CLASS PROGRAMME

Type approval
DNVGL-CP-0400 Edition July 2019

Lightweight electric cables

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FOREWORD

DNV GL class programmes contain procedural and technical requirements including acceptance
criteria for obtaining and retaining certificates for objects and organisations related to
classification.

© DNV GL AS July 2019

Any comments may be sent by e-mail to rules@dnvgl.com

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this
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for loss or damages resulting from any use of this document.
CHANGES – CURRENT

Changes - current
This document supersedes the December 2015 edition of DNVGL-CP-0400.
Changes in this document are highlighted in red colour. However, if the changes involve a whole chapter,
section or subsection, normally only the title will be in red colour.

Changes July 2019

Topic Reference Description

Alignment with IACS Rec Sec.3 Table 1, Replaced IEC 60332-1 with IEC 60332-1-1 and IEC 60332-1-2.
67 (Rev.1 June 2018) No. 24

Editorial corrections
In addition to the above stated changes, editorial corrections may have been made.

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CONTENTS

Contents
Changes – current.................................................................................................. 3

Section 1 General.................................................................................................... 5
1 Introduction.........................................................................................5
2 Documentation.....................................................................................5

Section 2 Product requirements..............................................................................7

1 Design requirements............................................................................7
2 Test requirements................................................................................9

Section 3 Test requirements................................................................................. 11

1 Table of tests.....................................................................................11

Changes – historic................................................................................................ 15

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SECTION 1 GENERAL

Section 1
1 Introduction

1.1 Objective
The objective of this class programme (CP) is to describe the type approval (TA) scheme for lightweight
electric cables.
For a description of the Society's type approval scheme in general and further information on general
conditions and procedures for obtaining the Society's TA certificate, see DNVGL-CP-0338 Type approval
scheme.
The procedures and requirements described in this CP are applicable for obtaining the Society's TA certificate
based on requirements given in:
— DNV GL rules for classification: Ships DNVGL-RU-SHIP Pt.4 Ch.8 Sec.1 Electrical installations
— DNV GL offshore standards DNVGL-OS-D201 Electrical installations
Guidance note:
This class programme is not applicable for obtaining EU Marine Equipment Directive (MED) certificates. Visit www.dnvgl.com for
information on MED certification.

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1.2 Scope
This CP gives a description of the procedures and requirements related to documentation, design and type
testing applicable for TA of Lightweight electric cables.
This CP does not set the design requirements for the lightweight electric cables. TA is based on compliance
with design requirements given in the rules and/or other regulations and standards. The CP describes the
applicable design requirements and how to document compliance with the requirements in order to obtain a
TA certificate for the equipment. This includes, where relevant, technical requirements for how the type tests
shall be performed.

1.3 Application
DNVGL-RU-SHIP Pt.4 Ch.8 Sec.1 requires that lightweight electric cables are type approved by the Society.
Type approval in accordance with this CP is thus mandatory for equipment to be installed on vessels classed
with the Society.
A TA certificate in accordance with this CP will confirm compliance with the requirements given in the rules as
specified in [1.1]. The TA certificate will not confirm compliance with requirements given in other parts of the
rules. In case additional requirements given in other parts of the rules shall be covered by the TA certificate,
this shall be specified in the application for TA and will be stated in the TA certificate.

2 Documentation
For TA of Lightweight electric cables the following documentation shall be submitted:
1) data sheet(s)
2) main drawings of all different cable construction covered by the type approval, showing conductors and
the different layers.
3) references to design standards, rules, specifications etc.
4) specification of applied material.
5) test results (from tests already carried out, if any).

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6) applicant’s proposal to type test (TT) and routine test (RT).

Section 1
7) documentation of reliability and endurance on board ships and mobile offshore units, if any.
8) special operational limitations.
9) field of application:
— general power and lighting
— control
— instrumentation and communication.
10) list of the cables covered by the type approval giving the following information for each variant:
— number of cores
2
— conductor cross-section (mm ) and number of strands
— insulation thickness (mm)
— fillers/bedding thickness (mm)
— inner/outer sheath thickness (mm)
— braiding wire diameter (mm)
— overall diameter (mm).
11) construction details:
— voltage class: 0.6/1 kV or 150/250 V
— temperature class: 90°C
— conductors: Class 2 or class 5. Stranded plain or tinned copper
— insulation material
— fillers/bedding material
— inner/outer sheath material: SHF1, SHF2
— metal covering: Braid or armour made of galvanised steel, bronze or copper
— material outer braid/armour if any.
12) special properties, if any (watertight, fire resistant etc.) Test programme, which as a minimum includes
the elements for type testing, Sec.3. The test programme shall refer to the relevant standards for each
test.
13) application for DNV GL type approval form TAA 901.
14) for items 9), 10) and 11) above, application form no. 82.01a shall be used.

