SIST EN ISO 8092-2:2004

SLOVENSKI STANDARD
SIST EN ISO 8092-2:2004
01-september-2004
&HVWQDYR]LOD3ULNOMXþNL]DHOHNWULþQRRSUHPRYJUDMHQLQDDUPDWXULYR]LODGHO
'HILQLFLMHSUHVNXVQHPHWRGHLQVSORãQH]DKWHYDQHODVWQRVWL,62
Road vehicles - Connections for on-board electrical wiring harnesses - Part 2:
Definitions, test methods and general performance requirements (ISO 8092-2:2000)
Straßenfahrzeuge - Steckverbindungen für das elektrische Fahrzeug-Bordnetz - Teil 2:
Begriffe, Prüfungen und allgemeine Anforderungen (ISO 8092-2:2000)
Véhicules routiers - Connexions pour faisceaux de câblage électrique embarqués -
Partie 2: Définitions, méthodes d'essai et exigences générales (ISO 8092-2:2000)
Ta slovenski standard je istoveten z: EN ISO 8092-2:2001
ICS:
43.040.10 (OHNWULþQDLQHOHNWURQVND Electrical and electronic
RSUHPD equipment
SIST EN ISO 8092-2:2004 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN ISO 8092-2:2004

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SIST EN ISO 8092-2:2004
EUROPEAN STANDARD
EN ISO 8092-2
NORME EUROPÉENNE
EUROPÄISCHE NORM
December 2001
ICS 43.040.10 Supersedes EN 28092-2:1998
English version
Road vehicles - Connections for on-board electrical wiring
harnesses - Part 2: Definitions, test methods and general
performance requirements (ISO 8092-2:2000)
Véhicules routiers - Connexions pour faisceaux de câblage Straßenfahrzeuge - Steckverbindungen für das elektrische
électrique embarqués - Partie 2: Définitions, méthodes Fahrzeug-Bordnetz - Teil 2: Begriffe, Prüfungen und
d'essai et exigences générales (ISO 8092-2:2000) allgemeine Anforderungen (ISO 8092-2:2000)
This European Standard was approved by CEN on 17 November 2001.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2001 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 8092-2:2001 E
worldwide for CEN national Members.

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SIST EN ISO 8092-2:2004
EN ISO 8092-2:2001 (E)
CORRECTED  2002-11-14
Foreword
The text of ISO 8092-2:2000 has been prepared by Technical Committee ISO/TC 22 "Road
vehicles" of the International Organization for Standardization (ISO) and has been taken over as
EN ISO 8092-2:2001 by CMC.
This European Standard shall be given the status of a national standard, either by publication of
an identical text or by endorsement, at the latest by June 2002, and conflicting national
standards shall be withdrawn at the latest by June 2002.
This document supersedes EN 28092-2:1998.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of
the following countries are bound to implement this European Standard: Austria, Belgium, Czech
Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg,
Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom.
Endorsement notice
The text of ISO 8092-2:2000 has been approved by CEN as EN ISO 8092-2:2001 without any
modifications.
2

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SIST EN ISO 8092-2:2004
INTERNATIONAL ISO
STANDARD 8092-2
Third edition
2000-12-15
Corrected and reprinted
2002-01-15
Road vehicles — Connections for on-board
electrical wiring harnesses —
Part 2:
Definitions, test methods and general
performance requirements
Véhicules routiers — Connexions pour faisceaux de câblage électrique
embarqués —
Partie 2: Définitions, méthodes d'essai et exigences générales
Reference number
ISO 8092-2:2000(E)
©
ISO 2000

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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
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ii © ISO 2000 – All rights reserved

