En Fahrzeug 06

Automotive Wires and Cables
LEONI connects People, Enterprises, Markets
The Quality Connection
Content
Edition: May 2006 Subject to change and error. by LEONI Kabel GmbH 2006 Please note: LEONI herewith warrants that the delivery items contained in this catalogue will be of the agreed nature and quality upon passing of the risk. Aforementioned nature of the delivered items shall be exclusively rated and measured by the sale and purchase agreements made in writing between LEONI and the purchaser about nature and quality, properties and characteristic performance features of the respective delivery item. Illustrations and information contained in catalogues, price lists and other information material disclosed to the purchaser by LEONI as well as any information describing the product shall be only legally binding, if expressly being referred to as binding 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
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
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 worlds 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.
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
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 worlds natural resources and basis of life. It is our objective to strike a harmony between natures needs and our companys 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 high quality of LEONI products is one of the most important factors behind the companys 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 Kbelgyr Hungaria, Hatvan (Hungary) LEONI Cable (Changzhou), Changzhou (China) LEONI Cable, Cuauhtmoc (Mexico) LEONI Kablo ve Teknolojileri, Gemlik (Turkey)
Type designation
Coding key
The type designation provides information on the type of wire, the insulation and sheath materials used and the principle design features in abbreviated and simplified form.
A type designation is made up of several groups. The type of wire is specified first and then its construction from inside to outside.
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.
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).
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)
Examples
Type designation
1. Single-core cables FL Y 0.5

Nominal cross-section 0.5 mm2 PVC insulation Automotive wire Automotive wire
FL
0.75
Nom. cross-section 0.75 mm2
FL
YK
25.0/
0.1
Max. individual wire-diameter
PVC insulation Reduced thickness of insulation Automotive wire
Nominal cross-section 25 mm2 Insulation (cold-resistant PVC)
2. Multi-core cables FL R Y 2x 1.5 sn- A

Symmetric conductor structure Tinned individual wire Nominal cross-section 1.5 mm Two cores PVC insulation Reduced thickness of insulation Automotive wire
2
FL Y Y
2x 0.5
Nominal cross-section 0.5 mm Two cores
2
FL R Y
B D YW 2x 0.5
Nominal crosssection 0.5 mm2 Two cores Outer sheath (heat-resistant PVC) Copper wire spiral shield Foil shield (static shielding)
PVC sheath PVC insulation Automotive wire
PVC insulation Reduced thickness of insulation Automotive wire
FL
(Y
Y)
(Y
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
Manufacturers markings 1. Single-core wires with a nominal cross-section of 0.35 mm2 and more are permanently marked with the manufacturers logo LEONI at maximum intervals of 200 mm (embossed or printed). The marking of wires with a nominal cross-section smaller than 0.35 mm2 is the subject of agreement between the manufacturer and user. 2. There are several alternative methods of marking multi-core wires: Marking of one (or more) core(s) as described under 1 above. Embossing or printing of the sheath.
Color coding 1. The colors commonly used for the insulation of automotive wires are: white, yellow, grey, green, red, violet, brown, blue, black, orange. (Colors according to DIN 47002 and DIN IEC 304). 2. Two-color automotive wires are marked by two diametrically opposed extruded longitudinal stripes. The width of every stripe must cover at least 7 % of the surface of the wire, with both marking stripes together covering at most 35 % of the surface. 3. Tricolor automotive wires are marked according to LV 112, Part 6: First color: primary color. Second color: longitudinal stripes (as under 2 above). Third color: in the form of rings. Width of rings: 3 1 mm. Distance between two successive rings: 6 to 20 mm. An offset of maximum 1 mm between the two ring halves is permissible.
Other markings On request the wires can also be supplied with numbers printed on them. Since automotive wires fall into the class of low-voltage wires, no CE marking is needed.
10
Insulation materials
Conductor and Insulation materials
LEONI develops and uses insulation materials that provide high reliability and durability under operating conditions. The structure and properties of the materials used are listed below and in the table on page 1213. Thermoplastics Plasticized or semi-crystalline polymers Viscoplastic properties in the service temperature range Plastically ductile at temperatures above the yield limit Thermoplastic elastomers Polymer soft and hard segments Rubber-like elastic properties in the service temperature range Plastically ductile at temperatures above the yield limit Elastomers / Crosslinked plastics Crosslinked polymer soft and hard segments Rubber-like elastic properties with high reversible deformability in the service temperature range No thermoplastic flow properties the crosslinked structure is retained up to decomposition temperature, i.e. well above service temperature Requirements and quality Material testing and development according to customer specifications and/or national and international standards Optimization of properties to meet changed or new requirements Regular quality control in the form of product audits
Selection criteria Service temperatures Electrical values Flexibility/hardness Mechanical stability under load Wear resistance Resistance to oil, fuels, brake fluid, acids/alcalines, organic agents Flame-retardant halogen-free low halogen Service temperatures The low service temperature range is determined by cold strength tests, dynamic bending strength tests or by wrapping tests at low 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
Insulation material properties
Symbol
Name
Code e.g. DIN 76722
Density DIN 53479 g/cm3
Ignition residue DIN 53568 T1 %
Extractable constituents DIN 53738 %
Halogen content
Hardness Shore A/D DIN 53505
Tensile strength DIN 53504 MPa
e.g. DIN ISO 1629 and 7728
approx. %
PVC-P PVC-P PVC-P PE PA FEP ETFE PP PP-FR PFA PVDF TPE-U TPE-E TPE-E TPE-S TPE-A TPE-O E/VA PVC-X PE-X PE-X
Polyvinyl chloride (plasticized)
Y YK YW 2Y 4Y 6Y 7Y 9Y 9Y 51Y 10Y 11Y 12Y 13Y 31Y 41Y 91Y 4G X 2X 2X
1.301.45 1.241.34 1.241.34 0.920.95 1.01 2.14 1.70 0.91 1.051.3 2.15 1.8
g/cm3
1030 1015 815 0 0 0 0 0 010 0 0

