ASTM D3032-98
(Test Method)Standard Test Methods for Hookup Wire Insulation
Standard Test Methods for Hookup Wire Insulation
SCOPE
1.1 These test methods cover procedures for testing hookup wire.
1.2 For the purposes of these test methods, hookup wire insulation includes all components of the insulation system used on single insulated conductors or an assembly of single insulated conductors such as a cable bundle and harness or flat ribbon cable. The insulating materials include not only the primary insulation over the conductor, but also insulating jackets over shielded constructions.
1.3 The test procedures and their locations are as follows: Section Axial Stability (Longitudinal Change) After Thermal Exposure 21 Bondability of Insulation to Potting Compounds 19 Capacitance 9 to 12 Cold Bend Test 26 Concentricity 16 Crush Resistance 20 Dielectric Breakdown Voltage 5 Dimensions 15 Dry-Arc Tracking 29 Dynamic Cut-Through 22 Fluid Immersion 23 High Temperature Shock 24 Insulation-Continuity Proof Tests 13 Insulation Resistance 6 Partial Discharge (Corona) Inception and Extinction Voltage 25 Relative Thermal Life and Temperature Index 14 Strip Force 27 Surface Resistance 7 Tensile Properties 17 Vertical Flame Test 18 Voltage Rating of Hook-Up Wire A2 Voltage Withstand Test 8 Wet Arc-Tracking 28
1.4 The values stated in SI are to be regarded as the standard.
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. For specific precaution statements, see Note 10, 12.4.1.8, 18.1.1.2, and Notes 19 and 21.
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An American National Standard
Designation: D 3032 – 98
Standard Test Methods for
Hookup Wire Insulation
This standard is issued under the fixed designation D 3032; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.
1. Scope bility of regulatory limitations prior to use. For specific
precaution statements, see Note 10, 12.4.1.8, 18.1.3and Note
1.1 These test methods cover procedures for testing hookup
18 and Note 20.
wire.
1.2 For the purposes of these test methods, hookup wire
2. Referenced Documents
insulation includes all components of the insulation system
2.1 ASTM Standards:
used on single insulated conductors or an assembly of single
D 149 Test Method for Dielectric Breakdown Voltage and
insulated conductors such as a cable bundle and harness or flat
Dielectric Strength of Solid Electrical Insulating Materials
ribbon cable. The insulating materials include not only the
at Commercial Power Frequencies
primary insulation over the conductor, but also insulating
D 150 Test Methods for AC Loss Characteristics and Per-
jackets over shielded constructions.
mittivity (Dielectric Constant) of Solid Electrical Insula-
1.3 The test procedures and their locations are as follows:
tion
Section
D 257 Test Methods for DC Resistance or Conductance of
Axial Stability (Longitudinal Change) After Thermal Exposure 21
Bondability of Insulation to Potting Compounds 19
Insulating Materials
Capacitance 9 to 12
D 374 Test Methods for Thickness of Solid Electrical Insu-
Cold Bend Test 26
lation
Concentricity 16
Crush Resistance 20
D 412 Test Methods for Vulcanized Rubber and Thermo-
Dielectric Breakdown Voltage 5
plastic Rubbers and Thermoplastic Elastomers—Tension
Dimensions 15
D 471 Test Method for Rubber Property—Effect of Liq-
Dry-Arc Tracking 29
Dynamic Cut-Through 22
uids
Fluid Immersion 23
D 543 Practices for Evaluating the Resistance of Plastics to
High Temperature Shock 24
Chemical Reagents
Insulation-Continuity Proof Tests 13
Insulation Resistance 6
D 618 Practice for Conditioning Plastics for Testing
Partial Discharge (Corona) Inception and Extinction Voltage 25
D 638 Test Method for Tensile Properties of Plastics
Relative Thermal Life and Temperature Index 14
D 1711 Terminology Relating to Electrical Insulation
Strip Force 27
Surface Resistance 7
D 1868 Test Method for Detection and Measurement of
Tensile Properties 17
Partial Discharge (Corona) Pulses in Evaluation of Insu-
Vertical Flame Test 18
lation Systems
Voltage Rating of Hook-Up Wire A2
Voltage Withstand Test 8
D 2303 Test Methods for Liquid-Contaminant, Inclined-
Wet Arc-Tracking 28
Plane Tracking and Erosion of Insulating Materials
1.4 The values stated in SI are the standard. The values
D 2307 Test Method for Relative Thermal Endurance of
given in parentheses are for information only.
Film-Insulated Round Magnet Wire
1.5 This standard does not purport to address all of the
D 2436 Specification for Forced-Convection Laboratory
safety concerns, if any, associated with its use. It is the
Ovens for Electrical Insulation
responsibility of the user of this standard to establish appro-
D 2865 Practice for Calibration of Standards and Equip-
priate safety and health practices and determine the applica-
ment for Electrical Insulating Materials Testing
D 3183 Practice for Rubber—Preparation of Pieces for Test
These test methods are under the jurisdiction of ASTM Committee D-9 on
Electrical and Electronic Insulating Materials and are the direct responsibility of
Subcommittee D09.18 on Solid Insulations, Non-Metallic Shieldings and Coverings Annual Book of ASTM Standards, Vol 10.01.
for Electrical and Telecommunication Wires and Cables. Annual Book of ASTM Standards, Vol 09.01.
