AS/NZS 1660.2.2:1998(Incorporating Amendment No. 1)Australian/New Zealand Standard ™Test methods for electric cables,cords and conductorsMethod 2.2: Insulation, extruded semi-conductive screens and non-metallic sheaths—Methods specific to elastomeric, XLPE and XLPVC materialsAS/NZS 1660.2.2s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:1998This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee EL-003, Electric Wires and Cables. It was approved on behalf of the Council of Standards Australia on 19 December 1997 and on behalf of the Council of Standards New Zealand on 5 December 1997. It was published on 5 March 1998.The following interests are represented on Committee EL-003:Australasian Railway Association Australian Electrical and Electronic Manufacturers Association Department of Defence, Australia Electrical regulatory authorities Electricity Supply Association of Australia Institution of Engineers, Australia Ministry of Commerce, New Zealand New Zealand Electrical Contractors Association New Zealand Electrical and Electronic Manufacturers Federation Office of Energy, N.S.W.Testing interestsKeeping Standards up-to-dateStandards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued.Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased.Detailed information about joint Australian/New Zealand Standards can be found by visiting the Standards Australia web site at .au or StandardsNew Zealand web site at and looking up the relevant Standard in the on-line catalogue.Alternatively, both organizations publish an annual printed Catalogue with full details of all current Standards. For more frequent listings or notification of revisions, amendments and withdrawals, Standards Australia and Standards New Zealand offer a number of update options. For information about these services,users should contact their respective national Standards organization.We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Please address your comments to the Chief Executive of either Standards Australia International or Standards New Zealand at the address shown on the back cover.This Standard was issued in draft form for comment as DR 97070.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:1998(Incorporating Amendment No. 1)Australian/New Zealand Standard ™Test methods for electric cables,cords and conductorsMethod 2.2: Insulation, extruded semi-conductive screens and non-metallic sheaths—Methods specific to elastomeric, XLPE and XLPVC materialsOriginated in Australia as part of AS 1660.2—1974.Previous Australian edition AS 1660.2.2—1993.Jointly revised and designated AS/NZS 1660.2.2:1998.Reissued incorporating Amendment No. 1 (July 2001).COPYRIGHT© Standards Australia/Standards New ZealandAll rights are reserved. No part of this work may be reproduced or copied in any form or by anys e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19982PREFACEThis Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee EL-003, Electric Wires and Cables, to supersede AS 1660.2.2—1993,Test methods for electric cables, Method 2.2:Insulation, extruded semi-conductive screens and non-metallic sheaths—Methods specific to elastomeric and XLPE compounds . It is one of a set of tests for electric cables included in the AS/NZS 1660 series. Details of the series are given in Appendix A.This Stand ard incorporates Amend ment No. 1 (July 2001). The changes required by the Amendment are indicated in the text by a marginal bar and amendment number against the clause, note, table, figure or part thereof affected.The objective of this Standard is to provide manufacturers and testers with appropriate test methods for elastomeric, XLPE and XLPVC insulation, screens and sheaths of electric cables and cords.This edition of the Standard differs from the 1993 edition as follows:(a)The title has been modified to include reference to XLPVC materials.(b)The indirect method of measuring air flow in ovens has been changed to therequirements of IEC 811-1-2, Common test method s for insulating and sheathing materials of electric cables , Part 1: Methods for general application , Section Two—Thermal ageing methods .(c)The reference to ASTM D 471, Stand ard test method for rubber property—Effect of liquids No. 2 oil has been changed to IRM 902 (Calumet No. 2) oil.(d)This edition is published as a Joint Australian/New Zealand Standard.(e)A compatibility test has been added.In the preparation of the Standard, consideration was given to IEC 811:1985, Common test methods for insulating and sheathing materials of electric cables , Part 2: Methods specific to elastomeric compound s . Acknowledgment is made of the assistance received from this source.The term 'informative' has been used in this Standard to define the application of the appendix to which it applies. An 'informative' appendix is only for information and guidance.