GB/T 25085 is predicted to consist 10 parts under the general title Road vehicles - Automotive cables:
——Part 1: Vocabulary and design guidelines;
——Part 2: Testing methods;
—— part 3: Dimensions and requirements for 30 V a.c. or 60 V d.c. single-core copper conductor cables;
—— part 4: Dimensions and requirements for 30 V a.c. or 60 V d.c. single-core aluminium conductor cables;
——Part 5: Dimensions and requirements for 600 V a.c. or 900 V d.c. as well as 1 000 V a.c. or 1 500 V d.c. single-core copper conductor cables;
——Part 6: Dimensions and requirements for 600 V a.c. or 900 V d.c. as well as 1,000 V a.c. Or 1,500 V d.c. single-core aluminium conductor cables;
——Part 7: Dimensions and requirements for 30 V a.c. or 60 V d.c. shielded and unshielded multi-core and single-core copper conductor cables with round sheath;
——Part 8: Dimensions and requirements for 30 V a.c. or 60 V d.c. shielded and unshielded multi-core and single-core aluminium conductor cables with round sheath;
——Part 9: Dimensions and requirements for 600 V a.c. or 900 V d.c. as well as 1,000 V a.c. or 1,500 V d.c. shielded and unshielded multi-core and single-core copper conductor cables with round sheath;
——Part 10: Dimensions and requirements for 600 V a.c. or 900 V d.c. as well as 1,000 V a.c. or 1,500 V d.c. shielded and unshielded multi-core and single-core aluminium conductor cables with round sheath.
This is Part 3 of GB/T 25085.
This part is developed in accordance with the rules given in GB/T 1.1-2009.
This part replaces GB/T 25085-2010 Road vehicles - 60 V and 600 V single-core cables, the following main technical changes have been made with respect to GB/T 25085-2010:
——The clause “Normative references” is modified (see clause 2; clause 2 of Edition 2010) ;
——The test content of cross-sectional area for dimension inspection is added (see 5.2.4);
——The test content of in-process cable outside diameter in dimension inspection is added (see 5.2.5);
——The test content of determination of temperature coefficients in electrical property test is added (see 5.3.2);
——The test content of withstand voltage after environmental testing in electrical property test is added (see 5.3.4);
——The test content of breaking force of the finished cable in mechanical property test is added (see 5.4.3);
——The cyclic bending test conditions in mechanical property test is added (see 5.4.4);
——The flexibility test content in mechanical property test is added (see 5.4.5);
——The test content of stress cracking resistance test in environmental test is added (see 5.5.13).
This part, by means of translation, is identical to ISO 19642-3: 2019 Road vehicles - Automotive cables - Part 3: Dimensions and requirements for 30 V a.c. or 60 V d.c. single core copper conductor cables.
Editorial changes have been made in this part as follows:
——The warning in ISO 19642-3: 2019 has been moved to 4.2 of this part;
——The "×" has been replaced with "√” (see Table 2);
——The "×" has been replaced with "-” (see Table 3, Table 5, Table 7 and Table A.1);
——Note has been added, and the reference information of relevant domestic standards has been given (see Note 2 in Table 1);
——The Annex A (informative) “Product model list” has been added;
——The "Bibliography" has been modified (see Bibliography).
This part was proposed by the Ministry of Industry and Information Technology of the People's Republic of China.
This part is under the jurisdiction of SAC/TC 114 National Technical Committee of Auto Standardization.
The previous edition of this part is as follow:
——GB/T 25085-2010.
Road vehicles - Automotive cables -
Part 3: Dimensions and requirements for 30 V a.c. or 60 V d.c. single-core copper conductor cables
1 Scope
This part of GB/T 25085 specifies the dimensions and requirements for single-core copper conductor cables intended for general purpose vehicle applications where the nominal system voltage is less than or equal to 30 V a.c. or less than or equal to 60 V d.c.
