Road vehicles -- 60 V and 600 V single-core cables

ISO 6722-1:2011 specifies the dimensions, test methods, and requirements for single-core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V d.c. or 25 V a.c.). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is greater than > (60 V d.c. or 25 V a.c.) to ≤ (600 V d.c. or 600 V a.c.). It also applies to individual cores in multi-core cables. ISO 6722-1:2011 specifies requirements for copper conductor cables.

Véhicules routiers -- Câbles monoconducteurs de 60 V et 600 V

General Information

Status
Published
Publication Date
05-Oct-2011
Current Stage
6060 - International Standard published
Start Date
12-Sep-2011
Completion Date
06-Oct-2011
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INTERNATIONAL ISO
STANDARD 6722-1
Fourth edition
2011-10-15
Road vehicles — 60 V and 600 V single-
core cables —
Part 1:
Dimensions, test methods and
requirements for copper conductor
cables
Véhicules routiers — Câbles monoconducteurs de 60 V et 600 V —
Partie 1: Dimensions, méthodes d'essai et exigences pour les câbles
conducteurs en cuivre
Reference number
ISO 6722-1:2011(E)
ISO 2011
---------------------- Page: 1 ----------------------
ISO 6722-1:2011(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2011

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means,

electronic or mechanical, including photocopying and microfilm, without permission in writing from either ISO at the address below or

ISO's member body in the country of the requester.
ISO copyright office
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Published in Switzerland
ii © ISO 2011 – All rights reserved
---------------------- Page: 2 ----------------------
ISO 6722-1:2011(E)
Contents Page

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

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

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

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

4  General ................................................................................................................................................... 2

4.1  Safety concerns ..................................................................................................................................... 2

4.2  Temperature classes ............................................................................................................................. 2

4.3  Conductors ............................................................................................................................................ 3

4.4  Tests ....................................................................................................................................................... 3

4.5  General test conditions......................................................................................................................... 5

4.6  Ovens ...................................................................................................................................................... 5

4.7  Representative conductor sizes for testing........................................................................................ 5

4.8  Recommended colours ......................................................................................................................... 5

5  Tests and requirements ........................................................................................................................ 5

5.1  Outside cable diameter ......................................................................................................................... 5

5.2  Insulation thickness .............................................................................................................................. 6

5.3  Conductor diameter .............................................................................................................................. 8

5.4  Conductor resistance ............................................................................................................................ 8

5.5  Withstand voltage ................................................................................................................................ 10

5.6  Insulation faults ................................................................................................................................... 11

5.7  Insulation volume resistivity .............................................................................................................. 12

5.8  Pressure test at high temperature ..................................................................................................... 13

5.9  Strip force ............................................................................................................................................. 14

5.10  Low temperature winding ................................................................................................................... 15

5.11  Cold impact .......................................................................................................................................... 17

5.12  Abrasion test ........................................................................................................................................ 19

5.13  Long term heat ageing, 3 000 h .......................................................................................................... 23

5.14  Short term heat ageing, 240 h ............................................................................................................ 24

5.15  Thermal overload ................................................................................................................................. 25

5.16  Shrinkage by heat ................................................................................................................................ 26

5.17  Fluid compatibility ............................................................................................................................... 26

5.18  Durability of cable marking ................................................................................................................ 30

5.19  Resistance to ozone ............................................................................................................................ 30

5.20  Resistance to hot water ...................................................................................................................... 31

5.21  Temperature and humidity cycling .................................................................................................... 33

5.22  Resistance to flame propagation ....................................................................................................... 34

Annex A (informative) Comparison temperature class rating ...................................................................... 36

Annex B (informative) Construction ............................................................................................................... 37

Annex C (informative) Recommended colours .............................................................................................. 40

Annex D (informative) Sources for reference materials ................................................................................ 41

Bibliography ...................................................................................................................................................... 42

© ISO 2011 – All rights reserved iii
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ISO 6722-1:2011(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.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards

adopted by the technical committees are circulated to the member bodies for voting. Publication as an

International Standard requires approval by at least 75 % of the member bodies casting a vote.

