ETS Tiler) oD > “4 5 id ia) z 5 5 = Zz 6 o id i Gl z Wire and Cable Signi gnets Ansaldo Academy » “7 ansaldoSTSWire and Cable INTRODUCTION Various different types of wire and cable are used in ral signalling installations, ‘They differ in the fllowing ways: ‘+ The mumber of separate cores (conductors) within each eble 0: wire, Le Single wires or multicore cables. Single wires are more suited tcireuity requiring individual interconnections between diverse terminal such as internal wiring in & location, whereas multicore cables ate mote suited to parallel connections between multiple-terminal items — such a5 ‘connections between a location and a signal ‘+ The degree of mechanical protection provided by the cabe's outer insulation ~ clearly more protection is required where more mechanical tres is expected, ‘+ The number of metal strands making up each core — cores vith many fine stands are mote flexible than fewer, thicker stands, making them ‘more suited to complex routing or resilience under vibration ‘+ The total crossseetional area of each core (conductor) affects the current carrying capacity and voltage drop atthe end ofthe circuit ‘Multicore Cables Multicore cables have individual electrical insulation eround each cor, and an ‘overall outer sheath which provides addtional mechanical protection In areas ‘where temites are present a termite proof layer of nylon (polyamide) is provided cover the outer sheath, There may be an additional sheath provide to rotect the nylon sheath form damage during cable laying. Each core is identified by a continuously printed coe number o by colour coding \ Sheath Cores. Insulation Conductor Muticore Cable Conetruction and Core Numbering ‘Tall eables run from a locaton for the short distance toa single piece of trackside equipment. The number of cores is chosen to suit the needs of thet type of esquipment, using the next largest avaiable size ((ypically upto 16 cores) ‘W Gepyvigh Sigal Saaions Untedisalda STS Py Lid 2008 Page Taf 15 "Ape 2008Lineside cables run from interlocking to location, or from location to locaton, carrying a variety of fferent circuits which all need to go that way. The number ‘of cores is large to minimise the numberof eables, using the next largest availble size (Qpically up to $0 cores, and including an allowance of 10% spare cores pls two designated "tes ine” cores Destructive Termite Risk in Australia (asd upon CSIRO data and APCA nto sve) ‘Type Lotters “The type letter describes the inherent robustness ofthe cable or wire, dependent ‘on how well itis mechanically protected Type A is suitable for intemal use in locations and relay rooms, where there wil be ahigh degree of mechanieal protection. + Type B is suitable for extemal use in trackside cable routes, where there will bea moderate degree of mechanical protection 1+ Type C is suitable for extemal use as tail cables running to equipment mounted on the tack, where there will be a low degree of mechanical protection ‘Type Numbers ‘A number following the type lter gives more deta ‘© Ifthe number is aI", it describes a single core cable or wire + Ifthe number is greater than 1, it can deseribe # multicore cable or & special construction Conductor Characteristics ‘The eross sectional area must be sufficient to: ‘Withstand the normal operating current without damage or overeating ‘Ensure that the voltage drop experienced hy the load is acceptable “The total cross sectional area of each core is specified in square millimetres (oum’), In practic, each core is made of a large number of very fire strands, “D Capyrag Signet Solsions LimtediArzala STS Py Ld 7000 Pige 3017" "Ap 2008which add upto the stated cross sectional ares, This stranded construction is very exible compared toa single solid conductr. ‘0.75 mm’ is commonly used for lower current circuits ‘+ 1.5 mm? is commonly used in tail eables, which may cary a higher eurent {A previous notation, used until recently and found in many existing recor, isto specify the conductor by the quantity of strands, and the diameter of each strand inmilimetes: ‘+ 24/0:20 mm has a total ross sectional area of 0.75 man? ‘710.0 mam has total cross sectional area of 1.5 mm Some older cables have a single solid conductor: ‘© 1/.13mum has total erss sectional area of I mm 1/1 38mm has total eross sectional area of 1.5 mit "“S Copyrght Sianet Solitons UmnieaTaneao STS Py G70 Pages 1 ‘pri 2008‘Common types of cable and wire Current [ Old Application notation _| notation Te 0.75 mam /9/0.30mm | General purpose intemal wiring i relay rooms and type AL single | locations, relay controlled installations Te LIS man [1600-30 | Heavy current intemal wiring in relay rooms and | type A single | locations, relay controlled installations Te 0.75 mm") 24/0.20mm |General purpose intemal wiring. in _infelocking \ype AL Single | eubicles and locations, $I controled installations te 2.25 mm] 320.30 [Heavy current intemal wiring in locations, SSI [type At ‘mm single_| controlled installations 2 015 man [NA ‘Screened twisted pair cable for TPWS Toop feeds, type Ad jnteral use = 506 1.5 mm] 506 Wi38| Multicore cables Tor extemal wse, protected in type B2 mum trackside cable route, Common sizes are 10, 20,30 oF SO core. 2e 35 mm" ]2e 197.33) 415V Power cables for extemal wse, protecied in type B2 mm trackside eable route. 26 mus type | 2c 77,04 | Single core cables for extemal use on the tack eg ce om ‘wack cireuit connections Te 1 mni"|10e W138] Multicore cables for extemal use on the wack — eg type C2 mom equipment tail cables. Common sizes are 2,4, 6, 8 oF oor, Be 25am | NA Screened Wwisted pair cable for TPWS Toop feeds, ‘ype C3 external use 20 25 mn [NIA Sereoned twisted pair cable for TPWS Toop feeds, ‘ype E3 external use, low smoke emission for sub surfice sites. “D Gopyright Slant Soluians LinteaTaneaida STS Py L008 Page SoS ‘ot 2008Termination of cables and wires. Wires and cable cores are almost always terminated by crimping. A crimp has a preformed meal sleeve which is compressed around the pre-prepared ea using & specific tool. When compressed, the erimp makes good electrical comection to the conductors, and mechanical connection to the insulation, ‘Where a wire terminates at a 930 series relay plugboard, a specific 930 seies crimp is used | 1930 Series Crimp Elsewhere, wires or cable cores are terminated using standant industrial imps, Which may provide a ring tongue connection (shown below), Nat blade or round barrel, depending onthe type of terminal to be connected to, arly cota nto eo “BCopyrght Signet Salone Umtediansala STS Py Lid 2008 Page 6a 1S "or 2008Some older multicore cables have a single solid conductor, This cannot be terminated by crimping, and instead is terminated by looping 2 singe turn of conductor in a clockwise direction around a terminal post. I is sandwiched between washers and pressed in place by atop nut ‘Looped Single Strand Termination Labeling Terminated Wires and Cables Each end of every wire or cable core is labelled with a “bead!” label to icentify the terminal number to which itis connected, The bead cannot be removed without re-rimping. ‘The bea doesnot identify ‘© Which relay or device the wir! core is terminated at - the installer routes the wire! core so that this cannot be confused, ‘© Where the other end ofthe wire! core goes to - this must be found on the diagram) + fthere are two wires cores connected to one terminal, which one is which ican only be found by hand-racing Beads at relay plugboard terminations ‘Ateach end, a cable is identified by a label which is zipted or heat-shnink tothe ‘outer sheath. The label identifies the destination and function ofthe able. Each ‘cores also beaded at its individual terminal as deseribed above. “BGopyright Signet Solutons Uniedtansado STS Py Ld 2008 Pag ToT” ‘ot 2008Labelling applied toa track circult tall cable ‘Two Wires on one Terminal Itis the practice that no more than two wites or cores are terminated tngether at the same terminal + The 930 Series erimp can take one oF two wires, Other crimps ean only take only one wire, but up to two ring tongue crimps may be stacked together ona single round terminal post, ‘Stacked Ring Tongue Terminals Lf there ee a large number of terminals which ll need to be connected together, @ “looping” arrangement may be necessary, to ensure thatthe two wites rule isnot broken. “B Copyight Signal Salone Limted Ansalo STS Py Lid 2008 Page Bf 16" "Ror 2008a ot ola O Se oe oa oR