ISO 19642-2:2023

Road vehicles — Automotive cables — Part 2: Test methods

This document defines test methods for electrical cables in road vehicles, which are used in other parts of the ISO 19642 series.

Véhicules routiers — Câbles automobiles — Partie 2: Méthodes d'essai

General Information

• Status: Published
• Publication Date: 30-Aug-2023
• ICS: 43.040.10 - Electrical and electronic equipment
• Technical Committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
• Drafting Committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
• Current Stage: 6060 - International Standard published
• Start Date: 31-Aug-2023
• Due Date: 18-Jun-2023
• Completion Date: 31-Aug-2023

Relations

• Revises: ISO 19642-2:2019 - Road vehicles — Automotive cables — Part 2: Test methods
• Effective Date: 06-Jun-2022

Standards Content (Sample)

INTERNATIONAL ISO
STANDARD 19642-2
Second edition
2023-08
Road vehicles — Automotive cables —
Part 2:
Test methods
Véhicules routiers — Câbles automobiles —
Partie 2: Méthodes d'essai
Reference number
ISO 19642-2:2023(E)
© ISO 2023

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ISO 19642-2:2023(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2023
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
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Published in Switzerland
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ISO 19642-2:2023(E)
Contents Page
Foreword .v
Introduction . vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 3
4 Specifications . 3
4.1 General test conditions . 3
4.1.1 General information on dimensional tests. 3
4.2 Safety concerns . 4
4.3 Ovens . 4
5 Test methods for single core cables.4
5.1 General . 4
5.2 Dimensional tests . . 4
5.2.1 Cable outside diameter . 4
5.2.2 Insulation thickness . 5
5.2.3 Conductor diameter . 5
5.2.4 Cross-sectional area (CSA) . 5
5.2.5 In-process cable outside diameter . 6
5.3 Electrical tests . 7
5.3.1 Conductor resistance . . 7
5.3.2 Determination of temperature coefficients . 8
5.3.3 Withstand voltage . 10
5.3.4 Withstand voltage after environmental testing . 11
5.3.5 Insulation faults . 11
5.3.6 Insulation volume resistivity .12
5.4 Mechanical tests .12
5.4.1 Strip force .12
5.4.2 Abrasion .13
5.4.3 Breaking force of the finished cable. 16
5.4.4 Cyclic bending . 17
5.4.5 Flexibility . 18
5.5 Environmental tests . 20
5.5.1 Test specimen preparation and winding tests . 20
5.5.2 Long term heat ageing, 3 000 h at temperature class rating .22
5.5.3 Short term heat ageing, 240 h at temperature class rating +25 °C .22
5.5.4 Thermal overload, 6 h at temperature class rating +50 °C .23
5.5.5 Pressure test at high temperature . 23
5.5.6 Shrinkage by heat .25
5.5.7 Low temperature winding . 25
5.5.8 Cold impact . 25
5.5.9 Temperature and humidity cycling . 27
5.5.10 Resistance to hot water .29
5.5.11 Resistance to liquid chemicals .30
5.5.12 Durability of cable marking . 32
5.5.13 Stress cracking resistance . 32
5.5.14 Resistance to ozone .33
5.5.15 Resistance to flame propagation .34
6 Test methods for sheathed and/or multi-conductor cables .35
6.1 General . 35
6.2 Dimensional tests . .36
6.2.1 Cable outside diameter . 36
6.2.2 Ovality of sheath .36
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ISO 19642-2:2023(E)
6.2.3 Thickness of sheath. 36
6.2.4 In-process cable outside diameter .36
6.2.5 Lay length . 37
6.3 Electrical tests .38
6.3.1 Electrical continuity .38
6.3.2 Withstand voltage at final inspection .38
6.3.3 Screening effectiveness .38
6.3.4 Sheath fault on screened cables . 41
6.3.5 General information on electrical test setups of unscreened balanced cables . 42
6.3.6 General information on low frequency electrical tests .46
6.3.7 Resistance unbalance .46
6.3.8 Capacitance . 47
6.3.9 Inductance . .48
6.3.10 General information on high radio frequency (RF) electrical tests .48
6.3.11 Velocity of propagation . . 51
6.3.12 Characteristic impedance in frequency domain (CIF).55
6.3.13 Characteristic impedance in time domain (CIT) .56
6.3.14 Insertion loss, (IL) .58
6.3.15 Return loss, (RL) .58
6.3.16 Unbalance attenuations .58
6.3.17 Near-end crosstalk, NEXT . 59
6.3.18 Far-end crosstalk, FEXT . 59
6.3.19 PS alien near-end crosstalk, PS-ANEXT – exogenous crosstalk . 59
6.3.20 PS attenuation to alien far-end crosstalk ratio, PS-AACR-F - exogenous
crosstalk . 59
6.4 Mechanical tests .60
6.4.1 Strip force of sheath.60
6.4.2 Cyclic bending .60
6.4.3 Flexibility .60
6.4.4 Cyclic bending test for RF cables . 61
6.4.5 Dynamic bending tests for RF cables .63
6.4.6 Test for assessment of minimum bending radius. 67
6.4.7 Strip force of screen .68
6.4.8 Abrasion test of sheath . 70