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SECTION 2 PRODUCT REQUIREMENTS

Section 2
1 Design requirements

1.1 General requirements

The lightweight electric cables shall comply with the relevant requirements given in the latest edition of the
following publications (including amendments):
— DNVGL-RU-SHIP Pt.4 Ch.8 Sec.2 (as applicable).
— DNVGL-OS-D201 as governed by applicable rules for offshore units
— requirements for insulation material as per Sec.2 and Sec.3
— IEC 60092-360: Insulating and sheathing materials for shipboard and offshore units, power, control,
instrumentation and telecommunication cables.

1.2 Special Properties

— IEC 60092-350: General construction and test methods of power, control and instrumentation cables for
shipboard and offshore applications.
— IEC 60332-1-1: Test for vertical flame propagation for a single insulated wire or cable - Apparatus.
— IEC 60332-1-2: Test for vertical flame propagation for a single insulated wire or cable – Procedure for 1
kW pre-mixed flame
— IEC 60332-3-10: Test for vertical flame spread of vertically-mounted bunched wires or cables -
Apparatus.
— IEC 60332-3-22: Test for vertical flame spread of vertically-mounted bunched wires or cables – category
A.
— IEC 60649: Calculation of maximum external diameter of cables for indoor installations.
— IEC 60684-2: Specification for flexible insulating sleeving. Methods of test.
— IEC 60754-1: Determination of the amount of halogen acid gas.
— IEC 60754-2: Determination of the degree of acidity of gases evolved during the combustion of materials
taken from electric cables by measuring pH and conductivity.
— IEC 60811-1-1: Methods for general application - Measurement of thickness and overall dimensions -
Tests for determining the mechanical properties.
— IEC 60811-1-2: Methods for general application – Section Two: Thermal ageing methods.
— IEC 60811-1-4: Methods for general application – Section Four: Tests at low temperature.
— IEC 60811-2-1: Methods specific to elastomeric compounds - Ozone resistance, hot set test and mineral
oil immersion test.
— IEC 60811-3-1: Methods specific to PVC compounds – Section One: Pressure test at high temperature -
Tests for resistance to cracking.
— IEC 61034-2: Measurement of smoke density of cables burning under defined conditions – Part Two: Test
procedure and requirements.
— IEC 60331-1: Test method for fire with shock at a temperature of at least 830 °C for cables of rated
voltage up to and including 0.6/1.0 kV and with an overall diameter exceeding 20 mm
— IEC 60331-2: Test method for fire with shock at a temperature of at least 830 °C for cables of rated
voltage up to and including 0.6/1.0 kV and with an overall diameter not exceeding 20 mm
— IEC 60331-21: Procedures and requirements – Cables of rated voltage up to and including 0.6/1 kV
— ISO 5659, Part 2: Determination of optical density by a single chamber test.
— IMO: Res. MSC. 61(67) International Code for Application of Fire Test Procedures.
— British Standards BS 3G 230: General requirements for aircraft electrical cable (second series)
— EN 50305: Railway Applications – Railway rolling stock cables having special fire performance – test
methods

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— EN 3475-502: Cables, electrical, aircraft use – Test methods – Notch propagation

Section 2
— NEK TS 606: Cables for Offshore installation, Halogen Free or Mud Resistant

1.3 Core details

Table 1 Metric standard cores

Minimum
Conductor Nominal conductor Maximum
insulation Target insulation Target core
nominal stranding conductor
thickness at thickness diameter
cross section no./ diameter resistance at 20°C
any point

(mm²) (mm) (ohms/km) (mm) (mm) (mm)

0.5 19/0.18 40.1 0.18 0.23 1.32

0.75 19/0.23 26.7 0.18 0.23 1.51

1.0 19/0.25 20.0 0.18 0.23 1.65

1.5 37/0.23 13.7 0.2 0.255 2.02

2.5 37/0.29 8.21 0.2 0.255 2.38

Valid for voltage class: 0.6/1 kV.

Table 2 AWG Standard cores

Minimum
Nominal
Maximum conductor insulation Target insulation Target core
Conductor conductor
resistance at 20°C thickness at thickness diameter
stranding
any point

AWG No./ AWG (ohms/km) (mm) (mm) (mm)

22 19/34 50.5 0.18 0.23 1.20

20 19/32 31.1 0.18 0.23 1.41

18 19/30 20.0 0.18 0.23 1.65

16 19/29 15.3 0.18 0.23 1.79

14 37/30 9.8 0.20 0.255 2.21

12 37/28 6.4 0.20 0.255 2.65

Valid for voltage class: 0.6/1 kV.

