.27 200 - 400/0.9A - 1.27A + 50006990
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Appendix III
TABLE 2: RAYCHEM HEAT SHRINK WRAPAROUND FOR NEW AND REPLACEMENT FOR STRAIGHT CABLES
Item Descriptions
Max. Joint Diameter (mm)
Min. Joint Diameter (mm) 8
Maxi. Joint Opening (mm) 200
Stock Code
Cable Size
Closure HSW Kit No. 1 without Branch Off Kit (Xaga 500 - 43/8 200) Closure HSW Kit No. 2 without Branch Off Kit (Xaga 500 - 75/15 320) Closure HSW Kit No. 3 without Branch Off Kit (Xaga 500 - 100/25 500) Closure HSW Kit No. 4 without Branch Off Kit (Xaga 500 - 125/30 500)
43
50006985 5 -30/0.4 - 0.9 5 - 30/0.4A - 0.9A 5/1.27
75
15
320
50006986 10 - 30/1.27 50 - 100/0.5 - 0.9 50 - 100/0.4A - 0.63A
100
25
500
50006987 100/0.9 - 1.27 200/0.5 - 0.63 200/0.5A - 0.63A
125
30
500
50006988 200 - 400/0.9 - 1.27 200 - 400/0.9A - 1.27A
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Appendix IV
1.
POSITION AND DIRECTION OF SETTING GROUND/BLOCKS (FOR WOODEN POLES)
Ground Brace/ Block When setting one Ground Brace/Block
Setting Position At one third of the depth of setting below the ground line. Intermediate Pole 1. Set in the same direction as the line run. 2. Not set at the side of each pole, but on opposite sides of alternative poles Fig. 1A
Setting Direction Angle Pole It is set at right angles to the centre line of the interior angle and the inside of the angle Fig. 2A. Terminal Pole It is set at right angles with the line and at opposite side to the terminal stay.
When setting two Ground Braces/Blocks.
Beneath the upper Brace/ Block.
1. Set at right angles to the line. 2. Not set at the same side to each pole, but on opposite sides of alternate poles Fig. 1B.
It is set in parallel with the upper ground brace/block Fig. 2B.
When setting additional ground brace/block.
At the end of the It is set in parallel with the upper brace/block and pole. opposite to it.
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Appendix IV
(i)
In the case of an intermediate pole, ground braces/blocks are set as in Fig. 1. Refer also above table. In the case of an angle pole, the ground braces/blocks are set by reference to the above table and, if necessary, ground brace/block at the end of the pole is set as show in Fig. 2. In the case of terminal pole and pole with strut, the ground brace/block is set in accordance with above table and, if necessary, an additional ground brace/block is added to the end of the pole. In a strong windy area, two ground braces/blocks are set in accordance with above table and, if necessary, an additional ground brace/block is added at the end of the pole. When a pole supports many cables and/or when it has extra tension applied, it is set as shown in Fig. 3 The above mentioned tension develops while crossing a valley or a river where the pole span is long. In the case of a pole strut, the ground braces/blocks are set as shown in Fig. 4 to prevent toppling or uprooting due to the line tension.
(ii)
(iii)
(iv)
(v)
(vi)
2.
METHOD OF SETTING THE GROUND BRACE/BLOCK. The method of setting the ground brace/block is shown in Fig. 5. The centre of the ground brace/block is placed to match the side of the wooden pole. Approximately 40 mm of the steel wire is bent at right angles and driven into the ground brace/block at the beginning and at the end of the wrapping. During the wire wrapping action, the steel wire is held in place with staples driven into the pole ground brace/block.
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Appendix. V
-1.
CLEARANCE OF OVERHEAD CABLE ABOVE GROUND
Location Along a country road on poles not more than 1 metre from fence line. Elsewhere along any road for across open country Crossing any road Inside railway reserve Crossing railway Navigable waterways Above gateways, entrances, etc. (i) Not normally used by vehicles of high loading e.g. house entrances, field entrances for live stock Used regularly by vehicular traffic, particularly trucks or other forms of high loading, e.g. entrances to stores, warehouses, main entrances to farms, and industrial areas.
Minimum Height of lowest point of wire or ultimate capacity of route 2.5 metre 3.7 metre 5.5 metre 2.5 metre 6.7 metre Refer to Penolong Pengurus Tempatan
(ii)
4.6 - 5.5 metre (according to type of vehicle regularly using gateway.
NOTE : (i) (ii) Wires are defined as any form of overhead wire, stay wire or overhead cable. Roads are defined as formed roads, or where no formed road exists, any track open to the public and regularly used for vehicular traffic.
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Appendix. V
2.
SEPARATION FROM POWER LINES (LOW OR MEDIUM VOLTAGE UP TO 650 VOLTS). 2.1 All separating distances must take account of the following conditions: 2.1.1 When a power line crosses below a Telecoms line the undertaker is required to give adequate clearance for the ultimate development of the Telecoms line. The Telecoms line should allow adequate clearance when wires or aerial cables are erected below a power line which is not fully developed.
2.1.2
2.2
Normally a minimum separating distance of 1.2 metre is required between any part of a Telecoms line (including poles and stays) and live power conductors and a minimum separating distance of 0.9 metre from any other part of the power line (including poles and stays). If at a point of crossing the circumstances are such that there will be no appreciable decrease in the clearance with change of temperature, a minimum vertical clearance of 1 metre between the nearest power conductors (both live and neutral) and the Telecoms wires or aerial cables is required.
2.3
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Appendix. VIII
A GUIDE TO INSTALLING AN EARTH ELECTRODE SYSTEM

