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ASTM D3032-04

(Test Method)

Standard Test Methods for Hookup Wire Insulation

Standard Test Methods for Hookup Wire Insulation

ABSTRACT
These test methods detail the standard procedures for testing hookup wire insulations including 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. The test procedures covered here shall be performed in the conditions or shall determine the properties, as follows: axial stability (longitudinal change) after thermal exposure; bondability to potting compounds; capacitance; cold bend test; concentricity; crush resistance; dielectric breakdown voltage; dimensions; dry-arc tracking; dynamic cut-through; fluid immersion; high temperature shock; insulation-continuity proof tests; insulation resistance; partial discharge (corona) inception and extinction voltage; relative thermal life and temperature index; strip force; surface resistance; tensile properties; vertical flame test; voltage rating of hook-up wire; voltage withstand test; and wet arc-tracking.
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:
1.4 The values stated in SI are the standard. The values given in parentheses are for information only.
1.5 sibility 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 12.2.1, 12.4.1.8, 18.1.3 and Note 17 and 25.4.

General Information

Status
Historical
Publication Date
31-Mar-2004
ICS
29.060.10 - Wires
Technical Committee
D09 - Electrical and Electronic Insulating Materials
Current Stage
Ref Project

Relations

Replaces
ASTM D3032-98 - Standard Test Methods for Hookup Wire Insulation
Effective Date
01-Apr-2004
Replaced By
ASTM D3032-10 - Standard Test Methods for Hookup Wire Insulation
Effective Date
01-Mar-2010
Referred By
ASTM D4565-20 - Standard Test Methods for Physical and Environmental Performance Properties of <brk/>Insulations and Jackets for Telecommunications Wire and Cable
Effective Date
01-Apr-2004
Referred By
ASTM D1711-22 - Standard Terminology Relating to Electrical Insulation
Effective Date
01-Apr-2004
Referred By
ASTM D8354-21 - Standard Test Method for Flammability of Electrical Insulating Materials Intended for Wires or Cables When Burning in a Vertical Configuration
Effective Date
01-Apr-2004

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ASTM D3032-04 - Standard Test Methods for Hookup Wire Insulation
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Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information.
An American National Standard
Designation: D3032 – 04
Standard Test Methods for
1
Hookup Wire Insulation
This standard is issued under the fixed designation D3032; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) 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 12.2.1, 12.4.1.8, 18.1.3and Note 17
1.1 These test methods cover procedures for testing hookup
and 25.4.
wire.
1.2 For the purposes of these test methods, hookup wire
2. Referenced Documents
insulation includes all components of the insulation system
2
2.1 ASTM Standards:
used on single insulated conductors or an assembly of single
D149 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
D150 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
D257 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
D374 Test Methods for Thickness of Solid Electrical Insu-
Cold Bend Test 26
lation
Concentricity 16
Crush Resistance 20
D412 Test Methods for Vulcanized Rubber and Thermo-
Dielectric Breakdown Voltage 5
plastic Elastomers—Tension
Dimensions 15
D471 Test Method for Rubber Property—Effect of Liquids
Dry-Arc Tracking 29
Dynamic Cut-Through 22
D543 Practices for Evaluating the Resistance of Plastics to
Fluid Immersion 23
Chemical Reagents
High Temperature Shock 24
D638 Test Method for Tensile Properties of Plastics
Insulation-Continuity Proof Tests 13
Insulation Resistance 6
D1711 Terminology Relating to Electrical Insulation
Partial Discharge (Corona) Inception and Extinction Voltage 25
D1868 Test Method for Detection and Measurement of
Relative Thermal Life and Temperature Index 14
Partial Discharge (Corona) Pulses in Evaluation of Insu-
Strip Force 27
Surface Resistance 7
lation Systems
Tensile Properties 17
D2303 Test Methods for Liquid-Contaminant, Inclined-
Vertical Flame Test 18
Plane Tracking and Erosion of Insulating Materials
Voltage Rating of Hook-Up Wire A2
Voltage Withstand Test 8
D2307 Test Method for Thermal Endurance of Film-
Wet Arc-Tracking 28
Insulated Round Magnet Wire
1.4 The values stated in SI are the standard. The values
D2865 PracticeforCalibrationofStandardsandEquipment
given in parentheses are for information only.
for Electrical Insulating Materials Testing
1.5 This standard does not purport to address all of the
D3183 Practice for Rubber—Preparation of Pieces for Test
safety concerns, if any, associated with its use. It is the
Purposes from Products
responsibility of the user of this standard to establish appro-
D3636 Practice for Sampling and Judging Quality of Solid
priate safety and health practices and determine the applica-
Electrical Insulating Materials
D3638 Test Method for Comparative Tracking Index of
Electrical Insulating Materials
1
These test methods are under the jurisdiction of ASTM Committee D09 on
Electrical and Electronic Insulating Materials and are the direct responsibility of
SubcommitteeD09.18onSolidInsulations,Non-MetallicShieldingsandCoverings
2
for Electrical and Telecommunication Wires and Cables. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved April 1, 2004. Published May, 2004. Originally contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
approved in 1972. Last previous edition approved in 1998 as D3032–98. DOI: Standards volume information, refer to the standard’s Document Summary page on
10.1520/D3032-04. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
1

