Group Standard VW 60306-3

Issue 2011-12
Class. No.: 8ME30

Descriptors: single-wire vehicle cable, sheathed line, cable bundle, current capacity, voltage drop, derating, fuse design,
LV 112, LV 112-3

Determining Current Capacity of Vehicle Cables

Preface
This Standard in the present issue is based on LV 112-3, which was drawn up by representatives of
automobile manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG, and Volkswagen AG.
Deviations from the LV 112-3 are listed on the cover sheet of this Standard. If modifications to indi‐
vidual test sections become necessary in individual cases, these must be agreed upon separately
between the appropriate department and the relevant manufacturer.
Test reports will be accepted as long as the tests were performed by an independent testing institute
that is accredited as per DIN EN ISO/IEC 17025. Acceptance of the test reports does not automatically
result in a release.
NOTE 1 The LV numbers listed in this document will be converted as per table 1.

Table 1
LV VW
LV 112-1 VW 60306-1
LV 112-2 VW 60306-2

Verify that you have the latest issue of the Standard before relying on it.
This electronically generated Standard is authentic and valid without signature. Page 1 of 21
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 Standards Department

EEKK/2 Dr. Liane Wiegel Tel.: +49 5361 9-36678 EKDV/4 Dirk Beinker EKDV
I/EE-23 Michael Pickl Tel.: +49 841 89-34925 Tel.: +49 5361 9-32438 Manfred Terlinden
Confidential. All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of the Standards Department of a Volkswagen Group
member.
This Standard is available to contracting parties solely via the B2B supplier platform www.vwgroupsupply.com.
© Volkswagen Aktiengesellschaft VWNORM-2011-08g
Page 2 of 21
LV 112-3: 2011-12

Content Page

1. Scope ................................................................................................................ 3
2. General information ......................................................................................... 3
3. Basics for single-wire cables .......................................................................... 4
3.1. Current capacity................................................................................................... 4
3.2. Heating by current ............................................................................................... 4
3.2.1 Dynamic transition status ................................................................................. 4
3.2.2 Steady state ..................................................................................................... 4
3.3. Maximum permissible conductor temperature .................................................. 4
3.4. Derating ................................................................................................................ 4
4. Simplified computational method ................................................................... 5
4.1. Definition of parameters ...................................................................................... 5
4.1.1 Characteristic cable parameters ....................................................................... 5
4.1.2 Additional parameters used .............................................................................. 5
4.2. Simplified equations ............................................................................................ 5
4.2.1 Conductor temperature difference ∆T in the steady case in K .......................... 6
4.2.2 Conductor temperature difference ∆T(t) in the dynamic transition status .......... 6
4.2.3 Conductor resistance R'(T) in Ω/m ................................................................... 6
4.2.4 Voltage drop per length E in V/m...................................................................... 6
5. Load cases for the cable comparison ............................................................ 6
6. Measuring methods ......................................................................................... 7
6.1. Recording the calibration curve R(T) ................................................................. 7
6.1.1 Sample length .................................................................................................. 7
6.1.2 Four-point measurement .................................................................................. 7
6.1.3 Temperatures to be adjusted............................................................................ 7
6.1.4 Evaluation, determination of R'20, αρ, and βρ ...................................................... 8
6.2. Current-loading test with determination of conductor temperature T ............. 9
6.2.1 Measuring setup............................................................................................... 9
6.2.2 Measurement of room temperature and initial resistance ............................... 10
6.2.3 Measurement of the resistance change with various current supplies ............ 11
6.2.4 Determining the characteristic cable parameters a and b ............................... 12
6.2.5 Determining the time constant τ , dynamic heating characteristics ................. 12
7. Documentation of the parameters to calculate the current capacity........ 13
8. Application of the simplified description model ......................................... 13
8.1. Calculating the current capacity – steady behavior ........................................ 13
8.1.1 Temperature increase and voltage drop with specified current ....................... 14
8.1.2 Permissible current depending on ambient temperature – derating ................ 14
8.2. Calculating the heating time – unsteady behavior .......................................... 16
8.2.1 Calculating the heating time with specified current ......................................... 16
8.2.2 Short-term behavior with load changes .......................................................... 17
8.2.3 Short-circuit derating ...................................................................................... 17
8.2.4 Selection of fuses ........................................................................................... 18
9. Outlook............................................................................................................ 18
 Page 3 of 21
LV 112-3: 2011-12

10. Appendix ......................................................................................................... 19

10.1. List of required measuring equipment (example) ............................................ 19
11. Normative references .................................................................................... 21
12. Literature......................................................................................................... 21