%
2030 30 40 2030 0 0 0 0 0 0 0 0
%
35 30 35 0 0 75 60 0 10 75 35
approx. %
85A 95A 80A 95A 92A 97A 50D 62D /72D /55D /75D /70D /70D /55D /78D 85A54D 40D72D /55D 55D 65D 75A70D 87A/ 80A 85A 95A/ 95A/ /42D
>10 >10 >15 >15 > 40 >15 >30 >15 >15 >20 >25
MPa
cold-resistant hot-pressure resistant, heat-resistant Polyethylene Polyamide Tetrafluoroethylene hexafluoropropylene Ethylen tetrafluoroethylene Polypropylene Polypropylene, flame-retardant Perfluoroalkoxy copolymer Polyvinylidenfluorid Thermoplastic polyether polyurethane Thermoplastic polyether ester elastomer Thermoplastic polyester elastomer Thermoplastic polystyrene block copolymer Thermoplastic polyamide elastomer Thermoplastic polyolefin elastomer Ethylene vinyl acetate Polyvinyl chloride, crosslinked Polyethylene, crosslinked (XLPE) Polyethylene, crosslinked, halogen-free (XLPE)
1.12 1.161.25 1.251.28 1.101.30 1.011.06 0.951.25

g/cm3
0 0 0 010 0 010
%
0 0 0 0 0 0
%
0 0 0 010 0 010
approx. %
>30 >25 >30 >15 >25 >10

MPa
1.301.40 1.35 1.1 1.4
4050 15 0 20
010 30 0 0
0 30 10 0
>7 >10 >10 >10
All compounds used are lead free
12
Service Temperatures Elongation at break DIN 53504 % Temperature index DIN ISO 2578 C/3000 hrs Thermal overload capacity ISO 6722 C/48 hrs Cold winding test ISO 6722 C Specific volume resistance DIN 53482 cm Dielectric strength DIN 53481 kV/mm Flame retardation
Resistance to Acids/ Alkalines Organic agents
Abrasion
Oil ISO 6722
Fuels
Brake fluid
ISO 6722
>150 >150 >150 >300 >300 >200 >200 >200 >200 >200 >100
%
105 105 125 90 105 210 180 125 125 260 150
C/3000 hrs
110/125 25/40 110 140 100 140 260 230 150 150 290 160
C/48 hrs
>1012 >10 >1012 >1016 >1012 >1015 >1015 >1016 >1014 >1015
12
>10 >10 >10 >30 >10 >30 >30 >30 >20 >30 >30
kV/mm
+ + + + ++ ++ ++ + + ++ ++ ++ ++ ++ ++ ++ + +
+ + + ++ ++ + ++ ++ +/ +/ +/ + + +
+ + + ++ ++ ++ + + ++ ++ ++ ++ ++ + ++ + + +
+ + + +/ ++ ++ ++ + + ++ ++ ++ ++ ++ + ++ + + +
+ ++ ++ ++ ++ + + + +
+ + + + + ++ ++ + + ++ + + + + + + + +
+ ++ ++ + + ++ + + + + + + + +
50 25/40 40 50 65 65 40 40 80 30
C
>1014
cm
> 400 > 400 >300 >200 > 400 >300

%
125 90 150 125 90 125

C/3000 hrs
150 150 180 150 120 150

C/48 hrs
40 40 40 40 50 40
C
>10 >109 >109 >1010 >1010

9
>10 >10 >10 >10 >10 >20

kV/mm
>1014
cm
>150 >150 >200 >200
140 105 125 125
180 140 150 150
40 40 40 40
>10
10 12
>10 >10 >20 >10
>10 >1014 >1014
++ +
Excellent Good Fair Poor
depends on recipe, as required
criterion: residual elongation at break > 50 %
13
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 Composition in % by weight Density g/m3 Melting point % IACS min. Notes on properties and use
Oxygenic copper Cu-ETP1 CW 003 A (E-Cu)
Cu 99.90 Oxygen max. 0.040
8.9
1083 C
101
Oxygenic (tough-pitch) copper with an electrical conductivity in the soft state of 58.58 m/mm2 at 20 C.
Oxygen-free copper, non-deoxidized Cu-OF1 CW 007 A Cu 99.95 (OF-Cu)
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/mm2 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/mm2 = 100 % IACS
14
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 Tin 99.90 7.29 g/cm3 232 C Sn Designation Density Melting point Symbol
High
Silver Fine silver 99.97 10.5 g/cm3 960 C Ag Designation Density Melting point Symbol
High
Nickel Nickel 99.90 8.9 g/cm3 1450 C Ni
Criteria for use Good solderability Effective protection against corrosion
Good
temperature resistance surface conductivity (skin effect)
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 0.38 mm Copper-plated steel wire (e.g. Staku) with single wire 0.38 m
Bare
Temperature range max. 200 C and tin-plated copper with single wire 0.38 mm Copper-plated steel wire (e.g. Staku) with single wire 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
Standards
Overview of standards
Abbreviations: Global Standards ISO 6722 LV112 + 212 PSA PSA FLRY IR FLRY ID FLRYW IR FLRYW ID SAE J 1128 TWP GPT HDT TXL GXL SXL TWE GTE HTE JASO D 609-90 AV AVS AVSS AVSSf CAVS AVX AEX Peugeot, Citron 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 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 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
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 mm2 No. of strands Diameter of single wire mm Diameter of conductor mm Electrical resistance at 20 C m/m
Insulation Wall thickness min. mm mm
Cable Weight max. mm kg/km
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
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
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 max. mm2 mm Diameter of conductor max. mm Electrical resistance at 20 C max. m/m
Insulation Wall thickness nom. mm min. mm O.D.
Cable Weight
max. mm
approx. kg/km
0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25
16 24 32 30 40 50 60 56 84 80 126 196
0.21 0.21 0.21 0.26 0.26 0.26 0.26 0.31 0.31 0.41 0.41 0.41
1.0 1.2 1.35 1.7 2.0 2.2 2.5 2.75 3.3 4.5 6.3 7.8
37.1 24.7 18.5 12.7 9.42 7.6 6.0 4.71 3.14 1.82 1.16 0.743
0.6 0.6 0.6 0.6 0.6 0.7 0.7 0.8 0.8 1.0 1.0 1.2
2.0 2.2 2.4 2.7 2.9 3.3 3.5 4.0 4.6 6.0 7.5 9.5
2.3 2.5 2.7 3.0 3.2 3.7 3.9 4.4 5.0 6.5 8.1 10.2
8 11 14 19 25 31 37 47 68 111 179 278

