Vw 60306-1-2013 汽车用低压电线第1部分单芯无屏蔽电缆

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 Mller
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 Groups 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
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.

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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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
VW 60306-1:2013-04
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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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 mm ................................................................................ 46
Testing on cross-sections 4 mm ................................................................................... 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
VW 60306-1:2013-04
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 mm, 16 mm, 25 mm, and 35 mm 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
VW 60306-1:2013-04
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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
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)
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LV 112-1: 2013-04
VW 60306-1:2013-04
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
VW 60306-1:2013-04
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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
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LV 112-1: 2013-04
VW 60306-1:2013-04
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.
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
VW 60306-1:2013-04
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 mm (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 mm
(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
VW 60306-1:2013-04
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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/mm
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
S0,4
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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LV 112-1: 2013-04
VW 60306-1:2013-04
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/mm
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)
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.
VW 60306-1:2013-04
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
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
T85
-40 to +85
+110 2
+135 3
T100
-40 to +100
+125 3
+150 3
B(105)
T105
-40 to +105
+130 3
+155 3
T125
-40 to +125
+150 3
+175 3
T150
-40 to +150
+175 3
+200 3
T175
-40 to +175
+200 3
+225 3
E(180)
T180
-40 to +180
+205 3
+230 4
T200
-40 to +200
+225 4
+250 4
T225
-40 to +225
+250 4
+275 4
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).
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LV 112-1: 2013-04
VW 60306-1:2013-04
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.
VW 60306-1:2013-04
Table 6
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LV 112-1: 2013-04
Voltage values/voltage class 1 (see Tabelle 1)
Nominal conductor
cross-section in mm
Test voltage
in kV
<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
Example Delivery quantities for NPS 400

FLR cables
Nominal cross-section in
mm2
Delivery quantity in m
0,22
14 000
0,35
12 000
0,5
10 000
1,0
8 000
1,5
7 000
2,5
5 000
4,0
2 500
6,0
1 500
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.
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LV 112-1: 2013-04
VW 60306-1:2013-04
Maximum permissible quantities per drum or coil at nominal cross section:

0,22 mm, 0,35 mm, 0,5 mm, 0,75 mm
3 ties or defects
1,0 mm, 1,5 mm, 2,5 mm
2 ties
4,0 mm
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
VW 60306-1:2013-04
Test matrix
Site test
Release test
Test matrix
A1
A2
B2
C2
B1
Test
Section
Table 8
Test scope
Process test
8.1
Requalification
test
General test conditions
Changes of
pre-materials
Page 17
LV 112-1: 2013-04
C1
7.3
Color
7.4.1
Visual inspection
7.4.2
9.1
Cable structure test
9.1.1
Outside cable diameter and minimum wall

thickness
9.1.2
Nominal conductor diameter
9.1.3
Conductor resistance
9.1.4
Wall thickness of the insulation
9.1.5
Insulation test wall thickness
9.2
Physical and chemical properties of the insulation
9.2.1
Density
9.2.2
Determination of viscosity
1)
1)
1)
9.2.3
Thermogravimetric analysis (TGA)
9.2.4
Differential scanning calorimetry (DSC)
9.2.5
Thermal stability for PVC
9.2.6
Determination of the infrared spectrum
9.2.7
Determination of tensile strength and elongation

at tear
9.2.8.1
Tear propagation resistance/test on the plate
9.2.8.2
Tear propagation resistance/test on the cable
9.2.9
Determination of cross-linking density
9.2.10
Microhardness
9.3
Mechanical properties in as-received condition
9.3.1
Insulation stripability/secure fit of conductor
9.3.2
Insulation abrasion resistance
9.3.3
Sliding behavior of the cables
9.3.4
Bending force of the cables
1)
1)
3)
X
X
Process test
A2
B2
C2
Requalification
test
A1
Changes of
pre-materials
Test scope
Site test
Release test
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Test
Section
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LV 112-1: 2013-04
B1
C1
9.3.5
Insulation notch strength
9.4
Flame retardance
9.5
Electrical properties in as-received condition
9.5.1
Specific volume resistance of the insulation
9.5.2
30-minute dielectric strength
9.6
Mechanical and electrical properties after mechanical, thermal, or chemical stress
9.6.1
Stress test
9.6.2
Insulation shrinkage under heat
9.6.3
Compressive strength of the insulation under

heat
9.6.4
Derating curve
1)
X
X
3)
3)
X
X
4)
9.6.5
Thermal stability in wound state
9.6.6.1
Thermal overload Tmax +50 C
9.6.6.2
Extreme thermal overload Tmax + x C/1 h
9.6.7
Short-term aging (240 h)
9.6.7.1
Winding test after short-term aging (240 h)
9.6.7.2
Determination of IR after short-term aging (240 h)
9.6.7.3

at tear after short-term aging (240 h)
9.6.8
Long-term aging (3 000 h)
9.6.8.1
Winding test after long-term aging (3 000 h)
9.6.8.2
Determination of IR after long-term aging

(3 000 h)
9.6.8.3

at tear after long-term aging (3 000 h)
9.6.8.4
Minimum permissible radius for static routing
9.6.9
Winding test at low temperature

(-40 C)
9.6.10
Impact test at low temperature (-15 C)
X
1)
9.6.11
Resistance of cable marking to wiping/smudging
9.6.12
Resistance to reverse bending stresses
3)
9.6.13
Kink test
9.6.14
Electrical properties during aging in water
9.6.15
Damp heat, constant (hydrolysis test)
9.6.16
1)
Ozone resistance
1)
9.7
Mycological test
9.8
Compatibility tests
9.8.1
Chemical resistance as per ISO 6722-1
9.8.2
Resistance to chemicals and wrapping tapes
9.8.3
Resistance to wiring harness components
10
Environmental protection
2)
Process test
A2
B2
C2
Requalification
test
A1
Changes of
pre-materials
Test scope
Site test
Release test
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LV 112-1: 2013-04
Test
Section
VW 60306-1:2013-04
B1
C1
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 mm.
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.
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LV 112-1: 2013-04
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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 mm) 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 mm, 0,5 mm, 1,5 mm, 2,5 mm,
4,0 mm, and 16 mm.
Short test A2/B2/C2: all other cross-sections.
VW 60306-1:2013-04
A2
B2
C2
B1
Process test
A1
Requalification
test
Test scope
Change of
pre-materials
Site test
Release test
Test matrix for single-wire cables that are used exclusively in sheathed cables
Test
Section
Table 9
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LV 112-1: 2013-04
C1
7.3
Color
7.4.1
Visual inspection
7.4.2
9.1
9.1.1
Outside cable diameter and minimum wall

