EXRAD ERGO FLEX™ ISO 19642-5 Class D Thin-Wall HV Battery Cable

    Product features:
  • ISO-19642-5
  • 1,000V
  • Class D

EXRAD ERGO FLEX™ 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 ERGO FLEX 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.

EXRAD ERGO FLEX™ is extremely flexible for easy routing in the tight confined areas of the car platform, yet tough enough to withstand the roughest environments without excessive scrapes or tears. EXRAD ERGO FLEX can be routed through twists and turns where other cables cannot.

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   

M per M        

EXRAD-EF150-3 3.0mm² (44/.29) 2.2 0.52 3.20 16 49 6.15
EXRAD-EF150-5 5.0mm² (70/.29) 2.7 0.59 4.05 20 56 3.94
EXRAD-EF150-6 6.0mm² (84/.30) 2.9 0.63 4.15 20 61 3.14
EXRAD-EF150-8 8.0mm2 (238/.20) 3.5 0.63 4.80  24 77 2.38
EXRAD-EF150-10 10mm² (144/.46) 4.0 0.70 5.65 28 105 1.82
EXRAD-EF150-12 12mm² (175/.29) 4.7 0.70 6.15 31 126 1.52
EXRAD-EF150-16 16mm² (224/.30) 5.2 0.80 6.80 34 193 1.16
EXRAD-EF150-20 20mm² (273/.29) 6.2 0.70 7.40 37 201 0.955
EXRAD-EF150-25 25mm² (364/.29) 6.8 0.75 8.30 42 243 0.743
EXRAD-EF150-35 35mm² (1083/.20) 7.8 0.90 9.90 59 343 0.527
EXRAD-EF150-40 40mm² (1235/.20) 9.4 0.95 11.30 67 395 0.470
EXRAD-EF150-50 50mm² (1615/.20) 9.9 1.00 11.60 71 487 0.368
EXRAD-EF150-70 70mm² (2128/.20) 11.9 1.00 13.70 85 699 0.259
EXRAD-EF150-95 95mm² (2926/.20) 13.97 1.00 16.00 99 1,170 0.196
ISO 19642 Section Description Requirement Typical Results (35mm2 Sample)
5.1.1 Outside Cable Diameter 10.4mm max. 9.91mm Pass
5.1.2 Insulation Thickness 0.64mm min. 0.99mm Pass
5.1.3 Conductor Diameter 9.0mm max. 7.87mm Pass
5.2.1 Conductor Resistance 0.527 mΩ/m  max. 0.450 mΩ/m Pass
5.2.2 Withstand Voltage 10kV for 5min No dielectric breakdown Pass
5.2.4 Insulation Faults Sparktest @ 8.0kV No breakdown Pass
5.2.5 Insulation Volume Resistivity 1012 Ω /mm min. 1.25 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

92% retention

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