DPNS 35-1:2013 ICS 29 - inmetro.gov.br · DPNS 35-1:2013 ICS 29.060 ... Polyvinyl Chloride (PVC) insulated flexible cords and fixture ... PNS 661:2009 - Plasticized polyvinyl chloride

DPNS 35-1:2013 ICS 29.060

Electric wires and cables - Thermoplastic-insulated copper wires and cables rated 600 volts - Part 1: General specifications

PHILIPPINE NATIONAL STANDARD DPNS 35-1: 2013 Contents

Tables

1 Insulation characteristics of type TW, 60°C, 600 volts wire

4

2 Insulation characteristics of type THW, 75°C, 600 volts wire . . . . . . . . . . . . . . . . . . . .

5 3 Insulation characteristics of

type THWN, 75°C, 600 volts wire . . . . . . . . . . . . . . . . . . . .

6 4 Insulation characteristics of

type THHN, 90°C, 600 volts wire . . . . . . . . . . . . . . . . . . .

7 5 Physical properties of type

TW wires . . . . . . . . . . . . . . . .


THW wires . . . . . . . . . . . . . . .


THWN wires . . . . . . . . . . . . . .


THHN wires . . . . . . . . . . . . . .

11 9 Temperature correction factor 12 10 Specimen loading . . . . . . . . . 16 11 Sampling scheme . . . . . . . . . 18

1 Scope . . . . . . . . . . . . . . . 2 References . . . . . . . . . . . 3 Definitions . . . . . . . . . . . 4 General requirements . . . 4.1 Material . . . . . . .. . . . . . . 4.2 Insulation thickness. . . . . 4.3 Performance and other

requirements . . . . . . . . 5 Test methods . . . . . . . . . 5.1 Insulation thickness . . . . 5.2 Dielectric withstand

voltage. . . . . . . . . . . . . . . 5.3 Insulation resistance . . . . 5.4 Accelerated aging test. . . 5.5 Tensile strength and elongation of insulation. . 5.6 Flame retardance . . . . . . 5.7 Heat shock . . . . . . . . . . . 5.8 Heat deformation . . . . . . 5.9 Oil resistance . . . . . . . . . 5.10 Wrap test of nylon jacket 6 Sampling . . . . . . . . . . . . . 7 Testing and frequency of test . . . . . . . . . . . . . . . 7.1 Routine tests . . . . . . . . . . 7.2 Type test . . . . . . . . . . . . . 8 Marking . . . . . . . . . . . . . .

1 1 1 3 3 3 3 3 3 3

1212

1314161617

17

18181819

Figures 1 Die cut specimen . . . . . . . . . .

14 2 Vertical Flame Test Setup . . . 15

PHILIPPINE NATIONAL STANDARD DPNS 35-1: 2013 Foreword This Philippine National Standard, Electric wires and cables - Thermoplastic-insulated copper wires and cables rated 600 volts - Part 1: General specifications, was prepared by the Bureau of Product Standards’ Technical Committee on Electric Wires and Cables, BPS/TC01. This 2013 edition comprises the consolidated PNS 35-1: 2004 edition and amendment 1: 2009 edition. Below are the significant technical changes with respect to the previous editions:

Clause/Sub-clause

Modification

Clause 1: Scope Indicated for building wires application

sub-clause 1.2 Indicated the exclusion of Composite and/or mixture of conductors in the scope

sub-clause 3.15 Include the definition of composite conductor

sub-clause 4.1.1 Indicated the PNS 1207 for stranded conductors

sub-clause 4.3.2 Replace “clause 6” in to “clause 5”

sub-clause 4.3.3 Inclusion of Length Requirement

sub-clause 5.2.1 Figure for Construction of spark tester and connection circuit was deleted

sub-clause 5.5.1 Figure for Die-cut specimen becomes Figure 1

sub-clause 5.6.1 - “0.349 radians“ is converted to “20 degrees“

- Figure 2 is referred to as Vertical Flame

Test Setup

sub-clause 5.6.2.1 - the paper indicator is specifically indicated as kraft-paper indicator

- distance of combustible material from

the tip of inner blue cone of the flame is specified

sub-clause 5.6.3.3 Test criteria for the combustible material is

included sub-clause 5.7.1 “120 °C ± 1 °C” is changed to “121 °C ± 1

°C” sub-clause 5.8.1 and 5.8.4 The following are modified;

- “135 °C ± 1 °C” into “136 °C ± 1 °C” - “120 °C ± 1 °C” into “121 °C ± 1 °C”

sub-clause 5.10.2 Requirements for the removal of specimen

from the desiccator are included.