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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Contents Page
Foreword.iv
1 Scope .1
2 Normative references .1
3 Terms and definitions .2
4 Tests and requirements .5
4.1 General.5
4.2 Visual examination .7
4.3 Connection and disconnection .7
4.4 Tensile strength of conductor-to-contact attachment.8
4.5 Locking device strength .8
4.6 Contact insertion force .9
4.7 Contact retention in housing.10
4.8 Connection resistance (voltage drop) .10
4.9 Influence of water .11
4.10 Temperature/humidity cycling.15
4.11 Combined temperature and vibration.17
4.12 Insulation resistance .19
4.13 Withstand voltage.19
4.14 Temperature rise.20
4.15 Connector coding and polarization .21
4.16 Salt spray.21
4.17 Current cycling.21
4.18 Thermal ageing .22
4.19 Mechanical shock .22
4.20 Drop.22
4.21 Dust .23
4.22 Rapid change of temperature (thermal shock).24
4.23 Chemical fluids .24
4.24 Flowing gas corrosion .25
Annex A (informative) Flowing single-gas corrosion test.26
Annex B (informative) Cable attachment by insulation-displacement connection (IDC) — Tensile
strength test .28
Bibliography.30
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO
member bodies). The work of preparing International Standards is normally carried out through ISO technical
committees. Each member body interested in a subject for which a technical committee has been established has
the right to be represented on that committee. International organizations, governmental and non-governmental, in
liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical
Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 3.
Draft International Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this part of ISO 8092 may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
International Standard ISO 8092-2 was prepared by Technical Committee ISO/TC 22, Road vehicles,
Subcommittee SC 3, Electrical and electronic equipment.
This third edition cancels and replaces the second edition (ISO 8092-2:1996), which has been technically revised.
ISO 8092 consists of the following parts, under the general title Road vehicles — Connections for on-board
electrical wiring harnesses:
— Part 1: Tabs for single-pole connections — Dimensions and specific requirements
— Part 2: Definitions, test methods and general performance requirements
— Part 3: Tabs for multi-pole connections — Dimensions and specific requirements
— Part 4: Pins for single- and multi-pole connections — Dimensions and specific requirements
Annexes A and B of this part of ISO 8092 are for information only.
iv © ISO 2000 – All rights reserved

