L1-CHE-SPE-299 TECHNIQUES & MATERIALS FOR THE JOINTING & REPAIR OF RAILWAY SIGNALLING MULTI CORE AND POWER SUPPLY CABLE

Transcription

1 Engineering Specification Signalling L1-CHE-SPE-299 TECHNIQUES & MATERIALS FOR THE JOINTING & REPAIR OF RAILWAY SIGNALLING MULTI CORE AND POWER SUPPLY CABLE Version: 1

2 ENGINEERING SPECIFICATION TECHNIQUES & MATERIALS FOR THE JOINTING & REPAIR OF RAILWAY SIGNALLING MULTI CORE AND POWER SUPPLY CABLE L1-CHE-SPE-299 Version: 1 Effective from: 1 st July 2018 Approval Name Position Signature Document Endorser Louisa Waymouth Manager Standards Approving Manager Phil Ellingworth Chief Engineer Amendment Record Approval Date Version Description 20/06/ Rebadge VRIOGS Techniques & Materials for the Jointing & Repair of Railway Signalling Multi Core and Power Supply Cable. No change to the technical content. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 50

3 ENGINEERING SPECIFICATION TECHNIQUES & MATERIALS FOR THE JOINTING & REPAIR OF RAILWAY SIGNALLING MULTI CORE AND POWER SUPPLY CABLE L1-CHE-SPE-299 Version: 1 Effective from: 1 st July 2018 PREFACE This Specification replaces VRIOGS Techniques & Materials for the Jointing & Repair of Railway Signalling Multi Core and Power Supply Cable. The contents of this Specification were prepared by the Victorian Rail Industry Operators Group (VRIOG). This VRIOG Standard has been rebadged as an MTM document due to the retirement of VRIOG Standards as of 30 th June This Specification will be managed under the Engineering Standards Development Procedure (L1-CHE-PRO-032). As documents are uncontrolled once printed, it is imperative to check the currency of the Document on The Depot or the MTM s Document Portal which is available externally at All MTM Standards and Specifications are periodically reviewed, and new editions are published which incorporate learnings and Technical Notes (formerly known as Design Practice Notes). Technical Notes are issued between editions which correct any errors or ambiguities contained in an MTM Standard/Specifications. Standards and Specifications may also be withdrawn and/or replaced. In the event of conflicts or discrepancies between different types of technical documents, refer to the order of precedence as defined in Chief Engineer s Guideline Engineering Standards Listing (L1-CHE-GDL-005). Note: Any clarification described in a Technical Note or Design Practice Note shall take precedence over the impacted clause or clauses in the associated MTM Standard/Specification. In the event a clause within a Standard/Specification is not achievable a waiver will need to be raised, please refer to the Engineering Waiver Procedure - L1-CHE-PRO-001. Note: MTM does not have the authority to grant waivers on any Standards/Specifications or clauses within a Standard/Specification which relate to Government Regulations or Legislation, e.g. Disability Discrimination Act. Referencing this document Clauses and subclauses of this document should be referenced using the following format style L1-CHE-XXX-YYY Clause Z.Z.Z. Referencing the VRIOGS document number is not required. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 50

4 ENGINEERING SPECIFICATION TECHNIQUES & MATERIALS FOR THE JOINTING & REPAIR OF RAILWAY SIGNALLING MULTI CORE AND POWER SUPPLY CABLE L1-CHE-SPE-299 Version: 1 Effective from: 1 st July 2018 THIS PAGE IS INTENDED TO BE BLANK Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 50

5 Victorian Rail Industry Operators Group Standards VRIOGS Techniques & Materials for the Jointing & Repair of Railway Signalling Multi Core & Power Supply Cable Revision: A Issue Date: 06/11/2009

6 ii VRIOGS Revision A VRIOGS Techniques & Materials for the Jointing & Repair of Railway Signalling Multi Core & Power Supply Cable Revision A Issue Date: 06/11/2009 APPROVAL STATUS APPROVER STATUS DATE QUALIFICATIONS Document Developer VRIOG Steering Committee Approved All Sections Accredited Rail Operator Metropolitan Train (Metro Trains Melbourne) Intrastate Train (V/Line) Interstate Train (ARTC) Tram (Yarra Trams) For any queries please contact vriogs@transport.vic.gov.au. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

7 VRIOGS Revision A iii PURPOSE OF THE STANDARD The Standard has been created through the collaboration of members of the Victorian Rail Industry Operators Group (VRIOG) for the purpose of establishing standards which, if implemented throughout the Victorian Rail Network, will facilitate the interoperability of infrastructure. The use of the Standard is not prescribed by law but, if adopted, conformity with the provisions of the Standard is mandatory in order that the purpose of the Standard be achieved. DISCLAIMER The Standard is published by the Director of Public Transport for information purposes only and does not amount to any kind of advice. Each person is responsible for making his or her own assessment of all such information and for verifying such information. The content of this publication is not a substitute for professional advice. The Director of Public Transport and VRIOG accept no liability for any loss or damage to any person, howsoever caused, for information contained in this publication, or any purported reliance thereon. COPYRIGHT STATEMENT Director of Public Transport This publication is copyright. No part may be reproduced by any process except in accordance with the provisions of the Copyright Act. Where information or material is so used, it should be used accurately and the Standard should be acknowledged as the source of the information.

8 iv VRIOGS Revision A TABLE OF CONTENTS SECTION 1.0 CONVENTIONS...1 SECTION 2.0 DEFINITIONS...2 SECTION 3.0 SCOPE AND GENERAL Scope Application Quality Assurance Quality Assurance Documentation Advisory Bulletins Occupational Health and Safety Safety...4 SECTION 4.0 CABLE JOINTING TOOLS AND MATERIALS Multi-core Cable Tools Materials kV Cables Tools Materials kV Cable Tools Materials V Cable Tools Materials Quad Cable (Used on UM71 Track Circuit) Tools Materials Multipair Communication Type Cable Tools Materials...10 SECTION 5.0 JOINTING MULTI-CORE CABLE Initial Check Cable Jointing Cable Preparation Cut and Jointing Cores Outer Insulation Epoxy Mould Method Reinstatement Actions...13 SECTION 6.0 JOINTING 2.2KV CABLE Initial Check Preparing Cable Preparing LH Cable Conductors Preparing RH Cable Conductors Crimping and Insulating Red and Black Conductors Jointing of the Armour Strands Jointing the Copper Outer Sheath Strands Jointing the Steel Outer Sheath Strands Outer Insulation Epoxy Mould Method Reinstatement Actions...17 NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