thickness
9.1.2
9.1.3
9.1.4
9.1.5
Insulation test wall thickness
9.2
9.2.1
Density
1)
1)
9.2.2
Determination of viscosity
9.2.3
1)
1)
9.2.4
9.2.5
9.2.6
9.2.7

at tear
9.2.8.1
Tear propagation resistance/test on the plate
9.2.8.2
Tear propagation resistance/test on the cable
9.2.9
1)
9.2.10
Microhardness
9.3
9.3.1
Insulation stripability/secure fit of conductor
9.3.2
9.3.3
Sliding behavior of the cables
9.3.4
Bending force of the cables
9.3.5
9.4
Flame retardance
9.5
3)
Process test
1)
A2
B2
C2
Requalification
test
A1
Change of
pre-materials
Test scope
Site test
Release test
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Test
Section
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LV 112-1: 2013-04
B1
C1
9.5.1
Specific volume resistance of the insulation
9.5.2
9.6
9.6.1
Stress test
9.6.2
9.6.3
Compressive strength of the insulation under

heat
9.6.4
Derating curve
9.6.5
Thermal stability in wound state
9.6.6.1
Thermal overload Tmax +50 C
9.6.6.2
Extreme thermal overload Tmax + x C/1 h
9.6.7
9.6.7.1
Winding test after short-term aging (240 h)
9.6.7.2
Determination of IR after short-term aging (240 h)
9.6.7.3

at tear after short-term aging (240 h)
9.6.8
9.6.8.1
Winding test after long-term aging (3 000 h)
9.6.8.2
Determination of IR after long-term aging

(3 000 h)
9.6.8.3

at tear after long-term aging (3 000 h)
9.6.8.4
Minimum permissible radius for static routing
9.6.9
Winding test at low temperature

(-40 C)
9.6.10
9.6.11
9.6.12
9.6.13
Kink test
9.6.14
9.6.15
9.6.16
1)
Ozone resistance
9.7
Mycological test
3)
3)
3)
1)
1)
9.8
Compatibility tests
9.8.1
9.8.2
9.8.3
Resistance to wiring harness components (only

connector housings, seals, contacts, cable lugs)
10
Environmental protection
2)
Process test
A2
B2
C2
Requalification
test
A1
Change of
pre-materials
Test scope
Site test
Release test
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Test
Section
VW 60306-1:2013-04
B1
C1
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 mm.
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.
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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.
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8.2
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LV 112-1: 2013-04
Test atmosphere
If no other test atmosphere is specified, testing is performed in the standard climate as per
ISO 554, 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 554 - 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
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
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
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
Test as per ISO 6722-1.
9.1.4

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
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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LV 112-1: 2013-04
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
9.2.3
Melt flow/volume (MFI/MVI) measurements
Material
Temperature
in C
Load weight in kg
Residual
moisture
in %
PP
TPU
PA
ETFE
FEP
TPS
PE
PBT
PFA
+230
+190
+275
+297
+372
+230
+190
+250
+372
5
21,6
2,16
5
5
5
2,16
2,16
5
<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 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 longterm 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
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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LV 112-1: 2013-04
9.2.6
VW 60306-1:2013-04
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 mm or 35 mm 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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LV 112-1: 2013-04
Figure 2
9.2.9
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/cm.
Requirements:
Elongation under load
Elongation after load removal
9.2.10
100%
25%
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
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
Secure fit of the conductor
Nominal conductor
cross section
Minimum force
in mm
0,22
0,35
0,5
0,75
1,0
1,5
2,5
4,0
6,0
in N
10
10
10
10
Maximum force
in N
20
30
30
40
40
50
60
70
70
For nominal conductor cross-sections >6,0 mm: 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
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
cross section
Contact force
in mm
0,22
0,35
in N
Number of cycles
0,5
0,75
1,0
1,5
2,5
4,0
6,0
25,0
1 500
1 500
7.00 0.05
Number of
minimum 150 200 300 350
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
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LV 112-1: 2013-04
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
Test specifications for sliding behavior
in mm
0,22
0,35
0,5
0,75
1,0
1,5
2,5
4,0
6,0
in N
10
10
in mm
20
20
30
40
40
50
60
80
80
This test is not to be performed on nominal conductor cross sections >6,0 mm.
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9.3.4
VW 60306-1:2013-04
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)
Specifications for the bending force test

in mm
0,22
0,35
in mm
Number of specimens (n)

Distance (lV)
in mm
Maximum bending force
in N
Table 15
15
15
0,5
0,75
1,0
1,5
2,5
50
70
20
30
20
25
30
30
40
4,0
6,0
70
90
Specifications for standard setup (see Table 6)
Nominal conductor
cross section
Specimen length (l)
in mm
10
16
25
in mm
35
50
70
95
70
90
110
150
Number of specimens (n)
Distance (lV)
in mm
Maximum bending force
in N
100
15
20
30
50
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.
VW 60306-1:2013-04
Figure 5
9.3.5
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Bending force test device
Requirements
The notching force must correspond to the values in Table 16.
Table 16
Nominal conductor
cross section
Minimum notching force
Notching force
in mm
0,22
0,35
0,5
0,75
1,0
1,5
2,5
4,0
6,0
in N
30
30
40
50
50
60
70
100
120
For nominal conductor cross-sections >6,0 mm: 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
Notch strength test device
Flame retardance

9.5
9.5.1
Specific volume resistance
Requirements
The specific volume resistance of the insulation must be at least 109 mm.
Test
As per ISO 6722-1 (but with 1% NaCl solution).
9.5.2
Requirements
Dielectric breakdown must not occur.
Test
As per ISO 6722-1.
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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 mm) 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
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
ETFE
(+225 5) C
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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Table 17
Nominal conductor
cross section
mm
Mandrel diameter
mm
9.6.2
0,22
Mandrel diameter
0,35
0,5
0,75
1,0
1,5
3
2,5
4
4,0
6,0
5

