ISO 19642-2:2019

INTERNATIONAL ISO
STANDARD 19642-2
First edition
2019-01
Road vehicles — Automotive cables —
Part 2:
Test methods
Véhicules routiers — Cables automobiles —
Partie 2: Méthodes d'essai
Reference number
ISO 19642-2:2019(E)
©
ISO 2019

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ISO 19642-2:2019(E)

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© 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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Published in Switzerland
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ISO 19642-2:2019(E)

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 Ovens . 2
5 Test methods for single core cables . 3
5.1 Dimensional tests . 3
5.1.1 General. 3
5.1.2 Cable outside diameter. 3
5.1.3 Insulation thickness . 3
5.1.4 Conductor diameter . 4
5.1.5 Cross-sectional area (CSA) . 4
5.1.6 In-process cable outside diameter . 5
5.2 Electrical tests . 5
5.2.1 Conductor resistance . 5
5.2.2 Determination of temperature coefficients . 7
5.2.3 Withstand voltage . 9
5.2.4 Withstand voltage after environmental testing .10
5.2.5 Insulation faults .10
5.2.6 Insulation volume resistivity .10
5.3 Mechanical tests .11
5.3.1 Strip force .11
5.3.2 Abrasion .12
5.3.3 Breaking force of the finished cable .14
5.3.4 Cyclic bending .15
5.3.5 Flexibility .17
5.4 Environmental tests .19
5.4.1 Test specimen preparation and winding tests .19
5.4.2 Long term heat ageing, 3 000 h at temperature class rating .21
5.4.3 Short term heat ageing, 240 h at temperature class rating +25 °C.21
5.4.4 Thermal overload, 6 h at temperature class rating +50 °C .22
5.4.5 Pressure test at high temperature .22
5.4.6 Shrinkage by heat .24
5.4.7 Low temperature winding .24
5.4.8 Cold impact .25
5.4.9 Temperature and humidity cycling .27
5.4.10 Resistance to hot water .28
5.4.11 Resistance to liquid chemicals .29
5.4.12 Durability of cable marking .31
5.4.13 Stress cracking resistance .31
5.4.14 Resistance to ozone .33
5.4.15 Resistance to flame propagation .33
6 Test methods for sheathed cables .34
6.1 Dimensional tests .34
6.1.1 Cable outside diameter.34
6.1.2 Ovality of sheath .35
6.1.3 Thickness of sheath .35
6.1.4 In-process cable outside diameter .35
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ISO 19642-2:2019(E)

6.2 Electrical tests .36
6.2.1 Electrical continuity .36
6.2.2 Withstand voltage at final inspection .36
6.2.3 Screening effectiveness .36
6.2.4 Sheath fault on screened cables .39
6.3 Mechanical tests .40
6.3.1 Strip force of sheath .40
6.3.2 Cyclic bending .40
6.3.3 Flexibility .40
6.4 Environmental tests .41
6.4.1 Test specimen preparation and winding tests .41
6.4.2 Long-term heat ageing, 3 000 h at temperature class rating .43
6.4.3 Short term heat ageing, 240 h at temperature class rating +25 °C.43
6.4.4 Thermal overload, 6 h at temperature class rating +50 °C .43
6.4.5 Pressure test at high temperature .44
6.4.6 Shrinkage by heat of sheath .44
6.4.7 Low temperature winding .44
6.4.8 Cold impact .45
6.4.9 Temperature and humidity cycling .45
6.4.10 Resistance to liquid chemicals .45
6.4.11 Durability of sheath marking .46
6.4.12 Resistance to ozone .46
6.4.13 Artificial weathering .47
6.4.14 Resistance to flame propagation .47
Annex A (informative) Examples of materials and sources suppliers .49
Annex B (informative) Flexibility apparatus .51
Annex C (normative) Flame test apparatus .56
Bibliography .58
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ISO 19642-2:2019(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 19642-2:2019(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 19642-2:2019(E)
Road vehicles — Automotive cables —
Part 2:
Test methods
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 defines test methods for electrical cables in road vehicles, which are used in other parts
of the ISO 19642 series.
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 1817, Rubber, vulcanized or thermoplastic — Determination of the effect of liquids
ISO 4892-2, Plastics — Methods of exposure to laboratory light sources — Part 2: Xenon-arc lamps
ISO 4926, Road vehicles — Hydraulic braking systems — Non-petroleum-base reference fluids
ISO 6931-1, Stainless steels for springs — Part 1: Wire
ISO 19642-1, Road vehicles — Automotive cables — Part 1 — Vocabulary and design guidelines
IEC 60811-201, Electric and optical fibre cables — Test methods for non-metallic materials — Part 201:
General tests — Measurement of insulation thickness
IEC 60811-403, Electric and optical fibre cables — Test methods for non-metallic materials — Part 403:
Miscellaneous tests — Ozone resistance test on cross-linked compounds
IEC 60811-501, Electric and optical fibre cables — Test methods for non-metallic materials — Part 501:
Mechanical tests — Tests for determining the mechanical properties of insulating and sheathing compounds
IEC 62153-4-3, Metallic communication cable test methods — Part 4-3: Electromagnetic compatibility
(EMC) - Surface transfer impedance — Triaxial method
IEC 62153-4-4, Metallic communication cable test methods — Part 4-4: Electromagnetic compatibility
(EMC) — Shielded screening attenuation, test method for measuring of the screening attenuation as up to
and above 3 GHz
IEC 62153-4-5, Metallic communication cables test methods — Part 4-5: Electromagnetic compatibility
(EMC) — Coupling or screening attenuation — Absorbing clamp method
SAE RM-66-06, Motor Vehicle Brake Fluid — High Boiling Compatibility/Reference Fluid
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 19642-1 apply.
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ISO 19642-2:2019(E)