9 VRIOGS Revision A v SECTION 7.0 JOINTING 6.6KV CABLE Initial Check Preparing the Cable Stripping Outer Sheath Preparing for Stress Relief Heat Shrink Tubing Stripping the Semi-conductive Layer Assembling the Joint Assembling Stress relief Heat Shrink Tubing Assembling the High Voltage Heat Shrink Tubing Assembling screen Outer Insulation Epoxy Mould Method Reinstatement Actions...22 SECTION 8.0 JOINTING 1000V CABLE Initial Check Cable Preparation Apply Red Mastic Tape Crimp Cores and Assemble Heat Shrink Tubing Crimp Conductor Shrink Heat Shrink Tubing Repeat Crimp Cores and Assemble Heat Shrink Tubing Assembling Shielding Outer Insulation Epoxy Mould Method Reinstatement Actions...26 SECTION 9.0 QUAD CABLE (USED ON UM71 TRACK CIRCUITS) Initial Check Cable Preparation Jointing & Insulating the Conductors & Screen Outer Insulation Epoxy Mould Method Reinstatement Actions...28 SECTION 10.0 MULTIPAIR COMMUNICATIONS TYPE CABLE IN RAILWAY SIGNALLING APPLICATIONS Initial Check Cable Jointing Cable Preparation Jointing & Insulating the Conductors & Screen Outer Insulation Epoxy Mould Method Reinstatement Actions...30 SECTION 11.0 REFERENCES...31 APPENDIX A MULTI-CORE CABLE...32 APPENDIX B 2.2KV CABLE...33 APPENDIX C 6.6KV CABLE...35 APPENDIX D 1000V CABLE...37 APPENDIX E QUAD CABLE (USED ON UM71 TRACK CIRCUIT)...38 APPENDIX F CRIMP LINKS AND CRIMPING TOOLS FOR CABLE JOINTING...40

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11 VRIOGS Revision A 1 SECTION 1.0 CONVENTIONS 1) Words or phrases that appear capitalised out of context are defined within the Definitions section of this VRIOG Standard. 2) The word Shall is to be understood as mandatory. 3) The word Should is to be understood as non-mandatory i.e. advisory or recommended. 4) Uncontrolled Standards may not be referenced within the VRIOG Standards. These include former PTC Standards, Franchisee Standards, Franchisee Subcontractor Standards and Infrastructure Lessee Standards. 5) Controlled Standards, including Australian Standards and other VRIOG Standards, may be referenced but only if: The referenced item cannot be adequately explained with an amount of text that could not reasonably be inserted into the body of the Standard. The reader is not referenced to another Controlled Standard necessary for the item to be adequately explained i.e. one document link only. The referenced document is a Figure or table and could not reasonably be included in the appendices of the Standard. 6) The format employed in the VRIOG Standards is compatible with Australian Standards, and will be used from this point on. 7) The numbering system for the VRIOG Standards is chronologically sequential from the point of introduction, and is not based on any form of interpretive system. 8) The VRIOG Standards contain engineering information necessary to operate a safe Railway. VRIOG Standards will not contain any information that can be construed as a work instruction, procedure, process or protocol. This information forms the basis of each individual entity s Safety Accreditation Certification, and, as such, is outside the scope of VRIOG Standards.

12 2 VRIOGS Revision A SECTION 2.0 DEFINITIONS Terminology used and/or applied in this Standard is defined as follows:- Terminology Accredited Rail Operator (ARO) Application for Variation of Accreditation Authorised Electrical Operator Constructor LPG Definition A Rail Infrastructure Manager or Rolling Stock Operator who is accredited under Part 5 of the Rail Safety Act An application to the Safety Director by an accredited rail operator for variation of its accreditation due to the accredited rail operator proposing to make change to or to the manner of carrying out, accredited rail operations that may reasonably be expected:- To change the nature, character and scope of the accredited rail operator; or To not be within the competence and capacity for which the accredited rail operator is accredited. An Authorised Electrical Operator who has been suitably trained and has been approved by the Train Electrical Manager may be authorised by the Group Manager, Infrastructure Power, to perform tests on live apparatus and issue and cancel the Testing Permit and certificates. Person or organisation undertaking supply, construction, manufacturing, installation, testing or commissioning works under this specification. Liquid Petroleum Gas LH Left Hand Purchaser RH Person or organisation to which the cable jointing material or services are supplied or being supplied. Note: They may not be a direct representative of the ARO. Right Hand VRIOG The Victorian Rail Industry Operators Group comprising the following members:- VicTrack V/Line Passenger Metro Trains Melbourne Yarra Trams Australian Rail Track Corporation (ARTC) Public Transport Division of the Department of Transport (PTD) VRIOGS XPLE Victorian Rail Industry Operators Group Standards. Cross-Linked Polyethylene Table 1 - Terminology NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

13 VRIOGS Revision A 3 SECTION 3.0 SCOPE AND GENERAL 3.1 Scope This Standard describes the techniques and materials to be used for the jointing and repair of railway signalling multi-core and power supply cable in the Victorian Railway Network. This Standard shall apply to cable jointing of the same type. This Standard does not apply to communications cables used for voice or data transmission. 3.2 Application The Constructor shall ensure that all the tools or materials used for cable jointing and repair of cables for railway signalling application are Type Approved by the ARO. 3.3 Quality Assurance The manufacturer shall be accredited to the appropriate Australian Quality Standards or recognised international equivalent if the manufacturer is based overseas. It is considered that the following are appropriate Australian Quality Standards:- - AS/ISO Quality Management Systems Requirements - AS/ISO Quality Management Systems Guidelines for Performances 3.4 Quality Assurance Documentation Quality assurance documentation shall be in accordance with the requirements of Australian Quality Standard Quality Management and Quality Assurance Standards AS/ISO or recognised international equivalent if the manufacturer is based overseas. 3.5 Advisory Bulletins The Purchaser shall check and act upon any related manufacturer and ARO issued product bulletins in order to ensure that they are aware of and action any safety related concerns regarding cable jointing material and/or applications. 3.6 Occupational Health and Safety The Constructor shall ensure that all personnel working on or near the cable shall comply with the Victorian Rail Safety Act 2006, the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2007.

