Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)

IEC 60502-1:2021 is available as IEC 60502-1:2021 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.IEC 60502-1:2021 specifies the construction, dimensions and test requirements of power cables with extruded solid insulation for rated AC voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV) for fixed installations such as distribution networks or industrial installations. Cables of rated AC voltage 1 kV (Um = 1,2 kV) designed and tested in accordance with this document can also be used, if declared by the manufacturer, in DC distribution systems having their nominal voltage ≤ 750 V DC (with a maximum of 900 V DC) between a live conductor and neutral/earth, or ≤ 1 500 V DC (with a maximum 1 800 V DC) between two live conductors. Applicable core identification for DC systems are considered in accordance with local installation regulations.

General Information

Status
Published
Publication Date
08-Feb-2021
Technical Committee
Current Stage
PPUB - Publication issued
Completion Date
09-Feb-2021
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IEC 60502-1:2021 - Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) - Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)
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IEC 60502-1
Edition 3.0 2021-02
INTERNATIONAL
STANDARD
Power cables with extruded insulation and their accessories for rated voltages
from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) –
Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)
IEC 60502-1:2021-02(en)
---------------------- Page: 1 ----------------------
THIS PUBLICATION IS COPYRIGHT PROTECTED
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---------------------- Page: 2 ----------------------
IEC 60502-1
Edition 3.0 2021-02
INTERNATIONAL
STANDARD
Power cables with extruded insulation and their accessories for rated voltages
from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) –
Part 1: Cables for rated voltages of 1 kV (Um = 1,2 kV) and 3 kV (Um = 3,6 kV)
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.060.20 ISBN 978-2-8322-9315-7

Warning! Make sure that you obtained this publication from an authorized distributor.

® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC 60502-1:2021 © IEC 2021
CONTENTS

FOREWORD ........................................................................................................................... 4

1 Scope .............................................................................................................................. 6

2 Normative references ...................................................................................................... 6

3 Terms and definitions ...................................................................................................... 8

4 Voltage designations and materials ................................................................................. 9

5 Conductors .................................................................................................................... 12

6 Insulation ....................................................................................................................... 12

7 Assembly of multicore cables, inner coverings and fillers ............................................... 14

8 Metal layers for single-core and multicore cables........................................................... 16

9 Metal screen .................................................................................................................. 16

10 Concentric conductor ..................................................................................................... 17

11 Metal sheath .................................................................................................................. 17

12 Metal armour ................................................................................................................. 17

13 Oversheath .................................................................................................................... 21

14 Test conditions .............................................................................................................. 22

15 Routine tests ................................................................................................................. 22

16 Sample tests ................................................................................................................. 24

17 Type tests, electrical...................................................................................................... 27

18 Type tests, non-electrical ............................................................................................... 29

19 Electrical tests after installation ..................................................................................... 35

Annex A (normative) Fictitious calculation method for determination of dimensions of

protective coverings .............................................................................................................. 45

Annex B (normative) Rounding of numbers .......................................................................... 51

Annex C (normative) Determination of hardness of HEPR insulation .................................... 52

Bibliography .......................................................................................................................... 55

Figure C.1 – Test on surfaces of large radius of curvature .................................................... 53

Figure C.2 – Test on surfaces of small radius of curvature .................................................... 54

Table 1 – Recommended rated AC voltages U .................................................................... 10

Table 2 – Insulating compounds ............................................................................................ 11

Table 3 – Maximum conductor temperatures for different types of insulating compound ........ 11

Table 4 – Sheathing compounds and maximum conductor temperatures for different

types of sheathing compound ............................................................................................... 12

Table 5 – Nominal thickness of PVC/A insulation .................................................................. 13

Table 6 – Nominal thickness of cross-linked polyethylene (XLPE) insulation ......................... 13

Table 7 – Nominal thickness of ethylene propylene rubber (EPR) and hard ethylene

propylene rubber (HEPR) insulation ...................................................................................... 14

Table 8 – Thickness of extruded inner covering .................................................................... 15

Table 9 – Nominal diameter of round armour wires ............................................................... 20

Table 10 – Nominal thickness of armour tapes ...................................................................... 20

Table 11 – Routine test voltages ........................................................................................... 23

---------------------- Page: 4 ----------------------
IEC 60502-1:2021 © IEC 2021 – 3 –

Table 12 – Number of samples for sample tests .................................................................... 24

Table 13 – Electrical type test requirements for insulating compounds .................................. 36

Table 14 – Non-electrical type tests (see Tables 15 to 23) ................................................... 37

Table 15 – Test requirements for mechanical characteristics of insulating compounds

(before and after ageing) ...................................................................................................... 38

