Hi-Flex - Habia Cable€¦ · 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

Cables for hybrid electric drive vehiclesHi-Flex

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................................................................................................................................................... 03

Hi-Flex

Military grade, flexible power cores ................................................................................ 04

ZH Commercial grade, LSZH flexible power cores .......................................................... 05

ZH-STJ 1 Commercial grade, LSZH screened and sheathed flexible power cores ........... 06

Materials

Insulation and sheath information ................................................................................... 07

Power

De-rating factors and curves ............................................................................................ 08

Contents

About the concept

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.

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................................................................................................................................................... 03

Hi-Flex

Military grade, flexible power cores ................................................................................ 04

ZH Commercial grade, LSZH flexible power cores .......................................................... 05

ZH-STJ 1 Commercial grade, LSZH screened and sheathed flexible power cores ........... 06

Materials

Insulation and sheath information ................................................................................... 07

Power

De-rating factors and curves ............................................................................................ 08

With over 75 years experience in the design and manufactureof wires and cables for demanding applications, our experiencein 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 14001.

Hi-FlexThe Hi-Flex concept was initially designed for use with militaryHybrid 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:

• Flexibility• High temperature performance• Oil & Fuel resistance• Non-Biological Contaminent (NBC) hardened• Abrasion resistance

Hi-Flex ZHFollowing the successful development of the original Hi-Flexproduct, the increasing demand in the civilian sector for KineticEnergy Recovery Systems (KERS) as well as HEDs as resultedin the development of the Hi-Flex ZH variant which has theadditional ability to be coloured in accordance with the industrystandards, 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.

CompatibilityHi-Flex materials ensure a long flex-life and reduced strain oncable terminations, thereby reducing the Mean Time BeforeFailure (MTBF) of the cable. Hi-Flex cables are mechanicallytough and feature low minimum bend radius of:

• 4x cable OD for static use• 8x cable OD for flexing use

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.

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300/500V AC U0/U -50oC to +140oCDescription Conductor Finished Wire Article Number

Hi-FlexSize

Tin Plated Copper(TPC)