1. ELECTRICAL REQUIREMENTS. An earth electrode system should provide a connection to earth not exceeding the specified resistance of 5 ohms at all times. In general it may be found that a standard arrangement of electrodes will produce an earth connection of resistance much less than 5 ohms, except on difficult sites. 2. TYPES OF EARTH ELECTRODE SYSTEM 2.1 Standard of Earth System This is a single electrode system comprising two or more earth rods up to a maximum of four rods coupled together and driven into the ground (Fig. 1) Areas where good earth can be obtained at depth can be ascertained by depth versus resistivity measurements and these areas will soon become known in a given district. Deep earth can often be obtained by driving extendible earth rods to depths up to 4 rods (4.8) metre. Initially 2 rods (2.4 metre) are driven and its earth resistance measured. If the required resistance cannot be achieved the third (Fig. 2) and the fourth rod are installed and earth resistance measurements made (Fig. 3) after each rod has been driven in so that the prospect of getting a good earth can be watched and driving can cease as soon as the value required has been reached. The head of the electrode should be approximately 150 mm below the ground level and connected securely by bare stranded copper wire 7/1.04 mm (tinned). Vibration of the rod, when being driven into the ground, will often cause the hole to be enlarged and result in poor electrical contact between the soil and the rod. Resistance measurements taken under these conditions may give false results. Muddy water poured into the hole during driving will help to maintain electrical contact and give a resistance reading which closely approaches the rod resistance after the soil has consolidated. It will also assist the consolidation process. For rods up to 2.4 metre hand driven tools or sledge hammers are satisfactory if the soil is not soft and loose. Motorized or pneumatic hammers associated with a driving jig should be used for driving rods over 2.4 metre.
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Appendix. VIII
For the earthing of bearer wire of aerial cable, a length of stranded copper earth wire 7/1.04 mm (tinned) should be used to connect to the bearer wire at one end using openable wire jointing connectors and the other end to :(a) (b) existing DP box earth terminal, if available (See Fig. 4) a standard earth electrode system to be installed at the foot of the pole (See Fig. 7)
2.2
Alternative Methods for Providing Additional Earth Electrode System Where 5 ohms or less cannot be achieved by the single electrode system, the SO can either accept the higher resistance value or in lightning prone areas decide to provide in conjunction with the single electrode system any of the alternative methods listed below:2.2.1 Integral Bearer Wire Earth System (1 st Alternative) To improve the earth resistance of DPs with single electrode system in areas where integral bearer cable are used, connect the integral bearer earth to DP earth terminal (Fig. 4). Use openable wire jointing connector to connect the 7/1.04 mm stranded copper wire (tinned) to the integral bearer wire. 2.2.2 Multiple Electrode System (2nd alternative) Multiple earth rods have a good chance of contacting pockets of low resistivity soil but are costly to install and often required a large area. Where the required resistance cannot be achieved by single electrode system, for example where soil conditions prevent further driving or where resistance measurements show no progressive improvement in resistance with depth, it may be necessary to install additional electrodes for interconnection with the initial electrode system (See Fig 5). The head of the electrode should be about 150 mm below the ground level and interconnected by bare stranded copper wire 7/1.04 mm(tinned) inside a 25 mm diameter PVC pipe buried at least 300 mm below the surface. To achieve the best results, multiple rods must be separated by distance at least equal to their depth in the ground.
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Appendix. VIII
2.2.3