Current edition approved Oct. 10, 1998. Published January 1999. Originally Annual Book of ASTM Standards, Vol 08.01.
published as D 3032 – 72. Last previous edition D 3032 – 97. Annual Book of ASTM Standards, Vol 10.02.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
D3032–98
Purposes from Products 3.1.12 harness, n—one or more bundles of hookup wire
D 3636 Practice for Sampling and Judging Quality of Solid tied, clamped, or otherwise fitted together for final installation;
Electrical Insulating Materials used for interconnecting electrical circuits.
D 3638 Test Method for Comparative Tracking Index of 3.1.13 hookup bundle, n—a group of insulated conductors
Electrical Insulating Materials
or hookup cables grouped into an assembly prior to installa-
E 29 Practice for Using Significant Digits in Test Data to tion, usually with multiple breakouts.
Determine Conformance with Specifications
3.1.14 hookup cable, n—two or more insulated conductors
E 104 Practice for Maintaining Constant Relative Humidity
in a common covering, or two or more insulated conductors
by Means of Aqueous Solutions
twisted or molded together without a common covering, or one
E 691 Practice for Conducting an Interlaboratory Study to
or more insulated conductors with a conductive shield with or
Determine the Precision of a Test Method
without an outer covering.
2.2 IEEE Standards:
3.1.15 hookup wire, n—an insulated conductor that is used
Standard 98 Guide for the Preparation of Test Procedures
to make point-to-point connections in an electrical or electronic
for the Thermal Evaluation of Electrical Insulating Mate-
system.
rials
3.1.16 insulated conductor, n—a conductor, covered by a
Standard 101 Statistical Analysis of Thermal Life Test Data
layer or layers of insulating material, whose prime function is
2.3 Federal Standard:
to carry electric current.
Federal Specification for Tape, Gummed; Paper, Rein-
3.1.17 insulation resistance—see Terminology D 1711.
forced and Plain, for Sealing and Securing (PPP-T-45C)
3.1.18 jacket, n—an integral covering (sometimes fabric
reinforced), which is applied over the insulation, core, shield,
3. Terminology
or armor of a cable and whose prime function is to provide
3.1 Definitions: mechanical or environmental protection for the component(s)
3.1.1 arc propagation—the movement of an electric arc that it covers.
from its point of inception to another location.
3.1.19 primary insulation, n—the first layer of two or more
3.1.2 braid, n—(1) woven, metallic wire used as a shield for layers of insulating materials over a conductor.
insulated conductors and cables. (2) a woven fibrous protec-
3.1.19.1 Discussion—The prime function of primary insu-
tive outer covering over an insulated conductor or cable.
lation is to act as an electrical barrier.
3.1.3 capacitance—see Terminology D 1711.
3.1.20 primary jacket, n—a layer of insulating material
3.1.4 capacitance unbalance (of a pair in a shielded cable),
applied over the primary insulation for the purpose of provid-
n—the ratio, expressed as a percentage, of the difference in
ing mechanical protection for the primary insulation.
capacitance between each of two insulated conductors and the
3.1.21 rope-lay conductor, n—a conductor composed of a
shield, to the capacitance between that conductor pair.
central core surrounded by one or more layers of helically laid
3.1.4.1 Discussion—Capacitance unbalance is also called
groups of strands.
coefficient of asymmetry or capacitance asymmetry, and is
3.1.21.1 Discussion—This kind of conductor differs from a
expressed in percent unbalance.
concentric-lay conductor in that the main wires are themselves
3.1.5 concentricity, n—the ratio, expressed in percent, of
stranded. In the most common type of rope-lay conductor, all
the minimum wall thickness to the maximum wall thickness.
strands are the same size and the central core is a concentric-
3.1.6 concentric-lay conductor, n—a conductor composed
lay conductor.
of a central core surrounded by one or more layers of helically
3.1.22 round conductor flat cable, n—a flat cable made with
laid strands.
parallel, round conductors in the same plane.
3.1.6.1 Discussion—In the most common type of
3.1.23 shield—a conducting layer placed around an insu-
concentric-lay conductor, all strands are of the same size and
lated conductor or cable to limit the penetration of electric or
the central core is a single strand.
electromagnetic fields.
3.1.7 dielectric breakdown voltage—see Terminology
3.1.23.1 Discussion—A shield can be braided or served
D 1711.
wires, foil wrap, foil-backed tape, a metallic tube or conductive
3.1.8 dissipation factor—see Terminology D 1711.
polymeric compositions.
3.1.9 flat cable, n—any cable with two smooth or corru-
3.1.24 solid conductor, n—a conductor consisting of one
gated, but essentially flat, surfaces.
strand.
3.1.10 flat conductor, n—a conductor with a width-to thick-
3.1.25 surface resistance—see Terminology D 1711.
ness ratio arbitrarily chosen as 5 to 1 or greater.