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SIST EN ISO 8092-2:2004
INTERNATIONAL STANDARD ISO 8092-2:2000(E)
Road vehicles — Connections for on-board electrical wiring
harnesses —
Part 2:
Definitions, test methods and general performance requirements
1 Scope
This part of ISO 8092 defines terms and specifies test methods and general performance requirements for single-
and multi-pole connections used with on-board electrical wiring harnesses in road vehicles.
This part of ISO 8092 is applicable to connectors designed to be disconnected after mounting in the vehicle for
repair and maintenance only. It does not cover one-part connections, i.e. where one part of the connection has
direct contact with the pattern of the printed circuit board.
This part of ISO 8092 is not applicable to the internal connections of electronic devices.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute provisions of
this part of ISO 8092. For dated references, subsequent amendments to, or revisions of, any of these publications
do not apply. However, parties to agreements based on this part of ISO 8092 are encouraged to investigate the
possibility of applying the most recent editions of the normative documents indicated below. For undated
references, the latest edition of the normative document referred to applies. Members of ISO and IEC maintain
registers of currently valid International Standards.
ISO 1817, Rubber, vulcanized — Determination of the effect of liquids.
ISO 6722-3, Road vehicles — Unscreened low-tension cables — Part 3: Conductor sizes and dimensions for thick-
wall insulated cables.
ISO 6722-4, Road vehicles — Unscreened low-tension cables — Part 4: Conductor sizes and dimensions for thin-
wall insulated cables.
ISO 7309, Road vehicles — Hydraulic braking systems — ISO reference petroleum base fluid.
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests.
IEC 60050-581, International Electrotechnical Vocabulary — Electromechanical components for electronic
equipment.
IEC 60068-2-27, Environmental testing — Part 2: Tests — Test Ea and guidance: Shock.
IEC 60512-11-7, Electromechanical components for electronic equipment — Basic testing procedures and
measuring methods — Part 11: Climatic tests — Section 7: Test 11 g: Flowing mixed gas corrosion test.
IEC 60529, Degrees of protection provided by enclosures (IP code).
SAE J311b, Fluid for passenger car type automatic transmissions.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
3 Terms and definitions
For the purposes of this part of ISO 8092, the terms and definitions given in IEC 60050-581 and the following
apply.
3.1
connection
two mated connectors or contacts
See Figure 1 for examples.
a) Cable-to-cable connection
b) Connection to apparatus
c) Connection to printed circuit board (vertical type)
d) Connection to printed circuit board (horizontal type)
Figure 1 — Typical examples of connections
3.2
connector
assembly of contact and housing that terminates conductors for the purpose of providing connection and
disconnection to a suitable mating connector
3.3
contact
conductive element in a connector (including means for cable attachment) that mates with a corresponding element
toprovideanelectricalpath
3.4
contact area
area in contact between two mated contacts that provides an electrical path
3.5
male contact
contact (including means for cable attachment) designed for electrical engagement on its outer surface and to enter
a female contact, thus forming an electrical connection
EXAMPLES Tab, pin, blade.
SeeFigure2.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Dimensions in millimetres
Key
1 Conductor crimp
2 Reference point
3 Cable
4 Cable attachment
5 Insulation support / sealing grip
6 Cable attachment by insulation displacement
Figure 2 — Male contact
3.6
female contact
contact (including means for cable attachment) designed for electrical engagement on its inner surface, and to
accept the entry of a male contact, thus forming an electrical connection
EXAMPLES Receptacle, sleeve.
SeeFigure3.
3.7
positive-locking female contact
female contact with automatic positive-locking and manual unlocking device engaging a hole or dimple in the male
contact
3.8
cable attachment
any permanent joining of cable to contact
EXAMPLES Crimp, insulation displacement, welding, screwing.
3.9
detent
raised portion of the female contact that engages a hole or dimple in the male contact thus providing a latch for the
mated parts
3.10
reference point
point 2 mm away from the rear-most edge of a male or female contact used for measuring the connection
resistance (voltage drop)
See Figures 2 and 3, and 4.8.
3.11
multi-pole connection
two mated connectors with more than one contact pair
SeeFigure4.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Dimensions in millimetres
Key
1 Conductor crimp
2 Reference point
3 Cable
4 Cable attachment
5 Insulation support / sealing grip
6 Cable attachment by insulation displacement
Figure 3 — Female contact
Key
1 Multiple cable seal 6 Housing seal
2 Male contact 7 Connector
3 Female contact 8 Connection
4 Single cable seal 9 Cable
5 Housing 10 Conductor
Figure 4 — Multi-pole connectors/connection
3.12
connector polarization
device or connector shape preventing connection in any but the manner specified
4 © ISO 2000 – All rights reserved

