ISO 19642-10:2019

Overview

ISO 19642-10:2019 specifies dimensions and requirements for aluminium conductor automotive cables used in road vehicles at nominal voltages of 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.. It applies to round, sheathed, screened or unscreened multi‑core and single‑core aluminium conductor cables and to individual cores within those cables. The standard is part of the ISO 19642 series and is intended to guide manufacturers, suppliers and vehicle OEMs on design, testing and documentation for higher‑voltage vehicle wiring.

Key topics and technical requirements

• Voltage ratings: Covers cable systems rated for 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.
• Temperature classes: Defined temperature class ratings for aluminium conductor cables (A–F):
  • A (T1): −40 to 85 °C
  • B (T2): −40 to 100 °C
  • C (T3): −40 to 125 °C
  • D (T4): −40 to 150 °C
  • E (T5): −40 to 175 °C
  • F (T6): −40 to 200 °C
• Conductor and insulation: Conductor material and core construction reference ISO 19642‑6; insulation wall thickness and maximum/minimum outside core diameters are aligned to that part.
• Sheath types: Allows thin‑wall and thick‑wall sheaths; sheath thickness and bedding rules follow ISO 19642‑1 calculation guidelines.
• Testing requirements (referenced to ISO 19642‑2 test methods):
  • Dimensional tests (outside diameter, sheath thickness, ovality)
  • Electrical tests (continuity, withstand voltage, screening effectiveness, sheath fault tests)
  • Mechanical tests (strip force, cyclic bending, flexibility)
  • Environmental tests (long/short term heat ageing, thermal overload, pressure at high temperature, cold impact, humidity cycling, chemical resistance, ozone, weathering, flame propagation)
• Representative testing: Permits testing of representative large/small conductor sizes for a cable family by agreement; all combinations of conductor size, insulation thickness and formulation nominally must meet requirements.
• Documentation: Supplier datasheet must list dimensions, maximum conductor resistance and minimum insulation thickness used for assessment.

Applications and users

ISO 19642-10:2019 is used by:

• Automotive cable manufacturers and material suppliers (design and production control)
• Vehicle OEMs and wiring harness suppliers (specification and procurement of high‑voltage cables)
• Automotive engineers, validation/test labs and quality managers (type approval, EMC screening and environmental testing)
• Electrified vehicle programs (EV/HEV high‑voltage wiring harnesses), commercial vehicles and specialist road vehicles requiring 600–1 500 V systems.

Related standards

• ISO 19642‑1 (vocabulary & design guidelines)
• ISO 19642‑2 (test methods)
• ISO 19642‑6 (single core aluminium conductor cables)

Keywords: ISO 19642-10:2019, automotive cables, aluminium conductor cables, high‑voltage vehicle wiring, 600 V, 1 000 V, cable dimensions, cable testing, road vehicles.