Test Report No.: 50093959 001 age 2 of 35 Test Report AS/NZS 5000.1:2005 including amendment 1 Electric cables olymeric insulated for working voltages up to 0.6/1kV Test item particulars: 1C 4mm 2 to 16 mm 2 Circular X-90 insulated, V-90HT sheathed electric cables 2C 1.5mm 2 to 16 mm 2 Circular X-90 insulated, V-90HT sheathed electric cables 3C 1.5mm 2 to 16 mm 2 Circular X-90 insulated, V-90HT sheathed electric cables 4C 1.5mm 2 to 16 mm 2 Circular X-90 insulated, V-90HT sheathed electric cables 5C 1.5mm 2 to 16 mm 2 Circular X-90 insulated, V-90HT sheathed electric cables General remarks: 1. This report shall not be reproduced, except in full. 2. Details in test data / test plan no.1113009436 3. Specification applied: AS/NZS 5000.1:2005 inc. amendment 1 AS/NZS 1125:2001 inc. amendment 1 AS/NZS 3808:2000 inc. amendment 1 & 2 4. Reporting of results herein is in accordance with NATA recommendations taking into account U of M. (a) For minimum limits - Where measurement is on the limit or above the limit it is deemed to comply. Where measurement is below the limit it is deemed not to comply. (b) For maximum limits - Where measurement is on the limit or below the limit it is deemed to comply. Where measurement is above the limit it is deemed not to comply. 5. For reporting of results estimated uncertainty for measurement taken into account at 95% confidence level 6. This test report is based on assessment and tests applied to the specific test item(s) as submitted by the client. TÜV Rheinland Australia disclaims any and all responsibility or obligation for any other item. 7. Thickness and conductor resistance test were conducted on all sizes. 8. Manufacturer has declared that X-90 and V-90HT material are identical across the range of the product. 9. XL-AXN/5C2.5 was chosen as representative model. Description of the test item: XL-AXN/1C4, 1C 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/1C6, 1C 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/1C10, 1C 10mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/1C16, 1C 16mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/2C1.5, 1C 1.5mm 2 + Earth 1.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/2C2.5, 1C 2.5mm 2 + Earth 2.5mm 2 0.6/1KV rated X-90 insulation, V-90HT -T sheath with class 2 plain copper conductors. XL-AXN/2C4, 1C 4mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/2C6, 1C 6mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/2C10, 1C 10mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/2C16, 1C 16mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation V-90HT sheath with class 5 plain copper conductors. XL-AXN/3C1.5, 2C 1.5mm 2 + Earth 1.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/3C2.5, 2C 2.5mm 2 + Earth 2.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/3C4, 2C 4mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/3C6, 2C 6mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/3C10, 2C 10mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors.
Test Report No.: 50093959 001 age 3 of 35 XL-AXN/3C16, 2C 16mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/4C1.5, 3C 1.5mm 2 + Earth 1.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/4C2.5, 3C 2.5mm 2 + Earth 2.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/4C4, 3C 4mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/4C6, 3C 6mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/4C10, 3C 10mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/4C16, 3C 16mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/5C1.5, 4C 1.5mm 2 + Earth 1.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/5C2.5, 4C 2.5mm 2 + Earth 2.5mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 2 plain copper conductors. XL-AXN/5C4, 4C 4mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/5C6, 4C 6mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. XL-AXN/5C10, 4C 10mm 2 + Earth 4mm 2 0.6/1KV rated X-90 insulation V-90HT sheath with class 5 plain copper conductors. XL-AXN/5C16, 4C 16mm 2 + Earth 6mm 2 0.6/1KV rated X-90 insulation, V-90HT sheath with class 5 plain copper conductors. Markings on cables:
Test Report No.: 50093959 001 age 4 of 35 Markings of cable drums:
Test Report No.: 50093959 001 age 5 of 35
Test Report No.: 50093959 001 age 6 of 35 Options/accessories/ancillary equipment: The equipment was tested without any optional accessory installed. Hence, this report does not cover parameters that are influenced by the installation of optional accessory that might affect safety in the meaning of this standard.
