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1 Translated English of Chinese Standard: TB/T RAILWAY INDUSTRY STANDARD TB OF THE PEOPLE S REPUBLIC OF CHINA ICS S 35 Partially replacing TB/T Specification for cables on board rolling stock - Part 2: Thin wall insulation cables 机车车辆电缆第 2 部分 : 薄壁绝缘电缆 Issued on: August 22, 2010 Implemented on: February 01, 2011 Issued by: Ministry of Railways of the People s Republic of China Page 1 of 29

2 Table of Contents Foreword Scope Normative references Terms and definitions Classification, code, specifications and structure of cables Technical requirements Electrical property Safety performance Inspection rules and inspection methods Delivery conditions Cable packaging, transportation and storage Annex A (Informative) Corona lifetime test method (3kV cables) Page 2 of 29

3 Foreword TB/T 1484 Cables on board rolling stock is divided into the following parts: - Part 1: Standard wall insulation cables up to AC 3 kv; - Part 2: Thin wall insulation cables; - Part 3: 30 kv Ethylene propylene rubber insulation single-phase electric power cables; - Part 4: Low-smoke halogen-free flame retardant cables for communications and network. This Part is the Part 1 of TB/T This Part is drafted according to the rules provided in GB/T This Part, together with Part 1, replaces TB/T The main technical changes, compared with TB/T , are as follows: - Add order s technical conditions of thin wall thick insulation; the cable conductor cross-section are changed from 0.5 mm 2 to 4.0 mm 2 (see Table 2 in 4.3); - Add inspection items of thin wall cable which are necessary for factory inspection (see Table 16, Table 10 in version 2001); - Add category of thin wall cable for locomotive vehicles (see 4.1); - Add rated voltage grade of thin wall cable for locomotive vehicles (see Table 2 in 4.3); - Add water absorption test and acidic-alkali resistances test for sheath (see 5.2.5, 5.2.6; Chapter 6 in version 2001); - Modify the requirements of surface marker rubbing resistance (see ; in version 2001); - Add flexibility requirements (see ); - Modify the mechanical properties test index after oil resistant test (see ; in version 2001); - The name of dielectric strength test is revised to breakdown voltage test (see ; in version 2001); - Add model naming rules and model specification range (see 4.2 and 4.3); - Add the requirements of insulation resistance (see 6.2 and ); Page 3 of 29

4 Specification for cables on board rolling stock Part 2: Thin wall insulation cables 1 Scope This Part specified the technical requirements, test methods and inspection rules of thin wall insulation cables up to AC 3 kv for cables on board rolling stock (including CRH train). This Part applies to board rolling stocks (including CRH train); other rolling stocks can refer to this Part. 2 Normative references The following documents are indispensable for application of this document. For the dated documents so quoted, only the dated versions apply to this document. For the undated documents so quoted, the latest versions (including all modification sheets) apply to this document. GB Light diesel fuels GB/T Electrotechnical vocabulary - Electric cables (IEC :1984, IDT) GB/T Common test methods for insulating and sheathing materials of electric and optical cables - Part 11: Methods for general application - Measurement of thickness and overall dimensions - Tests for determining the mechanical properties (IEC :2001, IDT) GB/T Common test methods for insulating and sheathing materials of electric and optical cables - Part 12: Methods for general application - Thermal ageing methods (IEC :1985, IDT) GB/T Common test methods for insulating and sheathing materials of electric and optical cables - Part 13: Methods for general application - Measurement for determining the density - Water absorption tests - Shrinkage test (IEC :2001, IDT) GB/T Common test methods for insulating and sheathing materials of electric and optical cables - Part 14: Methods for general application - Test at low temperature (IEC :1985, IDT) Page 5 of 29

5 GB/T Common test methods for insulating and sheathing materials of electric and optical cables - Part 21: Methods specific to elastomeric compounds - Ozone resistance, hot set and mineral oil immersion tests (IEC :2001, IDT) GB/T Test methods for electrical properties of electric cables and wires - Part 4: Test of DC resistance of conductors GB/T Test methods for electrical properties of electric cables and wires - Part 5: Test of insulation resistance GB/T Test methods for electrical properties of electric cables and wires - Part 8: AC voltage test GB/T Test methods for electrical properties of electric cables and wires - Part 9: Spark test of insulated cores GB/T Conductors of insulated cables (IEC 60228:2004, IDT) GB/T Test methods for bare wires - Part 2: Measurement of dimensions GB/T Test methods for bare wires - Part 3: Tensile test GB/T Test methods for bare wires - Part 11: Test for adherence of coating GB/T Tinned round copper wire GB/T 6995 Markings for electric wires and cables GB/T Rail vehicle cables with rated voltages up to and including 3kV GB/T Test on gases evolved during combustion of materials from cables - Part 1: Determination of the amount of halogen acid gas (idt IEC :1991) GB/T Test on gases evolved during combustion of materials from cables - Part 2: Determination of degree of acidity of gases by measuring ph and conductivity (idt IEC :1991) GB/T Measurement of smoke density of cables burning under defined conditions - Part 2: Test procedure and requirements (idt IEC :1997) GB/T Test on electric and optical fibre cables under fire conditions - Part 12: Test for vertical flame propagation for a single insulated wire or cable - Procedure for 1kW pre-mixed flame (IEC :2004, IDT) GB/T Tests on electric and optical fibre cables under fire conditions - Part 35: Test for vertical flame spread of vertically-mounted bunched wires or cables - Category C (IEC :2000, IDT) GB/T Tests on electric and optical fibre cables under fire conditions - Page 6 of 29

