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TELECOMMUNICATION CABLES

Telecommunication Cables

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Telecommunication Cables

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Page 1: Telecommunication Cables

TELECOMMUNICATION CABLES

Page 2: Telecommunication Cables

1

CONTENTINTrOduCTION ________________________________________________2

TELECOMMuNICATION CABLE ___________________________________3

FuLLY FILLEd, uNIT TWIN CABLE FOr SECONdArY NETWOrK (PEuT FF) _______________________________4

POLYETHYLENE INSuLATEd, 25 PAIr uNIT TWIN, MOISTurE BArrIEr SHEATHEd TELEPHONE CABLE (PEuT) _________6

POLYETHYLENE INSuLATEd MOISTurE BArrIEr SHEATHEd, uNIT TWIN TYPE, INTEGrAL BEArEr FOr AErIAL ErECTION (PEuT IB) _____________________________________9

CABLE PLASTIC TWIN PAIr, TrIPLE ANd uNIT TYPES, INTErNAL CABLE _____________________________________________11

JuMPEr WIrE ________________________________________________13

1 PAIr CABLE SELF SuPPOrTING drOP WIrE 0.63MM ANd 0.9MM ___14

2 PAIr CABLE SELF SuPPOrTING drOP WIrE 0.63MM _____________15

CABLE POLYETHYLENE INSuLATEd, uNIT TWIN, FuLLY FILLEd, MOISTurE BArrIEr SHEATHEd ___________________16

CABLE POLYETHYLENE uNIT TWIN ______________________________18

CABLE POLYETHYLENE uNIT TWIN ______________________________21

CABLE POLYETHYLENE TWIN & CABLE POLYETHYLENE TWIN - SCrEENEd _______________________24

POLYOLEFIN COPPEr CONduCTOr TELECOMMuNICATION CABLES ___25

SuPErVISOrY COMMuNICATION PILOT CABLE 250V ________________ 32

5 PAIr ANd 10 PAIr, PILOT, 1.5MM2, Cu/PE/dSTA/PVC CABLE _________ 34

SuPErVISOrY COMMuNICATION PILOT CABLE 250V ________________ 35

20 PAIr PILOT CABLES __________________________________________ 36

Page 3: Telecommunication Cables

2

INTrOduCTIONLeader Cable Industry Berhad (LCIB), incorporated in 1976, has grown steadily to become the country’s single largest cable manufacturer today since its 1990 merger with Universal Cable (M) Berhad under the flagship of its parent, Leader Universal Holdings Berhad (LEADER)

Through its far sighted planning and unceasing product and service innovation, LCIB has successfully cultivated a manufacturing profile of an extensive range of cable and wire products.

From household cables, XLPE cables, telecommunication cables for both domestic and export markets to aluminium rods and enamelled wires, LCIB has achieved a distinguished reputation as a leading supplier of power and telecommunication cables to major corporations both local and foreign.

Today, as a subsidiary of the LEADER group of companies, LCIB has one of the most advanced facilities for manufacturing telecommunication cables in the Asia Pacific region.

LCIB’s telecommunicatin cable products include internal wires, jumper wires, switchboard cables, multi-pair telephone cables and integral bearer cables. Integral bearer cables are polyethylene insulated, unit twin-type and moisture barrier sheathed. Telephone cables include P.E.U.T.F.F. (polyethylene insulated, unit twin-type, fully-filled, polyethylene sheathed) and P.E.U.T. (polyethylene insulated, unit twin-type, moisture barrier polyethylene sheathed) construction types. P.E.U.T. type telephone cables are normally used for local primary and junction network.

The telecommunication cables manufactured today by LCIB’s manufacturing processes and standards in the manufacturing of telecommunication cables.

Page 4: Telecommunication Cables

3

TELECOMMuNICATION CABLE

The diverse application environment in the telecommunication and information technology sectors requires a wide range of cable solutions. Today, two main configurations of cables are in use : paired cables and quad cables. The type of configuration used depends on the telephone system standard that is adopted by various countries. However, to satisfy different customer requirements, we have the capability to manufacture both paired and quad

configurations.

The manufacturing process of telephone cables involves several processes. However, depending on the cable specifications as provided by the customer,

certain processes may be by-passed or added.

The materials used in the manufacture of telephone cables and wires are carefully selected and controlled to ensure sustained reliable service in all products. Conductors used are annealed solid high conductivity copper which are drawn to the required sizes prior to insulation. The insulation material may be extruded solid or foam skin polyethylene. Some cables which are used in internal applications may also be insulated with polyvinyl chloride (PVC). These insulated wires are then twinned to form pairs or alternatively, four wires are twisted to form a quad configuration.

Generally, cables are then constructed from the basic insulated elements of either pairs or quads, which are twined and assembled into the

required final cable size. Customers may request for jelly-filled cables depending on their application requirements. In such specifications,

an approved electrical grade of petroleum jelly is applied to fully fill the interstices of the cable. A layer of mylar tape is then applied over the jelly-

filled cable.

Where specified by the customer, a moisture barrier sheath may be helically or longitudinally applied. Metallic screens, drain wires and rip cords can also be applied if

specified in the customer’s requirements.

The telephone cable then undergoes a final sheathing process where the outer jacket is extruded over the cable to provide protection from physical stress.

Through the use of state-of-the-art manufacturing technology that is matched by technically experienced personnel, we have been able to provide a range of well-engineered and cost effective telephone cable solutions for customers both locally and internationally.

Page 5: Telecommunication Cables

4

FuLLY FILLEd, uNIT TWIN CABLE FOr SECONdArY NETWOrK (PEuT FF)CABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe cellular insulation include a dual insulation with an inner core of cellular polyolefin and an outer skin of solid polyolefin.

Twinning / Quadding (For 2 pair cable only)Two insulated conductors twisted together to form a pair. For 2 pair cable, four insulated conductors shall betwisted together to form a compact and symmetrical quad, with insulation colour of white, red, blue and grey in order of rotation.

unit Stranding10 pair unit strandingThe cable shall comprise sub-units each of 5 or 10 pairs (except for 2 pair cable) .

