ISO 19642-1:2023

INTERNATIONAL ISO
STANDARD 19642-1
Second edition
2023-08
Road vehicles — Automotive cables —
Part 1:
Vocabulary and design guidelines
Véhicules routiers — Câbles automobiles —
Partie 1: Vocabulaire et lignes directrices pour la conception
Reference number
© ISO 2023
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ii
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
3.1 Terms related to voltage rating . 1
3.2 Terms related to temperatures . 2
3.3 Terms related to cables . 2
3.4 Terms related to RF systems and properties . 10
Annex A (informative) Design guidelines for calculation of dimensions in multi-core cables .15
Annex B (informative) Recommended colour concentrations .23
Annex C (informative) Expert opinion on re-testing of existing cables .24
Bibliography .27
iii
Foreword
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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 second edition cancels and replaces the first edition (ISO 19642-1:2019), which has been technically
revised.
The main changes are as follows:
— new parts have been added to the ISO 19642 series (ISO 19642-11 and ISO 19642-12);
— reflecting these additions ISO 19642-2 had to be amended;
— some new terms and definitions for screened RF cables have been added for a new standard of the
ISO 19642 series;
— Annex C has been added to give informative advice on how to address and manage requalification
of cables already released against the older ISO standards ISO 6722-1 and ISO 6722-2.
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.
iv
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. These standards will
stay valid at least until the next scheduled systematic review and will be replaced later by the ISO 19642
series.
For new automotive cable projects, customers and suppliers are advised to use the ISO 19642 series.
This document defines general terms used in cable engineering to lay a solid foundation for discussions
and written information transfer in this field.
Annex A informally defines a calculation method for many important cable parameters (e.g. resistance
limits, several cable dimension).
Annex B informally proposes preferred colour concentrations for automotive cables.
Annex C gives an expert opinion on how to address and manage requalification of single core cables
already released against the old, but still active, ISO standards ISO 6722-1 and ISO 6722-2.
v
INTERNATIONAL STANDARD ISO 19642-1:2023(E)
Road vehicles — Automotive cables —
Part 1:
Vocabulary and design guidelines
1 Scope
This document defines terms in the field of cables applied in road vehicle general purpose applications,
for use in the 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 19642-7, Road vehicles — Automotive cables — Part 7: Dimensions and requirements for 30 V a.c. or 60
V d.c. round, sheathed, screened or unscreened multi or single core copper conductor cables
ISO 19642-8, Road vehicles — Automotive cables — Part 8: Dimensions and requirements for 30 V a.c. or 60
V d.c. round, sheathed, screened or unscreened multi or single core aluminium conductor cables
3 Terms and definitions
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 Terms related to voltage rating
3.1.1
AC voltage
voltage in an alternating current circuit that also periodically reverses because the current has a
periodic function of time
Note 1 to entry: Whenever AC voltage is specified in the ISO 19642 series, the AC root mean square (r.m.s.) value
shall be used.
3.1.2
60 V cable
cable (3.3.7) intended for use in road vehicle applications where the nominal system voltage (3.1.6) is
less than or equal to 30 V a.c. or 60 V d.c.
3.1.3
900 V cable
cable (3.3.7) intended for use in road vehicle applications where the nominal system voltage (3.1.6) is
less than or equal to 600 V a.c. or 900 V d.c.
3.1.4
1 500 V cable
cable (3.3.7) intended for use in road vehicle applications where the nominal system voltage (3.1.6) is
less than or equal to 1 000 V a.c. or 1 500 V d.c.
