低压电线标准.pdf
Klass.-Nr./Class.No.69 32 1 November 2005 Electric Wiring in Motor Vehicles Single-Wire,Unshielded VW 603 06 Konzernnorm Descriptors:line,cable,wire,low-voltage cable,single-wire,unshielded,electric wiring Page 1 of 50 Fachverantwortung/Responsibility Normung/Standards(EZTD,1733)EEB/5 Frau Dr.Wiegel Tel.:+49-5361-9-36678 Just Tel.:+49-5361-9-25934 Sobanski Confidential.All rights reserved.No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.Parties to a contract can only obtain this standard via the B2B supplier platform“”.VOLKSWAGEN AG Norm vor Anwendung auf Aktualitt prfen/Check standard for current issue prior to usage.Form FE 41-01.05 Preface The content of this standard in the present issue has been agreed upon between representatives of Audi AG,BMW AG,DaimlerChrysler AG,Porsche AG and Volkswagen AG.The MS Word file is stored in the Volkswagen AG standards department.As it is possible that individual automobile manufacturers modify the specifications,exclusive testing according to supply specification LV 112 is not permitted.Instead,the supplier is obliged to ensure that the currently valid in-house standard of the respective automobile manufacturer is available to him.Deviations with respect to the agreed version of LV 112 are represented in italics in the individual in-house standards of the automobile manufacturers.Company-specific as well as informative tests are additionally specified in the Appendix.The above-mentioned companies agree on mutual recognition of test reports from cable manufacturers as long as the tests are performed by an independent testing institute that is accredited according to DIN EN ISO/IEC 17025.The above-mentioned companies reserve the right to require additional tests.The mutual acceptance of the test reports does not automatically result in a release.Changes The following changes have been made as compared to Volkswagen standard VW 603 06:2001-11:Standard completely revised Previous issues 1990-09;2001-11 Contents Page 1 Scope.3 2 General.3 2.1 Basic supply requirements.4 3 Dimensions and conductor composition.4 4 Drawing entry.4 5 Materials.5 5.1 Conductor,uninsulated.5 5.2 Conductor,tinned.6 5.3 Conductor,other surfaces.6 5.4 Insulation.7 6 Marking and supply specifications.7 6.1 Packaging marking.7 6.2 Manufacturers code.7 6.3 Color coding.7 The English translation is believed to be accurate.In case of discrepancies the German version shall govern.Page 2 VW 603 06:2005-11 6.4 Supply specifications.8 6.4.1 Visual test.8 6.4.2 Testing.8 6.4.3 Packaging units.8 6.4.4 Partial lengths,ties,defects.9 6.4.5 Marking of the delivery unit.9 7 General test conditions.10 7.1 Test matrix.10 7.2 Test climate.12 7.3 Specimens.12 7.4 Rounding of numerical values.12 8 Tests.12 8.1 Cable composition test.13 8.1.1 Insulation test wall thickness Sp(thin-walled cables).13 8.2 Physical and chemical properties of the insulation.13 8.2.1 Density.13 8.2.2 Determination of the extractable portion.13 8.2.3 Determination of viscosity.13 8.2.4 Temperature at 5%weight loss.13 8.2.5 Ignition residue.13 8.2.6 Thermal stability.14 8.2.7 Determining the infrared spectrum.14 8.2.8 Determining the tensile strength and elongation at tear.14 8.2.9 Tear propagation strength.14 8.2.10 Determination of cross-linking density.14 8.2.11 Microhardness.14 8.3 Mechanical properties in as-received condition.14 8.3.1 Insulation stripability and secure fit of conductor.14 8.3.2 Insulation abrasion resistance.15 8.3.3 Cable-to-cable abrasion resistance.16 8.3.4 Sliding behavior of the cables.17 8.3.5 Bending force of the cables.18 8.3.6 Insulation notch strength.19 8.4 Non-flammability.20 8.5 Electrical properties in as-received condition.20 8.5.1 Specific insulation resistance.20 8.5.2 Measurement of 30-minute voltage protection.20 8.5.3 Measurement of 1-minute voltage protection(after aging only).20 8.6 Mechanical and electrical properties after mechanical,thermal or chemical stress.20 8.6.1 Stress test.20 8.6.2 Insulation shrinkage under heat.21 8.6.3 Pressure resistance of the insulation under heat.21 8.6.4 Thermal stability in wound state.21 8.6.5 Thermal overload.22 8.6.6 Short-term aging(240 h).22 8.6.7 Long-term aging(3,000 h).22 8.6.8 Low-temperature winding test(-40 C).22 8.6.9 Low-temperature impact test(-15 C).22 8.6.10 Resistance of cable marking to wiping.22 Page 3 VW 603 06:2005-11 8.6.11 Dynamic flexural strength.23 8.6.12 Kink test.23 8.6.13 Electrical properties during water immersion.24 8.6.14 Humid heat,constant(hydrolysis test).25 8.6.15 Ozone resistance.25 8.7 Mycological test.26 8.8 Compatibility tests.26 8.8.1 Resistance to agents acc.to ISO 6722.26 8.8.2 Resistance to operating fluids and wrapping tapes.27 8.8.3 Resistance to harness components.30 9 Environmental protection and safety.32 10 Referenced standards.33 A.1 