SPEC NO.

: FRC-TPS-CHF-OS-A00

SPECIFICATION
FIRE RESISTANT TWISTED PAIR SHIELDED CABLE
500V CU/MICA/XLPE/OS/LSHF

Twisted Pair Copper Conductor, Cross-linked Polyethylene

Insulation, Overall Screen and Low Smoke Halogen Free
Sheathed Cables with Fire Resistant, Flame Retardant
and UV Sunlight Resistant.

REVISION ISSUED DATE

00 3 November 2022

PHELPS DODGE INTERNATIONAL (THAILAND) LIMITED

Phelps Dodge International (Thailand) Limited

CONTENTS

1. SCOPE .............................................................................................................................3
2. REFERENCE STANDARDS ..................................................................................................3
3. DEFINITIONS ...................................................................................................................4
4. APPLICATION / SERVICE CONDITIONS ..............................................................................4
5. CABLE CONSTRUCTION ....................................................................................................5
5.1 CONDUCTOR ....................................................................................................................5
5.2 INSULATION .....................................................................................................................5
5.3 CORE IDENTIFICATION .....................................................................................................5
5.4 TWISTED PAIR ..................................................................................................................5
5.5 PAIR GROUPING ...............................................................................................................6
5.6 OVERALL SCREEN AND DRAIN WIRE ................................................................................6
5.7 OUTER SHEATH ................................................................................................................6
6. CABLE MARKING AND IDENTIFICATION............................................................................7
7. TESTS AND INSPECTIONS .................................................................................................7
7.1 ROUTINE TESTS ................................................................................................................7
7.2 SAMPLE TESTS..................................................................................................................7
8. PACKING AND LABELING .................................................................................................8
ANNEX A - CABLE DRAWING AND TECHNICAL DATA ...............................................................9

Figure 1 – Cable drawing of 500V CU/MICA/XLPE/OS/LSHF Fire Resistant Twisted Pair Shielded Cable .... 9

Table 1 – Technical data of 500V CU/MICA/XLPE/OS/LSHF Single-Pair Cable ........................................... 10

Table 2 – Technical data of 500V CU/MICA/XLPE/OS/LSHF 2-Pair Cable ................................................... 11

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

1. SCOPE
This specification specifies the construction, dimensions and test requirements of electric
cables which the manufacturer shall comply in order to supply twisted pair copper
conductor with fire barrier, XLPE insulation, overall screen with plastic coated aluminum
foil shield and drain wire and LSHF sheathed cables for 500 V rated voltage in accordance
with BS EN 50288-7.

Behavior of the cables under fire conditions shall comply with requirements of
1.1 Circuit integrity test under fire conditions according to IEC 60331-21.
1.2 Circuit integrity under fire alone, fire with water and fire with mechanical shock test
according to BS 6387 (Category CWZ).
1.3 Vertical flame spread test of single cable according to IEC 60332-1-2
1.4 Vertical flame spread test according to IEC 60332-3-22 (Category A)
1.5 Vertical flame spread test according to IEC 60332-3-23 (Category B)
1.6 Vertical flame spread test according to IEC 60332-3-24 (Category C)
1.7 Test on gases evolved during combustion according to IEC 60754-1 and IEC 60754-2.
1.8 Smoke density test according to IEC 61034-2

2. REFERENCE STANDARDS
Except otherwise specified elsewhere in this specification, the cable shall be manufactured
and tested in conformity with the latest edition of the standards listed below:-

BS 6387, Specification for Performance requirements for cables required to maintain circuit
integrity under fire conditions
BS EN 50288-7, Multi-element metallic cables used in analogue and digital communication
and control - Part 7: Sectional specification for instrumentation and control cables
BS EN 50290-2-27, Communication cables - Part 2-27: Common design rules and
construction – Halogen free flame retardant thermoplastic sheathing compounds
BS EN 50290-2-29, Communication cables - Part 2-29: Common design rules and
construction – Cross-linked PE insulation compounds
BS EN 60228, Conductors of Insulated Cables
IEC 60331-21, Tests for electric cables under fire conditions - Circuit integrity - Part 21:
Procedures and requirements – Cables of rated voltage up to and including 0,6/1,0 kV
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 60332-3-22, Tests on electric cables under fire conditions –Part 3-22: Test for vertical
flame spread of vertically-mounted bunched wires or cables – Category A
IEC 60332-3-23, Tests on electric cables under fire conditions –Part 3-23: Test for vertical
flame spread of vertically-mounted bunched wires or cables – Category B
IEC 60332-3-24, Tests on electric cables under fire conditions –Part 3-24: Test for vertical
flame spread of vertically-mounted bunched wires or cables – Category C

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

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 61034-2, Measurement of smoke density of cables burning under defined conditions -
Part 2: Test procedure and requirements
DEF STAN 02-713 Issue 3, Determination of the Toxicity Index of the Products of
Combustion from Small Specimens of Materials.

