IEC 60840

Power cables with extruded insulation and their accessories for rated voltages above 30 kV (<i>U</i>_m = 36 kV) up to 150 kV (<i>U</i>_m = 170 kV) - Test methods and requirements

IEC 60840:2011 is available as IEC 60840:2011 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.

IEC 60840:2011 specifies test methods and requirements for power cable systems, cables alone and accessories alone, for fixed installations     and for  rated voltages above 30 kV (U_m = 36 kV) up to   and including 150 kV (U_m = 170 kV). The requirements apply to single-core cables and to individually screened three-core cables and to their accessories for usual conditions of installation          and operation, but not to special  cables and their accessories,  such as submarine cables, for which modifications to the standard tests may be necessary or special test    conditions may  need to be   devised. This standard does not cover transition joints between cables with extruded insulation and paper insulated cables. The significant technical change with respect to the previous edition is     as follows:
- introduction of a prequalification test procedure for cables with high electrical stresses and tested as a cable system including accessories.
NOTE: For a more detailed history of events leading up to this fourth edition, see the Introduction.

Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions assignées supérieures à 30 kV (<i>U</i>_m = 36 kV) et jusqu'à 150 kV (<i>U</i>_m = 170 kV) - Méthodes et exigences d'essai

IEC 60840:2011 est disponible sous forme de IEC 60840:2011 RLV qui contient la Norme internationale et sa version Redline, illustrant les modifications du contenu technique depuis l'édition précédente.

IEC 60840:2011 spécifie les méthodes et les exigences d'essai applicables aux systèmes de câbles d'énergie, câbles seuls et accessoires seuls, pour installations fixes, pour des tensions assignées supérieures à 30 kV (U_m = 36 kV) et jusqu'à 150 kV (U_m = 170 kV) compris. Les exigences sont applicables aux câbles unipolaires, aux câbles tripolaires à écran individuel et à leurs accessoires, pour des conditions habituelles d'installation et de fonctionnement, mais ne le sont pas à des câbles spéciaux et à leurs accessoires, comme les câbles sous-marins,  pour lesquels il peut être nécessaire d'apporter des modifications aux essais normaux ou d'élaborer des conditions d'essai particulières. Les jonctions assurant le raccordement des câbles à isolant extrudé aux câbles isolés au papier ne sont pas couvertes par la présente norme. La modification technique principale par rapport à l'édition précédente est la suivante:
- introduction d'une procédure d'essai de préqualification pour les câbles avec de hautes tensions électriques comme un système de câble incluant des accessoires.
  NOTE: Voir l'Introduction pour un historique plus complet sur les evenements qui conduissaient à la publication de cette quatrième édition.

Elektroenergetski kabli z ekstrudirano izolacijo in njihov pribor za naznačene napetosti nad 30 kV (Um = 36 kV) do 150 kV (Um = 170 kV) - Preskusne metode in zahteve

Standard IEC 60840:2011 določa preskusne metode in zahteve za sisteme močnostnih kablov, same kable in sam pribor, za fiksne namestitve in za nazivne napetosti nad 30 kV do vključno 150 kV. Zahteve se uporabljajo za enožilne kable in za individualno zaslonjene trižilne kable ter za njihov pribor za običajne pogoje montaže in delovanja, ne pa za posebne kable in njihov pribor, kot so podvodni kabli, za katere so morda potrebne spremembe standardnih preskusov ali pa je treba zasnovati posebne preskusne pogoje. Ta standard ne zajema prehodnih spojk med kabli z ekstrudirano izolacijo in papirnato izoliranih kablov. Znatna tehnična sprememba glede na predhodno različico je naslednja: vpeljava predizbirnega preskusnega postopka za kable z visoko električno obremenitvijo, preizkušene kot kabelski sistem, vključno s priborom.
OPOMBA: Za podrobnejšo zgodovino dogodkov, na podlagi katerih je nastala ta četrta izdaja, glej poglavje Uvod.

