SIRIM QAS International Sdn Bhd

TESTING AND CERTIFICATION ON

ELECTRICAL CABLE TESTING

28th Aug 2018

 Presentation
PresentationOutline
Outline

1. Introduction

2. Our roles & services

3. Procedure & standard requirement for electrical cable testing

4. Product Certification Scheme

A BRIEF INTRO
About Us

Malaysia’s Leading Certification,

Inspection and Testing Body
 Our Services

CERTIFICATION TESTING INSPECTION

• Management • Product • Engineering

System compliance Inspection
Certification testing to • Inspection on
• Product standards, behalf of other
Certification regulatory CBs
• Personnel requirements • Other 3rd party
Certification and inspections
specifications
FOR DETAILS…… http://www.sirim-qas.com.my/
Safety test & product safety
Type of cables
• Low voltage cables up to 1 kV
HV Cable
• Medium voltage cables up to 33 kV

• Submarine cable up to 175 kV

• PVC insulated, XLPE insulated, paper

-Aerial
impregnated
Bundled
• Aluminium conductor for transmission line Cable

• Communication cables and fiber optic

• Automotive cables

• Housing cable

• Flexible cable for appliance Housing cable Flexible cable 8

General
• There are a few types of cables used in Malaysia
using different standards

Type of cables Standards Area of usage

Flexible cords up to MS 2112-5, BS 6500, IEC Portable socket-outlet,
500V 60227-5 household appliances,
audio-video products

Housing cables up to MS 2112-1 to MS 2112-6, Fixed wiring and

750V BS 6004 lighting

PVC insulated 600V to MS 2100 to MS 2111, BS Low voltage electricity

1 kV 6346 supply

XLPE insulated from 1 IEC 60502-1 Low voltage electricity

kV to 3 kV supply

XLPE insulated from 6 IEC 60502-2 Medium voltage

kV to 30 kV electricity supply
Type of cables Standards Area of usage

XLPE insulated cable IEC 60840 Underground

transmission line 30 kV
to 150 kV

Fire rated cables IEC 60331, IEC 60332, BS Oil and gas industry,
6387, IEC 61034, IEC 754 high rise buildings

Bare conductor BS 215, ASTM D 233 Overhead transmission

line

Low frequency cables IEC 60189, SKMM Data and

communication cables

Fiber optic cables IEC 60794 Data and

communication cables

Automotive cable JIS or mfr spec Cables used in

automobile
Test Standards
Type of cables MS Standards for PVC cables

Electric Cable and Wire: MS 2112-1:2009 Part 1:General Requirements

Polyvinyl Chloride(PVC)
insulated cables of
rated voltages up to MS 2112-2:2009 Part 2:Test Method
and including 450/750 V
MS 2112-3:2009 Part 3:Non-Sheathed Cables for
Fixed Wiring

MS 2112-4:2009 Part 4:Sheathed Cables for Fixed

Wiring

MS 2112-5:2009 Part 5:Flexible Cables

MS 2112-6:2009 Part 6:Cables for Lift & Flexible

Connections

11
GENERAL TEST REQUIREMENT FOR CABLE

Cables testing
In general – to ensure that they are safe and that they fit for purpose.

Basically, test requirements for cable can be divided in to a few categories;

Some requirements apply only for specific type of cables

1. Electrical tests
a) Conductor resistance
b) Voltage test – on insulation & sheath
c) Long term stability

2. Mechanical (physical) test

a) Tensile test
b) Low temperature properties – bending / impact
c) Resistance to heat – heat shock

3. Fire test
a) Resistance to fire
b) Conductor and armour wire plating thickness
c) Smoke emission

4. Chemical test
a) Halogen gas determination
b) Flame retardance / propagation
c) Smoke emission
GENERAL TEST REQUIREMENT FOR CABLE (LV)

1. ELECTRICAL TESTS

a) Resistance of conductors

b) High Voltage at 1000V / 1500V / 2500V

c) Insulation Resistance at 70°C

 Certification Rating
Name of Cable’s type,
mark or name
manufacturer sizes and
of certification
material
body
Sub-Standard Cables
• Cables which are not designed, constructed, test approved,
installed or used in accordance their prescribed safety
standards and specifications.