Table 16 – Test requirements for particular characteristics of PVC insulating

compounds ........................................................................................................................... 39

Table 17 – Test requirements for particular characteristics of various cross-linked

insulating compounds ........................................................................................................... 40

Table 18 – Test requirements for mechanical characteristics of sheathing compounds

(before and after ageing) ...................................................................................................... 41

Table 19 – Test requirements for particular characteristics of PVC sheathing

compounds ........................................................................................................................... 42

Table 20 – Test requirements for particular characteristics of thermoplastic PE

sheathing compounds ........................................................................................................... 43

Table 21 – Test requirements for particular characteristics of halogen free sheathing

compounds ........................................................................................................................... 43

Table 22 – Test requirements for particular characteristics of elastomeric sheathing

compounds ........................................................................................................................... 44

Table 23 – Test methods and requirements for halogen free compounds .............................. 44

Table A.1 – Fictitious diameter of conductor ......................................................................... 46

Table A.2 – Assembly coefficient k for laid-up cores ............................................................. 47

Table A.3 – Increase of diameter for concentric conductors and metal screens ..................... 48

Table A.4 – Increase of diameter for additional bedding ........................................................ 50

---------------------- Page: 5 ----------------------
– 4 – IEC 60502-1:2021 © IEC 2021
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
POWER CABLES WITH EXTRUDED INSULATION
AND THEIR ACCESSORIES FOR RATED VOLTAGES
FROM 1 kV (U = 1,2 kV) UP TO 30 kV (U = 36 kV) –
m m
Part 1: Cables for rated voltages of 1 kV
(U = 1,2 kV) and 3 kV (U = 3,6 kV)
m m
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international

co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and

in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports,

Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their

preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with

may participate in this preparatory work. International, governmental and non-governmental organizations liaising

with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for

Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

consensus of opinion on the relevant subjects since each technical committee has representation from all

interested IEC National Committees.

3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

misinterpretation by any end user.

4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

transparently to the maximum extent possible in their national and regional publications. Any divergence between

any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter.

5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity

assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any

services carried out by independent certification bodies.

6) All users should ensure that they have the latest edition of this publication.

7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and

members of its technical committees and IEC National Committees for any personal injury, property damage or

other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and

expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC

Publications.

8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent

rights. IEC shall not be held responsible for identifying any or all such patent rights.

IEC 60502-1 has been prepared by IEC technical committee 20: Electric cables. It is an

International Standard.
This third edition cancels and replaces the second edition published in 2004 and
Amendment 1:2009. This edition constitutes a technical revision.

This edition includes the following significant technical changes with respect to the previous

edition:

a) references to IEC 60811 (all parts) have been updated and mechanical testing requirements

specific to halogen free low-smoke oversheath of material type ST have been considered;

b) the use of the types of sheathing material to be used is now clearly defined;

c) the applicability of cables for use in DC systems is now included in the scope;

---------------------- Page: 6 ----------------------
IEC 60502-1:2021 © IEC 2021 – 5 –

d) items which were earlier marked as "under consideration" were studied either for an

appropriate solution if found available, or for removal for the time being.
The text of this International Standard is based on the following documents:
Draft Report on voting
20/1938/FDIS 20/1949/RVD

Full information on the voting for its approval can be found in the report on voting indicated in

the above table.
The language used for the development of this International Standard is English.

This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in

accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available

at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are

described in greater detail at www.iec.ch/standardsdev/publications.

A list of all parts in the IEC 60502 series, published under the general title Power cables with

extruded insulation and their accessories for rated voltages from 1 kV (U = 1,2 kV) up to 30 kV

(U = 36 kV) can be found on the IEC website.

The committee has decided that the contents of this document will remain unchanged until the

stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to

the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 7 ----------------------
– 6 – IEC 60502-1:2021 © IEC 2021
POWER CABLES WITH EXTRUDED INSULATION
AND THEIR ACCESSORIES FOR RATED VOLTAGES
FROM 1 kV (U = 1,2 kV) UP TO 30 kV (U = 36 kV) –
m m
Part 1: Cables for rated voltages of 1 kV
(U = 1,2 kV) and 3 kV (U = 3,6 kV)
m m
1 Scope

This part of IEC 60502 specifies the construction, dimensions and test requirements of power

cables with extruded solid insulation for rated AC voltages of 1 kV (U = 1,2 kV) and 3 kV

(U = 3,6 kV) for fixed installations such as distribution networks or industrial installations.

Cables of rated AC voltage 1 kV (U = 1,2 kV) designed and tested in accordance with this

document can also be used, if declared by the manufacturer, in DC distribution systems having

their nominal voltage ≤ 750 V DC (with a maximum of 900 V DC) between a live conductor and

neutral/earth, or ≤ 1 500 V DC (with a maximum 1 800 V DC) between two live conductors.

