GB/T 25085.9-2026Road vehicles - Automotive cables - Part 9: 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. round, sheathed, screened or unscreened multi or single core copper 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 1.

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

Rated voltage shall be determined by the rated value of 600 V A.C. or 900 V D.C. and 1000 V

A.C. or 1500 V D.C. of the wire core.

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

4.4 Temperature grade

Rated temperature grades are determined by the rated temperatures of all wire core and the sheath.

The rated value of cable shall be equal to the minimum rated values of a single wire core and sheath.

For detailed information on temperature grade, see GB/T 25085.1-2024.

4.5 Conductor material

The conductor materials shall meet the requirements of ISO 19642-5.

4.6 Conductors

The conductors of each wire core in multi-core or single-core shall meet the requirements of

ISO 19642-5.

4.7 Sheath thickness

This Document allows to take two different sheath thicknesses.

--- Thick-wall sheath;

--- Thin-wall sheath.

The insulation wall thickness of each wire core in single core or multi core shall meet the requirements of ISO 19642-5.

4.8 Outer diameter of wire core

The maximum and minimum outer diameters of each wire cores in the multi-core or single- core shall be as required in ISO 19642-5.

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

Other manufacturing processes (such as stranding, braiding, and sheath extrusion) in multi-core cables can affect the performance of the wire core in the finished cable. Therefore, the dimensions of the used wire core and the maximum conductor resistance shall meet the requirements of ISO 19642-5, with the following supplementary information.

Minimum wall thickness can follow the design guidelines in A.4 of GB/T 25085.1-2024.

Maximum resistance of wire core can follow the design guidelines in A.5 of GB/T 25085.1-

2024.

The maximum conductor resistance value and the minimum wall thickness of the insulation layer should be recorded in the supplier's datasheet and used as a basis for evaluation.

Preferred structural dimensions for round, sheathed, shielded or unshielded, multi-core or single-core copper conductor cables are given in Tables A.1 ~ A.6 of Appendix A.

It is not feasible to provide a complete definition for all possible multi-core cables. In addition to the preferred structure, other structural designs can be performed using the calculation rules in Appendix A of GB/T 25085.1-2024.

The diameter before the sheath can be calculated according to A.3 of GB/T 25085.1-2024.

The wall thickness of the sheath and padding layer can be calculated according to A.6 of GB/T

25085.1-2024.

The maximum and minimum outer diameter of the cable can be calculated according to A.9 of

GB/T 25085.1-2024.

All cable dimensions should be recorded in the supplier's datasheet and used as a basis for evaluation.

Table 1 lists all relevant tests for round, sheathed, shielded or unshielded, multi-core or single- core cables in GB/T 25085.2-2024.

6.1 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 1.

6.2 Dimensional inspection

6.2.1 Outer diameter and inner layer diameter of cable

If applicable, measure the following parameters.

--- Outer diameter of the stranded cable core;

--- Outer diameter of the padding layer;

--- Outer diameter of the braid;

--- Outer diameter of the wrapping tape;

--- Outer diameter of the sheath.

Dimensions shall be within the range agreed upon by both the supplier and the purchaser.

6.2.2 Sheath ovality

Ovality shall be less than 10%, measured immediately after extrusion.

NOTE. Ovality may vary after processing due to mechanical deformation.

6.2.3 Sheath thickness

Sheath thickness shall be within the range agreed upon by both the supplier and the purchaser.

Measurements should not include the inner padding layer (padding layer).

6.2.4 Outer diameter of cable during manufacturing process

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

All measured values for outer diameter of cable during manufacturing process shall be within the specified limits.

6.3 Electrical performance test

6.3.1 Electrical continuity

The indicator shall show continuity.

6.3.2 Withstand voltage inspection of finished product

This test shall be performed directly on the entire cable length and on specimens that have undergone environmental test after production.

Apply 2 kV A.C. voltage to the end of the specimen for at least 3 s; no breakdown shall occur between the wire cores.

If shielding is present, no breakdown shall occur between the wire core and the shielding.

6.3.3 Shielding effectiveness

6.3.3.1 General

These tests apply only to shielded cables. The application of these tests shall be determined through negotiation between the supplier and the purchaser.

6.3.3.2 Shielding D.C. resistor

The requirements for this test shall be determined through negotiation between the supplier and the purchaser.

6.3.3.3 Surface transfer impedance - triaxial method

The requirements for this test shall be determined through negotiation between the supplier and the purchaser.

6.3.3.4 Shielding attenuation - absorption clamp method

The requirements for this test shall be determined through negotiation between the supplier and the purchaser.

6.3.3.5 Shielding attenuation - triaxial method

The requirements for this test shall be determined through negotiation between the supplier and the purchaser.

6.3.4 Sheath defect of shielded cable

A continuous 3 kV A.C. voltage shall be applied.

The sheath shall not break down.

6.4 Mechanical property test

6.4.1 Peeling force of sheath

The intact, unaffected portion of the sheath shall be removable without damaging the shield (if any) and the internal wire core.

The requirements for this test shall be determined through negotiation between the supplier and the purchaser.

......