Flexible cables for miner’s cap-lamps are specialised electrical cables used in mining operations to connect the miner’s cap-lamp headpiece with the battery unit.<\/p>\n
These cables play an important role in providing a reliable electrical connection between the battery and the lighting source used by underground mine workers.<\/p>\n
Since mining environments involve challenging operating conditions, including moisture, mechanical stress, abrasion and exposure to different environmental conditions, the cables must comply with prescribed electrical, mechanical and physical requirements.<\/p>\n
To ensure product quality and safety, the Government of India has made BIS certification mandatory for flexible cables for miner’s cap-lamps covered under the applicable Quality Control Order.<\/p>\n
The original applicable Indian Standard was IS 2593:1984 \u2013 Specification for Flexible Cables for Miner’s Cap-Lamps (First Revision)<\/strong>.<\/p>\n Manufacturers supplying covered products in India must obtain a BIS licence under Scheme-I of the BIS (Conformity Assessment) Regulations, 2018.<\/p>\n Important Standard Update:<\/strong> BIS revised IS 2593:1984 to IS 2593:2023 \u2013 Flexible Cables for Miners’ Cap Lamps \u2013 Specification (Second Revision)<\/strong>. The revised standard was published on 2 January 2024, and the earlier edition was withdrawn on 4 April 2024.<\/p>\n This article explains the BIS certification requirements, product construction, technical requirements, testing parameters, laboratory facilities, documentation and certification process for flexible cables for miner’s cap-lamps.<\/p>\n <badge color=”success”>Mandatory BIS Certification<\/badge><\/p>\n Yes. BIS certification is mandatory for flexible cables for miner’s cap-lamps covered under the Cables (Quality Control) Order, 2020<\/strong>.<\/p>\n The Department for Promotion of Industry and Internal Trade (DPIIT), Ministry of Commerce and Industry, notified the Cables Quality Control Order through Notification No. S.O. 280(E), dated 21 January 2020.<\/p>\n The Order requires covered cables to conform to the applicable Indian Standard and bear the BIS Standard Mark under a licence issued by BIS in accordance with Scheme-I.<\/p>\n The implementation date of the Cables Quality Control Order was 1 August 2020.<\/p>\n Goods or articles meant exclusively for export are excluded under the provisions of the Order.<\/p>\n BIS revised IS 2593:1984 and published IS 2593:2023 as the Second Revision.<\/p>\n Important points include:<\/p>\n Therefore, manufacturers planning new BIS certification should use IS 2593:2023 rather than relying on the withdrawn 1984 edition.<\/p>\n BIS product-specific documentation and laboratory testing information must be referred to for certification of flexible cables for miner’s cap-lamps.<\/p>\n The following documents and references are relevant:<\/p>\n The certification assessment covers:<\/p>\n The licence scope must identify the product as:<\/p>\n Flexible Cables for Miners’ Cap-Lamps as per IS 2593:2023.<\/strong><\/p>\n The proposed varieties and construction details should be declared by the manufacturer and assessed by BIS.<\/p>\n The final scope depends on the applicable standard, manufacturing facilities and testing capabilities.<\/p>\n <AsyncImage query=”miners cap lamp mining helmet LED lamp battery flexible connecting cable industrial mining equipment” aspectRatio=”16:9″ width=”100%” maxHeight={220}\/><\/p>\n Flexible cables for miner’s cap-lamps are special-purpose cables used to connect the lighting headpiece mounted on a miner’s helmet with the battery unit.<\/p>\n The cable allows electrical power to be transmitted from the battery to the lighting source while providing flexibility and suitable mechanical protection.<\/p>\n The original IS 2593:1984 specifically explains that the cable is used to connect the headpiece to the battery of a miner’s cap-lamp assembly.<\/p>\n These cables are associated with:<\/p>\n A typical miner’s cap-lamp cable may consist of:<\/p>\n The exact construction must comply with the applicable requirements of IS 2593:2023.<\/p>\n IS 2593 specifies technical requirements relating to conductor construction, insulation, central strain cord, sheath, dimensions and electrical and physical performance.<\/p>\n Some important requirements include:<\/p>\n The conductor must comply with the applicable requirements specified in the standard.<\/p>\n Important parameters include:<\/p>\n The insulation must provide adequate electrical separation between the conductors.