Vw 60306-1-2013 汽车用低压电线 第1部分 单芯无屏蔽电缆 (1)

VW 60306-1

Group standard

Issue 2013-04 Class. No.:

8ME30

Descriptors:

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

Electric/Electronic Systems Electric 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 in table 1. Table 1 Working group document num‐ ber

Volkswagen Standard number

PAG Standard number

LV 112 supplement 1

VW 60306-1 supplement 1

—

LV 112-3

VW 60306-3

—

LV 213-1

VW 75206-1

—

LV 213-2

VW 75206-2

—

LV 214-2

VW 75174-2

—

—

VW 96043

PN 780

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.

Technical responsibility

The Standards department

EEKK/4

Dr. Liane Wiegel

Tel.: +49 5361 9 36678

I/EE-23

Michael Pickl

Tel.: +49 841 89 34925

EKDV/4 Dirk Beinker

EKDV

EEE2

Andreas Müller

Tel.: +49 711 911 82433

Tel.: +49 5361 9 32438

Manfred Terlinden

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

VWNORM-2012-05q

Page 2 VW 60306-1: 2013-04

Deviating and supplementary Volkswagen AG specifications Supplement to section 10 of LV 112-1: The environmental requirements set forth in VW 91101 must be met. Deviating and supplementary Porsche AG specifications Supplement 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 in production if the assembler has confirmed proper usability, e.g.: – – – –

Stripping Crimpability and attachment of the contacts Weldability by ultrasonic welding or resistance welding Twistability of the cables, if applicable

in the form of a first-sample test report during first sampling. Supplement to section 10 of LV 112-1: Emission behavior as per PN 780.

VW 60306-1:2013-04

LV 112-1 2013-04

Descriptors:

cable, low-voltage cable, copper cable

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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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

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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

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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

Page 4 LV 112-1: 2013-04

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Changes 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

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1

Page 5 LV 112-1: 2013-04

Scope

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 AC

Voltage classes

DC

Veff (VRMS)

VPTP

VDC

Low voltage

1 (A )

≤30 V

≤42 V

≤60 V

High voltage

2

≤600 V

≤849 V

≤900 V

≤1 000 V

≤1 414 V

≤1 500 V

High voltage

(*)

(*)

3 (B )

This table was created on the basis of ISO 6469-3. Voltage class 2 is not considered in ISO 6469-3. (*) VPTP Veff (URMS)

Voltage class designation as per ISO 6469-3. Peak-to-peak voltage value RMS voltage value (RMS: root mean square)

Page 6 LV 112-1: 2013-04

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Referenced standards

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

Presentation of Numerical Data

DIN 72551-7

Road Vehicles – Low-Tension Cables – Part 7: Colours and Colour Marking of Low-Tension Cables

DIN 76722

Road Vehicles, Low Voltage Cables; Type Abbreviation

DIN EN 10270-1

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

DIN EN 13602

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

DIN EN 50525-2-21

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

DIN EN 60684-3

Flexible Insulating Sleeving – Part 3: Specifications for Individual Types of Sleeving

DIN EN 60811-1-1

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

DIN EN 60811-1-2

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

DIN EN 60811-2-1

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

DIN EN 60811-3-2

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

DIN EN ISO 846

Plastics – Evaluation of the Action of Microorganisms

DIN EN ISO 1133

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

DIN EN ISO 1183-1

Plastics – Methods for Determining the Density of Non-Cellular Plastics – Part 1: Immersion Method, Liquid Pyknometer Method and Titration Method

DIN EN ISO 1628-2

Plastics – Determination of the Viscosity of Polymers in Dilute Solution Using Capillary Viscometers – Part 2: Poly(vinyl Chloride) Resins

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Page 7 LV 112-1: 2013-04

DIN EN ISO/IEC 17025

General Requirements for the Competence of Testing and Calibration Laboratories

DIN ISO 1431-1

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

ISO 34-1

Rubber, Vulcanized or Thermoplastic – Determination of Tear Strength – Part 1: Trouser, Angle and Crescent Test Pieces

ISO 48

Rubber, Vulcanized or Thermoplastic – Determination of Hardness (Hardness between 10 IRHD and 100 IRHD)

ISO 554

Standard Atmospheres for Conditioning and/or Testing; Specifications

ISO 6469-3

Electrically Propelled Road Vehicles – Safety Specifications – Part 3: Protection of Persons against Electric Shock

