EXRAD® ERGOFLEX ISO 19642-5 Class D Thin-Wall HV Battery Cable
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Product features:
- ISO-19642-5
- 1,000V
- FHLR13X
EXRAD® ERGOFLEX thin-wall battery cable is a revolutionary highly flexible Irradiation Cross-linked Elastomeric Polyolefin insulation (XLPO) which meets ISO 19642-5 Class D (150°C). These ultra-flexible cables are easier to work with and install especially with regard to tight bend radii. EXRAD ERGOFLEX is designed to reduce operator ergonomic stress and fatigue while handling cable harnesses. This state-of-the-art insulation material has excellent compression set characteristics which allows for maintaining proper connector sealing over time and thermal stresses.
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.
See the Case Study below for the story of how this next-generation cable technology came to be.
- 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 |
Bare Copper
Conductors |
Conductor
Diameter mm / nom |
Insulation
Thickness mm / nom |
Finished
Diameter mm / nom |
Static
Bend Radius mm / min |
Finished
Weight kg/KM nom |
Max Conductor
Resistance 20°C MΩ per M |
| EXRAD-EF150-3 | 3mm² (44/.29) | 2.2 | 0.50 | 3.20 | 8 | 49 | 6.15 |
| EXRAD-EF150-5 | 5mm² (70/.29) | 2.7 | 0.67 | 4.05 | 10 | 56 | 3.94 |
| EXRAD-EF150-6 | 6mm² (84/.30) | 2.9 | 0.63 | 4.15 | 11 | 61 | 3.14 |
| EXRAD-EF150-8 | 8mm2 (238/.20) | 3.6 | 0.60 | 4.80 | 12 | 77 | 2.38 |
| EXRAD-EF150-10 | 10mm2 (322/.20) | 4.2 | 0.78 | 5.77 | 14 | 105 | 1.82 |
| EXRAD-EF150-12 | 12mm² (175/.29) | 4.7 | 0.73 | 6.15 | 19 | 126 | 1.52 |
| EXRAD-EF150-16 | 16mm² (224/.30) | 5.6 | 0.60 | 6.80 | 20 | 152 | 1.16 |
| EXRAD-EF150-20 | 20mm² (273/.29) | 6.2 | 0.60 | 7.40 | 23 | 201 | 0.955 |
| EXRAD-EF150-25 | 25mm² (364/.29) | 6.9 | 0.70 | 8.30 | 25 | 236 | 0.743 |
| EXRAD-EF150-30 | 30mm² (912/.20) | 6.9 | 1.15 | 9.20 | 27 | 287 | 0.647 |
| EXRAD-EF150-35 | 35mm² (1083/.20) | 7.9 | 1.00 | 9.90 | 30 | 341 | 0.527 |
| EXRAD-EF150-40 | 40mm² (1235/.20) | 8.2 | 1.15 | 10.50 | 31 | 365 | 0.473 |
| EXRAD-EF150-50 | 50mm² (1615/.20) | 9.7 | 1.00 | 11.70 | 35 | 471 | 0.368 |
| EXRAD-EF150-60 | 60mm² (1824/.20) | 10.2 | 1.23 | 12.65 | 31 | 567 | 0.315 |
| EXRAD-EF150-70 | 70mm² (2128/.20) | 11.9 | 1.05 | 14.00 | 35 | 675 | 0.259 |
| EXRAD-EF150-95 | 95mm² (2926/.20) | 14.0 | 1.00 | 16.00 | 40 | 910 | 0.196 |
| ISO 19642 Section | Description | Requirement | Typical Results (35mm2 Sample) | |
| 5.2.1 | Outside Cable Diameter | 10.4mm max. | 9.91mm | Pass |
| 5.2.2 | Insulation Thickness | 0.64mm min. | 0.99mm | Pass |
| 5.2.3 | Conductor Diameter | 9.0mm max. | 7.87mm | Pass |
| 5.3.1 | Conductor Resistance | 0.527 mΩ/m max. | 0.450 mΩ/m | Pass |
| 5.3.3 | Withstand Voltage | 10kV for 5min | No dielectric breakdown | Pass |
| 5.3.5 | Insulation Faults | Sparktest @ 8.0kV | No breakdown | Pass |
| 5.3.6 | Insulation Volume Resistivity | 1012 Ω /mm min. | 1.25 x 1015 Ω /mm | Pass |
| 5.4.5 | Flexibility Test | Customer-Defined | 34.9 N | NA |
| 5.5.2 | Long-Term Heat Aging | 150°C, 3000 hrs, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 5.5.3 | Short-Term Heat Aging | 175°C, 240hrs, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 5.5.4 | Thermal Overload | 200°C, 6 hrs, 5Kv | No cracks, No breakdown | Pass |
| 5.5.5 | Pressure at High Temperature | Under load @150°C, 5kV 5min, no breakdown | No cracks, No breakdown
92% retention |
Pass |
| 5.5.6 | Shrinkage by heat | 2mm max. @ 150°C | 0.0 mm | Pass |
| 5.5.7 | Low Temperature Winding | 4 hrs @ -40°C, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 5.5.8 | Cold Impact | 16 hrs @ -15°C, 1kV, no breakdown | No cracks, No breakdown | Pass |
| 5.5.9 | Temperature and Humidity Cycling | 40 x 8 hour cycles -40°C to 150°C, relative humidity 80 -100%, 3kV | No cracks, No breakdown | Pass |
| 5.5.10 | 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 |
| 5.5.11 | Resistance to liquid chemicals | Groups 1 and 2, no breakdown. | All fluids: No crack/damage/breakdown | Pass |
| 5.5.14 | Ozone Resistance | 65°C, 192 hours, Ozone (1+/- 0.05) x 10-6 | No cracks | Pass |
| 5.5.15 | Resistance to Flame Propagation | Must extinguish within 30 sec. max. and a min of 50mm unburned | 4.0 sec. | Pass |