Tables 1 to 4 - Inclusion of insulation properties for 300 mm2 nominal sectional area

Tables 6 - modification on the requirement of

tensile strength of unaged specimen - modification on the requirement of

elongation of aged specimen

Table 8 modification on the requirement of tensile strength and elongation of aged specimen

Clause 7: Testing and frequency of test Inclusion of Testing and frequency of test

References

- Differentiation of Normative references and Bibliography - Inclusion of UL 83:2005

DPNS 35-1:2013

PHILIPPINE NATIONAL STANDARD DPNS 35-1: 2013 Electric wires and cables - Thermoplastic-insulated copper wires and cables rated 600 volts - Part 1: General specifications 1 Scope

1.1 This standard specifies requirements for thermoplastic-insulated wires and cables covering copper conductor of 2.0 mm² up to 500 mm² rated 600 volts for building wires application. 1.2 The following are not covered by this standard: a) Polyvinyl Chloride (PVC) insulated flexible cords and fixture wires; b) Type UF (underground feeders) and NM (non-metallic) wires; c) Wires and cables employing conductor less than 2 mm² and larger than 500 mm² in

cross-sectional area; d) Wires and cables for use at potentials more than 600 volts, and; e) Wires and cables with composite conductors. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. PNS 260:2004 - Annealed copper wires - Specification PNS 661:2009 - Plasticized polyvinyl chloride compounds for electrical insulation - Specification PNS 1207:2006 and amd1:2009 - Soft drawn (Annealed) copper stranded conductors for electrical purposes - Specification UL 83:2005 - Thermoplastic – Insulated Wires and Cables 3 Definitions For the purpose of this standard, the following terms and definitions apply: 3.1 cable a stranded conductor with or without insulation and other coverings 3.2 type TW insulation a moisture-resistant thermoplastic (PVC) insulation suitable for the type of service where conductor temperature does not exceed 60°C in dry or wet location

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DPNS 35-1:2013

3.3 type THW insulation a heat-and moisture-resistant thermoplastic (PVC) insulation suitable for the type of service where the conductor temperature does not exceed 75°C in dry or wet location 3.4 type THWN insulation a heat-and moisture-resistant thermoplastic (PVC) insulation with nylon jacket suitable for the type of service where the conductor temperature does not exceed 75°C in dry and wet location 3.5 type THHN insulation a heat-resistant thermoplastic (PVC) insulation with nylon jacket suitable for the type of service where the conductor temperature does not exceed 90°C in dry location or 75°C in wet location. 3.6 conductor a material usually in the form of a wire or cable suitable for carrying electric current 3.7 bare conductor a conductor with no covering or insulation 3.8 insulated conductor a conductor covered with an insulation 3.9 solid conductor a conductor consisting of a single wire 3.10 stranded conductor a conductor composed of a group of wires or any combination of wire groups 3.11 dielectric strength the capability of the insulation of a finished wire or cable to withstand without breakdown the application of a test potential under specified conditions 3.12 insulation a non-conducting material used to serve as barrier between energized parts of an electric circuit thereby confining the flow of electric current to the conductor 3.13 jacket a protective covering over the insulation 3.14 wire a slender rod or filament of drawn metal. (The definition restricts the term to what would ordinarily be understood by the term “solid wire”. The sense is that the length is longer in comparison with the diameter. If the wire is covered with insulation, it is properly called an insulated wire, although primarily the term “wire” refers to the metal, nevertheless when the context that the wire is insulated, the term “wire” will be understood to include the insulation)

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DPNS 35-1:2013

3

3.15 composite conductor a combination of two or more materials differing in form or composition 4 General requirements 4.1 Materials 4.1.1 Conductor - The conductor shall be annealed copper wire conforming to the requirements of PNS 260 for solid conductor and PNS 1207 for stranded conductors. 4.1.2 Insulation - The insulation shall be PVC conforming to the requirements of PNS 661. 4.1.3 Jacket - The jacket shall be nylon conforming to the requirements of 5.10. 4.2 Insulation thickness The insulation thickness shall conform to tables 1, 2, 3, and 4. 4.3 Performance and other requirements 4.3.1 Appearance - The finished wires and cables shall be free from imperfections that are not consistent with the best commercial practice. 4.3.2 Physical properties of insulation - The insulation of finished wire or cable shall conform to tables 5, 6, 7 and 8 when tested by the method specified in clause 5. 4.3.3 Length - Length shall not be less than the declared length indicated on the tag or box. 5 Test methods 5.1 Insulation thickness 5.1.1 The insulation thickness shall be measured with an external micrometer or other appropriate measuring device. Caution shall be made so as not to exert much pressure to the sample during measurement. 5.1.2 The average insulation thickness shall be one-half the difference between the inside and outside diameters of the insulation. In case of direct measurement, measure the cross section at three or more points perpendicular to the cable axis and take the mean value. For the minimum thickness, the thinnest portion may be selected visually or by other means, and the thickness at this part shall be measured with pen gauge or profile projector. 5.2 Dielectric withstand voltage 5.2.1 Spark test using 60 hertz AC voltage - This test shall be conducted by applying an alternating current test voltage specified in tables 1, 2, 3 and 4, between the cable (connected to ground of the equipment) and the spark test electrode for at least 0.10 second. The cable shall withstand this test and 100 % of the production shall be subjected to AC spark test. A spark test is used as an alternate to water immersion test. High frequency spark testers can be used in placed of low frequency equipment.