Test Report No.: 50093959 001 age 7 of 35 AS/NZS 5000.1:2005 5 CONDUCTORS Conductors shall comply with the relevant requirements of AS/NZS 1125 lain stranded conductors for 1.5mm² - 2.5mm² lain flexible conductors (Class 5) for 4mm² - 16mm² Where tinning is provided, any wires taken from the completed cable need not comply with the continuity test for tin plating Aluminium may be used for conductors of cross sectional areas 16mm 2 and above For aerial cables conductors shall be hard-drawn copper or aluminium. Separator tape may be used over the conductor. If not adhere to insulation, it shall be coloured or opaque. Copper conductors Not aerial cable No separator tape used 6 INSULATION 6.1.1 Used insulation material X-90 Insulation shall comply with the requirements of the relevant parts of AS/NZS 3808 6.1.2 Aerial and fixed cables for outdoor applications shall be VC that contains a minimum of 1% carbon black by weight. 6.2 The insulation shall be applied over, but shall not adhere to, the conductor. For unsheathed multicore flat cables adjacent cores shall be connected by a web such that the cores can be easily separated by tearing. Sheathed cables 6.3 Thickness of insulation The average thickness of the insulation (ti) shall be not less than the thickness specified in Table 1 Required: Core 1.5-16mm 2 0.7mm Earth 1.5mm 2 0.5mm 2.5mm 2 0.6mm 4-6mm 2 0.7mm Measured: XL-AXN/1C4 (4mm²): White:1.0mm XL-AXN/1C6 (6mm²): White:0.7mm XL-AXN/1C10 (10mm²): White:1.0mm XL-AXN/1C16 (16mm²):
Test Report No.: 50093959 001 age 8 of 35 AS/NZS 5000.1:2005 White:0.8mm XL-AXN/2C1.5 (1.5mm²): Red:1.0mm Black:0.9mm XL-AXN/2C2.5 (2.5mm²): Red:0.8mm Black:0.8mm XL-AXN/2C4 (4mm²): Red:0.8mm Black:0.7mm XL-AXN/2C6 (6mm²): Red:0.9mm Black:0.9mm XL-AXN/2C10 (10mm²): Red:1.1mm Black:0.9mm XL-AXN/2C16 (16mm²): Red:0.8mm Black:0.9mm XL-AXN/3C1.5 (1.5mm²): Red:0.8mm Black:0.9mm Earth: 0.9mm XL-AXN/3C2.5 (2.5mm²): Red:0.9mm Black:0.9mm Earth: 0.8mm XL-AXN/3C4 (4mm²): Red:0.9mm Black:0.9mm Earth: 0.9mm XL-AXN/3C6 (6mm²): Red:1.0mm Black:0.9mm Earth: 0.9mm XL-AXN/3C10 (10mm²): Red:1.0mm Black:1.1mm Earth: 0.8mm XL-AXN/3C16 (16mm²): Red:1.1mm Black:1.0mm Earth: 0.8mm XL-AXN/4C1.5 (1.5mm²): Red:0.8mm White:0.9mm Blue:0.8mm Earth: 0.7mm XL-AXN/4C2.5 (2.5mm²): Red:0.9mm White:0.9mm Blue:0.8mm
Test Report No.: 50093959 001 age 9 of 35 AS/NZS 5000.1:2005 Earth: 0.8mm XL-AXN/4C4 (4mm²): Red:0.9mm White:0.9mm Blue:0.9mm Earth: 0.9mm XL-AXN/4C6 (6mm²): Red:0.9mm White:0.8mm Blue:0.9mm Earth: 0.8mm XL-AXN/4C10 (10mm²): Red:1.0mm White:1.0mm Blue:1.1mm Earth: 0.9mm XL-AXN/4C16 (16mm²): Red:0.8mm White:0.8mm Blue:1.0mm Earth: 0.8mm XL-AXN/5C1.5 (1.5mm²): Red:0.8mm White:0.9mm Black: 0.9mm Blue:0.9mm Earth: 0.9mm XL-AXN/5C2.5 (2.5mm²): Red:0.8mm White:0.8mm Black: 0.7mm Blue:0.8mm Earth: 0.8mm XL-AXN/5C4 (4mm²): Red:0.9mm White:0.9mm Black: 0.9mm Blue:1.0mm Earth: 0.9mm XL-AXN/5C6 (6mm²): Red:0.8mm White:0.8mm Black: 0.9mm Blue:1.0mm Earth: 0.9mm XL-AXN/5C10 (10mm²): Red:0.8mm White:0.9mm Black: 1.0mm Blue:1.0mm Earth: 0.8mm XL-AXN/5C16 (16mm²): Red:0.8mm
Test Report No.: 50093959 001 age 10 of 35 AS/NZS 5000.1:2005 Minimum thickness at any point shall not fall below the specified thickness by more than 10% of the specified thickness plus 0.10 mm, i.e.: minimum thickness = (0.90ti 0.10 mm). White:0.9mm Black: 0.8mm Blue:0.8mm Earth: 0.9mm Required: Core 1.5-16mm 2 0.53mm Earth 1.5mm 2 0.35mm 2.5mm 2 0.44mm 4-6mm 2 0.53mm Measured: XL-AXN/1C4 (4mm²): White:0.74mm XL-AXN/1C6 (6mm²): White:0.65mm XL-AXN/1C10 (10mm²): White:0.86mm XL-AXN/1C16 (16mm²): White:0.54mm XL-AXN/2C1.5 (1.5mm²): Red:0.68mm Black:0.54mm XL-AXN/2C2.5 (2.5mm²): Red:0.70mm Black:0.66mm XL-AXN/2C4 (4mm²): Red:0.59mm Black:0.53mm XL-AXN/2C6 (6mm²): Red:0.73mm Black:0.70mm XL-AXN/2C10 (10mm²): Red:1.00mm Black:0.75mm XL-AXN/2C16 (16mm²): Red:0.62mm Black:0.69mm XL-AXN/3C1.5 (1.5mm²): Red:0.66mm Black:0.79mm Earth: 0.66mm XL-AXN/3C2.5 (2.5mm²): Red:0.86mm Black:0.64mm Earth: 0.64mm XL-AXN/3C4 (4mm²): Red:0.81mm Black:0.68mm Earth: 0.64mm XL-AXN/3C6 (6mm²):
