VW_60306_1(LV112)

VW 60306-1

Issue 2013-04

Class. No.:Descriptors:

8ME30

cable, low-voltage cable, copper cable, LV 112, LV 112-1

Electric/Electronic SystemsElectric Wiring in Motor Vehicles

Part 1: Copper Cable; Single-Wire, Unshielded

Preface

NOTE 1: The Standard numbers stated in the document correspond to the Standards listed intable 1.

Table 1

Working group document num‐

ber

LV 112 supplement 1

LV 112-3LV 213-1LV 213-2LV 214-2

—

VW 60306-1 supersedes VW 60306, issue 2005-11.Earlier issues of VW 60306: 1990-09, 2000-11.

VW 60306-1 supersedes PN 14703-1, issue 2008-11.Earlier issues of PN 14703-1: 2006-11.

Page 1 of 2. Continued on 72 pages, LV 112-1.

Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature.

The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.Numerical notation acc. to ISO/IEC Directives, Part 2.

Volkswagen Standard numberVW 60306-1 supplement 1

VW 60306-3VW 75206-1VW 75206-2VW 75174-2VW 96043

PAG Standard number

—————PN 780

Technical responsibilityEEKK/4I/EE-23EEE2Dr. Liane WiegelMichael PicklAndreas MüllerTel.: +49 5361 9 36678Tel.: +49 841 34925Tel.: +49 711 911 82433The Standards departmentEKDV/4 Dirk BeinkerTel.: +49 5361 9 32438EKDVManfred TerlindenVWNORM-2012-05q

All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.

© Volkswagen Aktiengesellschaft

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VW 60306-1: 2013-04

Deviating and supplementary Volkswagen AG specificationsSupplement to section 10 of LV 112-1:

The environmental requirements set forth in VW 91101 must be met.

Deviating and supplementary Porsche AG specificationsSupplement to section 3 of LV 112-1:

Cables as per this standard are subject to build sample approval.

After build sample approval has been granted, the cables are only completely released for use inproduction if the assembler has confirmed proper usability, e.g.:––––

Supplement to section 10 of LV 112-1:Emission behavior as per PN 780.

Stripping

Crimpability and attachment of the contacts

Weldability by ultrasonic welding or resistance weldingTwistability of the cables, if applicable

in the form of a first-sample test report during first sampling.

Descriptors:

VW 60306-1:2013-04

cable, low-voltage cable, copper cable

LV 112-1

2013-04

Electric Wiring in Motor Vehicles Copper Cable; Single-Wire, Unshielded

Preface

This Supply Specification (LV) version was prepared by representatives of automobile manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG, and Volkswagen AG in working group 4.3.

This Supply Specification is stored as an MS Word file in the Audi AG Standards department.

No claim is made as to its completeness. The automobile manufacturers may require additional tests as per the respective state-of-the-art at any time.

Since the individual automobile manufacturers may make changes if necessary, only the in-house standards that the automobile manufacturers derive from this LV must be used.

Deviations from this supply specification are listed in the in-house standards on the cover sheet (in justified exceptional cases, deviations can be presented in italics in the text of the standard). If modifications of individual test sections are required in individual cases, these modifications must be agreed upon separately between the appropriate departments of the automaker and of the supplier.

For general development projects of the automobile manufacturers, test reports will be accepted as long as the tests were performed by an independent institute that is accredited as per DIN EN ISO/IEC 17025. Acceptance of the test reports will not automatically result in a release. Other test reports may be accepted at the discretion of the purchaser.

Page 1 of 72

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VW 60306-1:2013-04

Contents

Page

1 2 3 4 5 6 6.1 6.2 6.3 6.4 7 7.1 7.2 7.3 7.3.1 7.3.2 7.4 7.4.1 7.4.2 7.4.3 7.4.3.1 7.4.3.2 8 8.1 8.2 8.3 8.4 9 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.2.8.1 9.2.8.2 9.2.9 9.2.10 9.3 9.3.1 Scope ................................................................................................................................ 5 Referenced standards ....................................................................................................... 6 General information ........................................................................................................... 8 Dimensions and cable structure ......................................................................................... 9 Structure of the code ....................................................................................................... 10 Materials .......................................................................................................................... 11 Conductor, bare ............................................................................................................... 11 Conductor, tinned ............................................................................................................ 12 Conductor, other surfaces ............................................................................................... 12 Insulation ......................................................................................................................... 13 Marking and supply specifications ................................................................................... 14 Packaging marking .......................................................................................................... 14 Manufacturer's code ........................................................................................................ 14 Color ................................................................................................................................ 14 Color coding .................................................................................................................... 14 Color coding .................................................................................................................... 14 Supply specifications ....................................................................................................... 14 Visual inspection.............................................................................................................. 14 Test for insulation faults ................................................................................................... 14 Packaging units ............................................................................................................... 15 Partial lengths, ties, defects ............................................................................................. 15 Marking of the delivery unit .............................................................................................. 16 General test conditions .................................................................................................... 17 Test matrix ....................................................................................................................... 17 Test atmosphere.............................................................................................................. 25 Specimens ....................................................................................................................... 25 Rounding of numerical values.......................................................................................... 25 Tests ............................................................................................................................... 26 Cable structure test ......................................................................................................... 26 Outside cable diameter and minimum wall thickness ....................................................... 26 Nominal conductor diameter ............................................................................................ 26 Conductor resistance ....................................................................................................... 26 Wall thickness of the insulation ........................................................................................ 26 Insulation test wall thickness Sp (thin-walled cables) ....................................................... 26 Physical and chemical properties of the insulation ........................................................... 26 Density ............................................................................................................................ 26 Determination of the viscosity .......................................................................................... 26 Thermogravimetric analysis (TGA) .................................................................................. 27 Differential scanning calorimetry (DSC) ........................................................................... 27 Thermal stability for PVC ................................................................................................. 27 Determination of the infrared spectrum ............................................................................ 28 Determination of tensile strength and elongation at tear .................................................. 28 Tear propagation strength ............................................................................................... 28 Test on the plate .............................................................................................................. 28 Test on the cable ............................................................................................................. 28 Determination of cross-linking density ............................................................................. 29 Microhardness ................................................................................................................. 29 Mechanical properties in as-received condition ............................................................... 29 Insulation stripability and secure fit of conductor .............................................................. 29

9.3.2 9.3.3 9.3.4 9.3.5 9.4 9.5 9.5.1 9.5.2 9.5.3 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.6.1 9.6.6.2 9.6.7 9.6.7.1 9.6.7.2 9.6.7.3 9.6.8 9.6.8.1 9.6.8.2 9.6.8.3 9.6.8.4 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15 9.6.16 9.7 9.8 9.8.1 9.8.2 9.8.2.1 9.8.2.2 9.8.3 9.8.3.1 9.8.3.2 10

VW 60306-1:2013-04

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LV 112-1: 2013-04

Insulation abrasion resistance ......................................................................................... 30 Sliding behavior of the cable ............................................................................................ 30 Bending force of the cable ............................................................................................... 32 Insulation notch strength ................................................................................................. 33 Flame retardance ............................................................................................................ 34 Electrical properties in as-received condition ................................................................... 34 Specific volume resistance .............................................................................................. 34 30-minute dielectric strength ............................................................................................ 34 Measurement of 1-minute dielectric strength (only after stressing) .................................. 35 Mechanical and electrical properties after mechanical, thermal, or chemical stress ......... 35 Stress test ....................................................................................................................... 35 Insulation shrinkage under heat ....................................................................................... 36 Pressure resistance of the insulation under heat ............................................................. 36 Determination of the derating curve ................................................................................. 36 Thermal stability in the wound state ................................................................................. 37 Thermal overload ............................................................................................................ 37 Thermal overload Tmax +50 °C ......................................................................................... 37 Extreme thermal overload Tmax + x °C/1 h........................................................................ 37 Short-term aging (240 h) ................................................................................................. 38 Winding test after short-term aging .................................................................................. 38 Determination of the infrared spectrum after short-term aging ......................................... 38 Determination of tensile strength and elongation at tear after short-term aging ............... 38 Long-term aging (3 000 h) ............................................................................................... 38 Winding test after long-term aging ................................................................................... 38 Determination of the infrared spectrum after long-term aging .......................................... 39 Determination of tensile strength and elongation at tear after long-term aging ................ 39 Minimum permissible bend radius for static routing ......................................................... 39 Winding test at low temperature (-40 °C) ......................................................................... 41 Impact test at low temperature (-15 °C) ........................................................................... 41 Resistance of cable marking to wiping/smudging ............................................................ 41 Resistance to reverse bending stresses .......................................................................... 41 Kink test .......................................................................................................................... 42 Electrical properties during aging in water ....................................................................... 43 Damp heat, constant (hydrolysis test) .............................................................................. 44 Ozone resistance ............................................................................................................ 44 Mycological test ............................................................................................................... 45 Compatibility tests ........................................................................................................... 45 Chemical resistance as per ISO 6722-1 .......................................................................... 45 Resistance to chemicals and wrapping tapes .................................................................. 45 Testing on cross sections ≤2,5 mm² ................................................................................ 46 Testing on cross-sections ≥4 mm² ................................................................................... 48 Resistance to wiring harness components ....................................................................... 49 Testing on cross sections ≤ 6 mm2 .................................................................................. 49 Testing on cross sections >6 mm2 ................................................................................... 51 Environmental protection and safety ................................................................................ 52

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LV 112-1: 2013-04

Changes

VW 60306-1:2013-04

The following changes have been made as compared to LV 112: 2006-11: ─ Drawing note section expanded (example 2) ─ Table 5, temperature class added

─ Table 2, conductor cross-sections 10 mm², 16 mm², 25 mm², and 35 mm² added ─ Footnotes in the tables in the appendix standardized ─ Document number changed from LV 112 to LV 112-1

Previous issues

LV 112: 2001-10, 2005-06, 2006-11

1

Scope

VW 60306-1:2013-04

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LV 112-1: 2013-04

This supply specification describes requirements and tests for single-wire unshielded vehicle cables for a nominal voltage range ≤60 V DC as per voltage class 1 of Table 1.

The test points for the various requirements must be taken from the test matrix in 8.1.

Table 1

Voltage classes

Low voltage High voltage High voltage

1 (A(*)) 2 3 (B(*))

Voltage classes

AC

Veff (VRMS) ≤30 V ≤600 V ≤1 000 V

VPTP ≤42 V ≤849 V ≤1 414 V

DC VDC ≤60 V ≤900 V ≤1 500 V

This table was created on the basis of ISO 69-3. Voltage class 2 is not considered in ISO 69-3. (*) Voltage class designation as per ISO 69-3. VPTP Peak-to-peak voltage value Veff (URMS) RMS voltage value (RMS: root mean square)

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LV 112-1: 2013-04 2

Referenced standards

VW 60306-1:2013-04

The following documents cited in this Standard are necessary to its application.

Some of the cited documents are translations from the German original. The translations of German terms in such documents may differ from those used in this Standard, resulting in terminological inconsistency. Standards whose titles are given in German may be available only in German. Editions in other languages may be available from the institution issuing the standard.

For dated references, only the referenced issue is valid. For undated references, the most recent issue of the referenced document (including all changes) is valid.

DIN 1333 DIN 72551-7 DIN 76722 DIN EN 10270-1 DIN EN 13602 DIN EN 50525-2-21

DIN EN 60684-3 DIN EN 60811-1-1

DIN EN 60811-1-2

DIN EN 60811-2-1

DIN EN 60811-3-2

DIN EN ISO 846 DIN EN ISO 1133 DIN EN ISO 1183-1

DIN EN ISO 1628-2

Presentation of Numerical Data Road Vehicles – Low-Tension Cables – Part 7: Colours and Colour

Marking of Low-Tension Cables

Road Vehicles, Low Voltage Cables; Type Abbreviation

Steel Wire for Mechanical Springs – Part 1: Patented Cold Drawn Unalloyed Steel Wire

Copper and Copper Alloys – Drawn, Round Copper Wire for the Manufacture of Electrical Conductors

Electric Cables – Low Voltage Energy Cables of Rated Voltages up to and Including 450/750 V (U0/U) – Part 2-21: Cables for General

Applications – Flexible Cables with Crosslinked Elastomeric Insulation Flexible Insulating Sleeving – Part 3: Specifications for Individual Types of Sleeving

Insulating and Sheathing Materials of Electric Cables – Common Test Methods – Part 1-1: General Application; Measurement of Thickness and Overall Dimensions; Test for Determining the Mechanical Properties

Insulating and Sheathing Materials of Electric Cables – Common Test Methods – Part 1: General Application; Section 2: Thermal Ageing Methods

Insulating and Sheathing Materials of Electric and Optical Cables – Common Test Methods – Part 2-1: Methods Specific to Elastomeric Compounds; Ozone Resistance, Hot Set and Mineral Oil Immersion Tests

Insulating and Sheathing Materials of Electric and Optical Cables – Common Test Methods – Part 3-2: Methods Specific to PVC Compounds – Loss of Mass Test – Thermal Stability Test Plastics – Evaluation of the Action of Microorganisms

Plastics – Determination of the Melt Mass-Flow Rate (MFR) and the Melt Volume-Flow Rate (MVR) of Thermoplastics

Plastics – Methods for Determining the Density of Non-Cellular

Plastics – Part 1: Immersion Method, Liquid Pyknometer Method and Titration Method

Plastics – Determination of the Viscosity of Polymers in Dilute

Solution Using Capillary Viscometers – Part 2: Poly(vinyl Chloride) Resins

DIN EN ISO/IEC 17025 DIN ISO 1431-1

ISO 34-1 ISO 48 ISO 5 ISO 69-3 ISO 6722-1

ISO 11357-1 ISO 11358 ISO 14572

VDA 232-101 VDA Volume 6, Part 1 LV 112-1 Supplement 1 LV 112-1 Supplement 2 LV 112-3 LV 213-1 LV 213-2

VW 60306-1:2013-04

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LV 112-1: 2013-04

General Requirements for the Competence of Testing and Calibration Laboratories

Rubber, Vulcanized or Thermoplastic – Resistance to Ozone Cracking – Part 1: Static and Dynamic Strain Testing (as a replacement for DIN 53509-1)

Rubber, Vulcanized or Thermoplastic – Determination of Tear Strength – Part 1: Trouser, Angle and Crescent Test Pieces Rubber, Vulcanized or Thermoplastic – Determination of Hardness (Hardness between 10 IRHD and 100 IRHD)

Standard Atmospheres for Conditioning and/or Testing; Specifications Electrically Propelled Road Vehicles – Safety Specifications – Part 3: Protection of Persons against Electric Shock

Road vehicles – 60 V and 600 V Single-Core Cables – Part 1:

Dimensions, Test Methods and Requirements for Copper Conductor Cables

Plastics – Differential Scanning Calorimetry (DSC) – Part 1: General Principles

Plastics – Thermogravimetry (TG) of Polymers – General Principles Road Vehicles – Round, Sheathed, 60 V and 600 V Screened and Unscreened Single- or Multi-Core Cables – Test Methods and Requirements for Basic- and High-Performance Cables Global Automotive Declarable Substance List

Quality Management in the Automotive Industry – Part 1: QM System Audit; based on DIN EN ISO 9001 and DIN EN ISO 9004-1 List of Chemicals for Compatibility Testing Manufacturer's Code

Determining Current Capacity of Vehicle Cables

High-Frequency Cables for Motor Vehicles – Coaxial Cables High-Frequency Cables for Motor Vehicles That Are Not Individual Coaxial Cables

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LV 112-1: 2013-04 3

General information

VW 60306-1:2013-04

This supply specification only applies to new designs. Cables already used in production do not have to be modified. Subsequent modifications of material, dimensions, manufacturing processes, etc., must be reported to the respective engineering departments; these may necessitate a new release.

