Overview
ISO 19642-4:2019 - Road vehicles - Automotive cables - Part 4 specifies the dimensions and requirements for single-core aluminium conductor cables intended for general-purpose vehicle applications with nominal system voltages up to 30 V a.c. or 60 V d.c.. It also applies to individual cores within multi-core cables and defines material, dimensional, electrical, mechanical and environmental requirements for aluminium-conductor automotive cables.
Key topics and requirements
- Voltage rating: Limited to ≤ 30 V a.c. and ≤ 60 V d.c. (suitable for low-voltage vehicle systems).
- Conductor material: Annealed or annealed-compressed aluminium or aluminium-alloy strands per EN 573 series and referenced specifications (examples in Annex A). Material properties (tensile strength, elongation, conductivity) and strand characteristics are prescribed or agreed between supplier and customer.
- Temperature classes: Defined temperature ratings (T1–T6) for aluminium conductor cables:
- T1: −40 to 85 °C
- T2: −40 to 100 °C
- T3: −40 to 125 °C
- T4: −40 to 150 °C
- T5: −40 to 175 °C
- T6: −40 to 200 °C
- Dimensional requirements: Specifications for insulation thickness, conductor diameter, cable outside diameter and cross-sectional area (CSA) with in-process measurement criteria.
- Electrical tests: Conductor resistance, temperature coefficient determination, dielectric withstand voltage (including after environmental exposure), insulation volume resistivity and insulation fault criteria.
- Mechanical tests: Strip force, abrasion resistance, finished cable breaking force, cyclic bending and flexibility tests.
- Environmental tests: Long-term and short-term heat ageing, thermal overload, high-temperature pressure tests, shrinkage, low-temperature winding, cold impact, humidity/temperature cycling, water and chemical resistance, ozone and flame propagation resistance. Test methods reference ISO 19642-2.
- Safety note: The standard includes a warning about hazardous materials/operations and expects users to follow appropriate safety practices.
Applications and users
ISO 19642-4:2019 is intended for:
- Automotive OEMs specifying low-voltage wiring harnesses and single-core cables for vehicle systems.
- Cable manufacturers and suppliers designing and producing aluminium single-core automotive cables and cores for multi-core assemblies.
- Test laboratories and quality engineers performing dimensional, electrical, mechanical and environmental verification per ISO 19642-2 methods.
- Procurement and compliance teams ensuring components meet vehicle-level temperature classes, voltage ratings and material standards.
Practical applications include low-voltage power distribution, signal return conductors, chassis connections and other general-purpose wiring in passenger cars, commercial vehicles and off‑highway equipment where aluminium conductors are preferred for weight and cost.
Related standards
- ISO 19642-1 - Vocabulary and design guidelines (series context)
- ISO 19642-2 - Test methods (referenced for all tests)
- EN 573-1 / EN 573-3 - Aluminium chemical composition and product forms
- ASTM B231 - Aluminium conductor specifications
- Historical references: ISO 6722-1 / ISO 6722-2 (older automotive cable standards still in use during transition)
Keywords: ISO 19642-4:2019, automotive cables, aluminium conductor, single core, 30 V AC, 60 V DC, cable dimensions, temperature classes, conductor resistance, insulation thickness, automotive wiring standard.
Open preview (PDF)Road vehicles — Automotive cables — Part 4: Dimensions and requirements for 30 V a.c. and 60 V d.c. single core aluminium conductor cables
