RoHS
Ready
Wire and Cable Products
for the Automotive Industry
AU TO M OT I V E D I V I S I O N
T H E 5 A P P L I C AT I O N A R E A S
I
I N N OVAT I V E
TECHNOLOGIES
TE Automotive – a business segment of TE Connectivity – follows the globalization
goals of our customers, speeds up the integration of new technologies and enables
our customers access to our vast product portfolio and services.
TERMINALS & CONNECTORS
TE Automotive offers a broad range of high quality terminals and connectors.
Our electrical/electronic interconnection products and solutions are used to electrically
and mechanically join wires and cables, printed circuit boards, integrated circuit
packages and batteries. TE Automotive expanding capabilities include new copper
and fiber-optic connectors, wires, cables/cable management systems that are designed
to meet automotive industry demands. Our brands encompass the broadest range of
connectors in the world, including high-density, high-speed designs for leading-edge
communications equipment.
Hybrid & Electric Mobility Solutions
Complete the connections you need to safely, and reliably make hybrid and electric
mobility a reality for everyone, everyday. With over 50 years experience in automotive,
industrial and energy connectivity, TE is an expert in pushing innovation from one
industry to the next. Our portfolio of AMP+ high voltage relays, resistors, AMP+
headers, connectors, IPT/APT and cable assemblies and vehicle charging solutions are
designed to connect and protect electric distribution inside and outside of the vehicle.
C A B L E A S S E M B LY S Y S T E M S
TE Automotive is your partner for special cable assemblies.
We offer research and development capabilities, prototyping, samples as well as
manufacturing facilities for special cable assemblies. This includes overmold
technology, semi/fully automatic manufacturing, testing equipment and appliances
for handling of high volume production.
II
SENSORS
Contact-less measuring eliminates interference effects, wear and tear, and provides
increased reliability. TE Automotive, one of the largest technology providers for the
automobile industry, offers contact-less sensors for a variety of applications.
As sensor manufacturer and processing partner, TE Automotive also provides project
planning support for new sensor applications, assistance in the selection of the
appropriate sensor technology for the respective application, and assistance with
defining the corresponding mechanical, electrical and magnetic interface.
TE Automotive has a broad electro-mechanical portfolio that includes robust housing technologies,
connector systems, and temperature stable designs based on foil and cable networks. This combination of technologies and experience ensures that reliable and cost effective sensor solutions are
available for all application types.
I N F O TA I N M E N T
TE Automotive is the technology leader in high speed data communication in the
automotive industry. TE Automotive offers high performance connectors based on
optical, coaxial as well as shielded electrical cables.
Through a deep understanding of the technical properties and requirements of signal
integrity and combined with our application knowledge both in the vehicle as well as
in the logistics chain, TE Automotive is well positioned to offer the right solution for all
current and next generation Infotainment Systems.
I N D U C T I V E CO I L SYST E M S
TE Automotive is your source for interconnection technologies for automotive, truck
and off-highway OEMs and Tier 1 suppliers. With our global design center in Belgium
and manufacturing sites in all regions, TE Automotive’s Inductive Systems (ICS) group
is ready to design your next-generation coil modules and provide local production
support.
The ICS group maintains a leading market position in braking modules and other
automotive coil applications. Through early involvement with you on your next design,
TE Automotive can offer the benefits of miniaturization, design-in of platform components and
optimized process flow for your standard, hybrid and E.V. project needs.
III
“AT YO U R S E RV I C E ”
TE Automotive Online
The TE Automotive website is an innovative and interactive
source for application information, product updates and
technical solutions. Please contact us at:
www.te.com/automotive
Internet
www.te.com
www.te.com/automotive
www.te.com/automotive/sensors
www.te.com/automotive/most
www.te.com/en/industries/hybrid-electric-mobility-solutions
Electronic Internet Catalog
www.te.com/components
www.te.com/automotive
www.te.com/automotive/sensors
www.te.com/automotive/most
www.te.com/en/industries/hybrid-electric-mobility-solutions
IV
“AT YO U R S E RV I C E ”
Product and Machine Literature
TE Automotive offers a variety of product specific
catalogs, brochures and high impact flyers to help
better serve you!
For more information on literature for TE Automotive,
please contact your local organization or go to
www.te.com/automotive
Product Information Center (PIC)
You can rely on TE Connectivity’s PIC Team to provide
you support for answers to your general information or
technical questions in an efficient and effective manner.
To reach our PIC staff, please contact your local
organization or see our Global Contacts page.
Please contact us at:
http://www.te.com/customersupport/support.asp
V
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Quality Guidelines
Incorrect
Terminal twisted
Terminal damaged
Cut off tab too long
Crimp barrel distorted
Crimp height too tight
Cut off tab deformed
Insulation inside the wire crimp
Conductor Brush protruding into terminal body
Bellmouth on wrong end
Terminal bend
INSULATION CRIMP
Insulation is pierced and could damage conductor
Insulation material is pierced
Insulation legs are not closed
Insulation is not securely held
Legs do not overlap
Insulation is not
securely held
Insulation is over
crimped
WIRE CRIMP
Incorrect terminal/wire selection
Incorrect applicator adjustment
Asymmetric
crimp
Unacceptable
formation excessive
flash and/or cracks
Wire size too large
Wire size too small
Terminal feed
incorrectly adjusted
Anvil and crimper
not aligned or worn
Crimp barrel
does not close
Legs too close
to bottom of crimp.
Insufficient deformation of strands,
showing voids
VI
All specifications subject to change. Consult TE Connectivity for latest specifications.
Incorrect crimp height adjustment
Crimp height
too loose
Crimp height
too tight
Insufficient
deformation,
showing voids
Flash at under
side of crimp,
due to over crimping
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Quality Guidelines
WIRE CRIMP
Correct
Test
Bellmouth must always be present
Insulation Present
WIRE CRIMP
Crimp height measurement
Conductor Present
Bellmouth Permissible
Locking lances and terminal
body not deformed
Cut off tabs present
Correct selection of wire, terminal and applicator
Crimp heights and tolerances
For crimp height tolerances for any given
contact, please refer to the relevant
application specification.
Examples:
Crimp barrel is closed, legs support each other
Sufficient gap between legs and bottom of crimp
Contact
Part
No.
Wire
Range
(mm2)
Tolerance
(mm)
Application
Spec.
MQS
962885
962886
0.2–0.5
± 0.03
114-18025
JPT
927775
0.5–1.0
± 0.05
114-18050
JPT
927773
1.5–2.5
± 0.05
114-18050
All strands are equally distributed and deformed
INSULATION CRIMP
Correct Insulation Diameter, Applicator and Terminal
F-CRIMP
Digital Crimp Height Micrometer
(0.001 mm increments) acc. to DIN ISO 9001
Part No. 547203-1
Insulation is securely held
Crimp barrel closed
OVERLAP CRIMP
For double wire applications with different size wires always place wire with
smallest outer diameter in the bottom
INSULATION CRIMP
Insulation is securely held
Legs overlap
Wire crimp without conductor
°
30
WRAP OVER
CRIMP
°
30
Insulation securely held
Legs must pass each other
Insulation must be
securely held
after bend test
All specifications subject to change. Consult TE Connectivity for latest specifications.
VII
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Restriction on the Use of Hazardous Substances (RoHS)
Restriction on the Use
of Hazardous Substances
(RoHS)
At TE Connectivity, we’re ready to support your RoHS requirements. We’ve assessed more than
1.5 million end items/components for RoHS compliance, and issued new part numbers where
any change was required to eliminate the restricted materials. Part numbers in this catalog are
identified as:
RoHS Compliant
Part numbers in this catalog are RoHS Compliant, unless marked otherwise.
These products comply with European Union Directive 2002/95/EC as amended 1 January 2006
that restricts the use of lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE in certain electrical and electronic products sold into the EU as of 1 July 2006.
Note: For purposes of this Catalog, included within the definition of RoHS Compliant are products
that are clearly “Out of Scope” of the RoHS Directive such as hand tools and other non-electrical
accessories.
Non-RoHS Compliant
These part numbers are identified with a “” symbol. These products do not comply with the
material restrictions of the European Union Directive 2002/95/EC.
5 of 6 Compliant
A “” symbol identifies these part numbers. These products do not fully comply with the European
Union Directive 2002/95/EC because they contain lead in solderable interfaces (they do not
contain any of the other five restricted substances above allowable limits). However, these
products may be suitable for use in RoHS applications where there is an application-based
exception for lead in solders, such as the server, storage, or networking infrastructure exemption.
Note: Information regarding RoHS compliance is provided based on reasonable inquiry of our
suppliers and represents our current actual knowledge based on the information provided by our
suppliers. This information is subject to change. For latest compliance status, refer to our website
referenced below.
Getting the Information You Need
Our comprehensive on-line RoHS Customer Support Center provides a forum to answer your
questions and support your RoHS needs. A RoHS FAQ (Frequently Asked Questions) is available
with links to more detailed information. You can also submit RoHS questions and receive a
response within 24 hours during a normal work week. The Support Center also provides:
■
Cross-Reference from Non-compliant to Compliant Products
■
Ability to browse RoHS Compliant Products in our on-line catalog:
http://www.te.com/commerce/alt/RohsAltHome.do
■
Downloadable Technical Data Customer Information Presentation
■
More detailed information regarding the definitions used above
So whatever your questions when it comes to RoHS, we’ve got the
answers at http://www.te.com/customersupport/rohssupportcenter/
VIII
All specifications subject to change. Consult TE Connectivity for latest specifications.
RoHS
Customer
Support
Center
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
AWG Conversion Table (Average Value)
Conversion Tables
Most of the wire size ranges are
mentioned in mm2, as well as
the insulation diameters which
are in many cases only in mm’s.
We therefore included the
conversion tables on page X
and page XI.
Please note that wire and
insulation sizes are for guidance
only.
Consult the customer drawing
for precise detail.
FLK / FLR Cable
FLK and FLR stand for German
DIN (72551) abbreviations.
FLK means:
In German:
• Fahrzeug Leitung Kunststoff
In English:
• Vehicle Cable Plastic
FLR means:
In German:
• Fahrzeug Leitung Reduziert
In English:
• Thin Walled Cable
(reduced insulation thickness)
AWG Code
Diameter (Inch)
Diameter (mm)
F (mm2)
000000
00000
0000
000
00
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
0.5800
0.5165
0.4600
0.4096
0.3648
0.3249
0.2893
0.2576
0.2294
0.2043
0.1819
0.1620
0.1443
0.1285
0.1144
0.1019
0.0907
0.0808
0.0720
0.0641
0.0571
0.0508
0.0453
0.0403
0.0359
0.0320
0.0285
0.0253
0.0226
0.0201
0.0179
0.0159
0.0142
0.0126
0.0113
0.0100
0.0089
0.0080
0.0071
0.0063
0.0056
0.0050
0.0045
0.0040
0.0035
0.0031
0.0028
0.0025
0.0022
0.00198
0.00176
0.00157
0.00140
0.00124
0.00110
0.00099
14.733
13.130
11.684
10.400
9.270
8.25
7.34
6.55
5.82
5.18
4.62
04.115
3.66
3.26
2.90
2.59
2.30
2.05
1.83
1.63
1.45
1.29
1.14
1.02
0.91
0.81
0.72
0.64
00.57
00.51
00.455
00.400
00.360
00.320
00.287
00.254
00.226
00.203
00.180
00.160
00.142
00.127
00.114
00.101
00.089
00.079
00.071
00.064
00.056
00.050
00.045
00.040
00.036
00.031
00.028
00.025
170.0
135.0
103.8
079.0
067.5
053.4
042.2
33.7
26.6
21.0
16.9
13.25
10.25
8.34
6.6
5.27
4.15
3.3
2.63
2.08
1.65
1.305
1.01
0.79
0.65
0.51
0.407
0.32
0.255
0.205
0.162
0.125
0.102
0.08
0.0646
0.0516
0.04
0.0324
0.0255
0.02
0.0158
0.0127
0.01
0.008
0.0062
0.0049
0.00395
0.00321
0.00246
0.00196
Remark: Starting from 0.03 mm2 (AWG 32) a wire can be crimped.
All specifications subject to change. Consult TE Connectivity for latest specifications.
IX
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Conversion Table – Inch/mm
X
Inch
0
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
0
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
0.0000
0.2540
0.5080
0.7620
1.0160
1.2700
1.5240
1.7780
2.0320
2.2860
2.5400
0.0254
0.2794
0.5334
0.7874
1.0414
1.2954
1.5494
1.8034
2.0574
2.3114
2.5654
0.0508
0.3048
0.5588
0.8128
1.0668
1.3208
1.5748
1.8288
2.0828
2.3368
2.5908
0.0762
0.3302
0.5842
0.8382
1.0922
1.3462
1.6002
1.8542
2.1062
2.3622
2.6162
0.1016
0.3556
0.6096
0.8636
1.1176
1.3716
1.6256
1.8796
2.1336
2.3876
2.6416
0.1270
0.3810
0.6350
0.8890
1.1430
1.3970
1.6510
1.9050
2.1590
2.4130
2.6670
0.1524
0.4064
0.6604
0.9144
1.1684
1.4224
1.6764
1.9304
2.1844
2.4384
2.6924
0.1778
0.4318
0.6858
0.9398
1.1938
1.4478
1.7018
1.9558
2.2098
2.4638
2.7178
0.2032
0.4572
0.7112
0.9652
1.2192
1.4732
1.7272
1.9812
2.2352
2.4892
2.7432
0.2286
0.4826
0.7366
0.9906
1.2446
1.4986
1.7526
2.0066
2.2606
2.5146
2.7686
0.110
0.120
0.130
0.140
0.150
0.160
0.170
0.180
0.190
0.200
2.7940
3.0480
3.3020
3.5560
3.8100
4.0640
4.3180
4.5720
4.8260
5.0800
2.8194
3.0734
3.3274
3.5814
3.8354
4.0894
4.3434
4.5974
4.8514
5.1054
2.8448
3.0988
3.3528
3.6068
3.8608
4.1148
4.3688
4.6228
4.8768
5.1308
2.8702
3.1242
3.3782
3.6322
3.8862
4.1402
4.3942
4.6482
4.9022
5.1562
2.8956
3.1496
3.4036
3.6576
3.9116
4.1656
4.4196
4.6736
4.9276
5.1816
2.9210
3.1750
3.4290
3.6830
3.9370
4.1910
4.4450
4.6990
4.9530
5.2070
2.9464
3.2004
3.4544
3.7084
3.9624
4.2164
4.4704
4.7244
4.9784
5.2324
2.9718
3.2258
3.4798
3.7338
3.9878
4.2418
4.4958
4.7498
5.0038
5.2578
2.9972
3.2512
3.5052
3.7592
4.0132
4.2672
4.5212
4.7752
5.0292
5.2832
3.0226
3.2766
3.5306
3.7846
4.0386
4.2926
4.5466
4.8006
5.0546
5.3086
0.210
0.220
0.230
0.240
0.250
0.260
0.270
0.280
0.290
0.300
5.3340
5.5880
5.8420
6.0960
6.3500
6.6040
6.8580
7.1120
7.3660
7.6200
5.3594
5.6134
5.8674
6.1214
6.3754
6.6294
6.8834
7.1374
7.3914
7.6454
5.3848
5.6388
5.8928
6.1468
6.4008
6.6548
6.9088
7.1628
7.4168
7.6708
5.4102
5.6642
5.9182
6.1722
6.4262
6.6802
6.9342
7.1882
7.4422
7.6962
5.4356
5.6896
5.9436
6.1976
6.4516
6.7056
6.9596
7.2136
7.4676
7.7216
5.4610
5.7150
5.9690
6.2230
6.4770
6.7310
6.9850
7.2390
7.4930
7.7470
5.4864
5.7404
5.9944
6.2484
6.5024
6.7564
7.0104
7.2644
7.5184
7.7724
5.5118
5.7658
6.0198
6.2738
6.5278
6.7818
7.0358
7.2898
7.5438
7.7978
5.5372
5.7912
6.0452
6.2992
6.5532
6.8072
7.0612
7.3152
7.5692
7.8232
5.5626
5.8166
6.0706
6.3246
6.5786
6.8326
7.0866
7.3406
7.5946
7.8486
0.310
0.320
0.330
0.340
0.350
0.360
0.370
0.380
0.390
0.400
7.8740
8.1280
8.3820
8.6360
8.8900
9.1440
9.3980
9.6520
9.9060
10.1600
7.8994
8.1534
8.4074
8.6614
8.9154
9.1694
9.4234
9.6774
9.9314
10.1854
7.9248
8.1788
8.4328
8.6868
8.9408
9.1948
9.4488
9.7028
9.9568
10.2108
7.9502
8.2042
8.4582
8.7122
8.9662
9.2202
9.4742
9.7282
9.9822
10.2362
7.9756
8.2296
8.4836
8.7376
8.9916
9.2456
9.4996
9.7536
10.0076
10.2616
8.0010
8.2550
8.5090
8.7630
9.0170
9.2710
9.5250
9.7790
10.0330
10.2870
8.0264
8.2804
8.5344
8.7884
9.0424
9.2964
9.5504
9.8044
10.0584
10.3124
8.0518
8.3058
8.5598
8.8138
9.0678
9.3218
9.5758
9.8298
10.0838
10.3378
8.0772
8.3312
8.5852
8.8392
9.0932
9.3472
9.6012
9.8552
10.1092
10.3632
8.1026
8.3566
8.6106
8.8646
9.1186
9.3726
9.6266
9.8806
10.1346
10.3886
0.410
0.420
0.430
0.440
0.450
0.460
0.470
0.480
0.490
0.500
10.4140
10.6680
10.9220
11.1760
11.4300
11.6840
11.9380
12.1920
12.4460
12.7000
10.4394
10.6934
10.9474
11.2014
11.4554
11.7094
11.9634
12.2174
12.4714
10.4648
10.7188
10.9728
11.2268
11.4808
11.7348
11.9888
12.2428
12.4968
10.4902
10.7442
10.9982
11.2522
11.5062
11.7602
12.0142
12.2682
12.5222
10.5156
10.7696
11.0236
11.2776
11.5316
11.7856
12.0396
12.2936
12.5476
10.5410
10.7950
11.0490
11.3030
11.5510
11.8110
12.0650
12.3190
12.5730
10.5664
10.8204
11.0744
11.3284
11.5824
11.8364
12.0904
12.3444
12.5984
10.5918
10.8458
11.0998
11.3538
11.6078
11.8618
12.1158
12.3698
12.6238
10.6172
10.8712
11.1252
11.3792
11.6332
11.8872
12.1412
12.3952
12.6492
10.6426
10.8966
11.1506
11.4046
11.6586
11.9126
12.1666
12.4206
12.6746
Inch
0
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
All specifications subject to change. Consult TE Connectivity for latest specifications.