The test scope of this supply specification and special test conditions in individual cases must be defined in cooperation with and approved by the responsible design engineering departments.

4

VW 60306-1:2013-04

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LV 112-1: 2013-04

Dimensions and cable structure

The dimensions and conductor composition (see Figure 1) must be taken from the pertinent sections in the appendix. Unspecified details must be selected to suit the specific purpose as per ISO 6722-1.

s Insulation

d2 d1

Conductor

Figure 1 Conductor composition

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LV 112-1: 2013-04 5

Structure of the code

VW 60306-1:2013-04

The cable code is based on DIN 76722.

Example 1:

Designation of an unshielded low-voltage cable (FL) with thin-walled insulation (R), a nominal conductor cross-section of 1,5 mm² (1,5), type A conductor composition (-A) with tinned strands (Sn), symbol of the cross-linked PE insulating material (2X) as per DIN 76722, long-term service temperature Tmax +125 °C:

FLR2X 1,5/0,33Sn-A T125

Example 2:

Designation of an unshielded low-voltage cable (FL), a nominal conductor cross-section of 35 mm² (35), type B conductor composition (-B) with max. 0,21 mm (/0,21) bare strands, symbol of the silicone insulating material (2G) as per DIN 76722, long-term service temperature Tmax +200 °C:

FL2G 35/0,21-B T200

6

Materials

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LV 112-1: 2013-04

The properties as per sections 6.1 to 6.3 must be ensured by the manufacturer and apply to the unstranded state. 6.1

Conductor, bare

Strand Cu-ETP1, CW003A or Cu-ETP, CW004A as per DIN EN 13602. In exceptional cases, other Cu materials/alloys can be agreed upon. Bare Cu conductor: see Table 2.

Table 2

Designations

Bare Cu conductor

Diameter Tensile Elongation at

break At or (nominal strength

A200 mm dimension) Rm

in

mm

in N/mm²

Single- or multi-core wire in % min. 10 15 21 22 24 26 28 33

Material Condition

Multi- core wire A008 A013 A019 A020 A022 A024 A026 —

Code

Single-

Number core

wire

A010 A015 A021 A022 A024 A026 A028 A033

over up to 0,04 0,08 0,16 0,32 0,50 1,00 1,50 3,00

0,08 0,16 0,32 0,50 1,00 1,50 3,00 5,00

min. (200) (200) (200) (200) (200) (200) (200) (200)

Cu-ETP1 CW003A Cu-ETP CW004A

Table 3

Product designation example

Surface quality

P

Diameter nominal dimension

mm S0,4

Delivery form

Y

Designation Standard

Material Condition designation designation Cu-ETP-1

A022

Wire DIN EN 13602

Explanation of the example given above:

Condition designation: A = annealed (R = hard drawn) Surface finish: P = not tinned A, B = tinned

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LV 112-1: 2013-04

Diameter nominal dimension:

Delivery form: 6.2

Conductor, tinned

VW 60306-1:2013-04

S = single-core wire

M = multi-core wire Y = ring (Z = coil)

Requirements for the tin coating as per DIN EN 13602 determined on strand before stranding:

- Type A: for strand diameter ≤0,16 mm - Type B: for strand diameter >0,16 mm

Tinned Cu conductor: see Table 4.

Table 4 Designations

Tinned Cu conductor – properties

Diameter Tensile Elongation at (nominal strength break At or

A200 mm dimension) Rm

in

mm

in N/mm²

Single- or multi-core wire in % min. 7 13 19 20 22 24 26 31

Material Condition

Multi- core wire A005 A011 A017 A018 A020 A022 — —

Code

Single-

Number core

wire

A007 A013 A019 A020 A022 A024 A026 A031

over up to 0,04 0,08 0,16 0,32 0,50 1,00 1,50 3,00

0,08 0,16 0,32 0,50 1,00 1,50 3,00 5,00

min. (200) (200) (200) (200) (200) (200) (200) (200)

Cu-ETP1 CW003A Cu-ETP CW004A

6.3

Conductor, other surfaces

Other surfaces (e.g., silver plated) are permissible upon agreement.

6.4

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LV 112-1: 2013-04

Insulation

The minimum and maximum long-term service temperatures (Tmin and Tmax) for a load duration of 3 000 h must be selected as per the temperature classes (without mechanical load and not additive) given in Table 5, or in exceptional cases as per the drawing.

Table 5

Temperature classes

Short-term temperature (240 h) (Tmax + 25) °C

+110 ± 2 +125 ± 3 +130 ± 3 +150 ± 3 +175 ± 3 +200 ± 3 +205 ± 3 +225 ± 4 +250 ± 4 +275 ± 4 xyz + 25

Temperature for thermal

overload (6 h) (Tmax + 50) °C

+135 ± 3 +150 ± 3 +155 ± 3 +175 ± 3 +200 ± 3 +225 ± 3 +230 ± 4 +250 ± 4 +275 ± 4 +300 ± 4 xyz + 50

Long-term

Class service

Temperature

as per temperature

class

ISO 6722-1 (3 000 h)

Tmin °C to Tmax °C

A B B(105) C D E E(180) F G H

T85 T100 T105 T125 T150 T175 T180 T200 T225 T250 Txyz

-40 to +85 -40 to +100 -40 to +105 -40 to +125 -40 to +150 -40 to +175 -40 to +180 -40 to +200 -40 to +225 -40 to +250 -40 to xyz

In special cases, Txyz allows intermediate temperatures to be classified (for example, temperature class T135).

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LV 112-1: 2013-04 7 7.1

VW 60306-1:2013-04

Marking and supply specifications Packaging marking

Packaging must be marked as per VDA Volume 6 Part 1 and must be agreed upon between purchaser and supplier. 7.2

Manufacturer's code

See LV 112-1 supplement 2.

The unprinted distance between the texts must not exceed 200 mm. 7.3

Color

The color orange (similar to RAL 2003) must no longer be used as the base color for new designs. The color orange is reserved for high-voltage applications.

The colors of the aged (6 h, 240 h, and 3 000 h) and unaged cable must be documented in a photograph (see also sections 9.6.6, 9.6.7, and 9.6.8).

Only the most noticeable color changes must be documented in a photo as an example for each compound. 7.3.1

Color coding

Color coding based on DIN 72551-7 in German or English. Different color coding is permissible upon agreement. 7.3.2

Color coding

Colored longitudinal stripes are permissible for distinguishing several HV cables in the electric system. The colored longitudinal stripes must be integrated into the insulation in such a way that they cannot be smudged.

The color coding is based on DIN 72551-7. 7.4

Supply specifications

If these supply requirements are not met, the goods will be returned at the supplier's expense. 7.4.1

Visual inspection

The insulation must not exhibit any knots, cracks, blisters, or foreign inclusions and must be strippable using standard commercial stripping machines without leaving a residue and without damage to the conductor. 7.4.2

Test for insulation faults

As per ISO 6722, section \"Insulation faults\".

After the spark test, the cables must be tested as per Table 6. The stay time of the cable in the electrical field must be selected such that each cable section is stressed with at least 18 voltage peaks. When using tubular electrodes, the inside diameter of the electrode must be matched to the cable diameter.

Table 6

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LV 112-1: 2013-04

Voltage values/voltage class 1 (see Tabelle 1)

Test voltage

in kV

3 5

Nominal conductor cross-section in mm²

<0,5 ≥0,5

The emphasis in inspection must be placed on production inspection measures. The test plans and measured value documentation of the production and post-production inspections must include information on the measuring equipment used, frequency of measurements, and desired values and tolerances for all criteria that are important to proper functioning. If there are faults, proceed as per section 7.4.3.1. 7.4.3

Packaging units

The packaging units must be agreed upon between purchaser and manufacturer. An example of an agreement is provided in Table 7.

The cables must be delivered in drums free of damage, optionally in coils. The following requirements must be met:

─ The cable must be delivered in a drum or coil. The ends must be accessible and must not interfere with processing, and it must not be possible to damage the ends during transport. ─ The cable must be removable at a speed of 200 m/min from the drum and at a speed of 420 m/min from the coil into cable-cutting machines in intermittent operation.

Table 7

FLR cables

Nominal cross-section in

mm2

0,22 0,35 0,5 1,0 1,5 2,5 4,0 6,0

7.4.3.1 Partial lengths, ties, defects

A specified length can be composed of partial lengths in exceptional cases and must be marked separately.

─ Ties used for the partial lengths must not exceed the diameter of the cable and must not tear during processing.

─ Ties and defects must be marked by 30 to 100 mm of stripped insulation.

Delivery quantity in m

14 000 12 000 10 000 8 000 7 000 5 000 2 500 1 500

Example – Delivery quantities for NPS 400

Page 16 VW 60306-1:2013-04 LV 112-1: 2013-04

Maximum permissible quantities per drum or coil at nominal cross section: ─ 0,22 mm², 0,35 mm², 0,5 mm², 0,75 mm² 3 ties or defects ─ 1,0 mm², 1,5 mm², 2,5 mm² 2 ties ─ ≥4,0 mm² 1 tie

Deviating agreements between cable manufacturer and assembler are permissible. In this case, the vehicle manufacturer must be informed. 7.4.3.2 Marking of the delivery unit

The coil or drum marking must be applied so that it is always visible, even when packed on pallets. Retraceability must be ensured. Marking:

─ Cable designation as per section 5 ─ Manufacturer

─ Manufacturer's number ─ Date of manufacture

─ Compound number (optional) ─ Cable length

─ Position of ties and defects

8 8.1

General test conditions Test matrix

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LV 112-1: 2013-04

Table 8 Test matrix

Requalification test D X X X X X X X X X X X X X X X

Release test Changes of pre-materials Process test E X X X X X X X X X

7.3 7.4.1 7.4.2 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8.1 9.2.8.2 9.2.9 9.2.10 9.3 9.3.1 9.3.2 9.3.3 9.3.4

Color

Visual inspection Test for insulation faults Cable structure test

Test scope A1 X X

A2 B2 C2 X X

B1 X X

Site test Section Test C1 X X

Outside cable diameter and minimum wall thickness

Nominal conductor diameter Conductor resistance

Wall thickness of the insulation Insulation test wall thickness

1)

X X X X X

X X X X X

X X X X X

X X X X X

Physical and chemical properties of the insulation Density

Determination of viscosity Thermogravimetric analysis (TGA) Differential scanning calorimetry (DSC) Thermal stability for PVC

Determination of the infrared spectrum

Determination of tensile strength and elongation at tear

Tear propagation resistance/test on the plate Tear propagation resistance/test on the cable Determination of cross-linking density Microhardness

Mechanical properties in as-received condition Insulation stripability/secure fit of conductor Insulation abrasion resistance Sliding behavior of the cables Bending force of the cables

3)

1)

1)

1)

1)

X X X X X X X X X X X

X X X X

X X X X X X

X X X X X X X X X X X

X X X X

X X X

X X X

X X X

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LV 112-1: 2013-04

VW 60306-1:2013-04

Requalification test D X X X X X X X

Release test Changes of pre-materials 9.3.5 9.4 9.5 9.5.1 9.5.2 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6.1 9.6.6.2 9.6.7 9.6.7.1 9.6.7.2 9.6.7.3 9.6.8 9.6.8.1 9.6.8.2 9.6.8.3 9.6.8.4 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14

Insulation notch strength Flame retardance

Test scope A1 X X

A2 B2 C2

B1

C1 X

Electrical properties in as-received condition Specific volume resistance of the insulation 30-minute dielectric strength

3)

1)

X X

Mechanical and electrical properties after mechanical, thermal, or chemical stress Stress test

Insulation shrinkage under heat

Compressive strength of the insulation under heat

Derating curve

Thermal stability in wound state Thermal overload Tmax +50 °C

Extreme thermal overload Tmax + x °C/1 h Short-term aging (240 h)

Winding test after short-term aging (240 h) Determination of IR after short-term aging (240 h) Determination of tensile strength and elongation at tear after short-term aging (240 h) Long-term aging (3 000 h)

Winding test after long-term aging (3 000 h) Determination of IR after long-term aging (3 000 h)

Determination of tensile strength and elongation at tear after long-term aging (3 000 h) Minimum permissible radius for static routing Winding test at low temperature (-40 °C)

Impact test at low temperature (-15 °C)

Resistance of cable marking to wiping/smudging Resistance to reverse bending stresses Kink test

Electrical properties during aging in water

3)

1)

3)

X X X X X X X

X X

4)

X X X

X X X

X X X

X X X

X X X

X X X

X X X X X X X X X X

X

X

X

Process test E X X

Site test Section Test

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Requalification test D X

Release test Changes of pre-materials 9.6.15 9.6.16 9.7 9.8 9.8.1 9.8.2 9.8.3 10

Test scope

Damp heat, constant (hydrolysis test) Ozone resistance Mycological test Compatibility tests

Chemical resistance as per ISO 6722-1 Resistance to chemicals and wrapping tapes Resistance to wiring harness components Environmental protection

2)

1)1)

A1 X X X

A2 B2 C2

B1

C1

X X X X

1) The test is performed only on the largest cross-section of each compound. 2) Documentation must be provided by the cable manufacturer. 3) Not to be performed for cable cross-sections >6 mm². 4) Derating except for C2.

Documentation: The documentation of the tests as per test scopes A, B, and C must be sent to the purchaser. For test scopes D and E, the cable manufacturer bears the responsibility for documentation and archiving; submission to the purchaser is only necessary upon special request.

Process test E

Site test Section Test Page 20 VW 60306-1:2013-04 LV 112-1: 2013-04

Test scope/general information:

The reduced test scopes are permissible only if the issued release with the complete test scope forming the basis is not older than 10 years.

If an issued release is older than 10 years, the development departments of the OEMs may require a new complete test (A1) as per the current version of the particular in-house standard. In this case, the smallest cross-section (e.g., 0,35 mm²) of each compound is tested. Other agreements can be made with the development departments.

Test scope A1/A2: Testing for the main manufacturing site. Presentation: ─ new cables, or

─ already known cables with new compound.