Roctech & TPS 125 XLWeight Amps

StrandingDC resistance Wire Core Tolerance

AWG mm2 Ω/km Nom Ø Nom Ø Min Ø Max Ø Nom g/m @ 30oC

Hi-Flex 1.0 - 1.0 Class 5 20.0 1.20 2.50 2.35 2.70 15 30 903000100

Hi-Flex 1.5 - 1.5 Class 5 13.7 1.50 2.85 2.70 3.00 21 39 903000150

Hi-Flex 2.5 - 2.5 Class 5 8.21 1.95 3.45 3.30 3.60 32 55 903000250

Hi-Flex 4 - 4 Class 5 5.09 2.50 4.25 4.10 4.40 49 73 903000400


Hi-FlexSize





Hi-Flex 6 - 6 Class 6 3.39 3.60 4.85 4.60 5.00 65 98 903cc0600

Hi-Flex 10 - 10 Class 6 1.95 4.55 6.00 5.80 6.50 105 138 903cc1000

Hi-Flex 16 - 16 Class 6 1.24 5.70 7.70 7.45 8.30 170 185 903cc1600

Hi-Flex 25 - 25 Class 6 0.795 7.20 9.50 9.20 10.40 255 250 903cc2500

Hi-Flex 35 - 35 Class 6 0.565 8.40 11.15 10.70 11.60 420 312 903cc3500

Hi-Flex 50 - 50 Class 6 0.393 10.30 12.95 12.45 13.50 510 395 903cc5000

Hi-Flex 70 - 70 Class 6 0.277 12.40 14.80 14.30 15.50 700 496 903cc7000

Hi-Flex 95 - 95 Class 6 0.210 14.30 17.05 16.50 18.00 940 599 903cc9500

Hi-Flex 120 - 120 Class 6 0.164 16.00 19.30 18.90 19.70 1,180 713 903cc9120

Hi-Flex 150 - 150 Class 6 0.132 18.00 20.80 20.20 21.40 1,465 811 903cc9150

Hi-Flex 185 - 185 Class 6 0.105 20.00 23.30 22.30 24.30 1,820 921 903cc9185

Hi-Flex 240 - 240 Class 6 0.080 23.00 27.75 26.75 28.75 2,465 1,115 903cc9240

Hi-Flex 300 - 300 Class 6 0.060 26.00 30.70 29.45 31.95 2,990 1,296 903cc9300

Hi-Flex 400 - 400 Class 6 0.048 30.00 36.30 35.05 37.55 4,145 1,554 903cc9400


Hi-Flex 1000Size





Hi-Flex 6 1000 - 6 Class 6 3.39 3.60 6.00 5.85 6.15 77 98 910cc0600

Hi-Flex 10 1000 - 10 Class 6 1.95 4.55 7.20 7.00 7.40 120 138 910cc1000

Hi-Flex 16 1000 - 16 Class 6 1.24 5.70 8.60 8.35 8.85 189 185 910cc1600

Hi-Flex 25 1000 - 25 Class 6 0.795 7.20 10.30 10.00 10.60 275 250 910cc2500

Hi-Flex 35 1000 - 35 Class 6 0.565 8.40 11.85 11.40 12.30 380 312 910cc3500

Hi-Flex 50 1000 - 50 Class 6 0.393 10.30 13.65 13.15 14.15 525 395 910cc5000

Hi-Flex 70 1000 - 70 Class 6 0.277 12.40 15.50 15.00 16.00 719 496 910cc7000

Hi-Flex 95 1000 - 95 Class 6 0.210 14.30 17.80 17.25 18.35 962 599 910cc9500

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 6722-1:2011

Hi-FlexTPS 125 XL insulated power cores for flexible useIntended for military automotive applications

IdentificationColours - Replace ‘cc’ in the article number with the 2 digit number below

00

Black - - - - - - - - - - -

Habia Cable - Article No. - Year-Week - Batch code

Characteristics & key properties

RoHS2011/65/EU

REACH EC No.

1907/2006

LVD2014/35/EU

Current rat-ings in free air based on IEC

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Hi-Flex ZHSize


Roctech & HFI 121 XLWeight Amps



Hi-Flex 1.0 ZH - 1.0 Class 5 20.0 1.20 2.50 2.35 2.70 15 30 909cc0100



Hi-Flex 4 ZH - 4 Class 5 5.09 2.50 4.25 4.10 4.40 49 73 909cc0400


Hi-Flex ZHSize


Roctech & HFI 121 XLWeight Amps











Hi-Flex 120 ZH - 120 Class 6 0.164 16.00 19.30 18.90 19.70 1,180 713 909cc9120



Hi-Flex 240 ZH - 240 Class 6 0.080 23.00 27.75 26.75 28.75 2,465 1,115 909cc9240



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 6722-1:2011

Hi-Flex ZHHFI 121 XL insulated power cores for flexible use, LSZHIntended for automotive applications

IdentificationColours - Replace ‘cc’ in the article number with the 2 digit number below

00 11 22 33 44 55 66 77 88 99 29 -

Black Brown Red Orange Yellow Green Blue Violet Grey White Pink -

Habia Cable - Article No. - Year-Week - Batch code


RoHS2011/65/EU

REACH EC No.

1907/2006

LVD2014/35/EU


60287

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Hi-Flex ZH-STJ 1

600/1000V AC U0/U -50oC to +140oCDescription Arrangement Cores Finished Cable Article Number

Hi-Flex ZH-STJ 1 No. of cores

Conductor Insulation Shield/s Sheath/sWeight Amps

SizeStranding

TPC Roctech & HFI 121 XL

TPCbraid

HFI 121 XL

mm2 Nom Ø Nom Ø Nom Ø Nom Ø Nom g/m @ 30oC

Hi-Flex 6 ZH - STJ 1

1

6 Class 6 3.60 4.85 5.45 7.60 115 98 700030523

Hi-Flex 10 ZH - STJ 1 10 Class 6 4.55 6.00 6.60 8.60 160 138 700030524






Hi-Flex 95 ZH - STJ 1 95 Class 6 14.30 17.05 18.00 21.20 1,175 599 700028633

Hi-Flex 120 ZH - STJ 1 120 Class 6 16.00 19.30 20.20 24.20 1,485 713 700028634

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.