General Information

• Status: Not Published
• ICS: 29.060.20 - Cables
• Technical Committee: TA 20 - Analogue and digital audio
• Current Stage: PPUB - Publication issued
• Start Date: 23-Nov-2011
• Ref Project: SIST IEC 60840:2018 - Power cables with extruded insulation and their accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test methods and requirements

Overview

IEC 60840 defines test methods and requirements for high‑voltage power cables with extruded insulation and their accessories for rated voltages above 30 kV (Um = 36 kV) up to 150 kV (Um = 170 kV). Edition 4.0 (2011) is published as IEC 60840:2011 RLV and covers single‑core and individually screened three‑core cables for fixed installations. The standard specifies routine, sample, type and prequalification tests on cables, accessories and complete cable systems, and notes exclusions (for example, submarine cables and transition joints to paper‑insulated cables may need special test conditions).

Key topics and requirements

The standard focuses on practical, measurable quality and safety checks. Key technical topics include:

• Voltage range and materials
  • Scope: Um = 36 kV up to Um = 170 kV
  • Requirements for insulating compounds, metal screens/sheaths and oversheathing materials
• Test categories
  • Routine tests, sample tests, type tests, and electrical tests after installation
  • New in this edition: prequalification test procedure for cable systems under high electrical stress, tested as a complete system including accessories
• Electrical tests
  • Partial discharge measurement, power‑frequency voltage tests, lightning impulse tests, heating cycle tests, tan δ (dissipation factor) and bending tests
  • Tests on oversheath conductivity/insulation where applicable
• Mechanical and ageing tests
  • Mechanical property tests before and after ageing, hot‑set tests for XLPE/EPR/HEPR, shrinkage and hardness determinations
• Environmental and ingress tests
  • Water penetration test and specific tests for longitudinally applied metal tapes/foils bonded to oversheath
• Documentation and type approval
  • Range of type approval, extension of prequalification, test sequences, and examination procedures

Applications and who uses it

IEC 60840 is essential for stakeholders involved in specification, manufacture, testing, installation and approval of high‑voltage extruded insulation cable systems:

• Cable manufacturers and accessory suppliers - for product design, type testing and prequalification
• Independent test laboratories - for performing routine, type and system tests to verified methods
• Transmission and distribution utilities and EPC contractors - for procurement specifications and acceptance testing
• Consulting engineers and quality assurance teams - for system validation, installation checks and compliance demonstrations

Keywords: IEC 60840, power cables, extruded insulation, high‑voltage cables, test methods, cable system prequalification, partial discharge, lightning impulse test, XLPE, EPR, HEPR.

Related standards

Refer to other IEC and national standards that address cables for different voltage ranges, submarine cables or paper‑insulated systems, and installation/testing practices. Note that IEC 60840 explicitly excludes some special cable types (e.g., submarine) where modified or special test conditions are required.

For the official text and redline changes from the previous edition see IEC 60840:2011 RLV (https://webstore.iec.ch/publication/22264).

Standards Content (Sample)

SLOVENSKI STANDARD
01-december-2018
(OHNWURHQHUJHWVNLNDEOL]HNVWUXGLUDQRL]RODFLMRLQQMLKRYSULERU]DQD]QDþHQH
QDSHWRVWLQDGN98P N9GRN98P N93UHVNXVQHPHWRGHLQ
]DKWHYH
Power cables with extruded insulation and their accessories for rated voltages above 30
kV (Um = 36 kV) up to 150 kV (Um = 170 kV) - Test methods and requirements
Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions assignées
supérieures à 30 kV (Um = 36 kV) et jusqu'à 150 kV (Um = 170 kV) - Méthodes et
exigences d'essai
Ta slovenski standard je istoveten z: IEC 60840
ICS:
29.060.20 Kabli Cables
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
®
Edition 4.0 2011-11
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Power cables with extruded insulation and their accessories for rated voltages
above 30 kV (U = 36 kV) up to 150 kV (U = 170 kV) – Test methods and
m m
requirements
Câbles d'énergie à isolation extrudée et leurs accessoires pour des tensions
assignées supérieures à 30 kV (U = 36 kV) et jusqu'à 150 kV (U = 170 kV) –
m m
Méthodes et exigences d'essai
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX XB
ICS 29.060.20 ISBN 978-2-88912-752-8