DPNS 35-1:2013

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Table 1 - Insulation characteristics of type TW, 60 °C, 600 volts wire Conductor

Composition Minimum

acceptable insulation

thickness, mm

Test voltage, KV a.c.

Minimum insulation resistance,

MΩ-km Nominal sectional

area, mm2

Number of wires

Wire diameter,

mm

Nominal outside

diameter, mm Average At any

point

Approximate overall

diameter, mm Spark Immersion 20 °C 60 °C*

1 1.6 1.60 3.20 2.0 7 0.6 1.80 0.80 0.68 3.40 7.5 1.5 50 0.15

1 2.0 2.00 3.60 3.5 7 0.8 2.40 0.80 0.68 4.00 7.5 1.5 50 0.15

1 2.6 2.60 4.20 5.5 7 1.0 3.00 0.80 0.68 4.60 7.5 1.5 50 0.15

1 3.2 3.20 5.60 8.0 7 1.2 3.60 1.20 1.02 6.00 10 2.0 50 0.15

14 7 1.6 4.80 1.60 1.36 8.00 10.0 2.0 40 0.10 22 7 2.0 6.00 1.60 1.36 9.20 10.0 2.0 40 0.10 30 7 2.3 6.90 1.60 1.36 10.10 10.0 2.0 40 0.10 38 19 1.6 8.00 2.00 1.70 12.00 12.5 2.5 40 0.10 50 19 1.8 9.00 2.00 1.70 13.00 12.5 2.5 40 0.10 60 19 2.0 10.00 2.00 1.70 14.00 12.5 2.5 30 0.07 80 19 2.3 11.50 2.00 1.70 15.50 12.5 2.5 30 0.07

100 19 2.6 13.00 2.00 1.70 17.00 12.5 2.5 30 0.07 125 37 2.1 14.70 2.40 2.04 19.50 15.0 3.0 30 0.07 150 37 2.3 16.10 2.40 2.04 20.90 15.0 3.0 20 0.05 175 37 2.47 17.30 2.40 2.04 22.10 15.0 3.0 20 0.05 200 37 2.6 18.20 2.40 2.04 23.00 15.0 3.0 20 0.05 250 37 2.95 20.65 2.40 2.04 25.45 15.0 3.0 20 0.05 250 61 2.3 20.70 2.40 2.04 25.50 15.0 3.0 20 0.05 300 61 2.52 22.70 2.80 2.38 28.30 17.50 3.0 20 0.05 325 61 2.6 23.40 2.80 2.38 29.00 17.50 3.0 20 0.05 375 61 2.82 25.30 2.80 2.38 30.90 17.50 3.0 20 0.05 400 61 2.9 26.10 2.80 2.38 31.70 17.5 3.5 20 0.05 500 61 3.2 28.80 2.80 2.38 34.40 17.5 3.5 20 0.05

Legend: * - optional requirement

DPNS 35-1:2013

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Table 2 - Insulation characteristics of type THW, 75 °C, 600 volts wire Conductor

Composition Minimum


thickness, mm



MΩ-km Nominalsectional

area, mm2

Number of wires

Wire diameter,

mm

Nominal outside


point

Approximate overall

diameter, mm Spark Immersion 20 °C 60°C*

1 1.6 1.60 3.20 2.0 7 0.6 1.80 0.80 0.68 3.40 7.5 1.5 130 0.05

1 2.0 2.00 3.60 3.5 7 0.8 2.40 0.80 0.68 4.00 7.5 1.5 130 0.05

1 2.6 2.60 4.20 5.5 7 1.0 3.00 0.80 0.68 4.60 7.5 1.5 100 0.05

1 3.2 3.20 5.60 8.0 7 1.2 3.60 1.20 1.02 6.00 10.0 2.0 100 0.05

14 7 1.6 4.80 1.60 1.36 8.00 10.0 2.0 80 0.04 22 7 2.0 6.00 1.60 1.36 9.20 10.0 2.0 80 0.04 30 7 2.3 6.90 1.60 1.36 10.10 10.0 2.0 60 0.03 38 19 1.6 8.00 2.00 1.70 12.00 12.5 2.5 60 0.03 50 19 1.8 9.00 2.00 1.70 13.00 12.5 2.5 60 0.03 60 19 2.0 10.00 2.00 1.70 14.00 12.5 2.5 60 0.03 80 19 2.3 11.50 2.00 1.70 15.50 12.5 2.5 60 0.03

100 19 2.6 13.00 2.00 1.70 17.00 12.5 2.5 60 0.03 125 37 2.1 14.70 2.40 2.04 19.50 15.0 3.0 50 0.02 150 37 2.3 16.10 2.40 2.04 20.90 15.0 3.0 50 0.02 175 37 2.47 17.30 2.40 2.04 22.10 15.0 3.0 50 0.02 200 37 2.6 18.20 2.40 2.04 23.00 15.0 3.0 50 0.02 250 37 2.95 20.65 2.40 2.04 25.45 15.0 3.0 50 0.02 250 61 2.3 20.70 2.40 2.04 25.50 15.0 3.0 50 0.02 300 61 2.52 22.70 2.80 2.38 28.30 17.5 3.0 50 0.02 325 61 2.6 23.40 2.80 2.38 29.00 17.5 3.0 50 0.02 375 61 2.82 25.30 2.80 2.38 30.90 17.50 3.0 50 0.02 400 61 2.9 26.10 2.80 2.38 31.70 17.5 3.5 50 0.02 500 61 3.2 28.80 2.80 2.38 34.40 17.5 3.5 50 0.02


