Hi-Flex. Cables for hybrid electric drive vehicles

Transcription

1 Hi-Flex Cables for hybrid electric drive vehicles

2 Contents About the concept Hi-Flex Materials Military grade, flexible power cores ZH Commercial grade, LSZH flexible power cores ZH-STJ 1 Commercial grade, LSZH screened and sheathed flexible power cores Insulation and sheath information Power De-rating factors and curves All data within this publication indicates nominal values in millimetres (mm) unless otherwise stated. DISCLAIMER: Information is indicative and cannot be considered a binding representation or warranty for products and their use. Valid at the time of publication, it is subject to change without notice. 02

3 Flexible power cables for hybrid electric drives Established in 1941, Habia Cable has developed a wealth of experience in the design and manufacture of high performance wires and cables to meet the requirements of international standards and exacting customer specifications. With over 75 years experience in the design and manufacture of wires and cables for demanding applications, our experience in the industrial market is strong and diverse. Manufacturing facilities in Sweden, Germany, China and Poland together with Research and Development provide a high level of support to Habia Cable s network of Sales Offices throughout Europe and the Far East. The company holds accreditation to ISO 9001 and ISO Hi-Flex The Hi-Flex concept was initially designed for use with military Hybrid Electric Drive (HED) vehicles in order to meet an increasing demand for higher power ratings without the usual increase in copper size and weight. As a military product, the Hi-Flex concept combines a number of key characteristics for this market: Hi-Flex ZH Following the successful development of the original Hi-Flex product, the increasing demand in the civilian sector for Kinetic Energy Recovery Systems (KERS) as well as HEDs as resulted in the development of the Hi-Flex ZH variant which has the additional ability to be coloured in accordance with the industry standards, as well as offering Low Smoke Zero Halogen (LSZH) properties. For both cable options, the key benefits are an increased current rating when compared to standard insulation materials which results from the use of high-temperature insulation materials. This gives Hi-Flex a much improved space envelope since a smaller, lighter core can often be used for the same power rating as a larger, standard cable. Compatibility Hi-Flex materials ensure a long flex-life and reduced strain on cable terminations, thereby reducing the Mean Time Before Failure (MTBF) of the cable. Hi-Flex cables are mechanically tough and feature low minimum bend radius of: 4x cable OD for static use 8x cable OD for flexing use Flexibility High temperature performance Oil & Fuel resistance Non-Biological Contaminent (NBC) hardened Abrasion resistance 03

4 Hi-Flex TPS 125 XL insulated power cores for flexible use Intended for military automotive applications 300/500V AC U 0 Description Conductor Finished Wire Article Number Hi-Flex Tin Plated Copper Roctech & TPS 125 XL (TPC) DC resistance Wire Core Tolerance AWG mm 2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom 30 o C Hi-Flex Class Hi-Flex Class Hi-Flex Class Hi-Flex 4-4 Class /1000V AC U 0 Description Conductor Finished Wire Article Number Hi-Flex Tin Plated Copper Roctech & TPS 125 XL (TPC) DC resistance Wire Core Tolerance AWG mm 2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom 30 o C Hi-Flex 6-6 Class cc0600 Hi-Flex Class cc1000 Hi-Flex Class cc1600 Hi-Flex Class cc2500 Hi-Flex Class cc3500 Hi-Flex Class cc5000 Hi-Flex Class cc7000 Hi-Flex Class cc9500 Hi-Flex Class , cc9120 Hi-Flex Class , cc9150 Hi-Flex Class , cc9185 Hi-Flex Class ,465 1, cc9240 Hi-Flex Class ,990 1, cc9300 Hi-Flex Class ,145 1, cc /1900V AC U 0 Description Conductor Finished Wire Article Number Hi-Flex 1000 Tin Plated Copper Roctech & TPS 125 XL (TPC) DC resistance Wire Core Tolerance AWG mm 2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom 30 o C Hi-Flex Class cc0600 Hi-Flex Class cc1000 Hi-Flex Class cc1600 Hi-Flex Class cc2500 Hi-Flex Class cc3500 Hi-Flex Class cc5000 Hi-Flex Class cc7000 Hi-Flex Class cc9500 Current rating applies to a single core hanging in free air. Additional de-rating required for ambient temperature, bundling of multiple cores and/or method of installation. 300V and 600V sizes: 1.0 to 120 comply with ISO :2011 Identification 00 Colours - Replace cc in the article number with the 2 digit number below Black Characteristics & key properties RoHS 2011/65/EU REACH EC No. 1907/2006 LVD 2014/35/EU Habia Cable - Article No. - Year-Week - Batch code Current ratings in free air based on IEC