– 2 – 60840 © IEC:2011
CONTENTS
FOREWORD . 6
INTRODUCTION . 8
1 Scope . 9
2 Normative references. 9
3 Terms and definitions . 10
3.1 Definitions of dimensional values (thicknesses, cross-sections, etc.) . 10
3.2 Definitions concerning tests . 11
3.3 Other definitions . 11
4 Voltage designations and materials . 12
4.1 Rated voltages . 12
4.2 Cable insulating materials . 12
4.3 Cable metal screens/sheaths . 12
4.4 Cable oversheathing materials . 12
5 Precautions against water penetration in cables . 12
6 Cable characteristics . 13
7 Accessory characteristics. 13
8 Test conditions . 14
8.1 Ambient temperature . 14
8.2 Frequency and waveform of power frequency test voltages . 14
8.3 Waveform of lightning impulse test voltages . 14
8.4 Relationship of test voltages to rated voltages . 14
8.5 Determination of the cable conductor temperature . 14
9 Routine tests on cables and on the main insulation of prefabricated accessories . 15
9.1 General . 15
9.2 Partial discharge test . 15
9.3 Voltage test . 15
9.4 Electrical test on oversheath of the cable . 15
10 Sample tests on cables . 16
10.1 General . 16
10.2 Frequency of tests . 16
10.3 Repetition of tests . 16
10.4 Conductor examination . 16
10.5 Measurement of electrical resistance of conductor and metal screen . 16
10.6 Measurement of thickness of cable insulation and oversheath . 17
10.6.1 General . 17
10.6.2 Requirements for the insulation . 17
10.6.3 Requirements for the cable oversheath . 17
10.7 Measurement of thickness of metal sheath. 18
10.7.1 Lead or lead alloy sheath . 18
10.7.2 Plain or corrugated aluminium sheath . 18
10.8 Measurement of diameters . 19
10.9 Hot set test for XLPE, EPR and HEPR insulations . 19
10.9.1 Procedure . 19
10.9.2 Requirements . 19
10.10 Measurement of capacitance. 19

60840 © IEC:2011 – 3 –
10.11 Measurement of density of HDPE insulation . 19
10.11.1 Procedure . 19
10.11.2 Requirements . 19
10.12 Lightning impulse voltage test . 19
10.13 Water penetration test. 20
10.14 Tests on components of cables with a longitudinally applied metal tape or
foil, bonded to the oversheath . 20
11 Sample tests on accessories . 20
11.1 Tests on components . 20
11.2 Tests on complete accessory . 20
12 Type tests on cable systems . 20
12.1 General . 20
12.2 Range of type approval . 21
12.3 Summary of type tests . 21
12.4 Electrical type tests on complete cable systems . 22
12.4.1 Test voltage values . 22
12.4.2 Tests and sequence of tests . 22
12.4.3 Bending test . 23
12.4.4 Partial discharge tests . 24
12.4.5 Tan δ measurement . 24
12.4.6 Heating cycle voltage test . 24
12.4.7 Lightning impulse voltage test followed by a power frequency voltage
test . 25
12.4.8 Examination . 25
12.4.9 Resistivity of semi-conducting screens . 25
12.5 Non-electrical type tests on cable components and on complete cable . 26
12.5.1 Check of cable construction . 26
12.5.2 Tests for determining the mechanical properties of insulation before
and after ageing . 26
12.5.3 Tests for determining the mechanical properties of oversheaths
before and after ageing . 27
12.5.4 Ageing tests on pieces of complete cable to check compatibility of
materials . 27
12.5.5 Loss of mass test on PVC oversheaths of type ST . 28
12.5.6 Pressure test at high temperature on oversheaths . 28
12.5.7 Test on PVC oversheaths (ST ST ) at low temperature . 28
1, 2
12.5.8 Heat shock test for PVC oversheaths (ST and ST ) . 29
1 2
12.5.9 Ozone resistance test for EPR and HEPR insulations . 29
12.5.10 Hot set test for EPR, HEPR and XLPE insulations . 29
12.5.11 Measurement of density of HDPE insulation . 29
12.5.12 Measurement of carbon black content of black PE oversheaths (ST
and ST ). 29
12.5.13 Test under fire conditions . 29
12.5.14 Water penetration test . 30
12.5.15 Tests on components of cables with a longitudinally applied metal
tape or foil, bonded to the oversheath . 30
12.5.16 Shrinkage test for PE, HDPE and XLPE insulations . 30
12.5.17 Shrinkage test for PE oversheaths (ST and ST ) . 30
3 7
12.5.18 Determination of hardness of HEPR insulation . 30
12.5.19 Determination of the elastic modulus of HEPR insulation . 31

