En Fahrzeug 06

Automotive Wires and Cables

LEONI connects – People, Enterprises, Markets

The Quality Connection Content

Edition: May 2006

Subject to change and error.

© by LEONI Kabel GmbH 2006

Please note: LEONI herewith warrants that the delivery items contained in this catalogue will be of

the agreed nature and quality upon passing of the risk. Aforementioned nature of the delivered

items shall be exclusively rated and measured by the sale and purchase agreements made in writing

between LEONI and the purchaser about nature and quality, properties and characteristic performance

features of the respective delivery item. Illustrations and information contained in catalogues, price

lists and other information material disclosed to the purchaser by LEONI as well as any information

describing the product shall be only legally binding, if expressly being referred to as binding informa-

tion. Under no circumstances, such information shall be taken as guarantee for the special quality or

nature of the delivery item. Such quality guarantees must be explicitly agreed upon in writing. LEONI

herewith reserves the right to modify the content of this catalogue at any time.

LEONI – The Quality Connection

2 Content

4 LEONI sets standards

6 LEONI quality management

7 LEONI – the global player

Type designation

8 Coding key

9 Examples

Marking

10 Marking of automotive wires

Conductor and Insulation materials

11 Insulation materials

12 Insulation material properties

14 Conductor materials

Standards

16 Overview of standards

Product range

17 Automotive cables, single-core

45 Automotive cables, multi-core

Packaging

68 Packaging

The LEONI group

70 We also produce …

The Quality Connection

unshielded

18 FLY

19 FLYW

20 FLYK

21 FLYWK / FLRYWK

22 FLRY-A

23 FLRY-B

24 FLRYW

25 FLRY T2 IR

26 FLRY T2 ID

27 FLRY T3 IR

28 FLRY T3 ID

29 FLR4Y

30 LEONI Mocar® 125 P

31 LEONI Mocar® 125 X

32 LEONI Mocar® 150 A

33 LEONI Mocar® 180 E

34 LEONI Mocar® 210 F

35 LEONI Mocar® 260 T

36 TXL

37 TWP

38 AV

39 AVS

40 AVSS

41 FL91Y / FL11Y

42 FLYY

43 FLY0Y / FLYK0Y

shielded

44 FLRYDY

ABS/ESP sensor cables

46 FLR4G11Y / FL4G11Y

47 FLR2X11Y

48 FLR31Y11Y

49 FLRY11Y

Cables up to 105 °C

50 FLYY / FLRYY / FLYKYK

51 FLYYF

52 FLYZ

53 FLRYBY / FLRYDY / FLRYBDY / FLRYCY

54 FLRYY (GGVS) / FLRYY11Y

55 FLY(YDY)(YBY)CY 3x0.35+(1x0.35)+(2x0.35)


56 FLYWYW / FLRYWYW / FLRYWZ / FLRYWYWF

57 FLR91Y11Y / FLR12Y11Y / FLU7Y11Y / FLU6Y11Y

Cables from 150 °C

58 FLR13Y13Y / FLR13YC13Y / FLU7Y7Y /

FLU6Y6YF / FLR6YC6Y

LEONI Dacar® data cables

59 LEONI Dacar® 502 – LVDS

60 LEONI Dacar® 533 – Bus systems

61 LEONI Dacar® 550 – Sensor cables

62 LEONI Dacar® 570 – Car telephone cables

LEONI Dacar® coaxial cables

63 LEONI Dacar® 300

64 LEONI Dacar® 302

LEONI Hivocar®

65 LEONI Hivocar®

Flat cables

66 LEONI exFC®

Ribbon cables

67 Ribbon cables

page 17 page 45

Automotive cablessingle-core

Automotive cablesmulti-core

4

LEONI sets standardsThe Quality Connection

There is tradition and a future in expertise.

The production of wires and cables is a traditional activity at LEONI

going back several decades. In fact, the first automotive wires were

manufactured in the 1930s, and LEONI has been setting standards in

this product sector for the entire industry ever since. For example,

the first ever automotive wires with reduced insulation thickness –

which LEONI developed for a manufacturer of sports cars – are now

the industry-wide standard. It would be wrong, however, to think that

we have been content to rest on our laurels. New production start-ups

in Hungary, Poland, Mexico and China plus selective company take-

overs have turned LEONI into the world‘s biggest and most successful

producer of wires for automotive applications.

Our product engineers not only have considerable know-how in the

full range of automobile-related applications but are also highly expe-

rienced in the production of cables and in the solving of even the most

difficult cabling problems. Our customers know this and appreciate it.

LEONI is your partner for:

Consulting on product optimization

Development of system solutions

Development of prototypes and series

Laboratory, testing and RF instrumentation

This current catalogue provides a comprehensive overview of our

standard range of practice-proven automotive wire products.

If you fail to find the wire you need, please let us know. We will be glad

to make it to your specifications.

Your “Automotive & Standard Cables” Team.

5

The Quality Connection

Some of our customers

Audi

BMW

Bosch

Continental Teves

DaimlerChrysler

Delphi

Fiat

Ford

General Motors

JAH

Lear

MAN

Porsche

PSA

Renault

Siemens VDO

Sumitomo

Volkswagen Group

Yazaki

Top names place their trust in LEONI

6

LEONI quality management The Quality Connection

LEONI environmental management

For us, business success with ecological responsibility is not a contra-

diction in terms. As a globally active producer we acknowledge our

co-responsibility in protecting the world‘s natural resources and basis

of life. It is our objective to strike a harmony between nature‘s needs

and our company‘s interests. As such, environmental protection is an

intrinsic element of our corporate activities.

We motivate our contractual partners to follow environmental guide-

lines that are equivalent to our own and advise our customers on how to

use and dispose our products in an environmentally responsible manner.

Our environmental management system is certified as complying

with DIN EN ISO 14001, confirming that our environmental policy is

effectively implemented.

LEONI quality management

It receives special attention from us in the exactness with which we

conduct our planning, testing and draw up our documentation.

Without this attention we would be unable to satisfy the exception-

ally high standards of our customers from the automobile industry.

The quality management at all the LEONI Wire and Cable locations

throughout the world is certified as complying with ISO 9001:2002;

locations producing automotive cables are also certified according

to ISO/TS 16949:2002. Our efforts are concentrated on preventive

quality assurance involving fault-inhibiting instruments such as FMEA

or machine and process capability analysis.

We use state-of-the-art systems to continuously measure, monitor

and control the diameter and dielectric strength of our cables and

wires during the production process. Regular testing of random

samples (statistical process control methods) guarantees product

compliance with the required limit values. With these tests conducted

directly alongside the production line it is possible to respond quickly

to any faults.

Product properties are tested in accordance with our customers‘ own

specifications and/or German and international standards. They include:

cable and wire behavior under extreme temperature

conditions

functionality after artificial ageing

resistance to fuels, lubricants and environmental influences

resistance of the insulated covering to stretching,

abrasion and tearing

mechanical and electrical properties of the conductor

alternate bending strength and resistance to torsion

Through the combined efforts of these quality assurance activities we

are able to continuously optimize our ambitious quality goals.

7

The Quality ConnectionLEONI – the global player

Cable facilities of the business unit “Automotive & Standard Cables”

LEONI Kabel, Roth

(Germany)

LEONI Slowakia, Nova Dubnica

(Slovakia)

LEONI Kabel Polska, Kobierzyce

(Poland)

LEONI Kábelgyár Hungaria, Hatvan

(Hungary)

LEONI Cable (Changzhou), Changzhou

(China)

LEONI Cable, Cuauhtémoc

(Mexico)

LEONI Kablo ve Teknolojileri, Gemlik

(Turkey)

The high quality of LEONI products is one of the most important factors behind the company‘s success.

8

Coding keyType designation

1. Type of wire (German abbreviations)

FL = Automotive wire

FZL = Automotive ignition wire

2. Special conductor materials (excluding electrolytic copper)

M Materials other than E-Cu or resistance conductors

(e. g. aluminium, steel, steel copper, etc.)

W Resistance conductors

(usually copper alloys with Ni, Cr, Mn, etc.)

3. Geometric construction of insulation

Normal thickness of insulation (equivalent to ISO 6722 “Thick wall”)

is not coded.

U Greatly reduced thickness of insulation equivalent to ISO 6722

R Reduced thickness of insulation equivalent to ISO 6722

S Reinforced insulation

(thickness bigger than specified in ISO 6722) The code can also be used for other thicknesses.

The relevant standard or thickness is then also named.

4. Codes for the dielectrics

Code for the dielectrics used for the insulation and sheath.

Y Soft-PVC (polyvinyl chloride)

YW Soft-PVC, heat-resistant, hot-pressure resistant

YK Soft-PVC, cold-resistant

2Y PE (polyethylene)

4Y PA (polyamide)

6Y FEP (tetrafluoroethylene/hexafluoropropylene)

7Y E/TFE (ethylene/tetrafluoroethylene)

9Y PP (polypropylene)

11Y TPE-U (thermoplastic elastomer on polyurethane basis)

12Y TPE-E (thermopl. polyester elastomer on polyether ester basis)

13Y TPE-E (thermopl. polyester elastomer on polyester ester basis)

31Y TPE-S (thermopl. polyester elastomer on polystyrene basis)

41Y TPE-A (thermopl. polyester elastomer on polyamide basis)

51Y PFA (perfluoroalkoxy copolymer)

91Y TPE-O (thermopl. polyester elastomer on polyolefin basis)

X PVC-X (polyvinyl chloride crosslinked)

2X XLPE (polyethylene crosslinked)

4G EVA (ethylene/vinyl acetate)

10Y PVDF (polyvinylidenfluoride)

In foamed materials the code is preceded by a “zero”:

e. g. 02Y = foamed or cellular PE.

5. Codes for constructional elements

Codes for further constructional elements and non-extruded

coverings (where applicable).

B Foil shield

C Copper wire braiding

D Copper wire spiral shield

G Glass fiber braiding

P Insulation foil

T Textile braiding

6. Special design features

F Flat wire

Z Multi-core wire with separable cores

7. Finally …

… the number of cores (except in the case of single core wires) and

the nominal cross-section in mm2 are specified. Especially flexible or

highly flexible stranded conductors are identified by additional speci-

fication of the nominal cross-section of the single wire.

In some cases the type of metal plating is specified for metal-plated

copper wires as follows:

SN tin-plated

NI nickel-plated

AG silver-plated

Bare copper has no special code.

Various components joined by specific structural elements (e. g. inner

sheaths or inner shields) are grouped in parentheses in the type code

(see examples of coding).

The type designation provides information on the type of wire, the

insulation and sheath materials used and the principle design features

in abbreviated and simplified form.

A type designation is made up of several groups. The type of wire is

specified first and then its construction from inside to outside.

9

Type designationExamples

according to ISO 6722

1. Single-core cables

2. Multi-core cables

FL R Y 0.75

Nom. cross-section

0.75 mm2

PVC insulation

Reduced thickness of insulation

Automotive wire

FL YK 25.0/ 0.1

Max. individual

wire-diameter

Nominal cross-section 25 mm2

Insulation (cold-resistant PVC)

Automotive wire

FL Y 0.5

Nominal cross-section

0.5 mm2

PVC insulation

Automotive wire

FL Y Y 2x 0.5

Nominal cross-section 0.5 mm2

Two cores

PVC sheath

PVC insulation

Automotive wire

FL R Y 2x 1.5 sn- A

Symmetric

conductor structure

Tinned individual wire

Nominal cross-section 1.5 mm2

Two cores

PVC insulation


Automotive wire

FL R Y B D YW 2x 0.5

Nominal cross-

section 0.5 mm2

Two cores

Outer sheath

(heat-resistant PVC)

Copper wire spiral shield

Foil shield (static shielding)

PVC insulation


Automotive wire

FL Y (Y D Y) (Y B Y) C Y 3x0.35+ (1x0.35)+ (2x0.35)

2 cores with

foil shield and inner sheath

1 core with inner shield

(copper wire braiding and inner sheath)

3 cores (without inner shield and inner sheath)

PVC outer sheath for all elements

Complete shield (copper wire braiding) for all elements

PVC inner sheath for the specially grouped elements

Inner sheath (foil tape) for the specially grouped elements

PVC insulation for further specially grouped elements (cores)

PVC inner sheath for the specially grouped element

Inner shield (copper wire spiral shield) for the specially grouped element

PVC insulation for a specially grouped element (core)

PVC insulation

Automotive wire

10

Marking of automotive wiresMarking

Manufacturer’s markings

1. Single-core wires with a nominal cross-section of 0.35 mm2 and

more are permanently marked with the manufacturer’s logo “LEONI”

at maximum intervals of 200 mm (embossed or printed).

The marking of wires with a nominal cross-section smaller than

0.35 mm2 is the subject of agreement between the manufacturer and

user.

2. There are several alternative methods of marking multi-core wires:

Marking of one (or more) core(s) as described under 1 above.

Embossing or printing of the sheath.

Color coding

1. The colors commonly used for the insulation of automotive wires

are: white, yellow, grey, green, red, violet, brown, blue, black, orange.

(Colors according to DIN 47002 and DIN IEC 304).

2. Two-color automotive wires are marked by two diametrically

opposed extruded longitudinal stripes. The width of every stripe must

cover at least 7 % of the surface of the wire, with both marking stripes

together covering at most 35 % of the surface.