3. DEFINITIONS
3.1 circuit integrity
ability to continue to operate in the designated manner whilst subjected to a specified
flame source for a specified period of time
3.2 nominal cross-sectional area
value that identifies a particular size of conductor but is not subject to direct
measurement
3.3 nominal value
value by which a quantity is designated; it is checked by measurements taking into
account specified tolerances
3.4 routine tests
tests made by the manufacturer on all production lengths of cable to demonstrate their
integrity
3.5 sample tests
tests made on samples of completed cable or components taken from a completed
cable, adequate to verify that the product meets the designed specifications

4. APPLICATION / SERVICE CONDITIONS

These cables are designed to be suitable for connecting instrument and control systems for
analogue or digital signal transmission. The cables are not designed to be used for power
supply and shall not be connected directly to mains electricity supply or other low
impedance sources. The cables are suitable for fixed installations in duct, conduit, ladder
and tray.

The insulation and other components are capable of operation continuously at a maximum
conductor temperature of 90oC for normal operation.

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

5. CABLE CONSTRUCTION
The general construction of the cables is shown as cable drawing in Figure 1 and consists of
the followings

5.1 CONDUCTOR
The conductor shall be plain annealed circular stranded copper conductor. All
conductor constructions shall be conformable to BS EN 60228 Class 2. Minimum
number of wires and diameter of conductor shall be complying with BS EN 60228.

The conductor shall be wrapped helically by mica tape with the mica in contact with
the conductor as to form a fire barrier layer for the conductor.

5.2 INSULATION
The insulation shall be cross-linked polyethylene (XLPE) whose properties meet
electrical requirements, mechanical requirements and particular requirements of
cross-linked polyethylene insulation specify in BS EN 50290-2-29.

The minimum average thickness of the insulation shall be not less than the value
specified in Table 1 to Table 2 and the concentricity shall not fall below 75%.

5.3 CORE IDENTIFICATION

Cores in each pair shall be identified by different color of insulation and the color
shall be as below

Pair: Black and White

Pair in two (2) or more pair cables shall be identified by pair number (1, 2, . . .)
printed on the insulation of core in each pair throughout the length. The pair number
shall be allocated in order to form center layer to outer layers, and in the same
direction of rotation.

5.4 TWISTED PAIR

Two insulated cores shall be twisted together to form a pair with suitable lay length
and suitable filler if necessary.

The lay length shall not exceed 100 mm. for cables with conductor cross-section ≤ 1.5
mm2, nor 150 mm. for cables with conductor cross-section 2.5 mm2.

For single-pair cable, non-hygroscopic binding tape shall be applied over the twisted
pair.

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

5.5 PAIR GROUPING

The twisted pair of multi-pair cables shall be grouped together with left-hand lay in
the outermost layer. Non-hygroscopic binding tape shall be applied over the grouped
pair.

5.6 OVERALL SCREEN AND DRAIN WIRE

The laminated screening tape shall be applied on the grouped pair with a minimum
overlap of 20% and with the metallic side down in contact with a drain wire which
runs longitudinally over a non-hygroscopic binding tape.

Laminated screening tape shall comprise of aluminum bonded to polyester film. The
tape shall have a minimum thickness of aluminum of 0.008 mm. and a minimum
thickness of polyester of 0.010 mm. Non-hygroscopic LSHF FR tape shall be applied
over the laminated screening tape.

The drain wire shall be one tinned annealed copper wire with nominal diameter of
0.8 mm (1/0.8mm) with a total cross-sectional area not less than 0.5 sq.mm.

5.7 OUTER SHEATH

The outer sheath shall be an extruded layer of low smoke halogen free (LSHF) flame
retardant material whose properties meet mechanical requirements and particular
requirements of halogen free flame retardant sheathing compounds specified in BS
EN 50290-2-27.

The nominal thicknesses of the outer sheath are specified in Table 1 to Table 2. The
minimum thickness at any point of outer sheath shall not fall below the nominal
value by more than 15% + 0.1 mm

The color of the outer sheath shall be Orange and it shall be UV sunlight resistant.

Note: The cable with UV resistance is subjected to maintain mechanical properties

and flexibility of the outer sheath in outdoor application. However, color fading may
occur in non-black colored outer sheath under long exposure to sunlight.

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

6. CABLE MARKING AND IDENTIFICATION

The outer sheath of the cables shall be legibly marked with the following information
throughout the length of the cables by printing method.

" PHELPS DODGE FRC TWISTED PAIR SHIELDED 500V CU/MICA/XLPE/OS/LSHF-UV A X B

SQ.MM., TÜV SÜD CERTIFIED NO. B 091380 0036, BS EN 50288-7, BS 6387 CWZ, IEC 60332-
3 CAT A/B/C, IEC 60754-1&-2, IEC 61034-2, DEF STAN 02-713 "

Note A : Number of pair (e.g. 2P)

B : Nominal cross-sectional area of conductor

Sequential length number shall be marked on outer sheath of cable at 1 meter intervals.