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19983CONTENTSPageSECTION 1SCOPE AND GENERAL1.1SCOPE (4)1.2REFERENCED DOCUMENTS (4)1.3DEFINITIONS (4)1.4TESTING TEMPERATURE (4)1.5SELECTION OF SPECIMENS...................................................................................4SECTION 2METHODS OF TEST FOR INSULATION, EXTRUDED SEMI-CONDUCTIVE SCREENS AND NON-METALLIC SHEATHS2.1HOT SET TEST (5)2.2THERMAL AGEING (5)2.3MINERAL OIL IMMERSION TEST..........................................................................9APPENDIX A LIST OF METHODS OF TEST IN THE AS/NZS 1660 SERIES 12s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19984STANDARDS AUSTRALIA/STANDARDS NEW ZEALANDAustralian/New Zealand Standard Test methods for electric cables, cords and conductorsMethod 2.2: Insulation, extruded semi-conductive screensand non-metallic sheaths—Methods specific to elastomeric, XLPE and XLPVC materialsS E C T I O N 1 S C O P E A N D G E N E R A L1.1 SCOPEThis Standard sets out the methods of testing insulation, extruded semi-conductive screens and non-metallic sheaths of elastomeric, XLPE and XLPVC insulated electric cables.NOTE: Refer to individual cable Standards for test results criteria. Details of the AS/NZS series of Standards are given in Appendix A.1.2 REFERENCED DOCUMENTSThe following documents are referred to in this Standard:AS/NZS1660Test methods for electric cables, cords and conductors 1660.2.1M ethod 2.1: Insulation, extruded semi-conductive screens and non-metallic sheaths—Methods for general application ASTMD 471Standard test method for rubber property—Effect of liquids1.3 DEFINITIONSFor the purpose of this Standard, the definitions given in the relevant cable Standard and that below apply.1.3.1 Median value Value obtained from a succession of test results as follows:(a)Even number of results...................average value of the two middle results.(b)Odd number of results....................value of middle result.1.4 TESTING TEMPERATURE Unless otherwise specified, all tests shall be carried out in an ambient temperature of 23±5°C.1.5 SELECTION OF SPECIMENS All specimens used for testing shall be taken at least 300 mm from the end of a factory length of finished cable, flexible cable or flexible cord.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19985S E C T I O N 2 M E T H O D S O F T E S T F O RI N S U L A T I O N , E X T R U D E D S E M I -C O N D U C T I V ES C R E E N S A N D N O N -M E T A L L I C S H E A T H S2.1 HOT SET TEST2.1.1 Sampling and preparation of test pieces, and determination of their cross-sectional area2.1.1.1 GeneralTwo test pieces from each core or sheath to be tested, after they have been prepared and their cross-sectional areas measured, as specified in the test methods of AS/NZS 1660.2.1for insulation or for sheath, shall be used for the test. For insulation of cables above 1 kV,the dumb-bells shall be prepared from the inner part of the insulating wall after any ridges or semi-conducting layer, or both, have been removed.2.1.1.2 ApparatusThe test shall be carried out in an oven, as specified in Clause 2.2.1.2, maintained at the temperature specified for the material in the relevant cable Standard. The oven shall be fitted with a viewing window. The requirement of Clause 2.2.1.2 for air changing is not applicable to this Clause (2.1).Grips shall be provided, such that each test piece can be suspended from an upper grip in the oven and weights attached to a lower grip attached to the test piece.2.1.1.3 ProcedureThe test pieces shall be suspended in the oven and weights attached to the bottom jaws to exert a force of the value specified for the material in the relevant cable Standard.After 15 min in the oven at the temperature specified for the material in the relevant cable Standard, the distance between the marker lines shall be measured without opening the oven door and the percentage elongation calculated to the nearest 5 percent.The tensile force shall then be removed from the test piece, e.g. by cutting the test piece at the lower grip, and the test piece left to recover for 5 min at the specified temperature.The test pieces shall then be removed from the oven and allowed to cool slowly to ambient temperature, after which the distance between the marker lines shall be measured again to the nearest 0.5 mm and the percentage elongation calculated.2.1.1.4 Report The average of the two values shall be reported for both the elongation under load and the elongation after cooling.2.2 THERMAL AGEING 2.2.1 Ageing in an air oven 2.2.1.1 General An ageing treatment in an air oven may be required by the relevant cable Standard as follows:(a)For prepared test pieces, Clause 2.2.1.3 shall apply.(b)For pieces of completed cable, Clause 2.2.1.4 shall apply.