prEN ISO 8092-2

Road vehicles - Connections for on-board electrical wiring harnesses - Part 2: Definitions, test methods and general performance requirements (ISO/DIS 8092-2:2022)

Straßenfahrzeuge - Steckverbindungen für das elektrische Fahrzeug-Bordnetz - Teil 2: Begriffe, Prüfungen und allgemeine Anforderungen(ISO/DIS 8092-2:2022)

Véhicules routiers - Connexions pour faisceaux de câblage électrique embarqués - Partie 2: Définitions, méthodes d'essai et exigences de performances générales (ISO/DIS 8092-2:2022)

Cestna vozila - Priključki za električno opremo, vgrajeni na armaturi vozila - 2. del: Definicije, preskusne metode in splošne zahtevane lastnosti (ISO/DIS 8092-2:2022)

General Information

• Status: Not Published
• Publication Date: 14-Jan-2025
• ICS: 01.040.43 - Road vehicle engineering (Vocabularies)
• ICS: 43.040.10 - Electrical and electronic equipment
• Technical Committee: CEN/SS T03 - Road vehicles
• Drafting Committee: CEN/SS T03 - Road vehicles
• Current Stage: 4599 - Dispatch of FV draft to CMC - Finalization for Vote
• Start Date: 21-Apr-2023
• Completion Date: 21-Apr-2023
• Ref Project: oSIST prEN ISO 8092-2:2023 - Road vehicles - Connections for on-board electrical wiring harnesses - Part 2: Definitions, test methods and general performance requirements (ISO/DIS 8092-2:2022)

Relations

• Revises: EN ISO 8092-2:2005 - Road vehicles - Connections for on-board electrical wiring harnesses - Part 2: Definitions, test methods and general performance requirements (ISO 8092-2:2005)
• Effective Date: 14-Aug-2019

Standards Content (Sample)

SLOVENSKI STANDARD
oSIST prEN ISO 8092-2:2023
01-februar-2023

Cestna vozila - Priključki za električno opremo, vgrajeni na armaturi vozila - 2. del:

Definicije, preskusne metode in splošne zahtevane lastnosti (ISO/DIS 8092-2:2022)

Road vehicles - Connections for on-board electrical wiring harnesses - Part 2:

Definitions, test methods and general performance requirements (ISO/DIS 8092-2:2022)

Straßenfahrzeuge - Steckverbindungen für das elektrische Fahrzeug-Bordnetz - Teil 2:

Begriffe, Prüfungen und allgemeine Anforderungen (ISO/DIS 8092-2:2022)
Véhicules routiers - Connexions pour faisceaux de câblage électrique embarqués -
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
(ISO/DIS 8092-2:2022)
Ta slovenski standard je istoveten z: prEN ISO 8092-2
ICS:
43.040.10 Električna in elektronska Electrical and electronic
oprema equipment
oSIST prEN ISO 8092-2:2023 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN ISO 8092-2:2023
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oSIST prEN ISO 8092-2:2023
DRAFT INTERNATIONAL STANDARD
ISO/DIS 8092-2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:
2022-12-19 2023-03-13
Road vehicles — Connections for on-board electrical
wiring harnesses —
Part 2:
Definitions, test methods and general performance
requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique embarqués —
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
ICS: 43.040.10
This document is circulated as received from the committee secretariat.
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
ISO/CEN PARALLEL PROCESSING
THEREFORE SUBJECT TO CHANGE AND MAY
NOT BE REFERRED TO AS AN INTERNATIONAL
STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS
BEING ACCEPTABLE FOR INDUSTRIAL,
TECHNOLOGICAL, COMMERCIAL AND
USER PURPOSES, DRAFT INTERNATIONAL
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/DIS 8092-2:2022(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
PROVIDE SUPPORTING DOCUMENTATION. © ISO 2022
---------------------- Page: 3 ----------------------
oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
DRAFT INTERNATIONAL STANDARD
ISO/DIS 8092-2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:
Road vehicles — Connections for on-board electrical
wiring harnesses —
Part 2:
Definitions, test methods and general performance
requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique embarqués —
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
ICS: 43.040.10
This document is circulated as received from the committee secretariat.
COPYRIGHT PROTECTED DOCUMENT
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
© ISO 2022
ISO/CEN PARALLEL PROCESSING
THEREFORE SUBJECT TO CHANGE AND MAY

