EXRAD® HVFX ISO Thick-Wall Battery

    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       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 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