Lay up Of CablesThe pairs / sub units / units shall be laid up into compact and symmetrical cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierLaminated aluminium foil shall be applied longitudinally with an overlap over the core covering. The aluminium foil shall be coated on both sides with polymer.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For 5 Pairs And 10 Pairs units

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Colour Of Binder Tapes (10 Pair units)

Unit Number Colour Of Binder Tape123456789

10

BlueOrangeGreenBrownGrey

Blue - WhiteOrange - WhiteGreen - WhiteBrown - WhiteGrey - White

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber Of Size Of Groups In Centre And

Successive LayerCentre Layer First Layer Second

Layer25

10203050

100200

1 X 21 X 5

1 X 104 X 5

3 X 101 X 104 X 54 X 5

-----

4 X 108 X 108 X 10

-------

10 X 10

Page 6: Telecommunication Cables

5

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C

Elongation after removal

from completed cables

MutualCapacitance

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

Average Pair to Pair1 Pair to Ground Minimum

(mm) (ohms/km) (ohms/km) % nF/km pF/500m pF/km Mohms.km0.40.50.630.91.27

14391582814

15096603015

1015151515

52 ± 252 ± 252 ± 252 ± 252 ± 2

200200200200200

574574574574574

1000010000100001000010000

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Cable SizeSheath Thickness Maximum Cable

Overall DiameterApproximate Cable

WeightNumber Of Pairs Conductor Diameter(pairs) (mm) (mm) (mm) (kg/km)

2 (Quad)510203050100200

2 (Quad)5102030501002001020305010020010203050100200

0.40.40.40.40.40.40.40.40.50.50.50.50.50.50.50.5

0.630.630.630.630.630.630.90.90.90.90.90.9

2.12.12.12.12.12.12.12.22.12.12.12.12.12.12.12.32.12.12.12.12.22.42.12.12.12.22.42.9

9.010.010.211.913.215.319.326.510.011.011.513.915.318.323.832.413.715.718.522.028.739.416.221.123.929.841.956.0

6080

1051552052905008906595

135205275405710

1310180290395590

10702000295505705110020603960

Page 7: Telecommunication Cables

6

POLYETHYLENE INSuLATEd, 25 PAIr uNIT TWIN, MOISTurE BArrIEr SHEATHEd TELEPHONE CABLE (PEuT)CABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe cellular insulation include a dual insulation with an inner core of cellular polyolefin and an outer skin of solid polyolefin.

TwinningTwo insulated conductors twisted together to form a pair.

unit Stranding25 pair unit stranding The cable shall comprise sub-units (12 and 13 pair groups), unit (25 pair groups) or multiple unit (50 and 100 pair groups).

Lay up Of CablesThe pairs / sub units / units / multiple units shall be laid up into compact and symmetrical cable.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierLaminated aluminium foil shall be applied longitudinally with an overlap over the core covering. The aluminium foil shall be coated on both sides with polymer.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For Pairs Within 25 Pair unit

Pair Number

Colour Of Conductor Insulation

Pair Number

Colour Of Conductor Insulation

A - Wire B - wire A - Wire B - wire123456789

10111213

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlackBlackBlack

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreen

141516171819202122232425

BlackBlackYellowYellowYellowYellowYellowVioletVioletVioletVioletViolet

BrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

25 Pairs Group Identification For Cable Up To 600 Pair

25 Pair GroupNumber Colour Pair Count Colour Of Group

Identification Tape123456789

101112131415161718192021222324

1 - 2526 - 5051 - 75

76 - 100101 - 125126 - 150151 - 175176 - 200201 - 225226 - 250251 - 275276 - 300301 - 325326 - 350351 - 375376 - 400401 - 425426 - 450451 - 475476 - 500501 - 525526 - 550551 - 575576 - 600

White - BlueWhite - OrangeWhite - GreenWhite - BrownWhite - GreyRed - Blue

Red - OrangeRed - GreenRed - BrownRed - GreyBlack - Blue

Black - OrangeBlack - GreenBlack - BrownBlack - GreyYellow - Blue

Yellow - OrangeYellow - GreenYellow - BrownYellow - GreyViolet - Blue

Violet - OrangeViolet - GreenViolet - Brown

Page 8: Telecommunication Cables

7

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C

Elongation after removal

from completed cables

MutualCapacitance

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

Average Pair to Pair1 Pair to Ground Minimum

(mm) (ohms/km) (ohms/km) % nF/km pF/500m pF/km Mohms.km0.40.50.630.9

143915828

150966030

10151515

52 ± 252 ± 252 ± 252 ± 2

200200200200

574574574574

10000100001000010000

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Multiple unit Group Identifcation For Cable More Than 600 Pairs

Multiple Units Of Pair UnitColour Of Multiple

Unit Group Identification Tape

1st 24 Groups2nd 24 Groups3rd 24 Groups4th 24 Groups

1 - 600601 - 1200

1201 - 18001801 - 2400

WhiteRed

BlackYellow

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber Of Size Of Groups In Centre And

Successive LayerCentre Layer First Layer Second

Layer100200400600800

100012001400160020002400

4 X 251 X 50

1 X 1001 X 1002 X 1003 X 1004 X 1004 X 1001 X 1002 X 1003 X 100

-6 X 256 X 50

5 X 1006 X 1007 X 1008 X 100

10 X 1005 X 1006 X 1008 X 100

--------

10 X 10012 X 10013 X 100

Page 9: Telecommunication Cables

8

Construction data

Cable SizeSheath Thickness Maximum Cable

Overall DiameterApproximate Cable

WeightNumber Of Pairs Conductor Diameter(pairs) (mm) (mm) (mm) (kg/km)

1002004006008001000120014001600200024001002004006008001000120014001002004006008001000100200

0.40.40.40.40.40.40.40.40.40.40.40.50.50.50.50.50.50.50.5

0.630.630.630.630.630.630.90.9

2.12.12.32.42.52.52.82.92.93.13.22.12.22.42.52.82.93.03.12.12.32.52.93.03.22.32.8

20.527.035.040.546.551.556.059.565.570.076.025.030.742.749.556.662.568.875.029.037.652.661.070.480.036.049.0

405720

133519352530310537204310488060657245575

1050198028853805470055906480835

1570298544105790719516453170

Page 10: Telecommunication Cables

9

POLYETHYLENE INSuLATEd MOISTurE BArrIEr SHEATHEd, uNIT TWIN TYPE, INTEGrAL BEArEr FOr AErIAL ErECTION (PEuT IB)CABLE CONSTruCTION

4. Twinning (Conductor and Insulation)

5. Cable Core6. Core Wrapping

7. Moisture Barrier

8. Sheath

1. Sheath (For Bearer)

2. Bearer Wire

3. Web

M1

M2

Conductors Plain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.

Twinning / Quadding (For 2 pair cable only) Two insulated conductors twisted together to form a pair. For 2 pair cable, four insulated conductors shall be twisted together to form a compact and symmetrical quad, with insulation colour of white, red, blue and grey in order of rotation.

unit Stranding 10 pair unit stranding The cable shall comprise sub-units each of 5 or 10 pairs (except for 2 pair cable)

Lay up Of Cables The pairs / sub units / units shall be laid up into compactand symmetrical cable.

Core WrappingThe cable core shall be covered with nonhygroscopic andnonwicking dielectric material.

Moisture Barrier Laminated aluminium foil shall be applied longitudinally with an overlap over the core covering. The aluminium foil shall be coated on both sides with polymer.

Sheath Black colour polyethylene.