ISO 6722-1

Road vehicles – 60 V and 600 V Single-Core Cables – Part 1: Dimensions, Test Methods and Requirements for Copper Conductor Cables

ISO 11357-1

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

ISO 11358

Plastics – Thermogravimetry (TG) of Polymers – General Principles

ISO 14572

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

VDA 232-101

Global Automotive Declarable Substance List

VDA Volume 6, Part 1

Quality Management in the Automotive Industry – Part 1: QM System Audit; based on DIN EN ISO 9001 and DIN EN ISO 9004-1

LV 112-1 Supplement 1

List of Chemicals for Compatibility Testing

LV 112-1 Supplement 2

Manufacturer's Code

LV 112-3

Determining Current Capacity of Vehicle Cables

LV 213-1

High-Frequency Cables for Motor Vehicles – Coaxial Cables

LV 213-2

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

Page 8 LV 112-1: 2013-04

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General information

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.

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Page 9 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

Page 10 LV 112-1: 2013-04

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Structure of the code

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

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6

Page 11 LV 112-1: 2013-04

Materials

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

Bare Cu conductor

Designations

Material

Code

Condition

Number

Cu-ETP1 Cu-ETP

CW003A CW004A

Tensile strength Rm

Elongation at break At or A200 mm

in mm

in N/mm²

Single- or multi-core wire in %

Singlecore wire

Multicore wire

over

up to

min.

min.

A010

A008

0,04

0,08

(200)

10

A015

A013

0,08

0,16

(200)

15

A021

A019

0,16

0,32

(200)

21

A022

A020

0,32

0,50

(200)

22

A024

A022

0,50

1,00

(200)

24

A026

A024

1,00

1,50

(200)

26

A028

A026

1,50

3,00

(200)

28

A033

—

3,00

5,00

(200)

33

Table 3

Product designation example

Designation

Standard

Material designation

Wire

DIN EN 13602

Cu-ETP-1

Condition designation

Surface quality

Diameter nominal dimension mm

Delivery form

A022

P

S0,4

Y

Explanation of the example given above: Condition designation: (R = hard drawn) Surface finish:

Diameter (nominal dimension)

A = annealed P = not tinned A, B = tinned

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Diameter nominal dimension:

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

Delivery form:

6.2

Conductor, tinned

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

Tinned Cu conductor – properties

Designations

Diameter (nominal dimension)

Tensile strength Rm

Elongation at break At or A200 mm

in mm

in N/mm²

Single- or multi-core wire in %

Material

Code

Cu-ETP1 Cu-ETP

6.3

Number

CW003A CW004A

Condition

Singlecore wire

Multicore wire

over

up to

min.

min.

A007

A005

0,04

0,08

(200)

7

A013

A011

0,08

0,16

(200)

13

A019

A017

0,16

0,32

(200)

19

A020

A018

0,32

0,50

(200)

20

A022

A020

0,50

1,00

(200)

22

A024

A022

1,00

1,50

(200)

24

A026

—

1,50

3,00

(200)

26

A031

—

3,00

5,00

(200)

31

Conductor, other surfaces

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

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6.4

Page 13 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 Class Temperature as per class ISO 6722-1

Temperature classes

Long-term service temperature (3 000 h) Tmin °C to Tmax °C

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

Temperature for thermal overload (6 h) (Tmax + 50) °C

A

T85

-40 to +85

+110 ± 2

+135 ± 3

B

T100

-40 to +100

+125 ± 3

+150 ± 3

B(105)

T105

-40 to +105

+130 ± 3

+155 ± 3

C

T125

-40 to +125

+150 ± 3

+175 ± 3

D

T150

-40 to +150

+175 ± 3

+200 ± 3

E

T175

-40 to +175

+200 ± 3

+225 ± 3

E(180)

T180

-40 to +180

+205 ± 3

+230 ± 4

F

T200

-40 to +200

+225 ± 4

+250 ± 4

G

T225

-40 to +225

+250 ± 4

+275 ± 4

H

T250

-40 to +250

+275 ± 4

+300 ± 4

Txyz

-40 to xyz

xyz + 25

xyz + 50

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

Page 14 LV 112-1: 2013-04

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7

Marking and supply specifications

7.1

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.

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Table 6

Page 15 LV 112-1: 2013-04

Voltage values/voltage class 1 (see Tabelle 1)

Nominal conductor cross-section in mm²

Test voltage in kV