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:199862.2.1.2 Test equipmentAn oven with natural air flow or air flow by pressure shall be used. The air shall enter the oven in such a way that it flows over the surface of the test pieces and leaves near the top of the oven. The oven shall have not less than 8 and not more than 20 complete air changes per hour at the specified ageing temperature.Two methods of measuring the rate of air flow through an oven are given in Clause 2.2.2.2.2.1.3 Procedure for prepared test piecesThe ageing shall be carried out in an atmosphere having the composition and pressure of the ambient air.The test pieces, as specified in AS/NZS 1660.2.1, shall be suspended vertically and substantially in the middle of the oven so that each piece is at least 20 mm from any other piece.The test pieces shall be kept in the oven at the temperature and for the time specified for the material in the Standard for the type of cable.Materials of substantially different compositions shall not be tested in the same oven at the same time.As soon as the ageing period is completed, the test pieces shall be removed from the oven and left at ambient temperature, avoiding direct sunlight, for at least 16 h. The tensile test shall then be carried out in accordance with AS/NZS 1660.2.1.2.2.1.4 Procedure for pieces of complete cableThree pieces of complete cable about 200 mm long shall be taken, preferably from a position close to those where the samples for the tensile test without ageing (see AS/NZS 1660.2.1) are taken.The pieces of cable shall be suspended substantially in the middle of the oven at least 20 mm away from each other and shall occupy not more than 2 percent of the volume of the oven.The pieces of cable shall be kept in the oven at the temperature and for the time specified in the relevant cable Standard.As soon as the specified heating period is completed, the pieces of cable shall be removed from the oven and left at ambient temperature, avoiding direct sunlight, for at least 16 h.The three pieces of cable shall then be dismantled. Two test pieces shall be prepared from the insulation of each core (up to a maximum of three cores) and from the sheath of each piece of cable, as specified in AS/NZS 1660.2.1, so that there are six test pieces from each core and from the sheath.If the test pieces need to be cut or ground to reduce their thickness to not more than 2 mm,this operation shall be effected, so far as possible, on the side which was not facing a material of different type in the complete cable. If ridges must be cut or ground on the side which was facing the different type of material, the material removed on that side shall be minimum compatible with adequate smoothing.After measurement of their cross-sectional areas and after conditioning has been carried out, the test pieces shall be subjected to the tensile test, all in accordance with AS/NZS 1660.2.1.2.2.1.5 CompatibilityThree pieces of complete cable about 200 mm long shall be taken, preferably from a position close to where the samples without ageing (see AS 1660.2.1) were taken.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19987The pieces of cable shall be suspended substantially in the middle of an oven, complying with Clause 2.2.1.2, at least 20 mm away from each other, and shall not occupy more than 2 percent of the volume of the oven.The pieces shall be kept in the oven at the temperature and for the time specified in the relevant cable Standard.As soon as the specified heating period is completed, the pieces of cable shall be removed from the oven and left at ambient temperature, avoiding direct sunlight for at least 16 hours.The three pieces of cable shall then be dismantled. Where dissimilar materials are in direct contact with each other, then test pieces for the tensile test, in accordance with AS 1660.2.1, shall be prepared from each material in each cable sample. Fillers, barrier tapes and binders shall not be tested, only the material with which they come in contact.If the pieces need to be cut or ground to reduce their thickness to not more than 2 mm, this operation shall be effected, so far as possible, on the side which was not in contact with a dissimilar material. If ridges must be cut or ground on the side in contact with a dissimilar material, the material removed on that side shall be minimum compatible with adequate smoothing.After conditioning, and measurement of their cross-sectional areas, the test pieces shall be subjected to the tensile test, all in accordance with AS 1660.2.1.2.2.2 Methods of measuring air flow in ovens2.2.2.1 Method 1—Indirect or power consumption methodThe method shall be as follows:(a)The additional power required to maintain the oven at a given temperature with itsports open, over that required to maintain the oven at the same temperature with its ports closed, shall be used as a measure of the quantity of air passing through the oven when the ports are open. The average power (P 1 watts) required to maintain the oven temperature at the specified ageing temperature when the ports are open shall be determined over a period of 30 min or longer. The ventilation ports (and, if necessary,the thermometer aperture) shall then be closed and the average power (P 2 watts) to maintain the same temperature over a similar period shall be determined. The difference between the oven temperature and the room temperature shall be the same for the two tests to within 0.2°C. The room temperature shall be measured at a point about 2 m from the oven, approximately level with its base, and at least 0.6 m from any solid objects.