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Electric wires and cables – Thermoplastic Insulated Copper Wires and Cables Rated
600 Volts – Part 2 Non Metallic Flat Jacketed Electric Wires – Specification
1. Scope
This standard specifies requirements for thermoplastic insulated non- metallic flat- jacketed
electric wires with 2 or 3 conductors sizes 2.0 mm² to 5.5 mm² solid or stranded rated 60 ºC,
600 V.
2. References
The titles of the standard publications referred to in this standard are listed on the inside back
cover.
3. Definitions
For the purpose of this standard, the following definitions shall apply:
3.2 Filler –material used to fill the gaps between insulated conductors
4. General Requirements
4.1 Materials
4.1.1 Conductor - The conductor shall be annealed copper wire conforming to the
requirements of PNS 260 and PNS 1207.
4.1.2 Jacket and Insulation – The jacket and insulation shall be PVC conforming to the
requirements of PNS 661.
4.2.1 The average thickness of insulation shall not be less than the values indicated in Table
1 and the minimum thickness at any point shall not be less 85% of the values in this table.
DPNS 35-2: 2005
4.2.2 The average thickness of jacket shall not be less than 95% of the values indicated in
Table 1 and the minimum thickness at any point shall not be less than 80% of the values in
this table.
The identification shall be made by the color of the insulation and shall conform to Table 3.
4.5.1 Appearance – The finished wire shall be free from imperfections that are not
consistent with the best commercial practice.
4.5.2 Physical Properties of Insulation and Jacket – The insulation of finished wire shall
conform to table 4 when tested by the method specified in Clause 5.
5 Test Methods
5.2.1 The jacket thickness shall be measured with pin/thickness gauge or other appropriate
measuring device. Caution shall be made so as not to exert much pressure to the sample
during measurement.
5.2.2 The average jacket thickness shall be taken by measuring 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 a pin gauge or a profile projector.
For solid conductors, the distance between adjoining surfaces of metal conductors shall be
measured with an external caliper or other appropriate measuring device. For stranded
conductors, the distance between the centers of the stranded conductors shall be measured.
5.4.1 Spark test – Each single conductor of type NM cables shall individually comply with
spark test requirements of PNS 35 Part 1, prior to assembly and jacketing.
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DPNS 35-2: 2005
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5.4.2 After immersion in water at room temperature for 24 h and while still immersed,
specimens of finished cable wound around mandrel shall withstand for 60 s a 48-62 Hz
essentially sinusoidal potential of 5000V. The potential shall be applied from each conductor
separately, to the other conductor or conductors, any grounding conductor, and to the earth-
grounded water and mandrel.
5.4.2.1 The apparatus is to consist of an immersion tank; a set of metal mandrels, each a
right-circular cylinder having a diameter equal to seven times the diameter or length of minor
axis of the cable with which it is used; and a testing transformer, circuit breaker, and
voltmeter.
5.4.2.3 A specimen of finished cable of a length for making seven or more turns around the
applicable diameter of mandrel plus 28 in or 711 mm is to be opened at each end so that the
insulated circuit conductors extend 4 in or 102 mm from the rest of the cable. The insulation
is nor to be damaged. At one end of the specimen, each of the circuit conductors and any
grounding conductor are to be bared for 1 in or 25 mm to facilitate connection to the testing
circuit. The specimen of cable is then to be wound onto the mandrel starting at the center of
the specimen and winding simultaneously toward each end. The ends are then to be secured
so that no less than a 10 in or 254 mm length of cable extends away from the mandrel at each
end of the coil. The specimen and the mandrel on which it is wound are then to be immersed
in tap water at a room temperature for 24 h. During the immersion, the ends of the coil are to
extend at least 8 in or 200 mm above the surface of the water, and the ends are not to become
wet. After the coil has been immersed for 24 h, and while it is still immersed, the potential is
to be increased from near zero at an essentially uniform rate in the range of 10 – 60 V/s. The
increase is to continue in this manner until the voltage is 5000. If the 5000 V level is reached
without breakdown, the voltage is to be held constant at that level for 60 seconds and is then
to be reduced to near zero at an essentially uniform rate in the range of 10 – 60 V/s. The cable
is not acceptable if, during any application of voltage, breakdown occurs in less than 60 s at
5000 V or while the voltage is being increased or decreased.
5.4.3 Each circuit conductor and any grounding conductor shall be continuous throughout the
entire length of finished cable. Finished cable shall be tested for continuity for all sizes
conductor by the cable manufacturer at the cable factory.
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DPNS 35-2: 2005
5.7.2.1 For tubular specimen – the outer diameter of the insulation is measured at 3 or more
points, and the sectional are calculated from the following formula using the average
measured value.
A= / 4 (D² - d²)
A = WT
100 100
15 25 20 40 21 19 20 40
R25
5 25 5 10
R11
RAC
Unit: mm
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DPNS 35-2: 2005
5.7.3 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 sample shall be repeated on another sample.
5.7.4 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 obtained from the three specimens.
6 Sampling
Samples shall be obtained at random from packaged lots and shall have a minimum length of
75m per size.
7 Marking
7.1 A non–metallic sheathed wire shall have a permanent distinctive marking throughout
its entire length. The marking shall be by printing which is to be repeated with an interval of
500 mm or shorter. The marking on the surface shall indicate plainly the following:
7.1.2 The diameter of wire in mm for solid or the cross sectional area in mm² for stranded.
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DPNS 35-2: 2005
7.2 Tag, Reel or Carton Markings – Every shipping length of finished wire shall be
provided with a tag. It may be tied to a coil or glued to the carton ,or the tag may be
eliminated if information is printed in the carton or in the packaging reel . The following
information shall be indicated plainly:
7.2.2 The diameter of wire in mm for the cross- sectional area in mm² for stranded.
8 References
The following standards contain provisions that through reference in this text from part of
this national standard. At the time of publication of this PNS, the editions indicated were
valid:
PNS 35-1:2004 Electric wires and cables - Thermoplastic insulated copper wires and cables
rated 600 volts – Part 1: General specification
PNS 1207: 1997 Soft drawn (annealed) copper stranded conductors for electrical purposes -
Specifications
UL 719 (July 31,1998) Underwriters Laboratories Inc. Standard for Safety Nonmetallic –
Sheathed Cables