. BRITISH STANDARD
'
BS 6004 : 1991
!'.
.-
Specification for
PVC-insulated cables
(non~armoured) for
electric power and
lighting
,.
.
l,}r
.....~
..
Conducteurs et cables (non-annes) isoles au
polychlorure de vinyle (PVC) pour installations
- Specifications
--
Starkstromleitungen (nicht armierte) mit einer
Isolierung aus PVC
BS 6004 : 1991
JJSI - British Standards Institution
-:-16--i·r:~:-.·;.~:,-- :;--·;.-:;--:;--·i ·. ·;:\ ___
.
Jc.ll
B I ;~:~; ; '. J Cl c::, ... \ i< ~-·\
A p X ld L. : : 1\ F~ f . i !:' I 2. M U l .
I\'( I i; ·u Y
- · -··-·-·-- "--·--·--- ----··-- ----- ·· SI is the independent national body responsible for preparing British
Standards. It presents the UK view on standards in Europe and at the
international level. It is incorporated by Royal Charter.
Contract requirements
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.
Revisions
British Standards are updated by amendment or revision. Users of British
Standards should make sure that they possess the latest amendments or
editions.
Any person who finds an inaccuracy or ambiguity while using this British
Standard should notify BSI without delay so that the matter may be
investigated swiftly.
BSI offers members an individual updating service called PLUS which ensures
that subscribers automatically receive the latest editions of standards.
Buying British Standards
Orders for all British Standard publications should be addressed to the Sales
Department at Milton Keynes.
Information on standards
BSI provides a wide range of information on national, European and
international standards through its Library, the Standardline Database, the BSI
Information Technology Service (BITS) and its Technical Help to Exporters
Service. Contact Customer Information at Milton Keynes: Thl: 0908 221166.
Subscribing members of BSI are kept up to date with standards developments
and receive substantial discounts on the purchase price of standards. For
details of these and other benefits contact the Manager, Membership
Development at Milton Keynes: Thl: 0908 220022.
Copyright
Copyright subsists in all BSI publications. No part of this publication may be
reproduced in any form without the prior permission in writing of BSI. This
does not preclude the free use, in the course of implementing the standard , of
details such as symbols and size, type or grade designations. Enquiries about
copyright should be made to the Copyright Manager, Marketing at Milton
Keynes.
BSI
2 Park Street
London
WlA 2BS
":>./
BSI
Linford Wood
Milton Keynes
MK14 6LE
9111-7-1. 55k-B
CIL/20
BS 6004 : 1991
Committees responsible for this
British Standard
The preparation of this British Standard was entrusted by the Cables and
Insulation Standards Policy Committee (CIL/-) to Thchnical Committee CIL/20,
upon which the following bodies were represented:
Aluminium Federation
Association of Consulting Engineers
Association of Manufacturers of Domestic Electrical Appliances
British Approvals Service for Cables
British Cable Makers' Confederation
British Plastics Federation
British Railways Board
British Steel Industry
British Thlecommunications plc
Department of the Environment (Property Services Agency)
Department of Trade and Industry (Consumer Safety Unit, CA Division)
ERA Thchnology Ltd.
Electricity Supply Industry in England and Wales
Engineering Equipment and Materials Users' Association
Institution of Electrical Engineers
London Regional Transport
The following bodies were also represented in the drafting of the standard,
through subcommittees and panels:
.,
.
This British Standard, having
been prepared under the
direction of the Cables and
Insulation Standards Policy
Committee, was published under
the authority of the Standards
Board and comes into effect on
29 November 1991
Association of Manufacturers Allied to the Electrical and Electronic Industry
(BEAMA Ltd.)
Association of Supervisory and Executive Engineers
British Electrical Systems Association (BEAMA Ltd.)
British Non-Ferrous Metals Federation
Chartered Institution of Building Services Engineers
Electrical Contractors' Association
Electrical Installation Equipment Manufacturers' Association (BEAMA Ltd.)
Engineering Industries Association
GAMBICA (BEAMA Ltd.)
Lighting Industry Federation Ltd.
National Association of Lift Makers
Portable Electric Thol Manufacturers' Association
Transmission and Distribution Association (BEAMA Ltd.)
Amendments issued since publication
© BSI 1991
Amd. No.
First published August 1969
Second edition January 1976
Third edition May 1984
Fourth edition October 1990
Fifth edition November 1991
'{he following BSI references
relate to the work on this
standard:
Committee reference CIL/20
.\Vraft for comment 90/25381 DC
ISBN 0 580 19917 7
Date
Thxt affected
BS 6004 : 1991
Contents
.,
.
~1
·, i--
Page
Committees responsible
Inside front cover
Foreword
3
Specification
1
Scope
4
2
Definitions
4
Voltage designation
3
4
4
Conductors
5
5
Insulation
5
6
Core identification
5
7
Fillers and extruded inner covering
6
8
Sheath
6
Marking
9
6
10 Construction and overall dimensions
7
11 Electrical requirements
7
12 Thst under fire conditions
8
Appendices
A
Guide to the use of PVC-insulated cables
19
B
Guidance on procedure for routine tests on PVC-sheathed cables of
rated voltages U0 / U up to 450/750 V
20
C
Non-contamination test
21
D
Electrical tests
21
E
Procedure for checking the efficacy of the method of spark testing
22
Thbles
1
PVC-insulated, non-sheathed general purpose cable, 4501750 V,
single-core
8
PVC-insulated, non-sheathed cable for internal wiring, 300/500 V,
2
single-core
9
PVC-insulated, PVC-sheathed, light cable, 300/500 V, circular twin,
3
10
3-core, 4-core and 5-core
4
PVC-insulated, PVC-sheathed cable, 300/500 V, single-core, flat twin
and 3-core
12
PVC-insulated, PVC-sheathed cable with circuit protection conductor,
5
300/500 V, single-core, flat twin and 3-core
13
PVC-insulated, PVC-sheathed cable with or without circuit protective
6
conductor, 300/500 V, single-core and flat twin (alternative conductor
versions)
14
1
BS 6004 : 1991
7
8
9
10
11
12
13
14
Special PVC-insulated, non-sheathed cable, 450/750 V, single-core for
installation at low temperatures
PVC-insulated, non-sheathed, heat-resistant cable for internal wiring,
450/750 V, single core
PVC-insulated, non-sheathed, heat-resistant cable for internal wiring,
300/500 V, single-core
Summary of electrical tests
List of tests applicable to the various types of cable
Guide to the use of PVC-insulated cables
Spark test voltage
Insulation test voltage
15
16
16
17
18
19
20
20 '-'
Figures
1
Spark test check: removal of insulation
23
2
23
Spark test check: covering with tape
~
~,
{
2
BS 6004 : 1991
Foreword
This new edition of BS 6004 has been prepared under the direction of the Cables
and Insulation Standards Policy Committee, and supersedes BS 6004 : 1990
which is withdrawn.
This edition introduces technical changes but it does not reflect a full review or
revision of the standard, which will be undertaken in due course.
This standard takes into account CENELECl) Harmonization Document HD 21 S2
and includes the special PVC-insulated non-sheathed single-core cable for low
temperature installations as specified in HD 21.9 . Sl. It also takes into account
recent amendments to CENELEC HD 21 and in particular HD 21. 7 S1. The
opportunity has also been taken to delete reference to copper-clad aluminium
conductors.
Where harmonized code designations are given, the requirements are in
conformity with those of all countries which accept the basic principles of
harmonization in accordance with the requirements of CENELEC. Designs
shown as National types are not harmonized but are regarded as representing a
particular requirement in the United Kingdom which is not reflected in other
countries.
Colours for core identification as agreed within CENELEC have been included in
the appropriate tables. A guide to the use of PVC-insulated cables is given in
appendix A and guidance to manufacturers on procedures for routine testing in
appendix B. This standard and the Harmonization Document mentioned above
are generally in agreement with the technical provisions of the appropriate
recommendations issued by the International Electrotechnical Commission (IEC) .
Differences in the text between this edition and BS 6004 : 1990 are indicated by
a vertical line in the margin. Thbles 1(b), 4(b) and 5(b) are withdrawn. The table
numbers from BS 6004 : 1990 for tables 1(a), 1(c), 4(a) and 5(a) have been
preserved.
.,
.