All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may

NOT BE REFERRED TO AS AN INTERNATIONAL

be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on STANDARD UNTIL PUBLISHED AS SUCH.

the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below

IN ADDITION TO THEIR EVALUATION AS

or ISO’s member body in the country of the requester. BEING ACCEPTABLE FOR INDUSTRIAL,

TECHNOLOGICAL, COMMERCIAL AND
ISO copyright office
USER PURPOSES, DRAFT INTERNATIONAL
CP 401 • Ch. de Blandonnet 8
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
CH-1214 Vernier, Geneva
POTENTIAL TO BECOME STANDARDS TO
Phone: [phone]
WHICH REFERENCE MAY BE MADE IN
Reference number
Email: [e-mail]
NATIONAL REGULATIONS.
Website: www.iso.org ISO/DIS 8092-2:2022(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
Published in Switzerland
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
© ISO 2022 – All rights reserved
PROVIDE SUPPORTING DOCUMENTATION. © ISO 2022
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oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
32 Contents

33 Foreword ......................................................................................................................................................................... iv

34 1 Scope .......................................................................................................................................................................... 1

35 2 Normative references .......................................................................................................................................... 1

36 3 Terms and definitions .......................................................................................................................................... 2

37 4 Test conditions and requirements .................................................................................................................. 4

38 4.1 General ...................................................................................................................................................................... 4

39 4.2 Visual Examination ............................................................................................................................................ 11

40 5 Mechanical tests .................................................................................................................................................. 12

41 5.1 Connection and disconnection ....................................................................................................................... 12

42 5.2 Mating force – measurement and classification ...................................................................................... 13

43 5.3 Unlocking force – measurement and classification ................................................................................ 13

44 5.4 Unmating force – measurement and classification ................................................................................ 13

45 5.5 Locking device strength ................................................................................................................................... 13

46 5.6 Unintentional lever release force ................................................................................................................. 14

47 5.7 Locking force for CPA function ...................................................................................................................... 14

48 5.8 Disengage force for CPA function .................................................................................................................. 17

49 5.9 Locking force for TPA ........................................................................................................................................ 17

50 5.10 Disengage force for TPA ............................................................................................................................. 18

51 5.11 Effectiveness of connector coding and polarization ........................................................................ 18

52 5.12 Connector engagement sound ................................................................................................................. 19

53 5.13 Terminal insertion force (TPA disengaged) ....................................................................................... 19

54 5.14 Terminal insertion force (TPA engaged) ............................................................................................. 20

55 5.15 Terminal insertion force with incorrect orientation ...................................................................... 21

56 5.16 Terminal extraction force ......................................................................................................................... 22

57 5.17 Tensile strength of connection between terminal and wire ......................................................... 23

58 6 Electrical tests ...................................................................................................................................................... 25

59 6.1 Connection resistance (voltage drop) ......................................................................................................... 25

60 6.2 Temperature rise ................................................................................................................................................ 27

61 6.3 Current cycling at ambient temperature ................................................................................................... 29

62 6.4 Insulation resistance ......................................................................................................................................... 29

63 6.5 Withstand voltage ............................................................................................................................................... 30

64 7 Environmental tests ........................................................................................................................................... 31

65 7.1 Thermal shock ..................................................................................................................................................... 31

66 7.2 Thermal aging ...................................................................................................................................................... 32

67 7.3 Temperature and humidity cycle ................................................................................................................. 32

68 7.4 Vibration with thermal cycling ...................................................................................................................... 35

69 7.5 Mechanical shock ................................................................................................................................................ 37

70 7.6 Drop ......................................................................................................................................................................... 37

71 7.7 Water tightness ................................................................................................................................................... 38

72 7.8 Water tightness, dynamic ................................................................................................................................ 40

73 7.9 High-pressure/steam-jet cleaning ............................................................................................................... 42

74 7.10 Salt spray ......................................................................................................................................................... 44

75 7.11 Dust resistance .............................................................................................................................................. 44

76 7.12 Chemical loads ............................................................................................................................................... 45

77 7.13 Fretting corrosion ........................................................................................................................................ 45

78 7.14 Friction corrosion ........................................................................................................................................ 46

79 Bibliography ................................................................................................................................................................. 47

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81 Foreword

82 ISO (the International Organization for Standardization) is a worldwide federation of national standards

83 bodies (ISO member bodies). The work of preparing International Standards is normally carried out

84 through ISO technical committees. Each member body interested in a subject for which a technical

85 committee has been established has the right to be represented on that committee. International

86 organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO

87 collaborates closely with the International Electrotechnical Commission (IEC) on all matters of

88 electrotechnical standardization.