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Conversion Table – Inch/mm (continued)
Inch
0
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
0.500
0.510
0.520
0.530
0.540
0.550
0.560
0.570
0.580
0.590
0.600
12.7000
12.9540
13.2080
13.4620
13.7160
13.9700
14.2240
14.4780
14.7320
14.9860
15.2400
12.7254
12.9794
13.2334
13.4874
13.7414
13.9954
14.2494
14.5034
14.7574
15.0114
15.2654
12.7508
13.0048
13.2588
13.5128
13.7668
14.0208
14.2748
14.5288
14.7828
15.0368
15.2908
12.7762
13.0302
13.2842
15.5382
13.7922
14.0462
14.3002
14.5542
14.8082
15.0622
15.3162
12.8016
13.0556
13.3096
13.5636
13.8176
14.0716
14.3256
14.5796
14.8336
15.0876
15.3416
12.8270
13.0810
13.3350
13.5890
13.8430
14.0970
14.3510
14.6050
14.8590
15.1130
15.3670
12.8524
13.1064
13.3604
13.6144
13.8684
14.1224
14.3764
14.6304
14.8844
15.1384
15.3924
12.8778
13.1318
13.3858
13.6398
13.8938
14.1478
14.4018
14.6558
14.9098
15.1638
15.4178
12.9032
13.1572
13.4112
13.6652
13.9192
14.1732
14.4272
14.6812
14.9352
15.1892
15.4432
12.9286
13.1826
13.4366
13.6906
13.9446
14.1986
14.4526
14.7066
14.9606
15.2146
15.4686
0.610
0.620
0.630
0.640
0.650
0.660
0.670
0.680
0.690
0.700
15.4940
15.7480
16.0020
16.2560
16.5100
16.7640
17.0180
17.2720
17.5260
17.7800
15.5194
15.7734
16.0274
16.2814
16.5354
16.7894
17.0434
17.2974
17.5514
17.8054
15.5448
15.7988
16.0528
16.3068
16.5608
16.8148
17.0688
17.3228
17.5768
17.8308
15.5702
15.8242
16.0782
16.3322
16.5862
16.8402
17.0942
17.3482
17.6022
17.8562
15.5956
15.8496
16.1036
16.3576
16.6116
16.8656
17.1196
17.3736
17.6276
17.8816
15.6210
15.8750
16.1290
16.3830
16.6370
16.8910
17.1450
17.3990
17.6530
17.9070
15.6464
15.9004
16.1544
16.4084
16.6624
16.9164
17.1704
17.4244
17.6784
17.9324
15.6718
15.9258
16.1798
16.4338
16.6878
16.9418
17.1958
17.4498
17.7038
17.9528
15.6972
15.9512
16.2052
16.4592
16.7132
16.9672
17.2212
17.4752
17.7292
17.9832
15.7226
15.9766
16.2306
16.4846
16.7386
16.9926
17.2466
17.5006
17.7546
18.0086
0.710
0.720
0.730
0.740
0.750
0.760
0.770
0.780
0.790
0.800
18.0340
18.2880
18.5420
18.7960
19.0500
19.3040
19.5580
19.8120
20.0660
20.3200
18.0594
18.3134
18.5674
18.8214
19.0754
19.3294
19.5834
19.8374
20.0914
20.3454
18.0848
18.3388
18.5928
18.8468
19.1008
19.3548
19.6088
19.8628
20.1168
20.3708
18.1102
18.3642
18.6182
18.8722
19.1262
19.3802
19.6342
19.8882
20.1422
20.3962
18.1356
18.3896
18.6436
18.8976
19.1516
19.4056
19.6596
19.9136
20.1676
20.4216
18.1610
18.4150
18.6690
18.9230
19.1170
19.4310
19.6850
19.9390
20.1930
20.4470
18.1864
18.4404
18.6944
18.9484
19.2024
19.4564
19.7104
19.9644
20.2184
20.4724
18.2118
18.4658
18.7198
18.9738
19.2278
19.4818
19.7358
19.9898
20.2438
20.4978
18.2372
18.4912
18.7452
18.9992
19.2532
19.5072
19.7612
20.0152
20.2692
20.5232
18.2626
19.5166
18.7706
19.0246
19.2786
19.5326
19.7886
20.0406
20.2946
20.5486
0.810
0.820
0.830
0.840
0.850
0.860
0.870
0.880
0.890
0.900
20.5740
20.8280
21.0820
21.3360
21.5900
21.8440
22.0980
22.3520
22.6060
22.8600
20.5994
20.8534
21.1074
21.3614
21.6154
21.8694
22.1234
22.3774
22.6314
22.8854
20.6248
20.8788
21.1328
21.3868
21.6408
21.8948
22.1488
22.4028
22.6568
22.9108
20.6502
20.9042
21.1582
21.4122
21.6662
21.9202
22.1742
22.4282
22.6822
22.9362
20.6756
20.9296
21.1836
21.4376
21.6916
21.9456
22.1996
22.4536
22.7076
22.9616
20.7010
20.9550
21.2090
21.4630
21.7170
21.9710
22.2250
22.4790
22.7330
22.9870
20.7264
20.9804
21.2344
21.4884
21.7424
21.9964
22.2504
22.5044
22.7584
23.0124
20.7518
21.0058
21.2598
21.5138
21.7678
22.0218
22.2758
22.5298
22.7838
23.0378
20.7772
21.0312
21.2852
21.5392
21.7932
22.0472
22.3012
22.5552
22.8092
23.0632
20.8026
21.0566
21.3106
21.5646
21.8186
22.0726
22.3266
22.5806
22.8346
23.0886
0.910
0.920
0.930
0.940
0.950
0.960
0.970
0.980
0.990
1.000
23.1140
23.3680
23.6220
23.8760
24.1300
24.3840
24.6380
24.8920
25.1460
25.4000
23.1394
23.3934
23.6474
23.9014
24.1554
24.4094
24.6634
24.9174
25.1714
23.1648
23.4188
23.6728
23.9268
24.1808
24.4348
24.6888
24.9428
25.1968
23.1902
23.4442
23.6982
23.9522
24.2062
24.4602
24.7142
24.9682
25.2222
23.2156
23.4696
23.7236
23.9776
24.2316
24.4856
24.7396
24.9936
25.2476
23.2410
23.4950
23.7490
24.0030
24.2570
24.5110
24.7650
25.0190
25.2730
23.2664
23.5204
23.7744
24.0284
24.2824
24.5364
24.7904
25.0444
25.2984
23.2918
23.5458
23.7998
24.0538
24.3078
24.5618
24.8158
25.0698
25.3228
23.3172
23.5712
23.8252
24.0792
24.3332
24.5812
24.8412
25.0952
25.3492
23.3426
23.5966
23.8506
24.1046
24.3586
24.6126
24.8666
25.1206
25.3746
Inch
0
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
0.009
All specifications subject to change. Consult TE Connectivity for latest specifications.
XI
T E AU TO M OT I V E
Page
Wire and Cable Products
Introduction
1
The TE Connectivity’s Raychem Approach
2
Core Technologies
3–6
Cross Reference to DIN/ISO Part Numbering
7
Wire and Cable Applications
9
150 °C Rated T4 Class D Thin-Wall Engine Harness Wire
10 – 11
200 °C Rated T6, Class F Thin-Wall and Ultra Thin-Wall Engine Harness Wire
12 – 13
150 °C and 200 °C Cost Effective Battery and Power Cables
14 – 15
Lower Cost and Thinner Lighting Wires
16 – 17
Low Cost, Highly Fluid-Resistant Automatic Transmission Wire
18 – 19
High Performance Diesel Engine Injector Wires and Cables
20 – 21
Cost Competitive, Custom-Designed Engine Sensor Cables
22 – 23
High Performance ABS Cables
24 – 25
High Performance Truck Databus Cables to SAE J1939 Requirements
26 – 27
XII
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
THE PRODUCTS
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
XIII
T E AU TO M OT I V E
Page
Wire and Cable Products
ACW0219 – Automotive Composite Wire
30 – 31
ACW0229 – Automotive Composite Wire
32 – 33
55E0119
34 – 35
55E0219
36 – 37
ATF ✱0✱ 11
38 – 39
ASC – Automotive Sensor Cables
40 – 41
Power Cables
42 – 43
✓
✓
✓
✓
✓
✓
✓
✓
Packaging of Primary Wires
45
✓
Barrels
46
Niehoff Spools
47
Wooden Reels
48
Restriction on the Use of Hazardous Substances (RoHS)
49
Disclaimer and Trademarks
50
Wire and Cable Data Sheets
XIV
29
✓
✓
✓
✓
THE PRODUCTS
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
XV
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
XVI
All specifications subject to change. Consult TE Connectivity for latest specifications.
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Introduction
TE Connectivity’s Raychem
offers a wide range of
high performance wire
and cables that are
designed to meet or
exceed the most rigorous
automotive specs. Our
wire and cable products
use innovative materials
and are engineered to
be light-weight whilst
offering a cost effective
solution.
TE Connectivity’s Raychem
brand of Automotive Wire and
Cable products is recognized
worldwide, and is backed by
a history of proven performance, reliability, innovation and
superior quality.
For over forty-five years,
customers have recognized
the global capabilities of
TE Connectivity’s Raychem
products. Combining these advanced products with superior
technical support and a global
sales/services organization,
customers with worldwide
operations count on TE
Connectivity’s Raychem to
supply the knowledge and
products they need to solve
specific problems and help
them take advantage of opportunities, anywhere they arise.
1
This philosophy has earned
TE Connectivity’s Raychem
a reputation for leadership in
materials science technologies.
Developed from these technologies, TE Connectivity’s
Raychem high performance
Automotive Wires and Cables
perform from –40 °C to
+200 °C. They are engineered
to meet or exceed the most
rigorous automotive specifications, and are the solution for
challenging environments and
demanding applications.
All specifications subject to change. Consult TE Connectivity for latest specifications.
This catalog brings together
some of the unique, tried
and tested technologies pioneered by TE Connectivity’s
Raychem. Materials with
unique properties, manufacturing techniques finely honed
with experience and research
and development expertise
combine to provide some of
the most innovative Automotive
Wires and Cables today.
1
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
The TE Connectivity’s Raychem Approach
200°C
PFA
150°C
PTFE
($/k
m)
FEP
Pric
e
55E
ETFE
TPE
ACW
XLPE
PP
PVC
Performance (Temperature Class)
The TE Connectivity’s Raychem
brand started to produce wires in
the late 50s by introducing two
new technologies in the market:
Irradiation cross-linking and
dual-wall insulation systems
combining two different polymers
to offer the best benefits of both.
The “chem” in our brand comes
from chemistry, our product
development team are continuously looking for new ways to
enhance the performance of
“off-the-shelf” materials.
Our strategy was, and still is,
to add value to the market by
offering products which outperform commodities either in
cost or in properties to provide
the best value alternative to a
given specification.
2
This is what the graph above
shows:
■ 55E is the T6 wire offering
the best balance of cost/performance, in the automotive
market and we achieved it by
chemically modifying the
base polymer and then crosslinking it using an e-beam.
■ ACW is the T4 wire offering
the best balance of cost/performance, in the automotive
market and we achieved it by
creating a dual-wall insulation
system, chemically modified
and also e-beam irradiated.
A key factor in the success of
ACW is the fact that the two
walls are bonded and behave
as a single insulation during
the handling processes in
harness shops.
All specifications subject to change. Consult TE Connectivity for latest specifications.
2
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Core Technologies
TE Connectivity’s Raychem
Wire and Cable Technology:
Materials Challenges –
Leading Edge Solutions
Pioneers in Automotive
Wire and Cable
55E Wire: 200 °C Automotive
Engine Compartment Wire
TE Connectivity’s Raychem has
pioneered, since the 1950’s,
many of the breakthrough technologies used to create today’s
most advanced insulation/protection systems. TE Connectivity’s
Raychem products are in service
throughout the world in automotive, telecommunications,
power distribution, aerospace
and defence applications.
TE Connectivity’s Raychem was
the first company to commercialize radiation cross-linking of
insulation, initially for aerospace
applications. The high-performance technologies developed
were later adapted and further
developed for high-volume
automotive applications.
Maintaining its position as the
pre-eminent force in radiation
cross-linked insulation materials
to the present day.
First developed by TE Connectivity’s
Raychem for the aerospace industry, where ultra-reliability is a
must, the predecessor of this wire
has been in service in commercial
and military aircraft for the past
30 years with an unparalleled
safety record. It is a cross-linked
fluoropolymer insulation, and as
such, maintains an excellent
balance of properties at extremes
of temperature.
Renowned for their unrivalled
performance and reliability in the
most demanding of environments,
they include a comprehensive
range of Automotive Wire and
Cable products. Combined with
TE Connectivity’s Raychem stateof-the-art manufacturing facilities
and processes, these products
offer the most cost-effective and
robust solution to all your wiring
and interconnection needs.
In its automotive version, it
possesses superior robustness,
markability and overmolding characteristics to rival insulation
types, and is essentially immune
to all forms of chemical attack
by automotive fluids.
ACW: Automotive Composite Wire – Dual layer bonded insulation technology
Copper conductor
3
Polyolefin inner
insulation
Fluoropolymer outer insulation
layer for outstanding mechanical
and chemical resistance
All specifications subject to change. Consult TE Connectivity for latest specifications.
3
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Core Technologies
ACW Wire:
The Leader in Dual Wall
Technology for 150 °C
Automotive Applications
In the 1960s, TE Connectivity’s
Raychem developed the first
successful dual-layer insulation,
balancing some key performance
advantages of fluoropolymer
materials, with some of the cost
advantages of polyolefin insulation. This was achieved by
extruding a fluoropolymer outer
layer over an inner layer of
polyolefin insulation, and crosslinking the resulting product.
In the late 1990s, TE Connectivity’s
Raychem took this technology to
the next level, inventing a way to
bond these seemingly incompatible layers together, to create
a true composite insulation structure for the first time. In fact the
name “ACW” stands for
“Automotive Composite Wire”.
This breakthrough enabled
TE Connectivity’s Raychem to
provide the automotive industry
with an outstandingly robust and
cost-effective product, with
some critical advantages over
competing technologies (including non-bonded “lookalike”
products).