Table 3 Fire resistant cores 150/250 V

Conductor Nominal conductor Minimum insulation

Maximum conductor Target insulation Target core
nominal stranding thickness at
resistance at 20°C thickness diameter
cross section no./ diameter any point

(mm²) (mm) (ohms/km) (mm) (mm) (mm)

0.5 19/0.18 40.1 0.18 0.23 1.89

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 Conductor Nominal conductor Minimum insulation

Section 2
Maximum conductor Target insulation Target core
nominal stranding thickness at
resistance at 20°C thickness diameter
cross section no./ diameter any point

(mm²) (mm) (ohms/km) (mm) (mm) (mm)

0.75 19/0.23 24.7 0.18 0.23 2.00

1.0 32/0.20 20.0 0.18 0.23 2.17

1.5 30/0.25 14.1 0.2 0.255 2.51

Table 4 Fire resistant cores 0.6/1 kV

Conductor Nominal conductor Minimum insulation

Maximum conductor Target insulation Target core
nominal stranding thickness at
resistance at 20°C thickness diameter
cross section no./ diameter any point

(mm²) (mm) (ohms/km) (mm) (mm) (mm)

1.00 32/0.20 20.0 0.18 0.23 2.20

1.50 30/0.25 14.1 0.20 0.255 2.61

2.50 37/0.28 8.21 0.20 0.255 2.87

4.00 56/0.23 4.70 0.20 0.255 3.59

6.00 85/0.23 3.10 0.50 0.55 4.55

10.0 80/0.40 1.82 0.50 0.55 5.60

1.4 Braid wire

Braiding wire diameter shall be specified in the individual cable construction tables. Braid Coverage shall
meet the requirements given in Sec.3 Table 1 Test no. 4.

1.5 Sheath dimensions:

The fictitious diameter under the sheath (Df) is calculated using the rules specified in IEC 60649 Clauses 1.3,
1.4, 1.5, 1.6 and 1.7, as required, except that the diameter of insulated conductor (di) shall be replaced with
the appropriate target core diameter specified in Table 1 and Table 2.
Target sheath thickness (Dt) and minimum sheath thickness (Dmin) are defined as follows:
Target sheath thickness Dt = (0.04 · Df) + 0.8 [mm].
Minimum sheath thickness Dmin = (0.85 · Dt) – 0.1 [mm].

2 Test requirements
The testing is divided into:
— visual inspection
— electrical/mechanical tests.

2.1 Visual inspection

By visual inspection, it shall be verified that the test sample is in conformity with the approved plans.

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 Section 2
2.2 Electrical/mechanical tests
The tests shall be according to the relevant parts of Sec.3 Table 1.

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SECTION 3 TEST REQUIREMENTS

Section 3
1 Table of tests
Table 1 Required test types

Test Type Routine

Examination or test Test basis Requirements Test on
No. test test

General properties

Core details IEC 60811-1-1,

IEC 2.1.3
60092-350 Braid wire IEC 60811-1-1, Core X X
1. Dimensions
IEC 2.1.4 Cable X X
60811-1-1 Sheath dimension IEC
60811-1-1, 2.1.5

IEC 70% Minimum Insulation X X

2. Concentricity
60811-1-1 (50% for FR cores) Sheath X X

Material free of cracks,

Insulation X X
3. Workmanship By inspection splits, irregularities and
Sheath X X
foreign material

IEC 90% Minimum coverage

4. Braid coverage Cable X X
60092-350 density

IEC Conductor surface will be

Metallic coating of copper 60092-350 smooth and uniform.
5. Conductor X X
conductors (By Insulation will not adhere to
inspection) the conductor.