3. Tricolor automotive wires are marked according to LV 112, Part 6:

First color: primary color.

Second color: longitudinal stripes (as under 2 above).

Third color: in the form of rings. Width of rings: 3 ± 1 mm.

Distance between two successive rings: 6 to 20 mm.

An offset of maximum 1 mm between the two ring halves

is permissible.

Other markings

On request the wires can also be supplied with numbers printed on

them. Since automotive wires fall into the class of low-voltage wires,

no CE marking is needed.

11

Insulation materials Conductor and Insulation materials

LEONI develops and uses insulation materials that provide

high reliability and durability under operating conditions.

The structure and properties of the materials used are listed

below and in the table on page 12–13.

Thermoplastics

Plasticized or semi-crystalline polymers

Viscoplastic properties in the service temperature range

Plastically ductile at temperatures above the yield limit

Thermoplastic elastomers

Polymer soft and hard segments

Rubber-like elastic properties in the service temperature range

Plastically ductile at temperatures above the yield limit

Elastomers / Crosslinked plastics

Crosslinked polymer soft and hard segments

Rubber-like elastic properties with high reversible deformability

in the service temperature range

No thermoplastic flow properties – the crosslinked structure

is retained up to decomposition temperature, i.e. well above

service temperature

Requirements and quality

Material testing and development according to customer

specifications and/or national and international standards

Optimization of properties to meet changed or new requirements

Regular quality control in the form of product audits

Selection criteria

Service temperatures

Electrical values

Flexibility/hardness

Mechanical stability under load

Wear resistance

Resistance to oil, fuels, brake fluid, acids/alcalines, organic agents

Flame-retardant

halogen-free

low halogen

Service temperatures

The low service temperature range is determined by cold strength

tests, dynamic bending strength tests or by wrapping tests at low tem-

perature in accordance with ISO 6722. The maximum continuous service

temperature for materials with impairment of specific material proper-

ties is defined by the temperature index according to DIN ISO 2578.

Temperature-time curves with a 50 % reduction of the original elon-

gation at break after heat storage define the temperature index at

3000 h. Higher temperatures are permitted for shorter time intervals

(thermal overload capacity).

The diagram shows examples of how to determine the continuous

service temperature. The measurement curves lie above the tempera-

ture-time curves specified for the material. The zone in between rep-

resents the confidence interval.

temperature/time curve

measurement curve

12

Insulation material properties

Service Temperatures Resistance to

Symbol Name Codee.g. Density

Ignition residue

Extractable constituents

Halogen content

Hardness Shore A/D

Tensile strength

Elongation at break

Tempera-ture

index

Thermal overload capacity

Cold winding

test

Specific volume

resistanceDielectric strength Abrasion

Flame retardation Oil Fuels Brake fluid

Acids/ Alkalines

Organic agents

e.g. DIN ISO 1629 and 7728 DIN 76722 DIN 53479DIN 53568

T1 DIN 53738 DIN 53505 DIN 53504 DIN 53504DIN ISO

2578 ISO 6722

ISO 6722 DIN 53482 DIN 53481 ISO 6722 ISO 6722

g/cm3 % % approx. % MPa % °C/3000 hrs °C/48 hrs °C Ω · cm kV/mm

PVC-P Polyvinyl chloride (plasticized) Y 1.30–1.45 10–30 20–30 35 85A– 95A >10 >150 105 110/125 –25/–40 >1012 >10 + + + + – + –

PVC-P cold-resistant YK 1.24–1.34 10–15 30– 40 30 80A– 95A >10 >150 105 110 – 50 >1012 >10 + + + + – + –

PVC-P hot-pressure resistant, heat-resistant YW 1.24–1.34 8–15 20–30 35 92A– 97A >15 >150 125 140 –25/–40 >1012 >10 + + + + – + –

PE Polyethylene 2Y 0.92–0.95 0 0 0 50D– 62D >15 >300 90 100 – 40 >1016 >30 + – – – +/– – – + –

PA Polyamide 4Y 1.01 0 0 0 – /72D > 40 >300 105 140 – 50 >1012 >10 ++ – ++ ++ + + +

FEP Tetrafluoroethylene hexafluoropropylene 6Y 2.14 0 0 75 – /55D >15 >200 210 260 – 65 >1015 >30 ++ ++ ++ ++ ++ ++ ++

ETFE Ethylen tetrafluoroethylene 7Y 1.70 0 0 60 – /75D >30 >200 180 230 – 65 >1015 >30 ++ ++ ++ ++ ++ ++ ++

PP Polypropylene 9Y 0.91 0 0 0 – /70D >15 >200 125 150 – 40 >1016 >30 + – – + + – + +

PP-FR Polypropylene, flame-retardant 9Y 1.05–1.3 0–10 0 10 – /70D >15 >200 125 150 – 40 >1014 >20 + + + + – + +

PFA Perfluoroalkoxy copolymer 51Y 2.15 0 0 75 – /55D >20 >200 260 290 – 80 >1015 >30 ++ ++ ++ ++ ++ ++ ++

PVDF Polyvinylidenfluorid 10Y 1.8 0 0 35 –/78D >25 >100 150 160 –30 >1014 >30 ++ ++ ++ ++ ++ + +


TPE-U Thermoplastic polyether polyurethane 11Y 1.12 0 0 0 85A– 54D >30 > 400 125 150 – 40 >109 >10 ++ – ++ ++ + + +

TPE-E Thermoplastic polyether ester elastomer 12Y 1.16–1.25 0 0 0 40D–72D >25 > 400 90 150 – 40 >109 >10 ++ – ++ ++ + – +

TPE-E Thermoplastic polyester elastomer 13Y 1.25–1.28 0 0 0 – /55D >30 >300 150 180 – 40 >109 >10 ++ +/– ++ ++ + + +

TPE-S Thermoplastic polystyrene block copolymer 31Y 1.10–1.30 0–10 0 0–10 55D– 65D >15 >200 125 150 – 40 >1010 >10 – +/– + + – + –

TPE-A Thermoplastic polyamide elastomer 41Y 1.01–1.06 0 0 0 75A–70D >25 > 400 90 120 – 50 >1010 >10 ++ – ++ ++ + – +

TPE-O Thermoplastic polyolefin elastomer 91Y 0.95–1.25 0–10 0 0–10 87A/– >10 >300 125 150 – 40 >1014 >20 – +/– – – – + –


E/VA Ethylene vinyl acetate 4G 1.30–1.40 40– 50 0–10 0 80A– 85A >7 >150 140 180 – 40 >1010 >10 – – – – – – –

PVC-X Polyvinyl chloride, crosslinked X 1.35 15 30 30 95A/– >10 >150 105 140 – 40 >1012 >10 ++ + + + – + +

PE-X Polyethylene, crosslinked (XLPE) 2X 1.1 0 0 10 95A/– >10 >200 125 150 – 40 >1014 >20 + + + + – + +

PE-X Polyethylene, crosslinked, halogen-free (XLPE) 2X 1.4 20 0 0 – /42D >10 >200 125 150 – 40 >1014 >10 + + + + – + +

All compounds used are lead free


13

depends on recipe, as required criterion: residual elongation at break > 50 %

++ Excellent+ Good– Fair–– Poor

Service Temperatures Resistance to

Symbol Name Codee.g. Density

Ignition residue

Extractable constituents

Halogen content

Hardness Shore A/D

Tensile strength

Elongation at break

Tempera-ture

index

Thermal overload capacity

Cold winding

test

Specific volume

resistanceDielectric strength Abrasion

Flame retardation Oil Fuels Brake fluid

Acids/ Alkalines

Organic agents

e.g. DIN ISO 1629 and 7728 DIN 76722 DIN 53479DIN 53568

T1 DIN 53738 DIN 53505 DIN 53504 DIN 53504DIN ISO

2578 ISO 6722

ISO 6722 DIN 53482 DIN 53481 ISO 6722 ISO 6722


PVC-P Polyvinyl chloride (plasticized) Y 1.30–1.45 10–30 20–30 35 85A– 95A >10 >150 105 110/125 –25/–40 >1012 >10 + + + + – + –

PVC-P cold-resistant YK 1.24–1.34 10–15 30– 40 30 80A– 95A >10 >150 105 110 – 50 >1012 >10 + + + + – + –

PVC-P hot-pressure resistant, heat-resistant YW 1.24–1.34 8–15 20–30 35 92A– 97A >15 >150 125 140 –25/–40 >1012 >10 + + + + – + –

PE Polyethylene 2Y 0.92–0.95 0 0 0 50D– 62D >15 >300 90 100 – 40 >1016 >30 + – – – +/– – – + –

PA Polyamide 4Y 1.01 0 0 0 – /72D > 40 >300 105 140 – 50 >1012 >10 ++ – ++ ++ + + +

FEP Tetrafluoroethylene hexafluoropropylene 6Y 2.14 0 0 75 – /55D >15 >200 210 260 – 65 >1015 >30 ++ ++ ++ ++ ++ ++ ++

ETFE Ethylen tetrafluoroethylene 7Y 1.70 0 0 60 – /75D >30 >200 180 230 – 65 >1015 >30 ++ ++ ++ ++ ++ ++ ++

PP Polypropylene 9Y 0.91 0 0 0 – /70D >15 >200 125 150 – 40 >1016 >30 + – – + + – + +

PP-FR Polypropylene, flame-retardant 9Y 1.05–1.3 0–10 0 10 – /70D >15 >200 125 150 – 40 >1014 >20 + + + + – + +

PFA Perfluoroalkoxy copolymer 51Y 2.15 0 0 75 – /55D >20 >200 260 290 – 80 >1015 >30 ++ ++ ++ ++ ++ ++ ++

PVDF Polyvinylidenfluorid 10Y 1.8 0 0 35 –/78D >25 >100 150 160 –30 >1014 >30 ++ ++ ++ ++ ++ + +


TPE-U Thermoplastic polyether polyurethane 11Y 1.12 0 0 0 85A– 54D >30 > 400 125 150 – 40 >109 >10 ++ – ++ ++ + + +

TPE-E Thermoplastic polyether ester elastomer 12Y 1.16–1.25 0 0 0 40D–72D >25 > 400 90 150 – 40 >109 >10 ++ – ++ ++ + – +

TPE-E Thermoplastic polyester elastomer 13Y 1.25–1.28 0 0 0 – /55D >30 >300 150 180 – 40 >109 >10 ++ +/– ++ ++ + + +

TPE-S Thermoplastic polystyrene block copolymer 31Y 1.10–1.30 0–10 0 0–10 55D– 65D >15 >200 125 150 – 40 >1010 >10 – +/– + + – + –

TPE-A Thermoplastic polyamide elastomer 41Y 1.01–1.06 0 0 0 75A–70D >25 > 400 90 120 – 50 >1010 >10 ++ – ++ ++ + – +

TPE-O Thermoplastic polyolefin elastomer 91Y 0.95–1.25 0–10 0 0–10 87A/– >10 >300 125 150 – 40 >1014 >20 – +/– – – – + –


E/VA Ethylene vinyl acetate 4G 1.30–1.40 40– 50 0–10 0 80A– 85A >7 >150 140 180 – 40 >1010 >10 – – – – – – –

PVC-X Polyvinyl chloride, crosslinked X 1.35 15 30 30 95A/– >10 >150 105 140 – 40 >1012 >10 ++ + + + – + +

PE-X Polyethylene, crosslinked (XLPE) 2X 1.1 0 0 10 95A/– >10 >200 125 150 – 40 >1014 >20 + + + + – + +

PE-X Polyethylene, crosslinked, halogen-free (XLPE) 2X 1.4 20 0 0 – /42D >10 >200 125 150 – 40 >1014 >10 + + + + – + +


14

Conductor materials Conductor and Insulation materials

Extract from EN 13602 – copper and copper alloys – raw wire made of copper

International Annealed Copper Standard = IACS

Electrical conductivity of copper = min. 58 m/Ωmm2 = 100 % IACS

Most of our conductor material is copper (Cu). For the production of

our wires we mainly use Cu-ETP1 (oxygenic copper) and Cu-OF 1

oxygen-free copper for special applications (e. g. hydrogen resistance).

In addition to pure copper we also process a variety of copper alloys

for special applications.

Symbol Material number

Composition Density Melting point

% IACS min.

Notes on properties and use

in % by weight g/m3

Oxygenic copper

Cu-ETP1

(E-Cu)

CW 003 A Cu ≥ 99.90

Oxygen

max. 0.040

8.9 1083 °C 101 Oxygenic (tough-pitch) copper with an

electrical conductivity in the soft state of

≥58.58 m/Ωmm2 at 20 °C.

Oxygen-free copper, non-deoxidized

Cu-OF1

(OF-Cu)

CW 007 A Cu 99.95 8.9 1083 °C 101 High-purity copper, largely free of ele-

ments that evaporate in vacuum, with

an electrical conductivity in the soft state

≥58.58 m/Ωmm2 at 20 °C.

Intermediate material meeting high require-

ments on hydrogen resistance; welding and

hard soldering capability.

For vacuum systems and electronics.

15

Galvanic coatings: The metal materials used for galvanically refined copper wires are tin, silver or nickel, depending on the requirements.


