SIST EN ISO 8092-2:2001

SLOVENSKI STANDARD
SIST EN ISO 8092-2:2001
01-junij-2001
Road vehicles - Connections for on-board electrical wiring harnesses - Part 2:
Definitions, test methods and general performance requirements (ISO 8092-2:1996)
Road vehicles - Connections for on-board electrical wiring harnesses - Part 2:
Definitions, test methods and general performance requirements (ISO 8092-2:1996)
Straßenfahrzeuge - Steckverbindungen für das elektrische Fahrzeug- Bordnetz - Teil 2:
Begriffe, Prüfungen und allgmeine Anforderungen (ISO 8092-2:1996)
Véhicules routiers - Connexions pour faisceaux de câblage électrique embarqués -
Partie 2: Définitions, méthodes d'essai et exigences générales (ISO 8092-2:1996)
Ta slovenski standard je istoveten z: EN ISO 8092-2:1998
ICS:
43.040.10 (OHNWULþQDLQHOHNWURQVND Electrical and electronic
RSUHPD equipment
SIST EN ISO 8092-2:2001 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN ISO 8092-2:2001

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SIST EN ISO 8092-2:2001

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SIST EN ISO 8092-2:2001

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SIST EN ISO 8092-2:2001
INTERNATIONAL
STANDARD
Second edition
1996-02-01
Road vehicles - Connections for on-board
electrical wiring harnesses -
Part 2:
Definitions, test methods and general
Performance requirements
lkhicules routiers - Connexions pour faisceaux de cablage 6lectrique
embarques -
Partie 2: D6finitions, methodes d ’essai et exigences g&&ales
Reference number
ISO 8092-2:1996(E)

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SIST EN ISO 8092-2:2001
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. Esch 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.
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.
International Standard ISO 8092-2 was prepared by Technical Committee
lSO/TC 22, ßoad vehicles, Subcommittee SC 3, ElectricaI and electronie
equipmen t.
This second edition cancels and replaces the first edition
(ISO 8092-2:1988), of which it constitutes a technical revision.
ISO 8092 consists of the following Parts, under the general title ßoad ve-
hicles - Connections for on-board electrical wiring harnesses:
- Part 7: Tabs for single-pole connections - Dimensions and specific
requiremen ts
- Part 2: Definitions, test methods and general Performance require-
men ts
m ult;-pole connections - Dimensions
- Part 3: Tabs for and sp ecific
requiremen ts
- Part 4: Pins for Single- and m ult/pole connections -
Dimensions
and specific requiremen ts
0 ISO 1996
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced
or utilized in any form or by any means, electronie or mechanical, including photocopying and
microfilm, without Permission in writing from the publisher.
International Organization for Standardization
Case Postale 56 l CH-l 211 Geneve 20 l Switzerland
Printed in Switzerland
ii

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SIST EN ISO 8092-2:2001
INTERNATIONAL STANDARD 0 ISO ISO 8092-2: 1996(E)
- Connections for on-board electrical
Road vehicles
wiring harnesses -
Part 2:
Definitions, test methods and general Performance
requirements
ISO 6722-4:1993, ßoad vehicles - Unscreened low-
1 Scope
tension cables - Part 4: Conductor sizes and dimen-
sions for thin-wall insulated cables.
This part of ISO 8092 gives definitions, and specifies
test methods and general Performance requirements
ISO 9227:1990, Corrosion tests in artificial atmos-
for Single-pole and multi-pole connections for on-
pheres - Salt Spray tests.
board electrical wiring harnesses of road vehicles. lt
applies to connectors designed to be disconnected
I EC 50 (581): 1978, International Electrotechnical Vo-
after mounting in the vehicle for the purposes of re-
cabulary - Chapter 581: Electromechanical compo-
pair and/or maintenance only. ISO 8092 does not
nen ts for electronie equipmen t.
cover one-part connections, i.e. where one part of the
connection has direct contact to the Pattern of the
IEC 529:1989, Degrees of protection by enclosures
printed circuit board. The requirements are not in-
(IP Code).
tended for connections internal to electronie devices.
3 Definitions
For the purposes of all Parts of ISO 8092, the defi-
2 Normative references
nitions in IEC 50, chapter 581, and the following defi-
nitions apply.
The following Standards contain provisions which,
through reference in this text, constitute provisions
3.1 male contact: Electrical contact which tan be
of this part of ISO 8092. At the time of publication, the
pushed into a female contact forming an electric con-
editions indicated were valid. All Standards are subject
nection. (See figure 1.)
to revision, and Parties to agreements based on this
part of ISO 8092 are encouraged to investigate the
EXAM PLES
possibility of applying the most recent editions of the
Standards indicated below. Members of IEC and ISO
tab
maintain registers of currently valid International
Standards.
pin
ISO 6722-3:1993, ßoad vehicles - Unscreened low-
blade
tension cables - Part 3: Conductor sizes and dimen-
sions for thick-wall insulated cables.
1