19
Nominal value, tolerance of number of strands: 5 % ( 6.0 mm2)
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.
Cable Weight
max. mm
approx. kg/km
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
0.16 0.16 0.16 0.16 0.16 0.08 0.08 0.08 0.08 0.11
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
Cable Weight
max. mm
approx. kg/km
0.5 0.75 1 1.5 2.5
16 24 32 30 50
0.21 0.21 0.21 0.26 0.26
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
More cross-sections and strand constructions on request.
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 single wire max. mm2 mm Diameter of conductor Electrical resistance at 20 C bare/tinned min. m/m bare/tinned max. m/m
Insulation Wall thickness O.D.
Cable Weight
max. mm
min. mm mm
Limit tolerance mm
approx. kg/km
0.22 0.35 0.5 0.75 1 1.5 2 2.5

22
7 7 19 19 19 19 19 19
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
77.9 / 47.8 / 34.1 / 22.7 / 17.0 / 11.7 / 8.66 / 7.0 /
84.8 / 86.5 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
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
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 Diameter of single wire max. mm2 mm Diameter of conductor Electrical resistance at 20 C bare/tinned min. m/m bare/tinned max. m/m
Cable Weight
max. mm
min. mm mm
Limit tolerance mm
approx. kg/km
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
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
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
Nominal value, tolerance of number of strands: 5 % ( 6.0 mm2).
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 No. of strands Diameter of single wire Diameter of conductor Electrical resistance at 20 C bare/tinned min. m/m bare/tinned max. m/m
Cable Weight
max. mm
2
max. mm
min. mm mm
Limit tolerance mm
approx. kg/km
mm
0.35 0.35 0.5 0.75 1 1.5 2 2.5 3 4 6 10 16 25

24
7 12 16 24 32 30 30 50 45 56 84 80 126 196
0.26 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
0.8 0.9 1.0 1.2 1.35 1.7 1.9 2.2 2.4 2.75 3.3 4.5 6.3 7.8
47.8 / 47.8 / 34.1 / 22.7 / 17.0 / 11.7 / / 7.0 / / 4.32 / 2.85 / / / /
52.0 / 54.5 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 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.28 0.32 0.32 0.48 0.52 0.52
1.4 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
0.1 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.6 0.6 0.8
4.5 4.5 6.6 9 11 16 22 26 32.5 42 61 108 170 265
Nominal value, tolerance of number of strands: 5 % ( 6.0 mm2).
FLRY T2 IR
Single-core cables
unshielded
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. Standards and specifications PSA STE 96 418 794 99 IR
Conductor construction Nominal cross-section No. of strands Diameter of single wire Electrical resistance at 20 C max. m/m
Cable Weight
max. mm
approx. kg/km
mm2
mm
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
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
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. Standards and specifications PSA STE 96 418 794 99 ID
Conductor construction Nominal cross-section No. of strands Diameter of single wire max. mm2 mm Electrical resistance at 20 C max. m/m
Cable Weight
max. mm
approx. kg/km
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
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
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. Standards and specifications PSA STE 96 418 794 99 IR
Insulation Wall thickness min. mm mm O.D.
Cable Weight
max. mm
approx. kg/km
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
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
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. Standards and specifications PSA STE 96 418 794 99 ID
Insulation Wall thickness min. mm mm O.D.
Cable Weight
max. mm
approx. kg/km
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
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 single wire max. mm2 mm Diameter of conductor bare min. m/m Electrical resistance at 20 C tinned max. m/m
Cable Weight
max. mm
min. mm mm
Limit tolerance mm
approx. kg/km
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
7 19 19 19 19 19 12 16 24 32 30 50 56
0.26 0.19 0.23 0.26 0.32 0.41 0.21 0.21 0.21 0.21 0.26 0.26 0.31
0.8 1.0 1.2 1.35 1.7 2.2 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 / 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 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 0.20 0.22 0.24 0.24 0.24 0.28 0.32
1.3 1.6 1.9 2.1 2.4 3.0 1.4 1.6 1.9 2.1 2.4 3.0 3.7
0.1 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.3 0.3
4.2 5.8 8 11 15 24 4.2 5.8 8 11 15 24 40

29
Single-core cables
125 P
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
Cable Weight Limit tolerance
approx. kg/km
mm
mm
mm
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
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
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 Diameter of single wire max. mm2 mm
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm mm O.D.
Cable Weight Limit tolerance mm
Diameter of conductor max. mm
approx. kg/km
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
0.21 0.26 0.19 0.23 0.26 0.32 0.37 0.41 0.21 0.21 0.21 0.21 0.26 0.31 0.26 0.31 0.31 0.31
0.7 0.8 1.0 1.2 1.35 1.7 2.0 2.2 0.9 1.0 1.2 1.35 1.7 2.0 2.2 2.4 2.75 3.3
84.8 52.0 37.1 24.7 18.5 12.7 9.42 7.6 52.0 37.1 24.7 18.5 12.7 9.42 7.6 6.15 4.7 3.1
0.20 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.28 0.32 0.32
1.2 1.3 1.6 1.9 2.1 2.4 2.8 3.0 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.2 3.7 4.3
0.1 0.1 0.2 0.2 0.2 0.2 0.3 0.3 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.3
3.1 4.5 6.6 9 11 16 22 26 4.5 6.6 9 11 16 22 26 32.5 42 61

