EXRAD® HVFX ISO Thick-Wall Battery
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Product features:
- ISO 6722-1 Class D Thick Wall
- 1000V
- 150°C
EXRAD® HVFX ISO 6722-1 thick-wall battery cable is a new more flexible insulation designed for the higher voltage and electrical currents required by today’s hybrid and battery power vehicles. Our tough and high temperature insulations allow for lower weight and less space.
EXRAD HVFX battery cables have an irradiated cross-linked polyolefin insulation able to withstand temperatures of 240°C and higher. The EXRAD high flex conductor and insulation are designed to be thinner and lighter than other high voltage cables. It is extremely flexible for easy routing in the tight confined areas of the car platform, yet tough enough to withstand the roughest environments. EXRAD HVFX can be routed through twists and turns where other cables cannot. Save money and reduce weight by shortening the cable length. This product is also ideal for HVIL (High Voltage Interlock Loop) systems.
The end result is the EXRAD HVFX wire is ideally suited to applications, especially conventional, hybrid and electric vehicles where a combination of flexibility, long life and performance is required. ROHS and CE Compliant.
- High Temperature Rating: 150°C
- Low Temperature Rating: -55°C
- Voltage Rating: 1000V
- Flame Resistance: FT-2
- Oil Temperature Rating: 70°C
- Ultraviolet Resistance: Black
- Radiation Resistance: No
- Flexibility Rating: 4
- Fluid Resistance Rating: 4
- Cut-Through Resistance Rating: 3
Specifications
| Product Number | Std Conductors
Bare Copper |
Nom Conductor
Diameter mm. In. |
Nom. Insulation
Thickness mm. In. |
Nom Finished
Diameter mm. In. |
Min Static
Bend Radius mm. In. |
Finished Weight Kg/KM | Conductor Resistance Ω per KM at 20°C |
| EXRAD--HVFXI-6 | 6mm² (84/.30) | 2.92 .115 | 1.06 .042 | 4.80 .189 | 24 1.0 | 68 | 3.01 |
| EXRAD--HVFXI-10 | 10mm² (80/.40) | 3.99 .157 | 1.06 .042 | 6.20 .244 | 31 1.3 | 112 | 1.78 |
| EXRAD--HVFXI-12 | 12mm² (154/.32) | 4.88 .192 | 1.06 .042 | 7.00 .276 | 35 1.4 | 134 | 1.52 |
| EXRAD--HVFXI-16 | 16mm² (105/.46) | 5.21 .205 | 1.24 .049 | 8.00 .314 | 40 1.6 | 208 | 1.16 |
| EXRAD--HVFXI-20 | 20mm² (247/.32) | 6.17 .243 | 1.24 .049 | 8.60 .339 | 43 1.7 | 216 | 0.95 |
| EXRAD--HVFXI-25 | 25mm² (798/.20) | 6.85 .270 | 1.24 .049 | 9.90 .390 | 50 2.0 | 261 | 0.74 |
| EXRAD--HVFXI-35 | 35mm² (551/.28) | 8.12 .320 | 1.24 .049 | 10.60 .417 | 53 2.1 | 356 | 0.52 |
| EXRAD--HVFXI-40 | 40mm² (494/.32) | 8.89 .350 | 1.27 .050 | 11.80 .464 | 59 2.3 | 419 | 0.47 |
| EXRAD--HVFXI-50 | 50mm² (798/.28) | 9.78 .385 | 1.47 .058 | 12.70 .500 | 63 2.5 | 509 | 0.36 |
| EXRAD--HVFXI-70 | 70mm² (1140/.28) | 11.32 .446 | 1.47 .058 | 14.22 .560 | 87 3.4 | 711 | 0.26 |
| EXRAD--HVFXI-95 | 95mm² (1938/.25) | 13.20 .521 | 1.65 .065 | 16.71 .658 | 102 4.1 | 968 | 0.19 |
| EXRAD- HVFXI-120 | 120mm² (2442/.25) | 15.24 .600 | 1.65 .065 | 18.54 .730 | 112 4.5 | 1,278 | 0.16 |
| Section | Description | Requirement | Typical Results (35mm2 Sample) | |
| 5.1 | Outside Cable Diameter | 10.40 max. | 9.98mm | Pass |
| 5.2 | Insulation Thickness | 0.64mm min. | 0.84mm | Pass |
| 5.3 | Conductor Diameter | 8.50mm max. | 8.08mm | Pass |
| 5.4 | Conductor Resistance | 0.527 mohms/m @20°C max. | 0.521 mohms/m | Pass |
| 5.5 | Withstand Voltage | 600V 5kV for 5 minutes | No Dielectric Breakdown | Pass |
| 5.6 | Insulation Faults | Sparktest @ 12.5kV | No Faults | Pass |
| 5.7 | Insulation Volume Resistivity | 10 9 Ohms/mm min. | 1.66 1016 Ohms/mm | Pass |
| 5.8 | Pressure at High Temperature | ‘0.8N @150°C no dielectric breakdown | No Breakdown | Pass |
| 5.9 | Strip Force / Adhesion | Per customer agreement | NA | Pass |
| 5.1 | Low Temperature Winding | 3 tns 2.5kg - 40°C No dielectric breakdown | No Dielectric Breakdown, No Cracking | Pass |
| 5.11 | Impact | 300gm @-40°C No breakdown | No Breakdown | Pass |
| 5.12.4.1 | Sandpaper Abrasion | N/A | NA | Pass |
| 5.12.4.2 | Scrape Abrasion | N/A | NA | Pass |
| 5.13 | Long-Term Heat Aging | 150°C 3000 hours | No Breakdown, No Cracks | Pass |
| 5.15 | Thermal Overload | 200°C 6 hours | No Breakdown, No Cracks | Pass |
| 5.16 | Shrinkage by heat | 2mm max. 150°C | No Shrinkage | Pass |
| 5.17 | Fluid Compatibility | Gasoline 15% max. | 7.50% | Pass |
| Diesel Fuel 15% max. | 2.70% | Pass | ||
| Engine Oil 15% max. | 3.20% | Pass | ||
| Ethanol 15% max. | 4.70% | Pass | ||
| Power Steering 30% max | 4.10% | Pass | ||
| Automatic Transmission 25% max | 3.20% | Pass | ||
| Engine Coolant 15% max | 0.40% | Pass | ||
| Battery Acid no breakdown | No Breakdown | Pass | ||
| 5.19 | Ozone Resistance | 45oC 85% Relative Humidity 70 hours, Ozone 50 +/- 5 pphm, 1kV 1 min. (no breakdown) | No Breakdown | Pass |
| 5.2 | Resistance to hot water | not less than 10-5 ohm-mm | 10-14 ohm-mm | Pass |
| 5.21 | Temperature and Humidity Cycling | 40 - 8 hours cycles -40°C and 125°C 80 -100% relative humidity | No Dielectric Breakdown, No Cracking | Pass |