GB/T 25085.3-2020Road vehicles--Automotive cables - Part 3: Dimensions and requirements for 30 V a. c. or 60 V d. c. single-core copper conductor cables (English PDF)

4.1 General test conditions

Should be tested in accordance with the provisions of Table 2 under the test conditions specified in ISO 19642-2.

If both parties agree to modify or change the test methods and requirements, all changes and modifications shall be recorded.

4.2 Safety precautions

The use of this section may involve hazardous materials, operations and equipment. This section is not intended to address possible problems related to the use of this section

All security issues. Users of this section are responsible for formulating appropriate safety regulations and determining the applicability of legal restrictions before use.

4.3 Voltage range

The upper limit of the cable voltage in this section is AC 30V and DC 60V.

4.4 Temperature class

This part is implemented in accordance with all temperature classes in ISO 19642-1.

4.5 Conductor material

The conductor shall be made of stranded copper wires of bare copper or plated copper as shown in Table 1.

The conductor with a size greater than or equal to 0.5mm2 shall be composed of annealed soft copper wire or annealed compressed copper wire.

The conductor with a specification less than 0.5mm2 should be composed of annealed soft copper wire, annealed soft compressed copper wire, non-annealed hard copper wire or copper alloy wire.

The specific requirements of the conductor should meet the requirements of the material used. The elongation rate is determined through negotiation between the supplier and the buyer.

For all conductors except alloys, the resistance and cross-sectional area (CSA) of the finished cable should meet the requirements of Table 6.When using alloy guide

The resistance requirements should be negotiated between the supplier and the buyer.

Note. See Appendix A for examples of twisted structures.

Table 1 Conductor description

Conductor type standard number

Hard drawn copper wire ASTMB1

Soft or annealed copper wire ASTMB3 or EN13602

Tinned soft or annealed copper wire ASTMB33 or EN13602

Silver-plated soft or annealed copper wire ASTMB298

Nickel-plated soft or annealed copper wire ASTMB355

Note 1.Silver-plated or nickel-plated copper wire is used in cables with high "rated temperature class".

Note 2.Various types of conductor materials can also refer to GB/T 3953-2009, GB/T 4910-2009, GB/T 11019-2009, JB/T 3135-2011.

4.6 Conductor

The conductor of the finished cable should meet the requirements of CSA and resistance in Table 6.

The maximum diameter of the conductor should meet the requirements of Table 7.

The stranded structure of the conductor is not a normative requirement.

Note 1.For the existing stranded structure of copper conductors, see Table A.1.

Note 2.The recommended stranded structure of copper conductors is shown in Table A.2.

Other twisted structures shall be negotiated between the supplier and the buyer, but shall comply with the above-mentioned regulations.

4.7 Insulation thickness

This section specifies the following three different insulation thicknesses.

a) Thick-walled insulation;

b) Thin wall insulation;

c) Ultra-thin wall insulation.

The minimum wall thickness of different conductor specifications should meet the requirements of Table 7.

The nominal wall thickness is calculated according to formula (1).

Wnom=1.25xW min or Wnom=

W min

0.8

(1)

Where.

W min---minimum wall thickness, in millimeters (mm);

Wnom---nominal wall thickness, in millimeters (mm).

4.8 Cable outer diameter

The outer diameter of each conductor specification and insulation thickness of the cable should meet the requirements of Table 7.

4.9 Representative conductor specifications for testing

When a test is required, all combinations of conductor specifications, insulation thickness and insulation materials should meet the corresponding regulations.

However, when the supplier and the buyer negotiate to allow testing of representative specifications, only the larger and smaller conductor specifications can be tested to prove the cable

The conformity of the family.

4.10 Test items and requirements

Refer to Table 2 for relevant test items applicable to single-core cables in ISO 19642-2.2019.

