STANDARD SPECIFICATION No.

lagitadMENCII•EERS STANDARD SPECIFICATION

S1 ii KtegNIII
" WA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 8
Gent of In Undettakmo Page 1 of 8

Ridirm c;•sici * TITTW feltT

STANDARD SPECIFICATION FOR
SIGNAL CABLES

8 10.12.21 Revised and Reissued as Standard Specification RK ASDB

7 28.03.17 Revised and Reissued as Standard Specification SMK RK RG RN

6 15.12.10 Revised and Reissued as Standard Specification RSD RP TGM/JMS ND

5 03.05.05 Revised and Reissued as Standard Specification NPG AKG PM VJN

4 27.01.98 Revised and Reissued as Standard Specification PM RK BRS AS

Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by

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 STANDARD SPECIFICATION No.
laReieid-B-AENGINEERS STANDARD SPECIFICATION
0-zir !WNW .4.3.111011 NDIA UMITFD
IA GrAt of Indio Undertaiono
FOR SIGNAL CABLES 6-52-0046 Rev. 8
Page 2 of 8

Abbreviations:

DC Direct Current
EPR Ethylene-Propylene Rubber
FR Flame Retardant
FRLS Flame Retardant Low Smoke
PE Polyethylene
PETP Polyethylene Terepthalate
PVC Polyvinyl Chloride
XLPE Cross Linked Poly Ethylene

Instrumentation Standards Committee

Convener: Mr. Mainak Nandi

Members: Mr. Arupjyoti Saikia

Mr. Sachin Garg
Mr. Jerry Johnson
Mr. Mayank Kaushik
Mr. Saurav Mukherjee
Ms. K.Pratheepa
Mr. R.K.Gupta (Projects)
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 STANDARD SPECIFICATION No.
181fitad INGNIRS STANDARD SPECIFICATION
oar faiRegmor INDIA LIMITED
OIRTI tIPMIP
FOR SIGNAL CABLES 6-52-0046 Rev. 8
Page 3 of 8

CONTENTS
1.0 GENERAL 4

2.0 DESIGN AND CONSTRUCTION 5

3.0 NAMEPLATE 7

4.0 INSPECTION AND TESTING 8

5.0 SHIPPING 8

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 STANDARD SPECIFICATION No.
latitae fib-ENGINEERS STANDARD SPECIFICATION
Igazz UMITED FOR SIGNAL CABLES 6-52-0046 Rev. 8
(A Coot d loft Undortiona)
Page 4 of 8

1.0 GENERAL

1.1 Scope

1.1.1 This specification, together with the data sheets, covers the requirements for design, materials,
manufacturing, inspection, testing and shipping of signal cables.

1.1.2 Cables shall comply with latest edition of the following standards prior to the date of the
purchaser's enquiry.

ASTM American Society for Testing and Materials

D 2843 Standard Test Method for Density of Smoke from the
Burning or Decomposition of Plastics.
D 2863 Test method for measuring the minimum oxygen
concentration to support candle like combustion of
plastics (oxygen index).

BS British Standards

EN50288-7 Multi-element metallic cables used in and digital

communication and control. Sectional specification for
instrumentation and control cables.
EN 60228 Conductor of Insulated Cables

IEC International Electro technical Commission

60811-201 Electric and optical fibre cables — Test methods for non-
metallic materials — Part 201: General tests —
Measurement of insulation thickness.
60331 Testing of Fire Resistant cables.
60332 Tests on bunched wires and cables.
60092 Electrical Installations of Cables
60754 Test on Gases Evolved during Combustion of materials
from Cables — Part 1, 2.