1. Scope
This Supply Specification (LV) describes the procedure to be complied with for mathematically
determining
- the current capacity
- the voltage drop
- and the heating time
of single-wire vehicle cables.
The thermal behavior is modeled by a few separate, characteristic cable parameters. This ap-
proach has an advantage, in that thermal behavior can be done through simple calculation pro-
cesses when these parameters are known. This can be done in various ambient conditions.
Starting from known physical parameters (e.g., specific heat capacity, specific electrical conductor
resistance), the characteristic cable parameters can be calculated on the basis of known and
documented procedures. The computation is not presented in detail in this Supply Specification.
However, measuring methods will be indicated, which allow a verification with the aid of several
measurements.
Caution: The values calculated by means of this Standard are ideal data for cables installed freely
in air. Practice-oriented adaptations for other use conditions must be conducted.
Outlook: As a further consequence, the behavior of multi-wire cables (i.e., of bundles of single-
wire vehicle cables) with and without sheath insulation will be calculable. Therefore, it will be
possible to dimension the cables in a cable set in a practice-oriented manner, without using
complex mathematical models (e.g., finite elements). (Not part of this Supply Specification!)

2. General information
The following is described in this document:
- The definition of the characteristic parameters of single-wire cables
- The measuring methods to verify the calculated characteristic cable parameters of single-
wire cables
- Application examples for using the characteristic parameters
Page 4 of 21
LV 112-3: 2011-12

3. Basics for single-wire cables

3.1. Current capacity

The current capacity of single-wire vehicle cables depends on the following factors:
- Conductor cross section
- Conductor material
- Conductor composition
- Conductor diameter (inner diameter of insulation)
- Insulation material
- Conductor diameter (outer diameter of insulation)
- Ambient temperature
- Installation conditions
- Heat dissipation

3.2. Heating by current

In the measurements described below, the application of a constant current is always assumed!
If a cable has current flowing through it, heating takes place, the extent of which depends on
conductor resistance, time, and on the square of the current.
In principle when heating occurs, the dynamic transition status and the static condition must be
distinguished after a long period of current supply.

3.2.1 Dynamic transition status

The rate of the heating is determined above all by the electrical power input in the conductor
material, the specific heat capacity of the conductor and the insulation, and the heat dissipation
ratios. A thermal time constant τ is characteristic over the course of time, which may range from
several seconds (10 s to 20 s at 0,35 mm²) to several minutes in large battery cables, depending
on nominal cross section.

3.2.2 Steady state

The resulting temperature increase leads to a heat flow through the insulation material to the
surface of the cable, and from there by irradiation and convection to the ambient air. A thermal
equilibrium state takes place over time when current is supplied. In the process, the conductor
temperature converges asymptotically on an upper limit. The rate of heating is determined by the
time constant τ described below. One can assume in good approximation that the temperature at
the conductor no longer changes if the current supply lasts longer than ~5 τ.

3.3. Maximum permissible conductor temperature

The highest temperature occurs at the conductor. When a cable is in operation, care must be
taken that the specific limits for temperature resistance of the insulation material are not exceeded,
taking into account the ambient temperature and self-heating.

3.4. Derating
The connection between the ambient temperature and the permissible current load is described
by derating.
 Page 5 of 21
LV 112-3: 2011-12

4. Simplified computational method

The thermal behavior of a single-wire cable can be described using simplified equations.
6 characteristic cable parameters are required in these equations.

4.1. Definition of parameters

4.1.1 Characteristic cable parameters

a Linear current dependence of the conductor heating
in the steady state in K/A
b Quadratic current dependence of the conductor
heating in the steady state in K/A2
R'20 Length-related conductor resistance at +20 °C in Ω/m
αρ Linear temperature coefficient of the
material-specific conductor resistance in 1/K
βρ Quadratic temperature coefficient of the
material-specific conductor resistance in 1/K²
τ Heating time constant, characteristic value for the
rate of heating of the conductor in s

4.1.2 Additional parameters used

I Current that leads to conductor heating in A
TO Permissible long-term service temperature (3 000 h)
of the cable class in °C
TL Temperature of the conductor in °C
Ta Temperature of the ambient air around the cable,
excluding the convective layer,
(a for ambient) in °C
TL(t) Progress of the conductor temperature in the
dynamic transition area after
abrupt change of the load current in °C
TLmin Beginning temperature of the conductor in the steady
state before abrupt change of the
load current in °C
TLmax End temperature of the conductor after abrupt
change of the load current at the end of the
dynamic transition area in °C

4.2. Simplified equations

The following simplified equations are used to calculate the temperature increase as a result of
current supply.
Note: This simplified representation exactly describes only one definite area of application; how-
ever, it is sufficiently precise for the design of single-wire vehicle cables in practice. If, however,
the expected ambient temperatures deviate heavily from the temperatures at which the measure-
ments described below were made, new parameters must be determined for this.
Page 6 of 21
LV 112-3: 2011-12

4.2.1 Conductor temperature difference ∆T in the steady case in K

∆T = a ⋅I + b⋅ I 2 (eq. 1)

∆T = TL − Ta (eq. 2)

ΔT in K; conductor temperature difference as compared to the ambient temperature in the steady

state (after at least ~5 τ).

