Kerite Analysis in Thermal 

Environment of FIRE (KATE-Fire): 

Test Results

Final Report

Office of Nuclear Regulatory Research

NUREG/CR-7102

SAND2011-6548P
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Kerite Analysis in Thermal 

Environment of FIRE (KATE-Fire): 

Test Results

Manuscript Completed: June 2011

Date Published: December 2011

Prepared by

S.P. Nowlen and J.W. Brown

Sandia National Laboratories

Risk and Reliability Analysis Dept. 6231

P.O. Box 5800

Albuquerque, NM 87185-0748

Gabriel Taylor, NRC Project Manager

NRC Job Code N6959

Office of Nuclear Regulatory Research

NUREG/CR-7102

SAND2011-6548P

iii

ABSTRACT 

This report presents the results of cable functionality tests conducted on the cable product 

marketed under the trade name Kerite FR. Although Kerite FR is a thermoset polymer, reviews 

have identified prior tests that documented cable failure at relatively low temperatures compared 

to other known thermoset insulation materials. Other tests have indicated thermal performance 

limits consistent with other thermoset insulation materials. Hence, the actual high-temperature 

electrical performance limits of this material under fire exposure conditions were uncertain. 

New old stock samples of Kerite cables have been tested as a part of two recent programs. 

During some, but not all, of these tests, cable failures were observed at relatively low 

temperatures. Two separate phenomena working in concert, insulation cracking and production 

of a conductive liquid within the cable, are thought to be the mechanisms responsible for the 

observed cases of early degradation and failure. This report summarizes the previously available 

information for this cable product, presents all of the newly developed test data and provides an 

assessment of the material’s fire-exposure electrical performance. 

v

TABLE OF CONTENTS 

Section Page

ABSTRACT ................................................................................................................................................. iii 

TABLE OF CONTENTS .............................................................................................................................. v

LIST OF FIGURES ..................................................................................................................................... ix

LIST OF TABLES ..................................................................................................................................... xiii

EXECUTIVE SUMMARY ........................................................................................................................ xv

ACKNOWLEDGEMENTS ....................................................................................................................... xix

ACRONYMS ............................................................................................................................................. xxi

1 INTRODUCTION AND OBJECTIVES........................................................................................... 1-1

2 A SUMMARY OF PRIOR TESTING .............................................................................................. 2-1

2.1 SNL – Severe Accident Equipment Qualification Testing ........................................... 2-1

2.2 South Carolina Electric & Gas – Kaowool Fire Barrier Testing ................................... 2-2

2.3 Summary of Prior Knowledge Base and Guidance ....................................................... 2-3

3 KERITE CABLE SAMPLES ............................................................................................................ 3-1

3.1 Overview ................................................................................................................... 3-1 

3.2 Cable Descriptions ........................................................................................................ 3-1

3.3 Cable Sample Designations ........................................................................................... 3-3

4 CABLE ELECTRICAL PERFORMANCE MONITORING UNITS .............................................. 4-1

4.1 Alternating Current (ac) Systems .................................................................................. 4-1

4.1.1 Surrogate Circuit Diagnostic Unit ......................................................................... 4-1

4.1.2 The Insulation Resistance Measurement System ................................................... 4-4

4.2 Direct Current System ................................................................................................... 4-4

4.2.1 Direct Current Simulation Panels .......................................................................... 4-5

4.2.1.1 MOV1 and MOV2 .......................................................................................... 4-5

4.2.1.2 SOV1 and SOV2 ............................................................................................ 4-5

 
vi

TABLE OF CONTENTS 

(Continued) 

Section Page 

4.2.1.3 1-in. Valve ...................................................................................................... 4-5

4.2.1.4 Large Coil ....................................................................................................... 4-5

4.2.1.5 Switchgear ...................................................................................................... 4-6

4.2.2 The dc Battery Bank .............................................................................................. 4-6 

5 TEST CONDITIONS ........................................................................................................................ 5-1

5.1 Small Scale Experiments ............................................................................................... 5-1

5.2 Intermediate-Scale Experiments ................................................................................... 5-3

6 MATRIX OF KERITE TESTS ......................................................................................................... 6-1

6.1 DESIREE-Fire Small-Scale Experiments ..................................................................... 6-3

6.2 The Intermediate-Scale DESIREE-Fire Tests ............................................................... 6-4

6.2.1 DESIREE-Fire Intermediate-Scale Test 9 ............................................................. 6-4

6.2.2 DESIREE-Fire Intermediate-Scale Test 10 ........................................................... 6-5

6.3 KATE-Fire Small-Scale Penlight Experiments ............................................................. 6-7

7 OVERVIEW OF TESTING RESULTS............................................................................................ 7-1

7.1 Chapter Organization and Content ................................................................................ 7-1

7.2 Cable Item A: 2/C-12 AWG, FR .................................................................................. 7-1

7.3 Cable Item B: 2/C-10 AWG, FR-III ............................................................................. 7-3

7.4 Cable Item C: 4/C-10 AWG, FR-III ............................................................................. 7-5

7.5 Cable Item D: 5/C-12 AWG, FR (with zinc wrap) ...................................................... 7-5

7.6 Cable Item E: 7/C-12 AWG, FR (with zinc wrap) ..................................................... 7-10

7.7 Cable Item F: 9/C-14 AWG, FR ................................................................................ 7-15

7.8 Cable Item G: 10/C-16 AWG, FR-II .......................................................................... 7-17

7.9 Cable Item H: 10/C-12 AWG, FR (with zinc wrap) .................................................. 7-20

7.10 Cable Item I: 12/C-12 AWG, FR-III .......................................................................... 7-28

7.11 Cable Item J: 15/C-12 AWG, FR (with zinc wrap) .................................................... 7-30

7.12 Cable Item K: 3/C-6 AWG, HT ................................................................................. 7-34

 
vii

TABLE OF CONTENTS 

(Continued) 

Section Page 

8 SUMMARY OF TESTING RESULTS ............................................................................................ 8-1

8.1 Kerite FR Test Results and Observations ..................................................................... 8-1

8.2 Summary of Test Results for FR-II, FR-III and HT ..................................................... 8-7

9 CONCLUSIONS ............................................................................................................................... 9-1

9.1 Conclusions Regarding Kerite FR-Insulated Cables ..................................................... 9-1

9.2 Conclusions Regarding FR-II, FR-III and HT Insulations ............................................ 9-2

10 REFERENCES ................................................................................................................................ 10-1 

APPENDIX A - TEST SUPPORT SYSTEMS ......................................................................................... A-1

APPENDIX B - TEST RESULTS ............................................................................................................ B-1 
 
ix

 LIST OF FIGURES 

Figure Page

4.1 Circuit diagram for a generic SCDU including an active electrical interlock on 

the contactor pair........................................................................................................ 4-2

5.1 The Penlight apparatus. .............................................................................................. 5-1

5.2 Thermocouple placement within a cable sample during KATE-Fire. ....................... 5-3

5.3 Schematic representation of the DESIREE-Fire intermediate-scale test 

structure...................................................................................................................... 5-4

5.4 Schematic representation of the DESIREE-Fire intermediate-scale test 

structure located within the bunker facility. .............................................................. 5-5

5.5 Photo of the sand diffusion burner. ............................................................................ 5-6

6.1 Specialized tray B for the intermediate-scale tests. ................................................... 6-5

6.2 Specialized tray C for the intermediate-scale tests. ................................................... 6-6

6.3 Bundled tray A configuration for the intermediate-scale tests. ................................. 6-6

7.1 Liquid observed during the testing of Item A. ........................................................... 7-2

7.2 Longitudinal cracking along the conductors of Item A. ............................................ 7-2

7.3 Circumferential cracking extending to the bare wire of Item A. ............................... 7-2

7.4 IRMS data for Item A during test K16. ..................................................................... 7-3

7.5 Pre-test (left) and post-test (right) photos of liquid produced during 

 Item B testing. ............................................................................................................ 7-4

7.6 Conductors from the section of Item B located in the center of Penlight. ................. 7-4

7.7 Close-up of the conductors from Item B. ................................................................... 7-4

7.8 Progression of liquid observed during the testing of Item C. .................................... 7-5

7.9 Post-test analysis of conductors from Item C located in the center of Penlight 

during Test K10 – no insulation cracking evident. .................................................... 7-5

7.10 Item D target voltage increase during Test D13. ....................................................... 7-6

7.11 A pre-test view of the test cables (left) and a photo taken during the Test 15 

(right) showing liquid leaking from the cut ends of the both of the thermal 

response cables (the 10/C and 5/C cables). ................................................................ 7-6

7.12 IRMS results from Test K8. ....................................................................................... 7-7

7.13 Oily residue found between the jacket and zinc wrap of Item D. .............................. 7-8

7.14 Two holes found on the zinc wrap during post-test investigation of Item D in 

Test K8. ...................................................................................................................... 7-8

7.15 Larger hole found during the post-test analysis of Item D in Test K8. ..................... 7-8
x

LIST OF FIGURES 

(CONTINUED) 

Figure Page

7.16 Hole in the conductor insulation corresponding to the hole found in the 

 zinc wrap. ................................................................................................................... 7-9

7.17 Temperature and target voltage response of Item D during Test K5. ........................ 7-9

7.18 Liquid produced during testing being captured within a clean, glass jar. ................ 7-11

7.19 Wire nuts containing liquid formed during testing. ................................................. 7-11

7.20 Dried liquid coming through the jacket material during post-test examination. ..... 7-11

7.21 Longitudinal cracking found along the conductors of Item E ................................. 7-12

7.22 Temperature and voltage response of Item E from Test K1. ................................... 7-12

7.23 IRMS results from Test K6. ..................................................................................... 7-13

7.24 Zinc slag connecting conductors. ............................................................................. 7-13

7.25 Cable temperature and electrical response of Item E during Test IS10. .................. 7-14

7.26 Temperature and voltage observed during Test K2. ................................................ 7-15

7.27 Insulation resistance data from Test K21. ................................................................ 7-16

7.28 Progression of the liquid residue leaking from the cut end of the thermocouple 

cable: pre-test on the left, and then progressively later in the test for the center 

and right photos. ....................................................................................................... 7-16

7.29 Longitudinal cracking observed during post-test analysis of Item F. ...................... 7-16

7.30 Cable temperature and electrical response of Item F during Test IS10. .................. 7-17

7.31 Post-test damage to Item G. ..................................................................................... 7-18

7.32 Close up view of the presumed failure point. .......................................................... 7-19

7.33 Conductors of Item G spread apart after Test K3. ................................................... 7-19

7.34 SCDU results from Test K3 for Item G. .................................................................. 7-19

7.35 Electrical and temperature data for Test 13-qual. .................................................... 7-20

7.36 Oily residue found between the jacketing material and zinc wrap. ......................... 7-21

7.37 Co-located circumferential cracks discovered in two adjacent conductors 

during post-test examination of the cable from Test D13-qual. .............................. 7-21

7.38 Longitudinal cracking observed during the post-test analysis is visible as a 

dark line running along the right hand conductor near the center of the photo. ...... 7-22

7.39 Numbering scheme for Item H. ............................................................................... 7-22

7.40 Liquid observed from cut end of thermal response cable during Test K4. .............. 7-23 
xi

LIST OF FIGURES 

(CONTINUED) 

Figure Page

7.41 Modified target voltages from Test K4. ................................................................... 7-24

7.42 Modified target currents from Test K4. ................................................................... 7-24

7.43 Temperature and voltage response of Item H. ......................................................... 7-25

7.44 Large hole uncovered during the removal of the jacketing material. ...................... 7-25

7.45 Close-up image of the large hole formed in the zinc wrap. ..................................... 7-26

7.46 Jacketing material removed from the thermally exposed portion of the 

energized cable. ........................................................................................................ 7-26

7.47 Removal of the zinc wrap and charred insulation material reveal the bare 

copper conductors. ................................................................................................... 7-26

7.48 Post-test image of the conductors without insulation cracking for Item H. ............. 7-27

7.49 Cable temperature and electrical response of Item H during Test IS10. ................. 7-27

7.50 Temperature and target voltage response of Item I during Test K19. ..................... 7-28

7.51 Source voltage response during Test K19. .............................................................. 7-29

7.52 Burned section of Item I. ......................................................................................... 7-29

7.53 Unburned section of Item I next to the leading flame edge. .................................... 7-29

7.54 Opposite unburned section of Item I next to the leading flame edge. ..................... 7-30

7.55 Liquid produced during Test K20. ........................................................................... 7-31

7.56 Modified target voltages for Item J during Test K20. ............................................. 7-31

7.57 Modified target currents for Item J during Test K20. .............................................. 7-32

7.58 Temperature and voltage response of Item J. .......................................................... 7-32

7.59 Longitudinal cracking along the conductors outside the burned section of 

cable indicated by arrows. ........................................................................................ 7-33

7.60 Cable temperature and electrical response of Item J during Test IS10 .................... 7-33

7.61 Test results for the HT insulated cable in Test 17-qual. .......................................... 7-34

xiii

LIST OF TABLES 

Table Page

2.1 Cable performance during superheated steam exposure testing 

(failure criterion IR < 1 kΩ-100 m). .......................................................................... 2-1

2.2 Cable performance during superheated steam exposure testing 

(failure criterion IR < 0.1 kΩ-100 m). ....................................................................... 2-2

2.3 South Carolina Electric & Gas 1999 Kaowool protected cables functionality 

test results................................................................................................................... 2-3

2.4 Generic Criteria for the Assessment of the Ignition and Damage Potential of 

Electrical Cables under NUREG/CR-6850, EPRI 1011989, errata, 2006. ................ 2-3

3.1 Kerite cable designation and images. ......................................................................... 3-4

3.2 Kerite cable jacket markings as written on cable. ...................................................... 3-7

4.1 SCDU Target MOV Relays Pickup Voltages & Currents. ........................................ 4-3

4.2 Exide calcium flat plate battery cell specifications. ................................................... 4-7

5.1 Relationship between shroud temperature and shroud .............................................. 5-2

6.1 The complete matrix of all Kerite experiments conducted during DESIREEFire and KATE-Fire. .................................................................................................. 6-1

6.2 Small scale experiments involving Kerite cable during DESIREE-Fire. .................. 6-3

6.3 Intermediate-scale experiments involving Kerite cable during DESIREE-Fire. ....... 6-4

6.4 Heat release rate for Test IS9. .................................................................................... 6-5

6.5 Heat release rate for Intermediate-Scale Test 10. ...................................................... 6-7

6.6 Penlight scale experiments from the KATE-Fire program. ....................................... 6-8

7.1 Conductor connection to SCDU for Test K4. .......................................................... 7-23

8.1 Summary of the Penlight results for tests involving FR-insulated cables (see 

notes below table for explanation of nomenclature). ................................................. 8-2

8.2 Summary of intermediate scale test results for FR insulated cables. ......................... 8-5

8.3 Summary of the Penlight test results for the other Kerite insulation 

formulations. .............................................................................................................. 8-7
 
xv

EXECUTIVE SUMMARY 

Background

This report describes thermal damage tests of Kerite brand electrical cables sponsored by the 

U.S. Nuclear Regulatory Commission (NRC) Office of Nuclear Regulatory Research (RES). 

The Kerite Company marketed control cables to the nuclear power industry beginning in 1965. 

While Kerite continues to produce power cables today, its line of control cables was 

discontinued, apparently in the mid- to late-1980’s. It is known that Kerite brand cables were 

installed in some U.S. commercial nuclear power plants, although the exact number of facilities 

with Kerite cables installed is unknown. 

Over the course of production, Kerite control cables were available in at least four known 

insulation formulations; namely, FR, FR-II, FR-III, and HT (which is also referred to as HTK or 

HT-Kerite)2. The exact distinctions between these products are unknown because the 

formulations themselves are manufacturer proprietary information. The primary focus of the 

tests reported here was the Kerite FR formulation, but all four of these formulations were tested. 

Kerite cables were marketed as being based on thermoset material formulations. Thermoset 

insulation materials generally provide a higher degree of thermal resistance (i.e., higher thermal 

failure limits) than do thermoplastic materials. Thermoset materials are expected to provide 

adequate short-term electrical performance up to temperatures of at least 330oC and some 

common thermoset insulation materials have failure thresholds of 390°C or higher [4]. In 

contrast the lower bound failure temperature for thermoplastic insulated cables is approximately 

205oC and some of the most common thermoplastic materials have failure thresholds in the 250-

290°C range [4]. 

At least one prior fire barrier test program3

 [2] reported Kerite FR cable failures at unexpectedly 

low temperatures (i.e., in comparison to typical thermoset insulation materials). Failures were 

reported during one test where the maximum temperature within the protected raceway envelope 

reached just 184oC. Another prior test series involving severe accident equipment qualification 

tests (superheated steam exposures) [3] indicated some degradation of the Kerite FR insulation at 

temperatures as low as 153-171°C, but no outright failures until cable temperatures had reached 

372oC or higher. Overall, there was large uncertainty regarding the fire-induced thermal failure 

limits of, in particular, Kerite FR cables. 

Based largely on evidence of fire damage at relatively low temperatures, the recommended 

current practice for fire Probabilistic Risk Assessment (PRA) applications [4], including the 

NRC’s Significance Determination Process (SDP) [7], is to treat Kerite FR cables using the 

damage criteria associated with thermoplastic cables. Questions have been raised as to whether 

 

2

 These formulations are all trademark product names of the Kerite Corporation. 

3

 The original source report for the fire barrier tests titled “KAOWOOL Triple Wrap Raceway Fire Barrier Test for 

Conduits and Cable Trays” dated May 5, 2000 was obtained by Salley in the cited Masters’ Thesis. The original 

report is available through the NRC Agencywide Documents Access and Management System under accession 

number ML092080059. 
xvi

this recommended treatment is overly conservative or truly reflective of the material behavior. 

The tests described here were undertaken in an effort to resolve this uncertainty. 

Testing Overview

The cable samples used in testing were all new old stock (NOS) cables provided by the U.S. 

nuclear power industry through collaboration between RES and the Electric Power Research 

Institute (EPRI). The samples included cables based on all four of the material formulations 

noted above. Two scales of testing were pursued; namely, small-scale simulation tests using a 

facility called Penlight and intermediate-scale tests involving longer cable samples and actual 

fire exposure conditions. 

One point of uncertainty that was resolved is whether the Kerite insulation formulations were 

thermoset or thermoplastic materials. Testing verified that each of the four Kerite insulation 

formulations tested is a thermoset material. There were no signs in any of the tests that the 

Kerite insulation or jacketing materials themselves were melting, which is one defining 

characteristic of thermoplastic polymers. That is, thermoplastic materials will melt on heating 

and re-solidify on cooling. Thermoset materials will not melt, but if heated to high enough 

temperatures, will instead char and burn. All four Kerite formulations behaved like a thermoset 

in this regard. 

The tests did show uneven behavior of, in particular, the Kerite FR insulation. The tests clearly 

showed that Kerite FR insulated cables are subject to fire-induced insulation resistance 

degradation at relatively low temperatures for thermoset materials. Initial degradation was 

observed in the small-scale tests at temperatures as low as 247°C. Six test cases involved 

outright failure of the Kerite FR insulated cables at cable temperatures of 287-311°C. In other 

tests, the FR-insulated cables showed consistent substantive signs of electrical performance 

degradation at temperatures between 247-311°C but did not experience outright failures until 

much higher temperatures (i.e., 390°C or higher). 

The other three Kerite insulation formulations, FR-II, FR-III and HT, did not show substantive 

signs of electrical degradation until they reached temperatures more typical of thermoset cable 

insulation performance limits. All three of the alternate formulations also displayed higher 

thermal damage limits than did the Kerite FR material. Of the three alternate formulations, the 

FR-II material showed the lowest damage threshold at about 341°C. This is consistent with the 

lower bound estimates of thermoset cable failure thresholds as noted above. Specific results for 

all formulations are provided in the body of this report. All of the test data and photos are

available in electronic format in the companion CD-ROM provided with this publication. 

Conclusions:

The tests described in this report do show that Kerite FR insulated cables may experience 

substantial electrical degradation at temperatures as low as 247°C. Overall, it is recommended 

that fire PRA applications assume a nominal fire-induced failure threshold for Kerite FR cables 

of 247°C. This recommendation includes consideration of the fact that actual fire exposure 

scenarios will involve longer lengths of the cable than did the small-scale test which form the 
xvii

primary basis for the assessment. Longer cable exposure lengths could lead to higher levels of 

degradation, but should not impact temperature at which degradation is first observed. 

A working hypothesis has been developed that explains the observed results. The low 

temperature failure mode in Kerite FR insulated cables likely results from two observed 

behaviors verified by direct observations: 

• The first behavior of interest is the formation of cracks in the conductor insulation during 

the heating process. The presence of insulation cracks, both longitudinal and 

circumferential, in FR-insulated cable samples heated to no more than 320oC was verified 

during post-test examination of various cable samples through the course of the testing. 

Cracks were commonly observed that extended through the insulation exposing the bare 

copper wire. Longitudinal cracks extended as much as 5 cm (or more) along the length 

of the conductors. 

• The second behavior of interest is the formation of a conductive liquid inside the cable 

during heating. That is, a liquid material was seen oozing from the cut ends of the cables 

during the heating process in all of the Kerite FR tests conducted. The exact source of 

the liquid was not determined, but it did not appear to be coming from the insulation and 

jacket materials themselves. The likely source of the conductive liquid is either the 

fibrous cable filler materials present in the cables or residual materials present that were 

used in the manufacturing process (e.g., lubricants that may have been used during 

manufacture of the cables). Samples of the liquid were collected during a number of 

tests, and in each case the material was found to be electrically conductive. 

The postulated failure mode for Kerite FR is that short circuits (either conductor to conductor or 

conductor to ground) form when the conductive liquid fills cracks in the conductor insulation 

thereby creating a conduction path between adjacent conductors or between a conductor and 

ground (e.g., in the case of cables with a grounded shield wrap). 

For those cases where some degree of lower-temperature insulation resistance degradation was 

noted (e.g., below 311°C) but outright failure (i.e., low impedance short circuits) was not 

observed until much higher temperatures, it is likely that cracks did form, but not close enough 

together to allow for low-resistance short circuits to form. That is, while the liquid was 

electrically conductive, it was not a particularly good conductor. It is likely that the relative 

proximity of the cracks plays a role in the faulting behavior by influencing the ‘quality’ of the 

short circuits that form. Poorer quality circuit shorting paths would be reflected by insulation 

resistance degradation but not by outright failure. 
 
xix

ACKNOWLEDGEMENTS 

The authors gratefully acknowledge the efforts by Dan Funk, Harry Barrett, Jeffro Wagner, 

Michelle Kelly, Adam Stein, and Joelle DeJoseph who contributed insights on the testing of 

cables. We also thank Ken Canavan of EPRI for his relentless pursuit of the cable samples used 

in testing and those member utilities who actually provided the test samples. Finally, we once 

again thank Gabe Taylor and Mark Henry Salley, our sponsors at the U.S. NRC, for their 

continuing support of the fire programs. 
 
xxi

ACRONYMS AND ABBREVIATIONS 

ac alternating current 

ADAMS Agency-wide Documents Access and Management System 

AOV Air Operated Valve 

ASTM American Society of Testing and Materials 

AWG American Wire Gage 

CAROLFIRE the Cable Response to Live Fire project 

CFR Code of Federal Regulation 

CPT Control Power Transformer 

dc direct current 

DCSim Panel Direct Current Simulation Panels 

DESIREE-Fire the Direct Current Electrical Shorting in Response to Exposure Fire project 

EPR Ethylene Propylene Rubber

EPRI Electric Power Research Institute 

EQ Equipment Qualification 

FAQ Frequently Asked Question 

FB Fuse Blow 

HS Hot Short 

HT A product trade name of the Kerite Corporation 

IEEE Institute of Electrical and Electronics Engineers 

IR Insulation Resistance 

IRMS Insulation Resistance Measurement System 

IS Intermediate-Scale 

KATE-Fire Kerite Analysis in Thermal Environment of Fire 

FR A product trade name of the Kerite Corporation 

LOCA Loss of Coolant Accident 

MOU Memorandum of Understanding 

MOV Motor Operated Valve 

NA Not Applicable 

NEI Nuclear Energy Institute 

NFPA National Fire Protection Agency 

NOS New Old Stock 

NPP Nuclear Power Plant 

NRC Nuclear Regulatory Commission 

NRR Nuclear Reactor Regulation 

PORV Power Operated Valve 

PRA Probabilistic Risk Assessment 

RES NRC Office of Nuclear Regulatory Research 

SA Spurious Actuation 

SCDU Surrogate Circuit Diagnostic Units 
xxii

SCE&G South Carolina Electric & Gas 

SDP Significance Determination Process 

SNL Sandia National Laboratories 

SOV Solenoid Operated Valve 

SWGR-C/T Switchgear Close/Trip Circuit 

TC Thermocouple 

TSC Technical Support Center 

XLPO Cross-Linked Polyolefin 
1-1

1 INTRODUCTION AND OBJECTIVES 

This report presents the results of fire-induced thermal damage tests of Kerite brand electrical 

control cables focusing, in particular, on cables with Kerite FR insulation. Kerite FR is a trade 

name electrical cable product that is no longer available on the market, but that was used by 

some U.S. nuclear power plants (NPPs) during their original construction. According to the 

company’s web site4, Kerite began marketing a control cable specifically aimed at the nuclear 

power industry in 1965. That cable was Kerite FR. The Kerite Company continued to produce 

control cables for the nuclear industry into the 1980’s. While Kerite continues to produce power 

cables today, its line of control cables was discontinued, apparently in the mid- to late-1980’s. It 

is known that Kerite brand cables were installed in some U.S. commercial NPPs, although the 

exact number of facilities with Kerite cables installed is unknown. Over the course of 

production, Kerite control cables were made available with a number of different insulation 

material formulations. Known formulations include FR, FR-II, FR-III, HT (also sometimes 

referred to as HTK or HT Kerite)5

. The exact distinctions between these products are unknown 

because the formulations themselves are manufacturer proprietary information. While the 

primary focus of this study was the Kerite FR formulation, all four of these formulations were 

tested. 

The Kerite cable thermal damage tests were completed as a part of two test programs sponsored 

by the U.S. Nuclear Regulatory Commission (NRC) Office of Nuclear Regulatory Research 

(RES). All tests were performed at Sandia National Laboratories (SNL) facilities in 

Albuquerque, NM. The first program was called the Direct Current Electrical Shorting in 

Response to Exposure Fire, or DESIREE-Fire, project [1] (reference NRC Job Code Number 

N6579). DESIREE-Fire focused on fire-induced cable failure modes and effects for dc-powered 

control circuits and did include a limited set of tests involving Kerite brand cables. The second 

program is the Kerite Analysis in Thermal Environment of Fire, or KATE-Fire, project 

(reference N6959). KATE-Fire was specifically aimed at resolving uncertainties regarding 

Kerite FR fire performance limits and involved a more extensive series of tests and a broader 

range of Kerite cable samples. The current report covers all of the Kerite cable tests performed 

under both programs. 

The cable samples used in testing were all new old stock (NOS) cables provided by the U.S. 

nuclear power industry through collaboration under the terms of a Memorandum of 

Understanding (MOU) between RES and the Electric Power Research Institute (EPRI). Chapter 

3 provides a detailed description of the cables used in testing. The FR formulation is identified 

by the manufacturer as an “extruded thermoset vulcanized flame retardant synthetic rubber” [2]. 

Testing has verified that Kerite FR is a thermoset material (as opposed to a thermoplastic) as are 

the other three insulation formulations noted above. There were no signs in any of the tests that 

the Kerite insulation or jacketing materials themselves were melting, which is one defining 

characteristic of thermoplastic polymers. That is, thermoplastic materials will melt on heating 

and re-solidify on cooling. Thermoset materials will not melt, but if heated to high enough 

 

4

 Based on: http://www.kerite.com/about.asp. 

5

 These formulations are all trademark product names of the Kerite Corporation. 
1-2

temperatures, will instead char and burn. All four Kerite formulations behaved like a thermoset 

in this regard. 

Thermoset cable insulation materials generally provide a higher degree of thermal resistance 

(i.e., higher thermal failure limits) than do thermoplastic materials. Thermoset insulation 

materials are expected to provide adequate short-term electrical performance up to temperatures 

of at least 330oC and many common thermoset materials have failure thresholds of 390°C or 

higher [4]. In contrast the lower bound failure temperature for thermoplastic insulated cables is 

approximately 205oC and many of the common thermoplastic materials have failure thresholds in 

the 250-290°C range [4]. 

At least one prior fire barrier test program6 [2] reported Kerite FR cable failures at unexpectedly 

low temperatures (i.e., in comparison to typical thermoset insulation materials). In one case 

Kerite FR insulated cables failed during a test where the maximum temperature recorded within 

the protected raceway was just 184oC. In a second case cable failures were recorded where the 

maximum temperature measured was 329oC. Another prior test series involving severe accident 

equipment qualification tests (superheated steam exposures) [3] indicated some degradation of 

the Kerite FR insulation at temperatures as low as 153-171°C, but no outright failures until cable 

temperatures had reached 372oC or higher. Chapter 2 of this report provides a more complete 

discussion of the pre-existing knowledge base on the high-temperature performance of Kerite FR 

cables. 

Based largely on reference [2] and the cited evidence of fire damage at relatively low 

temperatures, the recommended current practice for fire Probabilistic Risk Assessment (PRA) 

applications [4], including the NRC’s Significance Determination Process (SDP) [7], is to treat 

Kerite FR cables using the damage criteria associated with thermoplastic cables. Questions have 

been raised as to whether this recommended treatment is overly conservative or truly reflective 

of the material behavior. The tests described here were undertaken in an effort to resolve this 

uncertainty, in particular, for the Kerite FR insulated cables. As a part of testing, nominal failure 

thresholds for the other three Kerite insulation materials noted above have also been developed. 

Note that in 2010 SNL published a preliminary report on Kerite cables that was based on a 

subset of the tests covered by this report [5]. The preliminary report covered only the smallscale fire tests performed as a part of the DESIREE-Fire project. These initial tests were not 

considered conclusive, but provided sufficient evidence to formulate a working hypothesis as to 

why the Kerite FR cables might experience cable failures at temperatures below 300°C. As 

discussed in Chapter 9 of this report, that hypothesis has been reinforced by the additional testing 

performed under KATE-Fire. The current report supersedes the preliminary report and covers 

the full set of all Kerite brand cable tests performed including those covered by the preliminary 

report. Given the much larger base of testing, the conclusions of the current report are 

considered definitive. 

 

6

 The original source report for the fire barrier tests titled “KAOWOOL Triple Wrap Raceway Fire Barrier Test for 

Conduits and Cable Trays” dated May 5, 2000 was obtained by Salley in the cited Masters’ Thesis. The original 

report is available through the NRC Agencywide Documents Access and Management System under accession 

number ML092080059. 
2-1

2 A SUMMARY OF PRIOR TESTING 

2.1 SNL – Severe Accident Equipment Qualification Testing 

As a part of the U.S. NRC-sponsored equipment aging research programs conducted at SNL [3], 

one test series was conducted involving Kerite FR cables. The objectives of this program were 

not specific to either fire or to the Kerite product, but rather, were to: 

• determine the life extension potential of popular cable products used in U.S. NPPs; and, 

• determine the potential of condition monitoring for residual life assessment. 

This particular experimental program consisted of simultaneous thermal (~95°C) and radiation 

aging (~0.09 kGy/hr) followed by a simulated loss of coolant accident (LOCA) high temperature 

(superheated) steam exposure. During this program, two different samples of Kerite FR 

insulated, FR jacketed, 1/C-12 American Wire Gauge (AWG) cable were tested. The original 

test report presents results using four potential electrical failure thresholds all of which are based 

on the insulation resistance (IR) of the conductor insulation material expressed in units of 

resistance (Ω) over a specified length (100 m) of cable. This approach reflects the fact that the 

performance limits of a control cable may be a function of the circuit characteristics and its 

tolerance for leakage currents. A fully functional non-degraded cable would typically provide an 

IR in excess of 1000 kΩ-100 m. Lower IR values indicate higher levels of degradation. These 

equipment qualification (EQ) tests did observe signs of Kerite FR degradation at lower 

temperatures than were noted for the other tested materials, all of which were thermoset type 

materials. The results of these tests are presented in Table 4 of the original test report [3] and are 

summarized below in Table 2.1 and Table 2.2. Using a failure criterion of IR less than (<) 1 kΩ100 m (the third of four progressively more severe degradation levels considered), the Kerite FR 

cable reached this level of degradation at temperatures significantly lower than did the other 

cables tested (i.e., 153–171oC for the Kerite FR samples versus 235oC or higher for the other 

cables). For the most severe degradation level considered, IR < 0.1 kΩ-100 m, the performance 

of the Kerite FR cable was broadly consistent with that of the other cables tested. 

Table 2.1: Cable performance during superheated steam exposure testing 

(failure criterion IR < 1 kΩ-100 m). 

Cable type Cable samples Temperature (°C)

XLPOa 13 254 - 378

EPRb 16 235 - 400+

Silicon Rubber 2 396 - 400+

Kerite FR 2 153 - 171

Polymide 1 399

{a} Cross-Linked Polyolefin (XLPO)

{b} Ethylene Propylene Rubber (EPR)
2-2

Table 2.2: Cable performance during superheated steam exposure testing 

(failure criterion IR < 0.1 kΩ-100 m). 

Cable type Cable samples Temperature (°C)

XLPO 13 299 - 388

EPR 16 370 - 400+

Silicon Rubber 2 396 - 400+

Kerite FR 2 372 - 382

Polymide 1 399

Around the time these tests were being conducted, SNL was also independently engaged in an 

effort to investigate the effects of fire on cable performance. Although the two types of 

exposures (i.e., superheated steam and a dry-air exposure) are different, Nowlen and Jacobus [6] 

argued that these thermal conditions are similar enough to allow for a comparison between 

results. 

These authors noted that the most severe portions of the exposure profile in the EQ tests involved 

a superheated steam environment. Although these conditions were followed by a saturated steam 

environment, Nowlen and Jacobus [6] argued that the degradation of the cable resistance was 

cause by the elevated temperature and not water condensation because: 

• there was little to no evidence of external cracking after the superheated steam exposure; 

• no additional degradation in cable resistance was noted when saturated steam conditions 

were dominant; and, 

• deionized and demineralized water was used in the steam system. 

Based on this logic, the results of the superheated steam exposure tests are considered relevant to 

an overall understanding of the behavior of Kerite FR under fire exposure conditions. 

2.2 South Carolina Electric & Gas – Kaowool Fire Barrier Testing 

Subsequent fire testing involving Kerite FR samples at South Carolina Electric & Gas (SCE&G) 

showed cable failure again at lower than anticipated temperatures for a thermoset material. 

Kerite FR samples were used during the fire barrier testing of Kaowool (a trade name product of 

the 3M Corporation) ceramic fiber blanket thermal insulation [2]. Sample cables were placed 

within a tray alongside a single stranded, bare copper 8 AWG conductor instrumented with 

thermocouples every 15.24 cm along the entire conductor length (the instrumented bare 

conductor is a standardized approach to measuring temperatures interior to the fire barrier system 

during the fire exposure test). The tray was then wrapped with three layers of Kaowool material 

which nominally represented a 1-hour fire barrier. From this series of tests, Kerite FR cable 

failures were recorded at relatively low temperatures for a thermoset insulation material (i.e., at 

or below 184oC for one test sample and 329oC for another). The results from the SCE&G testing 

were summarized by Salley [2] and are summarized in Table 3. 
2-3

Table 2.3: South Carolina Electric & Gas 1999 Kaowool protected cables functionality test results. 

Conductor 

Count/C-# AWG

Insulation / 

Jacket a

Post-test insulation 

resistance in (MΩ)

Maximum 

Temperature (°C)

2/C-9 AWG FR/FR Fail b 609

4/C-12 AWG FR/FR 11 to 13 184

5/C-12 AWG FR/FR Fail b 184

3/C-8 AWG HTK/FR ∞ 184

5/C-12 AWG FR/FR Fail b 329

{a} Insulation/Jacket refer to the Kerite cable materials

{b} Fail is defined as no resistance measured at the lowest scale (0.1 MΩ) with 1 kV 

applied. For test purposes, it's considered the conductor shorted.

2.3 Summary of Prior Knowledge Base and Guidance 

Although limited, the experimental evidence suggested that Kerite FR insulated cables might be 

substantially more vulnerable to thermal damage than are other thermoset materials. Based on 

those results, NRC guidance documents [3,7] recommend that the cables insulated with 

Kerite FR should be analyzed using failure criteria typical of thermoplastic, rather than 

thermoset, materials. Table 2.4 shows the existing guidance for the treatment of Kerite FR 

cables as provided in an errata sheet(7) to the existing fire PRA methodology guidance document 

[4]. 

Table 2.4: Generic Criteria for the Assessment of the Ignition and Damage Potential of Electrical 

Cables under NUREG/CR-6850, EPRI 1011989, errata, 2006. 

Cable Type Radiant Heating Criteria Temperature Criteria 

Thermoplastic or Kerite FR 6 kW/m2 205°C 

Thermoset 11 kW/m2 330°C 

Some licensees are currently transitioning to National Fire Protection Association (NFPA) 

standard 805 per 10 CFR 50A8.c. As a part of this process, the Office of Nuclear Reactor 

Regulation (NRR) and industry manage a frequently asked question (FAQ) process through 

which licensees can seek to resolve technical and programmatic implementation questions. A 

FAQ related to the treatment of Kerite FR cable failure thresholds as used in fire PRA was 

submitted to this process8

. The FAQ argued against using the sparse data described above as a 

basis for the thermal failure threshold. The FAQ argued that Kerite FR should be treated using 

the general guidance for thermoset insulation materials from the fire PRA guidance [4] for 

applications under NFPA 805. The proposed FAQ solution has never been approved by the 

NRC staff, and is awaiting the results of KATE-Fire for final resolution. 

 7

 The errata sheet was distributed with the annual RES/EPRI Fire PRA training materials in 2006. 

8

 See unresolved FAQ #08-0053. 

3-1

3 KERITE CABLE SAMPLES 

3.1 Overview 

As previously noted, it is no longer possible to procure Kerite FR cables from the manufacturer. 

However, the testing efforts were performed in collaboration with industry as represented by the 

EPRI and its member utilities. It was through this collaboration that samples were obtained for 

testing. It is common practice for U.S. NPPs to retain unused excess cable stocks left over from 

the original plant construction for use in ongoing plant maintenance activities (e.g., for new cable 

routings or as replacement cables in the event of some cable damage). Vintage unused (new old 

stock or NOS) cables originally procured in the late 1970’s and early 1980’s were provided for 

testing by three EPRI member utilities. The sections that follow describe each of the Kerite 

cables used in testing. 

3.2 Cable Descriptions 

Through the course of DESIREE-Fire and KATE-Fire, samples of 11 different Kerite cables 

were tested. The donated cables had varying conductor counts, wire gauges, shielding, fillers, 

and insulation materials. As noted above, Kerite FR is not the only cable insulation product 

produced by the manufacturer. The Kerite insulation materials tested were Kerite FR, FR-II, 

FR-III, and HT (also known as HTK or HT-Kerite). The concerns expressed in the prior 

guidance have focused on the Kerite FR formulation, but because samples of the other Kerite 

products were available, all four materials were evaluated in testing. 

This section presents a description, organized by contributing company and in ascending order 

by conductor count, of the cables provided through the RES and EPRI MOU. The descriptions 

provided here include information taken directly from the cable data and information sheets as 

provided by the contributing companies. 

• 2-conductor, 12 AWG (or 2/C-12 AWG) cable: This cable is a Kerite FR insulated and FR 

jacketed light power cable. The jacket is approximately 1.6 mm thick with an adhered cloth 

wrap separating the jacket from the conductors. Jute filler material is used to fill gaps left 

from the 2-conductor geometry to make a rounded shape. The insulation is approximately 

1.2 mm thick. The insulation on each conductor is gray with printed colors and numbers. 

The conductors are Class C concentric stranded (19 strands), tinned or lead alloy coated, 

annealed copper. The cable's outer diameter is 15 mm. 

• 2/C-10 AWG cable: This cable is a Kerite FR-III insulated and FR jacketed light power 

cable. The jacket is approximately 1.3 mm thick with an adhered cloth wrap separating the 

jacket from the conductors. Jute filler material is used to fill gaps left from the 2-conductor 

geometry to make a rounded shape. The insulation is approximately 1.0 mm thick. The 

insulation on each conductor is gray with printed colors and numbers. The conductors are 

Class C concentric stranded (19 strands), tinned or lead alloy coated, annealed copper. The 

cable's outer diameter is 14 mm. 
3-2

• 3/C-6 AWG cable: This cable is a Kerite HT insulated, Kerite FR jacketed light power 

cable. The jacket is approximately 2.0 mm thick. It has one wrap of fabric between the outer 

jacket and the insulated conductors. The Kerite HT conductor insulation was approximately 

1.0 mm thick. Jute material was used to fill the gaps between conductors to make a circular 

geometry. The insulation on each conductor is gray with printed numbers and colors. The 

conductors are Class B stranded (7 strands) copper. The outer diameter of the cable is 

22 mm. 

• 4/C-10 AWG cable: This cable is a Kerite FR-III insulated and FR jacketed light power 

cable. The jacket is approximately 1.7 mm thick with an adhered cloth wrap separating the 

jacket from the conductors. Jute filler material is used to fill the center of the cable and the 

gaps left from the 4-conductor geometry to make a rounded shape. The insulation is 

approximately 1.0 mm thick. The conductors are gray with printed colors and numbers. The 

conductors are Class C concentric stranded (19 strands), tinned or lead alloy coated, annealed 

copper. The cable's outer diameter is 18 mm. 

• 5/C-12 AWG cable: This cable is a Kerite FR insulated and jacketed control cable. The 

jacket that is approximately 1.7 mm thick. A zinc tape is spiral-wound directly beneath the 

jacketing material and two fabric wraps separate the insulated conductors from the zinc 

material. The five insulated conductors surround a central core of jute filler material. The 

conductor insulation is approximately 1.0 mm thick. The insulation on each conductor is gray 

with printed numbers and colors. The conductors are Class B stranding (7 strands), tin 

coated copper. The cable's outer diameter is 19 mm. 

• 7/C-12 AWG cable: This cable is a Kerite FR insulated and jacketed control cable. The 

jacket is approximately 1.7 mm thick with a black cloth tape adhered to the interior jacketing 

material. A zinc tape is spiral-wound directly beneath the jacketing material and two fabric 

wraps separate the insulated conductors from the zinc material. Six insulated conductors 

surround a central conductor. The Kerite FR conductor insulation material has an 

approximate thickness of 1.2 mm. The insulation on each conductor is gray with printed 

numbers and colors. The conductors are Class B stranding (7 strands), tin-coated copper. The 

cable's outer diameter is 20 mm. 

• 9/C-14 AWG control cable: This cable is a Kerite FR insulated and jacketed control cable. 

The jacket is approximately 1.7 mm thick and is red in color. Beneath this jacketing material 

is one layer of fabric wrap which surrounds the eight outermost conductors. There is one 

center conductor that is surrounded by filler jute material which stabilizes the circular 

pattern. The conductor insulation is approximately 1.3 mm thick. The insulation on each 

conductor is gray with printed colors and numbers. The conductors are Class B stranded (7 

strands). The cables is rated 600V, FPD code EK19J, and certified to Franklin Institute 

Report #F-C4020-2, DTD 3/75. The cable's outer diameter is 22 mm. 

• 10/C-16 AWG cable: This cable is a Kerite FR-II insulated and FR jacketed control cable. 

The jacket is approximately 1.7 mm thick with an adhered cloth wrap separating the jacket 

from the conductors. The adhered cloth has a rubber-like material which stabilizes the outer 

eight conductors in place. The center two conductors are wrapped separately with a cloth 

tape and extra spaces are filled with jute material. The insulation is approximately 0.8 mm 
3-3

thick. The insulation on each conductor is gray with printed colors and numbers. The 

conductors are Class C (19 strands) concentric stranded, tinned or lead alloy coated, annealed 

copper. The cable's outer diameter is 19 mm. 

• 10/C-12 AWG cable: This cable is a Kerite FR insulated and jacketed control cable. The 

jacket is approximately 2.0 mm thick with a spiral-wound zinc tape directly beneath the 

jacketing material. Two counter-wrapped spiral-wound fabric strips separate the insulated 

conductors from the zinc tape. Eight insulated conductors surround a center bundle of two 

conductors. Gaps created by this geometric configuration were filled with fabric wound 

bundles of stranded material. The center bundle is separated from the outer eight conductors 

by a single layer of fabric wrap. The conductor insulation is approximately 1.0 mm thick. 

Kerite FR insulated and jacketed control cable with shield wrap. The insulation on each 

conductor is gray with printed numbers and colors. The conductors are Class B stranded (7 

strands), tin-coated copper. The cable's outer diameter is 27 mm. 

• 12/C-12 AWG cable: This cable is a Kerite FR-III insulated and FR jacketed control cable. 

The jacket is approximately 2.0 mm thick with an adhered cloth wrap separating the jacket 

from the conductors. The adhered cloth has a rubber-like material which stabilizes the outer 

eight conductors in place. The center three conductors are wrapped separately with a cloth 

tape and extra spaces are filled with jute material. The insulation is approximately 1.0 mm 

thick. The insulation on each conductor is gray with printed colors and numbers. The 

conductors are Class C concentric stranded (19 strands), tinned or lead alloy coated, annealed 

copper. The cable's outer diameter is 26 mm. 

• 15/C-12 AWG cable: This cable is a Kerite FR insulated and jacketed control cable. The 

jacket is approximately 2.0 mm thick with a black cloth tape adhered to the interior jacketing 

material. A zinc tape is spiral-wound directly beneath the jacketing material and two fabric 

wraps separate the insulated conductors from the zinc material. Ten insulated conductors 

surround a center bundle of five conductors, and fabric materials fill the gaps created by this 

geometric configuration. The center bundle consists of five conductors and filler materials 

all of which are secured within a fabric wrap. The Kerite FR conductor insulation material 

has an approximate thickness of 1.7 mm. The insulation on each conductor is gray with 

printed numbers and colors. The conductors are Class B stranded (7 strands), tin-coated 

copper. The cable's outer diameter is 30 mm. 

3.3 Cable Sample Designations 

Table 3.1 identifies all the cables tested. For each cable sample, an “item” identifier is defined 

using the letters A-K as designators (left-most column). These letter designations are used in the 

balance of this report to identify each cable sample (e.g., “Item A” will be used when referring to 

the 2/C, 12 AWG Kerite FR cable which is the first cable sample listed in Table 3.1). The cables 

are organized in ascending order by conductor count except for the 3-conductor HT-Kerite cable 

(Item K), which was only used during the DESIREE-Fire tests. Cross-section and exploded 

views (i.e., outer jacket removed to display the conductors, fillers, etc.) are presented along with 

a brief description and the designation. The jacket markings were noted and are presented in 

Table 3.2. 
3-4

Table 3.1: Kerite cable designation and images. 

Item Description Cross-section Exploded view 

A 2/C-12 AWG FR insulated FR 

jacketed 

 

B 2/C-10 AWG FR III insulated, 

FR jacketed 

 

C 4/C-10 AWG FR-III insulated, 

FR jacketed 

 

D 5/C-12 AWG FR insulated FR 

jacketed 

 
3-5

Table 3.1: Kerite cable designation and images. 

Item Description Cross-section Exploded view 

E 7/C-12 AWG FR insulated FR 

jacketed 

 

F 9/C-14 AWG FR insulated FR 

jacketed 

 

G 10/C-16 AWG FR-II 

insulated, FR jacketed 

 

H 10/C-12 AWG FR insulated 

FR jacketed 

 
3-6

Table 3.1: Kerite cable designation and images. 

Item Description Cross-section Exploded view 

I 12/C-12 AWG FR-III 

insulated, FR jacketed 

 

J 15/C-12 AWG FR insulated 

FR jacketed 

 

K 3/C-6 AWG HT insulated, FR 

jacketed 
3-7

Table 3.2: Kerite cable jacket markings as written on cable. 

Item Cable jacket markings

A KERITE 1980 TYPE I 600V 

B KERITE 1984 2/C #10 AWG CU 600V FR3 90C D50-01 

C KERITE 1984 4/C #10 AWG CU 600V FR3 90C D50-02 

D KERITE 1981 5/C #12 AWG 600V EKB1K 

E KERITE 1976 7/C 600V #12 AWG EKB1L 

F NO MARKINGS, MODEL: EK-19J 

G KERITE 1981 10/C #16 AWG 600V CU FRII 90C D50-14 

H KERITE 1978 10/C #12 AWG 600V EKB1M 

I KERITE 1982 12/C #12 AWG 600V CU FR-III 90C D50-10 GREEN 

J KERITE 1976 15/C 600V #12 AWG EKB1N 

K KERITE 1994 3/C #6 AWG CU 600V FR3 EKA3G 

4-1

4 CABLE ELECTRICAL PERFORMANCE MONITORING UNITS 

4.1 Alternating Current (ac) Systems 

SNL used two diagnostic systems which provide information on ac-powered electrical cable 

failure. These systems have been used in multiple programs to analyze the failure modes and 

effects of cables subjected to adverse thermal environments. The characteristics of these two 

diagnostic systems are described in the following subsections. 

4.1.1 Surrogate Circuit Diagnostic Unit 

The Surrogate Circuit Diagnostic Unit (SCDU) was developed for CAROLFIRE and is described 

in detail in NUREG/CR-6931 [8]. Each of the four SCDU systems provides the ability to 

simulate one ac control circuit. Figure 4.1 provides a general system schematic representative of 

each SCDU. For CAROLFIRE the units were generally deployed to simulate an ac-motor 

operated valve (MOV) control circuit. However, as described below, during the testing of the 

Kerite cables the SCDU was used in more generic configuration. 

Each SCDU allows for the following circuit paths to be used: 

• One, two or three (switch selectable) energized source circuit paths: These are generally 

referred to as ‘S1’ through ‘S3’ and are represented by the top three circuit paths in Figure 

4.1. 

• One passive target path: This target is a 1.8 kΩ resistor nominally simulating an indicator 

lamp and is represented by the fourth circuit path from the top in Figure 4.1. This circuit 

path is generally referred to as ‘PT4’ or more simply 'PT' (for the passive target on circuit 

path 4). 

• Two active target circuit paths: These are the two motor contactors shown as ‘K1’ and ‘K2’ 

in the circuit diagram. These are typically referred to as ‘AT5’ and ‘AT6’ (for the active 

targets on circuit paths 5 and 6). 

• One, two or three (switch selectable) circuit ground paths: These are represented by the 

bottom three circuit paths as shown in Figure 4.1. If one of these circuit paths is used in 

testing but with the selector switch open (not grounded) then the conductor on that circuit 

path would act as a monitored spare conductor (i.e., no circuit function but monitored for 

voltage and current). 

The data graphs for each SCDU test as presented in the following chapters depict the electrical 

response for various circuit voltages and currents. A typical graph will identify a data trace as 

either “C# V#” or “C# A#”. Using this nomenclature, the "C#" identifies the specific SCDU 

circuit and the "V#" or "A#" identify the voltage or current path being plotted. For example, a 

plot that shows "C1 V5" represents SCDU circuit 1 (SCDU1) voltage on circuit path 5 (an active 
4-2

target). Similarly, "C2 A6" would indicate SCDU2 current on circuit path 6 (also an active 

target). 

The four SCDU units each used a different size Control Power Transformer (CPT); namely, a 

75 volt-ampere (VA) for SCDU4, 100 VA for SCDU1, 150 VA for SCDU2, and 200 VA for 

SCDU3. 

Figure 4.1: Circuit diagram for a generic SCDU including an active electrical interlock on the 

contactor pair. 

One design change has been implemented relative to the SCDUs since CAROLFIRE; namely, 

replacement of the original motor starter contactor sets at the start of DESIREE-Fire. The 

original motor starter contactors were replaced by more representative Joslyn-Clark(9) units of the 

same type used in the original EPRI/Nuclear Energy Institute (NEI) Fire Test Program [9]. The 

replacement contactors used on SCDU1, SCDU3 and SCDU4 included both mechanical and 

electrical interlocks while the replacement contactors used on SCDU2 only had the electrical 

interlocks. 

 9

 Note that the EPRI test report (TR-1003326, page 4-13) cites “AO Smith (Clark Controls Division) Catalog 

#30U031” as the make and model of the motor starters used in that test program. AO Smith has since merged with Joslyn 

controls. The combined company is known as Joslyn-Clark Controls. The same model motor starter relays are sold under the 

Joslyn-Clark brand using essentially the same catalog number (T30U031). 

S1

AT5

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S7

S8

S9

NC

NC

N/C

120 VAC

3A

AT

6

AT

5

A

A

PT4

1800

SCDU CIRCUIT PATH 

DESIGNATION

CONTROL POWER 

TRANSFORMER

N/C

S2

S3

PT

AT6

G
4-3

The threshold pickup and dropout voltages and the holding currents of all the Joslyn-Clark 

contactors were measured for the DESIREE-Fire project and are presented in Table 4.1. 

Table 4.1: SCDU Target MOV Relays Pickup Voltages & Currents. 