The procedure in the case of minor compound changes must be agreed upon with the engineering departments.

A prerequisite for test scopes B to E is a release as per A1.

Test scope B1/B2: Same compound, different site of the same cable manufacturer. Test scope C1/C2: For unchanged compound composition and:

─ chemically identical pre-materials supplied by different sub-contractors, or ─ change of compound manufacturing site.

Test scope D: To be performed regularly, at least every 5 years, by the cable manufacturer.

Test scope E: Recommended process-accompanying testing (e.g., batch-related or continuously). The supplier is responsible for process reliability.

Cross-section assignment:

Test scope A1/B1/C1: is performed on cross-sections 0,35 mm², 0,5 mm², 1,5 mm², 2,5 mm², 4,0 mm², and 16 mm².

Short test A2/B2/C2: all other cross-sections.

Table 9

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Test matrix for single-wire cables that are used exclusively in sheathed cables

Requalification test D X X X X X X X X X X X X X X

Release test Change of pre-materials 7.3 7.4.1 7.4.2 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8.1 9.2.8.2 9.2.9 9.2.10 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.4 9.5

Color

Visual inspection Test for insulation faults Cable structure test

Test scope A1 X X

A2 B2 C2 X X

B1 X X

C1 X X

Outside cable diameter and minimum wall thickness

Nominal conductor diameter Conductor resistance

Wall thickness of the insulation Insulation test wall thickness

1)

X X X X X

X X X X X

X X X X X

X X X X X

Physical and chemical properties of the insulation Density

Determination of viscosity Thermogravimetric analysis (TGA) Differential scanning calorimetry (DSC) Thermal stability for PVC

Determination of the infrared spectrum

Determination of tensile strength and elongation at tear

Tear propagation resistance/test on the plate Tear propagation resistance/test on the cable Determination of cross-linking density Microhardness

Mechanical properties in as-received condition Insulation stripability/secure fit of conductor Insulation abrasion resistance Sliding behavior of the cables Bending force of the cables Insulation notch strength Flame retardance

Electrical properties in as-received condition

3)

1)

1)

1)

1)

X X X X X X X X X X X

X X X X

X X X X X X

X X X X X X X X X X X

X

X

X

X

Process test E X X X X X X X X X

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Requalification test D X X X X X X

Release test Change of pre-materials 9.5.1 9.5.2 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6.1 9.6.6.2 9.6.7 9.6.7.1 9.6.7.2 9.6.7.3 9.6.8 9.6.8.1 9.6.8.2 9.6.8.3 9.6.8.4 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15 9.6.16 9.7

Test scope

Specific volume resistance of the insulation 30-minute dielectric strength

3)

1)

A1 X X

A2 B2 C2

B1

C1

Mechanical and electrical properties after mechanical, thermal, or chemical stress Stress test

Insulation shrinkage under heat

Compressive strength of the insulation under heat

Derating curve

Thermal stability in wound state Thermal overload Tmax +50 °C

Extreme thermal overload Tmax + x °C/1 h Short-term aging (240 h)

Winding test after short-term aging (240 h) Determination of IR after short-term aging (240 h) Determination of tensile strength and elongation at tear after short-term aging (240 h) Long-term aging (3 000 h)

Winding test after long-term aging (3 000 h) Determination of IR after long-term aging (3 000 h)

Determination of tensile strength and elongation at tear after long-term aging (3 000 h) Minimum permissible radius for static routing Winding test at low temperature (-40 °C)

Impact test at low temperature (-15 °C)

Resistance of cable marking to wiping/smudging Resistance to reverse bending stresses Kink test

Electrical properties during aging in water Damp heat, constant (hydrolysis test) Ozone resistance Mycological test

1)1)

3)

1)

3)

X X X X X

X

X X

X X X

X X X

X X X

X X X

X X X

X X X X X X X X

X

X

X

Process test E X X

Site test Section Test

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Requalification test D X

Release test Change of pre-materials 9.8 9.8.1 9.8.2 9.8.3 10

Compatibility tests

Test scope A1

A2 B2 C2

B1 C1

Chemical resistance as per ISO 6722-1 Resistance to chemicals and wrapping tapes Resistance to wiring harness components (only connector housings, seals, contacts, cable lugs) Environmental protection

2)

X X X

1) The test is performed only on the largest cross-section of each compound. 2) Documentation must be provided by the cable manufacturer. 3) Not relevant for cable cross-sections >6 mm².

Documentation: The documentation of the tests as per test scopes A, B, and C must be sent to the purchaser. For test scopes D and E, the cable manufacturer bears the responsibility for documentation and archiving; submission to the purchaser is only necessary upon special request.

Process test E

Site test Section Test Page 24 VW 60306-1:2013-04 LV 112-1: 2013-04

Test scope A1/A2: Testing for the main manufacturing site. Presentation: ─ new cables, or

─ already known cables with new compound.

The procedure in the case of minor compound changes must be agreed upon with the engineering departments.

A prerequisite for test scopes B to E is a release as per A1.

Test scope B1/B2: Same compound, different site of the same cable manufacturer. Test scope C1/C2: For unchanged compound composition and:

─ chemically identical pre-materials supplied by different sub-contractors, or ─ change of compound manufacturing site.

Test scope D: To be performed regularly, at least every 5 years, by the cable manufacturer.

Test scope E: Recommended process-accompanying testing (e.g., batch-related or continuously). The supplier is responsible for process reliability.

Cross-section assignment:

Test scope A1/B1/C1: The smallest cross-section used for each insulating material is tested. Short test A2/B2/C2: is performed on all other cross-sections of each insulating material.

8.2

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Test atmosphere

If no other test atmosphere is specified, testing is performed in the standard climate as per ISO 5, designation 23/50, with \"ordinary (normal) tolerance\". ISO 6722-1 applies to ovens (test item \"Ovens\"). 8.3

Specimens

Unless otherwise specified, at least 3 specimens of the cables must be tested in as-received condition.

Light colors must be used, not brown or black.

Before tests, the specimens must be aged for at least 16 h in the ISO 5 - 23/50 standard climate unless otherwise specified in the test description.

For each test, specimens must be used that have not been used in previous tests.

If a maximum of 1 of the 3 specimens fails in a test, the test must be repeated with 10 specimens and this must be documented. All of the 10 specimens must then pass the test, i.e., the test is not passed if one more specimen fails in the repeat test.

If more than 1 specimen fails, a repetition with 10 specimens is not possible; the test is considered not passed. 8.4

Rounding of numerical values

The determined numerical values must be rounded as per DIN 1333 to the number of digits used to specify the associated desired values.

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Tests

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The described tests are based on ISO 6722-1.

Unless otherwise agreed upon, the drawing note generally takes precedence over the standard if different specifications are given. 9.1

Cable structure test

The parameters indicated in the relevant appendices for the cable structure must be tested. The mean value of the measurements as well as the minimum and maximum values must be indicated in the test report. 9.1.1

Outside cable diameter and minimum wall thickness

The test is performed as per DIN EN 60811-1-1. 9.1.2

Nominal conductor diameter

The test must be performed as per DIN EN 60811-1-1 \"Measurement of Thickness and Overall Dimensions\".

Here, the inside diameter (nominal conductor diameter) is measured at least three times at regular distances (for the three measurements, the specimen must be rotated ≈60° each time). 9.1.3

Conductor resistance

Test as per ISO 6722-1. 9.1.4

Wall thickness of the insulation

Test as per ISO 6722-1. 9.1.5

Insulation test wall thickness Sp (thin-walled cables)

See tables in Appendix A.

If the insulation test wall thickness is too small in two cases, a cable batch may be rejected.

In cases of doubt, a microscopic analysis on the metallographic microsection must be performed. 9.2

Physical and chemical properties of the insulation

The measured values for each cable specimen obtained from the tests described below must be included as an appendix to the test report; they serve as a unique identification of the cable. 9.2.1

Density

Testing as per DIN EN ISO 1183-1, method A 9.2.2

Determination of the viscosity

The test for the PVC powder used in the compound is performed as per DIN EN ISO 1628-2 in the as-received condition. The PVC powder used must be specified by the cable manufacturer.

For all other materials, the test of the flowability is performed by means of melt flow index (MFI) as per DIN EN ISO 1133. The test is performed in the as-received condition and after aging for 3 000 h.

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For cross-linked materials, this test is not applicable.

Test parameters such as temperature, load weight, and residual moisture (see Table 10) must be agreed upon with the cable supplier and must be documented.

Table 10 Material PP TPU PA ETFE FEP TPS PE PBT PFA

9.2.3

Thermogravimetric analysis (TGA)

Melt flow/volume (MFI/MVI) measurements Temperature

in °C

+230 +190 +275 +297 +372 +230 +190 +250 +372

Load weight in kg

5 21,6 2,16 5 5 5 2,16 2,16 5

Residual moisture in %

<0,03

A thermogravimetric analysis of the insulation must be performed as per ISO 11358 and must be documented.

In deviation from ISO 11358, the test must be performed with a heating rate of +10 °C/min and a gas flow rate of 20 ml/min.

Tared, annealed aluminum oxide crucibles are permissible as crucibles and are preferred. Annealed Pt crucibles are also permissible as an alternative.

From room temperature to +800 °C, testing must be performed in a nitrogen atmosphere; from +800 °C to +950 °C, testing must be performed in an air atmosphere. 9.2.4

Differential scanning calorimetry (DSC)

Differential scanning calorimetry of the insulation must be performed on a specimen as per DIN EN ISO 11357-1 and must be documented.

The test is performed as a dynamic measurement as per section 9.4. of DIN EN ISO 11357-1.

The test must include at least a temperature range from -50 °C to +75 °C above the specified long-term service temperature and up to +20 °C above the melting temperature (if available) of the particular specimen.

The heating rate of the 1st heating must be +10 °C/min, the cooling rate must be -10 °C/min, and the heating rate of the 2nd heating must be +10 °C/min. A holding time of 2 min must be adhered to at the end points of the temperature profile.

The initial specimen weight must be between 2 mg and 20 mg. Deviating test conditions must be agreed upon. 9.2.5

Thermal stability for PVC

Testing only for PVC as per DIN EN 60811-3-2, section 9:

- Change from pH value 5 to pH value 3 - Requirement: >140 min (class T105)

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9.2.6 Determination of the infrared spectrum

The test must be performed using the ATR (attenuated total reflectance) method in the as-received condition.

Test

The cable is cut at an angle of 90° to the longitudinal axis.

The cut surface of the cable is cleaned with isopropanol. The measurement must be performed on the cleaned cut surface.

In exceptional cases, the outer surface can be tested after cleaning. 9.2.7

Determination of tensile strength and elongation at tear

Test as per DIN EN 60811-1-1.

For the number of specimens, section 9.7 must also be observed. 9.2.8

Tear propagation strength

The test of tear propagation strength is performed only on silicone material or silicone insulation. 9.2.8.1 Test on the plate

Testing only for silicone as per ISO 34-1, method B, procedure (b) (Graves angle test piece with nick).

Requirement: ≥15 N/mm for temperature class E ≥10 N/mm for temperature class F 9.2.8.2 Test on the cable

The test is performed on the basis of DIN VDE 0282-10 on the 25 mm² or 35 mm² cross-section, and for each material compound variant.

A sample of the insulation must be taken from the cable, and 5 specimens with the dimensions as per Figure 2 must be produced from the sample. For cables with an outer diameter less than 10 mm, the insulation size may correspond to the sample width.

The grooves (contour of the stranded copper wire) must be removed from the specimens. This can be performed using a suitable peeling device, so that there is an even wall thickness of the insulation sleeve. It must be ensured that only the grooves are removed.

As shown in Figure 2, the sample must be provided with a longitudinal cut in the center (for example, using a sharp razor blade).

The average thickness of each specimen must be determined by 3 measurements at uniform distances along the expected tear length.

The halves of the severed specimens must be clamped into the clamping heads of the tensile test machine as shown in Figure 2.

The speed at which the jaws are moved apart must be (250 ± 50) mm/min.

To compute the tear propagation strength, the maximum value of the force, in N, is divided by the average thickness of the specimen, in mm. The tear propagation strength is the average of the values computed in such a way.

Requirement: in accordance with sample.

Dimensions in mm.

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Figure 2

9.2.9

Determination of cross-linking density

Figure 3

The test for cross-linked polyethylene compounds is performed as per DIN EN 60811-2-1, section 9 (Thermal expansion test), at a temperature of (+200 ±3) °C and a load of 20 N/cm².

Requirements:

Elongation under load ≤100% Elongation after load removal ≤25% 9.2.10 Microhardness

The microhardness is determined as per ISO 48, method M (in accordance with sample). For especially hard materials this test must be performed according to agreement. 9.3

Mechanical properties in as-received condition

Generally, the conductor must be designed so that it can be processed properly. The processing details must be agreed upon between the cable supplier and the assembler. The insulation must not exhibit any blisters, cracks, nodes, or inclusions of foreign matter. 9.3.1

Insulation stripability and secure fit of conductor

Insulation strippability requirements

For cables that must be stripped, it must be possible to strip ≥20 mm of the insulation cleanly and without difficulty using commercially available tools.

Requirements on secure fit of the conductor

The forces required to strip the insulation on a length of (50 ±1) mm must be within the limits indicated in Table 11. Deviating values may be agreed upon in individual cases.

Table 11

Nominal conductor cross section Minimum force Maximum force

in mm² in N in N

Secure fit of the conductor 0,22 3 20

0,35 5 30

0,5 5 30

0,75 5 40

1,0 5 40

1,5 10 50

2,5 10 60

4,0 10 70

6,0 10 70

For nominal conductor cross-sections >6,0 mm²: in accordance with sample

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Test

Number of specimens ≥5 Specimen length (150 ± 5) mm

The insulation is stripped from the specimen over a length of (50 ± 1) mm, and the stripped end of the conductor is pulled through a sheet with a hole of (conductor diameter +0,1 mm). The pull-off speed is 100 mm/min. 9.3.2

Insulation abrasion resistance

Requirements

Resistance to abrasion by scraping is defined by the number of complete cycles that are required until the scraping needle has rubbed through the insulation and the electrical contact shuts off the machine. The minimum number of cycles (see Table 12) must be met by each individual measurement.

Table 12

Nominal conductor

in mm²

cross section Contact force

in N

Number of cycles 0,75

1,0

1,5

2,5

4,0

≥6,0 ≤25,0

0,22 0,35 0,5

7.00 ± 0.05

Number of

minimum 150 200 300 350 500 1 500 1 500 1 500 1 500

cycles Test

The test is setup and performed as per ISO 6722-1 (section \"Abrasion test\"). Needle diameter (0,45 ± 0,01) mm

The test can be stopped as soon as the number of cycles exceeds the minimum number of cycles by 50 %. Attention must be paid that the needle is lifted off at the reversal point. 9.3.3

Sliding behavior of the cable

The test is not relevant to release but serves for data collection. It will become relevant to release as soon as sufficient measured values are available for different insulating materials.

