BS-ISO-6856-2005.pdf

BRITISH STANDARD BS ISO 6856:2005 Road vehicles Unscreened high-voltage ignition cable assemblies Test methods and general requirements ICS 43.060.50 ? Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS ISO 6856:2005 This British Standard was published under the authority of the Standards Policy and Strategy Committee on 10 June 2005 © BSI 10 June 2005 ISBN 0 580 45937 3 National foreword This British Standard reproduces verbatim ISO 6856:2005 and implements it as the UK national standard. The UK participation in its preparation was entrusted to Technical Committee MCE/9, Ignition Equipment For Spark Ignition Engines, which has the responsibility to: A list of organizations represented on this committee can be obtained on request to its secretary. Cross-references The British Standards which implement international publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep UK interests informed; monitor related international and European developments and promulgate them in the UK. Summary of pages This document comprises a front cover, an inside front cover, the ISO title page, pages ii to iii, a blank page, pages 1 to 11 and a back cover. The BSI copyright notice displayed in this document indicates when the document was last issued. Amendments issued since publication Amd. No. DateComments Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI Reference number ISO 6856:2005(E) INTERNATIONAL STANDARD ISO 6856 Third edition 2005-02-15 Road vehicles Unscreened high-voltage ignition cable assemblies Test methods and general requirements Véhicules routiers Assemblages de câbles d'allumage haute tension non blindés Méthodes d'essai et exigences générales BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI ii BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI iii 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 2. The main task of technical committees is to prepare International Standards. 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 document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights. ISO 6856 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 1, Ignition equipment. This third edition cancels and replaces the second edition (ISO 6856:1990), which has been technically revised. BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI blank BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 1 Road vehicles Unscreened high-voltage ignition cable assemblies Test methods and general requirements 1 Scope This International Standard specifies test methods and general requirements for unscreened high-voltage ignition cable assemblies, and is applicable to all such assemblies used in road vehicle applications. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 9227, Corrosion tests in artificial atmospheres Salt spray tests ISO 3808-2, Road vehicles Unscreened high-tension ignition cables Part 2: Cable classes, types, applicable tests and special requirements 3 Test methods 3.1 General 3.1.1 Preconditioning Precondition all test samples at (23 ? 5) ?C and at 10 % to 75 % relative humidity for 24 h before starting any test sequence. 3.1.2 General test conditions All tests shall be carried out at an ambient temperature of (23 ? 5) ?C, unless otherwise specified. Each test sequence shall be started with unused test samples. Cables shall be in accordance with ISO 3808-2, and the cable(s) used shall be noted in the test report. Cable attachment shall be performed in accordance with customer requirements and/or industry specification. During the whole test sequence, no lubrication or other additional means on the contact surface making possible better test results shall be permitted. Production-related remains of lubricants on the contacts are allowed. BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 2 3.1.3 Visual examination 3.1.3.1 Test Carry out visual examination with the naked eye, corrected, if necessary, to give normal strength of vision and normal colour perception, at the most favourable viewing distance and with suitable illumination. 3.1.3.2 Requirements Visual examination in accordance with 3.1.3.1 shall allow identification, appearance, workmanship and finish of the item to be checked against the relevant specification. During visual examination, special care shall be taken to ensure that as a minimum requirement no cracking, significant discoloration, deformation or (where applicable) ingress of water is in evidence. 3.2 Insertion and removal forces of high-voltage connectors 3.2.1 General The insertion and removal forces shall be measured at an ambient temperature of (23 ? 5) ?C, using a gauge as shown in Figure 1, 2, 3 or 4 dependant on the high-voltage connector type. The gauge and the connector to be measured shall be dry and clean. Insertion and removal forces shall be the forces between the high-voltage terminal of the ignition coils, the distributors or the spark-plugs and the cable connector. Any other force from covers or boots shall not be taken into account. Perform ten insertions and removals. 3.2.2 Insertion force The insertion force shall be measured at the first insertion. Maximum value: 80 N 3.2.3 Removal force 3.2.3.1 Test The removal force measurement shall be carried out by using a suitable test apparatus at a constant test speed of 100 mm/min or 200 mm/min or 500 mm/min. The exact speed used shall be agreed between customer and supplier and recorded in the test report. The removal force shall be measured at the tenth removal. 3.2.3.2 Requirements Maximum value: 70 N Minimum value: 20 N BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 3 Dimensions in millimetres Surface roughness values in micrometres The gauge shall be of hardened steel. NOTE The tolerances given for the gauge dimensions also include wear tolerances. Dimensions A and D are the most critical. a Tangential slope from diameter A to radius D. b Tangential slope from radius D to radius F. The value of F is implicitly determined by the values of dimensions A, B, C, D and E. Figure 1 Gauge for measurement of insertion and removal forces of high-voltage connectors Socket type high-voltage connection for ignition coils and distributors BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 4 Dimensions in millimetres Surface roughness values in micrometres The gauge shall be of hardened steel. The tolerances given for the gauge dimensions also include wear tolerances. Dimension (6,4 mm ? 