Automotive Wires and Cables
Transcription
Automotive Wires and Cables
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 information. 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 Automotive cables single-core Automotive cables multi-core page 17 page 45 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) Cables up to 125 °C 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 The Quality Connection LEONI sets standards 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 takeovers 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 experienced 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. There is tradition and a future in expertise. The Quality Connection Top names place their trust in LEONI 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 The Quality Connection LEONI quality management 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 exceptionally 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. LEONI environmental management For us, business success with ecological responsibility is not a contradiction 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 guidelines 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 – the global player The Quality Connection The high quality of LEONI products is one of the most important factors behind the company‘s success. 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) Coding key Type designation 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. 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) A type designation is made up of several groups. The type of wire is specified first and then its construction from inside to outside. 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 specification 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). Examples Type designation 1. Single-core cables FL Y 0.5 0.5 mm2 FL Nominal cross-section R Y 0.75 Nom. cross-section PVC insulation Automotive wire FL 25.0/ 0.1 Max. individual 0.75 mm2 PVC insulation Reduced thickness of insulation✖ YK wire-diameter Nominal cross-section 25 mm2 Insulation (cold-resistant PVC) Automotive wire Automotive wire FL R Y 2x 1.5 sn- A FL Y Y 2x 0.5 FL R Y B D YW 2x 0.5 Nominal cross- Symmetric conductor structure✖ 2. Multi-core cables Tinned individual wire Nominal cross-section 1.5 mm 2 Two cores Nominal cross-section 0.5 mm2 Two cores PVC sheath PVC insulation Automotive wire PVC insulation Reduced thickness of insulation✖ Automotive wire section 0.5 mm2 Two cores Outer sheath (heat-resistant PVC) Copper wire spiral shield Foil shield (static shielding) PVC insulation Reduced thickness of 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 ✖ according to ISO 6722 Marking Marking of automotive wires 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). 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). 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. 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. 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. 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. 10 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 Conductor and Insulation materials 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 temperature in accordance with ISO 6722. The maximum continuous service temperature for materials with impairment of specific material properties is defined by the temperature index according to DIN ISO 2578. Temperature-time curves with a 50 % reduction of the original elongation 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 temperature-time curves specified for the material. The zone in between represents the confidence interval. temperature/time curve measurement curve 11 Conductor and Insulation materials Insulation material properties Symbol Name e.g. DIN ISO 1629 and 7728 Density Ignition residue Extractable constituents DIN 76722 DIN 53479 DIN 53568 T1 DIN 53738 Halogen content Hardness Shore A/D Tensile strength DIN 53505 DIN 53504 g/cm3 % % approx. % Y 1.30–1.45 10–30 20–30 35 85A– 95A >10 MPa PVC-P Polyvinyl chloride (plasticized) PVC-P PVC-P PE PA FEP ETFE PP PP-FR PFA cold-resistant✖ hot-pressure resistant, heat-resistant✖ Polyethylene Polyamide Tetrafluoroethylene hexafluoropropylene Ethylen tetrafluoroethylene Polypropylene Polypropylene, flame-retardant Perfluoroalkoxy copolymer YK YW 2Y 4Y 6Y 7Y 9Y 9Y 51Y 1.24–1.34 1.24–1.34 0.92–0.95 1.01 2.14 1.70 0.91 1.05–1.3 2.15 10–15 8–15 0 0 0 0 0 0–10 0 30– 40 20–30 0 0 0 0 0 0 0 30 35 0 0 75 60 0 10 75 80A– 95A 92A– 97A 50D– 62D –/72D –/55D –/75D –/70D –/70D –/55D >10 >15 >15 > 40 >15 >30 >15 >15 >20 PVDF Polyvinylidenfluorid 10Y 1.8 0 0 35 –/78D >25 g/cm3 % % approx. % MPa TPE-U TPE-E TPE-E TPE-S TPE-A Thermoplastic polyether polyurethane Thermoplastic polyether ester elastomer Thermoplastic polyester elastomer Thermoplastic polystyrene block copolymer Thermoplastic polyamide elastomer 11Y 12Y 13Y 31Y 41Y 1.12 1.16–1.25 1.25–1.28 1.10–1.30 1.01–1.06 0 0 0 0–10 0 0 0 0 0 0 0 0 0 0–10 0 85A–54D 40D–72D –/55D 55D– 65D 75A–70D >30 >25 >30 >15 >25 TPE-O Thermoplastic polyolefin elastomer 91Y 0.95–1.25 0–10 0 0–10 87A/– >10 g/cm3 % % approx. % MPa E/VA Ethylene vinyl acetate 4G 1.30–1.40 40–50 0–10 0 80A– 85A >7 PVC-X PE-X PE-X Polyvinyl chloride, crosslinked Polyethylene, crosslinked (XLPE) Polyethylene, crosslinked, halogen-free (XLPE) X 2X 2X 1.35 1.1 1.4 15 0 20 30 0 0 30 10 0 95A/– 95A/– –/42D >10 >10 >10 All compounds used are lead free 12 ✖ Code e.g. Conductor and Insulation materials Service Temperatures Resistance to Elongation at break Temperature index✖✖ Thermal overload capacity Cold winding test Specific volume resistance Dielectric strength DIN 53504 DIN ISO 2578 ISO 6722 ISO 6722 DIN 53482 DIN 53481 °C/48 hrs °C Abrasion Flame retardation Oil ISO 6722 Fuels Brake fluid Acids/ Alkalines Organic agents ISO 6722 Ω · cm kV/mm >1012 >10 + + + + – + – –50 –25/–40✖ – 40 –50 – 65 – 65 – 40 – 40 – 80 12 >10 >1012 >1016 >1012 >1015 >1015 >1016 >1014 >1015 >10 >10 >30 >10 >30 >30 >30 >20 >30 + + + ++ ++ ++ + + ++ + + –– – ++ ++ –– + ++ + + – ++ ++ ++ + + ++ + + +/– ✖ ++ ++ ++ + + ++ – – –– + ++ ++ – – ++ + + + + ++ ++ + + ++ – – – + ++ ++ + + ++ 160 –30 >1014 >30 ++ ++ ++ ++ ++ + + °C/3000 hrs °C/48 hrs °C Ω · cm kV/mm > 400 > 400 >300 >200 > 400 125 90 150 125 90 150 150 180 150 120 – 40 – 40 – 40 – 40 –50 9 >10 >109 >109 >1010 >1010 >10 >10 >10 >10 >10 ++ ++ ++ – ++ – – +/– ✖ +/– – ++ ++ ++ + ++ ++ ++ ++ + ++ + + + – + + – + + – + + + – + >300 125 150 – 40 >1014 >20 – +/– ✖ – – – + – % °C/3000 hrs °C/48 hrs °C Ω · cm kV/mm >150 140 180 – 40 10 >10 >10 – – – – – – – >150 >200 >200 105 125 125 140 150 150 – 40 – 40 – 40 >10 >1014 >1014 >10 >20 >10 ++ + + + + + + + + + + + – – – + + + + + + % °C/3000 hrs >150 105✖ >150 >150 >300 >300 >200 >200 >200 >200 >200 105 125 90 105 210 180 125 125 260 110 140 100 140 260 230 150 150 290 >100 150 % 110/125✖ –25/–40✖ 12 ++ + – –– Excellent Good Fair Poor ✖ depends on recipe, as required ✖ ✖ criterion: residual elongation at break > 50 % 13 Conductor and Insulation materials Conductor materials 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. Extract from EN 13602 – copper and copper alloys – raw wire made of copper Symbol Material number Oxygenic copper Cu-ETP1 CW 003 A (E-Cu) Composition Density in % by weight g/m3 Cu ≥ 99.90 Oxygen max. 0.040 Oxygen-free copper, non-deoxidized Cu-OF1 CW 007 A Cu 99.95 (OF-Cu) Melting point % IACS min. Notes on properties and use 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. 