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EXRAD® ERGOFLEX ISO 19642-9 Thick-Wall Shielded Battery Cable

    Product features:
  • Ultimate Flexibility
  • 1000V
  • EV / HEV

EXRAD® ERGO FLEX is the next generation of high performance irradiation cross-linked (XLPO) battery cables.  High-flex conductors matched with the highly flexible compound delivers ultimate cable flexibility while meeting or exceeding all ISO 19642-9 requirements, including all fluid tests such as battery acid, motor oils, power steering and ATF.

EXRAD® ERGO FLEX is a highly engineered irradiated XLPO insulation.  It meets heat age testing for ISO 19642-9 Class D 150C when other XLPO cables crack and fail.  It is extremely flexible with a reduced bend radius for easy routing in the confined areas of a vehicle platform, yet tough enough to withstand the roughest environments.  Perfectly suited for EV/HEV applications, opportunities also exist to save cost and reduce weight by reducing the conductor size.   This product is ideal for HVIL (High Voltage Interlock Loop) systems in single or multi-conductor configurations.

The EXRAD® ERGO FLEX 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. ROHS and CE Compliant.

  • High Temperature Rating: 150°C
  • Low Temperature Rating: -55°C
  • Voltage Rating: 1000V
  • 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                                                           Standard Conductor Bare Copper Nom.        Conductor Diameter mm.  Nom         Primary   Diameter   mm. Max.  Shield Diameter    mm. Nom. Shield Coverage Nom.  Final Diameter  mm. Min.    Static        Bend        Radius       mm. Nom.       Finished Weight (kg/KM) Conductor Resistance      Ω  per KM
EXRAD–EF/EF-KW-6    6.0mm² (84/.30) 2.92 4.8 5.6 95% 7.5 23 102 3.14
EXRAD–EF/EF-KW-12    12mm² (175/.29) 4.72 7.0 8.2 95% 10.5 31 204 1.52
EXRAD–EF/EF-KW-16    16mm² (224/.30) 5.59 8.0 9.1 95% 11.4 34 272 1.16
EXRAD–EF/EF-KW-20    20mm² (273/.29) 6.20 8.6 9.9 95% 12.4 37 295 0.96
EXRAD–EF/EF-KW-25    25mm² (364/.29) 6.86 9.9 11.2 95% 13.7 41 334 0.74
EXRAD–EF/EF-KW-35    35mm² (1083/.20) 7.87 10.6 12.4 95% 15.1 57 469 0.53
EXRAD–EF/EF-KW-50    50mm² (1615/.20) 9.91 12.5 14.3 95% 17.1 65 618 0.37
EXRAD-EF/EF-KW-70 70mm²  (1140/.28) 11.56 14.7 16.5 95% 19.3 73 865 0.26
EXRAD-EF/EF-KW-95 95mm²  (1938/.25) 13.51 17.0 19.0 95% 22.0 83 1,167 0.19
EXRAD-EF/EF-KW-120 120mm²  (2442/.25) 15.24 18.7 20.7 95% 23.7 90 1,465 0.15
ISO 19642 Section Description Requirement Typical Results (35mm2 Sample)
6.1.1 Outside Cable Diameter 15.4mm max. 15.13mm Pass
6.1.2 Ovality of Sheath 10% max 4.0% Pass
5.1.1 Inner Core Diameter 11.6mm max. 10.59mm Pass
5.1.2 Insulation Thickness 1.04mm min. 1.32mm 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. 6.08 x 1014 Ω /mm Pass
6.2.3.2 DC Resistance of Screen Per customer agreement 3.24mΩ/m NA
6.2.3.3 Surface Transfer Imp. - Tri Axial Per customer agreement Inquire NA
6.3.3 Flexibility Test Customer-Defined 87.3 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% 93% 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 2.76 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