14 4 VRIOGS Revision A 3.7 Safety The Constructor shall ensure that all personnel conducting cable jointing work or operating near the cable jointing work site shall utilise appropriate safety clothing, footwear and equipment. The Constructor shall ensure that all personnel conducting cable jointing work or operating near the cable jointing work site are accredited to the appropriate current certification in Train Track Safety Awareness. The Constructor shall ensure that all personnel conducting cable jointing work or operating near the high voltage cable jointing work site comply with the Train Infrastructure Electrical Safety Rules (High Voltage Rules) NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

15 VRIOGS Revision A 5 SECTION 4.0 CABLE JOINTING TOOLS AND MATERIALS 4.1 Multi-core Cable Tools a) Crimping tools b) Cable cutter c) Cable stripper d) Non-metallic tape measure e) Marking pen f) Timber supports g) LPG kit Materials a) Electrical insulation tape PVC black. b) Pre-insulated copper crimp links to suit conductor and insulation size. (Refer to Appendix F) c) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent) d) Cleaning cloth. e) Fine emery cloth.

16 6 VRIOGS Revision A kV Cables Tools a) Crimping tool b) Cable cutter c) Cable stripper d) Non-metallic tape measure e) Marking pen f) Timber supports g) LPG kit Materials a) 2 No. 16mm² crimp link (Utilux H1455 or approved equivalent. Refer to Appendix F). b) 1 No. 10mm² crimp link (Utilux H1454 or approved equivalent. Refer to Appendix F). c) Heat shrink kit shall consist of:- (i) (ii) 2 No. 80mm long Raychem 19/6 80/172 (or approved equivalent). 1 No. 300mm long Raychem 51/16 300/172 (or approved equivalent). d) Cleaning cloth. e) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent) NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

17 VRIOGS Revision A kV Cable Tools a) Crimping tool b) Stanley knife c) A pair of Pliers d) Cable stripper e) Non-metallic tape measure f) Marking pen g) Timber supports h) LPG kit Materials a) In line jointing kit consisting of:- (i) (ii) (iii) (iv) (v) 4 No. pieces of brown mastic tape. 4 No. pieces of stress control yellow mastic tape. 2 pieces of brown 300mm long 30/12 high voltage heat shrink tubing (BPTM 30/12 or approved equivalent). 2 pieces of 190mm long 19/10 stress relief heat shrink tubing (Raychem 19/10 ES 1277 or approved equivalent). Metal shielding tape (RF9022 or approved equivalent). b) Cleaning cloth. c) 2 No. 16mm² crimp links (Utilux H1455 or approved equivalent). d) Cleaning solvent (Applied chemicals Appsolve E71 or approved equivalent). e) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent)

18 8 VRIOGS Revision A V Cable Tools a) Crimping tool b) Cable cutter c) Cable strippers d) Non-metallic tape measure e) Marking pen f) Timber support g) LPG kit Materials a) Cleaning cloth. b) In line jointing kit (PTC 5KV001 G.V. Kinsman Pty Ltd or approved equivalent) which includes:- (i) (ii) (iii) 3 No. 250mm inner red heat shrink tubing (Raychem EW 1029 or approved equivalent). 3 No. middle red heat shrink tubing. 3 No. conductive black heat shrink tubing (Raychem CNTM 42/16 or approved equivalent). (iv) 2 No. 3 finger break out boxes (black) (Raychem 402W533 53/42 or approved equivalent). (v) (vi) (vii) (viii) (ix) 25mm and 16mm joining links. 2 No. stainless spring clips. 1 length of copper braid. Yellow mastic tape. Red mastic tape. c) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent) 4.5 Quad Cable (Used on UM71 Track Circuit) Tools a) Cable cutter NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

19 VRIOGS Revision A 9 b) Cable strippers c) Non-metallic tape measure d) Marking pen e) Solder kit f) LPG kit Materials a) Electrical insulation tape PVC black. b) Heat shrink tubing (Raychem or approved equivalent) c) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent) d) Cleaning cloth. e) Fine emery cloth

20 10 VRIOGS Revision A 4.6 Multipair Communication Type Cable Tools a) Cable cutter b) Cable strippers c) Non-metallic tape measure d) Marking pen e) Crimping tool f) LPG kit Materials a) Heat shrink tubing (Raychem or approved equivalent) b) Electrical insulation tape PVC black. c) Pre-insulated copper crimp links to suit conductor and insulation size. (Refer to Appendix F) d) Epoxy Encapsulated kit (for outer insulation) to suit the cable diameter. (Scotchcast 3M product or approved equivalent) e) Cleaning cloth. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

21 VRIOGS Revision A 11 SECTION 5.0 JOINTING MULTI-CORE CABLE This section of the specification details the cable jointing procedure for multi-core railway signalling cable used within Victorian Railway Network. 5.1 Initial Check a) Ensure that all cores of the cable are isolated. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.1 of this specification for the list of tools and materials required) c) Check that there is sufficient cable slack for jointing (400mm cable overlap). d) Check the crimping tool for wear by visually inspecting a sample crimp. e) Any tool that produces an incorrect crimp shall be taken out of service, designated as defective and returned for repair. f) Under no circumstances shall defective crimping tools be used. g) Check and clear work area is clear of any rubbish or moisture. h) Check crimping tools for correct operation in accordance with manufacturer specification. i) There shall be no snaking and deformation of the cables in the vicinity of the joints. j) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. k) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and for above ground joint. 5.2 Cable Jointing Cable Preparation a) Firstly, support both cable ends above the trough/trench/pit with small planks of timber. Ensure that both cables are in alignment. b) Next, overlap the cable and using the cable cutter to remove the cable outer sheathing for 400mm overlap. (See Appendix A, Figure 1) c) Using the cleaning cloth, wipe clean the cable ends for at least approximately 600mm. d) Using the marking pen, mark both cables, half the joint length in from the centre of the overlap. (Refer to Appendix A, Table 3)

