DPNS 163:2007

ICS 29.060

Electric wires and cables – Polyvinyl chloride insulated

flexible cords – Specification
PHILIPPINE NATIONAL STANDARD DPNS 163: 2007

Conte nts
1 Scope . . . . . . . . . . . . . . . . . . 1 Tables
2 References . . . . . . . . . . . . . . 1 1 Insulation characteristics of type
3 Definitions . . . . . . . . . . . . . . 1 TW, 60 °C, 600 volts wire . . . . . . 4
4 General requirements . . . . . . 2 2 Insulation characteristics of type
4.1 Material . . . . . . .. . . . . . . . . . 2 THW, 75 °C, 600 volts wire . . . . 5
4.2 Insulation thickness . . . . . . . 2 3 Insulation characteristics of type
4.3 Performance and other THWN, 75 °C, 600 volts wire . . . 6
requirements. . . . . . . . . . . . 2 4 Insulation characteristics of type
5 Test methods . . . . . . . . . . . . 3 THHN, 90 °C, 600 volts wire . . . 7
5.1 Insulation thickness . . . . . . . 3 5 Physical properties of type
5.2 Dielectric withstand voltage. 3 TW wires . . . . . . . . . . . . . . . . . . 8
5.3 Insulation resistance. . . . . . . 12 6 Physical properties of type
5.4 Accelerated aging test . . . . . 13 THW wires . . . . . . . . . . . . . . . . . 9
5.5 Tensile strength and 7 Physical properties of type
elongation of insulation . . . . 14 THWN wires . . . . . . . . . . . . . . . . 10
5.6 Flame retardance . . . . . . . . . 15 8 Physical properties of type
5.7 Heat shock . . . . . . . . . . . . . . 15 THHN wires . . . . . . . . . . . . . . . . 11
5.8 Heat deformation . . . . . . . . . 16 9 Temperature correction factor . . . 13
5.9 Oil resistance . . . . . . . . . . . . 17 10 Specimen loading . . . . . . . . . . . . 16
5.10 Wrap test of nylon jacket . . 17 11 Sampling scheme . . . . . . . . . . . . 18
6 Sampling . . . . . . . . . . . . . . . 17
7 Marking . . . . . . . . . . . . . . . 18 Figures
1 Construction of spark tester and
connection circuit . . . . . . . . . . . 12
2 Die cut specimen . . . . . . . . . . . . 15

Foreword
This Philippine National Standard, Electric wires and cables – Polyvinyl chloride insulated flexible
cords - Specification, was prepared by the Bureau of Product Standards’ Technical Committee on
Electric Wires and Cables, BPS/TC01.
This standard cancels and replaces PNS 163:1994. This revision was made to attune to the present
needs and demands of the consumers.
In this edition, the following technical changes were made:

Clause/Subclause Modification
1. Scope Revision of scope (conductor size range)
1.2 Scope Separate type UF and NM wires

Tables 1 to 4 Include alternative construction for 250 mm2

(37mm x 295mm)

Tables 1 to 4 Revision of minimum average and minimum

spot thickness

Tables 5 to 8 Revision of oven and oil ageing tables.

Table 2 Revision of PVC wall thickness for THW based
on UL 83: 1998 which was the latest edition
available at the time of development.

5.2.1 Spark test Modify specification/description of Sparker HV

testing equipment

5.6 Flame retardance Revision of flame test procedure

PHILIPPINE NATIONAL STANDARD DPNS 163:2007
Electric wires and cables – Polyvinyl chloride insulated flexible cords
and fixture wires – Specification

1 Scope

This standard specifies requirements for thermoplastic insulated flexible cords and fixture
wires rated up to 600 volts for use in accordance with the Philippine Electrical Code.

These requirements do not cover speaker wires, armored cords or assemblies of flexible cords
or fixture wires with fittings or wiring devices of any sort (such as cord sets, power supply
cords, and decorative- lighting outfits, e.g. Christmas lights wires, which are covered in
requirements separate from this standard) nor do these requirements cover any type of wire
cord for use at potential higher than 600 volts. However, individual cords and wires of said
assemblies shall comply with the requirements of this standard.

2 References

The titles of the standard publications referred to in this standard are listed on the inside back
cover.

3 Type, letter designation and application

The type, letter designation and usage of cords are given in Table 1.

Table 1 – Type , letter designation and application

Type Letter Temperature rating Rated voltage

designation °C V
Integral thermoplastic SPT 1 60 300
parallel cord
SPT 2 60 300
SPT 3 60 300
Vacuum cleaner cord SVT 60 300

SVT 70 300 V / 300 V

Oval cords (IEC) 300 V / 500 V

Hard service cord SJT 60 300

Oil-resistant hard SJTO 60 300
service cord
Extra-hard service cord ST 60 600
Oil-resistant extra-hard STO 60 600
service cord
Thermoplastic fixture TF 60 600
wire
Thermoplastic fixture TFN 90 600
wire with nylon
Decorative lighting
cords and wires 105 300
- parallel integral XTW
- twisted pair CXTW
- single conductor CXTW
 DPNS 163:2007

4 General requirements

4.1 Appearance – The cord shall be uniform in color, smooth, free from flaws, and other
imperfections.

4.2 Characteristics

The characteristics shall be as given in Table 2, when tested by the test methods specified in
Annexes A to K.

4.3 Materials

4.3.1 Conductor – The conductor shall be either solid or bunched-stranded wires

composed of the annealed copper wires specified in PNS 260.

4.3.2 Insulation – The insulation shall be PVC compounds conforming to PNS 661.

4.3.3 Jacket – The PVC jacket shall be conforming to PNS 661 while the nylon jacket
material shall comply with the physical and wrap test requirements of Table 2.