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.

ISO 6722-1 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 3, Electrical

and electronic equipment.

This fourth edition of ISO 6722-1 cancels and replaces ISO 6722:2006, which has been technically revised.

ISO 6722 consists of the following parts, under the general title Road vehicles — 60 V and 600 V single-core

cables:
 Part 1: Dimensions, test methods and requirements for copper conductor cables

 Part 2: Dimensions, test methods and requirements for aluminium conductor cables

1) To be published.
iv © ISO 2011 – All rights reserved
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INTERNATIONAL STANDARD ISO 6722-1:2011(E)
Road vehicles — 60 V and 600 V single-core cables —
Part 1:
Dimensions, test methods and requirements for copper
conductor cables

WARNING — The use of this International Standard may involve hazardous materials, operations,

and equipment. This International Standard 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 International Standard to

establish appropriate safety practices and determine the applicability of regulatory limitations prior to

use.
1 Scope

This part of ISO 6722 specifies the dimensions, test methods, and requirements for single-core 60 V cables

intended for use in road vehicle applications where the nominal system voltage is  (60 V d.c. or 25 V a.c.). It

also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle

applications where the nominal system voltage is greater than  (60 V d.c. or 25 V a.c.) to  (600 V d.c. or

600 V a.c.). It also applies to individual cores in multi-core cables.
This part of ISO 6722 specifies requirements for copper conductor cables.
2 Normative references

The following referenced documents are indispensable for the application 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 1817, Rubber, vulcanized or thermoplastic — Determination of the effect of liquids

ISO 6931-1, Stainless steels for springs — Part 1: Wire

IEC 60811-2-1, Common test methods for insulating and sheathing materials of electric and optical cables —

Part 2-1: Methods specific to elastomeric compounds — Ozone resistance, hot set and mineral oil immersion

tests
ASTM B1, Standard Specification for Hard Drawn Copper Wire
ASTM B3, Standard Specification for Soft or Annealed Copper Wire

ASTM B33, Standard Specification for Tin Coated Soft or Annealed Copper Wire for Electrical Purposes

ASTM B298, Standard Specification for Silver Coated Soft or Annealed Copper Wire
ASTM B355, Standard Specification for Nickel Coated Soft or Annealed Copper Wire

EN 13602, Copper and copper alloys — Drawn, round copper wire for the manufacture of electrical

conductors
© ISO 2011 – All rights reserved 1
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ISO 6722-1:2011(E)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.

NOTE Whenever a.c. voltage is specified throughout this part of ISO 6722, a.c. rms value shall be used.

3.1
60 volt (V) cable

cable intended for use in road vehicle applications where the nominal system voltage is equal to or less than

(60 V d.c. or 25 V a.c.)
3.2
600 volt (V) cable

cable intended for use in road vehicle applications where the nominal system voltage is greater than (60 V d.c.

or 25 V a.c.) and less than or equal to (600 V d.c. or 600 V a.c.)
3.3
cable family

group with multiple conductor sizes having the same conductor strand coating, insulation formulation, and wall

thickness type
3.4
nominal (value)
suitable approximate value used to designate or identify a component
4 General
4.1 Safety concerns
See the “Warning” notice at the beginning of this International Standard.
4.2 Temperature classes
Eight temperature classes are defined in Table 1.
Table 1 — Temperature class rating
Class Temperature
40 °C to 85 °C
40 °C to 100 °C
C 40 °C to 125 °C
40 °C to 150 °C
40 °C to 175 °C
40 °C to 200 °C
G 40 °C to 225 °C
H 40 °C to 250 °C
2 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
4.3 Conductors

The conductors shall consist of plain or coated copper strands as shown in Table 2. Conductor sizes

 0,5 mm shall consist of soft annealed copper or annealed compressed/compacted wires. Conductor sizes

 0,5 mm shall consist of soft annealed copper, soft annealed compressed/compacted copper, hard

unannealed copper, or a copper alloy. The specifications for the conductors shall be completed by material

specifications. Elongation requirements shall be established by agreement between customer and supplier.