Test Report No.: 50093959 001 age 11 of 35 AS/NZS 5000.1:2005 Red:0.83mm Black:0.78mm Earth: 0.78mm XL-AXN/3C10 (10mm²): Red:0.82mm Black:0.87mm Earth: 0.72mm XL-AXN/3C16 (16mm²): Red:0.77mm Black:0,78mm Earth: 0.68mm XL-AXN/4C1.5 (1.5mm²): Red:0.68mm White:0.59mm Blue:0.59mm Earth: 0.53mm XL-AXN/4C2.5 (2.5mm²): Red:0.65mm White:0.80mm Blue:0.68mm Earth: 0.67mm XL-AXN/4C4 (4mm²): Red:0.73mm White:0.85mm Blue:0.79mm Earth: 0.73mm XL-AXN/4C6 (6mm²): Red:0.77mm White:0.65mm Blue:0.78mm Earth: 0.70mm XL-AXN/4C10 (10mm²): Red:0.92mm White:0.97mm Blue:1.02mm Earth: 0.79mm XL-AXN/4C16 (16mm²): Red:0.75mm White:0.61mm Blue:0.71mm Earth: 0.58mm XL-AXN/5C1.5 (1.5mm²): Red:0.69mm White:0.76mm Black: 0.69mm Blue:0.68mm Earth: 0.54mm XL-AXN/5C2.5 (2.5mm²): Red:0.57mm White:0.79mm Black: 0.54mm Blue:0.54mm Earth: 0.60mm
Test Report No.: 50093959 001 age 12 of 35 AS/NZS 5000.1:2005 XL-AXN/5C4 (4mm²): Red:0.58mm White:0.80mm Black: 0.75mm Blue:0.64mm Earth: 0.58mm XL-AXN/5C6 (6mm²): Red:0.62mm White:0.53mm Black: 0.79mm Blue:0.79mm Earth: 0.68mm XL-AXN/5C10 (10mm²): Red:0.66mm White:0.71mm Black: 0.81mm Blue:0.75mm Earth: 0.60mm XL-AXN/5C16 (16mm²): Red:0.54mm White:0.66mm Black: 0.64mm Blue:0.60mm Earth: 0.57mm 6.4 Core identification 6.4.1 The colours green and yellow, either alone or in combination with any other colour shall not be used except: (a) when yellow printed characters identify cores by figures and words; or (b) for earth cores as described in Clause 6.4.2. 6.4.2 For other than unsheathed aerial cables, cores shall be clearly and durably identified by either colours or figures followed by words, in accordance with Clause 6.4.3 or Clause 6.4.4, as appropriate. For unsheathed multicore flat cables, including aerial cables, either one of the cores of a 2-core cable and the centre core of a 3-core cable shall be identified for use as a neutral by at least 4 evenly spaced (approximately) longitudinal ribs. Earth conductors shall be durably coloured with a combination of green and yellow, applied so that in any 15 mm length of core, one of these colours covers not less than 30% and not more than 70% of the surface of the core, the other colour covering the remainder of the surface. The mass of the insulation shall be either green or yellow, the other colour may be part of the mass or at the surface only. For earth cores as described in Clause 6.4.2. Core is identified by colours Not such cable
Test Report No.: 50093959 001 age 13 of 35 AS/NZS 5000.1:2005 For other than earth conductors, the colouring for identification may be within the mass or at the surface of the core insulation or, where cores covered the covering may be coloured. Both colouring methods are used 6.4.3 Recommended core colors: hase cores: red, white, blue Neutral core: black. Earth core: green/yellow 6.4.4 Each figure shall be followed by word that spells that figure (a) Numerals (1); (2); (3); etc. shall indicate active cores Zero (0) shall be used for neutral core (b) Height of characters (c) rinting in a contrasting colour (d) Figures spaced not more than 100mm apart 7 ASSEMBLY OF CORES 7.1 For multicore flat cables the cores shall be laid parallel in the same plane Not such cable 7.2 Circular cables 7.2.1 Cores, other than any centre core in circular cables, shall be laid up in helical, helical SZ, or waveform configuration. 7.2.2 When used, fillers, barrier/binder tapes and other binders shall be compatible with the other materials of the cable with which they are in contact. Unless specified otherwise, the use of fillers, barrier/binder tapes and other binders is optional. 8 BEDDING 8.1 Bedding complying with the requirements of this Clause or an oversheath complying with the requirements of Clause 13, shall be provided directly under any metallic layer. Where dissimilar metallic layers are used, i.e. where electrolysis and galvanic corrosion is possible or electric potential differences may occur (e.g. one metallic layer is used as a neutral while other metallic layers are earthed), electrical separation is required. In this case bedding shall not be used and the metallic layers shall be separated by a separation layer complying with Clause 10. No bedding