Tin Silver Nickel

Designation

Density

Melting point

Symbol

Tin 99.90

7.29 g/cm3

232 °C

Sn

Designation

Density

Melting point

Symbol

Fine silver 99.97

10.5 g/cm3

960 °C

Ag

Designation

Density

Melting point

Symbol

Nickel 99.90

8.9 g/cm3

1450 °C

Ni

Criteria for use

Good solderability

Effective protection against corrosion

High temperature resistance

Good surface conductivity (skin effect)

High resistance to corrosion and

temperature

Temperature limits for the use of conductor materials.

Directive CSA-C22.2 No. 210.2 assigns conductor materials to the following temperature limits:

Temperature range max. 150 °C Temperature range max. 200 °C Temperature range max. 250 °C

Bare and tin-plated copper with single

wire Ø ≤0.38 mm

Copper-plated steel wire (e.g. Staku)

with single wire Ø ≤0.38 m

Bare and tin-plated copper with

single wire Ø ≥0.38 mm

Copper-plated steel wire (e.g. Staku)

with single wire Ø ≥0.38 m

bare and tin-plated

Silver-plated copper

Copper alloy

Nickel-plated copper

Silver-plated alloys of cadmium-

chrome-copper

Nickel-plated steel wires

Pure nickel wires for flexible

applications and nickel alloys

16

Overview of standardsStandards

Abbreviations:

Global Standards

ISO 6722

LV112 + 212

PSA Peugeot, Citroën

PSA 96 418 794 99

FLRY IR Automotive standard cable with reduced insulation

FLRY ID Automotive standard cable with diminished insulation

FLRYW IR Automotive standard cable heat-resistant with reduced insulation

FLRYW ID Automotive standard cable heat-resistant with diminished insulation

SAE J 1128 Engineering Society for advancing mobility Land, Sea, Air and Space

TWP Thin wall, thermoplastic insulated

GPT General purpose, thermoplastic insulated

HDT Heavy duty, thermoplastic insulated

TXL Thin wall, cross (X) linked polyolefin insulated

GXL General purpose, cross (X) linked polyolefin insulated

SXL Special purpose, cross (X) linked polyolefin insulated

TWE Thin wall, thermoplastic elastomer insulated

GTE General purpose, thermoplastic elastomer insulated

HTE Heavy duty, thermoplastic elastomer insulated

JASO D 609-90 Japanese Automobile Standard

AV Vinyl insulated low tension electric cable for automobiles

AVS Low tension cable with reduced outside diameter for automobiles, general wall thickness

AVSS Low tension cable with reduced outside diameter for automobiles, thin wall thickness

AVSSf Low tension cable with reduced outside diameter for automobiles, thin wall thickness, high flexibility

CAVS Construction of conductors pressed in circular shape,

low tension cable with reduced outside diameter for automobiles, general wall thickness

AVX Crosslinked vinyl heat-resistant low-tension cable for automobiles

AEX Crosslinked polyethylene heat-restistant low-tension cable for automobiles

Customer Standards

FIAT 91107/17 + 91107/18

VW 60306

17

Automotive cablessingle-core

Product range

18

PVC automotive cable

Temperature range:

–40 °C to +105 °C (3000 hrs)

Construction / Materials

Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602,

bare. Conductor construction according to ISO 6722.

Insulation

Plasticized PVC with properties according to ISO 6722, Class B,

lead free.

Special properties

Conductors with cross-sections > 6 mm2 are also suitable as battery

cables.

Standards and specifications

LV 112

BMW 95007-2

VW 60306

Single-core cables

unshielded

FLY

Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2)

Conductor construction Insulation Cable


No. of strands

Diameter of single wire

Diameter of conductor

Electrical resistance

at 20 °C

Wall thickness

Weight

min. max.

mm2 mm mm mΩ/m mm mm mm kg/km

0.5 16 0.21 1.0 37.1 0.6 2.0 2.3 9

0.75 24 0.21 1.2 24.7 0.6 2.2 2.5 12

1 32 0.21 1.35 18.5 0.6 2.4 2.7 15

1.5 30 0.26 1.7 12.7 0.6 2.7 3.0 20

2 40 0.26 2.0 9.42 0.6 2.9 3.3 26

2.5 50 0.26 2.2 7.6 0.7 3.3 3.6 32

3 60 0.26 2.4 6.15 0.7 3.5 3.9 38

4 56 0.31 2.75 4.71 0.8 4.0 4.4 49

6 84 0.31 3.3 3.14 0.8 4.6 5.0 69

10 80 0.41 4.5 1.82 1.0 6.0 6.5 113

16 126 0.41 6.3 1.16 1.0 7.0 8.3 181

25 196 0.41 7.8 0.743 1.3 8.7 10.2 288

35 276 0.41 9.0 0.527 1.3 10.0 10.7 361

50 400 0.41 10.5 0.368 1.5 11.9 13.0 521

70 560 0.41 12.5 0.259 1.5 14.0 15.0 716

95 740 0.41 14.8 0.196 1.6 15.4 16.2 918

120 960 0.41 16.5 0.153 1.6 18.7 19.7 1220

19


Conductor



Insulation


lead free.

Special properties

Hot-pressure resistant test at 120 °C. Suitable for applications inside

the engine compartment.


Bosch 5 998 341…

Single-core cables

unshielded


hot-pressure resistant

Temperature range:

–40 °C to +125 °C (3000 hrs)

FLYW

Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2)



No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.5 16 0.21 1.0 37.1 0.6 2.0 2.3 8

0.75 24 0.21 1.2 24.7 0.6 2.2 2.5 11

1 32 0.21 1.35 18.5 0.6 2.4 2.7 14

1.5 30 0.26 1.7 12.7 0.6 2.7 3.0 19

2 40 0.26 2.0 9.42 0.6 2.9 3.2 25

2.5 50 0.26 2.2 7.6 0.7 3.3 3.7 31

3 60 0.26 2.5 6.0 0.7 3.5 3.9 37

4 56 0.31 2.75 4.71 0.8 4.0 4.4 47

6 84 0.31 3.3 3.14 0.8 4.6 5.0 68

10 80 0.41 4.5 1.82 1.0 6.0 6.5 111

16 126 0.41 6.3 1.16 1.0 7.5 8.1 179

25 196 0.41 7.8 0.743 1.2 9.5 10.2 278

20


cold-resistant with increased flexibility

Temperature range:

–50 °C to +105 °C (3000 hrs)


Conductor



Insulation


lead free.

Special properties

Cold bending test according to ISO 6722 at –50 °C.

Short-term and long-term ageing according to ISO 6722, Class B.

Single-core cables

unshielded

FLYK



No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.5 28 0.16 1.1 37.7 0.6 2.0 2.3 9

0.75 42 0.16 1.3 25.1 0.6 2.2 2.5 12

1 57 0.16 1.5 18.8 0.6 2.4 2.7 15

1.5 84 0.16 1.8 12.7 0.6 2.7 3.0 20

2.5 140 0.16 2.3 7.54 0.7 3.5 3.9 32

4 1015 0.08 3.3 4.71 0.8 4.5 4.9 53

6 1543 0.08 4.2 3.14 0.8 5.3 6.0 76

10 2510 0.08 5.2 1.85 1.0 6.7 7.3 124

16 4033 0.08 6.7 1.16 1.0 8.2 8.8 198

25 3169 0.11 8.0 0.743 1.2 9.9 10.5 298

21


Conductor


bare. Conductor construction according to DIN 46438 or customers‘

request.

Insulation

Plasticized PVC, heat- and cold-resistant, lead free.

Special properties

Cold bending test according to ISO 6722 at –50 °C.

Short-term and long-term ageing according to ISO 6722, Class B.


Bosch 5 998 342…

Single-core cables

unshielded


heat- and cold-resistant

Temperature range:

–50 °C to +105 °C (3000 hrs)

More cross-sections and strand constructions on request.

FLYWK / FLRYWK



No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.5 16 0.21 1.0 37.1 0.28 1.4 1.6 6

0.75 24 0.21 1.2 24.7 0.6 2.2 2.5 9

1 32 0.21 1.4 18.5 0.3 1.8 2.1 12

1.5 30 0.26 1.7 12.7 0.3 2.2 2.4 16

2.5 50 0.26 2.1 7.6 0.7 3.3 3.7 30

22


with concentric conductor (Type A)

and thin wall insulation

Temperature range:

–40 °C to +105 °C (3000 hrs)


Conductor


bare or tinned. Conductor construction according to ISO 6722 (concen-

tric construction).

Insulation

Plasticized PVC with properties according to ISO 6722, Class B.


BMW GS 95007-1

VW 60306

DBL 6312 / MB 22014

Ford WSK 1A348-A2

LV 112

MAN 3135

BOSCH 5 998 340

FIAT 91107/13

FIAT 91107/18

Single-core cables

unshielded

This cross-section with tinned stranded conductor is suitable for use with insulation displacement connectors.

FLRY-A


Nominal cross-

section

No. of strands


max.


max.

Electrical resistance at 20 °C

Wall thickness

min.

O.D. Weight

approx.

Limit

tolerancebare/tinned

min.bare/tinned

max.

mm2 mm mm mΩ/m mΩ/m mm mm mm kg/km

0.22 7 0.21 0.7 77.9 / – 84.8 / 86.5 0.20 1.2 –0.1 3.1

0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.3 –0.1 4.5

0.5 19 0.19 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 6.6

0.75 19 0.23 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 9

1 19 0.26 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11

1.5 19 0.32 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 16

2 19 0.37 2.0 8.66 / – 9.42 / 9.69 0.28 2.8 –0.3 22

2.5 19 0.41 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 26

23


Conductor


bare or tinned. Conductor construction according to ISO 6722.

Insulation


lead free.


BMW GS 95007-1

VW 60306

DBL 6312 / MB 22014

Ford WSK 1A348-A2

LV 112

MAN 3135

BOSCH 5 998 340

FIAT 91107/13

FIAT 91107/18

Single-core cables

unshielded


with conductor (Type B)

and thin wall insulation

Temperature range:

–40 °C to +105 °C (3000 hrs)

FLRY-B

Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2).


Nominal cross-

section

No. of

strandsDiameter of

single wire

max.


max.


Wall thickness

min.

O.D. Weight

approx.Limit


min.bare/tinned

max.


0.35 12 0.21 0.9 47.8 / – 52.0 / 54.5 0.20 1.4 –0.2 4.5

0.5 16 0.21 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 6.6

0.75 24 0.21 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 9

1 32 0.21 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 16

2 30 0.31 2.0 8.6 / – 9.42 / 9.69 0.28 2.8 –0.3 22.5

2.5 50 0.26 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 26

3 45 0.31 2.4 5.8 / – 6.15 / 6.36 0.28 3.2 –0.3 33.5

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 42

6 84 0.31 3.3 2.85 / – 3.1 / 3.2 0.32 4.3 –0.3 61

10 80 0.41 4.5 – / – 1.82 / 1.85 0.48 6.0 –0.6 108

16 126 0.41 6.3 – / – 1.16 / 1.18 0.52 7.9 –0.6 170

25 196 0.41 7.8 – / – 0.743 / 0.757 0.52 9.4 –0.8 265

24



with thin wall insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)


Conductor



Insulation

Plasticized PVC with properties according to ISO 6722, Class C,

lead free.

Special properties

Hot-pressure resistant test at 120 °C. Suitable for applications inside

the engine compartment.

Standards and Specifications

DBL 6312

Single-core cables

unshielded

FLRYW

Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2).


Nominal cross-

section

No. of

strandsDiameter of single wire

max.


max.


Wall thickness

min.

O.D. Weight

approx.Limit


min.bare/tinned

max.


0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.4 –0.1 4.5

0.35 12 0.21 0.9 47.8 / – 52.0 / 54.5 0.20 1.4 –0.2 4.5

0.5 16 0.21 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 6.6

0.75 24 0.21 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 9

1 32 0.21 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 16

2 30 0.31 1.9 – / – 9.42 / 9.69 0.28 2.8 –0.3 22

2.5 50 0.26 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 26

3 45 0.31 2.4 – / – 6.15 / 6.36 0.28 3.2 –0.3 32.5

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 42

6 84 0.31 3.3 2.85 / – 3.1 / 3.2 0.32 4.3 –0.3 61

10 80 0.41 4.5 – / – 1.82 / 1.85 0.48 6.0 –0.6 108

16 126 0.41 6.3 – / – 1.16 / 1.18 0.52 7.9 –0.6 170

25 196 0.41 7.8 – / – 0.743 / 0.757 0.52 9.4 –0.8 265

25


Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602.

Conductor construction according to ISO 6722 and PSA Standard.

Insulation

Plasticized PVC with properties according to ISO 6722,

Class B, lead free.