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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
3.13
connector coding
device, either visual, mechanical or sensitive, or combination of these, preventing connection of connectors from
the same family and having the same number of contacts, but with different coding
4 Tests and requirements
4.1 General
4.1.1 Preconditioning
All test samples shall be preconditioned at (23� 5) °C and 45 % to 75 % relative humidity for 24 h before the start
of any test sequence.
4.1.2 Test conditions
All tests shall be carried out at an ambient temperature of (23� 5) °C, unless otherwise stated in the test plan.
Each test sequence (see Table 1) shall be started with unused test samples manufactured to conform to the
dimensions specified in the applicable part of ISO 8092.
Contacts with a locking device shall be tested with adequate counterparts to permit locking.
Cables shall be in conformance with ISO 6722-3 or ISO 6722-4, and the cable or cables used shall be noted in the
test report.
Cable attachment shall be performed in accordance with the contact manufacturer’s recommendations.
Care shall be taken so that test samples do not influence each other (e.g. in a heat chamber).
Each connector shall have the full complement of contacts fitted, unless otherwise specified by the test method.
Measurements shall be taken on a minimum of four contacts per connector, unless otherwise specified in the test
method. For 1-, 2- and 3-pole connectors, all contacts shall be measured.
During the entire test sequence, lubrication or other means of attaining better test results shall not be added to the
test surface. However, production-related remains of lubricants on the contacts are permitted.
4.1.3 Multiple-position connections
Connectors or contacts that allow connections for multiple positions shall meet the requirements of this part of
ISO 8092 in all intended positions.
4.1.4 Test sequences
The test sequence for each sample group shall be in accordance with Table 1 (sequences are indicated by Xs,
ordered from top to bottom). Also given in the same table is the applicability of test sequences to sealed or
unsealed connectors.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Table 1 — Test sequences and requirements
a
Test Requirement
Test sample group /sequence
ABC D E F G H I K L M N
Unsealed connectors Subclause X X X X X X X X X X X Subclause
Sealedconnectors XXX XX XX XX XX
Visualexamination 4.2.1 XXX XX XX XX XX XX 4.2.2
Contact insertion 4.6.1 X 4.6.2
Contact retention in housing 4.7.1 X 4.7.2
Tensile strength of conductor-to-
4.4.1 X 4.4.2
contact attachment
Connector coding and
4.15.1 X 4.15.2
polarization
First connection 4.3.1 X 4.3.2
Connection resistance (voltage
4.8.1 X X X X X X X 4.8.2
drop)
1st connection to 10th
4.3.1 X 4.3.2
disconnection
Current cycling 4.17.1 X 4.17.2
Insulation resistance 4.12.1 X X 4.12.2
Withstand voltage 4.13.1 X X 4.13.2
Temperature/humidity cycling 4.10.1 X 4.10.2
Combined temperature and
4.11.1 X 4.11.2
vibration
Thermal ageing 4.18.1 X 4.18.2
Chemical fluids 4.23.2 X X 4.23.3
Temperature rise 4.14.1 X 4.14.2
Mechanical shock 4.19.2 X 4.19.3
Connection resistance (voltage
4.8.1 X X X 4.8.2
drop)
Locking device strength 4.5.2 X X X 4.5.3
Contact retention in housing 4.7.1 X 4.7.2
b
Water tightness 4.9.1.1 4.9.2.1
X
b
Insulation resistance 4.12.1 X X 4.12.2
X
b
High pressure water jet 4.9.1.2 X 4.9.2.2
X
Insulation resistance 4.12.1 X 4.12.2
Withstand voltage 4.13.1 X X X 4.13.2
Rapid change of temperature 4.22.1 X 4.22.2
Salt spray 4.16.1 X 4.16.2
Flowing gas corrosion 4.24.1 X 4.24.2
Connection resistance (voltage
4.8.1 X X X X X 4.8.2
drop)
Drop 4.20.1 X X 4.20.2
Dust 4.21.1 X 4.21.2
Visualexamination 4.2.1 XXX XX XX XX XX XX 4.2.2
a
See 4.1.4 and 4.1.5.
b
The subsequent test shall be performed within 1 h of the test indicated.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
4.1.5 Number of test samples
Each test sample group shall contain a minimum of
� 20 test samples in the case of single-pole connectors,
� 10 test samples in the case of 2-pole connectors,
� 7 test samples in the case of 3-pole connectors, or
� 5 test samples in the case of 4-pole connectors.
Moreover, no less than 20 contacts of each type shall be tested.
Unless otherwise specified, all test samples shall be used for all tests in a test sample group.
4.1.6 Material
The test report shall provide detailed information on the material used for the connectors.
4.2 Visual examination
4.2.1 Test
Carry out a visual examination of all connectors and contacts with the naked eye, at normal strength of vision and
colour perception, at the most favourable viewing distance, and with suitable illumination.
4.2.2 Requirements
Identification, appearance, workmanship and the finish of each item shall be as specified.
For crimped cable attachments, both insulation and the conductor shall be visible between the conductor crimp and
the insulation support on the male and female contacts, as shown in Figure 5. Conductors shall protrude from the
conductor crimp but shall not interfere with the mating part. All wire strands shall be enclosed by the conductor
crimp. There shall be no damaged wire strands.
For other types of cable attachment, no visible damage is allowed.
During visual examination of the connectors, for all test sample groups, special care shall be taken to ensure, as a
minimum requirement, that no cracking, discoloration, deformation or — where applicable — ingress of water is in
evidence.
4.3 Connection and disconnection
4.3.1 Test
Perform connection and disconnection as specified by the connector manufacturer at a constant speed between
25 mm/min and 100 mm/min. Note the speed applied in the test report.
Subject the connector to 10 connections and disconnections. Measure the force necessary at the first connection
and the first and tenth disconnection.
For positive-locking female connectors perform an eleventh cycle with the locking device engaged for the locking
device strength test as in 4.5.2.2.
4.3.2 Requirement
The contacts, tested according to 4.3.1, shall conform to the requirements specified in the applicable part of
ISO 8092. In the case of multi-pole connections, the connection and disconnection forces, determined in 4.3.1,
shall be as in the particular specification.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
Key
1 Conductor end
2Wirestrand
3 Conductor crimp
4 Conductor and insulation
5 Insulation support
a
Conductor end shall be visible.
b
Conductor and insulation shall be visible.
Figure 5 — Conductor crimp and insulation support
4.4 Tensile strength of conductor-to-contact attachment
4.4.1 Test
Test the tensile strength of the conductor-to-contact attachment using suitable test apparatus operated at a
constant speed within the range 25 mm/min to 100 mm/min. Note the speed applied in the test report.
Attach each test sample to the corresponding cable or cables as specified by the connector manufacturer.
If the contact has a crimped cable attachment, render the cable insulation support mechanically ineffective. Perform
the test with contacts alone. When more than one cable is attached, apply the force according to Table 2 to each
cable by using separate samples.
In the case of cable attachment by insulation displacement, the test may be performed with the contacts located in
the housing (see annex B).
NOTE Other types of cable attachment are under consideration [for insulation displacement connections (IDC), see
annex B].
4.4.2 Requirement
The tensile strength of the conductor crimp, tested according to 4.4.1, shall withstand the minimum values specified
in Table 2.
4.5 Locking device strength
4.5.1 Purpose
The purpose of the test is to check the ability of locked connectors to withstand a specific static load. Connectors
for single- and multi-pole connections shall be tested according to 4.5.2.1 or 4.5.2.2, as appropriate.
4.5.2 Test
4.5.2.1 For single-pole and multi-pole connectors with integral-housing locking devices and without a positive
locking female contact, carry out the following test procedure.
8 © ISO 2000 – All rights reserved

