ISO 19642-8:2019

Road vehicles — Automotive cables — Part 8: Dimensions and requirements for 30 V a.c. or 60 V d.c. round, sheathed, screened or unscreened multi or single core aluminium 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 30 V a.c. or 60 V d.c.. It also applies to individual cores in multi core cables.

Véhicules routiers — Cables automobiles — Partie 8: Dimensions et exigences des câbles en aluminium ronds, gainés, blindés, à plusieurs ou unique noyau blindés 30 V a.c ou 60 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: 6060 - International Standard published
• Start Date: 14-Dec-2018
• Completion Date: 30-Jan-2019

Standards Content (Sample)

INTERNATIONAL ISO
STANDARD 19642-8
First edition
2019-01
Road vehicles — Automotive cables —
Part 8:
Dimensions and requirements for
30 V a.c. or 60 V d.c. round, sheathed,
screened or unscreened multi or single
core aluminium conductor cables
Véhicules routiers — Cables automobiles —
Partie 8: Dimensions et exigences des câbles en aluminium ronds,
gainés, blindés, à plusieurs ou unique noyau blindés 30 V a.c ou 60 V c.c.
Reference number
ISO 19642-8:2019(E)
©
ISO 2019

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ISO 19642-8:2019(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
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ii © ISO 2019 – All rights reserved

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ISO 19642-8:2019(E)

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 . 3
5 Requirements for single core cables. 5
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 . 6
6.2.3 Thickness of sheath . 6
6.2.4 In-process cable outside diameter . 6
6.3 Electrical tests . 6
6.3.1 Electrical continuity . 6
6.3.2 Withstand voltage at final inspection . 6
6.3.3 Screening effectiveness . 6
6.3.4 Sheath fault on screened cables . 7
6.4 Mechanical tests . 7
6.4.1 Strip force of sheath . 7
6.4.2 Cyclic bending . 7
6.4.3 Flexibility . 7
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 . 8
6.5.6 Shrinkage by heat of sheath . 8
6.5.7 Low temperature winding . 8
6.5.8 Cold impact . 8
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 . 9
Annex A (informative) Dimensions of preferred constructions .10
Bibliography .16
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ISO 19642-8:2019(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.
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ISO 19642-8:2019(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. 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.
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INTERNATIONAL STANDARD ISO 19642-8:2019(E)
Road vehicles — Automotive cables —
Part 8:
Dimensions and requirements for 30 V a.c. or 60 V d.c.
round, sheathed, screened or unscreened multi or single
core aluminium 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 30 V a.c. or 60 V d.c. It also applies
to individual cores in multi 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 19642-4, Road vehicles — Automotive cables — Dimensions and requirements — 30 V a.c. or 60 V d.c.
single core aluminium 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 2.
If suppliers and customers agree upon modifications or changes to the methods and requirements, all
the changes and modifications shall be clearly documented.
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ISO 19642-8:2019(E)

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 30 V a.c. or 60 V d.c.
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. Temperature classes suitable
for aluminium conductor cables are defined in Table 1.
Table 1 — Temperature class rating
Temperature
Class Equivalent class
°C
A T1 −40 to 85
B T2 −40 to 100
C T3 −40 to 125
D T4 −40 to 150
E T5 −40 to 175
F T6 −40 to 200
4.5 Conductor material
The conductor material shall be according to ISO 19642-4.
4.6 Conductors
The conductors of the core or cores shall be according to ISO 19642-4.
4.7 Sheath thickness
Two different sheath thicknesses are allowed in this document:
1. thin wall sheath;
2. thick wall sheath.
The insulation wall thickness of the core or cores shall be according to ISO 19642-4.
4.8 Core cable outside diameter
The maximum and minimum outside cable diameter for the core or cores shall be according to
ISO 19642-4.
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.
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ISO 19642-8:2019(E)

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 19642-4 apply with the following
additions:
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 2 provides a list of all relevant tests in ISO 19642-2:2019 for round, sheathed, screened or
unscreened multi or single core cables.
Table 2 — Tests
c
Mandatory If required
Initial Initial
Test description
In
b b
certifica- Periodic certifica- Periodic
a
process
tion tion
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 — — — —
Key
X:   Test shall be performed according to ISO 19642-2
—:  Test is not required
a
A test made on entire cable length during or after manufacture.
b
The frequency of periodic testing shall be established by agreement between the customer and the supplier.
c
The usage of "If required” tests shall be established by agreement between the customer and the supplier.
d
These tests are only used in preparation and after environmental endurance tests.
e
Only one of the two abrasion tests has to be performed as to agreement between the customer and the supplier.
f
Compliance for a cable family may be demonstrated by testing examples of large and small conductor sizes only.
g
Some fluids are for “Initial certification” and ot
...