VW 60306 1 en

Group standard VW 60306-1
Issue 2018-09
Class. No.: 8ME30
Descriptors: cable, copper cable, low-voltage cable
Electrical Cables in Motor Vehicles

Part 1: Copper Cable; Single-Core, Unshielded
Previous issues
VW 60306-1: 2013-04
Changes
The following changes have been made to VW 60306-1: 2013-04:
– Standard completely revised
Contents
Page
1 Scope ......................................................................................................................... 3
2 Symbols and abbreviations ........................................................................................ 3
3 General ...................................................................................................................... 3
4 Dimensions and cable composition ............................................................................ 3
5 Composition of the code designations ....................................................................... 4
6 Materials ..................................................................................................................... 4
6.1 Conductor, bare ......................................................................................................... 4
6.2 Conductor, tinned ....................................................................................................... 5
6.3 Conductor, other surfaces .......................................................................................... 6
6.4 Insulation .................................................................................................................... 6
7 Marking and delivery conditions ................................................................................. 7
7.1 Container marking ...................................................................................................... 7
7.2 Manufacturer's code ................................................................................................... 7
7.3 Color/color coding ...................................................................................................... 7
7.4 Delivery conditions ..................................................................................................... 7
7.4.1 Visual inspection ........................................................................................................ 7
7.4.2 Test for insulation faults ............................................................................................. 8
Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature. Page 1 of 49
The English translation is believed to be accurate. In case of discrepancies, the German version controls.
Technical responsibility The Standards department

EEKK/2 Dr. Thomas Hänsel Tel.: +49 5361 9 40405
I/EE-24 Jonathan Leiteritz Tel.: +49 841 89-35448 K-ILI/5 Dirk Beinker K-ILI
EEB2 Andreas Müller Tel.: +49 711 911 82433 Tel.: +49 5361 9 32438 Uwe Wiesner
All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.
© Volkswagen Aktiengesellschaft VWNORM-2018-02
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VW 60306-1: 2018-09
7.4.3 Packaging units .......................................................................................................... 8

8 General test conditions .............................................................................................. 9
8.1 Test matrix ................................................................................................................. 9
8.2 Test atmosphere ...................................................................................................... 16
8.3 Specimens ............................................................................................................... 16
8.4 Rounding of numerical values .................................................................................. 17
9 Tests ........................................................................................................................ 17
9.1 Cable composition inspection .................................................................................. 17
9.1.1 Cable outer diameter and minimum wall thickness .................................................. 17
9.1.2 Nominal conductor diameter .................................................................................... 17
9.1.3 Conductor resistance ............................................................................................... 17
9.1.4 Insulation strippability factor ..................................................................................... 17
9.2 Physical and chemical properties of the insulation .................................................. 19
9.2.1 Density ..................................................................................................................... 19
9.2.2 Thermal stability for PVC ......................................................................................... 19
9.2.3 Determining the tensile strength and elongation at tear ........................................... 19
9.2.4 Tear propagation resistance .................................................................................... 19
9.2.5 Determining the degree of cross-linking ................................................................... 21
9.3 Mechanical properties in as-received condition ....................................................... 21
9.3.1 Insulation strippability/secure fit of conductor .......................................................... 21
9.3.2 Insulation abrasion resistance .................................................................................. 21
9.3.3 Bending force of the cable ....................................................................................... 22
9.3.4 Insulation notch strength .......................................................................................... 23
9.4 Flame retardance ..................................................................................................... 24
9.5 Electrical properties in as-received condition ........................................................... 25
9.5.1 Volume resistivity ..................................................................................................... 25
9.5.2 30-minute dielectric strength .................................................................................... 25
9.5.3 1-minute dielectric strength measurement (only after exposure to load) ................. 25
9.6 Mechanical and electrical properties after exposure to mechanical, thermal, or
chemical load ........................................................................................................... 25
9.6.1 Stress test ................................................................................................................ 25
9.6.2 Insulation shrinkage under heat ............................................................................... 26
9.6.3 Compressive strength of the insulation under heat .................................................. 27
9.6.4 Determining the derating curve ................................................................................ 27
9.6.5 Thermal stability in wound state ............................................................................... 27
9.6.6 Thermal overload ..................................................................................................... 28
9.6.7 Winding test after short-term aging (240 h) .............................................................. 28
9.6.8 Long-term aging (3 000 h) ........................................................................................ 29
9.6.9 Winding test at low temperature (-40 °C) ................................................................. 31
9.6.10 Impact test at low temperature (-15 °C) ................................................................... 31
9.6.11 Cable marking resistance to wiping ......................................................................... 31
9.6.12 Bending fatigue strength .......................................................................................... 31
9.6.13 Kink test ................................................................................................................... 31
9.6.14 Electrical properties with aging in water ................................................................... 32
9.6.15 Damp heat, constant (hydrolysis test) ...................................................................... 33
9.6.16 Ozone resistance ..................................................................................................... 33
9.7 Mycological test ........................................................................................................ 34
9.8 Compatibility tests .................................................................................................... 34
9.8.1 Resistance to chemicals as per ISO 6722-1 ............................................................ 34
9.8.2 Resistance to chemicals .......................................................................................... 34
10 Environmental protection and safety ........................................................................ 36
11 Applicable documents .............................................................................................. 36
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12 Bibliography ............................................................................................................. 38
Appendix A ................................................................................................................................ 39
1 Scope
This standard describes the requirements and tests for single-core, unshielded automotive cables
for a nominal-voltage range ≤ 60 V DC (voltage class 1 as per table 1).
The aspects to be tested for the respective requirements must be taken from section 8.1.
Table 1 – Voltage classes

Direct current
Alternating current (AC)
Voltage classes (DC)
Vrms Vpp VDC
Low voltage 1 (Aa)) ≤ 30 V ≤ 42 V ≤ 60 V
High voltage 2 ≤ 600 V ≤ 849 V ≤ 1 000 V
High voltage 3 (Ba)) ≤ 1 000 V ≤ 1 414 V ≤ 1 500 V
a) Voltage class designation as per ISO 6469-3
This table was created on the basis of ISO 6469-3. Voltage class 2 is not covered in ISO 6469-3.
2 Symbols and abbreviations

ATR Attenuated total reflectance
BMG Build sample approval
DSC Differential scanning calorimetry
TGA Thermogravimetric analysis
Tmax Maximum long-term service temperature
Tmin Minimum long-term service temperature
VDC Direct-current voltage
Vpp Peak-to-peak voltage value
Vrms Root-mean-square voltage value
3 General
The tests in this standard must be performed in an independent institute accredited as per
DIN EN ISO/IEC 17025.
4 Dimensions and cable composition

The dimensions and cable composition (see figure 1) must be taken from appendix A. Unspecified
details must be selected as appropriate as per ISO 6722-1.
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Legend
1 Conductor
2 Insulation
d1 Conductor diameter
d2 Outer diameter
t Minimum wall thickness of the insulation
Figure 1 – Cable composition
5 Composition of the code designations

The cable designations are based on DIN 76722.
Example 1:
Designation for an unshielded low-voltage cable (FL) with thin-walled insulation (R), code for radia‐
tion cross-linked PE insulation material (2X) as per DIN 76722, a nominal conductor cross section
of 1.5 mm2 (1,5), (/), a maximum strand diameter of 0.33 mm (0,33), with tinned strands (Sn), a
cable composition of type A (-A), and a maximum long-term service temperature Tmax = +125 °C
(T125):
FLR2X 1,5/0,33Sn-A T125
Example 2:
Designation for an unshielded low-voltage cable (FL), code for silicone insulation material (2G) as
per DIN 76722, a nominal conductor cross section of 35 mm2 (35), (/), with bare strands of max.
0.21 mm (0,21), a cable composition of type B (-B), and a maximum long-term service temperature
Tmax = +200 °C (T200):
FL2G 35/0,21-B T200
6 Materials
The properties as per section 6.1, section 6.2, and section 6.3 must be guaranteed by the manu‐
facturer and apply to the unstranded state.
6.1 Conductor, bare

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

Elongation at
Diameter (nominal dimen‐ Tensile
Designations break At or
sion) strength Rm
A200 mm
Single- and
Material State in mm in N/mm2 multi-core
wire in %
Single-core Multi-core
Code Number greater than to minimum minimum
wire wire
A010 A008 0.04 0.08 10
A015 A013 0.08 0.16 15
A021 A019 0.16 0.32 21
Cu-ETP1 CW003A A022 A020 0.32 0.50 22

200
Cu-ETP CW004A A024 A022 0.50 1.00 24
A026 A024 1.00 1.50 26
A028 A026 1.50 3.00 28
A033 − 3.00 5.00 33
Table 3 – Product designation example

Diameter
Material State desig‐ Surface fin‐ (nominal di‐ Delivery
Designation Standard
designation nation ish mension) in form
mm
DIN EN 136
Wire Cu-ETP-1 A022 P S0,4 Y
02
Explanations for the example in table 3 above:

State designation: A = annealed
(R = hard drawn)
Surface finish: P = not tinned
(A, B = tinned)
Nominal dimension for diameter: S = single-core wire
(M = multi-core wire)
Delivery form: Y = coil
(Z = spool)
6.2 Conductor, tinned

The surface finish for the tinning must be as per section "Surface finish" in DIN EN 13602.
The tinning must be evaluated by measuring the thickness of the unalloyed coating as per table
"Coating requirements" in DIN EN 13602:
– Type A: For strand diameters ≤ 0.2 mm
– Type B: For strand diameters > 0.2 mm
Tinned Cu conductor: See table 4.
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Table 4 – Tinned Cu conductor properties