4.2.2 Conductor temperature difference ∆T(t) in the dynamic transition status

 t

∆T (t ) = ∆Tmax 1 − e − τ 
  (eq. 3)
∆T (t ) = T (t ) − TL min (eq. 4)

∆Tmax = TL max − TL min (eq. 5)

ΔT(t) in K describes the chronological sequence of the difference in the latest conductor tempera-
ture as compared to the conductor temperature before the abrupt change of current supply. If the
conductor was previously exposed to the ambient temperature Ta without current and for a suffi-
ciently long time (> ~5τ), the conductor temperature TLmin corresponds to the ambient temperature
Ta.

4.2.3 Conductor resistance R'(T) in Ω/m

R' (TL ) = R ' 20 ⋅[1 + α ρ ⋅ (TL − 20 °C ) + β ρ ⋅ (TL − 20 °C )² ] (eq. 6)

4.2.4 Voltage drop per length E in V/m

E = R' (TL ) ⋅ I (eq. 7)

5. Load cases for the cable comparison

The simplified computational procedure described in this Supply Specification enables the
conductor heating to be calculated with great accuracy, depending on a different current load and
ambient temperature of the cable. However, often not the evaluation of a specific loading situation
is desired, but rather the comparison between different cables.
For this comparison, currents in ambient conditions are defined as follows, with reference to the
aging temperatures for short- and long-term aging designated in LV 112-1:
ID Long-term use current (derating current), defined as the current
which, in steady operation
at an ambient temperature of TO – 50 K, results in a
conductor temperature of TL = TO. in A
The associated test in LV 112-1 is the
long-term aging of 3 000 h at TO
IKU Short-term current, defined as the current which, in steady
operation at an ambient temperature of TO – 50 K, results in a
conductor temperature of TL = TO + 25 K. in A
The associated test in LV 112-1 is the
short-term aging of 240 h at TO + 25 K
IÜL Overload current, defined as the current which, in steady
operation at an ambient temperature of TO – 50 K, results in a
conductor temperature of TL = TO + 50 K. in A
 Page 7 of 21
LV 112-3: 2011-12
The associated test in LV 112-1 is the
thermal overloading test of 6 h at TO + 50 K
These three currents must be indicated by the cable manufacturer in addition to the characteristic
parameters of the cable in supplement 1.

6. Measuring methods
Starting from known physical parameters (e.g., specific heat capacity, specific electrical conductor
resistance), the characteristic cable parameters can be calculated on the basis of known and
documented procedures. The computation is not presented in detail in this Supply Specification.
However, measuring methods are indicated, which allow a verification with the aid of the example
measurement at selected cables.

6.1. Recording the calibration curve R(T)

Because the resistance of the cable is used later to determine the temperature of the conductor,
this calibration measurement is conducted first, provided the temperature coefficients of the
conductor material used are not inherently known.
The cable to be tested is heated to defined temperatures in a heatable bath with silicone oil.
As an alternative, measurements are permissible in suitable heating ovens.

6.1.1 Sample length

Nominal cross section Length
<2,5 mm² 10 m
≤2,5 mm² to 10 mm² 5m
≥10mm² 2m
At least 80% of the specimen must be immersed in the oil.

6.1.2 Four-point measurement

The injected current must be kept constant and selected such that the current does not
considerably heat the conductor.
Nominal cross section Max. permissible current
<2,5 mm² 10 mA
≤2,5 mm² to 10 mm² 50 mA
≥10mm² 200 mA
Contacting for the voltage measurement takes place directly in the oil. A measuring instrument
with sufficiently high internal resistance (>1 MΩ) must be provided to measure the voltage. The
length between the voltage measuring points must be defined as ±2 mm exactly.
The resistance of the conductor must be determined by measuring current and voltage for each
adjusted temperature.

6.1.3 Temperatures to be adjusted

Beginning with room temperature, measuring points must be selected with an interval every
approx. 20 K up to TO +50 K.
Note: TO as per temperature class of the sample.
The temperature of the oil bath must be measured and regulated. It must be ensured through
suitable circulation that the bath has a uniform temperature distribution. After the temperature is
increased to the next level, wait until the temperature measurement of the oil does not change for
longer than 1 min by more than ±3 K and the resistance value not by more than 0,40/00.
Page 8 of 21
LV 112-3: 2011-12

6.1.4 Evaluation, determination of R'20, αρ, and βρ

A calibration curve T(R') must be determined from the measured values.
T Temperature in °C
R' Resistance in Ω/m
ΔT = T – 20 °C in K
The resistance temperature value pairs R'(ΔT) – ΔT obtained must then be "fitted" with the follo-
wing resistance curve, and the parameters c, d, and e must be determined.