6 Part 36: Test for vertical flame spread of vertically-mounted bunched wires or cables - Category D (IEC :2000, IDT) SH/T Axle oil EN 50305:2002 Railway applications - Railway rolling stock cables having special fire performance - Test methods 3 Terms and definitions For the purpose of this document, the terms and definition determined in GB/T AND the following terms and definitions shall apply. 3.1 Rated voltage The reference voltage in cable structure design and electrical performance test, expressed in U0, the unit is volts (V). Note 1: U0 is the voltage effective value between one insulated conductor and ground (the metal sheath of cables or surrounding medium of cables). In AC systems, the rated voltage of one cable shall at least be equal to the system nominal voltage of this cable used. In DC systems, the nominal voltage of this system shall not be larger than 1.5 times of the rated voltage of this cable. Note 2: The working voltage of this system is allowed to exceed 10% of the nominal voltage of this system for a long time. If the rated voltage of one cable is at least equal to the nominal voltage of this system, the cable can work under the working voltage being higher than 10% of the rated voltage. 3.2 Thin wall insulation The wall insulation that, according to different voltage grade and different conductor cross section, adopts special high performance insulation properties, which meet the insulation thickness of reduction in this Part. 4 Classification, code, specifications and structure of cables 4.1 Classification Grades divided according to rated voltages 250 V, 750 V Classification divided according to oil resistivity Page 7 of 29

7 Table 2 Specification Model Rated voltage Cores Cross-section mm 2 WDZ - DC - B / 250 V, 750 V ~ 4 WDZ - DC - B - H / WDZ - DC - B - * - H / WDZ - DC - B - TH / WDZ - DC - B - * - TH / WDZ - DC - B - H / WDZ - DC B - * - H / WDZ - DC - B - TH / WDZ - DC B - * - TH / 250 V, 750 V 1 ~ ~ V, 750 V Note 1: * refers to shield form, including forms of FP, ZP and P; 1 ~ 19 pairs (2-38 cores) Note 2: # refers to temperature-resistance grade, including 100 C, 125 C and 150 C; Note 3: refers to oil-resistance grade, including types of I, II and III ~ Structure Conductor Conductors shall be composed of tinned soft annealed round copper wires; the tin coatings shall be continuous and uniform. The breaking elongation of tinned copper wires shall comply with provisions of Table 3. Table 3 Breaking elongation of conductors Nominal diameter d Breaking elongation mm % 0.05 <d <d <d <d <d Filament diameters of conductors shall comply with provisions of Table 4. Page 10 of 29

8 Isolation layer is allowed to use between the insulation and the sheath. The nominal thickness of the sheath shall comply with provisions of Table 5; the thickness of the thinnest point shall not be less than the thickness obtained from 90% of the specified value minus 0.1mm Sheaths shall be smooth without bumps, blistering, cracks and other detects. Unless otherwise specified, all cable sheaths are black The difference (value f) between the maximum diameter and the minimum diameter on any circular cross-section of cables shall not exceed 10% of the upper limit of specified average outer diameter. 5 Technical requirements 5.1 Minimum bending radius When the cable diameter (D) is less than or equal to 20 mm, the minimum bending radius shall not be more than 4D (the minimum bending radius of shied cables shall not be more than 6D); when the cable diameter (D) is larger than 20 mm, the minimum bending radius shall not be more than 6D (the minimum bending radius of shied cables shall not be more than 8D). 5.2 Physical and mechanical properties Original mechanical properties The mechanical properties of insulation, sheaths and single insulation of cables shall comply with provisions of Table 7. Table 7 Original mechanical properties Item Tensile strength Mpa Breaking elongation % Single insulated conductor Insulated layer with sheath Sheath Thermal aging After the single insulating cable is conducted with thermal ageing, it shall not be breakdown when immerse-water test is performed. Retention rate of tensile strength and elongation at break shall meet the provisions in Table 8, after the sheath layer is gone through thermal ageing. Page 13 of 29