22 12 VRIOGS Revision A e) Using the correct cable stripper remove the outer insulation of the cable (LH cable or RH cable) to the mark taking caution not to damage the inner insulation. (Refer to Appendix A, Figure 1) f) Peel back the outer most cores (highest core number) and neatly fold back along the cable. (i) (ii) Repeat for each core, working radially in layers, removing cable fillers progressively. Do not peel back the inner most core (normally marked with the number 1). Repeat for opposite cable Cut and Jointing Cores a) On the LH cable, cut core no. 1 approximately 30mm from the outer sheath. (Refer to Appendix A, Figure 2) b) Using the correct sized stripper, strip 6-8mm of insulation off the core. c) Insert bare conductor into pre-insulated lug and crimp. Check crimp in accordance with lug manufacturer specification. d) On the RH cable, cut the core so that:- (i) (ii) First core: - The distance between outer sheaths, after being crimped, equals the joint length. (Refer to Appendix A, Table 3) Subsequent cores: - The core will be taut when crimped. e) Insert bare conductor into pre-insulated lug and crimp. Check crimp in accordance with lug manufacturer specification. f) On the LH cable, extract the next core, and cut it 15mm away from the previous crimp link. g) Repeat steps (b) to (f) until either; (i) (ii) the cable is completed, or a crimp link is applied within 60mm of RH outer sheath, in which case start from step (a) again for the next core in the sequence Outer Insulation Epoxy Mould Method a) Roughen the first 150mm of outer sheath of both cable ends with fine emery cloth. b) Using the clean cloth, wipe clean the outer sheath. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

23 VRIOGS Revision A 13 c) Apply one layer of electrical insulation black PVC tape tightly over the unsheathed core using 50% overlap. d) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. e) Place the plastic mould sections central over the cable joint and clip tightly together. f) Visually check the plastic sections have sealed. g) Fit the nozzles to the mould. h) Apply several layers of amalgamation insulation tape over ends of the mould. i) Mix and pour epoxy in accordance with manufacturer s instructions. j) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. k) Cover the filler hole with several layers of insulation tape. 5.3 Reinstatement Actions a) Remove the cable supports. b) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. c) Dispose of waste from the work area. d) Remove tools and used materials from the work area. e) Test the continuity and insulation resistance of the joint cable. Refer to VRIOG Standard Testing and Commissioning of Safety Related Railway Signalling Systems VRIOGS

24 14 VRIOGS Revision A SECTION 6.0 JOINTING 2.2KV CABLE This section of the specification details the cable jointing procedure for 2.2kV railway signal high voltage single phase cable (PVC type) used within Victorian Railway Network. 6.1 Initial Check a) Obtain electrical access permit for the cable. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.2 of this specification for the list of tools and materials) c) Check that there is sufficient cable slack for jointing (400mm overlap). d) Using the cleaning cloth, wipe clean the cable sheath ends for at least 600mm. e) Check the crimping tool for wear by inspecting a test crimp. f) Any tool that produces an incorrect crimp shall be taken out of service, designated as defective and returned for repair. g) Under no circumstances shall defective crimping tools be used. h) Ensure the work area is clear of any rubbish or moisture. i) Check crimping tools for correct operation in accordance with manufacturer specification. j) There shall be no snaking and deformation of the cables in the vicinity of the joints. k) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. l) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and for above ground joint. 6.2 Preparing Cable a) Firstly, support both cable ends above the trough/trench/pit with small planks of timber. Ensure that both cables are in alignment. b) Next, measure and cut both the cables for 400mm overlap.(refer to Appendix B, Figure 3) c) Using the cleaning cloth, wipe clean the cable ends for at least approximately 800mm. d) Using a cable stripper, strip the outer sheath from both cables to the overlap. (Note: Ensure the depth of the cut does not exceed sheath thickness) NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

25 VRIOGS Revision A 15 e) Unravel and bend the armour strands back along the outer sheath of the cable. f) Identify all the copper conductors by scratching the outer coating of each armour strand with a knife blade and visually inspect the scratch area for a copper colour. (Normally between 1-3 strands are copper) g) Separate all the copper conductors from the steel armour strands. h) Apply 3-4 wraps of electrical tape at the end of the armour strands to secure them in place. i) Repeat steps (f) to (h) for RH cable. j) Slide heat shrink tubing over LH cable, covering the armour strands. (length 300mm) k) Measure and strip the inner sheath and cable fillers 80mm from the outer sheath. Take care not to cut the insulation on the conductors. (Refer to Appendix B, Figures 4 and 5) Preparing LH Cable Conductors a) Cut the red insulated conductor 80mm out from the inner sheath and remove 18-20mm of insulation. b) Cut the black insulated conductor 160mm out from the inner sheath and remove 18-20mm of insulation. c) Slide heat shrink tubing over black conductor (length 80mm). (Refer to Appendix B, Figure 4) Preparing RH Cable Conductors a) Cut the black insulated conductor 80mm out from the inner sheath and remove 18-20mm of insulation. b) Cut the red insulated conductor 160mm out from the inner sheath and remove 18-20mm of insulation. c) Slide heat shrink tubing over red conductor (length 80mm). (Refer to Appendix B, Figure 5) 6.3 Crimping and Insulating Red and Black Conductors a) Insert the exposed copper wire of the LH cable s red conductor to the copper link (Utilux H1455 for 16mm link). Crimp the link twice with the crimping tool (Utilux 18A)

26 16 VRIOGS Revision A b) Insert the exposed copper wire of the RH cable s red conductor to the copper link and crimp the link twice. c) Visually inspect the each crimp in accordance with manufacturer s instructions. d) Repeat steps (a) to (c) for the black conductor. e) Slide the heat shrink tubing (length 80mm) over both crimp links, overlap equally over the inner sheaths. f) Apply gentle heat to the heat shrink tubing, starting at the centre and working outwards. Take care not to burn or damage cable insulation. g) Remove the heat when the glue runs out of the heat shrink tubing at both ends. h) Slide the heat shrink tube (length 300mm) over the black and red conductors. i) Ensure the heat shrink tubing overlaps onto the inner sheath of both LH and RH cables by 30mm. j) Apply gentle heat to the heat shrink tubing. Start from the centre of the heat shrink tubing and move towards both ends. Take care not to burn or damage the cable insulation. k) Remove the heat when the glue runs out of the heat shrink tubing at both ends. 6.4 Jointing of the Armour Strands Jointing the Copper Outer Sheath Strands a) Straighten copper outer sheath strands on both cables. If there are less than 3 copper strands, choose evenly spaced steel strands to make up the difference. b) Twist the copper/steel conductor s together (1 twist per 50mm). c) Overlap and cut the prepared strands in the centre of the joint. d) Crimp the prepared strands into a copper link. (10mm copper link Utilux H1454 or approved equivalent) e) Visually inspect the each crimp in accordance with manufacturer s instructions Jointing the Steel Outer Sheath Strands a) Straighten the LH armour strands over the joint. b) Trim the armour strands so that they lay neatly over the inner sheath. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

