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D2802-14 – Standard Test Method Technical Guide
📐 Material Composition and Application Scope
This article provides an overview of ASTM D2802–14, the Standard Specification for Ozone-Resistant Ethylene-Alkene Polymer Insulation for Wire and Cable. This specification governs a crosslinked rubber insulation compound designed for outstanding ozone resistance. The required polymer base must consist substantially of ethylene-alkene copolymer (EAM) or ethylene-alkene diene terpolymer (EADM), which specifically includes Ethylene-Propylene Copolymer (EPM) and Ethylene-Propylene Diene Terpolymer (EPDM).
This insulation type is considered suitable for both wet and dry locations. It is rated for continuous conductor operations at temperatures up to 90°C, emergency overload conditions up to 130°C, and short-circuit conditions up to 250°C. The standard encompasses single and multi-conductor power cables up to 35,000 V phase-to-phase at the 100% insulation level, and up to 25,000 V at the 133% insulation level as referenced in Table 1D of Test Methods D470. Safety requirements mandate that single-conductor cables include a supplementary covering over the insulation, while multiple-conductor cables must have an overall covering.
Note: For definitions of terms used in this specification, refer to Terminology D1711.
⚙️ Physical Property Requirements and Aging
The physical performance of the insulation is validated using test methods prescribed in D470. The crosslinked insulation must conform to the requirements specified in Table 1 of the standard. A key dimensional constraint is that the values in Table 1 are strictly applicable only to insulation having a nominal wall thickness of 0.030 in. (0.76 mm) or greater. The standard formally defines the act of “aging” as the exposure of the material to circulating air at a temperature of 121°C for a duration of 168 hours.
| 🟦 Property Category | 📏 Condition / Test Method | 🎯 Requirement Notes |
|---|---|---|
| Unaged Tensile Strength | Tested per D470 at room temperature | Specified minimum value in Table 1 |
| Unaged Elongation at Break | Tested per D470 at room temperature | Specified minimum value in Table 1 |
| Oven Aging Exposure | 121°C for 168 hours | Standardized aging exposure per terminology |
| Tensile Strength Retention | After aging exposure | Specified retention percentage in Table 1 |
| Elongation Retention | After aging exposure | Specified retention percentage in Table 1 |
⚡ Electrical Testing and Voltage Withstand Requirements
The standard outlines strict electrical performance criteria and mandates a specific sequence for testing to avoid damaging the insulation. When any electrical tests are required, the AC voltage withstand test must be performed first, followed by the insulation resistance test, and finally the DC voltage withstand test.
| ⚡ Parameter | 📐 Specified Value / Condition |
|---|---|
| Voltage Class (100% Level) | Up to 35,000 V Phase-to-Phase |
| Voltage Class (133% Level) | Up to 25,000 V Phase-to-Phase |
| Continuous Operating Temp | 90 °C (Conductor Temperature) |
| Emergency Overload Temp | 130 °C (Conductor Temperature) |
| Short Circuit Temp | 250 °C (Conductor Temperature) |
| AC Withstand Duration | 5 minutes |
📌 Critical Application Note
Always verify the nominal insulation wall thickness before qualifying material to this standard. The physical property values in Table 1 are validated only for thicknesses of 0.030 in. (0.76 mm) and above. Furthermore, the voltage ratings are defined for specific insulation levels; ensure your cable design matches the 100% or 133% level requirements detailed in the standard.
💡 Testing Best Practice
Maintain the specified sequence of electrical tests to ensure valid results. Performing the DC voltage withstand test before the AC withstand test can pre-stress the insulation. Always conduct the AC voltage withstand test first (apply for 5 minutes), followed by the insulation resistance measurement, and finally the DC voltage withstand test.
❓ Frequently Asked Questions
© 2026 TNLab — This article is a technical interpretation for reference only. The original standard as published by ASTM International takes precedence.