Requirements

The measured values for the maximum tensile force must be attached to the first-sample test report.

Test

The test device (see Figure 4) consists of a variable-width roller that is fixed in place, and a tensile test machine.

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Figure 4

Test setup for sliding behavior

Wind the cable to be tested two turns around the cylindrical part of a test roller with a diameter according to Table 13. Take care that sufficient tension is applied to this support cable. The winding is pressed together and held by two flanges on the sides.

Place a piece of cable of suitable length from the same manufacturing batch as the support cable, loaded with a weight as per Table 13, in the gusset of the wound cable, and fix it in a suitable manner to the frame of the tensile test machine.

Then pull the DUT over the wound cable at a speed of 250 mm/min, and determine the maximum measured force for each individual measurement. Perform the measurement twice per DUT. Repeat the test twice more on specimens removed from other cable sections for a total of 6 measured values.

During the tests, the wound cable must not be replaced nor repositioned. Document the mean value as well as the maximum and minimum values in addition to the measured values obtained.

Table 13

Nominal conductor cross section Weight force (counterweight) Test roller diameter

in mm² in N in mm

Test specifications for sliding behavior 0,22 0,35 0,5 0,75 5 20

5 20

5 30

5 40

1,0 5 40

1,5 5 50

2,5 5 60

4,0 10 80

6,0 10 80

This test is not to be performed on nominal conductor cross sections >6,0 mm².

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9.3.4 Bending force of the cable

Requirements

The bending force must be within the values from Table 14 and Table 15. Deviating values may be agreed upon in individual cases.

Table 14

Nominal conductor cross section Specimen length (l) Number of specimens (n)

Distance (lV) Maximum bending force

Specifications for the bending force test in mm² in mm in mm in N

15

Table 15

Specifications for standard setup (see Table 6)

in mm² in mm in mm in N

15

20

30

10

16

25

35 150 1 100 50

70

90 110 50

70

95

Nominal conductor cross section Specimen length (l) Number of specimens (n)

Distance (lV) Maximum bending force

15

0,22

0,35 0,5 0,75 1,0 1,5 2,5 4,0 6,0

50 5 20 20

25

30

30

40 70 3 30 70

90

Test

The test device consists of two metal legs, a test mandrel, and a tensile test machine, and is shown schematically in Figure 5.

Straighten out the cable specimens (number n and lengths as per Table 14 and Table 15) and age them in this way for at least 16 h. Then place the n cables next to one another on the metal legs, which are located at a distance of lV as per Table 14 and Table 15. Mark the upper side of these cables under test with a felt-tip pen on the left and the right perpendicular to the longitudinal axis of the cable.

In a tensile test machine, press the test mandrel onto the cables at a test speed of 100 mm/min. Measure the force required to bend the cables.

Then straighten out the cables by hand and place them back on the legs on the side bearing the marking; then measure the force required to bend the cables once more. The mean value of the two measurements is the bending force.

Dimensions in mm.

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Figure 5

9.3.5

Insulation notch strength

Bending force test device

Requirements

The notching force must correspond to the values in Table 16.

Table 16

Nominal conductor

in mm² cross section

Minimum notching force in N

0,22 30

Notching force 0,35 30

0,5 40

0,75 50

1,0 50

1,5 60

2,5 70

4,0 100

6,0 120

For nominal conductor cross-sections >6,0 mm²: in accordance with sample Test

The test device (see Figure 6) consists of a tensile test machine or a force-measuring device, a notching tool (cutter), and a circuit with a low voltage. A round spring wire as per ISO 6722-1 (Abrasion resistance) and needle diameter (0,45 ± 0,01) mm must be used as the notching tool. Fix the specimen in the tensile test machine as per Figure 6. Press the steel wire with a constant speed of ≤10 mm/min through the insulation until electrical contact is established between the steel wire and the conductor of the specimen and the machine switches off as a result. The axes of the specimen and the cutter must be at right angles to one another. Record the force displayed when contact is made. After each reading, move the specimen at least 10 mm farther and turn it 90° about its longitudinal axis. This means that four measurements must be taken, and the notching force is determined from the average of the measurements.

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Figure 6

9.4

Flame retardance

Notch strength test device

Test as per ISO 6722-1. 9.5 9.5.1

Electrical properties in as-received condition Specific volume resistance

Requirements

The specific volume resistance of the insulation must be at least 109 Ωmm.

Test

As per ISO 6722-1 (but with 1% NaCl solution). 9.5.2

30-minute dielectric strength

Requirements

Dielectric breakdown must not occur.

Test

As per ISO 6722-1.

9.5.3

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Measurement of 1-minute dielectric strength (only after stressing)

This test is only performed after tests that contain a corresponding reference.

Requirements and tests

As per section 9.5.2 (30 minute dielectric strength); however, a test voltage of 1 kVeff (5 kV for cross-sections >6,0 mm²) is applied for 1 minute during the test.

The samples are aged in the salt water bath for ≥10 min. A deviating aging duration applies if the aging in the salt water bath is explicitly described in a test. (See also ISO 6722-1, e.g., 1 minute dielectric strength after long-term aging.) 9.6 9.6.1

Mechanical and electrical properties after mechanical, thermal, or chemical stress Stress test

This test applies to cables with insulation made of fluoropolymers such as FEP and ETFE.

Two specimens of sufficient length (≈2 m) are taken at least 1 m away from each other, and the insulation is removed from both ends.

The specimens are wound to a coil of ≈20 cm diameter and aged for 3 h in an oven at the temperature specified below:

─ Fluoropolymers, temperature class T200: FEP (+225 ± 5) °C Radiation cross-linked ETFE (+225 ± 5) °C ─ Fluoropolymers, temperature class T175: ETFE (+225 ± 5) °C ─ Fluoropolymers, temperature class T150: ETFE (+200 ± 5) °C

Subsequently, the specimens are removed from the oven and cooled down to room temperature for at least 16 h. Then, they are wound around a mandrel as per Table 17 in a tight spiral of at least 6 turns, and the ends without insulation are fixed (also see example in Figure 7). L1 must be >60 mm and L2 must be >10 mm.

The wound specimens including the mandrel are aged for another 3 h at the cable-specific temperatures given above. Then the specimens are allowed to cool down for at least 16 h, the mandrel is removed (without unwinding the cable), and the specimens are subjected to an electrical test as per section 9.5.3.

Figure 7

Example graphic of winding test

Evaluation

The test is considered passed if no dielectric breakdown occurs during the electrical test as per section 9.5.3.

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Nominal conductor cross section Mandrel diameter 9.6.2

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Table 17 mm² 0,22 mm

Mandrel diameter 0,35

2

0,5 0,75

1,0

3

1,5 2,5

4

4,0

5 6,0

Insulation shrinkage under heat

Requirements and tests As per ISO 6722-1.

Test temperature as per Table 5, column: \"Temperature for thermal overload.\"

The opening time for loading the specimens must not exceed 10 s. The aging time begins when Tmax + 50 °C has been reached.

The specimens must be suspended using a PTFE strip as shown in Figure 8.

Figure 8

9.6.3

Pressure resistance of the insulation under heat

Specimen preparation for the shrinkage test

Requirements and tests As per ISO 6722-1.

Test temperature: Tmax, Tmax + 10 °C, Tmax + 20 °C, Tmax + 30 °C, etc. until at least 1 of 3 specimens fails. The test until failure is used to collect data for an overview of material differences and for determining the \"temperature of compressive strength under heat.\" New specimens must be used for each test temperature. 9.6.4

Determination of the derating curve

The current capacity at ambient temperature and the measurement for temperature heating of the cable or the conductor are performed as per LV 112-3.

The smallest cross-section must be measured for each mixture or compound used. All cross-sections (including those measured) are computed as per LV 112-3.

The maximum permissible resistance and the smallest permissible outer diameter must be used for the computation.

The values of a and b must be specified in the test report for each cross-section. The parameters used for the computation must be specified for each cross-section.

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In addition, the computed 𝜏 for the following temperatures must be specified in the test report: Tmax - 20 °C Tmax - 35 °C Tmax - 50 °C RT 9.6.5

Thermal stability in the wound state

Requirements

Dielectric breakdown must not occur.

Test

Wind a cable specimen of sufficient length around a mandrel with a diameter as per Table 18 in 6 tight turns and tie it in place.

Age the specimen prepared in this way for 1 h in a natural convection oven as per ISO 6722-1, section \"Ovens\After cooling to room temperature, perform the test as per section 9.5.3

Table 18

Nominal conductor cross section Mandrel diameter 9.6.6

mm² mm

0,22

Mandrel diameter 0,35 5

0,5

0,75

1,0

9

1,5

2,5

4,0

13 6,0

Thermal overload

9.6.6.1 Thermal overload Tmax +50 °C

Requirements and tests

As per ISO 6722-1 (thermal overload and winding test in standard climate). Test temperature as per Table 5.

The subsequent high-voltage test is performed as per section 9.5.3. After the test, the color of the cable must still be identifiable.

The colors of the aged and unaged cable must be documented in a photograph. 9.6.6.2 Extreme thermal overload Tmax + x °C/1 h

This test simulates an extreme situation (e.g., short circuit). Therefore, the results of this test cannot be used exclusively for the cable design in the electric system.

Test

The test is performed as per test item 9.6.8.1, \"Winding test after long-term aging\". The subsequent high-voltage test is performed as per 9.5.3.

The starting temperature can be freely selected on the basis of empirical values.

For example, the starting temperature can be Tmax + 75 °C.

If all three specimens pass this test, the temperature must be increased by 10 °C and the test must be repeated with new specimens. If at least one specimen does not pass the test, the test is complete.

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If at the starting temperature (e.g., Tmax + 75 °C) at least one specimen is already not OK, the temperature is reduced by 10 °C until all three specimens are OK.

The starting temperature can deviate from Tmax + 75 °C depending on the material.

The highest temperature at which all three specimens passed the test must be documented in the test report.

Note:

A conclusion about the amperage at which the temperature determined in such a way arises at the conductor can be made by means of a computation or a derating measurement (see LV 112-3). 9.6.7

Short-term aging (240 h)

The aging is performed as per ISO 6722-1 at the oven temperature Tmax + 25 °C.

The specimens for the following test sub-items for 9.6.7.1, 9.6.7.2, and 9.6.7.3 can be aged together in an oven.

The colors of the aged and unaged cable must be documented in a photograph. 9.6.7.1 Winding test after short-term aging

As per ISO 6722-1.

Winding test, rotating mandrel and weight at -25 °C as per ISO 6722-1. The subsequent high-voltage test is performed as per 9.5.3.

After the aging, the color of the cable must still be identifiable.

9.6.7.2 Determination of the infrared spectrum after short-term aging The aging is performed as per ISO 6722-1 at the oven temperature Tmax + 25 °C. The infrared spectrum is determined as per 9.2.6

9.6.7.3 Determination of tensile strength and elongation at tear after short-term aging Specimens are prepared as per DIN EN 60811-1-2, section 8.1.3.3.

The aging is performed as per ISO 6722-1 at the oven temperature Tmax + 25 °C.

The specimens must be suspended vertically approximately in the center of the oven at least 20 mm from each other.

The tensile strength and elongation at tear are determined as per section 9.2.7. The results are used for data collection. 9.6.8

Long-term aging (3 000 h)

As per ISO 6722-1.

The aging is performed as per ISO 6722-1 at the oven temperature Tmax.

The specimens for the following test sub-items for 9.6.8.1, 9.6.8.2, 9.6.8.3, and 9.6.8.4 can be aged together in an oven.

The colors of the aged and unaged cable must be documented in a photograph. After the aging, the color of the cable must still be identifiable. 9.6.8.1 Winding test after long-term aging

Winding test in standard climate as per ISO 6722-1.

The subsequent high-voltage test is performed as per 9.5.3.

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9.6.8.2 Determination of the infrared spectrum after long-term aging The aging is performed as per ISO 6722-1 at the oven temperature Tmax. The infrared spectrum is determined as per section 9.2.6.

9.6.8.3 Determination of tensile strength and elongation at tear after long-term aging Specimens are prepared as per DIN EN 60811-1-2, section 8.1.3.3.

The aging is performed as per ISO 6722-1 at the oven temperature Tmax.

The specimens must be suspended vertically approximately in the center of the oven at least 20 mm from each other.

The tensile strength and elongation at tear are determined as per section 9.2.7. The results are used for data collection.

9.6.8.4 Minimum permissible bend radius for static routing

Long-term aging of the bent specimens provides verification that the cable can be routed with bend radii greater than or equal to the specified radius.

Cable samples

Strip two cable samples of approx. 400 mm length 25 mm at each end. For specimen preparation, see Table 19.

Table 19

Maximum cable diameter

dmax in mm ≤3,0

(≈ up to 2,5 mm²)

Smallest permissible bend radius in mm 2,0 × dmax

-

Maximum winding mandrel diameter in mm

Specimen preparation

Wind 360° around itself three times, see Figure 9

Wind 360° around mandrel two times, fastened with two cable ties:

1st cable tie at a distance of half of the arising loop diameter

2nd cable tie at a distance of half of the arising loop diameter from 1st tie, remove mandrel (see Figure 9)

Bend 180° around mandrel, fasten with cable ties:

1st cable tie at a distance equal to the arising loop diameter

2nd cable tie at a distance of half of the arising loop diameter from 1st tie, remove mandrel (see Figure 9)

>3,0 and ≤5,0 (≈ from 4,0 mm² to

6,0 mm²)

2,0 × dmax 1,5 × dmax

>5,0 (greater than ≈ 6,0 mm²)

3,0 × dmax 2,0 × dmax

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The cable ties must meet the following requirements:

− Their base material must be suitable for the corresponding aging temperature. − They must be compatible with the insulation material to be tested. − They must have external teeth. − They must not have sharp edges. − Width ≥0,8 × dmax

− The tightening force must be selected in such a way that no impressions or only slight

impressions are produced in the insulation surface in the neutral state.

Figure 9

Procedure

Figure 10

Figure 11

Age the prepared samples for 3 000 h as per section 9.6.7 and section 9.6.8. Then subject the still wound and fastened specimens to a high-voltage test as per the requirements in ISO 6722-1.

Requirement

Dielectric breakdown must not occur.

Additional test for data collection (informative)

After the fasteners have been removed, straighten the specimens by hand and perform another high-voltage test again.

9.6.9

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Winding test at low temperature (-40 °C)

Requirements and tests

As per ISO 6722 (section \"Winding test at low-temperature (-40 °C), rotating mandrel and weight\"). 9.6.10 Impact test at low temperature (-15 °C)

Requirements and tests As per ISO 6722-1.

Deviation: testing with a hammer weight of 100 g for cables with cross sections ≤0,5 mm². 9.6.11 Resistance of cable marking to wiping/smudging This test only applies to cables with printed markings.