Bearer Wire High tensile galvanised steel bearer wire.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For 5 Pairs And 10 Pairs units

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Colour Of Binder Tapes (10 Pair units)

Unit Number Colour Of Binder Tape123456789

10

BlueOrangeGreenBrownGrey

Blue - WhiteOrange - WhiteGreen - WhiteBrown - WhiteGrey - White

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber Of Size Of Groups In Centre And

Successive LayerCentre Layer First Layer Second

Layer25

10203050

100200400

1 X 21 X 5

1 X 104 X 5

3 X 101 X 104 X 54 X 5

1 X 100

-----

4 X 108 X 108 X 106 X 50

-------

10 X 10-

Page 11: Telecommunication Cables

10

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C

Elongation after removal

from completed cables

MutualCapacitance

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

Average Pair to Pair1 Pair to Ground Minimum

(mm) (ohms/km) (ohms/km) % nF/km pF/500m pF/km Mohms.km0.40.50.630.91.27

14391582814

15096603015

1015151515

52 ± 252 ± 252 ± 252 ± 252 ± 2

200200200200200

574574574574574

1000010000100001000010000

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Cable SizeSheath

Thickness

Bearer Wire Dimensions(Approximate) Approximate

Cable Weight

Number Of Pair

ConductorDiameter Size

Min Breaking

Load

Web Bearer Sheath

ThicknessWidth Height M1 M2

(pairs) (mm) (mm) (mm) (kN) (mm) (mm) (mm) (mm) (mm) (kg/km)2 (Quad)

510203050100200400

2 (Quad)510203050100200400

5102030501002005102030501005102030

0.40.40.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.50.630.630.630.630.630.630.630.90.90.90.90.90.91.271.271.271.27

2.12.12.12.12.12.12.12.12.32.12.12.12.12.12.12.12.22.42.12.12.12.12.12.22.42.12.12.12.12.22.42.12.12.22.3

1/2.51/2.51/2.51/2.51/2.51/2.57/1.27/1.67/2.01/2.51/2.51/2.51/2.57/1.27/1.27/1.67/2.07/2.01/2.51/2.51/2.57/1.27/1.27/1.67/2.01/2.51/2.57/1.27/1.27/1.67/2.01/2.57/1.27/1.67/2.0

5.05.05.05.05.05.011.019.030.05.05.05.05.011.011.019.030.030.05.05.05.011.011.019.030.05.05.011.011.019.030.05.011.019.030.0

2.02.02.02.02.02.02.02.53.02.02.02.02.02.02.02.53.03.02.02.02.02.02.02.53.02.02.02.02.02.53.02.02.02.53.0

1.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.51.5

1.01.01.01.01.01.01.31.51.51.01.01.01.01.31.31.51.51.51.01.01.01.31.31.51.51.01.01.31.31.51.51.01.31.51.5

14.614.916.318.320.823.629.733.545.815.315.717.520.327.428.436.141.453.416.919.022.129.731.538.648.319.222.929.234.342.753.125.131.345.456.6

8.59.0

10.112.214.717.522.125.935.19.39.811.414.219.820.826.630.742.710.612.916.020.323.830.937.612.916.721.626.633.242.418.825.735.845.9

10012514519023030552091516551101351752353304457751370237515521030543060510851965215310525695109519903205459601375

Page 12: Telecommunication Cables

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CABLE PLASTIC TWIN PAIr, TrIPLE ANd uNIT TYPES, INTErNAL CABLECABLE CONSTruCTION

Pair Type

1. Twinning (Conductor and Insulation)

2. Core Wrapping

3. Sheath

Triple Type

1. Twinning (Conductor and Insulation)

2. Core Wrapping

3. Sheath

ConductorsTinned annealed copper wire

InsulationThe insulation material shall be hard grade PVC.

Twinning / TripplingTwo or three insulated conductors twisted together to form a pair or triple.

unit Stranding10 pair unit strandingThe cable shall comprise sub-units each of 5 or 10 pairs.

Lay up Of CablesThe pairs / sub units / units shall be laid up into compact and symmetrical cable.

Core WrappingThe cable core shall be covered with binder tapes (Notapplicable for 1 pair and 3 wire cable).

SheathHard grade PVC.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Insulation Colours Of Conductors

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Cable Size Colour Of Conductor Insulation1 Pair Only Colour Of Conductor Insulation

3 Wire A-Wire: White; B-Wire: Orange; C-Wire: Green

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Colour Of Binder Tapes (10 Pair units)

Unit Number Colour Of Binder Tape123456789

10

BlueOrangeGreenBrownGrey

Blue - WhiteOrange - WhiteGreen - WhiteBrown - WhiteGrey - White

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber Of Size Of Groups In Centre And

Successive LayerCentre Layer First Layer Second

Layer25

10203050

100

1 X 21 X 5

1 X 104 X 5

3 X 101 X 104 X 5

-----

4 X 108 X 10

-------

Page 13: Telecommunication Cables

12

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C

Elongation after removal

from completed cables

MutualCapacitance

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

Average Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % nF/km pF/500m Mohms.km0.50.63

89.5556.42

91.4057.72

1520

9090

275275

300300

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Cable SizeSheath Thickness Maximum Cable

Overall DiameterApproximate Cable

WeightNumber Of Pairs Conductor Diameter(pairs) (mm) (mm) (mm) (kg/km)1 Pair

3 Wires5 Pair10 Pair20 Pair30 Pair50 Pair100 Pair

0.630.630.630.50.50.50.50.5

0.750.750.750.751.001.001.502.00

4.294.557.858.87

12.8614.1917.9824.83

25307595

175245420815

Page 14: Telecommunication Cables

13

JuMPEr WIrECABLE CONSTruCTION

1. Conductor 1. Conductor 1. Conductor

2. Insulation 2. Insulation 2. Insulation

Single Twin Triple QuinQuad

ConductorsTinned annealed copper wire

InsulationThe insulation material shall be hard grade PVC.

Twinning, Trippling, Quadding or QuinningTwo, three, four or five insulated conductors twisted together.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour And Composition Of Wires

Type Of Wire Sequence Of Stranding and Colour OfInsulation On Individual Wires

1 Wire White1 Pair Blue, White Or Orange, Red3 Wire Red, White, Green

4 Wire Quad Red, Green, White, Blue5 Wire Red, Green, White, Blue, Grey

TECHNICAL dATAElectrical Characteristics

TinnedConductorDiameter

Resistance at 20°C1

Elongationafter removal

from completed

cableNominal Nominal Maximum Minimum

(mm) (ohms/km) (ohms/km) (%)0.5 89.55 91.4 15

Notes: 1 Where resistance is measured on completed wires and additional tolerances of 1% may be allowed for twinning, trippling, quadding or quinning as applicable.

