EXRAD ERGO FLEX™ ISO-19642 Shielded Multi-Conductor Cables

    Product features:
  • Excellent Compression Set
  • Highly Flexible
  • Class D

EXRAD ERGO FLEX™ 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 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: 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