• Identity /Characteristics of a substandard cable;

1. Undersized
a) conductor construction not in accordance to prescribed
standards on dimensions such as;
» size & number of wires,
» thickness
» Length
b) conductor does not meet the minimum cross-sectional
area as determined by its specific resistance.
c) reduced size of copper resistance

2. Mixed content
Instead of pure copper – ‘they’ use mixed content or other
metal
Sub-Standard Cables
3. Reduced in insulation properties
a) insulation & protective layers construction not in
accordance to prescribed standards on size, thickness or
dimensions

b) Insulation & protective layers type does not meet the

required mechanical properties for long term ageing and
environmental tests

4. No identification / certification marking

Completed cables are not identified by markings as
stipulated by the standards.
Example of sub-standard cable

MARKING on Cable

• Marking vs No marking
• No manufacturer’s name/trademark
• No cable markings such as size, electrical parameters

• Marked with label / certification marked vs No label / not certified

• Certified / Approval body not identified

• Fake labels vs proper label

• Counterfeit
Example of sub-standard cable

PVC Flexible Cable

Non-compliant PVC Flexible Cable

• Undersized conductor – low conductivity – 1mm2 instead of 1.5mm2

• Cable sheath fall apart in low temperature bend test

• No compliant with standard marked on sheath

• For fire retardant –

• Not fire resistance –PVC insulation &PVC sheath – fails within 2
minutes instead of 30 minutes as required by standard
How to identify a sub-standard cable

1) Check and verify MARKINGS on Cable

– shall be as per standard requirement

2) Check and verify APPROVAL / CERTIFICATION Mark/Label

3) Measure conductor resistance ( need to have a proper meter)

4) Measure size(s)
• conductor
• each strand ( and no of strands)

5) Check and verify copper content

• normally by conductor resistance
• weight the sample
• Sometimes –by weighing the sample, with some
experience, we can identify if the samples /
weight of sample due to copper content or
sheath of insulation
 How can SIRIM assist?

SIRIM will always playing it’s roles in providing assistance to industry

& regulator in fighting issue of sub standard cable

How can we do that?–

a) through compliance testing

b) through our product certification scheme
c) through SIRIM’s market surveillance activities
d) by carrying out verification testing on samples picked up from
market - through enforcement & market surveillance –by
Suruhanjaya Tenaga
e) by providing a support to ST & MCMA initiatives to raise the
issue of sub-standard cable to the widest audience possible
Problems / Challenges

• The ability to buy cable from anywhere in the world means there
remains a need for better market surveillance as some imported
cable – of which are not in compliance with standard requirement

• Contractors have little interest in standards while some distributors

encourage the manufacturer of `undersized cable’

• Inferior cable product is sold unmarked - making it untraceable and

misuse of trade marks is common place

• No follow-up market surveillance (though is essential) to ensure

future compliance.
 Moving forward

CONCLUSION

• We all want safer cables and this can only be achieved with;
– acceptance of the problem,
– better monitoring and enforcement at every level of the supply
chain
 APPLICATION PROCESS

Application by *A supplier includes importer, manufacturer and trader.

*a SUPPLIER
A supplier submit test application to SIRIM
QAS International test lab

Submit to
SIRIM QAS International test lab performs a
type test to a standard (MS / IEC Std + National
Deviation(if any)

SIRIM QAS International test lab shall

SIRIM QAS INTL issue a full type test report
TEST LAB
The report shall then be used for
submission for a COA application with
a regulatory body
 PRODUCT
CERTIFICATION
SCHEME
Type 5 Product Certification Scheme
The International Organisation for Standardisation (ISO) and the International
Electrotechnical Committee (IEC) have set out a number of different routes to
conformity assessment in their document ISO/IEC 17067.
 Product Certification Process
General Certification Process (Type 5)

SIRIM-ST
CERTIFIED TO YY : XXXX
CERTIFICATION NO:xxxxxxxx
 Product Certification Process
Test Standards
1) Regulated cables by ST

2) Other cables
Test standards follow related product standards or other acceptable
standards.
 Product Certification Process
New Application
Application and Documents Evaluation

Questionnaire Form (ePCS/FOR/01-1)

Application Form (ePCS/FOR/01-2)

Declaration of Approval from relevant authority (ePCS/FOR/01-3)*

Declaration of Obtaining SIRIM Licence for the Purpose of Relevant

Authority Approval (ePCS/FOR/01-3.1)*

Declaration of Trade Mark (ePCS/FOR/01-4)

Authorization Letter of Trademark/Brand Name (ePCS/FOR/01-4.1)*

Authorization Letter of Test Report (ePCS/FOR/01-4.2)*

Declaration from Manufacturer (ePCS/FOR/01-5)*

Note: * - whenever applicable

http://www.sirim-qas.com.my/
28
 Product Certification Process
New Application
Application and Documents Evaluation

Type Test Report

Test Laboratory
- CB Scheme
Laboratories
accredited by
national
accreditation bodies
e.g. DSM, HOKLAS,
NATA, UKAS etc.