4.4 Construction

4.4.1 Insulation – The average thickness of the insulation shall not be less than 90 % of
the appropriate values in Tables 3 to 6 and the minimum measured value at any point shall
not be less than 80% of the appropriate values in these Tables.

4.4.2 Assembly of conductors – Assembly of cords shall be formed by stranding 2 or more

conductors in left hand lay, with lay length not greater than the values indicated in Table 2a
and Table 2b.

4.4.3 Jacket – For the outer covering of assembled cores, PVC shall be used, and the
average thickness shall not be less than 90 % of the appropriate value given in Tables 3-6,
and the minimum of the measured value at any point shall not be less than 70 % of the
appropriate value given in these Tables. For nylon jackets, the thickness shall not be less than
the value indicated in Table 8.

4.4.4 Flat cords – Flat cords shall be formed by arranging 2 conductors as specified in
4.3.1 in parallel with a certain space, and by applying PVC insulation having the appropriate
thickness given in Tables 3 to 6. The cord shall be so formed that 2 cores can be easily
divided into two.

4.4.5 Round cords – Round cords shall be formed by stranding requisite number of cores
utilizing fillers to fill up the space between cores.

NOTE Fillers, if used in flexible cord, shall be twisted with the conductors to make the
conductor assembly to form a circular cross-section.

4.4.6 Jacketed oval cords – Two insulated cores as specified in 4.3.2 shall be arranged
closely in parallel, then it shall be covered by the jacket as specified in 4.3.3. In this
procedure, the interstices by the 2 cores shall be filled up with a jacketing material.

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 DPNS 163:2007

Table 2 – Characteristics of flexible cords

Item Characteristics

Conductor resistance Not to exceed the values specified in Tables 3 to 6

In water To withstand 1,500 V for 1 minute
Dielectric In air To withstand 3000 V for 1 minute
Strength
Spark test To withstand 6000 V for at least 0.15 s
Room temp. 5 M? km min (20 °C)
Insulation
resistance High temp. 0.01 M? km min (60 °C)
Tensile 10.3 MPa, min. (1.05 kgf/mm2 ) for 60 °C and 105 °C
strength 13.7 MPa, min (1.4 kgf/ mm2 ) for 70 °C and 90 °C
Insulation
U 100 %, min.for 60 °C and 105 °C
n Elongation
150 %, min for 70 °C and 90 °C
a
g Tensile
Jacket 9.81 MPa, min. (1.0 kgf/mm2 )
e strength
d (for PVC
only)
Elongation 100 %, min.
Not less than 65 % of the values before ageing for 60 °C
(at test 100 °C ± 1 °C for 168 h)
Not less than 75% of the values before ageing for 70 °C
Tensile (at test 121 °C ± 1 °C for 168 h)
strength Not less than 65% of the values before aging for 90 °C
Insulation (at test 136 °C ± 1 °C for 168 h)
Not less than 70 % of the values before aging for 105 °C
A (at test 136 °C ± 1 °C for 168 h)
g
e
Elongation Not less than 65 % of the value before ageing
d

Tensile
Jacket Not less than 85 % of the value before ageing
strength
(for PVC
only)
Elongation Not less than 65 % of the value before ageing
Oil resistance1 Not less than 50% of the value before ageing
Heat shock No cracks, flaws to develop on the surface
Heat Insulation Thickness reduction not to exceed 50%
deformation Jacket Thickness reduction not to exceed 50%
Flame retardance Flame to extinguish within 60 seconds

The number of broken component wires in each conductor not

to exceed 50 %
Flexibility
(For flat cords only) Short circuit between conductors shall not take place.
No development of crack, flaws or other faults in the
insulation
Nylon jacket wrap No cracks and flaws to develop on the surface
1
Oil resistance test shall be conducted if the cable is marked with “oil-resistant”.

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 DPNS 163:2007

Table 2a – Length of lay for SVT cords

Nominal area Number of conductors and maximum acceptable length of lay

mm2 mm

2 3 4
0.75 35 44 64
1.25 38 51 70

Table 2b – Length of lay for SJT, SJYO, ST and STO

Nominal area Number of conductors and maximum acceptable length of lay

mm2 mm

2 3 4
0.75 51 57 64
1.25 57 64 70
2.0 64 83 95
3.5 76 89 108
5.5 89 108 121
8 114 127 152
14 127 152 178
22 152 178 216
30 178 203 254

Table 3 – Flat cord type , SPT

Conductor
Approximate
Nominal Number of Approx. Minimum Nominal overall Conductor
area component wires/ outside distance thickness of diameter resistance
Type Diameter of diameter between insulation at 20 °C
component wires conductors mm

mm² mm mm mm mm Minor Major Ω /km

0.3 12/0.18 0.7 2.3 4.6 58.8
SPTI 0.5 20/0.18 0.9 1.14 0.8 2.5 5.0 36.7
0.75 30/0.18 1.1 2.7 5.4 24.4
SPT2 1. 25 50/0.18 1.5 2.03 1.2 3.9 7.8 14.7
SPT3 2.0 37/0.26 1.8 2.79 2.0 5.8 11. 6 9.5

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 DPNS 163:2007

Table 4 – Type SVT cords

Conductor
Number of
Nominal Nominal Approx. Conductor
component
Number Nominal Approx. thickness thickness overall resistance
wires/
of area outside of of diameter at 20 °C
Diameter of
cores diameter insulation jacket
component
wires
mm² mm mm mm mm Ω /km
mm
0.75 30/0.18 1.1 0.4 0.8 5.4 25.1
2
1. 25 50/0.18 1.5 0.4 0.8 6.2 15.1

