ISO 19642-9:2019

Road vehicles - Automotive cables - Part 9: 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. round, sheathed, screened or unscreened multi or single core copper conductor cables

This document specifies the dimensions and requirements for multi or single core cables intended for use in road vehicle applications where the nominal system voltage is 600 V a.c. or 900 V d.c. and 1 000 V a.c. or 1 500 V d.c.. It also applies to individual cores in multi and single core cables.

Véhicules routiers — Cables automobiles — Partie 9: Dimensions et exigences des câbles en cuivre conducteurs ronds, gainés, blindés mono ou multi conducteurs de 600 V a.c. ou 900 V c.c. et 1 000 V a.c. ou 1 500 V c.c.

General Information

• Status: Published
• Publication Date: 29-Jan-2019
• 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/WG 4 - Automotive electrical cables
• Current Stage: 9092 - International Standard to be revised
• Start Date: 23-Jul-2025
• Completion Date: 13-Dec-2025

Overview

ISO 19642-9:2019 sets out the dimensions and requirements for round, sheathed, screened or unscreened multi-core and single-core copper conductor automotive cables intended for road vehicle electrical systems with nominal voltages of 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.. The part applies to finished cables and to individual cores, defining required tests, construction limits and documentation expectations for high-voltage automotive cabling used in road vehicles.

Key Topics and Technical Requirements

• Scope and voltage ratings: Covers cables and cores for the specified nominal voltages; voltage identification (colour guidance) is referenced in Annex B.
• Conductor and insulation: Conductor material and conductor construction follow ISO 19642-5; insulation thickness and conductor resistance limits are documented in supplier datasheets.
• Sheath options: Allows two sheath types - thin wall and thick wall - with prescribed test methods for thickness and strip force.
• Temperature classes: Cable temperature rating equals the lowest rating among cores and sheath; temperature class details are referenced to ISO 19642-1.
• Dimensional requirements: Tests for cable outside diameter, inner layer diameters, sheath ovality and sheath thickness; preferred constructions are listed in Annex A.
• Electrical tests: Electrical continuity, final inspection withstand voltage, screening effectiveness, and sheath fault tests for screened cables.
• Mechanical tests: Strip force, cyclic bending, flexibility and in-process diameter monitoring.
• Environmental tests: Long- and short-term heat ageing, thermal overload, high-temperature pressure test, shrinkage, low-temperature winding, cold impact, temperature/humidity cycling, resistance to chemicals, ozone, artificial weathering and flame propagation.
• Testing strategy: All combinations of conductor size, insulation thickness and formulation should meet requirements, but representative size testing is allowed by agreement between supplier and customer.
• Documentation: Supplier datasheets must record conductor resistance, insulation wall thickness and full cable dimensions for assessment.

Applications and Users

ISO 19642-9 is used by:

• Automotive OEMs and Tier-1 suppliers specifying high-voltage cable systems for electric and hybrid vehicles
• Cable and harness manufacturers designing and producing 600 V / 1 000 V class automotive power cables
• Test laboratories and quality engineers performing dimensional, electrical, mechanical and environmental testing
• Procurement and regulatory teams ensuring supplier compliance with international automotive cable standards

Practical applications include high-voltage power distribution, battery and traction cabling, and any road-vehicle wiring harnesses operating at the covered system voltages.

Related Standards

• ISO 19642 series: ISO 19642-1 (vocabulary/design guidelines), ISO 19642-2 (test methods), ISO 19642-5 (single-core copper conductor requirements)
• Note: ISO 19642 series is structured to succeed earlier automotive cable standards such as ISO 6722 and ISO 14572 for new projects.

Keywords: ISO 19642-9, automotive cables, road vehicles, 600 V, 1 000 V, multi-core cable, single-core cable, copper conductor, cable dimensions, cable testing, high-voltage automotive cabling.

Standards Content (Sample)

INTERNATIONAL ISO
STANDARD 19642-9
First edition
2019-01
Road vehicles — Automotive cables —
Part 9:
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. round, sheathed, screened
or unscreened multi or single core
copper conductor cables
Véhicules routiers — Cables automobiles —
Partie 9: Dimensions et exigences des câbles en cuivre conducteurs
ronds, gainés, blindés mono ou multi conducteurs de 600 V a.c. ou
900 V c.c. et 1 000 V a.c. ou 1 500 V c.c.
Reference number
©
ISO 2019
© ISO 2019
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.iso.org
Published in Switzerland
ii © ISO 2019 – All rights reserved

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Specifications . 1
4.1 General test conditions . 1
4.2 Safety concerns . 2
4.3 Voltage rating . 2
4.4 Temperature classes . 2
4.5 Conductor material . 2
4.6 Conductors . 2
4.7 Sheath thickness . 2
4.8 Core cable outside diameter . 2
4.9 Representative conductor sizes for testing . 2
4.10 Reference and requirements for the tests according to ISO 19642-2 . 2
5 Requirements for single core cables. 4
6 Requirements for round, sheathed, screened or unscreened multi or single core cables .5
6.1 General . 5
6.2 Dimensional tests . 5
6.2.1 Cable outside and inner layer diameters . 5
6.2.2 Ovality of sheath . 5
6.2.3 Thickness of sheath . 5
6.2.4 In-process cable outside diameter . 5
6.3 Electrical tests . 5
6.3.1 Electrical continuity . 5
6.3.2 Withstand voltage at final inspection . 6
6.3.3 Screening effectiveness . 6
6.3.4 Sheath fault on screened cables . 6
6.4 Mechanical tests . 6
6.4.1 Strip force of sheath . 6
6.4.2 Cyclic bending . 6
6.4.3 Flexibility . 6
6.5 Environmental tests . 7
6.5.1 Test specimen preparation and winding tests . 7
6.5.2 Long term heat ageing, 3 000 h at temperature class rating . 7
6.5.3 Short term heat ageing, 240 h at temperature class rating +25 °C. 7
6.5.4 Thermal overload, 6 h at temperature class rating +50 °C . 7
6.5.5 Pressure test at high temperature . 7
6.5.6 Shrinkage by heat of sheath . 7
6.5.7 Low temperature winding . 7
6.5.8 Cold impact . 7
6.5.9 Temperature and humidity cycling . 8
6.5.10 Resistance to liquid chemicals . 8
6.5.11 Durability of sheath marking . 8
6.5.12 Resistance to ozone . 8
6.5.13 Artificial weathering . 8
6.5.14 Resistance to flame propagation . 8
Annex A (informative) Dimensions of preferred constructions . 9
Annex B (informative) Harness and cable colours .15
Bibliography .16
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 documents 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).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
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.
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.
iv © ISO 2019 – All rights reserved