Testing and requirement As per ISO 6722-1.

9.6.12 Resistance to reverse bending stresses

Requirements

Number of cycles until failure: in accordance with sample.

No damage to the insulation (tear or fracture) visible.

Determine the number of bending cycles until the cable breaks. A cable break is detected by measuring the electrical continuity.

Test

+0 %.

) As per ISO 14572, but with R ≈ 6 × maximum specific outside cable diameter (−

20 %

Perform the test at room temperature and at Tmin. Visually inspect the insulation at least once a day.

Cross-sections to be tested Preferred cross-sections less than 25 mm² (test scope A1) Specimen length ≥1 m Sampling rate ≤10 ms

Distance of the bending jaws 1,5 × the maximum specified outer diameter ±0,5 mm Material of the bending jaws Stainless steel or aluminum Loading weight 1,0 kg/mm² (total nominal copper cross-section), the minimum

weight must be at least 250 g per cable and the maximum weight must not exceed 12 kg per cable

The complete cable must be fastened to the test equipment and to the loading weight (not only the conductor).

Note: For cables loaded in torsion, the torsional endurance test as per LV 213 must be used.

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9.6.13 Kink test

Requirement

Dielectric breakdown must not occur. Test

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This test is used only for cables with cross-sections ≤6,0 mm².

Before testing, a test device with an inner bend radius r corresponding to the cable cross-section to be tested is selected (Figure 12); fitted with the specified spacer rings as per Table 20.

Table 20

Nominal conductor cross

in mm²

section

Bend radius (r) Spacer ring thickness Tolerance of spacer ring

thickness

in mm in mm in mm

1,0 0,22

Spacer rings

0,35 0,5 0,75 1,0 1,5 2,5 1,0 1,1

1,3

1,6

1,5

1,8 2,1 2,6 3,3 -0,1

4,0

6,0

3,0 3,9

Strip cable specimens with a 200 mm minimum length 20 mm at the ends. Clamp the specimen perpendicularly between the jaws of the test device until the spacer rings reach a hard stop. Then subject the cable to 20 bending cycles. One cycle corresponds to bending the cable 180° to one side until the cable rests against the device, bending the cable 360° to the other side of the test device, and bending the cable 180° back to the initial position. It must be ensured that the cable is loaded in tension as little as possible during the test.

After the cable specimen has been unclamped, test the cable specimen as per section 9.5.3 (1-minute dielectric strength).

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Figure 12

9.6.14 Electrical properties during aging in water Requirements

The insulation resistance (measured as per section 9.5.1) during the aging in water must be at least 109 Ωmm. This value is measured every 7 days. The length-specific conductor resistance must not deviate from the initial value by more than 10%. After the test, the color of the cable must still be identifiable. Test

Wind a specimen of sufficient length in 10 turns around the center of a mandrel with a diameter as per Table 21. Tie the cable is tied and remove the mandrel.

Table 21

Nominal conductor cross section Mandrel diameter

in mm² in mm

Nominal conductor cross section Mandrel diameter

in mm² in mm

10 40

16 50

25

35 75

50

70 100

95

120 125

Mandrel diameter

1,0

10 1,5

2,5 15

4,0

6,0

Test device for kink test

0,22 0,35 0,5 0,75

6

20

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Connect each specimen to the positive terminal of a 48-V DC voltage source and age it for 1 000 h in a salt solution (1% NaCl in deionized water) at a temperature of (+85 ± 2) °C in a test vessel made of glass in such a way that ≈ 2 m of the specimen is completely immersed. The test vessel with the specimens must be uniformly heated by means of an external temperature-control bath. Ensure that the specimens and the electrode do not touch in the test vessel.

Immersed electrode surface (100 ± 10) cm2 Electrode material Cu

Immediately after aging in water, test the specimens as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\").

Only cables with the same insulation material must be aged in the same water bath. The water amount in the test vessel must be 2 l to 5 l and must be indicated in the test report. For larger cross-sections (≥10 mm²), deviating water amounts can be used and must be documented in the test report.

If a cable has failed, remove it from the water vessel.

Additionally, performed the test with reversed polarity on new DUTs. 9.6.15 Damp heat, constant (hydrolysis test) Requirement

Dielectric breakdown must not occur.

After the test, the color of the cable must still be identifiable. Test

Strip the ends of a (3 000 ± 50) mm long cable specimen. Lay the cable in rings with a radius ≥25 mm, fasten it to the base plate, and age it for 3 000 h at a temperature of (+85 ± 2) °C and a relative humidity of (85 ± 5)%. Subsequently, age the specimen for 30 min at room temperature, wind it within another 30 min as per section 9.6.8 (winding test), and test it as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\"). 9.6.16 Ozone resistance Requirements

Dielectric breakdown must not occur. Test

Wind cable specimens of sufficient length in 4 to 6 windings around a mandrel with a diameter of 3 × the outer diameter of the cable and fix the cable. The test is performed as per DIN 53509-1, method A.

) h in a standard climate and then for 48 h at 40 °C, a relative humidity Age the specimens for (70 +2−0

of (55 ± 10)%, and an ozone concentration of (50 ± 5) pphm (1 pphm = part per hundred million = 1 part ozone to 108 parts air by volume). After cooling to room temperature, unwind the specimens from the mandrel and test as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\").

9.7

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Mycological test

Requirements

Growth on the insulation must correspond to grade 3 at a maximum (growth visible with the naked eye, no more than 50% of the specimen surface must be overgrown) as per DIN EN ISO 846, method A (fungus growth test).

At growth level >2 the mean values of tensile strength and elongation at tear must not change by more than 50%.

Note: Tests that have been evaluated with a growth grade ≤1 as per DIN IEC 60068-2-10, ed. 5:1988, test method 1, are still considered passed.

The use of fungicides without consultation with the appropriate engineering departments is prohibited. Test

Testing must be performed as per DIN EN ISO 846, method A.

The cables with the largest cross-section, from which the specimens as per 9.2.7 have been taken as well, must be used. At least 5 specimens of each compound must be tested.

Clean the specimens using an ethanol-water mixture as per DIN EN ISO 846, section 7.1. Apply test fungus spores to the specimens.

Apply the test fungus spores to the specimens placed on mineral salt agar in a Petri dish; then incubate the specimens for 28 days at (29 ± 1) °C. An intermediate check for fungus growth is permissible after 14 days.

After 28 days of incubation, check the specimens for fungus growth as per DIN EN ISO 846, section 9.

Evaluate the fungus growth by the grade given in DIN EN ISO 846: 1997-10, table 4.

If a growth >2 is determined, perform a test as per 9.2.7 after the mycological test (without copper), and determine the change in tensile strength and elongation at tear. 9.8

Compatibility tests

Test scope

In this Section, tests are described that ensure compatibility of the cables with substances occurring in vehicles and in the vehicle surroundings. These materials may be: ─ Operating fluids (chemical group as per LV 112-1 supplement 1) ─ Wrapping tapes (Table A 8)

─ Other wiring harness components (Table A 9) 9.8.1

Chemical resistance as per ISO 6722-1

To determine swelling and shrinkage, a compatibility test as per ISO 6722-1, section \"Fluid compatibility\must be performed, as per method 2 (test item 5.17.4). In addition, resistance to AdBlue must be tested for 48 h at +50 °C as per LV 112-1 supplement 1. Always the smallest cross section of a compound is tested. 9.8.2

Resistance to chemicals and wrapping tapes

The tests of section 9.8.2 are mandatory; they are used for data collection.

Page 46 VW 60306-1:2013-04 LV 112-1: 2013-04

Requirements

The insulation must have no cracks, fractures, or other damage impairing function. There must be no dielectric breakdown during the voltage tests. Resistance of at least:

- 1 000 h with respect to chemicals of chemical group 1 (see LV 112-1 supplement 1)

- 240 h with respect to chemicals of chemical group 2 (see LV 112-1 supplement 1).

However, testing is performed for 1 000 h (see below).

If individual requirements of these tests are not met, a release is not generally ruled out. The results are evaluated by the appropriate engineering departments of the automobile manufacturers. If the resistance is less than 1 000 h, the appropriate protection from those agents in group 2 must be provided in the affected wiring harness area when the cable is used (e.g., by means of corrugated tube, protective hose).

9.8.2.1 Testing on cross sections ≤2,5 mm²

Specimen preparation

Twist two cables of the same material with a cross-section of 0,35 mm² each with each other (twist length ≈2 cm), and wrap with 50% overlap with adhesive tape (for test groups 1, 2, 4, and 5). Cut specimens with a length of 40 cm.

If other compounds are used for cross sections ≤2,5 mm², these must be tested as well. In this case, always the smallest cross section of a compound is tested as per Table 22.

Test groups

The following test groups must be prepared; test groups 1 to 3 must be tested with respect to chemicals of chemical group 1 as well as with respect to media of chemical group 2 (LV 112-1 supplement 1):

Test group 1:

Wrap the prepared specimens with a wrapping tape 1 to be selected from Table A 8. Bend the wrapped specimens in the center to form a U so as to fit in an open test tube with a diameter of ≈25 mm.

The test temperature depends on the temperature class of the cable. Select a wrapping tape of the same temperature class.

If no tape of the identical temperature class is available for a cable temperature class, select the next lower temperature class. In this case, testing is performed at the temperature class of the tape.

Test group 2:

Like test group 1, but using a wrapping tape 2 to be selected from Table A 8.

Test group 3:

Specimens without wrapping tape

Test group 4:

Specimens like test group 1, but without aging in chemicals (reference specimen).

Test group 5:

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Specimens like test group 2, but without aging in chemicals (reference specimen). Test

Submerge at least 4 specimens each of test groups 1, 2, and 3 in the particular chemical for 2 minutes in a standard climate (LV 112-1 supplement 1) (or lightly coat them with lubricating grease). The cable ends must not come into contact with the chemical. Then, let drip off for 2 minutes (10 minutes for fuels, lubricating grease remains).

Test against each chemical separately (no combination of chemicals).

After completion, suspend 1 specimen in a test tube with the cable ends upwards and age the test tubes in an oven for 1 000 h at Tmax. After 240 h, 480 h, 720 h, and 1 000 h, remove one specimen and immerse the remaining specimens in the particular chemical again. Then let them drip off and age them again.

For the chemical AdBlue, additionally age at a temperature of (+85 ± 2) °C and a relative humidity of (85 ± 5)% for 1 000 h. The remaining test procedure remains unchanged.

Immersion is not required for DUTs of test groups 4 and 5. Heat aging and testing are performed according to the time intervals of test groups 1 to 3.

Age the specimens without direct contact with any potential chemical sump. This prevents the undesired, permanent contact of the specimens with the particular chemical, since capillary effects, which cause re-feed of the chemical to the specimen, must be avoided. In this way, temporary wetting of the wiring harness with the chemical is simulated.

After the test duration has elapsed, condition the wiring harness at standard climate for at least 3 h (but at most 72 h) and then test it as follows:

Evaluate the U-section (lower 30 mm of the specimen) and the straight leg section separately.

Wind the wrapped specimen around a mandrel with a diameter of 20 mm. Then perform a voltage test as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\"). Failures must be documented separately for the leg area and the U-section.

Remove the adhesive tape from the specimen, separate the strands, and perform a visual inspection. Note any visual changes to the cable or wrapping tape in the test report. If the wrapping tape cannot be removed without apparent damage to the cable or if the individual wires are adhesively bonded to each other, document this and then perform a winding test with the large winding mandrel as per Table 22, and then perform a voltage test as per section 9.5.3.

Wrap one single strand at least twice tightly around a mandrel with a diameter of 2 mm, the other one around a mandrel with a diameter of 10 mm, then perform a visual evaluation of both. Afterwards, perform a voltage test as per section 9.5.3 on each strand.

If the U-section exhibits damage, remove the damaged part and continue the test on the remaining section.

For cross sections other than 0,35 mm², testing must be performed as per Table 22.

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Table 22

Winding mandrels after aging

Nominal conductor cross-section in mm² 0,35 0,50 0,75 1,00 1,50 2,50

Twist length Test tubes

Wrapped, twisted specimen (large) in mm 20 20 30 30 35 45

Single strand

Single strand

without

without

adhesive

adhesive tape

tape

(small)

(medium)

in mm 10 10 15 15 20 25

in mm 2 2 2 3 3 4

in mm

320+−5

in

mm 25 ± 2 25 ± 2 25 ± 2 30 ± 2 None, freely suspended None, freely suspended

320+−5 325+−5 330+−5 335+−5 340+−5

NOTE on mandrel selection:

The small mandrels are chosen in accordance with long-term aging as per ISO 6722-1. The

medium-sized mandrel corresponds to ≈7× the outer diameter of the single strand. The large mandrel corresponds to ≈7× the outer diameter of the twisted specimen with adhesive tape. 9.8.2.2 Testing on cross-sections ≥4 mm²

Specimen preparation

Testing is performed on 16 mm² cross sections. If other compounds are used for cross sections >4 mm², these must be tested as well. In this case, always the smallest cross section of a compound is tested. This test is not required if the compound has already been tested for cross sections ≤4 mm².

Test groups

As in section 9.8.2.1. Test

Testing is performed as for cross sections ≤4 mm², but with following adaptations: ─ Length of the specimen: at least 600 mm

─ Wrap only one cable with adhesive tape, then bend this cable around a mandrel (mandrel diameter 5 to 5,5× the outside cable diameter). Fix the legs with the same wrapping tape (see Figure 13).

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Figure 13

Specimen

After immersion in the prescribed agents, age the prepared specimens suspended in a natural convection oven with the bend facing downwards (test tube not required).

Remove the adhesive tape. Then, wind the cable around a mandrel as per section 9.6.8. Then perform a visual inspection and a voltage test as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\").

Note any visual changes to the cable or wrapping tape in the test report. Document it if the wrapping tape cannot be removed without apparent damage to the cable. 9.8.3

Resistance to wiring harness components

The tests in 9.8.3 are mandatory; they are used for data collection. If individual requirements of these tests are not met, a release is not generally ruled out. The results are evaluated by the appropriate engineering departments of the automobile manufacturers.

Make sample wiring harnesses with material combinations from Table A 9. For detailed material combinations and testing temperatures, see Table 10.

Fasten the components to come into direct contact with the cable insulation. Hoses must be filled at least 60%.

As a rule, testing must be performed at the temperature corresponding to the temperature class of the cable, provided that the component belongs to the same (or a higher) temperature class as the cable.

If the component belongs to a lower temperature class, the respective sample wiring harness must be tested at the lower temperature.

The tests must be performed as per the detailed test diagrams for the different temperature classes 0ff. and documented. If necessary, manufacturer and ordering designation of the components must be adapted.

Requirements

The insulation must have no cracks, fractures, or other damage impairing function. There must be no dielectric breakdown in the subsequent voltage test.

Discoloration and contraction (e.g. in the seal area) as well as damaged or destroyed components must be documented.