---------------------- Page: 1 ----------------------
D3032 – 04
D5032 Practice for Maintaining Constant Relative Humid- 3.2.6.1 Discussion—Forhookupwire,thesymbolTIisused
ity by Means of Aqueous Glycerin Solutions for temperature index and the preferred use of the TI symbol
D5374 Test Methods for Forced-Convection Laboratory implies a time of 20 000 h obtained by analysis of ag
...

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SIGNIFICANCE AND USE
5.1 This test method is useful in determining the thermal endurance characteristics and thermal indices of film-insulated round magnet wire in air (see 1.3). This test method is used as a screening test before making tests of more complex systems or functional evaluation. It is also used where complete functional systems testing is not feasible.  
5.2 Experience has shown that film-insulated wire and electrical insulating varnishes or resins can affect one another during the thermal exposure process. Test Method D3251 provides indications on the thermal endurance for a combination of insulating varnish or resin and film insulated wire. It is possible that interaction between varnish or resin and film insulation will increase or decrease the relative thermal life of the varnish and film insulated wire combination compared with the life of the film insulated wire tested without varnish.  
5.3 The conductor type or the surface condition of the conductor will affect the thermal endurance of film-insulated magnet wire. This test method is used to determine the thermal endurance characteristics of film insulation on various kinds of conductors. The use of sizes other than those specified in 7.1.1 is permissible but is not recommended for determining thermal endurance characteristics.  
5.4 The temperature index determined by this test method is a nominal or relative value expressed in degrees Celsius at 20 000 h. It is to be used for comparison purposes only and is not intended to represent the temperature at which the film insulated wire could be operated.  
5.5 There are many factors that influence the results obtained with this test method. Among the more obvious are the following:  
5.5.1 Wire size and film thickness.  
5.5.2 Moisture conditions during proof voltage tests.  
5.5.3 Oven construction:
5.5.3.1 Velocity of air.
5.5.3.2 Amount of replacement air.
5.5.3.3 Elimination of products of decomposition during thermal exposure.
5.5.3.4 Oven loading....
SCOPE
1.1 This test method covers determination of the thermal endurance of film-insulated round magnet wire in air at atmospheric pressure. It is not applicable to magnet wire with fibrous insulation, such as cotton or glass.  
1.2 This test method covers the evaluation of thermal endurance by observing changes in response to ac proof voltage tests. The evaluation of thermal endurance by observing changes in other properties of magnet wire insulation requires the use of different test methods.  
1.3 It is possible that exposure of some types of film insulated wire to heat in gaseous or liquid environments in the absence of air will give thermal endurance values different from those obtained in air. Consider this possibility when interpreting the results obtained by heating in air with respect to applications where the wire will not be exposed to air in service.  
1.4 It is possible that electric stress applied for extended periods at a level exceeding or even approaching the discharge inception voltage will change significantly the thermal endurance of film insulated wires. Under such electric stress conditions, it is possible that comparisons between materials will also differ from those developed using this method.  
1.5 This test method is similar to IEC 60172. Differences exist regarding specimen preparation.  
1.6 The values stated in inch-pound units are to be regarded as the standard. The SI units in parentheses are provided for information only and are not considered standard.  
1.7 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
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ASTM D3032-21a(Test Method)
Standard Test Methods for Hookup Wire Insulation