Elongation at
Diameter (nominal dimen‐ Tensile
Designations break At or
sion) strength Rm
A200 mm
Single- and
Material State in mm in N/mm2 multi-core
wire in %
Single-core Multi-core
Code Number greater than to minimum minimum
wire wire
A007 A005 0.04 0.08 7
A013 A011 0.08 0.16 13
A019 A017 0.16 0.32 19
Cu-ETP1 CW003A A020 A018 0.32 0.50 20

200
Cu-ETP CW004A A022 A020 0.50 1.00 22
A024 A022 1.00 1.50 24
A026 − 1.50 3.00 26
A031 − 3.00 5.00 31
6.3 Conductor, other surfaces

Other surfaces (e.g., silver plated) are permissible upon agreement.
6.4 Insulation
The minimum and maximum long-term service temperatures (Tmin and Tmax) for a load duration of
3 000 h must be selected according to the temperature classes (without mechanical load and not
additive) as per table 5 or in exceptional cases as per the drawing.
Table 5 – Temperature classes

Long-term service Short-term tempera‐ Thermal overload tem‐
Class as per temperature ture perature
Temperature class
ISO 6722-1 (3 000 h) (240 h) (6 h)
Tmin °C to Tmax °C (Tmax + 25) °C (Tmax + 50) °C
A T85 -40 to +85 +110 ±3 +135 ±3
B T100 -40 to +100 +125 ±3 +150 ±3
B (105) T105 -40 to +105 +130 ±3 +155 ±3
C T125 -40 to +125 +150 ±3 +175 ±3
D T150 -40 to +150 +175 ±3 +200 ±3
E T175 -40 to +175 +200 ±3 +225 ±4
E (180) T180 -40 to +180 +205 ±4 +230 ±4
F T200 -40 to +200 +225 ±4 +250 ±4
G T225 -40 to +225 +250 ±4 +275 ±4
H T250 -40 to +250 +275 ±4 +300 ±4
Txyz -40 to xyz xyz + 25 xyz + 50
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In special cases, Txyz enables the classification of intermediate temperatures (e.g., temperature
class T135).
7 Marking and delivery conditions
7.1 Container marking

The marking of containers must conform to VDA Volume 6 Part 1 and be agreed upon between
purchaser and supplier.
7.2 Manufacturer's code

The product must be marked with a manufacturer's code, e.g., by printing or embossing (raised
embossment). Adherence to the minimum wall thicknesses must always be ensured in the proc‐
ess. The manufacturer's code is repeated continuously at a spacing that creates an unprinted area
of 200 mm.
For cable cross sections ≤ 0.35 mm2, a different marking can be arranged in agreement with the
appropriate departments.
The marking must clearly indicate a minimum of the following information:
– Cable manufacturer (written out or code letter combination with max. 3 letters)
– Place of manufacture
– Temperature class
The individual letter combinations must have space in between them. Examples:
– COMPANY P T150 (COMPANY: Manufacturer, P: Place of manufacture, T150: Temperature
class)
– GG A T125 (GG: Manufacturer's code, A: Place of manufacture, T125: Temperature class)
Exception:
PVC cables with a temperature class of T105 do not have to be marked with "T105".
7.3 Color/color coding

The colors of the aged (6 h, 240 h, and 3 000 h) and unaged cables must be documented in one
photo (see also section 9.6.6, section 9.6.7, and section 9.6.8). An evaluation of the color must be
indicated under the subitem "Color" in table 8 and table 9.
Only the most noticeable discolorations must be documented as examples for each compound.
The color coding must be based on DIN 72551-7 in German or English.
Different color codes are permissible upon agreement.
7.4 Delivery conditions
7.4.1 Visual inspection

The insulation must not have any nodes, cracks, blisters, or inclusions and must be strippable us‐
ing standard commercial stripping machines without leaving a residue and without damaging the
conductor.
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7.4.2 Test for insulation faults

As per ISO 6722-1
After the spark test, the cables must be tested according to table 6. The dwell time of the cable in
the electrical field must be selected such that each cable section is loaded with at least 18 voltage
spikes. When using tubular electrodes, the inside diameter of the electrode must be matched to the
cable diameter.
Table 6 – Voltage values/voltage class 1

Nominal conductor cross
Test voltage in kV
section in mm2
< 0.5 3
≥ 0.5 5
The emphasis for inspection must be placed on production inspection measures. The test plans
and measured value documentation for the production and pre-delivery inspections must include
information on the measuring equipment used, frequency of measurements, desired values, and
tolerances for all criteria that are important to proper functioning.
Flaws must be handled as per section 7.4.3.1.
7.4.3 Packaging units

The packaging units must be agreed upon between the purchaser and the manufacturer. An exam‐
ple of such an agreement can be seen in table 7.
The cables must be delivered in drums free of damage or in coils. The following conditions must be
adhered to:
– The cable must be delivered in a drum or coil. The ends must be arranged such that they are
accessible, do not disrupt processing, and cannot be damaged during transport.
– The cable must support being pulled out of the drum at a speed of 200 m/min or out of the coil
at 420 m/min in intermittent operation on cut-to-length machines.
Table 7 – Example delivery quantities for NPS 400

FLR cables
Nominal cable cross sec‐
Delivery quantity in m
tion in mm2
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
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7.4.3.1 Partial lengths, joints, flaws

In exceptional cases, a specified length can be composed of partial lengths and must be separate‐
ly identified as such:
– Joints between the partial lengths must not exceed the diameter of the cable and must not rup‐
ture during processing.
– Joints and flaws must be identified by 30 to 100 mm of stripped insulation.
Maximum permissible quantities per drum or coil at nominal cable cross section:
0.35 mm2, 0.5 mm2, 0.75 mm2 3 joints or flaws
1.0 mm2, 1.5 mm2, 2.5 mm2 2 joints
≥ 4.0 mm 2
1 joint
7.4.3.2 Delivery unit marking

The coil or drum marking must be applied such that it is always visible, even when packed on pal‐
lets.
Traceability must be ensured.
The marking must contain the following data:
– Cable designation as per section 5
– Manufacturer
– Manufacturer's number
– Date of manufacture
– Compound number (optional)
– Cable length
– Position of joints and flaws
8 General test conditions
8.1 Test matrix