Applicable core identification for DC systems are considered in accordance with local

installation regulations.

NOTE 1 Recommendations for preferred core colours for line conductors in DC systems are given in IEC 60445.

However, local installation regulations for DC systems can already contain specific identification requirements.

This document includes cables which exhibit properties of reduced flame spread, low levels of

smoke emission and halogen-free gas emission when exposed to fire.

Cables for special installation and service conditions are not included, for example cables for

overhead networks, the mining industry, nuclear power plants (in and around the containment

area), submarine use or shipboard application, or cables directly connected to photovoltaic

systems.
NOTE 2 Cables for photovoltaic systems are covered by IEC 62930.
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements 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.

IEC 60060-1, High-voltage test techniques – Part 1: General definitions and test requirements

IEC 60183, Guidance for the selection of high-voltage A.C. cable systems
IEC 60228, Conductors of insulated cables
IEC 60230, Impulse tests on cables and their accessories

IEC 60332-1-2, Tests on electric and optical fibre cables under fire conditions – Part 1-2: Test

for vertical flame propagation for a single insulated wire or cable – Procedure for 1 kW

pre‑mixed flame
---------------------- Page: 8 ----------------------
IEC 60502-1:2021 © IEC 2021 – 7 –

IEC 60332-3-24, Tests on electric and optical cables under fire conditions – Part 3-24: Test for

vertical flame spread of vertically-mounted bunched wires or cables – Category C
IEC 60684-2, Flexible insulating sleeving – Part 2: Methods of test

IEC 60724, Short-circuit temperature limits of electric cables with rated voltages of 1 kV

(U = 1,2 kV) and 3 kV (U = 3,6 kV)
m m

IEC 60754-1, Test on gases evolved during combustion of materials from cables – Part 1:

Determination of the halogen acid gas content

IEC 60754-2, Test on gases evolved during combustion of materials from cables – Part 2:

Determination of acidity (by pH measurement) and conductivity

IEC 60811-201, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 201: General tests – Measurement of insulation thickness

IEC 60811-202, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 202: General tests – Measurement of thickness of non-metallic sheath

IEC 60811-203, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 203: General tests – Measurement of overall dimensions

IEC 60811-401, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 401: Miscellaneous tests – Thermal ageing methods – Ageing in an air oven

IEC 60811-402, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 402: Miscellaneous tests – Water absorption tests

IEC 60811-403, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 403: Miscellaneous tests – Ozone resistance test on cross-linked compounds

IEC 60811-404, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 404: Miscellaneous tests – Mineral oil immersion tests for sheaths

IEC 60811-409, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 409: Miscellaneous tests – Loss of mass test for thermoplastic insulations and sheaths

IEC 60811-501, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 501: Mechanical tests – Tests for determining the mechanical properties of insulating and

sheathing compounds

IEC 60811-502, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 502: Mechanical tests – Shrinkage test for insulations

IEC 60811-503, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 503: Mechanical tests – Shrinkage test for sheaths

IEC 60811-504, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 504: Mechanical tests – Bending tests at low temperature for insulations and sheaths

IEC 60811-505, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 505: Mechanical tests – Elongation at low temperature for insulations and sheaths

---------------------- Page: 9 ----------------------
– 8 – IEC 60502-1:2021 © IEC 2021

IEC 60811-506, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 506: Mechanical tests – Impact test at low temperature for insulations and sheaths

IEC 60811-507, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 507: Mechanical tests – Hot set test for cross-linked materials

IEC 60811-508, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 508: Mechanical tests – Pressure test at high temperature for insulation and sheaths

IEC 60811-509, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 509: Mechanical tests – Test for resistance of insulations and sheaths to cracking (heat

shock test)

IEC 60811-605, Electric and optical fibre cables – Test methods for non-metallic materials –

Part 605: Physical tests – Measurement of carbon black and/or mineral filler in polyethylene

compounds

IEC 60811-606, Electric and optical fibre cables –Test methods for non-metallic materials –

Part 606: Physical tests – Methods for determining the density

IEC 61034-2, Measurement of smoke density of cables burning under defined conditions –

Part 2: Test procedure and requirements
IEC 62230, Electric cables – Spark-test method

ISO 48-2:2018, Rubber, vulcanized or thermoplastic – Determination of hardness – Part 2:

Hardness between 10 IRHD and 100 IRHD
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

ISO and IEC maintain terminological databases for use in standardization at the following

addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1 Definitions of dimensional values (thicknesses, cross-sections, etc.)
3.1.1
nominal value
value by which a quantity is designated and which is often used in tables