R' (∆T ) = c ⋅ ∆T 2 + d ⋅ ∆T + e (eq. 8)

However, the representation as in (eq. 6) is common for the temperature dependence of the
resistance. Rewriting (eq. 6) results in the following:

R' (∆T ) = β ρ ⋅ R'20 ⋅∆T 2 +α ρ ⋅R'20 ⋅∆T + R'20

(eq. 9)
R'20 Length-related conductor resistance at +20 °C in Ω/m
αρ Linear temperature coefficient of the
material-specific conductor resistance in 1/K
βρ Quadratic temperature coefficient of the
material-specific conductor resistance in 1/K²
The constants R'20, αρ, and βρ result from comparing coefficients with the following formulas:
R'20 = e (eq. 10)
d
αρ =
e (eq. 11)
c
βρ =
e (eq. 12)
Note: The following approximate temperature coefficients can be assumed:

Conductor Temperature coefficients 1)

material αρ βρ
Cu ETP1 4,0 0,0
Al 99,7 4,1 0,0
CuMg 0,2 3,2 10-3 1/K 0,0 1/K²
CuAg 0,1 3,8 0,0
CuSn 0,3 2,9 0,0
1)
Apply as average values for the temperature interval
+20 °C to +200 °C
 Page 9 of 21
LV 112-3: 2011-12

6.2. Current-loading test with determination of conductor temperature T

6.2.1 Measuring setup

The cable to be tested must be suspended from non-metallic cords in a rectangular-shaped
chamber to prevent a draft of air. The chamber must have the approximate (i.e., with ±50 mm
tolerance in the main dimensions) dimensions of (figure 1) below. The number of required sus-
pension points may be decreased by tightening the straight conductor segments with horizontal
cords.
Heat dissipation by the suspension must be prevented as much as possible. The distance to the
floor must be at least 300 mm, the distance of the cables to one another at least 200 mm, and the
distance of the cable to the room walls at least 50 mm. If necessary, the cable may be laid in a
meandering pattern.
To achieve proper measuring accuracy, the length of the chosen cable to be tested must be as
large as possible, particularly for large nominal cross sections. It is limited in practice by the
dimensions and measuring chamber. For small nominal cross sections with a high length-related
resistance, the largest possible length is determined by the dimensions of the test chamber as
well as by the maximum possible supply voltage of the current source.
Figure 1
Page 10 of 21
LV 112-3: 2011-12

The required length of the sample may either be determined experimentally, or mathematically
using a theoretical computation of the overload current IÜL to be expected as per the following
formula.
U max
l max = (eq. 13)
I ÜL ⋅ R' (TO + 25 K )
Imax Largest possible length of the sample, including the
required length up to the external supply points in m
Umax Highest possible supply voltage of the current source in V
R' (TO + 25 K ) Length-related resistance of the sample at
TO + 25 K, calculated as per eq. 6 in Ω/m
The measurement length between the voltage tapping points must, however, not be less than 1 m,
even with small nominal cross sections.
The nominal cross section of both voltage measurement cables must be significantly smaller than
that of the cable to be tested, in order to minimize thermal influence on the measuring point. A
better thermal coupling is achieved e.g., by winding the measuring cable around the test line
before voltage tapping.
In order to retain a uniform temperature over this range, it is important that at least 1,5 m long
cable segments for supplying the current are located on both sides up to the voltage tapping point.
This results in a minimum possible cable length of 4 m.

6.2.2 Measurement of room temperature and initial resistance

Because the conductor temperature is determined using the resistance of the sample measured
during current-loading and taking into account the temperature coefficients αρ and βρ of the
electrical conductor resistance, the starting situation must be recorded exactly, in order to arrive at
an exact temperature statement.
After the measuring setup has been allowed to dwell at least 4 h without current, so that the
conductor assumes room temperature, the initial resistance and the associated conductor tempe-
rature = room temperature is measured with a current/voltage measurement.
When conducting the current-voltage measurement, do not select a current that is too low, in
order to ensure the required accuracy of reading during the voltage measurement. Care must be
taken to keep the measurement as short as possible to prevent a distortion of the measured value
by heating the conductor too much. Tested values are, e.g., 1 A for 0,35 mm² with a reading time
for voltage under 2 s.
The initial resistance is converted using the known length between the voltage taps to the length-
related resistance.
U
R' (Ta ) = (eq. 14)
I ⋅ lSp
U Measured voltage in V
I Measured current in A
ISp Distance between the voltage taps in m
R'(Ta) Measured length-related resistance at
room temperature Ta in Ω/m
Next, this value pair is used to calibrate the conductor temperature measurement, in which the
latest R'20 value from the rewritten (eq. 6) is calculated as follows, with the known temperature
coefficients αρ and βρ.
 Page 11 of 21
LV 112-3: 2011-12

