EXRAD® ERGOFLEX ISO-19642 Shielded Multi-Conductor Cables
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Product features:
- Excellent Compression Set
- Highly Flexible
- Class D
EXRAD® ERGOFLEX thin-wall multi-conductor power cables offer industry-leading flexibility across many size and core-count options. These highly flexible Irradiation Cross-linked Polyolefin (XLPO) cables meet all requirements of ISO 19642-9 Class D (150°C). 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 | Number
Of Cores |
Bare Copper
Conductor |
Conductor Diameter
mm / nom |
Insulated
Primary Diameter mm / nom |
Core
Diameter mm / nom |
Screened
Diameter mm / nom |
Outer Jacket
Diameter mm / nom |
Static
Bend Radius mm / min |
Conductor
Resistance at 20°C mΩ per m, max |
| EXRAD–EF-MCS-TW-2x1.5 | 2 | 1.5mm² (19/.33) | 1.45 | 2.30 | 4.6 | 4.70 | 7.20 | 36 | 12.50 |
| EXRAD–EF-MCS-TW-2x2.5 | 2 | 2.5mm² (37/.28) | 1.88 | 2.85 | 5.7 | 6.35 | 8.55 | 43 | 7.60 |
| EXRAD–EF-MCS-TW-2x4.0 | 2 | 4.0mm² (37/.38) | 2.62 | 3.60 | 7.2 | 7.85 | 10.25 | 51 | 4.71 |
| EXRAD–EF-MCS-TW-3x4.0 | 3 | 4.0mm² (37/.38) | 2.62 | 3.60 | 7.8 | 8.46 | 10.85 | 54 | 4.71 |
| EXRAD–EF-MCS-TW-2x6.0 | 2 | 6.0mm² (84/.30) | 2.92 | 4.15 | 8.3 | 9.10 | 11.55 | 58 | 3.14 |
| EXRAD–EF-MCS-TW-3x6.0 | 3 | 6.0mm² (84/.30) | 2.92 | 4.15 | 9.0 | 9.81 | 12.31 | 62 | 3.14 |
| EXRAD–EF-MCS-TW-2x10 | 2 | 10mm² (80/.40) | 3.99 | 5.65 | 11.3 | 12.10 | 14.55 | 73 | 1.82 |
| EXRAD–EF-MCS-TW-3x10 | 3 | 10mm² (80/.40) | 3.99 | 5.65 | 12.26 | 13.06 | 16.40 | 82 | 1.82 |
| 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 |