9 Breaking elongation after oil immersion Y2 = (4) Breaking elongation after oil immersion Diameter after oil immersion Y3 = (5) Diameter before oil immersion Water absorption of sheath layers The maximum weight of a cable sheath shall not exceed 15 mg/cm 2 after it absorbs water Acidic-alkali resistances There shall be no insulation breakdown for single insulating wire after voltage test is conducted at power frequency 50 Hz, 1.5 kv AC for 1 min, regardless of the specifications after treatment. The tensile strength changes of the outermost layers of single-core cables and multi-core cables with sheaths shall not exceed ± 30%; the breaking elongation of them shall not be less than 100% Thermal elongation The thermal elongation under load shall not be greater than 100%; the unloading permanent deformation rate shall not be greater than 25% Cold resistance Winding at low temperature When the diameters of cables are less than or equal to 12.5 mm, it shall adopt winding test at low temperature to determine the dynamic being performance of cables at low temperature (-40 C). There shall be no cracks on them after test; there shall be no breakdown after voltage test in water Tensile at low temperature When the diameters of cables are less than or equal to 12.5 mm, it shall adopt tensile test at low temperature to determine the mechanical properties of cables at low temperature (-40 C); the breaking elongation shall not be less than 20% Low-temperature impact Low temperature impact test (-40 C) is used to inspect the ability to withstand the impact at w temperature. There shall be no cracks on sheaths or insulation; there shall be no Page 15 of 29

10 breakdown for cables when they withstand DC test voltages specified in Table 15. Table 15 Moisture resistance of insulation Voltage grade V Applied voltage V 250 DC DC Safety performance 7.1 Vertical flammability of single cable Conduct tests under conditions specified in GB/T Residual-flam of cables shall be extinguished at their own, after the fire supply is stopped. The distance between the start-point and the end-point of the parts between the lower edge of upper bracket and carbonization part shall be larger than 50 mm; if the distance that the fire extends to the lower edge of supper bracket is not larger than 540mm, then the vertical flammability of the cable is qualified. 7.2 Combustion property of bunched cables When cable with diameter greater than 6mm are tested under specified conditions in Category C of GB/T , it is deemed as qualified, if the cable carbonized height is not more than 2.5 m after fire supply is stopped. When cable with diameter not greater than 6mm are tested under specified conditions in Category D of GB/T , it is deemed as qualified, if the cable carbonized height is not more than 1.5 m after fire supply is stopped. 7.3 Flame smoke density of cables The transmittance of cables shall not be lower than 80% when test is conducted under specified conditions. 7.4 ph value and electrical conductivity The ph value 4.3; the electrical conductivity 10μS/mm. 7.5 Halide Content The emission of hydrogen chloride shall not be larger than 0.5%. 7.6 Toxicity index The toxicity index of cables on board rolling stock shall not be larger then 5. 8 Inspection rules and inspection methods Page 18 of 29

11 8.1 Inspection rules Cable inspection and inspection items are shown in Table 16. Users can require the manufacturer to provide inspection test reports of all items or parts of items according to the order quantity. If users have any objection to the reports, they can require the manufacturer to do inspection to all items or parts of items again. Table 16 Inspection rules and inspection methods SN Inspection items Technical Inspection rules requirem Category of oil resistance ents I II III Samples Inspection type Inspection methods 1 Appearance Cables T, R Visual inspection 2 Cable diameter and roundness (Value f) Cables T, R GB/T Braided density and 3 diameter of braided wires Shield layers T, R GB/T Thickness of insulation, sheath and single insulation Insulation, sheath and single insulation T, R GB/T Conductor pitch Conductor and single wire T, R GB/T Filament diameter of conductors Breaking elongation of conductors Inspection of original Conductors T, R GB/T Conductors T, R GB/T mechanical properties of insulation, sheath and Insulation, sheath and single insulation T GB/T single insulation 9 Thermal aging test Insulation, sheath and single insulation T GB/T Ozona resistance test Insulation, sheath and single insulation T GB/T Oil resistance Tensile test after oil immersion Immersed in mineral oils Immersed In fuel oils Sheath and single insulation T GB/T Diameter Immersed change after in mineral oil immersion oils Page 19 of 29