27 VRIOGS Revision A 17 c) Tie the armour strands in place using several turns of copper wire and twisting tight. d) Straighten the RH armour strands over the joint. e) Tie the armour strands in place with 2 equally spaced wire ties:- (i) (ii) (iii) (iv) Cut a piece of scrap copper wire from a scrap piece of mains cable. Wrap a wire around the armour strands and twist the wire tight. Gently tap the twisted wire end into the armour and ensure there are no sharp edges protruding. Repeat (i) and (iii) at the next position. (Refer to Appendix B, Figure 6) Outer Insulation Epoxy Mould Method a) After placing a separate heat shrink over crimped active and neutral cores, join the armoured sheath using crimped links (grouping several armoured wires together to form up each crimped joint). b) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. c) Place the plastic mould sections central over the cable joint and clip tightly together. d) Visually check the plastic sections have sealed. e) Fit the nozzles to the mould. f) Apply several layers of amalgamation insulation tape over ends of the mould. g) Mix and pour epoxy in accordance with manufacturer s instructions. h) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. i) Cover the filler hole with several layers of insulation tape. (Refer to Appendix B, Figure 7) 6.5 Reinstatement Actions a) Remove the cable supports. b) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. c) Dispose of waste from the work area. d) Remove tools and used materials from the work area. e) Test the continuity and insulation resistance of the joint cable. f) The Officer in-charge of the test shall be an Authorised Electrical Operator. Refer to Train Infrastructure Electrical Safety Rules 1997.

28 18 VRIOGS Revision A SECTION 7.0 JOINTING 6.6KV CABLE This section of the specification details the cable jointing procedure for railway signalling power supply 6.6kV single phase signal power distribution cable used within Victorian Railway Network. 7.1 Initial Check a) Obtain electrical access permit for cable. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.3 of this specification for the list of tools and materials) c) Check that there is sufficient cable slack for jointing (400mm cable overlap). d) Check the crimping tool for wear by inspecting a test crimp. e) Any tool that produces an incorrect crimp shall be taken out of service, designated as defective and returned for repair. f) Under no circumstances shall defective crimping tools be used. g) Ensure the work area is clear of any rubbish or moisture. h) Check crimping tools for correct operation in accordance with manufacturer specification. i) There shall be no snaking and deformation of the cables in the vicinity of the joints. j) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. k) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and for above ground joint. 7.2 Preparing the Cable Stripping Outer Sheath a) Firstly, support both cable ends above the trough/trench/pit with the timber. Ensure that both cables are in alignment. b) Next, overlap the cables by at least 100mm. (Refer to Appendix C, Figure 9) c) Using the cleaning cloth, wipe clean the cable ends for at least approximately 900mm d) Using the marking pen, mark the center of the overlap. e) Using the measuring tape and marking pen, measure and mark 245mm from the center in both directions. (Refer to Appendix C, Figure 9) NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

29 VRIOGS Revision A 19 f) Using the stanley knife, strip outer sheath to the 245mm mark on each cable. (Note: Take care using stanley knife to strip cable insulation, the direction of all cuts must be away from the body) g) Fold back the cable screens on each cable. (Note: Try to bring the screens to one side of the cable, or as close as possible) h) Then remove the screen tape from each cable. i) Next, align the cable cores of both the cable ends so that they match. Each core is marked with either a 1 or 2. j) Then using a marker pen, mark the outer sheath with a 1 or 2 adjacent to the matching core. k) Measure and cut the cable at the center of the overlap Preparing for Stress Relief Heat Shrink Tubing a) Slide the stress relief heat shrink tubing (length 190mm) adjacent to the joint, ensuring it is central to the joint. (Refer to Appendix C, Figure 10) b) Using the marker pen, mark the semi-conductor layer where stress relief heat shrink tubing ends. c) Using the marker pen and measuring tape, measure and mark semiconductive layer a further 20mm towards center of joint. (Refer to Appendix C, Figure 10) Stripping the Semi-conductive Layer a) Mark the circumference of the semi-conductive layer at the 20mm mark. b) Mark from the 20mm mark to the end of the core. c) Cut a nick into the end of the core. d) Using a pair of pliers, peel the semi-conductive layer to the 20mm mark. e) Using stanley knife, strip 20mm of insulation from the end of core. (Note: Take care using stanley knife to strip cable insulation, the direction of all cuts must be away from the body) f) Repeat steps (a) to (e) for each core on both cable ends. 7.3 Assembling the Joint a) Dampen a cleaning cloth with cleaning solvent to wipe clean all the XPLE insulation and the entire semi-conductive layer. b) Wrap 2 overlapping layers of stress relief yellow mastic tape on the border of the semi-conductor layer and XPLE insulation. (Refer to Appendix C, Figure 11)

30 20 VRIOGS Revision A (i) (ii) (iii) Start 5mm over semi-conductive layer. Finishing the tape 10mm onto XPLE insulation. Repeat for each core on both cable ends. c) Slide the stress relief heat shrink tubing (length 190mm) over both cores. d) Cut high voltage heat shrink tubing in half and slide one half onto each core. Repeat for the other cable end. e) Insert and crimp copper link onto cores 1 and 2 on the first cable end. Use the 16mm crimp tool. Crimp the link in two places. Ensure the copper links are fully inserted onto the conductor. f) Insert the second cable cores into the copper links. Ensure cores 1 and 2 match the cores 1 and 2 of the first cable. Ensure the copper links are fully inserted onto the conductor. g) Crimp the copper links in two places. h) Visually inspect the copper links are correctly crimped to the conductors Assembling Stress relief Heat Shrink Tubing a) Wrap stress relief yellow mastic tape around each copper link until the mastic tape is the same diameter as XPLE insulation. b) Slide stress relief heat shrink tubing over the link. Ensure the ends of the heat shrink tubing are adjacent to marks on the semi-conductor layer. (Refer to Appendix C, Figure 10) c) Insert the high voltage heat shrink tubing inside the other high voltage heat shrink tubing on both cores. d) Using the LPG kit, apply gentle heat to the stress relief sleeve. (Note: Take care not to shrink high voltage heat shrink tubing). (i) (ii) (iii) (iv) (v) (vi) (vii) Heat from the center and working towards one end. Stop when glue oozes out the end of the stress relief sleeve. Repeat steps (i) to (ii) for the second core. Move high voltage heat shrink tubing to the other extreme of the joint, on both cores. Heat from the center and working towards one end. Stop when glue oozes out the end of the stress relief sleeve. Repeat steps (v) to (vi) for the second core Assembling the High Voltage Heat Shrink Tubing a) Slide one half of high voltage. heat shrink tubing so that end of heat shrink tubing is at middle of joint. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