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
Unless specified otherwise, the device under test (DUT) shall be preconditioned continuously for at
least 16 h at a room temperature (RT) of (23 ± 3) °C and a relative humidity (RH) of 45 % to 75 %.
Unless specified otherwise, all tests other than “In process” shall be conducted in 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.
Use the temperature tolerances shown in Table 1 unless specified in the individual tests.
Table 1 — Test Temperature Tolerance
Test temperature
Temperature tolerance
(t)
°C °C
t ≤ 100 ±2
100 < t ≤ 200 ±3
t > 200 ±4
Unintentional direct contact between different metals shall not occur with any of the test methods, in
order to avoid electrochemical effects on the test results.
All tests shall be performed on the same manufactured batch of cable. If, for any reason, a different
batch of cable is used for any of the tests, it should be noted accordingly on the test report and test
summary.
Unless otherwise specified, each test is to be performed on at least 3 test specimens.
If suppliers and customers agree upon modifications or changes to the methods and requirements, it is
required that all the changes and modifications 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 Ovens
An oven as described in IEC 60216-4-1 and/or IEC 60216-4-2 Type 1 should be used. The air shall enter
the oven in such a way that it flows over the surface of the test specimens and exits 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.
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ISO 19642-2:2019(E)

5 Test methods for single core cables
5.1 Dimensional tests
5.1.1 General
Measure with a device accurate to at least 0,01 mm. Other devices may be used. However, in case of
dispute, the referee shall be an optical device.
In case of disputed results due to specimen deformation in preparation, a referee method is
provided below.
Prepare three test specimens from a cable test specimen 3 m in length. Take these test specimens at
1 m intervals. A test specimen consists of a 20 mm length of cable. Take care not to deform the test
specimen. Immerse the test specimens in a casting resin. After hardening, take a section perpendicular
to the axis of the test specimen.
5.1.2 Cable outside diameter
5.1.2.1 Purpose
This test is intended to verify that the cable outside diameter is within the required tolerances for
intended functional applications.
5.1.2.2 Test specimen
Prepare one test specimen of 3 m in length.
5.1.2.3 Test
The cable outside diameter shall be measured at three separate cross-sections located 1 m apart from
each other. A minimum of two readings shall be taken at each cross-section. The specimen should be
rotated 90° between readings. The mean of the diameter readings shall determine the cable outside
diameter and shall be in accordance with the dimensions tables in the cable documents in the ISO 19642
series for the various cable types. Additionally, no single value, minimum or maximum, may fall outside
the range in the dimensions tables in the respective cable documents. For large cables (outside diameter
greater than or equal to 18,0 mm), the test method described in IEC 60811-203:2012, 4.2 b, may be used
for measuring the outside diameter.
5.1.3 Insulation thickness
5.1.3.1 Purpose
This test is intended to verify that the cable insulation thickness is within the required tolerances to
withstand electrical, mechanical and chemical abuse.
5.1.3.2 Test specimens
Prepare three test specimens from a cable test specimen 3 m in length. Take the test specimens at
1 m intervals. Strip the insulation from the cable. A test specimen consists of a thin cross-section of
insulation. Take care not to deform the test specimen during the preparation process. If cable marking
causes indentation of the insulation, take the first test specimen through this indentation.
5.1.3.3 Test
Use a measuring device which shall not cause deformation.