Physical properties

20MPa minimum, 150%

Tensile strength & ultimate IEC
6. minimum (insulation) Insulation X X
elongation 60811-1-1
(speed 50 ± 10 mm/min)

500 cycles minimum

EN50305 cl.
7. Scrape abrasion resistance (5N load, 0.45mm diam. Core X
5.2
rod, 20°C, 55 cycles/minute)

100N minimum
EN50305 cl.
8. Dynamic cut through (90° 0.45mm radius blade, Core X
5.6
20°C, 100g/s load) X

No dielectric breakdown
9. Notch propagation EN3475-502 (0.05mm notch, 6X mandrel, Core X
1.5kV AC for 1 minute)

IEC
Mechanical/particular 60092-350,
10. characteristic of sheathing IEC 60092- SHF1 or SHF2 Sheath X
compounds 360
Table 6 & 8

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 Test Type Routine

Section 3
Examination or test Test basis Requirements Test on
No. test test

Tensile and elongation

±25%
Volume swell 20% max
Weight increase 15% max Sheath
10a. SHF2 mud resistance NEK TS 606, (IRM 903 100°C, 7 d (SHF 2 cables X
Calcium bromide brine 70°C, only)
56 d
EDC 95-11 (oil based),
70°C, 56d)

Thermal properties

11. Lifetime BS 3G 230 >20 000h at 105°C Core X

No cracks, no dielectric
IEC breakdown
12. Accelerated ageing Core X
60811-1-2 (168h at 150°C, 1.5kV AC
for 5 minutes)

EN 50305 Cores must be easily

13. Insulation blocking Core X
10.2 separated (6h at 150°C)

No cracks, no dielectric
breakdown
Cold bend (-30°C, 10X mandrel, 1.5kV
IEC Core X
14. (Where outer diameter AC for 5 mins for 1m core)
60811-1-4 Cable X
<12.5mm) (-30°C, 10X mandrel, 3.5kV
AC for 5 min. sample of
cable)

No cracks, no dielectric
breakdown (30s at 250°C,
15. Current overload BS 3G 230 Core X
10X mandrel, wind as in test
11, 1.5kV AC for 5 minutes)

Electrical properties

IEC
16. Conductor resistance per Appendix 1 Core X X
60092-350

No dielectric breakdown
(2.5kV AC/4.5kV DC for 5
minutes for 1m of core )
(1.5kV AC / 5 minutes for
each delivery length of
IEC cable) Core X X
17. AC and DC voltage tests
60092-350 (150v rated: 1.5kV Cable X X
a.c /3.6kV DC for 5 mins for
1m core)
(600v rated: 3.5kV
AC /8.4kV DC for 5 mins for
1m core)

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 Test Type Routine

Section 3
Examination or test Test basis Requirements Test on
No. test test

No dielectric breakdown
Insulation - continuity proof IEC
18. At least 8kV impulse, 8kV Core X 100%
test 60092-350
DC or 5.3kV AC

Insulation resistance at IEC 500MΩkm min. at 20°C

19. Core X X
20°C 60092-350 (5m length, quote actual IR)

Insulation resistance at IEC 1.5MΩkm min. at 90°C

20. Core X
90°C 60092-350 (5m length, quote actual IR)

C14-C1 ≤ 0.15C1, C14-C7 ≤

Increase in AC capacitance IEC 0.05C7
21. Core X
after immersion in water 60092-350 (14 days at 50°C in tap
water)

Environmental properties

IEC
60092-350 No crazing or cracking
22. Ozone resistance Core X
IEC (250-300ppm, 25°C, 30h)
60811-2-1

Fluid immersion: 72h at

70°C – No cracking or dielectric
IRM 902, breakdown 7.5% max. swell
23. BS 3G 230 Core X
IRM 903 (6X mandrel, soak in water,
Diesel(F-76), 3.5% salt 1.5kV AC for 5 minutes)
water

Fire hazard properties

IEC Charring confined between

60332-1-1 50mm and 540 mm from
24. Flammability - small scale Core X
and lower edge of top support
60332-1-2 (single vertical wire)

25. Flammability - large scale IEC 60332-3 Category D, designation F Cable X

IEC 60684-2 Less than 0.5% for each

26. Halogen content Cable X
cl. 45 non-metallic component

IMO FTPC
It of less than 2, report Lc
27. Toxicity index Annex 1, Part Cable X
value
2

Smoke emission - small Ds4 150 max. and Dmax 150

28. ISO 5659-2 Core X
scale max. VOF4 300 max.

Smoke emission - large

29. IEC 61034-2 70% Minimum transmittance Cable X
scale

IEC 1000°C with shock, at rated

30. Fire resistance 60331-1/2 voltage, min. 2 hrs (fire Cable X
IEC 60331-21 resistant cables only)

All samples shall be conditioned for greater than 16 hours at room temperature prior to test (Routine test excluded).
Where sheath tests are performed at elevated temperatures, control samples may be conditioned at 70°C for 24 hours.

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TT = Type Test

Section 3
RT = Routine Test

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CHANGES – HISTORIC

Changes – historic
December 2015 edition
This is a new document.

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