ISO 19642-9:2019

Overview

ISO 19642-9:2019 sets out the dimensions and requirements for round, sheathed, screened or unscreened multi-core and single-core copper conductor automotive cables intended for road vehicle electrical systems with nominal voltages of 600 V a.c. / 900 V d.c. and 1 000 V a.c. / 1 500 V d.c.. The part applies to finished cables and to individual cores, defining required tests, construction limits and documentation expectations for high-voltage automotive cabling used in road vehicles.

Key Topics and Technical Requirements

• Scope and voltage ratings: Covers cables and cores for the specified nominal voltages; voltage identification (colour guidance) is referenced in Annex B.
• Conductor and insulation: Conductor material and conductor construction follow ISO 19642-5; insulation thickness and conductor resistance limits are documented in supplier datasheets.
• Sheath options: Allows two sheath types - thin wall and thick wall - with prescribed test methods for thickness and strip force.
• Temperature classes: Cable temperature rating equals the lowest rating among cores and sheath; temperature class details are referenced to ISO 19642-1.
• Dimensional requirements: Tests for cable outside diameter, inner layer diameters, sheath ovality and sheath thickness; preferred constructions are listed in Annex A.
• Electrical tests: Electrical continuity, final inspection withstand voltage, screening effectiveness, and sheath fault tests for screened cables.
• Mechanical tests: Strip force, cyclic bending, flexibility and in-process diameter monitoring.
• Environmental tests: Long- and short-term heat ageing, thermal overload, high-temperature pressure test, shrinkage, low-temperature winding, cold impact, temperature/humidity cycling, resistance to chemicals, ozone, artificial weathering and flame propagation.
• Testing strategy: All combinations of conductor size, insulation thickness and formulation should meet requirements, but representative size testing is allowed by agreement between supplier and customer.
• Documentation: Supplier datasheets must record conductor resistance, insulation wall thickness and full cable dimensions for assessment.

Applications and Users

ISO 19642-9 is used by:

• Automotive OEMs and Tier-1 suppliers specifying high-voltage cable systems for electric and hybrid vehicles
• Cable and harness manufacturers designing and producing 600 V / 1 000 V class automotive power cables
• Test laboratories and quality engineers performing dimensional, electrical, mechanical and environmental testing
• Procurement and regulatory teams ensuring supplier compliance with international automotive cable standards

Practical applications include high-voltage power distribution, battery and traction cabling, and any road-vehicle wiring harnesses operating at the covered system voltages.

Related Standards

• ISO 19642 series: ISO 19642-1 (vocabulary/design guidelines), ISO 19642-2 (test methods), ISO 19642-5 (single-core copper conductor requirements)
• Note: ISO 19642 series is structured to succeed earlier automotive cable standards such as ISO 6722 and ISO 14572 for new projects.

Keywords: ISO 19642-9, automotive cables, road vehicles, 600 V, 1 000 V, multi-core cable, single-core cable, copper conductor, cable dimensions, cable testing, high-voltage automotive cabling.