IS Indian Standards
1554 Part 1 PVC insulated (heavy duty) electric cables-working
Voltage up to and including 1100V.
3975 Mild steel wires, formed wires and tapes for armouring of
Cables.
5831 PVC insulation and sheath of electric cables.
6380 Elastomeric insulation and sheath of electric cables
7098 Cross-Linked Polyethylene Insulated PVC sheathed
Cables
10810 Method of test for cables.
Part 40 Method for testing uniformity of Zinc coating on Steel
armour
Part 41 Mass of zinc coating on steel armour
Part 58 Oxygen Index test
Part 59 Determination of the amount of halogen acid gas evolved
during combustion of polymeric material taken from
cables
Part 61 Flame Retardant test
Part 62 Flame Retardance test for bunched cables
Part 63 Smoke densities of electric cables under fire conditions
Part 64 Measurement of Temperature Index

1.1.3 In the event of any conflict between this standard specification, data sheets, statutory
regulations, related standards, codes etc., the following order of priority shall govern:

a) Statutory Regulations

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 STANDARD SPECIFICATION No.
-13teit4 dith ENGINEERS STANDARD SPECIFICATION
ligar taRegNur \IDIA LIMITED
(A Govt of India Undedakim)
FOR SIGNAL CABLES 6-52-0046 Rev. 8
Page 5 of 8

b) Data Sheets

c) Standard Specification

d) Codes and Standards

1.2 Bids
1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with the
material requisition.
1.2.2 All documentation submitted by vendor including their quotation, catalogues, drawings and
documents etc. shall be in English language only.
1.2.3 Vendor shall furnish unit price per metre for each type of cable, which shall be used for any
addition or deletion of the quantity.

1.3 Drawings and Data

1.3.1 Detailed drawings, data and catalogues required from the vendor are indicated by the purchaser
in the vendor data requirement sheets attached with the requisition.
1.3.2 Final documentation consisting of design and constructional data submitted by the vendor after
placement of order shall include the following, as a minimum.

a) Specification sheet for each type of cable along with test certificates and test reports.

b) Cable details giving electrical characteristics, overall diameter, weight, diameter

under armour and diameter over armour.

2.0 DESIGN AND CONSTRUCTION

2.1 Constructional Requirements

2.1.1 Cables shall be heavy-duty type, 500V grade.

For polyvinyl chloride (PVC) Type C cables, primary insulation shall withstand maximum
conductor temperature of 85°C and shall meet the requirement specified in IS 5831. Thickness
of primary insulation shall be 0.5 mm as a minimum. For PE insulated cables, primary
insulation shall withstand maximum conductor temperature of 70°C Polyethylene. For XLPE
insulated cables, primary insulation shall withstand maximum conductor temperature of 90° C
and shall meet the requirement specified in IS-7098 (Part-1).

The type of primary insulation shall be as specified in purchasers data sheets.

2.1.2 Inner sheath colour of signal cables shall be black. Outer sheath colour shall also be black
except for cables used in intrinsically safe systems. The outer sheath colour for all such cables
used in intrinsically safe application shall be light blue. The thickness of the sheath shall be as
per IS 1554 part 1.
2.1.3 Inner and outer sheath of cable shall be flame retardant made of extruded PVC Type ST2 (90°C)
as per IS 5831 and shall meet the following requirements:

a) Minimum Oxygen index of PVC shall be 30 at 27 °C ±2°C.

b) Temperature index shall be over 250 °C.

c) Inner and Outer sheath shall posses flame retardant properties meeting requirements for
bunched cables as per IS 10810 (Part 62) category AF or IEC 60332 category A.

d) A rip cord shall be provided for inner sheath.

e) Outer sheath shall be suitable for protecting the cable against rodent and termite attack.
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 STANDARD SPECIFICATION No.
Cf.= ENGINEERS STANDARD SPECIFICATION
sign &Aft INDIA LIMITED
MOM pRelfiVallW.1 (A Govt 01 Ma Undottlkingl
FOR SIGNAL CABLES 6-52-0046 Rev. 8
Page 6 of 8

0 Inner and Outer sheath of all cables shall be water resistivity type.

2.1.4 All types of cables shall be armoured type unless otherwise specified. Armour over inner sheath
shall be of galvanised steel wire (flat or round wire type). The dimensions of armour shall be as
per IS 1554 (Part 1). Requirement and methods of tests for armour material and uniformity of
galvanisation shall be as per IS 3975 and IS 10810 (Part 40) respectively.
2.1.5 Each pair/triad shall be shielded. Shield shall be of aluminium backed by mylar / polyester tape
bonded together helically applied with metallic side down having 25% overlap on either side
and 100% coverage. Minimum shield thickness shall, be 0.05 mm. Drain wire shall be 0.5 mm2
multi-strand bare tinned annealed copper conductor. The drain wire shall be in continuous
contact with aluminium side of the shield.
2.1.6 Overall shield shall be of aluminium backed up by mylar/polyester tape helically applied with
the metallic side down with either side having 25% overlap and 100% coverage. Minimum
shield thickness shall be 0.075 mm. Drain wire shall be similar to individual pair/triad drain
wire and shall be over the overall shield.
2.1.7 The cores of a pair triad shall be twisted with a minimum of 10 twists per metre of cable.