Table 5 – Type SJT and SJTO cords

Conductor
Number of Nominal Nominal Approx. Conductor
Number Nominal component Approx. thickness thickness overall resistance
of area wires/ outside of of diameter at 20 °C
cores Diameter of diameter insulation jacket
component
mm² wires mm mm mm mm Ω /km
mm
0.75 30/0.18 1.1 0.8 1.0 7.4 25.10
2 1.25 50/0.18 1.5 0.8 1.0 8.2 15.10
2.0 37/0.26 1.8 0.8 1.0 8.8 9.79
0.75 30/0.18 1.1 0.8 1.0 7.8 25.10
3 1.25 50/0.18 1.5 0.8 1.0 8.7 15.10
2.0 37/0.26 1.8 0.8 1.0 9.3 9.79
0.75 30/0.18 1.1 0.8 1.0 8.5 25.10
4 1.25 50/0.18 1.5 0.8 1.0 9.5 15.10
2.0 37/0.26 1.8 0.8 1.0 10.2 9.79

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 DPNS 163:2007

Table 6 – Type ST and STO cords

Conductor
Number of Nominal Nominal Approx. Conductor
Number Nominal Approx. thickness thickness overall resistance
component
area outside
of wires/ of of diameter at 20 °C
diameter insulation
cores Diameter of jacket
component wires
mm² mm
mm mm mm mm Ω /km
0.75 30/0.18 1.1 0.8 1.5 8.4 25.10
1.25 50/0.18 1.5 0.8 1.5 9.2 15.10
2.0 37/0.26 1.8 1.2 2.0 12.4 9.79
3.5 65/0.26 2.4 1.2 2.4 14.1
2 5.5 104/0.26 3.0 1.2 2.4 15.3
8.0 7/24/0.26 4.2 1.5 2.8 20.3
14 7/38/0.26 5.5 1.5 3.2 23.2
22 7/60/0.26 6.8 1.5 3.6 26.8
30 19/35/0.26 8.0 1.5 3.9 31.2
0.75 30/0.18 1.1 0.8 1.5 8.8 25.10
1.25 50/0.18 1.5 0.8 1.5 9.7 15.10
2.0 37/0.26 1.8 1.2 2.0 13.1 9.79
3.5 65/0.26 2.4 1.2 2.4 14.8
3 5.5 104/0.26 3.0 1.2 2.4 16.2
8.0 7/24/0.26 4.2 1.5 2.8 21.4
14 7/38/0.26 5.5 1.5 3.2 24.6
22 7/60/0.26 6.8 1.5 3.6 28.3
30 19/35/0.26 8.0 1.5 3.9 33.0
0.75 30/0.18 1.1 0.8 1.5 9.5 25.10
1.25 50/0.18 1.5 0.8 1.5 10.5 15.10
2.0 37/0.26 1.8 1.2 2.0 14.1 9.79
3.5 65/0.26 2.4 1.2 2.4 16.0
4 5.5 104/0.26 3.0 1.2 2.4 17.5
8.0 7/24/0.26 4.2 1.5 3.2 24.1
14 7/38/0.26 5.5 1.5 3.6 27.5
22 7/60/0.26 6.8 1.5 3.9 31.6
30 19/35/0.26 8.0 1.5 4.3 36.8

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 DPNS 163:2007

Table 7A – Oval jacketed cords 300 V / 300 V

Number of Nominal Insulation Jacket Mean overall Minimum

conductors area of thickness thickness thickness insulation
conductors mm resistance
mm2 mm mm Lower Upper MO.km
2 0.5 0.5 0.6 3 x 4.8 3.6 x 6.0 0.012
2 0.75 0.5 0.6 3.2 x 5.2 3.9 x 6.4 0.01

Table 7B – Oval jacketed cords 300 V / 500 V

Number of Nominal Insulation Jacket Mean overall Minimum

conductors area of thickne ss thickness thickness insulation
conductors mm resistance
mm2 mm mm Lower Upper MO.km
2 0.75 0.6 0.8 3.8 x 6.0 5.2 x 7.6 0.011

Table 8 – Thermoplastic fixture wires (TF/TFN) 600 V

Conductor
Nominal Number of Approx. Minimum Minimum Approx. Nominal
area component outside acceptable thickness over all conductor
wires/ diameter average of jacket diameter resistance
diameter of insulation at any at 20 °C
component thickness point
wires
2
mm mm mm mm mm mm O/km
TF 60 °C 600 V
0.75 SOLID 1.02 0.8 - 2.54 21.96
0.75 7 / 0.386 1.16 0.8 - 2.68 21.36
1.25 SOLID 1.29 0.8 - 2.81 13.19
1.25 7 / 0.488 1.47 0.8 - 2.99 13.45
TFN 90 °C 600 V
0.75 SOLID 1.02 0.4 0.1 1.98 21.96
0.75 7 / 0.386 1.16 0.4 0.1 2.12 21.36
1.25 SOLID 1.29 0.4 0.1 2.25 13.19
1.25 7 / 0.488 1.47 0.4 0.1 2.43 13.45