Table 2 Test items

Pilot projects

(The project number is consistent with ISO 19642-2.2019)

Mandatory test, select test c

Process a First certification cycle b First certification cycle b

5.1 Dimension check

5.1.2 Cable outer diameter-sqrt sqrt--

5.1.3 Insulation thickness-sqrt sqrt--

5.1.4 Conductor diameter---sqrt sqrt

5.1.5 Cross-sectional area---sqrt sqrt

5.1.6 Cable outer diameter during manufacturing sqrt----

5.2 Electrical performance test

5.2.1 Conductor resistance-sqrt sqrt--

5.2.2 Temperature coefficient test-sqrt---

5.2.3 Withstand voltage-sqrt sqrt--

5.2.4 Withstand voltage d after environmental test-----

5.2.5 Insulation defect sqrt----

5.2.6 Insulation volume resistivity---sqrt sqrt

5.3 Mechanical performance test

5.3.1 Peeling force---sqrt sqrt

5.3.2 Wear resistance

Table 2 (continued)

Pilot projects

(The project number is consistent with ISO 19642-2.2019)

Mandatory test, select test c

Process a First certification cycle b First certification cycle b

5.3.2.4 Drag test-sqrt sqrt--

5.3.2.5 Scraping test-sqrt sqrt--

5.3.3 Finished cable breaking force---sqrt-

5.3.4 Cyclic bending---sqrt-

5.3.5 Flexibility---sqrt-

5.4 Environmental test

5.4.1 Sample preparation and winding test d

5.4.2 3000h long-term thermal aging under rated temperature class-sqrt---

5.4.3 Rated temperature class plus 240h short-term thermal aging at 25 degrees C-sqrt sqrt--

5.4.4 Rated temperature class plus 6h thermal overload at 50 degrees C---sqrt sqrt

5.4.5 High temperature pressure test-sqrt sqrt--

5.4.6 Thermal shrinkage-sqrt sqrt--

5.4.7 Low temperature winding-sqrt sqrt--

5.4.8 Cold shock---sqrt sqrt

5.4.9 Alternating temperature and humidity f---sqrt-

5.4.10 Hot water f-sqrt---

5.4.11 Resistance to liquid chemicals f,g-sqrt-sqrt-

5.4.12 Cable marking durability f---sqrt sqrt

5.4.13 Stress crack resistance f---sqrt-

5.4.14 Ozone resistance f---sqrt-

5.4.15 Anti-flammability-sqrt sqrt--

Note 1."sqrt" means the test items complying with ISO 19642-2.

Note 2."-" means test items that do not need to be tested.

Note 3.Please refer to Appendix NA for product model and specification range.

a Test items for the entire batch of cables during or after manufacturing.

b The frequency of the periodic test should be negotiated between the supplier and the buyer.

c The use of "optional test" shall be determined through negotiation between the supplier and the buyer.

d This test item is only used after sample preparation and environmental durability test.

e Only one abrasion test shall be carried out after negotiation between the supplier and the buyer.

f The compliance of the cable family can be proved by testing only the large and small conductor specifications.

g Some liquids are used for "first identification", and the rest are used for "optional tests".

5.1 General

The cable shall be tested according to ISO 19642-2 according to its rated temperature class.

The cable should be tested in accordance with Table 2.

5.2 Dimension check

5.2.1 Cable outer diameter

The measured value of the cable outer diameter shall be within the limits specified in Table 7.

5.2.2 Insulation thickness

The measured value of the insulation thickness shall not be less than the minimum value specified in Table 7.

5.2.3 Conductor diameter

The measured conductor diameter should not be greater than the maximum value specified in Table 7.

5.2.4 Cross-sectional area (CSA)

The measured values of the cross-sectional area shall be within the limits specified in Table 6.

5.2.5 Cable outer diameter during manufacturing

The outer diameter of the cable shall be continuously monitored during the manufacturing process.

The measured value of the outer diameter of the cable during the manufacturing process should be within the limits specified in Table 7.

