ISO 19642-4:2019

INTERNATIONAL ISO
STANDARD 19642-4
First edition
2019-01
Road vehicles — Automotive cables —
Part 4:
Dimensions and requirements for
30 V a.c. and 60 V d.c. single core
aluminium conductor cables
Véhicules routiers — Cables automobiles —
Partie 4: Dimensions et exigences des câbles en aluminium mono
conducteurs de 30 V a.c. ou 60 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: +41 22 749 01 11
Fax: +41 22 749 09 47
Email: copyright@iso.org
Website: www.iso.org
Published in Switzerland
ii © ISO 2019 – All rights reserved

Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Specifications . 2
4.1 General test conditions . 2
4.2 Safety concerns . 2
4.3 Voltage rating . 2
4.4 Temperature classes . 2
4.5 Conductor material . 2
4.6 Conductors . 3
4.7 Insulation thickness. 3
4.8 Cable outside diameter . 4
4.9 Representative conductor sizes for testing . 4
4.10 Reference and requirements for the tests according to ISO 19642-2 . 4
5 Requirements . 5
5.1 General . 5
5.2 Dimensional tests . 6
5.2.1 Cable outside diameter. 6
5.2.2 Insulation thickness . 6
5.2.3 Conductor diameter . 6
5.2.4 Cross sectional area (CSA) . 6
5.2.5 In-process cable outside diameter . 6
5.3 Electrical tests . 6
5.3.1 Conductor resistance . 6
5.3.2 Determination of temperature coefficients . 6
5.3.3 Withstand voltage . 6
5.3.4 Withstand voltage after environmental testing . 6
5.3.5 Insulation faults . 6
5.3.6 Insulation volume resistivity . 6
5.4 Mechanical tests . 7
5.4.1 Strip force . 7
5.4.2 Abrasion . 7
5.4.3 Breaking force of the finished cable . 8
5.4.4 Cyclic bending . 8
5.4.5 Flexibility . 8
5.5 Environmental tests . 8
5.5.1 Test specimen preparation and winding tests . 8
5.5.2 Long term heat ageing, 3 000 h at temperature class rating . 8
5.5.3 Short term heat ageing, 240 h at temperature class rating +25 °C. 8
5.5.4 Thermal overload, 6 h at temperature class rating +50 °C . 8
5.5.5 Pressure test at high temperature . 9
5.5.6 Shrinkage by heat . 9
5.5.7 Low temperature winding . 9
5.5.8 Cold impact . 9
5.5.9 Temperature and humidity cycling . 9
5.5.10 Resistance to hot water . 9
5.5.11 Resistance to liquid chemicals .10
5.5.12 Durability of cable marking .10
5.5.13 Stress cracking resistance .10
5.5.14 Resistance to ozone .10
5.5.15 Resistance to flame propagation .10
Annex A (informative) ISO conductor sizes, number of strands and strand diameters .13
Bibliography .16
iv © ISO 2019 – All rights reserved

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.
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.
vi © ISO 2019 – All rights reserved

INTERNATIONAL STANDARD ISO 19642-4:2019(E)
Road vehicles — Automotive cables —
Part 4:
Dimensions and requirements for 30 V a.c. and 60 V d.c.
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 single-core cables intended for general
purpose vehicle applications where the nominal system voltage is less than or equal to 30 V a.c. or less
than or equal to 60 V d.c. It also applies to individual cores in multi-core cables.
This document specifies requirements for aluminium conductor 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 6892-1, Metallic materials — Tensile testing — Part 1: Method of test at room temperature
ISO 19642-1, Road vehicles — Automotive cables — Vocabulary and design guidelines
ISO 19642-2, Road vehicles — Automotive cables — Test methods
EN 573-1, Aluminium and aluminium alloys — Chemical composition and form of wrought products —
Part 1: Numerical designation system
EN 573-3:2013, Aluminium and aluminium alloys — Chemical composition and form of wrought products —
Part 3: Chemical composition and form of products
ASTM B 231, Standard Specification for Concentric-Lay-Standard Aluminium 1350 Conductors
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 3.
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 cable described in this document is limited to 30 V a.c. and 60 V d.c. maximum.
4.4 Temperature classes
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 conductors shall consist of annealed or annealed compressed aluminium or aluminium alloy
strands. The specifications for the single strand wires of the conductors shall be according Table 2
and completed by material specifications. Elongation requirements shall be established by agreement
between the customer and the supplier. The finished cable shall meet the resistance requirements of
Table 7 for all conductors.
The individual strands of the aluminium conductor shall be manufactured per 1 000 series aluminium
or other alloys according to EN 573-1. The chemical composition shall follow EN 573-3:2013, Table 1.
NOTE Examples for strands are shown in Annex A.
2 © ISO 2019 – All rights reserved

Table 2 — Characteristics of individual single strand wire after annealing
Tensile strength Elongation at break Conductivity
Reference
a,b a,b
R A k
m conductor 20
material 2
MPa % %IACS Sm/mm
70 to 120 1 000 series ≥16 ≥61,2 ≥35,5
(Recommended)
d d
Minimum 90 Other alloys ≥57,8 ≥33,5
c,d
≥8
a
The tensil strength and elongation at break shall be determined according to ISO 6892-1 and ASTM B 231.
b
The tensil strength and elongation at break shall be measured at clamping length of 200 mm.
c
This is not applicable for compressed conductors. The tensile strength, elongation and chemical
composition characteristics shall be established by agreement between the customer and the supplier.
d
Additional aluminium alloys may be used. The conductivity, tensile strength, elongation characteristics
and chemical composition shall be established by agreement between the customer and the supplier.
NOTE 1  See also EN-1715-2.
NOTE 2  %IACS is the Percentage of International Annealed Copper Standard.
4.6 Conductors
The conductors in the finished cable shall meet the cross-sectional area (CSA) and resistance
requirements of Table 7.
The maximum diameter of the conductors is standardized and presented in Table 8.
The construction of the stranded conductor is not standardized.
NOTE 1 Existing stranding configurations for aluminium conductors are presented in Table A.1.
NOTE 2 Preferred stranding configurations for aluminium conductors are presented in Table A.2.
Other stranding configurations can be used for aluminium conductors provided they meet the above
requirements and are agreed between the customer and the supplier.
4.7 Insulation thickness
Three different insulation thickness requirements are allowed in this document:
1. thick wall insulation;
2. thin wall insulation;
3. ultra-thin wall insulation.
The minimum wall thickness requirements for the different ISO conductor sizes are standardized and
presented in Table 8.
The nominal wall thickness is derived from the minimum wall thickness in Table 8 by the following
formulae:
w =×12,/50w or w = w ,8
nomnminmom in
where
w is the minimum wall thickness;
min
w is the nominal wall thickness.
nom
4.8 Cable outside diameter
The cable’s outside diameter for each ISO conductor size and insulation thickness is standardized and
specified in Table 8.
4.9 Representative conductor sizes for testing
When a test is required, all combinations of conductor size, insulation thickness and insulation
formulation shall
...