ISO 19642-5:2019

Overview

ISO 19642-5:2019 - Road vehicles - Automotive cables - Part 5 defines the dimensions and requirements for single core copper conductor cables intended for road vehicle applications with nominal system voltages of 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.. It also applies to individual conductor cores used in multi‑core cables and specifies requirements for copper conductors (bare or coated). The standard is part of the ISO 19642 series that replaces and restructures earlier automotive cable standards.

Key topics and technical requirements

• Voltage ratings: Limits set at 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.; ISO conductor size 0.35 mm is excluded for the higher rating.
• Conductor material and sizes: Specifies copper conductor types (bare, tinned, silver‑ or nickel‑coated) and references ASTM and EN material specifications; CSA and resistance requirements are mandated.
• Dimensions: Requirements for insulation thickness, cable outside diameter, conductor diameter and cross‑sectional area (CSA).
• Test regimes: Refers to ISO 19642-2 for test methods and mandates tests in four areas:
  • Dimensional tests (diameter, insulation thickness, CSA)
  • Electrical tests (conductor resistance, temperature coefficients, withstand voltage, insulation resistivity)
  • Mechanical tests (strip force, abrasion, breaking force, cyclic bending, flexibility)
  • Environmental tests (long‑ and short‑term heat ageing, thermal overload, pressure at high temperature, cold impact, humidity cycling, chemical and hot‑water resistance, ozone, flame propagation)
• Temperature classes: All temperature classes in ISO 19642-1 are applicable to copper conductor cables.
• Safety note: The document includes a warning that its use can involve hazardous materials and procedures; users must establish appropriate safety practices.

Applications

• Specification and qualification of high‑voltage automotive cables used in electric and hybrid vehicle power systems, traction circuits, battery and inverter connections, and wiring harnesses where single core copper conductors are required.
• Design and manufacturing guidance for cable makers, harness assemblers, and test laboratories to ensure consistent electrical, mechanical and environmental performance.
• Procurement and quality acceptance criteria for automotive OEMs and Tier‑1 suppliers.

Who should use this standard

• Cable manufacturers and material suppliers
• Automotive OEM electrical system designers and engineers
• Component and harness suppliers
• Test houses and certification bodies
• Procurement and quality assurance teams

Related standards

• ISO 19642-1 (vocabulary and design guidelines)
• ISO 19642-2 (test methods)
• ISO 6722 series, ISO 14572 (legacy automotive cable standards)
• EN 13602, ASTM B1/B3/B33/B298/B355 (conductor material specifications)

Keywords: ISO 19642-5:2019, automotive cables, road vehicles, single core copper conductor, 600 V, 900 V, 1000 V, 1500 V, dimensions, cable requirements, electrical tests, environmental tests.