MOV ID Pickup voltage 

(Vac)

Holding current 

(A)

Dropout voltage 

(Vac)

SCDU1

AT5 93.9 0.07 71.7

AT6 80.5 0.08 67.1

SCDU2

AT5 81.1 0.08 60.1

AT6 79.7 0.08 69.5

SCDU3

AT5 82.3 0.09 64.6

AT6 83.2 0.08 57.5

SCDU4

AT5 85.1 0.08 59.7

AT6 85.0 0.08 57.2

For the Kerite tests, the SCDUs were not connected using the standard MOV wiring 

configuration as was applied in CAROLFIRE. The goal of the Kerite cable testing was to 

explore the cable's damage threshold rather than to explore cable/circuit failure modes and 

effects. Hence, the SCDUs were used in a more generic manner designed to maximize the 

potential for detection of conductor-to-conductor or conductor-to-ground short circuit 

interactions. 

For the DESIREE-Fire tests, the test cable would generally be connected using either one or two 

energized source paths (S1 and/or S2) and both of the active target circuit paths (AT5 and AT6). 

The wiring configuration was adjusted depending on the number of conductors present, but in 

general, resulted in adjacent conductors alternating between an energized source and an active 

target. Given this configuration, conductor-to-conductor shorting between any adjacent 

conductor pair would activate the associated target motor contactor. Conductor-to-ground 

shorting for any of the energized conductors would result in a fuse blow failure. In some tests, 

one conductor was grounded. For these cases, a conductor-to-conductor short between an 

energized source and the grounded conductor would cause the circuit fuse to clear thus deenergizing the test circuit. This approach made detection of general insulation degradation 

possible, but not specific to a given conductor or conductor pair. 

For the KATE-Fire tests, multiple SCDU circuits were used on a single cable sample to 

maximize the potential for detection of conductor interactions. In Table 6.6, these cases are 

labeled with “SCDU (M)”. Again, the general wiring configuration set up adjacent conductors 

that were wired alternately as energized sources and active targets. The use of multiple SCDU 

circuits allowed for more specific detection of individual conductor or conductor pair 

interactions. 

In all tests the cable tray and, if present, the zinc tape shield wrap (see cable descriptions above) 

were grounded to a common facility and instrumentation ground. Grounding of the zinc tape is 

consistent with plant practice for the contributing company and is considered general practice for 

cables of a similar construction (conductive shield wraps are generally grounded during 
4-4

installation). These grounded elements provided additional mechanisms for fuse-blow failure to 

occur; namely, shorts between any energized conductor and either the external cable tray or the 

zinc wrap. 

4.1.2 The Insulation Resistance Measurement System 

The Insulation Resistance Measurement System (IRMS) was originally developed as a part of 

the RES collaboration on the 2001 EPRI/NEI Fire Test Program [9]. The system was also 

deployed during CAROLFIRE. IRMS uses 120 Vac (60 Hertz) line power as the energizing 

source potential. The design, operation, and data analysis associated with the IRMS remain as 

described in NUREG/CR-6931 [8]. In brief, the IRMS works by energizing one conductor at a 

time while monitoring for a return signal on each of the other conductors present. Any current 

flow from the energized conductor is an indication of insulation breakdown, and the IR values 

between conductor pairs (conductor-to-conductor or c-c resistance) and between conductors and 

ground (c-g resistance) can be calculated. A detailed description of the IRMS system may be 

found in NUREG/CR-6776 [10]. 

Although the IRMS was not used during DESIREE-Fire, results from the SCDU Kerite tests 

during DESIREE-Fire revealed degradation at relatively low temperatures for a thermoset 

material. Hence, the IRMS was utilized during KATE-Fire to help determine the severity of the 

early (lower temperature) degradation in the cable samples. In particular, the IRMS allows for a 

direct measurement of the minimum IR values over the course of the experiment. 

The graphs for each IRMS test presented in the following chapters will depict the electrical 

response of the test cable based on either “c-c minimum” or “c-g minimum”. In these graphs, 

"c-c minimum" refers to the lowest conductor-to-conductor IR value measured among the 

various conductor pairs within a cable sample at each time step. Similarly, c-g minimum refers 

to the lowest conductor-to-ground IR value among the various conductors within a cable sample 

at each time step. 

4.2 Direct Current System 

The primary purpose of DESIREE-Fire was to investigate the fire-induced cable failure modes 

and effects of dc-powered control circuits. As a matter of opportunity Kerite cables were added 

to both the Penlight and intermediate-scale test matrices. Seven of the eight control circuits 

constructed for DESIREE-Fire were utilized for testing Kerite. Given the very limited lengths of 

donated cable samples, the inter-cable circuit configuration was excluded from the matrix. The 

circuit diagrams for each of the dc-powered control circuits used in testing may be found in 

Appendix A. Detailed descriptions are also provided in the DESIREE-Fire test plan which is 

available through the NRC website(10). The subsections which follow provide a summary 

description of the dc test circuits. 

 10 ADAMS Accession No. ML082520518
4-5

4.2.1 Direct Current Simulation Panels 

The Direct Current Simulation Panels (DCSim Panels) were constructed to simulate and monitor 

the performance of each of the following circuit types: 

• dc reversing motor starters such as those used to control a motor operated valve (MOV) 

• small (pilot) solenoid operated valve (SOV) 

• medium sized (1-in. (25.4 mm) diameter) direct-acting vent-type SOV 

• large (20.3 cm) direct acting valve coil 

• large (15kV) switchgear breaker assembly 

4.2.1.1 MOV1 and MOV2 

Two separate dc-powered MOV circuits were used in testing. They are referred to as MOV1 and 

MOV2 in the balance of this report(11). Each MOV circuit was comprised of a matched pair of 

Joslyn-Clark-brand dc motor control contactors that were electrically and mechanically 

interlocked. One contactor is designated as the “open” contactor and the second as the “close” 

contactor (i.e., the contactors that, if energized, would cause the valve to open or close, 

respectively). 

4.2.1.2 SOV1 and SOV2 

Two separate small SOV circuits were also used in testing (referred to as SOV1 and SOV2). The 

two circuits each include a working solenoid valve of the type commonly used as a pilot control 

valve, for example, for a larger air-operated valve (AOV). The two small SOV circuits differed 

in that one circuit, SOV2, used a continuous duty “Class H” coil. SOV1 used a standard duty 

coil. Based on the manufacturer’s literature, the Class H coils will accommodate continuous 

duty over a wider voltage range; namely, 12% over normal and 28% under normal rated coil 

voltage. For a nominal 125 Vdc coil, this translates to a voltage range of 90 to 180 Vdc. 

4.2.1.3 1-in. Valve 

One test circuit was built around a relatively large, one inch (25 mm) SOV that was provided by 

the Target Rock Corporation through the EPRI collaboration. It is referred to as the "1-in. valve" 

throughout the remainder of this report. This was a normally open solenoid valve. The size 

(1-in.) refers to the nominal inlet and outlet pipe diameter. This was a fully functional valve and 

was similar to the type of valve that would be used as a head vent valve or in other safety relief 

applications (but smaller than a typical power operated relief valve (PORV)). The valve 

assembly included open and close indicator switches that were wired into the valve circuit. 

4.2.1.4 Large Coil 

One circuit was built around the coil assembly for a large, direct-acting SOV. In this case only 

the coil assembly itself was available (no valve mechanical elements present). Hence, the coil 

acted as a passive target for hot shorts. For a sense of scale, the coil assembly itself had a core 

diameter of approximately 200 mm and weighed approximately 114 kg. This coil was also 

 11 The reader should note that the dc-powered MOV circuits are consistently referred to as MOV1 and MOV2. 

Although testing also involved a set of ac-powered MOV circuits, the ac-circuits are uniformly referred to as the SCDU circuits

or as SCDU1 through SCDU4. This convention is maintained throughout the report whenever the various test circuits are 

discussed. 
4-6

provided by the Target Rock Corporation via the EPRI collaboration. Originally, one goal of the 

program was to include a representative PORV valve in the testing program, but EPRI was 

unable to obtain a suitable valve. When this valve coil became available, it was decided to 

include it in the testing program even though it was much larger than a typical PORV would be. 

Between the 1-in. valve and the large coil, the test circuits at the least bound a typical PORV. 

4.2.1.5 Switchgear 

One test circuit was built around an actual switchgear breaker unit. The unit used to test the 

Kerite samples was fully functional and would open (trip) and close in accordance with the 

control signals received. From the manufacturer’s summary description, "the vacuum circuit 

breaker uses sealed vacuum power interrupters to establish and interrupt a primary circuit. 

Primary connections to the associated metal-clad switchgear are made by horizontal bars and 

disconnect fingers, electrically and mechanically connected to the vacuum interrupters." The 

operating mechanism provided direct motion at each phase location in order to move the 

movable contact of the vacuum interrupters from an open position to a spring-loaded closed 

position and then back to the open position on command. The primary interrupters were not 

energized during testing, although the 125 Vdc control circuit was fully functional (i.e., no 

primary power, control power only). 

During a closing operation, the energy stored in the closing spring is used to close the vacuum 

interrupter contacts, compress the wipe springs that load the contacts, charge the opening spring, 

and overcome bearing and other friction forces. The energy then stored in the wipe springs and 

opening spring will open the contacts during an opening operation. 

Closing and opening operations are controlled electrically by the metal-clad switchgear or 

remote relaying. Mechanical control is provided by manual close and trip buttons on the circuit 

breaker. The closing spring may be manually charged. 

4.2.2 The dc Battery Bank 

The battery set used in testing was made available through the RES and EPRI MOU. The set 

was comprised of 68 Exide model ES-13 calcium flat-plate, lead/acid battery cells that were 

being taken out of service from the North Anna Nuclear Station technical support center (TSC). 

The batteries had reached their nominal end of life and were being replaced as a matter of 

preventative maintenance. All of the cells were tested for serviceability by an independent 

electrical contractor before receipt at SNL and all the cells used in the program were certified as 

fully functional in accordance with Institute of Electrical and Electronics Engineers (IEEE) 

Standard 450-2002 [11]. 

The battery bank provided a nominal 125 Vdc power output, this having been identified by the 

industry representatives as typical of the dc-control circuit power supplies used in U.S. NPPs. A 

total of 60 battery cells, each approximately 2.2 Vdc, were used to construct the battery bank. 

For a sense of scale, each individual cell weighed about 36.7 kg, and together the 60-cell battery 

bank weighed approximately 2200 kg. Additional information on the battery specifications may 

be obtained from Table 4.2. The completed battery bank provided an estimated short-circuit 

output current at the main terminals of over 13,000 A. 
4-7

Table 4.2: Exide calcium flat plate battery cell specifications. 

Model 

type

Overall dimensions (mm) Weights (kg) Volume (liters)

Length Width Height Cell Only Electrolyte Electrolyte only

ES-13 124 274 475 36.7 9.1 7.6

5-1

5 TEST CONDITIONS 

The equipment and physical test configurations used for the Kerite FR tests are essentially 

identical to those used during CAROLFIRE [8], an NRC-sponsored experimental program 

investigating ac-powered control circuits and their response to fire-induced cable failure. As in 

CAROLFIRE, two scales of testing were conducted. Volume 2 of the CAROLFIRE report [8] 

provides a detailed description of the small-scale and intermediate-scale tests facilities and the 

general test protocols applied. 

The following two subsections provide a brief overview of the small-scale Penlight and 

intermediate-scale test facilities. The reader should refer to the CAROLFIRE report for more 

complete descriptions. 

5.1 Small Scale Experiments 

The small-scale tests were conducted at the Thermal Test Complex at SNL in Albuquerque, NM 

using a radiant heating apparatus known as “Penlight.” The Penlight apparatus is placed beneath 

a ventilation hood within the Adverse Thermal Environments Laboratory, as shown in Figure 

5.1. 

Figure 5.1: The Penlight apparatus. 

Penlight uses computer-controlled, water-cooled quartz lamps to heat a stainless steel shroud. 

The shroud is painted flat-black and acts as a grey-body radiant heating source, re-radiating heat 

to a test sample located within the shroud. The exposure temperature is controlled and 

monitored based on thermocouples mounted on the inner surface of the shroud. Penlight creates 

a, primarily, radiant heating environment which is analogous to that seen by an object enveloped 

in a fire-induced hot gas layer. That is, the hot gas layer thermal exposure environment is 

dominated by radiant heat exchange between the hot, smoke-filled gases and any immersed 

objects. The hot, smoke-filled gases act largely as a gray-body radiator. Penlight simulates these 

conditions with the shroud temperature being analogous to the hot gas layer or smoke 
5-2

temperature. The relationship between shroud temperature and shroud heat flux assuming an 

emissivity of 0.815 (which has been measured) may be found in Table 5.1. 

Table 5.1: Relationship between shroud temperature and shroud 

 heat flux assuming an emissivity of 0.815. 

Temperature (°C) Heat flux (kW/m2)

260 3.7

295 4.8

300 5

325 5.9

330 6.1

350 7

400 9.5

425 11

460 13.4

470 14.1

475 14.5

500 16.5

525 18.8

600 26.9

650 33.6

665 35.8

675 37.3

700 41.4

900 87.5

All of the small-scale Kerite tests were conducted on a 30 cm wide ladder-back style cable tray 

suspended through the center of the Penlight shroud. The cable trays and other physical test 

conditions are effectively identical to those used in CAROLFIRE. Each test generally used 

symmetrically paired cables, one electrically energized and a second identical cable monitored 

for thermal response. This cable pairing approach allows for a direct correlation of temperature 

response and electrical performance without compromising the electrical integrity of the 

energized cable. In the DESIREE-Fire program, the thermal response cables were instrumented 

sub-jacket with two type-K thermocouples located in the center of Penlight to provide redundant 

temperature data. During the KATE-Fire program, an additional thermocouple was added 

approximately 23 cm in each direction off center to provide a more complete thermal profile. 

Typical thermocouple placement for KATE-Fire is shown in Figure 5.2. This spacing allowed 

the thermocouple to be centered between the rungs of the cable tray. The entrance holes created 

by the incision into the jacket were covered with fiberglass tape. 
5-3

TC 

1

TC 

2

TC 

3

TC 

4

Positioned on opposite 

sides of cable

West end of 

Penlight

East end of 

Penlight

22.3 cm (9 in)

Figure 5.2: Thermocouple placement within a cable sample during KATE-Fire. 

The exact heating protocol (i.e., the shroud set point temperature) varied from test to test 

depending on the specific test purpose (e.g., whether the test was conducted to investigate the 

low temperature failure mechanism or for performance under severe heating conditions). In 

some cases a specific set point value was established and maintained through the entire test. In 

other cases, the set point was varied through the course of the test. That is, a test would be 

started at a particular set point value, but that value would be increased as the measured cable 

temperature approached equilibrium. Step-wise increases were continued at, typically, 10 to 15-

minute intervals until cable failure was observed. The actual test profile is unique for each 

DESIREE-Fire test; however, it became more standardized during KATE-Fire. 

Since the potential for early (low temperature) failure was of primary interest, KATE-Fire began 

testing with a slow cable heating protocol. Based on the results of early testing, a nominal 

heating protocol started with an initial Penlight temperature of 325°C which was then increased 

by 10°C after 30 minutes. Successive temperature changes followed a stepwise pattern by 

increasing 10°C every 5 minutes until cable failure or test termination. 

5.2 Intermediate-Scale Experiments 

During DESIREE-Fire, a complementary test set was conducted at a scale more representative of 

in-plant conditions. These tests involved a more realistic open burn of larger arrays of cable 

under more varied and representative exposures. These tests were referred to as the 

intermediate-scale tests and represent an efficient method of evaluating the fire-induced circuit 

failure effects at actual scale without expending the time and effort full-scale testing would 

require. The intermediate-scale test approach is, again, identical to that used during the 

CAROLFIRE project with only slight modifications. This section provides a summary 

description of the test facility. For a more complete description, refer to the CAROLFIRE test 

report [8]. 

The intermediate-scale testing approach was developed during the CAROLFIRE project where a 

key goal of the research was to assess different exposure conditions, including cable failures due 
5-4

to a hot gas layer exposure, flame impingement, and fire plume conditions. The design of the 

intermediate-scale test enclosure was based on the American Society of Testing and Materials 

(ASTM) standard test room specified in ASTM Standard E-603 [12], but is not a true room 

structure. Rather, it is a far more open configuration that did not restrict air flow to the fire 

(well-ventilated fire conditions). The test structure is arguably a good analog for a very common 

in-plant configuration; namely, a beam pocket within a larger room (i.e., a typical in-plant 

situation where the floor above is supported by massive steel and/or concrete beams creating 

isolated ceiling-level beam pockets). 

The intermediate-scale test assembly is illustrated in Figure 5.3. Overall, the test structure 

measures approximately 2.4 m x 3.7 m x 3.0 m (W x L x H). The upper 1.2 m of the sides and 

the structure’s top were covered with a 13 mm-thick “fireproof” wall board (trade name 

Durock)(12). This test structure acts to focus the fire’s heat output initially to this confined 

volume, creating the desired hot gas layer exposure conditions. As the fire progresses the hot gas 

layer depth increases, and ultimately smoke and hot gasses spill out naturally from under the 

sides of the enclosed area. This again would be quite typical of the hot gas layer development 

behavior for a beam pocket configuration. 

Conduits and trays could be routed in any manner desired. For DESIREE-Fire, all raceways 

were routed as a single straight section passing through the full width of the test structure (i.e., 

across the 2.4 m dimension). The raceways used are identical to those used in CAROLFIRE. 

Figure 5.3: Schematic representation of the DESIREE-Fire intermediate-scale test structure. 

During DESIREE-Fire, two intermediate-scale experiments involving Kerite cable were 

conducted. For convenience, a shorthand identifier is commonly used to identify the 

intermediate-scale tests, for example, “Test IS9” for intermediate-scale test number 9. The 

detailed test descriptions and test matrices identify cables by location consistent with the letter 

 12 Durock® is a low-density concrete-based material with fiber-mesh reinforcement. The same material in smaller 

panels is commonly used as a “‘backer board” for tile installation. 
5-5

designation labels found in Figure 5.3. Through-wall penetration holes were cut in the side 

panels to accommodate raceway routing and insulation was placed around the opening between 

the raceways and enclosure to maintain a hot gas layer within the enclosed portion of the test 

assembly. 

The intermediate-scale test structure was positioned within a larger fire test facility. An existing 

SNL bunker facility served as the outer test structure. This isolated the test structure from the 

ambient environment (e.g., wind effects) and allowed for control of bulk air flow conditions 

through the facility to some extent. Figure 5.4 illustrates the placement of the test assembly 

within the larger facility and provides overall dimensions for the larger facility. 

Figure 5.4: Schematic representation of the DESIREE-Fire intermediate-scale test structure 

located within the bunker facility. 

The fires in all intermediate-scale tests were initiated using the same gas burner setup as was 

used in CAROLFIRE. The fuel in all cases was propene (propylene, C3H6). The burner used 

was a square “sand box” diffusion burner. Figure 5.5 provides a photograph of the burner. The 

top surface of the burner measured 40 cm on a side (outside dimensions). 8.5 m (28') 4.9 m (16') 5.5 m (18') 4.3 m (14') 3.8 m (12'-6") 1.9 m (6'-3")

North Side of Test Cell

South Side of Test Cell
5-6

Figure 5.5: Photo of the sand diffusion burner. 

For testing, the burner’s top surface was about 0.84 m above the floor of the enclosure. The 

burner was always placed in the center of the test structure and directly below cable raceway 

location A (as shown in Figure 5.3). The flow of gas to the burner was measured and controlled 

using the same electronic flow control valve as was used in CAROLFIRE [8]. In general, the 

initial heat release rate allowed for the flame to reach the bottom of the cable tray located in 

raceway position A. For the majority of the tests, this heat release rate was maintained for 15 to 

20 minutes. The propene flow was subsequently increased every 10 to 30 minutes until the 

maximum flow rate, if necessary, was reached in order to cause the circuits in the wing positions 

(i.e., raceway positions C and E) to fail. 
6-1

6 MATRIX OF KERITE TESTS 

The Kerite cables were tested during two recent experimental series (i.e., DESIREE-Fire and 

KATE-Fire). DESIREE-Fire included a total of 11 small-scale Penlight tests and two 

intermediate scale tests involving Kerite cables. KATE-Fire included 24 small-scale Penlight 

tests, all involving the Kerite cables. Each program uses its own test numbering scheme so some 

confusion is possible especially with regard to the small-scale Penlight tests. 

In order to maintain consistency with the DESIREE-Fire test report (publication pending), the 

DESIREE-Fire small-scale Penlight tests are cited based on the original test numbers used in that 

project. The only distinction made in this report is that the DESIREE-Fire small-scale tests are 

cited using a ‘D’ prefix (e.g., ‘Test D13’ would represent DESIREE-Fire Penlight Test 13). The 

intermediate scale tests are referred to using the prefix ‘IS’ and the original DESIREE-Fire test 

numbers (i.e., Tests IS9 and IS10). The KATE-Fire tests are cited using a ‘K’ prefix and are 

simply numbered K1-K24. Table 6.1 provides a complete matrix of the tests performed during 

both programs organized by test number. Note that the sections which follow will provide 

similar test matrices that have been re-organized by the cable item designators. 

For each test the cable items tested are identified. Boxes containing “XX” indicates that two of 

the same cable type were included in the given test while rows containing X's in more than one 

column indicates that multiple cable types were tested. The subsections that follow provide a 

more detailed discussion of the tests performed. 

Table 6.1: The complete matrix of all Kerite experiments conducted during 

DESIREE-Fire and KATE-Fire. 

 Test Identifier 

Tested cable(s) 

 A - 2/C, 12 AWG, FR  B - 2/C, 10 AWG, FR-III  C - 4/C, 10 AWG, FR-III  D - 5/C, 12 AWG, FR (with zinc wrap)  E - 7/C, 12 AWG, FR (with zinc wrap)  F - 9/C, 14 AWG, FR  G - 10/C, 16 AWG, FR-II  H - 10/C, 12 AWG, FR (with zinc wrap)  I - 12/C, 12 AWG, FR-III  J - 15/C, 12 AWG, FR (with zinc wrap)  K - 3/C, 6 AWG, HT 

D13-qual X 

D13 X X 

D14 X X 

D15 X X 

D16 X X 

D17-qual X 

D17 XX 

D18 XX 

D44 XX 
6-2

Table 6.1: The complete matrix of all Kerite experiments conducted during 

DESIREE-Fire and KATE-Fire. 

 Test Identifier 

Tested cable(s) 

 A - 2/C, 12 AWG, FR  B - 2/C, 10 AWG, FR-III  C - 4/C, 10 AWG, FR-III  D - 5/C, 12 AWG, FR (with zinc wrap)  E - 7/C, 12 AWG, FR (with zinc wrap)  F - 9/C, 14 AWG, FR  G - 10/C, 16 AWG, FR-II  H - 10/C, 12 AWG, FR (with zinc wrap)  I - 12/C, 12 AWG, FR-III  J - 15/C, 12 AWG, FR (with zinc wrap)  K - 3/C, 6 AWG, HT 

D49 XX 

D50 XX 

IS9 X X 

IS10 X XX X X X X 

K1 X 

K2 X 

K3 X 

K4 X 

K5 X 

K6 X 

K7 X 

K8 X 

K9 X 

K10 X 

K11 X 

K12 X 

K13 X 

K14 X 

K15 X 

K16 X 

K17 X 

K18 X 

K19 X 

K20 X 

K21 X 

K22 X 

K23 X 

K24 X 
6-3

6.1 DESIREE-Fire Small-Scale Experiments 

Table 6.2 provides an alternate listing of the DESIREE-Fire small-scale Penlight tests. In this 

version, the tests have been grouped by cable type (i.e., the cable ‘Item’ designators A-K) rather 

than by test number. Also indicated is the test circuit applied to the electrically energized cables. 

Recall that the SCDU systems are ac-powered. All of the other systems used during DESIREEFire were dc-powered. 

Table 6.2: Small scale experiments involving Kerite cable during DESIREE-Fire. Original test number 

Tested cable 

 A - 2/C, 12 AWG, FR  B - 2/C, 10 AWG, FR-III  C - 4/C, 10 AWG, FR-III  D - 5/C, 12 AWG, FR (with zinc wrap)  E - 7/C, 12 AWG, FR (with zinc wrap)  F - 9/C, 14 AWG, FR  G - 10/C, 16 AWG, FR-II  H - 10/C, 12 AWG, FR (with zinc wrap)  I - 12/C, 12 AWG, FR-III  J - 15/C, 12 AWG, FR (with zinc wrap)  K - 3/C, 6 AWG, HT Cable monitoring unit 

D13 X SCDU1 

D14 X SCDU1 

D15 X SCDU1 

D16 X SCDU2 

D44 X MOV1 

D44 X MOV2 

D49 X MOV1 

D49 X MOV2 

D50 X MOV1 

D50 X MOV2 

D13-qual X SCDU2 

D13 X SCDU2 

D14 X SCDU2 

D15 X SCDU2 

D16 X SCDU1 

D17-qual X SCDU1 

D17 X SCDU1 

D17 X SCDU2 

D18 X SCDU1 

D18 X SCDU2 
6-4

6.2 The Intermediate-Scale DESIREE-Fire Tests 

Table 6.3 provides a more detailed matrix for the two intermediate-scale tests performed during 

DESIREE-Fire. Again, the test matrix is arranged primarily by cable type (i.e., by cable ‘Item’ 

designators A-K) and identifies the test circuits used for each cable tested. Note that cable Items 

A-D and K were not tested during the intermediate-scale tests. The specific test configurations 

for the intermediate-scale tests are described in greater detail in Sections 6.2.1 and 6.2.2. 

Table 6.3: Intermediate-scale experiments involving Kerite cable during DESIREE-Fire. Original test number 

Tested cable 

 A - 2/C, 12 AWG, FR  B - 2/C, 10 AWG, FR-III  C - 4/C, 10 AWG, FR-III  D - 5/C, 12 AWG, FR (with zinc wrap)  E - 7/C, 12 AWG, FR (with zinc wrap)  F - 9/C, 14 AWG, FR  G - 10/C, 16 AWG, FR-II  H - 10/C, 12 AWG, FR (with zinc wrap)  I - 12/C, 12 AWG, FR-III  J - 15/C, 12 AWG, FR (with zinc wrap)  K - 3/C, 6 AWG, HT  Cable monitoring unit 

IS10 X 1-in. valve 

IS10 X MOV1 

IS10 X Large Coil 

IS9 X MOV1 

IS10 X SOV2 

IS9 X SOV1 

IS10 X MOV2 

IS10 X SOV1 

IS10 X SWGR-C/T 

6.2.1 DESIREE-Fire Intermediate-Scale Test 9 

As shown in Table 6.3, two Kerite samples were tested in Test IS9; namely, Item G (connected 

to MOV1) and Item H (connected to SOV1). Both cables were located in Position B as shown in 

Figure 5.3 (second tray above the fire source). Figure 6.1 presents the cable bundling 

information; that is, the location of each monitored cable within the tray. As a matter of 

consistency between DESIREE-Fire and this report, the nomenclature used to distinguish the 

cable tray configurations during that test series was left the same. Cable Items G and H 

correspond to the numbers “3” and “4”, respectively, as shown in Figure 6.1. Next to each 

energized test cable is a cable labeled “TC”, which stands for ‘thermocouple’, and represents the 

location of the thermal response cable monitoring for that specific circuit. The thermal response 

cables were paired with the energized test cables in all tests. Cables 1 and 2 in this particular test 

were not Kerite brand cables and therefore are not discussed further in this report. The gray area 

in Figure 6.1 represents a random cable fill. Cables were stacked three deep (i.e., three rows) 

within the tray. As shown in the drawing, the two Kerite cables were located in the middle layer 

of cables. By configuring the cables in this manner, both samples were sheltered, at least 
6-5

temporarily, from flames directly beneath the tray and from flames extending over the side rails 

of the cable tray. The heat release rate profile for Test IS9 may be found in Table 6.4. 

Figure 6.1: Specialized tray B for the intermediate-scale tests. 

Table 6.4: Heat release rate for Test IS9. 

Time 

(minutes into test)

Burner flow 

(L/min)

Heat release rate 

(kW)

0 148 173

15 180 210

29 213.6 250

39 241.2 282

55 0 0

6.2.2 DESIREE-Fire Intermediate-Scale Test 10 

As shown in Table 6.3, five different Kerite cable items (a total of six Kerite cable samples) were 

tested during Test IS10. Position B as shown in Figure 5.3 (second tray above the fire source) 

contained three different Kerite samples; namely, Item G (connected to SOV2), Item H 

(connected to MOV2), and Item J (connected to both the trip and close circuit of the switchgear). 

Similar to the description in 6.2.1, the circuit cables are represented by a number and the 

corresponding thermal monitoring cable is labeled as “TC” in Figure 6.2. Item G is depicted as 

cable 3, Item H is depicted as cable 1, and Item J is depicted as cable 2. The gray area of this 

drawing represents the three layers of random cable fill. 

TC 2 1 

3 TC 4 TC 

Specialized Tray B 
6-6

Figure 6.2: Specialized tray C for the intermediate-scale tests. 

Position C as shown in Figure 5.3 (one of the side hot gas layer exposure locations) included two 

different Kerite samples; namely, Item F (connected to MOV1) and Item I (connected to SOV1). 

The specific tray configuration in this position is shown in Figure 6.3. Cable 1 represented Item 

I and cable 2 represented its corresponding thermal monitoring cable. Cable 3 represented Item 

F and cable 4 represented its corresponding thermal monitoring cable. The cables without 

numbers represent fill cables which were used primarily to isolate the energized cables from 

direct contact with the tray. 

 

Figure 6.3: Bundled tray A configuration for the intermediate-scale tests. 

Position D as shown in Figure 5.3 (third tray above the fire source) held two different 

Kerite samples; namely Item E (connected to the 1-in. valve) and Item F (connected to the Large 

Coil). Position D used the same tray configuration as shown in Figure 6.3. For Position D, 

Cable 1 represented Item E and cable 2 represented its corresponding thermal monitoring cable. 

Cable 3 represented Item F and cable 4 represented its corresponding thermal monitoring cable. 

Similar to Position C, the cables without numbers represent fill cables which were used primarily 

to isolate the energized cables from direct contact with the tray. The heat release rate for Test 

IS10 may be found in Table 6.5. 

Bundled Tray A 

1 2

3 4

1 TC 2 TC 3 TC 

Specialized Tray C 
6-7

Table 6.5: Heat release rate for Intermediate-Scale Test 10. 

Time 

(minutes into test)

Burner flow 

(L/min)

Heat release rate 

(kW)

0 148 173

15 182.4 213

25 215.6 252

35 243.2 284

45 260.4 304

57 272 318

66 0 0

6.3 KATE-Fire Small-Scale Penlight Experiments 

Table 6.6 shows the matrix of tests performed during KATE-Fire, all of which are small-scale 

Penlight tests. Again, the tests have been organized by cable item and the electrical performance 

monitoring system used in each test is indicated. 

The KATE-Fire program involved two principal changes as compared to DESIREE-Fire. First, 

five additional cable samples were available for testing (Items A, B and C). Second, based on 

the initial analysis of the DESIREE-Fire data, it was determined that the new experimental series 

would include the IRMS in order to investigate the extent of cable insulation resistance 

degradation during the early stages of cable heating. Just over half of the experiments were 

conducted using the IRMS 

In the case of the SCDU system, as described in Section 4.1.1, for KATE-Fire multiple SCDU 

systems were typically used to monitor each cable tested. This is indicated in the matrix by the 

designation ‘SCDU (M)’. Wiring configurations were customized to each cable type using a 

combination of energized sources, active targets, passive targets, and grounded conductors. 

Details of the wiring configurations for both the IRMS and SCDU as used in each test are 

provided in Appendix B. 

 
6-8

Table 6.6: Penlight scale experiments from the KATE-Fire program. 

 Test Identifier

Tested cable

 A - 2/C, 12 AWG, FR B - 2/C, 10 AWG, FR-III C - 4/C, 10 AWG, FR-III D - 5/C, 12 AWG, FR (with zinc wrap) E - 7/C, 12 AWG, F Cable monitoring unit

R

(with zinc wrap) F - 9/C, 14 AWG, FR G - 10/C, 16 AWG, FR-II H - 10/C, 12 AWG, FR (with zinc wrap) I - 12/C, 12 AWG, FR-III J - 15/C, 12 AWG, F

R

(with zinc wrap) K - 3/C, 6 AWG, HT

K14 X IRMS

K15 X IRMS

K16 X IRMS

K12 X IRMS

K13 X IRMS

K17 X SCDU1

K10 X IRMS

K11 X IRMS

K18 X SCDU (M)

K5 X SCDU (M)

K8 X IRMS

K9 X IRMS

K1 X SCDU (M)

K6 X IRMS

K7 X IRMS

K2 X SCDU (M)

K21 X IRMS

K23 X SCDU (M)

K3 X SCDU (M)

K22 X IRMS

K24 X SCDU (M)

K4 X SCDU (M)

K19 X SCDU (M)

K20 X SCDU (M)
7-1

7 OVERVIEW OF TESTING RESULTS 

7.1 Chapter Organization and Content 

This section provides a broad overview of the testing results for each cable type tested with an 

emphasis on general observations and unique findings. Both the small- and intermediate-scale 

experiments will be discussed for each cable item if applicable. General points to note relative to 

the discussions that follow include the following: 

• The term “very low temperature degradation” refers to electrical degradation when the 

cable temperature was between 170–250°C. 

• The terms “early degradation” and “low temperature degradation” are used 

interchangeably and refer to electrical degradation observed when the cable’s temperature 

was 247–311°C. Early degradation may or may not be associated with an outright 

electrical failure. 

• An outright electrical failure is defined by a spurious actuation, hot short, or fuse blow 

for the SCDU and dc-powered systems. Degradation (short of outright failure) was 

defined as a persistent increase in the measured current on source conductors or in the 

measured voltage of target conductors. An estimated IR of less than 1000 Ω was also 

considered an outright electrical failure for SCDU tests. 

• For the IRMS, an IR of less than 1000 Ω was considered an outright electrical failure. 

An IR below 105 Ω, but above 103 Ω, would be considered degradation but not outright 

failure (the IRMS has an upper detection limit of approximately 105 Ω). 

• If a failure occurred during the initial heating phase (i.e. before the cable temperature had 

exceeded 310°C), it was referred to as a “low temperature failure” or an “early failure”. 

• In all cases, cable temperatures were obtained from sub-jacket thermocouples as depicted 

in Figure 5.2. As shown in this figure, the thermocouples are labeled as TC 1, TC 2, TC 

3, and TC 4. In the graphs of the KATE-Fire tests, TC 1 is synonymous with Cable 1, 

TC 2 with Cable 2, TC 3 with Cable 3, and TC 4 with Cable 4. 

Appendix B provides additional details for each test performed. 

7.2 Cable Item A: 2/C-12 AWG, FR 

Cable Item A was only tested during the KATE-Fire program. This cable was tested three times 

(i.e., Tests K14, K15, and K16), all tests using the IRMS. No early degradation was observed 

during these tests and the cable was only driven to failure during Test K16. The other two tests 

were concluded prior to failure to preserve the samples for post-test examination. It is worth 

noting that liquid appeared in each of the tests at observed temperatures ranging from 282–299°C 

as depicted in Figure 7.1. 

In addition to the liquid being observed, both longitudinal and circumferential cracks in the 

conductor insulation were found during post-test cable dissection of the cable from Tests K14 

and K15. In this case the maximum cable temperatures reached before the tests were stopped 

were 394°C and 406°C, respectively. Some of these cracks extended to the stranded copper 

wire. Photos from the post-test analysis may be seen in Figure 7.2 and Figure 7.3. 
7-2

Figure 7.1: Liquid observed during the testing of Item A. 

Figure 7.2: Longitudinal cracking along the conductors of Item A. 

Figure 7.3: Circumferential cracking extending to the bare wire of Item A. 
7-3

Figure 7.4 presents the failure of Item A during Test K16. Note that electrical failure occurred 

after ignition of the cable. The designation “c-c minimum” and “c-g minimum” represent 

conductor-to-conductor and conductor-to-ground IR values measured at each time step, 

respectively. The point of ignition is evident from the cable temperature plots based on the time 

(around 5600s) that these temperature traces suddenly depart from the general heating trend. 

From Figure 7.4, it is clear that the cable fails after ignition. Additional details from each of the 

Item A tests may be found in Appendix B. 

Figure 7.4: IRMS data for Item A during test K16. 

Overall, Item A did not show measurable signs of electrical degradation during the early stages 

of heating (i.e., at temperatures from 250–310°C) as did the other FR-insulated cable samples 

(see Sections 7.4, 7.5, 7.6, 7.9 and 7.11). This assessment was based on three samples tested 

during KATE-Fire. The first two samples were driven to maximum cable temperatures of 394°C 

and 406°C, respectively, with no failures recorded. The cable was driven to failure in the third 

test, and in that case, failure occurred abruptly and slightly after the cable had ignited at an 

approximate cable temperature of 432°C. However, cracking, both longitudinal and 

circumferential, and production of a conductive liquid were observed between 282–299°C. No 

explanation for the unique behavior of this FR-insulated cable in comparison to the other FRinsulated cable samples has been developed. Given the presence of both the conductive liquid 

and apparent through-insulation cracks, degradation prior to outright failure would nominally 

have been anticipated, but none was detected. 

7.3 Cable Item B: 2/C-10 AWG, FR-III 

Cable Item B was only tested during the KATE-Fire program. This cable was tested three times, 

twice using the IRMS (Tests K12 and K13) and once with the SDCU (Test K17). No early 

degradation was observed during these tests. The cable was driven to failure in two tests (Tests 

K12 and K17) and in each case failure only occurred after cable ignition. It is worth noting that 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
7-4

liquid appeared during each of the Item B Penlight tests at temperatures ranging from 273–

400°C as depicted in Figure 7.5. However, far less liquid was generated by this cable than seen 

with the FR cables. 

Figure 7.5: Pre-test (left) and post-test (right) photos of liquid produced during Item B testing. 

During Test K13, Penlight was increased to a maximum of 405°C. It was decided to conclude 

the test before cable ignition to preserve the cable sample for post-test examination. Upon 

investigation, insulation cracking was not observed along the conductors, as depicted in Figure 

7.6 and Figure 7.7, despite cable temperatures as high as 384°C. Figure 7.7 is a close up of the 

conductors which were located at the center of Penlight. 

Figure 7.6: Conductors from the section of Item B located in the center of Penlight. 

Figure 7.7: Close-up of the conductors from Item B. 

Overall, Item B did not show measurable signs of electrical degradation during the early stages 

of heating (i.e., at temperatures from 250–310°C). This post-test inspection of the cable from 

Test K13 revealed no signs of insulation cracking despite having been heated to 384°C. A 

conductive liquid was observed out of the cut cable ends between 273–400°C but in relatively 

low volumes. 
7-5

7.4 Cable Item C: 4/C-10 AWG, FR-III 

Cable Item C was only tested during the KATE-Fire program. This cable was tested three times, 

twice using the IRMS (Tests K10 and K11) and once with the SDCU (Test K18). No early 

degradation was observed during the tests and the cable was driven to failure in two tests, (Tests 

K11 and K18). It is worth noting that liquid did appear in each one of the tests at observed 

temperatures ranging from 273–400°C as depicted in Figure 7.8. 

Figure 7.8: Progression of liquid observed during the testing of Item C. 

Test K10 was stopped prior to cable ignition in order to preserve the cables for post-test 

examination. Penlight had been increased to as high as 425°C and the cable had reached a 

maximum temperature of 393°C. The cable was dissected during post-test analysis and little to 

no cracking was observed. Additionally, the conductors’ insulation was not brittle and was still 

flexible during investigation. Figure 7.9 displays a close-up of the conductors located at the 

center of Penlight. Details from each of the tests involving Item C may be found in Appendix B. 

Figure 7.9: Post-test analysis of conductors from Item C located in the center of Penlight during 

Test K10 – no insulation cracking evident. 

Overall, Item C did not show measurable signs of electrical degradation during the early stages 

of heating (i.e., at temperatures from 250–310°C). Post-test analysis revealed neither 

longitudinal nor circumferential cracking along the thermally exposed cable length despite 

heating to 393°C. During the three tests, liquid was observed out of the cut cable ends between 

275–389°C. 

7.5 Cable Item D: 5/C-12 AWG, FR (with zinc wrap) 

Cable Item D was tested during both the DESIREE-Fire and KATE-Fire programs. This cable 

was tested seven times total between both programs: Tests D13, D14, D15, D16, K5, K8, and 
7-6

K9. Two of the tests were conducted using the IRMS (Tests K8 and K9) and the remaining five 

tests utilized SCDU. This cable was not tested in the intermediate-scale experiments. 

During DESIREE-Fire, this cable was noted for degradation behavior at a relatively low 

temperature which is illustrated in Figure 7.10. When the voltage on SCDU target conductor 5 

(C1 V5) reached 2.5 Vac, based on field observations, liquid was first noticed coming out of the 

end of the cable instrumented for temperature response (the thermocouple cable). Post-test 

examination of a cable sample in subsequent tests revealed cracks forming along the conductor 

in this temperature range (i.e., 250–310°C). Given the formation of insulation cracks and 

conductive liquid, electrical degradation can be observed clearly during this test at lower 

temperatures than anticipated for a thermoset cable (in this case, 276°C). 

Figure 7.10: Item D target voltage increase during Test D13. 

The voltage and current increases, as well as the production of the liquid (see Figure 7.11), 

during this initial test of Item D were observed in the other DESIREE-Fire tests of this cable as 

well. 

 

Figure 7.11: A pre-test view of the test cables (left) and a photo taken during the Test 15 (right) 

showing liquid leaking from the cut ends of the both of the thermal response cables (the 10/C and 

5/C cables). 

0

1

2

3

4

5

6

7

8

9

10

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 5c

Side TC for 5c

Penlight

C1 V5

C1 V6
7-7

Three tests were conducted during KATE-Fire to gain additional insights on the failure behaviors 

for Item D. As previously mentioned, the IRMS system was utilized during two tests to 

investigate the extent of early cable degradation. Both of these tests revealed low impedance 

shorts (well below the nominal 1000 Ω criteria applied during CAROLFIRE) at relatively low 

temperatures. The results from Test K8, shown in Figure 7.12, indicate failure at 307°C. Results 

from Test K9, which failed at 311°C, may be found in Appendix B. 

Figure 7.12: IRMS results from Test K8. 

Cable dissection was conducted at the conclusion of Tests K8 and K9. Similar to the post-test 

analyses conducted during DESIREE-Fire, an oily residue was noticed between the zinc wrap 

and the jacketing material, as depicted in Figure 7.13. 

After removing the jacketing material, holes in the zinc wrap were observed in multiple locations 

along the length of the thermally exposed portion of energized cable which may be seen in both 

Figure 7.14 and Figure 7.15. Beneath the holes in the zinc wrap were “soft spots” in the 

insulation material. These soft spots were comprised of charred insulation material held in place 

by the oily residue and extended to the bare copper wire. The insulation surrounding the charred 

holes was still relatively flexible and resilient to the applied pressure of investigative tools. The 

first failure mode of Item D during Test 8 was conductor-to-ground shorting. Given that the zinc 

shield wrap was grounded, this was almost certainly caused by shorting between the conductor 

and the wrap. This would also explain the holes found in the zinc wrap and the corresponding 

burn-through spots in the conductor insulation (i.e., arcing at the time of failure). 

1.0E-02

1.0E-01

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

50

100

150

200

250

300

350

400

0 500 1000 1500 2000 2500 3000 3500

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
7-8

Figure 7.13: Oily residue found between the jacket and zinc wrap of Item D. 

Figure 7.14: Two holes found on the zinc wrap during post-test investigation of Item D in Test K8. 

Figure 7.15: Larger hole found during the post-test analysis of Item D in Test K8. 
7-9

Figure 7.16: Hole in the conductor insulation corresponding to the hole found in the zinc wrap. 

During Tests K8 and K9, low temperature degradation was not observed on the IRMS; however, 

both tests resulted in low temperature failures (i.e., low impedance shorting at less than 1000 Ω). 

Early degradation similar to that observed during DESIREE-Fire was captured during Test K5 as 

depicted in Figure 7.17. Since the cable ignited prior to the conclusion of the test, cable 

dissection and conductor investigation was not conducted. 

Figure 7.17: Temperature and target voltage response of Item D during Test K5. 

For Item D, early degradation was observed on multiple tests throughout both DESIREE-Fire 

and KATE-Fire at temperatures between 257–303°C. During Test D14 Penlight was initially set 

to 450°C and in Test D16 Penlight was started at 470°C, both initial exposure temperatures 

causing the cable samples to ignite prior to early degradation and ultimate failure. Given the 

0

2

4

6

8

10

0

100

200

300

400

500

0 1000 2000 3000 4000 5000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5
7-10

initial elevated exposure temperatures for these two tests, the hypothesized early degradation 

mechanisms may not have time to develop before cable ignition. There was another test (Test 

K9) that experienced a low temperature failure at 311°C; however, this failure was rather abrupt 

and the cable did not show signs of substantial degradation prior to failure. Upon post-test 

inspection of the sample from Test K9, similar holes in the zinc wrap and conductors to those 

witnessed in Test K8 were observed. 

Overall, Item D did display measurable signs of electrical degradation and failure during the 

early stages of heating (i.e., at temperatures from 250–310°C). Two cases of low temperature 

outright failures were observed. In both of these cases, the post-test analyses showed holes in the 

zinc wrap corresponding with holes in the conductor insulation which extended to the bare 

copper wire. Throughout the course of testing this cable, liquid was observed out of the cut 

cable ends between 258–284°C and post-test examination of pre-failure examples did reveal 

insulation cracking similar to other FR-insulated cables. 

7.6 Cable Item E: 7/C-12 AWG, FR (with zinc wrap) 

Cable Item E was initially tested during the intermediate-scale DESIREE-Fire series. For 

KATE-Fire, this cable was tested three times, twice on IRMS (Tests K6 and K7) and once on 

SCDU (Test K1). Each of the Item E Penlight tests indicated low temperature insulation 

resistance degradation; however, outright failure was not observed during the initial heating 

phase. 

For the IRMS tests, initial degradation was observed at temperatures ranging from 256–285°C 

and IR degradation to values in the 1105–2373 Ω range were observed during tests K6 and K7 

(recall that an IR of less than 1000 Ω was considered indicative of outright failure). Liquid was 

observed at the cut ends of the thermocouple cable between 257–280°C. 

The liquid was collected in the unused, clean glass jars attached to the cut ends of the thermally 

monitored cable; this may be seen in Figure 7.18. It would initially appear as a milky, yellow 

color before transitioning to a dark brown. The cut ends of the thermally monitored cable 

yielded a total of approximately 5 ml (for a sense of scale, approximately one teaspoon) of 

liquid. Item E produced the most liquid during the low and slow temperature heating phase of 

any cable tested. In comparison, other samples produced about 25% of this amount. After some 

of the tests, the wire nuts which capped the end of the electrically energized cable contained 

liquid produced during the thermal exposure, which may be observed in Figure 7.19. Also, as 

observed during the DESIREE-Fire tests, Item E provided indications of liquid seeping through 

the jacketing material before solidifying as observed in Figure 7.20. In general, the liquid had 

low viscosity, was oily to the touch, and possessed a harsh, chemical smell. 

A Fluke multimeter was used to determine the conductivity of this liquid in the jars. Probes 

connected to the multimeter were spaced 1.27 cm (0.5 in) apart and were then submerged into 

the liquid until the readings stabilized. The probes were subsequently cleaned with water, dried 

off with terrycloth, and the process was repeated two more times. At this spacing, the liquid 

after each of the three tests of Item E had an averaged resistance ranging from approximately 62–

246 Ω. 
7-11

Figure 7.18: Liquid produced during testing being captured within a clean, glass jar. 

Figure 7.19: Wire nuts containing liquid formed during testing. 

Figure 7.20: Dried liquid coming through the jacket material during post-test examination. 
7-12

Tests K1 and K6 were both ended prior to cable failure. At the time these two tests were ended, 

the cable temperatures were 298°C and 378°C, respectively. The samples were then subjected to 

post-test analysis and dissection. During the investigation longitudinal cracks were observed 

along the conductors although they did not appear to extend to the bare copper wire. The 

observed longitudinal cracking is depicted in Figure 7.21. 

For the SCDU tests, during Test K1, a voltage increase of approximately 5 Vac was observed on 

the active targets on SCDU 1, 2, and 4 beginning at a cable temperature of 262°C, as see in 

Figure 7.22. Ultimate failure did not occur during this initial heating period and the test was 

concluded prior to ignition in order to preserve the sample for post-test examination. 

Similar low temperature degradation was observed in Test K6 at a temperature of 271°C. The 

results from this test are shown in Figure 7.23. 

Figure 7.21: Longitudinal cracking found along the conductors of Item E 

Figure 7.22: Temperature and voltage response of Item E from Test K1. 

0

4

8

12

16

0

100

200

300

400

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C4 V5
7-13

Figure 7.23: IRMS results from Test K6. 

Similar low temperature degradation was observed in Test K7 beginning at a temperature of 

285°C. The cable was taken to ignition and full failure. Ignition occurred at a cable temperature 

of roughly 417°C. The post-test cable analysis revealed zinc wrap slag adhered to the conductors 

as well as located at the bottom of Penlight, as illustrated in Figure 7.24. The zinc wrap welded 

multiple conductors together. It is not clear if this shielding occurred because of thermal 

influence or if it was related to electrical arcing. Zinc has a relatively low melting point at 419°C 

[13] and therefore it is entirely plausible that the heat produced by the ignition of the cable 

caused the wrap to melt onto the conductors. Low impedance shorting occurred abruptly and 

failures were detected shortly after ignition. 

Figure 7.24: Zinc slag connecting conductors. 

1.0E+01

1.0E+02

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1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
7-14

During the Test IS10, Item E was tested on the 1-in. valve circuit of the DCSim Panels. The 

cable was located in Position D. Low temperature degradation was observed beginning at a 

cable temperature of approximately 213°C which is lower than the observed cable temperatures 

from the Penlight series of tests. There is uncertainty associated with these temperature data. In 

the intermediate-scale tests an eight-foot length of cable is exposed. The thermocouples are 

concentrated in the central portion of the exposed samples. It is possible that the outer ends of 

the cable (i.e., those segments closer to the walls of the test cell) could experience higher 

temperatures than the center section. However, it is also possible that the longer exposure length 

led to a higher degree of 'net' degradation due to the formation of cracks along the entire 

exposure length. The most significant observation from this test, however, is the fact that early 

degradation may be observed during the more representative intermediate-scale experiments. 

During Test IS10, the voltage increase detected on the target conductor is shown in Figure 7.25. 

The cable temperature is represented by a sub-jacket thermocouple located in the center of the 

thermally monitored cable. The as shown is the raw target voltage (i.e., V(S)) minus the 

negative battery reference voltage (i.e., V(Batt-). This "corrected voltage" reflects the actual 

voltage applied across the valve coil. The voltage started increasing at approximately 1760 s to a 

maximum of 10 Vdc and then experienced an abrupt increase to about 25 Vdc at approximately 

2400 s and a cable temperature of about 320°C. This cable ultimately experienced a hot short 

induced spurious actuation at about 2650 s. 

Figure 7.25: Cable temperature and electrical response of Item E during Test IS10. 

Overall, Item E displayed measurable signs of electrical degradation during both the small- and 

intermediate-scale experiments in the very early to early stages of heating Low temperature 

degradation occurred between 256–285°C and liquid was noticed at 257–280°C throughout the 

Penlight test series. During Test IS10, a voltage increase over the baseline was observed 

beginning at 1756 s and a cable temperature of 213°C. 

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

100

200

300

400

500

600

700

Voltage (Vdc)

0

10

20

30

40

50

60

70

Cable Temperature - Kerite 7c w - 5' 

{1"Valve} V(S) - V(Batt -) 
7-15

More liquid was produced during the heating of this cable than any other sample. Extensive 

insulation cracking was also observed for this cable. 

7.7 Cable Item F: 9/C-14 AWG, FR 

Cable Item F was tested during both the DESIREE-Fire and KATE-Fire programs. This cable 

was tested three times during KATE-Fire; twice with SCDU (Tests K2 and K23) and once using 

the IRMS (Test K21). During DESIREE-Fire, Item F was tested using the MOV circuits in the 

DCSim Panels (Tests D49, D50 and IS10) and was also testing using the dc-powered large coil 

circuit in Test IS10. Each of the tests during the DESIREE-Fire Penlight series included two 

circuits with a thermally monitored cable in between the two electrically energized cables. 

These tests revealed discernable drifts in the ground fault detection [5] and the data from these 

specific tests may be found in Appendix B. 

During the KATE-Fire tests, early degradation was observed during the SCDU tests but not 

during the IRMS test as depicted in Figure 7.26 and Figure 7.27, respectively. The initial 

temperature of Penlight during Test K2 was set to 350°C. Both Tests K21 and K23 were started 

with Penlight at 325°C. Ultimate failure of Item F did not occur prior to cable ignition in any of 

experiments from both test series. Ignition was primarily observed in a range from 411–454°C. 

During Test D50, Penlight was started at 450°C, a common set point for thermoset cable failure 

within a 10–30 minute timeframe. This caused ignition to occur at a cable temperature of 330°C. 