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
Specimen preparation for the shrinkage test
Pressure resistance of the insulation under heat

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 crosssections (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 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
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", at the thermal overload temperature as per Table 5 (suspended on the mandrel).
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
mm
0,22
mm
Mandrel diameter
0,35
0,5
0,75
1,0
1,5
2,5
4,0
6,0
13
Thermal overload
9.6.6.1 Thermal overload Tmax +50 C

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
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.
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 highvoltage 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 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 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
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.
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 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 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
Smallest
permissible
bend radius
in mm
3,0
( up to 2,5 mm)
2,0 dmax
>3,0 and 5,0

( from 4,0 mm to
6,0 mm)
>5,0
(greater than
6,0 mm)
2,0 dmax
3,0 dmax
Maximum
winding
mandrel
diameter
in mm
Specimen preparation
Wind 360 around itself three times, see

Figure 9
1,5 dmax
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)
2,0 dmax
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)
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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
Figure 10
Figure 11
Procedure
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
Additional test for data collection (informative)
After the fasteners have been removed, straighten the specimens by hand and perform another
high-voltage test again.
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9.6.9
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Winding test at low temperature (-40 C)

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

As per ISO 6722-1.
Deviation: testing with a hammer weight of 100 g for cables with cross sections 0,5 mm.
9.6.11
This test only applies to cables with printed markings.

Testing and requirement
As per ISO 6722-1.
9.6.12
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
Specimen length
Sampling rate
Distance of the bending jaws
Material of the bending jaws
Loading weight
Preferred cross-sections less than 25 mm (test scope A1)

1 m
10 ms
1,5 the maximum specified outer diameter 0,5 mm
Stainless steel or aluminum
1,0 kg/mm (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
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Kink test
This test is used only for cables with cross-sections 6,0 mm.
Requirement
Test
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
section
in mm
Bend radius (r)
in mm
Spacer ring thickness
in mm
Tolerance of spacer ring

thickness
in mm
0,22
Spacer rings
0,35
0,5
0,75
1,0
1,0
1,0
1,1
1,5
2,5
4,0
1,5
1,3
1,6
1,8
2,1
6,0
3,0
2,6
3,3
3,9
-0,1
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
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LV 112-1: 2013-04
Test device for kink test
Requirements
The insulation resistance (measured as per section 9.5.1) during the aging in water must be at
least 109 mm. This value is measured every 7 days. The length-specific conductor resistance
must not deviate from the initial value by more than 10%.
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
in mm
Mandrel diameter
in mm
Nominal conductor
cross section
in mm
10
Mandrel diameter
in mm
40
0,22
Mandrel diameter
0,35
0,5
0,75
1,0
16
10
25
50
1,5
35
75
50
2,5
15
70
100
95
4,0
6,0
20
120
125
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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 1minute 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 mm), 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
Requirement
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
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").
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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
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
The tests of section 9.8.2 are mandatory; they are used for data collection.
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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 mm
Twist two cables of the same material with a cross-section of 0,35 mm 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 mm, 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).
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Test group 5:
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 mm, testing must be performed as per Table 22.
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Table 22
Winding mandrels after aging
Nominal
conductor
crosssection
Twist length
Test tubes
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
0,35
20 +35
25 2
20
10
0,50
20 +35
25 2
20
10
0,75
25 +35
25 2
30
15
1,00
30 +35
30 2
30
15
1,50
35 +35
None, freely
suspended
35
20
2,50
40 +35
None, freely
suspended
45
25
Wrapped,
twisted
specimen
(large)
Single strand
Single strand
without
without
adhesive
adhesive tape
tape
(small)
(medium)
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 mm
Testing is performed on 16 mm cross sections. If other compounds are used for cross sections
>4 mm, 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 mm.
Test groups
As in section 9.8.2.1.
Test
Testing is performed as for cross sections 4 mm, 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
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LV 112-1: 2013-04
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

Each sample wiring harness consists of 6 cables with lengths of 300 to 400 mm and cross-sections
of 0,35 mm (3 cables) and 2,5 mm (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
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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
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LV 112-1: 2013-04
Mandrel diameter
in mm
in mm
0,35
6
2,5
15
9.8.3.2 Testing on cross sections >6 mm2

Testing is performed on 16 mm cross sections. If other compounds are used for cross sections
>6 mm, 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 mm.
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.
Page 52
LV 112-1: 2013-04
10
VW 60306-1:2013-04
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.
VW 60306-1:2013-04
Page 53
LV 112-1: 2013-04
Appendix A (normative)
Table A 1
FLR symmetric conductor composition type A with reduced wall thickness

Strand
Nominal
conductor
cross-section
Conductor
Quantity Diameter Diameter Twist

d1
length
5)
mm
Cable
CrossResistance Resistance
at 20 C,
section for
at 20 C,
bare
tinned
bare
1)
5)
strands
strands
conductors
m/m
Wall
thickness
of the
insulation
s
mm
mm
m/m
Cpk
value
(based
on s)
Test wall Concentricity