5 Hi-Flex ZH HFI 121 XL insulated power cores for flexible use, LSZH Intended for automotive applications 300/500V AC U 0 Description Conductor Finished Wire Article Number Hi-Flex ZH Tin Plated Copper Roctech & HFI 121 XL (TPC) DC resistance Wire Core Tolerance AWG mm 2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom 30 o C Hi-Flex 1.0 ZH Class cc0100 Hi-Flex 1.5 ZH Class cc0150 Hi-Flex 2.5 ZH Class cc0250 Hi-Flex 4 ZH - 4 Class cc /1000V AC U 0 Description Conductor Finished Wire Article Number Hi-Flex ZH Tin Plated Copper Roctech & HFI 121 XL (TPC) DC resistance Wire Core Tolerance AWG mm 2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom 30 o C Hi-Flex 6 ZH - 6 Class cc0600 Hi-Flex 10 ZH - 10 Class cc1000 Hi-Flex 16 ZH - 16 Class cc1600 Hi-Flex 25 ZH - 25 Class cc2500 Hi-Flex 35 ZH - 35 Class cc3500 Hi-Flex 50 ZH - 50 Class cc5000 Hi-Flex 70 ZH - 70 Class cc7000 Hi-Flex 95 ZH - 95 Class cc9500 Hi-Flex 120 ZH Class , cc9120 Hi-Flex 150 ZH Class , cc9150 Hi-Flex 185 ZH Class , cc9185 Hi-Flex 240 ZH Class ,465 1, cc9240 Hi-Flex 300 ZH Class ,990 1, cc9300 Hi-Flex 400 ZH Class ,145 1, cc9400 Current rating applies to a single core hanging in free air. Additional de-rating required for ambient temperature, bundling of multiple cores and/or method of installation. 300V and 600V sizes: 1.0 to 120 comply with ISO :2011 Identification Colours - Replace cc in the article number with the 2 digit number below Black Brown Red Orange Yellow Green Blue Violet Grey White Pink - Characteristics & key properties RoHS 2011/65/EU REACH EC No. 1907/2006 LVD 2014/35/EU Habia Cable - Article No. - Year-Week - Batch code Current ratings in free air based on IEC

6 Hi-Flex ZH-STJ 1 HFI 121 XL insulated & sheathed, shielded single cores for flexible use, LSZH Intended for automotive applications 600/1000V AC U 0 Description Arrangement Cores Finished Cable Article Number Hi-Flex ZH-STJ 1 Hi-Flex 6 ZH - STJ 1 No. of cores Conductor Insulation Shield/s Sheath/s TPC Roctech & TPC HFI 121 XL HFI 121 XL braid mm 2 Nom Ø Nom Ø Nom Ø Nom Ø Nom 30 o C 6 Class Hi-Flex 10 ZH - STJ 1 10 Class Hi-Flex 16 ZH - STJ 1 16 Class Hi-Flex 25 ZH - STJ 1 25 Class Hi-Flex 35 ZH - STJ Class Hi-Flex 50 ZH - STJ 1 50 Class Hi-Flex 70 ZH - STJ 1 70 Class Hi-Flex 95 ZH - STJ 1 95 Class , Hi-Flex 120 ZH - STJ Class , Other designs (including screened versions) are available for this part of the standard and will be incorporated on an on-going basis. Should you require an item that is not included within this table, please contact one of our sales offices. Identification Cores Colours Part Colours Notes / Printing Black Outer sheath Orange Habia Cable - Article No. - Year-Week - Batch code Characteristics & key properties RoHS 2011/65/EU REACH EC No. 1907/2006 LVD 2014/35/EU Current ratings in free air based on IEC

