Government of India

Ministry of Railways
Research, Designs & Standard Organisation
Manak Nagar, Lucknow – 226011

INSTRUCTION BULLETIN NO. MP-IB.EM.05.11.08 (Rev.-01), Dated: 18.10.18 18.03.2008.

TEST METHODS & REQUIREMENTS FOR LOCOMOTIVE INSULATED WIRE – SIZES AWG # 3 AND
SMALLER ELECTRON BEAM IRRADIATION CROSS-LINKED CABLE FOR DIESEL ELECTRIC
LOCOMOTIVES AS PER GM SPECIFICATION NO. EDPS– 179.

OBJECTIVE

This instruction Bulletin is being issued to define Type Tests, Routine Tests and Acceptance Tests for Locomotive Insulated Wire –
Sizes AWG # 3 and Smaller Electron Beam Irradiation Cross-Linked Cables for diesel electric locomotives as per GM specification no.
EDPS – 179.

 TEST METHODS & REQUIREMENTS

The tests are classified as :

 Type Tests
 Routine Tests
 Acceptance Tests

 Type Tests

The type test schedule includes all the tests specified in Table. Successful completion of type test is mandatory for application
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 on diesel-electric locomotives. Type test shall be witnessed by an authorized representative (or representatives) of the
purchaser, at the cost and premises of the manufacturer. Type tests shall be repeated every three five years as part of quality
audit. In case of any change in the material or design of the cable, complete type tests shall be repeated.

 Routine Tests
These tests shall be carried out by the manufacturer on all finished cable lengths to ensure consistency of the product. The
purchaser may however, carry out these tests on samples sealed at random as per the relevant specification to verify the
results observed by the manufacturer. The routine test schedule includes all those tests marked as Routine Tests in Table.
 Acceptance Tests
These tests to be carried out on samples taken from a lot for the purpose of acceptance of the lot. Acceptance tests shall not
be carried out on a particular size from the lot on which type tests have already been conducted. The acceptance test
schedule includes those tests marked as Acceptance Tests in Table.

1. SOURCES FOR LOCOMOTIVE INSULATED WIRE – SIZES AWG # 3 AND SMALLER E - BEAM IRRADIATED CABLES

Sources for Locomotive Insulated Wire – Sizes AWG # 3 and Smaller E - beam power and control cables have been mentioned in
RDSO Vendor Directory – QM-M-7.1-1 No. VENDOR LIST – QMO/0001 (Latest).

2. DISTRIBUTION

As per Mailing list enclosed.

(Vijay Kumar Goel)

Jt. Director/MP
for Director General / Motive Power Dte.

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TEST METHODS & REQUIREMENTS FOR LOCOMOTIVE INSULATED WIRE – SIZES AWG # 3 AND SMALLER
ELECTRON BEAM CABLES AS PER GM SPECIFICATION NO. EDPS – 179
TABLE
Clause TESTS Type Routi Accept- REQUIREMENTS TEST
test ne ance METHODS
Test Test
3.0 CONDUCTOR REQUIREMENTS
3.1 Conductor Construction   Soft annealed copper wire as per ASTM
B33 & stranded as per Chart 9094883
3.2 Conductor Joints  Only brazed or welded joints of individual
strands permitted
4.0 INSULATION REQUIREMENTS
4.1 Basic properties   As per EDPS 179 EDPS 179
4.2 Strippability   As per EDPS 179 EDPS 179
4.3 Concentricity   As per EDPS 179 IPCEA S-66-
Insulation thickness > 90% of nominal 524, Para
average wall thickness as shown on chart 6.4.3
9094883
4.4 Physical properties - Unaged    10 AWG & smaller 8 AWG & larger IPCEA S-19-
(a) Tensile Strength (Psi) 2200 min 1800 min 81,
(b) Elongation at Break (%) 250 min 250 min Para 6.4.13
4.5 Physical properties - Aged  IPCEA S-19-
(in air oven for 168 hrs. at 158 + 2ºC) 81,
(a) Tensile Strength Min. 90% of Unaged value Para 6.4.13 &
(b) Elongation Min. 50% of Unaged value 6.4.14
4.5.2 Tension Set  Max. 30% IPCEA S-19-
81
Para 6.4.13.4
4.6 Smoke Generation  As per EDPS 179 EDPS-179or
or IEC- 61034 -
for IEC- 61034: Light Transmission > 60% 2/1997
5.0 FINISHED WIRE REQUIREMENTS
5.1 Electrical Properties
5.1.1 Voltage Withstand    Table - I, EDPS 179 & DC volts as per EDPS 179
IPCEA S-66-524