DPNS 35-1:2013

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Table 3 - Insulation characteristics of type THWN, 75 °C, 600 volts wire Conductor

Composition Minimum


thickness, mm




area, mm2

Number of wires

Wire diameter,

mm

Nominal outside


point

Minimum acceptable

nylon thickness,

mm

Approximate diameter

over nylon,

mm Spark Immersion 20 °C 60 °C*

1 1.6 1.60 2.60 2.0 7 0.6 1.80 0.40 0.34 0.10 2.80 7.5 2.0 130 0.05

1 2.0 2.00 3.00 3.5 7 0.8 2.40 0.40 0.34 0.10 3.40 7.5 2.0 120 0.05

1 2.6 2.60 3.80 5.5 7 1.0 3.00 0.50 0.43 0.10 4.20 7.5 2.0 120 0.05

1 3.2 3.20 5.06 8.0 7 1.2 3.60 0.80 0.68 0.13 5.46 10.0 2.0 120 0.05

14 7 1.6 4.80 0.80 0.68 0.13 6.66 10.0 2.0 100 0.04 22 7 2.0 6.00 1.00 0.85 0.15 8.30 10.0 2.0 100 0.04 30 7 2.3 6.90 1.00 0.85 0.15 9.20 10.0 2.0 100 0.04 38 19 1.6 8.00 1.30 1.11 0.18 10.96 12.5 2.5 100 0.04 50 19 1.8 9.00 1.30 1.11 0.18 11.96 12.5 2.5 100 0.04 60 19 2.0 10.00 1.30 1.11 0.18 12.96 12.5 2.5 80 0.03 80 19 2.3 11.50 1.30 1.11 0.18 14.46 12.5 2.5 80 0.03

100 19 2.6 13.00 1.30 1.11 0.18 15.96 12.5 2.5 80 0.03 125 37 2.1 14.70 1.60 1.36 0.18 18.26 15.0 3.0 80 0.03 150 37 2.3 16.10 1.60 1.36 0.20 19.70 15.0 3.0 80 0.02 175 37 2.47 17.30 1.60 1.36 0.20 20.90 15.0 3.0 60 0.02 200 37 2.6 18.20 1.60 1.36 0.20 21.80 15.0 3.0 60 0.02 250 37 2.95 20.65 1.60 1.36 0.20 24.25 15.0 3.0 60 0.02 250 61 2.3 20.70 1.60 1.36 0.20 24.30 15.0 3.0 60 0.02 300 61 2.52 22.70 1.80 1.53 0.23 26.76 17.5 3.0 60 0.02 325 61 2.6 23.40 1.80 1.53 0.23 27.46 17.5 3.0 60 0.02 375 61 2.82 25.30 1.80 1.53 0.23 29.36 17.5 3.0 60 0.02 400 61 2.9 26.10 1.80 1.53 0.23 30.16 17.5 3.5 60 0.02 500 61 3.2 28.80 1.80 1.53 0.23 32.86 17.5 3.5 60 0.02


DPNS 35-1:2013

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Table 4 - Insulation characteristics of type THHN, 90 °C, 600 volts wire Conductor

Composition Minimum

acceptable Insulation

thickness, mm

Test voltage, KV ac



area, mm2

Number of wires

Wire diameter,

mm

Nominal outside


point

Minimum acceptable

nylon thickness,

mm

Approx. diameter

over nylon,

mm Spark Immersion 20 °C 75 C*

1 1.6 1.60 0.40 0.34 0.10 2.60 7.5 2.0 130 0.05 2.0 7 0.6 1.80 2.80 1 2.0 2.00 0.40 0.34 0.10 3.00 7.5 2.0 110 0.05 3.5 7 0.8 2.40 3.40 1 2.6 2.60 0.50 0.43 0.10 3.80 7.5 2.0 120 0.05 5.5 7 1.0 3.00 4.20 1 3.2 3.20 0.80 0.68 0.13 5.06 10.0 2.0 120 0.05 8.0 7 1.2 3.60 5.46

14 7 1.6 4.80 0.80 0.68 0.13 6.66 10.0 2.0 100 0.04 22 7 2.0 6.00 1.00 0.85 0.15 8.30 10.0 2.0 100 0.04 30 7 2.3 6.90 1.00 0.85 0.15 9.20 10.0 2.0 100 0.04 38 19 1.6 8.00 1.30 1.11 0.18 10.96 12.5 2.5 100 0.04 50 19 1.8 9.00 1.30 1.11 0.18 11.96 12.5 2.5 100 0.04 60 19 2.0 10.00 1.30 1.11 0.18 12.96 12.5 2.5 80 0.03 80 19 2.3 11.50 1.30 1.11 0.18 14.46 12.5 2.5 80 0.03

