GB/T 25085.6-2026Road vehicles - Automotive cables - Part 6: Dimensions and requirements for 600 V a. c. or 900 V d. c. and 1 000 V a. c. or 1 500 V d. c. single core aluminum conductor cables (English PDF)

4.1 General test conditions

The test conditions of GB/T 25085.2-2024 shall be applied.

Cables shall be tested according to the provisions of Table 3.

If the supplier and purchaser agree to modify or change the test methods and requirements, all changes and modifications shall be clearly recorded.

4.2 Safety precautions

The precautions described in the “WARNING” at the beginning of this Document shall be followed.

4.3 Voltage range

The upper limit of rated voltage of the cables described in this Document is as follows.

--- Maximum 600 V A.C. or 900 V D.C.;

--- Maximum 1000 V A.C. or 1500 V D.C.

NOTE. Appendix B contains cable color identification information for determining the rated voltage values in this Document.

4.4 Temperature grade

Table 1 defines the temperature grade applicable to aluminum conductor cables.

Table 1 – Rated temperature grade

4.5 Conductor material

The conductor shall consist of annealed or annealed compressed stranded wires of aluminum or aluminum alloy. The requirements for individual conductor wire shall conform to the provisions of Table 2 and be completed according to the material specifications. Elongation requirements shall be determined through negotiation between the supplier and the purchaser.

All conductors in the finished cable shall meet the resistance requirements in Table 11.

The wire of the aluminum conductor shall be made of 1000 series aluminum or other alloys as specified in EN 573-1.The chemical composition shall conform to the provisions of Table 1 in

EN 573-3.2013.

NOTE. Examples of conductor stranding structures are shown in Appendix A.

Table 2 -- Characteristics of annealed wire

4.6 Conductors

The conductors of finished cables shall conform to the provisions for cross-sectional area (CSA) and resistance in Table 11.

The maximum diameter of the conductor shall conform to the provisions of Table 12.

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

NOTE 1.Existing stranding structures for aluminum conductors are shown in Table A.1.

NOTE 2.Recommended stranding structures for aluminum conductors are shown in Table A.2.

Other stranding structures that meet the above requirements and are determined through negotiation between the supplier and the purchaser may be used for aluminum conductors.

4.7 Insulation thickness

This Document specifies the following two different insulation thicknesses.

--- Thick-wall insulation;

--- Thin-wall insulation.

The minimum wall thickness for different conductor specifications shall conform to the provisions of Table 12.

The nominal wall thickness is calculated from the minimum wall thickness in Table 12 using the following Formula.

Where.

or

Wmin – minimum wall thickness, in mm;

Wnom – nominal wall thickness, in mm.

4.8 Outer diameter of cable

The outer diameter of the cable for each conductor specification and insulation thickness shall conform to the provisions of Table 12.

4.9 Representative conductor specification for testing

When a test is required, all combinations of conductor specifications, insulation thickness, and insulation materials shall conform to the relevant provisions.

However, when the supplier and purchaser agree that testing of a representative specification is permitted, only the larger and smaller conductor specifications may be tested to demonstrate the conformity of the cable family.

4.10 Test items and requirements according to GB/T 25085.2-2024

Table 3 lists all relevant tests for single-core copper conductor [Translator Note. Here it shall be aluminum conductor] cables in GB/T 25085.2-2024.

5.1 General requirements

Cables shall be tested by their rated temperature grade according to GB/T 25085.2-2024.

Cables shall be tested according to the provisions of Table 3.

5.2 Dimension inspection

5.2.1 Outer diameter of cable

The measured values for the outer diameter of cable shall be neither greater than nor less than the standard values specified in Table 12.

5.2.2 Insulation thickness

The measured values of the insulation thickness shall be no less than the minimum values specified in Table 12.

5.2.3 Conductor diameter

The measured values of the conductor diameter shall be no greater than the maximum values specified in Table 12.

5.2.4 Cross-sectional area (CSA)

The measured values of the cross-sectional area shall be neither greater than nor less than the standard values specified in Table 11.

5.2.5 Outer diameter of cable during manufacturing process

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

The measured cable for the outer diameter of cable during manufacturing process shall be within the standard values specified in Table 12.

5.3 Electrical performance test

5.3.1 Conductor resistance

The measured value for the conductor resistance shall not exceed the maximum value specified in Table 11.

5.3.2 Determination requirements of temperature coefficient

For pure aluminum, alpharho = 4.03 × 10^-³ 1/K.

For aluminum alloys, alpharho should be measured according to the provisions of 5.3.2 in GB/T

25085.2-2024.

5.3.3 Withstand voltage

Apply the voltage specified in Table 4; the insulation shall not break down within the specified time.

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