ISO-6722-1-2011

ReferencenumberISO6722-1:2011(E)©ISO2011INTERNATIONALSTANDARDISO6722-1Fourthedition2011-10-15Roadvehicles—60Vand600Vsingle-corecables—Part1:Dimensions,testmethodsandrequirementsforcopperconductorcablesVéhiculesroutiers—Câblesmonoconducteursde60Vet600V—Partie1:Dimensions,méthodesd'essaietexigencespourlescâblesconducteursencuivreISO6722-1:2011(E)COPYRIGHTPROTECTEDDOCUMENT©ISO2011Allrightsreserved.Unlessotherwisespecified,nopartofthispublicationmaybereproducedorutilizedinanyformorbyanymeans,electronicormechanical,includingphotocopyingandmicrofilm,withoutpermissioninwritingfromeitherISOattheaddressbeloworISO'smemberbodyinthecountryoftherequester.ISOcopyrightofficeCasepostale56CH-1211Geneva20Tel.+41227490111Fax+41227490947E-mailcopyright@iso.orgWebwww.iso.orgPublishedinSwitzerlandii©ISO2011–AllrightsreservedISO6722-1:2011(E)©ISO2011–AllrightsreservediiiContentsPageForeword............................................................................................................................................................iv 1 Scope......................................................................................................................................................1 2 Normativereferences............................................................................................................................1 3 Termsanddefinitions...........................................................................................................................2 4 General...................................................................................................................................................2 4.1 Safetyconcerns.....................................................................................................................................2 4.2 Temperatureclasses.............................................................................................................................2 4.3 Conductors............................................................................................................................................3 4.4 Tests.......................................................................................................................................................3 4.5 Generaltestconditions.........................................................................................................................5 4.6 Ovens......................................................................................................................................................5 4.7 Representativeconductorsizesfortesting........................................................................................5 4.8 Recommendedcolours.........................................................................................................................5 5 Testsandrequirements........................................................................................................................5 5.1 Outsidecablediameter.........................................................................................................................5 5.2 Insulationthickness..............................................................................................................................6 5.3 Conductordiameter..............................................................................................................................8 5.4 Conductorresistance............................................................................................................................8 5.5 Withstandvoltage................................................................................................................................10 5.6 Insulationfaults...................................................................................................................................11 5.7 Insulationvolumeresistivity..............................................................................................................12 