..-
Certification. Attention is drawn to the certification services (see inside back
cover) of the British Approvals Service for Cables (BASEC) 2). These services
include licensing manufacturers to use BASEC certification trade marks as
independent assurance that cables or cords have been designed and
manufactured to appropriate British Standards. BASEC is a subscriber to an
agreement in CENELEC whereby cables or cords coming within Harmonized
Code Designations and manufactured under a BASEC licence can carry marks
acceptable to other signatory countries (CENELEC 'Common Marking') .
Compliance with a British Standard does not of itself confer immunity from
legal obligations.
I)
European Committee for Electrotechnical Standardization.
2l
Biitish Approvals Service for Cables, Silbury Court, 360 Silbury Boulevard, Milton Keynes,
MK9 2AF.
3
BS 6004 : 1991
Specification
1 Scope
This British Standard specifies requirements and
dimensions for non-armoured polyvinyl chloride
(PVC) insulated cables for fixed installation and for
operation at voltages up to and including 450 V to
earth and 750 V a.c. between conductors.
The types of cables included in the standard are:
(a) Table l(a), PVC-insulated,
and (c).
non-sheathed general
purpose cable,
single-core
4501750 V;
(b) Table 2.
PVC-insulated,
non-sheathed cable for
internal wiring,
single-core
300/500 V;
(c) Table 3.
PVC-insulated,
PVC-sheathed light
cable, circular twin,
3-core, 4-core and
5-core
300/500 V;
(d) Table 4(a). PVC-insulated,
PVC-sheathed cable,
single-core, flat
twin and 3-core
300/500 V;
(e) Table 5(a). PVC-insulated,
PVC-sheathed cable
with circuit
protective conductor,
single-core, flat twin
and 3-core
300/500 V;
PVC-insulated,
CD Table 6.
PVC-sheathed cable
with or without
protective conductor,
single-core and flat
twin (alternative
conductor versions)
300/500 V;
(g) Table 7(a) Special PVC-insulated
and (b).
non-sheathed cable,
single-core for
installation at low
temperatures
450/750 V;
(h) Table 8(a) PVC-insulated,
and (b).
non-sheathed, heatresistant cable,
single-core for internal
wiring
4501750 V;
(j) Table 9.
PVC-insulated,
non-sheathed, heatresistant cable,
single-core for internal
wiring
300/500 V.
4
A guide to the use of PVC-insulated cables for fixed
installation is given in appendix A Guidance to
manufacturers for routine testing is given in
appendix B.
NOTE. The titles of the publications referred to in this standard
are listed on the inside back cover.
2 Definitions
For the purposes of this British Standard, the
definitions given in BS 4727 apply together with the '' .
following.
2.1 rated voltage Uo
The power-frequency voltage to earth for which the
cable is designed.
2.2 rated voltage U
The power-frequency voltage between conductors
for which the cable is designed.
3 Voltage designation
The rated voltage of a cable is the reference voltage
for which the cable is designed, and which serves to
define the electrical tests, and shall be expressed, in
volts, by the following expression:
UiU
where
U0 is the r.m.s. value between any insulated
conductor and earth, i.e. metal covering of the
cable or the surrounding medium;
U is the r.m.s. value between any two phaseconductors of a multicore cable or of a system
of single-core cables.
In an alternating current system, the rated voltage
of a cable shall be at least equal to the nominal
voltage of the system for which it is intended and
this applies both to the value U 0 and to the value U.
In a direct current system, the nominal voltage of
the system shall be nothigher than 1.5 times the
rated voltage of the cable.
NOTE. The operating voltage of a system may permanently
exceed the nominal voltage of such a system by 10 %. A cable can
be used at 10 % higher operating voltage than its rated voltage if
the latter is at least equal to the nominal voltage of the system.
The rated voltages recognized for the purposes of
this standard shall be 300/500 V and 450/750 V.
BS 6004 : 1991
VI
.·
4 Conductors
1
4.1 The conductor shall be of annealed copper
conductor complying with BS 6360. It shall be
permissible for the wires to be tinned except for the
types detailed in tables 4, 5 and 6.
4.2 The class of conductor shall be as given in
tables 1 to 9, inclusive. Except for conductors with
table l(c), 7(b) and 8(b) constructions, conductors
shall be circular solid, circular stranded or
compacted circular standard.
5 Insulation
5.1 Types of insulation
The insulation shall be PVC of one of the following
types:
(a) type TI 1 ofBS 6746 for the cables detailed in
tables 1 to 6 inclusive;
(b) type TI 4 ofBS 6746 for the cable detailed in
table 7;
(c) type TI 3 ofBS 6746 for cables detailed in
tables 8 and 9.
Compliance shall be checked by carrying out the
I appropriate tests listed in table 11.
5.2 Application
The insulation shall be closely applied to the
conductor. It shall be possible to remove the
insulation without damage to the insulation itself,
the conductor or the tin coating, if any.
Compliance shall be checked by examination and by
a manual test.
5.3 Thickness
The mean value of the thickness of the insulation
shall be not less thaq the value given for each type
1·and cross section of cable in tables 1 to 9, as
appropriate. However, it shall be permissible for the
thickness at any place to be less than the value
specified provided that the difference does not
exceed 0.1 mm +10% of the value specified.
Compliance shall be checked using the method
I described in 2.1.1 ofBS 6469 : 1990.
From each core to be tested, one sample of core shall
be taken from each of three places separated by at
least 1m.
The mean of all the values obtained on the three
pieces of insulation shall be calculated to two
decimal places and then rounded to one decimal
place to obtain the mean value of insulation
thickness. If the calculation gives 5 or more for the
second decimal figure, the first figure shall be raised
to the next number: thus, for example, 1. 75 shall be
rounded to 1.8 and 1. 74 to 1. 7.
The smallest of all the values obtained shall be
taken as the minimum thickness of insulation at
any place.
6 Core identification
6.1 General
Each core shall be identified by its colour. The colour
shall be either throughout the whole of the
insulation or on the surface of the insulation.
6.2 Colours
The colours of the cores according to the number of
cores in the cable and also the sequence of these
colours shall be as given in tables 1 to 9, as
appropriate.
6.3 Harmonized code designations
Harmonized code designations are given in tables
l(a), l(c), 2, 7(a), 7(b), 8(a), 8(b) and 9 for single-core
non-sheathed cables; these cables are harmonized
types, except where explicitly shown as national
types, and shall be permitted to bear the Common
Marking in accordance with 9.2, provided the
colours comply with the following:
(a) the colours available shall include the
combination green/yellow and the mono-colour
blue;
(b) combinations of colours other than green/
yellow and also the colours green or yellow
separately shall not be considered harmonized.
Single-core non-sheathed cables complying with the
properties given in tables l(a), l(c), 2, 7(a), 7(b), 8(a),
8(b) and 9 where harmonized code designations are
given, but having core colours not in accordance
with the above requirements, are not harmonized
types and shall not bear the Common Marking.
NOTE 1. In addition to the combination green/yellow, and the
mono-colour blue, the following other mono-colours are
recognized as harmonized: black, brown, grey, orange, pink, red,
turquoise, violet and white.
NOTE 2. Attention is drawn to the fact that, according to the use
to which the cables are put, it may be necessary to comply with
core colour requirements specified in the 'Regulations for
Electrical Installations' published by the Institution of Electrical
Engineers, any British or other standard applicable, or any
appropriate regulations or statutory requirements.
6.4 Bi-colour combination
On the core marked with the hi-colour combination
green/yellow, the distribution of these colours shall
be such that for every 15 mm length of core, one of
these colours shall cover at least 30% and not more
than 70% of the surface of the core, while the other
colour covers the remainder of the surface.
NOTE 1. In case of dispute and where appropriate to the method
of colour marking of the insulation, see 2.7 ofBS 6469: 1990 for a
test method to check compliance.
5
BS 6004: 1991
·NOTE 2. Information on the use of the colours green/yellow and
blue. It is understood that the colours green and yellow when
they are combined as specified above are recognized exclusively
as a means of identification of the core intended for use at earth
connection or similar protection, and that the colour blue is
intended for the identification of the core intended to be
connected to neutral. If, however, there is no neutral, blue can be
used to identify any core except for earthing or protective
conductor.
6.5 Clarity and durability
The colours shall be clearly identifiable and durable.
Compliance shall be checked by trying to remove the
colours of the cores by rubbing the core 10 times
with a piece of cotton wool or cloth soaked in water.
7 Fillers and extruded inner covering
7.1 Fillers
When separate fillers are used they shall be
composed of one of the following (a) and (b) or a
combination of the two:
(a) an extruded compound based on unvulcanized
rubber or plastics;
(b) natural or synthetic textile fibres.
