ISO 8092-2:2023

INTERNATIONAL ISO
STANDARD 8092-2
Fifth edition
2023-09
Road vehicles — Connections for on-
board electrical wiring harnesses —
Part 2:
Terminology, test methods and
general performance requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique
embarqués —
Partie 2: Terminologie, méthodes d'essai et exigences de performances
générales
Reference number
© ISO 2023
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ii
Contents Page
Foreword . vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Test conditions and requirements . 4
4.1 General . 4
4.1.1 Preconditioning for environmental and mechanical durability test . 4
4.1.2 Test conditions . 4
4.1.3 Test sequences and sample quantities . 5
4.2 Visual examination . 9
4.2.1 Purpose . 9
4.2.2 Test . . . 9
4.2.3 Requirements . 9
5 Mechanical tests .10
5.1 Connection and disconnection . 10
5.1.1 Purpose . 10
5.1.2 Test . . . 10
5.1.3 Requirements . 10
5.2 Mating force – measurement and classification . 10
5.2.1 Purpose . 10
5.2.2 Test . . . 10
5.2.3 Requirement . 10
5.3 Unlocking force – measurement and classification . 11
5.3.1 Purpose . 11
5.3.2 Test . . . 11
5.3.3 Requirement . 11
5.4 Unmating force – measurement and classification . 11
5.4.1 Purpose . 11
5.4.2 Test . . . 11
5.4.3 Requirement . 11
5.5 Locking device strength . 11
5.5.1 Purpose . 11
5.5.2 Test . . . 11
5.5.3 Requirements .12
5.6 Unintentional lever release force .12
5.6.1 Purpose .12
5.6.2 Test . . .12
5.6.3 Requirements .12
5.7 Locking force for CPA function . .12
5.7.1 Purpose .12
5.7.2 Test . . .12
5.7.3 Requirements .12
5.8 Disengage force for CPA function . 13
5.8.1 Purpose . 13
5.8.2 Test . . .13
5.8.3 Requirements .13
5.9 Locking force for TPA .13
5.9.1 Purpose . 13
5.9.2 Test . . .13
5.9.3 Requirements .13
5.10 Disengage force for TPA. 13
5.10.1 Purpose .13
5.10.2 Test . . . 14
iii
5.10.3 Requirements . 14
5.11 Effectiveness of connector coding and polarization . 14
5.11.1 Purpose . 14
5.11.2 Test . . . 14
5.11.3 Requirements . 14
5.12 Connector engagement sound . 14
5.12.1 Purpose . 14
5.12.2 Test . . . 14
5.12.3 Requirements .15
5.13 Terminal insertion force (TPA disengaged) . 15
5.13.1 Purpose .15
5.13.2 Test . . . 15
5.13.3 Requirements .15
5.14 Terminal insertion force (TPA engaged) . 15
5.14.1 Purpose . 15
5.14.2 Test . . . 15
5.14.3 Requirements .15
5.15 Terminal insertion force with incorrect orientation . 16
5.15.1 Purpose . 16
5.15.2 Test . . . 16
5.15.3 Requirements . 16
5.16 Terminal extraction force . 17
5.16.1 Purpose . 17
5.16.2 Test . . . 17
5.16.3 Requirements . 17
5.17 Tensile strength of connection between terminal and wire . 18
5.17.1 Purpose . 18
5.17.2 Test . . . 18
5.17.3 Requirements . 19
6 Electrical tests .19
6.1 Connection resistance (voltage drop) . 19
6.1.1 Purpose . 19
6.1.2 Test . . . 19
6.1.3 Requirements . 21
6.2 Temperature rise . 22
6.2.1 Purpose . 22
6.2.2 Test . . .22
6.2.3 Requirements . 23
6.3 Current cycling at ambient temperature . 23
6.3.1 Purpose .23
6.3.2 Test . . . 23
6.3.3 Requirements . 23
6.4 Insulation resistance. 24
6.4.1 Purpose . 24
6.4.2 Test . . . 24
6.4.3 Requirements . 24
6.5 Withstand voltage . 24
6.5.1 Purpose . 24
6.5.2 Test . . . 24
6.5.3 Requirements .25
7 Environmental tests .25
7.1 Thermal shock. 25
7.1.1 Purpose . 25
7.1.2 Test . . . 25
7.1.3 Requirements . 25
7.2 Thermal aging . 26
7.2.1 Purpose . 26
iv
7.2.2 Test . . . 26
7.2.3 Requirements .26
7.3 Temperature and humidity cycle . 26
7.3.1 Purpose . 26
7.3.2 Test . . . 26
7.3.3 Requirements .29
7.4 Vibration with thermal cycling .29
7.4.1 Purpose .29
7.4.2 Test . . .29
7.4.3 Requirements .30
7.5 Mechanical shock . 31
7.5.1 Purpose . 31
7.5.2 Test . . . 31
7.5.3 Requirements . 31
7.6 Drop . 31
7.6.1 Purpose . 31
7.6.2 Test . . . 31
7.6.3 Requirements . 32
7.7 Water tightness . 32
7.7.1 Purpose . 32
7.7.2 Test . . . 32
7.7.3 Requirements .34
7.8 Water tightness, dynamic .34
7.8.1 Purpose .34
7.8.2 Test . . .34
7.8.3 Requirement .36
7.9 High-pressure/steam-jet cleaning . 36
7.9.1 Purpose . 36
7.9.2 Test . . .36
7.9.3 Requirements . 37