factor
thickness
2)
sP
K
Weight
mm
mm
mm
max.
max.
max.
0,21
0,70
27
0,203 0,220 84,8 78,5 86,5 80,1
1,2
-0,1
0,20
0,22
3,1
0,35
0,27
0,80
27
0,332 0,358 52,0 48,1 55,5 51,4
1,3
-0,1
0,20
0,22
4,6
0,5
19
0,20
1,00
45
0,465 0,502 37,1 34,4 38,2 35,4
1,6
-0,2
0,22
0,24
6,3
0,75
19
0,24
1,20
45
0,698 0,754 24,7 22,9 25,4 23,5
1,9
-0,2
0,24
0,26
1,0
19
0,27
1,35
50
0,932 1,01
18,5 17,1 19,1 17,7
2,1
-0,2
0,24
1,5
19
0,33
1,70
60
1,36
1,47
12,7 11,8 13,0 12,0
2,4
-0,2
2,5
19
0,41
2,20
75
2,27
2,45
7,60 7,04 7,82 7,24
3,0
2,5
37
0,30
2,20
75
2,27
2,45
7,60 7,04 7,82 7,24
4,0
37
0,38
2,75
75
3,66
3,95
6,0
37
0,45
3,40
75
5,49
5,93
0,22
4)
mm
Outer
diameter
d2
min.
max.
max.
min.
max.
min.
max.
Perm.
dev.
min.
min.
1,33
mm
min.
min.
45
g/m
9,2
0,26
12
0,24
0,26
17
-0,3
0,28
0,30
27
3,0
-0,3
0,28
0,30
27
4,71 4,36 4,85 4,49
3,7
-0,3
0,32
0,34
43
3,14 2,91 3,23 2,99
4,3
-0,3
0,32
0,34
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 mm deviate significantly from ISO 6722-1.
5) Measuring accuracy 50 m.
3)
Page 54
VW 60306-1:2013-04
LV 112-1: 2013-04
Table A 2
FLU symmetric conductor composition type A with ultrathin wall thickness
Strand
Quantity Diameter Diameter
d1
Twist
length
Conductor
Cross-section
for bare
1)
conductors
mm
mm
mm
mm
max.
max.
max.
0,21
0,70
27
0,35
0,27
0,80
0,5
19
0,20
0,75
19
1,0
Nominal
conductor
cross-section
6)
mm
Wall
thickness
of the
insulation
s
m/m
mm
mm
Cable
Cpk value
Test
(based
wall
on s)
thickness
sP
Weight
mm
g/m
min.
min.
max.
Perm.
dev.
min.
0,203 0,220
84,8
78,5
1,05
-0,10
0,16
0,17
2,9
27
0,332 0,358
52,0
48,1
1,20
-0,10
0,16
0,17
4,3
1,00
45
0,465 0,502
37,1
34,4
1,40
-0,10
0,16
0,17
5,8
0,24
1,20
45
0,698 0,754
24,7
22,9
1,60
-0,15
0,16
19
0,27
1,35
50
0,932
1,01
18,5
17,1
1,75
-0,15
0,16
1,5
19
0,33
1,70
60
1,36
1,47
12,7
11,8
2,10
-0,20
0,16
0,17
16
2,5
19
0,41
2,20
75
2,27
2,45
7,60
7,04
2,70
-0,20
0,20
0,21
26
2,5
37
0,30
2,20
75
2,27
2,45
7,60
7,04
2,70
-0,20
0,20
0,21
26
5) For resistance values of tinned conductors, see ISO 6722-1.
min.
Concentricity
factor
2)
K
min.
4)
max.
Outside
diameter
d2
max.
0,22
min.
Resistance at
20 C,
bare
strands
5)
(tinned )
1,33
0,17
0,17
45
8,4
11
3)
VW 60306-1:2013-04
Table A 3
FLR asymmetric conductor composition type B with reduced wall thickness

Strand
Nominal
conductor
cross
section
Quantity 6)
mm
5)
0,35
0,5
0,75
1,0
1,5
2,5
4,0
6,0
10,0
12
16
24
32
30
50
56
84
80
16,0
25,0
35,0
50
70
95
126
196
276
396
360
475
Page 55
LV 112-1: 2013-04
Conductor
Wire
diameter
Diameter
d1
Twist length
mm
mm
mm
max.
max.
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
0,90
1,00
1,20
1,40
1,70
2,20
2,75
3,40
4,50
7)
5,50
7,00
8,30
9,80
11,6
13,8
Not
specified
Cable
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
mm
m/m
m/m
mm
mm
Cpk value
(based
on s)
Test
wall
thickness
sP
Concentricity
factor
K 2)
Weight3)
mm
g/m
min.
min.
max.
max.
min.
max.
min.
max.
Perm.
dev.
min.
min.
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
0,358
0,502
0,754
1,01
1,47
2,47
3,95
5,93
10,2
16,1
25,1
35,3
50,6
71,9
95,0
52,0
37,1
24,7
18,5
12,7
7,60
4,71
3,14
1,82
48,1
34,4
22,9
17,1
11,8
7,04
4,36
2,91
1,69
55,5
38,2
25,4
19,1
13,0
7,82
4,85
3,23
1,85
51,4
35,4
23,5
17,7
12,0
7,24
4,49
2,99
1,71
1,4
1,6
1,9
2,1
2,4
3,0
3,7
4,3
5,8
-0,2
-0,2
-0,2
-0,2
-0,2
-0,3
-0,3
-0,3
-0,4
0,20
0,22
0,24
0,24
0,24
0,28
0,32
0,32
0,48
1,33
0,22
0,24
0,26
0,26
0,26
0,30
0,34
0,34
0,50
1,16
0,743
0,527
0,368
0,259
0,196
1,07
0,688
0,488
0,341
0,240
0,181
1,18
0,757
0,538
0,375
0,264
0,200
1,09
0,701
0,498
0,347
0,244
0,185
7,0
8,7
10,4
12,2
14,4
16,7
-0,5
-0,5
-0,6
-0,7
-0,9
-1,0
0,52
0,52
0,64
0,72
0,80
0,88
>1,0
4)
4) In the transition period, a Cpk value 1,0 will be accepted.
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.
0,54
0,66
0,82
0,74
0,82
0,90
45
Not
applicabl
e
4,7
6,4
9,2
12
17
27
43
63
111
171
260
368
524
743
979
Page 56
LV 112-1: 2013-04
A 3.1
VW 60306-1:2013-04
FLR asymmetric conductor composition type B with reduced wall thickness Intermediate cross-sections
Strand
Nominal
conductor
cross
section
Quantity 5)
mm
Conductor
Wire
diameter
Diameter
d1
Twist length
mm
mm
mm
max.
max.
max.
6)
Cable
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
mm
m/m
m/m
mm
mm
min.
max.
max.
min.
max.
min.
max.
Perm.
dev.
min.
Cpk value
(based
on s)
min.
Test
wall
thickness
sP
Concentricity
factor
K 2)
Weight3)
mm
g/m
min.
min.
Intermediate cross-sections >10 mm