The finished cable shall meet the resistance requirements of Table 5 for all conductors except alloys. When

an alloy is used, the resistance requirement shall be established by agreement between customer and

supplier.

NOTE Examples of strandings are shown in Table B.1. These strandings highlight examples of conceptual

configurations and are not intended to reflect any preferred constructions. Other strandings configurations may be used

provided they meet the requirements specified above and are agreed between customer and supplier.

Table 2 — Conductor specifications
ASTM B1 Hard-drawn copper wire
ASTM B3 or EN 13602 Soft or annealed copper wire
ASTM B33 or EN 13602 Tin-coated soft or annealed copper wire
ASTM B298 Silver-coated soft or annealed copper wire
ASTM B355 Nickel-coated soft or annealed copper wire
NOTE Silver and Nickel coated conductors are intended for use with high
“temperature class ratings”.
4.4 Tests
The cables shall be submitted to the tests as specified in Table 3.

NOTE A special set of requirements for trucks is intended to be added to the next revision of this International

Standard.
© ISO 2011 – All rights reserved 3
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ISO 6722-1:2011(E)
Table 3 — Tests
Mandatory If required
Sub-
Test description
clause
Initial Periodic Initial Periodic
progress
5.1 Outside cable diameter — X X — —
5.2 Insulation thickness — X X — —
5.3 Conductor diameter — — — X X
5.4 Conductor resistance — X X — —
5.5 Withstand voltage — Note 1 Note 1 — —
5.6 Insulation faults Note 1 — — — —
5.7 Insulation volume resistivity — — — X X
5.8 Pressure test at high temperature — X X — —
5.9 Strip force — — — X X
5.10 Low temperature winding — X X — —
5.11 Cold impact — — — X X
5.12 Abrasion test — Note 2 Note 2 — —
5.13 Long term heat ageing, 3 000 h — X — — —
5.14 Short term heat ageing, 240 h — X X — —
5.15 Thermal overload — — — X X
5.16 Shrinkage by heat — X X — —
Notes 3 Notes 3
5.17 Fluid compatibility — — —
and 4 and 4
5.18 Durability of cable marking — — — Note 4 Note 4
5.19 Resistance to ozone — — — Note 4 —
5.20 Resistance to hot water — — — Note 4 —
5.21 Temperature and humidity cycling — — — Note 4 —
5.22 Resistance to flame propagation — X X — —

NOTE 1 Some cables are rated at 60 V and others at 600 V. See 5.5.3 and 5.6.3 for details.

NOTE 2 See 5.12.

NOTE 3 Some fluids are for “Certification” and others are “If required”. See 5.17 for details.

NOTE 4 Compliance for a cable family may be demonstrated by testing examples of large and small conductor sizes only. See 4.7

for details.
A test made on an entire cable length during or after the manufacture.

The frequency of periodic testing shall be established by agreement between customer and supplier.

The usage of “If required” tests shall be established by agreement between customer and supplier.

4 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
4.5 General test conditions

Unless specified otherwise, the device under test (DUT) shall be preconditioned for at least 16 h at a room

temperature (RT) of (23  5) °C and a relative humidity (RH) of 45 % to 75 %. Unless specified otherwise, all

tests other than “In process” tests shall be conducted at these conditions.

Where no tolerance is specified, all values shall be considered to be approximate.

When a.c. tests are performed, they shall be at 50 Hz or 60 Hz. Applications at higher frequencies may

require additional testing.
4.6 Ovens

An oven with air exchange, either natural or by pressure, should be used. The air shall enter the oven in such

a way that it flows over the surface of the test pieces and exits near the top of the oven. The oven shall have

not less than 8 and not more than 20 complete air changes per hour at the specified ageing temperature.

