BRITISH STANDARD Conductors for overhead lines — Zinc coated steel wires ‘The European Standard EN 60180:2000 has the status of a British Standard NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BS EN 50189:2000BS EN 50189:2000 ‘This British Standard, having ‘boon prepared under the rection of the Electrotechnical Sector Coamitte, was published under dhe authonty of the ‘Standards Committee and comes into effect on 15 May 2000 © Bsi 052000 ISBN 0 580 54685 4 National foreword ‘This British Standard is the official English language version of EN 50189:2000. It supersedes BS 4565:1990 which is withdrawn, ‘The UK participation in its preparation was entrusted to Technical Committee GEL/7, Overhead electrical conductors, which has the responsibility to: — aid enquirers to understand the text; — present to the responsible European committee any enquiries on the interpretation, or proposals for change, and keep the UK interests informed; — monitor related international and European developments and promulgate them in the UK. Alist of organizations represented on this committee can be obtained on request to its secretary. Cross-references ‘The British Standards which implement intemational or European publications referred to in this document may be found in the BSI Standards Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Find” facility of the BSI Standards Electronic Catalogue. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application, Compliance with a British Standard does not of itself confer immunity from legal obligations. ‘Summary of pages ‘This document comprises a front cover, an inside front cover, the EN title page, pages 2 to 14, an inside back cover and a back cover. ‘The BSI copyright notice displayed in this document inicates when the document ‘was last seed Amendments issued since publication Amd No. [Date CommentsEUROPEAN STANDARD EN 50189 NORME EUROPEENNE EUROPAISCHE NORM January 2000 ICS 29,050.10 English version Conductors for overhead lines Zinc coated steel wires ‘Conducteurs pour lignes aériennes Leiter fir Freileitungen Fils d'acier zingué Verzinkte Stahidrahte This European Standard was approved by CENELEC on 1998-10-01. CENELEC members are bound to ‘comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of @ national standard without any alteration. Up-to-date lists and bibliographical references conceming such national standards may be obtained on application to the Central Secretariat or to any CENELEC member. ‘This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibilty of a CENELEC member into its own language and notified to the Central Secretariat has the same stalus as the offical versions, ‘CENELEC members are the national electrotechnical committees of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom. CENELEC Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europaisches Komitee for Elektrotechnische Normung Central Secretariat: rue de Stassart, 35 B - 1050 Brussels (©2000 CENELEC- Al rights of exploitation in any form and by any means reserved worldwide for CENELEC members. Ref, No. EN 50180:2000Page 2 EN 50189:2000 Foreword This European Standard was prepared by the Technical Committee CENELEC TC 7, Overhead electrical conductors. The text of the daft was submitted to the formal vote and was approved by CENELEC as EN 50189 on 1999-10-01 The following dates were fixed: — latest date by which the EN has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2000-10-01 = latest date by which the national standards conflicting with the EN have to be withdrawn (dow) 2002-10-04 ‘Annexes designated ‘normative’ are part of the body of the standard; In this standard, annex A is normative. © as! 05-2000Page 3 EN 50189:2000 Contents Scope Normative references... Defi 1 2 3 ions. 4 Values for zinc-coated steel wires 5 Material... 6 7 8 Wire surface Diameter and tolerance on diameter... Length and tolerance on length .. 9 Joints. 10 Sampling.... 