– 4 – 60840 © IEC:2011
13 Prequalification test of the cable system. 31
13.1 General and range of prequalification test approval . 31
13.2 Prequalification test on complete system . 32
13.2.1 Summary of prequalification tests . 32
13.2.2 Test voltage values . 32
13.2.3 Test arrangement . 32
13.2.4 Heating cycle voltage test . 33
13.2.5 Lightning impulse voltage test . 34
13.2.6 Examination . 34
13.3 Tests for the extension of the prequalification of a cable system. 34
13.3.1 Summary of the extension of prequalification test . 34
13.3.2 Electrical part of the extension of prequalification tests on complete
cable system. 34
14 Type tests on cables . 36
14.1 General . 36
14.2 Range of type approval . 36
14.3 Summary of type tests . 37
14.4 Electrical type tests on completed cables . 37
15 Type tests on accessories . 38
15.1 General . 38
15.2 Range of type approval . 38
15.3 Summary of type tests . 38
15.4 Electrical type tests on accessories . 39
15.4.1 Test voltage values . 39
15.4.2 Tests and sequence of tests . 39
16 Electrical tests after installation . 40
16.1 General . 40
16.2 DC voltage test of the oversheath . 40
16.3 AC voltage test of the insulation . 40
Annex A (informative) Determination of the cable conductor temperature . 47
Annex B (normative) Rounding of numbers . 52
Annex C (informative) List of type, prequalification and extension of prequalification
tests for cable systems, cables and accessories . 53
Annex D (normative) Method of measuring resistivity of semi-conducting screens . 56
Annex E (normative) Water penetration test . 58
Annex F (normative) Tests on components of cables with a longitudinally applied metal
tape or foil, bonded to the oversheath . 60
Annex G (normative) Tests of outer protection for joints . 63
Annex H (normative) Determination of hardness of HEPR insulations . 65
Bibliography . 67

Figure 1 – Example of the test arrangement for the prequalification test. 33
Figure 2 – Example of extension of prequalification test arrangement for the
prequalification of a system with another joint, designed for rigid and flexible installation . 35
Figure A.1 – Typical test set-up for the reference loop and the main test loop . 48
Figure A.2 – Example of an arrangement of the temperature sensors on the conductor
of the reference loop . 49

60840 © IEC:2011 – 5 –
Figure D.1 – Preparation of samples for measurement of resistivity ofconductor and
insulation screens . 57
Figure E.1 – Schematic diagram of apparatus for water penetration test . 59
Figure F.1 – Adhesion of metal foil . 60
Figure F.2 – Example of overlapped metal foil . 61
Figure F.3 – Peel strength of overlapped metal foil . 61
Figure H.1 – Test on surfaces of large radius of curvature . 66
Figure H.2 – Test on surfaces of small radius of curvature . 66

Table 1 – Insulating compounds for cables . 40
Table 2 – Oversheathing compounds for cables . 41
Table 3 – Tan δ requirements for insulating compounds for cables . 41
Table 4 – Test voltages . 41
Table 5 – Non-electrical type tests for insulating and oversheathing compounds for
cables . 42
Table 6 – Test requirements for mechanical characteristics of insulating compounds for
cables (before and after ageing) . 43
Table 7 – Test requirements mechanical characteristics of oversheathing compounds
for cables (before and after ageing) . 44
Table 8 – Test requirements for particular characteristics of insulating compounds for
cables . 45
Table 9 – Test requirements for particular characteristics of PVC oversheathing for
cables . 46
Table C.1 – Type tests on cable systems, on cables and on accessories . 54
Table C.2 – Prequalification tests on cable systems with a calculated nominal
conductor electric stress above 8,0 kV/mm or a calculated nominal insulation electric
stress above 4,0 kV/mm . 54
Table C.3 – Extension of prequalification tests on cable systems with a calculated
nominal conductor electric stress above 8,0 kV/mm or a calculated nominal insulation
electric stress above 4,0 kV/mm . 55
Table G.1 – Impulse voltage tests . 64