In addition to meeting the most
demanding 150 °C specifications,
the product possesses superb
automated handling and stripping
characteristics. As a result of
these benefits, ACW has quickly
become the dominant 150 °C
wire in use today by OEMs, and
its use continues to grow.
4
What is Radiation Cross-Linking?
Uncross-linked polymer chains in insulation immediately after extrusion:
Long chain molecules are free to slide over each other – polymer can be melted.
To cross-link the insulation, high energy electrons are fired at it in a special chamber:
Reactive sites are created on the
polymer chains. These sites may
combine with other sites on adjacent
polymer chains, linking them together.
The resulting structure is a network of linked molecules:
This acts as a single giant molecule. Because the chains are no longer free to move over one
another, the cross-linked molecules will not melt.
All specifications subject to change. Consult TE Connectivity for latest specifications.
4
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Core Technologies
TE Connectivity’s Raychem
Product Design Philosophy
• Innovation is Key:
We don’t focus on “me too”
products. We concentrate instead
on adding significant technology,
cost, and quality benefits to our
customers. We achieve this by
taking a radical approach to
product design, focussing on
the optimum solution for the
application, rather than on the
characteristics of existing
solutions.
As part of our advanced product development facility we have a
comprehensive suite of analytical equipment that aids product design.
Picture: Scanning electron microscope
During product development wires are tested against many requirements
outside of the OEMs specification. The way the wire behaves in the
many harness shop processes is critical to the design.
Picture: Ultrasonic welding machine
5
• Testing Products to their
Limits and Beyond:
We ensure the robustness of our
products by extensive testing,
not just to customers specification
requirements, but well beyond
them, to ensure that we fully
understand the performance
envelope of our products. Thus
we ensure that the claims we
make for the reliability and
performance of our wire and
cable products can be backed
up by hard experimental data.
• Meeting the Customer’s
Real Needs:
We have long recognised that a
great product need not only meet
the formal specifications, but also
a whole range of performance
characteristics. We have conducted extensive work with
a range of customers to define
these characteristics, and in
conjunction with them, have
developed our own “handling
specification”, an internal requirement which we ensure our
products pass before we release
them commercially. This document comprises a rigorous series
of tests, often under extreme
conditions. It assesses a wire’s
ability to pass successfully
through all the major operations
(e.g. cutting, stripping,
termination, welding) to which it
is likely to be subjected during
the manufacture of harnesses,
or installation into a vehicle.
All specifications subject to change. Consult TE Connectivity for latest specifications.
• Continuous Improvement:
We visit our customers frequently,
to ensure their ongoing satisfaction with our products, and
are always keen to listen to their
views on any further refinements
they would like to see. We also
continuously review the performance and competitiveness of
our products, and introduce
efficiency, quality, and/or technical improvements with every
iteration. Thus we ensure that
our customers are able to benefit
from TECHNICALLY advanced
products, and we aim always to
provide products with the leading price/performance ratio in
each temperature class.
• Commitment to Quality:
Our ISO TS 16949 approved
manufacturing plants are able
to provide guaranteed quality
products, manufactured to the
most demanding performance
and dimensional specifications
on precision extrusion and
processing equipment.
5
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Core Technologies
Summary
Quality/Environment
TE Connectivity’s Raychem –
Technical Leadership in the
Wire and Cable Industry
End of Life
Vehicles Directive
Declarable and Restricted
Materials Reporting
All of our products (in this
catalog – must be specific and
must be checked) meet the
requirements of the published
EC Directive on “End of Life
Vehicles”, 2000/53/EC, in that
they do not contain cadmium,
mercury, lead or hexavalent
chromium.
Our standard electronic reporting
method for product material
content, including declarable or
restricted materials, is via the
International Material Data
System (IMDS), by means of
Material Data Sheet (MDS)
submissions to our customers
upon request or new part
approval.
■ We were pioneers of radiation cross-linking, and one
of the leading supplier of
such products worldwide.
■ All our major product lines
use insulation formulations
developed in-house, and
tailored to give optimum
performance for each
specific need.
■ When we develop any new
product, we test it well
beyond the limits of
international and OEM
specifications, to ensure
that it will not only exceed
expectations in service, but
will be as easy to process
and install as possible.
According to amendment reference 2002/525/EC of Directive
2000/53/EC, we do not declare
materials below a maximum
concentration value up to 0.1%
by weight for lead, hexavalent
chromium and mercury and
up to 0.01% by weight for
cadmium, if these substances
are not intentionally introduced.
■ We employ state-of-the-art
manufacturing techniques
to ensure that consistent
product quality is achieved.
In the IMDS, all materials used
for car manufacture are archived
and maintained. Only in this
way is it possible to meet the
obligations placed on car
manufacturers, and thus on
their suppliers, by national and
international standards, laws and
regulations.
Compliance with other OEM’s
material reporting requirements
is maintained by submission of
relevant declaration forms as
required against individual OEM
specifications.
■ We provide comprehensive
handling guidelines with
our products, and our
expert technical support
team is always on hand to
respond to any technical
queries that may arise.
6
All specifications subject to change. Consult TE Connectivity for latest specifications.
6
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Color Code Cross Reference
Color Coding Chart
0
Black
1
Brown
2
Red
2L
Pink
3
Orange
4
Yellow
45
Yellow/Green
5
Green
6
Blue
7
Violet
8
Gray
9
White
(✱) to ACW0219-0.50-✱
ACW0219
Ordering Example:
ACW0219-0.50-54
The “ ✱ ” in the part number
shall be replaced by a standard
numerical color code designator
as per above.
Additional number after base
color indicates stripe:
e.g. ACW0219-0.50-54 is a green
base color with yellow stripe.
Where stripes are required the
wire carries two co-extruded
longitudinal stripes of the same
color.
The individual stripe width is a
minimum of 10 % of the wire
circumference with an overall
stripe coverage of 30 % maximum.
7
All specifications subject to change. Consult TE Connectivity for latest specifications.
7
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
8
All specifications subject to change. Consult TE Connectivity for latest specifications.
8
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
Automotive
Wire and Cable
Application Documents
9
All specifications subject to change. Consult TE Connectivity for latest specifications.
9
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
150 °C Rated T4
Class D Thin-Wall
Engine Harness Wire
TE Connectivity’s Raychem ACW
is mechanically tough and
provides smaller, lighter
150 °C engine harness wires.
Its high performance fluoropolymer outer layer provides
excellent fluid resistance.
The Challenge Facing
Manufacturers
The need for 150˚C rated engine
harness wires may occur
throughout the engine compartment. These wires have to
withstand attack from a range
of automotive fluids, including
water, antifreeze, brake fluid and
engine oil. These fluids can often
be trapped or kept in contact
with the harness at high temperatures. Engine oil, in particular,
can be very harmful to some
wire insulation types when hot.
Manufacturers need tough, yet
flexible wires, able to meet fluid
resistance requirements across
the operating temperature range.
The wire must be fully compatible
with the wide variety of automated handling equipment used
in harness assembly plants.
Conventional Solutions
Benefits
ETFE insulated wires offer
excellent mechanical strength
and fluid resistance, but are
expensive compared to other
insulation types. Polyester wires
offer good performance and low
cost, but can react adversely with
a number of different materials
commonly found in the engine
compartment. Cross-linked
polyethylene insulated wires
offer limited mechanical protection, poor resistance to oil and
are not sufficiently mechanically
robust to be used in thin-wall
constructions.
■ Lower unit cost – at true
T4 performance level.
The TE Connectivity’s Raychem
Solution
TE Connectivity’s Raychem ACW
is a composite construction with
a tough radiation cross-linked
fluoropolymer outer layer.
This outer layer is bonded to a
radiation cross-linked polyolefin.
■ Smaller, lighter more flexible
wires – providing easier
installation.
■ Designed to be compatible
with typical wire-handling
equipment used in harness
shops through the unique
bonding of the two layers.
■ High level of compatibility
with materials used in the
harnessing process.
■ Thin-wall designs – providing
improved handling and space
savings and manufactured
connector compatibility
benefits.
■ Low friction characteristics –
slides over bundles (resists
blocking at high temperatures).
TE Connectivity’s Raychem
Products
■ ACW
10
All specifications subject to change. Consult TE Connectivity for latest specifications.
10
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem ACW
ACW is a dual-wall automotive
wire with a polyalkene inner
layer and a tough fluoropolymer
outer layer. The unique bonding
between the dissimilar inner and
outer layers of ACW give the
additional benefit of substantial
improvement in the mechanical
performance of the wire.
Product Features
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Unique bonded composite-wall
insulation system
■ Tough, fluoropolymer outer
jacket
■ Superior fluid resistance
compared to cross-linked
polyolefins
■ Compatible with all harness
components
■ Available in thin wall
dimensions only
■ Very cost competitive
■ Mechanically tough
■ Designed to be compatible
with all harness shop
processes
For full technical information
on TE Connectivity’s Raychem
ACW please see pages 30–33.
11
All specifications subject to change. Consult TE Connectivity for latest specifications.
11
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
200 °C Rated T6,
Class F Thin-Wall
and Ultra Thin-Wall
Engine Harness Wire
Using TE Connectivity’s Raychem
high performance fluoropolymer
insulations provide smaller,
lighter and lower cost 200 °C
engine harness wires and is
particularly suitable for
environments with aggressive
fluids, such as hot oils.
The Challenge Facing
Manufacturers
200 °C engine harness wires are
usually specified for the hottest
underbonnet areas in cars.
These include wires running in
close proximity to the exhaust
system, wires in the link between
the Lambda (O2) sensor to the
ECU and wires inside the engine
cover in applications such as
common diesel injection, direct
injection, and electronic valves.
As well as high temperatures,
200 °C engine harness wires
must also be capable of coping
with engine movement and
vibration and resist automotive
fluids. Wire cost is, of course,
a critical issue for manufacturers,
but additional requirements
often include good flexibility,
reduced flammability, improved
handling and strippability.
12
Conventional Solutions
Many manufacturers use PTFE
and FEP insulated wires in
200 °C applications, however,
these materials are expensive
and have a number of problems.
PTFE offers poor mechanical
cut-through performance and as
a result, is often overprotected,
increasing costs still further.
In addition, PTFE and FEP cannot
be supplied in thin-wall wire
designs, which provide improved
handling, space savings and
constructional benefits,
particularly when designing
miniaturized connectors. PTFE
and FEP are also both susceptible
to cold flow.
It is important that wires do not
melt if in contact with a hot
surface for a period of time.
FEP insulated wires may exhibit
short circuit failure on contact
with hot surfaces such as exhaust
systems, since the uncrosslinked insulation will melt.
The TE Connectivity’s Raychem
Solution
Using tough advanced, TE
Connectivity’s Raychem radiation
cross-linked fluoropolymer insulation, offers exceptional high
temperature performance and
resistance to hot surface damage.
It also increases safety in case
of accidental contact with hot
surfaces, with a lower unit
cost compared to alternative
fluoropolymer solutions. The
tough mechanical characteristics
also allows TE Connectivity’s
Raychem to produce these wires
in thin-wall constructions,
providing superior harness shop
processing as well as significant
space and weight savings, whilst
offering the opportunity to
remove overprotection.
TE Connectivity’s Raychem
Products
Benefits
■ Lower unit cost at true
T6 performance level.
■ Designed to be compatible
with typical wire handling
equipment used in harness
shops.
■ Smaller, lighter wires –
with the same temperature
performance.
■ Thin-wall designs – providing
improved handling, space
savings and miniaturized
connector compatibility
benefits.
■ Improved mechanical and
abrasion performance –
compared to PTFE and FEP.
■ Irradiation cross-linked
insulation does not melt when
touching hot surfaces.
■ Offers the opportunity to
remove costly overprotection.
■ 55E Wire
All specifications subject to change. Consult TE Connectivity for latest specifications.
12
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem
55E Wire
TE Connectivity’s Raychem 55E
is a modified radiation crosslinked fluoropolymer insulated
wire combining flexibility for
easy handling with excellent all
round performance.
It has a high temperature rating
and the thin-wall construction
allows high wiring densities to
be achieved. TE Connectivity’s
Raychem 55E is easy to install
and can be processed using
standard lead preparation
equipment.
Product Features
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Mechanically tough across
operating temperature range
■ Resistance to hot surface
damage, e.g. accidental
contact with exhaust manifolds
■ Outstanding resistance to
automotive fluids
■ Small size, light-weight
■ Superior cold-flow and
cut-through performance
compared to PTFE or FEP
■ Solder iron resistance
For full technical information on
TE Connectivity’s Raychem 55E
wire please see pages 34–37.
13
All specifications subject to change. Consult TE Connectivity for latest specifications.
13
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
150 °C and 200 °C
Cost Effective Battery
and Power Cables
Tough TE Connectivity’s
Raychem modified polymer
insulated power cables can
cost-effectively replace
cables that require subsequent,
expensive overprotection
The Challenge Facing
Manufacturers
Conventional Solutions
The TE Connectivity’s Raychem
Solution
Automotive power cables, running from the alternator to the
battery, the battery to the starter
motor, the battery to the fuse
box, or when used in electric
vehicles such as motor wiring
can carry high current.
Cables carrying these high
currents present a significant
fire risk particularly if they short
circuit against other components
or the vehicle frame. Insulation
systems must therefore offer
adequate abrasion and cutthrough resistance in the automotive environment. This entails
resistance to automotive fluids
and extremes of temperature.
Temperature requirements vary
according to the routing of the
cable, the cable cross-section and
the current loading. The graph on
next page shows typical current
rating curves for 105 °C, 125 °C,
150 °C and 200 °C for 25 mm2
power cables in free air.
There is often a trade off between
the maximum permitted temperature of the insulation system, the
size of conductor used and the
level of mechanical overprotection
required.
PVC or silicone insulations are
traditionally used for power
cables in cars, however, their
poor mechanical strength and
abrasion resistance means they
usually have to be provided
with some form of thick overprotection, adding costs.
Cross-linked polyethylene insulation systems offer enhanced
performance over PVC but they
are costly and offer poor mechanical performance above the
crystalline melting point of polyethylene (~127 °C). Short-term
current ratings of these cables
are therefore very limited.
Battery cable currents peak when
the starter motor is turned but
the running load on these cables
is also considerable due to the
requirement to smooth power
consumption. New applications
including electrical heating place
high current drains on the battery
whilst the engine is not running.
It is therefore critical to consider
not only the ambient temperature
but also the temperature rise due
to resistance heating in the cable
when choosing the insulation
system.
14
All specifications subject to change. Consult TE Connectivity for latest specifications.
For 150 °C applications TE
Connectivity’s Raychem bonded
dual-wall technology offers a
unique combination of a crosslinked polyalkene inner layer and
a tough fluropolymer outer layer.
The result is a highly flexible
cable that is resistant to automotive fluids and mechanical
abuse at 150 °C and for shortterm excursions well above this
temperature.
Benefits
■ Reduced need for overprotection – through increased
abrasion resistance
■ Higher current rating at a
given ambient temperature
■ Safe operation during shortterm high current loading
■ Flexible for easy handling
Occasionally power cables must
withstand extreme temperatures.
In these cases TE Connectivity’s
Raychem offer a modified fluoroelastomer insulation system
that can be rated at 200 °C for
3000 hours in the automotive
environment.
TE Connectivity’s Raychem
Products
■ ACW
■ MPCB
■ HTPC
14
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem ACW
TE Connectivity’s Raychem MPCB
TE Connectivity’s Raychem HTPC
ACW is a dual-wall automotive
wire with a polyalkene inner layer
and a tough fluoropolymer outer
layer. The recently developed
unique bonding between the
dissimilar inner and outer layers
of ACW give the additional benefit
of substantial improvement in
the mechanical performance of
the wire.
MPCB has been developed to
offer cost-effective solutions for
power distributions in the car.
HTPC has been developed to
offer cost-effective solutions for
power distributions in the car.
Product Features
Product Features
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Available in reduced wall only
■ Available in reduced wall only
■ Very cost competitive
■ Very cost competitive
■ Mechanically tough
■ Mechanically tough
■ Outstanding resistance to
automotive fluids
■ Outstanding resistance to
automotive fluids
■ Compatible with all harness
components
■ Compatible with all harness
components
■ Light-weight
■ Light-weight
For full technical information on
TE Connectivity’s Raychem MPCB
please see pages 42–43.
For full technical information
on TE Connectivity’s Raychem
HTPC please see pages 42–43.