3.1.25.1 Discussion—For a fixed electrode separation, the
3.1.11 flat conductor cable, n—a cable of flat conductors.
measured surface resistance of a given hookup wire decreases
as the diameter increases.
3.1.26 temperature index, n—a number which permits com-
parison of the temperature/time characteristics of an electrical
Annual Book of ASTM Standards, Vol 14.02.
Annual Book of ASTM Standards, Vol 11.03.
insulating material, or a simple combination of materials, based
Available from the Institute of Electrical and Electronics Engineers, Inc., 345
on the temperature in degrees Celsius which is obtained by
E. 47th St., New York, NY 10017.
extrapolating the Arrhenius plot of life versus temperature to a
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS. specified time, usually 20 000 h.
D3032–98
3.1.26.1 Discussion—For hookup wire, the symbol TI is 5.4.1 Immerse the test specimen to within 152 mm (6 in.) of
used for temperature index and the preferred use of the TI the twisted ends in the water bath containing 5 % sodium
symbol implies a time of 20 000 h obtained by analysis of chloride (NaCl) and 0.05 to 0.10 % wetting agent.
aging data in which extrapolation is limited to no more than 5.4.2 Use the water solution as the ground electrode, and
25°C below the lowest aging temperature (See also Section apply the voltage to the twisted end of the conductor.
14). 5.4.3 Raise the voltage from zero at a rate of 500 V/s until
the specimen fails. If a flashover between the water solution
3.1.27 thermal endurance, n—an expression for the stability
of an electrical insulating material, or a simple combination of and the twisted ends of the wire occurs, discard the specimen
without retesting. Select longer specimens so that the distance
materials, when maintained at elevated temperatures for ex-
tended periods of time. between the water solution and the ends of the wire is sufficient
to prevent flashover.
3.1.27.1 Discussion—The stability of hookup wire insula-
5.5 Report:
tion is estimated from changes in the results of voltage
5.5.1 Report the following information:
withstand tests on hookup wire specimens that have been heat
5.5.1.1 Description of the specimen,
aged, cooled to room temperature, flexed over a mandrel,
5.5.1.2 Voltage at which breakdown occurred,
immersed in salt water, and subjected to a specific applied
5.5.1.3 Description of any previous environmental exposure
voltage.
given to the specimen before testing, and
3.2 Definitions of Terms Specific to This Standard:
5.5.1.4 Conditions under which the test was run.
3.2.1 cold bend test—a test in which a specimen is slowly
wrapped around a mandrel of a specified diameter after
6. Insulation Resistance
conditioning at a specified low temperature to determine that
the primary insulation, primary jacket, overall jacket and any 6.1 Significance and Use:
other layer of the wire or cable specimen maintains sufficient 6.1.1 In high impedance circuits, insulation resistance is
flexibility to withstand such bending at that low temperature functionally important. In some cases, changes in insulation
without evidence of cracking. resistance may indicate deterioration of other properties. Insu-
lation resistance is also useful for quality control.
3.2.2 relative thermal endurance—the comparison of the
thermal endurance (as described by their Arrhenius plots) of
NOTE 1—The term “insulation resistance” is a standard term used in the
two or more insulated wires designed for the same specific use;
hookup wire industry to designate the resistance of a specified length of
this usually implies the same size of conductor, but the
insulated wire, normally expressed as ohm-1000 ft. This is not a true
insulation is of the thickness required for the particular use of insulation resistance since a resistance for a known length can be
calculated and, also, the tests are conducted in a manner to eliminate
each insulation.
surface conduction. The value obtained in this type of measurement is
3.2.3 strip force—force required to remove a specified
actually a volume resistance, but will be referred to here as insulation
length of insulation from an insulated wire specimen as
resistance to avoid confusion in the hookup wire industry.
determined by a specified test procedure.
6.2 Apparatus:
3.2.4 voltage withstand (proof-voltage) test—the applica-
6.2.1 Battery Jar, or other insulated vessel, large enough to
tion of a specified voltage for a specified time to a specified
immerse the specimen, filled with water containing 0.05 to
configuration of the insulation. Results are expressed as “pass”
0.10 % wetting agent. The water bath shall serve as one
or “fail.”
electrode.
6.2.2 Use apparatus described in Test Methods D 257 for the
4. Sampling
resistance measurement.
4.1 Refer to the material specification for sampling plan
6.3 Test Specimens:
covering specific types of hookup wire insulations.
6.3.1 The test specimen shall consist of a 8.3-m (or 26-ft)
4.2 Use Practice D 3636 as a guide if the material specifi-
length of the insulated wire. Remove the insulation for a
cation does not include a sampling plan.
distance of 25 mm (1 in.) at each end and twist the ends
together.
5. Dielectric Breakdown Voltage
6.4 Procedure:
5.1 Significance and Use: 6.4.1 Immerse the specimen to within 152 mm (6 in.) of the
twisted ends in the water bath, which is maintained at 23 6
5.1.1 A detailed statement of significance is given in Ap-
5°C (73 6 9°F). Make an initial resistance measurement
pendix X1 of Tes
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