– 6 – 60840 © IEC:2011
INTERNATIONAL ELECTROTECHNICAL COMMISSION
______________
POWER CABLES WITH EXTRUDED INSULATION AND
THEIR ACCESSORIES FOR RATED VOLTAGES ABOVE 30 kV
(U = 36 kV) UP TO 150 kV (U = 170 kV) –
m m
TEST METHODS AND REQUIREMENTS
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,
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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.
International Standard IEC 60840 has been prepared by IEC technical committee 20: Electric
cables.
This fourth edition cancels and replaces the third edition, published in 2004, and constitutes a
major technical revision.
The significant technical change with respect to the previous edition is as follows:
– introduction of a prequalification test procedure for cables with high electrical stresses and
tested as a cable system including accessories.
NOTE For a more detailed history of events leading up to this fourth edition, see the Introduction.

60840 © IEC:2011 – 7 –
The text of this standard is based on the following documents:
FDIS Report on voting
20/1267/FDIS 20/1277A/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
The committee has decided that the contents of this publication will remain unchanged until the
stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data related to
the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 8 – 60840 © IEC:2011
INTRODUCTION
The first edition of IEC 60840, published in 1988, dealt only with cables. Accessories were
added to the second edition, published in February 1999, which separately covered test
methods and test requirements for
a) cables alone,
b) cables together with accessories (a cable system).
Some countries then suggested that a better discrimination be made between systems, cables
and accessories, particularly for the lower voltages of the scope, e.g. 45 kV. This was taken
into account in the third edition and is retained in this revision, which gives the type approval
requirements and the range of approvals for
a) cable systems,
b) cables alone,
c) accessories alone.
Manufacturers and users may choose the most appropriate option for type approval.
At its meeting in November 2004, TC 20 decided to prepare a further major revision of
HV and EHV extruded cables that were under preparation by CIGRE study committee B1 WG
B1.06. This work was made available as CIGRE technical brochure No. 303, before the
meeting of TC 20 in October 2006. The brochure, entitled “Revision of qualification procedures
for extruded (extra) high voltage a.c. underground cables”, has therefore been considered by
TC 20, and considerable parts implemented in this standard. Cables with high electrical
stresses at the conductor screen and/or insulation screen are now required to undergo a
prequalification test procedure (simplified compared to that in IEC 62067) as a cable system
inclusive of accessories.
Additionally the following other significant changes to this standard have been introduced:
a) The clause numbering of this standard and IEC 62067 (which has been revised at the
same time as this standard) has been coordinated to achieve as much commonality as
possible to assist users who use both standards.
b) In the case of the sample test, the lightning impulse voltage test is no longer followed by a
power frequency voltage test.
A list of relevant CIGRE references is given in the bibliography.