31 VRIOGS Revision A 21 b) Mark the semi-conductor layer where the high voltage heat shrink tubing ends and slide heat shrink tubing to one side. c) Using marking pen and measuring tape, measure 5mm towards the center and mark. (Refer to Appendix C, Figure 12) d) Apply 2 wraps of red mastic tape to the semi-conductive layer at 5mm mark. Ensure the red mastic tape is applied to the side closest to center of the joint. (Refer to Appendix C, Figure 12) e) Slide the one half of high voltage heat shrink tubing over the middle of joint. Ensure the red mastic tape is underneath one end of heat shrink tubing. f) Using the LPG kit, apply gentle heat to the high voltage heat shrink tubing. (Note: Take care not to shrink the second half of high voltage heat shrink tubing) (i) (ii) Heat from the center and working towards one end, then the other end. Stop when glue oozes out the end of the heat shrink tubing. g) Apply two wraps of red mastic tape onto the end of the cooling high voltage heat shrink tubing closest to the center of the joint. (Refer to Appendix C, Figure 13) h) Slide the second half of high voltage heat shrink tubing 5mm over the red mastic tape. i) Mark the semi-conductor layer where the high voltage heat shrink tubing ends and slide heat shrink tubing to one side. j) Using the measuring tape, measure 5mm towards the center and mark. (Refer to Appendix C, Figure 13) k) Apply two wraps of red mastic tape to the semi-conductive layer at 5mm mark. Ensure the tape is applied to the side closest to center of the joint. (Refer to Appendix C, Figure 13) l) Slide the second half of high voltage heat shrink tubing so it is covering the applied red mastic tape by 5mm at both ends. m) Repeat step (f). n) Repeat steps (a) to (m) for the second core of the cable Assembling screen a) Gather the cable screens up on one side of the cable. Twist the cable screens into one neat conductor. Repeat for the other cable end. b) Wrap metal screen tape over complete joint. (i) (ii) Start by applying 2 to 3 wraps at the base of cable screen. Continue to wrap onto outer sheath for 10mm and then back along cables under the cable screens, overlapping each wrap.

32 22 VRIOGS Revision A (iii) (iv) Wrap metal screen tape to the other end of the joint. Continue to wrap onto outer sheath for 10mm. (v) Finishing by applying 2 to 3 wraps at the base of cable screen and tie off with a half hitch. c) Lay both prepared cable screens along the joint. d) Cut the cable screens at the center of the overlap. e) Insert and crimp copper link onto the first cable screen end. Use the 16mm crimp tool. Ensure the copper link is fully inserted onto the conductors. f) Insert the second cable screen into the copper link. Ensure the copper link is fully inserted onto the conductors. g) Crimp the copper link. h) Visually inspect the copper link is correctly crimped to the conductors, has no sharp edges and apply tape around crimp link. 7.4 Outer Insulation Epoxy Mould Method a) After placing a separate heat shrink over crimped active and neutral cores, join the armoured sheath using crimped links (grounding several armoured wires together to form up each crimped joint). b) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. c) Place the plastic mould sections central over the cable joint and clip tightly together. d) Visually check the plastic sections have sealed. e) Fit the nozzles to the mould. f) Apply several layers of amalgamation insulation tape over ends of the mould. g) Mix and pour epoxy in accordance with manufacturer s instructions. h) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. i) Cover the filler hole with several layers of insulation tape. 7.5 Reinstatement Actions a) Remove the cable supports. b) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. c) Dispose of waste from the work area. d) Remove tools and used materials from the work area. e) Test the continuity and insulation resistance of the jointed cable. f) The Officer in-charge of the test shall be an Authorised Electrical Operator. Refer to Train Infrastructure Electrical Safety Rules NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

33 VRIOGS Revision A 23 SECTION 8.0 JOINTING 1000V CABLE This section of the specification details the cable jointing installation procedure for 1000V 3 phase signal power distribution cable used within Victorian Rail Network. 8.1 Initial Check a) Obtain electrical access permit for the cable. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.4 of this specification for the list of tools and materials) c) Check that there is sufficient cable slack for jointing (100mm cable overlap). d) Using the cleaning cloth, wipe clean the cable sheath ends for at least 500mm. e) Check the crimping tool for wear by inspecting a test crimp. f) Any tool that produces an incorrect crimp shall be taken out of service, designated as defective and returned for repair. g) Under no circumstances shall defective crimping tools be used. h) Ensure the work area is clear of any rubbish or moisture. i) Check crimping tools for correct operation in accordance with manufacturer specification. j) There shall be no snaking and deformation of the cables in the vicinity of the joints. k) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. l) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and above ground joints. 8.2 Cable Preparation a) Firstly, support both cable ends above the trough/trench/pit with the timber wood. Ensure that both cables are in alignment. b) Next, overlap the cable and using the cable cutter to remove the cable outer sheathing for 100mm overlap.(refer to Appendix D, Figure 1) c) Remove 500mm of outer sheath from the LH cable. d) Remove 300mm of outer sheath from RH cable. e) Cut the cable at the center of the overlap.

