ISO 19642-8:2019

Overview

ISO 19642-8:2019 specifies dimensions and performance requirements for round, sheathed, screened or unscreened multi‑core and single‑core aluminium conductor automotive cables intended for road vehicle systems with nominal voltages of 30 V a.c. or 60 V d.c.. The standard covers core and sheath dimensions, conductor materials, temperature class ratings, and required tests to verify electrical, mechanical and environmental performance. It applies equally to individual cores inside multi‑core cables.

Key topics and technical requirements

• Voltage rating: Designed for low‑voltage vehicle systems (30 V a.c. / 60 V d.c.).
• Temperature classes: Defined temperature class ratings for aluminium conductor cables:
  • 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 sheath specifications: Conductor material and conductor construction follow ISO 19642‑4; sheath thickness options include thin wall and thick wall. Insulation and sheath wall thickness, and outside diameter limits, are specified or calculated per ISO 19642‑1 guidelines.
• Test methods and verification: Tests referenced to ISO 19642‑2 cover dimensional checks (outside diameter, ovality, sheath thickness), electrical tests (continuity, withstand voltage, screening effectiveness), mechanical tests (strip force, cyclic bending, flexibility) and environmental tests (long/short‑term heat ageing, thermal overload, cold impact, humidity cycling, chemical resistance, ozone, weathering and flame propagation). Table 2 of the standard lists mandatory and periodic tests.
• Documentation: Manufacturers should document conductor resistance, minimum insulation thickness and cable dimensions in supplier datasheets as the basis for conformity assessment.

Applications and users

ISO 19642‑8:2019 is intended for:

• Automotive OEMs and Tier‑1/2 suppliers specifying low‑voltage aluminium cables for wiring harnesses, lighting circuits, sensors and auxiliary systems.
• Cable manufacturers designing and producing sheathed or screened aluminium conductor cables for road vehicles.
• Test laboratories and quality engineers performing conformity testing per ISO 19642‑2.
• Procurement and compliance teams requiring consistent dimensional and performance criteria for low‑voltage automotive wiring.

Related standards

• ISO 19642‑1 - Vocabulary and design guidelines
• ISO 19642‑2 - Test methods (referenced for all tests)
• ISO 19642‑4 - Dimensions and requirements for single‑core aluminium cables
• Historical/related references: ISO 6722‑1, ISO 6722‑2, ISO 14572

ISO 19642‑8:2019 provides a clear framework for specifying and testing aluminium conductor automotive cables for 30 V a.c. / 60 V d.c. systems, improving interchangeability, safety and supplier‑customer agreement on cable performance.