0,005 mm) and angle 15 1 0 ?° are the most critical. Figure 2 Gauge for measurement of insertion and removal forces of high-voltage connectors Spark-plugs with solid-post terminals, and ignition coils and distributors with plug-type high-voltage connections BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 5 Dimensions in millimetres The gauge shall be of hardened steel. The tolerances given for the gauge dimensions also include wear tolerances. Figure 3 Gauge for measurement of insertion and removal forces of high-voltage connectors Ignition coils and distributors (5 mm cable type) Dimensions in millimetres The gauge shall be of hardened steel. The tolerance given for the outside diameter of the gauge threaded part also includes wear tolerance. a Outside diameter. Figure 4 Gauge for measurement of insertion and removal forces of high-voltage connectors Spark-plugs with threaded terminals BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 6 3.3 Separation forces of cables from connector 3.3.1 Test Place the cable assembly in a hot air oven with natural draught and expose it to the test temperature for 1 h in accordance with Table 1. Table 1 Test temperatures for separation forces Cable classes according to ISO 3808 Test temperature ?C A, B 70 C, D, E, F 90 As soon as possible (1 min max.) after removing the specimen from the oven, or in the oven itself if the apparatus permits, measure the separation force using a suitable test apparatus at a constant test speed of 100 mm/min, 200 mm/min or 500 mm/min. The exact speed used shall be agreed between customer and supplier and recorded in the test report. 3.3.2 Requirements There shall be neither mechanical separation nor electrical interruption between the cable and the connector until the force is at least 10 N above the first measured removal force. Whether any change of ohmic resistance in the case of suppression cables may be permitted following the test is to be agreed between customer and supplier. 3.4 Electrical insulation tests 3.4.1 General The two following tests 3.4.2 and 3.4.3 are intended to be carried out alternatively. Either may be chosen according to the intention of the user; there is no need to perform both tests with one sample. 3.4.2 Sealing test (in NaCl/water solution) 3.4.2.1 Arrangement of samples Fit the samples with test cable(s) and connect them to the corresponding part(s) in accordance with the application. Do not disconnect the connections at any time during the entire test. 3.4.2.2 Preconditioning of the samples Preconditioning causes any trapped air to escape, producing a tight seat between the connecting parts. Expose the samples to 20 temperature shocks of (+ 90 ? 2) °C to (? 20 ? 2) °C. Then test the entire arrangement in accordance with Figure 5 in a 3 % NaCl/water solution. The ends of the sealing parts shall be a minimum of 2 mm below the surface of the liquid. BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 7 3.4.2.3 High-voltage pulses Apply pulses in accordance with the following specifications. Voltage rise time (0,1 to 0,9) Usec: (80 ? 25) s at 150 pF. Pulse width (0,1 Usec): (290 ? 85) s at 150 pF. 3.4.2.4 Test conditions Pulse rate: 50 Hz or 60 Hz. Test duration: 24 h. Voltage: see Table 2. Start of test: immediately after immersion of the sample in the liquid. Table 2 Voltage classes and peak voltages Voltage class a b c d e f Peak voltage kV ? 1,0 kV 13 16 19 22 26 31 3.4.2.5 Requirement During the entire test no spark-over or breakdown is permitted. 3.4.3 Breakdown test 3.4.3.1 Arrangement of the samples Fit the samples with test cable(s) and connect them to the corresponding part(s) in accordance with the application. Do not disconnect the connections at any time during the entire test. 3.4.3.2 Preconditioning of samples Preconditioning causes any trapped air to escape, producing a tight seat between the connecting parts. Expose the samples to 20 temperature shocks of (+ 90 ? 2) ?C to (? 20 ? 2) ?C. Then test the entire arrangement in steel balls in accordance with Figure 5. 3.4.3.3 High-voltage pulses Apply pulses in accordance with the following specifications. Voltage rise time (0,1 to 0,9) Usec: (80 ? 25) s at 150 pF. Pulse width (0,1 Usec): (290 ? 85) s at 150 pF. 3.4.3.4 Test conditions Pulse rate: 50 Hz or 60 Hz. Test duration: 1 h. Voltage: see Table 3. BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 8 Table 3 Voltage classes and peak voltages Voltage class a b c d e f Peak voltage kV ? 1,0 kV 19 22 25 28 31 35 3.4.3.5 Requirement During the entire test no spark-over or breakdown is permitted. Dimensions in millimetres Key 1 high-voltage pulse generator 2 high-voltage ignition cable 3 NaCl/water solution according to 3.4.2 or steel balls ? ? 3 mm according to 3.4.3 4 electrode (grounded) 5 high-voltage terminal (as agreed between vehicle and equipment manufacturers) (e.g. distributor, ignition coil) 6 spark-plug insulator 7 transparent container 8 high-voltage probe 1:1 000 9 oscilloscope Figure 5 Electrical insulation test set-up BS ISO 6856:2005 Licensed Copy: sheffieldun sheffieldun, na, Sun Nov 26 14:15:33 GMT+00:00 2006, Uncontrolled Copy, (c) BSI 9 3.5 Salt spray test 3.5.1 Test The specimen shall be subjected to a salt spray test for 48 h in accordance with ISO 9227. The connection side of the specimen shall be directed downward into the test chamber and be fitted to the appropriate mating part. At the end of the test time, the specimen shall be rinsed in flowing water with a temperature not exceeding + 38 ?C; the specimen shall then immediately be dried. 3.5.2 Requirement At visual examination the specimen shall not show any visible phenomena of corrosion. Changes in the appearance of the s