A centre filler shall not be used in multicore cables
unless specifically permitted in tables 3 to 6, as
appropriate.
7.2 Extruded inner covering
7.2.1 An inner covering shall consist of an extruded
compound based on unvulcanized rubber or plastic.
7.2.2 Inner coverings composed ofunvulcanized
rubber shall be compatible with PVC cores.
Compliance shall be checked using the noncontamination test given in appendix C and
compatibility confirmed if the median values after
ageing comply with the following.
Compatibility ofTI 1 insulation
(a) Tensile strength
Minimum value (N/mm 2 )
12.5
20
Maximum variation(%)
(b) Elongation at break
Minimum value(%)
125
Maximum variation(%)
20
NOTE. Variation is the difference between the median value
after ageing and the median value without ageing, expressed as a
percentage of the latter.
8 Sheath
8.1 Type of sheath
The sheath shall be PVC complying with BS 6746
I for type 6 or type TM 1, as given in tables 3 to 6, as
appropriate.
Compliance shall be checked by carrying out the
I appropriate tests given in table 11.
6
8.2 Application
The sheath shall be applied in a homogeneous layer:
(a) to the core, in the single-core cables;
(b) to the assembly of cores and inner covering
(if any) in other cables.
The sheath shall be capable of being removed
without damage to the cores.
NOTE. A separator consisting of a tape or film may be placed
under the sheath.
8.3 Thickness
··
ii ·
The mean value of the sheath thickness shall be not
less than the value given for each type and cross
section of cable in tables 3 to 6, as appropriate.
However, it shall be permissible for the thickness at
any place to be less than the value specified,
provided that the difference does not exceed
0.1 mm + 15% ofthe value specified.
Where the sheath fills the interstices between the
cores of flat cables the specified thickness shall
apply at the place where the thickness of the sheath
is at its minimum.
Compliance shall be checked using the method
described in 2.1.2 ofBS 6469: 1990.
One sample of cable shall be taken from each of
three places, separated by at least 1 m.
The mean of all the values obtained on the three
pieces of sheath shall be calculated to two decimal
places and rounded to one decimal place as
described in 5.3 to obtain the mean value of sheath
thickness.
The smallest of all the values obtained shall be
taken as the minimum thickness of sheath at any
place.
8.4 Colour
The colour of the sheath is specified only for cables
whose properties are given in tables 4 to 6; for these
cables the colour of the sheath shall be as given in
the appropriate table. The colour shall be
throughout the whole ofthe sheath or on its surface.
9 Marking
9.1 Indication of origin
All cables shall be provided with an indication of
origin consisting either of an identification thread or
threads or the continuous marking of the
manufacturer's name or trade mark.
If coloured threads are used, the colours shall
comply with those registered in PD 2379, where
applicable. The colours shall be easy to recognize or
shall become recognizable by cleaning with petrol,
or othe:Z. suitable solvent, if necessary.
BS 6004: 1991
.•
The marking of the manufacturer's name or trade
mark, if used, shall be by one of the three following
alternative methods:
(a) printed tape within the cable;
(b) printing, indenting or embossing on the
insulation of at least one core, (the core coloured
blue, if any);
(c) printing, indenting or embossing on the
sheath, if any.
The marking shall be legible and shall be regarded
as continuous if the gap between the end of one
complete inscription and the beginning of the next
does not exceed:
(1) 500 mm if the marking is on the sheath;
(2) 200 mm in all other cases.
9.2 CENELEC 'Common Marking'
It shall be permitted for a cable for which a
Harmonized Code Designation is given in tables 1 to
I 9 to carry an indication that it has been
manufactured under a licence issued by one of the
Approvals Organizations subscribing to the
CENELEC Agreement on the use of a commonly
agreed marking for cables and cords. If it does carry
such an indication this shall be one of the following.
(a) The mark of the Approvals Organization,
followed by the Common Marking <J HAR !>
applied by one of the three alternative methods
specified in 9.1 .
(b) An identification thread extending throughout
the length of the cable indicating the Approvals
Organization. The base colour shall be yellow and
this shall be serially dyed or printed red and
black. The lengths of the coloured sections shall
comply with dimensions laid down by CENELEC
. for that Approvals Organization (see PD 2379).
Neither of these indications shall be used for a cable
I shown in tables 1 to 9 as a national type.
The name CENELEC, in full or abbreviated, shall
not be directly marked on, or in, the cable.
/ 9.3 Durability
Any marking by printing shall be durable.
Compliance shall be checked by rubbing the
marking 10 times with a piece of cotton wool or cloth
soaked in water.
I 9.4
Cables for installation at low temperature
In addition to the requirements of9.1, cables given
in tables 7(a) and 7(b) shall have a continuous
marking applied, using the symbol 'V3' (indicating
suitability for installation at low temperature), by
printing, indenting or embossing on the insulation.
9.5 Cables with type TI 3 insulation
In addition to the requirements of9.1, cables given
in tables 8(a), 8(b), and 9 shall have a continuous
marking applied, using the symbol 'V2' (indicating
heat-resistant insulation), by printing, indenting or
embossing on the insulation.
10 Construction and overall
dimensions
10.1 Construction
The construction of the cables shall be as given in
tables 1 to 9, as appropriate.
Compliance shall be checked by examination and
measurement.
10.2 Mean overall dimensions
The mean overall dimensions of the cables shall be
within the limits given in tables 1 to 9, as
appropriate.
Compliance shall be checked using the method
described in 2.1.3 ofBS 6469 : 1990.
One sample of cable shall be taken from each of
three places, separated by at least 1m.
For flat cable the mean of the three determinations
of each of the major and minor axes shall be taken
as the mean overall dimensions.
For other cable, the mean ofthe six values obtained
shall be taken as the mean overall diameter.
10.3 Ovality
The difference between any two values of the overall
diameter of circular sheathed cables at the same
cross section (ovality) shall not exceed 15 % of the
upper limit given in tables 1 to 9, as appropriate, for
the mean overall diameter.
Compliance shall be checked using the method
described in 2.1.3 ofBS 6469: 1990.
One sample of cable shall be taken from each of
three places, separated by at least 1 m.
Two measurements shall be taken at the same cross
section of the cable covering the maximum and
minimum values.
11 Electrical requirements
11.1 Conductorresistance
The d. c. resistance of each conductor measured on a
sample of cable at least 1m in length shall comply
with BS 6360.
11.2 Voltage test on complete cable
When the cable is tested as described in D.1 and D.2
no breakdown of insulation shall occur.
7
BS 6004 : 1991
11.3 Voltage test on cores
When the core is tested as described in D.l and D.3
no breakdown of the insulation shall occur.
Table 1. PVC-insulated, non-sheathed
general purpose cable, 4501750 V, single-core
11.4 Insulation resistance
When the cable is tested as described in D.1
and D.4, the resistance shall be not less than the
minimum value specified in tables 1 to 9, as
appropriate.
NOTE 1. The cables may be suitable for voltages up to
1000 Va.c. or up to 750 Vto earth d.c. (see appendix A).
NOTE 2. Cables having conductor sizes smaller than 1.5 mm 2
are to be found in table 2.
(a) Rigid conductor
Harmonized code designation
H07V- U.
Solid conductor:
..
Stranded conductor: H07V-R."
Construction
Annealed copper conductor, class 1 solid conductor
and class 2 stranded conductor, as shown below.
PVC-insulation type TI 1.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
11.5 Long term resistance of insulation to d.c.
When the cable is tested as described in D.1
and D.5, the exterior of the insulation shall show no
damage.
NOTE. Discolouration of the insulation should be ignored.
11.6 Test to check the absence offaults on
insulation
When the cable is tested as described in D.1
and D.6, it shall withstand the applied voltage
without failure of the insulation.
12 Test under fire conditions
The cables whose properties are given in tables 1 to
/ 9 shall comply with BS 4066 : Part 1.
The test shall be carried out on a sample ofthe
complete cable.
Nominal Class of
crossconductor
sectional
area of
conduc·
tor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 70 oc
mm 2
mm
mm
M.Q·km
1.5
1.5
2.5
2.5
4
4
6
6
10
10
16
25
35
50
70
95
120
150
185
240
300
400
5001)
630 1)
Il
8
1
2
1
2
1
2
1
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Nationai type.