Similar to the observations made during DESIREE-Fire, liquid was produced from the cut ends 

of the thermal response cable as shown in Figure 7.28. Liquid was observed at temperature 

range from 129–296°C; however, only a few drops were produced during each test. Initially, the 

liquid would start out as a clear green color before transitioning to dark brown. Test K2 was 

concluded prior to failure and ignition of the cable. The maximum cable temperature reached 

was 327°C. Post-test cable analysis revealed longitudinal cracking along the conductors which 

is illustrated in Figure 7.29. 

Figure 7.26: Temperature and voltage observed during Test K2. 

0

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6

8

10

0

100

200

300

400

500

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
7-16

Figure 7.27: Insulation resistance data from Test K21. 

Figure 7.28: Progression of the liquid residue leaking from the cut end of the thermocouple cable: 

pre-test on the left, and then progressively later in the test for the center and right photos. 

Figure 7.29: Longitudinal cracking observed during post-test analysis of Item F. 

1.0E+00

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0

100

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0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
7-17

During Test IS10, two circuits were tested using Item F; namely, MOV1 in Position C and the 

large coil in Position D. During these tests, very low temperature degradation was observed in 

both circuits beginning at cable temperatures of 172°C and 245°C for the MOV1 and large coil 

circuits, respectively. This is illustrated in Figure 7.30. Also note that several voltage spikes to 

the target conductors on the MOV1 circuit occurred while the cable was still below 300°C 

indicating a very precarious functional condition. Ultimately, circuit MOV1 experienced a 

spurious actuation. The large coil circuit experienced a fuse blow failure. The most significant 

observation from these tests is the fact that early degradation may be observed during the more 

representative intermediate-scale experiments, especially given the low temperature degradation 

noted for MOV1. 

Based on the IRMS results, the early IR degradation ranged between 1383–9458 Ω given cable 

temperatures ranging from 267–303°C. Liquid was observed during all the tests between a 

temperature range of 129–296°C. Post-test analysis of the cable sample from Test K2, revealed 

longitudinal cracking along each of the conductors, some exceeding 5 cm in length. 

Figure 7.30: Cable temperature and electrical response of Item F during Test IS10. 

7.8 Cable Item G: 10/C-16 AWG, FR-II 

Cable Item G was the only Kerite FR-II insulated cable sample available for testing. This cable 

was tested during the intermediate-scale DESIREE-Fire experiments and KATE-Fire program. 

This cable was tested once using the IRMS unit (Test K22) and twice with SCDU (Tests K3 and 

K24). Item G was also tested during both Test IS9 and Test IS10. During Test IS9, Item G was 

connected to MOV1 and placed in Position B. For Test IS10, this cable was connected to the 

SOV2 circuit and was also placed in Position B. 

The initial Penlight test of Item G (i.e., Test K3) was the only test ended prior to cable ignition. 

Inspection of the cable from this test revealed severe damage to the jacketing material as well as 

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

Voltage (Vdc)

0

5

10

15

20

C Position - Kerite 9c wo - 5'

{MOV1} V(YC1) - V(Batt -) 

{MOV1} V(YO1) - V(Batt -) 
7-18

the conductors. The maximum cable temperature for this test was 388°C. The damage is 

illustrated in Figure 7.31, Figure 7.32, and Figure 7.33. It is presumed that the white ash mark in 

Figure 7.32 is indicative of the failure point and may have resulted from arcing given that a hotshort induced spurious actuation occurred. The cable’s electrical response to thermal exposure 

from this test is shown in Figure 7.34. 

During the post-test analysis of the cable, jacketing material flaked off with little effort. 

Additionally, the conductor insulation was badly damaged and fell off while the jacket was 

removed. As a result, determining if the insulation experienced longitudinal and/or 

circumferential cracking in the section of cable located at the center of Penlight was not possible; 

however, cracking in the insulation was observed in the outermost regions of the cable (i.e., 

those portions located towards either end of the Penlight cylindrical exposure shroud). These 

cracks were less than 0.65 mm (0.25 in) in length and were not as deep or as prevalent as the 

cracking observed in the Kerite FR samples. 

One particular item worthy of note was the fact that dried liquid was observed on the cut ends of 

the thermal response cable during the tests; however, it was not produced in great enough 

quantities to be collected in the attached glass jars. Field notes indicated that Item G cable 

temperatures would exceed 350°C before liquid was observed. Insulation resistance degradation 

was observed during the heating process; however, only at temperatures ranging from 341–

388°C. Failures during each of the three Penlight tests ultimately occurred between 367–388°C. 

Figure 7.31: Post-test damage to Item G. 
7-19

Figure 7.32: Close up view of the presumed failure point. 

Figure 7.33: Conductors of Item G spread apart after Test K3. 

Figure 7.34: SCDU results from Test K3 for Item G. 

0

30

60

90

120

150

0

100

200

300

400

500

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
7-20

During the intermediate-scale tests, this cable's failure range was approximately 374°C or higher. 

In one case the cable temperature at the time of failure was recorded as 484°C, but in this case 

the temperature is not considered reliable and likely indicates that the thermal response cable had 

already ignited. 

In general, while Item G displayed IR degradation before outright failure; however, degradation 

did not occur at temperatures below 341°C. The lowest cable temperature at outright failure was 

367°C (Test K24). Overall, limited amounts of liquid were produced but not until temperatures 

of greater than 350°C. Cracking along the insulation was observed during post-test analysis; 

however, these cracks were not as deep or as numerous as with the Kerite FR samples. 

7.9 Cable Item H: 10/C-12 AWG, FR (with zinc wrap) 

Cable Item H was tested during DESIREE-Fire Tests D13-qual, D13, D14, D15, D16 and during 

intermediate-scale tests IS9 and IS10. Only one test of this cable could be conducted during 

KATE-Fire before the supply was depleted (Test K4). The initial scoping test for Item H (i.e., 

Test D13-qual) was actually the first Kerite exposure test performed. The test produced a 

spurious actuation failure at a cable temperature of 287°C (see Figure 7.35). The cable did not 

ignite during this test, and post-test investigation revealed an oily residue between the jacketing 

material and the zinc wrap (see Figure 7.36). Inspection also revealed circumferential (see 

Figure 7.37) and longitudinal (see Figure 7.38) cracking. In particular, the inspection of the 

center section of the cable found two adjacent conductors that were initially adhered to each 

other and which had circumferential cracks at the same location extending fully through the 

conductor insulation. These cracks are highlighted in Figure 7.37. It is likely that this was, in 

fact, the point of failure. 

Figure 7.35: Electrical and temperature data for Test 13-qual. 

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC

Side TC

Penlight

C1 V5

C1 V6

C1 V1
7-21

 

Figure 7.36: Oily residue found between the jacketing material and zinc wrap. 

 

Figure 7.37: Co-located circumferential cracks discovered in two adjacent conductors during posttest examination of the cable from Test D13-qual. 
7-22

Figure 7.38: Longitudinal cracking observed during the post-test analysis is visible as a dark line 

running along the right hand conductor near the center of the photo. 

Subsequent Penlight tests of this cable during DESIREE-Fire did not result in any further 

outright failures at low temperatures (i.e., below 330°C); however, increased target voltages were 

observed during essentially all of the tests performed on this cable. As noted above, DESIREEFire did not apply the IRMS so the actual level of IR degradation for these tests was not 

measured. However, an analysis of the SCDU leakage current and voltage data from Tests D13 

and D15 based on application of Ohm’s law estimated that the cable experienced IRs of less than 

1000 Ω during the early low temperature degradation period. This is the failure criterion defined 

in NUREG/CR-6931 [8] for the interpretation of IRMS data. Hence, these cases would likely be 

considered outright failures during the low-temperature regime. 

Given the remaining sample length of Item H, only one test could be run in Penlight during the 

KATE-Fire series (Test K4). The cable numbering scheme and SCDU wiring connections are 

shown in Figure 7.39 and Table 7.1, respectively. Note that the wiring configuration meant that 

adjacent conductors in the outer ring alternated between sources and targets. The two cables in 

the center were wired as source conductors but using a voltage divider circuit such that 

conductor 1 was at approximately 40 V and conductor 2 was at about 80 V. The initial Penlight 

set point temperature for Test K4 was 325°C. 

Figure 7.39: Numbering scheme for Item H. 
7-23

Table 7.1: Conductor connection to SCDU for Test K4. 

Conductor 

number 

Conductor 

color 

SCDU 

circuit 

number 

SCDU 

circuit 

path 

Notes 

1 Black 2 SCDU2 

S2 to T4 

Connected through a 3.6 kΩ resistor 

2 White 3 SCDU3 

S2 to T4 

Connected through a 0.9 kΩ resistor 

3 Red 1 SCDU1-S1 Source 

4 Green 1 SCDU1-T5 Target 

5 Orange 2 SCDU2-S1 Source 

6 Blue 2 SCDU2-T5 Target 

7 White/Black 3 SCDU3-S1 Source 

8 Red/Black 3 SCDU3-T5 Target 

9 Green/Black 4 SCDU4-S1 Source 

10 Orange/Black 4 SCDU4-T5 Target 

Zinc Wrap NA NA NA Grounded to tray, but not monitored 

Initial degradation was observed approximately 1322 s into the test at a cable temperature of 

266°C. The voltages increased steadily to about 4 Vac before starting to decline. At a cable 

temperature of 289°C and 1800 s into the test, liquid was observed coming from the cut end of 

the thermal response cable as shown in Figure 7.40. At approximately 1980 s into the test and at 

a cable temperature of 296°C, a short and spurious actuation occurred between conductors 4 and 

5 (SCDU1-T5 and SCDU2-S1). The cable temperature reached a maximum of 326°C before the 

test was stopped (prior to ignition) so that the cable could be preserved for post-test cable 

examination. Figure 7.41, Figure 7.42, and Figure 7.43 illustrate the electrical failures. 

Figure 7.40: Liquid observed from cut end of thermal response cable during Test K4. 
7-24

Figure 7.41: Modified target voltages from Test K4. 

Figure 7.42: Modified target currents from Test K4. 

0

1

2

3

4

5

6

7

8

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

1200 1700 2200 2700 3200

Current (A)

Time (s)

C1 A5

C2 A5

C3 A5

C4 A5
7-25

Figure 7.43: Temperature and voltage response of Item H. 

During examination of the cable from Test K4, as the jacketing material was removed, similar to 

the DESIREE-Fire experiments, an oily residue was found between the jacket and zinc wrap. As 

more of the cable jacket was removed, a large hole in the zinc wrap was discovered. This is 

shown in Figure 7.44 and Figure 7.45. After the jacketing material was detached from the 

thermally exposed section of cable, the zinc wrap was carefully removed, as shown in Figure 

7.46 and Figure 7.47. Directly beneath the hole in the zinc wrap was a “soft spot” in the 

insulation material, very similar to that observed during the testing of Item D. This soft spot was 

comprised of charred insulation material held in place by the oily residue and the charring 

extended to the copper wire. The insulation surrounding the charred hole was still relatively 

flexible and resilient to the applied pressure of investigative tools. Unlike Test D13-qual, 

longitudinal and circumferential cracking along the conductors was not prevalent. The general 

cable condition is shown in Figure 7.48. 

Figure 7.44: Large hole uncovered during the removal of the jacketing material. 

0

30

60

90

120

150

0

100

200

300

400

500

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
7-26

Figure 7.45: Close-up image of the large hole formed in the zinc wrap. 

Figure 7.46: Jacketing material removed from the thermally exposed portion of the energized 

cable. 

Figure 7.47: Removal of the zinc wrap and charred insulation material reveal the bare copper 

conductors. 
7-27

Figure 7.48: Post-test image of the conductors without insulation cracking for Item H. 

Item H was tested during both Test IS9 and Test IS10 of the DESIREE-Fire intermediate-scale 

experiments. For Test IS9, Item H was connected to the SOV1 circuit and located in Position B. 

In Test IS10, this cable sample was connected to MOV2 and again located in Position B. Early 

electrical degradation was observed in both Test IS9 and Test IS10 beginning at cable 

temperatures of 316°C and 251°C, respectively. These values are generally consistent with those 

observed during the Penlight tests. The ultimate failure mode during Test IS9 was a hot short to 

an indication lamp. The indicated cable temperature at the time of failure was in excess of 

400°C. The results from Test IS10 are illustrated in Figure 7.49. During Test IS10, initial 

degradation was noted when the cable was at approximately 251°C and an outright failure 

(spurious actuation) occurred at a cable temperature of about 334°C. 

Figure 7.49: Cable temperature and electrical response of Item H during Test IS10. 

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

Voltage (Vdc)

0

5

10

15

20

B Position - Kerite 10c w

{MOV2} V(YC1) - V(Batt -) 

{MOV2} V(YO1) - V(Batt -) 
7-28

Overall, Item H experienced spurious actuations at temperatures below 300°C during Tests 

D13-qual and K4. Other tests, such as Tests D13 and D15, displayed low temperature 

degradation but outright failure at much higher temperatures (i.e., in excess of 380°C). Low 

temperature degradation was also observed for this cable during both of the intermediate-scale 

experiments. Liquid was observed at temperatures ranging from 268–300°C. Post-test 

examinations of Item H revealed both longitudinal and circumferential cracking. 

7.10 Cable Item I: 12/C-12 AWG, FR-III 

Cable Item I was tested once during the intermediate-scale DESIREE-Fire experiments (test 

IS10) and once during the KATE-Fire program (Test K19). During Test IS10, this cable was 

tested on the SOV1 circuit and located in Position C. For test K19, the SCDU in multi-unit 

mode was used to monitor the sample’s electrical performance. 

During the Penlight test K19, the exposure temperature was increased steadily, but Item I 

showed little signs of duress and electrical degradation until relatively high temperatures as 

indicated in Figure 7.50. At approximately 385°C cable temperature, liquid began to appear 

from the cut end of the thermal response cable; however, not in sufficient quantities to collect in 

the glass jars. The cable ignited at a Penlight exposure temperature of 430°C and a cable 

temperature of approximately 400°C. Three minutes after ignition, the SCDU fuses began to 

clear with all fuses clearing over a 180 s period as shown in Figure 7.51. No spurious actuations 

were observed. 

Even though the cable ignited during the experiment, as seen in Figure 7.52, a post-test 

investigation was conducted for evidence of longitudinal and circumferential cracking on the 

cable regions just beyond the burned area. As shown in Figure 7.53 and Figure 7.54, no cracking 

was observed. Additionally, the insulation was not brittle outside of the immediate region 

burned during the test. 

Figure 7.50: Temperature and target voltage response of Item I during Test K19. 

0

5

10

15

20

25

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C1 V7

C2 V5

C3 V5

C4 V5
7-29

Figure 7.51: Source voltage response during Test K19. 

Figure 7.52: Burned section of Item I. 

Figure 7.53: Unburned section of Item I next to the leading flame edge. 

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V1

C2 V1

C3 V1

C4 V1
7-30

Figure 7.54: Opposite unburned section of Item I next to the leading flame edge. 

During the intermediate-scale experiment, Item I showed no signs of early electrical degradation 

although failure of the thermocouples during the test make the actual temperature response 

uncertain. Overall, Item I performed similarly to other Kerite FR-III insulated samples in that 

liquid was produced at higher temperatures and that the conductors displayed no indications of 

cracking outside the area of flame impact. No early or lower temperature electrical degradation 

was observed throughout the Penlight tests and failures only occurred after the cable had already 

ignited. 

7.11 Cable Item J: 15/C-12 AWG, FR (with zinc wrap) 

Cable Item J was tested once during the intermediate-scale DESIREE-Fire testing (test IS10) and 

once in Penlight during the KATE-Fire testing (test K20). During the intermediate-scale test, 

this cable sample was connected to the switchgear trip and close circuits, and was tested in 

Position B (second tray above the gas burner). During test K20, this cable was tested using 

SCDU. 

During the test K20, liquid initially appeared at a cable temperature of 265°C, as shown in 

Figure 7.55. Shortly after the liquid was observed, at 1994 s and a cable temperature of 276°C, 

voltage and current increases were detected on the target conductors as shown in Figure 7.56, 

Figure 7.57, and Figure 7.58. A fuse blow occurred on SCDU2 prior to ignition at a cable 

temperature of 344°C. The test was continued until ignition occurred at a cable temperature of 

361°C. Shortly after ignition, the remaining SCDU fuses began to clear. 

The conductors immediately outside the burned region of the cable were closely studied for 

evidence of cracking after the test was concluded. Cracking was observed along with dried 

liquid residue present between the conductors. Figure 7.59 depicts the area of conductors outside 

the cable region exposed to fire. The red arrows point to cracks in the insulation material while 

the yellow arrows point to the dried liquid residue located between the conductors. 
7-31

Figure 7.55: Liquid produced during Test K20. 

Figure 7.56: Modified target voltages for Item J during Test K20. 

0

1

2

3

4

5

6

1500 2000 2500 3000 3500 4000 4500

Voltage (Vac)

Time (s)

C1 V5

C1 V6

C1 V7

C2 V5

C2 V6

C3 V5

C3 V6

C4 V5
7-32

Figure 7.57: Modified target currents for Item J during Test K20. 

Figure 7.58: Temperature and voltage response of Item J. 

0

0.02

0.04

0.06

0.08

0.1

0.12

1500 2000 2500 3000 3500 4000 4500

Current (A)

Time (s)

C1 A5

C1 A6

C2 A5

C2 A6

C3 A5

C3 A6

C4 A5

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C1 V6

C3 V5

C3 V6

C4 V5

C2 V1
7-33

Figure 7.59: Longitudinal cracking along the conductors outside the burned section of cable 

indicated by arrows. 

The results from the intermediate-scale tests were complimentary to the results obtained during 

the small scale experiments. Early degradation, in this case voltage leakage from the green 

indication lamp, was observed beginning at about 2646 s into the test and at a cable temperature 

of 261°C. Outright failure occurred at about 3108 s and at a cable temperature of about 337°C. 

This is shown in Figure 7.60 where the cable temperature shown in red and the voltage of 

conductor ‘G’ shown in black and the two arrows indicate the onset of initial degradation and 

outright failure. 

Figure 7.60: Cable temperature and electrical response of Item J during Test IS10 

Overall, cable item J experienced IR degradation (as low as 1365 Ω) during the Penlight tests at 

a temperature as low as 276°C. Liquid was observed at a cable temperature of 265°C. Outright 

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

100

200

300

400

500

600

700

Voltage (Vdc)

0

20

40

60

80

100

120

140

B Position - Kerite 15c w 

{SWGR-T} V(G) - V(Batt -) 
7-34

failures (a fuse blow) occurred at a cable temperature of 344°C. Post-test analysis of the cable 

sample from Test K20 found longitudinal cracking along each of the conductors outside of the 

region impacted by flame. 

7.12 Cable Item K: 3/C-6 AWG, HT 

Cable Item K was only tested during the DESIREE-Fire program and in the small-scale Penlight 

apparatus. This was the only HT insulated cable tested. This cable was tested three times (Tests 

D17-qual, D17, and D18) all using the SCDU. 

No liquid was observed during any of the tests. There were no indications of early cable 

degradation as were noted during the testing of the various FR insulated cables. Failures for this 

cable all occurred after cable ignition and cable ignition occurred at cable temperatures between 

386–409°C. Although each test resulted in cable ignition, post-test analysis of the unburned 

regions of the cable revealed no cracking along the insulation. Typical test results are shown in 

Figure 7.61. Details are provided in Appendix B. 

Figure 7.61: Test results for the HT insulated cable in Test 17-qual. 

0

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150

0

100

200

300

400

500

0 1000 2000 3000 4000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C1 V1

C1 V5

C1 V6
8-1

8 SUMMARY OF TESTING RESULTS 

8.1 Kerite FR Test Results and Observations 

Six different examples of Kerite FR insulated cables were tested (cable Items A, D, E, F, H, 

and J). A total of 29 small-scale Penlight exposure tests were performed involving these cables 

types, and the results of those tests are summarized in Table 8.1. Based on the Penlight results, 

there are two distinct failure modes active for the Kerite FR cables. With few exceptions, the 

Kerite-FR insulated cable samples showed similar behaviors during testing. The exceptions 

involve all three of the Cable Item A samples tested and four of the nine samples of Cable Item F 

tested. These exceptions will be discussed further below. 

When interpreting the test results to determine the minimum threshold of thermal damage, 

certain tests in the series are discounted (not considered). In particular, some of the early 

DESIREE-Fire Penlight tests involved cable samples exposed to very high initial shroud 

temperatures (450-470°C). Under these extreme heating conditions the cable jacket will ignite 

while interior cable temperatures are still relatively low (as low as 202°C in one case). As noted 

in prior test reports (e.g., see Reference [8]) cable temperatures obtained after the sample ignites 

are considered unreliable because (1) the thermocouple tip may lose contact with the insulation 

and may even emerge from the jacket due to jacket swelling, cracking or blistering in which case 

measured temperatures may reflect air or even flame temperatures rather than insulation 

temperatures and (2) even if the thermocouple tip remains embedded within the cable, it may not 

capture the worst-case insulation conditions because the tip location may not coincide with 

localized insulation hot-spots which tend to drive overall cable electrical breakdown. As a result, 

those tests involving an initial Penlight shroud temperatures of 450-470°C and early cable 

ignition are discounted in the final assessment of minimum damage thresholds (i.e., the four test 

samples in tests D14 and D16). Note that for tests where cable failure occurs after ignition the 

data summaries will report that cable failure occurred at a temperature greater than the last 

reliable pre-ignition temperature measurements (e.g., “>289°C”). Some of these cases did 

involve less severe exposure conditions and substantially higher internal cable temperatures. 

For the majority of the FR-insulated cables, a common pattern of degradation was observed. The 

first of the two active failure modes observed involved electrical degradation when the cable 

temperature was in the 247–317°C range (in the summary table this behavior is highlighted in 

the five columns grouped under the label “early degradation”). This early degradation behavior 

is evident in 18 of the 29 Penlight tests performed (the exceptions are clearly noted in the table). 

Of the 11 tests where this behavior was not observed, four involved early cable ignition so that 

any potential early degradation behavior would have been masked by the uncertain post-ignition 

cable temperatures, and the other seven represent the exception cases noted above and discussed 

further below. 

Out of the 18 early degradation cases, four (D13-Qual, K4, K8 and K9) involved an outright 

electrical failure during the early degradation period (i.e., a fuse blow (FB) or spurious actuation 

(SA) failure for the SCDU and MOV circuits, or an IR value below 1000 Ω for the IRMS). Two 

additional SCDU tests (D13 and D15) resulted in estimated IR values of less than 1000 Ω during 

the early degradation period but not an outright FB or SA failure. Note that the estimated cable 
8-2

IR for the SCDU system is based on a direct application of Ohm’s Law using the measured 

leakage currents and known source voltages. These two tests would also be considered outright 

failures if the IRMS failure criteria are applied (i.e., IR of less than 1000 Ω). 

Table 8.1: Summary of the Penlight results for tests involving FR-insulated cables (see notes below 

table for explanation of nomenclature). 

Test Setup 

Early Degradation 

Outright Failure Ignition Exposure 

condition 

Onset of 

early 

degradation 

Maximum extent of 

early degradation 

Test number Electrical performance monitoring unit

Time (s) Cable temperature (°C) 

Time (s) Cable temperature (°C) Estimated minimum cable IR (

Ω) 

Time (s) Cable temperature (°C) First failure mode Time (s) Max. cable temperature reached or pre-ignition cable temperature (°C) 

Penlight shroud temperature setting (°C) 

Cable Item: A - 2/C, 12 AWG, FR 

K14 IRMS No signs of early degradation Test stopped (1) NA 391 325-405 

K15 IRMS No signs of early degradation Test stopped NA 406 325-425 

K16 IRMS No signs of early degradation 5907 >426 C-G 5760 432 325-465 

Cable Item: D - 5/C, 12 AWG, FR (with zinc wrap) 

D13 SCDU1 1123 283 1341 290 2173 4571 >394 SA 4362 394 350-470 

D14 SCDU1 Cable ignited at 289°C (2) 965 >289 FB 600 289 450 

D15 SCDU1 2308 257 2566 265 1578 Test stopped NA 355 300-400 

D16 SCDU2 Cable ignited at 207°C 753 >207 FB 353 207 470 

K5 SCDU(M) 1065 281 1237 285 2233 4368 >389 FB 4341 389 325-415 

K8 IRMS 1831 303 1943 307 C-G Early degradation failure NA 339 325-365 

K9 IRMS 2040 311 2040 311 C-C Early degradation failure NA 322 325-345 

Cable Item: E - 7/C, 12 AWG, FR (with zinc wrap) 

K1 SCDU(M) 2465 256 2937 262 1105 Test stopped NA 298 325-375 

K6 IRMS 1680 271 2700 299 2219 Test stopped NA 378 325-435 

K7 IRMS 1395 285 1655 294 2373 5356 >417 C-G 5332 417 325-445 

Cable Item: F - 9/C, 14 AWG, FR 

D44 MOV1 2148 267 3514 289 NC 9073 ~443 SA 10277 454 325-485 

D44 MOV2 2104 267 2705 268 NC 10043 ~448 SA 10277 454 325-485 

D49 MOV1 1149 303 1274 317 NC 4394 >415 SA 4391 415 350-440 

D49 MOV2 No signs of early degradation 4823 >415 SA 4391 415 350-440 

D50 MOV1 No signs of early degradation 1279 >330 HS 822 330 450 

D50 MOV2 No signs of early degradation 1164 >330 HS 822 330 450 

K2 SCDU(M) 1295 275 2108 296 1383 Test stopped NA 327 350-380 

K21 IRMS No signs of early degradation 5465 >414 C-G 4834 414 325-435 

K23 SCDU(M) 1200 281 1786 297 1600 5232 >411 FB 4530 411 325-415 

Cable Item: H - 10/C, 12 AWG, FR (with zinc wrap) 

D13-

qual SCDU2 2200 247 3363 287 SA Early degradation failure NA 298 300-350 

D13 SCDU2 1240 260 1569 277 583 4590 >374 FB 4362 374 350-470 

D14 SCDU2 Cable ignited at 229°C 966 Ind. FB 600 229 450 

D15 SCDU2 2288 252 3031 274 500 Test stopped NA 352 300-400 

D16 SCDU1 Cable ignited at 202°C 834 Ind. FB 353 202 470 

K4 SCDU(M) 1322 266 1980 296 SA Early degradation failure NA 326 325-355 

Cable Item: J - 15/C, 12 AWG, FR (with zinc wrap) 

K20 SCDU(M) 1994 276 2084 279 1365 3468 344 FB 3933 361 325-405 
8-3

The second active failure mode is manifested at much higher cable temperatures. That is, if the 

particular sample did not experience an outright failure while passing through the early 

degradation stage, then an outright failure would occur at cable temperatures of 370°C or greater, 

and commonly after cable ignition. The typical behavior in these cases included recovery of 

some heightened electrical performance after passing through the early degradation stage. That 

is, once the cable temperature passed about 317°C, leakage currents from source conductors and 

voltages on target conductors would drop to near normal levels for the SCDU and MOV circuits. 

In the case of the IRMS test, the cable IR values would recover somewhat, typically not to pretest values but to in excess of 10,000 Ω. This functional recover would then be followed by an 

outright failure at the higher cable temperatures. 

The first exception to this general behavior is the Cable Item A samples (the 2/C-12AWG cable). 

This cable type was only tested three times, but did not show any signs of early degradation or 

failure. These particular cable samples failed abruptly and only when driven to temperatures in 

excess of 391°C. While the number of tests performed is relatively small, the behavior was 

consistent between tests and the data are considered reliable. No explanation for this unique 

behavior as compared to the other FR-insulated cables has been developed. 

The second exception involves four of the nine tested samples of Cable Item F; namely, one of 

the two samples in Test D49, both samples in test D50, and the single sample in test K21. In 

these specific cases the cables showed no signs of early degradation behavior and failed abruptly 

at the higher temperatures and in all cases only after cable ignition. Again, no definitive 

explanation for these cases is possible, but they may be explained by the general hypothesis 

regarding the mechanisms associated with the FR-insulated cable’s behavior as discussed further 

below. 

Two factors were shown to correlate with the observed early degradation and failure behaviors: 

• The first factor is a liquid material seen oozing from the cable ends during heating. 

• The second factor is the formation of cracks in the cable insulation during heating. 

Table 8.1 Notes: 

(1) "Test Stopped" indicates the test was ended prior to outright electrical failure. This was done to allow 

for post-test examination of a cable sample heated to at least 300°C (cable temperature) but that had 

not ignited and burned. 

(2) "Cable ignited at XXX°C" indicates that the intense heating from penlight (450°C or higher initial 

shroud temperature) caused an early cable ignition when the outer surface of the cable reached the 

auto-ignition temperature. The temperature indicated is the cable's sub-jacket temperature measured at 

the time of ignition. Post-ignition temperature data are considered unreliable. 

(3) General nomenclature: 

• FB = fuse blow failure; 

• SA = spurious actuation failure; 

• HS = hot short failure (conductor-to-conductor); 

• C-G = conductor to ground failure on the IRMS; 

• C-C = conductor-to-conductor failure on the IRMS; 

• NA = not applicable (i.e., the cable did not ignite during test); 

• NC = not calculated (i.e., cable IR has not been estimated for tests using dc-powered circuits); 

• Ind. = indeterminate (temperatures measured after cable ignition are not reliable indicators of 

actual cable temperature).
8-4

The first key observation made during testing of the various Kerite FR samples (including Cable 

Items A and F) was the production of a liquid material during the heating process. The liquid 

was observed oozing out the ends of the exposed cables. The liquid first appeared when cable 

temperature ranged between about 250–280°C. As discussed in Chapter 7, the liquid would 

typically undergo a color change as the cable temperature increased, darkening from a cloudy 

yellow or clear green to dark brown by the end of the test. 

Several samples of the liquid were captured in clean glass jars. The liquid was oily to the touch, 

had a strong chemical odor and remained liquid at room temperature. No chemical analysis was 

performed to determine the composition of the material, but the material was clearly not water (it 

would not evaporate over time) and was not melted thermoplastic material (it did not solidify on 

cooling). Each sample was tested for electrical resistance using a simple multi-meter. Probes 

connected to the multi-meter were spaced 1.27 cm apart and then submerged into the liquid. 

This process was repeated three times for each sample and the results were averaged. In all cases 

the material was found to be electrically conductive. Material gathered from the various samples 

of Kerite FR cable showed resistances ranging between 62–246 Ω. 

The second behavior of interest is the formation of cracks in the cable insulation during the 

heating process. At least one (and typically more) samples of each cable item were inspected 

following heating in Penlight. The samples were either taken from tests terminated before cable 

ignition, in some cases after an outright failure was observed (these cases are noted in the 

summary table by an entry of “test stopped” in the columns grouped under the heading “outright 

failure”), or from the unburned sections of a cable sample that had ignited (i.e., segments of the 

cable away from the center where the heating was most intense). As discussed in Chapter 7, 

post-test examinations of Kerite FR cable samples, including the Cable Items A and F, revealed 

longitudinal and/or circumferential conductor insulation cracks. Many of these cracks extended 

to the bare copper stranded wire. Due to the limited quantity of cables available, no effort was 

made to systematically explore the onset-temperature for the cracking behavior; however, the 

samples inspected revealed cracks present in cables heated in one case to less than 300°C and in 

other cases to no more than 320°C. 

One observation was that the samples of Cable Item A did show somewhat less cracking than did 

the other FR cables. There were typically fewer cracks in the insulation and the cracks that did 

form were typically shorter than those observed in other cable types. In the majority of cases, 

the cracks did appear to penetrate to the conductor itself. Additional information and 

illustrations are provided in Chapter 7. Cable Item F showed cracking behavior that was similar 

to the other FR-insulated cables. 

Another unique observation made during KATE-Fire was the occurrence of holes in the zinc 

shield wrap used in some cable types. These holes in the shield wrap typically coincided (were 

co-located) with holes in the underlying conductor insulation that were in turn filled with charred 

material. Upon the removal of the charred material, it was observed that an oily, tacky residue 

was binding the charred materials between the bare stranded copper wire and the grounded zinc 

shield wrap. Based on these observations, it was inferred that cracks formed along the insulation 

material, conductive liquid filled the cracks and this led to shorting between the energized 

conductors and the grounded zinc shield wrap. The shorting was apparently sufficient to cause 

arcing between the conductor and shield wrap and charring of the cable insulation. 
8-5

In summary, with the exception of the three samples of Cable Item A tested and four of the nine 

samples of Cable Item F tested, electrical degradation in Kerite FR insulated cables was 

consistently observed a cable temperatures in the 247–317°C range. In addition, four of 18 tests 

where the early degradation was observed resulted in outright failure generally when the cable 

reached temperatures from 287–311oC. Two additional tests saw estimated IR values using the 

SCDU systems that would have been considered failures using the criteria applied when using 

the IRMS. These observations, as well as the post test forensics described above, support the 

hypothesis that the early degradation and failure cases result from the combination of insulation 

cracking and production of a conductive liquid within the cable during heating. 

No explanation for the inconsistent behavior of cable Item A has been developed. Only three 

samples of this cable type were tested due to limited supplies of this cable type, and none showed 

signs of early electrical degradation. This cable did produce the conductive liquid and did 

experience insulation cracking. However, physical inspection of tested samples showed that this 

cable developed fewer, shorter, and generally shallower cracks. 

In the case of Cable Item F, five of the nine samples behaved in a manner nominally consistent 

with other FR-insulated cables. The fact that four of the samples did not experience early 

degradation may be attributed to a lack of cracks in close proximity on adjacent conductors (i.e., 

it may be a matter of simple chance). 

The intermediate scale tests were more limited in scope than the Penlight tests but do confirm the 

behaviors observed in Penlight. A total of six samples representing four examples of the FRinsulated cables (i.e., four cable items) were tested in DESIREE Fire Tests IS9 and IS10. The 

results are summarized in Table 8.2. The table indicates the time at which the first signs of cable 

degradation were observed and the corresponding cable temperature at that time. As with the 

Penlight tests, observations of initial cable degradation were based on voltage increases to 

various target conductors. The table also indicates the time when outright circuit failures were 

observed, the corresponding cable temperature at that time, and the mode of circuit failure 

observed. 

Table 8.2: Summary of intermediate scale test results for FR insulated cables. DESIREE Fire test number Cable Item number Test position Cable monitoring unit Time of initial degradation (s) {1} Cable temperature at time of initial degradation (°C) {2} Air temperature near cable at time of initial degradation (°C) {2} Time of first outright circuit failure (s) {3} Cable temperature at time of outright failure (C) First failure mode 

Cable Item: E - 7/C, 12 AWG, FR (with zinc wrap) 

IS10 E D 1-in. valve 1756 213 465 2502 345-372 HS 

Cable Item: F - 9/C, 14 AWG, FR 

IS10 F C MOV1 2312 172 421 3584 365-381 SA 

IS10 F D Large Coil 2006 245 474 2890 >400 FB 
8-6

DESIREE Fire test number Cable Item number Test position Cable monitoring unit Time of initial degradation (s) {1} Cable temperature at time of initial degradation (°C) {2} Air temperature near cable at time of initial degradation (°C) {2} Time of first outright circuit failure (s) {3} Cable temperature at time of outright failure (C) First failure mode 

Cable Item: H - 10/C, 12 AWG, FR (with zinc wrap) 

IS9 H B SOV1 2067 316 571 2429 >400 HS 

IS10 H B MOV2 2159 251 464 2798 ~334 SA 

Cable Item: J - 15/C, 12 AWG, FR (with zinc wrap) 

IS10 J B SWGR-C/T 2646 261 616 3108 ~337 SA 

During Test IS10 in particular, the cables showed signs of early degradation at somewhat lower 

cable temperatures than were observed during the Penlight tests. In one case (IS10/MOV1) 

degradation was noted when the recorded cable temperature was just 172°C and in a second 

sample (IS10/1-in. valve) at 213°C. In both of these cases the cable temperature at the time of 

initial degradation is substantially lower than the worst-case behavior noted in Penlight. The 

other samples are more consistent with the penlight tests showing degradation at cable 

temperatures of 245°C or higher. Note that the intermediate scale cable temperature results hold 

considerable uncertainty due to the nature of the cable temperature measurements. 

The intermediate scale tests include a higher degree of uncertainty regarding the test and cable 

conditions. Other than control over the rate of fuel flow to the gas burner, there is no control 

over the fire exposure conditions. Also, the cables cannot be observed during the tests due to the 

buildup of smoke in the test chamber. As a result, the timing of cable ignition and the extent of 

cable burning at any given time is largely unknown. Thermal response cable samples were 

included at each test location and adjacent to each cable sample monitored for electrical 

performance. However, the thermocouples are concentrated towards the center of the cable 

length and may not detect the actual maximum cable (or air) temperatures at any given time 

during the test. If, for example, a substantial wall plume was formed in the test cell, the cables 

could be hotter near the edges of the exposure cell than at the center. As a result, there is a much 

higher level of uncertainty regarding a cable’s actual hot-spot temperature response during the 

tests. As a result, the temperature data may not have captured the cable’s “hot spot” temperature 

and may therefore under-estimate the cables temperature conditions. 

The intermediate scale results are generally consistent with those obtained during the Penlight 

tests. There was some speculation prior to testing that the longer exposure lengths used in the 

intermediate scale tests (e.g., approximately 2.4 m) could be more functionally challenging in 

comparison to the shorter cable exposure lengths tested in Penlight (approximately 0.5 m 

effective exposure length). It seems unlikely that the intermediate scale test conditions would 

substantively impact the temperatures at which insulation cracks first appear and production of 

the conductive liquid begins as compared to the Penlight tests. However, a longer exposure 

length would generally mean that a larger number of insulation cracks would form in the 
8-7

exposed cable given the same cable temperatures. Second, the likelihood of insulation cracks in 

close proximity would increase given an increase in the overall number of cracks. With more 

cracks, the insulation resistance would be expected to degrade more quickly because each 

additional crack introduces a new possible electrical leakage pathway that would act in parallel 

with other leakage pathways (i.e., other cracks). As a result, one might anticipate a higher 

degree of electrical degradation given a longer cable exposure length and the same thermal 

conditions. 

In the balance, the cable exposure length does not appear to have been a substantive factor in the 

actual test results. The levels of degradation observed in the intermediate scale tests during the 

early low temperature degradation phase appear roughly equivalent to those observed in the 

Penlight tests. It is also worth noting that two of the cases appear to have involved outright early 

degradation failures (IS10/MOV2 and IS10/SWGR) but there was no obvious increase in the 

relative number of early degradation failures observed. 

8.2 Summary of Test Results for FR-II, FR-III and HT 

The test results for the other three Kerite insulation formulations tested, FR-II, FR-III and HT, 

are summarized in Table 8.3. Note that none of these alternate formulations showed any signs of 

early degradation. The worst-case example was the FR-II formulation which showed the first 

signs of degradation as temperatures of 341°C or higher, which is nearly 100°C higher than the 

worst-case early degradation temperatures observed for the FR insulated cables. 

Each of the cables does show different electrical failure thresholds with the HT insulation being 

the most resistant to thermally induced failure. For both the FR-III and HT cables, electrical 

failure was most typically observed only after the cable had ignited. Based on these results 

recommendations for electrical failure thresholds for each insulation type have been developed 

as discussed in Section 9.2 below. 

Table 8.3: Summary of the Penlight test results for the other Kerite insulation formulations. Test number Cable monitoring unit Time of first failure (s) Cable Temperature at time of first failure (°C) Failure mode Time of cable ignition (s) Cable temperature at time of cable ignition or shutdown (°C) Penlight shroud temperature setting (°C) 

Cable Item: B - 2/C, 10 AWG, FR-III

K12 IRMS 5486 >417 C-C 5217 435 325-445 

K13 IRMS Test ended prior to failure N/A N/A 325-405 

K17 SCDU(M) 6317 ~441 SA 6310 441 325-485 

Cable Item: C - 4/C, 10 AWG, FR-III 

K10 IRMS Test ended prior to failure N/A N/A 325-425 

K11 IRMS 5580 >422 C-G 5358 422 325-445 

K18 SCDU(M) 5259 >416 SA 5149 416 325-445 

Cable Item: G - 10/C, 16 AWG, FR-II 

K3 SCDU(M) 3968 377 SA N/A N/A 325-405 
8-8

Test number Cable monitoring unit Time of first failure (s) Cable Temperature at time of first failure (°C) Failure mode Time of cable ignition (s) Cable temperature at time of 

cable ignition or shutdown (°C) Penlight shroud temperature setting (°C) 

K22 IRMS 4907 423 C-G 4921 424 325-435 

K24 SCDU(M) 3084 Ind. SA 3084 367 325-375 

Cable Item: I - 12/C, 12 AWG, FR-III 

K19 SCDU(M) 5159 Ind. FB 4974 400 325-435 

Cable Item: K - 3/C, 6 AWG, HT 

D17-qual SCDU1 2777 Ind. FB 2412 386 375-470 

D17 SCDU1 1798 Ind. SA 1740 TC failure 430 

D17 SCDU2 1880 Ind. FB 1740 TC failure 430 

D18 SCDU1 5807 Ind. FB 5665 409 420-450 

D18 SCDU2 5665 Ind. SA 5665 409 420-450 

Table notes: 

- “Ind.” indicates that electrical failure occurred after cable ignition and cable temperatures are 

indeterminate. The temperature reported at the time of ignition is considered the last reliable 

indication of cable temperature during the test. 

- “N/A” indicates that the cable sample did not ignite so entry is not applicable. 

- “TC failure” indicates that the thermocouples experienced a functional failure and cable 

temperatures are indeterminate. 
9-1

9 CONCLUSIONS 

9.1 Conclusions Regarding Kerite FR-Insulated Cables 

As discussed in Chapter 8, two distinct failure modes are active for the Kerite FR-insulated 

cables. The first lower temperature mode is evident at cable temperatures of roughly 247–317°C 

and involves some degree of electrical insulation degradation up to and including outright circuit 

failures. This early degradation behavior was clearly evident in 18 of the 29 Penlight tests 

performed and in all six samples tested in the intermediate scale. These early degradations 

included four cases where an outright electrical failure occurred at cable temperatures of 287-

311°C (tests D13-Qual, K4, K8 and K9) and two additional cases (test D13 and D15) where 

estimated IR values fell below 1000 Ω during the early degradation period (the failure criterion 

applied when analyzing the IRMS data). 

 

The second active failure mode is manifested at much higher cable temperatures; namely, 370°C 

or greater, and commonly after cable ignition. That is, if the particular sample did not 

experience an outright failure while passing through the early degradation stage, then an outright 

failure would occur at these higher cable temperatures. 

There were three general cases among the 11 Penlight tests where this pattern of behavior was 

not observed. These exceptions are summarized as follows: 

- In four Penlight tests the initial shroud temperature set point was high enough that cable 

ignition occurred very quickly (within 2-3 minutes). As a result the cable temperatures at 

the time of failure are unknown. 

- In all three trials of Cable Item A, no evidence of early lower temperature degradation 

was observed and all three samples failed at the higher temperature range (370°C or 

higher). No explanation for the apparently anomalous behavior of this one example cable 

has been developed. 

- In four of the nine trials of Cable Item F, no evidence of the early lower temperature 

degradation was observed. However, the other five trials of Cable Item F did show 

evidence of early degradation. 

A working hypothesis to explain this pattern of behavior has been developed. Namely, the early 

degradation may be explained by the combination of the conductive liquid produced in the cable 

during heating and the cracking of the conductor insulation. Taken together, these two effects 

provide a potential short circuit path between conductors (or between a conductor and ground) at 

the location(s) of the cracked insulation; namely, the filling of insulation cracks with conductive 

liquid during early stage heating. Some additional observations relative to this hypothesis are 

discussed in Chapter 8. 
9-2

Given the relative consistency of the observed behavior, it is recommended that a temperature of 

247°C be assumed as the minimum threshold of electrical failure for Kerite FR cables. This is 

the minimum temperature at which signs of electrical degradation were detected during the 

Penlight tests. 

This recommendation may appear somewhat conservative given the Penlight data, but it allows 

for the known uncertainty associated with the short cable exposure lengths used in the Penlight 

tests. That is, the minimum cable temperature at which an outright FR insulated cable failure 

was observed in Penlight was 287°C. However, given the working hypothesis described above, 

it is likely that electrical failures will occur more readily at lower cable temperatures given a 

longer cable exposure length. For real fire scenarios the cable exposure length would generally 

be longer than that used in the Penlight tests. With a longer cable exposure length it would be 

expected that a more insulation cracks would form which would have two effects on cable 

performance. First, the likelihood that two cracks might form in close proximity on adjacent 

conductors would increase. Second, cable electrical performance would be degraded more 

severely due to the cumulative effect of multiple parallel conductor-to-conductor or conductorto-ground shorting paths. These observations do appear consistent with the intermediate scale 

tests although those tests have high uncertainty relative to the cable temperatures as discussed in 

Chapter 8. Hence, the recommended value for the electrical failure threshold is based on the 

minimum cable temperature at which substantive degradation was observed and should bound 

the effects of longer cable lengths exposed to fire. 

9.2 Conclusions Regarding FR-II, FR-III and HT Insulations 

All three of the other Kerite cable insulation formulations, FR-II, FR-II and HT, tested 

performed substantially better than did the FR insulation. None of these alternate formulations 

showed signs of the low-temperature degradation typical of the FR insulated cables. The test 

results and conclusions are summarized as follows: 

- Only one example of an FR-II insulated cable was available for testing (Cable 

Item G). Testing included three trials of that cable. The FR-II cable samples showed 

detectable signs of electrical degradation only at temperatures of 341°C or higher. 

However, the initial degradation was relatively minor and no failures were observed 

until cable temperatures exceeded 374°C (or higher). On this basis, a failure 

threshold of 374°C is recommended for FR-II insulated cables. 

- Three examples of an FR-III insulated cable were available for testing (Cable Items 

B, C and I), and all three examples performed quite consistently. The FR-III 

insulated cables showed no signs of early or low temperature degradation, failed 

consistently at temperatures of 384°C or higher, and often failed only after cable 

ignition had occurred. For the FR-III insulated cables, an electrical failure threshold 

of 384°C is recommended. 

- Only one example of an HT insulated cable was available for testing (Cable Item K). 

Over the course of five trials of that cable, no signs of early or low-temperature 

degradation were observed. The cable performed quite similar to the FR-III insulated 
9-3

cables. Electrical failures occurred abruptly at temperatures of 386°C or higher and 

often only after cable ignition had occurred. For the HT insulated cables, an electrical 

failure threshold of 386°C is recommended. 

10-1

10 REFERENCES 

1. U.S. Nuclear Regulatory Commission, Nowlen, S.P., Brown, J.W., Wyant, F.J., “Direct 

Current Electrical Shorting in Response to Exposure Fire (DESIREE-Fire): Test 

Results,” draft report, U.S. NRC, ADAMS Accession No. ML103230105, (2010). 

2. Salley, M.H., “An Examination of the Methods and Data Used to Determine 

Functionality of Electrical Cables when Exposed to Elevated Temperatures as a Result of 

a Fire in a Nuclear Power Plant,” University of Maryland, MS Thesis, 2000. 

3. NUREG/CR-5655, Jacobus, M.J., Fuehrer, G.F., Submergence and High Temperature 

Steam Testing of Class 1E Electrical Cables, May 1991. 

4. NUREG/CR-6850, Nowlen, S.P., Najafi, B., et.al., EPRI/NRC-RES Fire PRA 

Methodology for Nuclear Power Facilities, a joint NRC – EPRI publication, , EPRI TR 

1011989, Washington DC and Palo Alto CA, September 2005. 

5. SAND2010-4936, Nowlen, S.P., and Brown, J., A Preliminary Look at the Fire-Induced 

Electrical Failure Behavior of Kerite FR Insulated Electrical Cables - A Letter Report to 

the U.S. NRC/RES, Sandia National Laboratories, Albuquerque, NM, July 2010. 

6. SAND92-1404C, Nowlen, S.P. and M.J. Jacobus, The Estimation of Electrical Cable 

Fire-Induced Damage Limits, presented at Fire and Materials 1st International Conference 

and Exhibition, Sept. 24-25, 1992, Washington, DC. 

7. Inspection Manual Chapter, IMC 0308, Attachment 3, Appendix F, Technical Basis for 

Fire Protection Significance Determination Process (IMC 0609, Appendix F) at Power 

Operations, CN Number 05-007, February 25, 2005. 

8. NUREG/CR-6931, Nowlen, S. P., Wyant, F. J, Cable Response to Live Fire 

(CAROLFIRE) Volume 1: Test Descriptions and Analysis of Circuit Response Data, , 

Vol. 1, April 2008. 

9. EPRI TR 1003326, Characterization of Fire-Induced Circuit Faults – Results of Cable 

Fire Testing, EPRI, Palo Alto, CA, Dec. 2002. 

10. NUREG/CR-6776, Wyant, F.J., Nowlen, S.P., Cable Insulation Resistance 

Measurements Made During Cable Fire Tests, SAND2002-0447P, U.S. NRC, 

Washington DC, June 2002. 

11. IEEE Standard 450-2002, IEEE Recommended Practice for Maintenance, Testing, and 

Replacement of Vented Lead-Acid Batteries for Stationary Applications, 2003. 

12. ASTM Standard E603-06, Standard Guide for Room Fire Experiments, American 

Society of Testing and Materials, 100 Barr Harbor Drive, P.O. Box C700, West 

Conshohocken, PA 19428-2959, 2006. 

13. Zumdahl, S.S., Zumdahl, S.A., Chemistry, Boston, Houghton Mifflin Company, 2000. 

A - 1

APPENDIX A: TEST SUPPORT SYSTEMS 

 
A - 2

A.1 Introduction 

The appendix on test support systems provides the critical information necessary to conduct the 

experiments during both the DESIREE-Fire and KATE-Fire series. Included in the discussion 

are details on the cable monitoring equipment, circuits, data acquisition, data processing, and 

additional support systems. Since the KATE-Fire test series uses equipment from previously 

existing programs and published works (e.g., CAROLFIRE, DESIREE-Fire), this appendix seeks 

to summarize and incorporate the relevant main points found in previously published works 

without going into the same level of detail. 

A.2 Direct Current Simulation Panels 

The DCSim Panels were created for the DESIREE-Fire program in order to investigate the 

electrical performance of dc-powered circuits when their control cables are subjected to elevated 

thermal environments. This project provided a target opportunity to test in both the Penlight and 

intermediate-scale configurations. The circuits created for this testing includes: 

• Two MOV 

• Two SOV 

• One large coil 

• One 1-in. valve 

• One Switchgear trip and close 

• Intercable configuration 

These circuits were housed within three separate metal chassis and all were commonly grounded 

for each test. Nearly all the dc-circuits were used to investigate the failure modes and effects of 

Kerite; however, since there was a limited amount of the donated cable the intercable 

configuration circuit was not used. What follows is a brief description of the circuits used to 

investigate the performance of Kerite. Additional detail on each dc-circuit and the battery bank 

may be found in NUREG/CR-7100 [1]13. 

A.2.1 Direct Current (dc)-Powered Motor Operated Valve (MOV) Circuits 

The line drawing for the dc MOV control circuit may be found in Figure A.1. From this figure, 

the positive (P) and the green lamp (G) conductors are connected to the positive side of the 

battery. The negative (N) conductor is connected to the G and red lamp (R) conductors through 

individual 1800 Ω resistors. The auxiliary contacts for the open (YO1) and close (YC1) coil 

conductors on the motor controllers are normally closed. Upon actuation of YC1, the contact for 

YO1 will open and the G and R conductors will remain in the same state, namely, closed and 

open, respectively. If YO1 actuates, contact for YC1 opens, the R closes, and the G opens. Table 

A.1 identifies the conductor-to-conductor interactions required to occur within a cable sample to 

cause a specific circuit malfunction, including spurious opening of the valve. 

 

13 At the time of the printing of this document, NUREG/CR-7100 on DESIREE-Fire is pending publication.
A - 3

Figure A.1: DCSim panel layout for the control circuit on a dc MOV. 

Table A.1: Identification of specific intracable induced circuit failure modes for the dc MOV. 

Circuit Failure 

Effect 

Will occur if 

any of these 

conductors... 

Come into contact 

with any of these 

conductors... 

Notes 

Valve spuriously 

opens P, G YO1 

Loss of valve 

control N YO1, R 

Circuit fuse(s) will blow if an 

attempt is made to open the 

valve while this internal short 

condition exists. 

Loss of circuit 

power (blown 

fuse(s)) 

P, G N 

Erroneous/spurious 

valve position 

indication 

P, G R 

Loss of valve 

position indication — — Open circuit failure of conductor G or N. 

It is also worthwhile noting that no immediate discernible effect occurs if conductors P, YO1, 

YC1, or R experience an open circuit failure (conductor break) as the initial failure mode. 

G

P

YC1

YO1

R

N

SP

A

A

A

A

V

V

V

V

V

V

V

NC

NC

1800

+

-125 VDC

NO

NC

C

A

A

1800

DCSim CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

10A

10A

O

A

A

B

C
A - 4

The motor starters for MOV circuits were procured through Joslyn Clark14 and the details, 

including model numbers and description, may be found in Table A.2. 

Table A.2: Description of the motor controller from Joslyn Clark, 

250 Volts DC Max. 

NEMA 

Size Description Reference No.

1 Open Type dc Coil 2 Pole N.O. 7401-1020-12 

1 N.O. & N.C. Aux 5M65 

1 Mechanical Interlock 5999-4737 

1 Reversing Base Plate 23082.79-1 

To confirm proper circuit wiring, a procedure was followed to verify current and voltage 

readings for both circuits. The results of the testing were as anticipated; however, they did not 

reveal a defect with one of the connected motor controllers. This defect was not observed until 

a subsequent equipment analysis. 