14 Tests 12. Certificate of compliance 13. Acceptance or rejection 14 Rounding rules Annex A (normative) Special national conditions .. Soccecoanannaaene © Bs! 05-2000Page 4 EN 50189:2000 1 Scope This standard applies to round zinc-coated steel wires used in the construction and/or reinforcement of conductors for overhead power transmission purposes. It is intended to cover all wires used in constructions where the individual wire diameters, including coating, are in the range of 1,25 mm to 5,50 mm. Types of wire are designated STyz, where y represents the grade of steel and z represents the class of zinc coating. To reflect the needs of conductor users, the only combinations of steel grade and zinc coating covered by this standard are ST1A, ST2B, ST3D, ST4A, STSE and ST6C. The properties specified are those before stranding, 2. Normative references This European standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies. EN 10002-1 Metallic materials — Tensile testing — Part 1: Method of test at ambient temperature EN 10021 General technical delivery conditions for steel and stee! products EN 10218-1 Stee! wire and wire products — General — Part 1: Test methods EN 10244-2"’ Stee! wire and wire products — Non-ferrous metallic coatings on steel wire Part 2: Zinc or zinc alloy coatings IEC 60050-466 Intemational Electrotechnical Vocabulary (IEV) — Chapter 466: Overhead Lines Iso 7801 Metallic materials — Wire — Reverse bend test 3 Definitions In addition to the definitions given in IEC 60050-466, the following definition applies: a4 lot a group of reels or coils manufactured by the same manufacturer under similar conditions of production NOTE 1 Alot may consist of part of or all the purchased quantity, NOTE 2 The constitution of a lot may be agreed between the purchaser and the manufacturer. 41) In preparation © BSI 05-2000Page 5 EN 50189:2000 4 Values for zinc-coated steel wires For calculation purposes the following values for zinc-coated steel wires shall be used: Density at 20°C 7,78 kg/dm* Coefficient of linear expansion Modulus of elasticity Resistivity at 20°C 192 nO-m NOTE For more accurate calculations, measured values may be used 5 Material The steel wires shall have the properties specified hereinafter. The slab zinc shall be of 99,85 % minimum zinc content. The coating on the wires may be applied by the hot dip or electrolytic process, as agreed between the purchaser and manufacturer. 6 Wire surface The wire surface, before and after coating, shall be free from cracks, holes, inclusions of impurities, and any other imperfections which may detract from its functional performance as a wire for an electrical conductor. 7 Diameter and tolerance on diameter The diameter of the zinc-coated steel wire, expressed to two decimal places, shall not depart from the nominal diameter by more than the tolerance given in Tables 3 to 8. 8 Length and tolerance on length Unless otherwise agreed between the purchaser and manufacturer, steel wires shall be supplied with a minimum length specified by the purchaser with a permitted variation of “4 %. Random lengths shorter or longer than this requirement are only acceptable if prior agreement between the purchaser and manufacturer is made. 9 Joints Joints are allowed in the base hot rolled rod and semi-finished wire by the electric butt or flash welding process, before or after heat treatment and prior to final drawing. Joints which have been made in rod or during processing shall, after drawing to the final diameter, have a minimum tensile strength not less than 80 % of that obtained on a test on wire which has not been jointed. The manufacturer shall demonstrate that the proposed welding method is capable of meeting the specified requirements. Other required values for such wires are not changed except that the finished wire from that portion of the rod which was welded shall not be required to pass ductility wrapping tests, When the zinc coating has been removed in the course of welding prior to final drawing, the wire shall be suitably recoated by agreement between the purchaser and the manufacturer. No joints of any kind shall be made in the coated steel wires at final diameter. © Bs! 05-2000Page 6 EN 50189:2000 No joint shall be made after heat treatment in wires destined to be used in conductors containing only one steel wire. A drum or coil containing wire which has been welded after heat treatment shall be clearly marked 10 Sampling ‘One sample for tests shall be taken, in accordance with EN 10021, by the manufacturer from at least 10 % of the individual lengths of coated steel wire. In cases of wire supply in large quantities and where the manufacturer has a demonstrated capability of meeting or exceeding the requirements, the number of test samples may be reduced, with the agreement of the purchaser and the manufacturer, to a level which ensures that each production lot of wire is given adequate monitoring. 