8.9 1083 °C 101 High-purity copper, largely free of elements that evaporate in vacuum, with an electrical conductivity in the soft state ≥58.58 m/Ωmm2 at 20 °C. Intermediate material meeting high requirements on hydrogen resistance; welding and hard soldering capability. For vacuum systems and electronics. International Annealed Copper Standard = IACS Electrical conductivity of copper = min. 58 m/Ωmm2 = 100 % IACS 14 Conductor and Insulation materials Galvanic coatings: The metal materials used for galvanically refined copper wires are tin, silver or nickel, depending on the requirements. Tin Designation Density Melting point Symbol Silver Tin 99.90 7.29 g/cm3 232 °C Sn Criteria for use Good solderability Effective protection against corrosion Designation Density Melting point Symbol High Nickel Fine silver 99.97 10.5 g/cm3 960 °C Ag temperature resistance surface conductivity (skin effect) Good Designation Density Melting point Symbol Nickel 99.90 8.9 g/cm3 1450 °C Ni 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 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 Temperature range max. 200 °C 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 Bare Temperature range max. 250 °C copper Silver-plated alloys of cadmiumchrome-copper Nickel-plated steel wires Pure nickel wires for flexible applications and nickel alloys Nickel-plated 15 Overview of standards Standards Abbreviations: Global Standards ISO 6722 LV112 + 212 PSA PSA FLRY IR FLRY ID FLRYW IR FLRYW ID Peugeot, Citroën 96 418 794 99 Automotive standard cable with reduced insulation Automotive standard cable with diminished insulation Automotive standard cable heat-resistant with reduced insulation Automotive standard cable heat-resistant with diminished insulation SAE J 1128 TWP GPT HDT TXL GXL SXL TWE GTE HTE Engineering Society for advancing mobility Land, Sea, Air and Space Thin wall, thermoplastic insulated General purpose, thermoplastic insulated Heavy duty, thermoplastic insulated Thin wall, cross (X) linked polyolefin insulated General purpose, cross (X) linked polyolefin insulated Special purpose, cross (X) linked polyolefin insulated Thin wall, thermoplastic elastomer insulated General purpose, thermoplastic elastomer insulated Heavy duty, thermoplastic elastomer insulated JASO D 609-90 AV AVS AVSS AVSSf CAVS Japanese Automobile Standard Vinyl insulated low tension electric cable for automobiles Low tension cable with reduced outside diameter for automobiles, general wall thickness Low tension cable with reduced outside diameter for automobiles, thin wall thickness Low tension cable with reduced outside diameter for automobiles, thin wall thickness, high flexibility Construction of conductors pressed in circular shape, low tension cable with reduced outside diameter for automobiles, general wall thickness Crosslinked vinyl heat-resistant low-tension cable for automobiles Crosslinked polyethylene heat-restistant low-tension cable for automobiles AVX AEX Customer Standards FIAT 91107/17 + 91107/18 VW 60306 16 Automotive cables single-core Product range 17 Single-core cables FLY unshielded 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 Conductor construction Nominal cross-section No. of strands mm2 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25 35 50 70 95 120 18 16 24 32 30 40 50 60 56 84 80 126 196 276 400 560 740 960 Insulation Cable Diameter of single wire Diameter of conductor Electrical resistance at 20 °C Wall thickness Weight min. max. mm mm mΩ/m mm mm mm 0.21 0.21 0.21 0.26 0.26 0.26 0.26 0.31 0.31 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 1.0 1.2 1.35 1.7 2.0 2.2 2.4 2.75 3.3 4.5 6.3 7.8 9.0 10.5 12.5 14.8 16.5 37.1 24.7 18.5 12.7 9.42 7.6 6.15 4.71 3.14 1.82 1.16 0.743 0.527 0.368 0.259 0.196 0.153 0.6 0.6 0.6 0.6 0.6 0.7 0.7 0.8 0.8 1.0 1.0 1.3 1.3 1.5 1.5 1.6 1.6 2.0 2.2 2.4 2.7 2.9 3.3 3.5 4.0 4.6 6.0 7.0 8.7 10.0 11.9 14.0 15.4 18.7 2.3 2.5 2.7 3.0 3.3 3.6 3.9 4.4 5.0 6.5 8.3 10.2 10.7 13.0 15.0 16.2 19.7 ✖ kg/km 9 12 15 20 26 32 38 49 69 113 181 288 361 521 716 918 1220 Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2) FLYW Single-core cables unshielded PVC automotive cable hot-pressure resistant Temperature range: –40 °C to +125 °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 Hot-pressure resistant test at 120 °C. Suitable for applications inside the engine compartment. Standards and specifications Bosch 5 998 341… Conductor construction Nominal cross-section No. of strands Diameter of single wire Diameter of conductor max. mm 16 24 32 30 40 50 60 56 84 80 126 196 mm2 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25 ✖ Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. nom. min. max. approx. mm mΩ/m mm mm mm kg/km 0.21 0.21 0.21 1.0 1.2 1.35 37.1 24.7 18.5 0.6 0.6 0.6 2.0 2.2 2.4 2.3 2.5 2.7 8 11 14 0.26 0.26 0.26 0.26 0.31 0.31 0.41 0.41 0.41 1.7 2.0 2.2 2.5 2.75 3.3 4.5 6.3 7.8 12.7 9.42 7.6 6.0 4.71 3.14 1.82 1.16 0.743 0.6 0.6 0.7 0.7 0.8 0.8 1.0 1.0 1.2 2.7 2.9 3.3 3.5 4.0 4.6 6.0 7.5 9.5 3.0 3.2 3.7 3.9 4.4 5.0 6.5 8.1 10.2 19 25 31 37 47 68 111 179 278 Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2) O.D. Weight 19 Single-core cables FLYK unshielded PVC automotive cable cold-resistant with increased flexibility Temperature range: –50 °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 Cold bending test according to ISO 6722 at –50 °C. Short-term and long-term ageing according to ISO 6722, Class B. Conductor construction Nominal cross-section No. of strands mm2 0.5 0.75 1 1.5 2.5 4 6 10 16 25 20 28 42 57 84 140 1015 1543 2510 4033 3169 Diameter of single wire Diameter of conductor max. mm 0.16 0.16 0.16 0.16 0.16 0.08 0.08 0.08 0.08 0.11 Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. O.D. Weight nom. min. max. approx. mm mΩ/m mm mm mm kg/km 1.1 1.3 1.5 1.8 2.3 3.3 4.2 5.2 6.7 8.0 37.7 25.1 18.8 12.7 7.54 4.71 3.14 1.85 1.16 0.743 0.6 0.6 0.6 0.6 0.7 0.8 0.8 1.0 1.0 1.2 2.0 2.2 2.4 2.7 3.5 4.5 5.3 6.7 8.2 9.9 2.3 2.5 2.7 3.0 3.9 4.9 6.0 7.3 8.8 10.5 9 12 15 20 32 53 76 124 198 298 FLYWK / FLRYWK Single-core cables unshielded PVC automotive cable heat- and cold-resistant Temperature range: –50 °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 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. Standards and specifications Bosch 5 998 342… Insulation Conductor construction✖ Nominal cross-section No. of strands mm2 0.5 0.75 1 1.5 2.5 ✖ 16 24 32 30 50 Diameter of single wire Diameter of conductor max. mm 0.21 0.21 0.21 0.26 0.26 More cross-sections and strand constructions on request. Cable Wall thickness max. Electrical resistance at 20 °C max. O.D. Weight nom. min. max. approx. mm mΩ/m mm mm mm kg/km 1.0 1.2 1.4 1.7 2.1 37.1 24.7 18.5 12.7 7.6 0.28 0.6 0.3 0.3 0.7 1.4 2.2 1.8 2.2 3.3 1.6 2.5 2.1 2.4 3.7 6 9 12 16 30 21 Single-core cables FLRY-A unshielded PVC automotive cable with concentric conductor (Type A) and thin wall insulation Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor construction according to ISO 6722 (concentric construction). Insulation Plasticized PVC with properties according to ISO 6722, Class B. Standards and specifications 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 Conductor construction Nominal crosssection No. of strands Diameter of conductor max. max. bare/tinned min. bare/tinned max. min. mm mm mΩ/m mΩ/m mm 7 7 0.21 0.26 0.7 0.8 77.9 / – 47.8 / – 84.8 / 86.5 52.0 / 54.5 19 19 19 19 19 19 0.19 0.23 0.26 0.32 0.37 0.41 1.0 1.2 1.35 1.7 2.0 2.2 34.1 / – 22.7 / – 17.0 / – 11.7 / – 8.66 / – 7.0 / – 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 9.42 / 9.69 7.6 / 7.8 mm2 0.22 0.35✖ 0.5 0.75 1 1.5 2 2.5 22 Insulation Diameter of single wire Electrical resistance at 20 °C Cable Wall thickness O.D. Weight Limit tolerance approx. mm mm kg/km 0.20 0.20 1.2 1.3 –0.1 –0.1 3.1 4.5 0.22 0.24 0.24 0.24 0.28 0.28 1.6 1.9 2.1 2.4 2.8 3.0 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 6.6 9 11 16 22 26 ✖ This cross-section with tinned stranded conductor is suitable for use with insulation displacement connectors. FLRY-B Single-core cables unshielded PVC automotive cable with conductor (Type B) and thin wall insulation Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor construction according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B, lead free. Standards and specifications 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 Conductor construction Nominal crosssection No. of strands✖ mm2 0.35 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25 ✖ 12 16 24 32 30 30 50 45 56 84 80 126 196 Insulation Diameter of single wire Diameter of conductor max. max. bare/tinned min. bare/tinned max. min. mm mm mΩ/m mΩ/m mm 0.21 0.21 0.21 0.21 0.26 0.31 0.26 0.31 0.31 0.31 0.41 0.41 0.41 0.9 1.0 1.2 1.35 1.7 2.0 2.2 2.4 2.75 3.3 4.5 6.3 7.8 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 8.6 / – 7.0 / – 5.8 / – 4.32 / – 2.85 / – –/– –/– –/– 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 9.42 / 9.69 7.6 / 7.8 6.15 / 6.36 4.7 / 4.8 3.1 / 3.2 1.82 / 1.85 1.16 / 1.18 0.743 / 0.757 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.28 0.32 0.32 0.48 0.52 0.52 Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2). Electrical resistance at 20 °C Cable Wall thickness O.D. Weight Limit tolerance approx. mm mm kg/km 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.2 3.7 4.3 6.0 7.9 9.4 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 –0.3 –0.3 –0.3 –0.6 –0.6 –0.8 4.5 6.6 9 11 16 22.5 26 33.5 42 61 108 170 265 23 Single-core cables FLRYW unshielded PVC automotive cable hot-pressure resistant with thin wall insulation Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor construction according to ISO 6722. 