Construction data

Type Of Wires

Cond.Diam.(Nom)

InsulationThickness(Nominal)

Approx.Overall

Diameter

Approx.CableWeight

(mm) (mm) (mm) (kg/km)1 Wire

1 Pair

3 Wire

4 Wire Quad

5 Wire

0.5

0.5

0.5

0.5

0.5

0.2

0.2

0.2

0.2

0.2

0.9

1.8

1.9

2.2

2.4

2.5

5.1

7.7

10.3

12.8

Page 15: Telecommunication Cables

14

1 PAIr CABLE SELF SuPPOrTING drOP WIrE 0.63mm ANd 0.9mmCABLE CONSTruCTION

4. Twinning (Conductor and Insulation)

5. Core Wrapping

6. Sheath

1. Sheath (For Bearer)

2. Bearer Wire

3. Web

e

a

d

b

c

Conductors Plain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.Pair identification shall be White and Blue

Twinning Two insulated conductors twisted together to form a pair.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Sheath Black colour polyethylene.

Steel Bearer Wire Single galvanised steel wire.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

TECHNICAL dATA

Copper Conductor

ConductorDiameter

ConductorResistance at

20°C

Elongation after removal from thecompleted cables

Nominal Max. Average Minimum(mm) (ohms/km) (%) 0.63 0.9

5828

2525

Galvanised Steel Wire

Diameter BreakingLoad Elongation Tensile

StrengthNominal Minimum Minimum Minimum

(mm) (ohms/km) (ohms/km) (%)1.2 128 3 1110

Construction data

Descriptions

Cable Size1Pair 0.63mm 1Pair 0.90mm

Nominal Nominal(mm) (mm)

Sheath (For Bearer)Thickness, b 1.0 1.0

Sheath Thickness, d 1.0 1.0Web Dimension (HeightX Width), c 0.5 X 0.5 0.5 X 0.5

Approximate Approximate(mm) (mm)

Insulated Bearer WireDiameter, a 3.4 3.4

Sheathed Core Diameter, e 4.7 5.7Approximate Approximate

(kg/km) (kg/km)Cable Weight 37 48

Page 16: Telecommunication Cables

15

2 PAIr CABLE SELF SuPPOrTING drOP WIrE 0.63mmCABLE CONSTruCTION

4. Twinning (Conductor and Insulation)

5. Core Wrapping

6. Sheath

1. Sheath (For Bearer)

2. Bearer Wire

3. Web

e

b

d

a

c

Conductors Plain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.Pair identification shall be as below: Pair No. 1 : White and BluePair No. 2 : White and Orange

Twinning Two insulated conductors twisted together to form a pair.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Sheath Black colour polyethylene.

Steel Bearer Wire Single galvanised steel wire.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

TECHNICAL dATA

Copper Conductor

ConductorDiameter

ConductorResistance at

20°C

Elongation after removal from thecompleted cables

Nominal Max. Average Minimum(mm) (ohms/km) (%) 0.63 58 25

Galvanised Steel Wire

Diameter BreakingLoad Elongation Tensile

StrengthNominal Minimum Minimum Minimum

(mm) (ohms/km) (ohms/km) (%)1.2 128 3 1110

Construction data

Descriptions

Cable Size2 Pair 0.63mm

Nominal(mm)

Sheath (For Bearer) Thickness, a 1.0Sheath Thickness, d 1.0Web Dimension (Height X Width), c 0.5

Approximate(mm)

Insulated Bearer Wire Diameter, b 3.4Sheathed Core Diameter, e 4.6

Approximate(kg/km)

Cable Weight 62

Page 17: Telecommunication Cables

16

CABLE POLYETHYLENE INSuLATEd, uNIT TWIN, FuLLY FILLEd, MOISTurE BArrIEr SHEATHEdCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation include a dual insulation of inner foampolyethylene and an outer skin of solid polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

unit StrandingCables Below 50 Pairs:10 pair unit strandingThe cable shall comprise sub-units each of 5 or 10 pairs (except for 2 pair cable) .Cables Of 50 Pairs And Above:25 pair unit strandingThe cable shall comprise sub-units (12 and 13 pair groups), unit (25 pair groups) or multiple unit (50 and 100 pair groups).

Lay up Of CablesThe pairs / sub units / units / multiple units shall be laid up into compact and circular cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopicdielectric material.

Moisture BarrierLaminated aluminium foil shall be applied longitudinally with an overlap over the core wrapping. The aluminium foil shall have a polymer coating on the outside.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For Pairs Within 25 Pair unit

Pair Number

Colour Of Conductor Insulation

Pair Number

Colour Of Conductor Insulation

A - Wire B - wire A - Wire B - wire123456789

10111213

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlackBlackBlack

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreen

141516171819202122232425

BlackBlackYellowYellowYellowYellowYellowVioletVioletVioletVioletViolet

BrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Colour Scheme For Pairs Within 10 Pair unit

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Cables Of 50 Pairs And Above (25 Pair unit):Colour Of Tape Lappings in double and Quadruple units

Unit Position of sub-unit or unitFirst Second Third Fourth

Double Blue Blue Orange OrangeQuadruple Blue Orange Green Brown

Colour Of Tape Lappings In Centre and Layers

Position of UnitsFirst Intermediate Last

Orange Natural Green

Cables Below 50 Pairs (10 Pair unit):Colour Of Binder Tapes

Unit Number Colour Of Binder Tape1234

BlueOrangeGreenBrown

Page 18: Telecommunication Cables

17

Cable Make-up

Number Of PairsIn Cable

Cable Make UpNumber ofspare pairs

Number And Pair Size Of Units In Centre And Successive LayersNumber of Units At

The CentreNumber of Units InIntermediate Layer

Number of Units InLast Layer

4102050100200400600900120015002000

1 X 41 X 104 X 5

2 X ( 12 + 13 )4 X 251 X 50

1 X 1001 X 1004 X 50

3 X 1001 x 1004 X 50

-----

6 X 256 X 50

5 X 1007 X 1009 X 1005 X 1006 X 100

----------

9 X 10012 X 100

-----223568

10

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°CElongation after removal from

completed cables

MutualCapacitance

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

Average Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % nF/km pF/500m Mohms.km0.40.64

14356.4

15058

1015

5656

190190

60006000

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Cable SizeSheath Thickness Maximum Cable

Overall DiameterApproximate Cable

WeightNumber Of Pairs Conductor Diameter(pairs) (mm) (mm) (mm) (kg/km)

5102050100200400600900120015002000

45102050100200400600900

0.40.40.40.40.40.40.40.40.40.40.40.4

0.640.640.640.640.640.640.640.640.640.64

2.12.12.12.12.12.12.32.42.82.93.03.22.12.12.12.12.12.22.42.93.13.3

8.69.711.515.119.124.733.139.447.854.260.068.510.010.612.615.721.528.538.452.763.376.2

75100150285485875

16252355348545555630741510512018029561011152105404559308730

Page 19: Telecommunication Cables

18

CABLE POLYETHYLENE uNIT TWINCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be cellular polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

unit Stranding25 pair unit strandingThe cable shall comprise sub-units (12 and 13 pair groups), single unit (25 pair groups), double unit (50 pair groups) or quadruple unit (100 pair groups).