100 19 2.6 13.00 1.30 1.11 0.18 15.96 12.5 2.5 80 0.03 125 37 2.1 14.70 1.60 1.36 0.18 18.26 15.0 3.0 80 0.03 150 37 2.3 16.10 1.60 1.36 0.20 19.70 15.0 3.0 80 0.03 175 37 2.47 17.30 1.60 1.36 0.20 20.90 15.0 3.0 80 0.03 200 37 2.6 18.20 1.60 1.36 0.20 21.80 15.0 3.0 60 0.02 250 37 2.95 20.65 1.60 1.36 0.20 24.25 15.0 3.0 60 0.02 250 61 2.3 20.70 1.60 1.36 0.20 24.30 15.0 3.0 60 0.02 300 61 2.52 22.70 1.80 1.53 0.23 26.76 17.5 3.5 60 0.02 325 61 2.6 23.40 1.80 1.53 0.23 27.46 17.5 3.5 60 0.02 375 61 2.82 25.30 1.80 1.53 0.23 29.36 17.5 3.5 60 0.02 400 61 2.9 26.10 1.80 1.53 0.23 30.16 17.5 3.5 60 0.02 500 61 3.2 28.80 1.80 1.53 0.23 32.86 17.5 3.5 60 0.02


DPNS 35-1:2013

Table 5 - Physical properties of type TW wires

Test items

Requirements

Conductor resistance Shall comply to the requirements of PNS 260 and PNS 1207

Immersion To withstand the test voltage specified in table 1 Dielectric withstand voltage Spark To withstand the test voltage specified in table 1

Insulation resistance Not less than the value specified in table 1 Tensile strength Not less than 10.3 MPa (1.05 kgf/mm²) Tensile strength

and elongation –

unaged Elongation

Not less than 100 percent

Tensile strength Not less than 65 percent of the value of unaged Specimen Tensile strength

and elongation – aged 100 °C ± 1 °C at

168 h Elongation

Die cut specimen - Not less than 45 percent of the value of unaged specimen Other specimen - Not less than 65 percent of the value of unaged specimen

Oil resistance Tensile strengthand elongation

Not less than 65 percent of the value of the unaged value of the tubular specimen

Flame retardance Flame to extinguish naturally within 60 seconds

Heat shock No cracks and flaws to develop on the surface or internally

Heat deformation Thickness reduction shall not exceed 50 percent of the original thickness

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DPNS 35-1:2013

Table 6 - Physical properties of class THW wires

Test items

Requirements




and elongation –

unaged Elongation


Tensile strength All specimen - not less than 75 percent of the value of unaged specimen Tensile strength

and elongation - aged 121 °C ± 1 °C at

168 h Elongation

Die cut specimen - Not less than 45 percent of the value of unaged specimen Other specimen - Not less than 65 percent of the value of unaged specimen For 60 °C - Not less than 65 percent of the unaged value of the tubular specimen Oil resistance Tensile strength

and elongation For 75 C - Not less than 65 percent of the unaged value of the tubular specimen




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DPNS 35-1:2013

Table 7- Physical properties of class THWN wires

Test items

Requirements




and elongation –

unaged Elongation



and elongation - aged 136 °C ± 1 °C at

168 h Elongation


and elongation For 75 °C - Not less than 65 percent of the unaged value of the tubular specimen




Nylon jacket wrap test No cracks and flaws to develop on the surface

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DPNS 35-1:2013

Table 8 - Physical properties of class THHN wires

Test items

Requirements



Insulation resistance Not less than the value specified in table 4 Tensile strength Not less than 13.7 MPa (1.4 kgf/mm²) Tensile strength and

elongation - unaged Elongation Not less than 150 percent


and elongation – aged 136 °C ± 1 °C at

168 h Elongation


and elongation For 75 °C - Not less than 65 percent of the unaged value of the tubular specimen




Nylon jacket wrap No cracks and flaws to develop on the surface

11

DPNS 35-1:2013

5.2.2 Water immersion - The finished wire shall be immersed in water for a period of not less than six hours and then subject to the test voltage specified in tables 1, 2, 3 and 4 for 60 seconds while still immersed. One side of the test circuit shall be connected to the conductor of the wire and the other side shall be connected to an electrode that is earth-grounded and is in contact with the water in which the coiled wire is immersed.

5.3 Insulation resistance 5.3.1 Immediately after dielectric withstand voltage test, the finished wire shall be subjected to insulation resistance test for 60 seconds while still immersed. 5.3.2 The apparatus consists of a suitable tank and an insulation resistance meter (meg-ohmmeter) with an open circuit voltage of at least 500 volts, d.c. 5.3.3 The insulation resistance shall be corrected to 20 °C using the following formula and the temperature correction factor given in table 9: R20 = Rt x Kt x L where : R20 is the insulation resistance corrected at 20 °C, MΩ-km; Rt is the measured insulation resistance at t °C, MΩ; Kt is the temperature correction factor; and L is the length of wire, km.