Product Features
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Unique bonded composite-wall
insulation system
■ Tough, fluoropolymer outer
jacket
■ Superior fluid resistance
compared to cross-linked
polyolefins
■ Compatible with all harness
components
■ Available in thin wall
dimensions only
■ Very cost competitive
■ Mechanically tough
■ Designed to be compatible with
all harness shop processes
For full technical information on
TE Connectivity’s Raychem ACW
please see pages 30–33.
300
Maximum operating current (Amps)
200°C
250
150°C
125°C
200
150
100
105°C
50
Typical data for
25 mm2 power cable
0
0
25
50
75
100
125
150
175
200
Temperature (°C)
15
All specifications subject to change. Consult TE Connectivity for latest specifications.
15
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
Lower Cost and
Thinner Lighting Wires
TE Connectivity’s Raychem
high performance insulations
systems provide smaller,
lighter and lower cost high
temperature lighting wires
The Challenge Facing
Manufacturers
Vehicle head lamp and fog lamp
housings frequently contain
many wires – both to power and
control the lamp itself and to
connect associated components
such as light valves and adjusting
motors. Lamp housings get
extremely hot and insulation
materials capable of withstanding
high temperatures for sustained
periods are often required.
Small wire size can also be an
advantage for manufacturers in
helping to reduce lamp housing
sizes, and good flexibility is
essential to aid the installation
of wires, lamps and connectors
in enclosed lamp surrounds.
Conventional Solutions
Many manufacturers use ETFE
and fluoropolymer insulated
wires in high temperature
lighting applications, however,
these materials are expensive.
Silicon insulated wires are often
used in fog lamp housings due
to their low cost and excellent
flexibility. However, silicon offers
poor mechanical performance
and poor resistance to fluids
leading to the use of additional
expensive overprotection.
The TE Connectivity’s Raychem
Solution
TE Connectivity’s Raychem tough
insulations offer exceptional high
temperature performance with
lower unit costs compared to
ETFE and fluoropolymer insulated
designs. The properties of these
insulations also allows TE
Connectivity’s Raychem to
provide smaller wires for ease
of handling and installation in
crowded lighting housings.
TE Connectivity’s Raychem
Products
■ ACW
Benefits
■ High temperature lighting
wires – at a lower unit cost
compared to ETFE and
fluoropolymer designs.
■ Smaller, lighter wires –
providing improved handling
and space savings in enclosed
lighting housings.
■ Available in thin-wall designs
– with screening if required.
■ Improved mechanical performance compared to silicon
insulated wires – eliminating
the need for costly overprotection.
■ Compatible with wire-handling
equipment used in harness
shops.
■ ASC’s
16
All specifications subject to change. Consult TE Connectivity for latest specifications.
16
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem ACW
TE Connectivity’s Raychem ASC’s
ACW is a dual-wall automotive
wire with a polyalkene inner
layer and a tough fluoropolymer
outer layer. The unique bonding
between the dissimilar inner and
outer layers of ACW give the
additional benefit of substantial
improvement in the mechanical
performance of the wire.
TE Connectivity’s Raychem automotive signal wires can be constructed to meet the most
demanding lighting wire applications. The wide choice of components, screening options and
jacket materials means cables
can be tailored to suit virtually
any combination of temperature,
flexibility, screening and mechanical protection requirements.
Product Features
Product Features
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Unique bonded composite-wall
insulation system
■ Choice of conductors, screens
and jacket materials to suit
the most demanding lighting
and engine sensor applications
■ Tough, fluoropolymer outer
jacket
■ Superior fluid resistance
compared to cross-linked
polyolefins
■ Compatible with all harness
components
■ Available in thin wall
dimensions only
■ Very cost competitive
■ Screening options include
bare copper braid, braid with
drainwire, optimised braids
with guaranteed superior
surface transfer impedance
characteristics, and aluminum
foil with drainwire
■ Jacket material options to
provide high flexibility and
excellent mechanical protection
■ Mechanically tough
■ High diesel fuel resistance
■ Designed to be compatible
with all harness shop
processes
■ Designed for stripping and
over-molding
■ Choice of cable dimensions
For full technical information on
TE Connectivity’s Raychem ACW
please see pages 30–33.
■ Preferred Component Wires:
• ACW0219 – 150 °C rating
• 44E0119 – 150 °C rating
• 44E0111 – 150 °C rating
• FLTA0119 – 150 °C rating
• FLTA0111 – 150 °C rating
• 55E0119 – 200°C rating
■ Preferred Jackets:
• ACJ general purpose cable
• jacket – 150 °C rating
• Fluoroelastomer – 200 °C
• rating
For full technical information on
TE Connectivity’s Raychem ASC
please see pages 40–41.
17
All specifications subject to change. Consult TE Connectivity for latest specifications.
17
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
Low Cost, Highly FluidResistant Automatic
Transmission Wire
TE Connectivity’s Raychem
insulated ATF wire has
outstanding resistance
to automatic transmission fluid
and offers significantly reduced
wire costs compared with ETFE
and other fluoropolymer
insulated wires.
This wire has been approved for
use by US based OEM’s as an
automatic transmission wire.
The Challenge Facing
Manufacturers
Today’s automatic gearbox is a
complex electronically controlled
device which typically contains
sensors for speed, fluid temperature, fluid pressure and a range
of other functions. These sensors
are connected to an outside ECU
via several meters of wires inside
the gearbox. Internal gearbox
wires are often immersed in hot,
aggressive transmission fluid
which can rapidly degrade
standard polymer insulations.
Manufacturers have traditionally
selected high performance
polymer insulations which carry
significant cost penalties.
18
Conventional Solutions
The TE Automotive Solution
Benefits
ETFE and other fluoropolymer
insulation wires are often used
in automatic transmission
gearbox applications to provide
the necessary transmission
fluid-resistant performance.
However, these materials are
expensive and can present
significant cost penalties since
between 10 and 20 meters of
wire may be contained in an
automatic gearbox.
Using TE Connectivity’s Raychem
ATF wire which is a specially
modified radiation cross-linked
fluoropolymer material with
excellent long term performance
when immersed in hot automatic
transmission fluid. ATF wires
provide similar transmission
fluid-resistant performance to
ETFE and PTFE materials, but at
a lower price.
■ Reduces automatic
transmission wire costs
■ Outstanding resistance to
automatic transmission fluid
■ Mechanically tough –
to withstand shop processing
and in-service needs
TE Connectivity’s Raychem
Products
■ ATF Wire
All specifications subject to change. Consult TE Connectivity for latest specifications.
18
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem
ATF Wire
ATF wire is specifically designed
for electronic automatic
transmission applications and
combines durability with excellent
fluid resistance and thermally
stable insulation materials.
TE Connectivity’s Raychem
ATF wire provides a similar
performance to fluoropolymer
wires, at a lower price and is
easy to handle using standard
lead preparation equipment.
Product Features
■ Temperature rating –40 °C to
+150 °C (3000 hrs)
■ Outstanding transmission
fluid resistance
■ Light-weight, small size
For full technical information on
TE Connectivity’s Raychem ATF
Wire please see pages 38–39.
19
All specifications subject to change. Consult TE Connectivity for latest specifications.
19
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
High Performance
Diesel Engine Injector
Wires and Cables
TE Connectivity’s Raychem
diesel resistant cables
provide mechanical and diesel
fuel-resistant performance
comparable with fluoropolymer
cables, but at a lower price
The Challenge Facing
Manufacturers
In both – cars and trucks, the
injectors and the pump are connected to the electronic control
unit by wires or cables. These
wires and cables can come into
contact with hot diesel fuel and
mist which is very aggressive
and capable of weakening most
insulation materials.
Cables may also need to be
compatible with overmolding
processes where protection is
placed over the injector and
pump terminations. This places
further demands on cable
insulation materials and cable
production processes.
Conventional Solutions
Fluoropolymer insulations such
as FEP and PTFE are often used
on wires in this application to
provide resistance against diesel
fuel. However, these materials
are expensive and offer lower
levels of mechanical performance
compared to TE Connectivity’s
Raychem 55E or ACW options.
These conventional materials
also possess a vulnerability to
cold flow under conditions of
pressure, even below the crystalline melting point of the polymer.
TE Connectivity’s Raychem
Products
■ ACW
■ 55E
■ ASC’s with cross-linked
fluoroelastomer jacket
20
The TE Connectivity’s Raychem
Solution
Using TE Connectivity’s Raychem
55E and ACW wire which are both
radiation cross-linked modified
polymer insulation systems.
The polymer formulations
combined with the cross-linked
structure offer many benefits in
this application.
The fluid resistance of the insulation is improved, with increased
resistance to swelling of the
insulation in the presence of hot
oil and fuels. Cold flow is also
arrested by the cross-linking
process, improving the long
term performance of the wire.
TE Connectivity’s Raychem wires
have been extensively trialled
through automated handling
procedures. TE Connectivity’s
Raychem can also supply long
continuous lengths of wire and
cable to facilitate low cost
assembly.
All specifications subject to change. Consult TE Connectivity for latest specifications.
Benefits
■ Superior price/performance
ratio
■ Higher temperature, diesel
fuel resistance and pinch
resistance – than PVC and
cross-linked polyethylene
cables
■ Smaller size and lighter
weight – compared to PVC
and cross-linked polyethylene
cables
■ Balance of flexibility and
toughness
■ High column strengths –
aiding plugging of terminals
into connectors
■ Temperature ratings
to +200 °C
■ Compatible with overmolding
processes used for sensors
■ Outstanding diesel fuel
resistance
20
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem
ACW Wire
TE Connectivity’s Raychem
55E Wire
ACW is a dual-wall automotive
wire with a polyalkene inner
layer and a tough fluoropolymer
outer layer. The unique bonding
between the dissimilar inner and
outer layers of ACW give the
additional benefit of substantial
improvement in the mechanical
performance of the wire.
TE Connectivity’s Raychem 55E is
a modified radiation cross-linked
ETFE insulated wire combining
flexibility for easy handling with
excellent all round performance.
TE Connectivity’s Raychem 55E
is compatible with modern highdensity connectors and its wire
constructions are around 10 %
lighter than other ETFE, FEP and
PTFE-based wire systems.
Product Features
Product Features
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Unique bonded composite-wall
insulation system
■ Mechanically tough across
operating temperature range
■ Tough, fluoropolymer outer
jacket
■ Resistance to hot surface
damage, e.g. accidental
contact with exhaust manifolds
TE Connectivity’s Raychem
ASC with Radiation Cross-Linked
Modified Fluoroelastomer Jacket
TE Connectivity’s Raychem
automotive signal wires can be
combined with a radiation crosslinked modified fluoroelastomer
outer jacket to provide an extremely flexible cable with excellent
diesel fuel resistance.
Product Features
■ Superior fluid resistance
compared to cross-linked
polyolefins
■ Compatible with all harness
components
■ Outstanding resistance to
automotive fluids
■ Small size, light-weight
■ Available in thin wall
dimensions only
■ Superior cold-flow and cut
through performance
compared to PTFE or FEP
■ Very cost competitive
■ Solder iron resistance
■ Available in twisted pairs and
triples
■ Choice of conductors, screens
and jacket materials to suit
the most demanding lighting
and engine sensor applications
■ Screening options include
bare copper braid, braid with
drainwire, optimised braids
with superior surface transfer
impedance characteristics,
and aluminum foil with
drainwire
■ Jacket material options to
provide high flexibility and
excellent mechanical protection
■ Outstanding diesel fuel
resistance
■ Mechanically tough
■ Designed to be compatible
with all harness shop
processes
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
For full technical information
on TE Connectivity’s Raychem
55E Wire please see pages
34–37.
For full technical information
on TE Connectivity’s Raychem
ACW Wire please see pages
30–33.
■ Designed for stripping and
over-molding
■ Choice of cable dimensions
■ Preferred Component Wires:
• ACW0219 – 150 °C rating
• 44E0119 – 150 °C rating
• 44E0111 – 150 °C rating
• FLTA0119 – 150 °C rating
• FLTA0111 – 150 °C rating
• 55E0119 – 200°C rating
■ Preferred Jackets:
• ACJ general purpose cable
• jacket – 150 °C rating
• Fluoroelastomer – 200 °C
• rating
For full technical information
on TE Connectivity’s Raychem
ASC Cable please see pages
40–41.
21
All specifications subject to change. Consult TE Connectivity for latest specifications.
21
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
Cost Competitive,
Custom-Designed
Engine Sensor Cables
TE Connectivity’s Raychem’s
wide choice of components,
screening options and
jacket materials
offer manufacturers the
advantages of custom-designed
engine sensor cables, even
for low volume applications.
The Challenge Facing
Manufacturers
Modern car engines are now universally electronically controlled.
The car’s ECU receives data from
a range of engine sensors which
monitor functions such as water
and oil temperature, crankshaft
speed and position, fuel pump
pressure and ignition settings.
These sensors are connected to
the ECU via cables which plug
into the main harness. Each cable
is highly application specific and
needs to be constructed to withstand a particular set of environmental factors, from exposure to
fluids, to high temperatures and
mechanical abuse. In addition to
this many of these cables carry
sensitive electronic signals prone
to electromagnetic interference,
and high levels of screening are
often required to ensure the
signal integrity.
The TE Connectivity’s Raychem
Solution
A low cost range of products
with a wide choice of insulations,
components, jackets and screens
is required to allow cables to
be individually tailored to meet
specific needs.
TE Connectivity’s Raychem
combines its advanced materials
technology and robust manufacturing processes with its proven
design capabilities to offer:
Conventional Solutions
■ A choice of components and
jacket materials to match
demanding requirements.
Conventional engine sensor
cable products tend to be based
around a limited choice of
insulation or jacket materials –
typically fluoropolymers for
higher temperatures and polyurethane, polyethylene or PVCbased constructions for lower
temperatures. Inevitably this
approach leads to compromise
solutions – either in terms of
cable size, weight and stiffness,
or excessive cable cost.
■ Custom-designed engine
sensor cables, also available
for lower volume applications.
Benefits
■ Smaller cables providing
easier handling and space
savings
■ Lower unit cost at the true
performance level required
■ Compatible with wire-handling
equipment used in harness
shops
■ Compatible with over-molding
processes and materials used
in sensor assembly
■ The manufacturing capability
to make handleable, overmoldable cables.
■ The EMC expertise to deal
with all screening and
compatibility issues.
TE Connectivity’s Raychem
Products
■ ASC’s
■ ACW 6 Series
22
All specifications subject to change. Consult TE Connectivity for latest specifications.
22
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem
ASC’s
TE Connectivity’s Raychem
ACW 4 & 6 Series
TE Connectivity’s Raychem
automotive sensor cables can
be constructed to meet the most
demanding applications. The
wide choice of components,
screening options and jacket
materials means cables can be
tailored to suit virtually any
combination of temperature,
flexibility, screening and mechanical protection requirements.
TE Connectivity’s Raychem
standard ranges of T4 unshielded/
shielded sensor cables. Designed
for demanding engine and drivetrain applications, these cables
are light-weight and offer excellent temperature resistance.
Product Features
Product Features
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Choice of conductors, screens
and jacket materials to suit
the most demanding lighting
and engine sensor applications
■ Screening options include
bare copper braid, braid with
drainwire, optimised braids
with superior surface transfer
impedance characteristics,
and aluminum foil with
drainwire
■ Jacket material options to
provide high flexibility and
excellent mechanical protection
■ Outstanding diesel fuel
resistance
■ Designed for stripping and
over-molding
■ Continuous operating
temperature from –40 °C to
+150 °C (3000 hrs)
■ Choice of PET wrap or
aluminum foil screen with
drainwire termination
■ Available in a range of
conductor cross sections
with up to four ACW
component wires.
■ Small overall diameter for
light-weight and space savings
For full technical information
on TE Connectivity’s Raychem
ACW 4 & 6 Series Cable please
see pages 40–41.
■ Choice of cable dimensions
■ Preferred Component Wires:
• ACW0219 – 150 °C rating
• 44E0119 – 150 °C rating
• 44E0111 – 150 °C rating
• FLTA0119 – 150 °C rating
• FLTA0111 – 150 °C rating
• 55E0119 – 200°C rating
■ Preferred Jackets:
• ACJ general purpose cable
• jacket – 150 °C rating
• Fluoroelastomer – 200 °C
• rating
For full technical information
on TE Connectivity’s Raychem
ASC Cable please see pages
40–41.
23
All specifications subject to change. Consult TE Connectivity for latest specifications.