ABSTRACT
These test methods detail the standard procedures for testing hookup wire insulations including 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. The test procedures covered here shall be performed in the conditions or shall determine the properties, as follows: axial stability (longitudinal change) after thermal exposure; bondability to potting compounds; capacitance; cold bend test; concentricity; crush resistance; dielectric breakdown voltage; dimensions; dry-arc tracking; dynamic cut-through; fluid immersion; high temperature shock; insulation-continuity proof tests; insulation resistance; partial discharge (corona) inception and extinction voltage; relative thermal life and temperature index; strip force; surface resistance; tensile properties; vertical flame test; voltage rating of hook-up wire; voltage withstand test; and wet arc-tracking.
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 These test methods and their locations are as follows:    
Section  
Axial Stability (Longitudinal Change) After Thermal Exposure  
20  
Bondability of Insulation to Potting Compounds  
18  
Capacitance  
9 to 11  
Cold Bend Test  
25  
Concentricity  
25  
Crush Resistance  
19  
Dielectric Breakdown Voltage  
5  
Dimensions  
14  
Dry-arc Tracking  
28  
Dynamic Cut-through  
21  
Fluid Immersion  
22  
High Temperature Shock  
23  
Insulation-Continuity Proof Tests  
12  
Insulation Resistance  
6  
Partial Discharge (Corona) Inception and Extinction Voltage  
24  
Relative Thermal Life and Temperature Index  
13  
Strip Force  
26  
Surface Resistance  
26  
Tensile Properties  
16  
Vertical Flame  
17  
Vertical Flame Test A  
18.5
(Test Method D8354)  
Vertical Flame Test B  
17.6 – 17.11.4  
Voltage Rating of Hook-Up Wire  
Annex A1  
Voltage Withstand Test  
8  
Wet Arc-tracking  
27  
1.4 The values stated in SI units are to be regarded as standard. The values given in parentheses after SI units are provided for information only and are not considered standard.  
1.5 This standard measures and describes the response of materials, products, or assemblies to heat and flame under controlled conditions, but does not, by itself, incorporate all factors required for fire hazard or fire risk assessment of the materials, products, or assemblies under actual fire conditions.  
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SIGNIFICANCE AND USE
5.1 A major factor affecting the life of insulating materials is thermal degradation. It is possible that other factors, such as moisture and vibration, will cause failures after the material has been weakened by thermal degradation.  
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SCOPE
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1.2 This test method is applicable to insulating powders used over a substrate material of steel.  
1.3 Units—The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each system are not necessarily exact equivalents; therefore, each system shall be used independently of the other. Combining values from the two systems is likely to result in non-conformance with the standard.  
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ABSTRACT
These test methods cover the testing of fibrous-insulated electrical conductors, commonly referred to as magnet wire, which are used in electrical apparatus. The test methods are intended primarily for evaluation of the electrical insulating materials used. It is intended that these test methods be used, except where modified by individual specifications for particular applications. This elongation testing method covers the determination of the elongation of fibrous insulated magnet wire that results in a fracture of the conductor. The electrical resistance testing method covers the determination of the electrical resistance of fibrous insulated magnet wire conductors. The fibrous coverage testing method covers the determination of the quality of fibrous servings on round magnet wire or bare conductor. The measurement of dimensions test methods determine the dimensions of the bare or film insulated conductor and the fibrous-insulated magnet wire. The adhesion and flexibility test method covers the evaluation of the flexibility and adherence of varnished fibrous glass, and varnished or unvarnished fibrous polyester-glass insulating material on either bare conductor, or film-insulated magnet wire. The dielectric breakdown voltage test method covers the determination of the dielectric breakdown voltage in air of insulation on round, rectangular, and square wires at commercial power frequencies.
SCOPE
1.1 These test methods cover the testing of fibrous-insulated electrical conductors, commonly referred to as magnet wire, which are used in electrical apparatus. The test methods are intended primarily for evaluation of the electrical insulating materials used. It is intended that these test methods be used, except where modified by individual specifications for particular applications.  
1.1.1 These test methods apply to those magnet wires that are fiber-covered and in which the substrate is bare conductor or is coated with an underlying insulating film as covered by Test Methods D1676. Fiber-covered wires are produced by serving helically or wrapping fibers or fibrous-tape insulation uniformly around the wire in single and multiple layers. The served or wrapped materials are bonded or not bonded to the underlying wire.  
1.2 The test methods appear in the following sections:    
Procedure  
Section  
Measurement of Dimensions  
7  
Electrical Resistance of Conductors  
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Elongation  
4  
Adhesion and Flexibility  
8  
Fibrous Coverage  
6  
Dielectric Breakdown Voltage  
9  
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1.5 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.6 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use. See 8.4.1 and 9.4.1 for specific caution statements.  
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ASTM D1676-17(Test Method)
Standard Test Methods for Film-Insulated Magnet Wire