60840 © IEC:2011 – 9 –
POWER CABLES WITH EXTRUDED INSULATION AND
THEIR ACCESSORIES FOR RATED VOLTAGES ABOVE 30 kV
(U = 36 kV) UP TO 150 kV (U = 170 kV) –
m m
TEST METHODS AND REQUIREMENTS
1 Scope
This International Standard specifies test methods and requirements for power cable systems,
cables alone and accessories alone, for fixed installations and for rated voltages above 30 kV
(U = 36 kV) up to and including 150 kV (U = 170 kV).
m m
The requirements apply to single-core cables and to individually screened three-core cables
and to their accessories for usual conditions of installation and operation, but not to special
cables and their accessories, such as submarine cables, for which modifications to the
standard tests may be necessary or special test conditions may need to be devised.
This standard does not cover transition joints between cables with extruded insulation and
paper insulated cables.
2 Normative references
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.
NOTE The IEC 60811 series is currently undergoing a revision, which will lead to a restructuring of its parts. A
description of this, as well as a cross-reference table between the current and planned parts will be given in
IEC 60811-100.
IEC 60060-1, High-voltage test techniques – Part 1: General definitions and test requirements
IEC 60183, Guide to the selection of high-voltage cables
IEC 60228, Conductors of insulated cables
IEC 60229:2007, Electric cables – Tests on extruded oversheaths with a special protective
function
IEC 60230, Impulse tests on cables and their accessories
IEC 60287-1-1:2006, Electric cables – Calculation of the current rating – Part 1-1: Current
rating equations (100 % load factor) and calculation of losses – General
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
IEC 60811-1-1:1993, Common test methods for insulating and sheathing materials of electric
cables – Part 1: Methods for general application – Section 1: Measurement of thickness and
overall dimensions – Tests for determining the mechanical properties
Amendment 1 (2001)
– 10 – 60840 © IEC:2011
IEC 60811-1-2:1985, Common test methods for insulating and sheathing materials of electric
cables – Part 1: Methods for general application – Section Two: Thermal ageing methods
Amendment 1 (1989)
Amendment 2 (2000)
IEC 60811-1-3:1993, Common test methods for insulating and sheathing materials of electric
cables – Part 1-3: General application – Methods for determining the density – Water
absorption tests – Shrinkage test
Amendment 1 (2001)
IEC 60811-1-4:1985, Common test methods for insulating and sheathing materials of electric
cables – Part 1: Methods for general application – Section Four: Tests at low temperature
Amendment 1 (1993)
Amendment 2 (2001)
IEC 60811-2-1:1998, Common test methods for Insulating and sheathing materials of electric
and optical cables –Part 2-1: Methods specific to elastomeric compounds – Ozone resistance,
hot set and mineral oil immersion tests
Amendment 1 (2001)
IEC 60811-3-1:1985, Common test methods for insulating and sheathing materials of electric
cables – Part 3-1: Methods specific to PVC compounds –Pressure test at high temperature –
Tests for resistance to cracking
Amendment 1 (1994)
Amendment 2 (2001)
IEC 60811-3-2:1985, Common test methods for insulating and sheathing materials of electric
cables – Part 3: Methods specific to PVC compounds –Loss of mass test – Section two:
Thermal stability test
Amendment 1 (1993)
Amendment 2 (2003)
IEC 60811-4-1:2004, Insulating and sheathing materials of electric and optical cables –
Common test methods – Part 4-1: Methods specific to polyethylene and polypropylene
compounds – Resistance to environmental stress cracking –Measurement of the melt flow
index – Carbon black and/or mineral filler content measurement in polyethylene by direct
combustion – Measurement of carbon black content by thermogravimetric analysis (TGA) –
Assessment of carbon black dispersion in polyethylene using a microscope
IEC 60885-3, Electrical test methods for electric cables – Part 3: Test methods for partial
discharge measurements on lengths of extruded power cables
ISO 48, Rubber, vulcanized or thermoplastic – Determination of hardness (hardness between
10 IRHD and 100 IRHD)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
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 Usually, in this standard, nominal values give rise to values to be checked by measurements taking into
account specified tolerances.
60840 © IEC:2011 – 11 –
3.1.2
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
3.2 Definitions concerning tests
3.2.1
routine test
tests made by the manufacturer on each manufactured component (length of cable or
accessory) to check that the component meets the specified requirements
3.2.2
sample test
tests made by the manufacturer on samples of completed cable or components taken from a
completed cable or accessory, at a specified frequency as to verify that the finished product
meets the specified requirements
3.2.3
type test
tests made before supplying on a general commercial basis a type of cable system or cable or
accessory covered by this standard, in order to demonstrate satisfactory performance
characteristics to meet the intended application
NOTE Once successfully completed, these tests need not be repeated, unless changes are made in the cable or
accessory with respect to materials, manufacturing process, design or design electrical stress levels, which might
adversely change the performance characteristics.
3.2.4
prequalification test
test made before supplying on a general commercial basis a type of cable system covered by
this standard, in order to demonstrate satisfactory long term performance of the complete
cable system
3.2.5
extension of prequalification test
tests made before supplying on a general commercial basis a type of cable system covered by
this standard, in order to demonstrate satisfactory long term performance of the complete
cable system, taking into account an already prequalified cable system
3.2.6
electrical test after installation
tests made to demonstrate the integrity of the cable system as installed
3.3 Other definitions
3.3.1
cable system
cable with installed accessories including components used for thermo-mechanical restraint of
systems limited to those used for terminations and joints only
3.3.2
nominal electrical stress
electrical stress calculated at U using nominal dimensions
– 12 – 60840 © IEC:2011
4 Voltage designations and materials
4.1 Rated voltages
In this standard, the symbols U , U and U are used to designate the rated voltages of cables
0 m
and accessories where these symbols have the meanings given in IEC 60183.
4.2 Cable insulating materials
This standard applies to cables insulated with one of the materials listed in Table 1. It also
specifies for each type of insulating compound the maximum operating conductor temperatures
on which the specified test conditions are based.
4.3 Cable metal screens/sheaths
This standard applies to the various designs in use. It covers designs providing a radial
watertightness and other designs.
Designs that provide radial watertightness mainly consist of
• metal sheaths,
• longitudinally applied metal tapes or foils bonded to the oversheath,
• composite screens, involving a bunch of wires and, in addition, either a metal sheath or a
metal tape or foil bonded to the oversheath, acting as a radial water impermeable barrier
(see Clause 5),
and other designs such as
• metal tapes or foils not bonded to the oversheath,
• bunch of metal wires only.
NOTE In all cases the metal screen/sheath should be able to carry the total fault current.
4.4 Cable oversheathing materials
Tests are specified for four types of oversheath, as follows:
– ST and ST based on polyvinyl chloride (PVC);
1 2
– ST and ST based on polyethylene (PE).
3 7
The choice of the type of oversheath depends on the design of the cable and the mechanical,
thermal and fire constraints during installation and operation.
The maximum conductor temperatures in normal operation for the different types of
oversheathing materials covered by this standard are given in Table 2.
NOTE For some applications the oversheath can be covered by a functional layer (e.g. semi-conductive).
5 Precautions against water penetration in cables
When cable systems are installed in ground, in easily flooded galleries or in water, a radial
water impermeable barrier around the cable is recommended.
NOTE A test for radial water penetration is currently not available.
Longitudinal water barriers may also be applied in order to avoid the need to replace long
sections of cable in case of damage in the presence of water.