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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
With empty connector housings, and with the full complement of contacts fitted, make a fixture or fixtures that can
be secured to the connectors being tested, and whose securing shall not distort either connector during the testing.
�2
Mount the housing on the fixture or fixtures with the locking device engaged. Apply a test force of (100 ) N to the
0
�2
fixture in the disconnection direction and hold it constant for (10 )s.
0
Table 2 — Minimum tensile strength of conductor crimps
Nominal cross-sectional area of cable Minimum tensile strength
2
mm N
0,22 40
0,35 50
0,5 70
0,75 90
1 115
1,5 155
2 195
2,5 235
3 260
4 320
5 360
6 400
10 600
The minimum tensile strength of conductor crimp for cables with non-specified
nominal cross-sectional area shall be determined by interpolation.
4.5.2.2 For positive-locking female contacts and single-pole and multi-pole connectors with positive-locking
�2
female contacts, after the 11th connection as specified in 4.3.1, apply a test force of (100 ) N to the test sample
0
�2
with the locking device engaged in the disconnection direction and hold constant for (10 )s.
0
4.5.3 Requirement
The locking device of connectors for multi-pole connections, tested according to 4.5.2, shall withstand the test
force.
4.6 Contact insertion force
4.6.1 Test
Test the insertion force of the contact into the cavity by using the minimum- and maximum-sized cable that can be
attached, placing it in the insertion direction via a test fixture, and positioning it as close as possible to the cable
attachment. Take care that the contact under test is locked as intended.
Use a constant speed between 25 mm/min and 100 mm/min for insertion. The applied speed shall be noted in the
test report.
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SIST EN ISO 8092-2:2004
ISO 8092-2:2000(E)
4.6.2 Requirements
The contact insertion force, tested according to 4.6.1, shall be a maximum of 15 N for contacts with cables attached
2
that have a nominal cross-sectional areau1mm .
NOTE It is intended to change these values for the next revision of this part of ISO 8092.
For contacts with cables of larger nominal cross-sectional
...