Conductor setup,symmetrical,type A(normative).35 A.2 Conductor composition,asymmetrical,type B(normative).36 A.3 Conductor composition,asymmetrical,type b,used up to March 2005 not for new designs.37 A.4 Conductor composition,asymmetrical,finely stranded(f),type B with reduced outside diameters.38 A.5 Conductor composition,asymmetrical,extra-finely stranded(ff),type B.39 A.6 Survey of wrapping tapes.40 1 Scope VW 603 06 describes requirements and tests for single-wire,unshielded low-voltage cables in a nominal voltage range between 60 V and 600 V.Thin-walled cables with cross sections 6 mm:see Appendices A.1 and A.2 Thick-walled cables with cross sections 6 mm:see Appendices A.4 and A.5 It is recommended to use the basic color orange(RAL 2003)for cables used in nominal voltage range between 60 V and 600 V.2 General VW 603 06 only applies to new designs.Cables already used in standard production do not have to be modified.Re-testing can be required if new issues of the standard are released.Subsequent modifications of material,dimensions,manufacturing processes,etc.shall be reported to the respective design engineering departments;these may demand a new release.The test scope of VW 603 06 and in individual cases special test conditions must be defined in cooperation with and approved by the responsible engineering departments.Cables manufactured according to this standard are subject to technical engineering approval(BMG).Page 4 VW 603 06:2005-11 After technical engineering approval has been granted,the cables are only completely released for use in standard production if the assembler has confirmed proper usability in the form of a first-sample test report(EMPB)during first sampling,e.g.Stripping of the insulation Crimpability Ultrasonic weldability Twistability of the contacts,if applicable Crimping of contacts 2.1 Basic supply requirements Standard part drawings take precedence over this standard.Approval of first supply and changes according to Volkswagen standard VW 011 55.First samples must be delivered accompanied by a test certificate containing all data regarding the quality requirements listed below.In addition,the test certificate must contain the companys trade name,the manufacturing period of the cables and the companys recipe number for the insulating material.Deviations regarding the completeness of the data are only permissible in exceptional cases and only with the agreement of the relevant department.Long-term tests are a deciding factor for technical engineering release.Standard production shipments must include the manufacturing date.The manufacturing date must be visible on the cable tags.Different rules may be negotiated between the suppliers and the material testing laboratories or responsible engineering departments.3 Dimensions and conductor composition Dimensions and composition of the conductor(see Figure 1)are to be taken from the respective Sections in the Appendix.Unspecified details are to be selected to suit the specific purpose according to ISO 6722.Figure 1 Composition of the conductor 4 Drawing entry The drawing entry shall be made in the material specification field or near the title block.The cable shall be described according to DIN 72551-6 and DIN 72551-7.Example:Description example of an unshielded low-voltage cable(FL)with thin-walled insulation(R),a nominal conductor cross section of 1.5 mm(1,5),type A conductor composition(A)with tinned strands,2X symbol of the insulating material(cross-linked PE)according to DIN 76722,color coding based on DIN 72551-7 in German or English,permanent service temperature(TO)125 C:Cable -FLR2X-1,5sn-A RDBU/T125 Insulation Conductor Page 5 VW 603 06:2005-11 5 Materials The properties according to Sections 5.1 to 5.3 shall be guaranteed by the manufacturer.5.1 Conductor,uninsulated Strand Cu-ETP1,CW003A or Cu-ETP,CW004A acc.to DIN EN 13602 In exceptional cases other Cu materials can be agreed upon.Conductor,uninsulated:properties see Table 1.Table 1 Conductor,properties Designations Diameter(nominal dimension)Tensile strength Rm Elongation at break At or A200mm Material Condition mm N/mm Single-or multi-core wire%Code Number Single-core wire Multi-core wire over 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 Cu-ETP1 Cu-ETP CW003A CW004A A033 3.00 5.00(200)33 Product designation example:Designation Standard Material designation Condition designation Surface quality Diameter nominal dimension mm Delivery Wire DIN EN 13602 Cu-ETP-1 A022 P S0.4 Y Explanation of the example given above:Condition designation:A=annealed(R=hard drawn)Surface finish:P=not tinned A,B,C=tinned Diameter nominal dimension:S=single-core wire M=multi-core wire Delivery:Y=ring(Z=coil)Page 6 VW 603 06:2005-11 5.2 Conductor,tinned Properties see Table 2.Table 2-Properties Designations Diameter(nominal