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Clause TESTS Type Routi Accept- REQUIREMENTS TEST
test ne ance METHODS
Test Test
5.1.2 Insulation Resistance @ 25ºC   Table - II, EDPS 179 IPCEA S-19-
81, Para 6.23
5.1.3 Insulation Resistance @ 125ºC  > 2 mega ohms / 1000 ft. EDPS 179
5.1.4 100% Dielectric Test    As per EDPS 179 EDPS 179
5.2 Thermal Properties
5.2.1 Heat Test for 168 hrs. at 158 + 2ºC  As per EDPS 179 spec. EDPS 179
(a) Dielectric Strength
(b) Insulation Resistance
5.2.2 Heat Resistance for 96 hrs. at 175+ 2ºC 
(a) Dielectric Test As per EDPS 179 spec. table-III EDPS 179
(b) Insulation Shrinkage As per EDPS 179 spec. EDPS 179
5.2.3 Heat Shock at 225ºC for 1 hr.    Table - IV, EDPS 179, No cracks EDPS 179
5.2.4 Heat Distortion at 150+ 2ºC  Max 25% IPCEA S-61-
(3 AWG and smaller) As per EDPS 179 402,Para-
spec. 6.4.14.1
or or IEC-811-3-
Pressure Test at 150+ 2ºC As per IEC- 1
811-3-1
5.2.5 Electrical Overload – Single Conductor    Para 5.2.5.1 & Table -V, EDPS 179,test EDPS 179
may be done either with AC or DC current
5.2.6 Bundle Overload   Para 5.2.6.1 & Table -V, EDPS 179,test EDPS 179
may be done either with AC or DC current
5.2.7 Heat Resistance for 168 hrs at 158+ 2ºC  As per EDPS 179 spec. EDPS 179
5.2.8 Cold Shock – after heating for 168 hrs. at  As per EDPS 179 spec. EDPS 179
158 + 2ºC
5.3 Mechanical Properties
5.3.1 Flexibility    As per EDPS 179 spec. EDPS 179
5.3.2 Cold Bend at - 55 + 2ºC for 1 hr.    Para 5.3.2.1 & Table -VII, EDPS 179 IPCEA S-61-
402. Para
6.4.15.1
5.3.3 Cold Shock at – 40 + 2ºC for 1 hr.  Para 5.3.3.1 & Table -VIII, EDPS 179 EDPS 179
5.3.4 Impact Resistance  Should withstand dielectric test by 50% of UL subject 44
the value given in Table-I of EDPS 179 (XHHW) ,

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Clause TESTS Type Routi Accept- REQUIREMENTS TEST
test ne ance METHODS
Test Test
immediate after impact at - 40+ 2ºC EDPS 179
5.3.5 Penetration at 125ºC   Para 5.3.5.1 & Table – VI of EDPS 179 EDPS 179
5.3.6 Abrasion Resistance  Min 2500 cycles ( 5000 Double strokes) EDPS 179 or
Scrape Abrasion Tester, GE catalogue TDE/76/P/16.
no. 5120403 G1 or equivalent. cl.28
5.3.7 Crush Resistance at 25 + 5ºC    Greater than 6000 lb on sizes 3 AWG and Para 81.1 of
smaller. UL – 44
5.4 Environmental Resistance
5.4.1 Hot Oil Resistance for 96 hrs. at 150+ 2ºC  As per EDPS 179 EDPS 179.
5.4.2 Hot Oil Ageing for 18 hrs. at 121+ 2ºC  % of Original Tensile 60 (min) UL – 44 &
% of Original Elongation 60 (min) Para 61.6
5.4.3 Resistance to Fuel Oil & Mineral Spirits  Dia. increase shall not exceed 10% of EDPS 179
for 96 hrs. at 25 + 5ºC original.
5.4.4 Capacitance Stability @ 90ºC  As per IPCEA S-19-81. Para 6.9.2 EDPS 179
5.4.5 Long Term Water Absorption – SIC  SIC - < 10% EDPS 179
16 weeks. 90ºC Stability Factor - < 1
5.4.6 Long Term Water Absorption – IR  > 10 mega ohms / 1000 ft. UL – 44,
26 weeks. 90ºC Section 68
5.4.7 Ozone Resistance for 24 hrs. at 90+ 2ºC   Should show no cracks Para 6.8 of
IPCEA S-19-81
5.4.8 Relative Humidity for 120 hrs. at 40ºC,  As per EDPS 179 EDPS 179
95% RH
5.4.9 75ºC Salt Water Test for 120 hrs.  As per EDPS 179 EDPS 179
5.5 Flame Retardancy & Pyrolytic Properties
5.5.1 Vertical Flame Test    As per spec. EDPS 179 Para 6.19.6 of
IPCEA S-19-
81 with Timil
or Bunsen
gas burner
5.5.2 Oxygen Index   Min: 28 ASTM D- 2863
5.5.3 Copper Mirror Corrosion Test as per  For EDPS 179: Removal of copper film EDPS 179 or
EDPS 179 or Corrosivity of Combustion max 5%, IEC-754 -2
gases as per IEC 754-2 For IEC -754 - 2 : pH > 4.3 & Conductivity

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Clause TESTS Type Routi Accept- REQUIREMENTS TEST
test ne ance METHODS
Test Test
< 100 micro S/cm

5.5.4 Acid Gas Generation test as per EDPS   Acid content Max 300 ppm as per EDPS EDPS 179 or
179 or Toxicity of Combustion gases as 179 or as per UITP Part 2E7 for gases NES 713 &
per UITP Part 2E7 (for gases) UITP Part
2E7 for gases
5.6 Cable Identification
5.6.1 Colour    As per EDPS 179
5.6.2 Surface Printing    As per EDPS 179
5.6.3 Marker Thread    As per EDPS 179
Tests for identification of polymers  Infra Red Spectrograph results of polymer ASTM – D –
(Insulation cum sheath layer / should match with the spectrograph 3677 - 83
Insulation & sheath layer.) submitted by the manufacturer.
1. Thermal Endurance Test & duration  Arrhenious Plot IEC-216
of usability. (To be
conducted
2. Elongation at break absolute.  > 50% after 20000 h at 120 + 2ºC only during
first
prototype
approval)

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