Test Report No.: 50093959 001 age 14 of 35 AS/NZS 5000.1:2005 8.2 The bedding shall comprise non-metallic materials, either extruded or taped. 8.3.1 Taped bedding shall comprise one or more tapes applied to form a layer. For multicore cables with circular cores with a conductor size greater than 16mm2, fillers shall be used in the outer interstices. 8.3.2 Extruded bedding shall be applied over, but not adhere to the core assembly or underlying cable component. However, any binder or a barrier tape may adhere to the bedding. For multicore cables with circular cores with a conductor size greater than 16 mm2, the outer interstices between the cores shall be filled by either fillers or the bedding. No taped bedding used No extruded bedding used 8.4 Thickness of bedding 8.4.1 Except as provided for in Clause 8.4.2, the thickness of bedding shall be derived from Table 2. 8.4.2 Where the metallic screen or concentric conductor to be applied over the core or core assembly comprises one or more metallic tapes of not greater than 0.08 mm nominal thickness, or wires not greater than 0.50 mm nominal diameter, the approximate thickness of the taped bedding may be reduced to 0.1 mm. 9 METALLIC LAYERS The metallic layer applied to single-core cable or the individual cores of a multicore cable shall be nonferromagnetic, except where the cable is for d.c application only. Multiple metallic layers may be applied over the core or core assembly in any order as appropriate for the intended use of the cable. Unless otherwise specified (see Clauses 11 and 12) metallic layers shall be applied over a bedding complying with the requirements of Clause 8 or a separation layer complying with the requirements of Clause 10. 10 SEARATION LAYER 10.1 Extruded separation layer(s) shall be applied when electrical or electrochemical separation between metallic layers is required 10.2 The separation layer shall comprise an appropriate material as specified in Clause 13.2, and shall be applied as specified in Clause 13.3. (13.2) Separation layer material
Test Report No.: 50093959 001 age 15 of 35 AS/NZS 5000.1:2005 Separation layer shall comply with the requirements of the relevant parts of AS/NZS 3808 (13.3) The separation layer shall not adhere to the underlying cable component, except for any barrier tape or binder. 10.3 Thickness The average thickness of the separation layer (Ts) shall be not less than the nominal thickness calculated by the following equation Ts = 0.02Du + 0.60 mm rounded off to 0.1mm, subject to a minimum of 1.2mm Minimum thickness at any point shall not fall below the specified thickness by more than 20% of the specified thickness plus 0.20 mm, i.e.: minimum thickness = (0.80Ts 0.20 mm). 11 ARMOUR 11.1 Armour shall consist of galvanized low-carbon (mild) steel wires complying with AS/NZS 3863 or steel tape having a tensile strength in the range 300 to 450Ma. For non-ferromagnetic armour applications an aluminium wire armour may be used. 11.2 The nominal diameter of the armour wire or the nominal thickness of the armour tape shall be not less than the appropriate values given in Tables 3 and 4, respectively. 11.3.1 The armour shall be applied over an extruded bedding complying with the requirements of Clause 8, or over a separation layer complying with the requirements of Clause 10. 11.3.2 Wire armour shall be applied helically with minimal gap between adjacent wires. Where double-wire armour is required, a separator comprising a layer of non-hygroscopic material of approximately 0.5 mm thickness shall be applied between the concentric layers of armour. For single-wire armour, or the inner layer of double-wire armour, the lay direction shall be opposite to the lay direction of helically laidup cores, or left-hand over helical S-Z or waveform laid-up cores. The outer layer of double wire armour shall be in the opposite direction to the inner layer. Joints in the armour wires shall be brazed or welded and any surface irregularities shall be removed.