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 DPNS 163:2007

Table 9 – Decorative lighting cords and wires 105 °C 300 V

Conductor
Descriptive Nominal Number of Approx. Minimum Minimum Acceptable Conductor
name area component outside acceptable acceptable overall resistance
wire/ diameter average thickness diameter at 20 °C
diameter of thickness at any
component point
wire
mm2 mm mm mm mm mm O/km
Decorative Parallel integral aboveground XTW 105 °C 300 V Minor Major
lighting 0.3 12/0.18 0.7 0.76 0.69 2.22 5.13 58.8
cords 0.5 20/0.18 0.9 0.76 0.69 2.42 5.53 36.7
0.75 30/0.18 1.1 0.76 0/69 2.62 5.93 24.4
Twisted pair aboveground CXTW 105 °C 300 V
0.3 12/0.18 0.7 0.76 0.69 4.44 58.8
0.5 20/0.18 0.9 0.76 0.69 4.84 36.7
0.75 30/0.18 1.1 0.76 0/69 5.24 24.4
Decorative Single conductor aboveground CXTW 105 °C 300 V
lighting 0.3 12/0.18 0.7 0.76 0.69 2.22 58.8
wire 0.5 20/0.18 0.9 0.76 0.69 2.42 36.7
0.75 30/0.18 1.1 0.76 0/69 2.62 24.4

4.4.7 Identification of cores with jacket – The identification shall be made by the color of
the insulation, and generally shall conform to Table 10.

Table 10 – Color of insulation

Number of cores Color

2 Black, white

3 Black, white, red or black, white, green

4 Black, white, red, green

5 Sampling

Sampling shall be in accordance with Tables 11a and 11b.

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 DPNS 163:2007

Table 11a – Sampling of cords in production line

Lot size , Minimum length

Number of samples
m per sample, m

7,500 & below 1 75

7,501 - 15,000 2 75

15,001 - 25,000 3 75

25,001 & above 4 75

Table 11b – Sampling of cords in packages

Lot size
75 m/Package or Number of samples
150 m/Package
100 & below 1
101 - 250 2
251 - 500 3
501 & above 4

NOTE Lot size refers to the total length or packages per size.

6 Test methods and frequency of test

All wires and cables shall be tested as necessary to determine their compliance with the
requirements. When there is a conflict between the test methods given in Annex A to K and
the publications of other organizations to which reference is made, the requirement given in
Annex A to K shall apply.

Test on samples shall be made on samples selected at random. Each test sample shall be from
accessible end of different coil or reel. Each coil or reel selected and the sample taken from it
shall be identified. The length and number of sample per lot size is given in Table 8a and
Table 8b.

If all of the samples pass any test specified in this standard, the quantity of the cable they
represent shall be considered as meeting the requirements of this standard with regard to that
test. Failure of any sample shall not preclude re-sampling and re-testing the length of cable
from which the original sample was taken.

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 DPNS 163:2007

6.1 Routine tests

Test made on each manufactured length of cable to check that each length meets the specified
requirements. The number of lengths to be tested maybe reduced according to agreed quality
control procedure. Routine test shall be as follows:

a. Visual inspection of cable surface and marking,

b. Measurement of dimensions,
c. Conductor resistance, and
d. Dielectric strength.

6.2 Type tests

Test made before supplying, on a general commercial basis, a type of cable covered by this
standard, in order to demonstrate satisfactory performance characteristics to meet the
intended application. These tests are of such a nature that, after they have been made, they
need not be repeated, unless changes are made on the cable materials or design or
manufacturing process which might change the performance characteristics. Type tests shall
be as follows:

a. Measurement of dimensions,
b. Conductor resistance,
c. Insulation resistance,
d. Tensile strength and elongation,
e. Thermal ageing,
f. Heat shock,
g. Heat deformation,
h. Flame retardance,
i. Flexibility, and
j. Oil resistance.

7 Packaging

Each length of the cord shall be coiled into a bundle or wound on a drum/spool, and packaged
suitably to avoid damage of the cord during transport. The length of the cord shall not be less
than the specified length in the package marking.

8 Designation and marking

8.1 Designation – The product shall be designated by the type letter designations, the
number of cores (which may be omitted for other round cord) and nominal sectional area.

8.2 Marking on the cord – The following information shall be indelibly marked
repeatedly on the surface of the cord by a suitable method:

a Class or type letter designation;

b Number of cores (which may be omitted for other than round cord) and nominal
sectional area; and
c Manufacturer's trade name or brand name.

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 DPNS 163:2007

8.3 Marking on the package – The following information shall be marked on the
package by a suitable method:

a Class or type letter designation;

b Number cores;
c Length;
d Registered trade name or brand name;
e Manufacturer's trademark;
f Year and month of manufacture;
g Country of manufacture;
h Address of the manufacturer and importer, re-packer of the cords; and
i If the cords are manufactured, or repacked under license from a principal, the label shall
state so.

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 DPNS 163:2007

Annex A

Measurement of dimensions

A.l Apparatus

The diameter and thickness of wires shall be measured an external micrometer or other
appropriate measuring device.

A.2 Procedure

A.2.1 Diameter of the wires – The diameter of the wires shall be expressed as the average
of the values obtained by measuring the wire directly at two or more locations (1) (if a
circumference measure is used, at two or more locations along the wire) having
approximately the same angle on the same plane perpendicular to the axis of the wire. For
flat-type wires, the diameter shall be measured on the same plane (2) perpendicular to the
axis of the wire. In cases where direct measurement cannot be made, the diameter shall be
calculated (3) from the average value of the diameter of two or more constituting elements.

A.2.2 Thickness of the insulation – Thickness of the insulation shall be one- half of the
difference between the inside and outside diameters of the insulation measured in accordance
with A.2.1. For the minimum thickness, the thinnest portion shall be selected visually or by
other means, and the thickness at this portion shall be measured with a graduated magnifying
glass and so forth.

A.2.3 Thickness of the jacket – Thickness of the jacket shall be one half of the difference
between the inside and outside diameters of the jacket measured in accordance with A.2.1.
For the minimum thickness, the thinnest portion shall be selected visually or by other means,
and the thickness at this portion shall be measured with a graduated magnifying- glass and so
forth.