11 Tests 14.4 Visual test When inspected with the naked, or normally corrected eye the surface of the wire shall be free from cracks, holes, and inclusions of imput 14.2. Diameter The minimum and maximum diameter shall be determined at the same cross section. Each of these measurements shall lie within the tolerance given in Tables 3 to 8. It is recognised that the surface of zinc coatings, particularly those produced by hot dip galvanizing, are not perfectly smooth and free from irregularities. It is, therefore, intended that these tolerances be used in measuring the diameters within the uniform areas of zinc-coated wire. For calculation of the cross-sectional area, the mean of the two measurements shall be used. 14.3 Stress at 1% extension The test shall be made in accordance with EN 10002-1 on the coated wire at final diameter. One specimen from each of the test samples shall be gripped in the jaws of the tensile machine. An initial load equivalent to the initial stress given in Table 1 shall be applied and an extensometer applied on a 250 mm gauge length and adjusted to the initial setting given in Table 1 (other gauge lengths may be used if agreed between the purchaser and the manufacturer. In this case the initial setting of the extensometer shall be adjusted according to the note in Table 1). The gauge length shall be marked on the wire prior to application of load when it is required for subsequent measurements. The distance between the jaw and the gauge length mark shall be at least 25 mm. © si 05-2000Page 7 EN 50189:2000 Table 1 - Initial stress and extensometer settings for determination of stress at 1 % extension Nominal wire diameter Initial stress | Initial setting of extensometer for a mm ‘gauge length of 250 mm* Over Upto and Nimm= including 124) 228 100 0.125 228 3,00 200 0.280 3,00 478 300 0.375 475 5,50 400 0,500 * For other gauge lengths, multiply the intial setting by the gauge length in mm divided by 250, The initial load shall then be increased uniformly until the extensometer indicates an extension of 1% of the original gauge length. At this point the load shall be read, from which the value of the stress at 1 % extension shall be calculated by dividing this load by the area of the wire based on actual wire diameter measured before the load was applied. The value obtained for the specimen shall be not less than the value given in the appropriate column of Tables 3 to 8. The specimen may subsequently be used for the tensile and elongation tests. 11.4 Tensile strength The test shall be made in accordance with EN 10002-1 on the coated wire at final diameter. The breaking load of one specimen cut from each of the test samples shall be determined by means of a suitable testing machine. The load shall be applied uniformly above and below the 1% extension and the rate of increasing separation of the jaws of the testing machine shall be not less than 0,1 times the gauge length in millimetres per minute and not greater than 0,4 times the gauge length in millimetres per minute. The ultimate tensile stress calculated by dividing the breaking load by the area of the wire based on actual wire diameter shall not be less than the value, corresponding to the nominal diameter, given in the appropriate column of Tables 3 to 8 14.5 Ductility test The choice between a test for permanent elongation after fracture and a torsion test is to be made at the discretion of the manufacturer, unless previously agreed between the purchaser and the manufacturer. The choice of one test or the other in no way prejudices the quality of steel used. 11.5.1 Elongation test (where chosen) The permanent elongation after fracture (A,,,). measured on a 250 mm gauge length in accordance with EN 1002-1, shall be not less than the value given in the appropriate column of Tables 3 to 8. 11.5.2 Torsion test (where chosen) When specified in Tables 3 to 8, a specimen cut from each sample shall be given a simple torsion test, as described in EN 10218-1. The number of twists, on a length 100 times the wire diameter, that causes fracture shall not be less than the value given in the appropriate column of Tables 3 to 8. © BSI 05.2000Page 8 EN 50189:2000 14.5.3 Wrapping test ‘One specimen cut from each sample of coated wire shall be subjected to the test described in EN 10218-1 with the following additional requirements: The wire shall be wrapped at a rate not exceeding 15 turns per minute around a cylindrical mandrel of diameter given in the appropriate column of Tables 3 to 8 to form a close helix of eight turns. The wire shail not break. 