2.1.8 Sequential marking of the length of the cable in meters shall be provided on the outer sheath at
every one meter. The embossing /engraving/printing shall be legible and indelible.
2.1.9 Tolerance in overall diameter of cable shall be within ± 2 mm over offered value. The actual
overall diameter (O.D) of the manufactured cable shall meet the O.D specified by the vendor in
the offer and purchase requisition within the specified tolerance limits.

2.1.10 The cables used in installations under the jurisdiction of Director General of Mines and Safety
(DGMS) shall meet all requirements of DGMS. The word "Mining Cable" shall be embossed on
the cable outer sheath as per IS 1554 (Part 1).

2.1.11 Drum length and length tolerance

The length of the cables in each drum (drum length) shall be as specified in the purchaser data
sheets. Where no drum length is indicated in the data sheet /material requisition, the following
shall apply:
Drum length for single pair/ single triad cable : 500 metres
Drum length for multi-pair/ multi- triad cable : 1200 metres
Actual produced drum length shall not vary by more than ± 3% from the length indicated in
purchaser's datasheet.
2.1.12 Tolerance over the total ordered length shall not vary by more than +0% and (-) 2% for total
length for a type of cable.
2.1.13 Specific Requirements for fire resistant or fire survival cable.
2.1.13.1 The cables shall have circuit integrity as per IEC 60331 (Part-21).
2.1.13.2 Primary insulation shall be heat resisting elastomeric which can withstand temperature up to
90°C such as silicon rubber/mica glass tape/EPR (medium grade) as per IS 6380. Insulation
thickness shall be 1.0mm minimum (0.44 mm for Silicon rubber) and shall confirm to IEC
60092.
2.1.13.3 Individual pair triad shall be shielded. The shield shall be aluminium backed by mylar/PETP
tape with the metallic side down helically applied with 25% overlap on either side and 100%
coverage. Minimum shield thickness shall be as per IEC 60092. Drain wire shall be 0.5mm2
(7/0.3mm dia) multi-stranded bare tinned annealed copper conductor. Drain wire shall be in
continuous contact with aluminium side of the shield.

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 STANDARD SPECIFICATION No.
k311;1 ENGINEERS STANDARD SPECIFICATION
litar 1•IDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 8
(A Gort Indio Undsrtalang)
Page 7 of 8

.2.1.13.4 Inner and outer sheath shall be made of low smoke, heat resistant, oil resistant and flame
retardant material with oxygen index over 30, temperature index shall be over 250°C. Acid
generation shall be maximum 20% by weight as per IEC 60754. Smoke density rating not to
exceed 60% as per ASTM D 2843.
2.1.13.5 The thickness of the sheath shall be as per IEC 60092. Inner and outer sheath colour shall be
orange. A rip cord shall be provided for inner sheath.

2.2 Electrical Characteristics

2.2.1 Maximum DC resistance of the conductor of the finished cable shall not exceed 7.41 SI / km at
20°C for cables with 2.5 mm2 conductors, 12.3 I / km at 20°C for cables with 1.5 mm2
conductors and 39.7 SI / km at 20°C for cables with 0.5 mm2 conductors.

2.2.2 Capacitance

2.2.2.1 Mutual Capacitance for PVC Insulated cables

The mutual capacitance of between pairs/triads or adjacent cores shall not exceed of 250 pF /
metre at a frequency of 1 KHz.

2.2.2.2 Mutual Capacitance for PE/XLPE Insulated cables

The mutual capacitance between the pairs/triads shall not exceed of 100 pF / metre at a
frequency of 1 KHz.