For test matrix, see table 8.
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Table 8 – Test matrix
Modification of raw materials
Requalification testing
Location testing
Release testing
Process testing
Special testing
Section
Test
A2
Test scope A1 B2 B1 C1 D E F
C2
Section 7.3 Color X X X X
Section 7.4.1 Visual inspection X
Section 7.4.2 Test for insulation faults X
Section 9.1 Cable composition inspection
Cable outer diameter and minimum wall
Section 9.1.1 X X X X X X
thickness
Section 9.1.2 Nominal conductor diameter X X X X X X
Section 9.1.3 Conductor resistance X X X X X X
Section 9.1.4 Insulation strippability factor X X X X
Section 9.2 Physical and chemical properties of the insulation
Section 9.2.1 Density a) X X X
Section 9.2.2 Thermal stability for PVC X X X X X
Determining the tensile strength and elon‐
Section 9.2.3 X X X X X
gation at tear
Tear propagation resistance/testing on
Section 9.2.4.1 X X X X
sheet
Tear propagation resistance/testing on ca‐
ble
Section 9.2.5 Determining the degree of cross-linking X X X X X X
Section 9.3 Mechanical properties in as-received condition
Insulation strippability/secure fit of conduc‐
tor
Section 9.3.2 Insulation abrasion resistance X X X X X
Section 9.3.3 Bending force of the cable X X X X
Section 9.3.4 Insulation notch strength X
Section 9.4 Flame retardance X X X
Section 9.5 Electrical properties in as-received condition
Section 9.5.1 Volume resistivity of the insulation a) X
Section 9.5.2 30-minute dielectric strength X
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Location testing
Release testing
Process testing
Special testing
Section
Test A2
C2
Mechanical and electrical properties after exposure to mechanical, thermal, or
Section 9.6
chemical load
Section 9.6.1 Stress test b) X X X X
Section 9.6.2 Insulation shrinkage under heat X X X X X X
Compressive strength of the insulation un‐
Section 9.6.3 X
der heat
Section 9.6.4 Derating curve X X c)
Section 9.6.5 Thermal stability in wound state b) X
Section 9.6.6.1 Thermal overload Tmax + 50 °C X X
Section 9.6.6.2 Extreme thermal overload Tmax + x °C/1 h X
Section 9.6.7 Winding test after short-term aging (240 h) X X X X X
Section 9.6.8 Long-term aging (3 000 h)
Section 9.6.8.1 Winding test after long-term aging X
Minimum permissible radius for static rout‐
Section 9.6.8.2 X
ing
Section 9.6.9 Winding test at low temperature (at -40 °C) X X X X X
Section 9.6.10 Impact test at low temperature (-15 °C) X
Section 9.6.11 Cable marking resistance to wiping a) X
Section 9.6.12 Bending fatigue strength X
Section 9.6.13 Kink test b) X
Section 9.6.14 Electrical properties with aging in water X
Section 9.6.15 Damp heat, constant (hydrolysis test) X
Section 9.6.16 Ozone resistance a) X
Section 9.7 Mycological test a) X
Section 9.8 Compatibility tests
Resistance to chemicals as per
Section 9.8.1 X
ISO 6722-1
Section 9.8.2 Resistance to chemicals X
a) The test is only carried out on the largest cable cross section for each compound.
b) It is not to be carried out for cable cross sections > 6 mm2.
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c) Derating except C2
Documentation:
The documentation for tests as per cases A, B, C, and D must be sent to the purchaser. For ca‐
ses E and F, the cable manufacturer is responsible for documentation and archiving. Submission
to the purchaser is necessary only upon request.
Test scope/general specifications:
The reduced test scopes are only permissible if the underlying issued release with the complete
test scope is no older than 10 years.
If an issued release is older than 10 years, a requalification as per test scope A – in substantiated
cases as per test scope D – must be carried out in agreement with the appropriate department. In
this case, the smallest cross section (e.g., 0.35 mm2) of each compound is tested.
Other agreements can be reached with the appropriate department.
Test scope A1/A2:
Testing for the main place of manufacture or introduction of the following:
– New cables
– Existing cables using a new compound
The procedure in the case of minor compound modifications must be agreed upon with the appro‐
priate departments.
Test scope B1/B2:
Identical compound, different location of same cable manufacturer
Test scope C1/C2:
When the compound composition is unmodified and at least one of the following applies:
– Chemically identical raw materials supplied by different subcontractors
– Change to place of manufacture for compound
Test scope D:
Scope of the tests performed for requalification to renew the BMG release. After no more than
10 years, agreement must be reached with the appropriate department as to whether requalifica‐
tion is necessary.
Test scope E:
Recommended in-process testing (e.g., batch-related or continuously). The supplier is responsible
for process reliability.
Test scope F:
Special test scope: Only performed upon request by the appropriate department
Cable cross section allocation:
Test scope A1/B1/C1: These are performed for cable cross sections of
0.35 mm2, 0.5 mm2, 1.5 mm2, 2.5 mm2, 4.0 mm2, and
16 mm2.
Reduced test scope A2/B2/C2: All other cable cross sections
Cable composition:
For cable cross sections of 0.5 – 2.5 mm2, the following applies:
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Test results for the asymmetric copper-core composition – B can be used for the symmetric cop‐
per-core composition – A in agreement with the appropriate department.
Test matrix for single-core cables that are only used in sheathed cables: See table 9.
Table 9 – Test matrix for single-core cables that are only used in sheathed cables
Location testing
Release testing
Process testing
Special testing
Section
Test
A2
C2
Section 7.3 Color X X X X
Section 7.4.1 Visual inspection X
Section 7.4.2 Test for insulation faults X
Section 9.1 Cable composition inspection
Cable outer diameter and minimum wall
thickness
Section 9.1.2 Nominal conductor diameter X X X X X X
Section 9.1.3 Conductor resistance X X X X X X
Section 9.1.4 Insulation strippability factor X X
Section 9.2 Physical and chemical properties of the insulation
Section 9.2.1 Density a) X X X
Section 9.2.2 Thermal stability for PVC X X X X X
Determining the tensile strength and elon‐
Section 9.2.3 X X X X X
gation at tear
Tear propagation resistance/testing on
sheet
Tear propagation resistance/testing on ca‐
ble
Section 9.2.5 Determining the degree of cross-linking X X X X X X
Section 9.3 Mechanical properties in as-received condition
Insulation strippability/secure fit of conduc‐
tor
Section 9.3.2 Insulation abrasion resistance
Section 9.3.3 Bending force of the cable
Section 9.3.4 Insulation notch strength
Section 9.4 Flame retardance
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VW 60306-1: 2018-09
Location testing
Release testing
Process testing
Special testing
Section
Test
A2
C2
Section 9.5 Electrical properties in as-received condition
Section 9.5.1 Volume resistivity of the insulation a) X
Section 9.5.2 30-minute dielectric strength X
Mechanical and electrical properties after exposure to mechanical, thermal, or
Section 9.6
chemical load
Section 9.6.1 Stress test b) X X X X
Section 9.6.2 Insulation shrinkage under heat X X X X X X
Compressive strength of the insulation un‐
Section 9.6.3 X
der heat
Section 9.6.4 Derating curve
Section 9.6.5 Thermal stability in wound state b)
Section 9.6.6.1 Thermal overload Tmax + 50 °C X X
Section 9.6.6.2 Extreme thermal overload Tmax + x °C/1 h X
Section 9.6.7 Winding test after short-term aging (240 h) X X X X X
Section 9.6.8 Long-term aging (3 000 h)
Section 9.6.8.1 Winding test after long-term aging X
Minimum permissible radius for static rout‐
Section 9.6.8.2 X
ing
Section 9.6.9 Winding test at low temperature (at -40 °C) X X X X X
Section 9.6.10 Impact test at low temperature (-15 °C)
Section 9.6.11 Cable marking resistance to wiping a)
Section 9.6.12 Bending fatigue strength
Section 9.6.13 Kink test b) X
Section 9.6.14 Electrical properties with aging in water X
Section 9.6.15 Damp heat, constant (hydrolysis test) X
Section 9.6.16 Ozone resistance a) X
Section 9.7 Mycological test a) X
Section 9.8 Compatibility tests
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Location testing
Release testing
Process testing
Special testing
Section
Test A2
C2
Resistance to chemicals as per
Section 9.8.1 X
ISO 6722-1
Resistance to chemicals and harnessing
Section 9.8.2
tapes
a) The test is only carried out on the largest cable cross section for each compound.
b) It is not to be carried out for cable cross sections > 6 mm2.
Documentation:
The documentation for tests as per cases A, B, C, and D must be sent to the purchaser. For ca‐
ses E and F, the cable manufacturer is responsible for documentation and archiving. Submission
to the purchaser is necessary only upon request.
Test scope/general specifications:
The reduced test scopes are only permissible if the underlying issued release with the complete
test scope is no older than 10 years.
If an issued release is older than 10 years, a requalification as per test scope A – in substantiated
cases as per test scope D – must be carried out in agreement with the appropriate department. In
this case, the smallest cross section (e.g., 0.35 mm2) of each compound is tested.
Other agreements can be reached with the appropriate department.
Test scope A1/A2:
Testing for the main place of manufacture. Introduction of the following:
– New cables
– Existing cables using a new compound
The procedure in the case of minor compound modifications must be agreed upon with the appro‐
priate departments.
Test scopes B through E require a prior release as per A1.
Test scope B1/B2:
Identical compound, different location of same cable manufacturer
Test scope C1/C2:
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When the compound composition is unmodified and at least one of the following applies:
– Chemically identical raw materials supplied by different subcontractors
– Change to place of manufacture for compound
Test scope D:
Scope of the tests performed for requalification to renew the BMG release. After no more than
10 years, agreement must be reached with the appropriate department as to whether requalifica‐
tion is necessary.
Test scope E:
Recommended in-process testing (e.g., batch-related or continuously). The supplier is responsible
for process reliability.
Test scope F:
Special test scope: Only performed upon request by the appropriate department
Cable cross section allocation:
Test scope A1/B1/C1: The smallest cable cross section of each insulation
material is tested.
Reduced test scope A2/B2/C2: These are performed for all other cable cross sections
of each insulation material.
Cable composition:
For cable cross sections of 0.5 – 2.5 mm2, the following applies:
Test results for the asymmetric copper-core composition – B can be used for the symmetric cop‐
per-core composition – A in agreement with the appropriate department.
8.2 Test atmosphere

Unless a different test atmosphere is defined, testing is performed in a standard atmosphere as per
Volkswagen standard VW 50554 – 23/50-2.
ISO 6722-1 (section "Ovens") applies to ovens.
8.3 Specimens
Unless otherwise specified, at least 3 specimens of each of the cables must be tested in as-re‐
ceived condition.
The colors brown and black are only used in consultation with the appropriate department.
Unless otherwise specified in the test description, the specimens must be aged prior to the tests for
16 h in a standard atmosphere as per VW 50554 – 23/50-2.
For each test, specimens must be used that were not used in any 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. In this case, all of the 10 specimens must then pass the test; i.e.,
the test is not passed if one more specimen fails the repeated test.
If more than 1 specimen fails, a repetition with 10 specimens is not possible; the test is considered
not passed.
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8.4 Rounding of numerical values

The determined numerical values must be rounded to the number of digits used to specify the de‐
sired values as per DIN 1333.
9 Tests
The described tests are based on ISO 6722-1.
Unless otherwise agreed upon, the drawing note takes precedence over the standard if they con‐
tain differing specifications.
9.1 Cable composition inspection

The parameters indicated in the respective appendices for the cable composition must be tested.
The mean value of the measurements as well as the minimum and maximum values must be indi‐
cated in the test report.
9.1.1 Cable outer diameter and minimum wall thickness

Testing is performed as per DIN EN 60811-203 (cable outer diameter) and DIN EN 60811-201
(minimum wall thickness).
9.1.2 Nominal conductor diameter

Testing is performed on the basis of DIN EN 60811-203.
The inside diameter (nominal conductor diameter) is measured three times at regular distances (for
three measurements, the specimen must be further rotated by 60° in each case).
9.1.3 Conductor resistance

Testing as per ISO 6722-1
Requirements as per tables in appendix A
9.1.4 Insulation strippability factor

A rectangle is formed (see figure 2) that runs tangentially to the four outer edges of the cable.
The diagonals of the rectangle intersect at the reference center point for the cable.
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Figure 2 – Determining the reference center point
tmin and tmax are each measured on an imaginary line from the outer diameter to the reference cen‐
ter point (see figure 3).
tmin is the shortest possible uninterrupted distance on one such line within the insulation.
tmax is the longest possible uninterrupted distance on one such line within the insulation.
Figure 3 – Distance measurement for tmin and tmax