<\/p>\n Important characteristics include:<\/p>\n The central strain cord is an important component of the cable construction.<\/p>\n It provides mechanical support and helps the cable withstand tensile stresses during handling and use.<\/p>\n The material and construction must comply with the relevant provisions of the standard.<\/p>\n The sheath provides external mechanical and environmental protection.<\/p>\n The standard specifies requirements relating to:<\/p>\n The conductor construction must comply with the specified requirements.<\/p>\n The manufacturer must maintain suitable control over conductor dimensions and construction.<\/p>\n The cable cores must be identified according to the applicable requirements of the standard.<\/p>\n The conductors and other cable components must be assembled according to the prescribed construction requirements.<\/p>\n The cable must satisfy the applicable electrical performance requirements, including conductor resistance and insulation-related characteristics.<\/p>\n The cable insulation and sheath must comply with the applicable physical and mechanical testing requirements.<\/p>\n These characteristics are important for maintaining cable performance under the intended mining operating conditions.<\/p>\n Testing is one of the most important stages of BIS certification for flexible cables for miner’s cap-lamps.<\/p>\n The BIS Laboratory Information Management System identifies the following testing parameters for IS 2593.<\/p>\n The test list below includes the testing parameters displayed in BIS LIMS for the 1984 edition and the revised 2023 edition. The applicable clause references must be checked against the relevant edition before testing.<\/p>\n The exact applicability and clause references must be confirmed against the current edition of IS 2593:2023.<\/p>\n <AsyncImage query=”flexible copper electrical cable conductor strands close up industrial wire manufacturing” aspectRatio=”16:9″ width=”100%” maxHeight={170}\/><\/p>\n This test verifies the conductor material and construction.<\/p>\n The manufacturer must ensure that the conductor conforms to the specified requirements relating to material, construction and dimensions.<\/p>\n This test determines the electrical resistance of the conductor.<\/p>\n The resistance value is important for evaluating electrical performance and ensuring conformity with the applicable requirements.<\/p>\n This test verifies the average and minimum insulation thickness.<\/p>\n Suitable measuring instruments are used to evaluate the insulation dimensions.<\/p>\n This test evaluates the central strain cord used in the cable construction.<\/p>\n The component must comply with the applicable material and construction requirements.<\/p>\n The average and minimum sheath thickness are verified to ensure conformity with the standard.<\/p>\n This test verifies the identification and arrangement of cable cores.<\/p>\n The test evaluates the construction and arrangement of conductors and associated components within the cable.<\/p>\n The annealing test evaluates the applicable physical characteristics of the copper conductor.<\/p>\n These tests evaluate the mechanical properties of insulation and sheath materials.<\/p>\n Important parameters include:<\/p>\n This test evaluates the behaviour of insulation and sheath materials when exposed to the prescribed temperature conditions.<\/p>\n This test evaluates the burning characteristics of the cable according to the applicable test method.<\/p>\n The test evaluates the behaviour of cable materials when exposed to specified moisture conditions.<\/p>\n This test evaluates the resistance of cable materials to the applicable chemical exposure conditions.<\/p>\n The copper test evaluates the applicable requirements relating to conductor material.<\/p>\n This test evaluates the behaviour of cable materials under the prescribed oil exposure conditions.<\/p>\n The actual test procedures, acceptance criteria, test conditions and sample preparation requirements must be followed as specified in IS 2593:2023.<\/p>\n The sample quantity for BIS certification must be determined according to the current product manual, applicable test methods and instructions of the designated laboratory.<\/p>\n The BIS LIMS listing identifies individual test parameters and test-wise charges but does not, in the publicly displayed information reviewed here, establish a complete universal sample quantity for initial licence testing.