FprEN ISO 8092-2

SLOVENSKI STANDARD
oSIST prEN ISO 8092-2:2023
01-februar-2023
Cestna vozila - Priključki za električno opremo, vgrajeni na armaturi vozila - 2. del:
Definicije, preskusne metode in splošne zahtevane lastnosti (ISO/DIS 8092-2:2022)
Road vehicles - Connections for on-board electrical wiring harnesses - Part 2:
Definitions, test methods and general performance requirements (ISO/DIS 8092-2:2022)
Straßenfahrzeuge - Steckverbindungen für das elektrische Fahrzeug-Bordnetz - Teil 2:
Begriffe, Prüfungen und allgemeine Anforderungen (ISO/DIS 8092-2:2022)
Véhicules routiers - Connexions pour faisceaux de câblage électrique embarqués -
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
(ISO/DIS 8092-2:2022)
Ta slovenski standard je istoveten z: prEN ISO 8092-2
ICS:
43.040.10 Električna in elektronska Electrical and electronic
oprema equipment
oSIST prEN ISO 8092-2:2023 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

oSIST prEN ISO 8092-2:2023
oSIST prEN ISO 8092-2:2023
DRAFT INTERNATIONAL STANDARD
ISO/DIS 8092-2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:
2022-12-19 2023-03-13
Road vehicles — Connections for on-board electrical
wiring harnesses —
Part 2:
Definitions, test methods and general performance
requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique embarqués —
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
ICS: 43.040.10
This document is circulated as received from the committee secretariat.
THIS DOCUMENT IS A DRAFT CIRCULATED
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NATIONAL REGULATIONS.
ISO/DIS 8092-2:2022(E)
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NOTIFICATION OF ANY RELEVANT PATENT
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PROVIDE SUPPORTING DOCUMENTATION. © ISO 2022

oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
DRAFT INTERNATIONAL STANDARD
ISO/DIS 8092-2
ISO/TC 22/SC 32 Secretariat: JISC
Voting begins on: Voting terminates on:

Road vehicles — Connections for on-board electrical
wiring harnesses —
Part 2:
Definitions, test methods and general performance
requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique embarqués —
Partie 2: Définitions, méthodes d'essai et exigences de performances générales
ICS: 43.040.10
This document is circulated as received from the committee secretariat.
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
© ISO 2022
ISO/CEN PARALLEL PROCESSING
THEREFORE SUBJECT TO CHANGE AND MAY
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
NOT BE REFERRED TO AS AN INTERNATIONAL
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NATIONAL REGULATIONS.
Website: www.iso.org ISO/DIS 8092-2:2022(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
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NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
ii
PROVIDE SUPPORTING DOCUMENTATION. © ISO 2022

oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
32 Contents
33 Foreword . iv
34 1 Scope . 1
35 2 Normative references . 1
36 3 Terms and definitions . 2
37 4 Test conditions and requirements . 4
38 4.1 General . 4
39 4.2 Visual Examination . 11
40 5 Mechanical tests . 12
41 5.1 Connection and disconnection . 12
42 5.2 Mating force – measurement and classification . 13
43 5.3 Unlocking force – measurement and classification . 13
44 5.4 Unmating force – measurement and classification . 13
45 5.5 Locking device strength . 13
46 5.6 Unintentional lever release force . 14
47 5.7 Locking force for CPA function . 14
48 5.8 Disengage force for CPA function . 17
49 5.9 Locking force for TPA . 17
50 5.10 Disengage force for TPA . 18
51 5.11 Effectiveness of connector coding and polarization . 18
52 5.12 Connector engagement sound . 19
53 5.13 Terminal insertion force (TPA disengaged) . 19
54 5.14 Terminal insertion force (TPA engaged) . 20
55 5.15 Terminal insertion force with incorrect orientation . 21
56 5.16 Terminal extraction force . 22
57 5.17 Tensile strength of connection between terminal and wire . 23
58 6 Electrical tests . 25
59 6.1 Connection resistance (voltage drop) . 25
60 6.2 Temperature rise . 27
61 6.3 Current cycling at ambient temperature . 29
62 6.4 Insulation resistance . 29
63 6.5 Withstand voltage . 30
64 7 Environmental tests . 31
65 7.1 Thermal shock . 31
66 7.2 Thermal aging . 32
67 7.3 Temperature and humidity cycle . 32
68 7.4 Vibration with thermal cycling . 35
69 7.5 Mechanical shock . 37
70 7.6 Drop . 37
71 7.7 Water tightness . 38
72 7.8 Water tightness, dynamic . 40
73 7.9 High-pressure/steam-jet cleaning . 42
74 7.10 Salt spray . 44
75 7.11 Dust resistance . 44
76 7.12 Chemical loads . 45
77 7.13 Fretting corrosion . 45
78 7.14 Friction corrosion . 46
79 Bibliography . 47
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oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
81 Foreword
82 ISO (the International Organization for Standardization) is a worldwide federation of national standards
83 bodies (ISO member bodies). The work of preparing International Standards is normally carried out
84 through ISO technical committees. Each member body interested in a subject for which a technical
85 committee has been established has the right to be represented on that committee. International
86 organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO
87 collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
88 electrotechnical standardization.