9.8.3.1 Testing on cross sections ≤6 mm2

Specimen preparation

Each sample wiring harness consists of 6 cables with lengths of 300 to 400 mm and cross-sections of 0,35 mm² (3 cables) and 2,5 mm² (3 cables). Contact parts are attached to the cables at both ends. The wiring harness contains further components (see Table 10.). Always 5 identical sample

Page 50 VW 60306-1:2013-04 LV 112-1: 2013-04

wiring harnesses must be prepared (4 wiring harnesses for heat aging, 1 wiring harness as reference).

Test

Age the sample wiring harnesses prepared in this way for 3 000 h at the temperatures given in Table 10. in a natural convection oven as per DIN 6722-1, section \"Ovens,\" in such a way that there is no contact with the oven walls or other metal objects (see Figure 14).

Mounting Contact parts Cable bundle Wiring harness components

Figure 14

Wiring harness

The test is considered passed after 1 500 h. Remove the first sample wiring harness for testing after 1 500 h, then every 500 h.

Then, wind the cable specimen around a mandrel with a diameter as per Table 23, inspect it visually, unwind it, and perform a voltage test as per section 9.5.3 (\"Measurement of 1-minute dielectric strength\").

If winding is impossible due to the specimen geometry (e.g., cable outlet from compounds, heat shrink tubing), perform the following evaluation:

Bend each external single cable by ±90° around the half mandrel as per Table 23 at the outlet point (if possible in opposite direction; see Figure 15).

Line Half mandrel Outlet plane

Figure 15

Bending configuration

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Table 23

Nominal conductor cross section Mandrel diameter

9.8.3.2 Testing on cross sections >6 mm2

Mandrel diameter

0,35 6

2,5 15

in mm² in mm

Specimen preparation

Testing is performed on 16 mm² cross sections. If other compounds are used for cross sections >6 mm², these must be tested as well. In this case, always the smallest cross section of a compound is tested. This test is not required if the compound has already been tested for cross sections ≤6 mm².

The test is performed as per section 9.8.3. However, the following modifications must be made: ─ Length of the specimen ≈600 mm ─ Only one cable is used.

As described in section 9.8.3.1, attach the adapted component to the cable cross-section, or apply adhesive tape.

Then bend the specimens – as described in section 9.8.3.1 – bind them together with Teflon tape, and suspend in the oven.

Test

Perform a visual inspection of the specimen before removing the components. Then wind the cable around a mandrel as per section 9.6.9.

Perform a visual inspection and a voltage test as per section on the wound specimen 9.5.3.

On specimens with heat shrink tubing and longitudinal water seal (if winding test is not possible), bend the specimen once in both directions around the half mandrel (90° each) and evaluate the transition and test dielectric strength as per section 9.5.3.

Note any visual changes to the cable, contacts, components or wrapping tape in the test report. Document it if the wrapping tape cannot be removed without apparent damage to the cable.

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Environmental protection and safety

The materials must meet the requirements of VDA 232-101 (list of hazardous substances) and comply with the current legal specifications.

Appendix A (normative) Table A 1

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FLR – symmetric conductor composition type A with reduced wall thickness

Strand

Conductor

Cross-Resistance Resistance at 20 °C, section for at 20 °C, bare tinned bare

1) 5)

strands strands conductors

mm²

mΩ/m

mΩ/m

Outer

diameter d2

Cable

Cpk Wall Test wall Concentricity

factor thickness value thickness

2)

of the (based sP Kinsulation on s)

s mm

mm

%

Weight

≈

3)

Nominal Quantity Diameter Diameter Twist

d1 conductor length 5) cross-section

mm² mm mm mm mm Perm. dev.

g/m

max. max. max. min. max. max. min. max. min. max. min. min. min. min.

0,22 0,35 0,5 0,75 1,0 1,5 2,5 2,5 4,0 6,0

4)

7 7 19 19 19 19 19 37 37 37

0,21 0,27 0,20 0,24 0,27 0,33 0,41 0,30 0,38 0,45

0,70 0,80 1,00 1,20 1,35 1,70 2,20 2,20 2,75 3,40

27 27 45 45 50 60 75 75 75 75

0,203 0,220 84,8 78,5 86,5 80,1 1,2 0,332 0,358 52,0 48,1 55,5 51,4 1,3 0,465 0,502 37,1 34,4 38,2 35,4 1,6 0,698 0,7 24,7 22,9 25,4 23,5 1,9 0,932 1,01 18,5 17,1 19,1 17,7 2,1 1,36 1,47 12,7 11,8 13,0 12,0 2,4 2,27 2,45 7,60 7,04 7,82 7,24 3,0 2,27 2,45 7,60 7,04 7,82 7,24 3,0 3,66 3,95 4,71 4,36 4,85 4,49 3,7 5,49 5,93 3,14 2,91 3,23 2,99 4,3

-0,1 -0,1 -0,2 -0,2 -0,2 -0,2 -0,3 -0,3 -0,3 -0,3

0,20 0,20 0,22 0,24 0,24 0,24 0,28 0,28 0,32 0,32

≥1,33

0,22 0,22 0,24 0,26 0,26 0,26 0,30 0,30 0,34 0,34

45

3,1 4,6 6,3 9,2 12 17 27 27 43 63

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) Weight in accordance with sample, table values apply to PVC.

4) The resistance values for cross-section 0,35 mm² deviate significantly from ISO 6722-1. 5) Measuring accuracy 50 μm.

Page VW 60306-1:2013-04 LV 112-1: 2013-04 Table A 2 FLU – symmetric conductor composition type A with ultrathin wall thickness

Strand

Nominal Quantity Diameter Diameter conductor d1

6)

cross-section

Twist length

Conductor Cross-section for bare

1)

conductors

Resistance at

20 °C, bare strands

5)

(tinned )

mΩ/m max.

min.

Outside diameter

d2

Wall thickness of the insulation

s mm min.

Cable

Cpk value Test Concentricity (based wall factor

2)

on s) thickness K

sP

min.

mm min.

% min.

Weight

≈

3)mm²

mm max.

mm max.

mm max.

mm² min.

max.

mm max.

Perm. dev.

g/m

0,22 0,35 0,5 0,75 1,0 1,5 2,5 2,5

4)

7 7 19 19 19 19 19 37

0,21 0,27 0,20 0,24 0,27 0,33 0,41 0,30

0,70 0,80 1,00 1,20 1,35 1,70 2,20 2,20

27 27 45 45 50 60 75 75

0,203 0,220 0,332 0,358 0,465 0,502 0,698 0,7 0,932 1,01 1,36 2,27 2,27

1,47 2,45 2,45

84,8 52,0 37,1 24,7 18,5 12,7 7,60 7,60

78,5 48,1 34,4 22,9 17,1 11,8 7,04 7,04

1,05 1,20 1,40 1,60 1,75 2,10 2,70 2,70

-0,10 -0,10 -0,10 -0,15 -0,15 -0,20 -0,20 -0,20

0,16 0,16 0,16 0,16 0,16 0,16 0,20 0,20

1,33

0,17 0,17 0,17 0,17 0,17 0,17 0,21 0,21

45

2,9 4,3 5,8 8,4 11 16 26 26

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) Weight in accordance with sample, table values apply to PVC.

4) The resistance values for cross-section 0,35 mm² deviate significantly from ISO 6722-1. 5) For resistance values of tinned conductors, see ISO 6722-1. 6) Measuring accuracy 50 μm.

Table A 3

Nominal conductor cross section

Quantity

6)VW 60306-1:2013-04

FLR – asymmetric conductor composition type B with reduced wall thickness

Strand

Wire diameter

Diameter d1

7)

Page 55

LV 112-1: 2013-04

Cable

Conductor

Twist length

Cross-section for bare conductors1)

Resistance at

20 °C, bare strands

Resistance at

20 °C, tinned strands

Outer diameter d2

Wall thickness of the insulation s

Cpk value (based on s)

Test wall thickness sP

Concen-tricity factor K 2)

Weight3) ≈

g/m 4,7 6,4 9,2 12 17 27 43 63 111 171 260 368 524 743 979

mm² 0,35 0,5 0,75 1,0 1,5 2,5 4,0 6,0 10,0 16,0 25,0 35,0 50 70 95

5) 12 16 24 32 30 50 56 84 80 126 196 276 396 360 475

mm max. 0,21 0,21 0,21 0,21 0,26 0,26 0,31 0,31 0,41 0,41 0,41 0,41 0,41 0,51 0,51

mm max. 0,90 1,00 1,20 1,40 1,70 2,20 2,75 3,40 4,50 5,50 7,00 8,30 9,80 11,6 13,8

mm max.

mm² min. 0,332 0,465 0,698 0,932 1,36 2,27 3,66 5,49 9,47 14,9 23,2 32,7 46,9 66,6 88,0

max. 0,358 0,502 0,7 1,01 1,47 2,47 3,95 5,93 10,2 16,1 25,1 35,3 50,6 71,9 95,0

mΩ/m max. 52,0 37,1 24,7 18,5 12,7 7,60 4,71 3,14 1,82 1,16 0,743 0,527 0,368 0,259 0,196

min. 48,1 34,4 22,9 17,1 11,8 7,04 4,36 2,91 1,69 1,07 0,688 0,488 0,341 0,240 0,181

mΩ/m max. 55,5 38,2 25,4 19,1 13,0 7,82 4,85 3,23 1,85 1,18 0,757 0,538 0,375 0,2 0,200

min. 51,4 35,4 23,5 17,7 12,0 7,24 4,49 2,99 1,71 1,09 0,701 0,498 0,347 0,244 0,185

mm max. 1,4 1,6 1,9 2,1 2,4 3,0 3,7 4,3 5,8 7,0 8,7 10,4 12,2 14,4 16,7

Perm. dev. -0,2 -0,2 -0,2 -0,2 -0,2 -0,3 -0,3 -0,3 -0,4 -0,5 -0,5 -0,6 -0,7 -0,9 -1,0

mm min. 0,20 0,22 0,24 0,24 0,24 0,28 0,32 0,32 0,48 0,52 0,52 0, 0,72 0,80 0,88

min.

mm min. 0,22 0,24 0,26 0,26 0,26 0,30 0,34 0,34 0,50 0, 0,66 0,82 0,74 0,82 0,90

% min.

≥1,33

Not specified

45

>1,0

4)

Not applicabl

e

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) Weight in accordance with sample, table values apply to PVC. 4) In the transition period, a Cpk value ≥1,0 will be accepted.

5) The resistance values for cross-section 0,35 mm² deviate significantly from ISO 6722-1.

6) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 7) Measuring accuracy 50 μm.

Page 56

LV 112-1: 2013-04

A 3.1

Nominal conductor cross section

VW 60306-1:2013-04

FLR – asymmetric conductor composition type B with reduced wall thickness Intermediate cross-sections

Diameter d1

6)

Strand

Quantity

5)Conductor

Twist length

Cross-section for bare conductors1)

Resistance at

20 °C, bare strands

Resistance at

20 °C, tinned strands

Wire diameter

Outer diameter d2

Wall thickness of the insulation s

Cpk value (based on s)

Cable

Test wall thickness sP

Concen-tricity factor K 2)

Weight3) ≈

g/m

mm²

mm max.

mm max.

mm max.

mm² min.

max.

mΩ/m max.

min.

mΩ/m max.

min.

mm max.

Perm. dev.

mm min.

min.

mm min.

% min.

Intermediate cross-sections >10 mm²

12 20 30 40 60 85

4)4)4)4)4)4)

96 153 225 308 463 418

0,41 0,41 0,41 0,41 0,41 0,51

4,80 6,10 7,40 8,60 10,5 13,2

211,3 18,1

Not specified

26,6 36,5 ,7 78,7

12,3 19,5 28,8 39,4 59,1 85,0

1,52 0,955 0,7 0,473 0,315 0,219

1,41 0,884 0,599 0,438 0,292 0,203

1,60 0,999 0,684 0,500 0,333 0,232

1,48 0,925 0,633 0,463 0,308 0,215

6,5 7,8 9,6 11,1 13,3 15,3

-0,5 -0,5 -0,6 -0,7 -0,8 -0,9

0,48 0,52 0, 0,72 0,80 0,80

1,00

0,50 0, 0,66 0,74 0,82 0,82

45

131 205 303 413 614 874

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) Weight in accordance with sample, table values apply to PVC.

4) ISO 6722-1 intermediate cross-sections, use is permissible upon agreement with the development departments.

5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Measuring accuracy 50 μm.

Table A 4

VW 60306-1:2013-04

Asymmetric conductor composition type B, version until 03/2005

Strand Diameter d1 (7) Page 57

LV 112-1: 2013-04

Cable 6)Conductor Twist length Cross-section for bare 1)conductors Resistance at 20 °C, bare strands 3)(tinned ) Outer diameter d2 Wall thickness of the insulation s Nominal Quantity Diameter 5)conductor cross section Cpk value (based 7) on s) Test wall thickness sP Concen-tricity factor 2) K Weight ≈ 4)mm² 6,0 10,0 10,0 16,0 25,0 35,0 50,0 70,0 95,0 120,0 min. 84 80 290 126 196 276 396 360 2850 3 650 mm max. 0,31 0,41 0,21 0,41 0,41 0,41 0,41 0,51 0,21 0,21 mm max. 3,4 4,5 4,5 6,3 7,8 9,0 10,5 12,5 14,8 16,5 mm max. mm² max. 5,93 10,2 10,2 min. 5,49 9,47 9,47 14,9 mΩ/m max. 3,14 1,82 1,82 1,16 min. 2,91 1,69 1,69 1,07 mm max. 5,0 6,5 6,5 8,3 Tol. -0,6 -0,6 -0,6 -0,7 -0,6 -0,6 -0,8 -1,0 -1,0 mm min. 0, 0,80 0,80 0,80 1,04 1,04 1,20 1,20 1,28 1,28 min. mm min. 0,66 0,82 0,82 0,82 1,06 1,06 1,22 1,22 1,30 1,30 % min. 45 g/m 68 127 127 182 279 385 534 760 911 1 146 Not specified 16,1 25,1 35,3 50,6 71,9 95,0 122 23,2 0,743 32,7 0,527 46,9 0,368 66,6 0,259 88,0 0,196 113 0,153 0,688 10,4 0,488 11,6 0,341 13,5 0,240 15,5 0,181 18,0 0,142 19,7 ≥1,33 1) Computed with a value of the specific electrical conductivity of 58,5 Sm/mm² (conductivity for tinned cable as per DIN EN 13602: 56,8 Sm/mm²), quality control through resistance measurement. 2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) For resistance values of tinned conductors, see ISO 6722-1. 4) Weight in accordance with sample, table values apply to PVC. 5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers. 7) Measuring accuracy 50 μm.