SIRIM QAS International

- EEST
Laboratories listed
under
29 ASEAN EE MRA
 Product Certification Process
New Application
Product and Quality System Evaluation

Product Certification Requirements

30
 Product Certification Process
New Application

Product Evaluation
Critical Components and Raw Materials

Basic cable components

31
 Product Certification Process
New Application

Product Evaluation

Critical Components and Raw Materials

32
 Product Certification Process
New Application
Factory Audit
In-coming Inspection

All major raw materials /components that have direct influence on product properties / safety shall be
subjected to in-coming inspection prior to acceptance and/or production. Manufacturer shall identify
inspection / testing to be carried out on each raw material / component and compare the result to the
material’s / components specification / test reports for acceptance.

In-process Inspection

Manufacturer shall have sufficient control on the intermediate process to ensure that the intended
quality of product is achieved. The manufacturer shall identify test to be carried out at various in-
process stages and compare the result to the control specifications.

Final Inspection

Manufacturer shall carry out all tests specified under routine tests. These tests are normally carried
out on the finished product after assembly but the manufacturer may perform the tests at any
appropriate stage during the production, provided that subsequent manufacturing processes do not
affect the results.

Following tests are minimum tests to be conducted to cover the safety aspect of the product. The
frequency of testing is 100%. It is the manufacturer’s responsibility to decide if additional routine tests
are necessary.

a) Spark Test (as per BS 5099)

 Product Certification Process
New Application
Routine test
The following are minimum tests that shall be conducted to cover safety
aspect of the product. Testing conducted and witnessed during surveillance.

Test Test method Result

Functional Spark tester No breakdown
(100% at production)

Sampling for QA i) Conductor resistance As per standard

testing at lab test requirement
(sampling) ii) High voltage test
(Immersed in water)
iii) Constructional and
dimensional check
 Product Certification Process
New Application
Preparation of Certification Report
 Product Certification Process
New Application
Example of Product description:

Product name:
PVC-Insulated Cables (Sheathed) for Fixed Wiring.

Brand:
As declared by applicant in ePCS/FOR/01-4. If the brand does not belong to the
applicant, authorization letter from the owner of the brand has to be obtained.

Model:
As declared by applicant in ePCS/FOR/01-1 and ePCS/FOR/01-2.

Type:
e.g : MS VV 10

Rating:
Voltage : 300/500 V

Size:
e.g : (1.0, 1.5, 2.5, 4, 6, 10, 16, 25, 35) mm2

Marking and Labelling:

MS mark and label for regulated sizes (1.0, 1.5, 2.5, 4, 6, 10, 16, 25, 35) mm2
 Product Certification Process
New Application
Certification Panel Approval
 Product Certification Process
New Application
Approval and Award of Licence

SIRIM ST
CERTIFIED TO YY : XXXX
CERTIFICATION NO:xxxxxxxx
 Product Certification Process
Certification Maintenance
Yearly surveillance audit and licence renewal
Product Certification Agreement
Product Certification Requirements
Certification Report
Regulatory Approval

39
 Product Certification Process
Surveillance and Renewal

Does not comply Comply

Suspension /
Renewal
Revocation
Contact Information

Mr. M. Zamri Bin Mustaffa Mrs. Ariza bt Mohd. Yusof

Head Head
Electrical and Electronic Testing Section 1 Electrical & Electronic Certification &
Tel : +603-55446251 Insection Section (ECIS)
Fax : + 603-55446272 Tel : +603-55446418
email: [email protected] Fax : + 603-55446272
email: [email protected]

Mr. Mohamad Asnan bin Ahmad Ms Norzaila Jalaludin

Group Leader Testing Executive
Wiring Accessories Group Cable Testing Lab
Electrical and Electronic Testing Section 1 Electrical and Electronic Testing Section 1
Tel : +603-55446256 Tel : +603-55446167
Fax : + 603-55446272 Fax : + 603-55446272
email: [email protected] email: [email protected]
THANK YOU FOR YOUR KIND
ATTENTION

www.sirim-qas.com.my