As a part of post-test data analysis, pick-up and drop-out voltage tests were conducted for each 

of the four individual relay contactor units and the results are summarized in Table A.3. This 

was not performed before testing because the relay contactor units were delivered by JoslynClark nearly three months late. By the time the units arrived, construction of the entire set of dc 

surrogate circuits had been completed (with the exception of these relays), and all preparations 

for testing had been completed. A decision was made to measure the coil resistance for each 

unit, but to defer the pick-up and drop-out testing and proceed with testing. 

Table A.3: Coil characterizations for dc MOV. 

Device Cold Coil 

Resistance 

Average 

Pickup Voltage 

(Vdc) 

Average 

Pickup 

Current (A) 

Average 

Dropout 

Voltage 

(Vdc) 

Average 

Dropout 

Current (A) 

MOV1 (open) 154.9 29.0 0.1785 26.6 0.1625 

MOV1 (close) 154.6 89.3 0.4873 4.8 0.0263 

MOV2 (open) 155.3 50.7 0.2867 7.3 0.0420 

MOV2 (close) 155.3 N/A N/A N/A N/A 

The close contactor unit for MOV2 was found to not have a metal slug as part of its movable 

core assembly. Thus it was incapable of operating when the coil was energized. 

During the post-test examination, three of the four in-service relay contactor units tested out as 

expected, but the fourth unit, the “close” unit in circuit MOV2, failed to pick up (close) despite 

 

14 Additional information may be ascertained from the Joslyn Clark catalogue which is available at 

http://www.joslynclark.com/downloads.htm.
A - 5

application of up to 170 Vdc. An external physical inspection revealed no obvious flaw and the 

contactor could be closed manually. Also, the voltage and current observed during the pick-up 

test indicated that the relay coil was in place and operating as expected. A coil resistance 

measurement also yielded a value that was consistent with pre-test readings. 

At this point a decision was made to disassemble the non-functional unit. A second working unit 

was also disassembled for comparison. This inspection revealed that the moving core was 

missing from the non-functional unit. Figure A.2 shows the functional unit with the moving core 

in place and Figure A.3 shows the non-functional unit with the moving core absent. Figure A.4 

shows the two units side by side. The relay was received from the manufacturer without the 

moving core. An inspection was also performed for a fifth (spare) relay contactor unit, and it 

was found that the spare contactor was also missing the moving core. Hence, two of five relay 

contactor units obtained directly from Joslyn-Clark were non-functional. 

The implications for the data analysis are summarized as follows: 

• Circuit MOV1 is not effected in any way. 

• For circuit MOV2, the “open” contactor was fully functional but the “close” contactor 

was a non-functional passive coil target only. The “close” contactor was present as 

an inductive load on the circuit, but the relay would never have closed during testing. 

• The data can still be analyzed and interpreted, including for spurious actuations, but 

the following cases need to be considered: 

o Given an initial hot short to the close coil, the electrical and mechanical interlocks 

will not engage. A subsequent hot short to the open coil would cause the open 

coil to close and would trip the close coil out of the circuit via the electrical 

interlock. 

o Given an initial hot short to the open coil, the open contactor would close, 

triggering both the mechanical and electrical interlocks. A subsequent hot short 

to the close coil would behave exactly as if the close contactor was fully 

functional (i.e., there would be an indication of voltage applied to that circuit path 

but no current flow). 

o Overall, it was not possible to electrically engage (i.e., induce current flow) in 

both the open and close coils simultaneously despite the non-functional close 

contactor unit. 
A - 6

Figure A.2: Open motor controller with functional moving core for the MOV2 circuit. 

Figure A.3: Close motor controller missing the metal driver for the moving core for the MOV2 

circuit. 

Moving core present 

in operational motor 

control contactor 

unit 

Moving core absent 

from non- operational 

motor control contactor 

unit
A - 7

Figure A.4: Side-by-side comparison of the open and closed motor contactors for the MOV2 

circuit. 

A.2.2 dc-Powered Solenoid-Operated Valve (SOV) Circuits 

The line drawing for the dc SOV control circuit may be found in Figure A.5. From this figure, 

the positive (P), source (S1), and the green lamp (G) conductors are connected to the positive 

side of the battery. The negative (N) conductor is connected to the G and red lamp (R) 

conductors through individual 1800 Ω resistors. If the conductors connected to the positive side 

of the battery bank short to the solenoid (S2) conductor, a spurious operation may occur. 

The small solenoid valve is shown in its normally closed position. Table A.4 identifies the 

conductor-to-conductor interactions required to occur within test cable to cause a specific circuit 

failure mode, including spurious opening of the valve. It is also worthwhile noting that no 

immediate discernible effect occurs if conductors P, N, S1, S2, or R experience an open circuit 

failure (conductor break) as the initial failure mode. 
A - 8

Figure A.5: DCSim panel layout for a small SOV dc circuit. 

Table A.4: Identification of specific intracable induced circuit failure modes for the small SOV.

Circuit Failure Effect Will occur if any of 

these conductors... 

Come into contact 

with any of these 

conductors... 

Notes 

Valve spuriously 

opens P, S1, G S2 

Loss of valve control N S2, R 

Circuit fuse(s) will 

blow if an attempt is 

made to open the 

valve while this 

internal short 

condition exists. 

Loss of circuit power 

(blown fuse(s)) P, S1, G N 

Erroneous/spurious 

valve position 

indication 

P, S1, G R 

Loss of valve position 

indication — — Open circuit failure of conductor G. 

S1

G

R

S

N

SP

A P

A

A

A

A

V

V

V

V

V

V

V

5A

5A

SOV

1800

1800

+

-125 VDC

DCSim CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK
A - 9

The SOV circuits utilized two ASCO RedHat15 general service solenoid valves throughout the 

testing program. Information for these two solenoids may be found in Table A.5. 

Based on recommendations from the peer review committee, SOV2 used a continuous-duty 

Class H coil. Continuous-duty Class H coils are required for battery-charging circuits where 

wider voltage ranges are typically encountered. Based on the manufacturer’s literature, the Class 

H coils will accommodate continuous duty over a wider voltage range; namely, 12% over normal 

and 28% under normal rated coil voltage. For a nominal 125-Vdc coil, this translates to a 

voltage range of 90 to 180 Vdc. 

Table A.5: Description of the RedHat SOV. 

Circuit Item Series Part Order 

Number 

SOV1 Solenoid Operated Valve ASCO RedHat Series 

8320 8320G172 

SOV2 Solenoid Operated Valve with Class H 

Coil 

ASCO RedHat Series 

8320 EFHT8320G172

Also note that the wiring of the dc SOVs was not polarity-specific. That is, the two lead wires to 

the solenoid coil could be connected without consideration of the power source polarity. A 

member of the peer team clarified that dc solenoids are often configured with an integral 

(internal) rectifier, so that they will operate correctly regardless of whether the source applied is 

alternating current (ac) or dc, and regardless of the dc polarity applied. The SOVs used in 

DESIREE-Fire appear to be of this type (internally rectified). Hence, a “reverse polarity” dc hot 

short on an SOV such as those tested here would still cause a spurious operation. A reverse 

polarity short on a dc solenoid without the internal rectifier would not cause a spurious operation. 

Note that the test data has been reviewed for this effect, and no cases were observed that 

appeared to involve a reverse polarity short to the SOVs. Given the test configurations, a reverse 

polarity short would require, at a minimum, the following events to occur: 

• A positive source conductor must short to the (nominally) negative side of the valve 

coil. That is, a positive source must short to either conductor N or G as shown in the 

circuit schematic, thereby “back-feeding” a positive potential to the nominally 

negative side of the coil. Further, this short circuit must result in clearing of the 

negative fuse for this circuit (i.e., instead of the positive fuse). Note that the positive 

source could come from intracable shorting (i.e., with conductor S1) or from 

intercable shorting to a second cable. 

 

15 Additional information may be ascertained from the ASCO catalogue, which is available at 

http://www.ascovalvenet.com/AscoValvenet/Applications/LiteratureRequest/PublicSite/LRPublicWeb.aspx?action=add.
A - 10

• Because the negative fuse must clear, an independent negative energizing source 

would need to come into contact with the (nominally) positive side of the valve coil 

(conductor S2). Given the test configuration, this would require either an intercable 

hot sort or multiple shorts to ground on the negative battery potential that included 

conductor S2. 

The SOV solenoids were electrically characterized following the intermediate scale tests in order 

to determine their actual pick-up and drop-out voltage and current thresholds. Table A.6 

provides a summary of each SOV’s electrical characteristics. Note that the two valves have 

essentially identical electrical characteristics; that is, the Class H coil appears to have no impact 

on pick-up voltage, pick-up current, or drop-out voltage. 

Table A.6: Coil characterizations for small dc SOV devices. 

Device Cold Coil 

Resistance 

Average Pickup Voltage 

(Vdc) 

Average 

Pick-up 

Current (A) 

Average 

Dropout 

Voltage 

(Vdc) 

Average 

Dropout 

Current (A) 

SOV1 1280 56.9 0.042 43.8 0.033 

SOV2 1270 55.2 0.042 43.8 0.033 

A.2.3 dc-Powered 1-in. Valve and Large Coil 

Two valves were obtained for the purposes of DESIREE–Fire, namely a “1-in. valve” and a 

“Large Coil.” The line illustrations providing the overall description of the 1-in. valve circuit 

may be found in Figure A.6. From this figure, the positive (P) and the green lamp (G) 

conductors are connected to the positive side of the battery. The negative (N2) conductor is 

connected to the G and red lamp (R) conductors through individual 1800 Ω resistors. Although 

this drawing is pictured with the open and close contacts, during one of the DESIREE-Fire tests 

the R contact fused closed effectively modifying it to be a positive source. If the conductors 

connected to the positive side of the battery bank short to the solenoid (S) conductor, a spurious 

operation may occur. 

The 1-in. valve is shown in its normally closed position. Table A.7 identifies the conductor-toconductor interactions required to occur within test cable to cause a specific circuit failure mode, 

including spurious opening of the valve. It is also worthwhile noting that no immediate 

discernible effect occurs if conductors P, N1, N2, or R experience an open circuit failure 

(conductor break) as the initial failure mode. 

The line drawing for the Large Coil control circuit may be found in Figure A.7. From this 

figure, the positive (P) and the green lamp (G) conductors are connected to the positive side of 

the battery. The negative (N2) conductor is connected to the G and red lamp (R) conductors 

through individual 1800 Ω resistors. If the conductors connected to the positive side of the 

battery bank short to the solenoid (S) conductor, a spurious operation may occur. 
A - 11

The Large Coil is shown in its normally closed position. Table A.8 identifies the conductor-toconductor interactions required to occur within test cable to cause a specific circuit failure mode, 

including spurious opening of the valve. It is also worthwhile noting that no immediate 

discernible effect occurs if conductors P, N1, N2, or R experience an open circuit failure 

(conductor break) as the initial failure mode. 

Figure A.6: Line drawing of the DCSim panel layout for a 1-in. valve circuit. 

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

5A

1-INCH

COIL

1800

1800

+

-125 VDC

DCSim CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

5A NC

NO

A
A - 12

Figure A.7: Line drawing for the dc large coil circuit. 

Table A.7: Identification of specific intracable induced circuit failure modes for the 1-in. valve.

Circuit Failure Effect Will occur if any of 

these conductors... 

Come into contact 

with any of these 

conductors... 

Notes 

Valve spuriously 

opens P, G, R S 

Loss of valve control N1, N2 S, R 

Circuit fuse(s) will 

blow if an attempt is 

made to open the 

valve while this 

internal short 

condition exists. 

Loss of circuit power 

(blown fuse(s)) P, G, R N1, N2 

Erroneous/spurious 

valve position 

indication 

P, G, R R 

Loss of valve position 

indication — — Open circuit failure of conductor G. 

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

10A

LARGE

COIL

1800

1800

+

-125 VDC

DCSim CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

10A
A - 13

Table A.8: Identification of specific intracable induced circuit failure modes for the Large Coil.

Circuit Failure Effect Will occur if any of 

these conductors... 

Come into contact 

with any of these 

conductors... 

Notes 

Valve spuriously 

opens P, G, R S 

Loss of valve control N1, N2 S, R 

Circuit fuse(s) will 

blow if an attempt is 

made to open the 

valve while this 

internal short 

condition exists. 

Loss of circuit power 

(blown fuse(s)) P, G, R N1, N2 

Erroneous/spurious 

valve position 

indication 

P, G, R R 

Loss of valve position 

indication — — Open circuit failure of conductor G. 

The 1-in. valve solenoid was electrically characterized following the intermediate-scale tests in 

order to determine its actual pick-up and drop-out voltage and current thresholds. Table A.9 

provides a summary of the SOV’s electrical characteristics. Since it has no moving parts to 

determine when pick-up or drop-out occurs, the large coil was not characterized electrically. 

Table A.9: 1-in. valve solenoid and Large Coil characterizations. 

Device Cold Coil 

Resistance 

Average Pickup Voltage 

(Vdc) 

Average 

Pick-up 

Current (A) 

Average 

Dropout 

Voltage 

(Vdc) 

Average 

Dropout 

Current (A) 

1-in. coil 158.8 47.9 0.30 17.2 0.11 

Large Coil 36 N/A N/A N/A N/A 

A.2.4 4.16 kV GE PowerVac® Breaker 

A refurbished medium voltage circuit breaker configured with a 125-VDC control circuit that 

uses 20-A and 35-A fuses for the close and trip circuits was donated through the EPRI 
A - 14

collaboration. The breaker was a 5 kV class GE PowerVac®, Model VB1-4.16-250, 1200 A, 

4.16 kV. 

From the manufacturer’s summary description, the vacuum circuit breaker uses sealed vacuum 

power interrupters to establish and interrupt a primary circuit. Primary connections to the 

associated metalclad switchgear are made by horizontal bars and disconnect fingers, electrically 

and mechanically connected to the vacuum interrupters. The operating mechanism provides 

direct motion at each phase location in order to move the movable contact of the vacuum 

interrupters from an open position to a spring-loaded closed position and then back to the open 

position on command. 

The ML-18 and ML-18H mechanisms are of the stored-energy type and use a gear motor to 

charge a closing spring. During a closing operation, the energy stored in the closing spring is 

used to close the vacuum interrupter contacts, compress the wipe springs that load the contacts, 

charge the opening spring, and overcome bearing and other friction forces. The energy then 

stored in the wipe springs and opening spring will open the contacts during an opening operation. 

Closing and opening operations are controlled electrically by the metalclad switchgear or remote 

relaying. Mechanical control is provided by manual close and trip buttons on the circuit breaker. 

The closing spring may be manually charged. 

Figure A.8, Figure A.9, and Figure A.10 provide representative drawings for the new switchgear. 

PC

C1

G

R

T

SP

N2

PT

N1

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

+

125 VDC

60 A BKR

-

15A

35A

DCSim CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

15A

35A

1800

1800

A3

A5

A10

A8

A11

A9 & A12

A4 & A6

VB1 SWGR

SP

V

A

+

125 VDC

50 A BKR

-
A - 15

Figure A.8: DCSim panel layout for the control circuit on the GE VB1 switchgear dc control 

circuit. 

Figure A.9: GE VB1 4.16 kV circuit breaker elementary diagram. 

52Y 52Y 52_

SM/LS

52_

SM/LS

52Y 52_

CL/MS

CLOSE

COIL 52Y

52

b

52_

LCS

52_

IL/MS

52_

CHG

52

a

52

a

TRIP

COIL

M

7

1

3

9

7

4

L7

3

4

L5 L2

1

2

1

2

1

2

L1

L21

B

A

5 6

L6 L8

Y

Y

Y D

Y

LC

P

CC D

1

2

1

2

1

2

1

2

L3

L4

S

T

D

M

MOTOR

CLOSE SCHEME

P

P

TC

3

4

8

7

1

2

L9

L10

TRIP SCHEME

52

b

52

a

L12 L16

L11 L15

P P 9

10

11

12

INDICATION

BL1

L

R

CLOSE CIRCUIT CABLE

PC connects to L3

C1 connects to L5 & L7

N1 connects to L4 & L6

SP1 not connected

SP2 not connected

SP3 not connected

SP4 not connected

TRIP CIRCUIT CABLE

PT not connected

G connects to L11

R connects to L15

T connects to L9

SP1 not connected

SP2 not connected

N2 connects to L10, L12 & L16

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

20 19 18 17

24 23 22 21

CONNECTION PANEL “L”

VIEW FROM BACK OF BREAKER

Elementary Diagram for GE VB1 Switchgear 125VDC Control Circuit

(from Fig. 18 in GEK-86132G)
A - 16

Figure A.10: GE VB1 4.16 kV circuit breaker connection diagram. 

A.2.5 The Battery Bank and Power Distribution System 

A.2.5.1 Overview 

The battery bank was built to supply a nominal 125-Vdc power source. The batteries were 

obtained through the EPRI memorandum of understanding (MOU) and were being taken out of 

service from the North Anna Nuclear Station Technical Support Center as a part of preventative 

maintenance. The battery cells had reached their nominal end-of-life conditions, but were still in 

serviceable condition and were transported to Sandia National Laboratories (SNL) for use in this 

test project. 

A.2.5.2 Basic Design Parameters 

The dc power supply battery bank was constructed using a set of Exide model ES-13 calcium 

alloy flat plate, wet-acid, nominal 2.1-Vdc uninterruptible power supply (UPS) battery cells. 

Each cell contains approximately 9.1 liters (2 gallons) of sulfuric acid as the electrolyte. A total 

of 60 cells were used in the main battery bank and were connected intercell in series using leadplated copper bars. Eight spare cells were also available, but were not used in the program as no 

cell failures occurred during testing. 
A - 17

Before installation, all of the individual battery cells were tested by an independent testing 

laboratory using IEEE Standard 450-1995 [2]. All of the cells used in testing, including the 

spare cells, were certified as being in good working condition. 

Cell handling was performed in accordance with IEEE Standard 484-2002 [3]. Load/capacity 

calculations were performed in accordance with IEEE Standard 485-1997 [4]. 

The basic design parameters of the battery bank are summarized as follows: 

• Cell type: Exide ES-13, calcium alloy acid-filled cells 

• Nominal open circuit voltage: 2.06 V 

• Nominal cell float voltage: 2.17–2.26 V 

• Total cell count in main battery bank: 60 

• Nominal bank float voltage: 125 V 

• Available short circuit current at the battery terminals: approximately 13,680 A 

• Cell-to-cell connections: Exide lead-plated copper bars and bolts 

Table A.10 provides additional physical information for the individual battery cells as provided 

by Exide. 

Table A.10: Exide battery cell description from the manufacturer's literature. 

Model 

type

Overall dimensions (mm) Weights (kg) Volume (liters)

Length Width Height Cell Only Electrolyte Electrolyte only

ES-13 124 274 475 36.7 9.1 7.6

A.2.5.3 Battery Banking Housing and Connections 

The battery cells were installed in a portable transportainer providing personnel protection, spill 

containment (in the event of a cell leak or rupture), environmental protection to the cells, and the 

ability to transport the cells between testing sites. The transportainer was provided with both 

heating and cooling to ensure that the cells did not deviate from the manufacturer-specified 

operating or storage conditions. Figure A.11 provides a nominal schematic of the battery cell 

layout within the transportainer. 

Intercell connections were removed during transport. Once in place on site, the intercell 

connection plates were installed in accordance with manufacturer specifications. The 

connections were also tested for continuity using a micro-ohm meter and in accordance with 

manufacturer specifications. Any out of compliance connections were reworked to ensure an 

acceptable level of terminal-to-terminal resistance and consistency between connections. Figure 

A.12 provides a photograph of the battery cells during work to install the cell-to-cell connector 

plates. 
A - 18

Figure A.11: Battery enclosure layout. 

Figure A.12: Photo of the battery assembly. 

An automatic charging system capable of recharging the cells over night was also installed. The 

charger was capable of providing both a freshening charge and float charging. All cells received 

a freshening charge when they arrived at SNL. Once installed, the battery bank also received a 

freshening charge. The bank was then recharged periodically throughout the course of testing. 

In general, the bank would be recharged at least weekly during the small-scale tests where the 

loads on the cells were relatively modest. During the larger--scale tests, the cells would be 

charged as a minimum after completion of two tests. The charger was secured and disconnected 

from the battery bank during testing. 

The battery bank was ungrounded, although ground faults during testing were expected and a 

ground-fault monitoring circuit was included in the test design and monitored during testing. 
A - 19

A.2.5.4 Power Distribution 

The battery bank was connected to the DCSim panels via a series of fuses and breakers. The 

power distribution system is illustrated schematically in Figure A.13. In order, progressing from 

the battery cells to the DCSim panels, were the following electrical features: 

• The main terminal of the battery bank was connected to the power distribution system 

via two single-conductor 4/0 power cables (the battery bank was ungrounded). 

• A primary disconnect switch. 

o 250 - 125 Vdc bus - 200-A contacts. 

• 200-A fuse on each of the main output cables. 

o Two each Littelfuse fuse, part number JTD-200ID. 

• A dc breaker panel with separate breakers for each test branch circuit. 

o Two-pole dc circuit breakers rated at 250 Vdc. 

o Circuit breaker capacities range from 30 A to 60 A depending on the specific 

circuit. 

• 3/C, 8 AWG power cables connecting the dc breaker panel to the DCSim panels 

(each test circuit was serviced by an individual cable). 

• A fuse on each incoming power feed cable to the DCSim panel. 

o Fuse sizes are specific to each test circuit. Refer to the corresponding circuit 

descriptions for details. 

• 12 AWG cables connecting the DCSim panels to the test cables. 
A - 20

Figure A.13: Power skid schematic for the dc battery bank. 
A - 21

Figure A.14: Battery bank power connection layout for the intermediate-scale tests. 
A - 22

Figure A.14 provides a second schematic of the connections and cable lengths for each 

connection from the battery to the DCSim panels and to the test cables, including the lead cable 

to the switchgear unit itself. This figure includes specification of each cable’s wire gauge and 

length (e.g., for use in calculating voltage drops). 

It should be noted that for each of the test circuits, the primary circuit protection is provided by 

the individual circuit fuses. These fuses are intended to represent typical plant practices. The 

other circuit protection features (i.e., the breakers, 200-A main output fuses, and primary 

disconnect switch) are all provided for personnel protection and safety. These additional 

protective devices were selected to provide appropriate breaker-fuse coordination, but are not 

intended to represent in-plant practice. 

A.2.5.5 Battery Bank Ground Fault Detection Circuit 

The dc battery bank was nominally an ungrounded power supply system. A ground fault 

detection circuit provided the opportunity to monitor for shorts between the battery bank and 

ground (ground faults). Figure A.15 illustrates the line drawing for this circuit. 

Figure A.15: Line drawing for the dc ground detection circuit 

In practice, the ground detection circuit provides a monitored high-resistance (10,000 Ω) path 

between each side of the battery bank and the local ground plane. Under normal conditions (i.e., 

no ground faults present) the voltage monitor on the far right will read the full 125 Vdc battery 

voltage, and each of the other two voltage transducers, those measuring across the two ballast 

resistors, will read exactly one-half that value. Should a ground fault occur on either side of the 

battery bank, the overall bank voltage will not change; however, the voltages across the ballast 

resistors will both change. If, for example, there is a ground fault on the positive leg of the 

battery bank, the voltage across the positive-side ballast resistor will drop to zero, and that across 

the resistor on the negative side will rise to the full battery bank potential of 125 Vdc. 

V

V

10K

10K

+

-125 VDC

GROUND DETECTION PANEL

FROM DISTRIBUTION CIRCUIT 

BREAKER PANEL

V
A - 23

To ensure proper operation, all experimental systems and equipment were connected to a 

common ground plane (e.g., facility ground). The voltage transducers for the various dc circuit 

simulator panels measured circuit path voltages relative to this same common ground plane. 

A.3 Alternating Current (ac) Powered Surrogate Circuit Diagnostic Unit 

Figure A.16 shows the simulated MOV control circuit that was employed during the 

CAROLFIRE tests. An ac power source, an 1800 Ω resistor representing an indicator lamp, and 

two relay coil targets are connected to the simulated circuit. A seven-conductor cable connected 

to the Surrogate Circuit Diagnostic Unit (SCDU) is the device under test. Although it is possible 

to encounter a circuit in a NPP that is supplied with power directly for a power source, typically 

a CPT is used. In the SCDU chassis, four different circuits are used to monitor a cable’s 

performance throughout fire exposure. The primary difference between each circuit is the CPT 

size. SCDU1 uses a 100 VA CPT, SCDU2 uses a 150 VA CPT, SCDU3 uses a 200 VA CPT, 

and SCDU4 uses a 75 VA CPT. All CPTs are grounded. Additional information may be found 

in NUREG/CR-6931 [5]. 

Figure A.16: Simulated ac MOV control circuit, with CPT, for typical cable tests. 

The motor starters used during CAROLFIRE were, in hindsight, found to require far less motive 

power to lock in and hold a spurious actuation signal than anticipated. The intent in 

CAROLFIRE had been to obtain motor starters that required a nominal 100 VAC of power to 

2

Conductor

1

4

3

6

5

7

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

NC

NC

1800

K-2

K-1

A

A

1800

AC SCDU CABLE UNDER TEST CONTROL POWER 

TRANSFORMER120 VAC

3A

10

2

(White)

Conductor

1

(Black)

4

(Green)

3

(Red)

6

(Blue)

5

(Orange)

7

(White-Black)

9

8

7

3

4

5

2

1

6

5

6

4

3

2

1

7

LEAD CABLE

Junction Box

SCDU 

Terminal 

Block

SCDU 

Terminal 

Block

N/C

N/C
A - 24

lock in a relay actuation. In practice, while the relays obtained were cited as 100 Vac relays, it 

actually took a much smaller power level to lock in an actuation (on the order of 60 Vac). As a 

result, CAROLFIRE was unable to resolve one of the original Regulatory Information Summary 

(RIS) 2004-03, “Risk-Informed Approach for Post-Fire Safe-Shutdown Circuit Inspections,” 

unresolved issues; namely, that item related to how CPT size relative to the nominal circuit 

required power would impact spurious actuation likelihood. The CPT units used in 

CAROLFIRE were sized against the anticipated 100-Vac power requirement for the relays. 

Given the actual power requirement of the relays, the CPTs were, in effect, over-sized. As a 

result, the CAROLFIRE tests did not experience the same type of CPT power drawdown 

observed in the original NEI/EPRI testing program. 

The existing motor starter relays were replaced with Joslyn-Clark16 (current part number is 

T30U031) for the DESIREE-FIRE test series. SCDU1 and SCDU2 were replaced with the 

original motor starter sets used during the NEI tests while SCDU3 and SCDU4 were replaced 

with newly purchased, identical sets of these controllers. All of the sets of motor starters 

included the mechanical interlock devices except SCDU2, which was used as shipped by EPRI. 

These interlocks more realistically represented the actual plant circuit implementation and 

provided a new aspect to the test data not previously explored. 

The MOV contactors were electrically characterized following the intermediate-scale tests in 

order to determine their actual pick-up and drop-out voltage and current thresholds. Table A.11 

provides a summary of each MOV contactor’s electrical characteristics. 

Table A.11: ac MOV contactor coil pick-up and drop-out characteristics. 

Device 

Average Pickup Voltage 

(Vdc) 

Average 

Pick-up 

Current 

(A) 

Average 

Drop-out 

Voltage 

(Vdc) 

Average 

Drop-out 

Current 

(A) 

SCDU1 (T5) 93.9 0.07 71.7 N/A 

SCDU1 (T6) 80.5 0.08 67.1 N/A 

SCDU2 (T5) 81.1 0.08 60.1 N/A 

SCDU2 (T6) 79.7 0.08 69.5 N/A 

SCDU3 (T5) 82.3 0.09 64.6 N/A 

SCDU3 (T6) 83.2 0.08 57.5 N/A 

SCDU4 (T5) 85.1 0.08 59.7 N/A 

SCDU4 (T6) 85.0 0.08 57.2 N/A 

 

16 Note that the EPRI test report (TR-1003326, page 4-13) cites “AO Smith (Clark Controls Division) Catalog #30U031” as the 

make and model of the motor starters used in that test program. AO Smith has since merged with Joslyn controls. The combined 

company is known as Joslyn-Clark Controls. The same model motor starter relays are sold under the Joslyn-Clark brand using 

essentially the same catalog number (T30U031).
A - 25

A.3.1 Multiple SCDU Configuration 

In general, all the SCDU circuits are wired identically with the only differences being the CPT 

size and motor controller condition (i.e., new or from the NEI tests). For the KATE-Fire series 

of tests, multiple SCDU circuits were used on one cable sample. In Appendix B, tests utilizing 

this multiple SCDU configuration are identified by “SCDU (M)” in the table for test parameters. 

The use of multiple SCDU circuits was intended to maximize the potential source to target 

combinations and to aid in identifying the precise source and target interactions. For some of the 

tests, specifically those involving cables with higher conductor counts (i.e., seven conductors or 

greater), modified voltage sources were used to further identify source-to-target interactions as 

well as source-to-source interactions. Within the SCDU chassis at the terminal block, a resistor 

was placed between a source (e.g., terminal two) and passive target (i.e., terminal four). A 

conductor was connected to the passive target was then monitored for performance. This is 

depicted in Figure A.17. 

The remaining conductors within the test cable were connected to other SCDU circuits. In 

Appendix B, the conductor designation was presented by the test cable conductor number, 

conductor color, SCDU circuit number, SCDU circuit pathway, and notes. An example of 

conductor designation table may be found in Table A.12 which was taken from Test K1. As 

previously noted, Conductor 1 is a source conductor which was modified to provide 60 V. 

1

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

NC

NC

K-2

K-1

A

A

1800

AC SCDU CONDUCTOR BEING 

MONITORED

CONTROL POWER 

TRANSFORMER120 VAC

3A

10

2

(White)

Conductor

1

(Black)

4

(Green)

3

(Red)

6

(Blue)

5

(Orange)

7

(White-Black)

9

8

7

3

4

5

2

1

6

5

6

4

3

2

1

7

LEAD CABLE

Junction Box

SCDU 

Terminal 

Block

SCDU 

Terminal 

Block

N/C

N/C

1800
A - 26

Figure A.17: Modified SCDU circuit with a resistor between a source conductor and the passive 

target. 

Table A.12: Conductor designation for Item E, Test K1 

Kerite 7/C, 12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4

2 White 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

3 Red 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

4 Green 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

5 Orange 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

6 Blue 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

7 White/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5

Zinc Wrap NA 3 G7 Grounded to tray, but not monitored

A.4 Insulation Resistance Measurement System 

The Sandia National Laboratories (SNL) Insulation Resistance Measurement System (IRMS) is a 

patented system that enables the real-time monitoring of insulation resistance in a cable or cable 

bundle by sequentially energizing conductor pairs and observing the voltage states. Through 

easily developed mathematical relations, one can then calculate the corresponding resistances. 

The resulting time series of resistances thereby allow identification of adverse developments in 

the cable bundle at certain instances in time. Additional information may be found in 

NUREG/CR-6776 [6]. 

A.4.1 Theory of Operation 

The concept is based on the assumption that if one were to impress a unique signature voltage on 

each conductor in a cable (or cable bundle) then by systematically allowing for and monitoring 

known current leakage paths it should be possible to determine if leakage from one conductor to 

another, or to ground, is in fact occurring. That is, part of or the entire voltage signature may be 
A - 27

detected on any of the other conductors in the cable (or in an adjacent cable) or may leak to 

ground directly. 

To illustrate, consider a three-conductor (3/C) cable as shown in Figure A.18 (for now we will 

neglect leakage directly to ground). If a known voltage is applied to conductor 1, then the degree 

of isolation of conductors 2 and 3 from conductor 1 can be determined by systematically opening 

a potential conductor-to-conductor current leakage path and then logging the voltages of each 

conductor in turn while conductor 1 is energized. Determining the insulation resistance between 

conductors 1 and 2 (R1-2) at the time of voltage measurement on conductor 2 (V2) is a simple 

calculation employing Ohm's law: 

I1-2 = V2 / R 

and 

R1-2 = (V1 / I1-2) – R 

where I1-2 is the measured current flow between the conductors and R is the known value of the 

ballast resistors built into the system. In the same way, the insulation resistance existing between 

conductors 1 and 3 at the time V3 is measured can be determined. Continuously switching 

between the two conductors and recording the voltage drop across the ballast resistor R at each 

switch position yields a time-dependent history of R1-2 and R1-3. (Of course an alternate method 

would be to connect a resistor/voltmeter assembly to both conductors 2 and 3 simultaneously and 

keep a continuous record of the two voltages. This approach quickly becomes unwieldy as the 

number of conductors increases.) 

Figure A.18: Simple insulation resistance measuring circuit. 

The above method alone does not describe the isolation existing between conductors 2 and 3 

(because conductor 1 is always the energized conductor). However, by sequentially energizing 

each conductor and reading the impressed voltages on the remaining conductors one can 

determine the relative resistance existing between any conductor pair (see Figure A.19). 

This concept evolved to include the two sets of controlled switches, one set on the input side (i) 

and one on the output side (j) of the circuit. One switch on the voltage input side is closed 

(thereby energizing one conductor) followed by the sequential closing-measurement-opening of 
A - 28

each measurement side switch. Each sequential switching configuration measures leakage 

currents between one energized “source” conductor and one non-energized “target” conductor, 

and the various pairs are systematically evaluated in sequence. 

Figure A.19: Circuit for measuring insulation resistance between any conductor pair in a cable. 

The insulation resistance between pairs of conductors can be determined in the same way as 

discussed above. Note that when the input and measurement side switches are connected to the 

same conductor (i = j), the full input voltage will be measured across R. Since this provides no 

useful information about the isolation existing between any of the conductor pairs, these 

measurements can be ignored for the purpose of determining IR. (The presence of the full 

voltage, Vj = Vi, does however indicate conductor continuity and otherwise could be useful in 

identifying an open circuit condition.) 

This approach is fine as long as the cable can be kept electrically isolated from ground. If that is 

not possible (or not desirable, e.g., because short to ground failures are of interest) then changes 

to the design (simple ones) and resistance calculations (significant) are required. 

Figure A.20 shows how the number of possible leakage paths for each of the three conductors in 

the previous example changes when a ground path is considered. By adding a path to ground for 

each conductor, the complexity of determining the insulation resistance between pairs of 

conductors has grown from one resistance determination to now having to determine three 

resistances for each pair of conductors. A circuit change is required to enhance the number of 

independent measurements so as to retain a solvable problem. The revised circuit is shown in 

Figure A.21, and includes a ballast/load resistor on the input side in addition to the output side 

ballast/load resistor. 
A - 29

Figure A.20: Resistive leakage paths for each conductor with a ground present. 

Figure A.21: Insulation resistance measuring circuit with ground paths. 

The calculation of the three resistances for each conductor pair (one conductor-to-conductor path 

and each of the two conductor-to-ground paths) requires the measured voltages (Vi and Vj) for 

two complementary switching configurations. For example, the complement for the case 

illustrated in Figure A.21 is shown in Figure A.22. As illustrated in Figure A.21, conductor 2 is 

connected to the input side and conductor 3 is connected to the measurement side. The 

complementary case shows conductor 3 on the input side and conductor 2 on the measurement 
A - 30

side (shown in Figure A.22). This complementary pair provides four separate voltage readings 

that can be used to determine the three resistance paths affecting these two conductors; namely, 

R2-3, R2-G, and R3-G. 

Figure A.22: Complementary IR measuring circuit with respect to the circuit shown in Figure 4. 

The equations for determining the three resistances for this case are as follows: 

R2-G = [Vj2Vj3 - (V - Vi2)(V - Vi3)] / [(Vi3 / Ri - Vj2 / Rj)Vj3 - (Vi2 / Ri - Vj3 / Rj)(V - Vi3)] 

R3-G = Vj3 / [(Vi2 / Ri - Vj3 / Rj) - (V - Vi2) / R2-G] 

R2-3 = [(V - Vi2) - Vi3] / [(Vj3 / R3-G) + (Vj3 / Rj)] 

This concept is scalable for virtually any number of conductors in a cable or bundle of cables. 

Another advantage is that only the two voltage measurements for each switching configuration 

need to be recorded in real time; determination of the resistances can be deferred until after the 

test has been completed. This is the basic concept utilized in the design and application of the IR 

Measurement System. 

A.4.2 Design Features 

As configured for CAROLFIRE, each IRMS can monitor the insulation resistance of up to 

fourteen separate conductors. The limit of fourteen conductors was based on the capacity of the 

internal memory of the programmable logic control (PLC) units. In practice the system was 

typically run with fewer active channels. This is because the total cycle time increases 

exponentially as the number of monitored conductors increases. The goal was to keep cycle 

times as short a practical. A schematic diagram of the complete system is provided in Figure 

A.23. 
A - 31

AC

V1

V2

Computer PLC

Disconnect

5 A

100 

Power

Lamp

Relay 

Controlled 

Contacts

Wiring Harness

Wiring Harness

Cable Under 

Test

Data Bus

Data Bus

Data Bus

Relay 

Controlled 

Contacts

100 

Figure A.23: Schematic diagram of the IR Measurement System. 

A.4.3 Operation 

Operation of the SNL IR Measurement System is a relatively simple matter of connecting the 

two wiring harnesses to each end of the test cable bundle, turning on power to the main control 

cabinet, starting up the control software on the computer, and starting the IR measurement 

program by pushing the “Run” button. 

Connection of the wiring harnesses to the test cable during the KATE-Fire tests was 

accomplished using commercially available wire nuts. It is important that each end of a specific 

conductor in the test cable be connected to the corresponding conductors in both wiring 

harnesses. For example, the conductors marked “1” in each wiring harness needed to be 

connected to the ends of the same conductor in the test cable. This also applied to the conductors 

marked “2” through “N” in the harnesses, where N is the total number of conductors being 
A - 32

monitored during a given test. Proper connections are checked by performing a continuity check 

of the pairs of harness conductors at the patch panel ends of the wiring harnesses. 

A.4.4 Data Recording, Analysis, and Uncertainty 

Raw data is written initially to a simple text file in a specific format and order. The raw data files 

are preserved for archival purpose. For purposes of analysis, data from the raw files are imported 

into an ExcelTM spreadsheet and the necessary IR calculations are performed to determine the 

IRs as part of the post-test data analysis. The resulting IR data can then be used to determine the 

nature (e.g., conductor-to-conductor versus conductor-to-ground) and order (i.e., which 

conductors shorted and when) of any short-circuit failures observed. The data analysis can also 

include the generation of IR versus time plots for each conductor in each test. 

Some notes regarding IRMS sensitivity and uncertainty are also in order. The IRMS as 

configured for CAROLFIRE was intended to focus on lower IR values at the cost of sensitivity 

to high IR values. The maximum IR that will be recorded by the IRMS as configured for 

CAROLFIRE is approximately 3x105

Ω regardless of the actual IR value. In reality, cable IR 

values for an undamaged cable are typically much higher than this. This should be noted when 

reviewing the test results. 

In terms of general system accuracy, a comprehensive assessment of the overall uncertainty 

associated with the new IR system has not been undertaken. The sources of uncertainty would 

primarily be associated with the voltage monitoring equipment that measures the voltage drop 

across the two ballast resistors in the system. A general assessment of system accuracy was made 

as a part of the system “proof of operation” testing during CAROLFIRE. This involved the use 

of known-value resistors inserted across specific conductor/circuit paths with the IRMS then 

measuring the resulting ‘IR’ value. The focus of CAROLFIRE testing was on lower IR values 

(those associated with cable failure); hence, resistors ranging from 10 to 5000 Ω were used in 

this assessment. In all cases the IRMS reproduced the known resistance values to within ±3%. 

A second point to note is the fact that IR estimates are based on the manipulation of 

corresponding data pairs and this introduces an additional source of measurement uncertainty 

that is particularly relevant to periods of rapid change in the cable IR. That is, for any given pair 

of conductors (say C1 and C2), the IR for C1-to-ground, C2-to-ground, and C1-to-C2 are 

estimated based on the analysis of two measured data points – a complimentary pair of data 

points. The first of this complementary pair monitors current leakage given that C1 is energized 

and C2 is connected to the system return path. The second of the complimentary pair monitors 

leakage currents given that C2 is energized and C1 is connected to the system return path. These 

two data points must be taken at separate points in time because the two conductors must be 

separately and individually energized to obtain the needed leakage current data. This time 

separation is the source of the potential added uncertainty. 

In practice, the system control software collects the complimentary pair data points in immediate 

sequence for all conductor pairings. None the less, the two data points will still be separated in 

time, typically by 3 - 10 seconds depending on the system cycle time. This separation leads to an 

added level of measurement uncertainty that is most pronounced in cases where the IR is 
A - 33

changing quickly (e.g., as a cable is cascading to failure). The magnitude of the error cannot be 

estimated generically because it depends entirely on how large an IR change occurs between the 

times that the first data point is taken and when the second data point is taken. 

Overall, this source of uncertainty is not seen as significant in the context of CAROLFIRE 

because the focus here is placed on the gross failure behavior and mode of failure. These 

behaviors would not be masked by the added uncertainty associated with the separation of the 

complimentary data point pairs in time. However, the exact IR values during times of rapid IR 

transition do contain an inherently higher level of uncertainty than do those values measured 

during times of relative IR stability. 

A.5 Other Systems and Additional Information 

This section of the appendix is dedicated to the other support systems that were necessary for the 

successful implementation and completion of the experimental series. 

A.5.1 Transducers 

A.5.1.1 Current Transducers 

A note should be made regarding the current transducers17 used for monitoring the dc-powered 

test circuits. The transducers were based on Hall-effect current probes. Hall-effect probes were 

selected mainly because they are non-intrusive. Duke Energy had used current shunts in its 

testing. Shunts are low-resistance devices inserted into a circuit path that induce a small voltage 

drop proportional to current flow. Measuring the voltage drop provides a measure of current 

flow. In the Duke Energy tests these shunts proved problematic, in some cases failing due to 

sustained short-circuit currents. The EPRI peer team also expressed concern that the presence of 

shunts in the various circuit paths could act to limit short-circuit currents, potentially 

compromising or altering the fuse-blow behavior for the circuits. 

The current transducers were selected in two sizes. Most had a range of +/– 35 Adc (Ohio 

Semitronics Model CTL-51/35, signal conditioner Model CTA201RX5), but the main input 

power leads to each circuit were also equipped with larger +/– 500 A transducers (Ohio 

Semitronics Model CTL-601/500, signal conditioner Model CTA201X5). The intent was for the 

smaller transducers to pick up the smaller currents associated with normal circuit operation and 

early faulting behavior, and the larger transducers would pick up the higher-current behavior 

anticipated as gross cable failures occurred. Through the course of testing, three separate issues 

arose that impact the analysis and interpretation of the test data. 

The first issue encountered was an apparent drift in the zero-point offset of the transducers 

between the beginning and the end of a given test, and between the end of one test and the 

beginning of the next test. This problem was observed early during the Penlight test series. The 

 

17 All transducers were procured through Ohio Semitronics. Additional information may be ascertained from their catalog found 

on their website: https://www.ohiosemitronics.com/.
A - 34

supplier’s technical support was contacted and the source of the problem was identified. The 

Hall-effect sensors are basically magnetic coils that react to the fields created by the flow of 

electrical current producing a proportional voltage signal. When these devices are subjected to 

dc current flows, they will retain a certain degree of residual magnetism that is reflected as a 

non-zero voltage output. The magnetism will fade over time, and can be reversed by sending a 

reverse current signal through the pick-up core, but is an inevitable, but unadvertised, aspect of 

the devices when used for dc circuits. A separate drift existed during the first few minutes that 

instrument power (i.e., 120 VAC to turn on the equipment) was applied. These two unique 

occurrences prevented the uniform application of a zero-point offset. 

These issues were discussed among the full peer team and potential options were explored. One 

option was to replace the Hall-effect transducers with shunts, but this was rejected for the same 

reasons that Hall-effect transducers were selected in the first place (as described above). Instead, 

a decision was made to continue the test program using the Hall-effect transducers and to deal 

with the offset issue in data analysis. To support the required data analysis adjustments, the 

testing protocol was modified in two ways. First, the transducers were energized up to 30 

minutes before the beginning of a test to ensure that they were fully “warmed up” before testing. 

Second, data logging was initiated before energizing the test circuits and a set of baseline test 

data without any current flow was collected. Third, once the test circuits were energized (i.e., 

the connections to the battery bank were closed) an additional period of baseline data logging 

was allowed. Finally, after the completion of a given test, a period of post-test data was gathered 

with the battery engaged and continuing until after the battery bank was disconnected from the 

circuits. 

The analysis of test data has “corrected” the current transducer data by subtracting out the pretest, pre-battery initiation, zero current offset value for each transducer. That is, the pre-test zero 

condition data are used to calculate an average zero-point offset for each current transducer and 

that value is subtracted from all test readings. Note that this approach provides a nominal 

correction but is imperfect. This is because, as noted, the zero-point offset drifts through the 

course of a test depending on the current flow experienced by the transducer. No attempts were 

made to correct the data beyond reflecting the pre-test offset. The result is that the current 

measurements at the end of the test may indicate a small current flow even after the circuits are 

fully de-energized. 

The second issue identified was related to transducer sensitivity. The 35-A transducers were 

chosen at the outset because the peer team was interested in the characteristics of the short circuit 

currents, which were expected to be much larger than the normal circuit operating currents. 

However, this meant that the transducers were not especially sensitive to the normal circuit 

operating currents (typically 1 A or less). The early tests also showed that the transient short 

circuit current pulses were simply too fast for the data logging system to fully catch (i.e., the 

transducers would “see” the fault, but there was no assurance that the true peak current was 

being captured). After discussion with the peer team, a decision was made to increase the 

sensitivity of the current transducers by looping the conductors repeatedly through the Halleffect sensor coils. That is, by looping a conductor through the transducer five times, the signal 

strength sensed by the transducer is multiplied by five. In this manner, all of the 35-A 

transducers were amplified by a factor of five (five loops) and the 500-A transducers by a factor 

of two (two loops). This amplification effect was reversed during data processing so that the 
A - 35

processed data files and all of the plots presented in this report show the corrected data and the 

actual (corrected) current values. 

The final issue that was identified for the current transducers impacted the larger 500-A 

transducers only. The data from early tests showed that these transducers did not appear to be 

picking up the current signals at all. Diagnosis of the installed transducers showed that they 

were properly wired and that they could detect a steady current flow as expected. However, even 

after amplification of the signal by a factor of two, the transducers still appeared insensitive to 

the current transients. That is, even when a 35-A transducer (effectively reduced to +/-7 A 

transducers by the amplification) saturated, the 500-A transducers will not show a corresponding 

current flow. Several measures were taken in an attempt to address this issue. The final measure 

taken was to shift all of the 500-A transducers to a data logging system capable of much higher 

logging speeds (100 Hz). The system used for monitoring the high-ranged current transducers 

was, in fact, the system normally used to record data from the SCDU circuits. Even this change 

did not yield the desired result. Again, operability of the revised data logging system was 

verified, but still the 500-A transducers were not providing meaningful data signals when the 

transient short circuits were observed. The root cause of this issue has not been traced. It is 

thought that the larger Hall-effect coils may simply not be fast enough to respond to the transient 

faulting behaviors that seem to be manifested in tenths of a second. Overall, the 500-A 

transducers provided little or no data of value. 

A.5.1.2 Voltage Transducers 

Two types of voltage transducers were used for each circuit. When directly fed from a pole off 

the battery, a unidirectional transducer (Ohio Semitronics Model VTU-005X5) was used for 

monitoring the voltage. Typically, as an example, positive and negative source conductors were 

monitored using these types of transducers. 

When a conductor was not tied to a specific battery terminal, such as a spare, a bi-direction 

transducer (Ohio Semitronics Model VT7-005X5-11) was used to monitor the voltage. This 

provided an opportunity to learn how the conductor was being affected by the other failing 

conductors. 

A.5.2 Fuses, Fuse Holders, and Terminal Blocks 

The fuses for the dc circuits were ordered through Ferraz-Shawmut.18 The MOV circuits were 

fused with 10-A, fast-acting, midget fuses (Model Number ATM10) and connected with a twopole fuse block (Model Number 30352). The SOV circuits were typically fused with 5-A, fastacting, midget fuses (Model Number ATM5). The 1-in. valve and the switchgear close circuits 

were fused at 15 A using the ATM15, fast-acting, midget fuses. The large coil was fused with 

25-A, fast-acting, midget fuses. The switchgear trip circuit was fused at 35 A, Model Number 

FRZ A2Y35-1. 

 

18 Additional information on the Ferraz-Shawmut fuses may be ascertained from their website at http://us.ferrazshawmut.com/.
A - 36

Except for the 35-A fuses on the switchgear circuit, the fuses were housed within two-pole fuse 

blocks (Model Number 30352). The 35-A fuses were connected by two-pole fuse blocks, Model 

Number 20606. 

The terminal blocks (Buchanan Model 223) used in each circuit were rated for up to 600 VDC. 

A.5.3 Thermocouples 

This test series provided additional cable thermal response data for the fire model improvement 

effort started in the CAROLFIRE test program.19 In this particular program, providing cable 

thermal response data was a secondary objective. However, measurements of the cable thermal 

response are important to characterize the environmental conditions leading to the failure, and 

additional data in this regards is considered quite valuable. As a “target of opportunity,” cable 

thermal response data was gathered during the tests in a manner similar to that employed in 

CAROLFIRE, albeit with somewhat less instrument density. 

As noted for CAROLFIRE, it is not appropriate to instrument any single cable for both thermal 

and electrical response. This is because installation of a thermocouple on, or within, a cable 

could impact the electrical failure behavior. Instead, the approach to be applied involves 

mirroring a cable being monitored for electrical performance with a second cable (in an adjacent 

or symmetric location) that will be monitored for thermal response. Figure A.24 provides a 

graphical depiction of this dual-cable setup. In the majority of the small-scale tests, however, the 

orientation more often resembled Figure A.25. 

Figure A.24: Example thermocouple arrangement for temperature monitoring of sevenconductor cable located near the electrically monitored cable in tray. Cables will be in contact 

during conduit tests. 

 

19 CAROLFIRE Final Report, 2007.

~25mm.

Electrically Monitored Cable Temperature Monitored 

Cable
A - 37

Figure A.25: Alternative orientation for the two electrically monitored cables and the thermally 

monitored cable. 

Thermocouples measured the thermal response of cables upon heating. In Penlight, Type K 

thermocouples placed just below the outer cable jacket were used for cable thermal response 

monitoring, a technique proven during the CAROLFIRE tests. In this process, a small slit is cut 

in the jacket, allowing insertion of the thermocouple bead. The bead itself can typically be 

inserted to a distance of approximately 2.5 to 10 cm along the length of the cable, placing it well 

away from the cut in the outer jacket. Placement distance does vary depending on the cable type. 

The slit was then closed and secured with a single layer of fiberglass tape. 

For the armored cables, a pilot hole was drilled through the armor to allow for the insertion of a 

thermocouple next to the conductors. After the hole was drilled, a probe was used to further 

widen the gap for the thermocouple. In similar fashion, the bead was inserted approximately 1 to 

4 in. and the pilot hole was sealed with fiberglass tape. 

Where it was necessary to do so, such as in the Kerite® tests, the configurations of the 

thermocouple-instrumented cables/bundles exactly mimicked the configurations employed by the 

electrically monitored cables/bundles. The principal exceptions to this approach were those 

cases where three-cable bundles were run through a conduit. Here only a single thermocoupleinstrumented cable was included with the bundle due to space constraints within the conduit. 

Thermocouples were also widely used throughout the intermediate-scale experiments; however, 

because of the extensive effort expelled on circuit preparation, thermally monitored cables were 

not as prevalent. Instead, air temperatures were gathered at each test position. In Position A and 

Position B, the middle of the tray was assumed to be the hottest exposure area for the involved 

circuits and, as such, only the air temperatures at the center of the tray were monitored. In the 

three remaining positions, air temperatures were captured at 3 feet, the middle, and 7 feet of the 

10-foot tray. The only tests that contained thermocouple instrumented cables were ISTest9 and 

ISTest10, the Kerite® and armored cable tests, respectively. 
A - 38

During the course of testing, there were instances when the recorded thermocouple data yielded 

erratic results, such as pronounced increases and/or decreases in temperature. An example of 

this may be observed in the air temperature for B-Position in ISTest10 at approximately 2800 

seconds. Possible causes of this behavior may include failure at the junction point between the 

thermocouple connector and the thermocouple lead (e.g., debris interference, thermal impact) or 

interaction with electrical arcing; however, subsequent investigation of the off-normal readings 

did not occur upon the conclusion of this test or others with similar results. The data from the 

effected thermocouple should be discarded after the gross failure. 

A.5.4 Data Acquisition and Processing 

The dc circuits were connected to a National Instruments screw terminal block (Model Number 

SCXI-1300), 32-channel amplifier (Model Number SCXI-1102), and 12-slot chassis (Model 

Number SCXI-1001). The temperature data was collected by a similar system; however, it used 

a 4-slot chassis (Model Number SCXI-1000) rather than the 12-slot. The SCDU circuits, and 

later the CT500 current transducers, were monitored on a National Instruments SCB-100. 

