August 8, 2014

Telecommunications Basics

Introducing Each Other

Who I am,

Where I am from,
My experience,
Why I am here!

Telecommunications Basics

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Learning Objectives
At the end of this training, you will be able to
Use Jointing tools properly;
Select appropriate jointing materials;
Joint cables as per the given jointing plan;
Joint cables using Scotchlok (UY, UR) connectors.
Joint cables using Modular (4000-D, 4005DPM) connectors;
Make closure for the joints using a heat shrink closure;
Test cables for continuity, Insulation resistance and other
passible faults faults after jointing

Telecommunications Basics

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Methodology
Theory
Practical training

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Time schedule

Duration: 10 days

9:00 AM - 5:30 PM
Tea break:
10:30-10:45 AM

3:30-3:45 PM
Lunch break:
12:30 AM-1:30 PM

Telecommunications Basics

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Expectation

What do you expect from this

training?

Telecommunications Basics

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Ground Rules for Success

Lets set ground rules together

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Module 4: Cable Jointing

August 8, 2014

Telecommunications Basics

Course objectives
At the end of this module the trainee will be able to:
Use Jointing tools properly;
Select appropriate jointing materials;
Identify types of telephone cables and their constructional feature;
Differentiate color code of telephone cables;
Terminate cables in cross connection cabinet (CCC) and terminal boxes (TB);
Joint cables as per the given to the given jointing plan;
Joint cables using Scotchlok (UY, UR) connectors.
Joint cables using using Modular (4000-D, 4005DPM) connectors;
Make closure for the joints using a heat shrink closure;
Test cables for continuity and different faults after jointing;
Identify pairs of a cable using pair identifier;
Perform insulation test after jointing using insulation tester;
Observe maintenance procedure of a joint;

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I. Introduction to Jointing
Definition
.

When do we need jointing

Whenever more than one cable drum length is required for laying:
When a certain part of a cable is to be replaced Or rehabilitated
When a fault occurs in a cable
When branching of cables is necessary
When

Major jointing steps:

There are three major steps in jointing:

Preliminary Operations
Cable jointing pit should be so dug that the overlapping portion of
the cable to be jointed is roughly in the middle of the pit.
The cable pit should be kept dry and clean before cable is opened.
The overlap for the joint should be about 1.5 times the length of the
closure to be used.

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Introduction to Jointing contd

Conductor Jointing: In general, there are different methods of Conductor jointing. But
in this course only two types of methods will be covered. These are:
Scotchlok (UY, UR) Connectors and Modular Connectors
Thew scotchlok connector ensure a reliable electrical connection and no need of wire insulation
stripping. It connects two or three wire conductors. Scotchlok butt connectors include a factoryinstalled sealant to protect against corrosion and seal out moisture. The two types of Scotchlok
connectors that are of our interest are the UY and UR connectors.

The modular connector connects 25 pairs at the same time. Modules are available in pluggable and
splicing versions. Pluggable modules allow interruption-free transfer of circuits. the three commonly
used types of Modular connectors are; 4000 (for straight) 4005 (for cutover joint) and 4008 series
(for half tap joint.
Cable Joint closure

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Introduction to Jointing contd

a. 4000 series Super-Mini Module: This module is used for two
wires straight splicing. The module cover, body and base are
color coded ivory and gold respectively.

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Introduction to Jointing contd

b. 4005 Super mate pluggable Module: This module increases
productivity and reduce expense by avoiding the time and cost
intensive job of cutting and re-splicing conductors for
rearrangement, addition and removal of cables. You can make
changes of 25 pairs at a time without cutting or re-splicing the
conductors into new modules.

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Introduction to Jointing contd

c. The 4008 Super-Mini Modules are similar to the 4000 modules,
but without the cut-off blades in the bottom of the module
body. The through wires of a half-tap application are
electrically connected to the tap wires, but not cut off by the
module. The 4008 body bottom and base are colored green for
identification.

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Introduction to Jointing contd

Tools required for cable jointing
No.

Tools

1 Crowbar
2 Spade
3 Shovel
4 Tent (complete)
5 Megger,500V
6 Tool Box
7 Hack saw
8 Cutting plier
9 wire nipper
10 Hack knife
11 clasp Knife
12 File rasp
13 File(triangular)
14 Screw driver
15 Hammer Large
16 Hammer small
17 Chisel
18 Adjustable spanner
19 Brass rule
20 Dividers
21 Measuring tape

Purpose

For digging of pit

For digging of pit
For digging of pit
For protection of joint
For cable testing
For keeping tools
For cutting steel armor
For removing armor
For removing wire insulation and cutting conductors
For marking
for cleaning the sheath, cutting thread etc.
For removing the rough surface
For smooth finish
For terminating cable
For Cutting
For Cutting
For Cutting
For tightening of nuts
For measurements
For marking etc.
For measuring the length of cable
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Introduction to Jointing contd