Page 58 VW 60306-1:2013-04 LV 112-1: 2013-04 Table A 5 FL – asymmetric conductor composition type B until 12/2011

Strand Diameter d1 7) 6)Conductor Twist length Cross-section for bare 1)conductors Resistance at 20 °C, bare strands Outer diameter d2 Wall thickness of the insulation s Cable Cpk value (based 2) on s)Test wall thickness sP Concen-tricity factor 3) K Nominal Quantity Diameter 5) conductor cross-section Weight ≈ 4)mm² 4,0 6,0 10,0 16,0 25,0 35,0 50,0 70,0 95,0 120,0 nom. 56 84 80 126 196 276 396 360 475 608 mm max. 0,31 0,31 0,41 0,41 0,41 0,41 0,41 0,51 0,51 0,51 mm max. 2,75 3,4 4,5 5,5 7,0 8,3 9,8 11,6 13,8 15,1 mm max. mm² max. 3,66 5,49 9,47 min. 3,95 5,93 10,2 16,1 25,1 35,3 50,6 71,9 95,0 122 mΩ/m max. 4,71 3,14 1,82 1,16 0,743 0,527 0,368 0,259 0,196 0,153 min. 4,36 2,91 1,69 1,07 0,688 0,488 0,341 0,240 0,181 0,142 mm max. 4,4 5,0 6,5 7,5 9,6 10,9 12,8 14,6 17,0 18,3 Perm. dev. -0,4 -0,6 -0,6 -0,6 -0,8 -1,0 -1,0 -1,0 -1,2 -1,2 mm min. 0, 0, 0,80 0,80 1,04 1,04 1,20 1,20 1,28 1,28 min. mm min. 0,66 0,66 0,82 0,82 % min. g/m 47 68 127 182 Not specified 14,9 23,2 32,7 46,9 66,6 88,0 113 ≥1,33 1,06 1,06 1,22 1,22 1,30 1,30 45 279 385 534 760 911 1 146 1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement. 2) In the transition period, a Cpk value ≥1,0 will be accepted. 3) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 4) Weight according to sample, table values are only approximate values and apply to PVC. 5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers. 7) Measuring accuracy 50 μm.

Table A 6

VW 60306-1:2013-04

FL – asymmetric conductor composition finely stranded/flexible type B until 12/2011

Strand Diameter Diameter d1 8) Page 59

LV 112-1: 2013-04

Cable 6)Conductor Twist length Cross-section for bare 1)conductors Resistance at 20 °C, bare strands 3)(tinned ) Outer diameter d2Wall thickness of the insulation s Nominal Quantity5) conductor cross-section Cpk value (based 7) on s)Test Concentricity wall factor 2) thickness KsP Weight ≈ 4)mm² 4,0 6,0 10,0 16,0 25,0 35,0 50,0 70,0 95,0 120,0 nom. 120 183 305 500 790 1090 1600 2175 3000 3 700 mm max. 0,21 0,21 0,21 0,21 0,21 0,21 0,21 0,21 0,21 0,21 mm max. 2,75 3,4 4,5 6,3 7,8 9,0 10,5 12,5 14,8 16,5 mm max. mm² max. 3,66 5,49 9,47 min. 3,95 5,93 10,2 16,1 25,1 35,3 50,6 71,9 95,0 122 mΩ/m max. 4,71 3,14 1,82 1,16 0,743 0,527 0,368 0,259 0,196 0,153 min. 4,36 2,91 1,69 1,07 0,688 0,488 0,341 0,240 0,181 0,142 mm max. 4,4 5,0 6,5 8,3 10,4 11,6 13,5 15,5 18,0 19,7 Perm. dev. -0,4 -0,6 -0,6 -0,9 -1,2 -1,5 -1,5 -1,5 -1,8 -1,8 mm min. 0, 0, 0,80 0,80 1,04 1,04 1,20 1,20 1,28 1,28 min. mm min. 0,66 0,66 0,82 0,82 % min. g/m 47 68 127 182 Not specified 14,9 23,2 32,7 46,9 66,6 88,0 113 ≥1,33 1,06 1,06 1,22 1,22 1,30 1,30 45 279 385 534 760 911 1 146 1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement. 2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) For resistance values of tinned conductors, see ISO 6722-1. 4) Weight in accordance with sample, table values apply to PVC. 5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers. 7) For cables ≥0,75 mm2, a Cpk value ≥1,0 will be accepted in the transition period. 8) Measuring accuracy 50 μm.

Page 60 VW 60306-1:2013-04 LV 112-1: 2013-04 Table A 7 FLR – asymmetric conductor composition finely stranded/flexible type B

Strand6)

Nominal QuantityDiameter

5)

conductor cross-section mm²

0,35 0,5 0,75 1,0 1,5 2,5 4,0 1,5 2,5 4,0 6,0 10,0 16,0 25,0 35,0 50,0 70,0 95,0

Diameter d1

8)

Conductor

Twist length

Cross-section for bare conductors1)

mm² max.

0,358 0,502 0,7 1,01 1,47 2,45

Resistance at 20 °C, bare strands

max.

52,0 37,1 24,7 18,5 12,7 7,60 4,71 12,7 7,60 4,71 3,14 1,82 1,16 0,743 0,527 0,368 0,259 0,196

Resistance at 20 °C, tinned strands mΩ/m

Outer diameter d2

Cable

Wall thickness of the insulation

s mm min.

0,20 0,22

Cpk value (based on s)

Test Concen-wall tricity

factor thickness

sP K2)

mm min.

0,22 0,24

Weight4) ≈

g/m

4,5 6,6 9,0

nom.

45 63 94 125 182 304 500 48 74 123 184 318 504 784 1106 1582 2240 2 9

mm max.

mm max.

0,90 1,00 1,20

mm max.

mm Perm. dev.

1,4 1,7 1,9 2,1 2,4 3,0

0,3

3,7 2,4 3,0 3,7 4,3 5,8 7,0 8,8 10,5 12,6 14,9 17,2

-0,4 -0,5 -0,6 -0,7 -0,8 -0,9 -1,0 -0,3 0,2 -0,2

min.

% min.

min.

0,332 0,465 0,698 0,932 1,36 2,27 3,66 1,36 2,27 3,66 5,49 9,47 14,9 23,2 32,7 46,9 66,6 88,0

min.

48,1 34,4 22,9 17,1 11,8 7,04 4,36 11,8 7,04 4,36 2,91 1,69 1,07 0,688 0,488 0,341 0,240 0,181

max.

55,5 38,2 25,4 19,1 13,0 7,82 4,85 13,0 7,82 4,85 3,23 1,85 1,18 0,757 0,538 0,375 0,2 0,200

min.

51,4 35,4 23,5 17,7 12,0 7,24 4,49 12,0 7,24 4,49 2,99 1,71 1,09 0,701 0,498 0,347 0,244 0,185

≥1,33

0,11 1,35 1,70 2,20 2,85 1,70 2,20 2,75 3,4 4,5

Not specified

0,24 0,26 11 16

0,28 0,32 0,24 0,28 0,32 0,32 0,48 0,52 0,52 0, 0,72 0,80 0,88

>1,0

3)

0,30 0,34 0,26 0,30 0,34 0,34 0,50 0, 0, 0,66 0,74 0,82 0,90

45

26 42 16 26 42 61 118 174 263 377 529 747 983

3,95 1,47 2,45 3,95 5,93 10,2 16,1 25,1 35,3

0,21 5,5 7,0 8,3 10,5 12,5 14,7

50,6 71,9 95,0

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm2, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness.

3) For cables ≥0,75 mm2, a Cpk value ≥1,0 will be accepted in the transition period. 4) Weight in accordance with sample, table values apply to PVC.

5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers. 8) Measuring accuracy 50 μm.

VW 60306-1:2013-04

Page 61

LV 112-1: 2013-04

A 7.1 FLR – asymmetric conductor composition finely stranded/flexible type B; intermediate cross-sections

Nominal conductor cross-section mm²

Strand6)

Quantity5) Diameter

Diameter d1

8)

Conductor

Twist length

Cross-section for bare

1)

conductors

mm² max.

Resistance at 20 °C, bare strands

min.

max.

Resistance at 20 °C, tinned strands mΩ/m min.

max.

Outer diameter d2

Cable

Wall thickness of the insulation

s mm min.

Cpk value (based on s)

Test Concen-wall tricity

factor thickness

sP K2)

mm min.

% min.

Weight4) ≈

g/m

nom.

mm max.

mm max.

mm max.

mm Perm. dev.

min.

Intermediate cross-sections >10 mm²

127) 207) 307) 407) 607) 857)

381 609 903 1 232 1 841 2 584

0,21

4,8 6,6 8,2 9,4 11,4 13,5

11,3

12,3 19,5 28,8 39,4 59,1 85,0

21,52 0,955 0,7 0,473 0,315 0,219

1,41 0,884 0,599 0,438 0,292 0,203

1,60 0,999 0,684 0,500 0,333 0,232

1,48 0,925 0,633 0,463 0,308 0,215

6,2 8,1 9,9 11,4 13,6 15,8

-0,5 -0,6 -0,7 -0,7 -0,8 -0,9

0,48 0,52 0, 0,72 0,80 0,80

0,50 0, 0,66

132 206 307

Not

specified

18,1 26,6 36,5 ,7 78,7

>1,0

3)

0,74 0,82 0,82

45

417 620 8

1) Computed with a value of the specific electrical conductivity of 58,0 Sm/mm, quality control through resistance measurement.

2) K in % = (smin/smax)*100, smax does not have to be located opposite smin. smin: minimum wall thickness; smax: maximum wall thickness. 3) In the transition period, a Cpk value ≥1,0 will be accepted. 4) Weight in accordance with sample, table values apply to PVC.

5) Slight deviations are permissible: For >50 strands, ±5% as long as the electrical resistance and the maximum strand diameter are adhered to. Deviations are not permissible for ≤50 strands. 6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers. 7) ISO 6722-1 intermediate cross-sections, use is permissible upon agreement with the development departments. 8) Measuring accuracy 50 μm.

Page 62

LV 112-1: 2013-04

VW 60306-1:2013-04

Explanations for tables A1 to A7, changes 05/2012:

The cross-section is computed with a value of the specific electrical conductivity of 58,0 Sm/mm2 instead of 58,5 Sm/mm2. Quality control through resistance measurement. The geometric data of the conductor (conductor diameter, strand diameter, number of strands, etc.) remained the same. Measurements of the electrical conductivity of vehicle cables have shown that the previously assumed conductivity of 58,5 Sm/mm² must be corrected to 58,0 Sm/mm².

Therefore, it is necessary to adapt the cross-sections computed using the conductivity to the existing products.

Furthermore, with the conductivity of 58,0 Sm/mm² used as a basis, the maximum strand diameters must also be approx. 0,01 mm higher than previously specified. The actually delivered strand diameters are not changed as a result. The adaptation is based on ISO 6722-1, which already takes into account the conductivity of 58,0 Sm/mm².

The outer individual wire diameters at and above 20,0 mm² in LV 112-1 Table 7 and in LV 216-2 do not match. Adaptation is not desired, because changes to existing contact systems must be avoided.

The LV 216-2 outer individual wire diameters comply with ISO 6722-1.

Intermediate cross-sections:

In the computation of the intermediate cross-sections, it is found that the outer diameter of the cable as per ISO 6722-1 (up to an including 60,0 mm²) can be achieved with process assurance only with bunch-stranded assemblies. Therefore, the maximum stranded wire diameter for all assemblies was computed on the basis of bunched wire (table 3 to table 7).

Computation of the resistances and the cross-sections:

Proceeding from the maximum resistance value, the minimum cross-section is computed using the specific electrical conductivity of the conductor of, e.g., 58,0 Sm/mm². Then the maximum cross-section (8% higher than the minimum cross-section) is computed. The minimum resistance is computed back from the maximum cross-section using the aforementioned specific electrical conductivity.

The resulting factors, regardless of the initial values (maximum resistance and specific electrical conductivity), are as follows:

Minimum resistance = maximum resistance (maximum resistance x 7,407%)

Minimum cross-section = 1 000/(specific electrical conductivity x maximum resistance) The resistance is specified in mΩ/m.

Maximum cross-section = minimum cross-section + (8% x minimum cross-section)

All resistance values and cross-section values for all LV tables are computed using these factors.

Table A 8

VW 60306-1:2013-04

Survey of wrapping tapes

Temperature1)

+105 °C

+105 °C +125 °C +150 °C

Soft PVC

PET nonwoven PET fabric

Material

Page 63

LV 112-1: 2013-04

Wrapping tape 1(film) Beiersdorf Tesa 4173 Wrapping tape 2 (textile) Beiersdorf Tesa 51618/51619 Coroplast 839 Coroplast 837 X

Adhesive basis Acrylate Rubber Rubber Acrylate

PET fabric with smooth surface

1) Temperature specification corresponds to long-term service temperature resistance (3 000 h of aging)

Page VW 60306-1:2013-04 LV 112-1: 2013-04

Table A 9 Bill of materials, component compatibility

Serial

5)

number Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

213221321

Material CuSn, Sn CuFe2, Sn CuFe, Ag CuSn, Sn Silicone Silicone

4)

Contact part, tab receptacle (tin plated) Contact part, circular receptacle (tin plated)

Contact part, circular receptacle (silver plated) Cable lug (tin plated) Single-wire seal Single-wire seal

Circular connector housing with single-wire seal (25-PBT + 15% GF way)

Circular receptacle housing without single-wire seal (8-way) Socket housing with single-wire seal (6-way) Heat shrink tubing with adhesive Heat-shrink tubing Insulating hose TPU insulating hose

Braided sleeving (Revitex VSC) Corrugated tube

PA 6.6 POM

Synthetic-rubber-based adhesive PE modified

PVC as per DIN EN 60684-3 TPU

Silicone-coated glass braid PP modified

Cable tie (assembled with force-free contact of cable PA66 tie) and corrugated tube Joint connector sleeving

Longitudinal water sealing 3M butyl (to be installed with grommet) Grommet

Wrapping tape Certoplast 608 Wrapping tape Coroplast Y512 Wrapping tape Coroplast 837 X

Current standard and special cables of insulating materials other than the material of the cable to be tested (see Table 2 \"Application properties\" in LV 312)

Thermoplastic melting material based on polyamide Butyl rubber EPDM, Shore A60

PVC tape, acrylate adhesive

PVC tape (polyolefin), acrylate adhesive PET fabric, acrylate adhesive

As per agreement, e.g., PVC (Pb-free), FEP, ETFE, XPE, PP, TPU, etc. Temperature class +125 °C only for insulating materials with adequate resistance

1) 2) 3) The contact parts, housings, and single-wire seals marked with the same numbers are matched to each other. The diameters of the cable protection systems (corrugated tube, heat shrink tubing and braided sleeving, etc.) must be matched to the sample wiring harness, if applicable.

4) The material used is decisive for testing.

5) Specifications given in these columns are for information purposes.

Table A 10

e.g., PVC

VW 60306-1:2013-04

Page 65

LV 112-1: 2013-04

Bill of materials: Component compatibility for cables of temperature class B* +105 °C

The material is decisive for testing.