Forced air circulation, e.g. by a fan inside the oven may be used. However, in case of dispute, an oven without

forced air circulation shall be used.
4.7 Representative conductor sizes for testing

When a test is required, all combinations of conductor size, wall thickness, and insulation formulation shall

meet the appropriate requirements. However, if testing of representative conductor sizes is permitted (see

Table 3), compliance for a cable family may be demonstrated by testing examples of large and small

conductor sizes only. Permission to show compliance for a cable family by testing “representative conductor

sizes” shall be established by agreement between customer and supplier.
4.8 Recommended colours
A list of recommended colours is shown in Table C.1.
5 Tests and requirements
5.1 Outside cable diameter
5.1.1 Purpose

This test is intended to verify that the cable outside diameter is within the required tolerances to fit seal and

harness dimension requirements.
5.1.2 Test Sample
Prepare a test sample of 3 m in length.
5.1.3 Test

Use a measuring device which shall not cause deformation. Take three sets of measurements at positions

separated by 1 m and record the highest and lowest outside cable diameter at each position.

© ISO 2011 – All rights reserved 5
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ISO 6722-1:2011(E)
5.1.4 Requirement

All measurements shall be within the limits of the appropriate maximum and minimum “outside cable

diameter” specified in Table 4 and Table B.2. The values in Table 4 are normative. Since the values in

Table B.2 are informative, they are not required; however, they may be applied by agreement between

customer and supplier.
5.2 Insulation thickness
5.2.1 Purpose

This test is intended to verify that the cable insulation thickness is within the required tolerances to withstand

electrical, mechanical and chemical abuse.
5.2.2 Test samples

Prepare three test samples from a cable sample 3 m in length. Take the test samples at 1 m intervals. Strip

the insulation from the cable. A test sample consists of a thin cross-section of insulation. Take care not to

deform the test sample during the preparation process. If cable marking causes indentation of the insulation,

take the first test sample through this indentation.
5.2.3 Test
Use a measuring device which shall not cause deformation.

Place the test sample under the measuring equipment with the plane of the cut perpendicular to the optical

axis. Determine the minimum “insulation thickness”.
5.2.4 Requirement

No single value shall be less than the appropriate minimum insulation thickness specified in Table 4.

6 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
Table 4 — Dimensions
ISO conductor Thick wall Thin wall Ultra-thin wall
Outside Outside Outside
Size Insulation Insulation Insulation
Diameter cable cable cable
thickness thickness thickness
diameter diameter diameter
mm mm mm mm mm mm mm mm
max. nominal min. max. nominal min. max. nominal min. max.
0,13 0,55 1,05 0,95
0,22 0,70 1,20 1,05
0,25 0,20
0,35 0,90 1,20
1,40
0,50 1,10 2,30 0,28 0,22 1,60 1,40
0,20 0,16
0,75 1,30 2,50 1,90 1,60
1 1,50 2,70 2,10 1,75
0,60 0,48 0,30 0,24
1,25 1,70 2,95 2,30 2,00
1,5 1,80 3,00 2,40 2,10
2 2,00 3,30 2,80 2,40
0,35 0,28 0,25 0,20
2,5 2,20 3,60 3,00 2,70
0,70 0,56
3 2,40 4,10 3,40
4 2,80 4,40 3,70
5 3,10 4,90 0,40 0,32 4,20
0,80 0,64
6 3,40 5,00 4,30
8 4,30 5,90 5,00
10 4,50 6,50 6,00
0,60 0,48
12 5,40 1,00 0,80 7,40 6,50
16 5,80 8,30 7,20
20 6,90 1,10 0,88 9,10 0,65 0,52 7,80
25 7,20 10,40 8,70
30 8,30 1,30 1,04 10,90 9,60
0,80 0,64
35 8,50 11,60 10,40
40 9,60 1,40 1,12 12,40 11,10
0,90 0,71
50 10,50 13,50 12,20
60 11,60 1,50 1,20 14,60 13,30
1,00 0,80
70 12,50 15,50 14,40
95 14,80 18,00 1,10 0,90 16,70
1,60 1,28
120 16,50 19,70

NOTE Outside cable diameter minimum values for high volume cable constructions are shown in Table B.2. Since the values in

Table B.2 are informative, they are not required; however, they may be applied by agreement between customer and supplier.

a 2

The outside cable diameter for conductor size 0,35 mm with 7 strands shall be max. 1,30 mm.