Table 9 - Temperature correction factor, (Standard temperature - 20 °C)

Temp. °C

Kt Temp. °C

Kt Temp. °C

Kt Temp. °C

Kt

0 0.42 9 0.53 18 0.85 27 2.22 1 0.43 10 0.55 19 0.92 28 2.52 2 0.44 11 0.57 20 1.00 29 2.87 3 0.45 12 0.60 21 1.11 30 3.31 4 0.46 13 0.63 22 1.24 31 3.75 5 0.48 14 0.66 23 1.39 32 4.25 6 0.49 15 0.70 24 1.55 33 4.90 7 0.50 16 0.74 25 1.74 34 5.90 8 0.52 17 0.79 26 1.96 35 6.45

5.3.4 Testing of insulation resistance at elevated temperature is optional. 5.4 Accelerated aging test 5.4.1 On tubular specimens, any material applied over the thermoplastic insulation is to be removed prior to test 5.4.2 If die-cut specimens are employed, all buffing and die-cutting operations are to be completed at least 30 minutes before they are placed in the chamber or immersed in oil for aging.

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DPNS 35-1:2013

5.4.3 Measurements for determining the cross-sectional area are to be made as described for the physical tests insulation, before the specimens are subjected to accelerated aging or oil immersion. The marks for the determination of elongation are to be placed on the specimens after their removal from the chamber in which they are aged. 5.4.4 Physical tests are to be made on both unaged and aged specimens at the same time and at a room temperature of 24 °C ± 8 °C. Unaged specimens are to be maintained at this room temperature for a period of not less than 30 minutes prior to their being subjected to the physical test, and specimens which have been subjected to air-oven ageing are to have a rest period of not less than 16 nor more than 96 hours at this room temperature following their removal from the oven and prior to their being subjected to oil immersion are to be blotted lightly to remove any excess oil, and then suspended in air at the above mentioned room temperature for 3.5 hours to 4.5 hours before being subjected to physical tests. Specimens that are to be aged in an oven are to be suspended vertically in such a manner that they will not come in contact with one another or the sides of the chamber. Specimens having widely different properties or compositions are to be tested in separate ovens. 5.4.5 The specimens are to be heated at the required temperature for the specified time in an oven having a free circulation of fresh air, and oven temperature throughout is to be recorded, and shall conform to the requirements of tables 5, 6, 7, and 8. 5.5 Tensile strength and elongation of insulation 5.5.1 Preparation of test specimen - A minimum of three samples approximately 100 mm long that have been removed from the conductors shall be used. Samples that cannot be obtained from the finished product, or if the samples obtained is inappropriate, they shall be obtained from a sheet rolled out from a compound of the same lot, 1 mm to 3 mm thick, and left exposed at a temperature of 23 °C ± 2 °C for more than five hours. The specimen shall be die-cut shape for sizes greater than 8 mm2 and tubular shape for sizes 8 mm2 and lower, whose measurements shall be as close as possible to that shown in Figure 1 and shall have marks placed upon it 20 mm apart. Dumbbell specimen taken from a tube of insulation cut longitudinally, shall be buffed, laid flat and cut with an acceptable die and be free of surface incisions and imperfections. 5.5.2 Calculation of the cross-sectional area 5.5.2.1 For tubular specimen - The outer diameter of the insulation is measured at 3 or more points, and the sectional area calculated from the following formula using the average measured value. A = π/4(D² - d²) where: A is the cross-sectional area in mm²; D is the outside diameter of the insulation in mm; and d is the outside diameter of the conductor in mm. 5.5.2.2 For dumbbell specimen - A = WT

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DPNS 35-1:2013

where:

A is the cross-sectional area in mm² W is the width in mm T is the thickness in mm

Figure 1 - Die-cut specimen

5.5.3 Test procedure - A sample shall be arranged properly to ensure absence of deflection during the test, and stretch at a speed approximately 500 mm/min. The load and the distance between the marks corresponding to the cutting points shall be measured. If the sample breaks outside the marked points, the test shall be repeated on another sample. 5.5.4 Method of calculating tensile strength and elongation - The tensile strength and elongation shall be calculated using the formulas below. The values shall be represented by an average of the values obtained from the three specimens. measured load at rupture, Newton a) Tensile strength = cross-sectional area of sample, mm² final distance - initial distance b) Elongation, % = x 100 % initial distance 5.6 Flame retardance 5.6.1 This is a method of testing the flame retardant properties of finished electric wire by using standard flame equipment which consists of a chamber of sheet metal 300 mm wide, 350 mm deep, and 600 mm high, open at the top and front, and provided with means for supporting the samples in a vertical position and keeping it taut during the test. A Tirril position burner with an attached pilot light mounted on a block at an angle of 20 degrees shall have a nominal bore of 9.5 mm and a length of approximately 100 mm above the primary air inlets. Refer to Figure 2.