SIGNIFICANCE AND USE
7.1 Bond strength values obtained by flexural tests provide information with regard to the bond strength of a particular self-bonding outer coating in combination with a particular round film-insulated magnet wire when measured under conditions described in this test method.
SCOPE
1.1 These test methods cover procedures for testing film-insulated magnet wire that is used in electrical apparatus. These test methods are intended primarily for the evaluation of the electrical insulating materials used. The intent is that these test methods be used, except where modified, by individual specifications for particular applications.  
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1.3 The values stated in inch-pound units are the standard. The SI units in parentheses are provided for information only.  
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Sections  
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Burnout (AC Overload Resistance)  
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Chemical Resistance  
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90 – 99  
Dimensional Measurement  
100 – 106  
Dissipation Factor Measurement  
107 – 114  
Electrical Resistance  
115 – 121  
Elongation  
122 – 129  
Extractables, Refrigerant  
130 – 140  
Film Adherence and Flexibility  
141 – 148  
Formability:  
a) Elastic Ratio  
152  
b) Low Stress Elongation  
153  
c) Spring Back  
154-155  
Heat Shock  
156 – 162  
Oiliness  
163 – 169  
Scrape Resistance, Unidirectional  
170 – 177  
Solderability  
178 – 185  
Resistance to Insulating Liquids and Hydrolytic Stability  
186 – 195  
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Note 1: This test method is related to IEC 60851. Since both methods contain multiple test procedures, many procedures are technically equivalent while others differ significantly.  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM D4881-05(2017)(Test Method)
Standard Test Method for Thermal Endurance of Varnished Fibrous- or Film-Wrapped Magnet Wire

