Road vehicles -- Automotive cables

This document defines terms in the field of cables applied in road vehicle general purpose applications, for use in the other parts of the ISO 19642 series.

Véhicules routiers -- Cables automobiles

General Information

Status
Published
Publication Date
22-Apr-2019
Current Stage
9092 - International Standard to be revised
Start Date
18-Jun-2020
Ref Project

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INTERNATIONAL ISO
STANDARD 19642-1
First edition
2019-04
Road vehicles — Automotive cables —
Part 1:
Vocabulary and design guidelines
Véhicules routiers — Cables automobiles —
Partie 1: Vocabulaire et lignes directrices pour la conception
Reference number
ISO 19642-1:2019(E)
ISO 2019
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ISO 19642-1:2019(E)
COPYRIGHT PROTECTED DOCUMENT
© 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

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below or ISO’s member body in the country of the requester.
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Email: copyright@iso.org
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Published in Switzerland
ii © ISO 2019 – All rights reserved
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ISO 19642-1:2019(E)
Contents Page

Foreword ........................................................................................................................................................................................................................................iv

Introduction ..................................................................................................................................................................................................................................v

1 Scope ................................................................................................................................................................................................................................. 1

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

3 Terms and definitions ..................................................................................................................................................................................... 1

3.1 Terms related to voltage rating ................................................................................................................................................. 1

3.2 Terms related to temperatures ................................................................................................................................................. 1

3.3 Terms related to cables .................................................................................................................................................................... 2

Annex A (informative) Design guidelines for calculation of dimensions in multi-core cables .............11

Annex B (informative) Recommended colour concentrations ...............................................................................................20

Bibliography .............................................................................................................................................................................................................................21

© ISO 2019 – All rights reserved iii
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ISO 19642-1:2019(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 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
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ISO 19642-1:2019(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 later be replaced by the ISO 19642 series.

For new automotive cable projects, customers and suppliers are advised to use the ISO 19642 series.

© ISO 2019 – All rights reserved v
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INTERNATIONAL STANDARD ISO 19642-1:2019(E)
Road vehicles — Automotive cables —
Part 1:
Vocabulary and design guidelines
1 Scope

This document defines terms in the field of cables applied in road vehicle general purpose applications,

for use in the other parts of the ISO 19642 series.
2 Normative references
There are no normative references in this document.
3 Terms and definitions

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/
3.1 Terms related to voltage rating
3.1.1
a.c. voltage

voltage in an alternating current circuit that also periodically reverses because the current has a

periodic function of time

Note 1 to entry: Whenever a.c. voltage is specified in the ISO 19642 series, the a.c. r.m.s. value shall be used.

3.1.2
60 V cable

cable (3.3.8) intended for use in road vehicle applications where the nominal system voltage is less than

or equal to 30 V a.c. or 60 V d.c.
3.1.3
900 V cable

cable (3.3.8) intended for use in road vehicle applications where the nominal system voltage is less than

or equal to 600 V a.c. or 900 V d.c.
3.1.4
1 500 V cable

cable (3.3.8) intended for use in road vehicle applications where the nominal system voltage is less than

or equal to 1 000 V a.c. or 1 500 V d.c.
3.2 Terms related to temperatures
3.2.1
temperature class rating

temperature range for safe operation of the cable (3.3.8) divided into eight temperature classes as

defined in Table 1
© ISO 2019 – All rights reserved 1
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ISO 19642-1:2019(E)
Table 1 — Temperature class rating
Temperature
Class Is equivalent to Class
A T 1 −40 to 85
B T 2 −40 to 100
C T 3 −40 to 125
D T 4 −40 to 150
E T 5 −40 to 175
F T 6 −40 to 200
G T 7 −40 to 225
H T 8 −40 to 250
3.2.2
room temperature

situation with a temperature of (23 ± 3) °C and a relative humidity (RH) of 45 % to 75 %

3.3 Terms related to cables
3.3.1
Percentage of International Annealed Copper Standard
%IACS

percentage of the volume resistivity of a metal when compared to 100 % of pure annealed copper

having a volume resistivity of 0,01724 Ω × mm /m at 20 °C as defined in IEC 60028

3.3.2
bare conductor
plain conductor

metal cable (3.3.8) conductor (3.3.12) in which the strand or strands are not coated

3.3.3
bedding layer

non-metallic covering applied (normally extruded) around the assembly of the cores (3.3.14) [and fillers

(3.3.17), if any] of a multi-conductor cable (3.3.30) to obtain a more circular outline

3.3.4
braid
covering formed from plain or plated metallic or non-metallic material
3.3.5
braid parameter
parameter of a braid (3.3.4) as defined in Table 2 and Table 3
Table 2 — Braid coverage formulae
Outside diameter Number of single strands Optical coverage,
Coverage
of the braid in one direction braid percentage
n md×
D = D + 4 × d B = (2 × B − B )× 100
G S ma=× B= O
2 h×cosα
2 © ISO 2019 – All rights reserved
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ISO 19642-1:2019(E)
Table 3 — Braid parameters
d mm Diameter of the single strand
D mm Diameter of the core (3.3.14) below the braid
D mm Outside diameter of the braid
a Number of strands in one carrier
m Number of single strands in one direction
n Number of carriers
h mm Lay length (3.3.28)
α ° Angle of lay, see Figure 1
B Coverage, proportion of the covered surface by strands in one
direction compared to the whole surface.
B % Optical coverage. Also called braid percentage. Proportion of
the covered surface by strands in both directions compared to
the whole surface.