Lay up Of CablesThe pairs / sub units / single unit / double unit / quadruple unit shall be laid up into compact and symmetrical cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierThe moisture barrier shall consist of a longitudinally applied laminated aluminium foil. The foil shall have a polymer coating on the outside, and if specially ordered, shall have a polymer coating on the inside.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available upon request.• Armour features with reference to BT CW 1198C are available upon

request.• Spare pairs as stated in BPO CW 1236A shall be provided upon request.

Colour Scheme For Pairs Within 25 Pair unit

Pair Number

Colour Of Conductor Insulation

Pair Number

Colour Of Conductor Insulation

A - Wire B - wire A - Wire B - wire123456789

10111213

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlackBlackBlack

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreen

141516171819202122232425

BlackBlackYellowYellowYellowYellowYellowVioletVioletVioletVioletViolet

BrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Colour Of Tape Lappings in double and Quadruple units

Unit Position of sub-unit or unitFirst Second Third Fourth

Double Blue Blue Orange OrangeQuadruple Blue Orange Green Brown

Colour Of Tape Lappings In Centre and Layers

Position of UnitsFirst Intermediate Last

Orange Natural Green

Page 20: Telecommunication Cables

19

Cable Make-up

Number Of PairsIn Cable

Cable Make UpNumber ofspare pairs

Number And Pair Size Of Units In Centre And Successive LayersNumber of Units At

The CentreNumber of Units InIntermediate Layer

Number of Units InLast Layer

501002002003003004005005006006008008001000100012001200160020002400

2 X (12 + 13)4 X 254 X 501 X 501 X 50

1 X 1001 X 1003 X 50

1 X 1003 X 50

1 X 1004 X 501 X 50

3 X 1004 X 50

4 X 1003 X 1001 X 1004 X 50

3 X 100

---

6 X 255 X 508 X 256 X 507 X 508 X 509 X 50

5 X 1006 X 1005 X 50

7 X 1008 X 1008 X 1009 X 1005 X 1006 X 1008 X 100

------------

10 X 50----

10 X 10012 X 10013 X 100

00444444444444444488

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C

Elongation after removal

from completed cables

MutualCapacitance2

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

AverageMaximum for99% of cases Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % nF/km nF/km pF/500m Mohms.km0.40.50.630.9

143915828

150966030

10151515

56565659

64646465

275275275275

1500150015001500

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

2 Mutual capacitance values may be increased by 3% for cables with a nominal number of pairs less than 400.

Page 21: Telecommunication Cables

20

Construction data

Cable SizeSheath Thickness Maximum Cable

Overall DiameterApproximate Cable

WeightNumber Of Pairs Conductor Diameter(pairs) (mm) (mm) (mm) (kg/km)

50100200300400500600800100012001600200050100200300400500600800100012005010020030040050060080050100

0.40.40.40.40.40.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.50.5

0.630.630.630.630.630.630.630.630.90.9

1.61.71.81.91.92.02.12.22.32.42.62.61.61.71.92.02.12.22.22.42.52.61.71.82.02.22.32.42.52.71.82.0

16.020.526.030.535.037.540.546.551.556.065.570.019.023.530.537.042.546.049.556.562.569.022.028.037.546.052.556.561.070.527.538.0

255450830119515401895224529353625430557057050370670

12701835239029453475457556856765560

103019752880376046455545730010201930

Page 22: Telecommunication Cables

21

CABLE POLYETHYLENE uNIT TWINCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be cellular polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

unit Stranding25 pair unit strandingThe cable shall comprise sub-units (12 and 13 pair groups), single unit (25 pair groups), double unit (50 pair groups) or quadruple unit (100 pair groups).

Lay up Of CablesThe pairs / sub units / single unit / double unit / quadruple unit shall be laid up into compact and symmetrical cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierThe moisture barrier shall consist of a longitudinally applied laminated aluminium foil. The foil shall have a polymer coating on the outside, and if specially ordered, shall have a polymer coating on the inside.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available upon request.• Spare pairs as stated in BT CW 1224 Issue 6 shall be provided upon

request.

Colour Scheme For Pairs Within 25 Pair unit

Pair Number

Colour Of Conductor Insulation

Pair Number

Colour Of Conductor Insulation

A - Wire B - wire A - Wire B - wire123456789

10111213

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlackBlackBlack

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreen

141516171819202122232425

BlackBlackYellowYellowYellowYellowYellowVioletVioletVioletVioletViolet

BrownGreyBlue

OrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Colour Of Tape Lappings in double and Quadruple units

Unit Position of sub-unit or unitFirst Second Third Fourth

Double Blue Blue Orange OrangeQuadruple Blue Orange Green Brown

Colour Of Tape Lappings In Centre and Layers

Position of UnitsFirst Intermediate Last

Orange Natural Green

Page 23: Telecommunication Cables

22

Cable Make-up

Number Of PairsIn Cable

Cable Make Up Number of spare pairs in spare pair unit (If requested)

Number And Pair Size Of Units In Centre And Successive LayersCentre Layer First Layer Second Layer

501002002003003004005005006006008008001000100012001200160020002400

2 X (12 + 13)4 X 254 X 501 X 501 X 50

1 X 1001 X 1003 X 50

1 X 1003 X 50

1 X 1004 X 501 X 50

3 X 1004 X 50

4 X 1003 X 1001 X 1004 X 50

3 X 100

---

6 X 255 X 508 X 256 X 507 X 508 X 509 X 50

5 X 1006 X 1005 X 50

7 X 1008 X 1008 X 1009 X 1005 X 1006 X 1008 X 100

------------

10 X 50----

10 X 10012 X 10013 X 100

00444444444444444488

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C Conductor Elongation

MutualCapacitance2

CapacitanceUnbalance

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

AverageMaximum for99% of cases Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % nF/km nF/km pF/500m Mohms.km0.40.50.630.9

143915828

150966030

10151515

53535659

60606064

275275275275

6500650065006500

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

2 Mutual capacitance values may be increased by 3% for cables with a nominal number of pairs less than 400.

Page 24: Telecommunication Cables

23

Construction data

Cable Size Sheath Thickness With Moisture Barrier

(Minimum)

Maximum CableOverall Diameter

Approximate CableWeightNumber Of Pairs Conductor Diameter

(pairs) (mm) (mm) (mm) (kg/km)501002003004005006008001000120016002000240050100200300400500600800100012001600501002003004005006008001000120050100

0.40.40.40.40.40.40.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.50.50.5

