EXRAD® HVFX ISO Thin-Wall Shielded Battery Cable
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Product features:
- ISO 6722-1 Class D
- 600/1000V
- Enhanced Flexibility
EXRAD® HVFX ISO 6722-1 thin-wall shielded battery cable is the next generation of high performance cross-linked insulation designed specifically to handle the higher voltage and electrical currents required by today’s hybrid and electric vehicles and HVIL systems. Our thin wall and high temperature insulations allow for lower weight and less space. Champlain Cable offers UV resistance unlike most cross-linked polyolefins.
EXRAD HVFX shielded battery cables have an irradiated cross-linked polyolefin insulation able to withstand temperatures of 240°C and higher. The EXRAD high flex conductor and flexible insulation are designed to be thinner and lighter. 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 can not. Save money and reduce weight by shortening the cable length. This product is also ideal for HVIL (High Voltage Interlock Loop) systems in single or multi-conductor configurations.
The end result is the EXRAD HVFX product 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: 600/1000V
- Flame Resistance: FT-1
- Oil Temperature Rating: 90°C
- Ultraviolet Resistance: Black/Orange
- Radiation Resistance: No
- Flexibility Rating: 4
- Fluid Resistance Rating: 4
- Cut-Through Resistance Rating: 3
Specifications
| Product Number | Standard Conductor Bare Copper | Nom. Dia . of Conductor mm. | Nom Primary Diameter mm. | Nom. Shield Diameter | Shield Coverage | Nom. OD mm. | Min. Bend Radius Non flex mm. | Finished Weight (kg/KM) | Conductor Resistance Ω per KM * |
| EXRAD–HV/XLE-6 | 6mm² (84/.30) | 3.09 | 4.15 | 4.61 | 95% | 5.7 | 17 | 90 | 3.01 |
| EXRAD–HV/XLE-10 | 10mm² (80/.40) | 3.99 | 5.65 | 6.22 | 95% | 7.8 | 24 | 105 | 1.78 |
| EXRAD–HV/XLE-12 | 12mm² (154/.32) | 4.88 | 6.15 | 6.72 | 95% | 8.3 | 25 | 177 | 1.47 |
| EXRAD–HV/XLE-16 | 16mm² (105/.45) | 5.21 | 6.8 | 7.37 | 95% | 9.3 | 28 | 249 | 1.13 |
| EXRAD–HV/XLE-20 | 20mm² (247/.32) | 6.02 | 7.4 | 7.97 | 95% | 9.9 | 30 | 261 | 0.91 |
| EXRAD–HV/XLE-25 | 25mm² (798/.20) | 6.98 | 8.3 | 8.87 | 95% | 11 | 33 | 312 | 0.72 |
| EXRAD–HV/XLE-35 | 35mm² (551/.28) | 8.13 | 9.9 | 10.64 | 95% | 12.8 | 39 | 446 | 0.52 |
| EXRAD–HV/XLE-40 | 40mm² (494/.32) | 8.89 | 10.55 | 11.12 | 95% | 13.6 | 47 | 474 | 0.47 |
| 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 @20oC 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 | 109 Ω /mm min. | 1.66 1016 Ω /mm | Pass |
| 5.8 | Pressure at High Temperature | ‘0.8N @150oC no dielectric breakdown | no breakdown | Pass |
| 5.9 | Strip Force / Adhesion | Per customer agreement | NA | NA |
| 5.10 | Low Temperature Winding | 3 turns 2.5kg - 40oC no dielectric breakdown | No dielectric breakdown, no cracking, | Pass |
| 5.11 | Impact | 300gm @-40oC no breakdown | no breakdown, | Pass |
| 5.12.4.1 | Sandpaper Abrasion | NA | NA | Pass |
| 5.12.4.2 | Scrape Abrasion | NA | NA | Pass |
| 5.13 | Long-Term Heat Aging | 150oC 3000 hours | no breakdown, no cracks | Pass |
| 5.15 | Thermal Overload | 200oC 6 hours | no breakdown, no cracks, | Pass |
| 5.16 | Shrinkage by heat | 2mm max. 150oC | no shrinkage, | Pass |
| 5.17 | Fluid Compatibility | Gasoline 15% max. | 7.5% | Pass |
| Diesel Fuel 15% max. | 2.7% | Pass | ||
| Engine Oil 15% max. | 3.2% | Pass | ||
| Ethanol 15% max. | 4.7% | Pass | ||
| Power Steering 30% max | 4.1% | Pass | ||
| Automatic Transmission 25% max | 3.2% | Pass | ||
| Engine Coolant 15% max | 0.4% | 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 |
| 5.20 | 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 -40oC and 125oC 80 -100% relative humidity | no dielectric breakdown, no cracking, | Pass |
| 5.22 | Resistance to Flame | 70 sec. max. 50mm unburned | 1 sec. after burn | Pass |