6.5 Environmental tests . 70
6.5.1 Test specimen preparation and winding tests . 70
6.5.2 Long-term heat ageing, 3 000 h at temperature class rating.72
6.5.3 Short term heat ageing, 240 h at temperature class rating +25 °C .73
6.5.4 Thermal overload, 6 h at temperature class rating +50 °C .73
6.5.5 Pressure test at high temperature .73
6.5.6 Shrinkage by heat of sheath .73
6.5.7 Low temperature winding .74
6.5.8 Cold impact .74
6.5.9 Temperature and humidity cycling .74
6.5.10 Resistance to liquid chemicals . 75
6.5.11 Durability of sheath marking . 75
6.5.12 Resistance to ozone . 76
6.5.13 Artificial weathering . 76
6.5.14 Resistance to flame propagation . 76
Annex A (informative) Examples of materials and sources suppliers.78
Annex B (informative) Flexibility test apparatus .80
Annex C (normative) Flame test apparatus .84
Annex D (informative) Concentricity, A-Factor, F .86
x,A
Bibliography .88
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ISO 19642-2:2023(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO document should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
ISO draws attention to the possibility that the implementation of this document may involve the use
of (a) patent(s). ISO takes no position concerning the evidence, validity or applicability of any claimed
patent rights in respect thereof. As of the date of publication of this document, ISO had not received
notice of (a) patent(s) which may be required to implement this document. However, implementers are
cautioned that this may not represent the latest information, which may be obtained from the patent
database available at www.iso.org/patents. ISO shall not be held responsible for identifying any or all
such patent rights.
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to
the World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see
www.iso.org/iso/foreword.html.
This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 32,
Electrical and electronic components and general system aspects.
This second edition cancels and replaces the first edition (ISO 19642-2:2019), which has been technically
revised.
The main changes are as follows:
— new parts have been added to the ISO 19642 series (ISO 19642-11 and ISO 19642-12);
— both new International Standards refer to this document for definition of test procedures. Some
new test procedures are needed for the new standards of the ISO 19642 series and have been added
accordingly;
— some new test procedures for screened RF cables have been added for a new standard of the
ISO 19642 series.
A list of all parts in the ISO 19642 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www.iso.org/members.html.
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ISO 19642-2:2023(E)
Introduction
This document was prepared following a joint resolution to improve the general structure of the ISO
Automotive Electric Cable standards. This new structure adds more clarity and, by defining a new
standard family, opens up the standard for future amendments.
Many other standards currently refer to ISO 6722-1, ISO 6722-2 and ISO 14572. These standards will
stay valid at least until the next scheduled systematic review and will be replaced later on by the
ISO 19642 series.
For new automotive cable projects customers and suppliers are advised on using the ISO 19642 series.
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INTERNATIONAL STANDARD ISO 19642-2:2023(E)
Road vehicles — Automotive cables —
Part 2:
Test methods
WARNING — The use of this document can involve hazardous materials, operations and
equipment. This document 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 document to establish appropriate safety
practices and determine the applicability of regulatory limitations prior to use.
1 Scope
This document defines test methods for electrical cables in road vehicles, which are used in other parts
of the ISO 19642 series.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
1)
ISO 1817 , Rubber, vulcanized or thermoplastic — Determination of the effect of liquids
ISO 4141-1, Road vehicles — Multi-core connecting cables — Part 1: Test methods and requirements for
basic performance sheathed cables
ISO 4892-2, Plastics — Methods of exposure to laboratory light sources — Part 2: Xenon-arc lamps
ISO 4926, Road vehicles — Hydraulic braking systems — Non-petroleum-based reference fluid
ISO 6931-1, Stainless steels for springs — Part 1: Wire
ISO 19642-1, Road vehicles — Automotive cables — Part 1 — Vocabulary and design guidelines
ISO 19642-3, Road vehicles — Automotive cables — Part 3: Dimensions and requirements for 30 V a.c. or
60 V d.c. single core copper conductor cables