7.10 Salt spray .38
7.10.1 Purpose .38
7.10.2 Test . . .38
7.10.3 Requirements .38
7.11 Dust resistance .38
7.11.1 Purpose .38
7.11.2 Test . . .38
7.11.3 Requirements .38
7.12 Chemical loads .38
7.12.1 Purpose .38
7.12.2 Test . . .39
7.12.3 Requirements . 39
7.13 Fretting corrosion .39
7.13.1 Purpose . 39
7.13.2 Test . . .39
7.13.3 Requirements . 39
7.14 Friction corrosion . 39
7.14.1 Purpose .39
7.14.2 Test . . .40
7.14.3 Requirements .40
Bibliography .41
v
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
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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 document 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).
ISO draws attention to the possibility that the implementation of this document may involve the use
of (a) patent(s). ISO takes no position concerning the evidence, validity or applicability of any claimed
patent rights in respect thereof. As of the date of publication of this document, ISO had not received
notice of (a) patent(s) which may be required to implement this document. However, implementers are
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expressions related to conformity assessment, as well as information about ISO's adherence to
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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.
This fifth edition cancels and replaces the fourth edition (ISO 8092-2:2005), which has been technically
revised.
The main changes are as follows:
— adoption of the content according to new technical requirements,
— adoption of the content according to the new version of the ISO guidelines,
— alignment of the content regarding to the referred standards,
— subclause 4.24 "Flowing gas corrosion test" has been removed due to its technical irrelevance,
— former Annex A is adopted as an informative part under 4.1.2,
— Annex B has been removed due to its technical irrelevance.
A list of all parts in the ISO 8092 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.
vi
INTERNATIONAL STANDARD ISO 8092-2:2023(E)
Road vehicles — Connections for on-board electrical
wiring harnesses —
Part 2:
Terminology, test methods and general performance
requirements
1 Scope
This document provides terminology and specifies test methods for general performance requirements
of voltage class A connectors used in electrical wiring harnesses on road vehicles.
This document applies to connectors which, after mounting in the vehicle, are designed to only be
disconnected in connection with repair and maintenance.
This document does not apply to internal connections for electronic devices.
This document does not apply to signal communication quality or data integrity.
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 8092-5:2021, Road vehicles — Connections for on-board electrical wiring harnesses — Part 5: Test
methods and general performance requirements for wiring harness connector operation
ISO 16750-3:2023, Road vehicles - Environmental conditions and testing for electrical and electronic
equipment - Part 3: Mechanical loads
ISO 16750-4:2023, Road vehicles - Environmental conditions and testing for electrical and electronic
equipment - Part 4: Climatic loads
ISO 16750-5:2023, Road vehicles - Environmental conditions and testing for electrical and electronic
equipment - Part 5: Chemical loads
ISO 20653:2023, Road vehicles — Degrees of protection (IP-code) — Protection against foreign objects,
water and access –Electrical equipment
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at https:// www .electropedia .org/
3.1
voltage class A
classification of an electric component or circuit with a maximum working voltage of ≤ 30 V a.c. (rms)
or ≤ 60 V d.c., respectively
[SOURCE: ISO 21498-1:2021, 3.12]
3.2
housing
non-conducting feature for inserting the terminal and providing insulation between terminals
3.3
cable attachment
permanent junction of cable to terminal
Note 1 to entry: Crimp and weld are typical methods.
Note 2 to entry: For terms related to cables, see ISO 19642-1.
