EXRAD® ERGOFLEX ISO-19642 Shielded Multi-Conductor Cables

    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: 60C°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

m 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