Insulation Jacket

Insulation

Jacket Insulation

(a) (b) (c)

Figure A.l – Measuring locations for round wires

NOTE 1 The locations at which the measurements are taken shall be as shown in Figure A.I.
NOTE 2 The locations at which the measurements are taken shall be as shown in Figure A.2.

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 DPNS 163:2007

conductor
Figure A.2 – Measuring locations for flat cords

NOTE 3 For example, in a three-conductor wire, the outside diameter D shall be calculated
from the relation D = 2.154d after measuring d at the two points shown in Figure A.3 and by
averaging them.

Figure A.3 – Measuring locations for the outside diameter of a three-conductor wire

Fig A.4 – Measuring Location for Oval Cords

A.2.4 Thickness of the covering – Thickness of the covering shall either be taken as half
of the average value of the difference between the inside and outside diameters or be directly
measured.

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 DPNS 163:2007

Annex B

Conductor resistance test

B.1 Conductor resistance shall be measured by the Wheatstone Bridge method or other
appropriate means.

B.2 The equivalent conductor resistance (R) of the wire per kilometer at 20 °C shall be
calculated using the following formula:

Rt x at
R20 =
L

where

R20 is the equivalent conductor resistance per kilometer at 20 °C in Ω/km

Rt is the measured value at t °C, which excludes the resistance of lead wires in (Ω)
if any
at is the temperature coefficient given in Table B1 for converting the value at t °C
into that measured at 20 °C
L is the wire length in km

Table B.1 – Temperature coefficients for conductor resistance calculation

Temperature Copper Temperature Copper Temperature Copper

(t) °C (at ) (t) °C (at ) (t) °C (at )
0 1.085 12 1.033 24 0.985
1 1.081 13 1.028 25 0.981
2 1.076 14 1.024 26 0.977
3 1.072 15 1.020 27 0.973
4 1.067 16 1.016 28 0.970
5 1.063 17 1.012 29 0.966
6 1.058 18 1.008 30 0.962
7 1.054 19 1.004 31 0.959
8 1.050 20 1.000 32 0.955
9 1.045 21 0.996 33 0.951
10 1.041 22 0.992 34 0.948
11 1.037 23 0.988 35 0.944

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 DPNS 163:2007

Annex C

Dielectric strength test

The dielectric strength test shall be conducted by one of the following methods:

C.l Spark test – Using the spark tester shown in Figure C.1 in air, this test shall be
conducted by applying a 6000-volt sinusoidal voltage, 60 Hz between the conductor
connected to ground and the electrode for at least 0.15 second and the cord shall withstand
this test.

In the spark tester in Figure C.1, metal chains or beads 1) shall be suspended 12 mm or under
apart in the direction of the wire axis and 9 mm or under apart in the lateral direction. The
chains shall be longer than the depth of the metal box so that they may sufficiently contact
the wire surface regardless of the diameter of the wire.

Mark (2) shows the metal box of U-shape of V-shape, the width of the upper chain fitting part
shall be larger than the maximum wire diameter by 33 mm or more, and mark (1) shall be so
determined that passing time be 0.15 second or more from the passing speed of wire. Instead
of the above metal or bead- like electrode, a water electrode may be used.

NOTE Ten percent of the specimens which have passed this test shall be tested in water as
specified in C.3.

C.2 Test in air – The atmospheric test shall be conducted by applying 60 Hz sinusoidal
AC voltage between the conductors themselves, in atmosphere, gradually increasing this
voltage up to 3000 volts, and examining whether or not the wire withstands this for one
minute.

C.3 Test in water – The underwater test shall be conducted first by immersing the wire' in
advance at least for one hour in ground water and then applying 60 Hz sinusoidal AC voltage
between the conductors and the water for single-conductor wires, or between conductors
themselves and between each conductor and water for multi-conductor wires, gradually
increasing the voltage up to 1500 volts, and examining whether or not the wire withstand this
for one minute.

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 DPNS 163:2007
3

Key:

(1) Electrode (7) Device for detecting defective

(2) Electrode box insulation
(3) Protective box (8) Testing transformer
(4) Reel (9) Voltage regulator
(5) Ground (10) Over-current breaker
(6) Transformer ground

Fig. C.1 – Construction of spark tester and connection circuit

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 DPNS 163:2007

Annex D

Insulation resistance test

D.1 Normal temperature insulation resistance

D.1.1 The cord, subjected to the dielectric strength tests of C.1 or C.2, shall be grounded
and discharged and subjected to the dielectric strength test of sub-clause C.3, and shall be
immersed in water in advance for at least one hour. The test potential of 100 V DC or over
shall be applied between the conductor and the water for single-conductor wires, and between
the conductors themselves and between each conductor and the water for multi-conductor
wires for one minute and shall be subjected to measurement of insulation resistance using the
direct deflection method of Figure D.1 or super insulation tester of Figure D.2.

Figure D.1 – Insulation resistance measuring circuit based on direct deflection method

TWG02 to check this Annex

D.l.2 Formula for calculating insulation resistance by direct deflection method (Figure D.1)
5.3» in Annex B, R20 is defined as the equivalent conductor resistance.