2.2.2.3 Capacitance between any core or screen

The capacitance between any core and screen shall not exceed a maximum of 400 pF / metre at
a frequency of 1 KHz.

2.2.3 L/R ratio of adjacent core shall not exceed 60 n for cables with 2.5 mm2 conductors, 40
tH / 11 for cables with 1.5 mm2 conductors and 25 tH / SI for cables with 0.5 mm2 conductors.

2.2.4 The drain wire resistance including shield shall not exceed 30 SI / km.

2.2.5 Electrostatic noise rejection ratio of the finished cable shall be over 76 dB.

2.3 Type I (Single pair/Triad shielded).

2.3.1 Each core shall be 1.5/2.5 mm2 (as per respective data sheet) made of 7 stranded annealed
electrolytic copper conductor. Each strand shall be 0.53 mm dia for 1.5 mm2 conductor size
and 0.67 for 2.5 mm2 conductor size.

2.3.2 Colour of core insulation shall be black and blue in pair and black, blue and brown in a triad.

2.3.3 All other specifications shall be as per clauses 2.1. and 2.2 of this specification.

2.4 Type-II (Multi-pair/Multi-triad cable with individual pair/triad shield and overall shield)

2.4.1 Conductor sizes shall be 0.5mm2 made up of 7 strands of annealed electrolytic copper
conductor. Each strand shall be of 0.3 mm diameter.

2.4.2 Overall twist of all pair/triads shall be as per vendor's standard.

2.4.3 A pair of communication wire shall be provided for multipair / multitriad cables. Each wire
shall be 0.5 mm2 of plain annealed single or multistrand copper conductor with 0.4 mm thick
85°C PVC insulation. Insulation shall be green and red colour coded.

2.4.4 A pair identification shall be with numbers at interval of not more than 250 mm. Pair
identification to be printed on the primary insulation for multi-cables.

2.4.5 All other specifications shall be as per clauses 2.1. and 2.2 of this specification.

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 STANDARD SPECIFICATION No.
Oink:Alt ENaNEERs STANDARD SPECIFICATION
5 a- 1E0ft my INDIA LIMITED FOR SIGNAL CABLES 6-52-0046 Rev. 8
WWI rweerz MIJ(11711 (A Govt of n Und.t.1.1))
Page 8 of 8

2.5 Type-III (Multi-pair/ Multi-triad cable with individual pair/triad shield and overall shield)

2.5.1 The cable shall be same as type-II cable, except conductor size shall be 2.5 mm2 made of 7
stranded annealed electrolytic copper conductor. Each strand shall be of 0.67 mm dia.

2.6 Type-IV (Multi-pair /Multi-triad cable with individual pair shield and overall shield)

2.6.1 The cable shall be same as Type II, except conductor size shall be 1.5 mm2 made of 7 stranded
annealed electrolytic copper conductor. Each strand shall be of 0.53 mm dia.

2.7 RS-485 Cable

2.7.1 The cable shall be 2Pair x 1 mm2 made of 7 stranded annealed electrolytic copper conductor.
Each strand shall be of 0.43 mm dia. All other specifications shall be as per clauses 2.1. and 2.2
of this specification.

3.0 NAMEPLATE (Identification on Cable Drums)

Each cable drum shall be marked with the following information at a visible place;

a) Manufacturer's name

b) Type and size of the cable as per material requisition.

c) Length of the cable in meters contained in the drum.

d) Gross weight

e) Drum number

0 Direction of rotation of drum for unwinding by means of an arrow.

g) Purchase order number.

4.0 INSPECTION AND TESTING

4.1 Purchaser reserves the right to inspect and witness testing of all the items at vendor's works as
per Inspection Test Plan and approved quality documents. All these tests shall be completed by
the vendor and test reports shall be submitted to Purchaser for scrutiny.

4.2 Immediately after completion of electrical tests, the ends of the cable shall be sealed to prevent
Ingress of moisture with suitable PVC / rubber caps.

5.0 SHIPPING
Cables shall be dispatched in wooden drums securely battened, with takeoff end fully protected
against damage. Minimum number of eight PVC/rubber end caps shall be shipped with each
drum.

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