hwo Circuit Diagram Employing Looping ‘Terminating Multicore Cables Itis not practicable to terminate each core of a multicore cable directly a the relay temninal or other tenminal which is its eventual destination. Every core would hhave to be a diferent length, and testing or replacement of the eable would be very dificult. Instead all cores are terminated in exact numerical sequence ata vertical “row” of temninals, commonly SAK C10 terminals. An intemal wire then continues to the ‘eventual destination termina Fach SAK C10 terminal has a disconnection pin in the centre, which when pulled will temporarily isolate th cable core for testing purposes. Each core ofthe cable terminated on the right hand side; the corresponding internal wire(s) on the lft hand sie ofthe terminal “BS Copyright Sigal Soaione LimiediAnsado STS Py Ua 7000 Page 9175 “Ap 2008,SAK C10 Terminals ‘Terminals are arranged in vertical rows, A terminal number is given by: ‘+ Aleiter, which identifies the vetical ew, counting fom the left #Arnumber, which counts down that row from the top Te cable cores must always be terminated in exact numerical sequence. Usually, but not always, the (printed) core number corresponds to the link number, ‘The core and link number may not correspond because ‘+ A large cable has overflowed into a second ro. ‘© Sever! small cables are terminated in sequence onthe same row ‘Where the core ad link number do not correspond this can eause confusion Terminal and Cable Core Analysis ‘This diagram summarizes the usage of each terminal and cable core together, and records the mame of the function which each caries, and the diggram number ‘where the definitive diagram is shown, Terminal & Cable Analysis for Rows L & M Page oats of 2008 “Caspr Signet Sota Lined ansaa BTS Py Ld 20082 ae a i re Pe a & Sem | e I Circuit showing cable termination ‘The above shows how the 4 core cable (CI) is terminated on terminals L13 (Other cables (A1, A? & C2) are terminated above & below. Through Circuits When a line circuit i routed from an original feed location to destination load location, alineside cable which goes drelly between these two places is unlikely to exist. Instead, the circuit may reach its eventual destination via rumber of Separate linesde cables and intermediate locations. In each intermediate location, the circuit is connected through from the “incoming” cable to the “outgoing” cable by internal wires terminated on the left hand side ofthe respective terminals “S Copyight Signet Soksions Lintedinnsada STS Py 2008 Page 77 1S "apr 2008‘An example of this can be seen in the terminal and cable core analysis example ahove, ‘+The functions ariving into this location on cores 1-12 of the 30¢ cable (BM203) from the interlocking, terminated on Row C, terminals C1 — C30 depart again in cores I-12 ofthe 20¢ cable (BM205) to location N14, terminated on Row D, terminals D1 —_D20. ‘The intemal wires fom links C1-C12 to links D1-D12 are record on this analysis sheet, but are not always drawn in any other diagram, ‘tis not possible to tell from this diagram exactly where the orginal feed cor eventual destination of theve iceuile are - either how far or in what direction. The diagrams of the interiocking. and locations could be inspected to lead to this information, ‘There is no need for each function to oecupy the same numbered cores i different individual lineside cables. Ifthe core number does stay consistent, it assists understanding of the diagrams, however, “SSapyrgh Sigel SalsionsLntedArsala STS Py Us 2008 Pare DoT ‘Apr 2008Cable Core Plan ‘A cable core plan i an overview diagram which summarizes the usage of cores in lineside exbles. This can asist the fault finder in tracing a circuit which passes through number of intermediate locations betveen original feed anc eventual destination ‘An example ofa cable core plan is shown overeat, ilustrating various points: ‘© Locations are shown in geographie sequence, and the cores ofeach cable ‘between adjacent locations in numerical sequence. ‘+The termination of each cable in each location is represented by a vertical line, showing the Row and Core numbers ‘+ Circuits which have longest to travel are allocated into lower aumbered cores, so