12 Breaking elongation of the conductor The inspection shall be conducted according to GB/T ; choose 10% or 5 metal wires at random (the less shall be chosen) Test of physical and mechanical properties Inspection of original mechanical properties of insulation, sheath or single insulation The inspection of tensile strength and breaking elongation of cable insulation, sheath or single insulation shall be conducted according GB/T ; the results shall comply with the provisions of Thermal aging test The air box thermal aging test shall be conducted according to GB/T ; the results shall comply with the provisions of Ozone resistance test The ozone resistance test shall be conducted according to GB/T ; the test shall last for 3h; there shall be no crack on the sample surface after the test; then conduct the immersion voltage test; there shall be no breakdown during the test Oil resistance test Tensile test after oil immersion The test shall be conducted according to GB/T ; the oil immersion time, temperature and the calculated Y1 and Y2 values after the test shall comply with the provisions of Diameter variation measurement after oil immersion The measurement shall be conducted according to GB/T ; the oil immersion time, temperature and the Y3 value after the test shall comply with the provisions of Voltage test after oil immersion The voltage test after oil immersion shall be conducted according to GB/T ; there be no breakdown during the voltage test. The oil immersion time and temperature shall comply with the provisions of Breakdown voltage test after oil immersion The breakdown voltage test after oil immersion shall be conducted according to GB/T ; the breakdown voltage shall comply with the provisions of Table 11. The oil immersion time and temperature shall comply with the provisions of Page 23 of 29

13 Water absorption test of the cable sheath Immersed in 70 C±2 C water for 168 h; the test shall be conducted according to 9.2 in GB/T Acidic-alkali resistance test Conduct acidic test and alkali test respectively in the following conditions: - Acidic type 1 N - oxalic acid solution; - Alkali type 1 N - sodium hydroxide solution; - Temperature: 23 C±2 C; - Time: 168h. All insulated single cables shall be exerted to power frequency alternating current of 50 Hz and 1.5 kv for 1 minute, regardless of their size; after alkali treatment, no insulation breakdown shall occur when test is over. Outer cover layer of single core and multi-core cables with sheath shall be conducted with mechanical testing according to GB/T Thermal elongation test When the insulation and sheath are cross-linking materials, the thermal elongation test shall be conducted according to GB/T ; test temperature: 200 C±3 C, test load time: 15min, mechanical stress: 0.20 N/mm Low temperature resistance test Low-temperature winding test When the cable diameter is less than or equal to 12.5mm, -40 C low-temperature winding test shall be conducted according to GB/T There shall be no crack after the test and no breakdown during the immersion voltage test Low-temperature tensile test When the cable diameter is more than 12.5mm, -40 C low-temperature tensile test shall be conducted according to GB/T ; the breaking elongation shall not be lower than 20% Low-temperature impact test The low-temperature impact test shall be conducted according to GB/T There shall be no crack on the sample surface after the test, and no breakdown during the immersion voltage test. Page 24 of 29

14 8.4.4 Safety performance inspection Combustion test Combustion test of single cable and bunched cables shall be conducted in accordance with GB/T , GB/T and GB/T respectively Smoke density test It shall be conducted in accordance with GB/T PH and conductivity test It shall be conducted in accordance with GB/T Halogen content test It shall be conducted in accordance with GB/T Toxicity determination test It shall be conducted in accordance with 9.2 in EN 50305: Delivery conditions 9.1 Rules for product delivery acceptance Before delivery, products shall pass the inspections conducted by the quality inspection department of the manufacturer. Each package of the products to be delivered shall be attached with the product quality inspection certificates Products shall take acceptance according to the inspection items specified in this Part Cables with delivery length shall be wound in coils or circles by 100m or integral-multiples of 100m. In the delivery lengths, the shortest cable shall not be less than 30m, and the short section proportion shall not exceed 10% of the total number of delivery. Special conditions shall be negotiated by the supplier and purchaser. 9.2 Signs of finished cables The finished cables sheath shall have continuous signs, such as manufacturer name, product code and executive standard code. They shall be clear, easy to recognize and rubbing resistant 10 Cable packaging, transportation and storage Page 27 of 29

15 10.1 Packaging and transportation Cables shall be properly packaged on the cable reels for delivery. The cable ends shall be reliably sealed; the end stretching out of the reel shall be equipped with a shield; the stretching length shall not be less than 200mm. Short cables with a weight not exceeding 80 kg can be packaged in coils The outside of the cable reels or the additional label of the cable coils shall be marked with: a) Manufacturer name or trademark; b) Product code; c) Length (m); d) Gross weight (kg); e) Manufacture date: Y/M; f) Executive standard code Transportation and storage Transportation and storage shall comply with the following requirements: a) Prevent cables being stored in the open air; cable reels shall never be laid flat. b) Reels loaded with cables are prohibited to be thrown from height during the transportation; cable mechanical damage is prohibited. c) Never hoist several cable reels at the same time. Cable reels shall be stably placed and properly fixed on vehicles, ships and other transportation tools to prevent collision or turnover. Page 28 of 29