Test Report No.: 50093959 001 age 16 of 35 AS/NZS 5000.1:2005 11.3.3 Tape armour shall comprise steel tapes applied helically in two layers with the same direction of lay, so that the outer tape is centred approximately over the gap of the inner tape. The gap between adjacent turns of each tape shall not exceed 50 % of the width of the tape. The direction of lay shall be opposite to that of the cores in the case of helically laidup cores, or left-hand in the case of helical S-Z or waveform laid-up cores. Joints in the tape shall be welded and surface irregularities removed. 11.4 For a cable designed to be installed underground, armour shall be further protected by an oversheath in accordance with Clause 13. 12 METALLIC SHEATH 12.1 The metallic sheath shall be lead alloy E in accordance with AS/NZS 2893. 12.2 The metallic sheath shall be removable without damage to the insulation or underlying core assembly. For single-core cables it may be applied directly over the core. For multicore cables, it shall be applied over an extruded bedding or separation layer. 12.3. The average thickness of the metallic sheath (Tm) shall be not less than the nominal thickness calculated by the following equation Tm = 0.025DuM + 0.70 mm and rounded off to 0.1mm, subject to a minimum of 1.0mm Minimum thickness at any point shall not fall below the specified thickness by more than 5% of the specified thickness plus 0.10 mm, i.e.: minimum thickness = (0.95Tm 0.10 mm). 12.4 For a cable designed to be installed underground, the metallic sheath shall be further protected by an oversheath in accordance with Clause 13. 13 OVERSHEATH 13.2 Material of oversheath V-90HT Oversheath shall comply with the requirements of the relevant parts of AS/NZS 3808 13.3 The oversheath shall not adhere to the underlying cable component, except for any barrier tape or binder. The oversheath may fill the outer interstices. 13.4 Thickness of oversheath 13.4.1 The average thickness of the oversheath (ts) shall be not less than the nominal thickness calculated according to item (a), (b) or (c) and rounded to one XL-AXN/1C4 (4mm²): Required: 1.4mm Measured: 1.6mm
Test Report No.: 50093959 001 age 17 of 35 AS/NZS 5000.1:2005 decimal place, as appropriate. XL-AXN/1C6 (6mm²): Required: 1.4mm Measured: 1.6mm XL-AXN/1C10 (10mm²): Required: 1.4mm Measured: 1.5mm XL-AXN/1C16 (16mm²): Required: 1.4mm Measured: 1.8mm XL-AXN/2C1.5 (1.5mm²): Measured: 2.6mm XL-AXN/2C2.5 (2.5mm²): Measured: 1.9mm XL-AXN/2C4 (4mm²): Measured: 2.2mm XL-AXN/2C6 (6mm²): Measured: 1.9mm XL-AXN/2C10 (10mm²): Measured: 2.1mm XL-AXN/2C16 (16mm²): Measured: 2.1mm XL-AXN/3C1.5 (1.5mm²): Measured: 1.8mm XL-AXN/3C2.5 (2.5mm²): Measured: 2.0mm XL-AXN/3C4 (4mm²): Measured: 2.1mm XL-AXN/3C6 (6mm²): Measured: 2.4mm XL-AXN/3C10 (10mm²): Measured: 2.6mm XL-AXN/3C16 (16mm²): Measured: 2.3mm XL-AXN/4C1.5 (1.5mm²): Measured: 1.8mm XL-AXN/4C2.5 (2.5mm²): Measured: 2.0mm XL-AXN/4C4 (4mm²):
Test Report No.: 50093959 001 age 18 of 35 AS/NZS 5000.1:2005 13.4.2 The minimum thickness at any point shall not fall below the nominal thickness (ts) by more than one of the following: (a) Unarmoured cables, cables with metallic or metallized tape screen or metal sheath and flexible cables: minimum thickness = (0.85 ts 0.10 mm). Measured: 2.1mm XL-AXN/4C6 (6mm²): Measured: 2.2mm XL-AXN/4C10 (10mm²): Measured: 2.6mm XL-AXN/4C16 (16mm²): Measured: 3.0mm XL-AXN/5C1.5 (1.5mm²): Measured: 2.0mm XL-AXN/5C2.5 (2.5mm²): Measured: 1.8mm XL-AXN/5C4 (4mm²): Measured: 2.5mm XL-AXN/5C6 (6mm²): Measured: 2.1mm XL-AXN/5C10 (10mm²): Measured: 2.4mm XL-AXN/5C16 (16mm²): Measured: 2.6mm XL-AXN/1C4 (4mm²): Required: 1.09mm Measured: 1.30mm XL-AXN/1C6 (6mm²): Required: 1.09mm Measured: 1.45mm XL-AXN/1C10 (10mm²): Required: 1.09mm Measured: 1.44mm XL-AXN/1C16 (16mm²): Required: 1.09mm Measured: 1.31mm XL-AXN/2C1.5 (1.5mm²): Measured: 2.08mm XL-AXN/2C2.5 (2.5mm²): Measured: 1.83mm XL-AXN/2C4 (4mm²):
Test Report No.: 50093959 001 age 19 of 35 AS/NZS 5000.1:2005 Measured: 1.98mm XL-AXN/2C6 (6mm²): Measured: 1.69mm XL-AXN/2C10 (10mm²): Measured: 1.92mm XL-AXN/2C16 (16mm²): Measured: 2.23mm XL-AXN/3C1.5 (1.5mm²): Measured: 1.45mm XL-AXN/3C2.5 (2.5mm²): Measured: 1.83mm XL-AXN/3C4 (4mm²): Measured: 1.95mm XL-AXN/3C6 (6mm²): Measured: 2.24mm XL-AXN/3C10 (10mm²): Measured: 2.15mm XL-AXN/3C16 (16mm²): Measured: 1.89mm XL-AXN/4C1.5 (1.5mm²): Measured: 1.46mm XL-AXN/4C2.5 (2.5mm²): Measured: 1.76mm XL-AXN/4C4 (4mm²): Measured: 1.61mm XL-AXN/4C6 (6mm²): Measured: 1.75mm XL-AXN/4C10 (10mm²): Measured: 2.26mm XL-AXN/4C16 (16mm²): Measured: 2.56mm XL-AXN/5C1.5 (1.5mm²): Measured: 1.76mm XL-AXN/5C2.5 (2.5mm²): Measured: 1.56mm