5.8 Pressuretestathightemperature.....................................................................................................13 5.9 Stripforce.............................................................................................................................................14 5.10 Lowtemperaturewinding...................................................................................................................15 5.11 Coldimpact..........................................................................................................................................17 5.12 Abrasiontest........................................................................................................................................19 5.13 Longtermheatageing,3000h..........................................................................................................23 5.14 Shorttermheatageing,240h............................................................................................................24 5.15 Thermaloverload.................................................................................................................................25 5.16 Shrinkagebyheat................................................................................................................................26 5.17 Fluidcompatibility...............................................................................................................................26 5.18 Durabilityofcablemarking................................................................................................................30 5.19 Resistancetoozone............................................................................................................................30 5.20 Resistancetohotwater......................................................................................................................31 5.21 Temperatureandhumiditycycling....................................................................................................33 5.22 Resistancetoflamepropagation.......................................................................................................34 AnnexA(informative)Comparisontemperatureclassrating......................................................................36 AnnexB(informative)Construction...............................................................................................................37 AnnexC(informative)Recommendedcolours..............................................................................................40 AnnexD(informative)Sourcesforreferencematerials................................................................................41 Bibliography......................................................................................................................................................42 ISO6722-1:2011(E)iv©ISO2011–AllrightsreservedForewordISO(theInternationalOrganizationforStandardization)isaworldwidefederationofnationalstandardsbodies(ISOmemberbodies).TheworkofpreparingInternationalStandardsisnormallycarriedoutthroughISOtechnicalcommittees.Eachmemberbodyinterestedinasubjectforwhichatechnicalcommitteehasbeenestablishedhastherighttoberepresentedonthatcommittee.Internationalorganizations,governmentalandnon-governmental,inliaisonwithISO,alsotakepartinthework.ISOcollaboratescloselywiththeInternationalElectrotechnicalCommission(IEC)onallmattersofelectrotechnicalstandardization.InternationalStandardsaredraftedinaccordancewiththerulesgivenintheISO/IECDirectives,Part2.ThemaintaskoftechnicalcommitteesistoprepareInternationalStandards.DraftInternationalStandardsadoptedbythetechnicalcommitteesarecirculatedtothememberbodiesforvoting.PublicationasanInternationalStandardrequiresapprovalbyatleast75%ofthememberbodiescastingavote.Attentionisdrawntothepossibilitythatsomeoftheelementsofthisdocumentmaybethesubjectofpatentrights