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Example calculation
tmin (1)
Insulation strippability factor = × 100%
tmax
0.182
(Insulation strippability factor = × 100% = 30.4%)
0.598
9.2 Physical and chemical properties of the insulation

The measured values for each cable specimen obtained from the tests described below must be
included as an appendix to the test report and serve as unambiguous identification of the cable.
9.2.1 Density
Testing is performed as per section "Method A – Immersion method" from DIN EN ISO 1183-1.
9.2.2 Thermal stability for PVC

Testing for PVC only is performed as per DIN EN 60811-405:
– Change from pH value 5 to pH value 3
– Requirement: > 140 min (class T105)
9.2.3 Determining the tensile strength and elongation at tear

Testing is performed as per DIN EN 60811-501.
Section 9.7 must also be observed for the number of specimens.
9.2.4 Tear propagation resistance

The tear propagation resistance test is only performed on silicone material or silicone insulation.
9.2.4.1 Testing on sheet

Testing is performed for silicone only as per Method B, procedure (b) from DIN ISO 34-1.
Requirement:
– ≥ 15 N/mm for temperature class E
– ≥ 10 N/mm for temperature class F
9.2.4.2 Testing on cable

Testing is performed on the basis of DIN EN 50525-2-21 on cable cross sections of 25 mm2 or
35 mm2 in addition for each material compound variant.
A specimen of insulation must be removed from the cable and used to produce 5 specimens with
dimensions as per figure 4 (dimensions in mm). For cables with an outer diameter of less than
10 mm, the specimen width may correspond to the insulation circumference.
The grooves (contour from the copper strands) must be removed from the specimens. This can be
done using a suitable paring device to achieve a uniform insulation wall thickness. It must be en‐
sured that only the protruding parts creating the grooves are removed.
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As shown in figure 4, a longitudinal cut along the center of the specimen must be produced (e.g.,
using a sharp razor blade).
The mean thickness of the specimen must be determined by means of 3 measurements spaced
evenly along length of the expected tear.
The halves of the separated specimens must be clamped into the grips of a tensile testing machine
as shown in figure 5.
The speed at which the grips move apart must be (250 ±50) mm/min.
To determine the tear propagation resistance, the highest force value in N is divided by the mean
thickness of the specimen in mm. The tear propagation resistance is the mean value of the values
determined in this manner.
Requirement: As per sample
Legend
1 Cross section
2 Marking line
a) / b) For allocation, see figure 5.
Figure 4 – Insulation specimen dimensions in mm
Legend
a) / b) For allocation, see figure 4.
Figure 5 – Tensile direction for insulation specimen
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9.2.5 Determining the degree of cross-linking

Testing for radiation cross-linked cables is performed as per DIN EN 60811-507 at a test tempera‐
ture of (+200 ±3) °C and a load of 20 N/cm2.
Requirements:
Elongation under load ≤ 100%
Elongation after load ≤ 25%
9.3 Mechanical properties in as-received condition

Generally, the cable must be designed such that it can be processed properly. The processing de‐
tails must be agreed upon between the cable supplier and the cable manufacturer. The insulation
must not exhibit any blisters, cracks, nodes, or inclusions of foreign matter.
9.3.1 Insulation strippability/secure fit of conductor

For cables that have to be stripped, it must be possible to strip 20 mm of the insulation cleanly and
without difficulty using commercially available tools.
The cables must be strippable using commercially available machines.
For nominal conductor cross sections up to 6.0 mm2, the following applies:
The force required to strip the insulation with a length of (50 ±1) mm must be greater than the mini‐
mum force specified in table 10.
Table 10 – Secure fit of conductor

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Minimum force in N 5 5 5 5 10 10 10 10
Testing:
Number of speci‐ ≥5
mens:
Specimen length (150 ±5) mm
The specimen is stripped to a length of (50 ±1) mm and the stripped conductor end is pulled
through a panel with a hole (conductor diameter +0.1 mm). The stripping speed is 100 mm/min.
9.3.2 Insulation abrasion resistance

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 electric contact shuts off the
machine. Each measurement is required to reach the minimum number of cycles (see table 11).
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Table 11 – Number of cycles

Nominal conductor ≥ 6.0
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0
cross section ≤ 25.0
Contact force in N 7.00 ±0.05
mini‐
Number of cycles 200 300 350 500 1 500 1 500 1 500 1 500
mum
The setup and procedure are as per section "Resistance to abrasion" in ISO 6722-1.
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%. The needle must be lifted off at the reversal point.
9.3.3 Bending force of the cable

The bending force must be within the values specified in table 12 and table 13. Deviating values
may be agreed upon in individual cases.
Table 12 – Specifications for the bending force test

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Specimen length (l) in mm 50 70
Number of specimens Quan‐
5 3
(n) tity
Distance (IV) in N 20 30
Maximum bending
in mm 15 20 25 30 30 40 70 90
force
Table 13 – Specifications for standard setup

in mm2 10 16 25 35 50 70 95
section
Specimen length (l) in mm 150
Quanti‐
Number of specimens (n) 1
ty
Distance (IV) in N 100
Maximum bending force in mm 15 20 30 50 70 90 110
The test fixture consists of two metal legs, a test punch, and a tensile testing machine. This is
shown schematically in figure 6 (dimensions in mm).
The cable specimens (number n and lengths as per table 12 and table 13) are straightened and
aged in that position for at least 16 h. Then the n cables are placed next to one another on the
metal legs, which are positioned at a distance of lV as per table 12 and table 13. The upper side of
these specimens are marked with a felt-tip pen on the left and the right perpendicular to the longi‐
tudinal axis of the cable.
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In a tensile testing machine, the test mandrel is pressed onto the cables at a test speed of
100 mm/min. The force required to bend the cables is measured.
Then the cables are straightened by hand and placed back on the legs on the side bearing the
marking. The force required to bend the cables is measured again. The mean value of the two
measurements is the bending force.
Legend
I Specimen length
Iv Distance
F Bending force
1 Cable specimen
Figure 6 – Test fixture for bending force
9.3.4 Insulation notch strength

The penetration force must correspond to the values in table 14.
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Table 14 – Penetration force

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Minimum penetration
in N 30 40 50 50 60 70 100 120
force
For nominal conductor cross sec‐ As per sample

tions > 6.0 mm2:
The test fixture (see figure 7) consists of a tensile testing machine or a force measuring instrument,
a notching tool (cutter), and an extra-low-voltage circuit. A round spring wire as per section "Abra‐
sion test" of ISO 6722-1 with a needle diameter of (0.45 ±0.01) mm must be used as the notching
tool.
The specimen is fastened in the tensile testing machine as per figure 7. The steel wire is pressed
through the insulation at a constant speed of ≤ 10 mm/min until the electric contact between the
steel wire and the conductor of the specimen shuts off the machine. The axes of the specimen and
the cutter must be perpendicular to one another. The force indicated when contact is made is no‐
ted. After each reading, the specimen is shifted 10 mm and rotated by 90° about its longitudinal
axis until a total of 4 measurements are taken. The penetration force is the mean value of these
measurements.
Legend
1 Force
2 Specimen
3 Steel wire
Figure 7 – Test fixture for notch strength
9.4 Flame retardance

Testing and requirements are as per ISO 6722-1.
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9.5 Electrical properties in as-received condition
9.5.1 Volume resistivity

The volume resistivity of the insulation must be at least 109 Ωmm.
Testing is performed as per ISO 6722-1 (but with a 1% NaCl solution).
9.5.2 30-minute dielectric strength

Dielectric breakdown must not occur.
Testing is performed as per ISO 6722-1.
9.5.3 1-minute dielectric strength measurement (only after exposure to load)

This test is only performed after tests that include a corresponding reference.
According to section 9.5.2, however, a test voltage of 1 kVrms (5 kV for cable cross sec‐
tions > 6.0 mm2) is applied for 1 min for the test.
The specimens are aged in a saltwater bath for ≥ 10 min. Different aging durations might apply if
the aging in the saltwater bath is explicitly described in a test (see also ISO 6722-1: e.g., 1-min
dielectric strength after long-term aging).
9.6 Mechanical and electrical properties after exposure to mechanical, thermal, or chemical
load
9.6.1 Stress test

This test applies to cables with an insulation made of fluoropolymers, e.g., FEP and ETFE. Two
specimen pieces of sufficient length (2 m) are removed and used to produce the specimens for the
stress test.
The specimens are wound to a coil of 20 cm in diameter and aged for 3 h in an oven at the temper‐
ature specified below:
Fluoropolymers of temperature class FEP: (+225 ±4) °C
T200: Radiation cross-linked (+225 ±4) °C
ETFE:
Fluoropolymers of temperature class ETFE: (+225 ±4) °C
T175:
Fluoropolymers of temperature class ETFE: (+200 ±4) °C
T150:
Then the pieces are removed, cooled down over a period of at least 16 h in a standard atmosphere
as per VW 50554 – 23/50-2, and wound around a mandrel in a tight coil of at least 6 turns that lie
very close to one another as per table 15 with the stripped ends fastened in place (see also the
example in figure 8). The following values must be ensured: L1 > 60 mm and L2 > 10 mm.
The wound specimens are aged for another 3 h with the mandrel at the cable-specific tempera‐
tures specified above. Afterwards, the specimens are cooled down over a period of at least 16 h,
the mandrel is removed (without unwinding the cable), and an electrical test is performed on the
specimen as per section 9.5.3.
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Figure 8 – Winding test example
The test is considered passed if there is no dielectric breakdown during the electrical test as per
section 9.5.3.
Table 15 – Mandrel diameter