Note 1 to entry: Usually, in this document, nominal values give rise to values to be checked by measurements

taking into account specified tolerances.
3.1.2
approximate value

value which is neither guaranteed nor checked but is used, for example, for the calculation of

other dimensional values
---------------------- Page: 10 ----------------------
IEC 60502-1:2021 © IEC 2021 – 9 –
3.1.3
median value

when several test results have been obtained and ordered in an increasing (or decreasing)

succession, middle value if the number of available values is odd, and mean of the two middle

values if the number is even
3.1.4
fictitious value

value calculated in accordance with the "fictitious method'' described in Annex A

3.2 Definitions relating to tests
3.2.1
routine test

test made by the manufacturer on each manufactured length of cable to check that each length

meets the specified requirements
3.2.2
sample test

test made by the manufacturer on samples of completed cable or components taken from a

completed cable, at a specified frequency, so as to verify that the finished product meets the

specified requirements
3.2.3
type test

test made before supplying, on a general commercial basis, a type of cable covered by this

document, in order to demonstrate satisfactory performance characteristics to meet the

intended application

Note 1 to entry: Type tests are of such a nature that, after they have been made, they need not be repeated, unless

changes are made in the cable materials or design or manufacturing process which might change the performance

characteristics.
3.2.4
electrical test after installation

test made to demonstrate the integrity of the cable and its accessories as installed

4 Voltage designations and materials
4.1 Rated voltages
4.1.1 Rated AC voltages

The rated AC voltages U /U (U ) of the cables considered in this document are 0,6/1 (1,2) kV

0 m
and 1,8/3 (3,6) kV.

NOTE 1 The voltages given above are the correct designations although in some countries other designations are

used, e.g. 1,7/3 kV or 1,9/3,3 kV instead of 1,8/3 kV.

For the voltage designation of cables U /U (U ), the definitions in IEC 60183 apply i.e.:

0 m

U is the rated RMS power frequency voltage between conductor and earth or metal screen

for which the cable is designed;

U is the rated RMS power frequency voltage between conductors for which the cable is

designed;

U is the maximum RMS power frequency voltage between conductors for which the cable is

designed.
---------------------- Page: 11 ----------------------
– 10 – IEC 60502-1:2021 © IEC 2021

NOTE 2 U is the highest voltage that can be sustained under normal operating conditions at any time and at any

point in a system and excludes temporary voltage variations due to fault conditions and sudden disconnection of

large loads.

The rated voltage of the cable for a given application shall be suitable for the operating

conditions in the system in which the cable is used. To facilitate the selection of the cable,

systems are divided into three categories according to the duration of time the system can be

operated under earth fault conditions (see IEC 60183):

– Category A: this category comprises those systems in which any phase conductor that

comes in contact with earth or an earth conductor is disconnected from the
system within 1 min.

– Category B: this category comprises those systems which, under fault conditions, are

operated for a short time with one phase earthed. This period, in
accordance with IEC 60183, should, in general, not exceed 1 h. For cables
covered by this document, a longer period, not exceeding 8 h on any
occasion, can be tolerated. The total duration of earth faults in any year
should not exceed 125 h.

– Category C: this category comprises all systems which do not fall into category A or B.

NOTE 3 In a system where an earth fault is not automatically and promptly isolated, the extra stresses on the

insulation of cables during the earth fault reduce the life of the cables to a certain degree. If the system is expected

to be operated fairly often with a permanent earth fault, it can be advisable to classify the system in Category C.

The values of U recommended for cables to be used in three-phase systems are listed in

Table 1.
Table 1 – Recommended rated AC voltages U
Highest system voltage
Rated voltage (U )
(U )
kV kV
Categories A and B Category C
1,2 0,6 0,6
3,6 1,8
3,6
This category is covered by 3,6/6 (7,2) kV cables in accordance with
IEC 60502‑2.
4.1.2 Rated DC voltages
Under consideration.
4.2 Insulating compounds

The types of insulating compound covered by this document are listed in Table 2, together with

their abbreviated designations.
---------------------- Page: 12 ----------------------
IEC 60502-1:2021 © IEC 2021 – 11 –
Table 2 – Insulating compounds
Abbreviated
Insulating compound
designation
a) Thermoplastic
Polyvinyl chloride intended for cables with rated voltages U /U ≤ 1,8/3 kV
PVC/A
b) Cross-linked:
Ethylene propylene rubber or similar (EPM or EPDM) EPR
High modulus or hard grade ethylene propylene rubber HEPR
Cross-linked polyethylene XLPE
Insulating compound based on polyvinyl chloride intended for cables with rated
...

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