.ISOshallnotbeheldresponsibleforidentifyinganyorallsuchpatentrights.ISO6722-1waspreparedbyTechnicalCommitteeISO/TC22,Roadvehicles,SubcommitteeSC3,Electricalandelectronicequipment.ThisfourtheditionofISO6722-1cancelsandreplacesISO6722:2006,whichhasbeentechnicallyrevised.ISO6722consistsofthefollowingparts,underthegeneraltitleRoadvehicles—60Vand600Vsingle-corecables:Part1:Dimensions,testmethodsandrequirementsforcopperconductorcablesPart2:Dimensions,testmethodsandrequirementsforaluminiumconductorcables1)1)Tobepublished.INTERNATIONALSTANDARDISO6722-1:2011(E)©ISO2011–Allrightsreserved1Roadvehicles—60Vand600Vsingle-corecables—Part1:Dimensions,testmethodsandrequirementsforcopperconductorcablesWARNING—TheuseofthisInternationalStandardmayinvolvehazardousmaterials,operations,andequipment.ThisInternationalStandarddoesnotpurporttoaddressallofthesafetyconcerns,ifany,associatedwithitsuse.ItistheresponsibilityoftheuserofthisInternationalStandardtoestablishappropriatesafetypracticesanddeterminetheapplicabilityofregulatorylimitationspriortouse.1ScopeThispartofISO6722specifiesthedimensions,testmethods,andrequirementsforsingle-core60Vcablesintendedforuseinroadvehicleapplicationswherethenominalsystemvoltageis(60Vd.c.or25Va.c.).Italsospecifiesadditionaltestmethodsand/orrequirementsfor600Vcablesintendedforuseinroadvehicleapplicationswherethenominalsystemvoltageisgreaterthan(60Vd.c.or25Va.c.)to(600Vd.c.or600Va.c.).Italsoappliestoindividualcoresinmulti-corecables.ThispartofISO6722specifiesrequirementsforcopperconductorcables.2NormativereferencesThefollowingreferenceddocumentsareindispensablefortheapplicationofthisdocument.Fordatedreferences,onlytheeditioncitedapplies.Forundatedreferences,thelatesteditionofthereferenceddocument(includinganyamendments)applies.ISO1817,Rubber,vulcanizedorthermoplastic—DeterminationoftheeffectofliquidsISO6931-1,Stainlesssteelsforsprings—Part1:WireIEC60811-2-1,Commontestmethodsforinsulatingandsheathingmaterialsofelectricandopticalcables—Part2-1:Methodsspecifictoelastomericcompounds—Ozoneresistance,hotsetandmineraloilimmersiontestsASTMB1,StandardSpecificationforHardDrawnCopperWireASTMB3,StandardSpecificationforSoftorAnnealedCopperWireASTMB33,StandardSpecificationforTinCoatedSoftorAnnealedCopperWireforElectricalPurposesASTMB298,StandardSpecificationforSilverCoatedSoftorAnnealedCopperWireASTMB355,StandardSpecificationforNickelCoatedSoftorAnnealedCopperWireEN13602,Copperandcopperalloys—Drawn,roundcopperwireforthemanufactureofelectricalconductorsISO6722-1:2011(E)2©ISO2011–Allrightsreserved3TermsanddefinitionsForthepurposesofthisdocument,thefollowingtermsanddefinitionsapply.NOTEWhenevera.c.voltageisspecifiedthroughoutthispartofISO6722,a.c.rmsvalueshallbeused.3.160volt(V)cablecableintendedforuseinroadvehicleapplicationswherethenominalsystemvoltageisequaltoorlessthan(60Vd.c.or25Va.c.)3.2600volt(V)cablecableintendedforuseinroadvehicleapplicationswherethenominalsystemvoltageisgreaterthan(60Vd.c.or25Va.c.)andlessthanorequalto(600Vd.c.or600Va.c.)3.3cablefamilygroupwithmultipleconductorsizeshavingthesameconductorstrandcoating,insulationformulation,andwallthicknesstype3.4nominal(value)suitableapproximatevalueusedtodesignateoridentifyacomponent4General4.1SafetyconcernsSeethe“Warning”noticeatthebeginningofthisInternationalStandard.4.2TemperatureclassesEighttemperatureclassesaredefinedinTable1.Table1—TemperatureclassratingClassTemperatureA40°Cto85°CB40°Cto100°CC40°Cto125°CD40°Cto150°CE40°Cto175°CF40°Cto200°CG40°Cto225°CH40°Cto250°CISO6722-1:2011(E)©ISO2011–Allrightsreserved34.3ConductorsTheconductorsshallconsistofplainorcoatedcopperstrandsasshowninTable2.Conductorsizes0,5mm2shallconsistofsoftannealedcopperorannealedcompressed/compactedwires.Conductorsizes0,5mm2shallconsistofsoftannealedcopper,softannealedcompressed/compactedcopper,hardunannealedcopper,oracopperalloy.Thespecificationsfortheconductorsshallbecompletedbymaterialspecifications.Elongationrequirementsshallbeestablishedbyagreementbetweencustomerandsupplier.ThefinishedcableshallmeettheresistancerequirementsofTable5forallconductorsexceptalloys.Whenanalloyisused,theresistancerequirementshallbeestablishedbyagreementbetweencustomerandsupplier.NOTEExamplesofstrandingsareshowninTableB.1.Thesestrandingshighlightexamplesofconceptualconfigurationsandarenotintendedtoreflectanypreferredconstructions.Otherstrandingsconfigurationsmaybeusedprovidedtheymeettherequirementsspecifiedaboveandareagreedbetweencustomerandsupplier.Table2—ConductorspecificationsASTMB1Hard-drawncopperwireASTMB3orEN13602SoftorannealedcopperwireASTMB33orEN13602Tin-coatedsoftorannealedcopperwireASTMB298Silver-coatedsoftorannealedcopperwireASTMB355Nickel-coatedsoftorannealedcopperwireNOTESilverandNickelcoatedconductorsareintendedforusewithhigh“temperatureclassratings”.4.4TestsThecablesshallbesubmittedtothetestsasspecifiedinTable3.NOTEAspecialsetofrequirementsfortrucksisintendedtobeaddedtothenextrevisionofthisInternationalStandard.ISO6722-1:2011(E)4©ISO2011–AllrightsreservedTable3—TestsSub-clauseTestdescriptionMandatoryIfrequiredcInprogressaInitialPeriodicbInitialPeriodic5.1Outsidecablediameter—XX——5.2Insulationthickness—XX——5.3Conductordiameter———XX5.4Conductorresistance—XX——5.5Withstandvoltage—Note1Note1——5.6InsulationfaultsNote1————5.7Insulationvolumeresistivity———XX5.8Pressuretestathightemperature—XX——5.9Stripforce———XX5.10Lowtemperaturewinding—XX——5.11Coldimpact———XX5.12Abrasiontest—Note2Note2——5.13Longtermheatageing,3000h—X———5.14Shorttermheatageing,240h—XX——5.15Thermaloverload———XX5.16Shrinkagebyheat—XX——5.17Fluidcompatibility—Notes3and4—Notes3and4—5.18Durabilityofcablemarking———Note4Note45.19Resistancetoozone———Note4—5.20Resistancetohotwater———Note4—5.21Temperatureandhumiditycycling———Note4—5.22Resistancetoflamepropagation—XX——NOTE1Somecablesareratedat60Vandothersat600V.See5.5.3and5.6.3fordetails.NOTE2See5.12.NOTE3Somefluidsarefor“Certification”andothersare“Ifrequired”.See5.17fordetails.NOTE4Complianceforacablefamilymaybedemonstratedbytestingexamplesoflargeandsmallconductorsizesonly.See4.7fordetails.aAtestmadeonanentirecablelengthduringorafterthemanufacture.bThefrequencyofperiodictestingshallbeestablishedbyagreementbetweencustomerandsupplier.cTheusageof“Ifrequired”testsshallbeestablishedbyagreementbetweencustomerandsupplier.ISO6722-1:2011(E)©ISO2011–Allrightsreserved54.5GeneraltestconditionsUnlessspecifiedotherwise,thedeviceundertest(DUT)shallbepreconditionedforatleast16hataroomtemperature(RT)of(235)°Candarelativehumidity(RH)of45%to75%.Unlessspecifiedotherwise,alltestsotherthan“Inprocess”testsshallbeconductedattheseconditions.Wherenotoleranceisspecified,allvaluesshallbeconsideredtobeapproximate.Whena.c.testsareperformed,theyshallbeat50Hzor60Hz.Applicationsathigherfrequenciesmayrequireadditionaltesting.4.6OvensAnovenwithairexchange,eithernaturalorbypressure,shouldbeused.Theairshallentertheoveninsuchawaythatitflowsoverthesurfaceofthetestpiecesandexitsnearthetopoftheoven.Theovenshallhavenotlessthan8andnotmorethan20completeairchangesperhouratthespecifiedageingtemperature.Forcedaircirculation,e.g.byafaninsidetheovenmaybeused.However,incaseofdispute,anovenwithoutforcedaircirculationshallbeused.4.7RepresentativeconductorsizesfortestingWhenatestisrequired,allcombinationsofconductorsize,wallthickness,andinsulationformulationshallmeettheappropriaterequirements.However,iftestingofrepresentativeconductorsizesispermitted(seeTable3),complianceforacablefamilymaybedemonstratedbytestingexamplesoflargeandsmallconductorsizesonly.Permissiontoshowcomplianceforacablefamilybytesting“representativeconductorsizes”shallbeestablishedbyagreementbetweencustomerandsupplier.4.8RecommendedcoloursAlistofrecommendedcoloursisshowninTableC.1.5Testsandrequirements5.1Outsidecablediameter5.1.1PurposeThistestisintendedtoverifythatthecableoutsidediameteriswithintherequiredtolerancestofitsealandharnessdimensionrequirements.5.1.2TestSamplePrepareatestsampleof3minlength.5.1.3TestUseameasuringdevicewhichshallnotcausedeformation.Takethreesetsofmeasurementsatpositionsseparatedby1mandrecordthehighestandlowestoutsidecablediameterateachposition.ISO6722-1:2011(E)6©ISO2011–Allrightsreserved5.1.4RequirementAllmeasurementsshallbewithinthelimitsoftheappropriatemaximumandminimum“outsidecablediameter”specifiedinTable4andTableB.2.ThevaluesinTable4arenormative.SincethevaluesinTableB.2areinformative,theyarenotrequired;however,theymaybeappliedbyagreementbetweencustomerandsupplier.5.2Insulationthickness5.2.1PurposeThistestisintendedtoverifythatthecableinsulationthicknessiswithintherequiredtolerancestowithstandelectrical,mechanicalandchemicalabuse.5.2.2TestsamplesPreparethreetestsamplesfromacablesample3minlength.Takethetestsamplesat1mintervals.Striptheinsulationfromthecable.Atestsampleconsistsofathincross-sectionofinsulation.Takecarenottodeformthetestsampleduringthepreparationprocess.Ifcablemarkingcausesindentationoftheinsulation,takethefirsttestsamplethroughthisindentation.5.2.3TestUseameasuringdevicewhichshallnotcausedeformation.Placethetestsampleunderthemeasuringequipmentwiththeplaneofthecutperpendiculartotheopticalaxis.Determinetheminimum“insulationthickness”.5.2.4RequirementNosinglevalueshallbelessthantheappropriateminimuminsulationthicknessspecifiedinTable4.ISO6722-1:2011(E)©ISO2011–Allrightsreserved7Table4—DimensionsISOconductorThickwallThinwallUltra-thinwallSizeDiameterInsulationthicknessOutsidecablediameterInsulationthicknessOutsidecablediameterInsulationthicknessOutsidecablediametermm2mmmmmmmmmmmmmmmax.nominalmin.max.nominalmin.max.nominalmin.max.0,130,550,250,201,050,200,160,950,220,701,201,050,350,901,40a1,200,501,100,600,482,300,280,221,601,400,751,302,500,300,241,901,6011,502,702,101,751,251,702,952,302,001,51,803,002,402,1022,003,300,350,282,800,250,202,402,52,200,700,563,603,002,7032,404,100,400,323,4042,800,800,644,403,7053,104,904,2063,405,004,3084,305,905,00104,501,000,806,500,600,486,00125,407,406,50165,808,300,650,527,20206,901,100,889,107,80257,201,301,0410,408,70308,3010,900,800,649,60358,5011,6010,40409,601,401,1212,400,900,7111,105010,501,501,2013,5012,206011,6014,601,000,8013,307012,5015,5014,409514,801,601,2818,001,100,9016,7012016,5019,70NOTEOutsidecablediameterminimumvaluesforhighvolumecableconstructionsareshowninTableB.2.SincethevaluesinTableB.2areinformative,theyarenotrequired;however,theymaybeappliedbyagreementbetweencustomerandsupplier.aTheoutsidecablediameterforconductorsize0,35mm2with7strandsshallbemax.1,30mm.ISO6722-1:2011(E)8©ISO2011–Allrightsreserved5.3Conductordiameter5.3.1PurposeThistestisintendedtoverifythatthecableconductordiameteriswithintherequiredtolerancestofitterminalcrimpsandmechanicaldemands.5.3.2TestsamplesUsethetestsamplesasspecifiedin5.2.Incaseofdisputedresults,arefereemethodisprovidedbelow.Preparethreetestsamplesfromacablesample3minlength.Takethesesamplesat1mintervals.Asampleconsistsofa20mmlengthofcable.Takecarenottodeformthetestsample.Immersethesamplesinacastingresin.Afterhardening,takeasectionperpendiculartotheaxisofthetestsample.5.3.3TestUseameasuringdevicewhichshallnotcausedeformation.Determinetheconductordiameterbymeasuringtheinsidediameterofthetestsamplesandrecordthemaximuminsidediameterforeachtestsample.5.3.4RequirementNosinglevalueshallexceedthemaximumvalueasspecifiedinTable4.5.4Conductorresistance5.4.1PurposeThistestisintendedtoverifythatthecableconductorresistancedoesnotexceedthemaximumpermittedvalue.5.4.2TestsamplesPrepareatestsampleof1mlengthplusthelengthnecessaryforconnections.Otherlengthsmaybeusedprovidingthattheresistancereadingisadjustedusingthemethodshownin5.4.3.Theendsofthetestsamplemaybesoldered.5.4.3TestUsearesistancemeasuringdevicewithanaccuracyof0,5%ofthemeasuredvalueandathermometerwithanaccuracyof0,5°C.Measurethetemperatureofthetestsampleandtheunsolderedlength.Takecaretoensurethatconnectionsaresecure.Measuretheresistanceofthetestsample.CorrectthemeasuredvalueusingEquation(1):2010,0039320tRRLt(1)whereR20isthecorrectedconductorresistanceatthereferencetemperatureof20°C,expressedinmΩ/m;Rtistheconductorresistancemeasuredattheconductortemperaturei