Test Report No.: 50093959 001 age 20 of 35 AS/NZS 5000.1:2005 (b) Armoured or wire screened cables or cables with concentric conductor where the oversheath is applied directly over the armour, screen or concentric conductor: minimum thickness = (0.80 ts 0.20 mm). 13.4.3 Where the oversheath consists of two layers of material, the nominal thickness of either layer shall be not less than 40 % of the calculated thickness, but in no case less than 1.0 mm. The minimum thickness at any point of the combined layer shall not fall below the calculated thickness by more than that specified in Clause 13.4.2.For combined layers that can be separated then the minimum at any point of each layer shall not fall below the calculated value given by the equations in Clause 13.4.2, calculated for each layer and using the nominal thickness for that layer. XL-AXN/5C4 (4mm²): Measured: 2.19mm XL-AXN/5C6 (6mm²): Measured: 1.87mm XL-AXN/5C10 (10mm²): Measured: 2.29mm XL-AXN/5C16 (16mm²): Measured: 1.87mm 14 NON-METALLIC BRAID 15 ROTECTION FROM INSECT ATTACK 16 MARKING 16.1 Information to be marked on cable (a) A registered name or registered mark which enables the manufacturer or supplier of the cord to be identified. TRICAB marked (b) Year of manufacture 003 2017 marked (c) Designation of insulation. X-90 marked (d) (e) Words ELECTRIC CABLE followed by the rated voltage Cables designed for specific application (aerial, DC use only, fixed application only) 0.6/1kV marked Fixed application only (f) Material of conductor if larger than 16mm 2 16.2 Means of marking
Test Report No.: 50093959 001 age 21 of 35 AS/NZS 5000.1:2005 (a) Marking on outer surface by printing, embossing or stamping (indenting) The distance between two blocks of marking shall not exceed 550 mm (b) Alternative means of marking shall consist of printing on a tape which is included throughout the length of the cord or printing, embossing or stamping (indenting) on the surface of an active core The distance between two blocks of marking shall not exceed 275 mm. <550mm 16.3 Legibility of marking Easily legible 16.4 Marking of packaging (a) Every packaging unit shall have the following information identified by means of an attached tag or label, or by marking directly on the unit: A registered name or registered mark which enables the manufacturer or supplier of the cable to be identified. Marking labels placed on cable drums TRICAB marked (b) Reference to the standard: AS/NZS 5000.1 Marked (c) Voltage rating 0.6/1.0kV marked (d) The number of cores and the size of conductors marked (e) Designation of insulation and sheath X-90 marked, Manufacturer has declared that the sheath material V90-HT will be marked in all future productions (f) The catalogue number, type number, name or other marking to distinguish the cable. Refer to page 2 (g) Length of cable marked 17 TESTS according to Table 6 Test 1 Conductors comply with AS/NZS1125, except tin plating See page 23 Test 2 Conductor resistance See page 23 Test 3 Insulation complies with AS/NZS 3808 See page 27 Test 4 Separation layer complies with AS/NZS 3808 Test 4 Oversheath complies with AS/NZS 3808 See page 29 Test 5 Insulation thickness (clause 6) See page 7 Test 6 Separation thickness (clause 10) Test 6 Oversheath thickness (clause 13) See page 16
Test Report No.: 50093959 001 age 22 of 35 AS/NZS 5000.1:2005 Test 7 olyamide jacket thickness (clause 15) Test 8 Armour dimension (clause 11) Test 9 Metallic sheath thickness (clause 12) Test 10 High voltage test for 4h No breakdown Test 12 High voltage test for 5min (a) on single core cables No breakdown (b) 2-, 3- or 4 core cables with conductors 35mm 2 insulated (unsheathed) or insulated and oversheathed (unscreened, unarmoured) No breakdown Test 13 High voltage test for 5min on separation layer Test 14 Compatibility test after ageing Test parameters of ageing 1.a) Tensile Strength of insulation, min 75%of unaged materials 2.a) Elongation of insulation, min 65% of unaged material 1.a) Tensile Strength of separation layer, min 75%of unaged materials 2.a) Elongation of separation layer, min 65% of unaged material 1.b) Tensile Strength of oversheath, min 75%of unaged materials 2.b) Elongation of oversheath, min 65% of unaged material Duration: 240 h Temperature:100 ± 2 C Black: Required: 9.5Ma Measured: 14.0Ma Red: Required: 10.3Ma Measured: 12.0Ma G/Y: Required: 9.7Ma Measured: 11.9Ma Black: Required: 337% Measured: 502% Red: Required: 416% Measured: 490% G/Y: Required: 338% Measured: 489% Required: 10.9Ma Measured: 14.3Ma Required: 188% Measured: 258% Test 15 Vertical flame propagation Charring not extend beyond the limits >250mm below the limit No ignition of filter paper No flaming droplets Test 16 Legibility of marking