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 Conductor construction Nominal crosssection mm 24 strands✖ Diameter of single wire Diameter of conductor max. max. Insulation Electrical resistance at 20 °C bare/tinned min. Cable Wall thickness bare/tinned max. O.D. min. Weight Limit tolerance approx. mm mm mΩ/m mΩ/m mm mm mm kg/km 7 12 16 24 32 0.26 0.21 0.21 0.21 0.21 0.8 0.9 1.0 1.2 1.35 47.8 / – 47.8 / – 34.1 / – 22.7 / – 17.0 / – 52.0 / 54.5 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 0.20 0.20 0.22 0.24 0.24 1.4 1.4 1.6 1.9 2.1 –0.1 –0.2 –0.2 –0.2 –0.2 4.5 4.5 6.6 9 11 30 30 50 45 56 84 80 126 196 0.26 0.31 0.26 0.31 0.31 0.31 0.41 0.41 0.41 1.7 1.9 2.2 2.4 2.75 3.3 4.5 6.3 7.8 11.7 / – –/– 7.0 / – –/– 4.32 / – 2.85 / – –/– –/– –/– 12.7 / 13.0 9.42 / 9.69 7.6 / 7.8 6.15 / 6.36 4.7 / 4.8 3.1 / 3.2 1.82 / 1.85 1.16 / 1.18 0.743 / 0.757 0.24 0.28 0.28 0.28 0.32 0.32 0.48 0.52 0.52 2.4 2.8 3.0 3.2 3.7 4.3 6.0 7.9 9.4 –0.2 –0.3 –0.3 –0.3 –0.3 –0.3 –0.6 –0.6 –0.8 16 22 26 32.5 42 61 108 170 265 2 0.35 0.35 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25 No. of ✖ Nominal value, tolerance of number of strands: ± 5 % (≥ 6.0 mm2). FLRY T2 IR Single-core cables unshielded 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. Conductor construction according to ISO 6722 and PSA Standard. Insulation Plasticized PVC with properties according to ISO 6722, Class B, lead free. Conductor construction Nominal cross-section No. of strands mm2 0.35 0.5 0.75 1 1.5 2 2.5 3 4 5 6 7 7 16 24 32 30 37 50 45 56 70 84 105 Standards and specifications PSA STE 96 418 794 99 IR Insulation Cable Diameter of single wire Electrical resistance at 20 °C max. Wall thickness O.D. Weight nom. min. max. approx. mm mΩ/m mm mm mm kg/km 0.26 0.21 0.21 0.21 0.26 0.26 0.26 0.31 0.31 0.31 0.31 0.31 55.9 37.1 24.7 19.5 12.7 10.0 7.6 6.06 4.95 3.94 3.14 2.72 0.22 0.28 0.3 0.3 0.3 0.35 0.35 0.4 0.4 0.4 0.4 0.48 1.25 1.40 1.70 1.99 2.10 2.50 2.65 3.25 3.70 3.80 4.20 4.76 1.40 1.70 1.90 2.15 2.40 2.80 3.00 3.45 3.90 4.00 4.50 5.00 4.7 6.7 9.1 11.7 16.2 22.4 27.4 36.4 47.2 52.8 62.6 82 25 Single-core cables FLRY T2 ID unshielded 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. Conductor construction according to ISO 6722 and PSA Standard. Insulation Plasticized PVC with properties according to ISO 6722, Class B, lead free. Conductor construction Nominal cross-section No. of strands mm2 0.35 0.5 0.75 1 1.5 2 2.5 3 4 5 6 7 26 7 16 24 32 30 37 50 45 56 70 84 105 Diameter of single wire Standards and specifications PSA STE 96 418 794 99 ID Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. O.D. Weight nom. min. max. approx. mm mΩ/m mm mm mm kg/km 0.26 0.21 0.21 0.21 0.26 0.26 0.26 0.31 0.31 0.31 0.31 0.31 55.9 37.1 24.7 19.5 12.7 10.0 7.6 6.06 4.95 3.94 3.14 2.72 0.20 0.20 0.20 0.25 0.25 0.25 0.30 0.30 0.30 0.30 0.35 0.35 1.25 1.40 1.60 1.75 2.10 2.30 2.70 3.00 3.40 3.70 4.10 4.30 1.35 1.50 1.80 1.90 2.25 2.50 2.90 3.20 3.60 3.90 4.30 4.60 4.5 6.2 8.3 10.2 14.8 20 26.7 33.5 45.2 51.4 61 78 FLRY T3 IR Single-core cables unshielded PVC automotive cable hot-pressure resistant Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602. Conductor construction according to ISO 6722. Insulation Plasticized PVC, hot-pressure resistant, lead free. Conductor construction Nominal cross-section No. of strands mm2 0.35 0.5 0.75 1 1.5 2 2.5 3 4 5 6 7 7 16 24 32 30 37 50 45 56 70 84 105 Diameter of single wire Standards and specifications PSA STE 96 418 794 99 IR Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. O.D. Weight min. max. approx. mm mΩ/m mm mm mm kg/km 0.26 0.21 0.21 0.21 0.26 0.26 0.26 0.31 0.31 0.31 0.31 0.31 55.9 37.1 24.7 19.5 12.7 10.0 7.6 6.06 4.95 3.94 3.14 2.72 0.22 0.28 0.30 0.30 0.30 0.35 0.35 0.40 0.40 0.40 0.40 0.48 1.25 1.40 1.70 1.99 2.10 2.50 2.65 3.25 3.70 3.80 4.20 4.76 1.40 1.70 1.90 2.15 2.40 2.80 3.00 3.45 3.90 4.00 4.50 5.00 4.7 6.7 9.1 11.6 16.1 22.3 27.3 36.2 47 52.5 62.3 81.6 27 Single-core cables FLRY T3 ID unshielded PVC automotive cable hot-pressure resistant Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602. Conductor construction according to ISO 6722. Insulation Plasticized PVC, hot-pressure resistant, lead free. Conductor construction Nominal cross-section No. of strands mm2 0.35 0.5 0.75 1 1.5 2 2.5 3 4 5 6 7 28 7 16 24 32 30 37 50 45 56 70 84 105 Diameter of single wire Standards and specifications PSA STE 96 418 794 99 ID Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. O.D. Weight min. max. approx. mm mΩ/m mm mm mm kg/km 0.26 0.21 0.21 0.21 0.26 0.26 0.26 0.31 0.31 0.31 0.31 0.31 55.9 37.1 24.7 19.5 12.7 10.0 7.6 6.06 4.95 3.94 3.14 2.72 0.20 0.20 0.20 0.25 0.25 0.25 0.30 0.30 0.30 0.30 0.35 0.35 1.25 1.40 1.60 1.75 2.10 2.30 2.70 3.00 3.40 3.70 4.10 4.30 1.35 1.50 1.80 1.90 2.25 2.50 2.90 3.20 3.60 3.90 4.30 4.60 4.5 6.2 8.3 10.1 14.7 19.9 26.6 33.3 45 51.1 60.7 77.6 FLR4Y Single-core cables unshielded PA automotive cable Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed elctrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor construction according to ISO 6722. Insulation PA (Polyamide). Special properties Outstanding fuel resistance. Especially suitable as fuel gauge wire. Conductor construction Nominal crosssection No. of strands Diameter of conductor max. max. bare min. tinned max. min. mm mm mΩ/m mΩ/m mm 7 19 19 19 19 19 0.26 0.19 0.23 0.26 0.32 0.41 0.8 1.0 1.2 1.35 1.7 2.2 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 12 16 24 32 30 50 56 0.21 0.21 0.21 0.21 0.26 0.26 0.31 0.9 1.0 1.2 1.35 1.7 2.2 2.75 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 4.32 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 4.7 / 4.8 mm2 FLR4Y-A 0.35 0.5 0.75 1 1.5 2.5 FLR4Y-B 0.35 0.5 0.75 1 1.5 2.5 4 Insulation Diameter of single wire Electrical resistance at 20 °C Cable Wall thickness O.D. Weight Limit tolerance approx. mm mm kg/km 0.20 0.22 0.24 0.24 0.24 0.28 1.3 1.6 1.9 2.1 2.4 3.0 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 4.2 5.8 8 11 15 24 0.20 0.22 0.24 0.24 0.24 0.28 0.32 1.4 1.6 1.9 2.1 2.4 3.0 3.7 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 4.2 5.8 8 11 15 24 40 29 125 P Single-core cables unshielded PP automotive cable heat-resistant with thin wall insulation Temperature range: –40 °C to +125 °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 PP-FR (Polypropylene flame-retardant), low halogen. Special properties Marking according to customer requirement. Standards and specifications Renault 36-05-009/--L FIAT 91107/17 VW 60306 Conductor construction Nominal cross-section No. of strands mm2 0.22 0.35 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 30 7 7 19 24 32 30 40 50 45 56 84 80 126 Insulation Wall thickness max. Electrical resistance at 20 °C max. mm mm mΩ/m mm 0.21 0.26 0.19 0.21 0.21 0.26 0.26 0.26 0.31 0.31 0.31 0.41 0.41 0.7 0.8 1.0 1.2 1.35 1.7 1.9 2.2 2.4 2.75 3.3 4.5 6.3 84.8 52.0 37.1 24.7 18.5 12.7 9.42 7.6 6.06 4.7 3.1 1.82 1.16 0.20 0.20 0.22 0.24 0.24 0.24 0.24 0.28 0.28 0.32 0.32 0.48 0.52 Diameter of single wire Diameter of conductor max. Cable O.D. Weight Limit tolerance approx. mm mm kg/km 1.2 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.3 3.7 4.3 6.0 7.0 –0.1 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 –0.3 –0.3 –0.3 –0.6 –0.6 3.1 4.5 6.6 9 11 16 22 26 32.5 42 61 104 158 125 X Single-core cables unshielded PE-X automotive cable heat-resistant with thin wall insulation Temperature range: –40 °C to +125 °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 PE-X (Polyethylene crosslinked) with properties according to ISO 6722, Class