Design LV 216-2: 2012-05-08 Shielded high-voltage-sheathed cables for motor vehicles and their electric drives Requirements and tests LV 216-2 Tags; Sheathed cables, high voltage cables, electric drives, electric vehicles Continued on Page 2 to31 Application Warning Note Because the intended standard may differ from the draft version, may not in principle be carried out according to standard designs. If, nevertheless, a design applied in exceptional cases, so this must be agreed between the users. Foreword This course was developed in the present version of representatives of the automobile manufacturer AUDI AG, BMW AG, Daimler AG, Porsche AG and Volkswagen AG. This course is stored as a Word file in the Department of Standardization of AUDI AG. This course does not claim to be complete. The car manufacturers are free at any time to require the respective state of the art additional tests. Since the individual automakers make changes if necessary, work should be done according to the liabilities arising from this course work standards of the automobile manufacturers. Deviations to this LV are listed in the factory standards in the cover sheet (in exceptional cases, deviations can be represented in the standard text in italics). If, in individual cases the modification of individual test sections are necessary, they must be agreed separately between the competent departments of the car manufacturer and the supplier. In cross-development projects of automobile manufacturers test reports are accepted, provided that the tests were performed by a 17025 accredited according to DIN EN ISO / IEC, independent institute. The acceptance of test reports does not imply automatic approval. Other reports may be accepted at the discretion of the customer. Open issues are highlighted in green Recent changes are highlighted in yellow. Page 2 Design LV 216-2: 2012-05-08 Contents 1 Scope 3 2 General . 4 3 Dimensions and Pipe Construction 4 4 Drawing Entry . 6 5 Materials . 6 5.1 Conductor . 6 5.2 Isolation (Single Core and Cladding) . 6 6 Identification and Delivery specifications 7 6.1 Coomissioned . 7 6.2 Line Manufacturing Markings 7 6.3 Color . 7 6.4 Color Coding . 7 6.5 Delivery Specifications 8 6.5.1 Visual Inspection . 8 6.5.2 Testing for Insulation Failure to the Conductor Insulation and Jacket 8 6.5.3 Packaging . 8 7 General Test Conditions 9 7.1 Check Matrix . 9 7.2 Test Conditions . 13 7.3 Practice . 13 7.4 Rounds Of Numerical Values 13 8 Tests . 13 8.1 Checking Cable Structure . 13 8.1.1 Roundness 13 8.2 Physical and Chemical Properties of the Jacket 13 8.2.1 Density 13 8.2.2 Determination of the Viscosity . 13 8.2.3 Thermogravimetric Analysis (TGA) 13 8.2.4 Differential Scanning Calorimetry (DSC) . 13 8.2.5 Thermal Stability . 14 8.2.6 Determination of the Infra-Red Spectrum 14 8.2.7 Determination of Tensile Strength and Elongation at Break. 14 8.2.8 Tear Propagation Resistance 14 8.2.9 Determination of the Degree of Crosslinking . 14 8.2.10 Microhardness. 14 8.3 Mechanical Properties in the Delivery Condition 14 8.3.1 Strippability of the Jacket 14 8.3.2 Abrasion Resistance of the Sheath . 14 8.3.3 Flexural Fatigue Resistance 14 8.3.4 Sliding The Jacket . 14 8.3.5 Bending Force of the Jacketed Cable 14 8.3.6 Notch Strength of the Jacket Insulation . 15 8.4 Flame Resistance of the Sheathed Cable . 15 8.5 Electrical Properties of the Components 15 8.5.1 Volume Resistivity of the Wire Insulation and Jacket Material . 15 8.5.2 30-Minute Withstand Voltage 15 8.5.3 Measurement of the 1-Minute withstand voltage (only after aging) 15 8.6 Mechanical and Electrical Properties after Mechanical, Thermal or Chemical Stress 15 8.6.1 Stress-Test 15 8.6.2 Shrinkage of the Shell in the Heat . 15 Page 3 Design LV 216-2: 2012-05-08 8.6.3 Pressure Resistance of the Jacket in the Heat 15 8.6.4 Derating Curve Determination . 15 8.6.5 Thermal Overload . 15 8.6.6 Short-Term Aging (240 h) 16 8.6.7 Long Term Aging (3 000 h) . 16 8.6.8 Bending Test at Low Temperature (-40 ° C) . 17 8.6.9 Impact Test at Low Temperature (-15 ° C) 17 8.6.10 Wipe Resistance of the Cable (Jacket Marking) 17 8.6.11 Electrical Characteristics for Water Storage 17 8.6.12 Damp Heat, Constant 17 8.6.13 Resistance to Ozone . 17 8.7 Mycological Testing . 17 8.8 Compatibility with other Cable Harness Components 17 8.8.1 Chemical Resistance according to ISO 6722 17 8.8.2 Resistance to Chemicals and Wrapping Tapes . 17 8.8.3 Resistance to Cable Harness Components . 17 9 Test according to LV 213-1 18 9.1 High-Frequency characteristics (RF characteristics) 18 9.1.1 Capacitance/Inductance 18 9.1.2 Mean Impedance 18 9.1.3 Feedback Resistor 18 9.1.4 Jacketing Effectiveness . 21 10 Tests Specifically for High-Voltage Cables according to LV 216-2 21 10.1 Minimum Allowable Bending Radius for Fixed Installation . 21 10.2 Contact Resistance of 。