34 24 VRIOGS Revision A f) Gather and twist the shielding wire to make an earth conductor on both cables. g) Fold back both earth conductors along the cable. Adjust the earth conductor so it sits flush against outer sheath. h) Slip a cable breakout box over the end of the cable and mark outer cable sheath where it ends. Remove the cable breakout boxes. i) Secure the earth conductor to the cable by twisting tight two wraps of scrap copper wire 10mm from the mark. The wire must be clear of the cable breakout box. j) Wrap 2 to 3 layers of red mastic to the outer sheath of each cable, 5mm in from the end. Stretch the red mastic tape to half its original width whilst wrapping. k) Slide 3 finger cable breakout boxes over end of each cable with one core per finger. l) Using the LPG kit, apply gentle heat to the cable breakout box. (i) (ii) 8.3 Apply Red Mastic Tape Heat from the center and working towards one end. Stop when glue oozes out the each end of the cable breakout box. a) Place the heat shrink tubing (length 250mm) adjacent to the joint for one conductor. b) Adjust the heat shrink tubing so it is central to the joint. c) Using the marker pen, mark the conductor insulation where heat shrink tubing ends. d) Using the measuring tap and marker pen, measure and mark insulation a further 20mm towards center of joint. e) Apply two wraps of red mastic tape to the conductor insulation at the 20mm mark. Ensure the tape is applied to the side closest to center of the joint. f) Repeat steps (a) to (e) for each conductor. 8.4 Crimp Cores and Assemble Heat Shrink Tubing Crimp Conductor a) Remove 18mm of insulation from end of each core of both cables. b) Slide inner (red), middle (red) and then the conductive heat shrink tubing (black) over the red insulated conductor, on the left cable. NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

35 VRIOGS Revision A 25 c) Insert red insulated conductor ends into the copper link. Ensure the copper links are fully inserted onto the conductor. d) Crimp the link in two places for each conductor end. e) Visually inspect the copper links are correctly crimped to the conductors. f) Apply void filling tape:- (i) (ii) (iii) (iv) Remove one strip of paper from the void yellow filling tape and roll up the strip of tape. Wrap it around the conductor with a 50% overlap stretching it to about half of its original width. Fill up the connector area continuing onto the insulation for not more than 5mm. The final diameter of void filling tape should be only slightly greater than the core or connector diameter (whichever is larger). Do not use excessive void filling tape Shrink Heat Shrink Tubing a) Slip the inner heat shrink tubing central over the joint. Ensure the heat shrink tubing covers the red mastic tape. b) Using the LPG kit, apply gentle heat to the heat shrink tubing. (i) (ii) (iii) Heat from the center and work towards one end. Stop when glue oozes out the each end of the heat shrink tubing. Take care not to shrink other tubing. c) Repeat steps (a) to (b) for middle (red) and conductive (black) heat shrink tubing Repeat Crimp Cores and Assemble Heat Shrink Tubing a) Repeat all steps from Section and for the white conductor. b) Repeat all steps from Section and for the blue conductor. 8.5 Assembling Shielding a) Fold earth conductor back over the joint. b) Insert earth conductor ends into the 16mm copper link. Ensure the earth conductors are fully inserted into the copper link. c) Crimp the link in two places for each conductor end. d) Visually inspect the copper links are correctly crimped to the conductors. e) Wrap 1 layer of copper braid around the complete joint area. The copper braid must be wrapped with a 50% overlap and then continue onto the outer cable sheath by 20mm. f) Secure copper braid at each end with a stainless steel spring clip (supplied in the kit).

36 26 VRIOGS Revision A 8.6 Outer Insulation Epoxy Mould Method a) After placing a separate heat shrink over crimped active and neutral cores, join the armoured sheath using crimped links (grounding several armoured wires together to form up each crimped joint). b) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. c) Place the plastic mould sections central over the cable joint and clip tightly together. d) Visually check the plastic sections have sealed. e) Fit the nozzles to the mould. f) Apply several layers of amalgamation insulation tape over ends of the mould. g) Mix and pour epoxy in accordance with manufacturer s instructions. h) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. i) Cover the filler hole with several layers of insulation tape. 8.7 Reinstatement Actions a) Remove the cable supports. b) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. c) Dispose of waste from the work area. d) Remove tools and used materials from the work area. e) Test the continuity and insulation resistance of the jointed cable. f) The Officer in-charge of the test shall be an Authorised Electrical Operator. Refer to Train Infrastructure Electrical Safety Rules NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

37 VRIOGS Revision A 27 SECTION 9.0 QUAD CABLE (USED ON UM71 TRACK CIRCUITS) This section of the specification details the cable jointing installation procedure for quad cable used on UM71 track circuits within Victorian Rail Network. 9.1 Initial Check a) Ensure that all cores of the cable are isolated. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.5 of this specification for the list of tools and materials) c) Check that there is sufficient cable slack for jointing (400mm cable overlap). d) Using the cleaning cloth, wipe clean the cable sheath ends for at least 400mm. e) Ensure the work area is clear of any rubbish or moisture. f) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. g) There shall be no snaking and deformation of the cables in the vicinity of the joints. h) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and above ground joints. 9.2 Cable Preparation a) Firstly, prepare the cable to be joined by removing the outer heavy sheathing and individual conductor insulation. (See Appendix E, Figure 16) b) Next, overlap the cable and using the cable cutter to remove the cable outer sheathing for 400mm overlap. (See Appendix E, Figure 15) c) Using the cleaning cloth, wipe clean the cable ends for at least approximately 600mm. d) Twist the correct conductor cores together beginning at the insulation. This provides mechanical strength to the conductors due to the relative small size of the conductors. (See Appendix E, Figure 17) e) Continue twisting the cores together up to and including the exposed copper conductor. (See Appendix E, Figure 18) f) Trim off excess copper conductor. g) Repeat steps (d) to (f) for the other cores and the metal screen.