These systems interfaced were controlled by LabView Developer Suite, a software program 

developed by National Instruments. 

A.5.4.1 Computers/Software 

Individual computers were connected to the data acquisition systems for the dc circuits, ac 

circuits, and temperature data. This was to prevent data loss in the event of a system or power 

failure. 

The dc system was connected to a Hewlett-Packard desktop, Workstation XW4100 with a 

Pentium 4 Processor. 

The ac system was connected to a Dell desktop, Precision 350 with a Pentium 4 Processor. 

The temperature data acquisition system was connected to a Hewlett Packard laptop, Compaq 

nc6230 with an Intel Centrino Processor. 

All three systems were operated on Windows XP. 

A.5.4.2 Data Files 

A list of the data files for each test may be found in Table A.13. 

Table A.13 Matrix of the raw Penlight and intermediate-scale test data files. 

Burn Test* 

Raw Data Files 

Test Date 

Circuit Temperature 
A - 39

Table A.13 Matrix of the raw Penlight and intermediate-scale test data files. 

Burn Test* 

Raw Data Files 

Test Date 

Circuit Temperature 

D13_qual Test-13-qualification_SCDU-1 7-27-09-1410.csv July 27, 2009 

D13 Test-13_SCDU-1-2 7-27-09-1708.csv July 27, 2009 

D14 Test-14_SCDU-1-2 7-28-09-1000.csv July 28, 2009 

D15 Test-15_SCDU-1-2 7-28-09-1416.csv July 28, 2009 

D16 Test-16_SCDU-1-2 7-28-09-1750.csv July 28, 2009 

D17_qual Test-17-qual_SCDU-1-2 7-30-09-1041.csv July 30, 2009 

D17 Test-17_SCDU-1-2 7-31-09-0815.csv July 31, 2009 

D18 Test-18_SCDU-1-2 7-31-09-1107.csv July 31, 2009 

D44 Oct-5-09_MOV1_MOV2_Test-44.csv 10-05-09 0138.csv October 5, 2009 

D49 Oct-9-09_MOV1_MOV2_Test-49.csv 10-09-09 1310.csv October 9, 2009 

D50 

Oct-12-09_MOV1_MOV2_Test50.csv 10-12-09 1251.csv October 12, 

2009 

IS9 03-17-2010_Test-9_Burnsite.csv 3-17-10_.csv March 17, 2010 

IS10 03-25-2010_Test-10_Burnsite.csv 3-25-10_1040.csv March 25, 2010 

K1 Test1_9-22-10_Kerite7c-w 

9-22-10_ATE_ACCircuit-Fires_Test1.csv September 22, 

2010 

K2 Test2_9-23-10_Kerite9c-wo 

9-23-

10_ATE_Penlight_ACCurcuitFires_Test2.csv 

September 23, 

2010 

K3 Test3_9-24-10_Kerite10c-wo 

9-24-10_ATE_ACCurcuitFires_Test3.csv 

September 24, 

2010 

K4 Test4_11-08-10_Kerite10c-w 

Test4-ac-circuitfire-11-

8-10-1425.csv 

November 8, 

2010 

K5 Test5_11-09-10_Kerite5c-w 

Test5-ac-circuitfire-11-

9-10-1536.csv 

November 9, 

2010 

K6 Test6_9-28-10_Kerite7c-w.csv 

9-28-10-ate-ac-circuitfires-test-6.csv September 28, 

2010 

K7 Test7_10-28-10_Kerite7c-w.csv 

test7fr-circuitfire-10-

28-10-1148.csv 

October 28, 

2010 

K8 Test8_10-25-10_Kerite5c_w.csv 

8-10-25-10-kerite2cfr1-1600.csv October 25, 

2010 

K9 Test9_11-04-10_Kerite5c_FR-w.csv 

Test-9-ac-circuitfire11-4-10-1600.csv November 4, 

2010 

K10 Test10_10-27-10_Kerite4c_wo.csv 

test10fr3-circuitfire-10-

27-10-1546.csv 

October 27, 

2010 

K11 

Test11_11-01-10_Kerite4c_FR3-

wo.csv 

11-ac-circuitfire-11-1-

10-1355.csv 

November 1, 

2010 

K12 

Test12_11-04-10_Kerite2c_FR3-

wo.csv 

test-12-ac-circuitfire11-4-10-903.csv November 4, 

2010 

K13 

Test13_11-04-10_Kerite2c_FR3-

wo.csv 

test13-circuitfire-11-4-

10-1318.csv 

November 4, 

2010 
A - 40

Table A.13 Matrix of the raw Penlight and intermediate-scale test data files. 

Burn Test* 

Raw Data Files 

Test Date 

Circuit Temperature 

K14 

Test14_10-25-10_Kerite2c_FR1-

wo.csv 

14-10-25-10-kerite2cfr1-1132.csv October 25, 

2010 

K15 

Test15_11-01-10_Kerite2c_FR1-

wo.csv 

15-ac-circuitfire-11-1-

10-1608.csv 

November 1, 

2010 

K16 

Test16_11-02-10_Kerite2c_FR1-

wo.csv 

16-ac-circuitfire-11-2-

10-930.csv 

November 2, 

2010 

K17 Test17_11-09-10_Kerite2c-wo 

Test17-ac-circuitfire11-9-10-818.csv November 9, 

2010 

K18 Test18_11-09-10_Kerite4c-wo 

test18-ac-circuitfire11-9-10-1250.csv November 9, 

2010 

K19 Test19_11-10-10_Kerite12c-wo 

Test19-ac-circuitfire12c-11-10-10-1513.csv November 10, 

2010 

K20 Test20_11-11-10_Kerite15c-w 

Test20-ac-circuitfire11-11-10-1025.csv November 11, 

2010 

K21 Test21_10-27-10_Kerite9c_wo 

test21fr-circuitfire-10-

27-10-1055.csv 

October 27, 

2010 

K22 Test22_10-26-10_Kerite10c_wo.csv 

kerite22-circuitfire10cfr2-10-26-10-

1340.csv 

October 26, 

2010 

K23 Test23_11-10-10_Kerite9c-wo.csv 

Test23-ac-circuitfire9c-11-10-10-1100.csv November 10, 

2010 

K24 Test24_11-05-10_Kerite10c-wo 

test24-ac-circuitfire11-5-10-1530.csv November 5, 

2010 

* It should be noted that the D indicates that the test was conducted during the DESIREE-Fire test 

series. The IS indicates that the test is an intermediate-scale test which was conducted during 

DESIREE-Fire. The K indicates that the test was conducted during the KATE-Fire test series. 

A.5.4.3 Data Processing and Analysis 

Both the Penlight and intermediate-scale experiments have associated circuit files that contain 

the date and test number. The temperature data files contain the date and nominal test start time 

of each test. This data may be found in the associated software included with this report. 

The AC files are analyzed in similar fashion to the CAROLFIRE SCDU files. Essentially, a 

Microsoft Excel® template was created and may be populated with the relevant data captured 

from the SCDU system through the “Import Raw Data.” As with SCDU files from 

CAROLFIRE, specific test information had to be included on the Test Conditions sheet in order 

to correctly synchronize the circuit and fire data start times. Graphs located on separate sheets 

populate automatically. 

The data processing was significantly more complicated on the dc circuit systems. For each pair 

of circuits (i.e., MOV1 and MOV2, SOV1 and SOV2, etc), there was a separate Excel® template 

and graphing template developed to aid in data analysis. Similar to the SCDU template, a Test 
A - 41

Conditions page with specific information, such as circuit data acquisition and fire start times, 

must be filled out for each experiment. Once this information is entered, the circuit offset, fire 

offset, and the test duration are calculated and displayed. Time, circuit, and ground data from the 

raw circuit file may then be copied and pasted into the Raw Data sheet. As described in previous 

sections, the current offset must be adjusted for each test. Typically, the last 100 seconds before 

the battery was turned on was averaged and used as the offset. The Processed Data worksheet 

was used for data manipulation, such as incorporating the current offset information, adjusting 

the negative voltages monitored on the unidirectional transducers, and the filtering of the ground 

fault activity. In order to clearly interpret the data, it is important to filter out the ground fault 

behavior. Figure A.26, Figure A.28, and Figure A.29 display the progression of data analysis 

beginning with the raw positive, negative, and coil voltage and extending through the filtering of 

the ground detection circuit. The spurious actuation may be clearly observed in the final graph. 

Figure A.26: Unedited voltage data including the positive and negative sources. 

Figure A.27: Raw voltage plot for the MOV1 close coil. 

YC Voltage

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

MOV-1a_VTU_1_P

MOV-1a_VTU_2_N

MOV-1b_VT7_4_YC1

YC Voltage

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

MOV-1b_VT7_4_YC1

YC Voltage Modification

Time (s)

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

{MOV1} V(YC1) - V(Batt -)

{MOV1} V(YC1) - V(N)
A - 42

Figure A.28: Voltage with the ground filtered out. 

The specific ground, current, and voltage information may be copied and pasted into the Final 

Data worksheet. This worksheet is then used to populate the graphing templates. 

SigmaPlot® 11 was used to create the graphs for each circuit, excluding the SCDU. Each circuit 

pair had a separate graphing template developed to facilitate the analysis process. Each template 

contains graphs that may be edited to narrow in on failure behavior. In the subsequent 

appendices for each circuit pair, voltages are primarily displayed with the ground filtered out. In 

the caption for these graphs, the word “Modified” is displayed to differentiate between the 

original and modified data. 

A.6 Intermediate-Scale Tests 

Cable grouping and bundling was widely used for the circuit cables throughout the intermediate 

scale tests. When looking at the test data in subsequent sections, the orientation (e.g., in direct 

contact the tray, on top of fuel cables) of the cable bundle within the tray is important to note. 

The loaded cable tray orientation diagrams represents trays filled with 30 to 40 filler cables used 

to facilitate hot gas production. The bundled cable tray orientation diagrams illustrate trays that 

were modified with brackets to contain small bundles of fuel cables as well as the circuits. The 

specialized cable tray orientation defines the circuit location for two tests, ISTest9 and ISTest10. 

In both tests, Kerite was tested and specific orientations were necessary for the test conditions. 

These tests included thermally monitored cables as well as air temperature data. 

In all three tray conditions, the gray background represents filler cables and the white circles 

represent the circuit cables. For each test, the filler cables surrounding the circuit cables were of 

similar type. In other words, thermoset circuit cables were grouped with the thermoset filler 

cables. The only exception to this was the cable trays containing only filler cable. In these trays, 

it was most common to have similar cable types, but a limited amount of dissimilar cables were 

added if deemed necessary. As the data is presented in subsequent sections, Figure A.29 

illustrates the location of the circuit cables within the filler cables. 

Figure A.29: Circuit cable orientation within the cable trays. 
A - 43

A.6.1 Loaded Cable Tray Orientation 

During the intermediate-scale tests, the cable trays located in Position A and B were typically 

loaded with circuits and filler cables. The filler cables were included to provide fuel for the fire. 

The following diagrams display the location of the sample cables within the loaded tray. 

Fill Tray A Fill Tray B 

Fill Tray C Fill Tray D 

Fill Tray E Fill Tray F 

Fill Tray G Fill Tray H 
A - 44

A.6.2 Bundled Cable Tray Orientation 

During the intermediate-scale tests, the cable trays located in Position C, D, and E were typically 

loaded with circuits and filler cables. The filler cables were included to simulate loaded cable 

tray scenarios by orienting them in a 4 by 4 matrix and the following diagrams display the 

location of the sample cables within the matrix. 

Bundled Tray B 

Bundled Tray C 

Bundled Tray E Bundled Tray F 

Bundled Tray D 

Bundled Tray G Bundled Tray H 

Bundled Tray A 
A - 45

A.6.3 Specialized Cable Tray Orientation 

For IS9 and IS10, specific cable orientations were used to investigate particular failure 

conditions for Kerite and Armored cables. The following diagrams display the location of the 

sample cables within the specialized tray orientation. 

1 2 TC 3 4 

Specialized Tray A 

1 T 2

3 TC 4 TC 

Specialized Tray B 

1 TC 2 TC 3 TC 

Specialized Tray C 

Bundled Tray I Bundled Tray J 

Bundled Tray K 
A - 46

A.6.4 Intermediate-Scale Burner System 

Nearly identical to the propylene pressure system used in CAROLFIRE, the propylene pressure 

system was used to feed the gas from externally secured tanks to the sand burner within the 

bunker facility (Figure A.30). The sand burner was identical to the one used during this previous 

testing program. Typically, six bottles of propene were connected to 100-psig regulators 

attached to stainless steel flex line. This line connected to Swagelok® fittings and was piped 

through a ventilation valve, an isolation valve, and pressure gauge before penetrating a throughway into the bunker. The line was connected to an Omega Mass Flow Controller,20 which 

regulated the flow of propylene to the sand burner. The digital readout was run from within the 

bunker to the instrumentation transportainer just outside the bunker. 

Figure A.30: Illustration of the propene pressure system for the intermediate-scale experiments 

 

20 Additional information may be ascertained from Omega’s product literature found on the following website 

http://www.omega.com/manuals/index.html?s=all.

LPI LP

V

PRV

Regulato

r

PRV = pressure relief valve

LPI = low presure isolation

LPV = low pressure vent

Process Gas 

Cylinder

6ea propylene bottles w/ 

manifolds

1psig check valves

100psig relief valve

Swagelok 1⁄2” T and elbow fittings

1⁄2”, 0.035 wall, SS tubing

1⁄2” SS flex line

Omega Mass Flow Controller 0-

1000L/min, MAWP 500psig

Burner

Igloo Wall

vent valve

isolation

valve

pressure

gauge
A - 47

The top surface of the burner measured 400 mm on a side (outside dimensions). A metal lip 

around the upper edge of the burner was turned to the inside of the burner on all sides and 

measures 12 mm wide (a piece of standard mild steel angle iron was used to form the top rail of 

the burner). The sand box burner is illustrated in Figure A.31. 

Figure A.31: Illustration of the sand box burner. 

By itself, the burner stood a total of 400 mm high (a nominal cube). The lower half of the burner 

was an open support framework, while the upper half was an enclosed box section. That is, the 

upper 200 mm of each side of the support framework was enclosed with thin steel sheet panels 

welded and sealed with high-temperature caulk. Below this upper section a four-sided funnel 

shaped section was welded below the side panels. The lower funnel section acted as a plenum 

for gas entering the burner. A coarse copper screen was placed at the top of the funnel section 

and was supported by an X-shaped metal framework at the interface between the funnel section 

and the upper section side panels. A layer of 6 to 9 mm gravel was placed on top of the first 

screen filling the lower two-thirds of the upper box section. A second (finer) screen was placed 

on top of the gravel and a layer of course sand filled the upper one-third of the upper box section 

flush to the top lip of the burner. Gas flowed into the bottom of the sand box, percolated up 

through the gravel, through the sand, and then burned as a diffusion flame above the sand 

surface. 

For testing, the burner was elevated above the floor of the test enclosure. The top surface of the 

burner was about 840 mm above the floor of the enclosure. The burner was always placed in the 

center of the test structure and directly below cable raceway Location A. The flow of gas to the 

burner was measured and controlled by an electronic flow control valve.21 

The single largest source of uncertainty associated with the intermediate-scale test conditions 

was that associated with conversion of the gas burner measure flow rate into an effective HRR. 

That is, while the gas flow rate was monitored in all tests, the HRR must be calculated and 

 

21 The flow controller used was from Omega Controls and is electronic flow controller model FMA5545.
A - 48

specific assumptions must be made with respects to combustion efficiency. The HRR (MW) can 

be estimated based on the measure fuel flow rate as follows: 

g HVHRR c η ρ •••= , 

where η is the combustion efficiency, Hc is the heat of complete combustion (45.79 MJ/kg), ρ is 

the fuel gas density as standard conditions (1.802 kg/m3

), and Vg is the measured fuel gas 

volume flow rate (m3

/s). All but one of these parameters was either well known or directly 

measured, the exception being the combustion efficiency. The intent had been to estimate the 

burner efficiency based on cross-calculation of the HRR based on both the fuel flow rate and 

oxygen consumption calorimetry based on stack measurements. This proved to be impractical 

given the extremely long residence times for combustion products in the outer test cell that led to 

an untenably long delay between gas burner changes and the achievement of steady-state 

conditions at the stack. 

Typical values for this parameter for a sand burner and a fuel such as propene will generally 

range from 0.8 to 0.9. Note that throughout this report, whenever a value or plot of the nominal 

gas burner HRR has been cited, the calculation has assumed a combustion efficiency of 0.85 

(85%). The relatively low combustion efficiency reflects two factors. First, the sand burner 

creates a diffusion flame that is less efficient than a pre-mixed gas-air flame. Second, propene 

was chosen as the fuel gas specifically because under diffusion flame burning conditions propene 

burns with a luminous, sooty flame. However, such burning behavior is also indicative of a less 

complete, hence less efficient, combustion process than would be obtained with a cleanerburning fuel gas such as propane. Based on these conditions, 0.85 is considered a reasonable 

estimate of the overall combustion efficiency of the propene sand burner. Given the range of 

typically measured sand burner efficiencies, the resulting HRR calculations are estimated to have 

a nominal uncertainty of ± 5%. 

Gas flow to the gas burner was provided through a set-point flow control valve. The flow rate 

was recorded in standard liters per minute of gas. In practical application, the volume flow rate 

of the gas as reported by the mass flow meter must be multiplied by a constant “correction 

factor.” The correction factor was specified by the flow controller’s manufacturer and corrects 

for the flow of propene gas as compared to the flow of nitrogen gas against which the valve was 

calibrated. Hence, Equation A-2 is modified in application as follows: 

HRR V reportedg Hc η 4.0 − ρ ••••= 

where 0.4 is the calibration correction factor and Vg-reported is the measured fuel gas volume flow 

rate as reported by the flow meter. 

A.6.4.1 Intermediate-Scale Test Burner Settings 

The calculation inputs for the HRR is described in Table A.14. Table A.15 presents the flow and 

corresponding heat release rate for IS9. Table A.16 presents the flow and corresponding heat 

release rate for IS10. It should be noted that the flow rates did not stabilize on one value, but in 

fact fluctuated by approximately +/– 3 liters per minute. Additionally, the ambient temperatures 
A - 49

(e.g., extreme colds of -25°C) impacted the performance of the pressure system. These 

conditions will be noted as appropriate. 

Table A.14 Inputs for the heat release rate equation. 

Condition Symbol Units Value

Combustion Efficiency ŋ 0.85 

Heat of Combustion Hc MJ/kg 45.79 

Fuel Gas Density ρ kg/m3 1.802 

Correction Factor 0.4 

Table A.15: Heat release rate for Intermediate-Scale Test 9. 

Time (minutes into 

test) 

Burner Flow 

(L/min) 

Heat Release Rate 

(kW) 

0 148 173 

15 180 210 

29 213.6 250 

39 241.2 282 

55 0 0 

Table A.16: Heat release rate for Intermediate-Scale Test 10. 

Time (minutes into 

test) 

Burner Flow 

(L/min) 

Heat Release Rate 

(kW) 

0 148 173 

15 182.4 213 

25 215.6 252 

35 243.2 284 

45 260.4 304 

57 272 318 

66 0 0 
A - 50

A.7 References 

[1] NUREG/CR-7100, “Direct Current Electrical Shorting in Response to Exposure Fire 

(DESIREE-Fire),” Draft Document, U.S. Nuclear Regulatory Commission, Washington 

DC, September 2010. 

[2] Standard 450-1995, “IEEE Recommended Practice for Maintenance, Testing and 

Replacement of Vented Lead-Acid Batteries for Stationary Applications,” Published by 

The Institute of Electrical and Electronics Engineers, 3 Park Avenue, New York, NY 

10016-5997, June 1995. 

[3] Standard 484-2002, “IEEE Recommended Practice for Installation Design and 

Implementation of Vented Lead-Acid Batteries for Stationary Applications,” Published 

by The Institute of Electrical and Electronics Engineers, 3 Park Avenue, New York, NY 

10016-5997, September 2002. 

[4] Standard 485-1997, “IEEE Recommended Practice for Sizing Lead-Acid Batteries for 

Stationary Applications,” Published by The Institute of Electrical and Electronics 

Engineering, 3 Park Avenue, New York, NY 10016-5997, May 1997. 

[5] NUREG/CR-6931, “Cable Response to Live Fire (CAROLFIRE),” U.S. Nuclear 

Regulatory Commission, Washington DC, April 2006. 

[6] NUREG/CR-6776, “Cable Insulation Resistance Measurements Made During Cable Fire 

Tests,” U.S. Nuclear Regulatory Commission, Washington DC, June 2002. 
APPENDIX B: TEST RESULTS 

 

B - 1

B.1 Introduction 

The following sections provide the experimental data and test results for each cable item. The 

tests are first separated by cable identification, then test program (i.e., DESIREE-Fire or 

KATE-Fire), testing scale (i.e., small- or intermediate-scale), and finally original test number. 

Illustrations are provided at the cable item level to reflect the conductor numbering scheme. 

When looking at the diagram of the test cable, the dark gray region represents the jacketing 

material while the lighter gray region represents the insulation surrounding the wire. Each wire 

is white with a number representing the specific conductor within the cable. Some of the cable 

samples contained a zinc tape wrap for grounding. This zinc tape is represented by the ground 

symbol. 

At the test level, parameters are provided to identify specific details of the test including the date 

the experiment was conducted, cable monitoring unit utilized, and initial heating conditions. 

After the test parameters, a table containing wiring information for the sample cable to specific 

cable monitoring unit is presented. A time-line of the experimental including key results and 

graphs of the electrical data are then provided for each test. 

The thermocouple placement information for each test series and scale is provided in Figure B.1 

through Figure B.6. In all of the data plots, cable temperature are identified as “cable n” where 

‘n’ indicates the specific thermocouple (TC) and its corresponding placement in the thermal 

response cable. For the Penlight tests performed under DESIREE-Fire, two TCs were used as 

illustrated in Figures B.1 and B.2. Both TCs are located below the cable jacket at the 

longitudinal center of the exposed cable segment (i.e., relative to the Penlight shroud). The cable 

is placed in Penlight for testing such that TC2 is at the top of the cable and TC1 is on the side of 

the cable facing the center of the tray. In the Kate-Fire Penlight tests an additional two 

thermocouples were used each place at an “outboard” location as shown in Figures B.5 and B.6. 

The specific arrangement for a given Penlight test is therefore defined by whether there were two 

or four thermocouples present. In the case of the DESIREE-Fire intermediate scale tests, three 

thermocouples were used for each thermal response cable as illustrated in Figures B.3 and B.4. 

It should be noted that for the intermediate-scale experiments and for cables located in Position 

B (second tray directly above the burner), only the data for TC2 is reported. For this test 

location, the cable center heated much more quickly than did the outboard locations because the 

center section was generally in the burner’s flame zone. During the intermediate-scale 

experiments, air temperatures were measured approximately 5 cm above the cable location. 

There were cases during the intermediate scale tests where thermocouples failed during testing. 

The data for such cases have not been reported here but are retained in the raw data files. 
B - 2

Figure B.1: Illustration of the thermally monitored cable with circumferential 

thermocouple placement for Penlight DESIREE-Fire tests. 

Figure B.2: Illustration of the thermally monitored cable with longitudinal thermocouple 

placement for Penlight DESIREE-Fire tests. 

Figure B.3: Illustration of the thermally monitored cable with circumferential 

thermocouple placement for intermediate-scale DESIREE-Fire tests. 
B - 3

Figure B.4: Illustration of the thermally monitored cable with longitudinal thermocouple 

placement for intermediate-scale DESIREE-Fire tests. 

TC 

1

TC 

2

TC 

4

TC 

3

Electrically monitored 

cable

Thermocouples located 

underneath jacket

Figure B.5: Illustration of the thermally monitored cable with circumferential 

thermocouple placement for KATE-Fire Penlight tests.

Figure B.6: Illustration of the thermally monitored cable with longitudinal thermocouple 

placement for KATE-Fire tests. 
B - 4

B.2 Cable Item A: 2/C-12 AWG, FR 

Cable Item A is a 2/C-12 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.7. 

The cable was tested three times during the KATE-Fire test series, all on IRMS. The following 

sections detail the test parameters, conductor paths, circuit data, and test summary for each test. 

1

2

Figure B.7: Illustration of Cable Item A. 

B.2.1 Test K14 

Test K14 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.1. The conductor pathway for 

the cable monitoring unit may be found in Table B.2. Electrical performance of the cable may 

be found in Figure B.8. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. Throughout the thermal 

exposure, the insulation resistance did not degrade to the point of current leakage during the 

extended low temperature exposure at 325°C and gradual stepwise increase to 405°C. A 

summary of the test may be found in Table B.3. 

Table B.1: Test parameters for Test K14. 

Test Series KATE-FIRE

Test Name Test 14

Test Date 10/25/2010

Cable 1 Kerite 2/C-12 AWG, FR

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 405°C
B - 5

Table B.2: Conductor designation for Item A, Test K14. 

Kerite 2/C-12 AWG, FR. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS Circuit 

Number

Notes

1 Black 1

2 White 2

Figure B.8: Penlight shroud temperature, cable temperatures, and electrical performance data for 

Test K14. 

Table B.3: Summary of observed faulting behavior for Test K14.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-4260 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final set 

point temperature of Penlight was 405°C. 

4260 Penlight shutdown 

No electrical failures were detected. Penlight 

was shut down for cable dissection and 

analysis. Cables reached approximately 391°C 

at a Penlight set point of 405°C before the test 

was concluded. The cables did not ignite. 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 6

B.2.2 Test K15 

Test K15 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.4. The conductor pathway for 

the cable monitoring unit may be found in Table B.5. Electrical performance of the cable may 

be found in Figure B.9. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. Throughout the thermal 

exposure, the insulation resistance did not degrade to the point of current leakage during the 

extended low temperature exposure at 325°C and gradual stepwise increase to 425°C. A 

summary of the test may be found in Table B.6. 

Table B.4: Test parameters for Test K15. 

Test Series KATE-FIRE

Test Name Test 15

Test Date 11/1/2010

Cable 1 Kerite 2/C-12 AWG, FR

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 425°C

Table B.5: Conductor designation for Item A, Test K15. 

Kerite 2/C-12 AWG, FR. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2
B - 7

Figure B.9: Penlight shroud temperature, cable temperatures, and electrical performance data for 

Test K15. 

Table B.6: Summary of observed faulting behavior for Test K15.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-4800 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final set 

point temperature of Penlight was 425°C. 

4800 Penlight shutdown 

No electrical failures were detected. Penlight 

was shut down for cable dissection and 

analysis. Cables reached approximately 406°C 

before the test was concluded. The cables did 

not ignite. 

B.2.3 Test K16 

Test K16 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.7. The conductor pathway for 

the cable monitoring unit may be found in Table B.8. Electrical performance of the cable may 

be found in Figure B.10. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. The insulation resistance 

did not degrade to the point of current leakage during the extended low temperature exposure at 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 8

325°C. Since the previous two tests were concluded for post-test cable inspection prior to 

failure, Penlight temperatures for Test K16 were gradually increased stepwise until ignition. The 

cable ignited after the Penlight set point temperature was increased to 465°C and at a cable 

temperature of approximately 430°C. Shortly after ignition, initial electrical failure below 

1000 Ω was detected between conductor 2 and ground. A summary of the test may be found in 

Table B.9. 

Table B.7: Test parameters for Test K16. 

Test Series KATE-FIRE

Test Name Test 16

Test Date 11/2/2010

Cable 1 Kerite 2/C-12 AWG, FR

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 465°C

Table B.8: Conductor designation for Item A, Test K16. 

Kerite 2/C-12 AWG, FR. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2
B - 9

Figure B.10: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K16. 

Table B.9: Summary of observed faulting behavior for Test K16.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-5400 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final set 

point temperature of Penlight was 465°C. 

~5670 Ignition 

The cable temperature was approximately 

433°C before ignition. The approximate time 

was obtained from the field notes and then 

compared again the temperature plot for 

consistency. The observed ignition time 

corresponds reasonably well with the data. 

The Penlight set point temperature was not 

increased after ignition. 

5887-5907 Conductor 2 displaying initial 

signs of current leakage to ground. 

5907-5909 Conductor 2 shorts to ground and 

at less than 1000 Ω 

5909-6210 Conductor 2 shorts to ground and 

at less than 100 Ω

5957-5970 Conductor 1 displaying initial 

signs of current leakage to ground. 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 10

Table B.9: Summary of observed faulting behavior for Test K16.

Time (s) Event Comments 

5957-5972 

Conductor 1 displaying initial 

signs of current leakage to 

Conductor 2. 

5970-5975 Conductor 1 shorts to ground and 

at less than 1000 Ω

5972-6053 Conductor 1 shorts to Conductor 2 

and at less than 1000 Ω

5975-6210 Conductor 1 shorts to ground and 

at less than 100 Ω 

6053-6210 Conductor 1 shorts to Conductor 2 

and at less than 100 Ω 

6210 Penlight shutdown 

B.3 Cable Item B: 2/C-10 AWG, FR-III 

Cable Item B is a 2/C-10 AWG cable with FR-III insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.11. 

The cable was tested three times during the KATE-Fire test series, twice on IRMS and once on 

SCDU. The following sections detail the test parameters, conductor paths, circuit data, and test 

summary for each test. 

1

2

Figure B.11: Illustration of Cable Item B.

B.3.1 Test K12 

Test K12 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.10. The conductor pathway for 

the cable monitoring unit may be found in Table B.11. Electrical performance of the cable may 

be found in Figure B.12. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. The insulation resistance 

did not degrade to the point of current leakage during the extended low temperature exposure at 

325°C. Penlight temperatures for Test K12 were gradually increased stepwise until ignition. 
B - 11

The cable ignited after the Penlight set point temperature was increased to 445°C and at a cable 

temperature of approximately 416°C. Shortly after ignition, initial electrical failure below 

1000 Ω was detected between conductors 1 and 2. A summary of the test may be found in Table 

B.12. 

Table B.10: Test parameters for Test K12. 

Test Series KATE-FIRE

Test Name Test 12

Test Date 11/4/2010

Cable 1 Kerite 2/C-10 AWG, FR-III

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 445°C

Table B.11: Conductor designation for Item B, Test K12. 

Kerite 2/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2
B - 12

Figure B.12: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K12. 

Table B.12: Summary of observed faulting behavior for Test K12. 

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-5100 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final 

Penlight set point temperature of Penlight was 

445°C. 

~5217 Ignition 

The cable temperature was approximately 

416°C before ignition. The approximate time 

was obtained from the field notes and then 

compared again the temperature plot for 

consistency. The observed ignition time 

corresponds reasonably well with the data. 

5486-5621 Conductor 1 shorts to Conductor 2 

and at less than 1000 Ω

5486-5624 Conductor 1 shorts to ground and 

at less than 1000 Ω 

5621-5880 Conductor 1 shorts to Conductor 2 

and at less than 100 Ω

5624-5880 Conductor 1 shorts to ground and 

at less than 100 Ω

1.0E-01

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

700

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 13

Table B.12: Summary of observed faulting behavior for Test K12. 

Time (s) Event Comments 

5669-5689 Conductor 2 shorts to ground and 

at less than 1000 Ω 

5689-5880 Conductor 2 shorts to ground and 

at less than 100 Ω 

5880 Penlight shutdown 

B.3.2 Test K13 

Test K13 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.13. The conductor pathway for 

the cable monitoring unit may be found in Table B.14. Electrical performance of the cable may 

be found in Figure B.13. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. Throughout the thermal 

exposure, the insulation resistance did not degrade to the point of current leakage during the 

extended low temperature exposure at 325°C and gradual stepwise increase to 405°C. A 

summary of the test may be found in Table B.15. 

Table B.13: Test parameters for Test K13. 

Test Series KATE-FIRE

Test Name Test 13

Test Date 11/4/2010

Cable 1 Kerite 2/C-10 AWG, FR-III

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 405°C

Table B.14: Conductor designation for Item B, Test K13. 

Kerite 2/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2
B - 14

Figure B.13: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K13. 

Table B.15: Summary of observed faulting behavior for Test K13. 

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-4200 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final 

Penlight set point temperature of Penlight was 

405°C. 

4200 Penlight shutdown 

No electrical failures were detected. Penlight 

was shut down for cable dissection and 

analysis. Cables reached approximately 384°C 

before the test was concluded. The cables did 

not ignite. 

B.3.3 Test K17 

Test K17 utilized the SCDU to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.16. The conductor pathway for 

the cable monitoring unit may be found in Table B.17. Electrical performance of the cable may 

be found in Figure B.14. From this graph, the dark blue and light blue lines display the source 

and target voltages, respectively. The cable did not degrade electrically during the extended low 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 15

temperature exposure at 325°C; however, electrical degradation on the target conductor occurred 

at approximately 6000 s into the test during the gradual stepwise increase. At this time, Penlight 

and cable temperatures were 455°C and 428°C, respectively. At approximately 6310 s, the 

cables ignited at around 441°C. Shortly after ignition, there was a spurious operation on the 

active target for SCDU1. The actuation lasted for about 15 s before the fuse cleared. Penlight 

was shutdown 15 s after the fuse blow. A summary of the test may be found in Table B.18. 

Table B.16: Test parameters for Test K17. 

Test Series KATE-FIRE

Test Name Test 17

Test Date 11/9/2010

Cable 1 Kerite 2/C-10 AWG, FR-III

Cable Monitoring Unit Utilized SCDU1

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 485°C 

Table B.17: Conductor designation for Item B, Test K17. 

Kerite 2/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5
B - 16

Figure B.14: Conductor voltages for Test K17 showing spurious actuation of T5 lasting 

approximately 15 s followed by fuse blow. 

Figure B.15: Penlight shroud temperature, cable temperatures, and target conductor voltage for 

Test K17. 

0

20

40

60

80

100

120

140

6200 6250 6300 6350 6400

Voltage (Vac)

Time (s)

C1 V1

C1 V5

0

5

10

15

20

25

0

100

200

300

400

500

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5
B - 17

Table B.18: Summary of observed faulting behavior for Test K17. 

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

 The initial Penlight set point temperature was 

maintained for approximately 30 minutes before being 

increased. 

1800-6300 

Penlight set point 

temperature 

increased stepwise 

During this time span, the temperature was increased 

stepwise by 10°C every five minutes until the test was 

concluded. The final Penlight set point temperature of 

Penlight was 485°C. 

6000-6317 Voltage increase on 

the active target 

During this time period, the voltage increased from less 

than 1 V to approximately 4 V before spuriously 

actuating. The temperature at the initial point of voltage 

increase was approximately 428° B. 

~6310 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 441°C. 

6317-6332 

Spurious actuation 

of active target on 

SCDU1 

The active target on SCDU1 spuriously actuated and 

remained engaged for approximately 15s before the fuse 

cleared. 

6332 Fuse clear on 

SCDU1 

6347 Test concluded, 

Penlight shutdown 

B.4 Cable Item C: 4/C-10 AWG, FR-III 

Cable Item C is a 4/C-10 AWG cable with FR-III insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.16. 

The cable was tested three times during the KATE-Fire test series, twice on IRMS and once on 

SCDU. The following sections detail the test parameters, conductor paths, circuit data, and test 

summary for each test. 

Figure B.16: Illustration of Cable Item B.
B - 18

B.4.1 Test K10 

Test K10 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.19. The conductor pathway for 

the cable monitoring unit may be found in Table B.20. Electrical performance of the cable may 

be found in Figure B.17. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. Throughout the thermal 

exposure, the insulation resistance did not degrade to the point of current leakage during the 

extended low temperature exposure at 325°C and gradual stepwise increase to 425°C. The final 

cable temperature was approximately 393°C. A summary of the test may be found in Table 

B.21. 

Table B.19: Test parameters for Test K10. 

Test Series KATE-FIRE

Test Name Test 10

Test Date 10/27/2010

Cable 1 Kerite 4/C-10 AWG, FR-III

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 425°C

Table B.20: Conductor designation for Item C, Test K10. 

Kerite 4/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4
B - 19

Figure B.17: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K10. 

Table B.21: Summary of observed faulting behavior for Test K10. 

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-4800 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final set 

point temperature of Penlight was 425°C. 

4800 Penlight shutdown 

No electrical failures were detected. Penlight 

was shut down for cable dissection and 

analysis. Cables reached approximately 393°C 

before the test was concluded. The cables did 

not ignite. 

B.4.2 Test K11 

Test K11 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.22. The conductor pathway for 

the cable monitoring unit may be found in Table B.23. Electrical performance of the cable may 

be found in Figure B.18. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. The insulation resistance 

did not degrade to the point of current leakage during the extended low temperature exposure at 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 20

325°C. Penlight temperatures for Test K11 were gradually increased stepwise until ignition. 

The cable ignited after the Penlight set point temperature was increased to 445°C and at a cable 

temperature of approximately 422°C. Soon after ignition, initial electrical failure below 1000 Ω

was detected between conductors 4 and ground. A summary of the test may be found in Table 

B.24. 

Table B.22: Test parameters for Test K11. 

Test Series KATE-FIRE

Test Name Test 11

Test Date 11/1/2010

Cable 1 Kerite 4/C-10 AWG, FR-III

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 445°C

Table B.23: Conductor designation for Item C, Test K11. 

Kerite 4/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4
B - 21

Figure B.18: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K11. 

Table B.24: Summary of observed faulting behavior for Test K11. 

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

The initial Penlight set point temperature was 

maintained for approximately 30 minutes 

before being increased. 

1800-5100 Penlight set point temperature 

increased stepwise 

During this time span, the temperature was 

increased stepwise by 10°C every five minutes 

until the test was concluded. The final set 

point temperature of Penlight was 445°C. 

~5358 Ignition 

The cable temperature was approximately 

422°C before ignition. The approximate time 

was obtained from the field notes and then 

compared again the temperature plot for 

consistency. The observed ignition time 

corresponds reasonably well with the data. 

5580-5730 Conductor 4 shorts to ground at 

less than 1000 Ω Shorting path may be through ground (tray) 

5640-5670 Conductor 3 shorts to ground at 

less than 1000 Ω

5670-6300 Conductors 3 and 4 short to 

ground at less than 100 Ω 

5670-5730 Conductor 2 shorts to ground at 

less than 1000 Ω 

5700-6300 Conductor 3 shorts to Conductor 4 

at less than 100 Ω 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 22

Table B.24: Summary of observed faulting behavior for Test K11. 

Time (s) Event Comments 

5700-5730 Conductor 2 shorts to Conductor 4 

at less than 1000 Ω 

5700-5760 

Conductor 1 shorts to ground and 

also shorts to Conductor 4 at less 

than 1000 Ω

 

5700-5790 

Conductor 1 shorts to ground and 

also shorts to Conductor 2 at less 

than 1000 Ω

 

5730-6300 Conductor 4 shorts to ground at 

less than 100 Ω 

5730-6300 

Conductor 2 shorts to ground and 

also shorts to Conductor 4 at less 

than 100 Ω

5730-6000 Conductor 1 shorts to Conductor 3 

at less than 1000 Ω

5760-6300 

Conductor 1 shorts to ground and 

also shorts to Conductor 4 at less 

than 100 Ω

5790-6300 

Conductor 1 shorts to ground and 

also shorts to Conductor 2 at less 

than 100 Ω

5880-6120 Conductor 2 shorts to Conductor 3 

at less than 1000 Ω

6000-6300 Conductor 1 shorts to Conductor 3 

at less than 100 Ω

6120-6300 Conductor 2 shorts to Conductor 3 

at less than 100 Ω 

6300 Penlight shutdown 

B.4.3 Test K18 

Test K18 utilized the SCDU to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.25. The conductor pathway for 

the cable monitoring unit may be found in Table B.26. Electrical performance of the cable may 

be found in Figure B.19. From this graph, the dark blue and light blue lines display the source 

and target voltages for SCDU circuit 1, respectively. The light green and dark green lines 

display the source and target voltages for SCDU circuit 2, respectively. Throughout the thermal 

exposure, the insulation resistance did not degrade to the point of current leakage during the 

extended low temperature exposure at 325°C and gradual stepwise increase to 455°C. At 

approximately 5149 s into the test, the cables ignited at a nominal 416°C. Nearly two minutes 

later, the active target on SCDU2 spuriously operated and remained engaged for about 9 s before 

the fuse for SCDU1 cleared. This would indicate that the source from SCDU1 shorted to the 

active target in SCDU2. At 5374 s into the test, there was voltage increase on the active target 
B - 23

for SCDU2 until the fuse ultimately cleared 9 s later. Penlight was subsequently shutdown and 

the test was concluded. The temperature profile and electrical response may be found in Figure 

B.20. A summary of the test may be found in Table B.27. 

Table B.25: Test parameters for Test K18.

Test Series KATE-FIRE

Test Name Test 18

Test Date 11/9/2010

Cable 1 Kerite 4/C-10 AWG, FR-III

Cable Monitoring Unit Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 455°C 

Table B.26: Conductor designation for Item C, Test K18.

Kerite 4/C-10 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1 – 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1

Voltage = C1 V5; current = C1 I5

3 Red 2 S1 Energized source conductor for SCDU2 – 

Voltage = C2 V1; current = C2 I1 

4 Green 2 T5 Active target conductor for SCDU2

Voltage = C2 V5; current = C2 I5
B - 24

Figure B.19: Conductor voltage for Test K18 showing the clearing of fuses in SCDU1 and SCDU2. 

Figure B.20: Penlight shroud temperature, cable temperature, and target conductor voltages for 

Test K18. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V5

0

5

10

15

20

25

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5
B - 25

Table B.27: Summary of observed faulting behavior for Test K18.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

The initial Penlight set point temperature was 

maintained for approximately 30 minutes before being 

increased. 

1800-5100 

Penlight set point 

temperature 

increased stepwise 

During this time span, the temperature was increased 

stepwise by 10°C every five minutes until the test was 

concluded. The final set point temperature of Penlight 

was 455°C. 

~5149 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 416°C. 

5259-5268 

Spurious actuation 

on active target on 

SCDU2 

The spurious actuation occurred on SCDU2 active target 

through the SCDU1 source conductor. During this time 

span, the temperature was approximately 415°C. It 

should be noted that the cable ignited nearly two minutes 

prior to the spurious actuation. 

5269 Fuse clear SCDU1 Temperature at the time the fuse cleared was 

approximately 415°C. 

5374-5383 

Voltage increase on 

active target on 

SCDU2 

A voltage increase on the SCDU2 active target was 

detected during this time span. The voltage went from 

less than 1 V to approximately 7.7 V before the fuse 

cleared. At the time of the fuse clear, the temperatures 

were approximately 421°C. 

5383 Fuse clear SCDU2 

5520 Test concluded, 

Penlight shutdown 

B.5 Cable Item D: 5/C-12 AWG, FR, zinc wrap 

Cable Item D is a 5/C-12 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.21. 

Surrounding the conductors is a zinc tape wrap which was grounded during each test based on 

typical plant practice as specified by the donating company. The cable was tested four times 

during DESIREE-Fire, all on the SCDU, and three times during the KATE-Fire tests, twice on 

IRMS and once on SCDU. The following sections detail the test parameters, conductor paths, 

circuit data, and test summary for each test. 

 
B - 26

1

4

5 2

3

Figure B.21: Illustration of Cable Item D.

B.5.1 Test D13 

Test D13 utilized the SCDU to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.28. The conductor pathway for 

the cable monitoring unit may be found in Table B.29. Electrical performance of the cable may 

be found in Figure B.22. From this graph, the dark blue and light blue lines display the source 

and target voltages, the orange and dark green represent active targets, and the light green line 

represents the conductor monitoring ground. 

Penlight was initially set to 350°C for approximately 32 minutes. During this stabilized heating 

period, electrical degradation could be observed for the active target conductors and the 

grounded conductor as voltages and currents increased, as observed in Figure B.22. Smoke was 

observed about 10 minutes into the test and at around 200°C on the cable thermocouples, cable 

jacket popping and crackling was heard and liquid was later seen bubbling out of the temperature 

monitoring cables. After this initial heating period, Penlight was increased to 375°C for 13 

minutes. Penlight was then increased to 400°C for 10 minutes. The Penlight set point was 

increased to 425°C for 16 minutes before being increased to 470°C. Ignition occurred shortly 

after the increase at a cable temperature of 394°C. Slight voltage increases were detected at 

approximately 1129 s and 283°C. Target 6 actuated after ignition and persisted for 

approximately 8 s until the fuse cleared as shown in Figure B.23. The electrical response of the 

cable to temperature may be found in Figure B.24. A summary of the test results may be found 

in Table B.30. 

Table B.28: Test parameters for Test D13, Circuit. 

Test Series DESIREE-FIRE

Test Name Test 13

Test Date 7/27/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit SCDU1
B - 27

Table B.28: Test parameters for Test D13, Circuit. 

Utilized

Cable 2* Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 350 °C

Penlight Final Temperature 470°C

* See section B.9.2 for results 

Table B.29: Conductor designation for Item D, Test D13, Circuit 1. 

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

4 Green 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

5 Orange 1 G Grounded source conductor for SCDU1– 

Voltage = C1 V7; current = C1 I7 

Zinc Wrap NA Grounded to tray
B - 28

Figure B.22: Voltages for Test D13 showing increases on target conductors. 

Figure B.23: Overlay of target and source conductor currents and voltages for Test D13. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

C1 V7

0

1

2

3

4

5

6

7

0

20

40

60

80

100

120

140

4500 4520 4540 4560 4580 4600

Voltage (Vac)

Current (A)

Time (s)

C1 V2

C1 V6

C1 A2

C1 A6
B - 29

Figure B.24: Penlight shroud temperature and target conductor voltages for Test D13. 

Table B.30: Summary of Observed Faulting Behavior for Test D13, Circuit 1.

Time (s) Event Discussion 

0 

Penlight On; set 

at 350°C (6.97 

kW/m2

) 

 

1129-1342 

Increase in 

voltage observed 

on active target 5 

At 1129 s, the cable temperature reached about 283°C. The voltage on 

Target 5 increased to just over 2.5 V. 

1342-2695 

Decrease in 

voltage observed 

on active target 5 

At 1342 s, voltage on Target 5 decreased to just to a low of approximately 

1.14 V. 

1920 

Penlight 

increased to 

375°C 

2695-3791 

Increase in 

voltage observed 

on active target 5 

At 2695 s, the cable temperature reached about 339°C. The voltage on 

Target 5 increased to just over 2 V. 

2700 

Penlight 

increased to 

400°C 

3300 

Penlight 

increased to 

425°C 

3791-4362 

Decrease in 

voltage observed 

on active target 5 

At 3791 s, voltage on Target 5 decreased to just to a low of approximately 

1.14 V. The temperature was approximately 381°C. 

0

1

2

3

4

5

6

7

8

9

10

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 5c

Side TC for 5c

Penlight

C1 V5

C1 V6
B - 30

Table B.30: Summary of Observed Faulting Behavior for Test D13, Circuit 1.

Time (s) Event Discussion 

4260 

Penlight 

increased to 

470°C 

4362 Ignition Cables ignited at a cable temperature of 394°C and an exposure of 470°C. 

4570-4578 

Spurious 

actuation on 

active target 6 

The spurious operation occurred between source 2 and the active target 

resulting in actuation that persisted for approximately 8 s. 

4578 Fuse clear 

4662 

Test concluded, 

Penlight 

shutdown 

 

B.5.2 Test D14 

One of the objectives of Test D14 was to investigate how the cable sample would perform 

electrically under a higher initial temperature than Test D13. Test D14 utilized the SCDU to 

monitor the electrical performance of the cable throughout the thermal exposure. The test 

parameters may be found in Table B.31. The conductor pathway for the cable monitoring unit 

may be found in Table B.32. Penlight was initially set to 450°C and blistering and popping of 

the jacketing material was observed approximately six minutes into the test. At the initial 

exposure condition, ignition occurred approximately 10 minutes into the test at a cable 

temperature of approximately 288°C. Electrical performance of the cable may be observed in 

Figure B.25. From this figure, the target voltages in did not experience electrical degradation 

during the initial heating phase as was observed in previous tests (e.g., Test D13). The fuse 

would clear approximately 6 minutes after ignition. The electrical response of the cable to 

temperature may be found in Figure B.26. A summary of the test results may be found in Table 

B.33. 

Table B.31: Test parameters for Test D14, Circuit 1. 

Test Series DESIREE-FIRE

Test Name Test 14

Test Date 7/28/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2* Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 450°C

Penlight Final Temperature 450°C
B - 31

Table B.31: Test parameters for Test D14, Circuit 1. 

* See section B.9.3 for results 

Table B.32: Conductor designation for Item D, Test D14, Circuit 1.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

4 Green 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

5 Orange 1 G Grounded source conductor for SCDU1– 

Voltage = C1 V7; current = C1 I7 

Zinc Wrap NA Grounded to tray

Figure B.25: All source and target voltages for Test D14, Circuit 1. 

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

C1 V7
B - 32

Figure B.26: Penlight shroud temperature and conductor voltage for Test D14 displaying the fuse 

clear. 

Table B.33: Summary of Observed Faulting Behavior for Test D14, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set at 

450°C (12.64 

kW/m2

) 

 

600 Ignition The cable temperature was approximately 288°C. 

965 Fuse clear At this time, a short to ground occurred causing the fuse to clear. No 

components were activated. 

1006 Test concluded, 

Penlight shutdown 

B.5.3 Test D15 

Test D15 was conducted to replicate the heating protocol of DESIREE-Fire Test 13, qualification 

in which a low temperature failure was observed in Item H. SCDU was utilized to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.34. The conductor pathway for the cable monitoring unit may be found in 

Table B.35. Electrical performance of the cable may be found in Figure B.27. From this graph, 

the dark blue and light blue lines display the source and target voltages, the orange and dark 

green represent active targets, and the light green line represents the conductor monitoring 

ground. 

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 500 1000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 5c

Side TC for 5c

Penlight

C1 V2
B - 33

Penlight was initially set to 300°C for approximately 37 minutes. During this stabilized heating 

period, electrical degradation could be observed on the active target conductors and the grounded 

conductor as voltages and currents increased, which may be observed in Figure B.28 and Figure 

B.29. Smoke was observed approximately 15 minutes into the test at an approximate cable 

temperature of 215°C. Soon after smoke was noticed, jacket swelling and popping was observed 

and liquid was seen bubbling out of the temperature monitoring cables. After the initial heating 

period, the Penlight set point temperature would be increased to 325°C for 12 minutes. 

Concurrently, voltages were increasing to approximately 3.25 V on Target 6. Penlight was then 

increased to 350°C for 15 minutes. The temperature was then increased to 375°C for 

approximately 15 minutes before a final increase to 400°C for the remainder of the test (16 

minutes). The test was concluded prior to ultimate electrical failure (i.e., fuse clear or spurious 

operation) and ignition to inspect the conductor integrity after the exposure. Although ultimate 

circuit failure did not occur during this test, electrical degradation was observed during the low 

temperature heating phase. The temperature protocol and electrical response may be found in 

Figure B.30. A summary of the test results may be found in Table B.36. 

Table B.34: Test parameters for Test D15, Circuit 1. 

Test Series DESIREE-FIRE

Test Name Test 15

Test Date 7/28/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2* Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 300°C

Penlight Final Temperature 400°C 

* See section B.9.4 for results 

Table B.35: Conductor designation for Item D, Test D15, Circuit 1.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

4 Green 1 T6 Active target conductor for SCDU1 – 
B - 34

Table B.35: Conductor designation for Item D, Test D15, Circuit 1.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

Voltage = C1 V6; current = C1 I6

5 Orange 1 G Grounded source conductor for SCDU1– 

Voltage = C1 V7; current = C1 I7 

Zinc Wrap NA Grounded to tray

Figure B.27: All source and target conductor voltages for Test D15 displaying early degradation. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

C1 V7
B - 35

Figure B.28: Source conductors display early degradation as currents increase for Test D15. 

Figure B.29: Target conductors display early degradation as currents and voltages increase during 

Test D15. 

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0

20

40

60

80

100

120

140

0 2000 4000 6000 8000

Voltage (Vac)

Current (A)

Time (s)

C1 V1

C1 V2

C1 A1

C1 A2

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

0

0.5

1

1.5

2

2.5

3

3.5

4

0 2000 4000 6000 8000

Voltage (Vac)

Current (A)

Time (s)

C1 V5

C1 V6

C1 A5

C1 A6
B - 36

Figure B.30: Penlight shroud temperature and target conductor voltages for Test D15. 

Table B.36: Summary of Observed Faulting Behavior for Test D15, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set at 

300°C (4.99 

kW/m2

) 

The initial Penlight set point temperature and the subsequent heating 

protocol was to resemble the heating protocol for Test D13, qualification 

in which an ultimate failure was observed at lower than anticipated 

temperatures. 

2240 

Penlight 

temperature 

increased to 325° 

2960 

Penlight 

temperature 

increased to 350°C 

2308-3033 Voltage increase on 

Target 6. 

Target 6 increased to 3.25 V during this period of time. The cable 

temperature was approximately 257°C. 

3033-5885 Voltage decrease on 

Target 6. 

Over this time span, the voltage gradually decreased to the conclusion of 

the test. 

3860 

Penlight 

temperature 

increased to 375°C 

4790 

Penlight 

temperature 

increased to 400°C 

5885 Test concluded, 

Penlight shutdown 

 The test was concluded prior to ultimate electrical failure and ignition in 

order to preserve the specimen for physical inspection and analysis. 