12
4)
96
0,41
4,80
11,3
12,3
1,52
1,41
1,60
1,48
6,5
-0,5
0,48
0,50
131
20
4)
153
0,41
6,10
18,1
19,5
0,955
0,884
0,999
0,925
7,8
-0,5
0,52
0,54
205
30
4)
225
0,41
7,40
26,6
28,8
0,647
0,599
0,684
0,633
9,6
-0,6
0,64
40
4)
308
0,41
8,60
60
4)
463
0,41
85
4)
418
0,51
Not
specified
0,66
1,00
303
45
36,5
39,4
0,473
0,438
0,500
0,463
11,1
-0,7
0,72
0,74
413
10,5
54,7
59,1
0,315
0,292
0,333
0,308
13,3
-0,8
0,80
0,82
614
13,2
78,7
85,0
0,219
0,203
0,232
0,215
15,3
-0,9
0,80
0,82
874
4) ISO 6722-1 intermediate cross-sections, use is permissible upon agreement with the development departments.
VW 60306-1:2013-04
Table A 4
Asymmetric conductor composition type B, version until 03/2005

Strand
Nominal
conductor
cross
section
Page 57
LV 112-1: 2013-04
Quantity
6)
Conductor
Cable
Diameter
d1
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
mm
mm
mm
mm
m/m
mm
mm
min.
max.
max.
max.
6,0
84
0,31
3,4
5,93
5,49
3,14
10,0
80
0,41
4,5
10,2
9,47
10,0
290
0,21
4,5
10,2
16,0
126
0,41
6,3
25,0
196
0,41
7,8
5)
Diameter
(7)
mm
Not
max.
min.
max.
min.
Cpk value
(based
7)
on s)
Concentricity
factor
2)
K
Weight
mm
g/m
min.
min.
max.
Tol.
min.
2,91
5,0
-0,6
0,64
0,66
68
1,82
1,69
6,5
0,80
0,82
127
9,47
1,82
1,69
6,5
-0,6
0,80
0,82
127
16,1
14,9
1,16
1,07
8,3
-0,6
0,80
0,82
182
25,1
23,2
0,743
0,688
10,4
-0,7
1,04
specified
min.
Test
wall
thickness
sP
1,33
1,06
45
279
35,0
276
0,41
9,0
35,3
32,7
0,527
0,488
11,6
-0,6
1,04
1,06
385
50,0
396
0,41
10,5
50,6
46,9
0,368
0,341
13,5
-0,6
1,20
1,22
534
70,0
360
0,51
12,5
71,9
66,6
0,259
0,240
15,5
-0,8
1,20
1,22
760
95,0
2850
0,21
14,8
95,0
88,0
0,196
0,181
18,0
-1,0
1,28
1,30
911
120,0
3 650
0,21
16,5
122
113
0,153
0,142
19,7
-1,0
1,28
1,30
1 146
1) Computed with a value of the specific electrical conductivity of 58,5 Sm/mm (conductivity for tinned cable as per DIN EN 13602: 56,8 Sm/mm), quality control through resistance measurement.
6) Other strand diameters and strand quantities can be used if they are agreed upon between the development departments and suppliers.
4)
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
Nominal
conductor
crosssection
Quantity
6)
Conductor
Cable
Diameter
d1
Twist
length
Cross-section
for bare
1)
conductors
Resistance at
20 C,
bare
strands
Outer
diameter
d2
Wall
thickness
of the
insulation
s
mm
mm
mm
mm
m/m
mm
mm
nom.
max.
max.
max.
4,0
56
0,31
6,0
84
10,0
5)
Diameter
7)
mm
Cpk value
(based
2)
on s)
Test
wall
thickness
sP
Concentricity
factor
3)
K
Weight
mm
g/m
min.
min.
max.
min.
max.
min.
max.
Perm.
dev.
min.
2,75
3,66
3,95
4,71
4,36
4,4
-0,4
0,64
0,66
47
0,31
3,4
5,49
5,93
3,14
2,91
5,0
-0,6
0,64
0,66
68
80
0,41
4,5
9,47
10,2
1,82
1,69
6,5
-0,6
0,80
0,82
127
16,0
126
0,41
5,5
14,9
16,1
1,16
1,07
7,5
-0,6
0,80
0,82
182
25,0
196
0,41
7,0
23,2
25,1
0,743
0,688
9,6
-0,8
1,04
35,0
276
0,41
8,3
32,7
35,3
0,527
0,488
10,9
-1,0
1,04
50,0
396
0,41
9,8
46,9
50,6
0,368
0,341
12,8
-1,0
1,20
1,22
534
70,0
360
0,51
11,6
66,6
71,9
0,259
0,240
14,6
-1,0
1,20
1,22
760
95,0
475
0,51
13,8
88,0
95,0
0,196
0,181
17,0
-1,2
1,28
1,30
911
120,0
608
0,51
15,1
113
122
0,153
0,142
18,3
-1,2
1,28
1,30
1 146
Not
specified
min.
1,33
1,06
1,06
45
4) Weight according to sample, table values are only approximate values and apply to PVC.
279
385
4)
VW 60306-1:2013-04
Table A 6
FL asymmetric conductor composition finely stranded/flexible type B until 12/2011