R ' (Ta )
R '20 = (eq. 15)
1 + α ρ ⋅ (Ta − 20°C ) + β ρ ⋅ (Ta − 20°C )²
As an alternative to this approach, the value for R'20 can also be determined with a temperature-
compensated resistance measuring bridge, which can compensate for the conductor material
used. (Use caution with alloys!)

6.2.3 Measurement of the resistance change with various current supplies

The current to be injected is always kept constant, but is increased in a number of steps (at
least 10) suitable for the expected bend of the current-temperature curve until the conductor
temperature TO +50 K is reached. Subsequently, it is returned to the zero value with the same
steps.
The voltage drop between the voltage taps is measured for each current step, and its average
value determined after the dynamic transition status. The steady state is deemed to be reached
when the measured voltage does not change by more than ±1% over a period of at least ~5 τ.
τ must therefore be estimated beforehand using a theoretical computation.
As an alternative, one can analyze the measured chronological resistance process parallel to the
measurement, preferably in graphic form. A decision can then be made from this, whether the
steady state has already been reached in sufficient quantities.
The room temperature Ta slightly below the level of the cable suspension is always documented
as well.
Direct current (DC) must be used for the measurement. As an alternative, the actual shape of
signal must be taken into account in the computations by suitable corrective factors.
From the quotient R(I), derived from voltage U(I) and current I, taking into account the length
between the voltage taps ISp
U (I )
R ' (I ) = (eq. 16)
I ⋅ l Sp
the conductor temperature TL is calculated by solving (eq. 9) for ΔT as follows. Here, in many
cases (in small quadratic coefficients βρ), only the linear coefficient αρcan be taken into account, in
order to simplify the calculation:
- By neglecting the quadratic temperature coefficient βρ:

1  R ' (I ) 
TL − 20 °C = ∆T = ⋅ − 1 (eq. 17)
α ρ  R' 20 
- By taking into account both temperature coefficients αρ and βρ:

 R ' (I ) 
− α ρ + α ρ + 4⋅ β ρ ⋅ − 1
2

 20
R ' 
TL − 20 °C = ∆T = (eq. 18)
2⋅ β ρ
Page 12 of 21
LV 112-3: 2011-12

Since (eq. 18) can be too highly influenced by measuring errors due to quotients near zero, the
root is replaced by the first three terms of the Taylor series:
x x2
1+ x ≈ 1+ −
2 8 (eq. 19)
which leads to the following more precise result with a small βρ:

1  R ' (I )   β ρ  R ' (I )  
TL − 20 °C = ∆T ≈  − 1 ⋅1 − 2  − 1 (eq. 20)
α ρ  R' 20   α ρ  R ' 20 

6.2.4 Determining the characteristic cable parameters a and b

A table with (at least 8) current values and the assigned conductor temperatures arises as a result
of the measurement and subsequent computation in section 6.2.3.
The characteristic cable parameters a and b must be determined using suitable methods by
"fitting" from the determined values. Only measured values for a conductor temperature of
TO -50 K to TO +25 K must be taken into account in the process.
When using the computational tool, the same temperature range must be taken into account.
The functional association between (eq. 1) and (eq. 2) (see section 4.2.1) must be observed here.
After determining the constants a and b, it is possible to calculate the required load current Izu
from (eq. 1) and (eq. 2) with the specification of the ambient temperature Ta and the permissible
conductor temperature TLzu:

I zu =
1
2⋅b
[
⋅ − a + a ² + 4 ⋅ b ⋅ (TLzu − Ta ) ] (eq. 21)

Note: By solving the quadratic equation (eq. 1), the "+" before the root expression must be used.