31
Single-core cables
150 A
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 No. of strands Diameter of single wire max. mm
2
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm mm O.D.
Cable Weight Limit tolerance mm
approx. kg/km
mm
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
0.26 0.19 0.23 0.26 0.32 0.37 0.41 0.21 0.21 0.21 0.21 0.26 0.31 0.26 0.31 0.31
0.8 1.0 1.2 1.35 1.7 2.0 2.2 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 52.0 37.1 24.7 18.5 12.7 9.42 7.6 4.7 3.1
0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.20 0.22 0.24 0.24 0.24 0.28 0.28 0.32 0.32
1.3 1.6 1.9 2.1 2.4 2.8 3.0 1.4 1.6 1.9 2.1 2.4 2.8 3.0 3.7 4.3
0.1 0.2 0.2 0.2 0.2 0.3 0.3 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 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 Diameter of single wire max. mm2
Insulation Electrical resistance at 20 C Wall thickness O.D.
Cable Weight
Diameter of conductor bare min.
max. mm
tinned max. m/m
min. mm mm
Limit tolerance mm
approx. kg/km
mm
m/m
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
0.8 1.0 1.2 1.35 1.7 2.2 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 / 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 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 0.20 0.22 0.24 0.24 0.24 0.28 0.32
1.3 1.6 1.9 2.1 2.4 3.0 1.4 1.6 1.9 2.1 2.4 3.0 3.7
0.1 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.3 0.3
4.7 6.3 9 11.5 16.5 27.5 4.7 6.3 9 11.5 16.5 27.5 42
33
Ultra-thin wall thickness on request.
Single-core cables
210 F
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 No. of strands Diameter of single wire max. mm
2
Insulation Electrical resistance at 20 C Wall thickness
Cable O.D. Weight
max. mm
tinned max. m/m
min. mm mm
Limit tolerance mm
approx. kg/km
mm
m/m
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
0.8 1.0 1.2 1.35 1.7 2.2 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 / 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 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 0.20 0.22 0.24 0.24 0.24 0.28 0.32
1.3 1.6 1.9 2.1 2.4 3.0 1.4 1.6 1.9 2.1 2.4 3.0 3.7
0.1 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.3 0.3
5 7 10 13 18 29 5 7 10 13 18 29 44
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 m).
Conductor construction Nominal crosssection No. of strands Diameter of single wire max. mm
2
Insulation Electrical resistance at 20 C Wall thickness
Cable O.D. Weight
max. mm
tinned max. m/m
min. mm mm
Limit tolerance mm
approx. kg/km
mm
m/m
0.35 0.5 0.75 1 1.5 2.5 4
7 19 19 19 19 19 56
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
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
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 Size Nominal cross-section mm

2
Insulation Diameter of conductor nom. mm Wall thickness nom. mm min. mm O.D. max. mm
Cable Weight approx. kg/km
No. of strands
Diameter of single wire nom. mm
AWG
22 20 18 18 16 14 12 10
36
0.35 0.5 0.8 0.8 1 2 3 5
7 7 16 19 19 19 19 19
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
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 No. of strands Diameter of single wire nom. AWG mm2 mm Diameter of conductor nom. mm nom. mm
Insulation Wall thickness min. mm O.D.
Cable Weight
max. mm
approx. kg/km
22 20 18 18 16 14 12 10
0.35 0.5 0.8 0.8 1 2 3 5
7 7 16 19 19 19 19 19
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
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

37
Single-core cables
AV
unshielded
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 Diameter of single wire Diameter of conductor Electrical resistance at 20 C max. m/m
Cable Weight
nom. mm2 mm
nom. mm
nom. mm
min. mm
max. mm
approx. kg/km
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
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
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
The f in the nominal cross-section column indicates a flexible conductor with a finer wire diameter.
AVS
Single-core cables
unshielded
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 Diameter of single wire nom. mm2 mm Diameter of conductor nom. mm Electrical resistance at 20 C max. m/m
Cable Weight
max. mm
approx. kg/km
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
0.26 0.32 0.32 0.32 0.32 0.32 0.32 0.18 0.18 0.18 0.18 0.26
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
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 No. of strands Diameter of single wire nom. mm
2
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm min. mm O.D.
Cable Weight
Diameter of conductor nom. mm
max. mm
approx. kg/km
mm
0.3 0.5 0.85 1.25 2 (f) 0.3 f 0.5 f 0.75 f 1.25 f

40
7 7 19 19 37 19 19 19 37
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
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 No. of strands Diameter of single wire max. mm
2
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm min. mm O.D.
Cable Weight approx. max. mm kg/km
mm
6 10 16 25 35 50 70 95 120
84 80 126 196 276 400 560 740 960
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
66 109 176 273 355 511 705 905 1170

41
Nominal value, tolerance of number of strands: 5 %.
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. Special properties Sheath options: firmly bonded or separable.
Conductor construction Nominal crosssection mm2 No. of strands Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C max. m/m
Insulation Wall thickness nom. mm mm mm Diameter of Core Sheath wall thickness min. mm
Cable O.D. Weight
max. mm
approx. kg/km
0.5 0.75 1 1.5 2 2.5

42
16 24 32 30 40 50
0.21 0.21 0.21 0.26 0.26 0.26
1.0 1.2 1.35 1.7 2.0 2.2
37.1 24.7 18.5 12.7 9.42 7.6
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
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