3.4
connector
assembly of terminal, housing (3.2) and related parts that terminate cable for the purpose of providing
connection and disconnection to a suitable mating connector
3.5
connector coding
mechanical feature to provide differentiation, preventing mating of connectors (3.4) not intended to be
mated
3.6
connector polarization
method or design feature, which prevents connectors (3.4) that are intended to mate from mating in an
unintended orientation, rotation, or angular position, whilst allowing mating in the intended manner
3.7
CPA
connector position assurance
device that prevents accidental release of the connector (3.4) lock and serves as an indicator of full
connector mating
3.8
TPA
terminal position assurance
feature installed or seated after the terminals are inserted into their housing (3.2) to assure that the
terminals are properly positioned, and which reinforces the primary terminal locking mechanism or
provides a separate, redundant terminal lock
3.9
socket terminal
terminal, including means for cable attachment (3.3), designed for electrical engagement on its inner
surface, and to accept entry of a pin terminal (3.11), thus forming an electrical connection
Note 1 to entry: See Figure 1 for an example.
Note 2 to entry: Socket terminals are sometimes referred to as female terminals.
a) socket b) receptacle
Figure 1 — Example of a socket and a receptacle terminal
3.10
receptacle terminal
terminal, including means for cable attachment (3.3), designed for electrical engagement on its inner
surface, and to accept entry of a tab terminal (3.12), thus forming an electrical connection
Note 1 to entry: See Figure 1 for an example.
Note 2 to entry: Receptacle terminals are sometimes referred to as female terminals.
3.11
pin terminal
terminal, including means for cable attachment (3.3), designed for electrical engagement on its outer
surface and to enter a socket terminal (3.9), thus forming an electrical connection
Note 1 to entry: Pin terminals are sometimes referred to as male terminals.
Note 2 to entry: See Figure 2 for an example.
a) pin b) tab
Figure 2 — Example of a pin and a tab terminal
3.12
tab terminal
terminal, including means for cable attachment (3.3), designed for electrical engagement on its outer
surface and to enter a receptacle terminal (3.10), thus forming an electrical connection
Note 1 to entry: Tab terminals are sometimes referred to as male terminals.
Note 2 to entry: Tab terminals are sometimes referred to as blade terminals.
Note 3 to entry: See Figure 2 for an example.
3.13
multipole connector
two mated connectors (3.4) halves with more than one terminal pair [e.g. one receptacle and one tab
terminal (3.12)]
4 Test conditions and requirements
4.1 General
4.1.1 Preconditioning for environmental and mechanical durability test
All test samples shall be preconditioned at a standard ambient temperature of (23 ± 5) °C, and (25–
75) % relative humidity for 24 h before the start of any test sequence.
4.1.2 Test conditions
All tests shall be carried out at a standard ambient temperature of (23 ± 5) °C and (25–75) % relative
humidity unless otherwise stated in the test procedure. This is referred to as room temperature (RT).
A cable in compliance with applicable part of the ISO 19642 series is recommended. The cable or cables
used shall be specified in the test report.
The cross-sectional area of the wire mentioned in this specification refers to wires with a copper
conductor.
When the wire conductor is of a material other than copper, the cross–sectional area of the wire shall
be specified by agreement between customer and supplier.
Cable attachment shall be performed in accordance with the terminal manufacturer's specifications, or
as agreed between customer and supplier.
Care shall be taken so that test samples do not influence each other (e.g. in a heat chamber).
Each connector shall have the full complement of terminals fitted unless otherwise specified.
The terminals and connectors used in the test shall be fully assembled unless otherwise specified.
Connectors shall be tested in mated condition unless otherwise stated. In the case of a connector
connecting directly to a device, a mating dummy may be used to carry out tests. This dummy shall
represent the intended device’s interface and electrical properties.
For connector mechanical tests, unless otherwise specified, fix the pin or tab housing of the unmated
or mated connector in the appropriate fixture on the tension or force tester. Secure the other side in the
appropriate fixture and insert or pull the socket or receptacle housing straight in/out. Straight-in or
straight-out engagement is critical to avoid side loads and binding which can affect force measurements.
For terminal mechanical tests, unless otherwise specified, fix the pin or tab terminal of the unmated
or mated terminal in the appropriate fixture on the tension or force tester. Secure the other side in
the appropriate fixture and insert/pull the socket receptacle terminal straight in/out. Straight-in or
straight-out engagement is critical to avoid side loads and binding which can affect force measurements.
Measurements shall be taken on all terminals regardless of the number of poles per connector, unless
otherwise specified in the test methods or by agreement between customer and supplier.
Lubrication or other means of attaining better test results shall not be added to any surface unless
representative of assembly conditions. Production-related remains of lubricants on the terminals are
permitted.
Unless otherwise specified, all forces shall be applied at a constant speed of (50 ± 10) mm/min.
Unless otherwise specified, when a temperature of T is specified in a test, the applicable “highest
max
value” temperature as per Table 1 shall be used. When a temperature of T is specified in a test, the
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