<\/p>\n Manufacturers should prepare:<\/p>\n The exact sample length and quantity should be confirmed with the concerned BIS Branch Office or testing laboratory before dispatch.<\/p>\n This is important because different tests may require different sample preparations and specimen lengths.<\/p>\n Product grouping is important for manufacturers producing different varieties of flexible cables for miner’s cap-lamps.<\/p>\n The manufacturer should declare the proposed varieties and construction details for BIS certification.<\/p>\n The following technical parameters are relevant while preparing the proposed licence scope.<\/p>\n The conductor material must be identified according to the applicable standard.<\/p>\n The conductor cross-sectional area must be specified for each proposed cable variety.<\/p>\n The manufacturer should provide details of the conductor construction and number of wires.<\/p>\n The insulation material and thickness must be declared.<\/p>\n Details of the central strain cord construction and material should be provided.<\/p>\n The manufacturer should declare the sheath material, colour and thickness.<\/p>\n The overall cable diameter should be identified for the proposed varieties.<\/p>\n Consider a manufacturer proposing the following varieties:<\/p>\n The manufacturer should submit complete technical specifications and drawings for each variety.<\/p>\n Important:<\/strong> The exact grouping methodology and representative sample selection must be confirmed from the current BIS product manual. Do not assume that testing one conductor size automatically covers all other varieties.<\/p>\n Manufacturers must maintain suitable testing facilities for ensuring conformity with IS 2593:2023.<\/p>\n The laboratory should be capable of conducting the applicable routine and other prescribed tests.<\/p>\n The following equipment is relevant to the testing parameters identified in BIS LIMS.<\/p>\n The above list is indicative and must be finalised according to the equipment requirements specified in the current standard and BIS product manual.<\/p>\n Manufacturers should establish:<\/p>\n All measuring and testing equipment must be maintained in working condition.<\/p>\n Calibration should be carried out at suitable intervals, and calibration records must be available during BIS inspection.<\/p>\n Manufacturers must implement the applicable Scheme of Inspection and Testing and quality-control arrangements prescribed by BIS.<\/p>\n The manufacturer should establish a documented Quality Assurance Plan covering incoming materials, production inspection, routine testing and finished cable inspection.<\/p>\n The following raw materials should be controlled:<\/p>\n The manufacturer should maintain appropriate material specifications and supporting test certificates.<\/p>\n In-process inspection should cover:<\/p>\n Finished cable testing should include the applicable requirements for:<\/p>\n The manufacturer should define the control unit in accordance with the applicable BIS product manual and Scheme of Inspection and Testing.<\/p>\n The control unit should enable traceability between production, raw materials, inspection and testing results.<\/p>\n Manufacturers should maintain:<\/p>\n Note:<\/strong> The exact control unit definition, sampling frequency and recommended levels of control must be taken from the current BIS product manual and approved quality-control arrangements. The publicly available LIMS test list alone does not establish these frequencies.<\/p>\n After obtaining the BIS licence, manufacturers must ensure that flexible cables for miner’s cap-lamps are marked according to IS 2593:2023 and the applicable licence conditions.<\/p>\n The BIS Standard Mark must be applied according to the applicable marking provisions and licence conditions.<\/p>\n The ISI marking should include the relevant CM\/L licence number as prescribed by BIS.<\/p>\n The cable or its packaging should carry the applicable manufacturer identification and product details required by the Indian Standard.<\/p>\n The manufacturer should ensure suitable identification of:<\/p>\n Manufacturers should maintain traceability between:<\/p>\n The exact marking format and location must follow the current edition of IS 2593 and BIS licence conditions.<\/p>\n Manufacturers should prepare the following documents before submitting their BIS application.<\/p>\n The exact documentation requirements may vary depending on the manufacturing arrangement, proposed product varieties and applicable BIS instructions.<\/p>\n Testing charges depend on the applicable standard, laboratory, test scope and product construction.<\/p>\n The BIS Laboratory Information Management System (LIMS) displays the following laboratory-specific testing charges for IS 2593:1984.<\/p>\n1. Is BIS Certification Mandatory for Flexible Cables for Miner’s Cap-Lamps?<\/h2>\n