2
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm mm mm Diameter of Core Sheath wall thickness min. mm
Cable O.D. Weight
No. of strands
Diameter of single wire max. mm
max. mm
approx. kg/km
FLY0Y 4 6 10 16 FLYK0Y 50 50 / 0.2 70 / 0.2
56 84 80 126 396 1600 2200
0.31 0.31 0.41 0.41 0.41 0.21 0.21
2.75 3.3 4.5 6.3 10.5 10.9 13.3
4.7 3.1 1.82 1.16 0.368 0.386 0.272
0.8 0.8 1.0 1.0 0.8 0.8 1.0
4.2 4.8 6.2 7.7 12.0 12.0 14.7
2.0 2.0 3.0 2.0 1.4 1.4 1.6
8.0 8.6 12.2 11.5 14.5 14.5 17.5
8.4 9.0 12.8 12.1 15.1 15.1 18.3
106 125 208 245 540 550 79

43
Other cross-sections and dimensions on request.
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
Insulation Electrical resistance at 20 C max. m/m Wall thick ness nom. mm mm mm Diameter of core Sheath wall thickness min. mm
Cable O.D. Weight
No. of strands
max. mm
approx. kg/km
0.75 1 1.5
44
24 32 30
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
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 ABS/ESP sensor cables
FLR4G11Y / FL4G11Y
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). Special properties Cables in hot-pressure resistant version to 150 C available on request. Very high fatigue strength under reversed bending stresses and abrasion resistance. Conductors with three or four cores for additional functions. FLR4G11Y Reduced wall thickness.
Structure No. of cores x nominal cross-section mm2 No. of strands
Conductor construction Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C max. m/m
Insulation Wall thickness nom. mm mm mm Diameter of core Sheath wall thickness min. mm
Cable O.D. Weight
max. mm
approx. kg/km
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
46
19 28 28 28 28 16 42 30 16 30
0.16 0.16 0.16 0.16 0.16 0.21 0.16 0.26 0.21 0.26
0.8 1.0 1.0 1.0 1.0 1.0 1.2 1.7 1.0 1.7
54.5 40.1 40.1 40.1 40.1 40.1 27.1 13.7 40.1 13.7
0.35 0.35 0.35 0.35 0.35 0.6 0.5 0.6 0.6 0.7
1.45 1.65 1.65 1.65 1.65 2.2 2.2 2.8 2.2 2.9
0.5 0.55 0.9 0.8 0.6 0.85 0.9 0.65 0.8 1.1
3.8 4.1 5.0 5.0 5.0 5.9 6.0 6.6 6.0 8.1
4.0 4.5 5.3 5.4 5.4 6.3 6.4 7.0 6.4 8.7
20 27 34 39 42 44 47 66 51 107
Note: This chart shows an extract of our existent product portfolio. Other versions on request.
FLR2X11Y
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).
Conductor construction Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C bare tinned max. max. m/m m/m
Cable O.D. Weight
max. mm
approx. kg/km
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
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
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
47
FLR31Y11Y
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 mm2 No. of strands
Cable O.D. Weight
max. mm
approx. kg/km
2 x 0.5 2 x 0.5 2 x 0.75 2 x 0.75 3 x 0.5 3 x 0.75 3x1 4 x 0.5 4 x 0.5 5 x 0.5
48
28 28 42 96 19 19 19 28 64 64
0.16 0.16 0.16 0.11 0.19 0.23 0.26 0.16 0.1 0.1
1.0 1.0 1.2 1.2 1.0 1.2 1.2 1.0 1.0 1.0
37.1 37.1 24.7 24.7 37.1 24.7 18.5 37.1 37.1 37.1
0.30 0.30 0.30 0.30 0.30 0.30 0.35 0.30 0.30 0.30
1.5 1.5 1.8 1.8 1.6 1.8 2.0 1.5 1.6 1.6
0.7 1.0 1.2 1.2 0.8 1.0 0.8 1.2 1.2 1.0
4.3 4.8 6.0 6.0 5.0 5.7 5.7 6.0 6.0 6.0
4.7 5.2 6.4 6.4 5.2 6.1 6.1 6.4 6.4 6.4
27.5 35 47.5 48 37 49 56 51 51 54
FLRY11Y
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).
Cable O.D. Weight
max. mm
approx. kg/km
2 x 0.75 3x1 3 x 1.5
42 32 30
0.16 0.21 0.26
1.2 1.5 1.7
24.7 18.5 13.3
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
49
Multi-core cables Cables up to 105 C
FLYY / FLRYY / FLYKYK
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.
FLYY / FLRYY FLYKYK
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.
Cable O.D. Weight
max. mm
approx. kg/km
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 FLYKYK 2 x 0.5 2x1 3 x 0.5
50
16 24 24 32 30 7 19 16 24 32 24 16 24 32 24 32 16 16 32 16
0.21 0.21 0.21 0.21 0.26 0.26 0.19 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21 0.21
1.0 1.2 1.2 1.4 1.7 0.8 1.0 1.0 1.2 1.4 1.2 1.0 1.2 1.4 1.2 1.4 1.0 1.0 1.4 1.0
37.1 24.7 24.7 18.5 12.7 52.0 37.1 37.1 24.7 18.5 24.7 37.1 24.7 18.5 24.7 18.5 37.1 37.1 18.5 37.1
38.2 25.4 25.4 19.1 13.0 54.5 38.2 38.2 25.4 19.1 25.4 38.2 25.4 19.1 25.4 19.1 38.2 38.2 19.1 38.2
0.4 0.6 0.5 0.6 0.6 0.25 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.5 0.6 0.5
1.75 2.3 2.15 2.5 2.75 1.3 1.6 1.6 1.75 1.95 1.75 1.6 1.75 1.95 1.75 1.95 1.6 1.95 2.5 1.95
0.50 0.50 0.80 1.00 1.10 0.50 0.60 0.60 0.60 0.60 0.75 0.85 0.75 1.00 0.75 0.75 0.95 0.70 0.60 0.60
4.3 5.4 7.8 9.0 10.2 3.3 4.2 4.2 4.5 4.8 6.3 6.2 6.6 7.6 6.6 7.2 6.9 5.0 6.0 5.1
4.7 5.8 9.4 9.6 11.0 3.7 4.6 4.6 4.9 5.4 6.7 6.8 7.0 8.0 7.0 7.6 7.5 5.6 6.6 5.7
31 48 112 148 201 20 29 29 36 45 75 68 82 114 89 113 87 34 50 41
Other versions are available on request.
FLYYF
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.
Insulation Wall thickness nom. mm mm mm Diameter of core Sheath wall thickness mm
Cable Dimension Weight
Width
Height mm
approx. kg/km
2 x 0.75 2x1 2 x 1.5 2 x 2.5 3 x 1.5
24 32 30 50 30
0.21 0.21 0.26 0.26 0.26
1.2 1.4 1.7 2.2 1.7
24.7 18.5 12.7 7.6 12.7
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
51
FLYZ
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.
Insulation Wall thickness nom. mm mm Diameter of core Width mm
Cable Dimension Weight
Height mm
approx. kg/km
2 x 0.5 2 x 0.75 2 x 1.5