PSA STE 96 418 794 99 IR

Single-core cables

unshielded


Temperature range:

–40 °C to +105 °C (3000 hrs)

FLRY T2 IR



No. of strands



at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.

mm2 mm mΩ/m mm mm mm kg/km

0.35 7 0.26 55.9 0.22 1.25 1.40 4.7

0.5 16 0.21 37.1 0.28 1.40 1.70 6.7

0.75 24 0.21 24.7 0.3 1.70 1.90 9.1

1 32 0.21 19.5 0.3 1.99 2.15 11.7

1.5 30 0.26 12.7 0.3 2.10 2.40 16.2

2 37 0.26 10.0 0.35 2.50 2.80 22.4

2.5 50 0.26 7.6 0.35 2.65 3.00 27.4

3 45 0.31 6.06 0.4 3.25 3.45 36.4

4 56 0.31 4.95 0.4 3.70 3.90 47.2

5 70 0.31 3.94 0.4 3.80 4.00 52.8

6 84 0.31 3.14 0.4 4.20 4.50 62.6

7 105 0.31 2.72 0.48 4.76 5.00 82

26


Temperature range:

–40 °C to +105 °C (3000 hrs)


Conductor


Conductor construction according to ISO 6722 and PSA Standard.

Insulation

Plasticized PVC with properties according to ISO 6722,

Class B, lead free.


PSA STE 96 418 794 99 ID

Single-core cables

unshielded

FLRY T2 ID



No. of strands


max.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.35 7 0.26 55.9 0.20 1.25 1.35 4.5

0.5 16 0.21 37.1 0.20 1.40 1.50 6.2

0.75 24 0.21 24.7 0.20 1.60 1.80 8.3

1 32 0.21 19.5 0.25 1.75 1.90 10.2

1.5 30 0.26 12.7 0.25 2.10 2.25 14.8

2 37 0.26 10.0 0.25 2.30 2.50 20

2.5 50 0.26 7.6 0.30 2.70 2.90 26.7

3 45 0.31 6.06 0.30 3.00 3.20 33.5

4 56 0.31 4.95 0.30 3.40 3.60 45.2

5 70 0.31 3.94 0.30 3.70 3.90 51.4

6 84 0.31 3.14 0.35 4.10 4.30 61

7 105 0.31 2.72 0.35 4.30 4.60 78

27


Conductor


Conductor construction according to ISO 6722.

Insulation

Plasticized PVC, hot-pressure resistant, lead free.


PSA STE 96 418 794 99 IR

Single-core cables

unshielded



Temperature range:

–40 °C to +125 °C (3000 hrs)

FLRY T3 IR



No. of strands


max.


at 20 °C max.

Wall thickness

O.D. Weight

approx.min. max.


0.35 7 0.26 55.9 0.22 1.25 1.40 4.7

0.5 16 0.21 37.1 0.28 1.40 1.70 6.7

0.75 24 0.21 24.7 0.30 1.70 1.90 9.1

1 32 0.21 19.5 0.30 1.99 2.15 11.6

1.5 30 0.26 12.7 0.30 2.10 2.40 16.1

2 37 0.26 10.0 0.35 2.50 2.80 22.3

2.5 50 0.26 7.6 0.35 2.65 3.00 27.3

3 45 0.31 6.06 0.40 3.25 3.45 36.2

4 56 0.31 4.95 0.40 3.70 3.90 47

5 70 0.31 3.94 0.40 3.80 4.00 52.5

6 84 0.31 3.14 0.40 4.20 4.50 62.3

7 105 0.31 2.72 0.48 4.76 5.00 81.6

28



Temperature range:

–40 °C to +125 °C (3000 hrs)


Conductor


Conductor construction according to ISO 6722.

Insulation

Plasticized PVC, hot-pressure resistant, lead free.


PSA STE 96 418 794 99 ID

Single-core cables

unshielded

FLRY T3 ID



No. of strands


max.


at 20 °C max.

Wall thickness

O.D. Weight

approx.min. max.


0.35 7 0.26 55.9 0.20 1.25 1.35 4.5

0.5 16 0.21 37.1 0.20 1.40 1.50 6.2

0.75 24 0.21 24.7 0.20 1.60 1.80 8.3

1 32 0.21 19.5 0.25 1.75 1.90 10.1

1.5 30 0.26 12.7 0.25 2.10 2.25 14.7

2 37 0.26 10.0 0.25 2.30 2.50 19.9

2.5 50 0.26 7.6 0.30 2.70 2.90 26.6

3 45 0.31 6.06 0.30 3.00 3.20 33.3

4 56 0.31 4.95 0.30 3.40 3.60 45

5 70 0.31 3.94 0.30 3.70 3.90 51.1

6 84 0.31 3.14 0.35 4.10 4.30 60.7

7 105 0.31 2.72 0.35 4.30 4.60 77.6

29


Conductor

Soft-annealed elctrolytic copper Cu-ETP1 according to DIN EN 13602,


Insulation

PA (Polyamide).

Special properties

Outstanding fuel resistance. Especially suitable as fuel gauge wire.

Single-core cables

unshielded

PA automotive cable

Temperature range:

–40 °C to +105 °C (3000 hrs)

FLR4Y


Nominal cross-

section

No. of strands


max.


max.


Wall thickness

min.

O.D. Weight

approx.Limit

tolerancebaremin.

tinnedmax.


FLR4Y-A

0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.3 –0.1 4.2

0.5 19 0.19 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 5.8

0.75 19 0.23 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 8

1 19 0.26 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11

1.5 19 0.32 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 15

2.5 19 0.41 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 24

FLR4Y-B

0.35 12 0.21 0.9 47.8 / – 52.0 / 54.5 0.20 1.4 –0.2 4.2

0.5 16 0.21 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 5.8

0.75 24 0.21 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 8

1 32 0.21 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 15

2.5 50 0.26 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 24

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 40

30

PP automotive cable

heat-resistant with thin wall insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)


Conductor



Insulation

PP-FR (Polypropylene flame-retardant), low halogen.

Special properties

Marking according to customer requirement.


Renault 36-05-009/--L

FIAT 91107/17

VW 60306

Single-core cables

unshielded

125 P



No. of strands


max.


max.


at 20 °C max.

Wall thickness

O.D. Weight

approx.Limit

tolerance


0.22 7 0.21 0.7 84.8 0.20 1.2 –0.1 3.1

0.35 7 0.26 0.8 52.0 0.20 1.4 –0.2 4.5

0.5 19 0.19 1.0 37.1 0.22 1.6 –0.2 6.6

0.75 24 0.21 1.2 24.7 0.24 1.9 –0.2 9

1 32 0.21 1.35 18.5 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 12.7 0.24 2.4 –0.2 16

2 40 0.26 1.9 9.42 0.24 2.8 –0.3 22

2.5 50 0.26 2.2 7.6 0.28 3.0 –0.3 26

3 45 0.31 2.4 6.06 0.28 3.3 –0.3 32.5

4 56 0.31 2.75 4.7 0.32 3.7 –0.3 42

6 84 0.31 3.3 3.1 0.32 4.3 –0.3 61

10 80 0.41 4.5 1.82 0.48 6.0 –0.6 104

16 126 0.41 6.3 1.16 0.52 7.0 –0.6 158

31


Conductor



Insulation

PE-X (Polyethylene crosslinked) with properties according to ISO 6722,

Class C.

Single-core cables

unshielded

PE-X automotive cable

heat-resistant with thin wall insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)

125 X



No. of strands


max.


max.

Electrical resis-tance at 20 °C

max.

Wall thickness

nom.

O.D. Weight

approx.Limit

tolerance


LEONI Mocar® 125 X Type A

0.22 7 0.21 0.7 84.8 0.20 1.2 –0.1 3.1

0.35 7 0.26 0.8 52.0 0.20 1.3 –0.1 4.5

0.5 19 0.19 1.0 37.1 0.22 1.6 –0.2 6.6

0.75 19 0.23 1.2 24.7 0.24 1.9 –0.2 9

1 19 0.26 1.35 18.5 0.24 2.1 –0.2 11

1.5 19 0.32 1.7 12.7 0.24 2.4 –0.2 16

2 19 0.37 2.0 9.42 0.28 2.8 –0.3 22

2.5 19 0.41 2.2 7.6 0.28 3.0 –0.3 26

LEONI Mocar® 125 X Type B

0.35 12 0.21 0.9 52.0 0.20 1.4 –0.2 4.5

0.5 16 0.21 1.0 37.1 0.22 1.6 –0.2 6.6

0.75 24 0.21 1.2 24.7 0.24 1.9 –0.2 9

1 32 0.21 1.35 18.5 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 12.7 0.24 2.4 –0.2 16

2 30 0.31 2.0 9.42 0.28 2.8 –0.3 22

2.5 50 0.26 2.2 7.6 0.28 3.0 –0.3 26

3 45 0.31 2.4 6.15 0.28 3.2 –0.3 32.5

4 56 0.31 2.75 4.7 0.32 3.7 –0.3 42

6 84 0.31 3.3 3.1 0.32 4.3 –0.3 61

32

Automotive cable

heat-resistant with TPE-E insulation

Temperature range:

–40 °C to +150 °C (3000 hrs)

+180 °C (48 hrs)


Conductor


bare. Concentric resp. fine-wire stranded conductor according to

ISO 6722.

Insulation

TPE-E (Thermoplastic polyester elastomer).

Single-core cables

unshielded

Special properties

Suitable for headlight applications.

Limited resistance to hydrolysis.

150 A



No. of strands


max.


max.

Electrical resis-tance at 20 °C

max.

Wall thickness

nom.

O.D. Weight

approx.Limit

tolerance


LEONI Mocar® 150 A Type A

0.35 7 0.26 0.8 52.0 0.20 1.3 –0.1 4.5

0.5 19 0.19 1.0 37.1 0.22 1.6 –0.2 6

0.75 19 0.23 1.2 24.7 0.24 1.9 –0.2 9

1 19 0.26 1.35 18.5 0.24 2.1 –0.2 11

1.5 19 0.32 1.7 12.7 0.24 2.4 –0.2 16

2 19 0.37 2.0 9.42 0.28 2.8 –0.3 22

2.5 19 0.41 2.2 7.6 0.28 3.0 –0.3 26

LEONI Mocar® 150 A Type B

0.35 12 0.21 0.9 52.0 0.20 1.4 –0.2 4.5

0.5 16 0.21 1.0 37.1 0.22 1.6 –0.2 6

0.75 24 0.21 1.2 24.7 0.24 1.9 –0.2 9

1 32 0.21 1.35 18.5 0.24 2.1 –0.2 11

1.5 30 0.26 1.7 12.7 0.24 2.4 –0.2 16

2 30 0.31 2.0 9.42 0.28 2.8 –0.3 22

2.5 50 0.26 2.2 7.6 0.28 3.0 –0.3 26

4 56 0.31 2.75 4.7 0.32 3.7 –0.3 42

6 84 0.31 3.3 3.1 0.32 4.3 –0.3 61

33 Ultra-thin wall thickness on request.


Conductor


bare, tinned or silver-plated. Fine-wire stranded conductor according

to ISO 6722.

Insulation

ETFE (Ethylene tetrafluoroethylene) with properties according to

ISO 6722, Class E.

Special properties

Good mechanical and thermal properties with excellent resistance to

aggressive media. Suitable for applications inside the engine compart-

ment.

Single-core cables

unshielded

Automotive cable

high temperature resistant with ETFE insulation

Temperature range:

–65 °C to +180 °C (3000 hrs)

+230 °C (48 hrs)

180 E


Nominal cross-

section

No. of strands


max.


max.


Wall thickness

min.

O.D. Weight

approx.Limit

tolerancebaremin.

tinnedmax.


LEONI Mocar® 180 E Type A

0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.3 –0.1 4.7

0.5 19 0.19 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 6.3

0.75 19 0.23 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 9

1 19 0.26 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11.5

1.5 19 0.32 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 16.5

2.5 19 0.41 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 27.5

LEONI Mocar® 180 E Type B

0.35 12 0.21 0.9 47.8 / – 52.0 / 54.5 0.20 1.4 –0.2 4.7

0.5 16 0.21 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 6.3

0.75 24 0.21 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 9

1 32 0.21 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 11.5

1.5 30 0.26 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 16.5

2.5 50 0.26 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 27.5

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 42

34

Automotive cable

high temperature resistant with FEP insulation

Temperature range:

–65 °C to +210 °C (3000 hrs)

+260 °C (48 hrs)


Conductor


bare, tinned, silver-plated or nickel-plated. Fine-wire stranded conduc-

tor according to ISO 6722.

Insulation

FEP (Tetrafluoroethylene hexafluoropropylene) with properties accor-

ding to ISO 6722, Class F.

Special properties

Good mechanical and thermal properties with excellent resistance to

aggressive media. Suitable for applications inside the engine compart-Suitable for applications inside the engine compart-

ment.

Single-core cables

unshielded

Ultra-thin wall thickness on request.

210 F


Nominal cross-

section

No. of strands


max.


max.


Wall

thickness

min.

O.D. Weight

approx.Limit

tolerancebaremin.

tinnedmax.


LEONI Mocar® 210 F Type A

0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.3 –0.1 5

0.5 19 0.19 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 7

0.75 19 0.23 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 10

1 19 0.26 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 13

1.5 19 0.32 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 18

2.5 19 0.41 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 29

LEONI Mocar® 210 F Type B

0.35 12 0.21 0.9 47.8 / – 52.0 / 54.5 0.20 1.4 –0.2 5

0.5 16 0.21 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 7

0.75 24 0.21 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 10

1 32 0.21 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 13

1.5 30 0.26 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 18

2.5 50 0.26 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 29

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 44

35


Conductor


bare or silver-plated according to ASTM 298.

Insulation

PFA (Perfluoroalkoxy copolymer). Colors: according to order or

transparent. Properties according to ISO 6722, Class G.