This part is applicable to single-core cables for road vehicles, and also to the cores of multi-core cables.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 19642-1 Road vehicles - Automotive cables - Part 1: Vocabulary and design guidelines
ISO 19642-2: 2019 Road vehicles - Automotive cables - Part 2: Test methods
EN 13602 Copper and copper alloys - Drawn, round copper wire for the manufacture of electrical conductors
ASTM B1 Standard specification for hard drawn copper wire
ASTM B3 Standard specification for soft or annealed copper wire
ASTM B33 Standard specification for tin coated soft or annealed copper wire for electrical purposes
ASTM B298 Standard specification for silver coated soft or annealed copper wire
ASTM B355 Standard specification for nickel coated soft or annealed copper wire
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 19642-1 apply.
4 General requirements
4.1 General test conditions
The test shall be carried out according to Table 2 under the test conditions specified in ISO 19642-2.
If suppliers and customers agree upon modifications or changes to the methods and requirements, all the changes and modifications shall be clearly documented.
4.2 Safety concerns
The use of this part can involve hazardous materials, operations and equipment. This part does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this part to establish appropriate safety practices and determine the applicability of regulatory limitations prior to use.
4.3 Voltage range
The cable described in this part is limited to 30 V a.c. and 60 V d.c. maximum.
4.4 Temperature classes
All temperature classes in ISO 19642-1 are suitable for this part.
4.5 Conductor material
The conductors shall consist of plain or coated copper strands as shown in Table 1.
Conductor sizes greater than or equal to 0.5 mm2 shall consist of soft annealed copper or annealed compressed wires.
Conductor sizes less than 0.5 mm2 shall consist of soft annealed copper, soft annealed compressed copper, hard un-annealed copper or a copper alloy.
The specifications for the conductors shall be completed by material specifications. Elongation requirements shall be established by agreement between the customer and the supplier.
The finished cable shall meet the resistance and cross-sectional area (CSA) requirements of Table 6 for all conductors except alloys. When an alloy is used, the resistance requirement shall be established by agreement between the customer and the supplier.
Note: Examples for strands are shown in Annex A.
Table 1 Conductor specifications
Conductor type Standard number
Hard-drawn copper wire ASTM B1
Soft or annealed copper wire ASTM B3 or EN 13602
Tinned soft or annealed copper wire ASTM B33 or EN 13602
Silver-coated soft or annealed copper wire ASTM B298
Nickel-coated soft or annealed copper wire ASTM B355
Notes:
1 Silver and Nickel coated conductors are intended for use with high “temperature class ratings”.
2 Those specified in GB/T 3953-2009, GB/T 4910-2009, GB/T 11019-2009 and JB/T 3135-2011 may also referred to for various types of conductor materials.
4.6 Conductors
The conductors in the finished cable shall meet the CSA and resistance requirements of Table 6.
The maximum diameter of the conductors is standardized and presented in Table 7.
The configuration of the stranded conductor is not standardized.
Notes:
1 Existing stranding configurations for copper conductors are presented in Table A.1.
2 Preferred stranding configurations for copper conductors are presented in Table A.2.
Other stranding configurations may be used for copper conductors provided they meet the above requirements and are agreed between the customer and the supplier.
4.7 Insulation thickness
The following three different insulation thicknesses are allowed in this part:
a) thick wall insulation;
b) thin wall insulation;
c) ultra-thin wall insulation.
The minimum wall thickness requirements for the different conductor sizes are standardized and specified in Table 7.
The nominal wall thickness is derived by Equation (1):
(1)
where,
Wmin——the minimum wall thickness, mm;
Wnom——the nominal wall thickness, mm,
4.8 Cable outside diameter
The cable outside diameter for each conductor size and insulation thickness is standardized and specified in Table 7.
4.9 Representative conductor sizes for testing
When a test is required, all combinations of conductor size, insulation thickness and insulation formulation shall meet the specified requirements.