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Mandrel diameter in mm 2 3 4 5
9.6.2 Insulation shrinkage under heat

Testing is performed as per ISO 6722-1 at Tmax.
The test temperature is as per table 5, column "Thermal overload temperature."
The opening time for placing the components for aging must not exceed 10 s. The aging time
starts upon reaching Tmax + 50 °C.
For specimen preparation, see figure 9.
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Figure 9 – Specimen preparation for shrinkage testing
9.6.3 Compressive strength of the insulation under heat

The test temperature is Tmax until at least one of the 3 specimens fails. The testing until failure is
used for data gathering purposes to obtain an overview of differences in material and to determine
the "compressive strength under heat temperature."
9.6.4 Determining the derating curve

The current-carrying capacity at the ambient temperature and the measurement for temperature in‐
crease of the cable or conductor are determined as per VW 60306-3.
The smallest cable cross section of each mixture/compound used is measured. All cable cross
sections (including the measured ones) are calculated as per VW 60306-3.
The maximum permissible resistance and the smallest permissible outer diameter must be used
for the calculation.
9.6.5 Thermal stability in wound state

A cable specimen of sufficient length is wound around a mandrel with a diameter as per table 16
with 6 turns that lie very close to one another and tied in place.
The specimen prepared in this manner is aged for 1 h in an oven with natural ventilation at the
thermal overload temperature as per section "Ovens", table 5 in ISO 6722-1 (hanging on the man‐
drel). After cooling down in a standard atmosphere as per VW 50554 – 23/50-2, the test is per‐
formed as per section 9.5.3 (1-minute dielectric strength measurement).
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Table 16 – Mandrel diameter

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Mandrel diameter in mm 5 9 13
9.6.6 Thermal overload
9.6.6.1 Thermal overload Tmax + 50 °C

The test temperature is 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 cables must be documented in one photo.
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 alone
cannot be used for the cable design in the electrical system.
The test procedure is as per section 9.6.8.1. The subsequent high-voltage test is performed as per
section 9.5.3.
The start temperature can be freely selected based on experience.
The start temperature can, for example, be Tmax + 75 °C.
If all three of the 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 stopped.
If at least one specimen is not OK at the start temperature (e.g., Tmax + 75 °C), the temperature is
reduced by 10 °C until all of the specimens are OK.
The start 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 1: A conclusion on the amperage at which the conductor reaches the temperature deter‐
mined in this manner can be drawn by means of a calculation or a derating measurement (see
VW 60306-3).
9.6.7 Winding test after short-term aging (240 h)

The aging is performed as per ISO 6722-1 at an oven temperature of Tmax + 25 °C.
Winding test, rotating mandrel, and weight at -25 °C as per ISO 6722-1. The subsequent high-volt‐
age test is performed as per section 9.5.3.
After the aging, the color of the cable must still be identifiable.
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9.6.8 Long-term aging (3 000 h)

The aging is performed as per ISO 6722-1 at an oven temperature of Tmax.
The specimens for the subsequent subtests section 9.6.8.1 and section 9.6.8.2 can be aged to‐
gether in one oven.
After the aging, the color of the cable must still be identifiable.
9.6.8.1 Winding test after long-term aging

The winding test is performed as per ISO 6722-1 in a standard atmosphere as per VW 50554 –
23/50-2.
The subsequent high-voltage test is performed as per section 9.5.3.
9.6.8.2 Minimum permissible bending radius for static routing

Long-term aging of the bent specimens is used to verify that the cable can be routed with bending
radii greater than or equal to the specified radius.
For each cable, two cable samples with a length of approximately 400 mm have 25 mm of insula‐
tion stripped off both ends.
For specimen preparation, see table 17.
Table 17 – Specimen preparation

Maximum cable Smallest permissi‐ Maximum winding
diameter dmax in ble bending radius mandrel diameter Execution
mm in mm in mm
≤ 3.0 Wound 360° around itself 3 times, see
2.0 × dmax −
(to 2.5 mm2) figure 10
Wound 360° around mandrel 2 times,
fastened with two cable ties:
> 3.0 and ≤ 5.0 1. Cable tie at a distance of half of
(from 4.0 mm2 to 2.0 × dmax 1.5 × dmax the produced loop diameter
6.0 mm2) 2. Cable tie at a distance of half of
the produced loop diameter,
mandrel removed (see figure 11)
Bent 180° around mandrel, fastened

with cable ties:
1. Cable tie at a distance of the pro‐
> 5.0
3.0 × dmax 2.0 × dmax duced loop diameter
(from 6.0 mm2)
2. Cable tie at a distance of half of
the produced loop diameter,
mandrel removed (see figure 12)
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The cable ties used must meet the following requirements:

– Their base material must be suitable for the corresponding aging temperature.
– No incompatibility with the insulating material to be tested
– Teeth on outside
– No sharp edges
– Width ≥ 0.8 × dmax
– The tightening force must be selected such that no or only minor indentations are produced on
the insulation surface in the neutral state.
Figure 10 – Figure 11 – dmax > 3.0 mm and Figure 12 – dmax > 5.0 mm
dmax ≤ 3.0 mm ≤ 5.0 mm
The prepared samples must be aged for 3 000 h as per section 9.6.8. Then the specimens that are
still wound and fastened are subjected to a high-voltage test as per the requirements in
ISO 6722-1.
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9.6.9 Winding test at low temperature (-40 °C)

Testing is performed as per section "Winding test at low temperature -40 °C, rotating mandrel, and
weight" in ISO 6722-1.
9.6.10 Impact test at low temperature (-15 °C)

Deviating from this, however, cables with cross sections ≤ 0.5 mm2 are tested with a hammer mass
of 100 g.
9.6.11 Cable marking resistance to wiping

This test only applies to cables with printed markings.
9.6.12 Bending fatigue strength

Number of cycles until failure: As per sample
No visible insulation damage (crack or fracture)
Determining the bending cycles until cable fracture that is detected by measuring the electrical
continuity
Based on ISO 14572, but deviating with R 6 × maximum specified outer cable diameter (-20%)
Testing is performed in a standard atmosphere as per VW 50554 – 23/50-2 and at Tmin.
The insulation must be visually inspected at least once per day.
Specimen length: ≥1m
Sampling rate: ≤ 10 ms
Distance between the 1.5 × the maximum specified outer diameter ±0.5 mm
bending grips:
Material of the bend‐ Stainless steel or aluminum
ing grips:
Loading weight: 1.0 kg/mm2 (total nominal copper cross section); the minimum weight must
not fall below 250 g per cable and the maximum weight must not exceed
12 kg per cable.
The entire cable must be fastened to the test equipment and the loading weight (not just the con‐
ductor).
9.6.13 Kink test

This test only applies to cables with cross sections ≤ 6.0 mm2.
Before the test, the test fixture is selected (see figure 13) such that its inner bending radius r corre‐
sponds to the cable cross section to be tested and the specified spacer rings are used as per
table 18.
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Table 18 – Spacer rings

in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
section
Bending radius (r) in mm 1.0 1.5 3.0
Spacer ring thickness in mm 1.1 1.3 1.6 1.8 2.1 2.6 3.3 3.9
Tolerance of spacer ring
in mm -0.1
thickness
Cable samples with a minimum length of 200 mm must have 20 mm of insulation stripped off the
ends. The specimen is routed out of the test fixture perpendicular to the grips and clamped be‐
tween the grips of the test fixture until the spacer rings meet the block. Then the cable is subjected
to 20 bending cycles. One cycle corresponds to bending the cable 180° to one side until the cable
meets the fixture, bending it 360° to the other side of the test fixture, and returning it 180° to the
initial position. It must be ensured during the test that the cable subjected to as little tensile force as
possible.
After unclamping the cable specimen, it is tested as per section 9.5.3 (1-minute dielectric strength
measurement).
Legend
1 Spacer ring
2 ±180°
3 Close-up view
4 r = 4 mm
5 Bending radius r = as per table 18
Figure 13 – Test fixture for kink test
9.6.14 Electrical properties with aging in water

The insulation resistance (measured as per section 9.5.1) during aging in water must be at least
109 Ωmm. This value is measured every 7 days.
A specimen of sufficient length is wound 10 turns around the center of a mandrel with a diameter
as per table 19/table 20. The cable is tied and the mandrel is removed.
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Table 19 – Mandrel diameter I

Nominal conductor
in mm2 0.35 0.5 0.75 1.0 1.5 2.5 4.0 6.0
cross section
Mandrel diameter in mm 6 10 15 20
Table 20 – Mandrel diameter II

Nominal conductor
in mm2 10 16 25 35 50 70 95 120
cross section
Mandrel diameter in mm 40 50 75 100 125
Every specimen is connected to the positive terminal of a 48-V DC voltage source and aged 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 such that 2 m of the specimen is fully immersed. The test vessel with the
specimens must be heated uniformly in an external tempering bath. It must be ensured that the
specimens and the electrodes in the test vessel do not make contact.
Immersed electrode surface: (100 ±10) cm
Electrode material: Cu
Immediately after aging in water, the specimens are tested as per section 9.5.3 (1-minute dielectric
strength measurement).
Only cables with the same insulation material may be aged together in the same tempering bath.
The water volume in the test vessel must be from 2 l to 5 l. This must be indicated in the test re‐
port. Different water volumes can be used for larger cable cross sections (≥ 10 mm2). This must be
documented in the test report.
If a cable has failed, it must be removed from the tempering bath.
The test must also be performed with reversed polarity on new specimens.
9.6.15 Damp heat, constant (hydrolysis test)