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SIST EN ISO 8092-2:2001
ISO 8092-2: 1996(E)
CabCe seal
Reference Point
(discre te)
a) Gable-to-cable connection
-
b) Connection to apparatus
Gable attachment
Gable 2~
Male contact
Figure 1 -
c) Connection to printed circuit board
3.2 female contact: Electrical contact which re-
ceives the male contact forming an electric con-
nection. (See figure 2.)
d) Connection to printed circuit board
(horizontal type)
EXAMPLES
receptacle
Figure 3 - Typical examples of connections
sleeve
socket
Gable seal
4 Test procedures and Performance
Reference Point
(discre te)
requirements
4.1 General
4.1 .l Test methods, general specifications
L
Cable
Gable attachment
All test procedures shall be carried out at an ambient
Female contact
Figure 2 -
temperature of (23 + 5) “C and a relative humidity
between 45 % and 75 %, unless otherwise stated.
Esch test sequence (see table 1) shall be started with
3.3 positive locking female contact: Female con-
unused test samples manufactured to conform to the
tact with automatic positive locking and manual un-
dimensions specified in the applicable part of
locking device engaging a hole or dimple in the male
ISO 8092. Female contacts which have a locking de-
contact.
vice shall be tested with male contacts with hole or
dimple to permit locking.
3.4 detent: Raised Portion of the female contact
which engages a hole or dimple in the male contact
Contacts (where applicable) shall be fixed to the cable
thus providing a latch for the mating Parts.
with a crimping tool used in accordance with the
manufacturer ’s recommendations.
3.5 reference Point: Specially identified Point used
when making electric test measurements. (See fig-
Cables shall be in accordance with ISO 6722-3 or
Ures 1, 2, 6 and 7.)
ISO 6722-4, and the cable(s) used shall be noted in
the test report.
36 connection: Two mated connectors or contacts.
(See figure 3 for examples.) Care shall be taken that test samples do not influence
each other, for example in the heat chamber.
37 multi-pole connection: Two mated connectors
NOTE 1 The total number of samples is not specified.
With more than one contact pair. (See figure4.)

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SIST EN ISO 8092-2:2001
ISO 8092-2: 1996(E)
Contacts or
Housing Housing
terminaLs
\
\
t
t 1
t
1 1
Female contact or terminal (receptacle, sleeve, socket)
Male contact or terminal (Pin, blade, tab)
Housing seal
Housing
Multiple cable seal Discrete cable seal
- H ’H -
Conductor -
(Male) connector
Gable
. ,
(Fernale) tonnector
Connect on
Figure 4 - Multi-pole connectors/connections
20 test samples in the case of Single-pole con-
4.1.2 General Performance requirements
nectors;
Connectors and/or contacts that allow connections for
multiple positions shall meet the requirements in all 10 test samples in the case of 2-pole connectors;
intended positions.
7 test samples in the case of 3-pole connectors;
4.1.3 Test sequences
5 test samples in the case of 4-pole connectors.
For each test Sample group in table 1, a test sequence
is indicated by Xs from top to bottom. A minimum of 20 contacts of each type shall be
tested in the case of connectors with mixed types of
For unsealed connectors, apply tests as in the test
contacts.
Sample groups A, B, C, D, E, F, H, 1.
All test samples shall be used for all tests in a test
NOTE 2 Test Sample group G is for sealed connectors
Sample group.
and splash-proof connectors only.
Esch connector shall have the full complement of
For sealed connectors and splash-proof connectors,
contacts fitted, unless otherwise specified in the test
apply tests as in the test Sample groups A, B, C, D,
method.
E, G, H, 1.
Measurements shall be taken on a minimum of four
NOTE 3 Test Sample group F is for unsealed connectors
contacts per connector unless otherwise specified in
only.
the test methods. For l-, 2-, and 3-pole connectors,
all contacts shall be measured.
Esch test Sample group shall contain at least
3

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SIST EN ISO 8092-2:2001
ISO 8092-2: 1996(E)
Table 1 - Test sequences and Performance requirements
Test Test Sample group Performance
requirements
Title Subclause A B C D E F G H I
subclause
I
X X X
Visual examination 4.2.1 X X X X X X 4.2.2
Tensile strength of cable at-
4.4.1
X 4.4.2
tachment
Contact insertion 4.6.1 X
4.6.2
4.7.1 X
Contact retention 4.7.2
First insertion of connector 4.3.1 X 4.3.2
Connection resistance at milli-
4.8.1 X X
X X X 4.8.2
volt level and specified current
First disconnection to 10th
4.3.1 X 4.3.2
connection of connector
Current cycling 4.17.1 X
4.17.2
Insulation resistance 4.12.1 X X 4.12.2
Dielectric strength 4.13.1 X X
4.13.2
Temperaturelhumidity 4.10.1
X 4.10.2
Vibration 4.11.1 X
4.11.2
Ageing 4.18.1
X 4.18.2
Watertightness 4.9.1 X 4.9.2
Temperature rise 4.14.1 X
4.14.2
Polarizing 4.15.1
X 4.15.2
Connection resistance at milli-
4.8.1 X X X
4.8.2
volt level and specified current
Locking device strength 4.5.1 X
4.5.2
v
4.12.1
Insulation resistance z X 4.12.2
I e
Dielectric strength 4.13.1 x X x
4.13.2
4.16.1
Salt Spray X 4.16.2
Connection resistance at milli-
4.8.1 X X
4.8.2
volt level and specified current
Visual examination 4.2.1 X X X X X X X X X
4.2.2
NOTE - The arrows between the Xs indicate that the subsequent test shall be performed without interruption.
I
I

