Automotive Cable Standards & Compliance: What Procurement Teams Need to Know

When sourcing automotive cables for your manufacturing operation or fleet, understanding compliance requirements is critical. The right cable specification ensures vehicle safety, longevity, and regulatory adherence. For procurement teams and engineers navigating this landscape, here's what you need to know about automotive cable standards and compliance.

Understanding Key Automotive Cable Standards

The automotive cable industry operates under several internationally recognised standards, with ISO 6722 and ISO 19642 serving as the primary frameworks.

ISO 6722 covers single-core cables for circuits operating at up to 60V DC or 25V AC, with temperature classes from 85°C to 200°C. ISO 19642 has emerged as the successor standard, providing comprehensive coverage for low-voltage (30V AC or 60V DC) and high-voltage applications (600V AC, 900V DC, and higher).

In the UK and Europe, BS EN ISO standards align with these international specifications, ensuring compatibility with global supply chains whilst meeting local regulatory requirements.

Voltage Ratings: Matching Cable to Application

Standard automotive primary wiring is typically rated for 60V DC. Single core automotive cables handle lighting circuits and dashboard controls, whilst automotive battery cables manage high current loads during starting and charging cycles.

For electric and hybrid vehicles, high-voltage cables rated for 600V, 900V, or 1,500V DC are essential for battery management systems, inverters, and motor connections.

Temperature Performance: Operating Ranges That Matter

Automotive environments present extreme thermal challenges, from engine bay temperatures exceeding 125°C to cold-start conditions below -40°C.

FLRY-B thin wall cables offer temperature ratings typically in the 85°C to 105°C range, balancing thermal performance with space and weight efficiency. For applications near heat sources such as exhaust systems or turbochargers, GXL and TXL automotive cables provide enhanced thermal performance, with GXL rated to 125°C and TXL to 150°C.

Cold temperature performance is equally important. Standards specify low-temperature bend tests to ensure cables won't crack or fail in winter conditions which is particularly relevant for vehicles operating in cold climates.

PVC vs XLPE: Choosing the Right Insulation Material

The choice between PVC (Polyvinyl Chloride) and XLPE (Cross-Linked Polyethylene) insulation significantly affects cable performance, cost, and application suitability.

PVC Insulation

PVC insulated cables remain the most common choice for automotive applications. PVC is cost-effective, flexible, and provides good general-purpose performance for standard automotive circuits, handling typical vehicle environmental conditions including exposure to oils and automotive fluids.

However, PVC has limitations. Maximum continuous operating temperature typically reaches only 70°C to 90°C, restricting its use in high-temperature areas. Under fire conditions, PVC releases hydrochloric acid, and it has lower mechanical strength compared to cross-linked alternatives.

XLPE Insulation

XLPE undergoes a chemical cross-linking process that transforms polyethylene into a thermoset material with superior properties. XLPE cables offer higher temperature ratings (125°C to 150°C continuous operation), enhanced mechanical strength, and better resistance to chemicals and environmental stress.

For high-voltage applications in electric vehicles, XLPE has become the preferred choice due to its superior dielectric strength and thermal stability. The trade-off is cost. XLPE cables typically command a premium over PVC equivalents. Procurement teams should weigh initial cost against long-term performance, particularly where cable replacement would be costly or difficult.

Compliance and Testing Requirements

Meeting automotive cable standards involves rigorous testing: voltage withstand, conductor resistance, heat aging, low-temperature flexibility, abrasion resistance, tensile strength, fluid compatibility, and corrosion resistance. Working with suppliers who maintain comprehensive test documentation is essential. Certificates of conformity, test reports, and material declarations should be standard.

Sustainability and Environmental Compliance

Modern automotive manufacturing increasingly emphasises environmental responsibility, and cable procurement plays a vital role in meeting sustainability goals.

RoHS and REACH Compliance

RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorization and Restriction of Chemicals) regulations restrict harmful substances in electrical equipment. RoHS limits lead, cadmium, mercury, hexavalent chromium, and certain flame retardants to 0.1% (1,000 ppm) for most substances, with cadmium limited to 0.01% (100 ppm).

The EU End of Life Vehicle (ELV) directive also applies to automotive applications. Cross-linked polyethylene cables like GXL, TXL, and SXL generally comply with these directives, whilst PVC cables may contain lead stabilisers unless specifically formulated as RoHS-compliant. REACH monitors 250 Substances of Very High Concern (SVHCs) compliant suppliers maintain detailed material declarations.

Material Selection for Sustainability

Beyond regulatory compliance, procurement teams should consider broader environmental impact. XLPE insulation offers environmental advantages over PVC in fire safety, producing less toxic smoke and no hydrochloric acid when burned. Leading cable suppliers operate under ISO 9001 quality management systems, which increasingly incorporate environmental management principles.

Making Informed Cable Procurement Decisions

Navigating automotive cable standards requires understanding voltage ratings, temperature performance, insulation materials, and regulatory requirements. When specifying cables, evaluate application environment, temperature extremes, exposure to fluids, and installation constraints.

Ensure suppliers provide comprehensive compliance declarations including RoHS, REACH, and relevant ISO certifications. Whether you're sourcing multi-core cables for wiring harnesses or high voltage cables for electric vehicles, partner with suppliers offering both compliant products and technical expertise.

The automotive industry continues evolving with electrification and connectivity driving new cable requirements. Staying informed about standards and working with experienced suppliers ensures your procurement decisions support both current needs and future developments.

Need expert guidance on automotive cable standards and compliance?

Contact Cable House today. Our experienced team offers professional, knowledgeable service backed by comprehensive stock and fast delivery across the UK. Call 01858 410 550 or email sales@cablehouse.co.uk.

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