Strand
Nominal
conductor
crosssection
Page 59
LV 112-1: 2013-04
Quantity
5)
6)
Diameter
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
mm
mm
mm
m/m
mm
mm
8)
mm
mm
Cable
Diameter
d1
Test
wall
thickness
sP
Concentricity
factor
2)
K
Weight
mm
g/m
min.
min.
max.
min.
max.
min.
max.
Perm.
dev.
min.
2,75
3,66
3,95
4,71
4,36
4,4
-0,4
0,64
0,66
47
0,21
3,4
5,49
5,93
3,14
2,91
5,0
-0,6
0,64
0,66
68
305
0,21
4,5
9,47
10,2
1,82
1,69
6,5
-0,6
0,80
0,82
127
16,0
500
0,21
6,3
14,9
16,1
1,16
1,07
8,3
-0,9
0,80
0,82
182
25,0
790
0,21
7,8
23,2
25,1
0,743
0,688
10,4
-1,2
1,04
35,0
1090
0,21
9,0
32,7
35,3
0,527
0,488
11,6
-1,5
1,04
50,0
1600
0,21
10,5
46,9
50,6
0,368
0,341
13,5
-1,5
1,20
1,22
534
70,0
2175
0,21
12,5
66,6
71,9
0,259
0,240
15,5
-1,5
1,20
1,22
760
95,0
3000
0,21
14,8
88,0
95,0
0,196
0,181
18,0
-1,8
1,28
1,30
911
120,0
3 700
0,21
16,5
113
122
0,153
0,142
19,7
-1,8
1,28
1,30
1 146
nom.
max.
4,0
120
0,21
6,0
183
10,0
max.
Cpk value
(based
7)
on s)
max.
Not
specified
min.
1,33
1,06
1,06
45
7) For cables 0,75 mm2, a Cpk value 1,0 will be accepted in the transition period.
279
385
4)
Page 60
VW 60306-1:2013-04
LV 112-1: 2013-04
Table A 7
FLR asymmetric conductor composition finely stranded/flexible type B
Nominal
conductor
crosssection
Strand6)
Quantity Diameter
Conductor
Diameter
d1
Twist
length
Cross-section
for bare
conductors1)
mm
mm
mm
mm
max.
max.
max.
5)
8)
mm
nom.
max.
min.
Resistance
at 20 C,
bare
strands
Outer diameter
d2
m/m
mm
mm
min.
max.
min.
max.
min.
Perm. dev.
52,0
48,1
55,5
51,4
1,4
0,20
0,22
0,35
45
0,90
0,5
63
1,00
0,502
0,465
37,1
34,4
38,2
35,4
1,7
0,75
94
1,20
0,754
0,698
24,7
22,9
25,4
23,5
1,9
1,0
125
1,35
1,01
0,932
18,5
17,1
19,1
17,7
2,1
1,5
182
1,70
1,47
1,36
12,7
11,8
13,0
12,0
2,4
2,5
304
2,20
2,45
2,27
7,60
7,04
7,82
7,24
3,0
0,11
4,0
500
2,85
1,5
48
1,70
2,5
74
4,0
123
0,358
Not
0,332
min.
1,33
Test
wall
thickness
sP
Concentricity
factor
K2)
Weight4)
mm
g/m
min.
min.
0,22
4,5
0,24
6,6
-0,2
9,0
11
0,26
0,24
16
0,28
0,30
26
0,32
0,34
42
0,24
0,26
0,28
0,30
0,3
3,95
3,66
4,71
4,36
4,85
4,49
3,7
1,47
1,36
12,7
11,8
13,0
12,0
2,4
2,20
2,45
2,27
7,60
7,04
7,82
7,24
3,0
2,75
3,95
3,66
4,71
4,36
4,85
4,49
3,7
specified
Cable
Wall
Cpk value
thickness
(based
of the
on s)
insulation
s
Resistance
at 20 C,
tinned
strands
0,2
-0,3
0,32
45
16
26
0,34
42
0,32
0,34
61
3)
>1,0
6,0
184
3,4
5,93
5,49
3,14
2,91
3,23
2,99
4,3
10,0
318
4,5
10,2
9,47
1,82
1,69
1,85
1,71
5,8
-0,4
0,48
0,50
118
16,0
504
5,5
16,1
14,9
1,16
1,07
1,18
1,09
7,0
-0,5
0,52
0,54
174
25,0
784
7,0
25,1
23,2
0,743
0,688
0,757
0,701
8,8
-0,6
0,52
0,54
263
35,0
1106
8,3
35,3
32,7
0,527
0,488
0,538
0,498
10,5
-0,7
0,64
0,66
377
50,0
1582
10,5
50,6
46,9
0,368
0,341
0,375
0,347
12,6
-0,8
0,72
0,74
529
70,0
2240
12,5
71,9
66,6
0,259
0,240
0,264
0,244
14,9
-0,9
0,80
0,82
747
95,0
2 964
14,7
95,0
88,0
0,196
0,181
0,200
0,185
17,2
-1,0
0,88
0,90
983
0,21
3) For cables 0,75 mm2, a Cpk value 1,0 will be accepted in the transition period.
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
crosssection
Strand6)
Quantity5) Diameter
Conductor
Diameter
d1
Twist
length
Cross-section
for bare
1)
conductors
mm
mm
mm
mm
max.
max.
max.
8)
mm
nom.
max.
Resistance
at 20 C,
bare
strands
min.
max.
Cable
Wall
Cpk value
thickness
(based
of the
on s)
insulation
s
Resistance
at 20 C,
tinned
strands
Outer diameter
d2
m/m
mm
mm
Perm. dev.
min.
min.
max.
min.
Test
wall
thickness
sP
Concentricity
factor
K2)
Weight4)
mm
g/m
min.
min.
Intermediate cross-sections >10 mm

127)
381
7)
609
6,6
7)
903
8,2
20
30
0,21
4,8
7)
1 232
9,4
7)
1 841
7)
2 584
40
60
85
Not
specified
11,3
12,3
1,52
1,41
1,60
1,48
6,2
-0,5
0,48
0,50
132
18,1
19,5
0,955
0,884
0,999
0,925
8,1
-0,6
0,52
0,54
206
26,6
28,8
0,647
0,599
0,684
0,633
9,9
-0,7
0,64
0,66
307
3)
>1,0
45
36,5
39,4
0,473
0,438
0,500
0,463
11,4
-0,7
0,72
11,4
54,7
59,1
0,315
0,292
0,333
0,308
13,6
-0,8
0,80
0,82
620
13,5
78,7
85,0
0,219
0,203
0,232
0,215
15,8
-0,9
0,80
0,82
854
0,74
7) ISO 6722-1 intermediate cross-sections, use is permissible upon agreement with the development departments.
417
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/mm must be corrected to 58,0 Sm/mm.
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/mm 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/mm.
The outer individual wire diameters at and above 20,0 mm 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 mm) 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/mm. Then the maximum crosssection (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 m/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.
VW 60306-1:2013-04
Table A 8
Page 63
LV 112-1: 2013-04
Survey of wrapping tapes
Wrapping tape 1(film)
Temperature1)
Beiersdorf Tesa 4173
+105 C
Soft PVC
Acrylate
Beiersdorf Tesa 51618/51619
+105 C
PET nonwoven
Rubber
Coroplast 839
+125 C
PET fabric
Rubber
Coroplast 837 X
+150 C
PET fabric with smooth surface
Acrylate
Material
Adhesive
basis
Wrapping tape 2 (textile)
1) Temperature specification corresponds to long-term service temperature resistance (3 000 h of aging)
Page 64
LV 112-1: 2013-04
Table A 9
Serial
number
VW 60306-1:2013-04
Bill of materials, component compatibility