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.8
1.0
1.0
1.0
1.2
1.2
1.4
1.4
1.6
1.6
1.8
2.0
2.2
2.4
2.6
2.8
2.8
3.3
3.5
3.9
4.2
4.4
4.8
4.9
5.4
6.4
6.8
8.0
9.8
11.0
13.0
15.0
17.0
19.0
21.0
23.5
26.5
29.5
33.5
37.0
41.0
0.011
0.010
0.010
0.009
0.0085
0.0077
0.0070
0.0065
0.0070
0.0065
0.0050
0.0050
0.0040
0.0045
0.0035
0.0035
0.0032
0.0032
0.0032
0.0032
0.0030
0.0028
0.0028
0.0025
..
BS 6004:1991
-·
Table 1. PVC-insulated, non-sheathed
general purpose cable, 450/750 V, single-core
(concluded)
(c) Flexible copper conductor
NOTE 1. The cables may be suitable for voltages up to
1000 V a .c. or u p to 750 V to earth d.c. (see appendix A).
NOTE 2. Flexible cables smaller than 1.5 mm2 are to be found
in BS6500.
Harmonized code designation. H07V- K.
Construction
Annealed copper conductor, class 5 flexible
conductor.
PVC-insulation type TI 1.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 70 oc
mm 2
mm
mm
MQ·km
1.5
2.5
4
6
10
16
25
35
50
70
95
'- 120
150
185
240
0.7
0.8
0.8
0.8
1.0
1.0
1.2
1.2
1.4
1.4
1.6
1.6
1.8
2.0
2.2
3.5
4.2
4.8
6.4
7.6
8.8
11.0
12.5
14.5
17.0
19.0
21.0
23.5
26.0
29.5
0.010
0.009
0.007
0.006
0.0056
0.0046
0.0044
0.0038
0.0037
0.0032
0.0032
0.0029
0.0029
0.0029
0.0028
Nominal
crosssectional
area of
conductor
~
Table 2. PVC-insulated, non-sheathed cable
for internal wiring, 300/500 V, single-core
NOTE. Flexible conductor versions of the following three sizes
of internal wiring cables are specified in BS 6500.
Harmonized code designation. H05V- U.
Construction
Annealed copper conductor, class 1 solid
conductor.
PVC-insulation type T11.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3 for harmonized
types).
Nominal
crosssectional
area of
conductor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 70 oc
mm 2
mm
mm
MQ·km
0.5
0.75
1
0.6
0.6
0.6
2.4
2.6
2.8
0.015
0.012
0.011
Q
BS 6004: 1991
'
.
Table 3. PVC-insulated, PVC-sheathed, light cable, 300/500 V, circular twin, 3-core, 4-core
and 5-core
Code designation
NOTE 1. This type of cable is included in CENELEC Harmonization Document HD 21 82, but owing to lack of agreement on a
colour-code for rigid multi core cables, this cable type cannot be considered as harmonized, and no designation has been allocated.
Construction
Annealed copper conductor, class 1 solid conductor and class 2 stranded conductor as shown in the table.
PVC-insulation type TI 1.
.
The cores shall be twisted together. A centre filler may be used.
The twisted cores shall be covered by an extruded inner covering. It shall be possible to separate the
cores easily.
PVC sheath type TM 1.
The sheath shall fit closely but not adhere to the inner covering.
?:.
NOTE 2. The thickness of the inner covering given for guidance is not measured.
Colours for core identification (see note 1 above).
Twin:
3-core:
4-core:
5-core:
red and black.
red, yellow and blue.
red, yellow, blue and black.
red, yellow, blue black and green/yellow.
Colour of sheath. Not specified.
Number and
nominal
crosssectional
area of
conductors
Class of
conductor
Radial
thickness
of
insulation
Thickness
of inner
covering
mm
mm
1
2
1
2
1
2
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.8
1
2
2
2
2
1
2
1
2
1
2
1
2
mm 2
2x 1.5
1
2
2x 2.5
2x 4
2x 6
2x 10
2x 16
2 X 25
2x35
3x 1.5
3x 2.5
3x 4
3x 6
Mean overall
diameter
Minimum
insulation
resistance
at 70 oc
Lower
limit
Upper
limit
mm
mm
mm
MQ·km
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
8.4
9.6
9.6
10.5
10.5
11.5
11.5
10.0
10.5
11.5
12.0
12.5
13.0
13.5
14.0
0.011
0.010
0.010
0.009
0.0085
0.0077
0.0070
0.0065
1.0
1.0
1.0
1.2
1.2
0.6
0.6
0.6
0.8
1.0
1.4
1.4
1.4
1.4
1.6
14.5
15.0
16.5
20.5
23.0
16.5
17.5
20.0
24.0
27.5
0.0070
0.0065
0.0052
0.0050
0.0044
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
1.2
1.2
1.2
1.2
1.2
1.2
1.4
1.4
8.8
8.8
10.0
10.0
11.0
11.0
12.5
12.5
10.5
11.0
12.0
12.5
13.0
13.5
14.5
15.5
0.011
0.010
0.010
0.009
0.0085
0.0077
0.0070
0.0065
O.f>
-10
Radial
thickness
of sheath
8.4
'
..
BS 6004 : 1991
Table 3. PVC-insulated, PVC-sheathed, light cable, 300/500 V, circular twin, 3-core, 4-core
and 5-core (concluded)
Number and
nominal
crosssectional
area of
conductors
Radial
thickness
of
insulation
Thickness
of inner
covering
mm
mm
1
2
2
2
2
1.0
1.0
1.0
1.2
1.2
1
2
1
2
1
2
1
2
Class of
conductor
3x 16
3x25
3x35
4x 1.5
4x 2.5
4x 4
4x 6
4x 10
4x 16
4x25
4x35
5x 1.5
5x 2.5
·I~.
5x 4
5x 6
5 X 10
5x 16
5x25
5x35
Mean overall
diameter
Minimum
insulation
resistance
at 70 °C
Lower
limit
Upper
limit
mm
mm
mm
MQ·km
0.6
0.6
0.8
0.8
1.0
1.4
1.4
1.4
1.6
1.6
15.5
15.5
18.0
22.0
24.5
17.5
19.0
21.5
26.0
29.0
0.0070
0.0065
0.0052
0.0050
0.0044
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.8
0.4
0.4
0.4
0.4
0.4
0.4
0.6
0.6
1.2
1.2
1.2
1.2
1.4
1.4
1.4
1.4
9.6
9.6
11.0
11.0
12.0
12.5
14.0
14.0
11.5
12.0
13.0
13.5
14.5
15.0
16.0
17.0
0.011
0.010
0.010
0.009
0.0085
0.0077
0.0070
0.0065
1
2
2
2
2
1.0
1.0
1.0
1.2
1.2
0.6
0.6
0.8
1.0
1.0
1.4
1.4
1.4
1.6
1.6
16.5
17.0
20.0
24.5
27.0
19.0
20.5
23.5
28.5
32.0
0.0070
0.0065
0.0052
0.0050
0.0044
1
2
1
2
1
2
1
2
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.8
0.4
0.4
0.4
0.4
0.6
0.6
0.6
0.6
1.2
1.2
1.2
1.2
1.4
1.4
1.4
1.4
10.0
10.0
11.5
12.0
13.5
14.0
15.0
15.5
12.0
12.5
14.0
14.5
16.0
17.0
17.5
18.5
0.011
0.010
0.010
0.009
0.0085
0.0077
0.0070
0.0065
1.0
1.0
1.0
1.2
1.2
0.6
0.6
0.8
1.0
1.2
1.4
1.4
1.6
1.6
1.6
18.0
18.5
22.0
27.0
30.0
21.0
22.0
26.0
31.5
35.0
0.0070
0.0065
0.0052
0.0050
0.0044
mm2
3 X 10
Radial
thickness
of sheath
1
2
2
2
2
..
11
BS 6004 : 1991
Table 4. PVC-insulated, PVC-sheathed cable, 300/500 V, single-core, flat twin and 3-core
(a) Copper conductor
National type
Construction
Plain annealed copper conductor. Class 1 solid conductor and class 2 stranded conductor, as shown
below.
PVC-insulation type TI 1.
In twin and 3-core cables, the cores shall be laid parallel.
PVC sheath type 6.
The sheath shall fit closely but not adhere to the core(s).
Colours for core identification
Single: red or black.
Twin:
red and black, or, for 2 x 1 and 2 x 1.5 cables, red and red.
3-core: red, yellow (centre core) and blue.
Colour of sheath
Single-core:
black, brown, grey, red or white.
Flat twin and 3-core: grey or white.