3.1.5
DC voltage
non-alternating constant or pulsed voltage
3.1.6
nominal system voltage
maximum continuous voltage of a conductor (3.3.13) to its system ground under normal conditions
3.2 Terms related to temperatures
3.2.1
temperature class rating
temperature range for safe operation of the cable (3.3.7) divided into eight temperature classes as
defined in Table 1
Table 1 — Temperature class rating
Temperature
Class Is equivalent to Class
°C
A T 1 −40 to 85
B T 2 −40 to 100
C T 3 −40 to 125
D T 4 −40 to 150
E T 5 −40 to 175
F T 6 −40 to 200
G T 7 −40 to 225
H T 8 −40 to 250
3.2.2
room temperature
RT
situation with a temperature of (23 ± 3) °C and a relative humidity (RH) of 45 % to 75 %
3.3 Terms related to cables
3.3.1
bare conductor
metal cable (3.3.7) conductor (3.3.13) in which the strand or strands are not coated
3.3.2
bedding layer
non-metallic covering applied (normally extruded) around the assembly of the cores (3.3.14) (and fillers
(3.3.18), if any) of a multi-core cable (3.3.29) to obtain a more circular outline
3.3.3
braid
covering formed from bare or plated metallic or non-metallic material
3.3.4
braid parameter
parameter of a braid (3.3.3) as defined in Table 2
Table 2 — Braid parameter formulae
Diameter Number of single strands in one Angle of lay perpendicular
over braid direction to cable axis
2×L
n
L
C
θ =arctan
DD=+4× D
nn=×
BC S
dS
π×+()DD
BC
Optical coverage,
2)
Coverage Lay length
braid percentage
nD×
dS
B = B<1
n
S
L ×cos()θ
BB=×()2 − B² ×100
L L =×25,4
o
L
2×P
11B≥
Key to braid parameters
D diameter of single strand, in mm
S
D diameter of core below the braid, in mm
C
D diameter over braid, in mm
B
n number of strands in one carrier
S
n number of single strands in one direction
d
n number of carriers
c
L lay length, in mm
L
θ angle of lay perpendicular to cable axis, in degrees
P picks per inch (number of braid crossover points in 1” = 25,4 mm)
B coverage, proportion of the covered surface by strands in one direction compared to the whole surface
B optical coverage, also called braid percentage; proportion of the covered surface by strands in both directions
o
compared to the whole surface, in percentage
Note 1 to entry: For better accuracy the angle θ shall not be measured directly but be calculated from the
measured dimensional parameters referenced in the formulae above.
Note 2 to entry: A value of B > 1 is physically impossible so, if due to measurement tolerances, a value of B > 1 is
obtained, it shall be adjusted to 1.
Note 3 to entry: A braid is formed by a number of single strands which are grouped into carriers and applied to
the cable (3.3.7) surface in two different directions (left and right or S and Z) in a form that each carrier of one
direction is alternatively above and below the adjacent carrier of the other direction.
Note 4 to entry: See Figure 1.
Figure 1 — Angle of lay
3.3.5
bunched conductor
conductor (3.3.13) in which individual strands are assembled together in helical formation, all in the
same direction and with the same length of lay
3.3.6
bunching loss
F
x,b
ratio of conductor (3.3.13) resistance before and after the bunching process of stranded conductors
(3.3.36)
Note 1 to entry: The factor, F , is derived by the formula:
x,b
mR ·· κ
mean mean
F =
x,b
1 000 · ρ
where
κ is the conductivity of the used conductor material in Sm/mm ;
ρ is the density of the conductor material in kg/dm = kg/l;
m is the mean of measured conductor mass in g/m;
mean
R is the mean of measured conductor resistance at 20 °C in mΩ/m.
mean
3.3.7
cable
single or multi-core wire (3.3.39)
Note 1 to entry: Cable dimension definitions are shown in Figure 2.
3.3.8
cable family
group with multiple conductor (3.3.13) sizes having the same conductor, strand coating, insulation
(3.3.23) formulation, and wall thickness type
3.3.9
cable dimension
property of a cable (3.3.7) with physical unit (mm)
Note 1 to entry: Cable dimension definitions are shown in Figure 2.
Key
a conductor (3.3.13) diameter 2 core insulation (3.3.23)
b core (3.3.14) diameter 3 inner covering (3.3.22)
c twisted core diameter 4 filler (3.3.18)
d diameter under sheath 5 drain wire (3.3.17)
e outside cable d
...