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SIST EN ISO 8092-2:2001
ISO 8092-2: 1996(E)
0 ISO
Use a rate for connection and disconnection of a
4.2 Visual examination
50 mm/min
constant Speed between and
150 mm/min. The applied Speed shall be noted in the
4.2.1 Test method
test report.
Carry out the visual examination with the naked eye,
Subject the connectors to test 4.3.1 .l or 4.3.1.2 as
at normal strength of Vision and normal colour per-
appropriate.
ception, at the most favourable viewing distance, and
with suitable illumination.
4.2.2 Performance
4.3.1 .l Female contacts (without positive
locking)
Visual examination as detailed in 4.2.1 shall allow
identification, appearance, workmanship and finish of
Subject the connector to 10 connections and discon-
the item to be checked against the relevant specifi-
nections. Measure the forte necessary at
cation.
If the connector has a cable insulation support, the
first connection;
insulation grip shall not tut through the insulation and
first disconnection;
shall firmly enclose the cable.
Both insulation and the cable conductor shall be vis-
10th disconnection.
ible between the conductor crimp and the insulation
support on the male and female contacts, as shown
in figure 5, except for insulation displacement con-
4.3.1.2 Positive locking female contacts
nections.
Conductors shall protrude from the conductor attach-
Perform 11 cycles of connection and disconnection
ment but shall not interfere with the mating part. All
as follows.
wire Strands shall be enclosed by the conductor at-
tachment. There shall be no damaged wire Strand(s).
Perform the first 10 cycles operating the locking de-
vice at each cycle in accordance with the manufac-
During visual examination, after tests as in the test
turer ’s instruction and normal use.
Sample groups A to 1, special care shall be taken to
ensure that as a minimum requirement no cracking,
Measure the forte necessary at
discoloration, deformation, and no water ingress (for
test Sample group G only), is in evidente.
first connection;
first disconnection;
4.3 Connection and disconnection
10th disconnection.
4.3.1 Test method
Perform the 1 Ith cycle with the locking device en-
Perform connection and disconnection of connectors
gaged for the locking device strength test as in
as intended or as specified in the particular product
4.5.1.2.
specification.
Conductor and insulation
I Insulation support
shall be visible
Conductor crimp
Figure 5 - Conductor and insulation crimp
5

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SIST EN ISO 8092-2:2001
0 ISO
ISO 8092-2: 1996(E)
NOTE 4 Other types of cable attachment are under con-
4.3.2 Performance requirements
sideration.
Connectors for Single-pole connections, tested as in
4.3.1, shall conform to the requirements specified in
4.5 Lscking dewice strength
the applicable part of ISO 8092.
The purpose of this test is to check the ability of
In the case of connectors for multi-pole connections,
locked connectors to withstand a specific and static
the connection and disconnection forces, tested as in
actual load. Subject connectors for Single- and multi-
4.3.1, shall be as in the particular specification sf the
pole connections to the test in 4.5.1 .l or 4.5.1.2 as
user or supplier, or of the applicable patt of ISO 8092.
appropriate.
4.4 Tensile strength of cable attachment
4.5.1 Test method
4.4.1 Test method 4.5.1.1 Connectors for Single- and multi-pole
connections with locking dewices integral with
Test the tensile strength of the cable attachment by
housing (without positive Bocking femaie
using suitable test apparatus at a constant Speed
contacts)
within the range of 50 mm/min to 150 mm/min. The
applied Speed shall be noted in the test report.
Carry out the procedure:
ca ble(s)
Atta ch each test sa mple to the corresponding
a) with empty connectors; and
as s pecif ied by the connector manufacturer.
b) with the full complement of contacts fitted.
If the connector has a cable insulation support, it shall
be rendered mechanically ineffective. Make a fixture which tan be secured to the connec-
tors to be tested. The securing of this shall not distort
When more than one cable is attached, apply the
either of the connectors during testing. Mount the
forte specified in table 2 to each cable by using sep-
housing on the fixture(s) with the locking device en-
arate samples.
gaged. Apply the forte to the fixture in the discon-
nection direction and hold it constant for (IO ‘z) s.
4.4.2 Performance requirements
4.5.1.2 Connectors for Single- and multi-pole
The tensile strength of the crimped connection,
connections with positive locking
...