(b)The amount of air passing through the oven when the ports are open shall becalculated from the following equations:(a))(12p 21t t C P P m −−=(b)dmV 6003=where:m =mass of air, in grams per second P 1−P 2=difference in power consumption, as defined in Item (a)C p =specific heat of air at constant pressure (1.003 J/g)t 2=oven temperature, in degrees Celsius t 1=room temperature, in degrees Celsius V =volume of air, in litres per hour d =density of air in the laboratory at the time of test, in grams per litre.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:19988Hence: V =()()12003.1216003t t d P P −−or V =()()12215903t t d P P −−This method assumes that, when the ports are closed, no air passes through the oven.Therefore, there shall be no leakages. The air-tight door joints should be sealed with adhesive tape and all apertures, including the inlet port, should be effectively closed.(c)If the power consumption is measured with a wattmeter, the total length of time, inseconds, for which the oven heaters are 'on' shall be measured with a stop-watch and the reading of the wattmeter shall be taken once during each 'on' period.The average of the wattage readings multiplied by the total time registered by the stop-watch and divided by the duration of the test, in seconds, shall be taken as the power, in watts, required to maintain a constant temperature.(d)If a watt-hour or kilowatt-hour meter is used, the reading of the total energyconsumption registered by the meter shall be divided by the duration of the test,measured as a fraction of an hour. If a household kilowatt-hour meter is used, the dial units are too large to enable a sufficient accuracy to be obtained over a reasonably short test, and the rotating disc with which these meters are provided shall be used therefore as the power consumption indicator. The meter shall be put into operation until the index mark on the disc is opposite the centre of the window; it shall then be disconnected until the start of the test.To reduce the possible error, the period of test shall be long enough to permit 100revolutions of the disc and the test shall preferably be ended when the mark on the disc is visible. However, if the mark is out of sight at the end of the test, an estimated fraction of a revolution shall be added. The test shall be started and stopped at corresponding points on the 'on-off' heating cycle (e.g. at the moment when heaters are switched on by the thermostat).2.2.2.2 Method 2—Direct and continuous methodThe equipment for Method 2 shall comprise the following items:(a)Air pressure regulator —a device to reduce the air pressure from that of the supplymains to the low-pressure needed for feeding the oven. It is equipped with an adjustable valve which permits a constant pressure downstream.(b)Flowmeter —an instrument with which the rate of air flow can be measured. It is illustrated in Figure 2.1, and operates on a manometric principle, with—(a)capillary tube, of precision bore of about 2 mm, and a length of about 70 mm;Figure 2.2 shows a typical calibration diagram for airflows up to 500 L/h or600 L/h; and(b)manometric tube with a double graduation of pressure difference rangingbetween 0 mm and ±300 mm of water; distilled water is the manometric liquid.(c)Air oven —an ordinary air oven to be operated when carefully sealed, including sealing round the inlet tube, which should preferably enter the oven through the bottom. The outflow hole, which should be at the top of the oven, is the only port to be open.NOTE: The following two features facilitate the reliability of the method and the equipment:(a)The flowmeter described above can be considered as fully reliable, easy to manufacture and to calibrate, as well as suitable for the range of air rates involved.(b)As shown by tests, the adoption of a slightly 'forced' ventilation does not alter, in practice, the uniformity of the temperature at the various points in the ovens.