89 The procedures used to develop this document and those intended for its further maintenance are
90 described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
91 different types of ISO documents should be noted. This document was drafted in accordance with the
92 editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
93 Attention is drawn to the possibility that some of the elements of this document may be the subject of
94 patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any
95 patent rights identified during the development of the document will be in the Introduction and/or on
96 the ISO list of patent declarations received (see www.iso.org/patents).
97 Any trade name used in this document is information given for the convenience of users and does not
98 constitute an endorsement.
99 For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
100 expressions related to conformity assessment, as well as information about ISO's adherence to the World
101 Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see
102 www.iso.org/iso/foreword.html.
103 This document was prepared by Technical Committee ISO/TC 22,Road vehicles, Subcommittee SC 32,
104 Electrical and electronic components and general system aspects.
105 This fifth edition cancels and replaces the fourth edition (ISO 8092-2:2005), which has been technically
106 revised.
107 The main changes compared to the previous edition are as follows:
108 —      adoption of the content according to new technical requirements,
109 —      adoption of the content according to the new version of the ISO guidelines,
110 —      correction of the typos and mistakes in the text,
111 —      alignment of the content regarding to the referred standards,
112 —      section 4.24 Flowing gas corrosion test has been removed due to its technical irrelevance,
113 —      Annex A (normative) Additional cable dimensions is adopted as an informative part under section
114 4.1.2,
115 —      Annex B (informative) Cable attachment by insulation-displacement connection (IDC) — Bending
116 test has been removed due to its technical irrelevance.
117 A list of all parts in the ISO 8092 series can be found on the ISO website.
118 Any feedback or questions on this document should be directed to the user’s national standards body. A
119 complete listing of these bodies can be found at www.iso.org/members.html.
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oSIST prEN ISO 8092-2:2023
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oSIST prEN ISO 8092-2:2023
oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
121 Road vehicles — Connections for on-board electrical wiring
122 harnesses — Part 2: Definitions, test methods, and general
123 performance requirements
124 1 Scope
125 This document defines terms and specifies test methods for general performance requirements of voltage
126 class A connectors used in electrical wiring harnesses on road vehicles.
127 This document applies to connectors which, after mounting in the vehicle, are designed to only be
128 disconnected in connection with repair and maintenance.
129 This part of ISO 8092 does not apply to internal connections for electronic devices.
130 This part of ISO 8092 does not apply to signal communication quality or data integrity.
131 2 Normative references
132 The following documents are referred to in the text in such a way that some or all of their content
133 constitutes requirements of this document. For dated references, only the edition cited applies. For
134 undated references, the latest edition of the referenced document (including any amendments) applies.
135 ISO DIS 8092-5, Road vehicles — Connections for on-board electrical wiring harnesses – Part 5: Automotive
136 parts – Test methods and general performance requirements for wiring harness connector operation