6.2.5 Determining the time constant τ , dynamic heating characteristics

The time constant τis preferably determined mathematically by means of the computatio-
nal tool [6]. These values can be confirmed by the measuring method described below in
cases of doubt.
Note: This measuring method will be more optimized in the next revision of LV 112-3.
The time constant τ is measured in the measuring chamber at room temperature, where the
conductor temperatures TLmin and TLmax are adjusted to the following default values, by entering
load currents that were previously calculated with the help of (eq. 21) (see section 6.2.4):
Required current at Conductor tempe- Required current at
Conductor tempe-
Ta = RT rature Ta = RT
rature TLmin
Room temperature TLmax Room temperature
TO –50 K ITo-50 TO +25 K IKu = ITo+25

6.2.5.1. Determining the time constant τ

The temperature of the conductor is monitored and recorded in the measurements described
below by measuring the current and voltage, and determining the conductor resistance as per
equation (eq. 17) or (eq. 20) (see section 6.2.3)
The cable that is built on a measuring setup as per section 6.2.1 in a room at room temperature of
around 20 °C and at the start of the measurement is loaded with the current ITo-50 until no change
to the measured conductor temperature is any longer discerned. The conductor should then
exhibit a temperature approximate to TO –50 K.
 Page 13 of 21
LV 112-3: 2011-12
Next, the cable to be measured is heated with a jump to the current IKu = To+25 as long as necessa-
ry until any change to the measured conductor temperature is no longer discerned. By loading
with ITo+25, the temperature at the conductor ultimately arrives at TO +25 K.
A time constant is determined by this procedure, which corresponds to a continuous load current
approximate to IKU at Ta = TO –50 K; however, the measurement can take place here at room
temperature.
The periodic intervals between the individual recorded measured values must be selected such
that at least 20 measured values are available for the dynamic transition area. The following time
intervals have proven useful:
Nominal cross section Time intervals
<0,5 mm² 1s
≤4 mm² 3s
6 mm² to 10 mm² 10 s
≥10 mm² 20 s
The time constant τfrom the values determined by "fitting" must be determined. The functional
association in the process as per (eq. 3) (see section 4.2.2) must be observed.
Example: Unscreened low-voltage cable with thin-walled PVC insulation (FLRY) 2,5-B, a = 0,25,
b = 0,041, Ta =20 °C, τ = 60,6 s
ITo -50K = 30,2 A; IKu = ITo+25K = 48,8; TO = 105 °C; TO –50K = 65 °C, TO +25K = 130 °C

7. Documentation of the parameters to calculate the current capacity

The cable manufacturers must enter the parameters defined in LV 112-3, supplement 1 for each
cable, and provide them to the appropriate design engineering department.

8. Application of the simplified description model

8.1. Calculating the current capacity – steady behavior

The permissible current capacity of a cable depends on the following parameters:
- the ambient temperature to be expected
- the maximum permissible long-term service temperature TO, depending on the cable class
used or on the insulation material
- the characteristic cable parameters of the cable used
Page 14 of 21
LV 112-3: 2011-12

8.1.1 Temperature increase and voltage drop with specified current

The conductor temperature during continuous loading results from (eq. 1) and (eq. 2) (see sec-
tion 4.2.1) with the specified ambient temperature Ta and load current I:
TL ( I , Ta ) = Ta + a I + b I 2 (eq. 22)

Note: This formula yields a correct result only with positive current values!
The associated voltage drop per 1 m results from (eq. 6) (see section 4.2.3) and (eq. 7) (see
section 4.2.4)

[
E ( I ) = I ⋅ R'20 ⋅ 1 + α ρ ⋅ (TL − 20) + β ρ ⋅ (TL − 20) 2 ] (eq. 23)

In order to take into account the worst-case in voltage drop, the maximum permissible resistance
for R'20 is taken as a basis from LV 112-1 for the respective cable.
Example: FLRY 2,5-B, a = 0,25, b = 0,041, Ta = 65 °C,
R20 = 7,6 mΩ/m, αρ = 3,81∙10-3 1/K, βρ = 6∙10-7 1/K2

8.1.2 Permissible current depending on ambient temperature – derating

The maximum permissible current must be determined such that, under continuous loading,
taking into account the ambient temperature to be expected, the temperature at the conductor
remains lower than the long-term service temperature TO.
At maintained TO and varied ambient temperature Ta, the desired functional association for the
permissible current also results from (eq. 1) and (eq. 2) (see section 4.2.1)
Two representations are possible, where the same information can be derived from both conse-
quent diagrams. However, (eq. 24) or (eq. 25) are better suited for calculating a specific load case,
depending on the problem.
(eq. 23) is used again to calculate the voltage drops.
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8.1.2.1. Permissible ambient temperature with specified current

Ta ( I , TO ) = To − a I − b I 2 (eq. 24)

Note: This formula yields a correct result only with positive current values!
Example: FLRY 2,5-B, a = 0,25, b = 0,041, TO = 105 °C,
R20 = 7,6 mΩ/m, αρ = 3,81∙10-3 1/K, βρ = 6∙10-7 1/K2

8.1.2.2. Permissible current with specified ambient temperature

I (Ta , TO ) =
1
2⋅b
[
⋅ − a + a ² + 4 ⋅ b ⋅ (TO − Ta ) ] (eq. 25)

Note: By solving the quadratic equation, the "+" before the root expression must be used.
Example: FLRY 2,5-B, a = 0,25, b = 0,041, TO = 105 °C,
R20 = 7,6 mΩ/m, αρ = 3,81∙10-3 1/K, βρ = 6∙10-7 1/K2
Page 16 of 21
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8.2. Calculating the heating time – unsteady behavior

The size of the time constant τis very highly dependent on the ambient temperature Ta,
where τ is lower with a higher ambient temperature. If conductor temperature are estimated
taking the dynamic transition behavior as a basis, lower values for τ must be selected to en-
sure additional certainty.