Test Report No.: 50093959 001 age 23 of 35 AS/NZS 1125:2001 inc. amendment 1 2 COER CONDUCTORS 2.2 Material of conductor shall be high conductivity copper wire complying with the chemical composition designation C11000 in AS/NZS 1574. 2.3 Conductors shall be circular, shaped, solid, uniaxial, stranded, multiple-stranded circular, bunched circular, compressed, compacted, milliken or tinsel Manufacturer s statement accepted. stranded 2.4 Joints in conductor No joints 2.4.1 Joints are permitted in a solid conductor by welding only. Joints are also permitted in the individual wires of a stranded, uniaxial or bunched conductor and in the individual bunches or strands of a multiple-stranded conductor, from which it is formed. When joining conductors by silver-soldering, resistance butt welding or fusion welding, no joint in a wire shall be closer than 60 mm to that in any other wire or bunch in the same layer. Above restriction shall not apply when welding by cold pressure welding. 2.5 Solid conductors (class 1) Solid conductors shall be plain or metal-coated annealed or hard-drawn copper. Solid conductors used up to max 2.5 mm 2 unless cable standard specifies otherwise The d.c. resistance of conductors at 20 C shall be as specified in Table 2.2 for the relevant nominal cross-sectional area of conductor. Not such conductor Not such conductor Not such conductor 2.6 Stranded conductors (class 2) Stranded conductors shall be plain or metal-coated annealed or hard-drawn copper. The minimum number of wires shall be as specified in Table 2.3 for the relevant nominal cross-sectional area of conductor. 1.5 mm 2, 2.5 mm 2 lain copper 1.5 mm 2 Required number of wires: 3 Number of wires: 19 2.5 mm 2 Required number of wires: 3 Number of wires: 35
Test Report No.: 50093959 001 age 24 of 35 AS/NZS 1125:2001 inc. amendment 1 The d.c. resistance of conductors at 20 C shall be as specified in Table 2.3 for the relevant nominal cross-sectional area of conductor. For stranded circular, uniaxial and circular compressed conductors the individual wires shall be the same nominal diameter. For stranded shaped, circular compacted and Milliken conductors the ratio of the largest wire cross-sectional area to the smallest wire crosssectional area in the conductor shall not exceed 4. The use of circular compacted conductors shall be restricted to conductor sizes of 6 mm2 or greater unless otherwise specified in the appropriate cable Standard. When a Milliken conductor is required, the conductor shall consist of sector-shaped stranded conductors lightly insulated from each other. Required max: 21.6 Ω/km Measured: 19.4 Ω/km 1.5mm 2 : Required max: 13.6 Ω/km Measured: 13.2 Ω/km 2.5mm 2 : Required max: 7.41 Ω/km Measured: 7.29 Ω/km Wires are same diameter Not such conductor Not such conductor Not such conductor 2.8 Flexible conductors (class 5) The wires in Class 5 conductors shall be plain or metal-coated annealed copper. The individual wires shall be the same nominal diameter. The maximum wire diameter shall be as specified in Table 2.4 for the relevant nominal crosssectional area of conductor. The d.c. resistance of conductors at 20 C shall be as specified in Table 2.4 for the relevant nominal cross-sectional area of conductor. 4mm 2-16mm² lain copper 4mm 2 and 6mm² Required max: 0.31 mm Measured: 0.29 mm 10mm 2 and 16mm 2 Required max: 0.41 mm Measured: 0.29 mm 4mm 2 : Required max: 4.95 Ω/km Measured: 4.90 Ω/km 6mm 2 : Required max: 3.30 Ω/km Measured: 3.30 Ω/km 10mm 2 : Required max: 1.91 Ω/km Measured: 1.73 Ω/km 16mm 2 : Required max: 1.21 Ω/km Measured: 1.12 Ω/km 2.9 Flexible conductors (class 6) The wires in Class 5 conductors shall be plain or metal-coated annealed copper. Not such conductor
Test Report No.: 50093959 001 age 25 of 35 AS/NZS 1125:2001 inc. amendment 1 The individual wires shall be the same nominal diameter. The maximum wire diameter shall be as specified in Table 2.5 for the relevant nominal crosssectional area of conductor. The d.c. resistance of conductors at 20 C shall be as specified in Table 2.5 for the relevant nominal cross-sectional area of conductor. 2.10 Multiple Stranded conductors (rope lay) Wires in conductors shall be plain or tinned annealed copper. The individual wires shall be the same nominal diameter. The maximum wire diameter shall be as specified in Table 2.6 for the relevant nominal crosssectional area of conductor. The d.c. resistance of conductors at 20 C shall be as specified in Table 2.6 for the relevant nominal cross-sectional area of conductor. No multiple stranded conductors Table 2.1 TESTS FOR LAIN OR TINNED COER CONDUCTORS Elongation of annealed conductor wires from stranded circular and bunched circular conductors. 1.5mm²: Required min.: 14% Measured average: 19% No wire found having less than 50% of required elongation. 2.5mm²: Required min.: 14% Measured average: 20% No wire found having less than 50% of required elongation. 4mm²: Required min.: 14% Measured average: 24% No wire found having less than 50% of required elongation. 6mm²: Required min.: 14% Measured average: 25% No wire found having less than 50% of required elongation. 10mm²: Required min.: 14% Measured average: 18% No wire found having less than 50% of required elongation. 16mm²: Required min.: 14% Measured average: 18% No wire found having less than 50% of required elongation.