137 ISO 16750-3, Road vehicles - Environmental conditions and testing for electrical and electronic equipment
138 - Part 3: Mechanical loads
139 ISO 16750-4, Road vehicles - Environmental conditions and testing for electrical and electronic equipment
140 - Part 4: Climatic loads
141 ISO 16750-5, Road vehicles - Environmental conditions and testing for electrical and electronic equipment
142 - Part 5: Chemical loads
143 ISO 19642 (all parts), Road vehicles — Automotive Cables
144 ISO 20653, Degrees of protection (IP-code) — Protection against foreign objects, water and access –
145 Electrical equipment
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147 3 Terms and definitions
148 For the purposes of this document, the following terms and definitions apply.
149 ISO and IEC maintain terminological databases for use in standardization at the following addresses:
150 — ISO Online browsing platform: available at https://www.iso.org/obp
151 — IEC Electropedia: available at http://www.electropedia.org/
152 3.1
153 voltage class A
154 classification of an electric component or circuit with a maximum working voltage of ≤ 30 V AC (rms) or
155 ≤ 60 V DC, respectively
156 [SOURCE: ISO 21498-1:2021]
157 [SOURCE: ISO 6469-3:2021]
158 3.2
159 housing
160 housing for inserting the terminal and providing insulation between terminals
162 3.3
163 cable attachment
164 any permanent junction of cable to terminal
165 Note 1 to entry: Crimp and weld are typical methods
166 Note 2 to entry: Terms related to cables ISO 19642-1
167 3.4
168 connector
169 assembly of terminal, housing and related parts that terminate cable for the purpose of providing
170 connection and disconnection to a suitable mating connector
171 3.5
172 connector coding
173 mechanical feature to provide differentiation, preventing mating of connectors not intended to be mated
174 3.6
175 connector polarization
176 method or design feature, which prevents connectors that are intended to mate from mating in an
177 unintended orientation, rotation, or angular position, whilst allowing mating in the intended manner
178 3.7
179 connector position assurance, CPA
180 device that prevents accidental release of the connector lock and serves as an indicator of full connector
181 mating
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182 3.8
183 terminal position assurance, TPA
184 a feature installed or seated after the terminals are inserted into their housing to assure that the terminals
185 are properly positioned, and which reinforces the primary terminal locking mechanism or provides a
186 separate, redundant terminal lock
187 3.9
188 socket and receptacle terminal
189 terminal, including means for cable attachment, designed for electrical engagement on its inner surface,
190 and to accept entry of a pin or tab terminal, thus forming an electrical connection. See Figure 1 for
191 example.
192 Note 1 to entry: Socket and receptacle terminals are sometimes referred to as female terminals.
194 Figure 1— Example of a socket and a receptacle terminal
196 3.10
197 pin and tab terminal
198 terminal, including means for cable attachment, designed for electrical engagement on its outer surface
199 and to enter a socket or a receptacle terminal, thus forming an electrical connection. See Figure 2 for
200 example.
201 Note 1 to entry: Pin and tab terminals are sometimes referred to as male terminals”
202 Note 2 to entry: Tab terminals are sometimes referred to as blade terminals
204 Figure 2— Example of a pin and a tab terminal
205 3.11
206 multi‐pole connection
207 two mated connector halves with more than one terminal pair (for example one receptacle and one tab
208 terminal)
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oSIST prEN ISO 8092-2:2023
ISO/DIS 8092-2:2022(E)
209 4 Test conditions and requirements
210 4.1 General
211 4.1.1 Preconditioning for environmental and mechanical durability test
212 All test samples shall be preconditioned at a standard ambient temperature of (23 ± 5) °C, and (25–75) %
213 relative humidity for 24 h before the start of any test sequence.
214 [SOURCE: ISO 16750-1]
215 4.1.2 Test conditions
216 All tests shall be carried out at a standard ambient temperature of (23 ± 5) °C and (25–75) % relative
217 humidity unless otherwise stated in the test procedure. This is referred to as room temperature (RT).
218 Cable in compliance with applicable part of ISO 19642 is recommended. The cable or cables used shall be
219 specified in the test report.
220 The cross-sectional area of the wire mentioned in this specification refers to wires with a copper
221 conductor.
222 When the wire conductor is of a material other than copper, the cross–sectional area of the wire shall be
223 specified by agreement between customer and supplier.
224 Cable attachment shall be performed in accordance with the terminal manufacturer's specifications, or
225 as agreed between customer and supplier.
226 Care shall be taken so that test samples do not influence each other (e.g., in a heat chamber).
227 Each connector shall have the full complement of terminals fitted unless otherwise specified.
228 The terminals and connectors used in the test shall be fully assembled unless otherwise specified.
229 Connectors shall be tested in mated condition unless stated otherwise. In the case of a connector
230 connecting directly to a device, a mating dummy may be used to carry out tests. This dummy must
231 represent the intended device’s interface and electrical properties.
232 For connector mechanical tests, unless otherwise specified, fix the pin or tab housing of the unmated or
233 mated connector in the appropriate fixture on the tension or force tester. Secure the other side in the
234 appropriate fixture and insert or pull the socket or receptacle housing straight in/out. Straight-in or
235 straight-out engagement is critical to avoid side loads and binding which can affect force measurements.