Applicable Standard and Certification Details<\/h3>\n
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\n Particular<\/th>\n Details<\/th>\n<\/tr>\n \n Product<\/td>\n Flexible Cables for Miner’s Cap-Lamps<\/td>\n<\/tr>\n \n Original Standard<\/td>\n IS 2593:1984<\/td>\n<\/tr>\n \n Original Standard Title<\/td>\n Specification for Flexible Cables for Miner’s Cap-Lamps<\/td>\n<\/tr>\n \n Revised Standard<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n Revision<\/td>\n Second Revision<\/td>\n<\/tr>\n \n Certification Scheme<\/td>\n BIS Scheme-I (ISI Mark Scheme)<\/td>\n<\/tr>\n \n Applicable QCO<\/td>\n Cables (Quality Control) Order, 2020<\/td>\n<\/tr>\n \n QCO Notification<\/td>\n S.O. 280(E), dated 21 January 2020<\/td>\n<\/tr>\n \n QCO Implementation Date<\/td>\n 1 August 2020<\/td>\n<\/tr>\n \n Revised Standard Publication<\/td>\n 2 January 2024<\/td>\n<\/tr>\n \n Withdrawal of 1984 Edition<\/td>\n 4 April 2024<\/td>\n<\/tr>\n \n Certification Authority<\/td>\n Bureau of Indian Standards (BIS)<\/td>\n<\/tr>\n \n Standard Mark<\/td>\n ISI Mark<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n Important Update: IS 2593:2023<\/h3>\n
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2. Applicable BIS Product Manual and Certification Requirements<\/h2>\n
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Licence Scope<\/h3>\n
3. What Are Flexible Cables for Miner’s Cap-Lamps?<\/h2>\n
Major Applications<\/h3>\n
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Major Construction Components<\/h3>\n
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4. Technical Requirements Under IS 2593:2023<\/h2>\n
A. Conductor Requirements<\/h3>\n
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B. Insulation Requirements<\/h3>\n
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C. Central Strain Cord<\/h3>\n
D. Sheath Requirements<\/h3>\n
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E. Conductor Construction<\/h3>\n
F. Identification of Cores<\/h3>\n
G. Laying Up<\/h3>\n
H. Electrical Characteristics<\/h3>\n
I. Physical and Mechanical Characteristics<\/h3>\n
5. Testing Requirements for BIS Certification<\/h2>\n
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\n Sr. No.<\/th>\n Test Parameter<\/th>\n Applicable Reference<\/th>\n<\/tr>\n \n 1<\/td>\n Conductor Test<\/td>\n Clause 3<\/td>\n<\/tr>\n \n 2<\/td>\n Copper Conductor Resistance<\/td>\n Clause 3.1.2<\/td>\n<\/tr>\n \n 3<\/td>\n Insulation Test<\/td>\n Clause 4<\/td>\n<\/tr>\n \n 4<\/td>\n Central Strain Cord<\/td>\n Clause 5<\/td>\n<\/tr>\n \n 5<\/td>\n Sheath Test<\/td>\n Clause 6<\/td>\n<\/tr>\n \n 6<\/td>\n Construction \u2013 Conductor<\/td>\n Clause 7<\/td>\n<\/tr>\n \n 7<\/td>\n Nominal Cross-Sectional Area of Conductor<\/td>\n Clause 7<\/td>\n<\/tr>\n \n 8<\/td>\n Average Insulation Thickness<\/td>\n Clause 8.1<\/td>\n<\/tr>\n \n 9<\/td>\n Minimum Insulation Thickness<\/td>\n Clause 8.1<\/td>\n<\/tr>\n \n 10<\/td>\n Identification of Cores<\/td>\n Clause 9.1<\/td>\n<\/tr>\n \n 11<\/td>\n Laying Up<\/td>\n Clause 10.1<\/td>\n<\/tr>\n \n 12<\/td>\n Sheath Application<\/td>\n Clause 11.1<\/td>\n<\/tr>\n \n 13<\/td>\n Average Sheath Thickness<\/td>\n Clause 11.2<\/td>\n<\/tr>\n \n 14<\/td>\n Minimum Sheath Thickness<\/td>\n Clause 12.2<\/td>\n<\/tr>\n \n 15<\/td>\n Colour of Sheath<\/td>\n Clause 11.3<\/td>\n<\/tr>\n \n 16<\/td>\n Overall Diameter<\/td>\n Clause 12.1<\/td>\n<\/tr>\n \n 17<\/td>\n Annealing Test<\/td>\n Clause 13.1(b)<\/td>\n<\/tr>\n \n 18<\/td>\n Tensile Strength of Insulation<\/td>\n Clause 13.1(e)(1)<\/td>\n<\/tr>\n \n 19<\/td>\n Elongation at Break of Insulation<\/td>\n Clause 13.1(e)(1)<\/td>\n<\/tr>\n \n 20<\/td>\n Tensile Strength of Sheath<\/td>\n Clause 13.1(e)(1)<\/td>\n<\/tr>\n \n 21<\/td>\n Elongation at Break of Sheath<\/td>\n Applicable physical test provision<\/td>\n<\/tr>\n \n 22<\/td>\n Resistance to Heat<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n 23<\/td>\n Resistance to Burning<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n 24<\/td>\n Moisture Absorption Test<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n 25<\/td>\n Resistance to Chemical Action<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n 26<\/td>\n Copper Test<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n \n 27<\/td>\n Resistance to Oil<\/td>\n IS 2593:2023<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n A. Conductor Test<\/h3>\n