5.3 Electrical performance test

5.3.1 Conductor resistance

The measured value of conductor resistance should not be greater than the maximum value specified in Table 6.

5.3.2 Requirements for temperature coefficient measurement

For pure copper, alpharho=3.93x10-3K-1.

For copper alloys, alpharho should be determined in accordance with 5.2.2 of ISO 19642-2.2019.

5.3.3 Withstand voltage

Apply a voltage of 1kV and apply for 30 minutes, and the insulation should not be broken down.

Note. No need to climb voltage.

5.3.4 Withstand voltage after environmental test

Apply a voltage of 1kV, apply for 1min, and the insulation should not be broken down.

5.3.5 Insulation defect

Continuous application of AC 3kV voltage, insulation should not be broken down.

5.3.6 Insulation volume resistivity

Insulation volume resistivity should not be less than 1x109ohm.mm.

5.4 Mechanical performance test

5.4.1 Peel force

The measuring force should be within the negotiated value range between the supplier and the buyer.

5.4.2 Wear resistance

5.4.2.1 General

The test is only applicable to cables with conductor specifications not greater than 6mm2, and either drag or scrape test should be performed.

Both the supplier and the demander should clarify which test to use.

Cables with a conductor size greater than 6mm2 need not be subjected to abrasion test.

5.4.2.2 Drag test

The cable sample shall be tested after adding a heavy object according to the requirements of Table 3.

The average value of 4 readings of the cable sample should not be less than the specified value in Table 3.

Table 3 Dragging test requirements

Conductor specification

mm2

Thick wall thin wall ultra thin wall

Additional weight a

kg

Minimum belt length

mm

Additional weight a

kg

Minimum belt length

mm

Additional weight a

kg

Minimum belt length

mm

0.13

0.22

0.35

--0.1

0.05

0.5

0.75

1.25

1.5

0.5

0.2

0.1

2.5

1.5

0.5

0.2 125

--

Note. "-" means that the cable type does not exist.

a The vertical force exerted on the sample should be the sum of the force exerted by the bracket, the rotating arm, the support rod and the additional weight.

5.4.2.3 Scraping test

The cable sample shall be subjected to the total vertical force as specified in Table 4.

The minimum number of cycles should not be less than the specified value in Table 4.

Table 4 Scratch test requirements

Conductor specification

mm2

0.13 0.22 0.35 0.5 0.75 1 1.25 1.5 2 2.5 3 4 5 6

Vertical force

4.00 7.00

deviation

+/-0.05

Minimum number of cycles 100 125 150 300 350 400 400 450 500 550 600 700 700 700

5.4.3 Breaking force of finished cable

The cable specification and breaking force to be tested shall be negotiated between the supplier and the buyer.

5.4.4 Loop bending

The test is only applicable to cables with conductor sizes not greater than 25mm2.

The requirements of the test shall be negotiated between the supplier and the buyer.

5.4.5 Flexibility test

The test is applicable to cables with conductor specifications not less than 8mm2.

The requirements of the test shall be negotiated between the supplier and the buyer.

5.5 Environmental test

5.5.1 Sample preparation and winding test

ISO 19642-2.2019 5.4.1 specifies the size of the mandrel used to prepare the sample in the environmental test.

It also specifies the requirements for winding tests to detect defects caused by environmental stress.

5.5.2 3000h long-term thermal aging at rated temperature level

The sample should be aged for 3000h at the upper limit temperature of the rated temperature class.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.3 Rated temperature class plus 240h short-term thermal aging at 25 degrees C

The sample should be aged for 240h at the upper limit temperature of the rated temperature class plus 25 degrees C.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.4 Rated temperature class plus 6h thermal overload at 50 degrees C

The sample should be aged for 6h at the upper limit temperature of the rated temperature class plus 50 degrees C.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.5 High temperature pressure test

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.6 Heat shrink

The maximum shrinkage at either end of the specimen should not exceed 2mm.