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DPNS 35-1:2013

5.6.2 Procedure 5.6.2.1 A sample of wire 455 mm long is to be secured in vertical position in the chamber. A kraft-paper indicator of approximately 13 mm wide is to be applied to the sample so that the lower edge is 250 mm above the point at which the inner blue cone of the test flame is to be applied. The paper indicator is to be wrapped around the sample projecting 20 mm from the wire on the opposite side of the sample to which the flame is to be applied. The height of the flame is adjusted on 125 mm with the inner cone approximately 40 mm high. The distance of the combustible material (cotton) shall be between 230 mm to 240 mm below the tip of the inner blue cone of the flame. 5.6.2.2 The burner with only the pilot lighted is to be placed in front of the samples so that when the gas supply valve is opened, the point of application of the test flame is not less than 75 mm above the lower end of the sample. 5.6.2.3 The valve is to be opened for 15 seconds and then closed for 15 seconds, this process being repeated four times.

Figure 2 – Vertical Flame Test Setup

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DPNS 35-1:2013

5.6.3 Test criteria 5.6.3.1 If more than 25 percent of the extended portion of the indicator is burned away, after five application of the flame, the wire is to be considered to have conveyed flame. 5.6.3.2 The duration of the flaming of the sample after the fifth application of the flame shall not be more than one minute. 5.6.3.3 The specimen shall not convey flame to combustible materials in its vicinity. 5.7 Heat shock 5.7.1 The insulation shall not show any cracks either on the surface or internally after a specimen of finished wire is wound around a mandrel having a diameter three times that of the specimen, then subjected to a temperature of 121 °C ± 1 °C in an oven for one hour. 5.7.2 For 38 mm² or smaller conductor, four adjacent turns are to be tightly wound around the mandrel and both ends of the specimen are to be securely held in place by means of PVC tape. In the case of 50 mm² or larger conductor, a “U” bend is to be made with the specimen in contact with the mandrel for not less than 180 degrees, and the specimen is to be securely held in place by means of PVC tape. After one hour in the oven, internal cracks may be detected from circumferential depression in the outer surface. 5.8 Heat deformation 5.8.1 The insulation of finished wire is subjected to the load indicated in Table 10 while being maintained at a temperature of 136 °C ± 1 °C for class THHN and 121 °C ± 1 °C for other class of wires. The nylon jacket is to be in place on class THHN and THWN, and the measurements are to be made over the nylon.

Table 10 - Specimen loading

Size of conductor, mm²

Load exerted on a specimen by presser foot, N

2 - 8 14 - 38

50 - 100 125 - 500

5.0 7.5

10.0 20.0

5.8.2 For sizes 2 mm² to 100 mm², the insulation thickness T1 is to be determined from measurements made on a 25-mm length of finished wire. For 125 mm² to 500 mm², the 200 mm specimen is to be removed from the finished wire. A rectangular specimen 25 mm² by 14 mm is to be sliced and buffed to a uniform thickness of 1.27 mm² ± 0.25 mm with both surface smooth. Its thickness T1 is to be measured to the nearest 0.01 mm by means of a dead-weight dial micrometer whose presser foot exerts a load of 85 g ± 3 g or 0.84 N ± 0.02 N on the specimen. The presser foot is to have a flat face 6.4 mm ± 0.2 mm or 9.5 mm ± 0.2 mm in diameter. The anvil of the instrument is to be at least 38 mm in diameter and is to be parallel to the face of the presser foot.

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DPNS 35-1:2013

5.8.3 The insulation thickness of T2 at elevated temperature for both the round insulated conductor and rectangular (buffed) specimens is to be determined from measurements made by means of a dead-weight dial micrometer with a presser foot of 9.5 mm ± 0.2 mm in diameter and with graduations of 0.01 mm. The micrometer is to be actuated to press on a specimen positioned between the foot and the anvil with the load indicated in table 10. 5.8.4 With the applicable weight in place on its spindle, the micrometer is to be placed beside the test specimen in a full-draft circulating air oven that has been preheated to a temperature of 136 °C ± 1 °C for class THHN and 121 °C ± 1 °C for all other class of wire. The specimen and the micrometer are to remain side by side in the oven for one hour of preliminary heating at full draft. At the end of the hour, the specimen is to be placed on the anvil of the micrometer. The loaded presser foot is to be gently brought to bear on the specimen and is to continue to bear on the specimen while the micrometer and specimen remain in the oven for an additional hour at full draft. 5.8.5 At the end of the second hour, the overall diameter D of the round specimen (insulated conductor) is to be read from the dial on the loaded micrometer and is to be recorded to the nearest 0.01 mm. The thickness T2 of the round specimen is to be determined by subtracting the diameter of the metal conductor from D and dividing the result by two. 5.8.6 At the end of the second hour, the thickness T2 of the rectangular (buffed) specimen is to be read directly from the dial on the loaded micrometer and is to be recorded to the nearest 0.01 mm. 5.9 Oil resistance 5.9.1 The oil resistance of finished wire is determined by oil immersion ageing. The immersion vessel is to be a test tube having an overall diameter of 25 mm and a length of 300 mm. 5.9.2 The tube is to be filled with oil and placed in a bath having an automatic temperature control capable of maintaining the specimen at specified temperatures. The oil used is IRM oil No. 2, a medium swelling oil of a petroleum base or its equivalent. 5.9.3 Specimens of finished wire of 2.0 mm² to 8 mm² with or without the conductor removed are to be bent at the center to form a narrow U and are then to be suspended vertically in the oil with the ends of each specimen projecting above the oil. 5.9.4 If a PVC-insulated wire is rated oil-resistant at 60°C, it shall be immersed in oil for 96 hours at 100 °C ± 1 °C. If a PVC-insulated wire is rated oil-resistant at 75 °C, it shall be immersed in oil for 60 days at 75 °C ± 1 °C. 5.9.5 The nylon jacket on class THWN and THHN wires is to be intact on the wire during the immersion and removed prior to the tensile strength and elongation test. 5.10 Wrap test of nylon jacket The nylon jacket on a class THWN or THHN wire shall not crack when wrapped around a mandrel and tested under the following conditions: 5.10.1 A specimen of finished 2.0 mm² and 3.5 mm² wire is to be wrapped for four turns around a smooth metal mandrel of a diameter six times that of the specimen. The ends of the specimen are to be secured to the mandrel so that the four complete turns of the specimen are exposed to the air between the securing means.