RS x (DO x SO) x Kt x L
R20 =
DxS

where

R20 is the insulation resistance converted into its equivalent per kilometer at 20 °C,
MΩkm
RS is the standard resistance, MΩ

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 DPNS 163:2007

DO, SO is, respectively, deflection of the galvanometer, and the value of the shunt
when current is passed through the standard resistance with the tip of
measuring lead being grounded.
D, S is, respectively, deflection of the galvanometer, and the value of the shunt one
minute after the application .of the voltage with the tip of measuring lead
being connected to the conductor to be measured. However, if there is any
leakage from the lead wire, this shall be eliminated from the value.
Kt is the temperature conversion coefficient in Table B1 for converting a value at
t °C to that of 20 °C
L is the wire length, km

Figure D.2 - Insulation resistance measuring circuit using an insulation tester and the
formula for determining this resistance

NOTE 1 DC power supply E is a battery or stabilized DC power supply

NOTE 2 Standard resistance RS is sufficiently low compared with the insulation resistance
of the conductor to be subjected to measurement

NOTE 3 Indicated value of super insulation tester is Rt = RS x E/V where, V is the voltage
generating across RS at the time of measurement, E is the value of the DC supply voltage
used for measurement.

D.1.3 Formula for calculating insulation resistance (Figure D.1)

R20 = Rt x Kt x L

where

R20 is the insulation resistance converted to its equivalent per kilometer at 20 °C,
MΩkm

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 DPNS 163:2007

Rt is the indicated value at insulation tester at t °C, MΩ

Kt is the temperature conversion coefficient in Table D1 for converting a value at
t °C to that at 20 °C
L is the length of wire, km

D.1.4 If the value corresponding to charging over a period of one minute leads to doubt due
to absorbing phenomenon, etc., the above measurement may be made after charging for a
period of one to about five minutes, recording the charging time. Positive pole of supply for
measurement shall be grounded. Where the insulation resistance of electrical wire having
PVC insulation is measured at a temperature other than 20 °C, it shall be converted to the
corresponding value at 20 °C using Table D.1.

Table D.1 - Temperature coefficients for PVC insulation resistance

(Standard temperature 20 °C)

Temp. Coefficient Temp. Coefficient Temp. Coefficient Temp. Coefficient

°C °C °C °C
0 0.42 9 0.53 18 0.85 27 2.22
1 0.43 10 0.55 19 0.92 28 2.52
2 0.44 11 0.57 20 1.00 29 2.87
3 0.45 12 0.60 21 1.11 30 3.25
4 0.46 13 0.63 22 1.24 31 3.75
5 0.48 14 0.66 23 1.39 32 4.25
6 0.49 15 0.70 24 1.55 33 4.90
7 0.50 16 0.74 25 1.74 34 5.60
8 0.52 17 0.79 26 1.96 35 6.45

D.2 High-temperature insulation resistance – After preparing an appropriate length

(minimum shipping length) of core specimen (core for multi-core electrical wires) and
immersing it in water at specified temperature ± 1 °C until the insulation temperature
becomes constant, the high- temperature insulation resistance shall be measured in accordance
with the method specified in D1.

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 DPNS 163:2007

Annex E

Tensile strength and elongation test

E.1 Test specimens

E.1.1 Sampling of test specimens – A minimum of three test specimens shall be sampled.
If the test specimens cannot be sampled from finished wires, or if the test specimens so
sampled proved inappropriate they shall be obtained from a sheet rolled out from a compound
of identical quality, one to three millimeters thick, and left exposed at normal temperature for
five or more hours.

E.1.2 Shape and preparation of the test specimens

E.1.2.1 Test specimens shall be of tubular shape for insulation with an inside diameter less
than 5 mm, while for others, they normally have a dumbbell- like shape, except that insulation
less than 5 mm in thickness may be of dumbbell shape for specimens at least 2 mm in
thickness. Jackets shall be of dumbbell shape.

E.1.2.2 Dumbbell-shaped test specimens shall be free from irregularities by any suitable
method and be so treated as to give them a smooth surface.

E.1.2.3 Specified temperature

PVC-Insulated Cords, 60 °C ± 1 °C

E.1.2.4 Test specimens shall be as near the original in thickness as possible or shall be
adjusted to a thickness of approximately 3 mm in case the original thickness exceeds 3 mm.

E.1.2.5 Test specimens of shape (a) or (b) shall be punched out by dumbbell-shaped
punching die as shown in Figure E.I. The grips may be as low as 7 mm.

100 100

15 25 20 40 21 19 20 40

R25
5 25 5 10
R11
RAC
Unit: mm

Figure D.1 – Dumbbell-shaped test specimen

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 DPNS 163:2007

E.1.3 Calculation of the cross-sectional area – Cross-sectional area shall be calculated as

follows:

a) Tubular test specimens – Outside diameter of the insulation shall be measured at a

minimum of five points and using the minimum value obtained and the outside diameter
of the conductor, the cross-sectional area shall be calculated on the basis of the following
formula:

Cross-sectional area (mm²) = ∏/4 [(Outside diameter of the insulation, mm)² - (Outside
diameter of the conductor, mm)²)

b) Dumbbell-shaped test specimens – After having measured the thickness of the

dumbbell-shaped test specimen at five or more points with a micrometer or dial gauge,
the cross-sectional area shall be calculated by multiplying the minimum measured value
by the width of the parallel portion (the width of the punching die to be used).

E.2 Test conditions

E.2.1 Temperature – the test shall be conducted at 16 °C to 32 °C, and the room
temperature at the time of testing shall be recorded.

E.2.2 Conditions of test specimens – The test specimen shall be left at room temperature
specified in E.2.1 at least one hour or more before testing.

E.2.3 Testing machine – A pendulum-type or any suitable tension tester shall be used, and
its capacity shall be such that breaking load of the test specimen will fall within the range of
15 % to 85 % of its capacity. The tester shall be so adjusted that the tolerance of its indicated
value will always be within ± 2 %.

E.2.4 Testing method – The test specimen shall be checked properly to ensure absence of
deflection and so forth during the test, and tensioned at a tensile speed as shown in Table E.1
with tolerances of ± 10 %. The load and the distance between the lines corresponding to the
breaking point shall be measured.