© ISO 2011 – All rights reserved 7
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ISO 6722-1:2011(E)
5.3 Conductor diameter
5.3.1 Purpose

This test is intended to verify that the cable conductor diameter is within the required tolerances to fit terminal

crimps and mechanical demands.
5.3.2 Test samples

Use the test samples as specified in 5.2. In case of disputed results, a referee method is provided below.

Prepare three test samples from a cable sample 3 m in length. Take these samples at 1 m intervals. A sample

consists of a 20 mm length of cable. Take care not to deform the test sample. Immerse the samples in a

casting resin. After hardening, take a section perpendicular to the axis of the test sample.

5.3.3 Test
Use a measuring device which shall not cause deformation.

Determine the conductor diameter by measuring the inside diameter of the test samples and record the

maximum inside diameter for each test sample.
5.3.4 Requirement
No single value shall exceed the maximum value as specified in Table 4.
5.4 Conductor resistance
5.4.1 Purpose

This test is intended to verify that the cable conductor resistance does not exceed the maximum permitted

value.
5.4.2 Test samples

Prepare a test sample of 1 m length plus the length necessary for connections. Other lengths may be used

providing that the resistance reading is adjusted using the method shown in 5.4.3. The ends of the test sample

may be soldered.
5.4.3 Test

Use a resistance measuring device with an accuracy of  0,5 % of the measured value and a thermometer

with an accuracy of  0,5 °C.

Measure the temperature of the test sample and the unsoldered length. Take care to ensure that connections

are secure. Measure the resistance of the test sample. Correct the measured value using Equation (1):

R  (1)
Lt10,00 393 20
where

R is the corrected conductor resistance at the reference temperature of 20 °C, expressed in mΩ/m;

R is the conductor resistance measured at the conductor temperature in mΩ;
8 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
L is the unsoldered conductor length, expressed in m;
t is the conductor temperature at the time of measuring, expressed in °C.

NOTE The value of 0,00393 is the temperature coefficient for copper with 100 % conductivity at temperatures at

20 °C. For coated wires or alloys, the correction factor shall be established by agreement between customer and supplier.

5.4.4 Requirement

The corrected value shall not exceed the appropriate maximum resistance specified in Table 5.

Table 5 — Conductor resistance
Maximum conductor resistance per length
ISO conductor size
m/m at 20 °C
Plain copper Sn plated copper Ni plated copper
0,13 136 140 142
0,22 84,8 86,5 87,9
0,35 54,4 55,5 56,8
0,50 37,1 38,2 38,6
0,75 24,7 25,4 25,7
1 18,5 19,1 19,3
1,25 14,9 15,9 16,0
1,5 12,7 13,0 13,2
2 9,42 9,69 9,82
2,5 7,60 7,82 7,92
3 6,15 6,36 6,41
4 4,71 4,85 4,91
5 3,94 4,02 4,11
6 3,14 3,23 3,27
8 2,38 2,52 2,60
10 1,82 1,85 1,90
12 1,52 1,60 1,66
16 1,16 1,18 1,21
20 0,955 0,999 1,03
25 0,743 0,757 0,774
30 0,647 0,684 0,706
35 0,527 0,538 0,549
40 0,473 0,500 0,516
50 0,368 0,375 0,383
60 0,315 0,333 0,344
70 0,259 0,264 0,270
95 0,196 0,200 0,204
120 0,153 0,156 0,159

Conductors produced from silver coated strands shall not exceed the maximum conductor resistance per length for

plain copper.