236 For terminal mechanical tests, unless otherwise specified, fix the pin or tab terminal of the unmated or
237 mated terminal in the appropriate fixture on the tension or force tester. Secure the other side in the
238 appropriate fixture and insert/pull the socket receptacle terminal straight in/out. Straight-in or straight-
239 out engagement is critical to avoid side loads and binding which can affect force measurements
240 Measurements shall be taken on all terminals regardless of the number of poles per connector, unless
241 otherwise specified in the test methods or by agreement between customer and supplier.
242 Lubrication or other means of attaining better test results shall not be added to any surface unless
243 representative of assembly conditions. Production-related remains of lubricants on the terminals are
244 permitted.
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245 Unless otherwise specified, all forces shall be applied at a constant speed of (50 ± 10) mm/min.
246 Unless otherwise specified, when a temperature of T is specified in a test, the applicable “Highest value”
max
247 temperature as per Table 1 shall be used. When a temperature of T is specified in a test, the applicable
min
248 “Lowest value” temperature as per Table 1 shall be used.
249 Table 1 —Environmental and test temperatures
Typical application Environmental temperature range
Test temperature
°C Short term thermal
ageing
Class Lowest value Highest value
°C
Use for T of chamber Use for T of chamber
min max
 2 °C
± 2 °C ± 2 °C
T1 (G) interior 85 100
T2 (J) passenger compartment 100 125
T3 (O) engine compartment -40 125 150
T4 (R) engine applications used 150 175
near hot components
T5 (N/A) for use as needed 175 200 *
( ) value aligned with ISO 16750-4:2010, Table 1
* or agreed between customer and supplier
251 NOTE T and T apply to all environmental chamber temperatures where T and T are specified as
min max min max
252 using the applicable environmental temperature range except 7.2.2.1 Short term Thermal aging
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oSIST prEN ISO 8092-2:2023
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253 4.1.3 Test sequences and sample quantities
254 Table 2,
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255 Table 3, Table 4 and Table 5 list the test sequences. The test groups in the tables apply to sealed and
256 unsealed connectors as noted. New samples shall be used for each test group. The test sequence for each
257 test group shall be performed in accordance with the sequence number defined in the table’s rows for
258 each sequence. For each test group, the complete test sequence for the group on each sample shall be
259 performed.
260 Table 2—Mechanical test sequences groups A through H
Test group identification A B C D E F G H
u=apply test if samples are un-
u u u u u u u u
sealed
s=apply test if samples are sealed s s s s s s s s
Minimum test quantity of
10 10 10 10 10 10 10 10
terminals/connectors
Sample cable length (mm) - - - - - - - -
Sample cable Maximum - - - - - - - -
size
Minimum - - - - - - - -
1, 3 1, 3 1,3 1, 3 1, 3 1, 3 1,3 1,4
4.2 Visual Examination
g
5.1 Connection and disconnection 2
5.2 Mating force – measurement
and classification
5.3 Unlocking force – measurement
and classification
5.4 Unmating force – measurement
and classification
5.5 Locking device strength   2
5.6 Unintentional lever release
force
5.7 Locking force for CPA function    2 2
5.8 Disengage force for CPA
function
g
Perform force measurement for first mate and first unmate with part held in force tester.
Remaining mate and unmate cycles can be either hand mated or using the mechanized force test machine.
- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter to test result.
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oSIST prEN ISO 8092-2:2023
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263 Table 3—Mechanical test sequences groups I through P
Test group identification I J K L M N O P
u=apply test if samples are
u u u u u u u u
un- sealed
s=apply test if samples are sealed s s s s s s s s
Minimum test quantity of
f f f f f k
10 10 10 10 20 10 10 10
terminals/connectors
- - - - - - - >50
Sample cable length (mm)
Maximum - - - - 10 10 10 See “l”
Sample
cable size - - - - 10 - - See “l”
Minimum
1, 3 1, 4 1, 3 1, 3 1, 4 1, 3 1, 3 1, 3
4.2 Visual Examination
2 2
5.9 Locking force for TPA
5.10 Disengage force for TPA 3
5.11 Effectiveness of connector
coding and polarization
5.12 Connector engagement
sound
5.13 Terminal insertion force
(TPA disengaged)
5.14 Terminal insertion force
(TPA engaged)
5.15 Terminal insertion force
with incorrect orientation
5.16 Terminal extraction force   3
5.17 Tensile strength of
connection between terminal and    2
wire
f
Use unmated wire harness connector; the mating (header) connector is not used in the test.
k Sample is made from terminal and cable only.
l Test quantity is per terminal/cable combination; each combination shall be validated with a 10-piece sample, minimum.
- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter to test result.
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266 Table 4— Environmental and electrical test sequence groups Q through W
Test group identification Q R S T U V W
u u u u u u
u=apply test if samples are unsealed
q q
s=apply test if samples are sealed s s s s s s s
i i
Minimum test quantity of connectors 5 10 5 5 5 5 5
500 - min 500 min 150 - 1 250 Min 150
Sample cable length (mm)
See "p" all all all
Maximum
Sample cable size
Minimum  all all all
1 1, 6 1, 8, 10 1, 10, 14 1, 8 1, 3 1, 7
4.2 Visual Examination
2 2 2 2 2
5.1 Connection and disconnection
5.3 Unlocking force – measurement and
c
classification
c
5.6 Unintentional lever release force
5.8 Disengage force for CPA function
5.16 Terminal extraction force
6.1 Connection resistance (voltage drop) 3, 5 3, 6 3, 7, 13 3, 5, 7 2, 5
j
6.2 Temperature rise 3 (4), 7
4, 8
6.4 Insulation resistance
5, 9  3, 6
6.5 Withstand voltage
7.1 Thermal shock
7.2 Thermal aging  5
n
7.3 Temperature / humidity  6
d
7.4 Vibration with thermal cycling
d
7.5 Mechanical shock
7.6 Drop
7.10 Salt spray    4
c Perform either 5.3 or 5.6 as applicable.
d It is allowed to apply each shock/vibration direction directly before the vibration test for this direction. Take
intermediate resistance measurements between testing for each axis.
i
Samples require thermocouples to measure or monitor temperature rise.

j This test is to estimate initial current in test part.
n
Perform insulation resistance during condensation phase.
p
Test all cable sizes that are applicable.
q
Seal cable on far end.
( )  It is possible to omit this step by agreement between customer and supplier.
- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter.
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269 Table 5— Environmental and electrical test sequence groups Y through AG
Test group identification X Y Z AA AB AC AD AE AF
u=apply test if samples are
u  u u u u U
unsealed
s=apply test if samples are
q q
s s s s s s s s s
sealed
Minimum test quantity of
i
5 5 5 5 5 5 - 5 5
connectors
500 max 1 000 max 1 000 Min 150 - - - - -
Sample cable length (mm)
all all - - - -
Maximum
Sample
cable size Minimum all - all - all - -
1, 7 1, 9 1, 6 1, 7 1, 10, 12 1, 6 1, 10, 14 1, 3 1, 3
4.2 Visual Examination
5.1 Connection and
2 2 2  2
disconnection
5.5 Locking device strength   11
5.16 Terminal extraction
force
6.1 Connection resistance
3, 5 3, 6 2, 5 2, 4 13
(voltage drop)
6.3 Current cycling at
e
4 4  3
ambient temperature
8 3, 6 2, 5, 8 3, 7, 11
6.4 Insulation resistance
6.5 Withstand voltage   3, 6, 9 4, 8, 12
5  4
7.2 Thermal aging
b b
a
4, 7 3, 5  5 , 9
7.7 Water tightness
7.8 Water tightness,
dynamic
7.9 High-pressure/steam-jet
b
cleaning
7.11 Dust resistance   5
7.12 Oil and liquid resistance
7.13 Fretting corrosion    2
7.14 Friction corrosion     2
a
Aside from test sequence, test to failure can be performed using additional samples (n=5) for test 7.7 until the upper limit pressure is

reached.
b
Sealed connectors only
e
Monitor temperature rise during step.
q
Seal cable on far end.
- Cells containing "-" to be defined between supplier and customer. Selection typically does not matter.
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273 4.2 Visual Examination
274 4.2.1 Purpose
275 The purpose of this test is to document the physical appearance of the test samples. A comparison is made
276 after test between new and tested samples.
277 Examinations shall be performed by a person with normal or corrected vision, and normal colour
278 sensitivity.
279 4.2.2 Test
280 Carry out a visual examination with the naked eye, at normal strength of vision, with normal colour
281 perception, at the most favourable distance and with suitable illumination.