Table E.1 – Tensile speed

Thermal rating Tensile speed

mm/min
PVC-Insulation, 60 ºC 500

E.3 Method of calculating tensile strength and e0longation

E.3.1 Tensile strength - Tensile strength shall be computed in accordance with the
following formula:

Breaking load in N
Tensile strength in MPa =
Cross-sectional area of test specimen in mm²

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 DPNS 163:2007

E.3.2 Elongation - Elongation shall be computed in accordance with the following formula:

(Distance between mark lines at the time of Breaking, mm –

Distance between mark lines, mm)
Elongation (%) = x 100
Distance between mark lines, mm

E.3.3 Determination of values – The values shall be represented by an average of the

values obtained from the three test specimens.

E.4.4 Breaking outside the mark lines – Where the test specimen has been broken outside
the mark lines and does not conform to the specification, this shall be removed and a test
shall be conducted again on an additional test specimen.

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 DPNS 163:2007

Annex F

Thermal ageing test

F.1 Apparatus

F.1.1 Oven – The oven shall be of air ventilating type so that the air inside the tester will be
replaced at least once every hour.

F.1.2 The temperature difference between the individual specimens in the tester shall be
within ± 3 °C of the heating temperature.

F.1.3 The tester shall be of a construction allowing vertical suspension of the specimens
over the stand and for heating.

F.2 Procedure

The test specimens prepared in accordance with F.1 shall be placed within the tester,
maintaining a ratio of not more than one gram in mass of test specimen to 10 mL in volume
of the tester (test specimens shall neither contact each other nor the wall of the tester and no
agent interacting with them shall be placed in the tester with them) and shall be heated to the
temperature indicated in Table 6 before they are taken out, and left undisturbed at normal
temperature for at least four hours, and measure for tensile strength and elongation within 96
hours in accordance with E.2 to E.4. Also, the percentage of retention shall be computed in
accordance with the following formula. The cross-sectional area shall be the one calculated in
accordance with E.1.3 before heating and the mark lines shall be scribed after heating.

F.3 Calculation

Average value after heating

Percentage of retention (%) = x 100
Average value before heating

Table F.l – Ageing temperature and duration

Temperature Time
Thermal Rating
°C h

PVC-Insulation, 60 °C 100 ± 3 168

Heat Resistant PVC- Insulation, 75 °C 120 ± 3 168

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 DPNS 163:2007

Annex G

Heat shock test

G.1 Heat shock – The test shall be as follows and conducted at a heating temperature of
120 °C ± 3 °C in an appropriate length of test specimens taken from finished articles. The
number of winding turns and the diameter of mandrel shall conform to Table G.1.

The test specimens shall be wrapped closely (or bent) at specified number of turns, heated for
an hour in a constant-temperature box at the specified temperature, and visually examined for
formation of cleaves or cracks on the surface.

Table G.1 - Number of turns and diameter of mandrel for heat shock test

Class Number of turns Diameter of mandrel

Flat cord 6 Equal to the minor axis

Jacketed round cord 6 Twice the overall diameter

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 DPNS 163:2007

Annex H

Heat deformation test

The heating temperature shall be 120 °C ± 3 °C and the mass of dead weight shall conform to
Table H.1. When a plate test specimen is used, the mass of dead weight shall be one
kilogram.

H.1 Apparatus – Heat deformation tester

H.2 Test Specimen

H.2.1 Insulation

a) Core test specimen – A core length of approximately 30 mm or from a completed

product and used as test specimen.

b) Circular arc test specimen – A circular arc length of approximately 30 mm of the

insulation shall be cut out from a completed product in parallel with the core axis and
shall be used as the test specimen after having its inside surface smoothened.

c) Plate test specimen – In case (a) and (b) are not practical, the specimen shall be taken
from a compound identical in quality to the insulation, appropriately kneaded, pressed
to a plate of approximately 2 mm in thickness, 15 mm in width, and 30 mm in length,
and used as the test specimen.

H.2.2 Jacket

a) Tubular or circular arc test specimen – For tubular jackets, a test specimen
approximately 30 mm in length shall be cut in tubular form from a completed product
or shall be cut in circular arc form in parallel with the axis of electrical wire and used as
the test specimen.

b) Circular arc test specimen – A test specimen approximately 30 mm in length shall be

taken from a completed product, cut further in parallel with the axis of the electrical
wire to form a circular arc, and used as the test specimen after its inside surface has
been smoothened.

c) Plate test specimen – In case (a) and (b) are impracticable or inappropriate, a test
specimen shall be taken from compound of the same quality as the jacket, appropriately
kneaded, and pressed to a plate of approximately 2 mm in thickness, 15 mm in width
and 30 mm in length before using it as the test specimen.

H.3 Preparation of test specimens

H.3.1 Core test specimen – This shall conform to item (a) of H.2.1.

H3.2 Circular Arc Test Specimen - The test specimens prepared in accordance with item (b)
of H2.1 and item (a) and (b) of H2.2.

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 DPNS 163:2007

Table H.1 - Mass of dead weight for heat deformation test

Nominal sectional Mass of dead weight

area of conductor g
mm² Insulation Jacket
0.3 300 -

0.5 300 -

0.75 300 500

1.25 400 750

2.0 500 750

H.3.3 Tubular test specimen – An approximately 35 mm long, round bar with the same
diameter as the inside diameter of the test specimen specified in item (a) of H.1.2 shall be
inserted into the tube.

H.3.4 Plate test specimen – The test specimens prepared in accordance with item (c) of
H.1.1 and item (c) of H.1.2 shall be placed on an approximately 35 mm long semi-circular,
round bar with a radius of 5 mm.