52
16 24 30
0.21 0.21 0.26
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
FLRYBY / FLRYDY / FLRYBDY / FLRYCY
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. 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.
Cable O.D. Weight
max. mm
approx. kg/km
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
7 7 7 12 19 24 19 24 32 19 10 14 19 19 19
0.26 0.26 0.21 0.21 0.19 0.21 0.26 0.21 0.21 0.19 0.11 0.16 0.16 0.16 0.16
0.8 0.8 0.7 0.8 1.0 1.2 1.4 1.2 1.4 1.0 0.45 0.7 0.8 0.8 0.8
52.0 52.0 84.8 52.0 37.1 24.7 18.5 24.7 18.5 37.1 353 84.8 52.0 52.0 52.0
54.5 54.5 86.5 54.5 38.2 25.4 19.1 25.4 19.1 38.2 365 86.5 54.5 54.5 54.5
0.25 0.25 0.25 0.25 0.30 0.30 0.30 0.30 0.30 0.30 0.20 0.20 0.25 0.25 0.25
1.25 1.25 1.15 1.35 1.5 1.75 2.0 1.75 1.95 1.6 0.8 1.1 1.3 1.25 1.25
0.5 0.5 0.5 0.6 0.8 0.6 0.7 0.6 0.5 0.6 0.6 0.6 0.5 0.65 0.65
2.9 4.3 3.4 4.2 4.9 4.9 5.5 5.1 5.5 4.7 4.6 5.8 4.7 5.9 6.5
3.3 4.7 3.8 4.6 5.3 5.2 5.9 5.4 5.8 4.9 4.9 6.2 5.1 6.3 6.9
14 35 25 30 38 44 52 55 64 36 38 68 47 75 83
53
FLRYY (GGVS) / FLRYY11Y
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. 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.
Structure No. of cores x nominal cross-section mm2 mm2 Diameter of core max. mm
Core Color code
Core Diameter of core max. mm2 mm Color code O.D. max. mm
Cable Weight approx. kg/km
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
Structure Cross-section No. of strands
1 1.5 1.5 1.5 1.5
2.1 2.0 2.4 2.4 2.4
6 2.5 2.5 1.5 1.5 1.5 1.5 4
4.3 3.0 3.0 2.4 2.4 2.4 2.4 3.7
5.7 12.3 10.5 10.6 14.7
19.5 150 130 101 245
4 2.5 1 1
3.7 3.0 2.1 2.1

Conductor construction
11.3 10.5 9.2 12.5
212 130 82 125
Insulation Electrical resistance at 20 C max. m/m Wall thickness nom. mm
mm2
0.75 1 1.5 2.5 4 6

54
24 32 30 50 56 84
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

FLY(YDY)(YBY)CY 3x0.35+(1x0.35)+(2x0.35)
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. 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.
Structure No. of cores No. of x strands nominal crosssection mm2
Conductor construction Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C
Insulation Wall thickness Diameter of core
Inner sheath Wall thickness InnerO.D.
Complete cable Braiding Outer construction sheath No. of wall wires x thickness individual wire-O.D. mm mm O.D. Weight
max. m/m mm mm
nom. mm mm
min. mm
max. mm
approx. kg/km
3 x 0.35 (1 x 0.35) (2 x 0.35)
12 12 12
0.21 0.21 0.21
0.9 0.9 0.9
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
55
FLYWYW / FLRYWYW / FLRYWZ / FLRYWYWF
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. Versions Round cable (FLYWYW or FLRYWYW) Twin cable (FLRYWZ) Flat cable (FLRYWYWF)
Structure No. of cores x nominal cross-section mm

2
Conductor construction No. of strands Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C bare tinned max. max. m/m m/m
Insulation Wall thickness nom. mm mm Diameter of core Sheath wall thickness nom. mm
Cable O.D. Weight
min. mm
max. mm
approx. kg/km
FLYWYW 2 x 0.75 2 x 0.75 24 0.21 0.26 0.26 0.41 1.2 1.4 0.8 2.2 24.7 18.5 52.0 7.6 25.4 19.1 54.5 2.8 0.60 0.35 0.25 0.40 2.4 2.0 1.25 2.8 0.7 0.5 0.6 6.0 5.6 6.2 6.0 50 65 18 68 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
1.25 x 8.9 (h x w) 3.9 x 7.0 (h x w)
FLR91Y11Y / FLR12Y11Y / FLU7Y11Y / FLU6Y11Y
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).