23
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
High Performance
ABS Cables
High performance
TE Connectivity’s Raychem
sensor cable insulations,
allow the use of smaller
and lower cost conductors,
and provide enhanced flex life
The Challenge Facing
Manufacturers
ABS sensor cables – connecting
the wheel sensor to the extension
wire and onto the ECU – flex
millions of times during their
lifetime. They are also exposed
to a high degree of abrasion and
mechanical damage – caused
by flying stones and gravel.
Conventional Solutions
Most sensor cables use thickwall insulations to achieve the
required level of performance.
These insulations are typically
uncross-linked and are susceptible to melting if subjected
to thermal overload. The use of
thick-wall insulations result in
large cable designs, that restrict
the routing and positioning
options of the cable.
TE Connectivity’s Raychem
Products
■ ASC’s
24
The TE Connectivity’s Raychem
Solution
Using TE Connectivity’s Raychem
high performance irradiation
cross-linked insulation materials
in both the jacket and cable
components. The cross-linking
means that the cable is capable
of surviving excursions well
above the maximum continuous
service temperature for short
periods of time without melting.
The same tough, durable insulation allows the construction of
miniaturized cables with the
same copper section, providing
cheaper cables which are more
flexible, smaller and easier to
install.
All specifications subject to change. Consult TE Connectivity for latest specifications.
Benefits
■ Resistance to high temperature
excursions without melting
■ Low cost at the true
performance level required
■ Provides smaller, more flexible
cables that are easier to handle
and install
■ Tough durable insulations
with outstanding mechanical
and abrasion performance
■ Compatible with high-speed,
high temperature overmolding
machines
24
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem ASC’s
TE Connectivity’s Raychem
automotive sensor cables can be
constructed to meet the most
demanding applications. The
wide choice of components,
screening options and jacket
materials means cables can be
tailored to suit virtually any
combination of temperature,
flexibility, screening and mechanical protection requirements.
Product Features
■ Continuous operating
temperature from –40 °C to
+200 °C (3000 hrs)
■ Choice of conductors, screens
and jacket materials to suit
the most demanding lighting
and engine sensor applications
■ Screening options include
bare copper braid, braid with
drainwire, optimised braids
with superior surface transfer
impedance characteristics,
and aluminum foil with
drainwire
■ Jacket material options to
provide high flexibility and
excellent mechanical protection
■ Outstanding diesel fuel
resistance
■ Designed for stripping and
over-molding
■ Choice of cable dimensions
■ Preferred Component Wires:
• ACW0219 – 150 °C rating
• 44E0119 – 150 °C rating
• 44E0111 – 150 °C rating
• FLTA0119 – 150 °C rating
• FLTA0111 – 150 °C rating
• 55E0119 – 200°C rating
■ Preferred Jackets:
• ACJ general purpose cable
• jacket – 150 °C rating
• Fluoroelastomer – 200 °C
• rating
For full technical information
on TE Connectivity’s Raychem
ASC Cable please see pages
40–41.
25
All specifications subject to change. Consult TE Connectivity for latest specifications.
25
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
High Performance
Truck Databus Cables
to SAE J1939
Requirements
SAE J1939 sets new standards
for databus cabling in
commercial vehicles and
supports the complex information
gathering systems that will be
fitted to tomorrow’s trucks
The Challenge Facing
Manufacturers
The TE Connectivity’s Raychem
Solution
Benefits of TE Connectivity’s
Raychem SAE J1939 Cables
The search for improved vehicle
reliability means sensors are often
fitted to provide data on a range
of functions such as trailer tyre
pressures, freezer compartment
temperatures, braking system
performance, liftgate position and
suspension control. These sensors
are connected by cable back to a
central computer.
■ Highly flexible – screened
versions are more flexible than
alternatives through elimination of inner jackets and use
of special low permittivity
dielectric constant materials.
Satellite tracking and theft protection systems are also increasingly
being used, adding to the number
of wiring circuits required. Multiplexing reduces the numbers of
wires, sensors and actuators
needed to provide information and
allows large amounts of information to be transmitted through a
single twisted pair cable.
US specification SAE J1939 has
been recently introduced and
provides a protocol and system to
provide the functions described
above. The SAE J1939 system
needs a twisted pair cable, usually
screened with tightly controlled
impedance in order to operate.
Using TE Connectivity’s Raychem
SAE J1939 which is a small,
light-weight data cable with the
capacity to handle more information on trucks using less wiring
and less hardware. SAE J1939
provides a standard defining
architecture and protocol and
can be used for serial control
and communications networks.
TE Connectivity’s Raychem has
developed cables to meet the demanding electrical requirements
of SAE J1939 with its high data
rates of 25,000 baud per second.
These cables are constructed with
a tough radiation cross-linked
jacket with a specially formed
light-weight primary wire to give
excellent resistance to diesel fuel
and other fluids.
The unique characteristics of
TE Connectivity’s Raychem dielectric material offer the design
of a screened cable construction
with no inner jacket, improved
flexibility and reduced savings
compared to alternatives.
26
All specifications subject to change. Consult TE Connectivity for latest specifications.
■ Cost effective – simplified
construction leads to cost
benefits.
■ Easy to terminate – elimination of inner jacket reduced
termination costs.
■ Excellent screening performance – screened (recommended) and unscreened
cable designs available.
■ Light-weight – TE Connectivity’s
Raychem SAE J1939 cables
offers weight savings over
alternatives.
Benefits of TE Connectivity’s
Raychem SAE J1939 Databus
System
■ Handles more information –
with less wiring and less
hardware.
■ Improves data gathering on
trucks – allowing new systems
to be introduced.
■ Provides new diagnostic
capabilities and new repair
procedures – enhancing
vehicle reliability.
■ Allows common diagnostic
procedures and methods to be
developed – improving fault
identification and streamlining servicing procedures.
■ High speed information –
with baud rate of 25,000 bits
per second.
TE Connectivity’s Raychem
Products
■ SAE J1939 data cable
26
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Interconnection Wiring
TE Connectivity’s Raychem
SAE J1939 Data Cable
Foamed dielectrics are employed
to reduce weight and to minimize
cable diameters. SAE J1939 has
a tough radiation cross-linked
jacket which provides excellent
fluid resistance and is compatible
with over-molding processes.
Product Features
■ Continuous operating
temperature from –40 °C to
+125 °C (3000 hrs)
■ Excellent screening
performance
■ Small size and light-weight
■ SAE J1939 is a 120 Ohm
impedance twisted pair cable
available in screened and
unscreened versions.
For full technical information
on TE Connectivity’s Raychem
SAE J1939 data cables please
contact your TE Connectivity
Raychem representative.
27
All specifications subject to change. Consult TE Connectivity for latest specifications.
27
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
28
All specifications subject to change. Consult TE Connectivity for latest specifications.
28
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Automotive Wires
Automotive
Wire and Cable
Data Sheets
29
All specifications subject to change. Consult TE Connectivity for latest specifications.
29
Wire and Cable Products
ACW Automotive Composite Wire – ACW0219
Catalog 1654295-3
Revised 6-2012
Thin-Wall 150°C Automotive Engine Harness Wire ISO 6722 Class D
Product Features
■ T4 Rated
(3000 hours @ 150°C)
■ Unique dual-wall,
bonded insulation
■ Mechanically tough
■ Excellent resistance at high
temperature to engine fluids
■ Designed to be compatible with
all harness shop processes
■ Proven high level of compatibility with materials used
in the harnessing process
■ 50 Volts. Thin-wall
■ Available in twisted pairs and
triples
ACW or Automotive Composite
Wall wire was developed to be
the most cost effective wire in the
150 °C D class. It was designed
to meet both the requirements
of the OEMs and the harness
shops. The product is dual-wall
in construction using a modified
polyalkene inner layer and a high
performance fluoropolymer outer.
This combination of materials
offers outstanding performance
at optimum cost. What differentiates ACW from other dual-wall
technologies is the bonding that
joins the two layers together.
The unique bonding technology
ensures that the insulation
behaves as a single layered
product.
The ACW bonding increases the
resistance to mechanical damage
during harness manufacture that
has been the down side to conventional dual-wall technologies.
Taking advantage of the inherent
flexibility of the polyalkene inner
layer ACW offers excellent
handleability.
With conventional dual-wall
technologies another risk exists.
If the outer layer is damaged it
is feasible that fluids, like
windscreen wiper solution, can
wick down the interface of the
insulation to the connector
resulting in system interference
or failure.
The bonding prevents this
happening with ACW. ACW offers
a significant cost saving versus
traditional 150 °C wires like ETFE,
superior performance versus
cross-linked polyethylene and
vastly superior hydrolytic stability
versus polyesters. ACW is
approved and used by many
OEMs and is available in barrels
and Maschinenfabrik Niehoff
GmbH & Co. KG packaging
formats.
Ordering Information
Insulation – Radiation cross-linked, modified, polyalkene blend
Jacket –
Radiation cross-linked, modified fluoropolymer
Conductor –
Bare copper
Conductor
Part Number
CSA
ACW0219-0.35-✱
ACW0219-0.50-✱
ACW0219-0.75-✱
ACW0219-1.00-✱
ACW0219-1.50-✱
ACW0219-2.50-✱
ACW0219-4.0-✱
ACW0219-6.0-✱
ACW0219-10.0-✱
(mm2)
0.35
0.50
0.75
1.00
1.50
2.50
4.00
6.00
10.00
Stranding
Numbers/
Diameter
(mm)
7/0.25
19/0.18
19/0.23
19/0.25
19/0.31
19/0.42
56/0.30
84/0.30
80/0.40
Diameter
Maximum
(mm)
0.90
1.00
1.20
1.35
1.70
2.20
2.75
3.30
4.50
Minimum
Overall
Insulation
Thickness
(mm)
0.20
0.22
0.24
0.24
0.24
0.28
0.32
0.32
0.48
Code
0
1
2
2L
Maximum
Resistance
@ 20°C
(ohms/km)
52.00
37.10
24.70
18.50
12.70
7.60
4.70
3.10
1.82
Color
Orange
Yellow
Green
Blue
Finished Wire
Diameter
Lower
Spec.
Target
Limit
(mm)
(mm)
1.20
1.30
1.40
1.50
1.70
1.80
1.90
2.00
2.20
2.30
2.70
2.85
3.40
3.60
4.00
4.20
5.50
5.80
Code
3
4
5
6
Upper
Spec.
Limit
(mm)
1.40
1.60
1.90
2.10
2.40
3.00
3.70
4.30
6.00
Color
Violet
Gray
White
Approximate
Weight
(kg/km)
4.50
6.00
9.40
11.00
16.00
25.00
40.00
61.00
104.00
Copper
Weight
for
Information
(kg/km)
3.20
4.40
6.70
8.80
13.00
21.50
35.80
53.90
92.70
Standard Colors
Color
Black
Brown
Red
Pink
Code
7
8
9
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
Additional number after base color indicates stripe. e.g. ACW0219-0.50-96 is a white base color with blue stripe.
Where stripes are required the wire carries two co-extruded longitudinal stripes of the same color.
The individual stripe width is a minimum of 10 % of the wire circumference with an overall stripe coverage of
30 % maximum.
ACW0219 is available in twisted pairs and triples.
For e.g. a standard part number will be ACW0229-0.50-0/9- mm2 black and white pair.
30
All specifications subject to change. Consult TE Connectivity for latest specifications.
30
Wire and Cable Products
ACW Automotive Composite Wire – ACW0219
Catalog 1654295-3
Revised 6-2012
Thin-Wall 150°C Automotive Engine Harness Wire ISO 6722 Class D
Typical Properties of ACW0219-0.75
Operating temperature
Voltage
Thermal life
Heat shock
Abrasion (7 N, 0.45 mm radius blade)
Flammability
Insulation strip force
Volume resistivity
Hot oil (ASTM1)
10 minute dip in ASTM oil
Battery acid resistance
Auto transmission fluid (Dexron III)
Ozone resistance (100pphm @ 30°C)
Mycological (28 days @ 30°C)
Hydrolysis
Shrinkage @ 150°C for 15 minutes
PVC tape and wire compatibility
Method
ISO 6722
ISO 6722
ISO 6722
ISO 6722
ISO 6722
ISO 6722
24 hours @ 135°C
1000 hours @ 150°C
20 hours @ RT
20 hours @ 50°C
ISO 6722
BS2 011 Part 2 1J
21 days, 90°C, 48 V
ISO 6722
3000 hours @ 150°C
Typical Value
–40°C to +150°C
50 Volts
3000 hours @ 150°C
> 240 hours @ 175°C
> 1000 cycles
Pass. 45° < 30 seconds
< 40 N
2 x 10 6 Mohms m
No breakdown @ 1 KV for 1 minute
< 1% swell
Pass
Pass
Pass
< 1%
No breakdown @ 1 KV
Specifications
Release Specification:
Related Specifications:
TE Connectivity’s Raychem WSD 1223
FORD Motor Company Global Wire Specification ES-AU5T-1A348-AA
ISO 6722 CLASS D
Fiat Group Automobiles normazione 9.91107
Jaguar Land Rover – Engineering Test Procedure TPJLR.18.007
GM Europe – GM Europe Engineering Standards GME14022
FORD Motor Company – Engineering Specification WSK1A348-A4
ACW0219 Performance Highlights
Suitable for direct routing through high temperature areas without use of additional protection or heat-shields due to its
excellent mechanical properties at elevated temperatures.
Excellent mechanical and high temperature fluid resistance means that ACW is suitable for use in the harsh environment
of the car where 150°C performance is required.
Excellent low temperature performance down to –40°C.
Designed to be compatible with wire handling equipment used by all major manufacturers including ultrasonic welding.
Proven high level of compatibility with materials used in the harnessing process. In particular, pvc tapes and wires.
Tough enough to be used in harnesses without conventional secondary protection giving cost, size and weight savings.
Resistance to wicking of fluids between the interface of the insulation system.
Supplied in barrels or on Maschinenfabrik Niehoff GmbH & Co. KG spools for fast automatic handling and
lead preparation using standard equipment.
For Product Application Information please see Pages 10, 14, 16 and 20.
31
All specifications subject to change. Consult TE Connectivity for latest specifications.
31
Wire and Cable Products
ACW Automotive Composite Wire – ACW0229
Catalog 1654295-3
Revised 6-2012
Hot Oil Resistant Thin-Wall 150°C Automotive Engine Harness Wire ISO 6722 Class D
Product Features
■ T4 Rated
(3000 hours @ 150°C)
■ Unique dual-wall,
bonded insulation
■ Mechanically tough
■ Excellent resistance at high
temperature to engine fluids
■ Designed to be compatible with
all harness shop processes
■ Proven high level of compatibility with materials used
in the harnessing process
■ 50 Volts. Thin-wall
■ Available in twisted pairs and
triples
ACW or Automotive Composite
Wall wire was developed to be
the most cost effective wire in
the 150 °C class. It was designed
to meet both the requirements
of the OEMs and the harness
shops. The product is dual-wall
in construction using a modified
polyalkene inner layer and a high
performance fluoropolymer outer.
This combination of materials
offers outstanding performance
at optimum cost. What differentiates ACW from other dual-wall
technologies is the bonding that
joins the two layers together.
The unique bonding technology
ensures that the insulation
behaves as a single layered
product.
The ACW bonding increases the
resistance to mechanical damage
during harness manufacture that
has been the downside to conventional dual-wall technologies.
Taking advantage of the inherent
flexibility of the polyolefinic inner
layer ACW offers excellent
handleability.
With conventional dual-wall
technologies another risk exists.
If the outer layer is damaged it
is feasible that fluids, like windscreen wiper solution, can wick
down the interface of the insulation to the connector resulting
in system interference or failure.
The bonding prevents this
happening with ACW. ACW offers
a significant cost saving versus
traditional 150 °C wires like ETFE,
superior performance versus
cross-linked polyethylene and
vastly superior hydrolytic stability
versus polyesters. ACW is
approved and used by many
OEMs and is available in barrels
and Maschinenfabrik Niehoff
GmbH & Co. KG packaging
formats.
Ordering Information
Component wire – ACW0229
Finished Wire
Diameter
Part Number
CSA
ACW0229-0-0.50-✱ /✱
(mm2)
0.50
(36MM)
Lay
Length
Nominal
(mm)
36
Target
(mm)
3.0
Upper
Spec.