Minimum conductor resistance values for high volume cable constructions are shown in Table B.3. Since the values in Table B.3

are informative, they are not required; however, they may be applied by agreement between customer and supplier.

© ISO 2011 – All rights reserved 9
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ISO 6722-1:2011(E)
5.5 Withstand voltage
5.5.1 Purpose

This test is intended to verify that the cable insulation is capable of withstanding the required rated voltage. It

is also used to detect defects caused by mechanical, chemical and/or other environmental stress.

5.5.2 Test sample

Prepare a test sample of a minimum length of 350 mm. Strip 25 mm of insulation from each end and twist the

ends together to form a loop.
5.5.3 Test
5.5.3.1 General

Partially fill an electrically non-conductive vessel with salt water with 3 % by weight of NaCl in water with the

ends of the test sample emerging above the bath as shown in Figure 1. Use a 50 Hz or 60 Hz a.c. voltage

source.
5.5.3.2 60 V cable

Immerse the test sample in the bath as shown in Figure 1 for 4 h and then apply a test voltage of 1 kV (a.c.)

for 30 min between conductor and the bath. Then increase the voltage at a rate of 500 V/s until the following

value is reached:
 3 kV (a.c.) for cables  0,5 mm
 5 kV (a.c.) for cables  0,5 mm
5.5.3.3 600 V cable

After completing the procedure for a 60 V cable, hold the 3 kV or 5 kV for 5 min.

5.5.4 Requirement
Breakdown shall not occur.
10 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
Key
1 test voltage (terminals)
2 non-conductive vessel
3 electrode
4 test sample
5 salt-water bath
Figure 1 — Apparatus for withstand voltage test
5.6 Insulation faults
5.6.1 Purpose

This test is intended to verify that the cable insulation has no defects which can cause electrical failures.

5.6.2 Test sample
All cables produced are used.
5.6.3 Test

Use a sinusoidal voltage source set at the value shown in Table 6. The test electrode may consist of metal

ball chains, metal brushes, or any other type of suitable electrodes. Choose the electrode length and

frequency considering the speed of the cable running through the field of the electrode so that each point of

the cable is loaded by at least nine voltage cycles.
Table 6 — Insulation faults
Voltage rating (a.c.)
ISO conductor size
60 V cables 600 V cables
 0,5 3 6
 0,5 5 8
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ISO 6722-1:2011(E)

This test shall be carried out under production conditions. Subject all cables to this test. Other methods of test

may be used provided that insulation faults are detected with the same certainty.

5.6.4 Requirement

No breakdown shall occur when the earthed cable is drawn through the test electrode.

5.7 Insulation volume resistivity
5.7.1 Purpose

This test is intended to ensure limitation of leakage current by verifying that the volume resistivity meets the

requirements as specified.
5.7.2 Test sample

Prepare a test sample of 5 m length and remove 25 mm of insulation from each end.

5.7.3 Apparatus

Partially fill an electrically non-conductive vessel with tap water at a temperature of (70  2) °C. Use a

resistance measuring device with a d.c. voltage of 500 V. Voltages between 100 V and 500 V are allowed;

however, if a dispute arises, the referee apparatus shall be a resistance measuring device with a d.c. voltage

of 500 V.
5.7.4 Test

Immerse the test sample for 2 h with each end emerging from the bath by 250 mm. Apply the d.c. voltage

between the conductor and the bath. Measure the insulation resistance 1 min after application of the voltage.

Calculate the insulation volume resistivity using Equation (2):
(2)
2,725
where
ρ is the insulation volume resistivity, expressed in Ωmm;
L is the immersed length of the test sample in mm;
R is the measured insulation resistance in Ω;
D is the outside cable diameter in mm according to 5.1;
d is the conductor diameter in mm according to 5.3;
lg is logarithm to the base 10.
12 © ISO 2011 – All rights reserved
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ISO 6722-1:2011(E)
5.7.5 Requirement
The insulation volume resistivity shall not be less than
...

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