38 28 VRIOGS Revision A 9.3 Jointing & Insulating the Conductors & Screen a) Solder the copper conductors and apply heat shrink tubing insulation to the exposed conductor. (See Appendix E, Figure 19) b) The finished jointed cable will be as shown in Appendix E, Figure 20. c) Fold the jointed cores and screening conductor down flat along the cable Outer Insulation Epoxy Mould Method a) Roughen the first 150mm of outer sheath of both cable ends with fine emery cloth. b) Using the clean cloth, wipe clean the outer sheath. c) Apply one layer of electrical insulation black PVC tape tightly over the unsheathed core using 50% overlap. d) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. e) Place the plastic mould sections central over the cable joint and clip tightly together. f) Visually check the plastic sections have sealed. g) Fit the nozzles to the mould. h) Apply several layers of amalgamation insulation tape over ends of the mould. i) Mix and pour epoxy in accordance with manufacturer s instructions. j) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. k) Cover the filler hole with several layers of insulation tape. 9.4 Reinstatement Actions a) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. b) Dispose of waste from the work area. c) Remove tools and used materials from the work area. d) Test the continuity and insulation resistance of the jointed cable. Refer to VRIOG Standard Testing and Commissioning of Safety Related Railway Signalling Systems VRIOGS NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

39 VRIOGS Revision A 29 SECTION 10.0 MULTIPAIR COMMUNICATIONS TYPE CABLE IN RAILWAY SIGNALLING APPLICATIONS This section of the specification applies only to copper conductor communications cables which are used in hard wired vital signalling applications Initial Check a) Ensure that all cores of the cable are isolated. b) Ensure all tools and materials required for cable jointing are available before commencing. (See Section 3.6 of this specification for the list of tools and materials) c) Using the cleaning cloth, wipe clean the cable sheath ends for at least 400mm. d) Ensure the work area is clear of any rubbish or moisture. e) Check the cable label attached to the cable on each side of the proposed joint to ensure that the cable to be jointed is the correct cable. f) Check the crimping tool for wear by visually inspecting a sample crimp. g) Any tool that produces an incorrect crimp shall be taken out of service, designated as defective and returned for repair. h) Under no circumstances shall defective crimping tools be used. i) There shall be no snaking and deformation of the cables in the vicinity of the joints. j) Check crimping tools for correct operation in accordance with manufacturer specification. k) Epoxy encapsulated kit (for outer insulation) shall be used for buried cable joints or joints in a pit and for above ground joints Cable Jointing Cable Preparation a) Firstly, prepare the cable to be joined by removing the outer heavy sheathing and individual conductor insulation. b) Next, overlap the cable and using the cable cutter to remove the cable outer sheathing for 400mm overlap. c) Using the cleaning cloth, wipe clean the cable ends for at least approximately 600mm. d) Twist the correct conductor cores together beginning at the insulation. This provides mechanical strength to the conductors due to the relative small size of the conductors. e) Continue twisting the cores together up to and including the exposed copper conductor. f) Trim off excess copper conductor. g) Repeat steps (d) to (f) for the other cores and the metal screen.

40 30 VRIOGS Revision A Jointing & Insulating the Conductors & Screen a) Solder the copper conductors and apply heat shrink tubing insulation to the exposed conductor. b) Fold the jointed cores and screening conductor down flat along the cable Outer Insulation Epoxy Mould Method a) Roughen the first 150mm of outer sheath of both cable ends with fine emery cloth. b) Using the clean cloth, wipe clean the outer sheath. c) Apply one layer of electrical insulation black PVC tape tightly over the unsheathed core using 50% overlap. d) Cut the plastic mould sections to fit snugly to the exterior diameter of the cable being joined. e) Place the plastic mould sections central over the cable joint and clip tightly together. f) Visually check the plastic sections have sealed. g) Fit the nozzles to the mould. h) Apply several layers of amalgamation insulation tape over ends of the mould. i) Mix and pour epoxy in accordance with manufacturer s instructions. j) Remove the nozzles when epoxy has set in accordance with manufacturer s specification. k) Cover the filler hole with several layers of insulation tape Reinstatement Actions a) Place joined cable in position in trench or trunking, ensure minimal disturbance to joint in any movement of cable. b) Dispose of waste from the work area. c) Remove tools and used materials from the work area. d) Test the continuity and insulation resistance of the jointed cable. Refer to VRIOG Standard Testing and Commissioning of Safety Related Railway Signalling Systems VRIOGS NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

41 VRIOGS Revision A 31 SECTION 11.0 REFERENCES The following documents have been used and referenced for the preparation of this standard:- No. Ref No. Title 1. AS/ISO 9001 Quality Management Systems Requirements 2. AS/ISO 9004 Quality Management Systems Guidelines for Performances 3. AS/ISO Quality Management and Quality Assurance Standards 4. VRIOGS Testing and Commissioning of Safety Related Railway Signalling Systems 5. - Rail Safety Act 2006 (Victoria) 6. - Occupational Health and Safety Act 2004 (Victoria) 7. - Occupational Health and Safety Regulations 2007 (Victoria) 8. - Train Infrastructure Electrical Safety Rules (High Voltage Rules) 1997 (Victoria) Table 2 References

42 32 VRIOGS Revision A APPENDIX A MULTI-CORE CABLE CABLE CORE JOINT LENGTH 2 Core 100mm 4 Core 100mm 10 Core 150mm 20 Core 225mm 50 Core 250mm Table 3 - Joint Length Figure 1 Cable Overlap Figure 2 Cut and Jointing Cores NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

43 VRIOGS Revision A 33 APPENDIX B 2.2KV CABLE Figure 3 Cable Overlap Figure 4 LH Cable Conductor Figure 5 LH and RH Cable Conductor

44 34 VRIOGS Revision A Figure 6 Cable Jointing Arrangement Figure 7 Epoxy Encapsulation NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

45 VRIOGS Revision A 35 APPENDIX C 6.6KV CABLE Figure 8 6.6KV Cable Cross Section Figure 9 Cable Overlap Figure 10 Assembling of Stress Relief Heat Shrink Tubing

46 36 VRIOGS Revision A Figure 11 Yellow Tape Arrangement Figure 12 Assembling of LH High Voltage Heat Shrink Tubing Figure 13 Assembling of RH High Voltage Heat Shrink Tubing NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

47 VRIOGS Revision A 37 APPENDIX D 1000V CABLE Figure 14 Cable Jointing Arrangement

48 38 VRIOGS Revision A APPENDIX E QUAD CABLE (USED ON UM71 TRACK CIRCUIT) Figure 15 Cable Overlap Figure 16 Individual Cable Conductor Figure 17 Twisting of the Cores NOTE: This document is controlled only when viewed on the DOT Engineering Standards website. Any other copy of this document is uncontrolled, and the content may be inaccurate.

49 VRIOGS Revision A 39 Figure 18 Twisting of Exposed Copper Conductors Figure 19 Assembling of Heat Shrink Tubing Figure 20 Cable Jointing Arrangement