89 The procedures used to develop this document and those intended for its further maintenance are

90 described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the

91 different types of ISO documents should be noted. This document was drafted in accordance with the

92 editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).

93 Attention is drawn to the possibility that some of the elements of this document may be the subject of

94 patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any

95 patent rights identified during the development of the document will be in the Introduction and/or on

96 the ISO list of patent declarations received (see www.iso.org/patents).

97 Any trade name used in this document is information given for the convenience of users and does not

98 constitute an endorsement.

99 For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and

100 expressions related to conformity assessment, as well as information about ISO's adherence to the World

101 Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see

102 www.iso.org/iso/foreword.html.

103 This document was prepared by Technical Committee ISO/TC 22,Road vehicles, Subcommittee SC 32,

104 Electrical and electronic components and general system aspects.

105 This fifth edition cancels and replaces the fourth edition (ISO 8092-2:2005), which has been technically

106 revised.
107 The main changes compared to the previous edition are as follows:
108 — adoption of the content according to new technical requirements,

109 — adoption of the content according to the new version of the ISO guidelines,

110 — correction of the typos and mistakes in the text,
111 — alignment of the content regarding to the referred standards,

112 — section 4.24 Flowing gas corrosion test has been removed due to its technical irrelevance,

113 — Annex A (normative) Additional cable dimensions is adopted as an informative part under section

114 4.1.2,

115 — Annex B (informative) Cable attachment by insulation-displacement connection (IDC) — Bending

116 test has been removed due to its technical irrelevance.
117 A list of all parts in the ISO 8092 series can be found on the ISO website.

118 Any feedback or questions on this document should be directed to the user’s national standards body. A

119 complete listing of these bodies can be found at www.iso.org/members.html.
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120
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121 Road vehicles — Connections for on-board electrical wiring
122 harnesses — Part 2: Definitions, test methods, and general
123 performance requirements
124 1 Scope

125 This document defines terms and specifies test methods for general performance requirements of voltage

126 class A connectors used in electrical wiring harnesses on road vehicles.

127 This document applies to connectors which, after mounting in the vehicle, are designed to only be

128 disconnected in connection with repair and maintenance.

129 This part of ISO 8092 does not apply to internal connections for electronic devices.

130 This part of ISO 8092 does not apply to signal communication quality or data integrity.

131 2 Normative references

132 The following documents are referred to in the text in such a way that some or all of their content

133 constitutes requirements of this document. For dated references, only the edition cited applies. For

134 undated references, the latest edition of the referenced document (including any amendments) applies.

135 ISO DIS 8092-5, Road vehicles — Connections for on-board electrical wiring harnesses – Part 5: Automotive

136 parts – Test methods and general performance requirements for wiring harness connector operation

137 ISO 16750-3, Road vehicles - Environmental conditions and testing for electrical and electronic equipment

138 - Part 3: Mechanical loads

139 ISO 16750-4, Road vehicles - Environmental conditions and testing for electrical and electronic equipment

140 - Part 4: Climatic loads

141 ISO 16750-5, Road vehicles - Environmental conditions and testing for electrical and electronic equipment

142 - Part 5: Chemical loads
143 ISO 19642 (all parts), Road vehicles — Automotive Cables

144 ISO 20653, Degrees of protection (IP-code) — Protection against foreign objects, water and access –

145 Electrical equipment
146
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147 3 Terms and definitions

148 For the purposes of this document, the following terms and definitions apply.

149 ISO and IEC maintain terminological databases for use in standardization at the following addresses:

150 — ISO Online browsing platform: available at https://www.iso.org/obp
151 — IEC Electropedia: available at http://www.electropedia.org/
152 3.1
153 voltage class A

154 classification of an electric component or circuit with a maximum working voltage of ≤ 30 V AC (rms) or

155 ≤ 60 V DC, respectively
156 [SOURCE: ISO 21498-1:2021]
157 [SOURCE: ISO 6469-3:2021]
158 3.2
159 housing

160 housing for inserting the terminal and providing insulation between terminals

161
162 3.3
163 cable attachment
164 any permanent junction of cable to terminal
165 Note 1 to entry: Crimp and weld are typical methods
166 Note 2 to entry: Terms related to cables ISO 19642-1
167 3.4
168 connector