H.4 Procedure – After measuring the thickness (t) of the test specimen prepared in
accordance with H.3 shown in Figure H.I and after heating the test specimen and heat
deformation tester at a specified temperature for 30 minutes in advance, the test piece shall be
placed between the parallel plates of the measuring apparatus, subjected to a specified
weight, and left at the same temperature for 30 minutes more before measuring its thickness
under the same condition.

H.5 Computation – Reduction ratio shall be computed using the thicknesses before and
after heating in accordance with the following formula:

Thickness before - Thickness after

heating, mm heating, mm
Reduction ratio (%) = x 100
Thickness before heating, mm

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 DPNS 163:2007

t is the thickness of insulation or jacket

d is the diameter of conductor
D is the outside diameter of insulation or jacket

D–d
t = ------
2

t = thickness of insulation or jacket

d = radius of semi-circular bar
D=d+t
t=D- d

t = thickness of test piece

d = radius of semi-circular bar
D=d+t
t=D- d

Figure H.1 – Measuring method of the thickness for heat deformation test

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 DPNS 163:2007

Annex I

Flame retardance

I.1 This is a method of testing the flame retardant properties of finished electric wire by
using standard flame equipment which consists of a chamber of sheet metal 300 mm wide,
350 mm deep, and 600 mm high, open at the top and front, and provided with means for
supporting the samples in a vertical position and keeping it taut during the test. A Tirril
position burner with an attached pilot light mounted on a block at an angle of 0.349 radians
shall have a nominal bore of 9.5 mm and a length of approximately 100 mm above the
primary air inlets.

I.2 Procedure

I.2.1 A sample of wire 455 mm long is to be secured in vertical position in the chamber.
The paper indicator of approximately 13 mm wide is to be applied to the sample so that the
lower edge is 250 mm above the point at which the inner blue cone of the test flame is to be
applied. The paper indicator is to be wrapped around the sample projecting 20 mm from the
wire on the opposite side of the sample to which the flame is to be applied. The height of the
flame is adjusted on 125 mm with the inner cone approximately 40 mm high.

I.2.2 The burner with only the pilot lighted is to be placed in front of the samples so that
when the gas supply valve is opened, the point of application of the test flame is not less than
75 mm above the lower end of the sample.

I.2.3 The valve is to be opened for 15 seconds and then closed for 15 seconds, this process
being repeated four times.

I.3 Test criteria

I.3.1 If more than 25 percent of the extended portion of the indicator is burned away, after
five application of the flame, the wire is to be considered to have conveyed flame.

I.3.2 The duration of the flaming of the sample after the fifth application of the flame shall
not be more than one minute.

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 DPNS 163:2007

Annex J

Flexibility test

Flexibility test shall be made on cords of 0.75 mm² or more by the following procedure:

J.1 A specimen of suitable length taken from the product shall be brought through the gap
between two parallel cylinders of 5 mm in diameter each of the test device shown in Figure
J.1. One end of the specimen shall be fixed to the clamp and to the other end a weight shall be
suspended, and the mass of the weight shall be 150 g/mm2 of conductor sectional area (if it is
less than 500 g, then 500 g shall be bused). By passing the current equal to the allowable
current through the conductor, the specimen shall be bent about 180 ° each, by turning, in
right and left directions, alternately. (This operation shall be made once.) This operation shall
be repeated 100 times with a rate of 10 times per minute, and the specimen shall be examined
for the number of conductor of component wires broken. Further, two cylinders and the
clamp of the test device are built on a solid base as one body, and the turning thereof shall be
conducted.

J.2 Another specimen of suitable length taken from the product shall be kept at a
temperature of 100 °C for 48 h, and the breaking test specified in J.1 shall be conducted until
one core wire is broken. Then, the short-circuit between lines, chaps or cracks of insulation
and other defects shall be examined.

Figure J.1 – Bending test device

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 DPNS 163:2007

Annex K

Oil resistance test

K.1 Application – Oil resistance test shall be made only on oil-resistant cords.

K.2 Procedure – The test specimen shall be immersed in an electrical insulating oil of
No.2 class 1 as specified in JIS C 2320 and the heating temperature is equivalent to its
thermal rating ± 3 °C. After 6 hours of immersion, take out the specimens and lightly wipe
the surface to remove the oil deposits and leave them for at least 4 hours at room temperature
and measure the tensile strength and percent elongation in accordance with Annex E.

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 DPNS 163:2007

Annex L

Wrap test of nylon jacket

The nylon jacket on a class TFN wire shall not crack when wrapped around a mandrel and
tested under the following conditions:

L.1 A specimen of finished wire is to be wrapped for four turns around a smooth metal
mandrel of a diameter six times that of the specimen. The ends of the specimen are to be
secured to the mandrel so that the four complete turns of the specimen are exposed to the air
between the securing means.

L.2 The specimen and the mandrel are to be suspended for 24 hours in a full-draft
circulating air oven at a temperature of 95 °C ± 1 °C after which the specimen and mandrel
are to be removed from the oven and cooled for one hour in a desiccator maintained at 24 °C
± 3 °C.

31
References DPNS 163:2007

The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any amendments) applies:

UL 62:2001, Flexible Cord and Fixture Wire

PNS 35-1:2004, Electric wires and cables - Thermoplastic-insulated copper wires and cables
rated 600 volts - Part 1: General specifications

PNS 260:2004, Electric wires and cables – Annealed copper wires – Specification

IEC 227-5

Abbreviations:

IEC – International Electrotechnical Commission

PNS – Philippine National Standards

JIS – Japanese Industrial Standards