C. Conductor construction Nominal cross-section No. of strands mm2 LEONI Mocar 125 X Type A 0.22 7 0.35 7 0.5 19 0.75 19 1 19 1.5 19 2 19 2.5 19 LEONI Mocar ® 125 X Type B 0.35 12 0.5 16 0.75 24 1 32 1.5 30 2 30 2.5 50 3 45 4 56 6 84 Insulation Diameter of single wire Diameter of conductor Electrical resistance at 20 °C Wall thickness max. max. max. nom. mm mm mΩ/m mm 0.21 0.26 0.19 0.23 0.26 0.32 0.37 0.41 0.7 0.8 1.0 1.2 1.35 1.7 2.0 2.2 84.8 52.0 37.1 24.7 18.5 12.7 9.42 7.6 0.21 0.21 0.21 0.21 0.26 0.31 0.26 0.31 0.31 0.31 0.9 1.0 1.2 1.35 1.7 2.0 2.2 2.4 2.75 3.3 52.0 37.1 24.7 18.5 12.7 9.42 7.6 6.15 4.7 3.1 Cable O.D. Weight Limit tolerance approx. mm mm kg/km 0.20 0.20 0.22 0.24 0.24 0.24 0.28 0.28 1.2 1.3 1.6 1.9 2.1 2.4 2.8 3.0 –0.1 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 3.1 4.5 6.6 9 11 16 22 26 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.28 0.32 0.32 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.2 3.7 4.3 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 –0.3 –0.3 –0.3 4.5 6.6 9 11 16 22 26 32.5 42 61 ® 31 150 A Single-core cables unshielded Automotive cable heat-resistant with TPE-E insulation Temperature range: –40 °C to +150 °C (3000 hrs) +180 °C (48 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Concentric resp. fine-wire stranded conductor according to ISO 6722. Insulation TPE-E (Thermoplastic polyester elastomer). Special properties Suitable for headlight applications. Limited resistance to hydrolysis. Conductor construction Nominal cross-section mm No. of strands 2 LEONI Mocar ® 150 A Type A 0.35 7 0.5 19 0.75 19 1 19 1.5 19 2 19 2.5 19 LEONI Mocar ® 150 A Type B 0.35 12 0.5 16 0.75 24 1 32 1.5 30 2 30 2.5 50 4 56 6 84 32 Insulation Diameter of single wire Diameter of conductor Electrical resistance at 20 °C Wall thickness max. max. max. nom. mm mm mΩ/m mm 0.26 0.19 0.23 0.26 0.32 0.37 0.41 0.8 1.0 1.2 1.35 1.7 2.0 2.2 52.0 37.1 24.7 18.5 12.7 9.42 7.6 0.21 0.21 0.21 0.21 0.26 0.31 0.26 0.31 0.31 0.9 1.0 1.2 1.35 1.7 2.0 2.2 2.75 3.3 52.0 37.1 24.7 18.5 12.7 9.42 7.6 4.7 3.1 Cable O.D. Weight Limit tolerance approx. mm mm kg/km 0.20 0.22 0.24 0.24 0.24 0.28 0.28 1.3 1.6 1.9 2.1 2.4 2.8 3.0 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 4.5 6 9 11 16 22 26 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.32 0.32 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.7 4.3 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 –0.3 –0.3 4.5 6 9 11 16 22 26 42 61 180 E 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) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, 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 compartment. Conductor construction Nominal crosssection No. of strands Insulation Diameter of single wire Diameter of conductor max. max. bare min. tinned max. min. mm mm mΩ/m mΩ/m mm 0.8 1.0 1.2 1.35 1.7 2.2 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 0.9 1.0 1.2 1.35 1.7 2.2 2.75 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 4.32 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 4.7 / 4.8 mm2 LEONI Mocar 180 E Type A 0.35 7 0.26 0.5 19 0.19 0.75 19 0.23 1 19 0.26 1.5 19 0.32 2.5 19 0.41 LEONI Mocar ® 180 E Type B 0.35 12 0.21 0.5 16 0.21 0.75 24 0.21 1 32 0.21 1.5 30 0.26 2.5 50 0.26 4 56 0.31 Electrical resistance at 20 °C Cable Wall 6 thickness O.D. Weight Limit tolerance approx. mm mm kg/km 0.20 0.22 0.24 0.24 0.24 0.28 1.3 1.6 1.9 2.1 2.4 3.0 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 4.7 6.3 9 11.5 16.5 27.5 0.20 0.22 0.24 0.24 0.24 0.28 0.32 1.4 1.6 1.9 2.1 2.4 3.0 3.7 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 4.7 6.3 9 11.5 16.5 27.5 42 ® ✖ Ultra-thin wall thickness on request. 33 210 F Single-core cables unshielded Automotive cable high temperature resistant with FEP insulation Temperature range: –65 °C to +210 °C (3000 hrs) +260 °C (48 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare, tinned, silver-plated or nickel-plated. Fine-wire stranded conductor according to ISO 6722. Insulation FEP (Tetrafluoroethylene hexafluoropropylene) with properties according to ISO 6722, Class F. Special properties Good mechanical and thermal properties with excellent resistance to aggressive media. Suitable ���������������������������������������������������� for applications inside the engine compartment. Conductor construction Nominal crosssection mm 2 No. of strands Diameter of conductor max. max. bare min. tinned max. min. mm mm mΩ/m mΩ/m mm 0.8 1.0 1.2 1.35 1.7 2.2 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 0.9 1.0 1.2 1.35 1.7 2.2 2.75 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 4.32 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 4.7 / 4.8 LEONI Mocar ® 210 F Type A 0.35 7 0.26 0.5 19 0.19 0.75 19 0.23 1 19 0.26 1.5 19 0.32 2.5 19 0.41 LEONI Mocar ® 210 F Type B 0.35 12 0.21 0.5 16 0.21 0.75 24 0.21 1 32 0.21 1.5 30 0.26 2.5 50 0.26 4 56 0.31 34 Insulation Diameter of single wire Electrical resistance at 20 °C Cable Wall thickness O.D. Weight 6 Limit tolerance approx. mm mm kg/km 0.20 0.22 0.24 0.24 0.24 0.28 1.3 1.6 1.9 2.1 2.4 3.0 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 5 7 10 13 18 29 0.20 0.22 0.24 0.24 0.24 0.28 0.32 1.4 1.6 1.9 2.1 2.4 3.0 3.7 –0.2 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 5 7 10 13 18 29 44 ✖ Ultra-thin wall thickness on request. 260 T 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) Construction / Materials Conductor ✖✖ Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, 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. Conductor can also be supplied nickel-plated according to ASTM B355 on request (nickel layer: ≥1.0 µm). Conductor construction Nominal crosssection mm Insulation Diameter of single wire Diameter of conductor max. max. mm mm mΩ/m mΩ/m mm 0.26 0.19 0.23 0.26 0.32 0.41 0.31 0.8 1.0 1.2 1.35 1.7 2.2 2.75 47.8 / – 34.1 / – 22.7 / – 17.0 / – 11.7 / – 7.0 / – 4.32 / – 52.0 / 54.5 37.1 / 38.2 24.7 / 25.4 18.5 / 19.1 12.7 / 13.0 7.6 / 7.8 4.7 / 4.8 0.20 0.22 0.24 0.24 0.24 0.28 0.32 2 0.35 0.5 0.75 1 1.5 2.5 4 ✖ No. of strands 7 19 19 19 19 19 56 Ultra-thin wall thickness on request. Electrical resistance at 20 °C bare min. tinned max. Cable Wall thickness O.D. Weight 6 Limit tolerance approx. mm mm kg/km 1.3 1.6 1.9 2.1 2.4 3.0 3.7 –0.1 –0.2 –0.2 –0.2 –0.2 –0.3 –0.3 min. 5 7 10 13 18 29 44 35 Single-core cables TXL unshielded XLPE automotive cable thin wall with crosslinked insulation Temperature range: –40 °C to +125 °C Construction / Materials 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. Standards and specifications SAE J 1128 Conductor construction 36 Size Nominal cross-section AWG mm 22 20 18 18 16 14 12 10 0.35 0.5 0.8 0.8 1 2 3 5 No. of strands 2 7 7 16 19 19 19 19 19 Insulation Diameter of single wire nom. Diameter of conductor nom. nom. mm mm 0.25 0.32 0.25 0.23 0.28 0.36 0.45 0.57 0.76 0.97 1.17 1.17 1.45 1.8 2.29 2.87 Cable Wall thickness O.D. Weight min. max. approx. mm mm mm kg/km 0.40 0.40 0.40 0.40 0.40 0.40 0.46 0.50 0.28 0.28 0.28 0.28 0.28 0.28 0.32 0.35 1.7 1.9 2.2 2.2 2.4 2.7 3.3 4.0 5.4 7.7 10.7 10.7 14.6 22 34 53 TWP Single-core cables unshielded PVC automotive cable with thin wall Temperature range: –40 °C to+85 °C (3000 hrs) +105 °C (48 hrs) Construction / Materials 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. Standards and specifications SAE J 1128 Conductor construction Size Nominal cross-section AWG mm2 22 20 18 18 16 14 12 0.35 0.5 0.8 0.8 1 2 3 10 5 No. of strands Insulation Diameter of single wire Diameter of conductor nom. nom. nom. mm mm mm 7 7 16 19 19 19 19 0.25 0.32 0.25 0.23 0.28 0.36 0.45 0.76 0.97 1.17 1.17 1.45 1.8 2.29 19 0.57 2.87 Cable Wall thickness O.D. Weight min. max. approx. mm mm kg/km 0.40 0.40 0.40 0.40 0.40 0.40 0.46 0.28 0.28 0.28 0.28 0.28 0.28 0.32 1.7 1.9 2.2 2.2 2.4 2.7 3.3 5.4 7.7 10.7 10.7 14.6 22 34 0.50 0.35 4.0 53 37 Single-core cables AV unshielded PVC automotive cable Temperature range: –40 °C to +85 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to D 609-90, bare. Conductor construction according to JIS C 3102/JIS C3406. Insulation PVC (Polyvinyl chloride), lead free. Insulation material according to JIS C3406. Conductor construction Nominal cross-section No. of strands mm2 0.5 0.85 1.25 