282 Visually inspect each test sample prior to testing and/or conditioning. Any manufacturing or material
283 defects such as cracks, tarnishing, flash, etc., shall be documented. Special attention shall be paid to
284 contact points and locking mechanisms.
285 In the event an aspect of the test sample is questionable, use appropriate diagnostic equipment to
286 evaluate it.
287 Record in detail the condition of the test samples before and after the test procedures and document any
288 differences that may occur.
289 NOTE: If an aspect of the test sample is questionable and additional review is requested, inspect for
290 plating wear as a final inspection and use a method agreed upon between customer and supplier to assess
291 the percentage of the original surface coating that is still present.
292 4.2.3 Requirements
293 Identification, appearance, workmanship and the finish of each test sample shall be as specified. There
294 shall be no wear-through, cracks, corrosion, rough surface, damage, deformation or discoloration which
295 may affect the connector’s performance.
296 Customer and supplier shall agree on the criteria for plating wear.
297 For sealed connector systems, there shall be no ingress of a solution or substance.
298 Colour conformance and fading shall be agreed between customer and supplier.
299 An identical match is not required but each colour shall be clearly identifiable as the intended colour.
300 For crimped wire attachments, both conductor and insulation shall be visible between the conductor
301 crimp and the insulation support on the terminals. See example in Figure 3.
302 Wire strands shall protrude from the conductor crimp but shall not interfere with the mating part. In case
303 of damaged wire strands, the functional performance shall be confirmed. For other types of wire
304 attachment, no visible damage is allowed.
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oSIST prEN ISO 8092-2:2023
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306 Key
1 conductor end
2 wire strands
3 conductor connection
4 conductor
5 insulation
6 insulation support
307 Figure 3— Terminal crimp section
308 5 Mechanical tests
309 5.1 Connection and disconnection
310 5.1.1 Purpose
311 The purpose of this test is to precondition the connector for further tests and verify the mating and un-
312 mating forces required to manually mate and unmate the complete connector assembly.
313 Unmating forces are important criteria when determining that serviceability of design and for ensuring
314 that the connection will remain mated during the service life of the vehicle.
315 5.1.2 Test
316 Perform 10 connections and disconnections, or as agreed between customer and supplier, as specified by
317 the connector manufacturer.
318 5.1.3 Requirements
319 Each connector shall fulfil the requirements of the subsequently performed tests specified in Table 2,
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320 Table 3, Table 4 or Table 5.
321 5.2 Mating force – measurement and classification
322 5.2.1 Purpose
323 The purpose of this test is to document and classify the connector-mating properties.
325 5.2.2 Test
326 Refer to ISO 8092-5, section 4.2.
328 5.2.3 Requirement
329 Record and classify the connector in accordance with ISO 8092-5, tables 1, 2 and 3.
330 5.3 Unlocking force – measurement and classification
331 5.3.1 Purpose
332 The purpose of this test is to determine the force required to release the connector lock feature.
333 Document and classify the force required to unlock the locking mechanism.
335 5.3.2 Test
336 Refer to ISO 8092-5, 4.4.
338 5.3.3 Requirement
339 1. Record and classify the connector force required to unlock the mechanism in accordance with
340 ISO 8092-5, Table 4.
341 2. The force required to deflect the release button so that the lock mechanism is disengaged shall be
342 a minimum of 6 N.
344 5.4 Unmating force – measurement and classification
345 5.4.1 Purpose
346 The purpose of this test is to document and classify the force required to unmate a connector pair.
348 5.4.2 Test
349 Refer to ISO 8092-5, 4.5.
351 5.4.3 Requirement
352 Record and classify the connector in accordance with ISO 8092-5, Table 5.
354 5.5 Locking device strength
355 5.5.1 Purpose
356 The purpose of this test is to determine the strength of the locking device of a fully mated connector pair
357 without terminals. The test determines the retention forces which ensure that the connector will remain
358 mated for the service life of the vehicle.
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359 5.5.2 Test
360 Using completely mated connector, with CPA disengaged, fix one half of the connector in the force tester
361 and pull the other half of the connector by gradually applying a force of up to 100 N in a straight direction
362 at a speed that does not exceed 60 mm/minute.
363 Dwell at 100 N for 10 s
364 The connector shall be completely fixed in the force tester during the test and no side of the connector
365 shall be distorted during the test.