Number and
nominal
crosssectional
area of
conductors
Class of
conductor
1 x 1.0
1x 1.5
1 X 2.5
1
1X 4
2
1X 6
1 X 10
1 X 16
1 x 25
1 X 35
2
2
2
2
2x
2x
2X
2x
1.0
1.5
2.5
4
2X 6
2 X 10
2 X 16
3x 1.0
3x 1.5
3 X 2.5
3X 4
3X 6
3 X 10
3 X 16
1
1
2
1
1
1
2
2
2
2
1
1
1
2
2
2
2
Radial
thickness
of
insulation
Radial
thickness
of sheath
mm
Mean overall diameter ·
Lower
limit
Upper
limit
Minimum
insulation
resistance
at 70 oc
mm
mm
mm
M.Q·km
0.6
0.7
0.8
0.8
0.8
1.0
1.0
1.2
1.2
0.8
0.8
0.8
0.9
0.9
0.9
1.0
1.1
1.1
3.8
4.2
4.8
5.4
6.0
7.2
8.4
10.0
11.0
4.5
4.9
5.8
6.8
7.4
8.8
10.5
12.5
13.5
0.011
0.011
0.010
0.0077
0.0065
0.0065
0.0052
0.0050
0.0044
0.6
0.7
0.8
0.8
0.8
1.0
1.0
0.9
0.9
1.0
1.0
1.1
1.2
1.3
4.0x 6.2
4.4 X 7.0
5.2 X 8.4
5.6 X 9.6
6.4 X 10.5
7.8 X 13.0
9.0x 15.5
4.7 X 7.4
5.4 X 8.4
6.2x 9.8
7.2 X 11.5
8.0 X 13.0
9.6 X 16.0
11.0 X 18.5
0.011
0.011
0.010
0.008
0.0065
0.0065
0.0052
0.6
0.7
0.8
0.8
0.8
1.0
1.0
0.9
0.9
1.0
1.1
1.1
1.2
1.3
4.0 X 8.4
4.4 X 9.8
5.2 X 11.5
5.8 X 13.5
6.4 X 15.0
7.8 X 19.0
9.0 X 22.0
4.7 X 9.8
5.4 X 11.5
6.2 X 13.5
7.4 X 16.5
8.0 X 18.0
9.6 X 22.5
11.0 X 26.5
0.011
0.011
0.010
0.008
0.0065
0.0065
0.0052
NOTE. When required by the purchaser, alternative conductor versions of certain sizes may be available in the form given
in table 6.
J2
:
.
,~--·-- --~-- -- -
I b.. l CJ 1-(
··r H .E: I A
BS 6004 : 1991
Table 5. PVC-insulated, PVC-sheathed cable with circuit protective conductor, 300/500 V,
single-core, flat twin and 3-core
(a) Copper conductor
National type
!
Construction
Plain annealed copper conductor. Class 1 solid conductor and class 2 stranded conductor, as shown below.
PVC-insulation type TI 1.
The core or cores shall be laid parallel with the uninsulated circuit protective conductor.
PVC sheath type 6.
The sheath shall fit closely but not adhere to the cores.
Colours for core identification
Single-core: red or black.
red and black, or, for 2 x 1 and 2 x 1.5 cables, red and red.
Twin:
red, yellow (centre core) and blue.
3-core:
Position of circuit protective conductor
Twin:
centrally placed between cores in same plane.
3-core: centrally placed between yellow and blue cores in same plane.
Colour of sheath. Grey or white.
Number and
nominal
cross~
Class of
conductor
(see 4.2)
sectional
area of
conductors
mm 2
--
Radial
thickness
of
insulation
Radial
thickness
of sheath
mm
mm
Lower
limit
Upper
limit
Circuit
protective
conductor
minimum
nom. crosssectional
area
mm
mm
mm 2
MQ·km
Mean overall diameter
Minimum
insulation
resistance
at 70 oc
1 x 1.0
1 x 1.5
1
1
0.6
0.7
0.9
0.9
4.0 x 5.1
4.4 x 5.4
5.2 x 6.4
5.8 x 7.0
1.0
1.0
0.011
0.011
2 x 1.0
2 x 1.5
2 x 2.5
2x 4
2x 6
2 X 10
2 X 16
1
1
1
2
2
2
2
0.6
0.7
0.8
0.8
0.8
1.0
1.0
0.9
0.9
1.0
1.0
1.1
1.2
1.3
4.0x 7.2
4.4 x 8.2
5.2 x 9.8
5.6 X 10.5
6.4 X 12.5
7.8 X 15.5
9.0 X 18.0
4.7 x 8.6
5.4 X 9.6
6.2 X 11.5
7.2 X 13.0
8.0 x 15.0
9.6 X 19.0
11.0x 22.5
1.0
1.0
1.5
1.5
2.5
41)
61)
0.011
0.011
0.010
0.008
0.0065
0.0065
0.0052
3 x 1.0
3 x 1.5
3x 2.5
3x 4
3x 6
3 X 10
3 X 16
1
1
1
2
2
2
2
0.6
0.7
0.8
0.8
0.8
1.0
1.0
0.9
0.9
1.0
1.1
1.1
1.2
1.3
4.0 x 9.6
4.4 X 10.5
5.2 X 12.5
5.8 X 14.5
6.4 X 16.5
7.8 X 21.0
9.0 X 24.5
4.7 x 11.0
5.4 X 12.5
6.2 X 14.5
7.4 X 18.0
8.0 X 20.0
9.6 X 25.5
11.0 X 29.5
1.0
1.0
1.0
1.5
2.5
41)
61)
0.011
0.011
0.010
0.008
0.0065
0.0065
0.0052
ll
~
Class 2 conductors only.
NOTE. When required by the purchaser, alternative conductor versions of certain sizes may be available in the form given
in table 6.
13
BS 6004: 1991
Table 6. PVC-insulated, PVC-sheathed cable with or without circuit protective conductor,
300/500 V, single-core and flat twin (alternative conductor versions)
NOTE. This table gives alternative conductor (class 2) versions of certain sizes of the cables given in tables 4(a) and 5(a).
National type
The requirements for construction, PVC sheath, colours for core identification, position of circuit
protective conductor (if relevant) and colour of sheath shall be as given in tables 4(a) and 5(a), as
appropriate.
Number and
nominal
crosssectional
area of
conductors
Class of
conductor
(see 4.2)
mm 2
Radial
thickness
of
insulation
Radial
thickness
of sheath
mm
mm
Mean overall diameter
Circuit
protective
conductor
minimum
nom. crosssectional
area
Minimum
insulation
resistance
at 70 oc
Lower
limit
Upper
limit
mm
mm
mm 2
M.Q·km
4.5x 7.2
5.2x8.6
5.6x 8.8
6.6 X 10.5
-
0.011
0.010
Flat twin without circuit protective conductor
2 X 1.5
2x2.5
2
2
0.7
0.8
0.9
1.0
Flat twin with circuit protective conductor
1 X 1.5
2
0.7
0.9
4.4 X 5.4
5.8x 7.0
1.01)
0.011
2 X 1.5
2 X 2.5
2
2
0.7
0.8
0.9
1.0
4.5 X 8.4
5.2 X 9.8
5.6 X 10.0
6.6 X 12.0
l.Ol)
1.51)
0.011
0.010
Il
14
The circuit protective conductor remains as given in table 5(a), namely class 1.
'
BS 6004:1991
Table 7. Special PVC-insulated, non-sheathed
cable, 450/750 V, single-core for installation
at low temperatures
Table 7. Special PVC-insulated, non-sheathed
cable, 450/750 V, single-core for installation
at low temperatures (concluded)
(a) Rigid conductor
(b) Flexible copper conductor
NOTE. The cables may be suitable for voltages up to 1000 V a.c.
or up to 750 V to earth d.c. (see appendix A).
NOTE. The cables may be suit able for voltages up to 1000 V a.c.
or up to 750 V to earth d.c. (see appendix A).
Harmonized code designation
H07V3- U.
Solid condu ctor:
Stranded conductor: H07V3-R.
Construction
Annealed copper conductor, class 1 solid con ductor
and class 2 stranded conductor, as shown below.
PVC-insulation type TI 4.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
Harmonized code designation. H07V3- K.
Construction
Annealed copper conductor, class 5 flexible
conductor.