SIGNIFICANCE AND USE
4.1 Individual varnishes behave differently when applied to the same fibrous- or film-wrapped magnet wire when exposed to elevated temperatures. Likewise, a varnish does not always behave the same when applied to different types of fibrous or film-wrapped magnet wires and when exposed to elevated temperatures.
FIG. 1 Jig for Forming Wire
SCOPE
1.1 This test method covers the determination of thermal endurance of rectangular and square fibrous- or film-wrapped magnet wire coated with an insulating varnish.  
1.2 The values given in SI units are the standard. The values given in parentheses are for information only.  
1.3 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. A specific precautionary statement is given in Section 5.  
Note 1: There is no similar or equivalent IEC Standard.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ABSTRACT
This specification covers nickel-coated, round, copper-clad steel wire for electronic applications. The nickel-coated wire shall consist of the basis wire coated with nickel. Tensile strength and elongation of the nickel-coated wire shall conform to the specified requirements for the applicable size and class of copper-clad steel wire. The electrical resistivity shall not exceed the values specified. Continuity, adherence, and mass of the coating shall be determined. Necessary joints in the wire and rod prior to final coating and drawing shall be made.
SCOPE
1.1 This specification covers nickel-coated, round, copper-clad steel wire for electronic application.  
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1.3 Four classes of nickel-coated, copper-clad steel wire are covered as follows:  
1.3.1 Class N30HS—Nominal 30 % conductivity, hard drawn.  
1.3.2 Class N30A—Nominal 30 % conductivity, annealed.  
1.3.3 Class N40HS—Nominal 40 % conductivity, hard drawn.  
1.3.4 Class N40A—Nominal 40 % conductivity, annealed.  
1.4 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.4.1 Exception—The SI values for resistivity are to be regarded as standard.  
1.5 The following safety hazards caveat pertains only to the test method described in this specification. 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.(Warning—Consideration should be given to toxicity and flammability when selecting solvent cleaners.)  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM B502/B502M-23(Specification)
Standard Specification for Aluminum-Clad Steel Core Wire for Use in Overhead Electrical Aluminum Conductors

ABSTRACT
This specification covers round, aluminum-clad steel core wire used for mechanical reinforcement in the manufacture of aluminum conductors, aluminum-clad steel reinforced. The base metal shall be steel produced by the openhearth, electric-furnace, or basic-oxygen process and shall be of such composition that the finished clad wire shall have the properties and characteristics prescribed in this specification. The aluminum used for cladding shall have a purity and quantity sufficient to meet thickness and resistance requirements of this specification. The material shall conform to the required tensile properties such as stress, tensile strength, and elongation. The aluminum-clad steel core shall undergo elongation test, tension test, and torsion test. The elongation test shall be determined by an extensometer equipped with a vernier or other instrument reading. In the torsion test, a small tensile load shall be applied to the specimen during testing. The specimen shall be twisted by rotating one of the vises in the same direction until fracture occurs.
SCOPE
1.1 This specification covers round, aluminum-clad steel core wire with two designations of tensile strengths, AW2 (Normal Strength) and AW3 (High Strength).  
1.2 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each system are not necessarily exact equivalents; therefore, to ensure conformance with the standard, each system shall be used independently of the other, and values from the two systems shall not be combined.  
1.2.1 For conductor sizes designated by AWG, the requirements in SI units have been numerically converted from corresponding values stated or derived in inch-pound units. For conductor sizes designated by SI units only, the requirements are stated or derived in SI units.  
1.3 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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  • Technical specification
    4 pages
    English language
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ASTM
ASTM B869-07(2023)(Specification)
Standard Specification for Copper-Clad Steel Electrical Conductor for CATV Drop Wire

ABSTRACT
This specification covers hard-drawn round copper-clad steel electrical conductor for CATV drop wire (coaxial cable center conductor). The wire shall be composed of a steel core with a substantially uniform and continuous copper cladding thoroughly bonded to it throughout. The size shall be expressed as the diameter of the wire. The steel wire shall conform to the prescribed tensile strength, elongation, and breaking strength. Requirements for (1) tension and torsion tests, (2) method of determining the electrical resistance, (3) cladding uniformity in terms of thickness, and (4) joint construction are detailed. The prescribed density of the wire to be taken for calculating mass/unit length, cross section, and so forth is given.
SCOPE
1.1 This specification covers 21 % conductivity hard-drawn round copper-clad steel wire for coaxial cable center conductors (Note 1).  
Note 1: Wire ordered to this specification is not intended for redrawing since it is furnished in the hard-drawn temper. If wire is desired for the purpose, the manufacturer should be consulted.  
1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.3 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

  • Technical specification
    3 pages
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