Special properties

Excellent resistance to chemicals, very good mechanical stability.

Due to its high temperature resistance, an equivalent alternative to

PTFE.

Single-core cables

unshielded

Automotive cable

high temperature resistant with PFA insulation

Temperature range:

–80 °C to +260 °C (3000 hrs)

+290 °C (48 hrs)

Ultra-thin wall thickness on request.

Conductor can also be supplied nickel-plated according to ASTM B355 on request (nickel layer: ≥1.0 µm).

260 T


Nominal cross-

section

No. of strands


max.


max.


Wall

thickness

min.

O.D. Weight

approx.Limit

tolerancebaremin.

tinnedmax.


0.35 7 0.26 0.8 47.8 / – 52.0 / 54.5 0.20 1.3 –0.1 5

0.5 19 0.19 1.0 34.1 / – 37.1 / 38.2 0.22 1.6 –0.2 7

0.75 19 0.23 1.2 22.7 / – 24.7 / 25.4 0.24 1.9 –0.2 10

1 19 0.26 1.35 17.0 / – 18.5 / 19.1 0.24 2.1 –0.2 13

1.5 19 0.32 1.7 11.7 / – 12.7 / 13.0 0.24 2.4 –0.2 18

2.5 19 0.41 2.2 7.0 / – 7.6 / 7.8 0.28 3.0 –0.3 29

4 56 0.31 2.75 4.32 / – 4.7 / 4.8 0.32 3.7 –0.3 44

36

XLPE automotive cable

thin wall with crosslinked insulation

Temperature range:

–40 °C to +125 °C


Conductor

Soft-annealed copper according to ASTM B3.

Conductor construction according to customer specification.

Insulation

XLPE (Polythylene crosslinked), flame-retardant.

Insulation material according to SAE J 1128/ESB-M12 123-A/MS-8288/

UTMS 12501.

Special properties

Also available as SXL and GXL type.


SAE J 1128

Single-core cables

unshielded

TXL


Size Nominal cross-section

No. of strands


nom.


nom.

Wall thickness

O.D.

max.

Weight

approx.nom. min.

AWG mm2 mm mm mm mm mm kg/km

22 0.35 7 0.25 0.76 0.40 0.28 1.7 5.4

20 0.5 7 0.32 0.97 0.40 0.28 1.9 7.7

18 0.8 16 0.25 1.17 0.40 0.28 2.2 10.7

18 0.8 19 0.23 1.17 0.40 0.28 2.2 10.7

16 1 19 0.28 1.45 0.40 0.28 2.4 14.6

14 2 19 0.36 1.8 0.40 0.28 2.7 22

12 3 19 0.45 2.29 0.46 0.32 3.3 34

10 5 19 0.57 2.87 0.50 0.35 4.0 53

37


Conductor

Soft-annealed copper according to ASTM B3.

Conductor construction according to customer specification.

Insulation

PVC (Polyvinyl chloride), lead free.

Insulation material according to SAE J 1128/ESB-M1L 120-A/MS-7889/

UTMS 12501.

Special properties

Also available as GPT and HDT type.


SAE J 1128

Single-core cables

unshielded


with thin wall

Temperature range:

–40 °C to +85 °C (3000 hrs)

+105 °C (48 hrs)

TWP


Size Nominal cross-section

No. of strands


nom.


nom.

Wall thickness

O.D.

max.

Weight

approx.nom. min.

AWG mm2 mm mm mm mm mm kg/km

22 0.35 7 0.25 0.76 0.40 0.28 1.7 5.4

20 0.5 7 0.32 0.97 0.40 0.28 1.9 7.7

18 0.8 16 0.25 1.17 0.40 0.28 2.2 10.7

18 0.8 19 0.23 1.17 0.40 0.28 2.2 10.7

16 1 19 0.28 1.45 0.40 0.28 2.4 14.6

14 2 19 0.36 1.8 0.40 0.28 2.7 22

12 3 19 0.45 2.29 0.46 0.32 3.3 34

10 5 19 0.57 2.87 0.50 0.35 4.0 53


Temperature range:

–40 °C to +85 °C (3000 hrs)


Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to D 609-90,

bare. Conductor construction according to JIS C 3102/JIS C3406.

Insulation


Insulation material according to JIS C3406.

Single-core cables

unshielded

38

AV

The “f” in the nominal cross-section column indicates a flexible conductor with a finer wire diameter.



No. of strands


nom.


nom.


at 20 °C

max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.5 7 0.32 1.0 32.7 0.6 2.2 2.4 10

0.85 11 0.32 1.2 20.8 0.6 2.4 2.6 13

1.25 16 0.32 1.5 14.3 0.6 2.7 2.9 17

2 26 0.32 1.9 8.81 0.6 3.1 3.4 26

3 41 0.32 2.4 5.59 0.7 3.8 4.1 40

5 65 0.32 3.0 3.52 0.8 4.6 4.9 62

8 50 0.45 3.7 2.32 0.9 5.5 5.8 92

10 63 0.45 4.5 1.84 1.0 6.5 6.9 120

15 84 0.45 4.8 1.38 1.1 7.0 7.4 160

0.5 f 20 0.18 1.0 36.7 0.6 2.2 2.4 9

0.75 f 30 0.18 1.2 24.4 0.6 2.4 2.6 12

1.25 f 50 0.18 1.5 14.7 0.6 2.7 2.9 18

2 f 37 0.26 1.8 9.5 0.6 3.0 3.4 25

3 f 61 0.26 2.4 5.76 0.7 3.8 4.1 40


Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to D 609-90,

bare. Conductor construction according to JASO D 611-94.

Insulation


Insulation material according to JASO D 611-94.

Single-core cables

unshielded


Temperature range:

–40 °C to +85 °C (3000 hrs)

39

AVS




No. of strands


nom.


nom.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.3 7 0.26 0.8 50.2 0.5 1.8 1.9 6

0.5 7 0.32 1.0 32.7 0.5 2.0 2.1 8

0.85 11 0.32 1.2 20.8 0.5 2.2 2.3 12

1.25 16 0.32 1.5 14.3 0.5 2.5 2.6 16

2 26 0.32 1.9 8.81 0.5 2.9 3.1 25

3 41 0.32 2.4 5.59 0.6 3.6 3.8 39

5 65 0.32 3.0 3.52 0.7 4.4 4.6 60

0.3 f 15 0.18 0.8 48.9 0.5 1.8 1.9 6

0.5 f 20 0.18 1.0 36.7 0.5 2.0 2.1 8

0.75 f 30 0.18 1.2 24.4 0.5 2.2 2.3 11

1.25 f 50 0.18 1.5 14.7 0.5 2.5 2.6 17

2 f 37 0.26 1.8 9.5 0.5 2.9 3.1 24


with thin wall insulation

Temperature range:

–40 °C to +85 °C (3000 hrs)


Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to JIS C 3102,

bare. Conductor construction according to JASO D 611-94.

Insulation


Insulation material according to JASO D 611-94.

Single-core cables

unshielded



No. of strands


nom.


nom.


at 20 °C max.

Wall thickness

nom.

O.D. Weight

approx.min. max.


0.3 7 0.26 0.8 50.2 0.3 1.4 1.5 5

0.5 7 0.32 1.0 32.7 0.3 1.6 1.7 7

0.85 19 0.24 1.2 21.7 0.3 1.8 1.9 10

1.25 19 0.29 1.5 14.9 0.3 2.1 2.2 14

2 (f) 37 0.26 1.8 9.5 0.4 2.6 2.7 22

0.3 f 19 0.16 0.8 48.8 0.3 1.4 1.5 5

0.5 f 19 0.19 1.0 34.6 0.3 1.6 1.7 7

0.75 f 19 0.23 1.2 23.6 0.3 1.8 1.9 10

1.25 f 37 0.21 1.5 14.6 0.3 2.1 2.2 14

40

AVSS


FL91Y / FL11Y

Battery cable

Temperature range:

–40 °C to +110 °C (3000 hrs) FL11Y

+125 °C (3000 hrs) FL91Y

Single-core cables

unshielded


Conductor

Fine-wire stranded conductor of electrolytic copper Cu-ETP1

according to DIN EN 13602.

Insulation

FL11Y: TPE-U (Thermoplastic polyurethane elastomer) according to

ISO 6722, Class B.

FL91Y: TPE-O (Thermoplastic polyolefin elastomer) according to

ISO 6722, Class C.

Special versions

Also available as aluminium battery cables.



No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

O.D. Weight approx.

min. max.


6 84 0.31 3.3 3.14 0.8 4.6 5.0 66

10 80 0.41 4.5 1.82 1.0 6.0 6.5 109

16 126 0.41 6.3 1.16 1.0 7.0 8.1 176

25 196 0.41 7.8 0.743 1.3 8.7 10.2 273

35 276 0.41 9.0 0.527 1.3 10.0 10.7 355

50 400 0.41 10.5 0.368 1.5 11.9 13.0 511

70 560 0.41 12.5 0.259 1.5 14.0 15.0 705

95 740 0.41 14.8 0.196 1.6 15.4 16.2 905

120 960 0.41 16.5 0.153 1.6 18.7 19.7 1170

41 Nominal value, tolerance of number of strands: ±5 %.

42


Conductor



Insulation / sheath


lead free.

Special properties

Sheath options: firmly bonded or separable.

Single-core cables

unshielded

Automotive cable

with core insulation and PVC sheath

Temperature range:

–40 °C to +105 °C (3000 hrs)


Nominal cross-

section

No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

Diameter of Core

Sheathwall

thickness

O.D. Weight

approx.min. max.

mm2 mm mm mΩ/m mm mm mm mm mm kg/km

0.5 16 0.21 1.0 37.1 0.6 2.1 0.4 2.7 3.1 14

0.75 24 0.21 1.2 24.7 0.6 2.3 0.4 3.0 3.3 17

1 32 0.21 1.35 18.5 0.6 2.5 0.4 3.2 3.6 20

1.5 30 0.26 1.7 12.7 0.6 2.8 0.5 3.7 4.1 28

2 40 0.26 2.0 9.42 0.6 3.0 0.5 3.9 4.3 33

2.5 50 0.26 2.2 7.6 0.7 3.5 0.5 4.3 4.8 41

All cross-sections can also be supplied with reduced insulation thickness (FLRYY).

FLYY

43

Single-core cables

unshielded


Conductor

Fine or super-fine wire stranded conductor of Cu-ETP1 according

to DIN EN 13602.

Insulation

PVC according to ISO 6722, Class B.

Sheath

Foamed PVC, density approx. 1 g/cm3, lead free .

Special properties

Special low temperature flexibility.

Other cross-sections and dimensions on request.


Nominal cross-

section

No. of strands


max.


max.


at 20 °C max.

Wall thickness

nom.

Diameter of Core

Sheath wall

thickness

O.D. Weight

approx.min. max.


FLY0Y

4 56 0.31 2.75 4.7 0.8 4.2 2.0 8.0 8.4 106

6 84 0.31 3.3 3.1 0.8 4.8 2.0 8.6 9.0 125

10 80 0.41 4.5 1.82 1.0 6.2 3.0 12.2 12.8 208

16 126 0.41 6.3 1.16 1.0 7.7 2.0 11.5 12.1 245

FLYK0Y

50 396 0.41 10.5 0.368 0.8 12.0 1.4 14.5 15.1 540

50 / 0.2 1600 0.21 10.9 0.386 0.8 12.0 1.4 14.5 15.1 550

70 / 0.2 2200 0.21 13.3 0.272 1.0 14.7 1.6 17.5 18.3 79

FLY0Y / FLYK0Y

Special battery cable

sheathed

Temperature range:

–40 °C to +105 °C (3000 hrs)

44


Conductor


bare. Fine-wire stranded conductor according to ISO 6722.

Insulation


lead free.

Shielding

Soft-annealed electrolytic copper E-Cu 58 F21, bare.

Wire spun cover with high surface covering ratio (≥90 %).

Sheath


lead free.

Single-core cables

shielded


shielded with reduced insulation

and sheath wall thickness

Temperature range:

–40 °C to +105 °C (3000 hrs)

Also available with increased insulation and/or sheath wall thickness.

FLRYDY


Nominal cross-

section

No. of strands

Diameter of single

wire max.


max.


at 20 °C max.

Wall thick-ness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


0.75 24 0.21 1.2 24.7 0.3 1.75 0.3 2.5 2.7 18

1 32 0.21 1.35 18.5 0.3 1.95 0.3 2.7 2.9 21

1.5 30 0.26 1.7 12.7 0.3 2.25 0.3 3.0 3.2 27

45

Product rangeAutomotive cablesmulti-core

46

FLR4G11Y / FL4G11YMulti-core cables


ABS/ESP cable

with EVA insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)

Structure Conductor construction Insulation Cable

No. of cores x

nominal cross-section

No. of strands

Diameter of single wire max.


max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


FLR4G11Y

2 x 0.35 19 0.16 0.8 54.5 0.35 1.45 0.5 3.8 4.0 20

2 x 0.5 28 0.16 1.0 40.1 0.35 1.65 0.55 4.1 4.5 27

2 x 0.5 28 0.16 1.0 40.1 0.35 1.65 0.9 5.0 5.3 34

3 x 0.5 28 0.16 1.0 40.1 0.35 1.65 0.8 5.0 5.4 39

4 x 0.5 28 0.16 1.0 40.1 0.35 1.65 0.6 5.0 5.4 42

FL4G11Y

2 x 0.5 16 0.21 1.0 40.1 0.6 2.2 0.85 5.9 6.3 44

2 x 0.75 42 0.16 1.2 27.1 0.5 2.2 0.9 6.0 6.4 47

2 x 1.5 30 0.26 1.7 13.7 0.6 2.8 0.65 6.6 7.0 66

3 x 0.5 16 0.21 1.0 40.1 0.6 2.2 0.8 6.0 6.4 51

3 x 1.5 30 0.26 1.7 13.7 0.7 2.9 1.1 8.1 8.7 107

Note: This chart shows an extract of our existent product portfolio. Other versions on request.