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Place the test specimen under the measuring equipment with the plane of the cut perpendicular to the
optical axis. Determine the minimum insulation thickness in accordance with IEC 60811-201.
5.1.4 Conductor diameter
5.1.4.1 Purpose
This test is intended to verify that the cable conductor diameter is within the specified dimensions to
fit terminal crimps and mechanical demands.
5.1.4.2 Test specimens
Use the test specimens as specified in 5.1.3.
5.1.4.3 Test
Use a measuring device which shall not cause deformation.
Determine the conductor diameter by measuring the inside diameter of the test specimens and record
the maximum inside diameter for each test specimen.
5.1.5 Cross-sectional area (CSA)
5.1.5.1 Purpose
This test is intended to verify that the cable conductor fulfils the specified requirements.
5.1.5.2 Test of cross-sectional area, A
In case of dispute, Method 2 (weight method) is the referee method to determine the cross-sectional
area, A.
— Method 1: By using the obtained resistance value, R , according to 5.2.1, the CSA, A, is calculated
20
using the following formula:
1000×+1 f
()
b
A=
κ×R
20
where
2
A is the cross-sectional area in mm ;
R is the conductor resistance at 20 °C in mΩ/m;
20
2
κ is the conductivity of the used conductor material in Sm/mm :
2
for copper use a conductivity of 58,0 Sm/mm ;
2
for aluminium use a conductivity of 35,5 Sm/mm ;
2
for aluminium alloy use a conductivity of 33,5 Sm/mm ;
for other alloys with different conductivity, values can be used based on agreement between
the customer and supplier;
f is bunching loss, depending on strand construction (see ISO 19642-1).
b
— Method 2: Carefully strip the insulation from 1 m ± 5 mm of the cable under test. The conductor is
weighed with a scale capable of measurement to 0,5 % accuracy of the measured value. From the
result, A is calculated using the following formula:
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ISO 19642-2:2019(E)

W
A=
ρ
where
2
A is cross-sectional area in mm ;
W is the conductor weight in g/m;
3
ρ is the density of the used conductor material in g/cm :
3
for copper use a density of 8,89 g/cm ;
3
for aluminium use a density of 2,70 g/cm ;
applicable densities shall be used for alloys.
5.1.6 In-process cable outside diameter
5.1.6.1 Purpose
This in-process monitoring is intended to verify that the cable outside diameter is within the required
tolerances.
5.1.6.2 Test specimens
The test specimen is 100 % of the cable production; all cable produced is to be monitored.
5.1.6.3 Test
The measurement of diameter shall be performed in the most stable area of the extrusion process.
5.2 Electrical tests
5.2.1 Conductor resistance
5.2.1.1 Purpose
This test is intended to verify that the cable conductor resistance does not exceed the maximum
permitted value.
5.2.1.2 Test specimens
Prepare one test specimen of 2 m length, including the length necessary for connections.
5.2.1.3 Preparation of conductor ends
For copper and copper alloy conductors, the ends of the test specimen may be soldered.
For aluminium and aluminium alloy conductors, the oxide film on the aluminium surface shall be
removed before carrying out the measurement following one of the two methods mentioned below.
In case of dispute, Method 1 is the reference method.
— Method 1 for removal of oxide film on the aluminium surface by soldering
Remove the insulation from the wire, apply a soldering fluid on the aluminium surface and dip the
aluminium wire into the solder bath.
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ISO 19642-2:2019(E)

In case of doubt – for example, if the resistance requirements are not met – it is possible that the
soldering fluid is not applicable. The following referee soldering fluid shall be used.
The referee soldering fluid consists of the following components:
— Diethanolamine: 45 % to 65 %;
— Fluor
...