Limit
(mm)
3.2
Nominal
Weight
(kg/km)
12.6
Copper Weight
for
Information
(kg/km)
9.83
Construction
Lay length tolerance shall be ± 2.0 mm
Performance Requirement
Component wires shall meet all the requirements of the issue in effect of TE Connectivity’s Raychem Specification WSD 1223
Additional Testing
Insulation Flaws: 100% Spark Test on Finished Wire of 5.0 kV High Frequency AC RMS or equivalent
Standard Colors
Color
Black
Brown
Beige
Red
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
Additional number after base color indicates stripe. e.g. ACW0229-0.50-96/45 is a white base color with blue stripe
and yellow base color with green stripe. Where stripes are required the wire carries two co-extruded longitudinal
stripes of the same color.
The individual stripe width is a minimum of 10 % of the wire circumference with an overall stripe coverage of 30 %
maximum.
Code
0
1
1L
2
Color
Pink
Orange
Yellow
Green
Code
2L
3
4
5
Color
Blue
Violet
Gray
White
Code
6
7
8
9
The number in brackets at the end indicates the lay length of the pair.
A description example is: ACW0229-0.50-96/45 (13MM).
This is a twisted pair made of 0.50 sq/mm white/blue and yellow/green wires with a lay length of 13 mm.
32
All specifications subject to change. Consult TE Connectivity for latest specifications.
32
Wire and Cable Products
ACW Automotive Composite Wire – ACW0229
Catalog 1654295-3
Revised 6-2012
Hot Oil Resistant Thin-Wall 150°C Automotive Engine Harness Wire ISO 6722 Class D
Typical Properties of ACW0229-0.75
Operating temperature
Voltage rating
Thermal life
Abrasion (7 N, 0.45 mm radius blade)
Flammability
Flammability
Insulation strip force
Volume resistivity
Hot oil (ASTM 1)
10 minute dip in ASTM oil
Battery acid resistance
Auto Transmission fluid (Dexron III)
Ozone resistance (100 pphm @ 65°C
Mycological (28 days @ 30°C)
Hydrolysis
Shrinkage @ 150°C for 15 minutes
PVC tape and wire compatability
Method
ISO 6722
ISO 6722
ISO 6722
ISO 6722
Renault 36-05-009/-L
ISO 6722
ISO 6722
24 hours @ 135°C
1000 @ 150°C
20 hours @ RT
20 hours @ 50°C
ISO6722
BS 011 Part 2 1J
21 days, 90°C, 48 V
ISO6722
3000 hours @ 150°C
Typical Value
–40°C to +150°C
50 Volts
3000 hours @ 150°C
> 1000 cycles
Pass. 45° < 30 seconds
Pass Vertical
< 45 N
2 x 10 6 Mohns m
No breakdown @ 1 kV for 1 minute
< 1% swell
Pass
Pass
Pass
< 1%
No breakdown @ 1 kV for 1 minute
Specifications
Release Specification:
Related Specifications:
TE Connectivity’s Raychem WSD 1223
FORD Motor Company Global Wire Specification ES-AU5T-1A348-AA
ISO 6722 CLASS D
Fiat Group Automobiles normazione 9.91107
Jaguar Land Rover – Engineering Test Procedure TPJLR.18.007
GM Europe – GM Europe Engineering Standards GME14022
FORD Motor Company – Engineering Specification WSK1A348-A4
ACW0229 Performance Highlights
Suitable for direct routing through high temperature areas without use of additional.
protection or heat-shields due to its excellent mechanical properties at elevated temperatures.
Excellent mechanical and high temperature fluid resistance means that ACW is suitable for use in the harsh environment
of the car where 150°C is required.
Excellent low temperature performance down to –40°C.
Designed to be compatible with wire handling equipment used by all major manufacturers including sonic welding.
Proven high level of compatibility with materials used in the harnessing process. In particular PVC tapes and wires.
Tough enough to be used in harnesses without conventional secondary protection giving cost, size and weight savings.
Resistance to wicking of fluids between the interface of the insulation system.
Supplied in barrels or on Maschinenfabrik Niehoff GmbH & Co. KG spools for fast automatic handling and
lead preparation using standard equipment.
For Product Application Information please see Pages 10, 14, 16 and 20.
33
All specifications subject to change. Consult TE Connectivity for latest specifications.
33
Wire and Cable Products
55E0119
Catalog 1654295-3
Revised 6-2012
High Temperature, High Performance Automotive Wire ISO 6722 Class F
Product Features
■ T4 Rated
(3000 hours @ 200°C)
■ Mechanically tough
■ Excellent resistance to all
known automotive fluids
■ Compatible with all harness
components
■ Excellent harness shop
processability
■ 50 Volts. Ultra thin-wall
■ Excellent solder iron resistance
■ Available in twisted pairs and
triples
TE Connectivity’s Raychem 55E
wire is insulated with a modified
radiation cross-linked fluoropolymer. It has a temperature
rating of –40 °C to +200 °C
(ca. 3000 hours) and combines
the easy handling of a flexible
wire with excellent all round
performance.
Chosen for its balance of proper
ties, TE Connectivity’s Raychem
55E wire has outstanding resistance to chemicals and solvents.
The flame retarded flexible
polymer is easy to handle and
install and can be processed
using standard lead preparation
equipment.
The ultra thin-wall construction
enables high wiring densities
to be achieved and the high
temperature rating enables wire
bundles to be routed through
areas in which conventional wires
cannot be used.
TE Connectivity’s Raychem 55E
is approved and used by many
OEMs and is supplied in barrels
and Maschinenfabrik Niehoff
GmbH & Co. KG packaging
formats.
TE Connectivity’s Raychem 55E
offers excellent overmoldability
versus PTFE and FEP and due to
its cross-linked structure, resistance to melting if in unavoidable
contact with hot metal surfaces
as a result of routing.
TE Connectivity’s Raychem 55E
wire is a cost effective alternative
to PTFE and FEP insulated wires.
Ordering Information
Conductor –
Bare copper
Jacket –
Single wall radiation cross-linked fluoropolymer
Conductor
Part Number
CSA
55E0119-0.35-✱
55E0119-0.50-✱
55E0119-0.60-✱
55E0119-0.75-✱
55E0119-1.0-✱
55E0119-1.5-✱
55E0119-2.0-✱
55E0119-2.5-✱
55E0119-3.0-✱
55E0119-4.0-✱
55E0119-6.0-✱
(mm2)
0.35
0.50
0.60
0.75
1.00
1.50
2.00
2.50
3.00
4.00
6.00
Stranding
Numbers/
Diameter
(mm)
7/0.25
19/0.18
19/0.20
19/0.23
19/0.25
19/0.32
19/0.36
19/0.41
37/0.32
56/0.30
85/0.30
Diameter
Nominal
(mm)
0.75
0.87
0.97
1.06
1.23
1.49
1.73
1.91
2.16
2.42
2.88
Code
0
1
2
2L
Maximum
Resistance
@ 20°C
(ohms/km)
52.00
37.10
31.30
24.70
18.50
12.70
9.80
7.73
6.40
4.70
3.10
Finished Wire
Diameter
Lower
Spec.
Target
Limit
(mm)
(mm)
1.10
1.15
1.21
1.26
1.33
1.38
1.41
1.46
1.57
1.62
1.82
1.88
2.07
2.13
2.29
2.35
2.50
2.56
2.75
2.82
3.20
3.28
Color
Orange
Yellow
Green
Blue
Upper
Spec.
Limit
(mm)
1.20
1.31
1.43
1.51
1.67
1.95
2.20
2.42
2.63
2.88
3.35
Code
3
4
5
6
Nominal
Weight
(kg/km)
4.18
5.54
6.58
7.93
10.15
14.47
18.83
23.51
28.38
37.09
55.73
Color
Violet
Gray
White
Copper Weight
for
Information
(kg/km)
3.25
4.65
5.59
6.90
8.90
13.30
17.56
22.00
27.14
36.00
54.00
Standard Colors
Color
Black
Brown
Red
Pink
Code
7
8
9
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
Additional number after base color indicates stripe. e.g. 55E0119-0.50-96 is a white base color with blue stripe.
Where stripes are required the wire carries two co-extruded longitudinal stripes of the same color.
The individual stripe width is a minimum of 10 % of the wire circumference with an overall stripe coverage of
30 % maximum.
34
All specifications subject to change. Consult TE Connectivity for latest specifications.
34
Wire and Cable Products
55E0119
Catalog 1654295-3
Revised 6-2012
High Temperature, High Performance Automotive Wire ISO 6722 Class F
Typical Properties of 55E0119-1.00
Operating temperature
Voltage rating
Thermal life
Heat shock
Flammability
Shrinkage
Volume resistivity
Cold bend
Thermal overload
Hot oil (ASTM No 1)
IRM 902
IRM 903
Ozone resistance
Transmission oil (BOT 320)
Strip force
Fuel resistance (M15)
Method
ISO 6722
ISO 6722
Fiat 9 91107
ISO 6722
WSD 1254
ISO 6722
WSD 1254
WSD 1254
200 hours @ 200°C
200 hours @ 200°C
200 hours @ 200°C
100 pphm @ 65°C for 192 hours
240 hours @ 155°C
ISO 6722
1000 hours @ 60°C
Typical Value
–40°C to 200°C (3000 hours)
50 Volts
> 300 hours @ 200°C
> 375 hours @ 230°C
Pass. 45° 0 seconds afterburn
Pass (0%) 230°C for 1 hour
2.95 x 10 16 ohms/cm
Pass at -40°C
48 hours @ 255°C
No breakdown @ 1 KV for 1 minute
< 1% swell
Pass. No cracks
< 40 N
Pass < 1% swell
Specifications
Release Specification:
Related Specifications:
TE Connectivity’s Raychem WSD 1254
Fiat Auto normazione 9 91107
ISO 6722 CLASS F
Renault Automobiles 36-05-009/--L
55E0119 Performance Highlights
Suitable for direct routing through high temperature areas without use of additional protection or heat-shields.
Minimal deterioration of performance due to exposure to fluids, and can be used in applications where it is continually
immersed.
Tough enough to be used in harnesses without conventional secondary protection giving cost, size and weight savings.
Improved mechanical and abrasion performance compared to FEP or PTFE.
Superior cold-flow and cut-through performance compared to FEP or PTFE.
Supplied in barrels or on Maschinenfabrik Niehoff GmbH & Co. KG spools for fast automatic handling and
lead preparation using standard equipment.
For Product Application Information please see Pages 12 and 20.
35
All specifications subject to change. Consult TE Connectivity for latest specifications.
35
Wire and Cable Products
55E0219
Catalog 1654295-3
Revised 6-2012
High Temperature, High Performance Automotive Wire ISO 6722 Class F
Product Features
■ T4 Rated
(3000 hours @ 200°C)
■ Mechanically tough
■ Excellent resistance to all
known automotive fluids
■ Compatible with all harness
components
■ Excellent harness shop
processability
■ 50 Volts. Ultra thin-wall
■ Excellent solder iron resistance
■ Available in twisted pairs and
triples
Spec 55E wire is insulated with
a modified radiation crosslinked fluoropolymer. It has a
temperature rating of –40 °C to
+200 °C (3000 hours) and
combines the easy handling of
a flexible wire with excellent all
round performance.
Chosen for its balance of
properties, Spec 55E wire has
outstanding resistance to
chemicals and solvents. The
flame retarded flexible polymer
is easy to handle and install and
can be processed using standard
lead preparation equipment.
The ultra thin-wall construction
enables high wiring densities
to be achieved and the high
temperature rating enables wire
bundles to be routed through
areas in which conventional wires
canno be used.
Spec 55E is approved and used
by many OEMs and is supplied
in barrels and Maschinenfabrik
Niehoff GmbH & Co. KG
packaging formats.
Spec 55E offers excellent overmoldability versus PTFE and
FEP and due to its cross-linked
structure, resistance to melting
if in unavoidable contact with
hot metal surfaces as a result of
routing. Spec 55E wire is a cost
effective alternative to PTFE and
FEP insulated wires.
Ordering Information
Conductor –
Bare copper
Jacket –
Single wall radiation cross-linked fluoropolymer
Conductor
Part Number
CSA
55E0219-0.50-✱
55E0219-0.75-✱
55E0219-1.0-✱
55E0219-1.5-✱
(mm2)
0.50
0.75
1.00
1.50
Stranding
Numbers/
Diameter
(mm)
19/0.18
19/0.23
19/0.25
19/0.32
Diameter
Nominal
(mm)
0.87
1.07
1.23
1.49
Code
0
1
2
2L
Maximum
Resistance
@ 20°C
(ohms/km)
37.10
24.50
18.50
12.70
Finished Wire
Diameter
Lower
Spec.
Target
Limit
(mm)
(mm)
1.40
1.50
1.70
1.80
1.90
2.00
2.20
2.30
Color
Orange
Yellow
Green
Blue
Upper
Spec.
Limit
(mm)
1.60
1.90
2.10
2.40
Code
3
4
5
6
Nominal
Weight
(kg/km)
5.54
9.36
10.20
14.50
Color
Violet
Gray
White
Copper Weight
for
Information
(kg/km)
4.65
6.90
8.90
13.30
Standard Colors
Color
Black
Brown
Red
Pink
Code
7
8
9
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
Additional number after base color indicates stripe. e.g. 55E0219-0.50-96 is a white base color with blue stripe.
Where stripes are required the wire carries two co-extruded longitudinal stripes of the same color.
The individual stripe width is a minimum of 10 % of the wire circumference with an overall stripe coverage
of 30 % maximum.
36
All specifications subject to change. Consult TE Connectivity for latest specifications.
36
Wire and Cable Products
55E0219
Catalog 1654295-3
Revised 6-2012
High Temperature, High Performance Automotive Wire ISO 6722 Class F
Typical Properties of 55E0219-0.50
Operating temperature
Voltage rating
Winding resistance
Adherence of insulation
Flammability
Shrinkage
High temperature
Abrasion
Hot oil (ASTM No 1)
IRM 902
IRM 903
Ozone resistance
Transmission oil (BOT 320)
Strip force
Fuel resistance (M15)
Method
ISO 6722
ISO 6722
ISO 6722 (10-30N)
ISO 6722
WSD 1254
ISO 6722
ISO 6722
200 hours @ 200°C
200 hours @ 200°C
200 hours @ 200°C
100 pphm @ 65°C for 192 hours
240 hours @ 155°C
ISO 6722
1000 hours @ 60°C
Typical Value
–40°C to +200°C (3000 hours)
50 Volts
No damage Pass 1 kV/30 minutes
16.8N
Pass. 45° 0 seconds afterburn
Pass (0%) 230°C for 1 hour
No breakdown up to 3 kV
>500 cycles
No breakdown at 1 kV
for 1 minute
< 1% swell
Pass. No cracks
< 40 N
Pass < 1% swell
Specifications
Release Specification:
Related Specifications:
TE Connectivity’s Raychem WSD 1254
Renault Automobilies 36-05-009/--L
ISO 6722 CLASS F
55E0219 Performance Highlights
Suitable for direct routing through high temperature areas without use of additional over-protection or heat-shields.
Minimal deterioration of performance due to exposure to fluids, and can be used in applications where it is
continually immersed.
Tough enough to be used in harnesses without conventional secondary protection giving cost, size and weight savings.
Improved mechanical and abrasion performance compared to FEP or PTFE.
Superior cold-flow and cut-through performance compared to FEP or PTFE.
Supplied in barrels or on Maschinenfabrik Niehoff GmbH & Co. KG spools for fast automatic handling and
lead preparation using standard equipment.
For Product Application Information please see Pages 12 and 20.
37
All specifications subject to change. Consult TE Connectivity for latest specifications.
37
Wire and Cable Products
ATF ✱ 0 ✱ 11
Catalog 1654295-3
Revised 6-2012
Low Cost, Fluid Resistant Automatic Transmission Wire
Product Features
■ T4 Rated
(3000 hours @ 150°C)
■ Modified radiation cross-linked
fluoropolymer insulation
■ Mechanically tough
■ Outstanding resistance to
automatic transmission fluids
■ Designed to be compatible with
all harness shop processes
■ 600 Volts. Available in various
wall thicknesses
■ Available in twisted pairs and
triples
Today’s electronic automatic
transmissions have exacting
harness component performance
standards. ATF wire is specifically
fabricated for electronic automatic transmission applications.
The combination of durability,
fluid resistance and thermally
stable insulation materials enable
ATF wire to stand up to high
performance demands.
ATF ✱ 0611 is the standard
having a nominal wall thickness
of 0.3 mm whilst ATF0411 has a
wall thickness of 0.35 mm.
ATF wire is designed to be an
alternative to the more expensive
fluoropolymer wires, providing
similar performance at a lower
price. Traditional insulations
include ETFE and PTFE.