Buried Wire Electrode System (3 rd alternative) A buried wire electrode system , which normally consists of 7/1.04 mm stranded copper wire is laid in a trench at least 600 mm deep. The length depends upon the soil conditions and the earth resistance, and normally not less than 30 metre. See Fig 6. Choose a location for the trench which is not likely to lead to subsequent disturbance or damage to the earth wire, for example within the reserve for departmental ducts or cables may also be used to accommodate the earth wire. Do not install the earth wire close to exposed metal sheathed cables as this could lead to corrosion. When backfilling, thoroughly ram the soil around the earth wire. A well consolidated backfill will provide a better earth. Watering and puddling the soil during backfilling improves consolidation.
3.
LOCATION OF ELECTRODES Ensure security against subsequent disturbance, which could lead to damage to the earth system. Locate earth electrodes associated with pole mounted equipment approximately 1 metre from the foot of the pole to avoid disturbance if the pole is subsequently replaced. Avoid locations which may cause interference or damage to the plant of other undertakers. Keep the rods and earth wires well separated from metal sheathed cables to avoid corrosion.
4.
EARTHING COMPONENTS (SEE FIG. 8)
ITEM NO. 1. 2. 3. 4. 5. 6. 7. 8. 9.
COMPONENT Earth rod copper clad steel Coupling sleeve Earthing clamp Driving head Driving point Line connector Line connector bemetallic type Wire 7/1.04 mm copper (tinned) Pipe PVC 25 mm diameter
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Appendix. VIII
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Appendix. VIII
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Appendix. X
LAPORAN PEMERIKSAAN-RUTIN
Nama Ibusawat No. Kabinet Alamat Kabinet : : : ..................................................................... ..................................................................... .....................................................................
Perkara perkara berikut telah diperiksa dan setiap langkah membetul yang diambil adalah dicatakan NO. PERKARA PEMERHATIAN DAN ULASAN LANGKAH MEMBETUL YANG DIAMBIL
AM (a) Adakah kabinet ditampal dengan poster-poster dan notis-notis? (b) Adakah bahagian dalam penutup kabinet dalam keadaan bersih dan kering? (c) Adakah semua termination module berkeadaan baik dan tidak hilang?
SISTEM KUNCI (a) Adakah ketiga-tiga tempat penyendal (atas, bawah dan tengah) berfungsi dengan baik? (b) Adakah pintu dapat ditutup dengan rapat?
SISTEM PENAHAN KEMASUKAN AIR DAN KELEMBAPAN (a) Adakah sealing rubber di sekeliling pintu berkeadaan baik? (b) Adakah tanda-tanda pemeluwapan (condensation)? (c) Adakah sealing putty pada lubang masuk kabel berkeadaan baik dan tikak rosak?
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Appendix. X
PERKARA
PEMERHATIAN DAN ULASAN
LANGKAH MEMBETUL YANG DIAMBIL
(a) Dawai lintang yang mempunyai sambungan di tengah-tengah (b) Dawai lintang yang tertanggal dan masih terbiar di dalam kabinet. (c) Terlalu banyak dawai lintang di ruang tambatan lindung (jumper guard space). (d) Adakah dawai lintang melalui jumper guide pada module dengan betul? (e) Adakah dawai lintang lelalui jumper guide pada module dengan betul? (psg. 1-5 sebelah kiri, dan psg 6-10 sebelah kanan. Penamatan Dawai ke atas Termination Modules (a) Adakah pin-pin terminal berkarat? (b) Adakah termination pada sebelah kabel dilakukan dengan betul menurut colour coding yang sediada? Lain-lain perkara: .................................................................................................................... ................................................................................................................................................... ...................................................................................................................................................
Tindakan disyorkan (jika ada) : ................................................................................................ ................................................................................................................................................... ...................................................................................................................................................
Tandatangan Jawatan .................................................... Tarikh Pemeriksaan
:......................... :.........................
Nama Pemerikasa : .........................
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Appendix. X
INSTALLATION PROCEDURE FOR THE END SEAL FOR PRESSURISATION