The insulation is stripped off the ends of a cable specimen that is (3 000 ±50) mm in length. The
cable is coiled at a radius ≥ 25 mm, fastened to the support, and aged for 3 000 h at a temperature
of (+85 ±2) °C and a relative humidity of (85 ±5)%. Then the specimen is aged for 30 min in a
standard atmosphere as per VW 50554 – 23/50-2 and tested within another 30 min as per
section 9.6.8.1 (winding and dielectric strength).
9.6.16 Ozone resistance

Cable specimens of sufficient length are wound 4 to 6 turns around a mandrel with a diameter of
3 × the outer diameter of the cable and fastened in place. Testing is performed on the basis of
DIN ISO 1431-1, method A. The specimens are aged for (70 +2) h in a standard atmosphere as
per VW 50554 – 23/50-2 and then for 48 h at 40 °C, a relative humidity of (55 ±10)%, and an
ozone concentration of (50 ±5) pphm (1 pphm = part per hundred millions is equal to 1 part ozone
to 108 parts air by volume). After cooling down in a standard atmosphere as per VW 50554 –
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23/50-2, the specimens are unwound from the mandrel and tested as per section 9.5.3 (1-minute
dielectric strength measurement).
9.7 Mycological test

Growth on the insulation not exceed grade 3 (growth visible to the naked eye, up to 50% of the
specimen surface may be covered in growth) as per section "Method A: Fungal-growth test" in
DIN EN ISO 846.
The mean values for tensile strength and elongation at tear must not change by more than 50% at
a growth grade > 2.
NOTE 2: Tests that were previously passed with a growth grade ≤ 1 as per DIN EN 60068-2-10
are still considered passed.
The use of fungicides without consultation with the appropriate department is prohibited.
Testing is performed as per section "Method A: Fungal-growth test" in DIN EN ISO 846.
The cables with the largest cross section from which the specimens were also produced as per
section 9.2.3 must be used. At least 5 specimens of each compound must be tested.
The specimens must be cleaned with an ethanol/water solution as per section "Cleaning" in
DIN EN ISO 846. They are inoculated with test fungal spores.
The specimens must be inoculated with the test fungal spores on mineral salt agar in a Petri dish
and incubated for 28 days at (29 ±1) °C. An intermediate check for fungal growth is permissible
after 14 days.
After 28 days of incubation, the specimens must be checked for fungal growth as per section "As‐
sessment" in DIN EN ISO 846.
The fungal growth must be graded as specified in DIN EN ISO 846, table 4.
If a growth > 2 is determined, a test as per section 9.2.3 must be performed after the mycological
test (without copper), and the change in tensile strength and elongation at tear must be deter‐
mined.
9.8 Compatibility tests

This section describes tests that ensure compatibility of the cables with substances occurring in ve‐
hicles and their surroundings.
9.8.1 Resistance to chemicals as per ISO 6722-1

To determine the swelling and shrinkage, a compatibility test must be performed as per section
"Fluid compatibility", "Test method 2" in ISO 6722-1. Additional testing of resistance to AdBlue
must be performed for 48 h at +50 °C as per VW 60306-1 Supplement 1.
The smallest cable cross section of each compound is tested.
For fluoropolymers, the test can be omitted upon prior agreement with the appropriate department.
9.8.2 Resistance to chemicals

The insulation must not have any cracks, fractures, or other damage affecting function. There must
not be any dielectric breakdown during the voltage tests.
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Resistance of at least:
– 480 h of exposure to chemicals in group 1 (see VW 60306-1 Supplement 1)
– 240 h of exposure to chemicals in group 2 (see VW 60306-1 Supplement 1)
If individual aspects of these tests are not passed, this does not necessarily rule out a release. The
results are evaluated by the appropriate department.
If the resistance is less than 240 h, the appropriate protection from the chemicals in group 2 must
be provided in the area of the wiring harness (e.g., by means of corrugated tube, protective hose).
9.8.2.1 Testing on cross sections ≤ 2.5 mm2

If other compounds are used with cable cross sections ≤ 2.5 mm2, these must be tested as well. In
this case, the smallest cable cross section of each compound is tested as per table 21.
The test group is tested for chemicals in group 1 as well as chemicals in group 2 (see
VW 60306-1 Supplement 1).
At least 4 specimens of each test group are immersed in the respective chemical for 2 min in a
standard atmosphere as per VW 50554 – 23/50-2 (or lightly brushed with grease). The cable ends
must not come into contact with the chemical. The chemical is then allowed to drip off for 2 min
(10 min for fuels) (grease remains).
Each chemical must be tested separately (chemicals must not be combined).
The specimens are suspended in a test tube with the cable ends pointing upwards and the test
tubes are placed in an oven for 480 h of aging at Tmax. After 240 h and 480 h, two of each of the
specimens are removed and the remaining two specimens are aged for the remaining 240 h.
The aging with the chemical AdBlue must also be performed in a climatic chamber at a tempera‐
ture of (+85 ±2) °C and a relative humidity of (85 ±5)% for 480 h. The rest of the test procedure is
the same.
The specimens are aged without direct contact with any potential chemical sump. This prevents
the undesired, continuous contact of the specimens with the respective chemical, since capillary
effects that cause the chemical to be fed back to the specimen must be avoided. In this way, occa‐
sional wetting of the wiring harness with the chemicals is simulated.
After the test period has elapsed, the wiring harness is aged for at least 3 h and no longer than
72 h in a standard atmosphere as per VW 50554 – 23/50-2 and then tested as follows:
– The straight area that had contact with the chemicals is evaluated and documented.
– The specimen is tightly wound around a mandrel with a diameter of 2 mm, visually inspected,
and subjected to a voltage test as per section 9.5.3.
– For cable cross sections other than 0.35 mm2, testing is performed as per table 21.
Table 21 – Overview of winding mandrels

Nominal conductor cross sec‐
Test tubes Winding mandrels after aging
tion
in mm2 in mm in mm
0.35 25 ±2 2
0.50 25 ±2 2
0.75 25 ±2 2
1.00 30 ±2 3
Page 36
VW 60306-1: 2018-09
1.50 None, freely suspended 3

2.50 None, freely suspended 4
NOTE 3: The mandrel is selected according to the long-term aging as per ISO 6722-1.
9.8.2.2 Testing on cross sections ≥ 4 mm2

Testing is performed with a cable cross section of 16 mm2. If other compounds are used with cable
cross sections ≥ 4 mm2, these must be tested as well. In this case, the smallest cable cross section
of each compound is tested. This test is not required if the compound has already been tested for
cable cross sections < 4 mm2.
The test groups are divided up and prepared as per section 9.8.2.1.
Testing is performed as for cable cross sections < 4 mm2, but with the following differences:
– The length of the specimen is at least 600 mm.
After being immersed in the chemicals in group 1 and 2, the specimens prepared in this manner
are suspended in an oven with natural ventilation (bend facing downward) and aged (test tube not
required).
Following this, the cable is wound around a mandrel with a diameter of 2 mm as per section 9.6.8.
A visual inspection and a voltage test as per section 9.5.3 (1-minute dielectric strength measure‐
ment) are then performed.
Visual changes to the cable must be noted in the test report.
10 Environmental protection and safety

In addition to the applicable legal requirements, the requirements in VDA 232-101 (hazardous sub‐
stance list) must also be met.
11 Applicable documents
The following documents cited are necessary to the application of this document:
Some of the cited documents are translations from the German original. The translations of Ger‐
man terms in such documents may differ from those used in this standard, resulting in terminologi‐
cal 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.
VW 50554 Standard Atmospheres and Room Temperatures; Requirements on