2
Conductor construction No. of strands Diameter of single wire max. mm Diameter of conductor max. mm Electrical resistance at 20 C bare tinned max. max. m/m m/m
Cable O.D. Weight
max. mm
approx. kg/km
FLR91Y11Y 3 x 0.75 3 x 0.75 19 0.23 0.19 0.11 0.11 1.2 1.0 1.0 0.6 24.2 32.1 25.4 38.2 38.2 136.0 0.3 0.3 0.2 0.1 1.8 1.5 1.4 0.7 1.0 0.6 0.25 0.25 5.7 4.15 3.2 2.0 6.1 4.45 3.4 2.4 48 25 18.5 10
57
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
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).
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.

2
Conductor construction No. of strands Diameter Diameter of of conducsingle tor wire max. max. mm mm Electrical resistance at 20 C max. m/m
Insulation Wall thickness Diameter of core Sheath wall thickness min. mm mm mm
Cable O.D. Weight Temperature range
nom. mm
max. mm
approx. kg/km 3000 hrs
FLR13Y13Y 2 x 0.5 2 x 0.5 19 0.19 0.21 0.16 0.15 0.19 1.0 1.5 1.0 0.75 1.0 38.2 38.2 38.2 54.5 38.2 0.3 0.3 0.2 0.2 0.3 1.55 1.55 1.3 1.2 1.5 0.9 0.65 0.4 0.45 0.5 4.9 7.6 3.6 5.1 8.2 3.9 32 127 26 32 53 40 C to +150 C 40 C to +150 C 40 C to +175 C 40 C to +200 C 40 C to +200 C 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
2.1 x 5.5 (h x w) 4.45 4.75
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
Overview Product range data cables LVDS

Designation Construction Dielectric Impedance Sheath Temperature range Application
LEONI Dacar 501 LEONI Dacar 502 LEONI Dacar 503 LEONI Dacar 508 LEONI Dacar 509 LEONI Dacar 511 LEONI Dacar 535
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
PE PP Foam-PP PE PP Foam-PP PP
100 100 100 100 100 100 100
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
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
Overview product range data cables bus systems

Designation Construction Dielectric Impedance Sheath Temperature range Application
60
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)
Foam-PP PE Foam-PP Foam-PP PE-X PE-X Foam-PP
120 100 100 100 120 120 120
TPE-U PVC TPE-U PVC TPE-U TPE-U PVC
CAN FireWire Flexray e-Most CAN CAN CAN
550
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 mm2 No. of strands Conductor construction Diameter of Diameter of single conductor wire max. max. mm mm Electrical resistance at 20 C max. m/m Insulation Wall thickness nom. mm mm mm Diameter of core Sheath wall thickness min. mm Cable O.D. Weight
max. mm
approx. kg/km
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
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
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 Construction Sheath Temperature range Application
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 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 TPE-U PVC TPE-U PVC TPE-U PVC
UHI UHI UHP Car telephone Car telephone Car telephone Audio/Video
62
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 max. 106 pF/m max. 317 /km
Overview product range coaxial cables

Designation Impedance Conductor Dielectric O.D. [mm] / Material Shielding Sheath O.D. [mm] / Material Temperature range
LEONI Dacar 110 LEONI Dacar 310 LEONI Dacar 100 LEONI Dacar 300 LEONI Dacar 200 LEONI Dacar 218 LEONI Dacar 400 LEONI Dacar 450
50 50 50 50 75 75 50 75
Copper strand SN Copper strand SN Staku BL Staku BL Copper strand SN Copper strand BL Staku AG Staku AG
19 x 0.182 19 x 0.182 7 x 0.16 7 x 0.16 7 x 0.182 7 x 0.182 7 x 0.17 7 x 0.102
2.95 / PE 2.95 / PP 1.52 / PE 1.52 / PP 3.1 / PE 3.2 / PE 1.48 / FEP 1.6 / FEP
95 % Cu SN 95 % Cu SN 86 % Cu SN 86 % Cu SN 95 % Cu SN 95 % Cu SN 96 % Cu AG 92 % Cu AG
4.95 / PVC 4.95 / PVC 2.80 / PVC 2.80 / PVC 4.60 / PVC 4.60 / PVC 2.50 / FEP 2.60 / FEP
40 to +85 C 40 to +105 C 40 to +85 C 40 to +105 C 40 to +85 C 40 to +85 C 65 to +205 C 65 to +205 C

63
Multi-core cables LEONI Dacar coaxial cables
302
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 max. 85 pF/m max. 48.5 /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