1. Prepare the cable by abrading about 50 mm of the sheath approximately 30 mm from the end of the sheath (Fig. 1). Slit about 25 mm of the sheath for the earth tag. Using the cotton tape, pack the cable core at the end of the cable sheath. This is to limit the flow of the sealing compound into the cable . Install the earthing lead to the aluminium moisture barrier (Fig. 2) Wrap a few layers of electrical tape circumferentially to cover the silted sheath. Then wrap tightly the DR tape around the sheath 30 mm below the end of the sheath. Remove the release paper from the self-adhesive tape on the plastic sheet and form a cylinder over the DR tape so that the end of the plastic sheet is half way along the DR tape. Make sure the plastic sheet make a good contact to the DR tape by taping a few layers of elastic tape around the plastic sheet (over the DR tape). Apply electrical tape over the cylindrical plastic sheet to ensure a sturdy cylinder is formed. Pour the prepared sealing compound into the formed cylinder up to the brim (Fig. 5) Top up the compound if necessary and leave it to cure for about 24 hours.
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Issue, August 1993

TM Cable Requirement

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Specification Lines WE 0303

Issue, August 1993

Specification Lines WE 0303

Specification Lines WE 0303

EXTERNAL BLOCK CABLING:

Specification Lines WE 0303

Specification Lines WE 0303

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

SECTION III - INSTALLATION OF MAIN CABLE NETWORK

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Specification Lines WE 0303

Section III: Installation of Main Cable Network

2.1.3 2.1.4 2.2

2.2.4 2.2.5 2.3

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Specification Lines WE 0303

Section III: Installation of Main Cable Network

2.6.1.6 2.6.1.7 2.6.2

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

SIZES OF MECHANICAL CLOSURE (PSI) FOR PRIMARY CABLE

200/0.5, 200/0.63, 400/0.5 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5

200/0.5, 200/0.63, 400/0.5 200/0.5, 200/0.63, 400/0.5, 400/0.63, 600/0.5

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

Issue, August 1993

Specification Lines WE 0303

Section III: Installation of Main Cable Network

ORDER NO (MAHIRA ENG.)

Detail installation procedure is discussed in MTI Ref. 4390 ACD

Issue, August 1993

Specification Lines WE 0303

Section IV: Installation of Distribution Cable Network

SECTION IV - INSTALLATION OF DISTRIBUTION CABLE NETWORK

Specification Lines WE 0303

Section IV: Installation of Distribution Cable Network

2.4.2 2.4.3 2.4.4

Issue, August 1993

Specification Lines WE 0303

Section IV: Installation of Distribution Cable Network

Supporting the joint As for straight joint of Main Cable.

Specification Lines WE 0303