PVC-insulation type TI 4.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resista nce
at70 °C
mm
mm
M.Q·km
0.7
0.7
0.8
0.8
0.8
0.8
0.8
0.8
1.0
1.0
3.3
3.5
3.9
4.2
4.4
4.8
6
10
10
1
2
1
2
1
2
1
2
1
2
5.4
6.4
6.8
0.011
0.010
0.010
0.009
0. 0085
0.0077
0.0070
0.0065
0.0070
0.0065
16
25
35
50
70
95
120
150
185
240
300
400
2
2
2
2
2
2
2
2
2
2
2
2
1.0
1.2
1.2
1.4
1.4
1.6
1.6
1.8
2.0
2.2
2.4
2.6
8.0
9.8
11.0
13.0
15.0
17.0
19.0
21.0
23 .5
26.5
29.5
33.5
0.0050
0.0050
0.0040
0.0045
0.0035
0.0035
0.0032
0.0032
0.0032
0.0032
0.0030
0.0028
Nominal Class of
conductor
crosssectional
area of
conductor
Radial
thickness
of
insulation
mm 2
1.5
1.5
2.5
2.5
4
4
6
-'
4 .9
-·-
Nominal
crosssectional
area of
conductor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 70 oc
mm 2
mm
mm
M.Q·km
0.7
0.8
0.8
0.8
1.0
1.0
1.2
1.2
1.4
3.5
4.2
4.8
6.4
7.6
8.8
11.0
12.5
14.5
17.0
19.0
21.0
23.5
26.0
29.5
0.010
0.009
0.007
0.006
0.0056
0.0046
0.0044
0.0038
0.0037
0.0032
0.0032
0.0029
0.0029
0.0029
0.0028
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
240
1.4
1.6
1.6
1.8
2.0
2.2
15
BS 6004 : 1991
Table 8. PVC-insulated, non-sheathed, heatresistant cable for internal wiring, 450/750 V,
single-core
Table 9. PVC-insulated, non-sheathed, heatresistant cable for internal wiring, 300/500 V,
single-core
(a) Rigid conductor
NOTE. Flexible conductor versions of the following three
sizes of internal wiring cables are specified in BS 6500.
NOTE. Cables having conductor sizes smaller than 1.5
to be found in table 9.
mm 2
are
Harmonized code designation. H07V2- U.
Construction
Annealed copper co_n ductor, class 1 solid
conductor.
PVC-insulation type TI 3.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
Nominal
cross·
sectional
area of
conductor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 90°C
mm 2
mm
mm
M.Q·km
1.5
2.5
0.7
0.8
3.3
3.9
0.011
0.010
(b)
Flexible conductor
Harmonized code designation. H05V2- U.
Construction
Annealed copper conductor, class 1 solid
conductor.
PVC-insulation type TI 3.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
.
Nominal
crosssectional
area of
conductor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 90 oc
mm 2
mm
mm
M.Q·km
0.5
0.75
1
0.6
0.6
0.6
2.4
2.6
2.8
0.015
0.012
0.011
".:
NOTE. Flexible cables smaller than 1.5 mm 2 are to be found
inBS6500.
Harmonized code designation. H07V2-K.
Construction
Annealed copper conductor, class 5 flexible
conductor.
PVC-insulation type TI 3.
Colours for core identification. Green/yellow,
blue or other colours (see 6.3).
Nominal
crosssectional
area of
conductor
Radial
thickness
of
insulation
Mean
overall
diameter
(upper
limit)
Minimum
insulation
resistance
at 90°C
mm 2
mm
mm
M.Q·km
1.5
2.5
0.7
0.8
3.5
4.2
16
0.010
0.009
::
-
BS 6004 : 1991
Table 10. Summary of electrical tests
Test method
Unit
300/500V
cables
450/750V
cables
Conductor resistance (see 11.1)
Length of sample (min.)
m
1
1
m
h
20
1
20±5
2000
15
20
1
20±5
2500
15
m
h
5
1
20±5
-
v
v
2000
1500
5
-
m
h
5
2
70±2
90±2
5
2
70±2
90±2
m
day
5
10
60±5
10
No breakdown
5
10
60±5
10
No breakdown
No failure
No failure
2000
5000
5
No breakdown
2500
5000
5
No breakdown
Voltage test on complete cable (see 11.2)
Length of sample (min.)
Period of immersion (min.)
Temperature of water
Applied voltage (a.c.)
Time of application
Voltage test on cores (see 11.3)
Length of sample
Period of immersion (min.)
Temperature of water
Applied voltage (a.c.)
for insulation thickness exceeding 0.6 mm
for insulation thickness up to and including 0.6 mm
Time of application
Insulation resistance (see 11.4)
Length of sample
Period of immersion (min.)
I
Temperature of water (tables 1 to 7)
Temperature of water (tables 8 and 9)
Long term resistance of insulation to d. c. (see 11.5)
Length of sample
Period of immersion
Temperature of solution
Duration of applied voltage
,, Result to be obtained
Check on the absence of faults on insulation (see 11.6)
Spark test
Result to be obtained
Voltage test
Applied voltage a.c.
Applied voltage d.c. (min.)
Duration of test
Result to be obtained
oc
v
min
oc
min
oc
oc
oc
day
v
v
min
-
17
BS 6004: 1991
-
Table 11. List of tests applicable to the various types of cable
Clause
number
lLl
11.2
11.2
11.3
11.3
11.4
11.5
11.6
10.1
5.3
8.3
10.2
10.3
5.1
8.1
12
Test description
Electrical tests
Conductor resistance
Voltage test on complete cable at 2000 V
Voltage test on complete cable at 2500 V
Voltage test on cores at 2000 V1>
Voltage test on cores at 1500 V2>
Insulation resistance at 70 oc
Long term resistance to d.c.
Check on absence offaults on insulation
4
5
6
7
X
X
X
X
X
X
X
X
X
X
-
X
-
X
-
-
-
-
-
-
X
X
X
X
X
X
X
X
X
X
X X
X .X
X X
X X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
-
-
X
X
X
X
X
X
X
X
X
-
-
X
X
X
X
X
X
X
X
X
X
-
-
X
X
-
-
X
X
X
X
X
X
-
-
Constructional and dimensional tests
Check on construction
Measurement of insulation thickness
Measurement of sheath thickness
Measurement of overall dimensions
Measurement of ovality
Properties of insulation
Tensile strength before and after ageing
Elongation at break before and after ageing
Loss of mass test
Non-contamination test
Hot pressure test
Cold bend test
Cold elongation test
Cold impact test
Heat shock test
Thermal stability test
Table number
2
1
3
8
9
X
X
-
-
X
X
X
X
-
-
-
X
X
X
XB):
xs>
X X
X X
X
X
X
X
X
X
-
-
-
X
X
X
-
-
-
X
X
X
X
X
X
X
X
X
X
X
X
X3>
X
X
-
-
-
-
-
-
X
X
X
X
X
X
X
X
X
X
-
-
-
-
-
-
-
X
X
X
X
X
X
X
X
X
X
X
X
X4>
X7>
X
-
-
-
-
-
-
-
-
X
X
X
X
X
X
-
-
-
X
X
X
X
X
X
X
X
X
-
-
-
X
X
X
X
X X
X X
X4l -
xs> -
Properties of sheath
Tensile strength without ageing
Elongation at break without ageing
Tensile strength after ageing in air
Elongation at break after ageing in air
Loss of mass test
Hot pressure test or hot deformation test
Cold bend test
Cold elongation test
Cold impact test
Heat shock test
-
-
X
X
X
X
X
X
X
X4>
XB>
X
Test under fire conditions
X
X
X
-
-
-
-
-
-
X
-
-
-
X
X
X
X
-
NOTE. X indicates that the particular test is applicable to the cables in the table shown at the head of each column.
I l For insulation thickness exceeding 0.6 mm.
2>For insulation thickness up to and including 0.6 mm.
3>Only applicable if the insulation is in contact with a compound other than PVC (see 7.2).
4>Only applicable ifthe outer diameter of the core or cable exceeds the limit specified in the test method.
6>Table l(a) cables only.
6> Only applicable if the outer diameter of the cable exceeds the limit specified in the test method.
7>Table 7(a) cables only.
8> Test at 90 °C.
10
-
-
..
BS 6004 : 1991
..
Appendices
Appendix A. Guide to the use of PVCinsulated cables
maximum conductor temperature does not exceed
160 oc, up to and including 300 mm 2 and 140 °C for
sizes above 300 mm 2 •
NOTE 1. None of these types is intended to be laid underground.