169 assembly of terminal, housing and related parts that terminate cable for the purpose of providing

170 connection and disconnection to a suitable mating connector
171 3.5
172 connector coding

173 mechanical feature to provide differentiation, preventing mating of connectors not intended to be mated

174 3.6
175 connector polarization

176 method or design feature, which prevents connectors that are intended to mate from mating in an

177 unintended orientation, rotation, or angular position, whilst allowing mating in the intended manner

178 3.7
179 connector position assurance, CPA

180 device that prevents accidental release of the connector lock and serves as an indicator of full connector

181 mating
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182 3.8
183 terminal position assurance, TPA

184 a feature installed or seated after the terminals are inserted into their housing to assure that the terminals

185 are properly positioned, and which reinforces the primary terminal locking mechanism or provides a

186 separate, redundant terminal lock
187 3.9
188 socket and receptacle terminal

189 terminal, including means for cable attachment, designed for electrical engagement on its inner surface,

190 and to accept entry of a pin or tab terminal, thus forming an electrical connection. See Figure 1 for

191 example.

192 Note 1 to entry: Socket and receptacle terminals are sometimes referred to as female terminals.

193
194 Figure 1— Example of a socket and a receptacle terminal
195
196 3.10
197 pin and tab terminal

198 terminal, including means for cable attachment, designed for electrical engagement on its outer surface

199 and to enter a socket or a receptacle terminal, thus forming an electrical connection. See Figure 2 for

200 example.

201 Note 1 to entry: Pin and tab terminals are sometimes referred to as male terminals”

202 Note 2 to entry: Tab terminals are sometimes referred to as blade terminals
203
204 Figure 2— Example of a pin and a tab terminal
205 3.11
206 multi‐pole connection

207 two mated connector halves with more than one terminal pair (for example one receptacle and one tab

208 terminal)
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209 4 Test conditions and requirements
210 4.1 General
211 4.1.1 Preconditioning for environmental and mechanical durability test

212 All test samples shall be preconditioned at a standard ambient temperature of (23 ± 5) °C, and (25–75) %

213 relative humidity for 24 h before the start of any test sequence.
214 [SOURCE: ISO 16750-1]
215 4.1.2 Test conditions

216 All tests shall be carried out at a standard ambient temperature of (23 ± 5) °C and (25–75) % relative

217 humidity unless otherwise stated in the test procedure. This is referred to as room temperature (RT).

218 Cable in compliance with applicable part of ISO 19642 is recommended. The cable or cables used shall be

219 specified in the test report.

220 The cross-sectional area of the wire mentioned in this specification refers to wires with a copper

221 conductor.

222 When the wire conductor is of a material other than copper, the cross–sectional area of the wire shall be

223 specified by agreement between customer and supplier.

224 Cable attachment shall be performed in accordance with the terminal manufacturer's specifications, or

225 as agreed between customer and supplier.

226 Care shall be taken so that test samples do not influence each other (e.g., in a heat chamber).

227 Each connector shall have the full complement of terminals fitted unless otherwise specified.

228 The terminals and connectors used in the test shall be fully assembled unless otherwise specified.

229 Connectors shall be tested in mated condition unless stated otherwise. In the case of a connector

230 connecting directly to a device, a mating dummy may be used to carry out tests. This dummy must

231 represent the intended device’s interface and electrical properties.

232 For connector mechanical tests, unless otherwise specified, fix the pin or tab housing of the unmated or

233 mated connector in the appropriate fixture on the tension or force tester. Secure the other side in the

234 appropriate fixture and insert or pull the socket or receptacle housing straight in/out. Straight-in or

235 straight-out engagement is critical to avoid side loads and binding which can affect force measurements.

236 For terminal mechanical tests, unless otherwise specified, fix the pin or tab terminal of the unmated or

237 mated terminal in the appropriate fixture on the tension or force tester. Secure the other side in the

238 appropriate fixture and insert/pull the socket receptacle terminal straight in/out. Straight-in or straight-

239 out engagement is critical to avoid side loads and binding which can affect force measurements

240 Measurements shall be taken on all terminals regardless of the number of poles per connector, unless

241 otherwise specified in the test methods or by agreement between customer and supplier.

242 Lubrication or other means of attaining better test results shall not be added to any surface unless

243 representative of assembly conditions. Production-related remains of lubricants on the terminals are

244 permitted.
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245 Unless otherwise specified, all forces shall be applied at a constant speed of (50 ± 10) mm/min.