14.6 Mass of zinc coating The mass of coating shall be obtained by either a volumetric or gravimetric method, as described in EN 10244-2. The mass shall not be less than the appropriate value given in Table 2. Table 2 - Zinc coating requirements Nominal Class A Class Cla Class E diameter (mam) Over | Up | Min. [ min. | Min. | min. | win. | Min. | Min. | Min. Min. to | mass | no. of | mass | no. of | mass | no.of | mass | no. of no. of and | orzn | “one | ofzn | ‘one | ofzn | one | ofzn | ‘one ‘one incl. minute minute minute minute minute dips dips dips dips dips aim’ aim’ ate alm" aim’ 124 [4go| tes | 2 | a70 | 3% | 150 | 1m | 365 | ax | 105 | 2 10] 475 | 20 | 2 | 400 | 3% | te | 1% | 450 | 3% | 200 | 2 175 |200| 25 | ax | 490 | 4 | a5 | 2 550 4 | 2s | 2% 200} 225 | 218 | 2% | 490 | 4 | 5 | 2 850 4 | 250 | 3% 22s|275| 230 | 3 | 80 | 4 | t90 | 2% | 640 8 | 250 | 3% 275|3o0| 20 | 3 | 460 | 4 | 190 | 2% | 640 5 | 250 | 3% 300} 3s0| 215 | 3% | 490 | 4 | 205 | 3 730 6 | 250 | 3% 350 | 425 | 260 | 3% | sz | 4 | 260 | 3% | 730 6 | 20 | 3% 425 |47s| 27s | 4 | s50 | 4 | ars | 4 75 6 | 2s | 4 ars | 500 | 20 | 4 | sco | 5 | 20] 4 ars. 6 | 20] 4 soo] 5,25 | 20 | 4 | se | 5s | 20 | 4 2s. 6 | 20 | 4 s2s|ss0| 20 | 4 | seo | 5 | 290 | 4 as, 6 | 20 | 4 NOTE: 1 dip signifies a 30 s dip. 14.7 Adherence of zinc coating ‘One specimen cut from each of the samples of coated steel wire shall be subjected to an adherence of zinc coating test. The wire shall be wrapped at a rate not exceeding 15 turns per minute in a close helix of at least eight turns around a cylindrical mandrel having a diameter of four times the diameter of the wire for wires of diameter up to and including 3,50 mm and five times the diameter of the wire for wires of diameter greater than 3,50 mm, The zinc coating shall remain firmly adhered to the steel and shall not crack nor flake to such an extent that any zine can be removed by rubbing with the bare fingers. © si 05-2000Page 9 EN 50189:2000 11.8 Uniformity of zinc coating One specimen cut from each of the samples of coated steel wire shall be subjected to the dipping test described in EN 10244-2. The appropriate number of dips given in Table 2 shall be applied without the formation of adherent copper deposits as described in the above standard 12 Certificate of compliance The manufacturer shall, if requested, supply the purchaser with a certificate of compliance with the results of all tests made on all samples. 13 Acceptance or rejection 13.1 Failure of a test specimen to comply with any of the requirements of this standard shall constitute grounds for rejection of the lot represented by the specimen 13.2 If any lot is so rejected, the manufacturer shall have the right to test, only once, all individual coils of wire in the lot and submit those which meet the requirements for acceptance. Only those tests which do not meet the requirements for acceptance on the original specimen, shall be carried out. 14 Rounding rules The following rounding rules shall be used for determination of compliance with this standard: 14.1 When the figure immediately after the last figure to be retained is less than 5, the last figure to be retained remains unchanged 14.2 When the figure immediately after the last figure to be retained is greater than 5, or equal to 5 and followed by at least one figure other than zero, the last figure to be retained is increased by one. 14.3 When the figure immediately after the last figure to be retained is equal to 5 and followed by zeros only, the last figure to be retained remains unchanged if even and is increased by one if odd. © BSI 05.2000Page 10 EN 50189:2000 Table 3 - Mechanical properties of ST1A wires Nominal wire diameter | Diameter | Stress at | Tensile | Elongation | Mandrel | No. of tolerance | 1% strength | on 250mm | diameter | torsion am extension a tm | weeny | att R10 tet Over | Uptoand | mm Nimm® | N/mm % including Minimum | Minimum | Minimum | xD | Minimum 1.24 1.50 20,03 1170 1400 30 1 18 1,50 175 £0.03 4470 1400 30 1 18 4,75 225 + 0,08 4170 4400 30 1 18 225 278 £004 4140 4380 30 1 16 278 3,00 + 0,05 4140 4380 a5 1 16 3,00 3,50 + 0,05 1100 1300 35 1 4 3,50 425 + 0,06 1100 1300 40 1 2 425 458 £0.06 1100 1.300 40 1 2 475 5.50 20,07 1100 1.300 40 1 2 Table 4 - Mechanic: properties of ST2B wires Nominal wire diameter | Diameter Tensile | Elongation | Mandrel mm tolerance strength | on 250mm | diameter Re At | wrapping test ‘Over | Uptoand | mm Nome % including Minimum | Minimum xD 124 1,50 0,05 +100 1300 1 1,50 475 0,05 1100 1.300 40 1 475 2.25 0,05 1100 1300 40 1 2.25 275 £ 0,06 1070 1250 40 1 275 3,00 + 0,06 1070 1.250 40 1 3,00 3.50 £0.07 1000 1200 40 1 380 425 0,00 1-000 1-200 40 1 425 475 20,10 +000 4.200 40 1 475 5,60 20,11 1.000 1.200 4.0 1 © BSI 05-2000Table 5 - Mechanical properties of ST3D wiri Page 11 EN 50189:2000 Nominal wire diameter | Diameter | Stress at | Tensile | Elongation | Mandrel | No. of a tolerance | 1% strength | on 250mm | diameter | torsion extension a tm | weeny | att R10 tet ‘Over | Uptoand | mm Nimm® | N/mm? % including Minimum | Minimum | Minimum | xD | Minimum 