Standard Atmospheres
VW 60306-1 Electrical Cables for Motor Vehicles – Part 1: Copper Cable; Single-
Supplement 1 Core, Unshielded
VW 60306-3 Determining Current Capacity of Vehicle Cables
VW 75210-2 High-Voltage, Shielded, Sheathed Cables for Motor Vehicles and Their
Electric Drives; Requirements and Tests
DIN 1333 Presentation of numerical data
Page 37
VW 60306-1: 2018-09
DIN 72551-7 Road vehicles - Low-tension cables - Part 7: Colours and colour marking
of low-tension cables
DIN 76722 Road vehicles - Electrical cables - Design rule for abbreviation codes
DIN EN 13602 Copper and copper alloys - Drawn, round copper wire for the manufac‐
ture 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 Applica‐
tions – Flexible Cables with Crosslinked Elastomeric Insulation; German
version EN 50525-2-21:2011
DIN EN 60068-2-10 Environmental testing - Part 2-10: Tests - Test J and guidance: Mould
growth
DIN EN 60811-201 Electric and Optical Fibre Cables – Test Methods for Non-Metallic Mate‐
rials – Part 201: General Tests – Measurement of Insulation Thickness
(IEC 60811-201:2012); German version EN 60811-201:2012
rials – Part 203: General Tests – Measurement of Overall Dimensions
rials – Part 405: Miscellaneous Tests – Thermal Stability Test for PVC
Insulations and PVC Sheaths (IEC 60811-405:2012); German version
EN 60811-405:2012
rials – Part 501: Mechanical Tests – Tests for Determining the Mechani‐
cal Properties of Insulating and Sheathing Compounds
rials – Part 507: Mechanical Tests – Hot Set Test for Cross-Linked Mate‐
rials (IEC 60811-507:2012); German version EN 60811-507:2012
DIN EN ISO/ General requirements for the competence of testing and calibration labo‐
IEC 17025 ratories
DIN EN ISO 1183-1 Plastics - Methods for determining the density of non-cellular plastics -
Part 1: Immersion method, liquid pyknometer method and titration meth‐
od
DIN EN ISO 846 Plastics - Evaluation of the action of microorganisms
DIN ISO 1431-1 Rubber, vulcanized or thermoplastic - Resistance to ozone cracking -
Part 1: Static and dynamic strain testing
DIN ISO 34-1 Rubber, vulcanized or thermoplastic - Determination of tear strength -
Part 1: Trouser, angle and crescent test pieces
ISO 14572 Road vehicles - Round, sheathed, 60 V and 600 V screened and
unscreened single- or multi-core cables - Test methods and require‐
ments for basic- and high-performance cables
ISO 6469-3 Electrically propelled road vehicles - Safety specifications - Part 3: Pro‐
tection of persons against electric shock
Page 38
VW 60306-1: 2018-09
ISO 6722-1 Road vehicles - 60 V and 600 V single-core cables - Part 1: Dimensions,
test methods and requirements for copper conductor 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, Serial Production
12 Bibliography
[1] Regulation ECE R10 can be found at Regulation No 10 of the Economic Commission for
Europe of the United Nations (UN/ECE) – Uniform Provisions Concerning the Approval
of Vehicles with Regard to Electromagnetic Compatibility [2017/260].
[2] Directive 2011/65/EU can be found at Directive 2011/65/EU on the Restriction of the
Use of Certain Hazardous Substances in Electrical and Electronic Equipment.
[3] Directive 2014/53/EU can be found atDirective 2014/53/EU on the Harmonisation of the
Laws of the Member States Relating to the Making Available on the Market of Radio
Equipment and Repealing Directive 1999/5/EC .
Page 39
VW 60306-1: 2018-09
Appendix A (normative)
The following are included in the appendix:
Table A.1 "FLR – Cable composition, symmetric, type A with reduced wall thickness"
Table A.2 "FLR – Cable composition, symmetric, type A with ultra-thin wall thickness"
Table A.3 "FLR – Cable composition, asymmetric, type B with reduced wall thickness"
Table A.4 "FLR – Cable composition, asymmetric, type B with reduced wall thickness (intermediate cable cross sections)"
Table A.5 "FLR – Cable composition, asymmetric, finely stranded/flexible, type B"
Page 40
VW 60306-1: 2018-09
Table A.1 – FLR – Cable composition, symmetric, type A with reduced wall thickness
Strand Conductor Cable
Quantity
Diameter
Weight d)
strands a)
factor A c)
Lay length
insulation t
tinned strands
Diameter d1 a)
bare conductor b)
Outer diameter d2
Resistance at 20 °C,
Wall thickness of the
Insulation strippability
Cpk value (based on t)

Test wall thickness ttest
Cable cross section for
Nominal conductor cross section

mm2 Pieces mm mm mm mm2 mΩ/m mΩ/m mm mm mm % g/m
deviation
minimum
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
0.35 e) 7 0.27 0.80 27 0.332 0.358 52.0 48.1 55.5 51.4 1.3 -0.10 0.20 0.22 4.6
0.50 19 0.20 1.00 45 0.465 0.502 37.1 34.4 38.2 35.4 1.6 -0.20 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 -0.20 0.24 0.26 9.2
1.0 19 0.27 1.35 50 0.932 1.01 18.5 17.1 19.1 17.7 2.1 -0.20 0.24 0.26 12
1.5 19 0.33 1.70 60 1.36 1.47 12.7 11.8 13.0 12.0 2.4 -0.20 0.24 ≥ 1.33 0.26 45 17
2.5 19 0.41 2.20 75 2.27 2.45 7.60 7.04 7.82 7.24 3.0 -0.30 0.28 0.30 27
2.5 37 0.30 2.20 75 2.27 2.45 7.60 7.04 7.82 7.24 3.0 -0.30 0.28 0.30 27
4.0 37 0.38 2.75 75 3.66 3.95 4.71 4.36 4.85 4.49 3.7 -0.30 0.32 0.34 43
6.0 37 0.45 3.40 75 5.49 5.93 3.14 2.91 3.23 2.99 4.3 -0.30 0.32 0.34 63
a) Measurement accuracy: 50 µm
b) Calculated with a specific electrical conductivity value of 58.0 Sm/mm2, quality control through resistance measurement
c) The insulation strippability factor is determined as per section 9.1.4. The provisional target value is at least 45%. The insulation strippability factor can be between 35% and 45% transitionally in consulta‐
tion with the appropriate department.
d) Weight according to sample; the values in the table apply to PVC.
Page 41
VW 60306-1: 2018-09
e) The resistance values for a cable cross section of 0.35 mm2 deviate significantly from ISO 6722-1.
Page 42
VW 60306-1: 2018-09
Table A.2 – FLR – Cable composition, symmetric, type A with ultra-thin wall thickness
Quantity
Diameter
Weight e)
(tinned c))
factor A d)
Lay length
insulation t
bare strands
Diameter d1 a)
bare conductor b)
Outer diameter d2
Cpk value (based on t)


mm2 Pieces mm mm mm mm2 mΩ/m mm mm mm % g/m
deviation
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
0.35 f) 7 0.27 0.80 27 0.332 0.358 52.0 48.1 1.20 -0.10 0.16 0.17 4.3
0.50 19 0.20 1.00 45 0.465 0.502 37.1 34.4 1.40 -0.10 0.16 0.17 5.8
0.75 19 0.24 1.20 45 0.698 0.754 24.7 22.9 1.60 -0.15 0.16 0.17 8.4
1.0 19 0.27 1.35 50 0.932 1.01 18.5 17.1 1.75 -0.15 0.16 ≥ 1.33 0.17 45 11
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
a) Measurement accuracy: 50 µm
b) Calculated with a specific electrical conductivity value of 58.0 Sm/mm2, quality control through resistance measurement
c) The resistance values for tinned conductors must be taken from ISO 6722-1.
d) The insulation strippability factor is determined as per section 9.1.4. The provisional target value is at least 45%. The insulation strippability factor can be between 35% and 45% transitionally in consulta‐
e) Weight according to sample; the values in the table apply to PVC.
f) The resistance values for a cable cross section of 0.35 mm2 deviate significantly from ISO 6722-1.
Page 43
VW 60306-1: 2018-09
Table A.3 – FLR – Cable composition, asymmetric, type B with reduced wall thickness
bare
Outer
tinned
strands
strands
at 20 °C,
at 20 °C,
cross section
Cpk value
Diameter
Weight e)
factor A d)
Lay length
Quantity a)
insulation t
Resistance
Resistance
diameter d2
(based on t)
Diameter d1 b)
Nominal conductor
bare conductor c)

deviation
minimum
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
0.35 f) 12 0.21 0.90 0.332 0.358 52.0 48.1 55.5 51.4 1.3 -0.10 0.20 0.22 4.6
≥ 1.33
0.50 16 0.21 1.00 0.465 0.502 37.1 34.4 38.2 35.4 1.6 -0.20 0.22 0.24 6.3
0.75 24 0.21 1.20 0.698 0.754 24.7 22.9 25.4 23.5 1.9 -0.20 0.24 0.26 9.2
1.0 32 0.21 1.40 0.932 1.01 18.5 17.1 19.1 17.7 2.1 -0.20 0.24 0.26 12
45
1.5 30 0.26 1.70 1.36 1.47 12.7 11.8 13.0 12.0 2.4 -0.20 0.24 0.26 17
2.5 50 0.26 2.20 2.27 2.47 7.60 7.04 7.82 7.24 3.0 -0.30 0.28 0.30 27
4.0 56 0.31 2.75 3.66 3.95 4.71 4.36 4.85 4.49 3.7 -0.30 0.32 0.34 43
6.0 84 0.31 3.40 5.49 5.93 3.14 2.91 3.23 2.99 4.3 -0.30 0.32 0.34 63
10 80 0.41 4.50 9.47 10.2 1.82 1.69 1.85 1.71 5.8 -0.40 0.48 > 1.0 g) 0.50 111
Not specified
16 126 0.41 5.50 14.9 16.1 1.16 1.07 1.18 1.09 7.0 -0.50 0.52 0.54 171
25 196 0.41 7.00 23.2 25.1 0.743 0.688 0.757 0.701 8.7 -0.50 0.52 0.66 160
35 276 0.41 8.30 32.7 35.3 0.527 0.488 0.538 0.498 10.4 -0.60 0.64 0.82 368
50 396 0.41 9.80 46.9 50.6 0.368 0.341 0.375 0.347 12.2 -0.70 0.72 0.74 524
Not applicable
70 360 0.51 11.6 66.6 71.9 0.259 0.240 0.264 0.244 14.4 -0.90 0.80 0.82 743
95 475 0.51 13.8 88.0 95.0 0.196 0.181 0.200 0.185 16.7 -1.00 0.88 0.90 979
a) Minor deviations are permissible:

– For 50 strands ±5% in adherence to the resistance and the maximum strand diameter
– For ≤ 50 strands, no deviation is permissible.
Page 44
VW 60306-1: 2018-09
b) Measurement accuracy: 50 µm
c) Calculated with a specific electrical conductivity value of 58.0 Sm/mm2, quality control through resistance measurement
f) The resistance values for a cable cross section of 0.35 mm2 deviate significantly from ISO 6722-1.
g) A Cpk value ≥ 1 will be accepted transitionally.
Page 45
VW 60306-1: 2018-09
Table A.4 – FLR – Cable composition, asymmetric, type B with reduced wall thickness (intermediate cable cross sections)
Outer
Cpk value
Diameter
Weight e)
factor A d)
Lay length
Quantity a)
insulation t
diameter d2
(based on t)
bare strands
tinned strands
Diameter d1 b)
bare conductor c)

mm2 Pieces mm mm mm mm2 mΩ/m mΩ/m mm deviation mm mm % g/m
minimum
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
Intermediate cable cross sections > 10 mm2
12 f) 96 0.41 4.80 11.3 12.3 1.52 1.41 1.60 1.48 6.5 -0.30 0.48 0.50 131
20 f) 153 0.41 6.10 18.1 19.5 0.955 0.884 0.999 0.925 7.8 -0.40 0.52 0.54 205
30 f) 225 0.41 7.40 26.6 28.8 0.647 0.599 0.684 0.633 9.6 -0.50 0.64 0.66 303
1.00 45
40 f) 308 0.41 8.60 36.5 39.4 0.473 0.438 0.500 0.463 11.1 -0.50 0.72 0.74 413
Not specified
60 f) 463 0.41 10.50 54.7 59.1 0.315 0.292 0.333 0.308 13.3 -0.60 0.80 0.82 614
85 f) 418 0.51 13.20 78.7 85.0 0.219 0.203 0.232 0.215 15.3 -0.70 0.80 0.82 874

Page 46
VW 60306-1: 2018-09

f) ISO 6722-1 for intermediate cable cross sections; use in agreement with the appropriate department
Page 47
VW 60306-1: 2018-09
Table A.5 – FLR – Cable composition, asymmetric, finely stranded/flexible, type B

Outer
Cpk value
Diameter
Weight e)
factor A d)
Lay length
Quantity a)
insulation t
diameter d2
(based on t)
bare strands
tinned strands
Diameter d1 b)
bare conductor c)

nominal
deviation
minimum
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
0.35 45 0.90 0.332 0.358 52.0 48.1 55.5 51.4 1.4 0.20 0.22 4.5
≥ 1.33
0.50 63 1.00 0.465 0.502 37.1 34.4 38.2 35.4 1.6 0.22 0.24 6.6
0.75 94 1.20 0.698 0.754 24.7 22.9 25.4 23.5 1.9 -0.20 9.0
1.0 125 0.11 1.40 0.932 1.01 18.5 17.1 19.1 17.7 2.1 0.24 0.26 11
1.5 182 1.70 1.36 1.47 12.7 11.8 13.0 12.0 2.4 16
2.5 304 2.20 2.27 2.45 7.60 7.04 7.82 7.24 3.0 0.28 0.30 26
-0.30
4.0 500 2.85 3.66 3.95 4.71 4.36 4.85 4.49 3.7 0.32 0.34 45 42
1.5 48 1.70 1.36 1.47 12.7 11.8 13.0 12.0 2.4 -0.20 0.24 > 1.0 f) 0.26 16
Not specified
2.5 74 2.20 2.27 2.45 7.6 7.04 7.82 7.24 3.0 0.28 0.30 26
4.0 123 2.75 3.66 3.95 4.71 4.36 4.85 4.49 3.7 -0.30 0.32 0.34 42
0.21
6.0 184 3.40 5.49 5.93 3.14 2.91 3.23 2.99 4.3 0.32 0.34 61
10 318 4.50 9.47 10.2 1.82 1.69 1.85 1.71 5.8 -0.40 0.48 0.50 118
16 504 5.50 14.9 16.1 1.16 1.07 1.18 1.09 7.0 -0.50 0.52 0.54 174
Page 48
VW 60306-1: 2018-09
Outer
Cpk value
Diameter
Weight e)
factor A d)
Lay length
Quantity a)
insulation t
diameter d2
(based on t)
bare strands
tinned strands
Diameter d1 b)
bare conductor c)

nominal deviation
minimum
minimum
minimum
minimum
minimum
minimum
minimum
maximum
maximum
maximum
maximum
maximum
maximum
maximum
Permissible
25 784 7.00 23.2 25.1 0.743 0.688 0.757 0.701 8.8 -0.60 0.52 0.54 263
35 1 106 8.30 32.7 35.3 0.527 0.488 0.538 0.498 10.5 -0.70 0.64 0.66 377
50 1 582 0.21 10.5 46.9 50.6 0.368 0.341 0.375 0.347 12.6 -0.80 0.72 > 1.0 f) 0.74 45 529
70 2 240 12.5 66.6 71.9 0.259 0.240 0.264 0.244 14.9 -0.90 0.80 0.82 747
Not specified
95 2 964 14.7 88.0 95.0 0.196 0.181 0.200 0.185 17.2 -1.00 0.88 0.90 983

f) A Cpk value ≥ 1 will be accepted transitionally.
Page 49
VW 60306-1: 2018-09
Explanations for table A.1 to table A.5:

The cable cross section is calculated with a specific electrical conductivity value of 58.0 Sm/mm2 in place of 58.5 Sm/mm2. The quality is controlled by
means of resistance measurement. The geometric data for the conductor (conductor diameter, wire diameter, wire quantity, etc.) remain the same.
Electrical conductivity measurements on automotive cables have shown that the previously accepted conductivity of 58.5 Sm/mm2 must be corrected
to 58.0 Sm/mm2. This makes it necessary to adjust the cable cross sections calculated on the basis of conductivity to existing products.
Furthermore, with the underlying conductivity of 58.0 Sm/mm2, the maximum strand diameter must also be around 0.01 mm higher than previously
specified. This does not change the strand diameters that are actually supplied. The adjustment is based on ISO 6722-1, which already uses the
conductivity of 58.0 Sm/mm2.
Starting from 20.0 mm2, the outer single-core diameters in table 7 do not match those in VW 75210-2 (standard is currently being prepared). An ad‐
justment is not desired, because changes to existing contacting systems must be avoided.
The outer single-core diameters in VW 75210-2 (standard is currently being prepared) match those in ISO 6722-1.
Intermediate cable cross sections:
For the calculation of intermediate cable cross sections, it has been demonstrated that the outer cable diameters as per ISO 6722-1 (up to and includ‐
ing 60.0 mm2) can only be reliably achieved with bunch-stranded assemblies. Therefore, it was assumed when calculating the maximum outer cable
diameter for all of the assemblies (table 3, table 4, table 5, table 6, and table 7) that a bunch is used.
Calculation of resistances and cable cross sections:
Starting on the basis of the maximum resistance value, the minimum cable cross section is calculated using the conductor electrical conductivity of,
for example, 58.0 Sm/mm2. Then the maximum cable cross section is calculated (8% higher than the minimum cable cross section). The minimum
resistance is calculated from the maximum cable cross section using the specific electrical conductivity specified above.
The resulting factors are as follows regardless of the initial values (maximum resistance and specific electrical conductivity):
– Minimum resistance = maximum resistance - (maximum resistance × 7.407%)
– Minimum cable cross section = 1 000 / (specific electrical conductivity × maximum resistance)
The resistance is specified in mΩ/m.
– Maximum cable cross section = minimum cable cross section + (8% × minimum cable cross section)

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Group standard VW 60306-1

Descriptors: cable, copper cable, low-voltage cable

Electrical Cables in Motor Vehicles

Always use the latest version of this standard.

Technical responsibility The Standards department

7.4.3 Packaging units .......................................................................................................... 8

Table 1 – Voltage classes

2 Symbols and abbreviations

4 Dimensions and cable composition

5 Composition of the code designations

6.1 Conductor, bare

Table 2 – Bare Cu conductor

Cu-ETP1 CW003A A022 A020 0.32 0.50 22

Table 3 – Product designation example

Explanations for the example in table 3 above:

6.2 Conductor, tinned

Table 4 – Tinned Cu conductor properties

Cu-ETP1 CW003A A020 A018 0.32 0.50 20

6.3 Conductor, other surfaces

Table 5 – Temperature classes

7 Marking and delivery conditions

7.1 Container marking

7.2 Manufacturer's code

7.3 Color/color coding

7.4 Delivery conditions

7.4.1 Visual inspection

7.4.2 Test for insulation faults

Table 6 – Voltage values/voltage class 1

7.4.3 Packaging units

Table 7 – Example delivery quantities for NPS 400

7.4.3.1 Partial lengths, joints, flaws

7.4.3.2 Delivery unit marking

8 General test conditions

8.1 Test matrix

Table 8 – Test matrix

Modification of raw materials

Modification of raw materials

Modification of raw materials

Modification of raw materials

Modification of raw materials

8.2 Test atmosphere

8.4 Rounding of numerical values

9.1 Cable composition inspection

9.1.1 Cable outer diameter and minimum wall thickness

9.1.2 Nominal conductor diameter

9.1.3 Conductor resistance

9.1.4 Insulation strippability factor

Figure 2 – Determining the reference center point

Figure 3 – Distance measurement for tmin and tmax

9.2 Physical and chemical properties of the insulation

9.2.2 Thermal stability for PVC

9.2.3 Determining the tensile strength and elongation at tear

9.2.4 Tear propagation resistance

9.2.4.1 Testing on sheet

9.2.4.2 Testing on cable

9.2.5 Determining the degree of cross-linking

9.3 Mechanical properties in as-received condition

9.3.1 Insulation strippability/secure fit of conductor

Table 10 – Secure fit of conductor