0

1

2

3

4

5

6

7

8

9

10

0

100

200

300

400

500

0 2000 4000 6000 8000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 5c

Side TC for 5c

Penlight

C1 V5

C1 V6
B - 37

B.5.4 Test D16 

One of the objectives of Test D16 was to investigate how the cable sample would perform 

electrically under a typical Penlight set point value for thermoset materials. Test D16 utilized the 

SCDU to monitor the electrical performance of the cable throughout the thermal exposure. The 

test parameters may be found in Table B.37. The conductor pathway for the cable monitoring 

unit may be found in Table B.38. Electrical performance of the cable may be observed in Figure 

B.31 and Figure B.32. From these figures, the target voltages in Figure B.25 did not experience 

electrical degradation during the initial heating phase as was observed in previous tests (e.g., 

Test D13). In this graph, the orange and dark green represent active targets, and the light green 

line represents the conductor monitoring ground. 

Penlight was initially set to 470°C and blistering and popping of the jacketing material was 

observed approximately five minutes into the test and ignition occurred shortly after at a cable 

temperature of approximately 210°C. The fuse would clear approximately seven minutes after 

ignition and spurious operation was not observed. The electrical response of the cable to 

temperature may be found in Figure B.33. A summary of the test results may be found in Table 

B.39. 

Table B.37: Test parameters for Test D16, Circuit 2. 

Test Series DESIREE-FIRE

Test Name Test 16

Test Date 7/28/2010

Cable 1* Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 470°C

Penlight Final Temperature 470°C

* See section B.9.5 for results 

Table B.38: Conductor designation for Item D, Test D16, Circuit 2.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

2 White 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

3 Red 2 S2 Energized source conductor for SCDU2– 
B - 38

Table B.38: Conductor designation for Item D, Test D16, Circuit 2.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

Voltage = C2 V2; current = C2 I2 

4 Green 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

5 Orange 2 G Grounded source conductor for SCDU2– 

Voltage = C2 V7; current = C2 I7 

Zinc Wrap NA Grounded to tray

Figure B.31: Voltages for Test D16 showing a fuse clear. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000

Voltage (Vac)

Time (s)

C2 V1

C2 V2

C2 V5

C2 V6

C2 V7
B - 39

Figure B.32: Target voltages for Test D16 without degradation. 

Figure B.33: Penlight shroud temperature and target conductor voltages for Test D16. 

0

1

2

3

4

5

6

0 500 1000 1500 2000

Voltage (Vac)

Time (s)

C2 V5

C2 V6

C2 V7

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 500 1000 1500 2000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 5c

Side TC for 5c

Penlight

C2 V1
B - 40

Table B.39: Summary of Observed Faulting Behavior for Test D16, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set at 

470°C (14.09 

kW/m2

) 

The initial Penlight set point temperature is a typical value for testing 

thermoset cables. 

353 Ignition The cable temperature was approximately 210°C. 

750 Fuse clear There were no indications of voltage increase on the Targets of Circuit 2. 

922 Test concluded, 

Penlight shutdown 

B.5.5 Test K5 

Test K5 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.40. The conductor pathway for the cable monitoring unit may be found in 

Table B.41. Overall electrical performance of the cable may be found in Figure B.34. From this 

graph, the dark blue and light blue lines display the source and target voltages for SCDU circuit 

1, respectively. The light green and dark green lines display the source and target voltages for 

SCDU circuit 2, respectively. Electrical degradation on the target conductors occurred at 

approximately 1065 s into the test at a Penlight and cable temperature of 325°C and 281°C, 

respectively. The active targets increased to approximately 2.5 V and 1.5 V. The early 

degradation may be found in Figure B.35. This was the only electrical activity before the cables 

ignited at approximately 4341 s into the test and at a temperature of 389°C. Shortly after 

ignition, the fuse for SCDU2 cleared. At 4709 s, the fuse on SCDU1 cleared. The test was 

subsequently concluded and Penlight was shutdown. An overlapping graph depicting the overall 

electrical performance for a given temperature exposure may be found in Figure B.36. A 

summary of the test may be found in Table B.42. 

Table B.40: Test parameters for Test K5. 

Test Series KATE-FIRE

Test Name Test 5

Test Date 11/9/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 425°C
B - 41

Table B.41: Conductor designation for Item D, Test K5. 

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

4 Green 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

5 Orange 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

Zinc Wrap NA NA NA Grounded to tray, but not monitored

Figure B.34: Voltages for Test K5 showing increases on target conductors followed by fuse clears. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V4

C2 V5
B - 42

Figure B.35: Target conductor voltages for Test K5 showing early degradation. 

Figure B.36: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K5. 

0

0.5

1

1.5

2

2.5

3

500 1500 2500 3500 4500 5500

Voltage (Vac)

Time (s)

C1 V5

C2 V5

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000 5000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V1

C2 V1

C1 V5

C2 V5
B - 43

Table B.42: Summary of observed faulting behavior for Test K5.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1065-1400 

Voltage increase on 

active targets in 

SCDU1 and SCDU2 

The voltage and current increase in active targets for 

SCDU1 and 2 reached a maximum of approximately 2.5 

V and 1.5 V as well as 0.038 A and 0.022 A, 

respectively. For the remainder of the test, both the 

voltages and currents declined until the fuses cleared on 

each unit. The temperature at the initial increase was 

approximately 281°C. 

1800-4200 

Penlight set point 

temperature 

increased step wise 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 415°C. 

~4341 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 389°C. 

4368 Fuse clear on 

SCDU2 

4709 Fuse clear on 

SCDU1 

4726 Test concluded, 

Penlight shutdown 

B.5.6 Test K8 

Test K8 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.43. The conductor pathway for 

the cable monitoring unit may be found in Table B.44. Electrical performance of the cable may 

be found in Figure B.37. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. It should be noted that 

the insulation resistance between conductor 4 and ground degraded to less than 1000 Ω at an 

internal temperature of 307°C and exposure temperature of 335°C. Conductor 4 most likely 

shorted to the grounded zinc tape which was located just beneath the jacketing material. 

Approximately one minute later, conductor 4 would short to ground at less than 100 Ω. The 

Penlight set point temperature was increased step wise to 365°C, at which the test was 

intentionally concluded for post-test analysis. A summary of the test may be found in Table 

B.45. 
B - 44

Table B.43: Test parameters for Test K8. 

Test Series KATE-FIRE

Test Name Test 8

Test Date 10/25/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized IRMS

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 365°C

Table B.44: Conductor designation for Item D, Test K8.

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

Zinc Wrap NA NA
B - 45

Figure B.37: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K8. 

Table B.45: Summary of observed faulting behavior for Test K8.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

1800-3000 Penlight set point temperature 

increased step wise 

Penlight temperature was increased stepwise 

by 10°C every 5 minutes during this time 

period until the conclusion of the test. The 

final Penlight set point was 365°C, at which 

the test was concluded for analysis. 

1831 Conductor 3 and 4 begin to short 

to ground. 

At a cable temperature of 303°C, conductors 

display onset degradation. Conductors 3 and 4 

begin to short to ground. The conductors may 

be shorting to the zinc wrap directly or through 

a conductor that is previously grounded. 

1932 Conductor 5 begins to short to 

ground Shorting path may be to the zinc wrap 

1943-2011 Conductor 4 shorts to ground at 

less than 1000 Ω

Shorting path may be to the zinc wrap. Cable 

temperature was 307°C 

2011-3000 Conductor 4 shorts to ground at 

less than 100 Ω

Shorting path may be to the zinc wrap. Cable 

temperature was 309°C 

2430-2527 Conductor 2 begins to short to 

ground. 

1.0E-02

1.0E-01

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

50

100

150

200

250

300

350

400

0 500 1000 1500 2000 2500 3000 3500

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 46

Table B.45: Summary of observed faulting behavior for Test K8.

Time (s) Event Comments 

2527-2531 

Conductor 2 shorts to ground, 

Conductor 2 shorts to Conductor 3 

at less than 1000 Ω

These two conductors are adjacent to one 

another. 

2531-3000 Conductor 2 shorts to Conductor 5 

at less than 100 Ω

These two conductors are adjacent to one 

another. 

2545-3000 

Conductor 2 shorts to ground, 

Conductor 2 shorts to Conductor 3 

at less than 100 Ω

 

2549-3000 Conductor 5 shorts to ground at 

less than 100 Ω

Conductor 5 may be shorting to the zinc wrap 

directly or through a conductor that is 

previously grounded. 

3000 Penlight shutdown 

B.5.7 Test K9 

Test K9 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.46. The conductor pathway for 

the cable monitoring unit may be found in Table B.47. Electrical performance of the cable may 

be found in Figure B.38. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. It should be noted that 

the insulation resistances between conductor 4 and ground and between conductor 4 and 

conductor 5 degraded to less than 1000 Ω at an internal temperature of 311°C and exposure 

temperature of 345°C. Conductor 4 most likely shorted to the grounded zinc tape which was 

located just beneath the jacketing material. Approximately one minute later, conductor 4 would 

short to both ground and conductor 5 at less than 100 Ω. The Penlight set point temperature was 

increased step wise to 345°C, at which the test was intentionally concluded for post-test analysis. 

A summary of the test may be found in Table B.48. 

Table B.46: Test parameters for Test K9. 

Test Series KATE-FIRE

Test Name Test 9

Test Date 11/4/2010

Cable 1 Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized IRMS

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C
B - 47

Table B.46: Test parameters for Test K9. 

Penlight Final Temperature 345°C

Table B.47: Conductor designation for Item D, Test K9. 

Kerite 5/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

Zinc Wrap NA NA

Figure B.38: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K9. 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 500 1000 1500 2000 2500 3000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 48

Table B.48: Summary of observed faulting behavior for Test K9.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

1680-2280 Penlight set point temperature 

increased step wise 

Penlight temperature was increased stepwise 

by10°C every 5 minutes during this time 

period until the conclusion of the test. The 

final Penlight set point was 345°C, at which 

point the test was concluded for examination. 

2040-2100 Conductor 4 shorts to ground and 

also shorts to 5 at less than 1000 Ω The cable temperature at this time is 311°C 

2100-2280 Conductor 4 shorts to ground and 

also shorts to 5 at less than 100 Ω The cable temperature at this time is 314°C 

2280 Penlight shutdown 

B.6 Cable Item E: 7/C-12 AWG, FR, zinc wrap 

Cable Item E is a 7/C-12 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.39. 

Surrounding the conductors is a zinc tape wrap which was grounded during each test based on 

typical plant practice as specified by the donating company. The cable was tested once during 

the DESIREE-Fire intermediate-scale series on the dc powered 1-in. valve circuit and three 

times during the KATE-Fire tests, twice on IRMS and once on SCDU. The following sections 

detail the test parameters, conductor paths, circuit data, and test summary for each test. 

Figure B.39: Illustration of Cable Item E.

B.6.1 Test IS10 

The intermediate-scale test series conducted during DESIREE-Fire was a target opportunity to 

investigate the performance of Kerite cable in a more representative fire environment. During 
B - 49

Test IS10, Item E was connected to the dc-powered 1-in. valve and situated in Position D. The 

test parameters may be found in Table B.49. The conductor pathway for the cable monitoring 

unit may be found in Table B.50. Electrical performance of the cable may be found in Figure 

B.40 and Figure B.41. In the former graph, the positive and negative sources as well as the 

energized green lamp conductor were graphed with the coil voltage. The latter graph displays 

the voltage of the lamps through the test. From these two graphs, it should be noted that there is 

a voltage increase at approximately 2055 s which corresponds to a cable temperature of 258°C. 

False indication of the red lamp occurred at 2502 s for approximately 32 s before a spurious 

operation occurred on the 1-in. valve. The actuation continued for approximately 9 s until the 

negative fuse cleared. The temperature profile and voltage response may be found in Figure 

B.42. In this figure, the air temperature is listed as the location of the cable and the length along 

the tray while the sub-jacket temperature is listed with the location of the cable, cable type, and 

length along the sample. A summary of the test results may be found in Table B.51. 

Table B.49: Test parameters for Test IS10, Item E. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for 1-in. Valve Kerite, 7/C-12 AWG, FR, zinc wrap

1-in. Valve Position Position D

Cable Fill Type Bundled Tray A, Cable 1

Cables Co-Located in Raceway

Cable 2 - TC Cable for 1-in. Valve

Cable 3 - Large Coil

Cable 4 - TC Cable for Large Coil

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table B.50: Conductor designation for Item E, Test IS10. 

Test IS10, 1-in. valve, 7/C-12 AWG, zinc wrap 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 2 P 1 Black

2 White TB 5 R 2 White

3 Red TB 3 G 3 Red

4 Green TB 6 SP 4 Green

5 Orange TB 9 N1 5 Orange

6 Blue TB 7 N2 6 Blue

7 White/Black TB 8 SP 7 White/Black
B - 50

Figure B.40: Voltage and current response of the coil connected to Item E during Test IS10. 

Figure B.41: Voltage and current response of the lamps connected to Item E during Test IS10. 

0 1000 2000 3000 4000

Voltage (Vdc)

0

20

40

60

80

100

120

140

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

Time (s)

0 1000 2000 3000 4000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

G = 6.8932A at 2498s

Time (s)

0 1000 2000 3000 4000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative 1

N2 - Negative 2

0 1000 2000 3000 4000

Voltage (Vdc)

0

20

40

60

80

100

120

140

R - Red Lamp

G - Green Lamp

G = 6.8932A at 2498s
B - 51

Figure B.42: Temperature profile of Test IS10 and the voltage response of the 1-in. valve coil. 

Table B.51: Summary of observed faulting behavior for Test IS10, Item E. 

Time (s) Event Discussion 

0 Fire Initiated 

2055 Voltage increase 

detected on coil 

The voltage begins to increase on the coil conductor. At this time, the 

corresponding cable temperature is approximately 258°C 

2502-2535 False Indication Red 

Light ON 

2635-2644 Spurious Actuation The current at this time is 0.7131 A. 

2646 Negative Fuse Clear 

3646 Positive Fuse Clear 

3960 Fire Off 

B.6.2 Test K1 

Test K1 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.52. The conductor pathway for the cable monitoring unit may be found in 

Table B.53. Overall electrical performance of the cable may be found in Figure B.43. The 

electrical performance of the 120 V sources and the targets may be observed in Figure B.44 and 

Figure B.45, respectively. 

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

D Position - 3' 

D Position - 5' 

D Position - 7' 

D Position - Kerite 7c w - 3' 

D Position - Kerite 7c w - 5' 

S - Coil
B - 52

The initial Penlight set point temperature was 325°C. From this graph, approximately 7 minutes 

into the test, the switch was closed for SCDU3, Circuit Path 2 energizing the center conductor 

bringing the voltage from 0 V to approximately 62 V for the remainder of the test. Electrical 

degradation on the source and target conductors may be observed at approximately 2600 s into 

the test at a Penlight set point and cable temperature of 325°C and 256°C, respectively. At 

nearly 41 minutes into the test, a current increase was observed on the grounded zinc wrap. 

About three minutes later and continuing for 10 minutes, voltage and current increased on the 

three active targets to a maximum of 5.34 V and 0.11 A. Just over 53 minutes into the test, the 

voltage and current for each of the active targets slowly decreased to 3 V and 0.05 A at the 

conclusion of the test. The final Penlight temperature was 375°C and the maximum cable 

temperature was just under 300°C. There were no spurious actuations, fuses were not cleared, 

and the cable did not ignite. Penlight was shutdown and the test was subsequently concluded for 

post-test examination of the cable specimen. Upon preliminary data analysis of the test 

temperatures, it was discovered that the incorrect TC was monitoring the Penlight set point 

temperature. This ultimately resulted in lower than anticipated exposure temperatures; however, 

the cable temperature data was found to be wired correctly. An overlapping graph depicting the 

overall electrical performance for a given temperature exposure may be found in Figure B.46. A 

summary of the test may be found in Table B.54. 

Table B.52: Test parameters for Test K1. 

Test Series KATE-FIRE

Test Name Test 1

Test Date 9/22/2010

Cable 1 Kerite 7/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 375°C 

Table B.53: Conductor designation for Item E, Test K1. 

Kerite 7/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4
B - 53

Table B.53: Conductor designation for Item E, Test K1. 

Kerite 7/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

2 White 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

3 Red 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

4 Green 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

5 Orange 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

6 Blue 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

7 White/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5

Zinc Wrap NA 3 G7 Grounded to tray, but not monitored

Figure B.43: All conductor voltages for Test K1 showing a decrease in 120V sources and increase 

on the target voltages. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V5

C3 V4

C3 V7

C4 V1

C4 V5
B - 54

Figure B.44: All 120 V source conductor voltages for Test K1 displaying a voltage drop. 

Figure B.45: All target conductor voltages for Test K1 showing a voltage increase. 

120

122

124

126

128

130

132

134

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C2 V1

C4 V1

0

1

2

3

4

5

6

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C4 V5
B - 55

Figure B.46: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K1. 

Table B.54: Summary of observed faulting behavior for Test K1.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

417 

Switch was closed to 

energize the 

conductor 1 with the 

burden resistor 

Before this time, conductor 1 was not energized. Upon 

being energized, the conductor voltage increased to 

approximately 62 V as was intended given the circuit 

configuration. 

1800-4800 

Penlight set point 

temperature 

increased step wise 

Penlight temperature was increased stepwise by10°C 

every 10 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 375°C. 

2465-2700 Ground experiences 

leakage current 

Ground is the first to noticeably see current leakage, 

starting at a nominal 0.013 A to 0.036 A, compared to 

the other target conductors. The cable temperature is 

about 256°C. At approximately 2700 s, the current 

experienced on the other target conductors is about equal 

to that on ground. 

0

5

10

15

20

0

100

200

300

400

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C4 V5
B - 56

Table B.54: Summary of observed faulting behavior for Test K1.

Time (s) Event Discussion 

2600-3200 

Voltage and current 

increases on all 

active targets 

The increases in both voltages and currents occur 

simultaneously on each of the active target conductors. 

During this span, the voltage ranges from 1 to 

approximately 5.34 V while the current increased from 

0.01 to 0.11 A. Cable temperature at the onset of 

voltage and current increase was 260°C. According to 

the field notes, liquid was observed out of the cut 

thermocouple cable end. 

3072 

Insulation resistance 

on SCDU2, Target 5 

decreases below 

1000 Ω

The cable temperature was approximately 263°C. 

3200-4800 

Voltage and current 

decreases on all 

targets 

Voltages and currents on all active targets steadily 

declined until the conclusion of the test. The voltages on 

the active targets stabilized at just over 3 V. 

Correspondingly, the currents were maintained at 

approximately 0.05 A. 

4800 Test concluded, 

Penlight shutdown 

B.6.3 Test K6 

Test K6 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.55. The conductor pathway for 

the cable monitoring unit may be found in Table B.56. Electrical performance of the cable may 

be found in Figure B.47. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. It should be noted that 

initial degradation occurred at approximately 1680 s. Although conductor-to-conductor current 

leakage was detected, conductor-to-ground shorting was more severe. The established failure 

threshold of 1000 Ω was not breached throughout the step wise increases in temperature and the 

test was concluded prior to ignition to preserve the sample for examination. The maximum 

Penlight set point and cable temperatures were 435°C and 378°C and the associated electrical 

response may be observed in Figure B.47. A summary of the test may be found in Table B.57. 

Table B.55: Test parameters for Test K6. 

Test Series KATE-FIRE

Test Name Test 6

Test Date 9/28/2010

Cable 1 Kerite 7/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit IRMS
B - 57

Table B.55: Test parameters for Test K6. 

Utilized

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 435°C

Table B.56: Conductor designation for Item E, Test K6. 

Kerite 7/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

6 Blue 6

7 White/Black 7

Zinc Wrap NA NA The zinc wrap was grounded for the test; 

however, it was not electrically monitored. 
B - 58

Figure B.47: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K6. 

Table B.57: Summary of observed faulting behavior for Test K6.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

1680-1860 Initial degradation of Conductor 3 

and Conductor 6 to ground. 

The cable temperature at this time was 

approximately 271°C. 

1740-1860 

Initial degradation of Conductor 1, 

Conductor 2, Conductor 4, and 

Conductor 5 to ground. 

The cable temperature at this time was 

approximately 271°C. 

1800-4920 Conductor 2 shorts to ground and 

Conductor 4 at less than 10 kΩ

The cable temperature at this time was 

approximately 271°C. It is likely that the 

conductors are shorting to the zinc wrap which 

is grounded. 

1800 Conductor 1 shorts to Conductor 6 

and Conductor 7 at less than 10 kΩ 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 59

Table B.57: Summary of observed faulting behavior for Test K6.

Time (s) Event Comments 

1860-4920 

Conductor 1, Conductor 3, 

Conductor 4, and Conductor 5 fail 

to ground at less than 10 kΩ. 

Conductor 3 shorts to Conductor 4 

at less than 10 kΩ, possibly 

through ground. Conductor 6 

shorts to Conductor 7 at less than 

10 kΩ, possibly through ground. 

The cable temperature at this time was 

approximately 280°C. 

1920 

Conductor 4 shorts to Conductor 6 

at less than 10 kΩ. Conductor 5 

shorts to Conductor 7 at less than 

10 kΩ. 

 

1980 

Conductor 2 and Conductor 3 

short to Conductor 5 at less than 

10 kΩ. Conductor 3 shorts to 

Conductor 7 at less than 10 kΩ. 

Conductor 4 shorts to Conductor 7 

at less than 10 kΩ. 

 

2010 Conductor 2 shorts to Conductor 6 

at less than 10 kΩ. 

2040 Conductor 3 shorts to Conductor 6 

at less than 10 kΩ. 

2220-4920 

Conductor 1 shorts to ground 

between 1622-2917 Ω. Conductor 

3 shorts to ground between 2417-

8352 Ω. Conductor 4 shorts to 

ground between 2336-8027 Ω. 

Conductor 5 shorts to ground 

between 2219-8352 Ω. Conductor 

6 shorts to ground between 2420-

9087 Ω. 

The average ohm reading for Conductor 1 

between this time period was 2120 Ω. 

Conductor 1 shorted to ground at 1622 Ω at 

3300 s and 322°C. The average ohm reading 

for Conductor 3 between this time period was 

4604 Ω. Conductor 3 shorted to ground at 

2415 Ω at 2700 s and 299°C. The average 

ohm reading for Conductor 4 between this time 

period was 4041 Ω. Conductor 4 shorted to 

ground at 2336 Ω at 3270 s and 321°C. The 

average ohm reading for Conductor 5 between 

this time period was 3921 Ω. Conductor 5 

shorted to ground at 2219 Ω at 2700 s and 299 

B. The average ohm reading for Conductor 6 

between this time period was 4549 Ω. 

Conductor 6 shorted to ground at 2420 Ω at 

2700 s and 299°C. 

2340 Conductor 1 shorts to Conductor 5 

at less than 10 kΩ. 
B - 60

Table B.57: Summary of observed faulting behavior for Test K6.

Time (s) Event Comments 

2400-4920 

Conductor 2 shorts to ground 

between 1697-8704 Ω. Conductor 

7 shorts to ground between 

2518.9087 Ω. 

The average ohm reading for Conductor 2 

between this time period was 4050 Ω. 

Conductor 2 shorted to ground at 1697 Ω at 

3720 s and 337°C. The average ohm reading 

for Conductor 7 between this time period was 

4887 Ω. Conductor 7 shorted to ground at 2518 

Ω at 2700 s and 299°C. 

2760 Conductor 1 shorts to Conductor 4 

at less than 10 kΩ. 

2790 Conductor 1 shorts to Conductor 3 

at less than 10 kΩ. 

2820 Conductor 1 shorts to Conductor 2 

at less than 10 kΩ. 

4920 Penlight shutdown 

The side panel on Penlight opened causing the 

test to automatically shutdown. The final 

Penlight and corresponding cable temperatures 

were 435°C and 378°C, respectively. Ignition 

did not occur. 

B.6.4 Test K7 

Test K7 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.58. The conductor pathway for 

the cable monitoring unit may be found in Table B.59. Electrical performance of the cable may 

be found in Figure B.48. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. It should be noted that 

initial degradation occurred at approximately 1395 s. All conductors appear to have shorting to 

ground. The established failure threshold of 1000 Ω or 100 Ω were not breached throughout the 

step wise increases in temperature; however, immediately upon ignition the cable experienced 

shorting to ground at less than 100 Ω. The maximum Penlight set point and cable temperatures 

were 445°C and 417°C and the associated electrical response may be observed in Figure B.48. 

A summary of the test may be found in Table B.60. 

Table B.58: Test parameters for Test K7. 

Test Series KATE-FIRE

Test Name Test 7

Test Date 10/28/2010

Cable 1 Kerite 7/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized IRMS
B - 61

Table B.58: Test parameters for Test K7. 

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 445°C

Table B.59: Conductor designation for Item E, Test K7. 

Kerite 7/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

6 Blue 6

7 White/Black 7

Zinc Wrap NA NA The zinc wrap was grounded for the test; 

however, it was not electrically monitored. 
B - 62

Figure B.48: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K7. 

Table B.60: Summary of observed faulting behavior for Test K7.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

1395-1476 All conductors begin to short to 

ground. 

The cable temperature was at 285°C. The 

short to ground is most likely to the zinc wrap 

surrounding the bundle of seven conductors. 

1461-5332 Conductor 6 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 287°C at 1461 s. 

From 1540-2069 s, Conductor 6 shorts to 

ground ranging from 2647-6901 Ω and at an 

average of 3964 Ω. From 2069-5332 s, 

Conductor 6 shorts to ground ranging from 

4429-47288 Ω and at an average of 16358 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1576 s, Conductor 6 

shorted to Conductor 5 at 2692 Ω. 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 63

Table B.60: Summary of observed faulting behavior for Test K7.

Time (s) Event Comments 

1462-5332 Conductor 5 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 287°C at 1462 s. 

From 1537-2067 s, Conductor 5 shorts to 

ground ranging from 2373-6440 Ω and at an 

average of 3825 Ω. From 2067-5332 s, 

Conductor 5 shorts to ground ranging from 

4650-46988 Ω and at an average of 16100 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1714 s, Conductor 5 

shorted to Conductor 1 at 2453 Ω. 

1467-5332 Conductor 7 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 288°C at 1467 s. 

From 1543-2072 s, Conductor 7 shorts to 

ground ranging from 2574-7850 Ω and at an 

average of 4128 Ω. From 2072-5332 s, 

Conductor 7 shorts to ground ranging from 

4139-49188 Ω and at an average of 18859 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1703 s, Conductor 7 

shorted to Conductor 6 at 2716 Ω. 

1470-5332 Conductor 2 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 288°C at 1470 s. 

From 1588-1999 s, Conductor 2 shorts to 

ground ranging from 2493.5851 Ω and at an 

average of 3589 Ω. From 1999-5332 s, 

Conductor 2 shorts to ground ranging from 

2742-79279 Ω and at an average of 19628 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1666 s, Conductor 2 

shorted to Conductor 4 at 2493 Ω. 

1473-5332 Conductor 1 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 288°C at 1473 s. 

From 1588-2335 s, Conductor 1 shorts to 

ground ranging from 2356-3963 Ω and at an 

average of 3098 Ω. From 2335-5332 s, 

Conductor 1 shorts to ground ranging from 

3153-7875 Ω and at an average of 5343 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1770 s, Conductor 1 

shorted to Conductor 4 at 2450 Ω. 
B - 64

Table B.60: Summary of observed faulting behavior for Test K7.

Time (s) Event Comments 

1473-5332 Conductor 3 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 288°C at 1473 s. 

From 1532-2061 s, Conductor 3 shorts to 

ground ranging from 2558-6825 Ω and at an 

average of 4086 Ω. From 2061-5332 s, 

Conductor 3 shorts to ground ranging from 

4592-78924 Ω and at an average of 23472 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1795 s, Conductor 3 

shorted to Conductor 4 at 2753 Ω. 

1476-5332 Conductor 4 shorts to ground at 

less than 10 kΩ. 

The cable temperature was 288°C at 1476 s. 

From 1593-2064 s, Conductor 4 shorts to 

ground ranging from 2529-8115 Ω and at an 

average of 3930 Ω. From 2064-5332 s, 

Conductor 4 shorts to ground ranging from 

4077-49192 Ω and at an average of 16701 Ω. 

This behavior is indicative of a potential early 

failure mechanism followed by a recovery. It 

is also worth noting that at 1770 s, Conductor 4 

shorted to Conductor 1 at 2450 Ω. 

~5332 Ignition 

The ignition time was compared to the 

observed time in the notes and there appears to 

be a reasonable correspondence. The cable 

ignited at approximately 417°C. 

5356 Conductor 4 shorts to ground at 

less than 1000 Ω. 

5381 Conductor 4 shorts to ground at 

less than 100 Ω. 

5393-5398 

Conductor 4 shorts to Conductor 5, 

Conductor 6, and Conductor 7 at 

less than 100 Ω. 

 

5440-5449 

Conductor 3 shorts to ground, 

Conductor 6, and Conductor 7 at 

less than 100 Ω. 

 

5465 Conductor 6 shorts to ground and 

Conductor 7 at less than 1000 Ω. 

5479 Conductor 6 shorts to ground at 

less than 100 Ω. 

5482 Conductor 7 shorts to ground at 

less than 100 Ω. 

5490-5502 Conductor 5 shorts to ground and 

Conductor 3 at less than 100 Ω. 

5519-5524 

Conductor 5, Conductor 6, and 

Conductor 7 short together at less 

than 100 Ω. 

 
B - 65

Table B.60: Summary of observed faulting behavior for Test K7.

Time (s) Event Comments 

5558 Conductor 3 shorts to Conductor 4 

at less than 100 Ω. 

5600 Conductor 1 shorts to Conductor 7 

at less than 1000 Ω. 

5603-5614 

Conductor 2 shorts to ground, 

Conductor 3, Conductor 4, 

Conductor 5, Conductor 6, and 

Conductor 7 at less than 1000 Ω. 

 

5645 Conductor 1 shorts to Conductor 2 

at less than 100 Ω. 

5647-5656 

Conductor 1 shorts to ground, 

Conductor 3, Conductor 4, 

Conductor 5, and Conductor 6 at 

less than 1000 Ω. 

 

5661-5664 

Conductor 2 shorts to ground, 

Conductor 3, and Conductor 4 at 

less than 100 Ω. 

 

5703-5709 

Conductor 1 shorts to ground, 

Conductor 3, Conductor 4 at less 

than 100 Ω. 

5835 Conductor 1 shorts to Conductor 7 

at less than 100 Ω. 

5843-5849 

Conductor 2 shorts to Conductor 5 

and Conductor 7 at less than 100 

Ω. 

5888 Conductor 1 shorts to Conductor 5 

at less than 100 Ω. 

5940 Penlight shutdown 

B.7 Cable Item F: 9/C-14 AWG, FR 

Cable Item F is a 9/C-14 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.49. 

The cable was tested four times during the DESIREE-Fire series, three for Penlight and once for 

intermediate-scale. The three Penlight tests were conducted on the MOV circuits. During the 

intermediate-scale test, it was tested on the 1-in. valve circuit. The cable was also tested three 

times during the KATE-Fire tests, once on IRMS and twice on SCDU. The following sections 

detail the test parameters, conductor paths, circuit data, and test summary for each test. 
B - 66

Figure B.49: Illustration of Cable Item F.

B.7.1 Test D44 

DESIREE-Fire provided a target opportunity to preliminarily investigate the performance of 

Kerite cable under thermal duress. During Test D44, Item F was connected to each of the 

dc-powered MOV circuits. The test parameters may be found in Table B.61. The conductor 

pathway for the cable monitoring unit may be found in Table B.62. Electrical performance of 

the cable may be found in the following two sections, namely Circuit 1 and Circuit 2. 

Table B.61: Test parameters for Test D44. 

Test Series DESIREE-FIRE

Test Name Test 44

Test Date 10/5/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV1

Cable 2 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV2

Penlight Starting Temperature 325°C

Penlight Final Temperature 485°C

Table B.62: Conductor designation for Item F, Test D44, Circuit 1 and Circuit 2. 

DCSim MOV, 9/C-14 AWG, FR 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 3 Red

2 White TB 3/C G 4 Green

3 Red TB 7/C YC1 5 Orange

4 Green TB 4/C R 6 Blue

5 Orange TB 6i SP 7 White/Black
B - 67

Table B.62: Conductor designation for Item F, Test D44, Circuit 1 and Circuit 2. 

DCSim MOV, 9/C-14 AWG, FR 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

6 Blue TB 5i N 8 Red/Black

7 White/Black TB 6c YO1 9 Green/Black

8 Red/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected

9 Green/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected

B.7.1.1 Circuit 1 

The electrical performance of this circuit may be found in Figure B.50 and Figure B.51. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 9073 s and a cable temperature of 435°C, the close coil 

spuriously actuated for approximately 20 minutes. False indication of the red lamp occurred at 

11204 s for approximately 60 s before a fuse clear. It should be noted that the auxiliary contacts 

were not performing as anticipated throughout the test. At the conclusion of the test, the 

auxiliary contact was inspected and it was discovered that the metal contacts were not making 

complete connections upon actuation. This would reflect the lack of when the red lamp was 

actuated upon the spurious operation of the close coil. The temperature profile and voltage 

response may be found in Figure B.52 and a modified plot displaying low temperature 

degradation can be observed in Figure B.53. A summary of the test results may be found in 

Table B.63. 
B - 68

Figure B.50: Voltage and current response for the active target in Test D44, Circuit 1. 

Figure B.51: Voltage and current response for the lamps in Test D44, Circuit 1. 

8500 9000 9500 10000 10500

Current (A)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Transducer

saturation

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

8500 9000 9500 10000 10500

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

G - Green Lamp

R - Red Lamp

Transducer

saturation
B - 69

Figure B.52: Temperature profile and electrical response for Test D44, Circuit 1. 

Figure B.53: Modified temperature profile and electrical response for Test D44, Circuit 1 showing 

the early degradation. 

Time (s)

0 2000 4000 6000 8000 10000 12000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil

Time (s)

0 2000 4000 6000 8000 10000 12000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

2

4

6

8

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil
B - 70

Table B.63: Summary of observed faulting behavior for Test D44, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 325°C (5.92 

kW/m2

) 

 

396 

Liquid observed 

exiting end of 

TC cable 

 Cable temperature at approximately 129°C 

821 Smoke observed 

1993 

Increased flow 

of liquid exiting 

TC cable 

 

2760 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 350°C 

4560 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 375°C 

5760 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 400°C 

6660 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 430°C 

7260 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 470°C 

7860 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 485°C 

9073-10276 

Spurious 

Actuation Close 

Coil 

At this time, the current was approximately 0.9 A and the cable 

temperature was approximately 435°C 

10204-10276 False Indication 

Red Lamp ON 

It should be noted that the auxiliary contacts are not functioning as 

anticipated. 

10277 Negative Fuse 

Clear – MOV1 At this time, the cable arced and caused ignition. 

10277 Ignition Ignition occurred as a result of electrical arcing 

10349 Positive Fuse 

Clear – MOV1 

10950 Penlight off 
B - 71

B.7.1.2 Circuit 2 

The electrical performance of this circuit may be found in Figure B.54 and Figure B.55. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 10043 s and a cable temperature of 435°C, the open coil 

spuriously actuated for approximately 5 minutes. The temperature profile and voltage response 

may be found in Figure B.56 and a modified plot displaying low temperature degradation can be 

observed in Figure B.53. A summary of the test results may be found in Table B.64. 

Figure B.54: Voltage and current response for the active target in Test D44, Circuit 2. 

8500 9000 9500 10000 10500

Current (A)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Transducer

saturation
B - 72

Figure B.55: Voltage and current response for the lamps in Test D44, Circuit 2. 

Figure B.56: Temperature profile and electrical response for Test D44, Circuit 2. 

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

8500 9000 9500 10000 10500

Time (s)

Current (A)

-0.2

-0.1

0.0

0.1

0.2

G - Green Lamp

R - Red Lamp

Time (s)

0 2000 4000 6000 8000 10000 12000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil
B - 73

Figure B.57: Modified temperature profile and electrical response for Test D44, Circuit 2 showing 

the early degradation. 

Table B.64: Summary of observed faulting behavior for Test D44, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 325°C (5.92 

kW/m2

) 

 

396 

Liquid observe 

exiting end of 

TC cable 

 Cable temperature at approximately 129°C 

821 Smoke observed 

1993 

Increased flow 

of liquid exiting 

TC cable 

 

2760 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 350°C 

4560 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 375°C 

5760 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 400°C 

Time (s)

0 2000 4000 6000 8000 10000 12000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

2

4

6

8

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil
B - 74

Table B.64: Summary of observed faulting behavior for Test D44, Circuit 2. 

Time (s) Event Discussion 

6660 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 430°C 

7260 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 470°C 

7860 

Penlight set 

point 

temperature 

increased 

Penlight set point increased to 485°C 

10043-10349 

Spurious 

Actuation Open 

Coil 

At this time, there was a hot short on the Open Coil for MOV2 

10277 Arcing – Cable 

Ignition 

There was an arc in one of the cables that lead to the ignition of each 

sample cable. 

10349 Positive Fuse 

Clear – MOV2 

10950 Penlight off 

B.7.2 Test D49 

DESIREE-Fire provided a target opportunity to preliminarily investigate the performance of 

Kerite cable under thermal duress. Similar to Test D44, Test D49 was connected to each of the 

dc-powered MOV circuits. During this test, however, the Penlight set point was set to 400°C to 

investigate the performance of the cable under greater initial temperatures. The test parameters 

may be found in Table B.61. The conductor pathway for the cable monitoring unit may be found 

in Table B.62. Electrical performance of the cable may be found in the following two sections, 

namely Circuit 1 and Circuit 2. 

Table B.65: Test parameters for Test D49. 

Test Series DESIREE-FIRE

Test Name Test 49

Test Date 10/9/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV1

Cable 2 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV2

Penlight Starting Temperature 400°C

Penlight Final Temperature 440°C
B - 75

B.7.2.1 Circuit 1 

The electrical performance of this circuit may be found in Figure B.58 and Figure B.59. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 4394 s and a cable temperature of 405°C, the close coil 

spuriously actuated for approximately 7 s before a fuse clear. The temperature profile and 

voltage response may be found in Figure B.60. Similar to Test D44, there was early degradation 

observed during this test which may be seen in Figure B.61. A summary of the test results may 

be found in Table B.68. 

Table B.66: Conductor designation for Item F, Test D49, Circuit 1 and Circuit 2. 

DCSim MOV1, 9/C-14 AWG, FR 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 3 Red

2 White TB 3/C G 4 Green

3 Red TB 7/C YC1 5 Orange

4 Green TB 4/C R 6 Blue

5 Orange TB 6i SP 7 White/Black

6 Blue TB 5i N 8 Red/Black

7 White/Black TB 6c YO1 9 Green/Black

8 Red/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected

9 Green/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected
B - 76

Figure B.58: Voltage and current response for the active target in Test D49, Circuit 1. 

Figure B.59: Voltage and current response for the lamps in Test D49, Circuit 1. 

4300 4350 4400 4450 4500

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

4300 4350 4400 4450 4500

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Transducer

saturation

4300 4350 4400 4450 4500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

4300 4350 4400 4450 4500

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

Transducer

saturation
B - 77

Figure B.60: Temperature profile and electrical response for Test D49, Circuit 1 

Figure B.61: Modified temperature profile and electrical response for Test D49, Circuit 1 showing 

the early degradation. 

Time (s)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil

Time (s)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

2

4

6

8

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil
B - 78

Table B.67: Summary of observed faulting behavior for Test D49, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 400°C (9.49 

kW/m2

) 

 

755 Liquid exiting 

TC cable Cable temperature at approximately 265°C 

2400 

Penlight 

increased to 

440°C 

 

4394-4401 

Spurious 

Actuation Close 

Coil 

 

4394 Ignition The cables ignited upon electrical arcing occurring from the spurious 

actuation. 

4402 MOV1 Fuse 

Clear 

4402-4824 Battery Negative 

shorts to ground 

4620 Penlight off 

~4820 

Interactions 

between MOV1 

and MOV2 

circuits 

This was based on field notes and validated with the data during post-test 

analysis. 

B.7.2.2 Circuit 2 

The electrical performance of this circuit may be found in Figure B.62 and Figure B.63. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 4620 s, Penlight was shutdown. At 4823 s, the open coil 

spuriously actuated for approximately 1 s before a fuse clear. The temperature profile and 

voltage response may be found in Figure B.64. Unlike Circuit 1, early degradation was not 

observed for this circuit. A summary of the test results may be found in Table B.68. 
B - 79

Figure B.62: Voltage and current response for the active target in Test D49, Circuit 2. 

Figure B.63: Voltage and current response for the lamps in Test 49, Circuit 2. 

MOV2

4740 4760 4780 4800 4820 4840

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

4740 4760 4780 4800 4820 4840

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

1.94 A

4740 4760 4780 4800 4820 4840

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

4740 4760 4780 4800 4820 4840

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

3.14 A
B - 80

Figure B.64: Temperature profile and electrical response for Test D49, Circuit 2. 

Table B.68: Summary of observed faulting behavior for Test D49, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 400°C (9.49 

kW/m2

) 

755 Liquid exiting 

TC cable 

2400 

Penlight 

increased to 

440°C 

4402-4824 Battery Negative 

shorts to ground 

4620 Penlight off 

~4820 

Interactions 

between MOV1 

and MOV2 

circuits 

4823 

Spurious 

Actuation Open 

Coil The duration of the spurious actuation was approximately 1 s. 

4824 MOV2 Fuse 

Clear 

Time (s)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

Cable 2 

YC1 - Close Coil

YO1 - Open Coil
B - 81

B.7.3 Test D50 

This was the final Penlight test for Item F during the DESIREE-Fire series. The Penlight set 

point temperature was set to 450°C. There were no temperature increases during this test since 

the cables ignited approximately 14 minutes into the test. Similar to the previous two tests, Test 

D50 was connected to each of the dc-powered MOV circuits. The test parameters may be found 

in Table B.69. The conductor pathway for the cable monitoring unit may be found in Table 

B.70. Electrical performance of the cable may be found in the following two sections, namely 

Circuit 1 and Circuit 2. 

Table B.69: Test parameters for Test D50. 

Test Series DESIREE-FIRE

Test Name Test 50

Test Date 10/12/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV1

Cable 2 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized MOV2

Penlight Starting Temperature 450°C

Penlight Final Temperature 450°C

Table B.70: Conductor designation for Item F, Test D50, Circuit 1 and Circuit 2. 

DCSim MOV, 9/C-14 AWG, FR

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 3 Red

2 White TB 3/C G 4 Green

3 Red TB 7/C YC1 5 Orange

4 Green TB 4/C R 6 Blue

5 Orange TB 6i SP 7 White/Black

6 Blue TB 5i N 8 Red/Black

7 White/Black TB 6c YO1 9 Green/Black

8 Red/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected

9 Green/Black Not 

Connected

Not 

Connected

Not 

Connected

Not 

Connected
B - 82

B.7.3.1 Circuit 1 

The electrical performance of this circuit may be found in Figure B.65 and Figure B.66. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 1279 s, there was a false actuation of the red lamp for 21 s 

before a fuse clear. There were no spurious operations observed on Circuit 1 during the test. 

The temperature profile and voltage response may be found in Figure B.67. Early degradation 

was not observed for this circuit. A summary of the test results may be found in Table B.71. 

Figure B.65: Voltage and current response for the active target in Test D50, Circuit 1. 

1000 1100 1200 1300 1400

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

2.77 A
B - 83

Figure B.66: Voltage and current response for the lamps in Test D50, Circuit 1. 

Figure B.67: Temperature profile and electrical response for Test D50, Circuit 1. 

Time (s)

1000 1100 1200 1300 1400

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

3.68 A

2.66 A

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

0 200 400 600 800 1000 1200 1400 1600

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

YC1 - Close Coil

YO1 - Open Coil
B - 84

Table B.71: Summary of observed faulting behavior for Test D50, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 450°C (12.64 

kW/m2

) 

420 Liquid exiting 

end of TC cable 

822 Cable Ignition 

1242-1334 Battery Positive 

shorts to ground 

1279-1300 False Indication 

– Red lamp ON 

1334 Negative Fuse 

Clear MOV1 

1440 Penlight off 

B.7.3.2 Circuit 2 

The electrical performance of this circuit may be found in Figure B.68 and Figure B.69. In the 

former figure, the positive and negative sources are graphed with the open and close coil targets. 

The latter graph displays the energized green lamp conductor were graphed with the positive and 

negative sources. At approximately 1164 s, there was a false actuation of the red lamp for 17 s. 

There was a spurious operation observed at 1242 s on Circuit 2 close coil during the test. The 

duration was approximately 22 s before the negative fuse cleared. The temperature profile and 

voltage response may be found in Figure B.70. Early degradation was not observed during this 

test. A summary of the test results may be found in Table B.72. 
B - 85

Figure B.68: Voltage and current response for the active target in Test D50, Circuit 2. 

Figure B.69: Voltage and current response for the lamps in Test D50, Circuit 2. 

1000 1100 1200 1300 1400

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

4.93 A

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

1000 1100 1200 1300 1400

Current (A)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

G - Green Lamp

R - Red Lamp
B - 86

Figure B.70: Temperature profile and electrical response for Test D50, Circuit 2. 

Table B.72: Summary of observed faulting behavior for Test D50, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set 

at 450°C (12.64 

kW/m2

) 

 

420 Liquid exiting 

end of TC cable 

822 Cable Ignition 

1164-1181 

False Indication 

MOV2 – Red 

lamp ON 

 

1242-1334 Battery Positive 

shorts to ground 

1242-1264 

Spurious 

Actuation Close 

Coil 

The duration of the spurious actuation was approximately 22 s. 

1267 Negative Fuse 

Clear MOV2 

1440 Penlight off 

Time (s)

0 200 400 600 800 1000 1200 1400 1600

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

30

60

90

120

Penlight

Cable 1 

YC1 - Close Coil

YO1 - Open Coil
B - 87

B.7.4 Test IS10 

The intermediate-scale test series conducted during DESIREE-Fire was a target opportunity to 

investigate the performance of Kerite cable in a more representative fire environment. Item F 

was tested on two different dc-circuits and exposure locations, namely the Large Coil (Position 

D) and MOV1 (Position C). The performance of these circuits will be described in the following 

two sections. 

B.7.4.1 Circuit 1 

During Test IS10, Item F was connected to the dc-powered Large Coil and situated in Position 

D. The test parameters may be found in Table B.73. The conductor pathway for the cable 

monitoring unit may be found in Table B.74. Electrical performance of the cable may be found 

in Figure B.71 and Figure B.72. In the former graph, the positive and negative sources as well as 

the energized green lamp conductor were graphed with the coil voltage. The latter graph 

displays the voltage of the lamps through the test. From these two graphs, it should be noted that 

there is a voltage increase at approximately 2055 s which corresponds to a cable temperature of 

258°C. False indication of the red lamp occurred at 2502 s for approximately 32 s before a 

spurious operation occurred on the 1-in. 1-in. valve. The actuation continued for approximately 

9 s until the negative fuse cleared. The temperature profile and voltage response may be found 

in Figure B.73. In this figure, the air temperature is listed as the location of the cable and the 

length along the tray while the sub-jacket temperature is listed with the location of the cable, 

cable type, and length along the sample. A summary of the test results may be found in Table 

B.75. 

Table B.73: Test parameters for Test IS10, Large Coil. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for Large Coil Kerite, 9/C-14 AWG, FR

Large Coil Position Position D

Cable Fill Type Bundled Tray A, Cable 1

Cables Co-Located in Raceway

Cable 1 - 1-in. Valve

Cable 2 - TC Cable for 1-in. Valve

Cable 4 - TC Cable for Large Coil

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc
B - 88

Table B.74: Conductor designation for Item F, Test IS10, Large Coil. 

Test IS10, Large Coil, 9/C-14 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 2 P 1 Black

2 White TB 5 R 2 White

3 Red TB 3 G 3 Red

4 Green TB 6 SP 4 Green

5 Orange TB 9 N1 5 Orange

6 Blue TB 7 N2 6 Blue

7 White/Black TB 8 SP 7 White/Black

Figure B.71: Voltage and current response for the active target in Test IS10, Large Coil. 

2000 2500 3000 3500 4000

Voltage (Vdc)

0

20

40

60

80

100

120

140

P - Positive

G - Green Lamp

S - Coil

N2 - Negative 2

Time (s)

2000 2500 3000 3500 4000

Current (A)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
B - 89

Figure B.72: Voltage and current response for the lamps in Test IS10, Large Coil. 

Figure B.73: Temperature profile and electrical response for Test IS10, Large Coil. 

Time (s)

2000 2500 3000 3500 4000

Current (A)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

P - Positive

G - Green Lamp

N1 - Negative 1

N2 - Negative 2

2000 2500 3000 3500 4000

Voltage (Vdc)

0

20

40

60

80

100

120

140

R - Red Lamp

G - Green Lamp

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

D Position - 3' 

D Position - 5' 

D Position - 7' 

D Position - Kerite 9c wo - 3' 

D Position - Kerite 9c wo - 5' 

S - Coil
B - 90

Table B.75: Summary of observed faulting behavior for Test IS10, Large Coil.

Time (s) Event Discussion 

0 Fire initiated 

2735 

Current increase 

on the coil 

conductor 

The current increased to approximately 2.65 A for the remainder of the 

test. Although the fuses cleared, the transducer indicated the same 

nominal 2.65 A which most likely represents a failure with that particular 

transducer. This increase in current corresponds to the increase in 

voltage. The shorting is most likely the cause of transducer failure. 

2735-2795 

Voltage increase 

to approximately 

47 V 

 

2890 

Positive and 

negative fuses 

clear 

The displayed voltages are referenced to ground. Since multiple circuits 

are connected to the same dc power supply, the graphed voltages will 

drift with the reference as other fuses throughout the test clear. 

3960 Fire Off 

B.7.4.2 Circuit 2 

During Test IS10, Item F was connected to the dc-powered MOV1 circuit and situated in 

Position B. The test parameters may be found in Table B.76. The conductor pathway for the 

cable monitoring unit may be found in Table B.77. Electrical performance of the cable may be 

found in Figure B.74 and Figure B.75. In the former graph, the positive and negative sources 

were graphed with the coil voltage. The latter graph displays the voltage of the lamps through 

the test. It should be noted that the positive current transducer displayed signs of failure during 

the course of this test starting at 1650 s. The current on this transducer eventually saturates and 

is therefore not seen on in the figure. 

From these two graphs, it should be noted that there is a voltage increase at approximately 2109 s 

which corresponds to a cable temperature of 152°C. At this point, the temperature corresponding 

to the electrical response appears to be lower than anticipated; however, given the nature of the 

intermediate-scale experiments, it is plausible that the hottest point of the cable was not captured 

by the sub-jacket TCs. The initial spurious actuation occurred on the open coil at 3579 s and 

continued for approximately 7 s. Seconds later, the close coil spurious actuated and continued 

for approximately 52 s before the positive fuse cleared. The temperature profile and 

corresponding voltage response may be observed in Figure B.76. In this figure, the air 

temperature is listed as the location of the cable and the length along the tray while the subjacket temperature is listed with the location of the cable, cable type, and length along the 

sample. A modified graph of the temperature profile and voltage response may be found in 

Figure B.77 which displays the early degradation of the cable sample. A summary of the test 

results may be found in Table B.78. 
B - 91

Table B.76: Test parameters for Test IS10, MOV1. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for MOV1 Kerite 9/C-14 AWG, FR, zinc wrap

MOV1 Position Position C

Cable Fill Type Bundled Tray A, Cable 3

Cables Co-Located in Raceway

Cable 1 - SOV1

Cable 2 - TC Cable for SOV1

Cable 4 - TC Cable for MOV1

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table B.77: Conductor designation for Item F, Test IS10, MOV1. 

Test IS10, MOV 1, 9/C-14 AWG

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 1 Black

2 White TB 3/C G 2 White

3 Red TB 7/C YC1 3 Red

4 Green TB 4/C R 4 Green

5 Orange TB 6i SP 5 Orange

6 Blue TB 5i N 6 Blue

7 White/Black TB 6c YO1 7 White/Black
B - 92

Figure B.74: Voltage and current response for the active target in Test IS10, MOV1. 

Figure B.75: Voltage and current response for the lamps in Test IS10, MOV1. 

2000 2500 3000 3500 4000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

2000 2500 3000 3500 4000

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Transducer

saturation

2000 2500 3000 3500 4000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

2000 2500 3000 3500 4000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

Transducer

saturation
B - 93

Figure B.76: Temperature profile and electrical response for Test IS10, MOV1. 

Figure B.77: Modified temperature profile and electrical response for Test IS10, MOV1 which 

more clearly illustrates the early degradation. 

MOV1

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

C Position - 3'

C Position - 7'

C Position - Kerite 9c wo - 3'

C Position - Kerite 9c wo - 5' 

YC1 - Close Coil

YO1 - Open Coil

MOV1

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

4

8

12

16

C Position - 3'

C Position - 7'

C Position - Kerite 9c wo - 3'

C Position - Kerite 9c wo - 5' 

YC1 - Close Coil

YO1 - Open Coil
B - 94

Table B.78: Summary of observed faulting behavior for Test IS10, MOV1.