NOTE 2. The short-circuit temperature is based on the intrinsic
properties of the insulating material. It is essential that the
accessories which are used in the cable system with mechanical
and/or soldered connections are suitable for the temperature
adopted for the cable. Further guidance on short-circuit
temperature is being considered in CENELEC for heat-resistant
types in tables 8 and 9.
NOTE 3. Installation requirements and current ratings are
detailed in the Regulations for Electrical Installations, published
by the Institution of Electrical Engineers, or in individual
appliance specifications.
IMPORTANT. Details given in this appendix are
I
intended only as general technical guidance and not
as an interpretation of any UK statutory
requirements, where these apply.
The cables are suitable for use where the
combination of ambient temperature and
temperature rise due to load results in a conductor
temperature not exceeding 70 °C (90 oc for heatresistant types in tables 8 and 9) and in the case of a
short-circuit (maximum allowable time 5 s) the
I
Typical uses of the different types of cable are given
in table 12.
Table 12. Guide to the use of PVC-insulated cables
Table
Cable type and use
1(a) and 1(c)
Single-core, non-sheathed general purpose
Installation in surface mounted or
embedded conduits, or similar closed
systems.
2
3
4(a), 5(a)
and6
.
~
7(a) and 7(b)
8(a), 8(b)
and9
Single-core, non-sheathed, for internal wiring
Fixed protected installation inside appliances
and in or on lighting fittings.
Light PVC-sheathed
Fixed installation in dry or damp premises.
Single-core, flat twin and flat 3-core,
PVC-sheathed, with and without protective
conductor
.
·'·
Fixed installation in dry or damp premises.
Single-core, non-sheathed low temperature
installation
As for tables l(a) and l(c) above, but suitable
for installation at low temperatures.
Single-core, heat-resistant non-sheathed
For internal wiring only.
Comments
Suitable for use in channels with cover.
Suitable for fixed protected installation
in or on lighting fittings and inside
appliances, switchgear and controlgear,
for voltages up to 1000 V a .c. or up to
750 V to earth, d.c.
Suitable for installation in surface
mounted or embedded conduits, only for
signalling or control circuits.
Unsuitable for outdoor use or embedding
in concrete.
Suitable for installation in walls, on
boards and in channels or embedded in
plaster.
Suitable for use in channels with cover.
Suitable for fixed protected installation
in or on lighting fittings and inside
appliances, switchgear and controlgear,
for voltages up to 1000 V a. c. or up to
750 V to earth, d. c.
Maximum conductor temperature in
normal use 90 °C. Not be used in contact
with objects higher than 85 oc.
Not suitable for fixed installations in
distribution systems.
19
BS 6004: 1991
:..
Appendix B. Guidance on procedure
for routine tests on PVC-sheathed
cables of rated voltages U/U up to
4501750 v
NOTE. The following information is intended to provide guidance
to the cablemaker on suitable procedures for the routine testing
of cores and completed cables. They may be instituted by the
manufacturer at his option and should not be regarded as
requirements of this standard.
B.l Core stage tests
B.l.l General
All cores for cables and flexible cables should be
subjected either to the spark test described in B.1.2
or to the voltage and insulation resistance tests
described in B.1.3 and B.1.4, respectively.
B.1.2 Spark test
Carry out the spark test in accordance with BS 5099
using the test voltages given in table 13.
Table 13. Spark test voltage
Tabulated radial
thickness of
insulation
Test voltage
Above
Up to and
including
a.c. (r.m.s.)
d.c.
mm
mm
kV
kV
1.0
1.5
2.0
2.5
1.0
1.5
2.0
2.5
6
9
15
23
30
38
-
10
15
20
25
B.1.3 Voltage test
B.1.3.1 Procedure. Mter the core has been immersed
in water for not less than 12 h, apply a voltage
between the water in which the core is immersed,
which is earthed, and the conductor. Make the test
at room temperature with an alternating voltage of
approximately sine-wave form having a frequency
in the range 49Hz to 61Hz.
Increase the applied voltage gradually and maintain
I it at the full r.m.s. value shown in table 14 for 5 min.
B.1.3.2 Recommended test criteria. No breakdown of
insulation should occur.
20
Table 14. Insulation test voltage
Test voltage
Tabulated radial
thickness of
insulation
Above
Up to and
including
a.c. (r.m.s.)
mm
mm
kV
-
0.7
1.0
1.5
2.0,.
2.5
0.7
1.0
...
-
B.1.4 Insulation resistance test
B.1.4.1 Procedure. Immediately after completion of
the voltage test described in B.1.3, apply a d. c.
voltage of 300 V to 500 V between the conductor and
the water in which the core is immersed for 1 min,
the electrification proceeding in a regular manner,
the deflection ofthe galvanometer, if used,
decreasing steadily during the period of application.
Maintain the temperature of the water in which the
core is immersed at or near to 20 oc.
B.1.4.2 Recommended test criteria. The insulation
resistance ofthe length of cable, in megohm
kilometres should be not less than that resulting
from calculation using the following expression:
Rwoo =Kloglo
where
K
D
d
R 1000
D
d
is the insulation resistance constant at
20 oc (equal to 35 MQ·km);
is the diameter over insulation (in mm);
is the diameter over conductor (in mm);
is the insulation resistance of cable
(in MQ·km).
B.1.5 Heat shock test
B.1.5.1 Procedure. Take samples ofPVC-insulated
cores at regular intervals and subject them to the
heat shock test in accordance with test method 4.4.2
ofBS 6469: 1990 and table 2 or 3 ofBS 6746: 1990.
B.1.5.2 Recommended test criteria. The PVCinsulated cores should comply with the
requirements given in table 2 or 3 ofBS 6746: 1990.
BS 6004 : 1991
~
I
I
B.2 Tests on completed cable
B.2.5 Heat shock test
B.2.1 General
Completed cables should be subjected to the tests
described in B.2.2 to B.2.6.
B.2.5.1 Procedure. Take samples oftested cables at
regular intervals and subject them to the heat shock
test on sheath in accordance with 4.4.3 ofBS 6469 :
1990 and table 2 or 3 ofBS 6746: 1990.
B.2.2 Conductor resistance
B.2.2.1 Procedure. Leave the cable in the test area,
which is at a reasonably constant temperature, for
sufficient time to ensure that the cable temperature
is equal to the ambient temperature. Measure the
d.c. resistance of the conductor at room
temperature.
B.2.2.2 Recommended test criteria. Calculate the
resistance per unit length from the production
length of the completed cable and not from the
length of the individual cores or wires.
The d.c. resistance ofthe conductor, measured at
room temperature and corrected to 20 oc by the
factors given in BS 6360 should comply with
BS 6360.
B.2.3 Voltage test
B.2.3.1 Procedure. Subject completed twin and
multicore cables to the voltage test without
immersion in water.
Apply the voltage between conductors and between
each conductor and the protective conductor (where
provided), which should be earthed.
NOTE. Completed single-core sheathed cables may be tested in
water.
Make the test at room temperature with an
alternating voltage of approximately sine-wave form
having a frequency in the range 49Hz to 61Hz.
Increase the voltage gradually and maintain it at
the full r .m.s. value shown in table 14 for 5 min.
'B.2.3.2 Recommended test criteria. No breakdown
of insulation should occur.
B.2.4 Insulation resistance
Immediately after the completion of the voltage test
described in B.2.3, carry out an insulation
resistance test.
Follow the method described in B.1.3 but make the
measurement between conductors and between each
conductor and the protective conductor (where
provided), which should be earthed.
For multicore cables, group the cores such that the
cores adjacent to those being tested are connected to
earth.
Where single-core sheathed cables are tested in
water, use the method described in B.1.4 .
B.2.5.2 Recommended test criteria. The tables
should comply with the requirements of table 2 or 3
ofBS 6746: 1990.
B.2.6 Constructional and dimensional check
A sample of completed cable should be checked for
compliance with tables 1 to 9, as appropriate.
Appendix C. Non-contamination test
Subject three pieces of completed cable about
200 mm long, each taken at least 1m from the other
two, to accelerated ageing treatment in the
equipment described in 2.3.1.2 ofBS 6469 : 1990 for
7 days at 80 ± 2 oc. The cable pieces shall occupy not
more than 2% of the volume of the oven.
Immediately after completion of the treatment,
remove the cable pieces from the oven and leave at
room temperature away from direct sunlight for at
least 16 hand prepare test pieces of cable as
described in 2.2 ofBS 6469: 1990.