0.630.630.630.630.630.630.630.630.630.630.90.9

1.61.61.71.81.91.92.02.12.22.32.42.52.61.61.71.81.92.02.12.12.32.42.52.61.61.71.92.02.12.22.32.52.62.71.71.9

15.519.024.528.532.035.038.043.047.551.558.564.570.017.022.028.533.537.541.544.551.556.061.569.519.525.033.539.544.549.553.561.067.573.524.532.5

215370685990

128515751860243530053585470558406955305550

104015001955241028453750463555207260440810

15602265296036654355574571108470815

1545

Page 25: Telecommunication Cables

24

CABLE POLYETHYLENE TWIN & CABLE POLYETHYLENE TWIN - SCrEENEdCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be cellular polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

Twinning / Quadding (For 2 pair cable only)Two insulated conductors twisted together to form a pair. For 2 pair cable, four insulated conductors shall be twisted together to form a compact and symmetrical quad, with insulation colour of orange, green, white and black in order of rotation.

unit Stranding10 pair unit strandingThe cable shall comprise sub-units each of 5 or 10 pairs (except for 2 pair cable) .

Lay up Of CablesThe pairs / sub units / units shall be laid up into compact and symmetrical cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierThe moisture barrier shall consist of a longitudinally applied laminated aluminium foil. The foil shall have a polymer coating on the outside, and if specially ordered, shall have a polymer coating on the inside.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available upon request.• Armour features with reference to BT CW 1198C are available upon

request.• Integral Bearer with reference to BT CW 1252 Issue 8 are available upon

request.

Colour Scheme For 5 Pairs And 10 Pairs units

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Colour Of Binder Tapes (10 Pair units)

Unit Number Colour Of Binder Tape123456789

10

BlueOrangeGreenBrownGrey

Blue - WhiteOrange - WhiteGreen - WhiteBrown - WhiteGrey - White

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber And Pair Size Of Units In

Centre And LayersCentre Layer First Layer

25

1020205050

100100100

1 X 21 X 5

1 X 104 X 5

2 X 105 X 101 X 102 X 103 X 104 X 5

------

4 X 108 X 107 X 108 X 10

Page 26: Telecommunication Cables

25

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C Conductor Elongation

MutualCapacitance2

CapacitanceUnbalance3

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Maximum

AverageMaximum for99% of cases Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % nF/km nF/km pF/500m Mohms.km0.40.50.60.630.9

14391635828

15096676030

1515151515

5656425659

6464466465

275275275275275

15001500150015001500

Notes: 1The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

2Mutual capacitance values may be increased by 3% for cables with a nominal number of pairs less than 400. 3Capacitance unbalance fo two pair (Quad) cable shall be 800pF.

Construction data

Cable Size Sheath Thickness (Minimum)

Maximum CableOverall Diameter1

Approximate CableWeightNumber Of Pairs Conductor Diameter

(pairs) (mm) (mm) (mm) (kg/km)5102050100

2 (Quad)5102050100

2 (Quad)5102050100

2 (Quad)5102050100

2 (Quad)5102050100

0.40.40.40.40.40.50.50.50.50.50.50.60.60.60.60.60.6

0.630.630.630.630.630.630.90.90.90.90.90.9

1.11.11.11.21.31.11.11.11.21.31.41.11.21.21.31.41.61.11.11.21.21.41.51.11.21.21.31.51.7

7.58.5

10.014.018.57.58.09.5

12.016.522.08.511.013.016.024.032.08.09.511.514.020.527.59.011.514.018.026.536.0

5580

12525044045751151903806805511017530063511805095

155255555

102070

155255450

10101920

Notes: 1For screened cables the maximum external diameters may be increased by 1.5mm

Page 27: Telecommunication Cables

26

POLYOLEFIN COPPEr CONduCTOr TELECOMMuNICATION CABLESCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core With Jelly Filling

3. Core Wrapping

4. Moisture Barrier

5. Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation of the conductor shall be of cellular, foamskin or solid polyolefin.

Twinning / Quadding (For 2 pair cable only)Two insulated conductors twisted together to form a pair. For 2 pair cable, four insulated conductors shall be twisted together to form a compact and symmetrical quad, with insulation colour of orange, green, white and black in rotation.

unit Stranding10 pair unit strandingThe cable shall comprise sub-units each of 5 or 10 pairs(except for 2 pair cable) .

Lay up Of CablesThe pairs / sub units / units shall be laid up into compact and circular cable.

Jelly FillingThe interstices of the cable core shall be filled with petroleum jelly compound.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

Moisture BarrierLaminated aluminium foil shall be applied longitudinally with an overlap over the core covering. The aluminium foil shall be coated on the outside with polymer.

SheathBlack colour polyethylene.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available upon request.• Armour features with reference to BS 3573 are available upon request.• Integral Bearer with reference to BS 3573 are available upon request.

Colour Scheme For 5 Pairs And 10 Pairs units

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

WhiteWhiteWhiteWhiteWhiteRedRedRedRedRed

BlueOrangeGreenBrownGreyBlue

OrangeGreenBrownGrey

Notes: 1st 5 pair is from Pair Number 1 to 5 2nd 5 pair is from Pair Number 6 to 10

Colour Of Binder Tapes (10 Pair units)

Unit Number Colour Of Binder Tape123456789

10

BlueOrangeGreenBrownGrey

Blue - WhiteOrange - WhiteGreen - WhiteBrown - WhiteGrey - White

Cable Make-up

Number OfPairs InCable

Cable Make UpNumber Of Size Of Groups In Centre

And Successive LayerCentre Layer First Layer

25

1020205050

100100100

1 X 21 X 5

1 X 104 X 5

2 X 105 X 101 X 102 X 103 X 104 X 5

------

4 X 108 X 107 X 108 X 10

Page 28: Telecommunication Cables

27

TECHNICAL dATA

Electrical Characteristics

NominalConductorDiameter

Resistance at 20°C ConductorElongation

CapacitanceUnbalance2

InsulationResistance

MaximumAverage

Maximum for 99% of cases Minimum Pair to Pair1 Minimum

(mm) (ohms/km) (ohms/km) % pF/500m Mohms.km0.40.50.60.630.9

14391635828

15096676030

1515151515

275275275275275

15001500150015001500

Notes: 1 The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

2 Capacitance unbalance fo two pair (Quad) cable shall be 800pF.

Mutual Capacitance

NominalConductorDiameter

Mutual Capacitance Of Filled Cable1 Mutual Capacitance Of Unfilled Cable1

Type Of Conductor InsulationCellular / Foam Skin Solid Solid

MaximumAverage

Maximum for99% of cases

MaximumAverage

Maximum for99% of cases

MaximumAverage

Maximum for99% of cases

(mm) nF/km nF/km nF/km nF/km nF/km nF/km0.40.50.60.630.9

5656425659

6464466465

6767566775

7575607581

5757475762

6767536769

Notes: 1For screened cables of 20 pairs or less the average mutual capacitance of the pairs shall be increased by 5%

