EXRAD® ERGOFLEX ISO Class D 150°C Thick-Wall HV Flexible Battery Cable
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Product features:
- EV / HEV
- 1000V
- Ultimate XLPO Flexibility
EXRAD® ERGOFLEX ISO 19642-5 150°C thick-wall battery cable is designed with a new, more flexible Irradiation Cross-linked Elastomeric Polyolefin insulation. These highly flexible cables are easier to bend than other thick-wall cables, making it easier to work with especially with tight bend radii. EXRAD ERGOFLEX is designed to make it easier to mate connectors and reduce operator ergonomic stress and fatigue while handling cable harnesses.
EXRAD ERGOFLEX is extremely flexible for easy routing in the tight confined areas of a car platform, yet tough enough to withstand the roughest environments without excessive scrapes or tears. EXRAD ERGOFLEX can be routed through twists and turns where other cables can not. Save money and reduce weight by shortening the cable length.
The EXRAD ERGOFLEX product is perfectly suited for applications; especially conventional, hybrid and electric vehicles; where a combination of flexibility, long life, thermal robustness and high performance is required.
- High Temperature Rating: 150°C
- Low Temperature Rating: -55°C
- Voltage Rating: 1000V
- Flame Resistance: FT-2
- Oil Temperature Rating: 60°C
- Ultraviolet Resistance: Black
- Radiation Resistance: No
- Flexibility Rating: 5
- Fluid Resistance Rating: 4
- Cut-Through Resistance Rating: 3
Specifications
|
Product Number |
Std Conductors Bare Copper |
Nom Conductor
Diameter mm. In. |
Nom. Insulation
Thickness mm. In. |
Nom Finished
Diameter mm. In. |
Min Static
Bend Radius mm. In. |
Finished
Weight Kg/KM |
Conductor Resistance Ω per KM at 20°C |
| EXRAD–EF150K-6 | 6.0mm² (84/.30) | 2.92 .115 | 1.06 .042 | 4.80 .189 | 24 1.0 | 68 | 3.01 |
| EXRAD-EF150K-10 | 10mm² (80/.40) | 3.99 .157 | 1.06 .042 | 6.20 .244 | 31 1.3 | 112 | 1.78 |
| EXRAD–EF150K-12 | 12mm² (154/.32) | 4.88 .192 | 1.06 .042 | 7.00 .276 | 35 1.4 | 134 | 1.47 |
| EXRAD–EF150K-16 | 16mm² (105/.46) | 5.21 .205 | 1.24 .049 | 8.00 .314 | 40 1.6 | 208 | 1.13 |
| EXRAD-EF150K-20 | 20mm² (247/.32) | 6.17 .243 | 1.24 .049 | 8.60 .339 | 43 1.7 | 216 | 0.91 |
| EXRAD-EF150K-25 | 25mm² (798/.20) | 6.85 .269 | 1.24 .049 | 9.90 .390 | 50 2.0 | 261 | 0.72 |
| EXRAD-EF150K-35 | 35mm² (551/.28) | 8.12 .320 | 1.24 .049 | 10.60 .417 | 53 2.1 | 356 | 0.52 |
| EXRAD-EF150K-40 | 40mm² (494/.32) | 8.89 .350 | 1.27 .050 | 11.80 .464 | 59 2.3 | 419 | 0.47 |
| EXRAD-EF150K-50 | 50mm² (798/.28) | 9.91 .390 | 1.27 .050 | 12.50 .492 | 63 2.5 | 509 | 0.36 |
| EXRAD-EF150K-70 | 70mm² (1140/.28) | 11.83 .466 | 1.40 .055 | 14.50 .571 | 87 3.4 | 711 | 0.26 |
| EXRAD-EF150K-95 | 95mm² (1938/.25) | 13.20 .521 | 1.90 .075 | 17.00 .669 | 102 4.1 | 968 | 0.19 |
| EXRAD-EF150K-120 | 120mm² (2442/.25) | 15.24 .600 | 1.90 .075 | 19.04 .750 | 112 4.5 | 1211 | 0.15 |
| Section | Description | Requirement | Typical Results (35mm2 Sample) | |
| 5.1 | Outside Cable Diameter | 11.60 max. | 10.31mm | Pass |
| 5.2 | Insulation Thickness | 1.04mm min. | 1.19mm | Pass |
| 5.3 | Conductor Diameter | 9.00mm max. | 8.00mm | Pass |
| 5.4 | Conductor Resistance | 0.527 mΩ/m @20oC max. | 0.515 mΩ/m | Pass |
| 5.5 | Withstand Voltage | 60V 5kV | no dielectric breakdown | Pass |
| 5.6 | Insulation Faults | Sparktest @ 5kV | no faults | Pass |
| 5.7 | Insulation Volume Resistivity | 109 Ω/mm min. | 2.564 1017 Ω /mm | Pass |
| 5.8 | Pressure at High Temperature | Under load @150oC no dielectric breakdown | No breakdown | Pass |
| 5.9 | Strip Force / Adhesion | Per customer agreement | NA | NA |
| 5.10 | Low Temperature Winding | 3 tns 30kgm - 40oC no breakdown | no dielectric breakdown, | Pass |
| 5.11 | Impact | 400gm @-40oC no breakdown | no breakdown, | Pass |
| 5.12.4.1 | Sandpaper Abrasion | NA | NA | Pass |
| 5.12.4.2 | Scrape Abrasion | NA | NA | Pass |
| 5.13 | Long-Term Heat Aging | 150oC 3000 hours | No breakdown, No cracks | Pass |
| 5.15 | Thermal Overload | 200oC 6 hours | No breakdown, No cracks | Pass |
| 5.16 | Shrinkage by heat | 2mm max. 150oC | no shrinkage, | Pass |
| 5.17 | Fluid Compatibility | Gasoline 15% max. | 7.5% | Pass |
| Diesel Fuel 15% max. | 2.7% | Pass | ||
| Engine Oil 15% max. | 3.2% | Pass | ||
| Ethanol 15% max. | 4.7% | Pass | ||
| Power Steering 30% max | 4.1% | Pass | ||
| Automatic Transmission 25% max | 3.2% | Pass | ||
| Engine Coolant 15% max | 0.4% | Pass | ||
| Battery Acid no breakdown | No breakdown, | Pass | ||
| 5.19 | Ozone Resistance | 45oC 85% Relative Humidity, 70 hours, Ozone 50 +/- 5 pphm 1kV 1 min. (no breakdown) | No breakdown, | Pass |
| 5.20 | Resistance to hot water | not less than 10-5 Ωm-mm | 1.82 X 10-16 Ωhm-mm | Pass |
| 5.21 | Temperature and Humidity Cycling | 40 - 8 hours cycles -40oC and 125oC 80 -100% relative humidity | no dielectric breakdown, no cracking | Pass |
| 5.22 | Resistance to Flame | 70 sec. max. 50mm unburned | 0 - 2 sec. after burn | Pass |