Determine the median values of the tensile strength
and elongation at break for these test pieces as
described in 2.2 ofBS 6469: 1990. Compare these
values with the median values obtained on the test
pieces taken from the 100 mm lengths which have
not been subjected to ageing.
Appendix D. Electrical tests
D.l Test conditions
Unless otherwise specified, make tests at ambient
temperature with alternating voltages of
approximately sine-wave form, having a frequency
in the range of 49Hz to 61Hz, and ofthe r.m.s.
values given in table 10. The ratio peak value/r.m.s.
value being equal to -12with a tolerance of± 7 %.
D.2 Voltage test on complete cable
D.2.1 Test sample
Take a sample of cable, as delivered oflength as
given in table 10.
D.2.2 Procedure
Immerse the sample of cable in water at the
temperature given in table 10. Ensure that the ends
of the cores protrude above the water by a distance
sufficient to prevent excessive surface leakage when
the test voltage is applied.
21
BS 6004: 1991
-- "'
I Apply a voltage of the magnitude given in table 10
in turn between each conductor and all the others
connected together and to the water, and between
all conductors and the water for the time given in
I table 10. In both cases earth the protective
conductor (where provided) but do not include it in
the conductors to be tested.
D.3 Voltage test on cores
D.3.1 Test sample
Prepare a sample of core of the length given in table
10 by carefully removing the sheath and any other
covering or filling from a length of complete cable.
D.3.2 Procedure
Immerse the core in water at the temperature given
in table 10 and apply a voltage of the magnitude
given in table 10 between the conductors and the
water for the time given in table 10. Ensure that the
ends of the cores protrude above the water by a
distance sufficient to prevent excessive surface
leakage when the test voltage is applied.
D.4 Insulation resistance
D.4.1 Test sample
Make the test on a core sample of the length given in
I table 10 previously submitted to the test specified
in D.3 or if this is not applicable, to the test specified
inD.2.
D.4.2 Procedure
Immerse the sample in water previously heated to
I the temperature given in table 10 with a length of
about 250 mm at each end of the sample projecting
I above the water, for the time given in table 10.
Apply a d.c. voltage of between 80 V and 500 V
between the conductor and the water.
Measure the insulation resistance 1 min after
application ofthe voltage. Correct the value to
MQ·km.
D.5 Long term resistance of insulation to d.c.
D.5.1 Test samples
Carry out the test on a sample of core of the length
I given in table 10 from which all coverings have
been removed.
D.5.2 Procedure
Immerse the sample in an aqueous solution of
sodium chloride having a concentration of 10 giL
previously brought to the temperature given in table
10, with a length of about 250 mm at each end of the
sample projecting above the solution. Connect the
negative pole of a 220 V d. c. supply to the conductor
of the sample and the positive pole to a copper
electrode immersed in the solution for the time
given in table 10.
D.6 Test to check the absence of faults on
insulation
D.6.1 Test length
Take all cable that is in the final stage of
manufacture and either in delivery lengths or in
manufacturing lengths prior to being cut into
delivery lengths.
D.6.2 Procedure
D.6.2.1 General. Test single-core cables by the
spark test in accordance with D.6.2.2 and multicore
cables and sheathed flat cables by the voltage test in
accordance with D.6.2.3.
D.6.2.2 Spark test
D.6.2.2.1 Apparatus. The spark test equipment
shall provide a magnitude and presence of the
voltage that, together with the electrode system
employed and the speed of passage employed for the
passage of the cable through the equipment, is
capable of detecting a puncture in the insulation
having a diameter equal to or greater than half of
the specified insulation thickness. The recovery
time of the spark tester shall be not greater than 1 s.
NOTE. The voltage applied by the spark tester may be power
frequency a. c., d. c., high frequency or of other form.
When a spark test equipment is tested as described
in appendix E all the faults shall be registered by
the equipment.
D.6.2.2.2 Procedure. Test the cable at the voltage
and speed of passage specified in D.6.2.2.1.
D.6.2.3 Voltage test. With the cable in the dry state
and at room temperature apply a voltage of the
magnitude given in table 10 derived either from an
a.c. source or from a d.c. source between each
conductor and all the other conductors connected to
earth. Increase the voltage gradually and maintain
it at the full value for the duration given in table 10.
Appendix E. Procedure for checking
the efficacy of the method of spark
testing
E.l Principle
The principle of this method is to standardize the
method by which manufacturers may demonstrate
that their spark testing method is effective in
detecting faults in the insulation as specified
in D.6.2.2.
It is imperative that the manufacturer's
instructions for production and control procedures
provide that cable for which spark testing is
required is effectively tested in practice.
'"""'ill'"""""""'
' -:~
2.::,
2 _ _"""'"'"_ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...;.,~·~---~---~----=·· .:.
·- -
-
·_.,----
-~-~-...
E.2 Selection and preparation of test pieces
E.2.1 Sampling
Prepare two test-lengths of cores, one with the
smallest insulation thickness for the relevant types
of cable, the other core with the largest insulation
thickness for the relevant types of cable.
E.2.2 Preparation ofpunctures
Prepare the punctures in the insulation as follows.
(a) Remove the insulation from the core for a
length of about five times the nominal insulation
thickness.
·
(b) From the piece of insulation which has been
removed, remove a segment of about 30°. Then
replace the remaining piece of the insulation on
the conductor (see figure 1).
(c) Over the replaced piece of the insulation, place
one layer of adhering tape, e.g. polyethylene
terephthalate, with a length of at least ten times
the nominal insulation thickness, in a
longitudinal direction, with an overlap. Situate
this overlap on the opposite side of the core to the
BS 6004: 1991
position where the insulation was removed
(see figure 2).
(d) In this layer, in the middle of the place where
the insulation has been removed, use a hot needle
to punch a hole in the tape with a diameter equal
to half of the allowed minimum insulation
thickness.
Prepare the other test piece in the same way.
E.3 Procedure
E.3.1 Efficacy ofdetecting
Pass the prepared test piece through the spark test
equipment at the highest speed for which the
equipment is intended, the voltage applied between
the electrode and the conductor being that normally
used.
E.3.2 Recovery time
Pass at least two faults through the spark test
equipment at its actual operating speed u, in metres
per second, the distance in metres between two
faults being not greater than the value ofv .
·-
approx. 30°
i
(a)
(b)
Figure 1. Spark test check: removal of
insulation (see E.2.2)
Figure 2. Spark test check: covering w ith
tape
23
BS 6004 : 1991
Publication(s) referred to
BS 4066
BS 4727
BS 5099
BS 6360
BS 6469
BS 6500
BS 6746
PD 2379
HD 21 S2
Tests on electric cables under fire..·conditions
Part 1 Method of test on a single vertical insulated wire or cable
Glossary of electrotechnical, power, telecommunication, electronics, lighting and colour
terms
Specification for spark testing of electric cables
Specification for conductors in insulated cables and cords
Methods of test for insulation and sheath of electric cables
Specification for insulated flexible cords and cables
Specification for PVC insulation and sheath of electric cables
Register of colours of manufacturers' identification threads for electric cables and cords
Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V
Regulations for Electrical Installations. Fifteenth Edition. 1981 1>
I)
Published by the Institution of Electrical Engineers.
BASEC'S Certification Trade Marks and Approval Threads
The British Approvals Service for Cables (BASEC) is the owner of certification trade marks. These marks, which are shown below,
may be used only by manufacturers who are licensed under the certification mark schemes operated by BASEC. The presence of
·any one of these marks pn or in rel ation to electric cables is an assurance that they have been produced und er a system of
supervision and control operated during manufacture, and including frequent independent sampling and testing of production,
designed to provide assurance of compliance with appropriate British Standards.
Certification 'Ii·ade Mark
Symbol:
2. Identification marking: 'BASEC'
3. Identification thread: plain yellow and of a material soluble in acetone.
BASEC is a subscriber to an agreement in CENELEC whereby cables or corcls coming within harmonized code designations and
manufactured under a BASEC licence can, under certain conditions, carry marks acceptable to other signatory countries
(CENELEC 'Common Marking').
4. Identification marking: 'BASEC <l HAR 1>'
5. Identification thread: a single thread on which a sequence of a black section (10 mm), a red section (10 mm) and a
yellow section (30 mm) is run.
Particulars of the conditions under which licences are granted may be obtained from the Secretary, British Approvals Service for
Cables Ltd., Silbury Court, 360 Silbury Boulevard, Milton Keynes MK9 2AF.
:!-"
1.
~-