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EXRAD® ERGOFLEX 125 ISO 19642-3 Class C Thin-Wall High-Flex Door Wire

    Product features:
  • Door & Hatch Applications
  • Long Flex Life
  • Low Temp Flex

EXRAD® ERGO FLEX 125 is a high-flex door and hatch wire designed specifically for flexibility and long flex life, even in cold temperatures.  The temperature performance range of EXRAD ERGO FLEX is –70°C to +125°C, well beyond the failure point of conventional wires.  Standard connectors match exactly and seal well with this wire because it is the same size as other common automotive conductors.

Even though it is flexible, EXRAD ERGO FLEX has enough column strength to allow easy insertion through the seals of water-resistant connectors. The high temperature performance and fluid resistance means it can be routed throughout the vehicle including the engine compartment. Superior abrasion and pinch resistance ensures durability and helps keep the wire harness safe and free from defect even with hundreds of thousands of flexes.

Given today’s longer warranties you need a wire that will perform more bends and twists than ever before. EXRAD ERGO FLEX provides up to 9 times more flexing than conventional wire.  The end result is an automotive wire ideally suited to applications where a combination of flexibility, long flex life and performance is required.

  • High Temperature Rating: 125°C
  • Low Temperature Rating: -70°C
  • Voltage Rating: 60V
  • Flame Resistance: FT-2
  • Oil Temperature Rating: 60°C
  • Ultraviolet Resistance: Black
  • Radiation Resistance: No
  • Flexibility Rating: 4
  • Fluid Resistance Rating: 4
  • Cut-Through Resistance Rating: 3

Specifications

Product

Number

 Standard

Bare Copper

Conductors (1)

 Conductor

Diameter (nom)      

mm          in

  Insulation

Thickness (nom)

mm          in

 Nom.

OD   

mm       in

 Bend Radius

Non. Flex (min)

mm       in

 Finished

Weight (nom)

(kg/KM)

 Conductor   

Resistance          

Ω per KM  (max)
EXRAD-EF125-0.35        0.35mm² (37/.11)  0.79        .031 0.26         .010    1.30     .051 4        .20 0.7 54.4
EXRAD-EF125-0.50 0.50mm2 (41/.13)  0.89        .035 0.28         .011    1.50     .059 5        .24 0.7 37.1
EXRAD-EF125-0.75      0.75mm² (41/.16)  1.19        .047 0.31         .012    1.80     .071 7        .28 0.9 24.7
EXRAD-EF125-1.00      1.00mm² (61/.14)  1.24        .049 0.38         .015    2.00     .079 8        .32 1.1 18.5
EXRAD-EF125-1.50      1.50mm² (84/.15)  1.55        .061 0.38         .015    2.30     .091 9        .36 1.6 12.7
EXRAD-EF125-2.0      2.00mm² (105/.16)  1.85        .071 0.40         .016    2.65     .104 11      .41 2.2 9.42
EXRAD-EF125-2.5      2.50mm² (140/.16)  2.13        .084 0.36         .014    2.85     .112 11      .45 2.6 7.60
EXRAD-EF125-3.0      3.00mm² (161/.152)  2.26        .089 0.46         .018    3.20     .126 13      .51 3.3 6.15
EXRAD-EF125-4.0      4.00mm² (224/.16)  2.80        .110 0.40         .016    3.60     .142 14      .57 4.1 4.71
ISO 19642 Section Description Requirement Typical Results (0.35mm2 Sample)
4.1.1 Outside Wire Diameter 1.40mm max. 1.34mm Pass
4.1.2 Insulation Thickness 0.20mm min. 0.27mm Pass
4.1.3 Conductor Diameter 0.90mm max. 0.76mm Pass
4.2.1 Conductor Resistance 54.4 mΩ/m  max. 46.7 mΩ/m Pass
4.2.2 Withstand Voltage 1kV for 30min // 5kV for 5min. No dielectric breakdown Pass
4.2.4 Insulation Faults Sparktest @ 3.0kV No breakdown Pass
4.2.5 Insulation Volume Resistivity 109 Ω /mm min. 1.21 x 1015 Ω /mm Pass
5.3.5 Flexibility Test Customer-Defined 34.9 N NA
5.4.2 Long-Term Heat Aging 150°C, 3000 hrs, 3kV, no breakdown No cracks, No breakdown Pass
5.4.3 Short-Term Heat Aging 175°C, 240hrs, 3kV, no breakdown No cracks, No breakdown Pass
5.4.4 Thermal Overload 200°C, 6 hrs, 5Kv No cracks, No breakdown Pass
5.4.5 Pressure at High Temperature Under load @150°C, 5kV 5min, no breakdown No cracks, No breakdown Pass
5.4.6 Shrinkage by heat 2mm max. @ 150°C 0.0 mm Pass
5.4.7 Low Temperature Winding 4 hrs @ -40°C, 3kV, no breakdown No cracks, No breakdown Pass
5.4.8 Cold Impact 16 hrs @ -15°C, 1kV,  no breakdown No cracks, No breakdown Pass
5.4.9 Temperature and Humidity Cycling 40 x 8 hour cycles -40°C to 150°C, relative humidity  80 -100%, 3kV No cracks, No breakdown Pass
5.4.10 Resistance to hot water 35 days in 85C water, IR not less than 1012 Ω/mm 4.46 x 1014 Ω/mm, no breakdown Pass
5.4.11 Resistance to liquid chemicals Groups 1 and 2, no breakdown. All fluids:  No crack/damage/breakdown Pass
5.4.14 Ozone Resistance 65°C, 192 hours, Ozone (1+/- 0.05) x 10-6 No cracks Pass
5.4.15 Resistance to Flame Propagation Must extinguish within 30 sec. max. and a min of 50mm unburned 4.0 sec. Pass