HFI 121 XL insulated & sheathed, shielded single cores for flexible use, LSZHIntended for automotive applications

IdentificationColours

Part Colours Notes / Printing

Cores Black

Outer sheath Orange Habia Cable - Article No. - Year-Week - Batch code


RoHS2011/65/EU

REACH EC No.

1907/2006

LVD2014/35/EU


60287

07h a b i a . c o m

TPS 125 XL

Used as insulation for Hi-Flex

Materials // Insulation and sheath information

Hi-Flex cables are constructed using high-performance insulation and sheath materials.

ConductorsTin 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.

InsulationHi-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.

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).

SheathsHi-Flex ZH - STJ cables also use Habia Cables HFI 121 XL materials for an overall mechanically tough and flexible sheath.

ImportantThis 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.

Spider graphsOur material performance can be compared via these simple key-property grpahs. More detailed information can be provided on request.

HFI 121 XL

Used as: - Insulation for Hi-Flex ZH - Outer sheath for Hi-Flex ZH STJ 1

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Power // De-rating factors and curves

Multicore de-rating factorsNumber of cores

2 3 4 6 8 10 12 16 20 24 28 36 40Factor 1.00 0.88 0.80 0.69 0.62 0.59 0.55 0.51 0.48 0.43 0.41 0.38 0.36

Installation de-rating factorsClipped to a

vertical structureClipped to a

horizontal structureOn solid metal trays On aerated metal trays

Number of cores 1 2 3 1 2 3 1 2 3 1 2 3Without spacing 0.94 0.80 0.76 0.89 0.76 0.57 0.97 0.85 0.74 1.00 0.87 0.74With spacing 0.94 0.90 0.87 0.89 0.81 0.77 0.97 0.96 0.93 1.00 1.00 1.00

Temperature de-rating curves

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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 temperaturesAnother 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 +85oC• Prolonged contact or handling: +69oC

De-rating factors assume the insulation to be operating at its maximum temperature (e.g. a 150oC rated material at 40oC ambient air temperature: the heat generated by the current passing through the conductor will increase the temperature by an additional 110oC to its maximum 150oC rating).

ImportantThis 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.

HEAD OFFICE, SWEDENHabia Cable ABTel: +46 (0) 8 630 74 40Email: [email protected]

CHINAHabia Cable China LtdTel: +86 (0) 5198 511 8010Email: [email protected]

DENMARKHabia Cable ABTel: +46 (0) 72 214 4492Email: [email protected]

FINLANDHabia Cable ABTel: +358 (0) 20 155 25 30Email: [email protected]

FRANCEHabia Cable SATel: +33 (0) 2 38 22 15 70Email: [email protected] GERMANYHabia Cable GmbHTel: +49 (0) 731 70 47 95 0Email: [email protected]

INDIAHabia CableTel: +91 99 728 82254Email: [email protected]

KOREAHabia Cable Asia LtdTel: +82 (0) 2 504 6674Email: [email protected]

NETHERLANDSHabia Cable BVTel: +31 (0) 76 541 6400Email: [email protected]

NORWAYHabia Cable ABTel: +47 99 09 09 30Email: [email protected]

UNITED KINGDOMHabia Cable LimitedTel: +44 (0) 1454 412522Email: [email protected]

FULL CONTACT DETAILScan be found at habia.com

© Habia Cable 2018All rights reserved.

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 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 technical competence with competitive lead times and low minimum order quantities.

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Hi-F

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2018

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Documents

Hi-Flex - Habia Cable€¦ · 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