Time (s) Event Discussion 

0 Fire initiated 

1650 

Positive current 

transducer 

failure 

The current transducer monitoring the positive conductor begins to 

display signs of failure. The current rises steadily and then peaks at a 

saturation point for the remainder of the test and after the battery bank 

system is isolated from the circuit. 

3541-3647 Current increase 

on green 

Green current transducer saturates for the final 12s before the fuse clears 

3579-3646 Voltage increase 

on red 

3584-3591 

Spurious 

actuation on 

open coil 

 The current was approximately 0.5303 A at the time of operation. 

3594-3646 

Spurious 

actuation on 

close coil 

 The current was approximately 0.0912 A at the time of operation. 

3594-3605 Hot short open 

coil 

3646 Positive fuse 

clears 

3960 Fire off 

B.7.5 Test K2 

Test K2 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.79. The conductor pathway for the cable monitoring unit may be found in 

Table B.80. Overall electrical performance of the cable may be found in Figure B.78. A graph 

displaying the target behavior may be observed in Figure B.79. 

Penlight was initially set to 350°C. Approximately 21 minutes into the test, at a cable 

temperature of approximately 275°C, the voltage and current began to increase on the conductors 

connected to the active targets. This increase persisted gradually for about 10.5 minutes before 

steadily declining. After the initial half hour heating period, the Penlight control temperature 

was increased by 10°C every 5 minutes until reaching a maximum of 380°C. The maximum 

cable temperature reached approximately 327°C before the heating apparatus was shut down for 

post-test examination of the conductors. The cable did not ignite, the fuses did not clear, and 

there were no spurious actuations. The electrical performance for the temperature exposure may 

be found in Figure B.80. A summary of the electrical performance of the cable may be found in 

Table B.81. 
B - 95

Table B.79: Test parameters for Test K2. 

Test Series KATE-FIRE

Test Name Test 2

Test Date 9/23/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 350°C

Penlight Final Temperature 380°C

Table B.80: Conductor designation for Item F, Test K2. 

Kerite 9/C-14 AWG, FR. Red cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4

2 White 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

3 Red 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

4 Green 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

5 Orange 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

6 Blue 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

7 White/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

8 Red/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

9 Green/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5
B - 96

Figure B.78: All conductor voltages for Test K2 showing an increase on the target voltages. 

Figure B.79: All target conductor voltages for Test K2 showing a voltage increase. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V5

0

1

2

3

4

5

6

1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5
B - 97

Figure B.80: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K2. 

Table B.81: Summary of observed faulting behavior for Test K2.

Time (s) Event Discussion 

0 Penlight On; set at 

350°C (6.97 kW/m2

) 

1295-1920 

Voltage and current 

increases on all 

active targets 

During this time, the voltage and current for each active 

target increases from less than 1 V to approximately 2.3 

V and 0.0075 A to 0.035 A, respectively. During the 

initial phases of voltage and current increase, the cable 

temperature was approximately 275°C. 

1489 

Insulation resistance 

on SCDU4, Target 5 

decreases to 1795 Ω

The cable temperature was approximately 278°C. 

1548 

Insulation resistance 

on SCDU3, Target 5 

decreases to 1692 Ω

The cable temperature was approximately 278°C. 

1775 

Insulation resistance 

on SCDU2, Target 5 

decreases to 1812 Ω

The cable temperature was approximately 283°C. 

1800-2700 

Penlight temperature 

increased by 10°C 

every 5 minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period. The final 

Penlight set point was 380°C. 

0

5

10

15

20

25

0

100

200

300

400

500

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
B - 98

Table B.81: Summary of observed faulting behavior for Test K2.

Time (s) Event Discussion 

1920-2700 

Voltage and current 

decreases on all 

active targets 

The voltage and current for the active targets declined 

for the remainder of the test to approximately 1.5 V and 

0.025 A, respectively. 

1927 

Insulation resistance 

on SCDU1, Target 5 

decreases to 1977 Ω

The cable temperature was approximately 288°C. 

2108 

Insulation resistance 

on SCDU1, Target 5 

decreases to 1383 Ω

The cable temperature was approximately 296°C. 

2700 Test concluded, 

Penlight shutdown 

 The test was concluded prior to failure in order to 

preserve the cable sample for post-test analysis. 

B.7.6 Test K21 

Test K21 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.82. The conductor pathway for 

the cable monitoring unit may be found in Table B.83. Electrical performance of the cable may 

be found in Figure B.81. From this graph, the green and black lines display the conductor-toground and conductor-to-conductor minimum resistances, respectively. It should be noted that 

electrical degradation did not occur prior to ignition. Shortly after ignition, the cable 

experienced electrical shorting to less than 1000 Ω. The maximum Penlight set point and cable 

temperatures were 435°C and 400°C and the associated electrical response may be observed in 

Figure B.81. A summary of the test may be found in Table B.84. 

Table B.82: Test parameters for Test K21. 

Test Series KATE-FIRE

Test Name Test 21

Test Date 10/27/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 435°C
B - 99

Table B.83: Conductor designation for Item F, Test K21. 

Kerite 9/C-14 AWG, FR. Red cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS 

Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

6 Blue 6

7 White/Black 7

8 Red/Black 8

9 Green/Black 9

Figure B.81: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K21. 

Table B.84: Summary of observed faulting behavior for Test K21. 

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000 7000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 100

Table B.84: Summary of observed faulting behavior for Test K21. 

Time (s) Event Comments 

1800-4834 Penlight temperature increased 

stepwise by 10°C every 5 minutes 

Penlight temperature was increased stepwise 

by10°C every 5 minutes during this time period 

until ignition. Upon ignition, the Penlight set 

point temperature remained constant until the 

conclusion of the test. The final Penlight set 

point was 435°C. 

~4834 Ignition 

The cable temperature was approximately 

414°C before ignition. The approximate time 

was obtained from the field notes and then 

compared again the temperature plot for 

consistency. The observed ignition time 

corresponds reasonably well with the data. 

5378-5460 

Conductor 8 and Conductor 3 

begin to display signs of leakage to 

one another and ground. 

Shortly thereafter, Conductors 4, 5, 6, 7, and 9 

also displayed signs of initial degradation by 

shorting together and to ground. 

5443-5465 Conductor 2 displays signs of 

insulation degradation 

5465-5586 Conductor 2 shorts to ground at 

less than 1000 Ω

Conductors 3, 4, 5, 6, 7, 8, and 9 short to 

ground at less than 1000 Ω at this time. 

5507-5820 Conductor 4 shorts to ground at 

less than 100 Ω

Conductors 5 and 7 short to ground at less than 

100 Ω at this time. 

5513-5820 Conductor 9 shorts to Conductor 4 

at less than 100 Ω 

5545-5644 Conductor 1 shorts to ground at 

less than 1000 Ω 

5569-5820 Conductor 2 shorts to ground at 

less than 100 Ω 

5574-5820 Conductor 6 and 8 shorts to 

ground at less than 100 Ω 

5586-5820 Conductor 3 shorts to ground at 

less than 100 Ω 

5644-5820 Conductor 1 shorts to ground at 

less than 100 Ω 

5820 Penlight shutdown 

B.7.7 Test K23 

Test K23 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.85. The conductor pathway for the cable monitoring unit may be found in 

Table B.86. Overall electrical performance of the cable may be found in Figure B.82. A time 

modified graph of the source voltages may be observed in Figure B.83. This was included to 
B - 101

illustrate the clearing of the fuses throughout the test. A graph displaying the target behavior 

may be observed in Figure B.84. 

The penlight was initially set to 325°C and increased 10°C after a 30 minute heating period. 

After the first increase, the heating apparatus was increased 10°C every 5 minutes. Electrical 

degradation on the target conductors occurred at approximately 1200 s into the test at a Penlight 

and cable temperature of 335°C and 281°C, respectively. At approximately 4530 s, the cables 

ignited around 411°C. The fuses for both SCDU1 and 4 cleared at 5232 s after high current 

shorting to ground. The source conductor on SCDU2 hot shorted to the source conductors on 

SCDU1 and 4 before the fuse cleared at 5325 s. At 5346 s, a spurious operating lasting for 

approximately 1 s occurred on SCDU3 and then cleared the fuse. Penlight was shut down 

shortly after the fuse blow on SCDU3. The electrical performance throughout the thermal 

exposure may be found in Figure B.85. 

Table B.85: Test parameters for Test K23. 

Test Series KATE-FIRE

Test Name Test 23

Test Date 11/10/2010

Cable 1 Kerite 9/C-14 AWG, FR

Cable Monitoring Unit Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 455°C

Table B.86: Conductor designation for Item F, Test K23. 

Kerite 9/C-14 AWG, FR. Red cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4

2 White 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

3 Red 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

4 Green 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

5 Orange 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5
B - 102

Table B.86: Conductor designation for Item F, Test K23. 

Kerite 9/C-14 AWG, FR. Red cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

6 Blue 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

7 White/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

8 Red/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

9 Green/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5

Figure B.82: All conductor voltages for Test K23 showing an increase on the target voltages. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V5
B - 103

Figure B.83: All 120 V source conductor voltages for Test K23 showing when each fuse cleared. 

Figure B.84: All target conductor voltages for Test K23 showing a voltage increase. 

0

20

40

60

80

100

120

140

5100 5150 5200 5250 5300 5350 5400

Voltage (Vac)

Time (s)

C1 V1

C2 V1

C3 V1

C4 V1

0

1

2

3

4

5

6

1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5
B - 104

Figure B.85: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K23. 

Table B.87: Summary of observed faulting behavior for Test K23.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1200-1800 Voltage increase on 

the active targets 

Voltage increases from less than 1 V to 2 V on the active 

targets during this time span. The cable temperature was 

approximately 281°C. 

1800-4530 

Penlight temperature 

increased stepwise 

by 10°C every 5 

minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 455°C. 

1800-5410 

Voltage decreases 

and stabilizes on the 

active targets at 

approximately 1 V 

After reaching approximately 2 V, the voltage stabilizes 

to 1.5 V for the remainder of the test. 

~4530 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 411°C. 

5218-5232 

High current short to 

ground on source 

conductor for 

SCDU4 

During this period of time, the voltage gradually declines 

from 128 V until the fuse clear and the current is 

maintained from less than 1 A initially to over 5 A. 

0

5

10

15

20

25

30

0

100

200

300

400

500

600

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
B - 105

Table B.87: Summary of observed faulting behavior for Test K23.

Time (s) Event Discussion 

5231-5232 

High current short to 

ground on source 

conductor for 

SCDU1 

During this period of time, the voltage gradually declines 

from 128 V until the fuse cleared and the current is 

maintained from less than 1 A initially to over 5 A. 

5232 Fuse clear SCDU1 

and SCDU4 

5321-5325 

Hot short between 

source conductors on 

SCDU2 and SCDU1 

and 4 

 

5325 Fuse clear SCDU2 

5346-5347 Spurious actuation 

on SCDU3 

5347 Fuse clear on 

SCDU3 

5410 Test concluded, 

Penlight shutdown 

B.8 Cable Item G: 10/C-16 AWG, FR-II 

Cable Item G is a 10/C-16 AWG cable with FR-II insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure B.86. 

The cable was tested during the DESIREE-Fire series intermediate-scale tests 9 and 10. In Test 

IS9, the cable was tested on MOV1. During Test IS10, the cable was tested on SOV2. It was 

tested three times during the KATE-Fire tests, once on IRMS and twice on SCDU. The 

following sections detail the test parameters, conductor paths, circuit data, and test summary for 

each test. 

3

7

1

5

9

10

4

6

8 2

Figure B.86: Illustration of Cable Item G.
B - 106

B.8.1 Test IS9 

The intermediate-scale test series conducted during DESIREE-Fire provided a target opportunity 

to investigate the performance of Kerite cable in a more representative fire environment. During 

Test IS9, Item G was connected to the dc-powered MOV1 circuit and situated in Position B. The 

test parameters may be found in Table B.88. The conductor pathway for the cable monitoring 

unit may be found in Table B.89. Electrical performance of the cable may be found in Figure 

B.87 and Figure B.88. In the former graph, the positive and negative sources were graphed with 

the coil voltage. From here, a spurious actuation occurs at 2613 s and continues for 

approximately 21 s before a subsequent fuse clear. The latter graph displays the voltage of the 

lamps throughout the test. When looking at the graphs, it should be noted that the voltages are 

referenced to ground. Since the other fused circuits are connected to the same dc power supply, 

the ground continues to drift after the negative fuse clears on MOV1. The temperature profile 

and voltage response may be found in Figure B.89. In this figure, the air temperature is listed as 

the location of the cable and the length along the tray while the sub-jacket temperature is listed 

with the location of the cable, cable type, and length along the sample. A summary of the test 

results may be found in Table B.90. 

Table B.88: Test parameters for Test IS9. 

Test Name Test IS9

Test Date 3/17/2010

Cable Type for MOV1 Kerite, 10/C-16 AWG, FR-II

MOV1 Position Position B

Cable Fill Type Fill Tray C, Circuit 1

Cables Co-Located in Raceway

Cable 1 - 1–in. Valve

Cable 2 - Large Coil

Cable 4 - SOV1

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Table B.89: Conductor designation for Item G, Test IS9. 

Test IS9, MOV1, 10/C-16 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 3 Red

2 White TB 3/C G 4 Green

3 Red TB 7/C YC1 5 Orange

4 Green TB 4/C R 6 Blue

5 Orange TB 6i SP 7 White/Black
B - 107

Table B.89: Conductor designation for Item G, Test IS9. 

Test IS9, MOV1, 10/C-16 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

6 Blue TB 5i N 8 Red/Black

7 White/Black TB 6c YO1 9 Green/Black

Figure B.87: Voltage and current response for the active target in Test IS9, MOV1. 

2500 2550 2600 2650 2700 2750 2800

Current (A)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

2500 2550 2600 2650 2700 2750 2800

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Transducer

saturation
B - 108

Figure B.88: Voltage and current response for the lamps in Test IS9, MOV1. 

Figure B.89: Temperature profile and electrical response for Test IS9, MOV1. 

2500 2550 2600 2650 2700 2750 2800

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

2500 2550 2600 2650 2700 2750 2800

Current (A)

-0.1

0.0

0.1

0.2

0.3

0.4

G - Green Lamp

R - Red Lamp

MOV1

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

B Position - Middle

B Position - Kerite 10c w/o

YC1 - Close Coil

YO1 - Open Coil
B - 109

Table B.90: Summary of observed faulting behavior for Test IS9, Item G. 

Time (s) Event Discussion 

0 Fire initiated 

2613-2634 

Spurious 

actuation close 

coil (0.2410A) 

Target 6 was actuated and maintained actuation for approximately 21 s. 

2638 Negative Fuse 

Clears 

The main battery bank is used to power all the dc circuits during the 

intermediate-scale experiments. Since the graphed voltage is referenced 

to the common ground and not all circuit fuses clear at the same time, 

some graphs may indicate that electrical activity is occurring after this 

noted time. 

3300 Fire Off 

B.8.2 Test IS10 

Item G was tested a second time during the intermediate-scale test series. In this second test, the 

cable sample was connected to the dc-powered SOV2 circuit and situated in Position B. The test 

parameters may be found in Table B.91. The conductor pathway for the cable monitoring unit 

may be found in Table B.92. Electrical performance of the cable may be found in Figure B.90 

and Figure B.91. In the former graph, the positive and negative sources are graphed with the coil 

voltage. From here, a gradual voltage increase may be seen on the solenoid conductor; however, 

there was not sufficient enough voltage to cause spurious actuation before a subsequent fuse 

clear. The latter graph displays the voltage of the lamps throughout the test. The voltage reaches 

a point where false indication of the red light is observed. When looking at the graphs, it should 

be noted that the voltages are referenced to ground. Since the other fused circuits are connected 

to the same dc power supply, the ground continues to drift after the negative fuse clears on 

SOV2. The temperature profile and voltage response may be found in Figure B.92. In this 

figure, the air temperature is listed as the location of the cable and the length along the tray while 

the sub-jacket temperature is listed with the location of the cable, cable type, and length along 

the sample. A summary of the test results may be found in Table B.93. 

Table B.91: Test parameters for Test IS10, Item G. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for SOV2 Kerite, 10/C-16 AWG, FR-II

SOV2 Position Position B

Cable Fill Type Specialized Tray C, Cable 3

Cables Co-Located in Raceway Cable 1 - MOV2

Cable 2 - SWGR Close and Trip
B - 110

Table B.91: Test parameters for Test IS10, Item G. 

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table B.92: Conductor designation for Test IS10, Item G. 

Test IS10, SOV2, 10/C-16 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB2 P 3 Red

2 White TB4 G 4 Green

3 Red TB3 S1 5 Orange

4 Green TB6 R 6 Blue

5 Orange TB9 N 7 White/Black

6 Blue TB7 SP 8 Red/Black

7 White/Black TB8 S2 9 Green/Black

Figure B.90: Voltage and current response for the active target in Test IS10, SOV2. 

 

Time (s)

2000 2200 2400 2600 2800 3000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

S1 - Positive Source

G - Green Lamp

S2 - Coil

N - Negative

2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-40

0

40

80

120

160

P- Positive

S2 - Coil

N - Negative

S1 = 6.30 A at 2461 s N = 7.02 A at 2500 s
B - 111

Figure B.91: Voltage and current response for the lamps in Test IS10, SOV2. 

Figure B.92: Temperature profile and electrical response for Test IS10, SOV2. 

Table B.93: Summary of observed faulting behavior for Test IS10, Item G. 

Time (s) Event Discussion 

0 Fire initiated 

Time (s)

2000 2200 2400 2600 2800 3000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

S1 - Positive Source

G - Green Lamp

N - Negative

2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-40

0

40

80

120

160

G - Green Lamp

R - Red Lamp

S1 = 6.30 A at 2461 s N = 7.02 A at 2500 s

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

Voltage (Vdc)

0

40

80

120

160

B Position - Middle

B Position - Kerite 10c w

S2 - Coil
B - 112

Table B.93: Summary of observed faulting behavior for Test IS10, Item G. 

Time (s) Event Discussion 

2298-2463 

Voltage increase 

from 1.06V to 

38V on solenoid 

 The voltage never reaches the point to which actuation occurred. 

2458-2463 False indication 

red light on 

2465 Positive fuse 

clears 

The main battery bank is used to power all the dc circuits during the 

intermediate-scale experiments. Since the graphed voltage is referenced 

to the common ground and not all circuit fuses clear at the same time, 

some graphs may indicate that electrical activity is occurring after this 

noted time. 

2502 Negative fuse 

clears 

3960 Fire off 

B.8.3 Test K3 

Test K3 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.94. Penlight was initially set to 325°C for a half hour before the temperature 

was increased 10°C every five minutes. The final Penlight set point temperature was 385°C. 

Electrical degradation on the target conductors occurred at approximately 3498 s into the test at a 

Penlight and cable temperature of 385°C and 345°C, respectively. A spurious actuation on the 

active target for SCDU4 occurred at approximately 3968 s and a temperature of 377°C. About 

15 s later, there was a spurious actuation on the active target for SCDU3. Three minutes later, 

the active target for SCDU2 operated at 384°C. The active target on SCDU1 actuated 

approximately three and a half minutes later at 4373 s into the test and 387°C. All spurious 

actuations continued until Penlight was shutdown at 4680 s; ignition did not occur. During the 

cool down, SCDU2 engaged and disengaged on two different occasions. All fuses remained 

intact until the cable monitoring unit was ultimately terminated. The electrical performance for 

the temperature exposure may be found in Figure B.95. The conductor pathway for the cable 

monitoring unit may be found in Table B.95. Overall electrical performance of the cable may be 

found in Figure B.93. A graph displaying the target behavior may be observed in Figure B.94. 

A summary of the electrical performance of the cable may be found in Table B.96. 

Table B.94: Test parameters for Test K3. 

Test Series KATE-FIRE

Test Name Test 3

Test Date 9/24/2010

Cable 1 Kerite 10/C-16 AWG, FR-II

Cable Monitoring Unit Utilized SCDU (M)
B - 113

Table B.94: Test parameters for Test K3. 

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 400°C

Table B.95: Conductor designation for Item G, Test K3. 

Kerite 10/C-16 AWG, FR-II. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

2 White 3 S2/T4 Adjusted source conductor which was 

connected through 0.9 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 80 V – SCDU3

Voltage = C3 V4; current = C3 I4

3 Red 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

4 Green 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

5 Orange 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

6 Blue 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

7 White/Black 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

8 Red/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

9 Green/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

10 Orange/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5
B - 114

Figure B.93: All conductor voltages for Test K3. 

Figure B.94: Modified target conductor voltages for Test K3 displaying spurious actuation on each 

of the active targets. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V4

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V5

0

20

40

60

80

100

120

140

3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5
B - 115

Figure B.95: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K3. 

Table B.96: Summary of observed faulting behavior for Test K3.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1800 Penlight temperature 

raised 10°C 

1800-4680 

Penlight temperature 

raised 10°C every 5 

minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until the 

conclusion of the test. The final Penlight set point was 

385°C. 

3498-3968 

Voltage and current 

increase on active 

target for SCDU4 

Active target for SCDU4 experiences a voltage increase 

from a nominal 0 V to 9 V and a rise in current from 

approximately 0 A to 0.15 A before a spurious actuation 

occurs. Penlight was set 385°C and the cable 

temperature was approximately 345°C at the onset of 

electrical degradation. 

3498-3983 

Voltage and current 

increase on active 

target for SCDU3 

Active target for SCDU3 experiences a voltage increase 

from a nominal 0 V to 5 V and a rise in current from 

approximately 0 A to 0.09 A before a spurious actuation 

occurs. Penlight was set 385°C and the cable 

temperature was approximately 345°C at the onset of 

electrical degradation. 

0

30

60

90

120

150

0

100

200

300

400

500

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
B - 116

Table B.96: Summary of observed faulting behavior for Test K3.

Time (s) Event Discussion 

3498-4160 

Voltage and current 

increase on active 

target for SCDU2 

Active target for SCDU2 experiences a voltage increase 

from a nominal 0 V to 8 V and a rise in current from 

approximately 0 A to 0.14 A before a spurious actuation 

occurs. Penlight was set 385°C and the cable 

temperature was approximately 345°C at the onset of 

electrical degradation. 

3498-4373 

Voltage and current 

increase on active 

target for SCDU1 

Active target for SCDU1 experiences a voltage increase 

from a nominal 0 V to 10 V and a rise in current from 

approximately 0 A to 0.15 A before a spurious actuation 

occurs. Penlight was set 385°C and the cable 

temperature was approximately 345°C at the onset of 

electrical degradation. 

3968-4680 

Spurious actuation 

on active target for 

SCDU4 

Spurious actuation on active target for SCDU4 at a 

voltage and current of 121 V and 0.16 A, respectively. 

At this time, the voltage on the 80 V center conductor 

increases to 90 V. The cable temperature was 

approximately 377°C. 

3983-4680 Spurious actuation 

on active target 3 

Spurious actuation on active target 3 at a voltage and 

current of 122 V and 0.17 A, respectively. At this time, 

the voltage on the 90 V center conductor increases to 95 

V. The voltage on this center conductor gradually 

increases to a maximum of 106 V by the time Penlight 

was shutdown. The cable temperature was 

approximately 378°C. 

4160-4680 

Spurious actuation 

on active target for 

SCDU2 

Spurious actuation on active target for SCDU2 at a 

voltage and current of 121 V and 0.17 A, respectively. 

The cable temperature was approximately 384°C. 

4373-4680 

Spurious actuation 

on active target for 

SCDU1 

Spurious actuation on active target for SCDU4 at a 

voltage and current of 121 V and 0.18 A, respectively. 

The cable temperature was approximately 387°C. 

4680 Penlight was 

shutdown 

The heating apparatus was set as high as 405°C before 

being shutdown. The temperature recorded at the center 

of the cable was at an average of 388°C. SCDU was 

kept running during the cooling phase. 

5676-5682 

Locking in and out 

on active target for 

SCDU2 

The cable temperature was 207°C. 

5914-5959 

Locking in and out 

heard on active 

target for SCDU2 

The cable temperature was 169°C. 

6480 SCDU Shutdown 
B - 117

B.8.4 Test K22 

Test K22 utilized the IRMS to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.97. The conductor pathway for 

the cable monitoring unit may be found in Table B.98. It should be noted that Conductors 8, 9, 

and 10 were not monitored during the test. Electrical performance of the cable may be found in 

Figure B.96. From this graph, the green and black lines display the conductor-to-ground and 

conductor-to-conductor minimum resistances, respectively. It should be noted that insulation 

degradation occurred prior to ignition at a temperature of approximately 388°C. At 4907 s, the 

cable experienced electrical shorting to less than 100 Ω between Conductor 3 and ground. 

Shortly after this electrical shorting, the cables ignited. The maximum Penlight set point and 

cable temperatures were 435°C and 400°C, respectively, and the associated electrical response 

may be observed in Figure B.96. A summary of the test may be found in Table B.99. 

Table B.97: Test parameters for Test K22.

Test Series KATE-FIRE

Test Name Test 22

Test Date 10/26/2010

Cable 1 Kerite 10/C-16 AWG, FR-II

Cable Monitoring Unit Utilized IRMS

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 435°C

Table B.98: Conductor designation for Item G, Test K22. 

Kerite 10/C-16 AWG, FR-II. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS Circuit 

Number

Notes

1 Black 1

2 White 2

3 Red 3

4 Green 4

5 Orange 5

6 Blue 6

7 White/Black 7

8 Red/Black Not 

Connected

9 Green/Black Not 

Connected

10 Orange/Black Not 
B - 118

Table B.98: Conductor designation for Item G, Test K22. 

Kerite 10/C-16 AWG, FR-II. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

IRMS Circuit 

Number

Notes

Connected

Figure B.96: Penlight shroud temperature, cable temperatures, and electrical performance data 

for Test K22. 

Table B.99: Summary of observed faulting behavior for Test K22.

Time (s) Event Comments 

0 Penlight On; set at 325°C (5.92 

kW/m2

) 

Conductors 8, 9, and 10 were not monitored 

during Test 22. 

1800-5340 Penlight temperature increased 

stepwise by 10°C every 5 minutes 

Penlight temperature was increased stepwise 

by10°C every 5 minutes during this time 

period until ignition. Upon ignition, the 

Penlight set point temperature remained 

constant until the conclusion of the test. The 

final Penlight set point was 435°C. 

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000

Insulation Resistance (

Ω)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

c-g minimum

c-c minimum
B - 119

Table B.99: Summary of observed faulting behavior for Test K22.

Time (s) Event Comments 

4158-4940 Initial degradation is observed 

during this time period. 

Conductor 1 displays current leakage to 

Conductor 2 at 4158 s. The cable temperature 

was approximately 388°C. Shortly thereafter, 

both Conductor 2 and Conductor 7 begin to 

short to ground at 4194 s. The remaining 

conductors subsequently displayed similar 

degradation. 

4907 Conductor 3 shorts to ground at 

less than 100 Ω. Cable temperature was 423°C. 

~4921 Ignition 

The cable temperature was approximately 

436°C before ignition. The approximate time 

was obtained from the field notes and then 

compared again the temperature plot for 

consistency. The observed ignition time 

corresponds reasonably well with the data. 

4940-5340 Conductor 5 shorts to ground at 

less than 100 Ω. 

During this time span, the other conductors 

begin shorting together and also to ground. 

4942-4980 Conductor 4 shorts to ground at 

less than 1000 Ω. 

4942-5040 Conductor 2 shorts to ground at 

less than 1000 Ω. 

4947-4984 Conductor 6 shorts to ground at 

less than 1000 Ω. 

4950-4986 Conductor 7 shorts to ground at 

less than 1000 Ω. 

4950-5191 Conductor 2 shorts to Conductor 7 

at less than 1000 Ω. 

4961-5213 Conductor 3 shorts to Conductor 4 

at less than 1000 Ω. 

4980-5340 Conductor 4 shorts to ground at 

less than 100 Ω. 

Conductor 6 and 7 also short to ground at less 

than 100 Ω at 4984 s and 4986 s, respectively. 

4981-5233 Conductor 4 shorts to Conductor 5 

at less than 1000 Ω. 

Conductor 4 also shorts at less than 1000 Ω to 

Conductor 6 and 7 at 4984 s and 4986 s, 

respectively. 

4998-5124 

Conductor 5 shorts to Conductor 6 

and Conductor 7 at less than 

1000 Ω. 

 

5012-5264 Conductor 6 shorts to Conductor 7 

at less than 1000 Ω. 

5033-5159 Conductor 3 shorts to Conductor 7 

at less than 1000 Ω. 

5040-5045 Conductor 1 shorts to ground at 

less than 1000 Ω. 

5040-5166 Conductor 1 shorts to Conductor 2 

at less than 1000 Ω. 
B - 120

Table B.99: Summary of observed faulting behavior for Test K22.

Time (s) Event Comments 

5040-5340 Conductor 2 shorts to ground at 

less than 100 Ω. 

5045-5340 Conductor 1 shorts to ground at 

less than 100 Ω. 

Conductor 1 also shorts at less than 100 Ω to 

Conductor 6 and 7 at 5051 s and 5054 s, 

respectively. 

5065-5191 Conductor 2 shorts to Conductor 3 

at less than 1000 Ω. 

Shortly thereafter, Conductor 2 also shorts at 

less than 1000 Ω to Conductor 4 (5068 s), 

Conductor 5 (5071 s), and Conductor 6 

(5073 s). 

5076-5340 Conductor 2 shorts to Conductor 7 

at less than 100 Ω. 

Shortly thereafter, Conductor 2 also shorts at 

less than 100 Ω to Conductor 3 (5191 s), 

Conductor 4 (5193 s), and Conductor 6 

(5199 s). 

5090-5216 Conductor 3 shorts to Conductor 5 

at less than 1000 Ω. 

Conductor 3 also shorts at less than 1000 Ω to 

Conductor 6 at 5093 s. 

5110-5340 

Conductor 4 shorts to Conductor 5 

and Conductor 6 at less than 

100 Ω. 

 

5124-5340 

Conductor 5 shorts to Conductor 6 

and Conductor 7 at less than 

100 Ω. 

 

5166-5340 Conductor 1 shorts to Conductor 2 

at less than 100 Ω. 

5168-5340 Conductor 1 shorts to Conductor 3 

at less than 100 Ω. 

5159-5340 Conductor 3 shorts to Conductor 7 

at less than 100 Ω. 

5171-5340 

Conductor 1 shorts to Conductor 4 

and Conductor 5 at less than 

1000 Ω. 

 

5213-5340 

Conductor 3 shorts to Conductor 4 

and Conductor 5 at less than 

100 Ω. 

 

5233-5340 Conductor 4 shorts to Conductor 5 

at less than 100 Ω. 

5264-5340 Conductor 6 shorts to Conductor 7 

at less than 1000 Ω. 

5300-5340 Conductor 1 shorts to Conductor 5 

at less than 100 Ω. 

5340 Penlight shutdown 
B - 121

B.8.5 Test K24 

Test K24 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.100. The conductor pathway for the cable monitoring unit may be found in 

Table B.101. Overall electrical performance of the cable may be found in Figure B.97. A time 

modified graph of the source voltages may be observed in Figure B.98. The altered source 

voltage performance may be found in Figure B.99. The target performance may be observed in 

Figure B.100. These graphs were included to illustrate the cable degradation over temperature 

exposure, altered source performance, and spurious actuations throughout the test. The electrical 

performance for the temperature exposure may be found in Figure B.101. 

Penlight was initially set to 325°C for a half hour before the temperature was increased 10°C 

every five minutes. The final Penlight set point temperature was 375°C. Electrical degradation 

on the target conductors occurred at approximately 2870 s into the test at a Penlight and cable 

temperature of 365°C and 341°C, respectively. At approximately 3084 s, the cables ignited at a 

sub-jacket temperature of 367°C. Shortly after ignition, there was a spurious operation on the 

active target for all SCDU units, first on 3 (duration of 118 s), then 2 (duration of 115 s), 

followed by 4 (duration of 111 s), and finally 1 (duration of 25 s). Both of the modified sources 

(i.e., 80V and 40V) shorted to the 120 V sources. The each spurious actuation was concluded 

upon the respective unit's fuse clearing. Penlight was shutdown 59 s after the fuse blow on 

SCDU1. A summary of the electrical performance of the cable may be found in Table B.102. 

Table B.100: Test parameters for Test K24. 

Test Series KATE-FIRE

Test Name Test 24

Test Date 11/5/2010

Cable 1 Kerite 10/C-16 AWG, FR-II

Cable Monitoring Unit Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 375°C

Table B.101: Conductor designation for Item G, Test K24. 

Kerite 10/C-16 AWG, FR-II. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 
B - 122

Table B.101: Conductor designation for Item G, Test K24. 

Kerite 10/C-16 AWG, FR-II. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

2 White 3 S2/T4 Adjusted source conductor which was 

connected through 0.9 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 80 V – SCDU3

Voltage = C3 V4; current = C3 I4

3 Red 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

4 Green 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

5 Orange 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

6 Blue 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

7 White/Black 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

8 Red/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

9 Green/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

10 Orange/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5
B - 123

Figure B.97: All conductor voltages for Test K24. 

Figure B.98: Modified source conductor voltages for Test K24 displaying the fuse clears. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V4

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V5

0

20

40

60

80

100

120

140

3150 3170 3190 3210 3230 3250

Voltage (Vac)

Time (s)

C1 V1

C2 V1

C3 V1

C4 V1
B - 124

Figure B.99: Modified altered source conductor voltages for Test K24. 

Figure B.100: Modified target conductor voltages for Test K24 displaying actuation. 

0

20

40

60

80

100

120

2700 2800 2900 3000 3100 3200 3300

Voltage (Vac)

Time (s)

C2 V4

C3 V4

0

20

40

60

80

100

120

140

2700 2800 2900 3000 3100 3200 3300

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5
B - 125

Figure B.101: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K24. 

Table B.102: Summary of observed faulting behavior for Test K24.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1800-3084 

Penlight temperature 

increased 10°C 

every 5 minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 375°C. 

2870-3082 

Voltage increase on 

the nominal 40 V 

conductor 

During this time span, the voltage on the nominal 40 V 

conductor (reading 43 V) increased to approximately 58 

V. The temperature at the initial increase was 

approximately 341°C. 

2870-3082 

Voltage decrease on 

the nominal 80 V 

conductor 

During this time span, the voltage on the nominal 80 V 

conductor (reading 85 V) decreased to approximately 77 

V. 

2870-3084 

Voltage increase on 

the active target on 

SCDU3 

The voltage increased from 1 V to 76 V on the active 

target for SCDU3 before actuating. 

2870-3087 

Voltage increase on 

the active target on 

SCDU2 

The voltage increased from 1 V to 55 V on the active 

target for SCDU2 before actuating. 

2870-3091 

Voltage increase on 

the active target on 

SCDU4 

The voltage increased from 1 V to 64 V on the active 

target for SCDU4 before actuating. 

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
B - 126

Table B.102: Summary of observed faulting behavior for Test K24.

Time (s) Event Discussion 

2870-3186 

Voltage increase on 

the active target on 

SCDU1 

The voltage increased from 1 V to 66 V on the active 

target for SCDU4 before actuating. 

~3084 Ignition 

It is not clear whether ignition occurred before or after 

the spurious actuation. The cable temperature at this 

time was approximately 367°C. 

3084-3202 

Spurious actuation 

on active target for 

SCDU3 

 

3087-3202 

Spurious actuation 

on active target for 

SCDU2 

 

3091-3202 

Spurious actuation 

on active target for 

SCDU4 

 

3186-3211 

Spurious actuation 

on active target for 

SCDU1 

 

3194-3202 

High current short 

on source conductor 

for SCDU3 

During this period of time, the voltage gradually declines 

from 128 V until the fuse clear and the current is 

maintained from less than 2 A initially to over 5 A. 

3197-3203 

High current short 

on source conductor 

for SCDU4 

During this period of time, the voltage gradually declines 

from 128 V until the fuse clear and the current is 

maintained from less than 2 A initially to over 5 A. 

3203 Fuse clear SCDU3 

Upon the fuse clearing, SCDU3 continued to see voltage 

on the source and active target indicating that these two 

conductors had shorted to another energized source. 

3204 Fuse clear SCDU4 

Upon the fuse clearing, SCDU4 continued to see voltage 

on the source and active target indicating that these two 

conductors had shorted to another energized source. 

3206-3208 

High current short 

on source conductor 

for SCDU2 

During this period of time, the voltage gradually declines 

from 128 V until the fuse clear and the current is 

maintained from less than 1 A initially to over 5 A. 

3208 Fuse clear on 

SCDU2 

Upon the fuse clearing, SCDU2 continued to see voltage 

on the source and active target indicating that these two 

conductors had shorted to another energized source. 

3207-3211 

High current short 

on source conductor 

for SCDU1 

During this period of time, the voltage gradually declines 

from 128 V until the fuse clear and the current is 

maintained from less than 1 A initially to over 5 A. 

3211 Fuse clear on 

SCDU1 

Upon the fuse clearing, all remaining voltages on various 

active target and source conductors dropped to a nominal 

0 V. 

3270 Test concluded, 

Penlight shutdown 
B - 127

B.9 Cable Item H: 10/C-12 AWG, FR, zinc wrap 

Cable Item H is a 10/C-12 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure 

B.102. Surrounding the conductors is a zinc tape wrap which was grounded during each test, as 

is typical with plant practices. The cable was tested eight times during DESIREE-Fire; all five 

Penlight scale tests were on the SCDU and the intermediate-scale tests were conducted on the dc 

MOV and dc SOV circuits. It was tested once during the KATE-Fire tests on a modified SCDU. 

The following sections detail the test parameters, conductor paths, circuit data, and test summary 

for each test. 

Figure B.102: Illustration of Cable Item H.

B.9.1 Test D13-Qualification 

Test 13-qualification (shorthand Test D13, qual) was the first test of Cable Item H. This test was 

the initial investigation on the failure mechanisms and electrical response to thermal stresses on 

Kerite FR cable. Test D13, qual utilized the SCDU cable monitoring unit to monitor the 

electrical performance of the cable throughout the heat exposure. The test parameters may be 

found in Table B.103. The conductors were grouped together to provide a simplistic, initial 

assessment of the cable performance. The outer most alternating conductors were ganged and 

between source and target pathways while one center conductor was connected to a separate 

source and target. The conductor pathway for the cable monitoring unit may be found in Table 

B.104. 

Penlight was initially set to 300°C for approximately 35 minutes. After 35 minutes, Penlight was 

increased to 325°C. Twelve minutes later, the Penlight set point temperature was increased to 

350°C for the remainder of the test. At a cable temperature of 200°C, the jacket was observed to 

be popping and liquid was later seen out of the temperature monitoring cable. Blistering and 

swelling of the cable jacket was noticed at an approximate cable temperature of 250°C. When 

the cable temperature reached 287°C, Target 6, located on the ganged outer ring, was actuated 

and Penlight temperature was maintained for over 7 minutes before being shutdown. Ignition 
B - 128

did not occur during the test and the cable remained energized during the cool down period. 

Electrical performance of the cable may be found in Figure B.22. The electrical response of the 

cable to temperature may be found in Figure B.104. A summary of the test results may be found 

in Table B.105. 

Table B.103: Test parameters for Test D13, Qual. 

Test Series DESIREE-FIRE

Test Name Test D13-Qualification

Test Date 7/27/2010

Cable 1 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 300°C

Penlight Final Temperature 350°C

Table B.104: Conductor designation for Item H, Test D13, Qual. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

4 Green 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

5 Orange 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

6 Blue 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

7 White/Black 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

8 Red/Black 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

9 Green/Black 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

10 Orange/Black 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

Zinc Wrap NA Grounded to tray
B - 129

Figure B.103: All conductor voltages for Test D13, Qual. 

Figure B.104: Penlight shroud temperature and target conductor voltages for Test D13, Qual. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC

Side TC

Penlight

C1 V5

C1 V6
B - 130

Table B.105: Summary of observed faulting behavior for Test D13, Qual, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set at 

300°C (4.99 

kW/m2

) 

 

2100 

Penlight 

temperature 

increased to 

325°C. 

2195-2857 

Increase in 

voltage observed 

on active target 6 

Voltage begins to increase to a maximum of approximately 2V. This 

correlated with the increase in Penlight temperature from 300°C to 

325°C. 

2820 

Penlight 

temperature 

increased to 

350°C 

3360-5579 Target conductor 

6 was actuated 

Target 6 was actuated and maintained actuation for the duration of the 

experiment. The cable temperature was approximately 287°C. 

3804 Test concluded, 

Penlight shutdown 

5579 SCDU 

deenergized 

B.9.2 Test D13 

Test D13 utilized the SCDU to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.106. The conductor pathway 

for the cable monitoring unit may be found in Table B.107. Electrical performance of the cable 

may be found in Figure B.105. From this graph, the dark blue and light blue lines display the 

source and target voltages, the orange and dark green represent active targets, and the light green 

line represents the conductor monitoring ground. 

Penlight was initially set to 350°C for approximately 32 minutes. During this stabilized heating 

period, electrical degradation could be observed for the active target conductors as voltages and 

currents increased, as observed in Figure B.105. Just over twenty minutes into the test, voltages 

increased on both Target 5 and Target 6 to about 4 V and 12 V, respectively. These voltages 

stabilized until ignition. Smoke was noticed at 10 minutes into the test and at 200°C on the cable 

thermocouples, cable jacket popping and crackling was heard and liquid was later seen bubbling 

out of the temperature monitoring cables. After this initial heating period, Penlight was 

increased to 375°C for 13 minutes. Penlight was then increased to 400°C for 10 minutes. The 

Penlight set point was increased to 425°C for 16 minutes before being increased to 470°C. 

Ignition occurred shortly after the increase at a cable temperature of 374°C. Both Target 5 and 6 

did not actuate before the fuse was tripped; however, voltages on Target 6 increased to 47 V. The 

electrical response of the cable to temperature may be found in Figure B.106. A summary of the 

test results may be found in Table B.108. 
B - 131

Table B.106: Test parameters for Test D13, Circuit 2. 

Test Series DESIREE-FIRE

Test Name Test D13

Test Date 7/27/2010

Cable 1* Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 350°C

Penlight Final Temperature 470°C

* See section B.5.1 for results

Table B.107: Conductor designation for Item H, Test D13. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

2 White 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

3 Red 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

4 Green 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

5 Orange 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

6 Blue 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

7 White/Black 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

8 Red/Black 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

9 Green/Black 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

10 Orange/Black 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

Zinc Wrap NA Grounded to tray
B - 132

Figure B.105: Voltages for Test D13 showing increases on target conductors. 

Figure B.106: Penlight shroud temperature and target conductor voltages for Test D13. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C2 V1

C2 V2

C2 V5

C2 V6

0

10

20

30

40

50

0

100

200

300

400

500

0 2000 4000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 10c

Side TC for 10c

Penlight

C2 V5

C2 V6
B - 133

Table B.108: Summary of observed faulting behavior for Test D13, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set at 

350°C (6.97 

kW/m2

) 

 

1260-1768 

Increasing voltage 

occurs on Target 5 

and Target 6 

Increased voltages were being detected on both Target 5 and Target 6 

when the cable temperatures were approximately 261°C. Target 5 

hovered at 4 V while Target 6 reached just over 12 V. 

1768-2790 

Voltages stabilize 

on both Target 5 

and Target 6 

The voltage increase on Target 5 stabilized at around 2.5 V until 4450 s. 

Target 6 stabilized at approximately 5.7 V until rougly the same time as 

Target 5. 

1920 Penlight increased 

to 375°C 

2700 Penlight increased 

to 400°C 

3300 Penlight increased 

to 425°C 

4260 Penlight increased 

to 470°C 

4362 Ignition Cables ignited at a cable temperature of 374°C and an exposure of 

470°C. 

4450 

Target 5 and 6 

experienced an 

increase in voltages 

At this approximate time, the cables within Penlight ignited. Voltages 

steadily increased on both Target 5 and 6 until the ultimate failure at 

4590. Target 5 edged to around 3 V while Target 6 reached 8 V. 

4590 

Target 6 

experienced a 

voltage increase and 

subsequently 

tripped the 3 A fuse. 

Upon ignition, the cable experienced degradation which ultimately lead 

to shorting behavior that tripped the fuse. Though Target 6 did not 

actuate, there was an increase in voltage to approximately 47 V. 

4662 Test concluded, 

Penlight shutdown 

B.9.3 Test D14 

One of the objectives of Test D14 was to investigate how the cable sample would perform 

electrically under a higher initial temperature than Test D13. Test D14 utilized the SCDU to 

monitor the electrical performance of the cable throughout the thermal exposure. The test 

parameters may be found in Table B.109. The conductor pathway for the cable monitoring unit 

may be found in Table B.110. Penlight was initially set to 450°C and blistering and popping of 

the jacketing material was observed approximately six minutes into the test. At the initial 

exposure condition, ignition occurred approximately 10 minutes into the test at a cable 

temperature of approximately 288°C. Electrical performance of the cable may be observed in 

Figure B.107. From this figure, the target voltages in did not experience electrical degradation 

during the initial heating phase as was observed in previous tests (e.g., Test D13). Upon 

ignition, the cable displayed signs of degradation prior to ultimate failure (fuse clear). The fuse 

would clear approximately 6 minutes after ignition. The electrical response of the cable to 
B - 134

temperature may be found in Figure B.108. A summary of the test results may be found in Table 

B.111. 

Table B.109: Test parameters for Test D14, Circuit 2. 

Test Series DESIREE-FIRE

Test Name Test D14

Test Date 7/28/2010

Cable 1* Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 450°C

Penlight Final Temperature 450°C

* See section B.5.2 for results

Table B.110: Conductor designation for Item H, Test D14, Circuit 2. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

2 White 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

3 Red 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

4 Green 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

5 Orange 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

6 Blue 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

7 White/Black 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

8 Red/Black 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

9 Green/Black 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

10 Orange/Black 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

Zinc Wrap NA Grounded to tray
B - 135

Figure B.107: All conductor voltages for Test D14 displaying the target voltage increase followed 

by fuse clear. 

Figure B.108: Penlight shroud temperature and target conductor voltages for Test D14 displaying 

the slight voltage increase prior to fuse clear. 

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400

Voltage (Vac)

Time (s)

C2 V1

C2 V2

C2 V5

C2 V6

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 500 1000 1500

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 10c

Side TC for 10c

Penlight

C2 V5

C2 V6

C2 V2
B - 136

Figure B.109: Modified target conductor voltages and Penlight shroud temperature for Test D14 

displaying the slight voltage increase on the target voltages prior to fuse clear. 

Table B.111: Summary of observed faulting behavior for Test D14, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set at 

450°C (12.64 

kW/m2

) 

 

600 Ignition The cable temperature was approximately 226°C. 

760 Voltage increase 

on Target 6 

At this time, the voltage steadily increased to approximately 4V. The 

voltage decreased to about 2V over the span of about three minutes. 

966 Fuse clear No components were activated. 

1006 Test concluded, 

Penlight shutdown 

B.9.4 Test D15 

Test D15 was conducted to replicate the heating protocol of DESIREE-Fire Test 13, qualification 

in which a low temperature failure was observed. SCDU was utilized to monitor the electrical 

performance of the cable throughout the thermal exposure. The test parameters may be found in 

Table B.112. The conductor pathway for the cable monitoring unit may be found in Table 

B.113. Electrical performance of the cable may be found in Figure B.110. 

Penlight was initially set to 300°C for approximately 37 minutes. During this stabilized heating 

period, electrical degradation could be observed on the active target conductors and the grounded 

0

1

2

3

4

5

6

7

0

100

200

300

400

500

600

700

0 500 1000 1500

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 10c

Side TC for 10c

Penlight

C2 V5

C2 V6
B - 137

conductor as voltages and currents increased, which may be observed in Figure B.111 and Figure 

B.112. Smoke was observed approximately 15 minutes into the test at an approximate cable 

temperature of 215°C. Soon after smoke was noticed, jacket swelling and popping was observed 

and liquid was seen bubbling out of the thermal monitoring cables at a cable temperature of 

253°C. After the initial heating period, the Penlight set point temperature would be increased to 

325°C for 12 minutes. Concurrently, voltages were increasing on both Target 5 and Target 6 to 

approximately 12 V and 4 V, respectively. Penlight was then increased to 350°C for 15 minutes. 

The temperature was then increased to 375°C for approximately 15 minutes before a final 

increase to 400°C for the remainder of the test (16 minutes). The test was concluded prior to 

ultimate electrical failure (i.e., fuse clear or spurious operation) and ignition to inspect the 

conductor integrity after the exposure. Although ultimate circuit failure did not occur during this 

test, electrical degradation was observed during the low temperature heating phase. The 

temperature protocol and electrical response may be found in Figure B.113. A summary of the 

test results may be found in Table B.114. 

Table B.112: Test parameters for Test D15. 

Test Series DESIREE-FIRE

Test Name Test D15

Test Date 7/28/2010

Cable 1* Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 300°C

Penlight Final Temperature 400°C

* See section B.5.3 for results

Table B.113: Conductor designation for Item H, Test D15, Circuit 2. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2 Energized source conductor for SCDU2– 

Voltage = C2 V2; current = C2 I2 

2 White 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

3 Red 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

4 Green 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

5 Orange 2 S1 Energized source conductor for SCDU2– 
B - 138

Table B.113: Conductor designation for Item H, Test D15, Circuit 2. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

Voltage = C2 V1; current = C2 I1 

6 Blue 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

7 White/Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

8 Red/Black 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

9 Green/Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

10 Orange/Black 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

Zinc Wrap NA Grounded to tray

Figure B.110: All source and target conductor voltages for Test D15 displaying early degradation. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C2 V1

C2 V2

C2 V5

C2 V6
B - 139

Figure B.111: Source and target conductors located on the outer ring display early degradation as 

currents and voltages increase for Test D15. 

Figure B.112: Source and target conductors located in the inner core display early degradation as 

currents and voltages increase for Test D15. 

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0

20

40

60

80

100

120

140

0 2000 4000 6000 8000

Voltage (Vac)

Current (A)

Time (s)

C2 V1

C2 V5

C2 A1

C2 A5

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0

20

40

60

80

100

120

140

0 2000 4000 6000 8000

Voltage (Vac)

Current (A)

Time (s)

C2 V2

C2 V6

C2 A2

C2 A6
B - 140

Figure B.113: Penlight shroud temperature and target conductor voltages for Test D15. 

Table B.114: Summary of observed faulting behavior for Test D15, Circuit 2.

Time (s) Event Discussion 

0 

Penlight On; set at 

300°C (4.99 

kW/m2

) 

 

2240 

Penlight 

temperature 

increased to 

325°C 

2308-3258 

Voltage increase 

on Target 5 and 

Target 6 

Target 5 experienced an increase of 12 V while Target 6 experienced 

about 4 V. The cable temperature at this initial time was approximately 

253°C. 

2960 

Penlight 

temperature 

increased to 

350°C 

3258-4820 

Voltage decrease 

on Target 5 and 

Target 6 

Over this time span, the voltage gradually decreases before stabilizing. 

The cable temperature at this initial time was approximately 285°C. 

3860 

Penlight 

temperature 

increased to 

375°C 

4790 

Penlight 

temperature 

increased to 

0

3

6

9

12

15

0

100

200

300

400

500

0 2000 4000 6000 8000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 10c

Side TC for 10c

Penlight

C2 V5

C2 V6
B - 141

Table B.114: Summary of observed faulting behavior for Test D15, Circuit 2.

Time (s) Event Discussion 

400°C 

4820-5885 Targets 5 and 6 

stabilize 

Targets 5 and 6 stabilize to about 7 V and 3 V, respectively, for the 

duration of the test. The cable temperature at this initial time was 

approximately 328°C. 

5885 Test concluded, 

Penlight shutdown 

B.9.5 Test D16 

One of the objectives of Test D16 was to investigate how the cable sample would perform 

electrically under a typical Penlight set point value for thermoset materials. Test D16 utilized the 

SCDU to monitor the electrical performance of the cable throughout the thermal exposure. The 

test parameters may be found in Table B.115. The conductor pathway for the cable monitoring 

unit may be found in Table B.116. Penlight was initially set to 470°C and blistering and popping 

of the jacketing material was observed approximately five minutes into the test and ignition 

occurred shortly after at a cable temperature of approximately 210°C. Electrical performance of 

the cable may be observed in Figure B.114. From this figure, the target voltages experienced 

slight electrical degradation as voltage increased to approximately 2 V on Target 6 before the 

fuse cleared. Spurious actuation did not occur during this test. The electrical response of the 

cable to temperature may be found in Figure B.115. A summary of the test results may be found 

in Table B.117. 

Table B.115: Test parameters for Test D16. 

Test Series DESIREE-FIRE

Test Name Test D16

Test Date 7/28/2010

Cable 1 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU1

Cable 2* Kerite 5/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU2

Penlight Starting Temperature 470°C

Penlight Final Temperature 470°C

* See section B.5.4 for results
B - 142

Table B.116: Conductor designation for Item H, Test D16, Circuit 1. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

4 Green 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

5 Orange 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

6 Blue 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

7 White/Black 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

8 Red/Black 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

9 Green/Black 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

10 Orange/Black 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

Zinc Wrap NA Grounded to tray
B - 143

Figure B.114: Conductor voltages for Test D16 showing a fuse clear. 

