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汽车线标准 Low-Voltage Cables in Motor Vehicles Single-Wire, Unshielded, Requirements and Tests

时间:2013-6-20 15:51:54 作者:251574881 来源:汽车 阅读:2465次
汽车线标准 Low-Voltage Cables in Motor Vehicles Single-Wire, Unshielded, Requirements and Tests
Fachverantwortung/Responsibility Normung/Standards )
EEIB 5  Fr. Dr. Tikwe                            Tel. 05361-9-36678 I/ET-3Tel.  0841-89-33904Gradl
Vertraulich. Alle Rechte vorbehalten. Weitergabe oder Vervielfältigung ohne vorherige schriftliche Zustimmung der Volkswagen AG, nicht gestattet.
Vertragspartner erhalten die Norm nur über die zuständige Beschaffungsabteilung.
Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of the Volkswagen Group,  Standard Department.
Parties to a contract can only obtain this standard via the responsible procurement department.
    VOLKSWAGEN AG
Form FE 41 - 10.99
Changes
The following changes have been made as compared to the September 1990 issue:
─  Adaptation to Team Paper LV 112
Previous issues: First issue: 09/90
Contents Page
1Scope and Aim.............................................................................................................2
2General Supply Requirements......................................................................................2
3Dimensions, Conductor Setup, Examples of Designation.............................................3
4Drawing Entry...............................................................................................................3
5Materials.......................................................................................................................3
5.1Requirements for the Conductor...................................................................................3
5.2Insulation......................................................................................................................4
6Identification.................................................................................................................4
6.1Manufacturer's Identification.........................................................................................4
6.2Color Coding................................................................................................................ 4
7General Test Conditions...............................................................................................5
7.1Test Climate.................................................................................................................5
7.2Specimens................................................................................................................... 5
7.3Rounding of Numerical Values.....................................................................................5
8Tests............................................................................................................................5
8.1Cable Design Test........................................................................................................5
8.2Physical and Chemical Properties of the Insulation......................................................5
8.3Mechanical Properties in As-Received Condition.........................................................6
8.4Non-Flammability........................................................................................................11
8.5Electrical Properties in As-Received Condition...........................................................11
8.6Mechanical and Electrical Properties after Mechanical, Thermal and/or Chemical Stress
...................................................................................................................................12
8.7Mycological Test.........................................................................................................17
8.8Compatibility with Other Cable Loom Components.....................................................17
9Supply Specifications .................................................................................................22
9.1Visual Inspection ........................................................................................................22
9.2Test ............................................................................................................................22
9.3Packaging Units (Only for Delivery to VW-Group Production Units)............................22
10Notes on testing: Method for Qualitative Determination of Lead in Polymers..............23
11Referenced Standards................................................................................................24
A.1Conductor Setup, Symmetrical, Type A (Normative)...................................................26
A.2Conductor Setup, Asymmetrical, Type B (Normative).................................................27
A.3Conductor Setup, Asymmetrical, Thick-Walled, Type B (Normative) .....................28
A.4Survey of Winding Tapes (Informative).......................................................................29
A.5List of Agents (Informative).........................................................................................30
A.6Electrical Wiring (Classification) (Informative).............................................................31
The English translation is believed to be accurate. In case
of discrepancies the German version shall govern.Page 2
VW 603 06: 2000-11
Preface
The content of this standard has been adapted from Team Paper LV 112, which was agreed upon
by representatives of the companies AUDI AG, BMW AG, DaimlerChrysler AG, Porsche AG and
Volkswagen AG.
Deviations from the agreed-upon version of LV 112 are indicated in VW 603 06 with  italic
type.
The companies listed above 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-named companies reserve the right to require additional
testing. The mutual acceptance of the test reports does not mean automatic release.
1 Scope and Aim
This in-house standard defines requirements and tests for single-wire, unshielded low-voltage ca-
bles with thin-walled or thick-walled insulation for a nominal-voltage range of ≤ 60 V.
The test scope of this standard and special test conditions in individual cases must be defined in
cooperation with and approved by the responsible development departments.
Cables made according to this standard are subject to mandatory technical engineering approval.