7 Materials // Insulation and sheath information Hi-Flex cables are constructed using high-performance insulation and sheath materials. Conductors Tin plated copper condutors and braided screens provide good all-round mechanical performance. Stronger that bare copper and without the cost of silver or nickel plating, tin plated cores are easy to solder whilst our stranding ensures both good flex-life and flexibility. Hi-Flex ZH cable types use Habia Cable s HFI 121 XL insulation to ensure a flexible, robust product which can be coloured and is fully Low Smoke Zero Halogen (LS0H). Sheaths Hi-Flex ZH - STJ cables also use Habia Cables HFI 121 XL materials for an overall mechanically tough and flexible sheath. Insulation Hi-Flex cables types use Habia Cable s TPS 125 XL insulation; this is a flexible, yet abrasion resistant, high temperature material with good chemical resistance properties. TPS 125 XL HFI 121 XL Used as insulation for Hi-Flex Used as: - Insulation for Hi-Flex ZH - Outer sheath for Hi-Flex ZH STJ 1 Spider graphs Our material performance can be compared via these simple key-property grpahs. More detailed information can be provided on request. Important This information is offered solely as a convenience to Habia Cable s customers and is intended only as a guide. Data is based on typical values and might vary depending on cable construction and processing method. Habia Cable has compiled the information contained herein from what it believes to be accurate and factual sources as of the date compiled. Any changes in the data will be made without notification. 07

8 Power // De-rating factors and curves Factor Number of cores Without spacing With spacing Clipped to a vertical structure Multicore de-rating factors Number of cores Installation de-rating factors Clipped to a horizontal structure Temperature de-rating curves 08 habia.com On solid metal trays On aerated metal trays

9 De-rating factors are calculated based on the size of the conductor and the materials used within a cable. Please note that high conductor temperatures can cause damage to their surroundings and that temperature increases in a confined space more than is calculated and that high conductor temperatures also create a high voltage drop. De-rating factors are cumulative and cables should be de-rated for number of cores and installation method and temperature. Safe handling temperatures Another important consideration. Regardless of what temperature the insulation can take, it is equally important that it doesn t injure or damage anyone or anything it comes into contact with. Habia Cable s recommended safe handling temperatures (taken from MIL-STD-1472) are proposed as: Momentary contact +85 o C Prolonged contact or handling: +69 o C De-rating factors assume the insulation to be operating at its maximum temperature (e.g. a 150 o C rated material at 40 o C ambient air temperature: the heat generated by the current passing through the conductor will increase the temperature by an additional 110 o C to its maximum 150 o C rating). Important This information is offered solely as a convenience to Habia Cable s customers and is intended only as a guide. Data is based on typical values and might vary depending on cable construction and processing method. Habia Cable has compiled the information contained herein from what it believes to be accurate and factual sources as of the date printed. Any changes in the data will be made without notification. 09

10 Habia Cable is one of Europe s leading wire and cable manufacturers. We develop, manufacture and market custom design cables and harness systems for demanding applications in a number of diverse industries. The company has a global HEAD OFFICE, SWEDEN Habia Cable AB Tel: +46 (0) info.se@habia.com CHINA Habia Cable China Ltd Tel: +86 (0) info.cn@habia.com DENMARK Habia Cable AB Tel: +46 (0) info.dk@habia.com INDIA Habia Cable Tel: info.in@habia.com KOREA Habia Cable Asia Ltd Tel: +82 (0) info.kr@habia.com NETHERLANDS Habia Cable BV Tel: +31 (0) info.nl@habia.com FULL CONTACT DETAILS can be found at habia.com Habia Cable 2018 All rights reserved. presence and worldwide sales of custom design and standard products in more than 50 countries. We aim to provide a high level of customer service and FINLAND Habia Cable AB Tel: +358 (0) info.fi@habia.com FRANCE Habia Cable SA Tel: +33 (0) info.fr@habia.com NORWAY Habia Cable AB Tel: info.no@habia.com UNITED KINGDOM Habia Cable Limited Tel: +44 (0) info.uk@habia.com technical competence with competitive lead times and low minimum order quantities. GERMANY Habia Cable GmbH Tel: +49 (0) info.de@habia.com Hi-Flex_2018_07