5 samplewiring harnesses each

Test temperature

+105 °C

Cable Contacts/ cable lugs 11

1 2 3 4 5 6 7 8 9 0 1

2 222Test cable 0,35 mmand 2,50 mm, 3x 0,35 mm, 3x 2,50 mm CuSn, Sn tab receptacle, Kostal 221 24 49207 0 CuFe2, Sn circular receptacle, Tyco, 0-09285-2 CuFe, Ag circular receptacle, Tyco, 0-0927788-2 CuSn, Sn cable lug, Lear, 25168 331 322

Silicone, single wire seal, Kostal, 108 00 444523 Silicone, single wire seal, Tyco, 0-0820-1

PBT+15% GF circular connector housing, Tyco, 2-0963295-1

PA 6.6, circular connector housing, Tyco, 1-0828736-1 POM, socket housing, Hirschmann, 972-537-001 Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 0000 090 PE modified, heat shrink tubing, DSG Canusa, 14/1 45TR AI 50 mm

PVC 9248 as per DIN 40621, insulating hose, HC, 2125013

TPU, insulating hose, Sahlberg, 351

Silicone coated glass braid, braided sleeving, Relats, VSR 25 NW6

PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 Thermoplastic hot-melt adhesive, cavity connector sleeving,

Henkel, Macromelt 6208

Butyl rubber, longitudinal water seal, Hellermann, DSG, 460-05029/19-1,5/105AL 30 mm EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16

Connector Seals housing 6 5 1 6

5 6 1 6 5 5 1

1

1

1 1

1

1

1

1

1

1

No. 17

Components 1

No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

1 1

1

1 1

1

1 1

1 1

1

Page 66 VW 60306-1:2013-04 LV 112-1: 2013-04

Table A 11 Bill of materials: Component compatibility for cables of temperature class

C +125 °C

e.g., XPE

The material is decisive for testing.

5 samplewiring harnesses each

Cable Contacts/ cable lugs Test cable 0,35 mmand 2,50 mm, 3x 0,35 mm, 3x 2,50 mmCuSn, Sn tab receptacle, Kostal 221 24 49207 0 CuFe2, Sn circular receptacle, Tyco, 0-09285-2 CuFe, Ag circular receptacle, Tyco, 0-0927788-2 CuSn, Sn cable lug, Lear, 25168 331 322

Silicone, single wire seal, Kostal, 108 00 44452 3 Silicone, single wire seal, Tyco, 0-0820-1

PBT+15 % GF circular connector housing, Tyco, 2-0963295-1

PA 6.6, circular connector housing, Tyco, 1-0828736-1 POM, socket housing, Hirschmann, 972-537-001 Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 0000 090 PE modified, heat shrink tubing, DSG Canusa, 14/1 45TR AI 50 mm

PVC 9248 as per DIN 40621, insulating hose, HC, 2125013

TPU, insulating hose, Sahlberg, 351

Silicone coated glass braid, braided sleeving, Relats, VSR 25 NW6

PP modified, Corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 Thermoplastic hot-melt adhesive, cavity connector sleeving,

Henkel, Macromelt 6208

Butyl rubber, longitudinal water seal,

Hellermann, DSG, 460-05029/19-1,5/105AL 30 mm EPDM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9

2 222 Test temperature +125 °C +105 °C

11

1 2 3 4 5 6 7 8 9 0 1 6 5 1

5 6 1

5 6 1

Seals 6 6

1

Connector housing 1

1 1

No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16

1

1

1

1

1

1

No. 17

Components 1

No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

1

1 1

1

1 1

1

1 1

1

1

Table A 12

e.g., XPE

VW 60306-1:2013-04

Page 67

LV 112-1: 2013-04

Bill of materials: Component compatibility for cables of temperature class D +150 °C

The material is decisive for testing.

5 samplewiring harnesses each

Cable Contacts/ cable lugs Test cable 0,35 mmand 2,50 mm, 3x 0,35 mm, 3x 2,50 mm CuSn, Sn tab receptacle, Kostal 221 24 49207 0 CuFe2, Sn circular receptacle, Tyco, 0-09285-2 CuFe, Ag circular receptacle, Tyco, 0-0927788-2 CuSn, Sn cable lug, Lear, 25168 331 322

Silicone, single wire seal, Kostal, 108 00 44452 3 Silicone, single wire seal, Tyco, 0-0820-1

PBT+15 % GF circular connector housing, Tyco, 2-0963295-1

PA 6.6, circular connector housing, Tyco, 1-0828736-1 POM, socket housing, Hirschmann, 972-537-001 Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 0000 090 PE modified, heat shrink tubing, DSG Canusa, 14/1 45TR AI 50 mm

PVC 9248 as per DIN 40621, insulating hose, HC, 2125013

TPU, insulating hose, Sahlberg, 351

Silicone coated glass braid, braided sleeving, Relats, VSR 25 NW6

PP modified, Corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 Thermoplastic hot-melt adhesive, cavity connector sleeving,

Henkel, Macromelt 6208

Butyl rubber, longitudinal water seal, Hellermann, DSG, 460-05029/19-1,5/105AL 30 mm EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16

2 222Test temperature

+150 °C +125 °C +105 °C

11

1 2 3 4 5 6 7 8 9 0 1 6 5 1

6 5 6 5 5 6 1 1 1 6 6

1

Seals 6

Connector housing 1

1 1

1

1

1

1

1

1

Components No. 17

1

No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

1

1 1

1

1

1

1

1

1 1

1

Page 68 VW 60306-1:2013-04 LV 112-1: 2013-04

Table A 13 Bill of materials: Component compatibility for cables of temperature class

F +200 °C

silicone

e.g.,

The material is decisive for testing.

5 samplewiring harnesses each

Cable Contacts/ cable lugs Test cable 0,35 mmand 2,50 mm, 3x 0,35 mm, 3x 2,50 mmCuSn, Sn tab receptacle, Kostal 221 24 49207 0 CuFe2, Sn circular receptacle, Tyco, 0-09285-2 CuFe, Ag circular receptacle, Tyco, 0-0927788-2 CuSn, Sn cable lug, Lear, 25168 331 322

Silicone, single wire seal, Kostal, 108 00 44452 3 Silicone, single wire seal, Tyco, 0-0820-1

PBT+15 % GF circular connector housing, Tyco, 2-0963295-1

PA 6.6, circular connector housing, Tyco, 1-0828736-1 POM, socket housing, Hirschmann, 972-537-001 Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 0000 090 PE modified, heat shrink tubing, DSG Canusa, 14/1 45TR AI 50 mm

PVC 9248 as per DIN 40621, insulating hose, HC, 2125013

TPU, insulating hose, Sahlberg, 351

Silicone coated glass braid, braided sleeving, Relats, VSR 25 NW6

PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 Thermoplastic hot-melt adhesive, cavity connector sleeving,

Henkel, Macromelt 6208

Butyl rubber, longitudinal water seal, Hellermann, DSG, 460-05029/19-1,5/105AL 30 mm EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9

2 222 Test temperature

+150 °C +125 °C +105 °C 11

1 2 3 4 5 6 7 8 9 0 1 6 5 1

6 4 1 5 6 1 5 6 1

Seals 6

6 6

1

Connector housings 1

1 1

No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16

1

1

1

1

1

1

Components No. 17

1

No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

1

1 1

1

1

1

1

1

1 1

1

Table A 14

e.g., PVC

VW 60306-1:2013-04

Page 69

LV 112-1: 2013-04

Bill of materials: Component compatibility for cables of temperature class B* +105 °C (large cross-sections)

The material is decisive for testing.

5 samplewiring harnesses each

Test temperature

+105 °C

11

1 2 3 4 5 6 7 8 9 0 1 1 1

1 1

Cable Contacts/ cable lugs Test cable = 16 mm, (1x cross-section)

2

No. 1 CuSn, Sn flat contact, (order no. N.102.146.01), without

CuSn, Sn flat contact, (order no. N.102.146.02), with SEAL No. 2

No. 3 NA

CuSn, Sn cable lug, AMP no. 969209-1

Silicone, single-wire seal (order no. 357.972.744.B)

NA

PBT fuse adapter (order no. 3A0.937.501A) Lisi Autom. no. 1388

PA 6.6 fuse adapter (order no. 3A0.937.501) Lisi Autom. no. 1439 NA

Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 191 510 5C PE modified, heat shrink tubing,

DSG Canusa, 6-1,4/1,45TR.AL50mm 6240060011G PVC, insulating hose, Tyco NETM-2000-NR-10-0 TPU, insulating hose,

Sahlberg, 303-109 14x0,6x15,6 1185

Silicone-coated glass braid, braided sleeving, Federal Mogul Textalu 1202 5-55 ALU PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 NA

Butyl rubber, longitudinal water seal, Hellermann, Tyton 460-05039 EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16 No. 17 No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

Seals 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Components Connector housing

Page 70 VW 60306-1:2013-04 LV 112-1: 2013-04

Table A 15 Bill of materials: Component compatibility for cables of temperature class

C +125 °C (large cross-sections)

e.g., XPE

The material is decisive for testing.

5 samplewiring harnesses each

Test temperature +125 °C +105 °C

11

1 2 3 4 5 6 7 8 9 0 1 1 1 1 1

Cable Contacts/ cable lugs Test cable = 16 mm, (1x cross-section)

CuSn, Sn flat contact, (order no. N.102.146.01), without CuSn, Sn flat contact, (order no. N.102.146.02), with SEAL NA

CuSn, Sn cable lug, AMP no. 969209-1

Silicone, single-wire seal (order no. 357 972 744 B) Veritas no. F18363 NA

PBT fuse adapter (order no. 3A0.937.501A) Lisi Autom. no. 1388

PA 6.6 fuse adapter (order no. 3A0 937 501) Lisi Autom. no. 1439 NA

Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 191 510 5C PE modified, heat shrink tubing,

DSG Canusa, 6-1,4/1,45TR.AL50mm 6240060011G PVC, insulating hose, Tyco NETM-2000-NR-10-0 TPU, insulating hose,

Sahlberg, 303-109 14x0,6x15,6 1185

Silicone-coated glass braid, braided sleeving, Federal Mogul Textalu 1202 5-55 ALU PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 NA

Butyl rubber, longitudinal water seal, Hellermann, Tyton 460-05039 EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

2 No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16 No. 17 No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

Seals 2 2 1 1 1 1

1

Connector housing 1 1 1 1

1 1

Components 1

1 1

1 1 1 1 1

1

Table A 16

e.g., XPE

VW 60306-1:2013-04

Page 71

LV 112-1: 2013-04

Bill of materials: Component compatibility for cables of temperature class D +150 °C (large cross-sections)

The material is decisive for testing.

5 samplewiring harnesses each

Cable

Test cable = 16 mm, (1x cross-section)

CuSn, Sn flat contact, (order no. N.102.146.01), without seal AMP no. 962 832.1

CuSn, Sn flat contact, (order no. N.102.146.02), with seal AMP no. 962 938.1 NA

CuSn, Sn cable lug, AMP no. 969209-1

Silicone, single-wire seal (order no. 357 972 744 B) Veritas no. F18363 NA

PBT fuse adapter (order no. 3A0.937.501A) Lisi Autom. no. 1388

PA 6.6 fuse adapter (order no. 3A0.937.501) Lisi Autom. no. 1439 NA

Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 191 510 5C PE modified, heat shrink tubing,

DSG Canusa, 6-1,4/1,45TR.AL50mm 6240060011G PVC, insulating hose, Tyco NETM-2000-NR-10-0 TPU, insulating hose, Sahlberg, 303-109 14x0,6x15,6 1185

Silicone-coated glass braid, braided sleeving, Federal Mogul Textalu 1202 5-55 ALU PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 NA

Butyl rubber, longitudinal water seal, Hellermann, Tyton 460-05039 EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

2 No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16 No. 17 No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

Test temperature

+150 °C +125 °C +105 °C

11

1 2 3 4 5 6 7 8 9 0 1 1

Contacts/ cable lugs

1

1 1 2 2

Seals Connector housing 1

1 2

1

1

1

1

1

1

1

Components 1

1 1

1

1

1

1

1

1 1

1

Page 72 VW 60306-1:2013-04 LV 112-1: 2013-04

Table A 17 Bill of materials: Component compatibility for cables of temperature class

F +200 °C (large cross-sections)

e.g., XPE

The material is decisive for testing.

5 samplewiring harnesses each

Cable Contacts/ cable lugs Test cable = 16 mm, (1x cross-section)

CuSn, Sn flat contact, (order no. N.102.146.01), without seal AMP no. 962 832.1

CuSn, Sn flat contact, (order no. N.102.146.02), with seal AMP no. 962 938.1 NA

CuSn, Sn cable lug, AMP no. 969209-1

Silicone, single-wire seal (order no. 357 972 744 B) Veritas no. F18363 NA

PBT fuse adapter (order no. 3A0.937.501A) Lisi Autom. no. 1388

PA 6.6 fuse adapter (order no. 3A0.937.501) Lisi Autom. no. 1439 NA

Synthetic rubber basis, heat shrink tubing, DSG Canusa, 621 191 510 5C PE modified, heat shrink tubing,

DSG Canusa, 6-1,4/1,45TR.AL50mm 6240060011G PVC, insulating hose, Tyco NETM-2000-NR-10-0 TPU, insulating hose,

Sahlberg, 303-109 14x0,6x15,6 1185

Silicone-coated glass braid, braided sleeving, Federal Mogul Textalu 1202 5-55 ALU PP modified, corrugated tube, Fränkische Rohrwerke, Uniwell

PA 66, cable tie, Hellermann, 111-019 50 PA 66, corrugated tube, Fränkische Rohrwerke 400008 08 NA

Butyl rubber, longitudinal water seal, Hellermann, Tyton 460-05039 EDPM Shore A60, grommet, WOKO, 02 5539

PVC, acrylate adhesive, wrapping tape, Certoplast, 608/609 19 mm

Polyolefin, acrylate adhesive, wrapping tape, Coroplast Y 512 19 mm

PET, acrylate adhesive, wrapping tape, Coroplast 837X 19 mm Silicone, cables (class E/F) ETFE, cables (class D) X-PE, cables (class D) PP, cables (class C) X-PE, cables (class C) PVC, cables (class B 105 °C) TPS, cables (class C)

2 No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 No. 10 No. 11 No. 12 No. 13 No. 14 No. 15 No. 16 No. 17 No. 18 No. 19 No. 20 No. 21 No. 22 No. 23a No. 23a1 No. 23b No. 23c No. 23d No. 23e No. 23f

Test temperature

+150 °C +125 °C +105 °C

11

1 2 3 4 5 6 7 8 9 0 1 1

1

1

1

1 1 2 2

Seals Connector housing 1

1 2

1

1

1

1

1

1

1

Components 1

1 1

1

1

1

1

1

1 1

1