Test Report No.: 50093959 001 age 26 of 35 AS/NZS 1125:2001 inc. amendment 1 Coating continuity test for tinned conductors Not required, see page 4 Conductor resistance See page 14
Test Report No.: 50093959 001 age 27 of 35 AS/NZS 3808:2000 inc. amendment 2 4 MATERIALS - 4.1 Insulation material type X-90-4.2 Separation layer material type - 4.2 Ovesheath material type V-90HT - 5 TESTS AND CRITERIA - The properties of materials are specified in the following tables: - Requirements applicable for Insulation material: Table 9, column 2 - Requirements applicable for separation layer material: - Requirements applicable for Oversheath material: Table 5, column 4 - Table 5 Tests and criteria for insulation A Mechanical tests without ageing: A.1 Tensile strength - min. 12.5 Ma 2.5mm² Measured: Red: 13.7 Ma Black:12.7 Ma Earth: 12.9 MA A.2 Elongation at rupture - min. 200% 2.5mm² Measured: Red: 640% Black: 519% Earth: 520% B Mechanical tests after ageing in air oven: 168 h at 135 ± 3 C B.1 Tensile strength - min. 75% of value of unaged specimens 2.5mm² Required: Red: 10.3 Ma Black: 9.5 Ma Earth: 9,7 Ma Measured: Red: 12.0 Ma Black: 11.8 Ma Earth: 10.2 Ma
Test Report No.: 50093959 001 age 28 of 35 AS/NZS 3808:2000 inc. amendment 2 B.2 Elongation at break - min. 70% of value of unaged specimens 2.5mm² Required: Red: 480% Black: 389% Earth: 390% Measured: Red: 481% Black: 426% Earth: 401% C Melt flow index, maximum D Hot-set test: 15min at 200 ±3 C, load: 200ka D.1 Elongation under load max 175% 2.5mm² Measured: Red 55% D.2 Residual Elongation after cooling max 15% Black 40% Earth 60% 16mm² Measured: Red 10% Black 5% Earth 50% 2.5mm² Measured: Red 7.5% Black 12.5% Earth 2.5% 16mm² Measured: Red 5% Black 2.5% Earth 5% E Carbon black content, minimum F Carbon black dispersion G Electrical Characteristics:
Test Report No.: 50093959 001 age 29 of 35 AS/NZS 3808:2000 inc. amendment 2 1. Insulation resistance constant (Ki) at 20 C minimum 3000 (GΩm) 2. Insulation resistance constant (Ki) at elevated temperature minimum 3.0 (GΩm) at 90 C 4mm² Measured: Red: 10603GΩ.m Black: 12749GΩ.m Earth: 5807GΩ.m 16mm² Measured: Red: 21681GΩ.m Black: 27600GΩ.m Earth: 14921GΩ.m 4mm² Measured: Red: 28.4GΩ.m Black: 43.9GΩ.m Earth: 24.5GΩ.m 16mm² Measured: Red: 179.2GΩ.m Black: 233.5GΩ.m Earth: 67.7GΩ.m Table 6 TESTS AND CRITERIA FOR OVERSHEATH A Mechanical tests without ageing: A.1 Tensile strength - min. 12.5Ma Measured: 14.5Ma A.2 Elongation at rupture - min. 150% Measured: 289% B Mechanical tests after ageing in air oven: 504h at 120 ± 2 C B.1 Tensile strength min. 75% of value of unaged specimens Required: 10.9Ma Measured: 14.4Ma B.2 Elongation at break min. 65% of value of unaged specimens C Loss of mass: 120h at 120 ±2 C - max. 2.5 mg/cm 2 of exposed area D ressure test at high temperature: 90 ± 2 C, Indentation - max. 50% Required: 188% Measured: 218% 1.5mm 2 Measured: 0.4 mg/cm 2 1.5mm² Measured: 26% 16mm² Measured: 23% E Heat shock test - No cracks No cracks F Hot-set test: F.1 Elongation under load F.2 Residual Elongation after cooling
Test Report No.: 50093959 001 age 30 of 35 AS/NZS 3808:2000 inc. amendment 2 G Exudation of plasticiser There shall be no greasiness or droplets of liquid No greasiness or droplets of liquid
Test Report No.: 50093959 001 age 31 of 35 HOTOS
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Test Report No.: 50093959 001 age 33 of 35
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Test Report No.: 50093959 001 age 35 of 35 END OF TEST REORT