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:199892.3 MINERAL OIL IMMERSION TEST 2.3.1 Sampling and preparation of the test pieces Five test pieces shall be prepared in accordance with the procedure described in AS/NZS 1660.2.1.2.3.2 Determination of the cross-sectional areas of the test piece The test method in AS/NZS 1660.2.1 shall apply.2.3.3 Oil to be usedUnless otherwise specified in the relevant cable Standard, the mineral oil shall be IRM 902,as specified in ASTM D471.2.3.4 ProcedureThe test pieces shall be immersed in the oil previously heated at the specified test temperature and shall be maintained in the oil at that temperature for the specified time (see relevant cable Standard).At the end of the specified duration, the test pieces shall be removed from the oil, blotted lightly to remove excess oil and suspended in air at ambient temperature for at least 16 h but not more than 24 h, unless otherwise specified in the relevant cable Standard. At the end of this period any further excess oil shall be removed by lightly blotting the test pieces.2.3.5 Determination of the mechanical characteristicsThe test method in AS/NZS 1660.2.1 shall apply.2.3.6 Expression of results and requirementsThe calculation for tensile strength shall be based on the area of the test piece measured before immersion (see AS/NZS 1660.2.1).The median value obtained on the five test pieces immersed in oil shall be expressed as a percentage of the median value of the five values obtained on the untreated test pieces.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:199810s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:199811FIGURE 2.2 CALIBRATION DIAGRAM OF THE CAPILLARY TUBE (d = 2.0 mm,l = 70 mm) OF THE FLOWMETER FOR AIR-FLOW CONTROL IN AIR OVENSs e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008AS/NZS 1660.2.2:199812APPENDIX ALIST OF METHODS OF TEST IN THE AS/NZS 1660 SERIES(Informative)The Standards in the AS/NZS 1660 series are as follows:Number Title AS/NZS 1660Test methods for electric cables, cords and conductors AS/NZS 1660.1Method 1: Conductors and metallic components AS/NZS 1660.2.1Method 2.1: Insulation, extruded semi-conductive screens and non-metallic sheaths—Methods for general application AS/NZS 1660.2.2Method 2.2: Insulation, extruded semi-conductive screens andnon-metallic sheaths—M ethods specific to elastomeric, XLPEand XLPVC materialsAS/NZS 1660.2.3Method 2.3: Insulation, extruded semi-conductive screens andnon-metallic sheaths—Methods specific to PVC and halogen freethermoplastic materialsAS/NZS 1660.2.4Method 2.4: Insulation, extruded semi-conductive screens andnon-metallic sheaths—M ethods specific to polyethylene andpolypropylene materialsAS/NZS 1660.2.5Method 2.5: Insulation, extruded semi-conductive screens andnon-metallic sheaths—Methods specific to cables above 1 kVAS/NZS 1660.3Method 3: Electrical testsAS/NZS 1660.4Method 4: Complete cable and flexible cordAS/NZS 1660.5.1Method 5.1: Fire tests—Tests on bunched cablesAS/NZS 1660.5.2Method 5.2: Fire tests—Smoke densityAS/NZS 1660.5.3Method 5.3: Fire tests—Determination of the amount of halogenacid gas evolved during the combustion of polymeric materialstaken from cablesAS/NZS 1660.5.4M ethod 5.4: Fire tests—Determination of degree of acidity ofgases evolved during the combustion of materials taken fromelectric cables by measuring pH and conductivityAS/NZS 1660.5.5Method 5.5: Fire tests—Circuit integrity under fire conditionsAS/NZS 1660.5.6Method 5.6: Fire tests—Test for combustion propagation s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008Standards AustraliaStandards Australia is an independent company, limited by guarantee, which prepares and publishes most of the voluntary technical and commercial standards used in Australia. 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The requirements or recommendations contained in published Standards are a consensus of the views of representative interests and also take account of comments received from other sources. They reflect the latest scientific and industry experience. Australian/New Zealand Standards are kept under continuous review after publicationand are updated regularly to take account of changing technology.International Involvement Standards Australia and Standards New Zealand are responsible for ensuring that the Australian and New Zealand viewpoints are considered in the formulation of international Standards and that the latest international experience is incorporated in national and Joint Standards. This role is vital in assisting local industry to compete in international markets. Both organizations are the national members of ISO (the International Organization for Standardization) and IEC (the International Electrotechnical Commission).Visit our Web sites .au s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008GPO Box 5420 Sydney NSW 2001AdministrationPhone (02) 8206 6000Fax (02) 8206 6001Email mail@.auCustomer ServicePhone 1300 65 46 46Fax 1300 65 49 49Email sales@.auInternet .auLevel 10 Radio New Zealand House 155 The Terrace Wellington 6001(Private Bag 2439 Wellington 6020)Phone (04) 498 5990Fax (04) 498 5994Customer Services (04) 498 5991Information Service (04) 498 5992Email snz@ Internet s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008This page has been left intentionally blank.s e d b y U N I V E R S I T Y O F S O U T H A U S T R A L I A o n 02 J u n 2008。
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