B. Conductor Resistance Test<\/h3>\n
C. Insulation Thickness Test<\/h3>\n
D. Central Strain Cord Test<\/h3>\n
E. Sheath Thickness Test<\/h3>\n
F. Identification of Cores<\/h3>\n
G. Laying Up Test<\/h3>\n
H. Annealing Test<\/h3>\n
I. Tensile Strength and Elongation Test<\/h3>\n
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J. Resistance to Heat Test<\/h3>\n
K. Resistance to Burning Test<\/h3>\n
L. Moisture Absorption Test<\/h3>\n
M. Resistance to Chemical Action<\/h3>\n
N. Copper Test<\/h3>\n
O. Resistance to Oil<\/h3>\n
6. Sample Quantity Required for BIS Testing<\/h2>\n
Important Sample Submission Requirements<\/h3>\n
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7. Product Grouping Guidelines Under IS 2593:2023<\/h2>\n
A. Conductor Material<\/h3>\n
B. Nominal Cross-Sectional Area<\/h3>\n
C. Conductor Construction<\/h3>\n
D. Insulation<\/h3>\n
E. Central Strain Cord<\/h3>\n
F. Sheath<\/h3>\n
G. Overall Cable Diameter<\/h3>\n
Practical Example of Product Scope Declaration<\/h3>\n
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\n Model<\/th>\n Conductor Area<\/th>\n Insulation<\/th>\n Sheath<\/th>\n<\/tr>\n \n Model A<\/td>\n As per declared specification<\/td>\n Applicable construction<\/td>\n Applicable construction<\/td>\n<\/tr>\n \n Model B<\/td>\n As per declared specification<\/td>\n Applicable construction<\/td>\n Applicable construction<\/td>\n<\/tr>\n \n Model C<\/td>\n As per declared specification<\/td>\n Applicable construction<\/td>\n Applicable construction<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n 8. Factory Laboratory Requirements<\/h2>\n
Major Laboratory Equipment<\/h3>\n
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\n Equipment<\/th>\n Purpose<\/th>\n<\/tr>\n \n Vernier Calliper<\/td>\n Cable Dimensions<\/td>\n<\/tr>\n \n Micrometer<\/td>\n Insulation and Sheath Thickness<\/td>\n<\/tr>\n \n Measuring Microscope<\/td>\n Conductor and Insulation Dimensions<\/td>\n<\/tr>\n \n Kelvin Double Bridge<\/td>\n Conductor Resistance<\/td>\n<\/tr>\n \n Digital Resistance Meter<\/td>\n Electrical Resistance<\/td>\n<\/tr>\n \n Tensile Testing Machine<\/td>\n Tensile Strength and Elongation<\/td>\n<\/tr>\n \n Annealing Test Arrangement<\/td>\n Conductor Annealing<\/td>\n<\/tr>\n \n Hot Air Oven<\/td>\n Heat Resistance<\/td>\n<\/tr>\n \n Heat Testing Arrangement<\/td>\n Resistance to Heat<\/td>\n<\/tr>\n \n Burning Test Apparatus<\/td>\n Resistance to Burning<\/td>\n<\/tr>\n \n Water Bath<\/td>\n Moisture Absorption Testing<\/td>\n<\/tr>\n \n Chemical Resistance Test Arrangement<\/td>\n Resistance to Chemical Action<\/td>\n<\/tr>\n \n Oil Resistance Test Arrangement<\/td>\n Resistance to Oil<\/td>\n<\/tr>\n \n Suitable Electrical Testing Equipment<\/td>\n Applicable Electrical Tests<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n Laboratory Management Requirements<\/h3>\n
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Calibration Requirements<\/h3>\n
9. Scheme of Inspection and Testing (SIT)<\/h2>\n
A. Raw Material Inspection<\/h3>\n
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B. In-Process Inspection<\/h3>\n
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C. Finished Product Testing<\/h3>\n
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D. Control Unit<\/h3>\n
E. Records to Be Maintained<\/h3>\n
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10. Packing and Marking Requirements<\/h2>\n
A. BIS Standard Mark<\/h3>\n
B. Manufacturer Identification<\/h3>\n
C. Product Identification<\/h3>\n
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D. Traceability Requirements<\/h3>\n
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11. Documents Required for BIS Certification of Flexible Cables for Miner’s Cap-Lamps<\/h2>\n
A. Company and Legal Documents<\/h3>\n
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B. Manufacturing Documents<\/h3>\n
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C. Product Technical Documents<\/h3>\n
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D. Quality Control Documents<\/h3>\n
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E. BIS Application Documents<\/h3>\n
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12. BIS Testing Charges for Flexible Cables for Miner’s Cap-Lamps<\/h2>\n
Example: BIS LIMS Testing Charges<\/h3>\n