2 3 5 8 10 15 0.5 f 0.75 f 1.25 f 2f 3f 38 7 11 16 26 41 65 50 63 84 20 30 50 37 61 Diameter of single wire Diameter of conductor nom. mm 0.32 0.32 0.32 0.32 0.32 0.32 0.45 0.45 0.45 0.18 0.18 0.18 0.26 0.26 Insulation Cable Electrical resistance at 20 °C Wall thickness nom. max. nom. min. max. approx. mm mΩ/m mm mm mm kg/km 1.0 1.2 1.5 1.9 2.4 3.0 3.7 4.5 4.8 1.0 1.2 1.5 1.8 2.4 32.7 20.8 14.3 8.81 5.59 3.52 2.32 1.84 1.38 36.7 24.4 14.7 9.5 5.76 0.6 0.6 0.6 0.6 0.7 0.8 0.9 1.0 1.1 0.6 0.6 0.6 0.6 0.7 2.2 2.4 2.7 3.1 3.8 4.6 5.5 6.5 7.0 2.2 2.4 2.7 3.0 3.8 2.4 2.6 2.9 3.4 4.1 4.9 5.8 6.9 7.4 2.4 2.6 2.9 3.4 4.1 10 13 17 26 40 62 92 120 160 9 12 18 25 40 ✖ O.D. Weight The “f” in the nominal cross-section column indicates a flexible conductor with a finer wire diameter. AVS Single-core cables unshielded PVC automotive cable Temperature range: –40 °C to +85 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to D 609-90, bare. Conductor construction according to JASO D 611-94. Insulation PVC (Polyvinyl chloride), lead free. Insulation material according to JASO D 611-94. Conductor construction Nominal cross-section No. of strands mm2 0.3 0.5 0.85 1.25 2 3 5 0.3 f 0.5 f 0.75 f 1.25 f 2f ✖ 7 7 11 16 26 41 65 15 20 30 50 37 Diameter of single wire Diameter of conductor nom. mm 0.26 0.32 0.32 0.32 0.32 0.32 0.32 0.18 0.18 0.18 0.18 0.26 Insulation Cable Wall thickness nom. Electrical resistance at 20 °C max. nom. min. max. approx. mm mΩ/m mm mm mm kg/km 0.8 1.0 1.2 1.5 1.9 2.4 3.0 0.8 1.0 1.2 1.5 1.8 50.2 32.7 20.8 14.3 8.81 5.59 3.52 48.9 36.7 24.4 14.7 9.5 0.5 0.5 0.5 0.5 0.5 0.6 0.7 0.5 0.5 0.5 0.5 0.5 1.8 2.0 2.2 2.5 2.9 3.6 4.4 1.8 2.0 2.2 2.5 2.9 1.9 2.1 2.3 2.6 3.1 3.8 4.6 1.9 2.1 2.3 2.6 3.1 6 8 12 16 25 39 60 6 8 11 17 24 The “f” in the nominal cross-section column indicates a flexible conductor with a finer wire diameter. O.D. Weight 39 Single-core cables AVSS unshielded PVC automotive cable with thin wall insulation Temperature range: –40 °C to +85 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to JIS C 3102, bare. Conductor construction according to JASO D 611-94. Insulation PVC (Polyvinyl chloride), lead free. Insulation material according to JASO D 611-94. Conductor construction Nominal cross-section mm 2 0.3 0.5 0.85 1.25 2 (f) 0.3 f 0.5 f 0.75 f 1.25 f 40 No. of strands 7 7 19 19 37 19 19 19 37 Diameter of single wire Diameter of conductor nom. nom. Insulation Electrical resistance at 20 °C max. Cable Wall thickness nom. O.D. min. Weight max. approx. mm mm mΩ/m mm mm mm kg/km 0.26 0.32 0.24 0.29 0.26 0.16 0.19 0.23 0.21 0.8 1.0 1.2 1.5 1.8 0.8 1.0 1.2 1.5 50.2 32.7 21.7 14.9 9.5 48.8 34.6 23.6 14.6 0.3 0.3 0.3 0.3 0.4 0.3 0.3 0.3 0.3 1.4 1.6 1.8 2.1 2.6 1.4 1.6 1.8 2.1 1.5 1.7 1.9 2.2 2.7 1.5 1.7 1.9 2.2 5 7 10 14 22 5 7 10 14 ✖ The “f” in the nominal cross-section column indicates a flexible conductor with a finer wire diameter. FL91Y / FL11Y Single-core cables unshielded Battery cable Temperature range: –40 °C to +110 °C (3000 hrs) FL11Y +125 °C (3000 hrs) FL91Y Construction / Materials 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. Conductor construction Nominal cross-section mm 6 10 16 25 35 50 70 95 120 ✖ No. of strands 2 84 80 126 196 276 400 560 740 960 Diameter of single wire Diameter of conductor max. Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. nom. min. max. mm mm mΩ/m mm mm mm 0.31 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 3.3 4.5 6.3 7.8 9.0 10.5 12.5 14.8 16.5 3.14 1.82 1.16 0.743 0.527 0.368 0.259 0.196 0.153 0.8 1.0 1.0 1.3 1.3 1.5 1.5 1.6 1.6 4.6 6.0 7.0 8.7 10.0 11.9 14.0 15.4 18.7 5.0 6.5 8.1 10.2 10.7 13.0 15.0 16.2 19.7 Nominal value, tolerance of number of strands: ±5 %. O.D. Weight approx. kg/km 66 109 176 273 355 511 705 905 1170 41 Single-core cables FLYY unshielded Automotive cable with core insulation and PVC sheath 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 / sheath Plasticized PVC with properties according to ISO 6722, Class B, lead free. Insulation Conductor construction Nominal crosssection No. of strands mm2 0.5 0.75 1 1.5 2 2.5 42 16 24 32 30 40 50 Diameter of single wire Diameter of conductor max. mm 0.21 0.21 0.21 0.26 0.26 0.26 Special properties Sheath options: firmly bonded or separable. Wall thickness max. Electrical resistance at 20 °C max. mm mΩ/m 1.0 1.2 1.35 1.7 2.0 2.2 37.1 24.7 18.5 12.7 9.42 7.6 Cable Diameter of Core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 0.6 0.6 0.6 0.6 0.6 0.7 2.1 2.3 2.5 2.8 3.0 3.5 0.4 0.4 0.4 0.5 0.5 0.5 2.7 3.0 3.2 3.7 3.9 4.3 3.1 3.3 3.6 4.1 4.3 4.8 14 17 20 28 33 41 nom. O.D. Weight ✖ All cross-sections can also be supplied with reduced insulation thickness (FLRYY). FLY0Y / FLYK0Y Single-core cables unshielded Special battery cable sheathed Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials 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. Conductor construction Nominal cross✖ section mm No. of strands FLY0Y 4 6 10 16 FLYK0Y 50 50 / 0.2 70 / 0.2 Diameter of conductor max. Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. mm mm mΩ/m mm mm 56 84 80 126 0.31 0.31 0.41 0.41 2.75 3.3 4.5 6.3 4.7 3.1 1.82 1.16 0.8 0.8 1.0 1.0 396 1600 2200 0.41 0.21 0.21 0.368 0.386 0.272 0.8 0.8 1.0 2 Diameter of single wire ✖ Other cross-sections and dimensions on request. 10.5 10.9 13.3 Diameter of Core Sheath wall thickness nom. O.D. Weight min. max. approx. mm mm mm kg/km 4.2 4.8 6.2 7.7 2.0 2.0 3.0 2.0 8.0 8.6 12.2 11.5 8.4 9.0 12.8 12.1 106 125 208 245 12.0 12.0 14.7 1.4 1.4 1.6 14.5 14.5 17.5 15.1 15.1 18.3 540 550 79 43 Single-core cables FLRYDY shielded PVC automotive cable shielded with reduced insulation and sheath wall thickness Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Fine-wire stranded conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B, lead free. Shielding Soft-annealed electrolytic copper E-Cu 58 F21, bare. Wire spun cover with high surface covering ratio (≥ 90 %). Sheath Plasticized PVC with properties according to ISO 6722, Class B, lead free. Conductor construction Nominal crosssection mm 2 0.75 1 1.5 44 No. of strands 24 32 30 Diameter of single wire max. Diameter of conductor Insulation Cable Wall thick✖ ness max. Electrical resistance at 20 °C max. Diameter of core mm mm mΩ/m mm mm 0.21 0.21 0.26 1.2 1.35 1.7 24.7 18.5 12.7 0.3 0.3 0.3 1.75 1.95 2.25 Sheath wall ✖ thickness nom. O.D. Weight min. max. approx. mm mm mm kg/km 0.3 0.3 0.3 2.5 2.7 3.0 2.7 2.9 3.2 18 21 27 ✖ Also available with increased insulation and/or sheath wall thickness. Automotive cables multi-core Product range 45 Multi-core cables FLR4G11Y / FL4G11Y ABS/ESP sensor cables ABS/ESP cable with EVA insulation Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, 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 longitudinally under the insulation. Sheath TPE-U (Polyether polyurethane with especially high resistance to hydrolysis). Structure No. of cores x nominal cross-section 46 FLR4G11Y Reduced wall thickness. Conductor construction No. of strands Diameter of single wire max. Diameter of conductor mm 19 28 28 28 28 16 42 30 16 30 mm2 FLR4G11Y 2 x 0.35 2 x 0.5 2 x 0.5 3 x 0.5 4 x 0.5 FL4G11Y 2 x 0.5 2 x 0.75 2 x 1.5 3 x 0.5 3 x 1.5 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. Insulation Wall thickness max. Electrical resistance at 20 °C max. mm mΩ/m 0.16 0.16 0.16 0.16 0.16 0.8 1.0 1.0 1.0 1.0 0.21 0.16 0.26 0.21 0.26 1.0 1.2 1.7 1.0 1.7 Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 54.5 40.1 40.1 40.1 40.1 0.35 0.35 0.35 0.35 0.35 1.45 1.65 1.65 1.65 1.65 0.5 0.55 0.9 0.8 0.6 3.8 4.1 5.0 5.0 5.0 4.0 4.5 5.3 5.4 5.4 20 27 34 39 42 40.1 27.1 13.7 40.1 13.7 0.6 0.5 0.6 0.6 0.7 2.2 2.2 2.8 2.2 2.9 0.85 0.9 0.65 0.8 1.1 5.9 6.0 6.6 6.0 8.1 6.3 6.4 7.0 6.4 8.7 44 47 66 51 107 nom. O.D. Weight Note: This chart shows an extract of our existent product portfolio. Other versions on request. FLR2X11Y Multi-core cables ABS/ESP sensor cables ABS/ESP cable with PE-X insulation Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Insulation PE-X (Polyethylene crosslinked). Sheath TPE-U (Polyether polyurethane with especially high resistance to hydrolysis). Structure No. of cores x nominal cross-section Conductor construction No. of strands mm2 2 x 0.35 2 x 0.5 2 x 0.5 2 x 