ISO 19642-4, Road vehicles — Automotive cables — Part 4: Dimensions and requirements for 30 V a.c. and
60 V d.c. single core aluminium conductor cables
ISO 19642-5, Road vehicles — Automotive cables — Part 5: Dimensions and requirements for 600 V a.c. or
900 V d.c. and 1 000 V a.c. or 1 500 V d.c. single core copper conductor cables
ISO 19642-6, Road vehicles — Automotive cables — Part 6: Dimensions and requirements for 600 V a.c. or
900 V d.c. and 1 000 V a.c. or 1 500 V d.c. single core aluminium conductor cables
SAE RM-66-06, Motor Vehicle Brake Fluid — High Boiling Compatibility/Reference Fluid
IEC 60216-4-1, Electrical insulating materials — Thermal endurance properties — Part 4-1: Ageing
ovens — Single-chamber ovens
IEC 60216-4-2, Electrical insulating materials — Thermal endurance properties — Part 4-2: Ageing
ovens — Precision ovens for use up to 300 °C
1) Eight edition under preparation. Stage at the time of publication: ISO/DIS 1817:2023.
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ISO 19642-2:2023(E)
IEC 60811-201, Electric and optical fibre cables — Test methods for non-metallic materials — Part 201:
General tests — Measurement of insulation thickness
IEC 60811-202, Electric and optical fibre cables — Test methods for non-metallic materials — Part 202:
General tests — Measurement of thickness of non-metallic sheath
IEC 60811-401, Electric and optical fibre cables — Test methods for non-metallic materials — Part 401:
Miscellaneous tests - Thermal ageing methods - Ageing in an air oven
IEC 60811-403, Electric and optical fibre cables — Test methods for non-metallic materials — Part 403:
Miscellaneous tests — Ozone resistance test on cross-linked compounds
IEC 60811-501, Electric and optical fibre cables — Test methods for non-metallic materials — Part 501:
Mechanical tests — Tests for determining the mechanical properties of insulating and sheathing compounds
IEC 60811-508:2012, Electric and optical fibre cables — Test methods for non-metallic materials — Part
508: Mechanical tests — Mechanical tests - Pressure test at high temperature for insulation and sheaths
IEC 61156-1, Multicore and symmetrical pair/quad cables for digital communications - Part 1 — Generic
specification
IEC TR 61156-1-2:2009+AMD1: 2014, CSV Consolidated version, Multicore and symmetrical pair/quad
cables for digital communications — Part 1-2: Electrical transmission characteristics and test methods
of — Symmetrical pair/quad cables
IEC 61196-1, Coaxial communication cables — Part 1: Generic specification — General, definitions and
requirements
IEC 61196-1-100, Coaxial communication cables — Part 1-100: Electrical test methods — General
requirements
IEC 61196-1-103, Coaxial communication cables — Part 1-103: Electrical test methods — Test for
capacitance of cable
IEC 61196-1-108, Coaxial communication cables — Part 1-108: Electrical test methods — Test for
characteristic impedance, phase and group delay, electrical length and propagation velocity
IEC 61196-1-112, Coaxial communication cables — Part 1-112: Electrical test methods — Test for return
loss (uniformity of impedance)
IEC 61196-1-113, Coaxial communication cables — Part 1-113: Electrical test methods — Test for
attenuation constant
IEC 61196-1-114, Coaxial communication cables — Part 1-114: Electrical test methods — Test for inductance
IEC 61196-1-116, Coaxial communication cables — Part 1-116: Electrical test methods — Test for impedance
with time domain reflectometry (TDR)
IEC 62153-4-3, Metallic communication cable test methods — Part 4-3: Electromagnetic compatibility
(EMC) - Surface transfer impedance — Triaxial method
IEC 62153-4-4, Metallic communication cable test methods — Part 4-4: Electromagnetic compatibility
(EMC) —Test method for measuring of the screening attenuation as up to and above 3 GHz, triaxial method
IEC 62153-4-5, Metallic communication cables test methods — Part 4-5: Electromagnetic compatibility
(EMC) — Coupling or screening attenuation — Absorbing clamp method
IEC 62153-4-9, Metallic communication cables test methods — Part 4-9: Electromagnetic compatibility
(EMC) — Coupling attenuation of screened balanced cables, triaxial method
EN 50289-1-1, Communication cables— Specifications for test methods— Electrical test methods —
General requirements
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ISO 19642-2:2023(E)
EN 50289-1-5, Communication cables— Specifications for test methods— Electrical test methods —
Capacitance
EN 50289-1-12, Communication cables— Specifications for test methods— Electrical test methods —
Inductance
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 19642-1 and the follow
...