Dielectric O.D. [mm] / Material Sheath O.D. [mm] / Material
Designation
Impedance
Conductor
Shielding
Temperature range
LEONI Dacar 034 LEONI Dacar 031 LEONI Dacar 302 LEONI Dacar 360 LEONI Dacar 077
64
50 50 50 75 120
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
87 % 92 % 90 % 90 % 75 %
Cu SN Cu SN + AL Cu SN + AL Cu SN + AL Cu BL
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
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 No. of strands Diameter of conductor Electrical resistance
Insulation Wall thickness Diameter of core Sheath wall thickness
Cable O.D. Weight
max. mm2 mm
max. mm
max. m/m
nom. mm mm mm
min. mm
approx. kg/km
LEONI Hivocar 105-F cables for 40 C up to +105 C in highly flexible version (F) LEONI Hivocar 105-F 70 LEONI Hivocar 105-F 2 x 2.5 LEONI Hivocar 105-F 2 x 4 LEONI Hivocar 105-F 2 x 16 LEONI Hivocar 105-F 2 x 25 LEONI Hivocar 105-F 2 x 1.5 LEONI Hivocar 125-F 5 LEONI Hivocar 125-F 8 LEONI Hivocar 125-F 25 LEONI Hivocar 125-F 35 LEONI Hivocar 125-F 50 LEONI Hivocar 125-F 2 x 2.5
1 x 70 2 x 2.5 2x4 2 x 16 2 x 25 2 x 1.5 1x5 1x8 1 x 25 1 x 35 1 x 50 2 x 2.5
2205 651 1020 2079 3185 392 651 1008 3185 4473 6370 651
12.4 2.2 2.6 5.5 7.0 1.7 3.7 4.0 6.8 8.5 10.8 2.2
0.27 7.6 4.71 1.16 0.75 12.7 3.6 2.55 0.75 0.53 0.37 7.6
1.2 0.8 0.8 1.0 1.3 1.1 1.0 1.0 1.4 1.4 1.6 0.8
14.8 3.75 4.2 7.5 9.0 3.7 5.5 5.8 9.6 10.8 13.8 3.75
1.2 1.0 1.1 1.6 2.4 1.0 1.0 1.0 1.3 1.4 1.4 1.0
17.6 0.4 10.0 0.3 11.0 0.4 18.6 0.4 23.3 0.6 99.0 0.3 7.9 0.3 8.2 0.3 12.6 0.3 14.0 0.4 17.0 0.4 10.0 0.3
860 145 182 553 700 125 109 139 360 481 670 131
65
LEONI Hivocar 125-F cables for 40 C up to +105 C in highly flexible version (F)
Multi-core cables
Extruded flat cables
Flat cables
separation groove
pitch
conductor thickness insulation wall thickness
conductor width core insulation material
Construction Conductors Soft-annealed electrolytic copper Cu-ETP1 according to DIN EN 13599. Insulation Heat-resistant PVC, lead free Thermoplastic polyurethane-based elastomer Thermoplastic polyolefin elastomer Polypropylene, flame-retardant Ethylene/tetrafluoroethylene
Chart of standard dimensions
Material designations Insulation materials Y PVC YW Heat-resistant PVC 11Y PUR (Polyurethane) 12Y TPE-E 9Y PP-FR 7Y ETFE Conductor materials BL Bare copper SN Tinned copper AG Silver-plated copper
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
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.
Example of a material designation exFCYW 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 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
0.076 0.100 0.120 0.130 0.150 0.200 0.450
66
Ribbon cables
Multi-core cables
Ribbon cables
thickness of insulation between the tracks
pitch
core insulation material
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 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.
Material designations Insulation materials Y PVC YW Heat-resistant PVC 9Y PP-FR Conductor materials BL Bare copper SN Tinned copper AG Silver-plated copper
40 C to +105 C 40 C to +110 C 40 C to +110 C
67
Packaging
Packaging
Our cables can be supplied in all standard forms of packaging to suit the customers 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 Type Material
KTG-Drum (re-usable)
KT050 KT080 K3502 K5000 K8002 H6008 H7601
plastic plastic plastic plastic plastic wood wood
LEONI-Drum (re-usable)
LEONI-Drum (one-way)
68
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 mm Core diameter d2 mm Height h mm Weight empty kg
F 5000 F 5001
500 500
315 320
410 710
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
The LEONI group
We also produce
Cable

Wiring Systems
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

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 for
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
70
LEONI Kabel GmbH
Stieberstrasse 5 91154 Roth Germany Phone +49 (0)9171-804-2218 Fax +49 (0)9171-804-2232 E-mail cable-info@leoni.com www.leoni-cable.com

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Automotive Wires and Cables

LEONI connects People, Enterprises, Markets

The Quality Connection

The Quality Connection

Automotive cables single-core

Automotive cables multi-core

The Quality Connection

LEONI sets standards

There is tradition and a future in expertise.

The Quality Connection

Top names place their trust in LEONI

The Quality Connection

LEONI quality management

LEONI the global player

The Quality Connection

Cable facilities of the business unit Automotive & Standard Cables

The relevant standard or thickness is then also named.

1. Single-core cables FL Y 0.5

PVC insulation Reduced thickness of insulation Automotive wire

Nominal cross-section 25 mm2 Insulation (cold-resistant PVC)

2. Multi-core cables FL R Y 2x 1.5 sn- A

PVC sheath PVC insulation Automotive wire

PVC insulation Reduced thickness of insulation Automotive wire

according to ISO 6722

Marking of automotive wires

Conductor and Insulation materials

temperature/time curve measurement curve

Conductor and Insulation materials

Insulation material properties

Code e.g. DIN 76722

Density DIN 53479 g/cm3

Ignition residue DIN 53568 T1 %

Extractable constituents DIN 53738 %

Hardness Shore A/D DIN 53505

Tensile strength DIN 53504 MPa

e.g. DIN ISO 1629 and 7728

Polyvinyl chloride (plasticized)

Y YK YW 2Y 4Y 6Y 7Y 9Y 9Y 51Y 10Y 11Y 12Y 13Y 31Y 41Y 91Y 4G X 2X 2X

1030 1015 815 0 0 0 0 0 010 0 0

1.12 1.161.25 1.251.28 1.101.30 1.011.06 0.951.25

>30 >25 >30 >15 >25 >10

1.301.40 1.35 1.1 1.4

>7 >10 >10 >10

All compounds used are lead free

Conductor and Insulation materials

Resistance to Acids/ Alkalines Organic agents

Oil ISO 6722

> 400 > 400 >300 >200 > 400 >300

125 90 150 125 90 125

150 150 180 150 120 150

>10 >109 >109 >1010 >1010

>10 >10 >10 >10 >10 >20

>150 >150 >200 >200

140 105 125 125

180 140 150 150

>10 >10 >20 >10

>10 >1014 >1014

Excellent Good Fair Poor

depends on recipe, as required

criterion: residual elongation at break > 50 %

Conductor and Insulation materials

Oxygenic copper Cu-ETP1 CW 003 A (E-Cu)

Cu 99.90 Oxygen max. 0.040

Oxygen-free copper, non-deoxidized Cu-OF1 CW 007 A Cu 99.95 (OF-Cu)