60840 © IEC:2011 – 13 –
A test for longitudinal water penetration is given in 12.5.14.
6 Cable characteristics
For the purpose of carrying out the cable system or cable tests described in this standard and
recording the results, the cable shall be identified. The following characteristics shall be known
or declared:
a) Name of manufacturer, type, designation and manufacturing date or date code.

b) Rated voltage: values shall be given for U , U, U (see 4.1 and 8.4).
0 m
c) Type of conductor, its material and nominal cross-sectional area, in square millimetres;
conductor construction; presence, if any, and nature of measures taken to reduce skin
effect; presence, if any, and nature of measures taken to achieve longitudinal
watertightness; if the nominal cross-sectional area is not in accordance with IEC 60228,
the d.c. conductor resistance, corrected to 1 km length and to 20 °C.
) (see 4.2). If the insulation is XLPE,
d) Material and nominal thickness of insulation (t
n
special additives shall be declared if the higher value of tan δ according to Table 3 is
applicable.
e) Type of manufacturing process for insulation system.
f) Presence, if any, and nature of watertightness measures in the screening area.
g) Material and construction of metal screen, e.g. number and diameter of wires. (The d.c.
resistance of the metal screen shall be declared.) Material, construction and nominal
thickness of metal sheath, or longitudinally applied metal tape or foil bonded to the
oversheath, if any.
h) Material and nominal thickness of oversheath.
i) Nominal diameter of the conductor (d).
j) Nominal overall diameter of the cable (D).
k) Nominal inner diameter (d ) and calculated nominal outer diameter (D ) of the insulation.
ii io
l) Nominal capacitance, corrected to 1 km length, between conductor and metal
screen/sheath.
m) Calculated nominal electrical stress at conductor screen (E ) and at insulation screen (E ):
i o
2U
E =
i
d ×ln(D / d )
ii io ii
2U
E =
o
D ×ln(D / d )
io io ii
where
D = d + 2t ;
io ii n
D is the calculated nominal outer diameter of the insulation;
io
d is the declared nominal inner diameter of the insulation;
ii
t is the declared nominal insulation thickness.
n
The value of U is given in Table 4.
7 Accessory characteristics
For the purpose of carrying out the cable system or accessory tests described in this standard
and recording the results, the accessory shall be identified.