5.5.7 Low temperature winding

The sample should be placed at the lower limit temperature of the rated temperature class for 4h.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.8 Cold shock

The sample should be tested in accordance with the weight required in Table 5.

After the sample is impacted, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

Table 5 Cold shock test requirements

Conductor specification (a)

mm2

Weight

Thick wall thin wall ultra thin wall

a<=0.35

0.35 \u003ca<=2.5

2.5 \u003ca<=4

5.5.9 Alternating temperature and humidity

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.10 Hot water

Connect the sample conductor to the "" pole and the copper electrode to the "-" pole for testing.

Use a new sample, change the polarity and re-test.

For both samples, the insulation volume resistivity should not be less than 1x109ohm.mm.

Visually inspect the insulation for cracks.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation should not be broken down.

5.5.11 Resistant to liquid chemicals

The sample is wound after being impregnated with liquid chemicals, and the conductor should not be exposed after winding.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.12 Cable mark durability

All cable markings should be kept clear.

5.5.13 Stress crack resistance

The test is applied to the use of insulating materials that are susceptible to environmental stress cracking problems (such as FEP and ETFE, and the conductor size is less than

For cables of 6mm2), whether to carry out the test is negotiated by both parties.

After the sample is tested, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.14 Ozone resistance

After the sample is tested, visually check that there should be no cracks on the insulating surface.

5.5.15 Anti-flammability

Any burning flame on the insulating material should be extinguished within 30s after ignition, and the insulation at least 50mm on the top of the sample should be maintained

Unburned.

All 5 samples should pass the test.

Table 6 CSA and conductor resistance

conductor

specification

mm2

CSA

mm2

Maximum conductor resistance at 20 degrees C

mohm/m

Maximum a Minimum bare copper or silver-plated copper tin-plated copper nickel-plated copper

0.13 0.137 0.127 136 140 142

0.22 0.220 0.203 84.8 86.5 87.9

0.35 0.345 0.317 54.4 55.5 56.8

0.50 0.502 0.465 37.1 38.2 38.6

0.75 0.754 0.698 24.7 25.4 25.7

1 1.01 0.932 18.5 19.1 19.3

1.25 1.25 1.16 14.9 15.9 16.0

1.5 1.47 1.36 12.7 13.0 13.2

2 1.98 1.83 9.42 9.69 9.82

2.5 2.45 2.27 7.60 7.82 7.92

Table 6 (continued)

conductor

specification

mm2

CSA

mm2

Maximum conductor resistance at 20 degrees C

mohm/m

Maximum a Minimum bare copper or silver-plated copper tin-plated copper nickel-plated copper

3 3.03 2.80 6.15 6.36 6.41

4 3.95 3.66 4.71 4.85 4.91

5 4.73 4.38 3.94 4.02 4.11

6 5.93 5.49 3.14 3.23 3.27

8 7.82 7.24 2.38 2.52 2.60

10 10.2 9.47 1.82 1.85 1.90

12 12.3 11.3 1.52 1.60 1.66

16 16.1 14.9 1.16 1.18 1.21

20 19.5 18.1 0.955 0.999 1.03

25 25.1 23.2 0.743 0.757 0.774

30 28.8 26.6 0.647 0.684 0.706

35 35.3 32.7 0.527 0.538 0.549

40 39.4 36.5 0.473 0.500 0.516

50 50.6 46.9 0.368 0.375 0.383

60 59.1 54.7 0.315 0.333 0.344

70 71.9 66.6 0.259 0.264 0.270

85 85.0 78.7 0.219 0.225 0.228

95 95.0 88.0 0.196 0.200 0.204

120 122 113 0.153 0.156 0.159

a Maximum CSA allows other target values. However, the target value of the maximum CSA should be negotiated between the supplier and the buyer.