Thin-walled and thick-walled cable types are distinguished only by the dimensions listed in Appen-
dix A, Tables A.1, A.2 and A.3.
2 General Supply Requirements
Standard parts drawings take precedence over this standard.
Approval of first supply and changes per 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 company's trade
name, the manufacturing period of the cables and the company's recipe number for the insulation
material.
Deviations regarding the completeness of the data are only permissible in exceptional cases and
only with the agreement of the relevant materials testing department.
Long-term tests are a deciding factor for the production sample release test.
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 mate-
rials testing laboratories or responsible engineering departments.
Environmental standard VW 911 00 must be observed.
Emissions behavior per VW 501 80 and per usage guideline No. 3211 issued by Audi laboratory in
Ingolstadt, GermanyPage 3
VW 603 06: 2000-11
3 Dimensions, Conductor Setup, Examples of Designation
Dimensions (see Figure 1:) and conductor setups can be found in Appendix A1 [Symmetrical con-
ductor setup (Type A)) and Appendix A2 (Asymmetrical conductor setup (Type B)]. In general, the
cable must be designed so that it can be processed properly and welded using commercial de-
vices.
Figure 1:
Designation of an unshielded low-voltage cable (FL) with thin-walled insulation (R), insulation ma-
terial heat-resistant PVC (YW), nominal conductor cross section 1.5 mm2
 (1.5), conductor setup
Type A (A), bright individual wires, two-color coding, 1st color = basic color black (bk), 2nd color =
code color white (wh)
Cable VW 603 06  FLRYW *) 1.5 A black (bk) white (wh)
In the case of tin-coated conductors, (sn) should be added after the nominal conductor cross sec-
tion:
Cable VW 603 06  FLRYW *) 1.5 (sn) A black (bk) white (wh)
4 Drawing Entry
See standard part drawing
5 Materials
5.1 Requirements for the Conductor
The surface must be clean and free of lubricants and corrosion.
5.1.1 Bright Conductors
Softened, bright copper wires made of E-Cu58 F21 per DIN 40 500-4.
5.1.2 Tin-Coated Conductors
Softened, tin-coated copper wires made of E-Cu58 F21-V per DIN 40 500-5.
*) Insulation material symbol per DIN 76 722
Conductor
Insulation
d2
d1
sPage 4
VW 603 06: 2000-11
5.2 Insulation
The insulation material must correspond to the requirements of VDA 231-106.
The minimum and maximum service life temperatures (TU and TO) for a stress duration of 3,000 h
can be found in Table 1: according to the temperature classes or in the standard part drawing.
Table 1: Temperature classes
ClassService live
temperature
(3,000 h)
Short-term -
temperature
(240 h)
Temperature for thermal
overload (6 h)
  TU ° C to TO ° C(TO + 25)° C(TO +50)° C
A-40 to 85 110 ± 2135 ± 3
B -40 to 100  *) 125 ± 3150 ± 3
C-40 to 125 150 ± 3175 ± 3
D-40 to 150 175 ± 3200 ± 3
E-40 to 175 200 ± 3225 ± 3
F-40 to 200 225 ± 4250 ± 4
G-40 to 225 250 ± 4275 ± 4
H-40 to 250 275 ± 4300 ± 4
  *) Except for PVC up to 105° C
6 Identification
6.1 Manufacturer's Identification
For cross sections ≥ 0.5 mm², the manufacturer's identification must be either printed or stamped
on.
For cross sections < 0.5 mm2
, the identification method may be negotiated between the supplier
and the development department.
6.2  Color Coding
6.2.1 First Code Color in the Form of Lengthwise Colored Stripes
per DIN 72 551-7
6.2.2 Second Code Color in the Form of Colored Circles
per DIN 72 551-7
6.2.3 Meaning and Sequence of Code Colors
The code colors allow many wiring cables in a cable bundle to be distinguished with certainty. The
code colors and their sequence can be selected freely in an individual wiring cable, i.e., the two
code colors in a three-color wiring cable are interchangeable and therefore equivalent.Page 5
VW 603 06: 2000-11.2465
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