124 1.50 £0.05 1210 1 500 40 2 16 1,50 175 20,07 1210 1500 40 2 16 475 2.25 +£0.08 1210 1500 40 2 16 225 2758 £0.10 1210 1500 40 3 16 278 3,00 20,12 4210 +500 40 3 16 3,00 380 20,1 4100 4400 40 a 16 3,50 4.25 20,13 1100 1 400 40 3 4 4.25 475 £013 1100 1-400 40 3 4 475 5,50. £013 1100 1.400 40 3 4 Table 6 - Mechanical properties of ST4A wirt Nominal wire diameter | Diameter | Stress at | Tensile | Elongation | Mandrel | No. of am tolerance | 1% strength | on 250mm | diameter | torsion extension R An for twists R10 wrapping test ‘Over mm Nimm= | Nrmm* % Minimum | Minimum | Minimum | xD | Minimum 124 1,50 = 0,08 1275 1670 a8 2 2 1.50 4.75 + 0,08 4275 1670 35 2 2 4.75 225 £0,083 4275 1670 35 2 2 225 278 20,08 4275 1670 40 3 2 278 3,00 20,08 4278 1670 40 3 2 3,00 3,80 £005 4225 4620 40 3 2 3,60 425 +006 1225 1620 40 3 2 425 45 + 0,06 1225 1620 40 3 2 475 5,50. £0.07 1225 1620 40 3 2 © BSI 05-2000Page 12 EN 50189:2000 Table 7 - Mechanic: properties of STSE wires Nominal wire diameter | Diameter | stress at | Tensile | Elongation | Mandre! tolerance | 1% strength | on 250 mm | diameter Sa} extension Re Aas for RAO wrapping test over | Uptoand | mm Nimm= | Nimm % including Minimum | Minimum | Minimum xD 124 175 20,08 7420 7620 38 4 1,75 2,30 + 0,04 1420 1620 35 4 2,30 2,55 + 0,04 1370 1620 40 4 2,55 a7. + 0,04 1370 1670 40 4 278 3,50 + 0,08 1370 1670 40 4 3,50 478 £0,06 1370 1670 40 5 475 5,50, +0,07 1370 1670 40 5 * Values in this table do not fellow the normal pattern of increasing tensile strength with decreasing diameter. This is because some of the values have been based on wires for particular high strength conductors used for specific projects. Table 8 - Mechanic: properties of ST6C wires Diameter | Stress at | Tensile strength | Elongation | Mandrel | No. of tolerance | 1% on 250mm | diameter | torsion ‘nm extension Re Ave for | twists” R10 of mean of individual | "alot ‘Over | Uptoand | mm Nimm= Nim % Including Minimum | Minimum | Minimum | Minimum xD—_| Minimum 24 | 180 +=0,08 1450 +700 + 800 20 4 “ 10 | 1,75 £0.03 1450 1700 1800 20 4 “4 175 | 2,25 20,04 1450 1700 | 1800 20 4 1" 2.258 2.78 20,04 1410 1650 | 1750 2.0 4 1“ 275) 3.00 20,05 1410 1650 | 1750 25 4 12! 300 | 3.50 £0.05 1380 1600 | 1700 25 4 12 aso | 4.25 £0.06 1340 1600 1700 28 5 10 425 | 475 +£0.06 1340 1600 1700 28 5 10 475 | 5.50 20,07 1340 1600 | 1700 25 5 10 * When galvanized before drawing, the minimum number of torsion twists shall be increased by 2 and the minimum elongation reduced by 1%. © si 05-2000Page 13 EN 50189:2000 Annex A (normative) Special national cond ns ‘Special national condition: National characteristic or practice that cannot be changed even over a long period, e.g. climatic conditions, electrical earthing conditions. If it affects harmonization, it forms part of the European Standard or Harmonization Document: For the countries in which the relevant special national con normative; for other countries they are informative. jons apply, these provisions are Clause Special national condition 1.4 Norway An additional grade of steel may be used to accommodate the climatic conditions. This grade shall have the properties given below and shall have a Class A zinc coating. In all other respects the requirements of this specification shall be followed. Tensile strength (Rn) = 980 N/mm? minimum, 1480 N/mm? maximum Stress at 1% extension (Rz 1,0) ; 880 N/mm? minimum 1080 N/mm? maximum 11.5.2 Norway STSE wire shall be subjected to a bend test in place of the torsion test. The test method shall be as described in ISO 7801, with the radius of the cylindrical support and number of bends required before breaking given in Table A.1. Table A-1 Nominal wire diameter Radius of cylindrical | Number of bends mm ‘support ‘Over Up to and ™m including 1.24 1.50 3.75 7 1.50 2,00 5.0 7 2,00 2,30 18 10 2,30 288 18 8 2.55 2.70 18 6 270 3,00 18 5 3,00 4,00 100 5 4,00 5.50 15.0 4 © Bs! 05-2000Page 14 EN 50189:2000 STIA wire shall be subjected to a bend test in place of the torsion test. The test method shall be as described in ISO 7801, with the radius of the cylindrical support and number of bends required before breaking given in Table A.2. Table A.2 Nominal wire diameter Radius of cylindrical | Number of bends mm ‘support Over Up to and mm including 124 1,80 a8 ° 1.60 2,00 50 ° 2,00 2,30 75 2 2,30 255 75 10 2.55 270 75 8 2.70 3,00 75 7 3.00 4,00 10,0 7 4,00 5,50 18.0 6 © BSI 05-2000blankBS EN 50189:2000 BSI 889 Chiswick High Road London Wa 4aL BSI — British Standards Institution BST is the independent national body responsible for preparing British Standards. 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