Page 29: Telecommunication Cables

28

Construction data

NominalConductorDiameter

Filled /Unfilled

Cable Size SheathThickness(Minimum)

Maximum Cable Overall

Diameter

Approximate Cable WeightNumber Of

PairsConductorDiameter

(pairs) (mm) (mm) (mm) (kg/km)Foam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam SkinFoam Skin

FilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilled

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

100

0.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.60.60.60.60.60.60.60.60.630.630.630.630.630.630.630.630.90.90.90.90.90.90.90.9

1.11.11.11.21.21.31.31.11.11.11.21.21.31.31.41.11.21.21.31.31.41.51.61.11.11.21.21.31.41.41.51.11.21.21.31.41.51.61.7

7.58.510.012.014.016.518.57.58.09.512.014.016.519.022.08.511.013.016.019.024.027.532.08.09.511.514.016.520.524.527.59.011.514.018.021.526.532.536.0

55851251752553554504575110180245375525680551101803054206509301205

50951552603655658001040

70155255455650102514851950

Page 30: Telecommunication Cables

29

Construction data

NominalConductorDiameter

Filled /Unfilled

Cable Size SheathThickness(Minimum)

Maximum Cable Overall

Diameter

Approximate Cable WeightNumber Of

PairsConductorDiameter

(pairs) (mm) (mm) (mm) (kg/km)CellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellularCellular

FilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilled

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

100

0.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.60.60.60.60.60.60.60.60.630.630.630.630.630.630.630.630.90.90.90.90.90.90.90.9

1.11.11.11.21.21.31.31.11.11.11.21.21.31.31.41.11.21.21.31.31.41.51.61.11.11.21.21.31.41.41.51.11.21.21.31.41.51.61.7

7.58.510.012.014.016.518.57.58.09.512.014.016.519.022.08.511.013.016.019.024.027.532.08.09.511.514.016.520.524.527.59.011.514.018.021.526.532.536.0

5580125170245345435457511017524036551566055110175300410635910117550951552553555507851015

70150255445640101014651915

Page 31: Telecommunication Cables

30

Construction data

NominalConductorDiameter

Filled /Unfilled

Cable Size SheathThickness(Minimum)

Maximum Cable Overall

Diameter

Approximate Cable WeightNumber Of

PairsConductorDiameter

(pairs) (mm) (mm) (mm) (kg/km)SolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolid

FilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilledFilled

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

100

0.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.60.60.60.60.60.60.60.60.630.630.630.630.630.630.630.630.90.90.90.90.90.90.90.9

1.11.11.11.21.21.31.31.11.11.11.21.21.31.31.41.11.21.21.31.31.41.51.61.11.11.21.21.31.41.41.51.11.21.21.31.41.51.61.7

7.58.510.012.014.016.518.57.58.09.512.014.016.519.022.08.511.013.016.019.024.027.532.08.09.511.514.016.520.524.527.59.011.514.018.021.526.532.536.0

5580125170250355450457511018024537552568050105165280385595855110550951552603655708101050

65150250445640101014651915

Page 32: Telecommunication Cables

31

Construction data

NominalConductorDiameter

Filled /Unfilled

Cable Size SheathThickness(Minimum)

Maximum Cable Overall

Diameter

Approximate Cable WeightNumber Of

PairsConductorDiameter

(pairs) (mm) (mm) (mm) (kg/km)SolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolidSolid

UnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilledUnfilled

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

1002 (Quad)

51020305075

100

0.40.40.40.40.40.40.40.50.50.50.50.50.50.50.50.60.60.60.60.60.60.60.60.630.630.630.630.630.630.630.630.90.90.90.90.90.90.90.9

1.11.11.11.21.21.31.31.11.11.11.21.21.31.31.41.11.21.21.31.31.41.51.61.11.11.21.21.31.41.41.51.11.21.21.31.41.51.61.7

7.58.510.012.014.016.518.57.58.09.512.014.016.519.022.08.511.013.016.019.024.027.532.08.09.511.514.016.520.524.527.59.011.514.018.021.526.532.536.0

5070110145220305390356090155210320445575458513523031549070090540801302203054756758806013021538554586512501635

Page 33: Telecommunication Cables

32

SuPErVISOrY COMMuNICATION PILOT CABLE 250VCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core3. Core Wrapping

5. Bedding4. Screen

6. Armour7. Outer Sheath

ConductorsTinned annealed copper wire

InsulationThe insulation material shall be solid polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

Lay up Of CablesThe pairs shall be laid up into compact and symmetricalcable core.

Core WrappingThe cable core shall be covered with nonhygroscopic and nonwicking dielectric material.

ScreenAluminium tape shall be applied with an overlap overthe core covering.

BeddingBlack colour PVC with termite repellent additives.

ArmourGalvanised Steel Wires

SheathBlack colour PVC with termite repellent additives.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For Pairs Arrangement For 19 Pairs and 37 Pairs Cable

Layer Pair Number

Colour Of Conductor InsulationA - Wire B - wire

Center Layer 1 Black Red1st Layer 2

34567

BlackBlackBlackBlackBlackBlack

BlueWhiteGreenYellowBrownGrey

2nd Layer 89

10111213141516171819

BlackBlackRedRedRedRedRedRedRedRedBlueBlue

OrangeVioletBlueWhiteGreenYellowBrownGrey

OrangeVioletWhiteGreen

3rd Layer 202122232425262728293031323334353637

BlueBlueBlueBlueBlueWhiteWhiteWhiteWhiteWhiteWhiteYellowGreenGreenGreenGreenYellowYellow

YellowBrownGrey

OrangeVioletGreenYellowBrownGrey

OrangeVioletGrey

BrownGrey

OrangeVioletBrownGreen

Page 34: Telecommunication Cables

33

TECHNICAL dATA

Electrical Characteristics

Nominal ConductorDiameter

Conductor Resistance

at 20°C

InsulationResistance Mutual Capacitance Capacitance Unbalance

Pair to Pair1

(Max.) (Min.) (Max.) (Max.)mm ohms/km Mohm.km nF/km pF/161m

0.914 27.04 10000 60 200Notes: 1The measure values shall be divided by 1/2 [ L/161 + Ö(L/161) ], where L is the length in meters of the cable under test. Length less than 100 meters being

considered as 100 meters.

Construction data

Number ofPairs

NominalConductorDiameter

InsulationThickness

(Min.)