Note 1 to entry: A braid is formed by a number of single strands which are grouped into carriers and applied to

the cable (3.3.8) surface in two different directions (left and right or S and Z) in a form that each carrier of one

direction is alternatively above and below the adjacent carrier of the other direction.

Note 2 to entry: See Figure 1.
Figure 1 — Angle of lay
3.3.6
bunched conductor

conductor (3.3.12) in which individual strands are assembled together in helical formation, all in the

same direction and with the same length of lay
3.3.7
bunching loss

ratio of conductor (3.3.12) resistance before and after the bunching process of stranded conductors

(3.3.40)
Note 1 to entry: The factor, f , is derived by the formula:
mR××κ
mean mean
f =
1000×ρ
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ISO 19642-1:2019(E)
where
κ is the conductivity of the used conductor material in Sm/mm ;
ρ is the density of the conductor material in kg/dm = kg/l;
m is the mean of measured conductor mass in g/m;
mean
R is the mean of measured conductor resistance at 20 °C mΩ/m.
mean
3.3.8
cable
single or multi-core wire (3.3.42)
Note 1 to entry: Cable dimension descriptions are shown in Figure 2.
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ISO 19642-1:2019(E)
Key
a conductor (3.3.12) diameter 2 conductor insulation (3.3.13)
b core (3.3.14) diameter 3 inner covering (3.3.22)
c twisted core diameter 4 filler (3.3.17)
d diameter under sheath (3.3.38) 5 drain wire (3.3.42)
e outside cable diameter 6 foil
f wall thickness sheath 7 screen (3.3.36)
1 conductor 8 sheath
Figure 2 — Cable dimension descriptions
3.3.9
cable family

group with multiple conductor (3.3.12) sizes having the same conductor strand coating, insulation

(3.3.25) formulation, and wall thickness type
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ISO 19642-1:2019(E)
3.3.10
colour code

code of a cable (3.3.8) colour to make it visually distinguishable from the others

Note 1 to entry: The recommended colours are listed in Table 4.

Note 2 to entry: Annex B indicates recommended colour concentrations for the colours listed in Table 4.

Table 4 — Recommended colours
Colour Code
Black BK
Blue BU
Brown BN
Green GN
Orange OG
Red RD
Violet (Purple) VT
White WH
Yellow YE

NOTE Other colours can be used based on agreement between customer and supplier (see IEC 60757).

3.3.11
compressed conductor

stranded conductor (3.3.40) in which the interstices between the strands have been reduced by

mechanical compression into a circular shape with reduced outside diameter
Note 1 to entry: See Figure 3.
a) Compressed conductor b) Compressed conductor with insulation
(3.3.25) only
Figure 3 — Compressed conductor
3.3.12
conductor
one or multitude of plain, coated or cladded electrically conductive strands
3.3.13
conductor insulation
dielectric material applied on a conductor (3.3.12)
6 © ISO 2019 – All rights reserved
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ISO 19642-1:2019(E)
3.3.14
core

insulated conductor (3.3.12) assembly comprising a conductor with its own insulation (3.3.25) [and

screens (3.3.36), if any]
3.3.15
cross-sectional area
CSA
calculated or measured area of the conductor (3.3.12)
3.3.16
drain wire
continuity wire

un-insulated or conductive coated conductor (3.3.12) laid in contact with a screen (3.3.36) or a shield

(3.3.36)
3.3.17
filler

component used to fill the interstices between the cores (3.3.14) or fill a void for roundness of a multi-

conductor cable (3.3.30)
3.3.18
flexibility

property of a cable (3.3.8) that allows for bending under the influence of an outside force

3.3.19
flexible conductor

metallic conductor (3.3.12) built from a multitude of single stranded wires (3.3.42)

3.3.20
flex life
property of a cable (3.3.8) to withstand repeated bending
3.3.21
general purpose cable
cable (3.3.8) meeting basic requirements for general automotive applications
3.3.22
inner covering

non-metallic covering which surrounds the assembly of the cores (3.3.14) [and fillers (3.3.17), if any] of a

multi-conductor cable (3.3.30) and over which the protective covering is applied
3.3.23
inner sheath
inner jacket

non-metallic sheath (3.3.38) generally applied under a metallic sheath, reinforcement or armour

3.3.24
insulated cable
assembly consisting of:
— one or more cores (3.3.14),
— their individual covering(s) (if any),
— assembly protection (if any),
— protective covering(s) (if any).
© ISO 2019 – All rights reserved 7
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ISO 19642-1:2019(E)
3.3.25
insulation

set of insulating materials incorporated on a conductor (3.3.12) or screen (3.3.36) with a specific

function of insulating and/or protecting the conductive elements
3.3.26
ISO conductor size

nominal value (3.3.32) of the ISO wire (3.3.42) used as a reference in this document

3.3.27
lay direction
direction
...

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