Cable Jointing Material

1. Jointing Box

5. Kerosene Oil

2. Jointing Kit

6. Copper Wire

3. PVC Sleeves

7. Emery Paper

4. Resin Core

8. Fire Wood

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Introduction to Jointing contd

Jointing kits
Different types of kits are used according to size of cable. Each
kit contains following contents:
1.Heat-shrinkable sleeve

9. Cleaning liquid kit

2. Stainless steel channel

10. Sealant tape

3. Retention clip

11. Transparent PE sheet

4. Aluminum canister

12. Splice filling compound

5. Branch-off clip

13. Cleaning tissue

6. Sheath connector assembly

14. Emery strip

7. Adhesive aluminum foil

15. Armor continuity wire

8. PVC tape

16. Adhesive polyester tape

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Introduction to Jointing contd

Size of TSF joint kit can be selected according to cable size as
shown in table below.

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4.2 Jointing of Jelly filled (JF) Cables using Scotch lock

connectors (UY & UR)
4.2.1 Cable Preparation and jointing Procedures
1. Dug a pit and erect a tent over it. Keep the cables to be jointed about 50 cm above
the ground level. Select suitable size of kit according to size of cables.
2. Dug a pit and erect a tent over it. Keep the cables to be jointed about 50 cm above the
ground level. Select suitable size of kit according to size of cables.
3. Remover outer sheath up to M2. For armored cables remove armor and bedding up to
15 mm, LESS THAN M2.
4. Position aluminum canister centrally and mark the Crown ends as M3.
5. Remove poly-al-sheath up to M3. Retain the identification marker .
6. Make two 10 mm wide parallel cuts on poly-al-sheath.
7. Crimp the main sheath connector to poly-al-sheath of either cable .

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Cable Preparation and jointing Procedures contd

8. In branch joints, crimp the auxiliary sheath connector to the poly-al-sheath of the
branch cables. Interconnect the assembly using the bridge clip.
9. Stretch and wrap sealant tape under and over the sheath connector clips.
10. Adjust the splice length by positioning the canister.
11. Twist corresponding pairs and cut off excess length. Remember to stagger the pairs
as shown above.
12. Splice the conductors using suitable wire connectors.
13. Splice bundle.
14. Affix transparent PE sheet on to the sealant tape and secure the ends with PVC Tape
15. Fill the splice bundle with splice filling compound.

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Cable Preparation and jointing Procedures contd

16. Wrap the PE sheet over the splice bundle and squeeze the filling compound
uniformly.
17. Apply PVC tape, with half overlap, firmly from middle of the splice bundle up to
one end, continue to apply in the opposite direction up to the other end and travel
back to the middle.
18. Filled splice bundle.
19. Install aluminum canister around the splice bundle, such that the parting lines of the
canister are on the sides.
20. Apply one round of PVC tape in the middle to hold the canister. Apply one layer of
PVC tape on the canister partition line. Apply two layers of PVC tape starting from
the crown and ending a little beyond the canister finger ends.
21. Centre the thermo-shrink sleeve and mark the ends. The surface between the ends
of the canister and this mark is bonding surface.

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Cable Preparation and jointing Procedures contd

22. Clean the bonding surface with cleaning tissue. Don not touch the surface after
cleaning.
23. Abrade the bonding surface using abrasive strip. Do not touch the surface after
abrading.
24. Wrap the adhesive aluminum foil around the cable by keeping ONLY 15 mm OF
COIL INSIDE THE BONDING SURFACE.
25. Flame brush the bonding surface till it becomes slightly glossy. DO NOT
OVERHEAT.
26. Remove protective film from the thermo-shrink sleeve.
27. Position thermo-shrink sleeve centrally and insert stainless steel channel(s) through
the rails. Ensure that the channel(s) is/are on the top.
28. Insert channel retention clip over the channel joint, where two channels have been
used.
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Cable Preparation and jointing Procedures contd

28. In case of branch offs, position the branch off clip(s) as shown in the
illustration , ensure that the channel comes on the largest cables.
29. Insert branch off clips between the cables on the thermo-shrink sleeve.
Ensure that the branch off clip(s) is/are perpendicular to the plane of the
cables. The thermo-shrink sleeve should be evenly distributed over all the
cables.
30. Start thermo-shrink from the middle to either side, in branch joints shrink
the side with the lesser number of cables first.
31. Tap the channel gently at the transition points adjacent to the canister
crown. Thermo-shrinking is complete when the thermo-chromic paint
changes color and the adhesive oozes from the ends.
32. Tap the channel gently at the transition points adjacent to the canister
crown. Thermo-shrinking is complete when the thermo-chromic paint
changes color and the adhesive oozes from the ends.