However, if testing of representative conductor sizes is permitted by agreement between the customer and the supplier, compliance for a cable family may be demonstrated by testing examples of large and small conductor sizes only.
4.10 Test items and requirements
Table 2 provides a list of all relevant tests in ISO 19642-2:2019 for single core cables.
Table 2 Test items
Test items
(Serial numbers of items are consistent with those in ISO 19642-2:2019) Mandatory If required c
In process a Initial certification Periodic b Initial certification Periodic b
5.1 Dimensional tests
5.1.2 Cable outside diameter - √ √ - -
5.1.3 Insulation thickness - √ √ - -
5.1.4 Conductor diameter - - - √ √
5.1.5 Cross sectional area - - - √ √
5.1.6 In‑process cable outside diameter √ - - - -
5.2 Electrical tests
5.2.1 Conductor resistance - √ √ - -
5.2.2 Determination of temperature coefficients - √ - - -
5.2.3 Withstand voltage - √ √ - -
5.2.4 Withstand voltage after environmental testing d - - - - -
5.2.5 Insulation faults √ - - - -
5.2.6 Insulation volume resistivity - - - √ √
5.3 Mechanical tests
5.3.1 Strip force - - - √ √
5.3.2 Abrasion e
5.3.2.4 Sandpaper abrasion test - √ √ - -
5.3.2.5 Scrape abrasion test - √ √ - -
5.3.3 Breaking force of the finished cable - - - √ -
5.3.4 Cyclic bending - - - √ -
5.3.5 Flexibility - - - √ -
5.4 Environmental tests
5.4.1 Specimen preparation and winding tests d
5.4.2 Long term heat ageing, 3,000 h at temperature class rating - √ - - -
5.4.3 Short term heat ageing, 240 h at temperature class rating +25℃ - √ √ - -
5.4.4 Thermal overload, 6 h at temperature class rating +50℃ - - - √ √
5.4.5 Pressure test at high temperature - √ √ - -
5.4.6 Shrinkage by heat - √ √ - -
5.4.7 Low temperature winding - √ √ - -
5.4.8 Cold impact - - - √ √
5.4.9 Temperature and humidity cycling f - - - √ -
5.4.10 Resistance to hot water f - √ - - -
5.4.11 Resistance to liquid chemicals f,g - √ - √ -
5.4.12 Durability of cable marking f - - - √ √
5.4.13 Stress cracking resistance f - - - √ -
5.4.14 Resistance to ozone f - - - √ -
5.4.15 Resistance to flame propagation - √ √ - -
Notes:
1 “√”: Test shall be performed according to ISO 19642-2.
2 “-”: Test is not required.
3 See Annex NA for the type and specification of product.
a A test made on the entire cable lot during or after manufacture.
b The frequency of periodic testing shall be established by agreement between the customer and the supplier.
c The usage of "If required” tests shall be established by agreement between the customer and the supplier.
d These tests are only used in preparation and after environmental endurance tests.
e Only one of the abrasion tests has to be performed by agreement between the customer and the supplier.
f Compliance for a cable family may be demonstrated by testing examples of large and small conductor sizes only.
g Some fluids are for “Initial certification” and others are “If required”
5 Technical requirements
5.1 General
The cables shall be tested per ISO 19642-2 according to their temperature class rating.
The cables shall be tested as specified in Table 2.
Foreword i
1 Scope
2 Normative references
3 Terms and definitions
4 General requirements
4.1 General test conditions
4.2 Safety concerns
4.3 Voltage range
4.4 Temperature classes
4.5 Conductor material
4.6 Conductors
4.7 Insulation thickness
4.8 Cable outside diameter
4.9 Representative conductor sizes for testing
4.10 Test items and requirements
5 Technical requirements
5.1 General
5.2 Dimensional tests
5.3 Electrical tests
5.4 Mechanical tests
5.5 Environmental tests
Annex A (informative) Conductor sizes, number of strands and strand diameters
Annex NA (informative) Product model list
Bibliography
