ISO 19642-6:2019

Overview

ISO 19642-6:2019 specifies dimensions and performance requirements for single core aluminium conductor automotive cables used in road vehicles. It covers cables and individual conductor cores intended for nominal system voltages of 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c. The standard is part of the ISO 19642 series that defines vocabulary, test methods and product requirements for automotive cables and complements ISO 19642‑1 (vocabulary) and ISO 19642‑2 (test methods).

Key topics and technical requirements

• Scope and application: Single core aluminium conductor cables for general-purpose road vehicle use; also applies to individual cores in multi‑core cables.
• Voltage ratings: Limited to 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 (examples):
  • Class A (T1): −40 to 85 °C
  • Class B (T2): −40 to 100 °C
  • Class C (T3): −40 to 125 °C
  • Class D (T4): −40 to 150 °C
  • Class E (T5): −40 to 175 °C
  • Class F (T6): −40 to 200 °C
• Conductor material: Annealed or annealed-compressed aluminium or aluminium-alloy strands (1 000 series or equivalent per EN 573 standards). Mechanical and electrical properties (tensile, elongation, conductivity) are specified and tested per referenced methods.
• Dimensional and physical requirements: Conductor diameter, cross-sectional area, insulation thickness, cable outside diameter, and in‑process diameter limits.
• Electrical tests: Conductor resistance, temperature coefficients, withstand voltage (including after environmental testing), insulation faults and volume resistivity.
• Mechanical tests: Strip force, abrasion resistance, breaking force, cyclic bending, flexibility.
• Environmental tests: Long‑term and short‑term heat ageing, thermal overload, pressure at high temperature, shrinkage, cold impact, humidity cycling, resistance to hot water, chemicals, ozone, flame propagation, and marking durability.
• Testing standards referenced: ISO 19642‑2 test methods, ISO 6892‑1 for tensile tests, EN 573 series, ASTM B231 for conductor specifications.

Applications and users

ISO 19642-6 is used by:

• Automotive OEMs specifying high-voltage single-core aluminium cables.
• Cable manufacturers designing and producing aluminium conductor automotive cables.
• Component suppliers and harness manufacturers validating conductor cores used in multi-core assemblies.
• Test laboratories performing electrical, mechanical and environmental qualification.
• Engineers working on EV/HEV high-voltage systems, auxiliary power distribution, and on-board wiring where higher nominal voltages are present.

Related standards

• ISO 19642‑1 - Vocabulary and design guidelines
• ISO 19642‑2 - Test methods for automotive cables
• EN 573‑1 / EN 573‑3 - Aluminium chemical composition
• ASTM B231 - Aluminium conductor specification
• ISO 6892‑1 - Tensile testing methods

For implementation or procurement, consult the full ISO 19642‑6:2019 document through your national standards body or ISO.