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Cable Preparation and jointing Procedures contd

33. Concentrate the flame on the metal part of the branch off clip till the
adhesive on the clip(s) melts and oozes out. Post heat the channels with a
moving flame for 15 seconds.
34. Wind three rounds of the armor continuity wire over the exposed armor and
solder it. Wrap one layer of sealant tape and apply three layers of polyester
tape.
35. Allow the joint to cool for 15 minutes before handling. Complete joint is
shown below.

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4.3 Jointing of Jelly filled (JF) Cables using Modular connectors

4.3.1 Necessary Tools and Modules
a. Rig set
b. Crimping tool
c. Modules
4.3.1.1 Rig set-up
Attach support tube to cable

Attach buckle

Tighten strap.
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Rig set-up contd

Attach traverse clamp assembly.

Slide head clamp on traverse bar.

Insert pedestal with splice head or heads in head

clamp. Double splice head is shown.

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Introduction to Jointing contd

Locate splice head
a. Splice, back-bottom group first

b. For inline splicing, adjust head(s) to

group being handled.
c. Splice head should be higher than
group being spliced

Set retainer spring to proper wire

gauge.

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Introduction to Jointing contd

In the 4041 Splice Head, the gold splice adapter is used
with the Super-Mini Modules only.
Wire Placement in Module
Note: Follow Color Code.
Using Super-Mini Module Install base
Using Super-Mate Module Install body/
Insulator

Follow the color code according to the

white wire guides. Wire pair to right side of
corresponding color coded wire guide. Separate
pair over pair separator, TIP (A) left and RING
(B) right.

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Introduction to Jointing contd

Check for correct wire placement
using the orange check comb.

Install module cover.

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Introduction to Jointing contd

Select a 25-pair group and place wires
in module.
Draw wires snug into wire channels in
module.
Secure in retainer springs.
Thumb placed too far from splice head
rear could cause twist in pair, resulting
in a shiners.
Make sure all wires are lying flat in

module channel.
Look for empty channels, 2 wires in one
channel or reversed pairs with the
check comb.
Slide comb left, only TIP (A) wires should
show. Slide comb right, only RING (B)
wires should show.
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3M MS2 Hand Hydraulic Crimper 403625 contd

4.3.1.1 3M MS2 Hand Hydraulic Crimper
403625
The 4036-25 crimper is a self-contained, pistolgripped crimper designed to crimp 3M MS2
Splicing and Pluggable Modules 4000-D and
4005DPM series.
a. Rapid advance lever
b. Fixed handle
c. Moveable handle
d. Release trigger
e. Press bar
f. Ball plungers

Use standard MS2 splicing practice to prepare

cable, set up splice head, and wire module.
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3M MS2 Hand Hydraulic Crimper 403625 contd

Place crimper rockers into yoke of splice head.
Rotate crimper until it locks into upright position.
Adjust ball plungers (indicated by arrows) in or out with
standard Screw driver if necessary to allow rotation
and locking.
Using rapid advance lever, advance press bar until it
presses down firmly on the module

Pump handle until pressure bypass operates,

indicating module is fully crimped.

Remove cut off conductors by lifting straight up from

retainer spring and pulling gently.
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3M MS2 Hand Hydraulic Crimper 403625 contd

Pull release trigger to reset press bar.

Remove crimper by reversing rotation

described above. Remove module from splice
head.

Periodically (about every 1000 cycles)

lubricate moving parts of the rotating handle
with a lightweight machine oil or water
displacing lubricant.

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3M MS2 Hand Hydraulic Crimper 403625 contd

To guard against general corrosion, spray
blackened steel surfaces with a lightweight
machine oil or water displacing lubricant.
This is especially important before extended
periods of storage.
Note: Carefully follow safety, health and environmental information
given on product label or the MSDS sheet.

Crimpers may be cleaned by brushing carefully

with a citrus-based cleaning solution.
Do not immerse the entire crimper in the solution.
After cleaning, wipe dry and lubricate as described
in preceding paragraphs.
Note: Carefully follow safety, health and environmental information
given on product label or the MSDS sheet.

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Module Types
Module Description
Modules:
Connect and cut off up to 25 pairs of conductors from both the CO
and field at one time, without the craftsperson having to strip
insulation.
Accept size (0.32 - 0.6 mm) solid copper conductors insulated with
PIC, pulp or paper with a maximum insulation O.D. of 1.35 - 1.7 mm).
Accept a mixture of wire gauges and insulation types in one module.
The modules have:
Individual elements
Individual cutoff blades
Test entry ports
Removable covers and bases for reentry
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Introduction to Jointing contd

The three commonly used modules are:
1 Super-Mini 3M MS2 Super Mini Test Module 4000D/TR

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Introduction to Jointing contd

2 Half-Tapping 3M MS2 Super Mini Half-Tap Module 4008 D/TR

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Introduction to Jointing contd

3 Super-Mate Pluggable 3M MS2 Super Mate Pluggable Module
4005-DPM/TR

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Thanks!