8.2.1 Calculating the heating time with specified current

With specified ambient temperature and permissible conductor temperature, the permissible
continuous load current I (Ta, TO) arises from (eq. 25), at which the long-term service temperature
of the cable TO is not exceeded. This equation can also be used for calculating any limit currents
IGr, if a different limit temperature TGr is used instead of TO.
From (eq. 26), taking into account the time constant τ for currents that are higher than the limit
current IGr, the heating time tE can be calculated, which is required after an abrupt switching-on of
the current I. This is so that at the ambient temperature Ta, starting from the no-current status, the
conductor temperature TGr can be reached.
a ⋅ I + b⋅ I²
t E = τ ⋅ ln (eq. 26)
a ⋅ I + b ⋅ I ² − (TGr − Ta )
As an alternative, one can determine the limit current IGr with (eq. 25) and calculate it with the
simplified equation (eq. 27).
I2
t ≈ τ ⋅ln (eq. 27)
I 2 − I Gr
2

In the following example, the heating times for various load currents are presented in a diagram,
where the short-term current IKU defined in section 5 is used as the limit current IGr.

Example: FLRY 2,5-B, τ = 68 s, heating of Ta = 65 °C to TL = 130 °C,

IGr = IKU = 39,8 A, Compare tE as per (eq. 26) or t as per. (eq. 27)

The peak current IKu is the current at which exactly the short-term temperature TKu is reached at
the conductor, with specified ambient temperature Ta in the steady borderline case. The curve in
the diagram thus approaches the steady current IKu asymptotically.
One can recognize well in the example, that the error when using the simplified (eq. 27) is only
very low.
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8.2.2 Short-term behavior with load changes

The chronological sequence in load changes can be calculated with the equations (eq. 3) , (eq. 4) ,
and (eq. 5).

Example: FLRY 2,5-B, τ = 68 s, Ta = To-50 K = 55 °C,

TLmin = 105 °C, TLmax = 155 °C, ID = 32,0 A, IKu = 46,4 A

This example demonstrates the time behavior during short-term overload. Initially, the conductor
has the permissible class temperature of TLmin = TO = 105 °C. This is reached at the selected
ambient temperature Ta = TO –50 K = 55 °C by the derating current ID = 32,0 A. With increase to
the overload current IÜL = 46,4 A, the conductor temperature approaches the short-term tempera-
ture TÜL = TO +50 K = 155 °C with the time constant τ = 68 s. However, the conductor temperature
does not quite reach the short-term temperature, since the lower current is again supplied after
300 s, whereby cooling to TO takes place with the same time constant.
Note: Both currents ID and IÜL can be calculated with (eq. 25) (see section 8.1.2.2).

8.2.3 Short-circuit derating

(eq. 27) (see section 8.2.1) can be rewritten as follows, where also IGr is replaced by IÜL:

1
I (t ) ≈ IÜL ⋅ t
−
1− e τ (eq. 28)

The overload current IÜL has been defined in the preceding example, at which the temperature for
the thermal overload test TÜL = TO +50 K, defined in LV 213-1, is not exceeded in the steady case.
All cables must withstand this temperature for 6 h without incurring damage.
Starting with this overload current IÜL, it can be calculated using (eq. 28), how long short-circuit
currents must be present at maximum at the initially current-free conductor, to ensure that the
thermal overload temperature TÜL is not exceeded.
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Example: FLRY 2,5-B, τ = 68 s, Ta = TO –50 K = 55 °C,

TÜL = TO +50 K = 155 °C, IÜL = 46,4 A

8.2.4 Selection of fuses

The guaranteed triggering time of the fuse to be used at the specified short-circuit current strength
must be less than or equal to the times calculated in section 8.2.3, to ensure that the conductor
temperature remains less than TÜL.
In practice, low short-circuit currents are problematic above all, such as those occurring in cree-
ping short circuits, because many fuses then require a very long time to trigger. This means that
the guaranteed triggering times are generally far longer than the time constant τ of the cables.
When selecting the fuse, therefore, the thermal overload current IÜL of the cable must be observed
above all.