Designation
5)
4)
Material
Contact part, tab receptacle (tin plated)
CuSn, Sn
Contact part, circular receptacle

(tin plated)
CuFe2, Sn
Contact part, circular receptacle

(silver plated)
CuFe, Ag
Cable lug (tin plated)
CuSn, Sn
4
5
Single-wire seal
Silicone
Single-wire seal
Silicone
Circular connector housing with single-wire seal (25- PBT + 15% GF

way)
Circular receptacle housing

without single-wire seal (8-way)
PA 6.6
Socket housing with

single-wire seal (6-way)
POM
10
Heat shrink tubing with adhesive
Synthetic-rubber-based adhesive
11
Heat-shrink tubing
PE modified
12
Insulating hose
PVC as per DIN EN 60684-3
TPU insulating hose
TPU
14
Braided sleeving (Revitex VSC)
Silicone-coated glass braid
15
Corrugated tube
PP modified
16
Cable tie (assembled with force-free contact of cable PA66

tie) and corrugated tube
17
Joint connector sleeving
Thermoplastic melting material based on

polyamide
18
Longitudinal water sealing 3M butyl (to be installed

with grommet)
Butyl rubber
19
Grommet
EPDM, Shore A60
20
Wrapping tape Certoplast 608
PVC tape, acrylate adhesive
21
Wrapping tape Coroplast Y512
PVC tape (polyolefin), acrylate adhesive
22
Wrapping tape Coroplast 837 X
PET fabric, acrylate adhesive
23
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)
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
13
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.
VW 60306-1:2013-04
Table A 10
Bill of materials: Component compatibility for cables of temperature class

B* +105 C
The material is decisive for testing.
Test cable 0,35 mm and 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, 0-0928985-2
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, 0-082890-1
PBT+15% GF circular connector housing, Tyco, 20963295-1
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, 6435641
Silicone coated glass braid, braided sleeving,
Relats, VSR 25 NW6
PP modified, corrugated tube,
Frnkische Rohrwerke, Uniwell
PA 66, cable tie, Hellermann, 111-019 50 PA 66,
corrugated tube, Frnkische 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)
Connector
housing
Seals
Cable
Components
Test temperature
+105 C
5 sample
wiring
harnesses
each
Contacts/
cable lugs
e.g.,
PVC
Page 65
LV 112-1: 2013-04
5
6
1
0
No. 1
No. 2
No. 3
No. 4
No. 5
5
1
6
No. 6
No. 7
1
1
No. 8
No. 9
1
1
No. 10
No. 11
No. 12
No. 13
No. 14
5
5
1
1
1
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
No. 21
No. 22
1
1
No. 23a
ETFE, cables (class D)
No.
23a1
X-PE, cables (class D)
No. 23b
PP, cables (class C)
No. 23c
X-PE, cables (class C)
No. 23d
PVC, cables (class B 105 C)
No. 23e
TPS, cables (class C)
No. 23f
1
1
Page 66
LV 112-1: 2013-04
Table A 11

C +125 C
5 sample
wiring
harnesses
each
5
6
Test temperature
+125 C
+105 C
1 1
3 4 5 6 7 8 9 0 1

No. 1
No. 4
5
1
Silicone, single wire seal, Kostal, 108 00 44452 3

PBT+15 % GF circular connector housing, Tyco, 20963295-1
DSG Canusa, 621 0000 090
HC, 2125013
Sahlberg, 6435641
Relats, VSR 25 NW6
PP modified, Corrugated tube,
sleeving,
EPDM Shore A60, grommet,
WOKO, 02 5539
No. 5
No.
23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
Components
Connector
housing
Seals
Cable
Contacts/
cable lugs
e.g.,
XPE
VW 60306-1:2013-04
No. 2
No. 3
No. 6
No. 7
1
1
No. 8
No. 9
5
6
1
1
1
No. 10
No. 11
No. 12
No. 13
No. 14
No. 15
No. 16
1
1
No. 17
No. 18
No. 19
No. 20
No. 21
No. 22
1
1
No. 23a
1
1
1
VW 60306-1:2013-04
Table A 12
e.g.,
XPE
Page 67
LV 112-1: 2013-04
Bill of materials: Component compatibility for cables of temperature

class D +150 C
5 sample
wiring
harnesses
each
1
2

No. 1

DSG Canusa, 621 0000 090
HC, 2125013
Sahlberg, 6435641
Relats, VSR 25 NW6
PP modified, Corrugated tube,
sleeving,
WOKO, 02 5539
No. 5
No. 23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
Components
Connector
housing
Seals
Cable
Contacts/
cable lugs
Test temperature
+125 C
+105 C
1 1
3 4 5 6 7 8 9 0 1
+150 C
5
1
No. 2
No. 3
No. 4
No. 6
5
6
1
5
6
1
6
6
6
1
No. 7
No. 8
No. 9
No. 10
No. 11
No. 12
No. 13
No. 14
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
1
1
No. 21
No. 22
1
1
No. 23a
1
1
Page 68
LV 112-1: 2013-04
Table A 13
e.g.,
VW 60306-1:2013-04

F +200 C
5 sample
wiring
harnesses
each
silicone
1
2

No. 1

DSG Canusa, 621 0000 090
HC, 2125013
Sahlberg, 6435641
Relats, VSR 25 NW6
sleeving,
WOKO, 02 5539
No. 5
No. 23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
Components
Connector
housings
Seals
Cable
Contacts/
cable lugs
Test temperature
+125 C
+105 C
1 1
3 4 5 6 7 8 9 0 1
+150 C
5
1
4
1
No. 2
No. 3
No. 4
No. 6
5
6
1
5
6
1
6
6
6
1
No. 7
No. 8
No. 9
No. 10
No. 11
No. 12
No. 13
No. 14
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
1
1
No. 21
No. 22
No. 23a
1
1
1
1
VW 60306-1:2013-04
Table A 14
e.g.,
PVC
Page 69
LV 112-1: 2013-04

B* +105 C (large cross-sections)
Test temperature
+105 C
5 sample
wiring
harnesses
each
1 1
1 2 3 4 5 6 7 8 9 0 1
Contacts/
cable lugs
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
No. 4
1 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)
NA
DSG Canusa, 621 191 510 5C
DSG Canusa, 6-1,4/1,45TR.AL50mm 6240060011G
No. 5
2 2
PVC, insulating hose, Tyco NETM-2000-NR-10-0
No. 12
Components
Connector
housing
Test cable = 16 mm , (1x cross-section)
Seals
Cable