Armour WireDiameter(Nominal)

Approximate Cable

Overall Diameter

ApproximateCable Weight

Breakdown TestVoltage For 1

Minutemm mm mm mm kg/km kV DC

37371937

0.9140.9140.9140.914

0.5080.80.80.8

1.626222

39.543.537.647.9

2440295023253335

10102525

Notes: 1For screened cables of 20 pairs or less the average mutual capacitance of the pairs shall be increased by 5%

Page 35: Telecommunication Cables

34

5 PAIr ANd 10 PAIr, PILOT, 1.5mm2, Cu/PE/dSTA/PVC CABLECABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core (Application of fillers at manufacturer’s discretion)3. Core Wrapping

5. Screen4. Inner Sheath

6. Bedding7. Armour7. Outer Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

Lay up Of CablesThe pairs shall be laid up into compact and symmetrical cable core.

Core WrappingThe cable core shall be covered with nonhygroscopic andnonwicking dielectric material and polyethylene tape.

Inner SheathBlack colour polyethylene.

ScreenCopper tape shall be applied with an overlap over theinner sheath.

BeddingBlack colour polyethylene.

ArmourGalvanised steel tape armour.The two layers shall be laid on helically with a left hand lay so that the outer tape is approximately central over the gap of the inner tape.

SheathBlack colour PVC with termite repellent additives.

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For 5 Pairs And 10 Pairs units

Colour Block

Pair Number

Colour Of Conductor InsulationA - Wire B - wire

BaseColour

Line, Rings

orHelices

BaseColour

Line, Rings

orHelices

1

12345

WhiteWhiteWhiteWhiteWhite

-OrangeGreenBrownGrey

BlueOrangeGreenBrownGrey

-----

2

6789

10

RedRedRedRedRed

-OrangeGreenBrownGrey

BlueOrangeGreenBrownGrey

RedRedRedRedRed

Notes: Use only colour block 1 for 5 pair pilot cableNotes: Use both colour block 1 and colour block 2 for 10 pair pilot cable

TECHNICAL dATA

Electrical Characteristics

ConductorSize

ConductorResistant at 20°C

InsulationResistance

CapacitanceUnbalancePair to Pair1

(Max.) (Min.) (Max.)mm2 ohms/km Mohm.km pF/500m1.5 12.1 1500 275

Notes: 1 The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Descriptions Unit Pilot CableNumber of pairs 5 10Conductor Size mm2 1.5 1.5Insulation Thickness(Min.) mm 0.8 0.8

Armour TapeThickness (Nominal) mm 0.5 0.5

Approximate CableOverall Diameter mm 27.5 33

Approximate CableWeight kg/km 1080 1520

Breakdown Test Voltage for 2 seconds kV DC 12 12

Page 36: Telecommunication Cables

35

SuPErVISOrY COMMuNICATION PILOT CABLE 250VCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core (Application of fillers at manufacturer’s discretion)

3. Core Wrapping

5. Bedding4. Screen

6. Armour7. Outer Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

Lay up Of CablesThe pairs shall be laid up into compact and symmetrical cable.

Core WrappingThe cable core shall be covered with nonhygroscopic andnonwicking dielectric material.

ScreenLaminated aluminium foil shall be applied longitudinally with an overlap over the core covering.

BeddingBlack colour polyethylene.

ArmourGalvanised Steel Wires

SheathBlack colour PVC

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For 10 Pair

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

10

RedWhiteBlackVioletBlackVioletBlackVioletBlackViolet

WhiteBlue

YellowOrange

RedGreenGreenBrownWhiteBlue

TECHNICAL dATA

Electrical Characteristics

Descriptions UnitConductor Diameter mm 1.13Conductor Resistanceat 20°C (Max.) ohms/km 18.4

Mean Mutual Capacitance(Max.) nF/km 50

Insulation Resistance (Min.) Mohm.km 40000Capacitance Unbalance- Pair to Pair 1 (Max.) pF/500m 500

Notes: 1 The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ], where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Descriptions Unit Pilot CableNumber of pairs 10Conductor Diameter mm 1.13Insulation Thickness(Min.) mm 0.5

Armour Wire Diameter(Nominal) mm 1.6

Approximate CableOverall Diameter mm 25.8

Approximate CableWeight kg/km 1230

Voltage Withstand Testsfor 1 minute kV ac 5

Page 37: Telecommunication Cables

36

20 PAIr PILOT CABLESCABLE CONSTruCTION

1. Twinning (Conductor and Insulation)

2. Cable Core (Application of fillers at manufacturer’s discretion)

3. Core Wrapping

5. Bedding4. Screen

6. Armour7. Outer Sheath

ConductorsPlain annealed copper wire

InsulationThe insulation material shall be solid polyethylene.

TwinningTwo insulated conductors twisted together to form a pair.

Lay up Of CablesThe pairs shall be laid up into compact and symmetricalcable.

Core WrappingThe cable core shall be covered with nonhygroscopic andnonwicking dielectric material.

ScreenLaminated aluminium foil shall be applied longitudinally with an overlap over the core covering.

BeddingBlack colour polyethylene.

ArmourGalvanised Steel Wires

SheathBlack colour PVC

Notes: • Anti termite and anti rodent are available upon request.• Special insulation and sheath colour are available

Colour Scheme For 20 Pair

Pair NumberColour Of Conductor InsulationA - Wire B - wire

123456789

1011121314151617181920

BlueBlueWhiteYellowWhiteYellowOrange

BlueWhiteYellowWhiteYellowWhiteYellowWhiteYellowWhiteYellowWhite

Orange

RedBlackBlackBlackBlackBlackBlackRedRedRedRedRedRedRedRedRedRedRedRedRed

TECHNICAL dATA

Electrical Characteristics

Descriptions UnitConductor Diameter mm 1.13Conductor Resistanceat 20°C (Max.) ohms/km 18.4

Mean Mutual Capacitance (Max.) nF/km 40Insulation Resistance (Min.)Capacitance Unbalance Mohm.km 40000

- Pair to Pair 1 (Max.) pF/500m 500Notes: 1 The measure values shall be divided by 1/2 [ L/500 + Ö(L/500) ],

where L is the length in meters of the cable under test. Length less than 100 meters being considered as 100 meters.

Construction data

Descriptions Unit Pilot CableNumber of pairs 20Conductor Diameter mm 1.13Insulation Thickness(Min. Average) mm 0.8

Armour Wire Diameter(Nominal) mm 1.6

Approximate CableOverall Diameter mm 37.6

Approximate Cable Weight kg/km 2190Voltage Withstand Testsfor 1 minute kV ac 15

Page 38: Telecommunication Cables

Leader Cable Industry Berhad (26936-P)

Lot 1385, Tikam Batu Industrial Estate 08600 Sungai Petani, Kedah, MalaysiaTel: 604-438 9988 Fax: 604-438 8497 www.leadercable.com.my

Selangor Sales OfficeUnit 8.2, Level 8, Building A, Peremba Square Saujana Resort, Seksyen U2 40150 Shah Alam, Selangor, Malaysia.Tel: 603-7845 7788/6699 Fax: 603-7845 2258/8323