From The Lab: Environmental testing of Harnessflex™ cable glands

Successfully tested to offer IP69 protection, Harnessflex cable glands help minimize the risk of electrical failure by keeping critical wiring safe during routine cleaning or wash down.

Protection under pressure

In the latest edition of our “From the Lab” series, we test Harnessflex Type CGS Cable Glands to IP69 (IEC BS EN 60529) standard.

Electrical systems need reliable cable protection to safeguard electrical wiring – the heartbeat of any heavy automotive vehicle. As a heavy-duty vehicle navigates treacherous terrain and demanding environments, securing wiring is critical to maintain vehicle productivity and safety.

It’s not just during intensive applications where vehicle wiring needs to be protected, but also in day-to-day maintenance. High pressure washing is a common way of cleaning buses, trucks and other large specialist vehicles to remove dirt, oils and debris. However, without safeguarding susceptible cables against immense pressure and liquid ingress, it can leave vehicle wiring vulnerable to damage.

With systems that offer ingress protection up to IP67-68, ABB’s Harnessflex™ cable glands protect and help minimize the risk of an electrical failure by keeping critical wiring safe during routine cleaning and wash down. When a Harnessflex sealed fitting or gland is used, this boosts protection up to the IP69 level, to protect against high pressure washing as well as excessive cable strain and mechanical abrasion.

In a previous edition of “From the Lab,” we tested the resilience of our Harnessflex Sealed Conduit systems in our in-house Ingress Protection (IP) testing chamber. This time we tested how our Harnessflex cable glands perform in the same Ingress Protection test.

Pressure Testing

Through our Ingress Protection Test Chamber, the Harnessflex Research and Development team replicate a variety of real-world scenarios – from sprays reproducing light rain fall to power water jets that come as a result of a vehicle being cleaned in high intensity washing. Based on how the conduit system performs under the testing conditions, it is granted an IP rating used to classify the degree of protection provided by enclosures of electrical equipment.

To see how our Harnessflex cable glands protect vehicle wiring against close-range, high pressure, high temperature spray downs, we tested a sample under IPX9 to IEC BS EN 60529 conditions.

Three of each size (metric) of cable gland were selected from the Harnessflex Type CGS range to test. These were all visually inspected before testing began and then assembled with dry kitchen paper placed in the center of the fitting. Once assembled, the part was secured to the turntable of the Ingress Protection Test Chamber.

Three tests were conducted on each size of gland, using the three different samples of each size as follows:

  1. The water was heated to 80 degrees (+/-5) Celsius.
  2. The delivery rate of the water was at 15L/minute.
  3. The pressure was set at 90 Bar.

With the turntable speed set at a constant 5 rotations per minute (+/- 1 r/min), these three tests aimed to replicate the common elements Harnessflex cable glands will encounter.

Once the testing began, the cable glands were sprayed with water at 0, 30, 60 and 90-degree angles. This is performed for 30 seconds at each angle to ensure the cable gland is properly tested from all sides.

Proven Protection

After each test is completed, the gland is visually inspected to see if any ingress occurred causing the dry paper to dampen. After all 15 tests (five sizes tested three times inside the chamber), the paper remained dry in each case to pass the IPX9 test.

This means by installing a Harnessflex sealed conduit system or protecting cables using Type CGS cable glands, you can help ensure that vulnerable connectors are protected from the elements, foreign bodies and jet washing. Successfully tested to offer IP69 protection, Harnessflex cable glands help minimize the risk of electrical failure by keeping critical wiring safe during routine cleaning or wash down.

Learn more about ABB’s Harnessflex cable glands here:

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About the author

Nathan Cook

Nathan is the Global Business Development Manager for ABB’s Harnessflex Brand of products, the leading and best range of cable and connector protection systems in the Heavy Automotive Sector. Harnessflex is dedicated to innovating and delivering maximum circuit integrity and performance in productivity critical heavy vehicles, including construction, agricultural & mining machinery, bus, truck, and drive train technology. Harnessflex is moving into the future with specialty ranges and advancements for growth industry sectors and high-spec applications such as EV development and high temperature protection. Nathan is based in the UK and works with customers and colleagues around the globe to protect electrical systems from in-field failure and the resulting machine downtime.
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