– 14 – 60840 © IEC:2011
The following characteristics shall be known or declared:
a) cables used for testing accessories shall be correctly identified as in Clause 6;
b) conductor connections used within the accessories shall be correctly identified, where
applicable, with respect to
– assembly technique,
– tooling, dies and necessary setting,
– preparation of contact surfaces,
– type, reference number and any other identification of the connector,
– details of the type test approval of the connector, if applicable;
c) accessories to be tested shall be correctly identified with respect to
– name of manufacturer,
– type, designation and manufacturing date or date code,
– rated voltage (see 6 b) above),
– installation instructions (reference and date).
8 Test conditions
8.1 Ambient temperature
Unless otherwise specified in the details for the particular test, tests shall be carried out at an
ambient temperature of (20 ± 15) °C.
8.2 Frequency and waveform of power frequency test voltages
Unless otherwise indicated in this standard, the frequency of the alternating test voltages shall
be in the range 49 Hz to 61 Hz. The waveform shall be substantially sinusoidal. The values
quoted are r.m.s. values.
8.3 Waveform of lightning impulse test voltages
In accordance with IEC 60230, the front time of the standard lightning impulse voltage shall be
between 1 µs and 5 µs. The time to half value shall be 50 µs ± 10 µs as specified in
IEC 60060-1.
8.4 Relationship of test voltages to rated voltages
Where test voltages are specified in this standard as multiples of the rated voltage U , the
value of U for the determination of the test voltages shall be as specified in Table 4.
For cables and accessories of rated voltages not shown in the table, the value of U for
determination of test voltages may be the same as for the nearest rated voltage which is given,
provided that the value of U for the cable and accessory is not higher than the corresponding
m
value in the table. Otherwise, and particularly if the rated voltage is not close to one of the
values in the table, the value of U on which the test voltages are based shall be the rated
value, i.e. U divided by 3 .
The test voltages in this standard are based on the assumption that the cables and accessories
are used on systems of category A or B, as defined in IEC 60183.
8.5 Determination of the cable conductor temperature
It is recommended that one of the test methods described in Annex A is used to determine the
actual conductor temperature.
60840 © IEC:2011 – 15 –
9 Routine tests on cables and on the main insulation of prefabricated
accessories
9.1 General
The following tests shall be carried out on each manufactured length of cable:
a) partial discharge test (see 9.2);
b) voltage test (see 9.3);
c) electrical test on oversheath of the cable, if required (see 9.4).
The order in which these tests are carried out is at the discretion of the manufacturer.
The main insulation of each prefabricated accessory shall undergo partial discharge (see 9.2)
and voltage routine tests (see 9.3) according to either 1), 2) or 3) below:
1) on accessories installed on cable;
2) by using a host accessory into which a component of an accessory is substituted for test;
3) by using a simulated accessory rig in which the electrical stress environment of a main
insulation component is reproduced.
In cases 2) and 3), the test voltage shall be selected so as to obtain electrical stresses at least
the same as those on the component in a complete accessory when subjected to the test
voltages specified in 9.2 and 9.3.
NOTE The main insulation of prefabricated accessories consists of the components that come in direct contact
with the cable insulation and are necessary to control the electric stress distr
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