dimension)Tensile strength Rm Elongation at break At or A200mm Material Condition mm N/mm Single-or multi-core wire%Code Number Single-core wire Multi-core wire over 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 Cu-ETP1 Cu-ETP CW003A CW004A A031 3.00 5.00(200)31 5.3 Conductor,other surfaces Other surfaces(e.g.,silver plated)are permissible upon agreement.Page 7 VW 603 06:2005-11 5.4 Insulation The minimum and maximum permanent service temperatures(TU and TO)for a load duration of 3,000 h shall be selected according to the temperature classes given in Table 3,or in exceptional cases according to the drawing.Table 3 Temperature classes Class Permanent service temperature(3,000 h)TU C to TO C Short-term temperature(240 h)(TO+25)C Thermal overload temperature(6 h)(TO+50)C A-40 to 85 110 2 135 3 B-40 to 100 125 3 150 3 B(105)-40 to 105 130 3 155 3 C-40 to 125 150 3 175 3 D-40 to 150 175 3 200 3 E-40 to 175 200 3 225 3 E(180)-40 to 180 205 3 230 4 F-40 to 200 225 4 250 4 G-40 to 225 250 4 275 4 H-40 to 250 275 4 300 4 In justified exceptional cases,special temperature classes such as B(105)or E(180)are permissible.6 Marking and supply specifications 6.1 Packaging marking Packaging must be marked conform with VDA band 6 part 1 and shall be agreed upon between purchaser and supplier.6.2 Manufacturers code For cross sections 0.5 mm,the manufacturers code must be printed or stamped on,for example.For cross sections 0.5 mm marking is carried out according to agreement.6.3 Color coding Color coding based on DIN 72551-7 in German or English.Different color coding is permissible upon agreement.Page 8 VW 603 06:2005-11 6.4 Supply specifications If these supply requirements are not met,the goods will be returned at the suppliers expense.6.4.1 Visual test The insulations must have no nodes,cracking,blistering or foreign inclusions and must be strippable using a standard commercial stripping machine without leaving a residue and without damage to the conductor.6.4.2 Testing According to ISO 6722(Section Insulation faults)After the spark test,the cables shall be tested according to Table 4.The stay time of the cable in the electrical field shall be selected such that each cable section is stressed with at least 18 voltage spikes.When using tubular electrodes,the inside diameter of the electrode must be matched to the cable diameter.Table 4-Voltage values Nominal conductor cross-section mm2 Voltage for 60-V cable kV Voltage for 600-V cable kV 16.Test scope B:Identical compound,different site of same cable manufacturer Test scope C:For unchanged compound composition and chemically identical pre-materials supplied by different sub-contractors or change of compound manufacturing site.Test scope D:Regularly at least every 5 years.Test scope E:Recommended process-accompanying test(e.g.,batch-related or continuously)The supplier bears responsibility for process assurance.7.2 Test climate If no other test climate is specified,testing will be carried out in the DIN 50014-23/50-2 standard climate.7.3 Specimens If not otherwise specified,at least 3 specimens of the cables shall be tested in as-received condition.Light colors shall be used,not brown or black.For tests that are directly connected to the manufacturing process for process assurance,the specimens must be aged for at least 16 h beforehand in the DIN 50014-23/50-2 standard climate.For each test only specimens shall be used which have not been used in previous tests.If maximum 1 of the 3 specimens fails,the test shall be repeated with 10 specimens and documented.In this case,all of the 10 specimens shall 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.7.4 Rounding of numerical values The determined numerical values shall be rounded to the number of digits with which the desired values are listed,according to DIN 1333.8 Tests The tests described are based on ISO 6722.Unless otherwise agreed upon,the drawing entry takes precedence over the standard if different specifications are given.Page 13 VW 603 06:2005-11 8.1 Cable composition test The parameters indicated in the relevant Appendices for the cable setup must be tested for.The mean value of the measurements as well as the minimum and maximum values shall be indicated in the test report.8.1.1 Insulation test wall thickness Sp(thin-walled cables)The following applies to all nominal conductor cross sections:Sp=minimum wall thickness+0.02 mm See Tables A.1,A.2,A.4 and A.5.If the insulation test wall thickness is too small in two cases,a cable batch may be rejected.In cases of doubt,a microscopic investigation on the metallographic microsection shall be performed.8.2 Physical and chemical properties of the insulation The measured values for each cable specimen obtained from the tests described below shall be included as an appendix to the test report and