0.5 2 x 0.75 12 19 28 64 42 Insulation Diameter of single wire max. Diameter of conductor max. Electrical resistance at 20 °C bare tinned max. max. mm mm mΩ/m mΩ/m 0.21 0.19 0.16 0.10 0.16 0.9 1.0 1.0 1.0 1.2 52.0 37.1 37.1 38.2 24.7 54.5 40.1 40.1 40.1 27.1 Note: This chart shows an extract of our existent product portfolio. Other versions on request. Wall thickness Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 0.25 0.3 0.3 0.35 0.5 1.35 1.5 1.5 1.6 2.2 0.5 0.65 0.65 0.95 0.9 3.5 4.2 4.2 5.0 6.0 3.9 4.6 4.6 5.4 6.4 18 25 25 36 46 nom. O.D. Weight 47 Multi-core cables FLR31Y11Y ABS/ESP sensor cables ABS/ESP cable with TPE-S insulation Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Insulation TPE-S (Thermoplastic polystyrene block copolymer). Sheath TPE-U (Polyether polyurethane with especially high resistance to hydrolysis). Structure No. of cores x nominal crosssection Conductor construction No. of strands mm2 48 Diameter of single wire max. Diameter of conductor mm Insulation Wall thickness max. Electrical resistance at 20 °C max. mm mΩ/m Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km nom. O.D. Weight 2 x 0.5 2 x 0.5 2 x 0.75 2 x 0.75 3 x 0.5 3 x 0.75 28 28 42 96 19 19 0.16 0.16 0.16 0.11 0.19 0.23 1.0 1.0 1.2 1.2 1.0 1.2 37.1 37.1 24.7 24.7 37.1 24.7 0.30 0.30 0.30 0.30 0.30 0.30 1.5 1.5 1.8 1.8 1.6 1.8 0.7 1.0 1.2 1.2 0.8 1.0 4.3 4.8 6.0 6.0 5.0 5.7 4.7 5.2 6.4 6.4 5.2 6.1 27.5 35 47.5 48 37 49 3x1 4 x 0.5 4 x 0.5 5 x 0.5 19 28 64 64 0.26 0.16 0.1 0.1 1.2 1.0 1.0 1.0 18.5 37.1 37.1 37.1 0.35 0.30 0.30 0.30 2.0 1.5 1.6 1.6 0.8 1.2 1.2 1.0 5.7 6.0 6.0 6.0 6.1 6.4 6.4 6.4 56 51 51 54 Note: This chart shows an extract of our existent product portfolio. Other versions on request. FLRY11Y Multi-core cables ABS/ESP sensor cables ABS/ESP cable with PVC insulation reduced wall thickness Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Insulation PVC (Polyvinyl chloride). Sheath TPE-U (Polyether polyurethane with especially high resistance to hydrolysis). Structure No. of cores x nominal crosssection Conductor construction No. of strands mm2 2 x 0.75 3x1 3 x 1.5 42 32 30 Diameter of single wire max. Diameter of conductor mm 0.16 0.21 0.26 Insulation Wall thickness max. Electrical resistance at 20 °C max. mm mΩ/m 1.2 1.5 1.7 24.7 18.5 13.3 Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 0.4 0.35 0.4 1.9 2.0 2.4 0.8 0.7 0.75 5.2 5.6 6.5 5.6 6.0 6.9 39 56 75 nom. Note: This chart shows an extract of our existent product portfolio. Other versions on request. O.D. Weight 49 Multi-core cables FLYY / FLRYY / FLYKYK Cables up to 105 °C PVC automotive cable Temperature range: –40 °C to +105 °C (3000 hrs) –50 °C to +90 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B. Sheath Plasticized PVC with properties according to ISO 6722, Class B. Structure No. of cores x nominal cross-section FLYKYK 2 x 0.5 2x1 3 x 0.5 50 Insulation Diameter of single wire max. Diameter of conductor max. mm mm mΩ/m mΩ/m 16 24 24 32 30 0.21 0.21 0.21 0.21 0.26 1.0 1.2 1.2 1.4 1.7 37.1 24.7 24.7 18.5 12.7 7 19 16 24 32 24 16 24 32 24 32 16 0.26 0.19 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.8 1.0 1.0 1.2 1.4 1.2 1.0 1.2 1.4 1.2 1.4 1.0 16 32 16 0.21 0.21 0.21 1.0 1.4 1.0 mm2 FLYY 2 x 0.5 2 x 0.75 7 x 0.75 7x1 7 x 1.5 FLRYY 2 x 0.35 2 x 0.5 2 x 0.5 2 x 0.75 2x1 5 x 0.75 6 x 0.5 6 x 0.75 6x1 7 x 0.75 7x1 8 x 0.5 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. Conductor construction No. of strands Electrical resistance at 20 °C bare tinned max. max. FLYY / FLRYY FLYKYK Wall thickness Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 38.2 25.4 25.4 19.1 13.0 0.4 0.6 0.5 0.6 0.6 1.75 2.3 2.15 2.5 2.75 0.50 0.50 0.80 1.00 1.10 4.3 5.4 7.8 9.0 10.2 4.7 5.8 9.4 9.6 11.0 31 48 112 148 201 52.0 37.1 37.1 24.7 18.5 24.7 37.1 24.7 18.5 24.7 18.5 37.1 54.5 38.2 38.2 25.4 19.1 25.4 38.2 25.4 19.1 25.4 19.1 38.2 0.25 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 1.3 1.6 1.6 1.75 1.95 1.75 1.6 1.75 1.95 1.75 1.95 1.6 0.50 0.60 0.60 0.60 0.60 0.75 0.85 0.75 1.00 0.75 0.75 0.95 3.3 4.2 4.2 4.5 4.8 6.3 6.2 6.6 7.6 6.6 7.2 6.9 3.7 4.6 4.6 4.9 5.4 6.7 6.8 7.0 8.0 7.0 7.6 7.5 20 29 29 36 45 75 68 82 114 89 113 87 37.1 18.5 37.1 38.2 19.1 38.2 0.5 0.6 0.5 1.95 2.5 1.95 0.70 0.60 0.60 5.0 6.0 5.1 5.6 6.6 5.7 34 50 41 nom. O.D. Weight Other versions are available on request. FLYYF Multi-core cables Cables up to 105 °C Flat PVC 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. Fine-wire stranded conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B. Sheath Plasticized PVC with properties according to ISO 6722, Class B. Structure No. of cores x nominal crosssection Conductor construction No. of strands Diameter of single wire max. Diameter of conductor mm 0.21 0.21 0.26 0.26 0.26 mm2 2 x 0.75 2x1 2 x 1.5 2 x 2.5 3 x 1.5 24 32 30 50 30 Other versions are available on request. Insulation Wall thickness max. Electrical resistance at 20 °C max. mm mΩ/m 1.2 1.4 1.7 2.2 1.7 24.7 18.5 12.7 7.6 12.7 Cable Diameter of core Sheath wall thickness Width Height approx. mm mm mm mm mm kg/km 0.6 0.6 0.6 0.7 0.6 2.3 2.5 2.7 3.4 2.7 0.6 0.6 0.5 0.6 0.5 5.8 ± 0.3 6.2 ± 0.3 6.4 ± 0.3 8.1 ± 0.3 9.2 ± 0.4 3.5 ± 0.2 3.7 ± 0.2 3.8 ± 0.2 4.6 ± 0.2 3.8 ± 0.2 35 42 53 78 79 nom. Dimension Weight 51 Multi-core cables FLYZ Cables up to 105 °C PVC twin 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. Fine-wire stranded conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B. Structure No. of cores x nominal crosssection Conductor construction No. of strands mm2 2 x 0.5 2 x 0.75 2 x 1.5 52 16 24 30 Diameter of single wire max. Diameter of conductor mm 0.21 0.21 0.26 Insulation Cable Wall thickness max. Electrical resistance at 20 °C max. Diameter of core Width Height approx. mm mΩ/m mm mm mm mm kg/km 1.0 1.2 1.7 37.1 24.7 12.7 0.5 0.6 0.6 2.1 2.35 2.8 4.4 ± 0.2 4.7 ± 0.3 5.6 ± 0.3 2.1 ± 0.15 2.35 ± 0.15 2.8 ± 0.15 15 23 39 nom. Dimension Weight Other versions are available on request. FLRYBY / FLRYDY / FLRYBDY / FLRYCY Multi-core cables Cables up to 105 °C PVC cable multi-core with complete shielding Temperature range: –40 °C bis +105 °C (3000 h) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B. 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. Structure No. of cores x nominal crosssection Conductor construction No. of strands FLRYBY 1 x 0.35+(0.35) 4 x 0.35+(0.35) FLRYDY 2 x 0.22 2 x 0.35 2 x 0.5 2 x 0.75 2x1 3 x 0.75 3x1 FLRYBDY 2 x 0.5 FLRYCY 9 x 0.08 10 x 0.25 5 x 0.35 8 x 0.35 10 x 0.35 Insulation Diameter of single wire max. Diameter of conductor max. mm mm mΩ/m mΩ/m 7 7 0.26 0.26 0.8 0.8 52.0 52.0 7 12 19 24 19 24 32 0.21 0.21 0.19 0.21 0.26 0.21 0.21 0.7 0.8 1.0 1.2 1.4 1.2 1.4 19 0.19 10 14 19 19 19 0.11 0.16 0.16 0.16 0.16 mm2 Other versions are available on request. 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 Plasticized PVC with properties according to ISO 6722, Class B. Electrical resistance at 20 °C bare tinned max. max. Wall thickness Cable Diameter of core Sheath wall thickness min. max. approx. mm mm mm mm mm kg/km 54.5 54.5 0.25 0.25 1.25 1.25 0.5 0.5 2.9 4.3 3.3 4.7 14 35 84.8 52.0 37.1 24.7 18.5 24.7 18.5 86.5 54.5 38.2 25.4 19.1 25.4 19.1 0.25 0.25 0.30 0.30 0.30 0.30 0.30 1.15 1.35 1.5 1.75 2.0 1.75 1.95 0.5 0.6 0.8 0.6 0.7 0.6 0.5 3.4 4.2 4.9 4.9 5.5 5.1 5.5 3.8 4.6 5.3 5.2 5.9 5.4 5.8 25 30 38 44 52 55 64 1.0 37.1 38.2 0.30 1.6 0.6 4.7 4.9 36 0.45 0.7 0.8 0.8 0.8 353 84.8 52.0 52.0 52.0 365 86.5 54.5 54.5 54.5 0.20 0.20 0.25 0.25 0.25 0.8 1.1 1.3 1.25 1.25 0.6 0.6 0.5 0.65 0.65 4.6 5.8 4.7 5.9 6.5 4.9 6.2 5.1 6.3 6.9 38 68 47 75 83 nom. O.D. Weight 53 Multi-core cables FLRYY (GGVS) / FLRYY11Y Cables up to 105 °C PVC special cable with thin insulation Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Concentric stranded conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class B. Sheath Plasticized PVC with properties according to ISO 6722, Class B. Structure Core No. of cores x nominal cross-section mm2 FLRYY (GGVS) 2x1 3 x 1.5 + 2 x 6 4 x 1.5 + 3 x 2.5 7 x 1.5 10 x 1.5 + 3 x 2.5 + (2 x 1.5) PP data pair FLRYY11Y 2 x 4 + 3 x 1.5 3 x 2.5 + 4 x 1.5 7 x 1 + 1 x 1.5 9x1+1x4 54 Color code mm2 mm 1 1.5 Ø 2.1 Ø 2.0 ■ 1.5 Ø 2.4 ■■■ 1.5 1.5 Ø 2.4 Ø 2.4 ■■■ 4 2.5 1 1 Ø 3.7 Ø 3.0 Ø 2.1 Ø 2.1 ■■ Diameter of core max. mm2 ■ ■■■■■ ■■ ■■ ■■■■■■■ ■■■■■■■ Cable Color code mm 24 32 30 50 56 84 O.D. Weight max. approx. mm kg/km 5.7 12.3 19.5 150 6 Ø 4.3 2.5 Ø 3.0 ■■ 10.5 130 2.5 1.5 Ø 3.0 Ø 2.4 ■ ■ ■ 10.6 14.7 101 245 1.5 1.5 1.5 4 Ø 2.4 Ø 2.4 Ø 2.4 Ø 3.7 ■■ ■■ Conductor construction No. of strands mm2 0.75 1 1.5 2.5 4 6 Core Diameter of core max. Structure Cross-section Special properties FLRYY11Y – Combined multi-core cable. Outer sheath made of TPE-U (thermoplastic polyurethane elastomer) with especially high resistance to abrasion (11Y). Standards and specifications German approval for transportation of hazardous materials (GGVS). Tested in accordance with GGVS/ADR. ■■■ 11.3 10.5 9.2 12.5 212 130 82 125 Insulation Diameter of single wire max. Diameter of conductor max. Electrical resistance at 20 °C max. Wall thickness nom. mm mm mΩ/m mm 0.21 0.21 0.26 0.26 0.31 0.31 1.2 1.4 1.7 2.2 2.75 3.3 24.7 18.5 12.7 7.6 4.7 3.1 0.3 0.3 0.35 0.35 0.4 0.4 Other versions are available on request. FLY(YDY)(YBY)CY 3x0.35+(1x0.35)+(2x0.35) Multi-core cables Cables up to 105 °C CD player control cable Temperature range: –40 °C to +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602. 