Sahlberg, 303-109 14x0,6x15,6 1185
Silicone-coated glass braid, braided sleeving,
Federal Mogul Textalu 1202 5-55 ALU
NA
Hellermann, Tyton 460-05039
WOKO, 02 5539
No. 6
No. 7
1
1
No. 8
No. 9
No. 10
No. 11
No. 13
No. 14
1
1
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
No. 21
No. 22
1
1
No. 23a
No.
23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
Page 70
LV 112-1: 2013-04
Table A 15
e.g.,
XPE
Components
Connector
housing
Seals
Contacts/
cable lugs
Cable
VW 60306-1:2013-04

C +125 C (large cross-sections)
5 sample
wiring
harnesses
each
Test temperature
+125 C
+105 C
1 1
1 2 3 4 5 6 7 8 9 0 1

CuSn, Sn flat contact, (order no. N.102.146.02), with
SEAL
NA
Silicone, single-wire seal (order no. 357 972 744 B)
Veritas no. F18363
NA
PA 6.6 fuse adapter (order no. 3A0 937 501)
NA
DSG Canusa, 621 191 510 5C
No. 1
No. 12

Sahlberg, 303-109 14x0,6x15,6 1185
NA
WOKO, 02 5539
No. 2
No. 3
No. 4
1 1
No. 5
2 2
No. 6
No. 7
1
1
No. 8
No. 9
No. 10
No. 11
1
1
No. 13
No. 14
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
No. 21
No. 22
1
1
No. 23a
No.
23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
1
1
1
VW 60306-1:2013-04
Table A 16
e.g.,
XPE
Page 71
LV 112-1: 2013-04

D +150 C (large cross-sections)
5 sample
wiring
harnesses
each
Connector
housing
Seals
Contacts/
cable lugs
Cable

seal AMP no. 962 832.1
NA
Veritas no. F18363
NA
NA
DSG Canusa, 621 191 510 5C
Components
Test temperature
+125 C
+105 C
1 1
3 4 5 6 7 8 9 0 1
+150 C

Sahlberg, 303-109 14x0,6x15,6 1185
NA
WOKO, 02 5539
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
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
1
1
No. 21
No. 22
1
1
No. 23a
No.
23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
1
1
Page 72
LV 112-1: 2013-04
Table A 17
e.g.,
XPE
VW 60306-1:2013-04

F +200 C (large cross-sections)
5 sample
wiring
harnesses
each
Connector
housing
Seals
Contacts/
cable lugs
Cable

NA
Veritas no. F18363
NA
NA
DSG Canusa, 621 191 510 5C
Components
Test temperature
+125 C
+105 C
1 1
3 4 5 6 7 8 9 0 1
+150 C

Sahlberg, 303-109 14x0,6x15,6 1185
NA
WOKO, 02 5539
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
1
1
No. 15
No. 16
No. 17
No. 18
No. 19
No. 20
1
1
No. 21
No. 22
No. 23a
No.
23a1
No. 23b
No. 23c
No. 23d
No. 23e
No. 23f
1
1
1
1

Vw 60306-1-2013 汽车用低压电线 第1部分 单芯无屏蔽电缆

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VW 60306-1

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

Volkswagen Standard number

PAG Standard number

VW 60306-1 supersedes VW 60306, issue 2005-11.

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

Always use the latest version of this standard.

The Standards department

Dr. Liane Wiegel

Tel.: +49 5361 9 36678

Tel.: +49 841 89 34925

EKDV/4 Dirk Beinker

Tel.: +49 711 911 82433

Tel.: +49 5361 9 32438

Deviating and supplementary Volkswagen AG specifications

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

cable, low-voltage cable, copper cable

Electric Wiring in Motor Vehicles

Insulation abrasion resistance ......................................................................................... 30

Voltage class designation as per ISO 6469-3.

Presentation of Numerical Data

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

Road Vehicles, Low Voltage Cables; Type Abbreviation

Steel Wire for Mechanical Springs Part 1: Patented Cold Drawn

Electric Cables Low Voltage Energy Cables of Rated Voltages up to

Flexible Insulating Sleeving Part 3: Specifications for Individual

Insulating and Sheathing Materials of Electric Cables Common Test

Insulating and Sheathing Materials of Electric Cables Common Test

Insulating and Sheathing Materials of Electric and Optical Cables

Insulating and Sheathing Materials of Electric and Optical Cables

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

DIN EN ISO 1183-1

Plastics Methods for Determining the Density of Non-Cellular

DIN EN ISO 1628-2

Plastics Determination of the Viscosity of Polymers in Dilute

DIN EN ISO/IEC 17025

General Requirements for the Competence of Testing and Calibration

DIN ISO 1431-1

Rubber, Vulcanized or Thermoplastic Resistance to Ozone

Rubber, Vulcanized or Thermoplastic Determination of Tear

Rubber, Vulcanized or Thermoplastic Determination of Hardness

Standard Atmospheres for Conditioning and/or Testing; Specifications

Electrically Propelled Road Vehicles Safety Specifications Part 3:

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

Plastics Differential Scanning Calorimetry (DSC) Part 1: General

Plastics Thermogravimetry (TG) of Polymers General Principles

Road Vehicles Round, Sheathed, 60 V and 600 V Screened and

Global Automotive Declarable Substance List

VDA Volume 6, Part 1

Quality Management in the Automotive Industry Part 1: QM System

List of Chemicals for Compatibility Testing

Determining Current Capacity of Vehicle Cables

High-Frequency Cables for Motor Vehicles Coaxial Cables

High-Frequency Cables for Motor Vehicles That Are Not Individual

Dimensions and cable structure

Structure of the code

The cable code is based on DIN 76722.

Strand Cu-ETP1, CW003A or Cu-ETP, CW004A as per DIN EN 13602.

Product designation example

Explanation of the example given above:

Vw 60306-1-2013 汽车用低压电线第1部分单芯无屏蔽电缆

Vw 60306-1-2013 汽车用低压电线第1部分单芯无屏蔽电缆