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5.10.2 The specimen and the mandrel are to be suspended for 24 hours in a full-draft circulating air oven at a temperature of 95 °C ± 1 °C after which the specimen and mandrel are to be removed from the oven and cooled for one hour in a desiccator maintained at 24 °C ± 3°C. The specimen is to be unwound at a minimum rate of 4 seconds per turn immediately upon removal from desiccator and is then to be inspected for surface cracks. Any cracking of the jacket on any specimen constitutes non-complying performance. 6 Sampling 6.1 Samples shall be obtained at random from packaged lots. 6.2 Sampling scheme shall be in accordance with table 11.

Table 11 - Sampling scheme

Size of wire and cable, mm² Minimum length per size, m 8 and smaller 14 to 30 38 and larger

300 20 10

Note: Insulation resistance and dielectric withstand voltage shall be tested at the plant site 7 Testing and frequency of test All wires and cables shall be tested as necessary to determine their compliance with the requirements .When there is a conflict between the test methods given in 5.1 to 5.10 and the publication of other organizations to which reference is made, the requirement given in 5.1 to 5.10 shall apply. Test on samples shall be made on samples selected at random. Each test sample shall be from accessible end of different coil or reel selected and the sample taken from it shall be identified. The length and sample per lot size is given in table 11. If all of the samples pass any test specified in this standard, the quantity of the cable they represent shall be considered as meeting the requirements of this standard with regards to that test. In case of failure of any sample, re-sampling and re-testing shall be allowed once from the original sample. 7.1 Routine tests Test made on each manufactured lot/batch of cable to check that it meets the specified requirements. The number of samples to be tested may be reduced according to agreed quality control procedure. Routine tests shall be as follows: a. Visual inspection of cable surface and marking b. Measurement of dimensions, c. Conductor electrical resistance d. Dielectric strength Note: In case of failure after re-sampling and re-testing, the manufactured lot/batch are considered non-conforming to the standard.

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DPNS 35-1:2013

7.2 Type test Test made before supplying, on a general commercial basis, a type of cable covered by this standard, in order to demonstrate satisfactory performance characteristics to meet the intended application. These tests are of such a nature that, after they have been made, they need not be repeated, unless changes are made on the cable materials or design or manufacturing process which might change the performance characteristics. Type test shall be as follows: a. Measurement of dimensions, b. Conductor resistance, c. Insulation resistance, d. Tensile strength and elongation, e. Thermal ageing f. Heat shock, g. Heat deformation, h. Flame retardance, i. Wrap test j. Oil resistance 8 Marking 8.1 An insulated wire shall have a permanent distinctive marking throughout its entire length. The marking shall be either by printing or embossing which is to be repeated at 500 mm or shorter interval throughout the length. The marking on the surface shall indicate plainly the following: 8.1.1 The type of wire; 8.1.2 The size of wire; 8.1.3 The rated voltage and temperature of the wire; and 8.1.4 The manufacturer’s name or tradename. 8.2 Tag, reel or carton marking - Every shipping length of finished wire or cable shall be provided with a tag. It may be tied to a coil, stapled to the reel or glued to the carton, or the tag may be eliminated and the information printed or stenciled directly into the reel or carton. The following information shall be indicated plainly: 8.2.1 The type of wire; 8.2.2 The size of wire; 8.2.3 The rated voltage and temperature of the wire; 8.2.4 The manufacturer’s name or trade name; 8.2.5 The date of manufacture by month and year;

8.2.6 The length in meters; and 8.2.7 The country of origin.

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Bibliography IEC 60227-1:2007 – Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V - Part 1: General requirements IEC 60227-2:2003 – Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V - Part 2: Test methods IEC 60228:2004 – Conductors of insulated cables

Documents

DPNS 35-1:2013 ICS 29 - inmetro.gov.br · DPNS 35-1:2013 ICS 29.060 ... Polyvinyl Chloride (PVC) insulated flexible cords and fixture ... PNS 661:2009 - Plasticized polyvinyl chloride