7. TESTS AND INSPECTIONS

7.1 ROUTINE TESTS
The following tests shall be carried out in accordance with BS EN 50288-7 on each
manufactured length of cable.
a) Measurement of conductor resistance
b) Dielectric strength test (2 kVac or 3 kVdc / 1 minutes)
c) Measurement of insulation resistance at ambient temperature
d) Mutual capacitance
e) Capacitance unbalance (pair)
f) Inductance to Resistance ratio (L/R ratio)

7.2 SAMPLE TESTS

The following sample tests shall be carried out in accordance with BS EN 50288-7.
a) Conductor examination
b) Measurement of thickness of insulation and non-metallic sheath
c) Measurement of external diameter
d) Hot set test for XLPE insulation

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

8. PACKING AND LABELING

The cable shall be packed on non-returnable wooden reel or returnable steel reel which
covered with suitable covering to provide the cable with physical protection during storage
and transportation.

Following description shall be marked on a flange of the reel.

a) Direction of rotation of the reel
b) Type of cable, Voltage grade
c) Number of pair and size of conductor
d) Length
e) Net weight
f) Gross weight
g) Manufacturer’s name
h) Year of manufacturing
i) Reel No.

Each end of cable shall be hermetically sealed with cap.

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

ANNEX A - CABLE DRAWING AND TECHNICAL DATA

DRAWING & CONSTRUCTION OF
500V CU/Mica/XLPE/OS/LSHF
Standard.: BS EN 50288-7, IEC 60332-3 CAT A/B/C, BS 6387 (CWZ), IEC 60754-1&-2, IEC 61034-2, DEF STAN 02-713

No. Description Type

1 1 Conductor Round Stranded Copper with Mica Tape

XLPE
2
2 Insulation 1 Pair: Black and White
3 2 Pairs: Black and White with pair number
3 Binding tape
4 Drain wire (Tin coated solid copper wire)
5 One side copolymer coated aluminium foil
4
6 LSHF FR Tape (Non-hygroscopic)
5 LSHF
Orange
6
7 Outer sheath +UV Sunlight Resistance

Figure 1 – Cable drawing of 500V CU/MICA/XLPE/OS/LSHF Fire Resistant Twisted Pair Shielded Cable

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

Table 1 – Technical data of 500V CU/MICA/XLPE/OS/LSHF Single-Pair Cable

1 Pair 1 Pair 1 Pair
Description unit
1.0 mm2 1.5 mm2 2.5 mm2
Conductor material Copper Copper Copper
Class / Standard - 2 / BS EN 60228 2 / BS EN 60228 2 / BS EN 60228

Diameter of Conductor (Approx.) mm 1.3 1.6 2.1

Fire barrier material - Mica Mica Mica

Insulation material XLPE XLPE XLPE

Insulation Thickness (Nominal) mm 0.5 0.5 0.6

Diameter over Insulation (Approx.) mm 3.5 3.8 4.4
Diameter over Laid-up core (Approx.) mm 6.9 7.5 8.8
Screen (Overall)
Screen tape thickness (Approx.) mm 0.024 0.024 0.024
Nominal cross-section area of Drain wire (Nominal) mm2 0.5 0.5 0.5

Outer sheath material LSHF LSHF LSHF

Outer Sheath Thickness (Nominal) mm 0.9 0.9 0.9

Overall Diameter (Minimum) mm 8.2 8.8 10.1

(Maximum) mm 12.2 12.8 14.1
Weight of Cable (Approx.) kg/km 90 110 140
Maximum conductor DC resistance at 20°C Ohm/km 18.1 12.1 7.41

Minimum Insulation Resistance at 20°C Mohm-km 1,000 1,000 1,000

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022
Phelps Dodge International (Thailand) Limited

Table 2 – Technical data of 500V CU/MICA/XLPE/OS/LSHF 2-Pair Cable

2 Pair 2 Pair 2 Pair
Description unit
1.0 mm2 1.5 mm2 2.5 mm2
Conductor material Copper Copper Copper
Class / Standard - 2 / BS EN 60228 2 / BS EN 60228 2 / BS EN 60228

Diameter of Conductor (Approx.) mm 1.3 1.6 2.1

Fire barrier material - Mica Mica Mica

Insulation material XLPE XLPE XLPE

Insulation Thickness (Nominal) mm 0.5 0.5 0.6

Diameter over Insulation (Approx.) mm 3.5 3.8 4.4
Diameter over Laid-up core (Approx.) mm 9.9 10.8 12.7
Screen (Overall)
Screen tape thickness (Approx.) mm 0.024 0.024 0.024
Nominal cross-section area of Drain wire (Nominal) mm2 0.5 0.5 0.5

Outer sheath material LSHF LSHF LSHF

Outer Sheath Thickness (Nominal) mm 1.0 1.0 1.1

Overall Diameter (Minimum) mm 11.4 12.3 14.4

(Maximum) mm 15.4 16.3 18.4
Weight of Cable (Approx.) kg/km 150 180 250
Maximum conductor DC resistance at 20°C Ohm/km 18.1 12.1 7.41

Minimum Insulation Resistance at 20°C Mohm-km 1,000 1,000 1,000

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Spec No.: FRC-TPS-CHF-OS-A00 Rev.: 00 Date: 3 Nov 2022