that they ean, as much as posible, use the same core numbers in ‘secessive cables, ‘+ Functions which have similar names, such as repeat relays, ocetpying the ‘ame numbered cores in adjacent cables, may cause confusion ‘+ Smnller standard sized cables are chosen where fever functions are to be carried 210% spare capacity most be maintained at ll times. ‘+ The balance of spare cores in each cable are generally the higher ‘numbered cores, physically towards the outside ofthe cable. ‘+The spare cores ae intended to be used for temporary diversion of circuits from other cores which have been damaged, pending permanent replacement or repair ofthe damaged cable Example of a Cable Core Plan “D capyriht Signal Saione Linked Arcala STS Py Ls 2008 Pape TOT "ap 2008Voltage Drop in Power Cables For ll conductors in cables and wite, ther isa specified rated cureat. This is the maximum continuous current that the conductor ean withstand without ‘melting or overheating the conductor or insulation, Since copper is expensive, it makes sense that the rating ofthe conductor used in a circuit is resonably matched to the expected maximum curret in that circuit. Counter to this, there is a benefit in adopting a smal range of standard size, to reduoe eockholding and manufacturing ent, “Mos signaling circuits cary relatively low currents and the common conductor sizes (0.75 mm? or 24/020 typically) are standardised to accommodate the ‘maximum curtent of commonplace circuit, Occasionally, higher curent circuits must use conductors of a slighlly higher rating, such as doubled-up I mm (1/040) type AI intemal wieing, used in points ‘Type C, 1.5 mn" conductors are generally used forall signaling equipment i cables this size of conductor is significantly overrated for most signalling, aplication, but the sie caries benefits of standardisation and reiience under mechanical stresses. Since most such eteuits are relatively short (Jess than 2001), the votage drop along the length ofthe wire or eable, due to its internal resistance, i not generally significant. Power cables, used to transmit power at 415V AC along the linside, reed to be rated sufficiently to cary the currents found in these eieuits. However, since the length of power feders is generally quite Tong (many km), the voltage drop along the length ofthe cable becomes very significant. In order to maintain an adequate voltage (415 - 10% = 374V) atthe furthest extremity ofthe eabe, its often found that the type of cable required is much more substantial than the rating alone would indicate “Deak Signal Sottions LintodTnealdo STS PWV LIS 2008 Pago T4011 “Ape 2008Example Cable of type 2e 35 mn type B2 is commonly usd for power cables. It has a rated current of 10 amps, nd each coe as a esitance oF 087 ohms ps km. Suppose that a single location consumes 3250 VA, and is 10 km from the 415V feeder supply point. ‘To provide 3250 VA from a 415V supply the curent drawn at 415V will be 3250/415 = 7.83, A cable witha rating of [OVA would seem tobe excessive to supply thisoad. fa curent of7.83A flows in a 10km length ofthis cable, the voltage drop por kilometre will be 7.83 * 2 = 0.87 = 13.62 volts. (the factor of 2 accounts forthe voltage drop in the outgoing and reum cores ofthe cable) ' The total voltage drop in 10km of cable will be 13.62 10 = 1362 volts The actual voltage measured at the load end ofthe eable wil be 415 — 1362 278.8 volt, “The voltage atthe load end ofthis feeder cable is unacceptably low, despite the fact that the cable appeared tobe significantly over-rated forthe job In practice, the exercise of power ealelations needs to be performed separately foreach section of cable betveen adjacent locations: ‘+ The total loading at each location on the feeder must be calculated ~ usually using assumed “average” power loadings for common items of equipment + For each section of cable, the total current to feed all locations “downstream” ofthat section must be used + Fach section of cable in tum feeds the next, so the vollage drop sccumulates towards the end ofthe feeder. 4 Ifthe voltage drop isto great, it may be necessary to use a diferent sized cable and r-calculte “B Conyright Signet SoiionsLinediAnaado STS Py Li 208 Page 181 “Ap 2008,