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. Structure Conductor construction No. of cores No. of x strands nominal crosssection mm2 3 x 0.35 (1 x 0.35) (2 x 0.35) 12 12 12 Insulation Diameter of single wire Diameter of conductor max. max. max. mm mm 0.21 0.21 0.21 0.9 0.9 0.9 Other versions are available on request. Electrical resistance at 20 °C 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 Plasticized PVC according to ISO 6722, Class B. 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. Inner sheath Wall thickness InnerO.D. Complete cable Wall thickness Diameter of core min. max. approx. mΩ/m mm mm mm mm mm mm mm mm kg/km 52.0 52.0 52.0 0.40 0.25 0.22 1.6 1.35 1.3 0.4 0.35 2.4 3.4 144 x 0.13 0.7 8.0 8.4 97 nom. Braiding Outer construction sheath No. of wall wires x thickness individual wire-O.D. O.D. Weight 55 Multi-core cables FLYWYW / FLRYWYW / FLRYWZ / FLRYWYWF Cables up to 125 °C Round, flat and twin cable Temperature range: –40 °C bis +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. Insulation Plasticized PVC with properties according to ISO 6722, Class C, hot-pressure resistant. Sheath Plasticized PVC with properties according to ISO 6722, Class C, hot-pressure resistant. Structure No. of cores x nominal cross-section mm Conductor construction No. of strands 2 Versions ■ Round cable (FLYWYW or FLRYWYW) ■ Twin cable (FLRYWZ) ■ Flat cable (FLRYWYWF) Insulation Diameter of single wire max. Diameter of conductor max. Electrical resistance at 20 °C bare tinned max. max. Wall thickness mm mm mΩ/m mΩ/m mm 0.21 1.2 24.7 25.4 0.60 0.26 1.4 18.5 19.1 0.26 0.8 52.0 0.41 2.2 7.6 Diameter of core Cable Sheath wall thickness nom. min. max. approx. mm mm mm kg/km 2.4 0.7 6.0 6.2 50 0.35 2.0 0.5 5.6 6.0 65 54.5 0.25 1.25 – 1.25 x 8.9 (h x w) 18 2.8 0.40 2.8 0.6 3.9 x 7.0 (h x w) 68 nom. mm O.D. Weight FLYWYW 2 x 0.75 2 x 0.75 24 FLRYWYW 4 x 1 4x1 19 FLRYWZ 4 x 0.35 4 x 0.35 7 FLRYWYWF 2 x 2.5 2 x 2.5 19 56 Other versions are available on request. FLR91Y11Y / FLR12Y11Y / FLU7Y11Y / FLU6Y11Y Multi-core cables Cables up to 125 °C Special cable Temperature range: –40 °C to +125 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. 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). Structure No. of cores x nominal cross-section mm Conductor construction No. of strands 2 Insulation Diameter of single wire max. Diameter of conductor max. Electrical resistance at 20 °C bare tinned max. max. Wall thickness Diameter of core mm mm mΩ/m mΩ/m mm mm 0.23 1.2 24.2 25.4 0.3 0.19 1.0 32.1 38.2 0.11 1.0 – 0.11 0.6 – Cable Sheath wall thickness nom. O.D. Weight min. max. approx. mm mm mm kg/km 1.8 1.0 5.7 6.1 48 0.3 1.5 0.6 4.15 4.45 25 38.2 0.2 1.4 0.25 3.2 3.4 18.5 136.0 0.1 0.7 0.25 2.0 2.4 10 FLR91Y11Y 3 x 0.75 3 x 0.75 19 FLR12Y11Y 2 x 0.5 2 x 0.5 19 FLU7Y11Y 2 x 0.5 2 x 0.5 64 FLU6Y11Y 4 x 0.14 4 x 0.14 18 Other versions are available on request. 57 Multi-core cables Cables from 150 °C FLR13Y13Y / FLR13YC13Y / FLU7Y7Y FLU6Y6YF / FLR6YC6Y Special cable Temperature range (see chart below) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. Insulation Thermoplastic elastomers based on polyesters (13Y), fluoropolymeres, e. g. ETFE (7Y) or FEP (6Y). Structure No. of cores x nominal cross-section mm Conductor construction No. of strands Diameter Diameter of of conducsingle tor wire max. max. 2 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. Insulation Electrical resistance at 20 °C Wall thickness max. nom. Diameter of core Cable Sheath wall thickness mm O.D. Weight min. max. approx. mm mm kg/km Temperature range mm mm mΩ/m mm mm 3000 hrs 0.19 1.0 38.2 0.3 1.55 0.9 4.9 5.1 32 –40 °C to +150 °C 0.21 1.5 38.2 0.3 1.55 0.65 7.6 8.2 127 –40 °C to +150 °C 0.16 1.0 38.2 0.2 1.3 0.4 3.6 3.9 26 –40 °C to +175 °C 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 0.19 1.0 38.2 0.3 1.5 0.5 53 –40 °C to +200 °C FLR13Y13Y 2 x 0.5 2 x 0.5 19 FLR13YC13Y 10 x 0.5 10 x 0.5 16 FLU7Y7Y 3 x 0.5 3 x 0.5 28 FLU6Y6YF 4 x 0.35 4 x 0.35 19 FLR6YC6Y 2 x 0.5 2 x 0.5 19 58 4.45 4.75 Other versions are available on request. 502 Multi-core cables LEONI Dacar© data cables 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) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare or tinned. Conductor according to ISO 6722. 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 Overview Product range data cables – LVDS Designation LEONI Dacar® 501 LEONI Dacar® 502 LEONI Dacar® 503 LEONI Dacar® 508 LEONI Dacar® 509 LEONI Dacar® 511 LEONI Dacar® 535 Construction FL2YBCY 4 x 2 x 0.22 (+ 0.22) FL9YBCY 4 x 2 x 0.22 (+ 0.22) FL09YBCY 4 x 2 x 0.22 FL2YBCY 5 x 2 x 0.22 FL9YBCY 5 x 2 x 0.22 FL09YBCY 5 x 2 x 0.22 FL9YBCY 4 x 0.14 Other versions are available on request. Dielectric Impedance Sheath Temperature range Application PE PP Foam-PP PE PP Foam-PP PP 100 Ω 100 Ω 100 Ω 100 Ω 100 Ω 100 Ω 100 Ω PVC PVC PVC PVC PVC PVC PVC –40 to +85 °C –40 to +105 °C –40 to +105 °C –40 to +85 °C –40 to +105 °C –40 to +105 °C –40 to +105 °C LVDS LVDS LVDS LVDS LVDS LVDS LVDS 59 533 Multi-core cables LEONI Dacar© data cables Cable for bus systems FL09YBY 2 x 0.35 + (0.35) Temperature range: –40 °C bis +105 °C (3000 hrs) Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Conductor according to ISO 6722. Insulation PP foamed (Polypropylene). Shielding Aluminium-coated foil, visual covering 100 %. Sheath Plasticized PVC with properties according to ISO 6722, Class B. Electrical properties Impedance 100 ± 15 Ω Overview product range data cables – bus systems Designation LEONI Dacar® 520 LEONI Dacar® 507 LEONI Dacar® 532 LEONI Dacar® 533 LEONI Dacar® 560 LEONI Dacar® 562 LEONI Dacar® 565 60 Construction FL09YS11Y 2 x 0.35 FLY2YY 2 x 2 x 0.14 FL09YB11Y 2 x 0.35 FL09YBY 2 x 0.35 + (0.35) FL2X11Y 2 x 0.35 FL2X11Y 2 x 0.55 FL09YSBY 2 x 0.75 + (0.75) Dielectric Impedance Sheath Temperature range Application Foam-PP PE Foam-PP Foam-PP PE-X PE-X Foam-PP 120 Ω 100 Ω 100 Ω 100 Ω 120 Ω 120 Ω 120 Ω TPE-U PVC TPE-U PVC TPE-U TPE-U PVC –40 to +105 °C –40 to +85 °C –40 to +105 °C –40 to +105 °C –40 to +120 °C –40 to +120 °C –40 to +120 °C CAN FireWire Flexray e-Most CAN CAN CAN Other versions are available on request. 550 Multi-core cables LEONI Dacar© data cables Drain wire Sensor cable for lambda probe 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 according to ISO 6722. Insulation Plasticized PVC according to ISO 6722, Class B. Sheath for the drain wire Conductive PVC. Shielding Foil shield of spirally wrapped overlapping tape of aluminium-coated PVC foil. Sheath TPE-U (polyether polyurethane) with especially high resistance to hydrolysis (11Y). Overview product range data cables – Lambda probe Structure No. of cores x nominal cross-section Conductor construction No. of strands mm2 1 x 0.35+(0.35) 2 x 0.35+(0.35) 3 x 0.35+(0.35) 4 x 0.35+(0.35) 5 x 0.35+(0.35) 7 7 7 7 7 Other versions are available on request. Diameter of Diameter of single conductor wire max. max. Insulation Electrical resistance at 20 °C max. Wall thickness Cable Diameter of core Sheath wall thickness nom. O.D. Weight min. max. approx. mm mm mΩ/m mm mm mm mm mm kg/km 0.26 0.26 0.26 0.26 0.26 0.8 0.8 0.8 0.8 0.8 52.0 52.0 52.0 52.0 52.0 0.25 0.25 0.25 0.25 0.25 1.25 1.25 1.25 1.25 1.25 0.6 0.6 0.6 0.6 0.6 3.9 4.1 4.4 4.8 5.4 4.3 4.5 4.8 5.2 5.8 21 24 30 39 46 61 570 Multi-core cables LEONI Dacar© data cables Car telephone cable FLR7YC11Y 12 x 0.22 SN + coax Z 50 Temperature range: –40 °C bis +85 °C (3000 hrs) Construction core Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, bare. Conductor according to ISO 6722. 