Figure B.115: Penlight shroud temperature and conductor voltages for Test D16. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 500 1000 1500 2000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 10c

Side TC for 10c

Penlight

C1 V1

C1 V2
B - 144

Table B.117: Summary of Observed Faulting Behavior for Test D16, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set at 

470°C (14.09 

kW/m2

) 

 

353 Ignition The cable temperature was approximately 202°C. 

630 Voltage increase 

on Target 6 Voltages remained around 2V until the ultimate fuse clear. 

834 Fuse clear 

922 Test concluded, 

Penlight shutdown 

B.9.6 Test IS9 

The intermediate-scale test series conducted during DESIREE-Fire provided a target opportunity 

to investigate the performance of Kerite cable in a more representative fire environment. During 

Test IS9, Item H was connected to the dc-powered SOV1 circuit and situated in Position B. The 

test parameters may be found in Table B.118. The conductor pathway for the cable monitoring 

unit may be found in Table B.119. Electrical performance of the cable may be found in Figure 

B.116 and Figure B.117. In the former graph, the positive and negative sources were graphed 

with the coil voltage. From here, a spurious actuation occurs at 2584 s and continues for 

approximately 112 s before a subsequent fuse clear. The latter graph displays the voltage of the 

lamps throughout the test. From this graph, two separate hot shorts occurred causing a false 

indication on the red indication lamp. When looking both figures, it should be noted that the 

voltages are referenced to ground. Since the other fused circuits are connected to the same dc 

power supply, the ground continues to drift after the fuses clear on SOV1. The temperature 

profile and voltage response may be found in Figure B.118. In this figure, the air temperature is 

listed as the location of the cable and the length along the tray while the sub-jacket temperature 

is listed with the location of the cable, cable type, and length along the sample. A summary of 

the test results may be found in Table B.120. 

Table B.118: Test parameters for Test IS9. 

Test Name Test IS9

Test Date 3/17/2010

Cable Type for SOV1 Kerite, 10/C-12 AWG, FR, zinc wrap

SOV1 Position Position B

Cable Fill Type Specialized Tray B, Cable 4

Cables Co-Located in Raceway

Cable 1 - 1-in. Valve

Cable 2 - Large Coil

Cable 3 - MOV1
B - 145

Table B.118: Test parameters for Test IS9. 

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Table B.119: Conductor designation for Item H, Test IS9. 

Test IS9, SOV 1, 10/C-12 AWG, zinc wrap 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB2 P 3 Red

2 White TB4 G 4 Green

3 Red TB3 S1 5 Orange

4 Green TB6 R 6 Blue

5 Orange TB9 N 7 White/Black

6 Blue TB7 SP 8 Red/Black

7 White/Black TB8 S2 9 Green/Black

Figure B.116: Voltage and current response for the active target in Test IS9, SOV1. 

 

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Current (A)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

S1 - Positive Source

G - Green Lamp

S2 - Coil

N - Negative

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-40

0

40

80

120

160

200

P - Positive

S2 - Coil

N - Negative

P = 6.95 A at 2417 s

N = 4.58 A at 2698 s
B - 146

Figure B.117: Voltage and current response for the lamps in Test IS9, SOV1. 

Figure B.118: Temperature profile and electrical response for Test IS9, SOV1. 

Table B.120: Summary of observed faulting behavior for Test IS9, Item H.

Time (s) Event Discussion 

0 Fire initiated 

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Current (A)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

S1 - Positive Source

G - Green Lamp

N - Negative

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-40

0

40

80

120

160

200

G - Green Lamp

R - Red Lamp

6.95 A at 2417 s

N = 4.58 A at 2698 s

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

1000

Voltage (Vdc)

0

40

80

120

160

B Position - Middle

B Position - Kerite 10c w

S2 - Coil
B - 147

Table B.120: Summary of observed faulting behavior for Test IS9, Item H.

Time (s) Event Discussion 

2101-2225 

Voltage increase 

from 1.58V to 

12.05V on 

solenoid 

2227-2418 

Voltage on 

Solenoid 

Nominally 

Steady from 

12.14V 

2421-2582 

Voltage on 

Solenoid 

Nominally 

Steady from 

39.45V 

2429-2432 False indication 

red light 

2435-2584 False indication 

red light The red lamp experienced a short at this time. 

2584-2696 

Spurious 

actuation on 

solenoid 

The spurious actuation continued for approximately 112 s. 

2699 

Positive and 

negative fuses 

clear 

The main battery bank is used to power all the dc circuits during the 

intermediate-scale experiments. Since the graphed voltage is referenced 

to the common ground and not all circuit fuses clear at the same time, 

some graphs may indicate that electrical activity is occurring after this 

noted time. 

3300 Fire Off 

B.9.7 Test IS10 

During Test IS10, Item H was connected to the dc-powered MOV2 circuit and situated in 

Position B. The test parameters may be found in Table B.121. The conductor pathway for the 

cable monitoring unit may be found in Table B.122. Electrical performance of the cable may be 

found in Figure B.119 and Figure B.120. In the former graph, the positive and negative sources 

were graphed with the coil voltage. From here, a spurious actuation occurs at 2798 s and 

continues for approximately 37 s before a subsequent fuse clear. The latter graph displays the 

voltage of the lamps throughout the test. When looking at the graphs, it should be noted that the 

voltages are referenced to ground. Since the other fused circuits are connected to the same dc 

power supply, the ground continues to drift after the negative fuse clears on MOV2. The 

temperature profile and voltage response may be found in Figure B.121. In this figure, the air 
B - 148

temperature is listed as the location of the cable and the length along the tray while the subjacket temperature is listed with the location of the cable, cable type, and length along the 

sample. A summary of the test results may be found in Table B.123. 

Table B.121: Test parameters for Test IS10. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for MOV2 Kerite, 10/C-12 AWG, FR, zinc wrap

MOV2 Position Position B, Cable 1

Cable Fill Type Fill Tray

Cables Co-Located in Raceway Cable 2 - SWGR Close and Trip

Cable 3 - SOV2

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table B.122: Conductor designation for Item H, Test IS10. 

Test IS10, MOV2, 10/C-12 AWG, zinc wrap 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB 3i P 3 Red

2 White TB 3/C G 4 Green

3 Red TB 7/C YC1 5 Orange

4 Green TB 4/C R 6 Blue

5 Orange TB 6i SP 7 White/Black

6 Blue TB 5i N 8 Red/Black

7 White/Black TB 6c YO1 9 Green/Black
B - 149

Figure B.119: Voltage and current response for the active target in Test IS10, MOV2. 

Figure B.120: Voltage and current response for the lamps in Test IS10, MOV2. 

2000 2500 3000 3500 4000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (s)

2000 2500 3000 3500 4000

Voltage (Vdc)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

1.61 A

2000 2500 3000 3500 4000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (s)

2000 2500 3000 3500 4000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp
B - 150

Figure B.121: Temperature profile and electrical response for Test IS10, MOV2. 

Table B.123: Summary of observed faulting behavior for Test IS10, Item H.

Time (s) Event Discussion 

0 Fire initiated 

2159 Voltage increase 

on the open coil The temperature of the cable at this time was approximately 251°C 

2764-2836 Current increase 

on green light 

2798-2835 

Spurious 

actuation close 

coil 

At this time, the current was 0.63347 A. The spurious actuation 

continued for 37 s. 

2802 Air TC failure 

The air TC located in the middle of the tray during this test displayed 

failure after this point. Temperatures were erratic and jumped between 

uncharacteristically high and low readings. 

2836 

Positive and 

negative fuses 

clear 

 

3960 Fire off 

B.9.8 Test K4 

Test K4 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

B Position - M iddle

B Position - Kerite 10c w

Close Coil

Open Coil
B - 151

found in Table B.124. The conductor pathway for the cable monitoring unit may be found in 

Table B.125. Penlight was initially set to 325°C for a half hour before the temperature was 

increased 10°C every five minutes. The final Penlight set point temperature was 365°C. 

Electrical degradation on the altered source conductors occurred at approximately 1322 s into the 

test at a Penlight and cable temperature of 325°C and 270°C, respectively. The degradation was 

initially observed on the two center conductors with an increase of 17 V on the nominal 40 V 

conductor and a decrease of 8 V on the nominal 80 V conductor. At the onset of this voltage 

change, each of the active targets experienced a voltage increase. The degradation on the target 

conductors occurred at approximately 1392 s into the test at a Penlight and cable temperature of 

335°C and 266°C, respectively. At 1980 s, there was a spurious actuation on the active target for 

SCDU1 from the source conductor from SCDU2. The cable temperature was 296°C at the time 

of actuation. The spurious operation continued for approximately 12 minutes. At 2184 s, the 

active target for SCDU3 increased to approximately 60 V and 0.74 A before the fuse cleared. At 

2700 s, Penlight was shut down prior to ignition in order to preserve the sample for post-test 

examination. Only the fuse in SCDU3 cleared. In Figure B.122, all the test conductor voltages 

are graphed displaying the overall performance of the cable during thermal exposure. All 120 V 

source voltages were graphed in Figure B.123 to display the fuse clear at 2184 s. The 80 V and 

40 V conductor voltages were graphed in Figure B.124 to display the early degradation at 1322 s. 

The target voltages were displayed in Figure B.125 which displays the early degradation and the 

spurious actuation at 1980 s. The overall temperature profile and electrical response may be 

found in Figure B.126. A summary of the electrical performance of the cable may be found in 

Table B.126. 

Table B.124: Test parameters for Test K4. 

Test Series KATE-FIRE

Test Name Test K4

Test Date 11/8/2010

Cable 1 Kerite 10/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 365°C
B - 152

Table B.125: Conductor designation for Item H, Test K4. 

Kerite 10/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

2 White 3 S2/T4 Adjusted source conductor which was 

connected through 0.9 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 80 V – SCDU3

Voltage = C3 V4; current = C3 I4

3 Red 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

4 Green 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

5 Orange 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

6 Blue 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

7 White/Black 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

8 Red/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

9 Green/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

10 Orange/Black 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5

Zinc Wrap NA NA NA Grounded to tray, but not monitored
B - 153

Figure B.122: All conductor voltages for Test K4 displaying early degradation on the target and 

modified source voltages. 

Figure B.123: All 120 V source conductor voltages for Test K4 displaying a fuse clear at 2187 s. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C2 V1

C2 V4

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V5

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C1 V1

C2 V1

C3 V1

C4 V1
B - 154

Figure B.124: Altered source conductor voltages for Test K4 displaying degradation. 

Figure B.125: All target conductor voltages for Test K4 displaying a spurious actuation. 

0

10

20

30

40

50

60

70

80

90

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Time (s)

C2 V4

C3 V4

0

20

40

60

80

100

120

140

1200 1700 2200 2700 3200

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5
B - 155

Figure B.126: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K4. 

Table B.126: Summary of observed faulting behavior for Test K4.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1322-1980 

Voltage increase on 

40 V conductor, 

voltage decrease on 

80 V conductor 

The voltages began to converge indicating incipient 

leakage to one another. The voltage on the 40 V 

conductor (stable at 43 V prior to leakage) increased to 

nominally 57 V while the 80 V (stable at 84 V prior to 

leakage) conductor decreased to 76 V. At the initial 

time, the temperature is approximately 266°C. 

1392-1980 

Voltage increase on 

active target for 

SCDU1 

The voltage on the active target for SCDU1 increased 

steadily to 8 V until locking in. The temperature of the 

cable was approximately 270°C at the initial time of 

increase. 

1392-2187 

Voltage increase on 

active targets for 

SCDU2, 3, and 4 

The voltage on active targets for SCDU2, 3, and 4 

continued until the fuse clear on SCDU3. The maximum 

voltage on SCDU2, 3, and 4 were approximately 4 V, 

3.8 V, and 2.5 V, respectively. 

1800-2700 

Penlight temperature 

increased by 10°C 

every 5 minutes 

The Penlight set point temperature at the conclusion of 

the test was 365°C. 

0

20

40

60

80

100

120

140

0

100

200

300

400

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C2 V5

C3 V5

C4 V5
B - 156

Table B.126: Summary of observed faulting behavior for Test K4.

Time (s) Event Discussion 

1980-2700 

Spurious actuation 

on active target for 

SCDU1 

During this time period, the active target for SCDU1 

spuriously actuated and continued for the duration of the 

test. The locked in voltage and current were 

approximately 124 V and 0.17 A. When looking at the 

data, the 120 V source conductor for SCDU2 was the 

major contributor to the actuation. The cable 

temperature at actuation was 296°C. 

2184-2187 

Active target for 

SCDU3 experienced 

voltage and current 

leakage 

The active target for SCDU3 experienced a maximum of 

nearly 60 V and 0.74 A during this time period before 

the fuse cleared. 

2187 Fuse clears for 

SCDU3 

Although the fuse clears on SCDU3, the 80 V conductor 

continued to see 10.13 V from another conductor while 

the nominal 40V conductor declined to approximately 

37V. 

2700 Test concluded, 

Penlight shutdown 

Penlight was shut down before the cables could ignite. 

The cable temperatures reached 326°C before the test 

was concluded. 

B.10 Cable Item I: 12/C-12 AWG, FR-III 

Cable Item I is a 12/C-12 AWG cable with FR-III insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure 

B.127. The cable was tested once during the DESIREE-Fire series intermediate-scale tests on 

the dc powered SOV1 circuit. It was tested once during the KATE-Fire tests on the modified 

SCDU circuit. The following sections detail the test parameters, conductor paths, circuit data, 

and test summary for each test. 

Figure B.127: Illustration of Cable Item I.
B - 157

B.10.1Test IS10 

The intermediate-scale test series conducted during DESIREE-Fire provided a target opportunity 

to investigate the performance of Kerite cable in a more representative fire environment. During 

Test IS10, Item I was connected to the dc-powered SOV1 circuit and situated in Position B. The 

test parameters may be found in Table B.127. The conductor pathway for the cable monitoring 

unit may be found in Table B.128. Electrical performance of the cable may be found in Figure 

B.128 and Figure B.129. In the former graph, the positive and negative sources are graphed with 

the coil voltage. From here, a gradual voltage increase may be seen on the solenoid conductor; 

however, there was not sufficient enough voltage to cause spurious actuation before a subsequent 

fuse clear. The latter graph displays the voltage of the lamps throughout the test. The voltage 

reaches a point where false indication of the red light is observed. When looking at the graphs, it 

should be noted that the voltages are referenced to ground. Since the other fused circuits are 

connected to the same dc power supply, the ground continues to drift after the negative fuse 

clears on SOV1. The temperature profile and voltage response may be found in Figure B.130. 

In this figure, the air temperature is listed as the location of the cable and the length along the 

tray while the sub-jacket temperature is listed with the location of the cable, cable type, and 

length along the sample. A summary of the test results may be found in Table B.129. 

Table B.127: Test parameters for Test IS10. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for SOV1 Kerite 12/C-12 AWG, FR-III

SOV1 Position Position C

Cable Fill Type Bundle Tray A, Cable 1

Cables Co-Located in Raceway

Cable 2 - TC Cable for SOV1

Cable 3 - MOV1

Cable 4 - TC Cable for MOV1

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table B.128: Conductor designation for Item I, Test IS10. 

Test IS10, SOV1, 12/C-12 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1 Black TB2 P 4 Green

2 White TB4 G 5 Orange

3 Red TB3 S1 6 Blue

4 Green TB6 R 7 White/Black
B - 158

Table B.128: Conductor designation for Item I, Test IS10. 

Test IS10, SOV1, 12/C-12 AWG 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

5 Orange TB9 N 8 Red/Black

6 Blue TB7 SP 9 Green/Black

7 White/Black TB8 S2 10 Orange/Black

Figure B.128: Voltage and current response for the active target in Test IS10, SOV1. 

Time (s)

2800 3000 3200 3400 3600 3800 4000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

S1 - Positive Source

G - Green Lamp

S2 - Coil

N - Negative

2800 3000 3200 3400 3600 3800 4000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

S2 - Coil

N - Negative

G = 6.33 A at 3360 s S1 = 3.41 A at 3370 s
B - 159

Figure B.129: Voltage and current response for the lamps in Test IS10, SOV1. 

Figure B.130: Temperature profile and electrical response for Test IS10, SOV1. 

Table B.129: Summary of observed faulting behavior for Test IS10, Item I. 

Time (s) Event Discussion 

0 Fire initiated 

Time (s)

2800 3000 3200 3400 3600 3800 4000

Current (A)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

S1 - Positive Source

G - Green Lamp

N - Negative

2800 3000 3200 3400 3600 3800 4000

Voltage (Vdc)

-40

0

40

80

120

160

G - Green Lamp

R - Red Lamp

G = 6.33 A at 3360 s S1 = 3.41 A at 3370 s

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

Voltage (Vdc)

0

40

80

120

160

C Position - 3'

C Position - 7'

C Position - Kerite 12c wo - 3'

S2 - Coil
B - 160

Table B.129: Summary of observed faulting behavior for Test IS10, Item I. 

Time (s) Event Discussion 

2298-2463 

Voltage increase 

from 1.06V to 

38V on Solenoid 

2458-2463 False indication 

red light 

3372 Positive fuse 

clears 

The main battery bank is used to power all the dc circuits during the 

intermediate-scale experiments. Since the graphed voltage is referenced 

to the common ground and not all circuit fuses clear at the same time, 

some graphs may indicate that electrical activity is occurring after this 

noted time. 

3960 Fire off 

B.10.2 Test K19 

Test K19 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.130. Penlight was initially set to 325°C for a half hour before the temperature 

was increased 10°C every five minutes. The final Penlight set point temperature was 445°C. At 

3000 s into the test and a cable temperature of 330 °C, the voltage on the 40 V center conductor 

increased from 43 V to 47 V over a 37 minute time span. At approximately 4974 s into the test, 

the cables ignited at a Penlight and cable temperature of 435 °C and 400 °C, respectively. The 

fuse for SCDU1 cleared approximately 3 minutes later. At 5210 s, the fuse on SCDU2 cleared. 

About 9 s later, there was a voltage increase of less than 1 V to 21 V over a 5 s span on the active 

target for SCDU3 before the fuse on SCDU4 cleared. The final fuse cleared at 5311 s and the 

test was subsequently concluded. The conductor pathway for the cable monitoring unit may be 

found in Table B.131. Overall electrical performance of the cable may be found in Figure B.131. 

A graph displaying the target behavior may be observed in Figure B.133. A graph displaying the 

fuse clears may be found in Figure B.132. The electrical performance for the temperature 

exposure may be found in Figure B.134. A summary of the electrical performance of the cable 

may be found in Table B.132. 

Table B.130: Test parameters for Test K19. 

Test Series KATE-FIRE

Test Name Test 19

Test Date 11/10/2010

Cable 1 Kerite 12/C-12 AWG, FR-III

Cable Monitoring Unit Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit Utilized NA
B - 161

Table B.130: Test parameters for Test K19. 

Penlight Starting Temperature 325 °C

Penlight Final Temperature 445 °C

Table B.131: Conductor designation for Item I, Test K19. 

Kerite 12/C-12 AWG, FR-III. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

2 White 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4

3 Red 4 S2/T4 Adjusted source conductor which was 

connected through 0.9 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 80 V – SCDU3

Voltage = C3 V4; current = C3 I4

4 Green 1 G7 Grounded conductor for SCDU1– 

Voltage = C1 V7; current = C1 I7 

5 Orange 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

6 Blue 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

7 White/Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

8 Red/Black 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

9 Green/Black 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

10 Orange/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

11 Blue/Black 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

12 Black/White 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5
B - 162

Figure B.131: All conductor voltages for Test K19. 

Figure B.132: All 120 V source conductor voltages for Test K19 displaying fuse clears. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C1 V7

C2 V1

C2 V4

C2 V5

C3 V1

C3 V4

C3 V5

C4 V1

C4 V4

C4 V5

0

20

40

60

80

100

120

140

5000 5100 5200 5300 5400

Voltage (Vac)

Time (s)

C1 V1

C2 V1

C3 V1

C4 V1
B - 163

Figure B.133: All target conductor voltages for Test K19 displaying voltage increase, but did not 

result in actuation. 

Figure B.134: Penlight shroud temperature, cable temperatures, and conductor voltages for 

Test K19. 

0

5

10

15

20

25

5000 5100 5200 5300 5400

Voltage (Vac)

Time (s)

C1 V5

C2 V5

C3 V5

C4 V5

0

30

60

90

120

150

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V1

C2 V1

C3 V1

C4 V1
B - 164

Table B.132: Summary of observed faulting behavior for Test K19.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1800-5335 

Penlight temperature 

increased by 10°C 

every 5 minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 445°C. 

3000-5219 

Voltage increase on 

the 40 V center 

conductor 

During this time span, the voltage increased on the 

nominal 40 V conductor (reading approximately 43 V 

throughout the first part of the test) to a maximum of 47 

V. The temperature at the initial voltage increase was 

approximately 330 °C. 

~4974 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 400 °C. 

5159 Fuse clear SCDU1 

5210 Fuse clear SCDU2 

5219-5224 

Voltage increase on 

the active target of 

SCDU3 

The voltage increased from 1 V to a maximum of 21 V 

on the active target of SCDU3 before the SCDU4 fuse 

cleared. During this period of time, the current increased 

from approximately 0.04 A to 0.33 A. There was no 

actuation. 

5224 Fuse clear SCDU4 

5311 Fuse clear SCDU3 

Although the fuses on SCDU1, 2, and 4 cleared earlier 

than SCDU3, the 60 V conductor continued to provide 

up to 9 V and 4 V on the 40 and 80 V conductors, 

respectively, until the ultimate fuse clear. 

5335 Test concluded, 

Penlight shutdown 

B.11 Cable Item J: 15/C-12 AWG, FR, zinc wrap 

Cable Item J is a 15/C-12 AWG cable with FR insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure 

B.135. Surrounding the conductors is a zinc tape wrap which was grounded during each test 

based on typical plant practices as specified by the donating company. The cable was tested 

once during DESIREE-Fire using the switchgear trip and close circuits. It was tested once 

during KATE-Fire on a modified SCDU. The following sections detail the test parameters, 

conductor paths, circuit data, and test summary for each test. 
B - 165

Figure B.135: Illustration of Cable Item J.

B.11.1Test IS10 

The intermediate-scale test series conducted during DESIREE-Fire provided a target opportunity 

to investigate the performance of Kerite cable in a more representative fire environment. During 

Test IS10, Item J was connected to the dc-powered switchgear trip and close circuit and situated 

in Position B. The test parameters may be found in Table B.133. The conductor pathway for the 

cable monitoring unit may be found in Table B.134. From here, it may be discerned that the 

inner core of conductors were connected to the close coil circuit and the outer core conductors 

were connected to the trip circuit. The electrical performance of the cable may be found in 

Figure B.136, Figure B.137, and Figure B.138 which represents the close coil, trip coil, and 

indication lamps during the thermal exposure. At 2644 s and a cable temperature of 261°C, 

voltage on the green conductor began to decrease. At 2802 s, the TC monitoring the air 

temperature started to display erratic behavior, fluctuating between 0 and 1400°C for the 

remainder of the test. At 3108 s and a cable temperature of 331°C, the trip coil actuated. The 

temperature profile and voltage response may be found in Figure B.139. In this figure, the air 

temperature is listed as the location of the cable and the length along the tray while the subjacket temperature is listed with the location of the cable, cable type, and length along the 

sample. A summary of the test results may be found in Table B.135. 

Table B.133: Test parameters for Test IS10. 

Test Name Test IS10

Test Date 3/25/2010

Cable Type for SWGR T/C Kerite, 15/C-12 AWG, FR, zinc wrap

SWGR T/C Position Position B

Cable Fill Type Specialized Tray C, Cable 2

Cables Co-Located in Raceway Cable 1 - MOV2

Cable 3 - SOV2

Battery Voltage (Pre-test) 121.96 Vdc
B - 166

Table B.133: Test parameters for Test IS10. 

Battery Voltage (Post-test) 122.21 Vdc

Table B.134: Conductor designation for Item J, Test IS10. 

Test IS10, Switchgear, 15/C-12 AWG, zinc wrap 

Lead Cable 

Conductor 

number

Lead cable 

conductor 

color

Terminal 

block location 

in DCSim 

Panel

Terminal 

block circuit 

identification

Test Cable 

conductor 

number

Test cable 

conductor 

color

1a Black TB 2 PC 1 Black

2a White n/a n/a 2 White

3a Red TB 3 C1 3 Red

4a Green n/a n/a 4 Green

5a Orange TB 5 N1 5 Orange

6a Blue n/a n/a 6 Blue

7a White/Black n/a n/a 7 White/Black

1b Black TB2 PT 8 Red/Black

2b White TB3 G 9 Green/Black

3b Red TB6 T 10 Orange/Black

4b Green TB4 R 11 Blue/Black

5b Orange TB9 N2 12 Black/White

6b Blue TB8 SP 13 Red/White

7b White/Black TB7 SP 14 Green/White

NA NA NA NA 15 Orange/White
B - 167

Figure B.136: Voltage and current response for the close coil in Test IS10, SWGR. 

Figure B.137: Voltage and current response for the trip coil in Test IS10, SWGR. 

Time (s)

2000 2500 3000 3500 4000

Current (A)

0

2

4

6

8

PC - Positive (Close)

N1 - Negative (Close)

2000 2500 3000 3500 4000

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

160

PC - Positive (Close)

C1 - Close Coil

N1 - Negative (Close)

Time (s)

2000 2500 3000 3500 4000

Current (A)

0

2

4

6

8

PT - Positive (Trip)

G - Green Lamp

R - Red Lamp

N2 - Negative (Trip)

2000 2500 3000 3500 4000

Voltage (Vdc) -40

0

40

80

120

160

T - Trip Coil
B - 168

Figure B.138: Voltage and current response for the lamps in Test IS10, SWGR. 

Figure B.139: Temperature profile and electrical response for Test IS10, SWGR. 

Time (s)

2000 2500 3000 3500 4000

Current (A)

0

2

4

6

8

PT - Positive (Trip)

G - Green Lamp

R - Red Lamp

N2 - Negative (Trip)

2000 2500 3000 3500 4000

Voltage (Vdc)

-40

0

40

80

120

160

PT - Positive (Trip)

G - Green Lamp

R - Red Lamp

N2 - Negative (Trip)

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

100

200

300

400

500

600

700

Voltage (Vdc)

0

20

40

60

80

100

120

140

B Position - 5' - Kerite 15c w

G - Green Lamp

C1 - Close Coil

T - Trip Coil

B Position - Middle (air)
B - 169

Table B.135: Summary of observed faulting behavior for Test IS10. 

Time (s) Event Discussion 

0 Fire Initiated Breaker is closed, there is a jumper installed between C1 and PB. 

657- 968 

Negative going 

to ground 

potential 

 

968-2484 Negative shorted 

to ground 

2644-3090 

SWGR-T: 

Voltage on G 

decreasing 

slowly 

 The cable temperature was approximately 261°C when the voltage began 

decreasing. 

2802 

Air TC not 

functioning 

properly 

The air temperatures recorded by the TC fluctuated between 0 and 

1400°C erratically. 

3108 

SWGR-T: 

Spurious 

actuation on trip 

coil (T) 

 Breaker is open. At this time, the cable temperature was approximately 

338°C. 

3177 

SWGR-C: 

Positive fuse 

clears 

 

3236 

SWGR-C: 

Negative fuse 

clears 

 

3960 Fire off 

B.11.2 Test K20 

Test K20 utilized the multiple SCDU configuration detailed in Appendix A to monitor the 

electrical performance of the cable throughout the thermal exposure. The test parameters may be 

found in Table B.136. Penlight was initially set to 325°C for a half hour before the temperature 

was increased 10°C every five minutes. The final Penlight set point temperature was 415°C. 

Starting at 1994 s and 276°C, the voltages increased from less than 1 V to more than 5 V on the 

active targets in the inner and outer core over nearly a 7 minute time span. Additionally, during 

this period, the energized center conductors experienced voltage changes, the most dramatic was 

the 15 V drop in the nominal 80 V conductor. At 2400 s, the voltages steadily declined until the 

fuse on SCDU2 cleared at 3468 s. Ignition occurred at approximately 3933 s at a temperature of 

361°C. Shortly after ignition, the fuse on SCDU3 cleared. At 4321 s, a voltage increase from 5 

V to 39 V was detected on the source conductor for SCDU2 indicating shorting behavior from an 
B - 170

energized source, most likely from SCDU4, to that conductor. A spurious actuation was 

witnessed on the active target 6 for SCDU3 which persisted for 3 s. A high current short was 

observed on the SCDU1 and SCDU4 source until the fuses cleared at 4332 s. The test was 

subsequently concluded 25 s after these fuses cleared. The conductor pathway for the cable 

monitoring unit may be found in Table B.137. Overall electrical performance of the cable may 

be found in Figure B.140. A graph displaying the fuse clears may be found in Figure B.141. A 

graph displaying the target behavior may be observed in Figure B.142. The altered source 

conductors (i.e., the 40, 60, and 80 V) may be found in Figure B.143. These altered conductors 

were located in the center bundle of conductors along with two targets from SCDU2. The target 

performance from the center bundle may be found in Figure B.144. The electrical performance 

for the temperature exposure may be found in Figure B.145. A summary of the electrical 

performance of the cable may be found in Table B.138. 

Table B.136: Test parameters for Test K20. 

Test Series KATE-FIRE

Test Name Test 20

Test Date 11/11/2010

Cable 1 Kerite 15/C-12 AWG, FR, zinc wrap

Cable Monitoring Unit 

Utilized SCDU (M)

Cable 2 NA

Cable Monitoring Unit 

Utilized NA

Penlight Starting Temperature 325°C

Penlight Final Temperature 415°C

Table B.137: Conductor designation for Item J, Test K20. 

Kerite 15/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 2 S2/T4 Adjusted source conductor which was 

connected through 3.6 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 40 V – SCDU2

Voltage = C2 V4; current = C2 I4

2 White 3 S2/T4 Adjusted source conductor which was 

connected through 1.8 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 60 V – SCDU3

Voltage = C3 V4; current = C3 I4

3 Red 2 T5 Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5
B - 171

Table B.137: Conductor designation for Item J, Test K20. 

Kerite 15/C-12 AWG, FR, zinc wrap. Black cable, gray conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

4 Green 4 S2/T4 Adjusted source conductor which was 

connected through 0.9 kΩ resistor. By 

doing this, the output source voltage was 

reduced to 80 V – SCDU3

Voltage = C3 V4; current = C3 I4

5 Orange 2 T6 Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

6 Blue 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

7 White/Black 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

8 Red/Black 1 S2 Energized source conductor for SCDU1– 

Voltage = C1 V2; current = C1 I2 

9 Green/Black 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6

10 Orange/Black 2 S1 Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

11 Blue/Black 3 T5 Active target conductor for SCDU3 – 

Voltage = C3 V5; current = C3 I5

12 Black/White 3 S1 Energized source conductor for SCDU3– 

Voltage = C3 V1; current = C3 I1 

13 Red/White 3 T6 Active target conductor for SCDU3 – 

Voltage = C3 V6; current = C3 I6

14 Green/White 4 S1 Energized source conductor for SCDU4– 

Voltage = C4 V1; current = C4 I1 

15 Blue/White 4 T5 Active target conductor for SCDU4 – 

Voltage = C4 V5; current = C4 I5

Zinc Wrap NA 1 G7 Grounded conductor for SCDU1– 

Voltage = C1 V7; current = C1 I7 
B - 172

Figure B.140: All conductor voltages for Test K20 displaying early degradation and ultimate fuse 

clears. 

Figure B.141: All 120 V source conductor voltages for Test K20 displaying fuse clears. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C1 V5

C1 V6

C1 V7

C2 V1

C2 V4

C2 V5

C2 V6

C3 V1

C3 V4

C3 V5

C3 V6

C4 V1

C4 V4

C4 V5

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C1 V1

C1 V2

C2 V1

C3 V1

C4 V1
B - 173

Figure B.142: All target conductor voltages for Test K20 displaying early degradation. 

Figure B.143: All the altered conductor voltages for Test K20 displaying the early degradation and 

fuse clears. 

0

1

2

3

4

5

6

1500 2000 2500 3000 3500 4000 4500

Voltage (Vac)

Time (s)

C1 V5

C1 V6

C1 V7

C2 V5

C2 V6

C3 V5

C3 V6

C4 V5

0

10

20

30

40

50

60

70

80

90

0 1000 2000 3000 4000 5000

Voltage (Vac)

Time (s)

C2 V4

C3 V4

C4 V4
B - 174

Figure B.144: Target conductor voltages within the center bundle of conductors for Test K20. 

Figure B.145: Penlight shroud temperature, cable temperatures, and target conductor voltages for 

Test K20. 

0

1

2

3

4

5

6

1500 2000 2500 3000 3500 4000 4500

Voltage (Vac)

Time (s)

C2 V5

C2 V6

0

1

2

3

4

5

6

7

8

9

10

0

100

200

300

400

500

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

Temperature (°C)

Time (s)

Penlight

Cable 1

Cable 2

Cable 3

Cable 4

C1 V5

C1 V6

C3 V5

C3 V6

C4 V5
B - 175

Table B.138: Summary of observed faulting behavior for Test K20.

Time (s) Event Discussion 

0 Penlight On; set at 

325°C (5.92 kW/m2

) 

1800-4357 

Penlight temperature 

increased by 10°C 

every 5 minutes 

Penlight temperature was increased stepwise by10°C 

every 5 minutes during this time period until ignition. 

Upon ignition, the Penlight set point temperature 

remained constant until the conclusion of the test. The 

final Penlight set point was 415°C. 

1994-2400 Voltage increase on 

the active targets 

The active targets in the inner and outer core grouping of 

conductors all experienced an increase in voltage during 

this time span. The inner and outer core of active target 

conductors increased from less than 1 V to 

approximately 5 V. The temperature at the initial 

voltage increase was approximately 276°C. After this 

period of voltage increase, the voltages all declined until 

the fuses subsequently cleared. The energized sources in 

the center core of conductors experienced the most 

dramatic change in voltage as the nominal 80 V 

conductor (reading 85 V) dropped to approximately 60 

V, the nominal 60 V conductor (reading 63 V) dropped 

to approximately 50 V, and the nominal 40 V conductor 

(reading 43 V) dropped to 40 V. 

2083-2229 

Period of insulation 

resistance 

degradation 

From 2083-2229 s, the average IR on SCDU1, Target 5 

was approximately 1840 Ω. From 2083-2229 s, the 

average IR on SCDU1, Target 6 was approximately 

1691 Ω. From 2083-2229 s, the average IR on SCDU3, 

Target 5 was approximately 2756 Ω. From 2083-2229 s, 

the average IR on SCDU3, Target 6 was approximately 

1580 Ω with a low of 1365 at 2084 s. From 2083-2229 

s, the average IR on SCDU4, Target 5 was 

approximately 1640 Ω with a low of 1527 Ω at 2129 s. 

The cable temperature was approximately 279°C at 2083 

s. 

3468 Fuse clear on 

SCDU2 The cable temperature was approximately 344°C. 

~3933 Ignition 

The time denoted was approximated from the field 

notes; however, the time appears reasonable given the 

data. The cable temperature at ignition was 

approximately 361°C. 

3939 Fuse clear on 

SCDU3 

4321-4332 

Voltage increase on 

SCDU2 and 3 source 

conductors and 

voltage decrease on 

SCDU4 

During this time span, the voltage on the source 

conductor for SCDU2 increased from 5 V to 39 V and 

the source on SCDU3 increased from approximately 2.5 

V to 45 V. Meanwhile, the voltage on the source 

conductor for SCDU4 decreased gradually from 126 V 

to less than 1 V and the current increased from less than 

1 A to approximately 5.3 A indicating a high current 

short to ground 
B - 176

Table B.138: Summary of observed faulting behavior for Test K20.

Time (s) Event Discussion 

4322-4325 Spurious actuation 

on SCDU3 

A spurious actuation occurred on the active target 6 on 

SCDU3. 

4332 

Fuse clear on 

SCDU1 and on 

SCDU4 

Upon the fuse clearing, as expected, all other test 

conductors declined to less than 1 V. 

4357 Test concluded, 

Penlight shutdown 

B.12 Cable Item K: 3/C-6 AWG, HT 

Cable Item K is a 3/C-6 AWG cable with HT insulation, according to the bill of materials 

provided by the donating company, and the conductors are numbered as depicted in Figure 

B.146. The cable was tested three times during the DESIREE-Fire test series, all on SCDU. The 

following sections detail the test parameters, conductor paths, circuit data, and test summary. 

During Test D17 and D18, two different SCDU circuits were tested in each experiment. 

1

2 3

Figure B.146: Illustration of Cable Item K.

B.12.1Test D17, Qualification 

Test D17, Qualification (i.e., Test D17, Qual) was the first test of this cable sample. The purpose 

of this test was to quantify the failure mechanisms and possible failure temperature threshold. 

This test utilized the SCDU to monitor the electrical performance of the cable throughout the 

thermal exposure. The test parameters may be found in Table B.139. The conductor pathway 

for the cable monitoring unit may be found in Table B.140. Electrical performance of the cable 

may be found in Figure B.147 and Figure B.148. The cable did not degrade electrically prior to 

ignition. The first Penlight set point was 375°C for 20 minutes, then 400°C for 10 minutes, then 

435°C for 10 minutes, and then to a maximum of 470°C before the cables ignited. The 

approximate cable temperature was 387°C prior to ignition. Shortly after ignition, there was a 

fuse clear on SCDU1 and Penlight was subsequently shutdown. There were no spurious 

actuations. A graph displaying the electrical response over the thermal exposure may be found 

in Figure B.149. A summary of the test results may be found in Table B.141. 
B - 177

Table B.139: Test parameters for D17, Qual. 

Test Series DESIREE-FIRE

Test Name Test 17, Qualification

Test Date 7/30/2010

Cable 1 Kerite 3/C-6 AWG, HTK

Cable Monitoring Unit Utilized SCDU1

Cable 2 NA

Cable Monitoring Unit Utilized NA

Penlight Starting Temperature 375°C

Penlight Final Temperature 470°C

Table B.140: Conductor designation for Item K, Test D17, Qual. 

Kerite 3/C-6 AWG, HTK. Black cable, tan conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

2 White 1 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

3 Red 1 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6 
B - 178

Figure B.147: All conductor voltages for Test D17, Qual indicating a fuse clear. 

Figure B.148: Modified course conductor currents and voltages for Test D17, Qual. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C1 V6

0

1

2

3

4

5

6

7

0

20

40

60

80

100

120

140

2700 2720 2740 2760 2780 2800

Voltage (Vac)

Current (A)

Time (s)

C1 V1

C1 A1
B - 179

Figure B.149: Penlight shroud temperature and source conductor voltages for Test D17, Qual. 

Table B.141: Summary of observed faulting behavior for D17, Qual, Circuit 1.

Time (s) Event Discussion 

0 

Penlight On; set at 

375°C (8.16 

kW/m2

) 

 

1235 

Penlight set point 

temperature 

increased 

The Penlight set point temperature was increased to 400°C 

1835 

Penlight set point 

temperature 

increased 

The Penlight set point temperature was increased to 435°C 

2375 

Penlight set point 

temperature 

increased 

The Penlight set point temperature was increased to 470°C 

2412 Ignition The cable ignited at a temperature of 386°C and an exposure of 470°C. 

2769 Fuse clear 

2817 Test concluded, 

Penlight shutdown 

B.12.2 Test D17 

Given the results of the previous test, Test D17 provided the opportunity to further investigate 

the failure mechanism and threshold temperatures. Two SCDU units (i.e., Circuit 1 and Circuit 

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 1000 2000 3000 4000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C1 V1
B - 180

2) were utilized to monitor the electrical performance of the cable samples throughout the 

thermal exposure. The test parameters may be found in Table B.142. The conductor pathway 

for the both cable monitoring units may be found in Table B.143. Electrical performance of the 

cable samples may be found in the following two sections, namely Circuit 1 and Circuit 2. 

Table B.142: Test parameters for Test D17. 

Test Series DESIREE-FIRE

Test Name Test 17

Test Date 7/31/2010

Cable 1 Kerite 3/C-6 AWG, HTK

Cable Monitoring Unit Utilized SCDU1

Cable 2 Kerite 3/C-6 AWG, HTK

Cable Monitoring Unit Utilized SCDU2

Penlight Starting Temperature 430°C

Penlight Final Temperature 430°C

B.12.2.1 Circuit 1 

The Penlight temperature was set to 430°C for the entire test. Approximately 8 minutes into the 

test, swelling of the jacketing material and light smoke was observed from the test cables. 

Smoldering of the cable jacket was noticed about 4 minutes later; however, ignition would not 

occur until 29 minutes into the test. Two minutes after ignition, Targets 5 and 6 experienced 

electrical interactions which lead to alternating spurious actuation activity over a 60 s period at 

which point the fuse cleared. The cable did not degrade electrically prior to ignition. Electrical 

performance of the cable may be found in Figure B.150 and Figure B.151. The latter graph 

Table B.143: Conductor designation for Item K, Test D17, Circuit 1 and Circuit 2. 

Kerite 3/C-6 AWG, HTK. Black cable, tan conductors with white print 

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 and 2 S1 Energized source conductor for SCDU1– 

Voltage = C1 V1; current = C1 I1 

Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

2 White 1 and 2 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

3 Red 1 and 2 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6 

Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6
B - 181

displays the electrical activity on a smaller time scale which provides greater detail into the 

failure behavior. A graph displaying the electrical response over the thermal exposure may be 

found in Figure B.152. A summary of the test results may be found in Table B.144. 

Figure B.150: All conductor voltages for Test D17, Circuit 1 showing target actuation and fuse 

clear. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C1 V6
B - 182

Figure B.151: Modified conductor voltages for Test D17, Circuit 1 providing more detail on the 

shorting and failure behavior of the cable sample. 

Figure B.152: Penlight shroud temperature and target conductor voltages for Test D17, Circuit 1. 

0

20

40

60

80

100

120

140

1700 1750 1800 1850 1900

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C1 V6

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 500 1000 1500 2000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C1 V5

C1 V6
B - 183

Table B.144: Summary of observed faulting behavior for Test D17, Circuit 1.

Time (s) Event Discussion 

0 

Penlight On; set at 

430°C (11.3 

kW/m2

) 

 

1740 Ignition Cable TCs most likely popped out of cable jacket since the temperatures 

were reading higher than anticipated temperatures. 

1764-1848 

Shorting behavior 

between source 

and targets 

At this time, spurious actuations were observed between Target 5 and 

Target 6 until the fuse cleared. 

1848 Fuse clear The activity on Targets 5 and 6 ceased as the fuse for Circuit 1 tripped. 

1984 Test concluded, 

Penlight shutdown 

B.12.2.2 Circuit 2 

The Penlight temperature was set to 430°C for the entire test. Approximately 8 minutes into the 

test, swelling of the jacketing material and light smoke was observed from the test cables. 

Smoldering of the cable jacket was noticed about 4 minutes later; however, ignition would not 

occur until 29 minutes into the test. Shortly after ignition, the source conductor experienced 

electrical degradation until initially shorting to Target 6 prior to the fuse clear. The shorting was 

not sufficiently strong enough to result in spurious actuation. The cable did not degrade 

electrically prior to ignition. Electrical performance of the cable may be found in Figure B.153. 

A graph displaying the electrical response over the thermal exposure may be found in Figure 

B.154. A summary of the test results may be found in Table B.145. 
B - 184

Figure B.153: All conductor voltages for Test D17, Circuit 2 displaying the fuse clear. 

Figure B.154: Penlight shroud temperature and target conductor voltages for Test D17, Circuit 2. 

0

20

40

60

80

100

120

140

0 500 1000 1500 2000 2500

Voltage (Vac)

Time (s)

C2 V1

C2 V5

C2 V6

0

4

8

12

16

20

24

28

0

100

200

300

400

500

600

700

0 500 1000 1500 2000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C2 V5

C2 V6
B - 185

Table B.145: Summary of observed faulting behavior for Test D17, Circuit 2.

Time (s) Event Discussion 

0 

Penlight On; set at 

430°C (11.3 

kW/m2

) 

 

1740 Ignition Cable TCs most likely popped out of cable jacket. 

1785 

Voltage 

degradation on 

the source 

conductor 

At this time, the voltage on the source conductor began to degrade. This 

degradation lasted approximately 115 s before the fuse tripped. 

1900 Fuse clear 

1984 

Test concluded, 

Penlight 

shutdown 

 

B.12.3 Test D18 

Test D18 was the final test for this cable sample. Two SCDU units (i.e., Circuit 1 and Circuit 2) 

were utilized to monitor the electrical performance of the cable samples throughout the thermal 

exposure. The test parameters may be found in Table B.146. The conductor pathway for the 

both cable monitoring units may be found in Table B.147. Electrical performance of the cable 

samples may be found in the following two sections, namely Circuit 1 and Circuit 2. 

Table B.146: Test parameters for Test D18. 

Test Series DESIREE-FIRE

Test Name Test 18

Test Date 7/31/2010

Cable 1 Kerite 3/C-6 AWG, HTK

Cable Monitoring Unit Utilized SCDU1

Cable 2 Kerite 3/C-6 AWG, HTK

Cable Monitoring Unit Utilized SCDU2

Penlight Starting Temperature 420°C

Penlight Final Temperature 450°C

Table B.147: Conductor designation for Item K, Test D18, Circuit 1 and Circuit 2. 

Kerite 3/C-6 AWG, HTK. Black cable, tan conductors with white print

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

1 Black 1 and 2 S1 Energized source conductor for SCDU1– 
B - 186

Table B.147: Conductor designation for Item K, Test D18, Circuit 1 and Circuit 2. 

Kerite 3/C-6 AWG, HTK. Black cable, tan conductors with white print

Conductor 

Number

Conductor 

Color

SCDU 

Circuit 

Number

SCDU 

Circuit Path

Notes

Voltage = C1 V1; current = C1 I1 

Energized source conductor for SCDU2– 

Voltage = C2 V1; current = C2 I1 

2 White 1 and 2 T5 Active target conductor for SCDU1 – 

Voltage = C1 V5; current = C1 I5

Active target conductor for SCDU2 – 

Voltage = C2 V5; current = C2 I5

3 Red 1 and 2 T6 Active target conductor for SCDU1 – 

Voltage = C1 V6; current = C1 I6 

Active target conductor for SCDU2 – 

Voltage = C2 V6; current = C2 I6

B.12.3.1 Circuit 1 

The initial Penlight temperature was set to 420°C and increased to 450°C after 42 minutes. 

Approximately 9 minutes into the test, swelling of the jacketing material and light smoke was 

observed from the test cables. Smoldering of the cable jacket was observed during the test prior 

to ignition. Ignition most likely occurred as a result of shorting in Circuit 2; however, the flames 

self-extinguished within 15 s according to the field notes. Approximately 90 s later, the cables 

would ignite again most likely due to the fuse clear for SCDU1. The cable did not degrade 

electrically prior to ignition. Electrical performance of the cable may be found in Figure B.155. 

A graph displaying the electrical response over the thermal exposure may be found in Figure 

B.156. A summary of the test results may be found in Table B.148. 
B - 187

Figure B.155: All conductor voltages for Test D18, Circuit 1 showing a fuse clear. 

Figure B.156: Penlight shroud temperature and conductor voltages for Test D18, Circuit 1. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C1 V1

C1 V5

C1 V6

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 2000 4000 6000 8000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C1 V1
B - 188

Table B.148: Summary of Observed Faulting Behavior for Test D18, Circuit 1. 

Time (s) Event Discussion 

0 

Penlight On; set at 

420°C (10.67 

kW/m2

) 

 

2510 Penlight set point 

increased Penlight temperature was increased to 450°C. 

5685 Ignition 

Cable temperature was approximately 410°C at an exposure temperature 

of 450°C. Ignition most likely occurred due to shorting behavior in 

Circuit 2. 

5701 Flame selfextinguishes 

5807 Fuse cleared 

5807 Ignition 

5877 Test concluded, 

Penlight shutdown 

B.12.3.2 Circuit 2 

The initial Penlight temperature was set to 420°C and increased to 450°C after 42 minutes. 

Approximately 9 minutes into the test, swelling of the jacketing material and light smoke was 

observed from the test cables. Smoldering of the cable jacket was observed during the test prior 

to ignition. Ignition most likely occurred as a result of shorting and spurious actuation of Target 

6 for Circuit 2; however, the flames self-extinguished within 15 s just as the fuse cleared in 

accordance with the field notes and electrical data. Approximately 90 s later, the cables would 

ignite again most likely due to the fuse clear for SCDU1. The cable did not degrade electrically 

prior to ignition. Electrical performance of the cable may be found in Figure B.157 and Figure 

B.158. The latter graph provides more detail into how the cable fails electrically over a shorter 

time span. A graph displaying the electrical response over the thermal exposure may be found in 

Figure B.159. A summary of the test results may be found in Table B.149. 
B - 189

Figure B.157: All conductor voltages for Test D18, Circuit 2 illustrating the spurious actuation and 

fuse clear. 

Figure B.158: Modified voltages for the source and target conductors in Test D18, Circuit 2. 

0

20

40

60

80

100

120

140

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

Time (s)

C2 V1

C2 V5

C2 V6

0

20

40

60

80

100

120

140

5650 5670 5690 5710 5730 5750

Voltage (Vac)

Time (s)

C2 V1

C2 V5

C2 V6
B - 190

Figure B.159: Penlight shroud temperature and conductor voltages for Test D18, Circuit 2. 

Table B.149: Summary of Observed Faulting Behavior for Test D18, Circuit 2. 

Time (s) Event Discussion 

0 

Penlight On; set at 

420°C (10.67 

kW/m2

) 

 

2520 Penlight set point 

increased Penlight temperature increased to 450°C 

5685-5700 Target 6 actuated Target 6 was actuated and Target 5 displayed signs of voltage increase. 

5685 Ignition Ignition most likely occurred as a result of the shorting behavior. 

5700 Fuse clear 

5701 Flame selfextinguishes 

5807 Ignition Ignition most likely occurred due to shorting behavior in Circuit 1. 

5877 Test concluded, 

Penlight shutdown 

0

20

40

60

80

100

120

140

0

100

200

300

400

500

600

700

0 2000 4000 6000 8000

Voltage (Vac)

Temperature (°C)

Time (s)

Top TC for 3c

Side TC for 3c

Penlight

C2 V1

C2 V5
BIBLIOGRAPHIC DATA SHEET

(See instructions on the reverse)

NRC FORM 335

(12-2010)

NRCMD 3.7

U.S. NUCLEAR REGULATORY COMMISSION 1. REPORT NUMBER

 (Assigned by NRC, Add Vol., Supp., Rev.,

 and Addendum Numbers, if any.)

NUREG/CR-7102

SAND2011-6548P

3. DATE REPORT PUBLISHED

MONTH

December

YEAR

2011

4. FIN OR GRANT NUMBER

USNRC JCN N6959

2. TITLE AND SUBTITLE

Kerite Analysis in Thermal Environment of FIRE (KATE-Fire): Test Results

5. AUTHOR(S)

S.P.Nowlen and J.W.Brown

6. TYPE OF REPORT

Technical

7. PERIOD COVERED (Inclusive Dates)

2/26-2010 - 10/5/2011

8. PERFORMING ORGANIZATION - NAME AND ADDRESS (If NRC, provide Division, Office or Region, U.S. Nuclear Regulatory Commission, and mailing address; if contractor,

Sandia National Laboratories

9. SPONSORING ORGANIZATION - NAME AND ADDRESS (If NRC, type "Same as above"; if contractor, provide NRC Division, Office or Region, U.S. Nuclear Regulatory Commission, 

Division of Risk Analysis

provide name and mailing address.)

and mailing address.)

10. SUPPLEMENTARY NOTES

G. Taylor, NRC Project Manager

11. ABSTRACT (200 words or less)

This report presents the results of cable functionality tests conducted on the cable product marketed under the trade name

Kerite FR. Although Kerite FR is a thermoset polymer, reviews have identified prior tests that documented cable failure at

relatively low temperatures compared to other known thermoset insulation materials. Other tests have indicated thermal

performance limits consistent with other thermoset insulation materials. Hence, the actual high-temperature electrical

performance limits of this material under fire exposure condtions were uncertain. New old stock samples of Kerite cables have

been tested as a part of two recent programs. During some, but not all of these tests, cable failures were observed at relatively

low temperatures. Two seperate phenomena working in concert, insluation cracking and production of a conductive liquid within

the cable are thought to be the mechanisms responsible for the observed cases of early degradation and failure. This report

summarizes the previously available information for this cable product, presents all of the newly developed test data and

provides an assessment of the materials fire-exposure electrical performance.

12. KEY WORDS/DESCRIPTORS (List words or phrases that will assist researchers in locating the report.)

Electric cables, cables, fire, cable failure, fire risk, fire PRA, fire PSA, post-fire safe shutdown, spurious

actuaiton, spurious operation, hot short 14. SECURITY CLASSIFICATION

13. AVAILABILITY STATEMENT

unlimited

(This Page)

unclassified 

(This Report)

unclassified

15. NUMBER OF PAGES

16. PRICE

NRC FORM 335 (12-2010)

Risk and Reliability Analysis Dept. 6231

P.O. Box 5800

Albuquerque, NM 87185-0748

Office of Nuclear Regulatory Research

U.S. Nuclear Regulatory Commission

Washington, DC 20555-0001


UNITED STATES 

NUCLEAR REGULATORY COMMISSION

WASHINGTON, DC 20555-0001

--------------------

OFFICIAL BUSINESS
 

 

NUREG/CR-7102 Kerite Analysis in Thermal Environment of FIRE (KATE-Fire): Test Results