246 Unless otherwise specified, when a temperature of T is specified in a test, the applicable “Highest value”

max

247 temperature as per Table 1 shall be used. When a temperature of T is specified in a test, the applicable

min
248 “Lowest value” temperature as per Table 1 shall be used.
249 Table 1 —Environmental and test temperatures
Typical application Environmental temperature range
Test temperature
°C Short term thermal
ageing
Class Lowest value Highest value
Use for T of chamber Use for T of chamber
min max
 2 °C
± 2 °C ± 2 °C
T1 (G) interior 85 100
T2 (J) passenger compartment 100 125
T3 (O) engine compartment -40 125 150
T4 (R) engine applications used 150 175
near hot components
T5 (N/A) for use as needed 175 200 *
( ) value aligned with ISO 16750-4:2010, Table 1
* or agreed between customer and supplier
250

251 NOTE T and T apply to all environmental chamber temperatures where T and T are specified as

min max min max

252 using the applicable environmental temperature range except 7.2.2.1 Short term Thermal aging

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253 4.1.3 Test sequences and sample quantities
254 Table 2,
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255 Table 3, Table 4 and Table 5 list the test sequences. The test groups in the tables apply to sealed and

256 unsealed connectors as noted. New samples shall be used for each test group. The test sequence for each

257 test group shall be performed in accordance with the sequence number defined in the table’s rows for

258 each sequence. For each test group, the complete test sequence for the group on each sample shall be

259 performed.
260 Table 2—Mechanical test sequences groups A through H
Test group identification A B C D E F G H
u=apply test if samples are un-
u u u u u u u u
sealed
s=apply test if samples are sealed s s s s s s s s
Minimum test quantity of
10 10 10 10 10 10 10 10
terminals/connectors
Sample cable length (mm) - - - - - - - -
Sample cable Maximum - - - - - - - -
size
Minimum - - - - - - - -
1, 3 1, 3 1,3 1, 3 1, 3 1, 3 1,3 1,4
4.2 Visual Examination
5.1 Connection and disconnection 2
5.2 Mating force – measurement
and classification
5.3 Unlocking force – measurement
2
and classification
5.4 Unmating force – measurement
2
and classification
5.5 Locking device strength 2
5.6 Unintentional lever release
2
force
5.7 Locking force for CPA function 2 2
5.8 Disengage force for CPA
3
function

Perform force measurement for first mate and first unmate with part held in force tester.

Remaining mate and unmate cycles can be either hand mated or using the mechanized force test machine.

- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter to test result.

261
262
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263 Table 3—Mechanical test sequences groups I through P
Test group identification I J K L M N O P
u=apply test if samples are
u u u u u u u u
un- sealed
s=apply test if samples are sealed s s s s s s s s
Minimum test quantity of
f f f f f k
10 10 10 10 20 10 10 10
terminals/connectors
- - - - - - - >50
Sample cable length (mm)
Maximum - - - - 10 10 10 See “l”
Sample
cable size - - - - 10 - - See “l”
Minimum
1, 3 1, 4 1, 3 1, 3 1, 4 1, 3 1, 3 1, 3
4.2 Visual Examination
2 2
5.9 Locking force for TPA
5.10 Disengage force for TPA 3
5.11 Effectiveness of connector
2
coding and polarization
5.12 Connector engagement
2
sound
5.13 Terminal insertion force
2
(TPA disengaged)
5.14 Terminal insertion force
2
(TPA engaged)
5.15 Terminal insertion force
2
with incorrect orientation
5.16 Terminal extraction force 3
5.17 Tensile strength of
connection between terminal and 2
wire

Use unmated wire harness connector; the mating (header) connector is not used in the test.

k Sample is made from terminal and cable only.

l Test quantity is per terminal/cable combination; each combination shall be validated with a 10-piece sample, minimum.

- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter to test result.

264
265
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266 Table 4— Environmental and electrical test sequence groups Q through W
Test group identification Q R S T U V W
u u u u u u
u=apply test if samples are unsealed
q q
s=apply test if samples are sealed s s s s s s s
i i
Minimum test quantity of connectors 5 10 5 5 5 5 5
500 - min 500 min 150 - 1 250 Min 150
Sample cable length (mm)
See "p" all all all
Maximum
Sample cable size
Minimu
...