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 TPE-U (polyether polyurethane) with especially high resistance to hydrolysis (11Y). Construction coaxial element Z 50 Conductor Fine tinned stranded conductor of Cu-ETP1 according to DIN EN 13602. Dielectric PE (Polyethylene). Shielding Braiding of tinned copper wires of Cu-ETP1 according to DIN EN 13602, 0.10mm, visual covering appr. 85 %. Sheath Plasticized PVC, lead free. Overview product range data cables Designation 62 Construction Sheath Temperature range Application LEONI Dacar® 505 LEONI Dacar® 506 LEONI Dacar® 514 LEONI Dacar® 570 LEONI Dacar® 573 FL2YBC11Y 4 x 2 x 0.22 FL6YBC11Y 4 x 2 x 0.22 FLR12YBCY 5 x 2 x 0.14 + 2 x 0.5 FLR7YC11Y 12 x 0.22 + Z 50 FLRY (YB12Y) BY 3 x 0.56 + 3 x 0.14 + 2 x 0.14 TPE-U TPE-U PVC TPE-U PVC –40 to +85 °C –40 to +125 °C –40 to +105 °C –40 to +85 °C –40 to +105 °C UHI UHI UHP Car telephone Car telephone LEONI Dacar® 590 LEONI Dacar® 800 FLR7YC11Y 8 x 0.22 + 2 x 0.35 + Z 50 FL(R2YCY) (09YCY)CY 2 x (0.14) + 2 x (Coax B-75-1.68-2.7) TPE-U PVC –40 to +85 °C –40 to +85 °C Car telephone Audio/Video Other versions are available on request. 300 Multi-core cables LEONI Dacar© coaxial cables RF coaxial cable with solid dielectric Temperature range: –40 °C bis +105 °C (3000 hrs) Construction / Materials Conductor Copper clad steel wire, bare, 7 x 0.16, diameter 0.48 mm. Dielectric PP (Polypropylene), diameter 1.52 mm. Shielding Braiding of tinned copper wires of Cu-ETP1 according to DIN EN 13602, visual covering nom. 90 %, diameter 1.92 mm. Sheath Plasticized PVC according to ISO 6722, Class B, lead free, diameter 2.8 mm. Electrical properties Impedance Capacitance at 1 kHz Conductor resistance at 20 °C 50 ± 3 Ω max. 106 pF/m max. 317 Ω/km Overview product range coaxial cables Designation Impedance LEONI Dacar® 110 LEONI Dacar® 310 LEONI Dacar® 100 LEONI Dacar® 300 50 Ω 50 Ω 50 Ω 50 Ω Copper strand SN Copper strand SN Staku BL Staku BL LEONI Dacar® 200 LEONI Dacar® 218 LEONI Dacar® 400 LEONI Dacar® 450 75 Ω 75 Ω 50 Ω 75 Ω Copper strand SN Copper strand BL Staku AG Staku AG Other versions are available on request. Dielectric O.D. [mm] / Material Shielding Sheath O.D. [mm] / Material Temperature range 19 x 0.182 19 x 0.182 7 x 0.16 7 x 0.16 2.95 / PE 2.95 / PP 1.52 / PE 1.52 / PP 95 % Cu SN 95 % Cu SN 86 % Cu SN 86 % Cu SN 4.95 / PVC 4.95 / PVC 2.80 / PVC 2.80 / PVC –40 to +85 °C –40 to +105 °C –40 to +85 °C –40 to +105 °C 7 x 0.182 7 x 0.182 7 x 0.17 7 x 0.102 3.1 / PE 3.2 / PE 1.48 / FEP 1.6 / FEP 95 % Cu SN 95 % Cu SN 96 % Cu AG 92 % Cu AG 4.60 / PVC 4.60 / PVC 2.50 / FEP 2.60 / FEP –40 to +85 °C –40 to +85 °C –65 to +205 °C –65 to +205 °C Conductor 63 302 Multi-core cables LEONI Dacar© coaxial cables RF coaxial cable with foamed dielectric Temperature range: –40 °C bis +105 °C (3000 hrs) Construction / Materials 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. Electrical properties Impedance Capacitance at 1 kHz Conductor resistance at 20 °C 50 ± 3 Ω max. 85 pF/m max. 48.5 Ω/km Special features Coax cables with foamed dielectric show an outstanding transmission 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. Overview product range coaxial cables 64 Designation Impedance Conductor Dielectric O.D. [mm] / Material LEONI Dacar® 034 LEONI Dacar® 031 LEONI Dacar® 302 LEONI Dacar® 360 LEONI Dacar® 077 50 Ω 50 Ω 50 Ω 75 Ω 120 Ω Copper strand BL 7 x 0.30 Copper strand BL 7 x 0.27 Copper strand BL 7 x 0.27 Copper strand BL 7 x 0.127 Staku BL 7 x 0.10 2.25 / Foam-PE 2.1 / Foam-PE 2.1 / Foam-PP 1.68 / Foam-PP 3.1 / Foam-PE Shielding 87 % 92 % 90 % 90 % 75 % Cu SN Cu SN + AL Cu SN + AL Cu SN + AL Cu BL Sheath O.D. [mm] / Material Temperature range 3.5 / PVC 3.2 / PVC 3.3 / PVC 2.7 / PVC 4.8 / PVC –40 to +85 °C –40 to +85 °C –40 to +105 °C –40 to +105 °C –40 to +85 °C Other versions are available on request. Multi-core cables LEONI Hivocar© 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 Construction / Materials Conductor Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602, 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 %. 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 Conductor construction Type of conductor Nominal crosssection mm2 No. of strands Diameter of conductor max. mm Insulation Electrical resistance Wall thickness max. max. nom. mm mΩ/m mm Cable Diameter of core Sheath wall thickness O.D. Weight mm mm min. approx. mm kg/km 14.8 1.2 17.6 ± 0.4 860 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 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 2x4 1020 2.6 4.71 0.8 4.2 1.1 11.0 ± 0.4 182 LEONI Hivocar® 105-F 2 x 16 2 x 16 2079 5.5 1.16 1.0 7.5 1.6 18.6 ± 0.4 553 LEONI Hivocar® 105-F 2 x 25 2 x 25 3185 7.0 0.75 1.3 9.0 2.4 23.3 ± 0.6 700 LEONI Hivocar® 105-F 2 x 1.5 2 x 1.5 392 1.7 1.1 3.7 1.0 99.0 ± 0.3 125 12.7 LEONI Hivocar® 125-F cables for –40 °C up to +105 °C in highly flexible version (F) LEONI Hivocar® 125-F 5 1x5 651 3.7 3.6 1.0 5.5 1.0 7.9 ± 0.3 109 LEONI Hivocar® 125-F 8 1x8 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 LEONI Hivocar® 125-F 2 x 2.5 2 x 2.5 651 2.2 7.6 0.8 1.0 10.0 ± 0.3 131 Other versions are available on request. 3.75 65 Multi-core cables Extruded flat cables Flat cables separation groove conductor thickness pitch conductor width core insulation wall thickness insulation material Construction Conductors Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13599. Material designations Insulation materials Y PVC YW Heat-resistant PVC 11Y PUR (Polyurethane) 12Y TPE-E 9Y PP-FR 7Y ETFE –40 °C to +105 °C –40 °C to +110 °C –40 °C to +110 °C –40 °C to +105 °C –40 °C to +110 °C –65 °C to +180 °C Chart of standard dimensions 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. 66 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 Chart of standard dimensions Conductor thickness mm 0.076 0.100 0.120 0.130 0.150 0.200 0.450 Conductor width mm 0.80 1.00 1.23 1.35 1.40 1.54 2.05 4.08 6.62 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Ribbon cables Multi-core cables Ribbon cables thickness of insulation between the tracks Construction Conductors Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13602. Insulation Heat-resistant PVC, lead free PP, flame-retardant Dimensions according to LV 112 max. 24 conductors core pitch Material designations Insulation materials Y PVC YW Heat-resistant PVC 9Y PP-FR insulation material –40 °C to +105 °C –40 °C to +110 °C –40 °C to +110 °C Conductor materials BL Bare copper SN Tinned copper AG Silver-plated copper Marking options Imprint Edge marking to indicate the first conductor Dyed insulation material Pitch 2.54 mm (standard). Other pitch dimensions are available on request. 67 Packaging Packaging Our cables can be supplied in all standard forms of packaging to suit the customer’s further processing needs: barrels drums coils coni-packs coiled Packaging of special cables on request. 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 KTG-Drum (re-usable) LEONI-Drum (re-usable) LEONI-Drum (one-way) 68 Type Material KT050 KT080 plastic plastic K3502 K5000 K8002 H6008 H7601 plastic plastic plastic wood wood Packaging 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. 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 diameter d2 Height h mm mm mm F 5000 F 5001 500 500 315 320 410 710 Weight empty kg approx. 9.0 approx. 10.8 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. 69 We also produce… The LEONI group Cable 70 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 Wiring Systems 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 Wire 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 LEONI Kabel GmbH 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
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