Conductor


tinned. Fine or super-fine high flexible stranded conductor.

Insulation

E/VA (Ethylene vinyl acetate) with properties based on ISO 6722,

Class C.

Optional: Polyester foil according to DIN 40634 can be laid longitudi-

nally under the insulation.

Sheath

TPE-U (Polyether polyurethane with especially high resistance to

hydrolysis).

Special properties

Cables in hot-pressure resistant version to 150 °C available on

request.

Very high fatigue strength under reversed bending stresses and

abrasion resistance.

Conductors with three or four cores for additional functions.

FLR4G11Y

Reduced wall thickness.

47

Multi-corecables




No. of cores x


No. of strands

Diameter of single

wiremax.

Diameter of conduc-

tor max.


bare tinned max. max.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.

mm2 mm mm mΩ/m mΩ/m mm mm mm mm mm kg/km

2 x 0.35 12 0.21 0.9 52.0 54.5 0.25 1.35 0.5 3.5 3.9 18

2 x 0.5 19 0.19 1.0 37.1 40.1 0.3 1.5 0.65 4.2 4.6 25

2 x 0.5 28 0.16 1.0 37.1 40.1 0.3 1.5 0.65 4.2 4.6 25

2 x 0.5 64 0.10 1.0 38.2 40.1 0.35 1.6 0.95 5.0 5.4 36

2 x 0.75 42 0.16 1.2 24.7 27.1 0.5 2.2 0.9 6.0 6.4 46


Conductor

Soft-annealed electrolytic copper Cu-ETP1 according to

DIN EN 13602, bare or tinned.

Insulation

PE-X (Polyethylene crosslinked).

Sheath


hydrolysis).

ABS/ESP cable

with PE-X insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)

FLR2X11Y

48

Multi-core cables



No. of cores x


No. of strands



max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


2 x 0.5 28 0.16 1.0 37.1 0.30 1.5 0.7 4.3 4.7 27.5

2 x 0.5 28 0.16 1.0 37.1 0.30 1.5 1.0 4.8 5.2 35

2 x 0.75 42 0.16 1.2 24.7 0.30 1.8 1.2 6.0 6.4 47.5

2 x 0.75 96 0.11 1.2 24.7 0.30 1.8 1.2 6.0 6.4 48

3 x 0.5 19 0.19 1.0 37.1 0.30 1.6 0.8 5.0 5.2 37

3 x 0.75 19 0.23 1.2 24.7 0.30 1.8 1.0 5.7 6.1 49

3 x 1 19 0.26 1.2 18.5 0.35 2.0 0.8 5.7 6.1 56

4 x 0.5 28 0.16 1.0 37.1 0.30 1.5 1.2 6.0 6.4 51

4 x 0.5 64 0.1 1.0 37.1 0.30 1.6 1.2 6.0 6.4 51

5 x 0.5 64 0.1 1.0 37.1 0.30 1.6 1.0 6.0 6.4 54



Conductor


bare.

Insulation

TPE-S (Thermoplastic polystyrene block copolymer).

Sheath


hydrolysis).

ABS/ESP cable

with TPE-S insulation

Temperature range:

–40 °C to +125 °C (3000 hrs)

FLR31Y11Y

49

Multi-corecablesFLRY11YABS/ESP sensor cables


No. of cores x


No. of strands



max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


2 x 0.75 42 0.16 1.2 24.7 0.4 1.9 0.8 5.2 5.6 39

3 x 1 32 0.21 1.5 18.5 0.35 2.0 0.7 5.6 6.0 56

3 x 1.5 30 0.26 1.7 13.3 0.4 2.4 0.75 6.5 6.9 75



Conductor


bare or tinned.

Insulation

PVC (Polyvinyl chloride).

Sheath


hydrolysis).

ABS/ESP cable with PVC insulation

reduced wall thickness

Temperature range:

–40 °C to +105 °C (3000 hrs)

50

Multi-core cables


Other versions are available on request.

FLYY / FLRYY / FLYKYK


Conductor Soft-annealed electrolytic copper Cu-ETP1 according to

DIN EN 13602, bare or tinned. Conductor according to ISO 6722.

Insulation


Sheath Plasticized PVC with properties according to ISO 6722, Class B.

Special properties

FLYY – Heat- and hot-pressure resistant designs can be supplied on

request (see page 56).

FLRYY – Versions with space-saving, thin wall insulation.

Application for operating voltage up to 60 V (DC).

FLYKYK – Especially flexible at low temperatures.


Temperature range:

–40 °C to +105 °C (3000 hrs) FLYY / FLRYY

–50 °C to +90 °C (3000 hrs) FLYKYK


No. of cores x


No. of strands

Diameter of single

wiremax.

Diameter of conduc-

tor max.



Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


FLYY

2 x 0.5 16 0.21 1.0 37.1 38.2 0.4 1.75 0.50 4.3 4.7 31

2 x 0.75 24 0.21 1.2 24.7 25.4 0.6 2.3 0.50 5.4 5.8 48

7 x 0.75 24 0.21 1.2 24.7 25.4 0.5 2.15 0.80 7.8 9.4 112

7 x 1 32 0.21 1.4 18.5 19.1 0.6 2.5 1.00 9.0 9.6 148

7 x 1.5 30 0.26 1.7 12.7 13.0 0.6 2.75 1.10 10.2 11.0 201

FLRYY

2 x 0.35 7 0.26 0.8 52.0 54.5 0.25 1.3 0.50 3.3 3.7 20

2 x 0.5 19 0.19 1.0 37.1 38.2 0.3 1.6 0.60 4.2 4.6 29

2 x 0.5 16 0.21 1.0 37.1 38.2 0.3 1.6 0.60 4.2 4.6 29

2 x 0.75 24 0.21 1.2 24.7 25.4 0.3 1.75 0.60 4.5 4.9 36

2 x 1 32 0.21 1.4 18.5 19.1 0.3 1.95 0.60 4.8 5.4 45

5 x 0.75 24 0.21 1.2 24.7 25.4 0.3 1.75 0.75 6.3 6.7 75

6 x 0.5 16 0.21 1.0 37.1 38.2 0.3 1.6 0.85 6.2 6.8 68

6 x 0.75 24 0.21 1.2 24.7 25.4 0.3 1.75 0.75 6.6 7.0 82

6 x 1 32 0.21 1.4 18.5 19.1 0.3 1.95 1.00 7.6 8.0 114

7 x 0.75 24 0.21 1.2 24.7 25.4 0.3 1.75 0.75 6.6 7.0 89

7 x 1 32 0.21 1.4 18.5 19.1 0.3 1.95 0.75 7.2 7.6 113

8 x 0.5 16 0.21 1.0 37.1 38.2 0.3 1.6 0.95 6.9 7.5 87

FLYKYK

2 x 0.5 16 0.21 1.0 37.1 38.2 0.5 1.95 0.70 5.0 5.6 34

2 x 1 32 0.21 1.4 18.5 19.1 0.6 2.5 0.60 6.0 6.6 50

3 x 0.5 16 0.21 1.0 37.1 38.2 0.5 1.95 0.60 5.1 5.7 41

51

Multi-corecables



Conductor



Insulation


Sheath


Flat PVC cable

Temperature range:

–40 °C to +105 °C (3000 hrs)

FLYYF



No. of cores x


No. of strands



max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

Dimension Weight

approx.Width Height


2 x 0.75 24 0.21 1.2 24.7 0.6 2.3 0.6 5.8 ± 0.3 3.5 ± 0.2 35

2 x 1 32 0.21 1.4 18.5 0.6 2.5 0.6 6.2 ± 0.3 3.7 ± 0.2 42

2 x 1.5 30 0.26 1.7 12.7 0.6 2.7 0.5 6.4 ± 0.3 3.8 ± 0.2 53

2 x 2.5 50 0.26 2.2 7.6 0.7 3.4 0.6 8.1 ± 0.3 4.6 ± 0.2 78

3 x 1.5 30 0.26 1.7 12.7 0.6 2.7 0.5 9.2 ± 0.4 3.8 ± 0.2 79

52


Conductor



Insulation


Multi-core cables

PVC twin cable

Temperature range:

–40 °C to +105 °C (3000 hrs)

FLYZ



No. of cores x


No. of strands



max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Dimension Weight

approx.Width Height

mm2 mm mm mΩ/m mm mm mm mm kg/km

2 x 0.5 16 0.21 1.0 37.1 0.5 2.1 4.4 ± 0.2 2.1 ± 0.15 15

2 x 0.75 24 0.21 1.2 24.7 0.6 2.35 4.7 ± 0.3 2.35 ± 0.15 23

2 x 1.5 30 0.26 1.7 12.7 0.6 2.8 5.6 ± 0.3 2.8 ± 0.15 39


53

Multi-corecablesFLRYBY / FLRYDY / FLRYBDY / FLRYCY

PVC cable multi-core

with complete shielding

Temperature range:

–40 °C bis +105 °C (3000 h)

Shielding

Foil shield (B), spirally wrapped overlapping aluminium-coated foil.

Spiral shield of copper wires (D).

Braiding of copper wires (C) of Cu-ETP1 according to

DIN EN 13602 as well as combined shieldings (e. g. BD).

Sheath



Conductor


bare or tinned. Conductor according to ISO 6722.

Insulation


Sheath for drain wire made of conductive PVC.

Drain wire

Drain wire of tinned copper wires of Cu-ETP1 according to

DIN EN 13602 to contact the shielding.



No. of cores x


No. of strands

Diameter of single

wiremax.

Diameter of conduc-

tor max.



Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


FLRYBY

1 x 0.35+(0.35) 7 0.26 0.8 52.0 54.5 0.25 1.25 0.5 2.9 3.3 14

4 x 0.35+(0.35) 7 0.26 0.8 52.0 54.5 0.25 1.25 0.5 4.3 4.7 35

FLRYDY

2 x 0.22 7 0.21 0.7 84.8 86.5 0.25 1.15 0.5 3.4 3.8 25

2 x 0.35 12 0.21 0.8 52.0 54.5 0.25 1.35 0.6 4.2 4.6 30

2 x 0.5 19 0.19 1.0 37.1 38.2 0.30 1.5 0.8 4.9 5.3 38

2 x 0.75 24 0.21 1.2 24.7 25.4 0.30 1.75 0.6 4.9 5.2 44

2 x 1 19 0.26 1.4 18.5 19.1 0.30 2.0 0.7 5.5 5.9 52

3 x 0.75 24 0.21 1.2 24.7 25.4 0.30 1.75 0.6 5.1 5.4 55

3 x 1 32 0.21 1.4 18.5 19.1 0.30 1.95 0.5 5.5 5.8 64

FLRYBDY

2 x 0.5 19 0.19 1.0 37.1 38.2 0.30 1.6 0.6 4.7 4.9 36

FLRYCY

9 x 0.08 10 0.11 0.45 353 365 0.20 0.8 0.6 4.6 4.9 38

10 x 0.25 14 0.16 0.7 84.8 86.5 0.20 1.1 0.6 5.8 6.2 68

5 x 0.35 19 0.16 0.8 52.0 54.5 0.25 1.3 0.5 4.7 5.1 47

8 x 0.35 19 0.16 0.8 52.0 54.5 0.25 1.25 0.65 5.9 6.3 75

10 x 0.35 19 0.16 0.8 52.0 54.5 0.25 1.25 0.65 6.5 6.9 83


54

Multi-core cables



Conductor


bare. Concentric stranded conductor according to ISO 6722.

Insulation


Sheath


Special properties

FLRYY11Y – Combined multi-core cable. Outer sheath made of

TPE-U (thermoplastic polyurethane elastomer) with especially high

resistance to abrasion (11Y).


German approval for transportation of hazardous materials (GGVS).

Tested in accordance with GGVS/ADR.

PVC special cable

with thin insulation

Temperature range:

–40 °C to +105 °C (3000 hrs)

FLRYY (GGVS) / FLRYY11Y

Structure Core Core Cable

No. of cores x nominal cross-section

Diameter of core

max.

Color code Diameter of core

max.

Color code O.D.

max.