9. Outlook
In addition to the single-wire cables described in this Standard, the following components are also
used for supplying current to the electrical components in vehicles:
1. Multi-wire cables
2. Harnesses
3. Fuses
4. Current distributor boxes
By using and further developing the simplified mathematical approach described in this document,
standardized computation procedures are planned to be prepared in the future for these areas.
As described in the references (see section 0), it is also possible to arrive at the characteristic
parameters by computation using a few practical control measurements, if the physical material
constants of the materials used are known. There is a computational tool (software package) [6]
for this purpose, which is offered for sale.
 Page 19 of 21
LV 112-3: 2011-12

10. Appendix

10.1. List of required measuring equipment (example)

1. Test chamber with approx. 1,8 m³ space volume (see Figure 1)
2. Power supply unit for current injection, manufactured by Fug,
Type "Low Voltage Power Supply NTN 700M – 65"
Input
Mains connection, single-phase 230 V ±10%
47 to 63 Hz
max. 6 A
or 115 V ±10%
47 to 63 Hz
max. 12 A
Output
Output current 0 to 10 A
Output voltage 0 to 65 V
Accuracy
All data related to maximum value
<1 x 10-4 ss +
Residual ripple 10 mVss
Normal deviation of current or voltage
At ±10% mains power deviation at idle state <1 x 10-5
At ±10% mains power deviation at full throttle <2 x 10-4
Over 8 h constant conditions <±1 x 10-4
With temperature change <±1 x 10-4/K
Absolute precision
<±0,2% of
For all rated voltages nominal value
<±0,2% of
For all rated currents >5 mA to <10 A nominal value
3. High-current device, manufactured by Jovyatlas, custom build without type designation
Input
Mains connection, three-phase 230 V ±10%
47 to 63 Hz
Max. 7 A
Output
Output current 0 to 1 200 A
Output voltage 0 to 5,1 V
Limits
Current ripple 0,3% max.
Leap in desired value, current
Readjustment time 0 to 1 200 A 635 ms typ.
Page 20 of 21
LV 112-3: 2011-12
4. Multimeter for current measurement, manufactured by HP, type HP 34401A
24 h (23 ±1) °C 24 h (23 ±1) °C
Accuracy of reading Measuring range accuracy
DC V % %
100 mV ±0,0030 ±0,0030
1V ±0,0020 ±0,0006
10 V ±0,0015 ±0,0004
DC I
10 mA ±0,005 ±0,01
100 mA ±0,010 ±0,004
1A ±0,050 ±0,006
3A ±0,100 ±0,020
5. Multimeter for current measurement, manufactured by Keithley, type 2700,
with data recording by LabView programming
24 h (23 ±1) °C 24 h (23 ±1) °C
Accuracy of reading Measuring range accuracy
DC V % %
100 mV ±0,0015 ±0,0030
1V ±0,0015 ±0,0006
10 V ±0,0010 ±0,0004
DC I
20 mA ±0,0060 ±0,0030
100 mA ±0,0100 ±0,0300
1A ±0,0200 ±0,0030
3A ±0,1000 ±0,0015
6. Temperature measurement with thermopair TE type K, Testo data logger T4 for recording
room temperature in derating box and conductor temperature
24 h (23 ±1) °C
Measuring range
accuracy
%
Measuring instrument (-100
±0,3 °C
to 70) °C
Thermopair with
TE plug, flexible, length ±0,0075•δ
1 500 mm, filament glass ±2,5 °C (referenced to
yarn, temperature in °C)
TE type K
Sensor deviation measured
±0,2 °C
at +80 °C
 Page 21 of 21
LV 112-3: 2011-12

11. Normative references

The following cited documents are required for application of this document. 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.

LV 112-1 Electric wiring in motor vehicles, copper cable; single-wire, unscreened

LV 112-2 Electric wiring in motor vehicles, aluminum cables; single-wire, unscreened

12. Literature
[1] VDI Heat Atlas, issuing body: Association of German Engineers (VDI), Berlin (Springer
Verlag), 10th edited and expanded edition, 2006, ISBN 3-540-25504-4
[2] Kabel und Leitungen für Starkstrom (Cables and lines for heavy current – only available in
German), part 1, issuing body Lothar Heinhold, Berlin, Munich (Siemens AG), 4th revised
edition 1987, ISBN 3-8009-1472-7
[3] Bestimmung der Strombelastbarkeit von Fahrzeugleitungen (Determining the current-
loading capacity of vehicle cables – only available in German), H.-D. Ließ, Universität der
Bundeswehr, Munich, 2010
[4] Berechnungswerkzeug (Softwaretool) (Calculation tool (Software tool) – only available in
German), H.-D. Ließ, Universität der Bundeswehr, Munich