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. So 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.
INTERNATIONAL STANDARD ISO 19642-9:2019(E)
Road vehicles — Automotive cables —
Part 9:
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. round, sheathed, screened
or unscreened multi or single core copper conductor cables
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 specifies the dimensions and requirements for multi or single core cables intended
for use in road vehicle applications where the nominal system voltage is 600 V a.c. or 900 V d.c. and
1 000 V a.c. or 1 500 V d.c. It also applies to individual cores in multi and single core cables.
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.
ISO 19642-1, Road vehicles — Automotive cables — Vocabulary and design guidelines
ISO 19642-2, Road vehicles — Automotive cables — Test methods
ISO 19642-5, Road vehicles — Automotive cables — Dimensions and requirements — 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
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 19642-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
4 Specifications
4.1 General test conditions
The test conditions of ISO 19642-2 shall apply.
The cables shall be submitted to the tests as specified in Table 1.
If suppliers and customers agree upon modifications or changes to the methods and requirements, all
the changes and modifications shall be clearly documented.
4.2 Safety concerns
The precautions as described in the WARNING at the beginning of this document shall be followed.
4.3 Voltage rating
The voltage rating is established by the rating of the cores 600 V a.c. or 900 V d.c., 1 000 V a.c. or
1 500 V d.c.
NOTE Annex B contains information regarding colouring for cables identified for the voltage ratings in this
document.
4.4 Temperature classes
The temperature class rating is established by the rating(s) of the cores and sheath.
The rating of the cable shall be equal to the lowest rating of the individual cores and sheath.
For details on temperature classes, see ISO 19642-1.
4.5 Conductor material
The conductor material shall be according to ISO 19642-5.
4.6 Conductors
The conductors of the core or cores shall be according to ISO 19642-5.
4.7 Sheath thickness
Two different sheath thicknesses are allowed:
1. thin wall sheath;
2. thick wall sheath.
The insulation wall thickness of the core or cores shall be according to ISO 19642-5.
4.8 Core cable outside diameter
The maximum and minimum outside cable diameter for the core or cores shall be according to
ISO 19642-5.
4.9 Representative conductor sizes for testing
When a test is required, all combinations of conductor size, insulation thickness and insulation
formulation shall meet the specified requirements.
However, if testing of representative conductor sizes is permitted by agreement between the customer
and the supplier, compliance for a cable family may be demonstrated by testing examples of large and
small conductor sizes only.
4.10 Reference and requirements for the tests according to ISO 19642-2
Additional production processes in a multi core cable (such as twisting, braiding, jacket extrusion)
influence the properties of the cores in the finished cable. Thus for the dimensions and maximum
conductor resistance of the used cores the requirements of ISO 19642-5 apply with the following
additions:
2 © ISO 2019 – All rights reserved

1)
The minimum wall thickness may follow the design guidelines in ISO 19642-1:— , A.4.
The maximum resistance of cores may follow the design guidelines in ISO 19642-1:—, A.5.
The values for maximum conductor resistance and minimum wall thickness of the insulation should be
documented in the data sheet of the supplier and are the basis for assessment.
Dimensions of preferred constructions for round, sheathed, screened or unscreened multi or single
core copper conductor cables are presented in Annex A, Tables A.1 through A.6.
A complete definition of all possible multi core cables is not feasible. In addition to the preferred
constructions other constructions are permissible using the calculation rules in ISO 19642-1:—,
Annex A.
The diameter under sheath may be calculated according to ISO 19642-1:—, A.3.
The wall thickness of sheath and the bedding layer may be calculated according to ISO 19642-1:—, A.6.
The maximum and minimum outside cable diameter may be calculated according to ISO 19642-1:—, A.9.
The dimensions of all cables should be documented in the datasheet of the supplier and are the basis for
assessment.
Table 1 provides a list of all relevant tests in ISO 19642-2:2019 for round, sheathed, screened or
unscreened multi or single core cables.
Table 1 — Tests
c
Mandatory If required
Test description
In Initial Initial
b b
Periodic Periodic
a
process certification certification
6.1 Dimensional tests
6.1.1 Cable outside and inner layer diameters — X X — —
6.1.2 Ovality of sheath — — — X X
6.1.3 Thickness of sheath — X X — —
6.1.4 In-process cable outside diameter X — — — —
6.2 Electrical tests
6.2.1 Electrical continuity — X X — —
6.2.2 Withstand voltage at final inspection X X X — —
6.2.3 Screening effectiveness
6.2.3.1 Purpose
6.2.3.2 d.c. resistance of the screen — — — X X
Key
X:   Test shall be performed according to ISO 19642-2
—:  Test is not required
a
A test ma
...