Weight

approx.

mm2 mm2 mm mm2 mm mm kg/km

FLRYY (GGVS)

2 x 1 1 Ø 2.1 5.7 19.5

3 x 1.5 + 2 x 6 1.5 Ø 2.0 6 Ø 4.3 12.3 150

4 x 1.5 + 3 x 2.5 1.5 Ø 2.4 2.5 Ø 3.0 10.5 130

7 x 1.5 1.5 Ø 2.4 10.6 101

10 x 1.5 + 3 x 2.5 + (2 x 1.5)PP data pair

1.5 Ø 2.4 2.5 1.5

Ø 3.0 Ø 2.4

14.7 245

FLRYY11Y

2 x 4 + 3 x 1.5 4 Ø 3.7 1.5 Ø 2.4 11.3 212

3 x 2.5 + 4 x 1.5 2.5 Ø 3.0 1.5 Ø 2.4 10.5 130

7 x 1 + 1 x 1.5 1 Ø 2.1 1.5 Ø 2.4 9.2 82

9 x 1 + 1 x 4 1 Ø 2.1 4 Ø 3.7 12.5 125

Structure Conductor construction Insulation

Cross-section No. of strands Diameter of single wire

max.


max.


max.

Wall thickness

nom.

mm2 mm mm mΩ/m mm

0.75 24 0.21 1.2 24.7 0.3

1 32 0.21 1.4 18.5 0.3

1.5 30 0.26 1.7 12.7 0.35

2.5 50 0.26 2.2 7.6 0.35

4 56 0.31 2.75 4.7 0.4

6 84 0.31 3.3 3.1 0.4


55

Multi-corecables

CD player control cable

Temperature range:

–40 °C to +105 °C (3000 hrs)


Conductor


Concentric stranded conductor according to ISO 6722.

Drain wire

Multi-wire stranded conductor of Cu-ETP1 according to DIN EN 13602,

(nominal cross-section 0.35 mm2).

Insulation

Plasticized PVC according to ISO 6722, Class B.

FLY(YDY)(YBY)CY 3x0.35+(1x0.35)+(2x0.35)

Internal shielding

1. Spiral shield of tinned copper wires (individual wire

diameter max. 0.13 mm). Visual covering min. 95 %.

2. Foil shield of aluminium-coated polyester foil.

Spirally wrapped overlapping tape. Metal side in electric contact

with the drain wire.

Inner sheath


Complete shielding

Braiding of tinned copper wires of Cu-ETP1 according to DIN EN 13602.

Visual covering min. 75 %.

Outer sheath

Plasticized PVC according to ISO 6722, Class B, matt.


Structure Conductor construction Insulation Inner sheath Complete cable

No. of cores x

nominal cross-

section

No. of strands

Dia-meter

of single wire

max.

Dia-meter of conductor

max.


at 20 °C

max.

Wall thick-ness

Dia-meter of core

Wall thickness

nom.

Inner- O.D.

Braiding construction

No. of wires x

individual wire-O.D.

Outer sheath

wall thickness

O.D. Weight

approx.min. max.

mm2 mm mm mΩ/m mm mm mm mm mm mm mm mm kg/km

3 x 0.35 12 0.21 0.9 52.0 0.40 1.6

(1 x 0.35) 12 0.21 0.9 52.0 0.25 1.35 0.4 2.4 144 x 0.13 0.7 8.0 8.4 97

(2 x 0.35) 12 0.21 0.9 52.0 0.22 1.3 0.35 3.4


56

Multi-core cables


FLYWYW / FLRYWYW / FLRYWZ / FLRYWYWF

Round, flat and twin cable

Temperature range:

–40 °C bis +125 °C (3000 hrs)


Conductor



Insulation


hot-pressure resistant.

Sheath


hot-pressure resistant.

Versions

Round cable (FLYWYW or FLRYWYW)

Twin cable (FLRYWZ)

Flat cable (FLRYWYWF)



No. of cores x


No. of strands

Diameter of single

wiremax.

Diameter of conduc-

tor max.



Wall thickness

nom.

Diameter of core

Sheathwall

thicknessnom.

O.D. Weight

approx.min. max.


FLYWYW 2 x 0.75

2 x 0.75 24 0.21 1.2 24.7 25.4 0.60 2.4 0.7 6.0 6.2 50

FLRYWYW 4 x 1

4 x 1 19 0.26 1.4 18.5 19.1 0.35 2.0 0.5 5.6 6.0 65

FLRYWZ 4 x 0.35

4 x 0.35 7 0.26 0.8 52.0 54.5 0.25 1.25 – 1.25 x 8.9 (h x w) 18

FLRYWYWF 2 x 2.5

2 x 2.5 19 0.41 2.2 7.6 2.8 0.40 2.8 0.6 3.9 x 7.0 (h x w) 68

57

Multi-corecables


Conductor



Insulation

Thermoplastic elastomers based on polyolefins (91Y)

resp. polyesters (12Y), fluoropolymeres, e.g. ETFE (7Y) or FEP (6Y).

Sheath

TPE-U (polyether polyurethane) with especially high resistance to

hydrolysis (11Y).

Special cable

Temperature range:

–40 °C to +125 °C (3000 hrs)

FLR91Y11Y / FLR12Y11Y / FLU7Y11Y / FLU6Y11YCables up to 125 °C



No. of cores x


No. of strands

Diameter of single

wiremax.

Diameter of conduc-

tor max.



Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


FLR91Y11Y 3 x 0.75

3 x 0.75 19 0.23 1.2 24.2 25.4 0.3 1.8 1.0 5.7 6.1 48

FLR12Y11Y 2 x 0.5

2 x 0.5 19 0.19 1.0 32.1 38.2 0.3 1.5 0.6 4.15 4.45 25

FLU7Y11Y 2 x 0.5

2 x 0.5 64 0.11 1.0 – 38.2 0.2 1.4 0.25 3.2 3.4 18.5

FLU6Y11Y 4 x 0.14

4 x 0.14 18 0.11 0.6 – 136.0 0.1 0.7 0.25 2.0 2.4 10

58

Multi-core cables


Conductor



Insulation

Thermoplastic elastomers based on polyesters (13Y), fluoropolymeres,

e. g. ETFE (7Y) or FEP (6Y).

FLR13Y13Y / FLR13YC13Y / FLU7Y7Y FLU6Y6YF / FLR6YC6Y

Special cable

Temperature range

(see chart below)

Shielding

Braiding of tinned copper wires of Cu-ETP1 according to DIN EN 13602

with high visual covering (≥90 %).

Sheath

Thermoplastic elastomers based on polyesters resp. fluoropolymeres,

e. g. ETFE or FEP. Round or flat version.

Cables from 150 °C


No. of cores x

nominal cross-sec-

tion

No. of strands

Diameter of

single wire max.

Diameter of conduc-

tor

max.


at 20 °C

max.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.

Temperature range

min. max.

mm2 mm mm mΩ/m mm mm mm mm mm kg/km 3000 hrs

FLR13Y13Y 2 x 0.5

2 x 0.5 19 0.19 1.0 38.2 0.3 1.55 0.9 4.9 5.1 32 –40 °C to +150 °C

FLR13YC13Y 10 x 0.5

10 x 0.5 16 0.21 1.5 38.2 0.3 1.55 0.65 7.6 8.2 127 –40 °C to +150 °C

FLU7Y7Y 3 x 0.5

3 x 0.5 28 0.16 1.0 38.2 0.2 1.3 0.4 3.6 3.9 26 –40 °C to +175 °C

FLU6Y6YF 4 x 0.35

4 x 0.35 19 0.15 0.75 54.5 0.2 1.2 0.45 2.1 x 5.5 (h x w) 32 –40 °C to +200 °C

FLR6YC6Y 2 x 0.5

2 x 0.5 19 0.19 1.0 38.2 0.3 1.5 0.5 4.45 4.75 53 –40 °C to +200 °C


59

Multi-corecables

Low voltage differential signaling

cable (LVDS), e.g. data transfer

4 x 2 x 0.22 + (0.22)

Temperature range:

–40 °C bis +105 °C (3000 hrs)

502


Conductor



Insulation

PP (Polypropylene).

Shielding

Aluminium-coated foil.

Braiding of tinned copper wires and drain wire.

Sheath

Plasticized PVC, lead free.

Electrical properties

Impedance 100 ±15 Ω

LEONI Dacar©

data cables

Overview Product range data cables – LVDS

Designation Construction Dielectric Impedance Sheath Temperature range Application

LEONI Dacar® 501 FL2YBCY 4 x 2 x 0.22 (+ 0.22) PE 100 Ω PVC –40 to +85 °C LVDS

LEONI Dacar® 502 FL9YBCY 4 x 2 x 0.22 (+ 0.22) PP 100 Ω PVC –40 to +105 °C LVDS

LEONI Dacar® 503 FL09YBCY 4 x 2 x 0.22 Foam-PP 100 Ω PVC –40 to +105 °C LVDS

LEONI Dacar® 508 FL2YBCY 5 x 2 x 0.22 PE 100 Ω PVC –40 to +85 °C LVDS

LEONI Dacar® 509 FL9YBCY 5 x 2 x 0.22 PP 100 Ω PVC –40 to +105 °C LVDS

LEONI Dacar® 511 FL09YBCY 5 x 2 x 0.22 Foam-PP 100 Ω PVC –40 to +105 °C LVDS

LEONI Dacar® 535 FL9YBCY 4 x 0.14 PP 100 Ω PVC –40 to +105 °C LVDS


60

Multi-core cables


Conductor


bare. Conductor according to ISO 6722.

Insulation

PP foamed (Polypropylene).

Shielding

Aluminium-coated foil, visual covering 100 %.

Cable for bus systems

FL09YBY 2 x 0.35 + (0.35)

Temperature range:

–40 °C bis +105 °C (3000 hrs)

533

Sheath



Impedance 100 ± 15 Ω

LEONI Dacar©

data cables

Designation Construction Dielectric Impedance Sheath Temperature range Application

LEONI Dacar® 520 FL09YS11Y 2 x 0.35 Foam-PP 120 Ω TPE-U –40 to +105 °C CAN

LEONI Dacar® 507 FLY2YY 2 x 2 x 0.14 PE 100 Ω PVC –40 to +85 °C FireWire

LEONI Dacar® 532 FL09YB11Y 2 x 0.35 Foam-PP 100 Ω TPE-U –40 to +105 °C Flexray

LEONI Dacar® 533 FL09YBY 2 x 0.35 + (0.35) Foam-PP 100 Ω PVC –40 to +105 °C e-Most

LEONI Dacar® 560 FL2X11Y 2 x 0.35 PE-X 120 Ω TPE-U –40 to +120 °C CAN

LEONI Dacar® 562 FL2X11Y 2 x 0.55 PE-X 120 Ω TPE-U –40 to +120 °C CAN

LEONI Dacar® 565 FL09YSBY 2 x 0.75 + (0.75) Foam-PP 120 Ω PVC –40 to +120 °C CAN

Overview product range data cables – bus systems


61

Multi-corecables

Sensor cable for lambda probe

Temperature range:

–40 °C to +105 °C (3000 hrs)

Drain wire

550


Conductor



Insulation


Sheath for the drain wire

Conductive PVC.

Shielding

Foil shield of spirally wrapped overlapping tape of aluminium-coated

PVC foil.

Sheath


hydrolysis (11Y).

LEONI Dacar©

data cables


No. of cores x


No. of strands



max.


at 20 °Cmax.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min. max.


1 x 0.35+(0.35) 7 0.26 0.8 52.0 0.25 1.25 0.6 3.9 4.3 21

2 x 0.35+(0.35) 7 0.26 0.8 52.0 0.25 1.25 0.6 4.1 4.5 24

3 x 0.35+(0.35) 7 0.26 0.8 52.0 0.25 1.25 0.6 4.4 4.8 30

4 x 0.35+(0.35) 7 0.26 0.8 52.0 0.25 1.25 0.6 4.8 5.2 39

5 x 0.35+(0.35) 7 0.26 0.8 52.0 0.25 1.25 0.6 5.4 5.8 46

Overview product range data cables – Lambda probe


62

Multi-core cables

Car telephone cable

FLR7YC11Y

12 x 0.22 SN + coax Z 50

Temperature range:

–40 °C bis +85 °C (3000 hrs)

570

Construction core

Conductor



Insulation

Ethylene tetrafluoroethylene (ETFE) with properties according to

ISO 6722, Class D.

Construction cable

Shielding

Braiding of tinned copper wires of Cu-ETP1 according to DIN EN 13602,

0.10 mm, visual covering appr. 90 %.

Sheath


hydrolysis (11Y).

Construction coaxial element Z 50

Conductor

Fine tinned stranded conductor of Cu-ETP1 according to DIN EN 13602.

Dielectric

PE (Polyethylene).

Shielding


0.10mm, visual covering appr. 85 %.

Sheath

Plasticized PVC, lead free.

LEONI Dacar©

data cables

Designation Construction Sheath Temperature range Application

LEONI Dacar® 505 FL2YBC11Y 4 x 2 x 0.22 TPE-U –40 to +85 °C UHI

LEONI Dacar® 506 FL6YBC11Y 4 x 2 x 0.22 TPE-U –40 to +125 °C UHI

LEONI Dacar® 514 FLR12YBCY 5 x 2 x 0.14 + 2 x 0.5 PVC –40 to +105 °C UHP

LEONI Dacar® 570 FLR7YC11Y 12 x 0.22 + Z 50 TPE-U –40 to +85 °C Car telephone

LEONI Dacar® 573 FLRY (YB12Y) BY 3 x 0.56 + 3 x 0.14 + 2 x 0.14

PVC –40 to +105 °C Car telephone

LEONI Dacar® 590 FLR7YC11Y 8 x 0.22 + 2 x 0.35 + Z 50 TPE-U –40 to +85 °C Car telephone

LEONI Dacar® 800 FL(R2YCY) (09YCY)CY 2 x (0.14) + 2 x (Coax B-75-1.68-2.7)

PVC –40 to +85 °C Audio/Video

Overview product range data cables


63

Multi-corecables

RF coaxial cable

with solid dielectric

Temperature range:

–40 °C bis +105 °C (3000 hrs)

300


Conductor

Copper clad steel wire, bare, 7 x 0.16, diameter 0.48 mm.