ATF is designed to be used in
DC circuits only. ATF wire is
available in sizes 22 to 14 AWG
with conductors using 7, 19 or
37 strands. It is also available in
a range of wall thicknesses.
Ordering Information
Tin plated
conductor
Insulation –
Radiation cross-linked, modified fluoropolymer
Conductor
Part Number
CSA
ATFC0311-22-✱
ATFC0311-20-✱
ATFC0311-18-✱
ATFC0311-16-✱
ATFC0311-14-✱
ATFD0311-16-✱
ATFD0311-14-✱
ATFB0411-20-✱
ATFB0411-18-✱
ATFC0611-21-✱
ATFC0611-20-✱
ATFC0611-18-✱
ATFC0611-16-✱
ATFC0611-14-✱
ATFC0611-16-✱
ATFC0611-14-✱
(mm2)
22
20
18
16
14
14
14
20
18
21
20
18
16
14
16
14
Stranding
Numbers/
Diameter
(mm)
19/34
19/32
19/30
19/29
19/27
37/32
37/32
7/28
19/30
19/33
19/32
19/30
19/29
19/27
19/32
19/30
Diameter
Maximum
(mm)
0.80
1.00
1.19
1.35
1.70
1.42
1.91
0.97
1.19
0.91
0.97
1.19
1.35
1.70
1.42
1.91
Minimum
Overall
Insulation
Thickness
(mm)
0.16
0.16
0.18
0.17
0.21
0.14
0.18
0.32
0.33
0.28
0.28
0.28
0.27
0.26
0.25
0.23
Code
0
1
2
2L
Maximum
Resistance
@ 20°C
(ohms/km)
51.80
33.10
21.00
16.10
10.20
16.40
10.20
34.10
21.00
39.00
33.10
21.00
16.10
10.20
16.40
10.20
Color
Orange
Yellow
Green
Blue
Finished Wire
Diameter
Lower
Spec.
Target
Limit
(mm)
(mm)
1.12
1.17
1.32
1.37
1.55
1.60
1.68
1.75
2.11
2.18
1.70
1.78
2.26
2.36
1.61
1.66
1.84
1.89
1.47
1.52
1.52
1.57
1.75
1.80
1.88
1.96
2.21
2.29
1.91
1.98
2.36
2.46
Code
3
4
5
6
Upper
Spec.
Limit
(mm)
1.22
1.42
1.65
1.83
2.26
1.85
2.46
1.71
1.94
1.57
1.63
1.85
2.03
2.36
2.06
2.57
Color
Violet
Gray
White
Approximate
Weight
(kg/km)
4.46
6.70
9.82
12.20
19.20
12.50
22.50
7.59
11.30
6.92
7.37
10.80
13.30
19.90
13.40
23.10
Standard Colors
Color
Black
Brown
Red
Pink
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
For e.g. ATFC0311-20-6 is a blue 20 AWG wire.
38
All specifications subject to change. Consult TE Connectivity for latest specifications.
Copper
Weight
for
Information
(kg/km)
3.35
5.48
8.51
10.77
16.85
10.96
17.14
5.08
8.51
3.45
5.48
8.51
10.77
16.90
10.96
16.90
Code
7
8
9
38
Wire and Cable Products
ATF ✱ 0 ✱ 11
Catalog 1654295-3
Revised 6-2012
Low Cost, Fluid Resistant Automatic Transmission Wire
Typical Properties of ATFC0311-20Operating temperature
Voltage
Thermal life
Immersion at 150°C in Motorcraft Mercon V
Immersion at 150°C in Exxon H-FN-1975
Immersion at 150°C in Dexron III
Immersion at 150°C in Valvoline II E
Tensile strength before ageing
Tensile strength after ageing
(168 hours @ 200°C)
Elongation before ageing
Elongation after ageing (168 hours @ 200°C)
Pinch resistance
Method
ISO 6722
ISO 6722
1000 hours @ 150°C
1000 hours @ 150°C
1000 hours @ 150°C
> 20.6 Mpa
Typical Value
–40°C to +150°C
600 Volts
3000 hours @ 150°C
3000 hours @ 150°C, 0.8% diameter swell
8000 hours @ 150°C
All pass 2x
4000 hours @ 150°C
mandrel wrap with
12000 hours @ 150°C no cracking etc.
44 Mpa
冧
38 Mpa
150 % minimum
SAE J1128
423 %
411 %
22.3 lbs
Specifications
Release Specification:
TE Connectivity’s Raychem Spec 63
See individual product specification control drawings (SCD)
ATF ✱ 0 ✱ 11 Performance Highlights
Outstanding resistance to automatic transmission fluid.
Excellent mechanical and high temperature fluid resistance means that ATF is suitable for use in the harsh environment
of the car where 150°C performance is required.
Excellent low temperature performance down to –55°C.
Designed to be compatible with wire handling equipment used by all major manufacturers.
To be used in DC circuits only.
For Product Application Information please see Page 18.
39
All specifications subject to change. Consult TE Connectivity for latest specifications.
39
Wire and Cable Products
Automotive Sensor Cables – ASC
Catalog 1654295-3
Revised 6-2012
High Temperature Automotive Sensor Cables
Product Features
■ T4, T6 rated (3000 hours @
150 °C or 200 °C)
■ Choice of component wires
■ Choice of insulation materials
■ Choice of cable dimensions
■ Full range of screening
options
■ Designed for stripping and
overmolding
TE Connectivity’s Raychem
Automotive Sensor Cables (ASCs)
have been developed to offer
harness makers and sensor
manufacturers a robust and
cost-effective solution for sensor
cabling.
These cables are designed to
survive in oil-contaminated high
temperature environments where
they are exposed to abrasion and
constant flexing. The automotive
industry demands that cables
are compatible with high speed
stripping, termination and overmolding processes. Compatibility
with over-molding resins is
fundamental to achieving reliable
sensor assemblies.
TE Connectivity’s Raychem ASC
cables are built on advanced
materials-based technologies:
high performance automotive
150 °C and 200 °C primary wires,
a range of electro-magnetic
screening options and advanced
insulation options.
Using the latest high volume
cable assembly techniques and
TE Connectivity’s Raychem
proprietary processes these
technologies can be married
together to produce cost efffective, high performance cables.
Cable Information
TE Automotive
standard
primary wires
High performance insulation systems
Choice of screening systems
Jacket
Insulation Description
ACJ
Fluoroelastomer
Polymer Base
Cross-linked modified polyolefin
Cross-linked fluoroelastomer
Temperature Rating (°C)
150°C
200°C
Component Wire
Description
Polymer Base
Conductor
FLTA0111/FLTA0119
ACW0219
55E0119
55E0219
Cross-linked PVDF over XLPE
Cross-linked PVDF over XLPE
Cross-linked ETFE
Cross-linked ETFE
Sn/Cu
Cu
Cu
Cu
Screening Options
Description
None
Aluminum/PET wrap
Spiral copper braid
Copper braid
Optimised copper braid
Termination
N/A
Drain wire
Braid or drain wire
SolderSleeve or drain wire
SolderSleeve or drain wire
Cable Examples
Components
Jacket
Screening
2 x FLTA0119-0.50
2 x FLTA0119-0.50
2 x FLTA0111-0.50
2 x ACW0219-0.50
2 x FLTA0119-1.00
2 x 55E0119-0.50
2 x 55E0119-0.50
ACJ
ACJ
ACJ
ACJ
ACJ
Fluoroelastomer
Fluoroelastomer
None
None
None
Aluminum wrap and drain wire
None
None
Optimized copper and drain wire
40
All specifications subject to change. Consult TE Connectivity for latest specifications.
Temperature
Rating (°C)
150°C
150°C
200°C
200°C
Outer Diameter
(mm)
3.2 mm
4.4 mm
4.4 mm
4.4 mm
6.2 mm
4.4 mm
4.4 mm
40
Wire and Cable Products
Automotive Sensor Cables – ASC
Catalog 1654295-3
Revised 6-2012
High Temperature Automotive Sensor Cables
Typical Jacket Properties
Operating temperature
Short-term operating temperature
Cold bend
Flammability
Abrasion (ISO 6722)
Petrol
Diesel
Battery acid
Screenwash fluid
Engine coolant
Transmission fluid
Brake fluid
Engine oil
ACJ
3000 hours @ 150°C
240 hours @ 175°C
–40°C
45° 70 seconds
> 500 cycles
15 minutes @ 23°C < 10% swell
6 hours @ 23°C < 10% swell
6 hours @ 23°C < 10% swell
6 hours @ 23°C < 10% swell
6 hours @ 50°C < 10% swell
6 hours @ 50°C < 10% swell
6 hours @ 50°C < 10% swell
6 hours @ 50°C < 10% swell
Fluoroelastomer
3000 hours @ 200°C
160 hours @ 250°C, 6 hours @ 300°C
–25°C
45° 30 seconds
> 1000 cycles
30 minutes @ 23°C < 1% swell
30 minutes @ 23°C maximum 1% swell
20 hours @ 23°C maximum 1% swell
20 hours @ 23°C maximum 1% swell
20 hours @ 50°C maximum 1% swell
20 hours @ 50°C maximum 1% swell
Not tested in brake fluid
24 hours @ 90°C maximum 1% swell
Specifications
Release Specification:
ASC Performance Highlights
Designed for high-speed automated cutting, stripping and termination.
The jacket materials have proven over-molding characteristics and bond to industry standard molding materials.
ASCs offer appropriate EMC levels for a given system, many modern sensors operate with very low voltages and/or
high frequencies. The increasingly complex EMC environment within a car has lead to significant improvements in
automotive cable screening technologies.
ACW0219 meets the most demanding 150°C primary wire specifications in the world and is widely accepted by OEMs.
55E0119 meets the most demanding 200°C primary wire specifications in the world and is widely accepted by OEMs.
ASCs meet all the existing automotive environmental European legislations.
Suitable for direct routing through high temperature areas without use of additional protection or heat-shields due to
excellent mechanical properties at elevated levels.
Part Number
CSA
(mm2)
No. of
Components
TE Connectivity’s Raychem WSD 1525
TE Connectivity’s Raychem WCD 51
TE Connectivity’s Raychem WSD 1800
TE Connectivity’s Raychem WSD 2366
Overall Diameter (mm)
Minimum
Maximum
Nominal Weight
(kg/km)
Copper Weight
(kg/km)
3.6
4.3
4.5
4.0
4.6
5.0
4.5
5.2
5.7
21.0
28.0
30.0
23.0
28.0
37.0
31.0
43.0
53.0
9.8
14.5
19.0
14.7
19.9
26.1
19.7
29.0
38.0
Standard Range of T4 150 °C Unshielded Cables available
ACW4229-0.35-X/X-0
0.35
2
3.8
4.2
18.1
ACW4229-0.50-X/X-0
0.50
2
4.2
4.6
22.5
ACW4229-0.75-X/X-0
0.75
2
4.8
5.2
28.7
ACW4229-1.00-X/X-0
1.00
2
5.2
5.6
35.2
ACW4239-0.35-X/X/X-0
0.35
3
4.0
4.4
23.2
ACW4239-0.50-X/X/X-0
0.50
3
4.4
4.8
29.1
ACW4239-0.75-X/X/X-0
0.75
3
5.1
5.5
39.0
ACW4239-1.00-X/X/X-0
1.00
3
5.5
5.9
47.1
ACW4249-0.35-X/X/X/X-0
0.35
4
4.3
4.7
30.5
ACW4249-0.50-X/X/X/X-0
0.50
4
4.8
5.2
38.7
ACW4249-0.75-X/X/X/X-0
0.75
4
5.5
5.9
51.3
ACW4249-1.00-X/X/X/X-0
1.00
4
6.0
6.4
62.4
For Product Application Information please see Pages 16, 20, 22 and 24.
6.4
9.2
13.5
17.6
9.6
13.8
20.2
26.4
12.8
18.3
27.0
35.2
Standard Range of T4 150 °C Shielded Cables available
ACW6219-0.50-X-0
0.50
1
ACW6219-0.75-X-0
0.75
1
ACW6219-1.00-X-0
1.00
1
ACW6229-0.50-X/X-0
0.50
2
ACW6229-0.75-X/X-0
0.75
2
ACW6229-1.00-X/X-0
1.00
2
ACW6239-0.50-X/X/X-0
0.50
3
ACW6239-0.75-X/X/X-0
0.75
3
ACW6239-1.00-X/X/X-0
1.00
3
41
4.0
4.7
4.9
4.4
5.0
5.4
4.9
5.6
6.1
All specifications subject to change. Consult TE Connectivity for latest specifications.
41
Wire and Cable Products
Power Cables
Catalog 1654295-3
Revised 6-2012
150°C and 200°C Cost-Effective Battery and Power Cables
Product Features
■ T4, T6 rated (3000 hours)
■ Mechanically tough
■ Excellent resistance to
automotive fluids
■ Compatible with all harness
components
■ Light-weight
■ 600 Volts. Thin-wall
TE Connectivity’s Raychem automotive power cables have been
developed to offer cost-effective
solutions for power distribution
in the car. Often required to carry
several hundred Amps the
insulation must be resistant to
abrasion and cut-through damage
as well as being resistant to
automotive fluids and extremes
of temperature.
The range of insulation materials
offered means that there is a
solution for all routing requirements. Often power cables have
to be routed through high temperature regions. TE Connectivity’s
Raychem power cables have a
solution at 150°C and 200°C.
If flexibility is an issue there are
a range of products available that
take advantage of high strand
count conductors or flexible
insulation materials.
ACW is available. For 4, 6 and
10 sq mm please see ACW0219
datasheet.
If a high level of flexibility is
required fluoroelastomer insulated
power cables are available.
Ordering Information
Conductor –
Bare copper
A choice of jacket –
Dual wall ACW or single wall fluoroelastomer
Conductor
Examples of
Part Number
Insulation
Material
MPCB-16.0-✱
MCPB-20.0-✱
Fluoroelastomer
Fluoroelastomer
CSA
(mm2)
16.00
20.00
Stranding
Numbers/
Diameter
(mm)
133/0.40
259/0.30
Code
0
1
2
2L
Diameter
Maximum
(mm)
5.99
6.20
Maximum
Resistance
@ 20°C
(ohms/km)
1.16
0.96
Color
Orange
Yellow
Green
Blue
Finished Wire
Diameter
Lower
Spec.
Target
Limit
(mm)
(mm)
N/A
N/A
N/A
N/A
Code
3
4
5
6
Upper
Spec.
Limit
(mm)
7.21
7.67
Color
Violet
Gray
White
Copper
Approximate
Weight
(kg/km)
174.00
210.00
Standard Colors
Please note that for some sizes
colors are restricted
Color
Black
Brown
Red
Pink
Ordering Description
The ‘ ✱ ’ in the part number shall be replaced by a standard numerical color code designator as per above.
For e.g. ACW0219-10-0 is a black cable.
42
All specifications subject to change. Consult TE Connectivity for latest specifications.
Weight
for
Information
(kg/km)
150.00
21.00
Code
7
8
9
42
Wire and Cable Products
Power Cables
Catalog 1654295-3
Revised 6-2012
150°C and 200°C Cost-Effective Battery and Power Cables
Typical properties of power cables
Operating temperature
Short-term operating temperature
Cold bend
Flammability
Abrasion (ISO 6722)
Petrol
Diesel
Battery acid
Screenwash fluid
Engine coolant
Transmission fluid
Brake fluid
Engine oil
ACW0219-10-0
3000 hours @ 150°C
240 hours @ 175°C
–40°C
45° 30 seconds
–
30 mins @ 23°C, no breakdown
@ 1 kV, < 1% swell
30 mins @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
–
20 hours @ 50°C, no breakdown
@ 1 kV, < 1% swell
24 hours @ 135°C, no breakdown
@ 1 kV, < 1% swell
–
20 hours @ 50°C, no breakdown
@ 1 kV, < 1% swell
MPCB-16
3000 hours @ 150°C
240 hours @175°C
–40°C
45° 30 seconds
> 3500 cycles (Ford 597)
30 mins @ 23°C, no breakdown
@ 1 kV, < 1% swell
30 mins @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
–
24 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
HTPC-16
3000 hours @ 200°C
240 hours @ 225°C
–40°C
45° 30 seconds
> 3500 cycles (Ford 597)
30 mins @ 23°C, no breakdown
@ 1 kV, < 1% swell
30 mins @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 mins @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 mins @ 23°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
20 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
–
24 hours @ 50°C, no breakdown
@ 1 kV, maximum 1% swell
Specifications
Release Specification:
Related Specifications:
TE Connectivity’s Raychem WSD 1223, 1734 & 2234
ISO 6722
Ford Motor Company – Engineering Specification WSK 1A348-A4
LV112 (2002)
Fiat Group Automobiles normazione 9.91107
Ford Motor Company Global Wire Specification ES-AU5T-1A348-AA
Power Cable Performance Highlights
Suitable for direct routing through high temperature areas without use of additional protection or heat-shields due to
its excellent mechanical properties at elevated temperatures.
