EXRAD® ERGOFLEX ISO 19642-9 Thin-Wall Shielded HV Battery Cable
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Product features:
- Ultimate Flexibility
- Superior Compression Set
- FHLR13XC13X
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, including all fluid tests such as battery acid, motor oils, power steering and ATF.
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: 1,000V
- Flame Resistance: FT-2
- Oil Temperature Rating: 60°C
- Ultraviolet Resistance: Black/Orange
- Flexibility Rating: 5
- Fluid Resistance Rating: 4
- Cut-Through Resistance Rating: 3
Specifications
| Product
Number |
Conductor
Bare Copper |
Conductor
Diameter mm / nom |
Primary
Diameter mm / nom |
Shield
Diameter mm / nom |
Shield
Coverage min |
Finished
Diameter mm / nom |
Static
Bend Radius mm / min |
Finished
Weight kg/KM, nom |
Max Conductor
Resistance 20°C MΩ per M |
| EXRAD-EF/EF-TW-3 | 3.0m² (44/.29) | 2.16 | 3.2 | 3.57 | 95% | 4.6 | 11 | 58 | 6.15 |
| EXRAD-EF/EF-TW-5 | 5.0mm² (70/.29) | 2.72 | 4.05 | 4.42 | 95% | 5.8 | 14 | 74 | 3.94 |
| EXRAD–EF/EF-TW-6 | 6.0mm² (84/.30) | 2.92 | 4.15 | 4.66 | 95% | 5.9 | 14 | 90 | 3.14 |
| EXRAD–EF/EF-TW-12 | 12mm² (175/.29) | 4.72 | 6.15 | 6.7 | 95% | 8.3 | 21 | 177 | 1.52 |
| EXRAD–EF/EF-TW-16 | 16mm² (224/.30) | 5.59 | 6.8 | 7.3 | 95% | 9.3 | 23 | 226 | 1.16 |
| EXRAD–EF/EF-TW-20 | 20mm² (273/.30) | 6.02 | 7.4 | 8.6 | 95% | 9.9 | 25 | 261 | 0.96 |
| EXRAD–EF/EF-TW-25 | 25mm² (364/.29) | 6.86 | 8.3 | 8.8 | 95% | 11 | 27 | 321 | 0.74 |
| EXRAD–EF/EF-TW-35 | 35mm² (1083/.20) | 7.87 | 9.9 | 10.4 | 95% | 12.9 | 39 | 439 | 0.53 |
| EXRAD–EF/EF-TW-50 | 50mm² (1615/.20) | 9.91 | 11.6 | 12.2 | 95% | 14.9 | 45 | 615 | 0.37 |
| EXRAD-EF/EF-TW-70 | 70mm² (2128/.20) | 11.94 | 14.0 | 14.7 | 95% | 17.0 | 56 | 900 | 0.26 |
| EXRAD-EF/EF-TW-95 | 95mm² (2926/.20) | 13.97 | 16.0 | 16.7 | 95% | 19.5 | 64 | 1,081 | 0.19 |
| ISO 19642 Section | Description | Requirement | Typical Results (35mm2 Sample) | |
| 6.1.1 | Outside Cable Diameter | 13.2mm max. | 12.97mm | Pass |
| 6.1.2 | Ovality of Sheath | 10% max | 3.4% | Pass |
| 5.1.1 | Inner Core 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 |
| 6.2.3.2 | DC Resistance of Screen | Per customer agreement | 3.95mΩ/m | NA |
| 6.2.3.3 | Surface Transfer Imp. - Tri Axial | Per customer agreement | Inquire | NA |
| 6.3.3 | Flexibility Test | Customer-Defined | 101.4 N | NA |
| 5.4.2 6.4.2 | Long-Term Heat Aging | 150°C, 3000 hrs, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 5.4.3 6.4.3 | Short-Term Heat Aging | 175°C, 240hrs, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 5.4.4 6.4.4 | 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 |
| 6.4.5 | Pressure at High Temperature | Thickness of insulation to be > 40% | 92% | Pass |
| 5.4.6 6.4.6 | Shrinkage by heat Insulation and Sheath | 2mm max. @ 150°C | 0.0 mm | Pass |
| 6.4.7 | Low Temperature Winding | 4 hrs @ -40°C, 3kV, no breakdown | No cracks, No breakdown | Pass |
| 6.4.8 | Cold Impact | 16 hrs @ -15°C, 1kV, no breakdown | No cracks, No breakdown | Pass |
| 6.4.9 | 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 |
| 6.4.10 | 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 |
| 6.4.14 | Resistance to Flame Propagation | Must extinguish within 30 sec. max. and a min of 50mm unburned | 5.2 sec. | Pass |