Table 7 Cable size requirements

conductor

specification

mm2

conductor

Outer diameter

mm

Max a

Thick wall thin wall ultra thin wall

Insulation thickness

mm

Cable outer diameter

mm

Insulation thickness

mm

Cable outer diameter

mm

Insulation thickness

mm

Cable outer diameter

mm

Min b max a min c min b max a min c min b max a min c

0.13 0.55 0.20 1.05 0.95 0.16 0.95 0.85

0.22 0.70---0.20 1.20 1.10 0.16 1.05 0.95

0.35 0.90 0.20 1.40 1.20 0.16 1.20 1.10

0.50 1.10 0.48 2.30 2.00 0.22 1.60 1.40 0.16 1.40 1.30

0.75 1.30 0.48 2.50 2.20 0.24 1.90 1.70 0.16 1.60 1.45

1 1.50 0.48 2.70 2.40 0.24 2.10 1.90 0.16 1.75 1.55

Table 7 (continued)

conductor

specification

mm2

conductor

Outer diameter

mm

Max a

Thick wall thin wall ultra thin wall

Insulation thickness

mm

Cable outer diameter

mm

Insulation thickness

mm

Cable outer diameter

mm

Insulation thickness

mm

Cable outer diameter

mm

Min b max a min c min b max a min c min b max a min c

1.25 1.70 0.48 2.95 2.40 0.24 2.30 2.10 0.16 2.00 1.70

1.5 1.80 0.48 3.00 2.70 0.24 2.40 2.20 0.16 2.10 1.90

2 2.00 0.48 3.30 3.00 0.28 2.80 2.50 0.20 2.40 2.20

2.5 2.20 0.56 3.60 3.30 0.28 3.00 2.70 0.20 2.70 2.50

3 2.40 0.56 4.10 3.80 0.32 3.40 3.10

4 2.80 0.64 4.40 4.00 0.32 3.70 3.40

5 3.10 0.64 4.90 4.50 0.32 4.20 3.90

6 3.40 0.64 5.00 4.60 0.32 4.30 4.00

8 4.30 0.64 5.90 5.00 0.32 5.00 4.60

10 4.50 0.8 6.50 5.90 0.48 6.00 5.30

12 5.40 0.8 7.40 6.60 0.48 6.50 5.80

16 6.30 0.8 8.30 7.70 0.52 7.20 6.40

20 6.90 0.88 9.10 8.10 0.52 7.80 7.00

25 7.80 1.04 10.40 9.40 0.52 8.70 7.90

30 8.30 1.04 10.90 9.70 0.64 9.60 8.70

35 9.00 1.04 11.60 9.60 0.64 10.40 9.40

40 9.60 1.12 12.40 11.20 0.71 11.10 10.00

50 10.50 1.2 13.50 11.50 0.71 12.20 11.00

60 11.60 1.2 14.60 13.40 0.80 13.30 12.00

70 12.50 1.2 15.50 13.50 0.80 14.40 13.00

85 13.60 1.28 16.80 14.80 0.90 15.80 14.40

95 14.80 1.28 18.00 16.00 0.90 16.70 15.30

120 16.50 1.28 19.70 17.70---

Note. "-" means that the cable type does not exist.

a The maximum cable outer diameter listed in the table is the specified value for stranded conductors. Negotiation between the supplier and the demander, allowing multiple twisting and other twisting methods to have a different maximum

Conductor diameter. This difference may affect the size of the cable outer diameter in the table.

b The nominal insulation thickness Wnom is calculated according to the following formula.

Wnom =1.25xWmin or Wnom =

Wmin

0.8

Where.

Wmin---Minimum wall thickness, in millimeters (mm);

Wnom---nominal wall thickness, in millimeters (mm).

c For compressed conductors, the minimum cable outer diameter is not assessed.

Appendix A

(Informative appendix)

Conductor specifications, number of filaments and diameter of filaments

A.1 Conductor---existing stranded structure

...

......