Excellent fluid resistance at elevated temperatures.
Easily processable on standard stripping equipment.
Proven high level of compatibility with materials used in the harnessing process. In particular, pvc tapes and wires.
Supplied in barrels or on Maschinenfabrik Niehoff GmbH & Co. KG spools for fast automatic handling and
lead preparation using standard equipment.
For Product Application Information please see Pages 14.
43
All specifications subject to change. Consult TE Connectivity for latest specifications.
43
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
44
All specifications subject to change. Consult TE Connectivity for latest specifications.
44
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Packaging of Primary Wires
Packaging
45
All specifications subject to change. Consult TE Connectivity for latest specifications.
45
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Packaging of Primary Wires
Barrels
Selection Guide by Product
Quantity per pack indicated
46
Benefits
Dimensions
■ Multi use cost effective
returnable package
■ Large volume capacity
■ Compact package
Height: 463 mm
Outer Diameter: 400 mm
Weight: 2.5 kg empty
CSA
55E0119
55E0219
0.35
7.5 km
not available
0.50
7.5 km
5.0 km
0.60
7.5 km
not available
0.75
5.0 km
5.0 km
1.0
5.0 km
4.0 km
1.5
4.0 km
2.5 km
2.0
2.5 km
not available
2.5
2.0 km
not available
3.0
1.5 km
not available
4.0
1.0 km
not available
All specifications subject to change. Consult TE Connectivity for latest specifications.
46
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Packaging of Primary Wires
Maschinenfabrik Niehoff
GmbH & Co. KG Spools
Selection Guide by Product
Quantity per pack indicated
47
Benefits
Dimensions
■ Robust package for long
distance shipment
■ The natural lay of the wire in
the barrel minimizes set
■ Recyclable
Height: 410 mm
Outer Diameter: 500 mm
Core Diameter: 315 mm
Weight: 4.5 kg empty
CSA
ACW
55E
0.35
15.0 km
15.0 km
0.50
10.0 km
10.0 km
0.60
not available
not available
0.75
8.0 km
8.0 km
1.0
6.0 km
6.0 km
1.5
4.0 km
4.0 km
2.0
not available
not available
2.5
3.0 km
3.0 km
All specifications subject to change. Consult TE Connectivity for latest specifications.
47
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Packaging of Primary Wires
Wooden Reels
Pintel hole size: 52 mm
Transport Cradle
X
Y
Z
V
Standard Reel Sizes
Reel
16
24
30
36
48
Flange
Diameter
(Z)
400
600
750
914
1216
External
Width
(X)
320
330
384
492
553
Core
Diameter
(Y)
210
243
302
368
512
Reel
Weight
(kg)
2
6
10
22
65
Cradle
Width
(V)
660
660
711
711
711
Cradle
Weight
(kg)
6
6
9
9
9
All dimensions (in mm) are nominal
Sensor Cables
A standard reel would be selected from reel sizes 16–36 with the actual size being determined by the cable OD,
quantity required and any customer weight limit.
Power Cables
CSA
10
16
25
30
35
50
70
Typical
Outer Dia.
(mm)
6.60
8.00
10.00
10.30
11.00
13.00
15.00
Standard Reel Sizes
16
24
30
Typical Maximum Quantity
(m)
(m)
(m)
450
1250
2250
300
850
1500
200
500
1000
150
500
750
150
400
750
n/a
n/a
500
n/a
n/a
n/a
36
48
(m)
n/a
n/a
n/a
1000
1000
750
500
(m)
n/a
n/a
n/a
n/a
n/a
1000
750
Minimum
Length
(m)
50
50
50
50
50
25
25
Lengths
per Reel
5
5
5
5
5
5
5
• Special reel sizes available based on quantity required and any customer weight limit.
• For cable weight refer to the product data sheet.
48
All specifications subject to change. Consult TE Connectivity for latest specifications.
48
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Restriction on the Use of Hazardous Substances (RoHS)
Restriction on the Use
of Hazardous Substances
(RoHS)
At TE Connectivity, we’re ready to support your RoHS requirements. We’ve assessed more than
1.5 million end items/components for RoHS compliance, and issued new part numbers where
any change was required to eliminate the restricted materials. Part numbers in this catalog are
identified as:
RoHS Compliant
Part numbers in this catalog are RoHS Compliant, unless marked otherwise.
These products comply with European Union Directive 2002/95/EC as amended 1 January 2006
that restricts the use of lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE in certain
electrical and electronic products sold into the EU as of 1 July 2006.
Note: For purposes of this Catalog, included within the definition of RoHS Compliant are products
that are clearly “Out of Scope” of the RoHS Directive such as hand tools and other non-electrical
accessories.
Non-RoHS Compliant
These part numbers are identified with a “” symbol. These products do not comply with the
material restrictions of the European Union Directive 2002/95/EC.
5 of 6 Compliant
A “” symbol identifies these part numbers. These products do not fully comply with the European
Union Directive 2002/95/EC because they contain lead in solderable interfaces (they do not
contain any of the other five restricted substances above allowable limits). However, these
products may be suitable for use in RoHS applications where there is an application-based
exception for lead in solders, such as the server, storage, or networking infrastructure exemption.
Note: Information regarding RoHS compliance is provided based on reasonable inquiry of our
suppliers and represents our current actual knowledge based on the information provided by our
suppliers. This information is subject to change. For latest compliance status, refer to our website
referenced below.
Getting the Information You Need
Our comprehensive on-line RoHS Customer Support Center provides a forum to answer your
questions and support your RoHS needs. A RoHS FAQ (Frequently Asked Questions) is available
with links to more detailed information. You can also submit RoHS questions and receive a
response within 24 hours during a normal work week. The Support Center also provides:
■
Cross-Reference from Non-compliant to Compliant Products
■
Ability to browse RoHS Compliant Products in our on-line catalog:
http://www.te.com/commerce/alt/RohsAltHome.do
■
Downloadable Technical Data Customer Information Presentation
■
More detailed information regarding the definitions used above
RoHS
Customer
Support
Center
So whatever your questions when it comes to RoHS, we’ve got the
answers at http://www.te.com/customersupport/rohssupportcenter/
49
All specifications subject to change. Consult TE Connectivity for latest specifications.
49
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Disclaimer and Trademarks
Disclaimer
While TE has made every reasonable effort to ensure the accuracy of the information in this
catalog, TE does not guarantee that it is error-free, nor does TE make any other representation,
warranty or guarantee that the information is accurate, correct, reliable or current. TE reserves
the right to make any adjustments to the information contained herein at any time without notice.
TE expressly disclaims all implied warranties regarding the information contained herein, including,
but not limited to, any implied warranties of merchantability or fitness for a particular purpose.
The dimensions in this catalog are for reference purposes only and are subject to change without
notice. Specifications are subject to change without notice. Consult TE for the latest dimensions
and design specifications.
www.te.com
www.te.com/automotive
www.te.com/automotive/sensors
www.te.com/automotive/most
RAYCHEM, SolderSleeve, TE Connectivity and TE connectivity (logo) are trademarks.
MOST is a trademark.
Other product names, logos, and company names mentioned herein may be trademarks
of their respective owners.
Copyright 2012. Tyco Electronics AMP GmbH a TE Connectivity Ltd. company,
AMPèrestr. 12–14, 64625 Bensheim / Germany
50
All specifications subject to change. Consult TE Connectivity for latest specifications.
50
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
51
All specifications subject to change. Consult TE Connectivity for latest specifications.
51
Wire and Cable Products
Catalog 1654295-3
Revised 6-2012
Engineering Notes
52
All specifications subject to change. Consult TE Connectivity for latest specifications.
52
Global Contacts
Americas
Argentina – Buenos Aires
Phone: +54-11-4733-2202
Fax:
+54-11-4733-2250
Brasil – São Paulo
Phone: +55-11-2103-6105
Fax:
+55-11-2103-6204
Chile – Santiago
Phone: +56-2-345-0300
Fax:
+56-2-223-1477
Canada – Toronto
Phone: +1-905-475-6222
Fax:
+1-905-474-5520
Product Information Center:
Phone: +1-905-470-4425
Fax:
+1-905-474-5525
Colombia – Bogotá
(Venezuela /Ecuador)
Phone: +57-1-319-8999
Fax:
+57-1-319-8989
Mexico – Mexico City
Phone: +52-55-1106-0800
+01-800-733-8926
Fax:
+52-55-1106-0910
For Latin/South American
Countries not shown
Phone: +54-11-4733-2015
Fax:
+54-11-4733-2083
United States
Harrisburg, PA
Phone: +1-717-564-0100
Fax:
+1-717-986-7575
Product Information Center:
Phone: +1-800-522-6752
Fax:
+1-717-986-7575
Asia/Pacific
Australia – Sydney
Phone: +61-2-9554-2600
Fax:
+61-2-9502-2556
Product Information Center:
Phone: +61-2-9840-8200
Fax:
+61-2-9634-6188
Korea – Seoul
Phone: +82-2-3415-4500
Fax:
+82-2-3486-3810
Indonesia – Jakarta
Phone: +65-6482-0311
Fax:
+65-6482-1012
New Zealand – Auckland
Phone: +64-9-634-4580
Fax:
+64-9-634-4586
Japan – Kawasaki, Kanagawa
Phone: +81-44-844-8111
Fax:
+81-44-812-3207
Philippines – Makati City
Phone: +632-848-0171
Fax:
+632-867-8661
Malaysia – Kuala Lumpur
Phone: +60-3-7805-3055
Fax:
+60-3-7805-3066
People’s Republic of China
Hong Kong
Phone: +852-2738-8731
Fax:
+852-2735-0243
Shanghai
Phone: +86-21-2407-1588
Fax:
+86-21-2407-1599
Singapore – Singapore
Phone: +65-6482-0311
Fax:
+65-6482-1012
Taiwan – Taipei
Phone: +886-2-8768-2788
Fax:
+886-2-8768-2268
Thailand – Bangkok
Phone: +66-2-955-0500
Fax:
+66-2-955-0505
Vietnam – Ho Chi Minh City
Phone: +84-8-930-5546
Fax:
+84-8-930-3443
Europe/Middle East /Africa
Austria – Vienna
Phone: +43-1-905-60-0
Fax:
+43-1-905-60-1333
Product Information Center:
Phone: +43-1-905-60-1228
Fax:
+43-1-905-60-1333
Finland – Helsinki
Phone: +358-95-12-34-20
Fax:
+46-8-50-72-50-01
Product Information Center:
Phone: +46-8-50-72-50-20
Fax:
+46-8-50-72-52-20
Belarus – Minsk
Phone: +375-17-237-47-94
Fax:
+375-17-237-47-94
Product Information Center:
Phone: +7-495-790-7902
Fax:
+7-495-721-1893
France – Cergy-Pontoise Cedex
Phone: +33-1-3420-8888
Fax:
+33-1-3420-8800
Product Information Center:
Phone: +33-1-3420-8686
Fax:
+33-1-3420-8623
Belgium – Kessel-Lo
Phone: +31-73-6246-246
Fax:
+31-73-6212-365
Product Information Center:
Phone: +31-73-6246-999
Fax:
+31-73-6246-998
Bulgaria – Sofia
Phone: +359-2-971-2152
Fax:
+359-2-971-2153
Czech Republic and Slovakia
Czech Republic – Kurim
Phone: +420-541-162-108
Fax:
+420-541-162-104
Product Information Center:
Phone: +420-541-162-113
Fax:
+420-541-162-104
Denmark – Glostrup
Phone: +45-43-48-04-00
Fax:
+46-8-50-72-50-01
Product Information Center:
Phone: +46-8-50-72-50-20
Fax:
+46-8-50-72-52-20
Egypt – Cairo
Phone: +20-2417-7647
Fax:
+20-2419-2334
Estonia – Tartu
Phone: +372-5138-274
Fax:
+372-7400-779
Lithuania and Latvia
Lithuania – Vilnius
Phone: +370-5-213-1402
Fax:
+370-5-213-1403
Netherlands – ’s-Hertogenbosch
Phone: +31-73-6246-246
Fax:
+31-73-6212-365
Product Information Center:
Phone: +31-73-6246-999
Fax:
+31-73-6246-998
South Africa – Port Elizabeth
Phone: +27-41-503-4500
Fax:
+27-41-581-0440
Spain – Barcelona
Phone: +34-93-291-0330
Fax:
+34-93-201-7879
Product Information Center:
Phone: +34-93-291-0366
Fax:
+34-93-209-1030
France Export Divisions –
Cergy-Pontoise Cedex
Phone: +33-1-3420-8866
Fax:
+33-1-3420-8300
Norway – Nesbru
Phone: +47-66-77-88-50
Fax:
+46-8-50-72-50-01
Product Information Center:
Phone: +46-8-50-72-50-20
Fax:
+46-8-50-72-52-20
Sweden – Upplands Väsby
(Switchboard)
Phone: +46-8-50-72-50-00
Fax:
+46-8-50-72-50-01
Product Information Center:
Phone: +46-8-50-72-50-20
Fax:
+46-8-50-72-52-20
Germany – Bensheim
Phone: +49-6251-133-0
Fax:
+49-6251-133-1600
Product Information Center:
Phone: +49-6251-133-1999
Fax:
+49-6251-133-1988
Poland – Warsaw
Phone: +48-22-4576-700
Fax:
+48-22-4576-720
Product Information Center:
Phone: +48-22-4576-704
Fax:
+48-22-4576-720
Switzerland – Steinach
Phone: +41-71-447-0447
Fax:
+41-71-447-0444
Product Information Center:
Phone: +41-71-447-0447
Fax:
+41-71-447-0400
Greece – Athens
Phone: +30-210-9370-396/397
Fax:
+30-210-9370-655
Romania – Bucharest
Phone: +40-21-311-3479/3596
Fax:
+40-21-312-0574
Hungary – Budapest
Phone: +36-1-289-1000
Fax:
+36-1-289-1010
Product Information Center:
Phone: +36-1-289-1016
Fax:
+36-1-289-1017
Russia – Moscow
Phone: +7-495-790-7902
Fax:
+7-495-721-1893
Product Information Center:
Phone: +7-495-790-7902
Fax:
+7-495-721-1893
Turkey – Istanbul
Phone: +90-212-281-8181/2/3
+90-212-282-5130/5430
Fax:
+90-212-281-8184
India – Bangalore
Phone: +91-80-2854-0800
Fax:
+91-80-2854-0814
Italy – Collegno (Torino)
Phone: +39-011-4012-111
Fax:
+39-011-4031-116
Product Information Center:
Phone: +39-011-4012-632
Fax:
+39-011-4028-7632
http://www.te.com/customersupport/support.asp
Russia – Yekaterinburg
Phone: +7-343-2531-153
Fax:
+7-343-2531-152
Russia – Nizhniy Novgorod
Phone: +7-831-220-33-05/-06
Fax:
+7-831-220-33-39/-40
Slovenia – Ljubljana
Phone: +386-1561-3270
Fax:
+386-1561-3240
Ukraine – Kiev
Phone: +380-44-206-2265
Fax:
+380-44-206-2264
Product Information Center:
Phone: +380-44-206-2265
Fax:
+380-44-206-2264
United Kingdom and
Ireland – Swindon
Phone: +44-8706-080208
Fax:
+44-208-954-6234
Product Information Center:
Phone: +44-800-267-666
Fax:
+44-208-420-8095
www.te.com/automotive • www.te.com/automotive/sensors • www.te.com/automotive/most
Tyco Electronics AMP GmbH
a TE Connectivity Ltd. company
AMPèrestr. 12–14
64625 Bensheim/Germany
Phone: +49-(0)6251-133-0
Fax:
+49-(0)6251-133-1600
www.te.com
www.te.com/automotive
www.te.com/automotive/sensors
www.te.com/automotive/most
TE Connectivity and TE connectivity (logo)
are trademarks.
Tyco Electronics AMP GmbH certified
acc. ISO 14001 and ISO/TS 16949:2002
© 2012 Tyco Electronics AMP GmbH
1654295-3 Revised 6-2012 3M ST
工商网监
湘ICP备2023018690号
