ISO 19642-7:2019

Overview

ISO 19642-7:2019 specifies the dimensions and technical requirements for round, sheathed, screened or unscreened multi‑core and single‑core copper conductor cables intended for road vehicles with nominal system voltages of 30 V a.c. or 60 V d.c.. It applies to complete cables and to individual cores in multi‑core constructions. The standard is part of the ISO 19642 automotive cable series and is intended for use in new automotive cable projects, supplier data sheets and conformity testing.

Key topics and technical requirements

• Scope and applicability: Multi‑core and single‑core copper conductor cables for 30 V a.c. / 60 V d.c. road vehicle systems; individual cores are covered.
• Referenced standards: Test methods and vocabulary/design rules are provided by ISO 19642-2, ISO 19642-1 and ISO 19642-3.
• Conductor and insulation: Conductor material and conductor construction follow ISO 19642-3; conductor resistance and insulation wall thickness are documented on supplier datasheets.
• Sheath options: Two sheath classes are defined - thin wall and thick wall - with sheath and bedding layer thickness calculation rules referenced to ISO 19642-1.
• Temperature class and voltage rating: Temperature class is determined by the cores and sheath; the cable rating equals the lowest individual rating. Voltage rating is by core rating (30 V a.c. / 60 V d.c.).
• Dimensional rules: Preferred constructions and dimensions are provided in Annex A (Tables A.1–A.6); calculation rules for outside diameter, wall thickness and allowable tolerances are referenced to ISO 19642-1.
• Testing requirements: Tests are defined by ISO 19642-2 and include:
  • Dimensional tests (outside diameter, ovality, sheath thickness)
  • Electrical tests (continuity, withstand voltage, screening effectiveness, surface transfer impedance)
  • Mechanical tests (strip force, cyclic bending, flexibility)
  • Environmental tests (long‑term and short‑term heat ageing - including 3 000 h and 240 h tests at specified temperatures, thermal overload, pressure at high temperature, shrinkage, low‑temperature winding, cold impact, humidity cycling, chemical resistance, ozone, artificial weathering, flame propagation, and marking durability)
• Testing strategy: All combinations of conductor size, insulation thickness and formulation must meet requirements; representative size testing is possible by agreement between supplier and customer.

Applications and who uses it

• Automotive OEMs and wiring harness designers specifying cables for low‑voltage vehicle systems.
• Cable manufacturers and suppliers for product design, quality control and datasheet documentation.
• Test laboratories performing type, in‑process and periodic certification tests.
• Quality, compliance and procurement teams ensuring cable conformity in automotive electrical systems.

Related standards

• ISO 19642-1 (vocabulary & design guidelines)
• ISO 19642-2 (test methods)
• ISO 19642-3 (single‑core dimensions & requirements)
• Note: ISO 19642 series is structured to replace older automotive cable standards (e.g., ISO 6722 series) over time.

Keywords: ISO 19642-7, automotive cables, road vehicles, 30 V a.c., 60 V d.c., multi-core cable, single-core cable, copper conductor, sheath thickness, screening effectiveness, cable testing.