Dielectric

PP (Polypropylene), diameter 1.52 mm.

Shielding


visual covering nom. 90 %, diameter 1.92 mm.

Sheath

Plasticized PVC according to ISO 6722, Class B,

lead free, diameter 2.8 mm.



Capacitance at 1 kHz max. 106 pF/m

Conductor resistance at 20 °C max. 317 Ω/km

LEONI Dacar©

coaxial cables

Overview product range coaxial cables

Designation Impedance ConductorDielectric

O.D. [mm] / MaterialShielding

Sheath O.D. [mm] / Material

Temperature range

LEONI Dacar® 110 50 Ω Copper strand SN 19 x 0.182 2.95 / PE 95 % Cu SN 4.95 / PVC –40 to +85 °C

LEONI Dacar® 310 50 Ω Copper strand SN 19 x 0.182 2.95 / PP 95 % Cu SN 4.95 / PVC –40 to +105 °C

LEONI Dacar® 100 50 Ω Staku BL 7 x 0.16 1.52 / PE 86 % Cu SN 2.80 / PVC –40 to +85 °C

LEONI Dacar® 300 50 Ω Staku BL 7 x 0.16 1.52 / PP 86 % Cu SN 2.80 / PVC –40 to +105 °C

LEONI Dacar® 200 75 Ω Copper strand SN 7 x 0.182 3.1 / PE 95 % Cu SN 4.60 / PVC –40 to +85 °C

LEONI Dacar® 218 75 Ω Copper strand BL 7 x 0.182 3.2 / PE 95 % Cu SN 4.60 / PVC –40 to +85 °C

LEONI Dacar® 400 50 Ω Staku AG 7 x 0.17 1.48 / FEP 96 % Cu AG 2.50 / FEP –65 to +205 °C

LEONI Dacar® 450 75 Ω Staku AG 7 x 0.102 1.6 / FEP 92 % Cu AG 2.60 / FEP –65 to +205 °C


64

Multi-core cables 302

RF coaxial cable with foamed dielectric

Temperature range:

–40 °C bis +105 °C (3000 hrs)


Conductor

Copper wire, bare, 7 x 0.27, diameter 0.81 mm.

Dielectric

PP foamed (Polypropylene), diameter 2.1 mm.

Shielding

Aluminium-coated foil, visual covering 100 %.

Braiding of tinned copper wires, visual covering nom. 90 %,

diameter 2.5 mm.

Sheath

PVC (Polyvinyl chloride), lead free, diameter 3.3 mm.



Capacitance at 1 kHz max. 85 pF/m

Conductor resistance at 20 °C max. 48.5 Ω/km

Special features

Coax cables with foamed dielectric show an outstanding trans-

mission performance combined with a significant reduction of

the cable dimensions. A typical feature of this product range is,

amongst others, their high velocity ratio of approx. 78 % of the

speed of light.

LEONI Dacar©

coaxial cables

Designation Impedance ConductorDielectric

O.D. [mm] / MaterialShielding

Sheath O.D. [mm] / Material

Temperature range

LEONI Dacar® 034 50 Ω Copper strand BL 7 x 0.30 2.25 / Foam-PE 87 % Cu SN 3.5 / PVC –40 to +85 °C

LEONI Dacar® 031 50 Ω Copper strand BL 7 x 0.27 2.1 / Foam-PE 92 % Cu SN + AL 3.2 / PVC –40 to +85 °C

LEONI Dacar® 302 50 Ω Copper strand BL 7 x 0.27 2.1 / Foam-PP 90 % Cu SN + AL 3.3 / PVC –40 to +105 °C

LEONI Dacar® 360 75 Ω Copper strand BL 7 x 0.127 1.68 / Foam-PP 90 % Cu SN + AL 2.7 / PVC –40 to +105 °C

LEONI Dacar® 077 120 Ω Staku BL 7 x 0.10 3.1 / Foam-PE 75 % Cu BL 4.8 / PVC –40 to +85 °C


Overview product range coaxial cables

65


Conductor


bare.

Insulation

Plasticized PVC according to ISO 6722, Class B, resp. Class C. PVC

(heat-resistant) or TPE-O (thermoplastic polyolefin elastomer), copper

stabilised, lead free.

Shield

High flexible braiding of bare or tinned copper wires.

Minimum visual covering 95 %.

Special cable for vehicles with battery,

hybrid or fuel cell drive systems

Temperature range:

–40 °C to +105 °C (3000 hrs) 105-F

–40 °C to +125 °C (3000 hrs) 125-F

LEONI Hivocar©


Type of conductor Nominal cross-

section

No. of strands

max.


max.


max.

Wall thickness

nom.

Diameter of core

Sheathwall

thickness

O.D. Weight

approx.min.

mm2 mm mm mΩ/m mm mm mm mm kg/km

LEONI Hivocar® 105-F cables for –40 °C up to +105 °C in highly flexible version (F)

LEONI Hivocar® 105-F 70 1 x 70 2205 12.4 0.27 1.2 14.8 1.2 17.6 ± 0.4 860

LEONI Hivocar® 105-F 2 x 2.5 2 x 2.5 651 2.2 7.6 0.8 3.75 1.0 10.0 ± 0.3 145

LEONI Hivocar® 105-F 2 x 4 2 x 4 1020 2.6 4.71 0.8 4.2 1.1 11.0 ± 0.4 182




LEONI Hivocar® 125-F cables for –40 °C up to +105 °C in highly flexible version (F)

LEONI Hivocar® 125-F 5 1 x 5 651 3.7 3.6 1.0 5.5 1.0 7.9 ± 0.3 109

LEONI Hivocar® 125-F 8 1 x 8 1008 4.0 2.55 1.0 5.8 1.0 8.2 ± 0.3 139

LEONI Hivocar® 125-F 25 1 x 25 3185 6.8 0.75 1.4 9.6 1.3 12.6 ± 0.3 360

LEONI Hivocar® 125-F 35 1 x 35 4473 8.5 0.53 1.4 10.8 1.4 14.0 ± 0.4 481

LEONI Hivocar® 125-F 50 1 x 50 6370 10.8 0.37 1.6 13.8 1.4 17.0 ± 0.4 670



Multi-corecables

Sheath

Plasticized PVC according to ISO 6722, Class B, resp. Class C. PVC

(heat-resistant) or TPE-U (specific hydrolysis resistant polyether

polyurethane).

Other versions according to customer specifications available

E. g. high flexible, unshielded version LEONI Hivocar® 125-FU

or with aluminium conductors LEONI Hivocar® 125-A

66

Multi-core cables

Flat cables

Extruded flat cables

Chart of standard dimen-sions

Construction

Conductors


Insulation

Heat-resistant PVC, lead free

Thermoplastic polyurethane-based elastomer

Thermoplastic polyolefin elastomer

Polypropylene, flame-retardant

Ethylene/tetrafluoroethylene

Insulation wall thicknesses from 0.1 – 0.25 mm are available,

depending on the insulation material and cable structure involved.

Tolerances

Insulation wall thickness ± 0.04 mm

Cable width ± 0.30 mm (up to cable width of 70 mm)

Pitch: ± 0.15 mm (up to cable width of 20 mm)

Marking options

Imprint

Edge marking to indicate the first conductor

Dyed insulation material

Separation grooves

It is possible to produce the cable with separation grooves. These

can be utilized during further processing when cutting the cable.

Pitch

2.54 mm (standard). Other pitch dimensions are available on request.

Material designations

Insulation materials

Y PVC –40 °C to +105 °C

YW Heat-resistant PVC –40 °C to +110 °C

11Y PUR (Polyurethane) –40 °C to +110 °C

12Y TPE-E –40 °C to +105 °C

9Y PP-FR –40 °C to +110 °C

7Y ETFE –65 °C to +180 °C

Conductor materials

BL Bare copper

SN Tinned copper

AG Silver-plated copper

Example of a material designation

exFC–YW 5x1.54+3x4.08/0.2 BL

extruded flat cable

heat-resistant PVC insulation

5 x conductors (1.54 x 0.2 mm) + 3 x conductors (4.08 x 0.2 mm)

bare copper conductor material

insulation wall thickness core

insulation material

separation groove

conductor widthconductor thickness

pitch

Chart of standard dimensions

Conductor thickness

mm

Conductor width mm

0.80 1.00 1.23 1.35 1.40 1.54 2.05 4.08 6.62

0.076 6

0.100 6 6 6 6

0.120 6 6

0.130 6 6

0.150 6

0.200 6 6 6 6

0.450 6 6

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Ribbon cables

Multi-corecables

pitchthickness of insula-tion between the tracks

core

insulation material

Ribbon cables

Construction

Conductors


Insulation

Heat-resistant PVC, lead free

PP, flame-retardant

Dimensions

according to LV 112

max. 24 conductors

Marking options

Imprint

Edge marking to indicate the first conductor

Dyed insulation material

Pitch

Material designations

Insulation materials

Y PVC –40 °C to +105 °C

YW Heat-resistant PVC –40 °C to +110 °C

9Y PP-FR –40 °C to +110 °C

Conductor materials

BL Bare copper

SN Tinned copper

AG Silver-plated copper

2.54 mm (standard). Other pitch dimensions are available on request.

68

Our cables can be supplied

in all standard forms of packag-

ing to suit the customer’s further

processing needs:

barrels

drums

coils

coni-packs

coiled

Packaging of special cables on

request.

Packaging

Drums

Single-core cables of large cross section and multi-core cables are

generally supplied on wooden or plastic drums from the drum pool of

KTG Kabeltrommel GmbH & Co. KG, Schanzenstrasse 30, 51043

Cologne, Germany. Drum rental is governed by KTG`s terms and

conditions.

A copy is available upon request.

If requested, we can supply LEONI drums at a charge.

Popular drum types:

Manufacturer Type Material

KTG-Drum (re-usable)KT050 plastic

KT080 plastic

LEONI-Drum (re-usable)

K3502 plastic

K5000 plastic

K8002 plastic

LEONI-Drum (one-way)H6008 wood

H7601 wood

Packaging

69

Coni-packs

The Niehoff re-usable coni-pack is a particularly advanced form of

packaging. It consists of a re-usable, high-grade plastic spool which

can be disassembled into an upper flange with core and a lower,

removable flange.

The coni-pack is moved by means of a hoist inserted in holes on

the flange. A pay-off device is used to feed cable from the pack.

Partly used packs can be moved and restacked with ease.

As many as 100 re-usable packs can be stacked inside one another on

one pallet for return shipment.

The LEONI-BOX

The LEONI-BOX is a practical and environmentally-friendly, cardboard

package for conductors. The corrugated cardboard is made of organic,

recyclable and environmentally friendly materials. The return of the

empties to the cable manufacturer is not necessary.

Full LEONI-BOXES are shipped with closed lids on pallets

103 x 103 cm. The pallets are taken back on request.

A maximum of 8 LEONI-BOXES can be stacked on a pallet.

Barrels

To protect the environment and to conform with legislation, our

barrels are re-usable cardboard barrels almost without exception.

The most popular barrel types:

Typ O.D. d1 Core diame-ter d2

Height h Weight empty

mm mm mm kg

F 5000 500 315 410 approx. 9.0

F 5001 500 320 710 approx. 10.8

Packaging

70

The LEONI group We also produce…

Cable WireWiring Systems

Single wires, tin, silver, gold and nickel

plated made of copper and copper based

alloys Bunched and stranded conductors for

the cable industry

Highly flexible copper strands, ropes

and braids

Tinsel conductors and braided tubes Copper alloy wires (resistance wires) Metallic gold and silver threads;

bouillon

Wiring systems for automobiles, trucks

and buses

tractors and forklifts Conventional and preformed cable

harnesses Plastic mouldings, also in foamed version Electronic solutions for automobile

construction (part and full multiplex) Cable assemblies for ABS systems and

sensors

Automotive wires UL and CSA approved cables Insulated power cables Earthing ropes Control cables, shielded and unshielded Insulated Hook-up wires according to

DIN, VDE Fiber optic cables

with glass and plastic optical fibers Copper data cables Coaxial cables Customised special cables for robotics,

seismology, medicine, sensor systems,

audio/video, environmental engineering ... Cord sets Spiral cables Cable assemblies Special cables assembled to customer

specification Connection cables and car kits for

mobile phones Automotive cables for electronic drive

controls, engine management, mobile

communication Extruded flat cables Battery, starter and generator cables

with copper and aluminium conductors

Stieberstrasse 5

91154 Roth

Germany

Phone +49 (0)9171-804-2218

Fax +49 (0)9171-804-2232

E-mail [email protected]

www.leoni-cable.com

LEONI Kabel GmbH

Documents

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