366 NOTE: If a test to failure force is required and agreed between customer and supplier, apply a gradually
367 increasing force and record the force at which the connectors unmate.
368 5.5.3 Requirements
369 The connectors shall not break or unmate when a force of 100 N is applied.
370 5.6 Unintentional lever release force
371 5.6.1 Purpose
372 The purpose of this test is to determine the lever release force in order to ensure that the lever cannot
373 move unintentionally from its locked position.
374 5.6.2 Test
375 Ensure the connector is completely locked, but with CPA disengaged. Gradually apply a force up to 200 N
376 in the direction required to release the lever at a speed that does not exceed 60 mm/minute.
377 If the mechanical lever leaves the locked position, record the force applied when this happens.
378 Remove and inspect the sample. Mate and unmate it to determine whether the lock mechanism still
379 functions properly. Reassemble the connector to the fully-locked position. Reattach it in the force-testing
380 fixture. Gradually apply force (same force direction and speed as before) until the lock releases.
381 Measure the applied force at the moment the mechanical lever leaves the locked position.
382 5.6.3 Requirements
383 a) The force applied when the mechanical lever leaves its locked position shall exceed 100 N;
384 b) After the initial release, the connector lock shall still function properly and the inspection shall not
385 show any damage to the connector system;
386 c) The lever release force when applied a 2nd time shall be a minimum of 100 N.
387 5.7 Locking force for CPA function
388 5.7.1 Purpose
389 The purpose of this test is to determine whether a secondary connector lock is sufficiently locked in its
390 shipping position and will remain in its intended position (not unintentionally activated). It is also used
391 to assess the ergonomic capability to easily actuate the lock.
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392 5.7.2 Test
393 Note that this test is performed with the connectors mated in one test sequence and with the connectors
394 unmated in another test sequence. See Table 2,
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oSIST prEN ISO 8092-2:2023
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395 Table 3, Table 4 and Table 5Fehler! Verweisquelle konnte nicht gefunden werden. for the applicable
396 configuration. The test is conducted by measuring the load as the CPA is moved from its shipping position
397 to its fully-seated position by pushing it at a speed that does not exceed 60 mm/minute.
398 5.7.3 Requirements
399 a) The locking force for the CPA with the connector mated correctly shall be between 5 N and 30 N.
401 b) The force required to seat the CPA with the connector in the unmated position shall meet or
402 exceed the greater of 80 N or 1,5 times the maximum force measured in 5.2.
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403 5.8 Disengage force for CPA function
404 5.8.1 Purpose
405 The purpose of this test is to determine the required disengage force for a CPA in order to assess its
406 ergonomic capability and to assure the CPA will not unlock in service.
407 5.8.2 Test
408 With the connector mated and the CPA fully engaged, measure the load required to release the CPA by
409 applying a force at a speed that does not exceed 60 mm/min.
410 Apply the force in the direction required to disengage the CPA. Record the force at which the CPA is
411 disengaged, then continue the motion and record the force at which the CPA is fully removed.
412 5.8.3 Requirements
413 a) The CPA release force shall be between 5 N and 30 N.
414 b) The force required to fully remove the CPA from a connector shall be a minimum of 80 N.
415 5.9 Locking force for TPA
416 5.9.1 Purpose
417 The purpose of this test is to determine the mating force that is required to move the TPA device to its
418 assembled position in order to assess its ability to resist unintentional activation and its ability to detect
419 when a terminal is incorrectly positioned.
420 The justification for requiring a maximum locking force is to prevent the assembly of connectors with
421 incorrectly seated TPAs in serial production.
422 5.9.2 Test
423 Move the TPA to its final position and measure the load required to move the TPA. Move the TPA at a
424 speed that does not exceed 60 mm/minute. Perform this test for the following two conditions:
425 a) TPA insertion and extraction force when the terminal is correctly seated (connector with terminals
426 correctly placed in all positions);
427 b) TPA insertion and extraction force when the terminal is incorrectly seated (connector with terminals
428 correctly placed in all positions except one location in which the terminal is partially inserted and not
429 locked in position).
430 5.9.3 Requirements
431 a) The force required to move the TPA to its final position with the terminals in their correct positions
432 shall be between 15 N and 60 N.
433 b) The force required to move the TPA to its final position with one incorrectly positioned terminal shall
434 be greater than measured insertion force measured in 5.9.2.a + 50 N.
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436 5.10 Disengage force for TPA
437 5.10.1 Purpose
438 This test shall be conducted on
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