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Product

ISO 19642 / LV 216 High-Voltage EV Powertrain CablesISO 19642-5600 V AC / 1000 V DC (extend-40 to +180 °C

FHL2G Automotive High-Voltage CableISO 19642-5 / LV 216 unscreened fine-stranded silicone rubber (2G) orange high-voltage EV

FHL2G is an unscreened automotive high-voltage power cable engineered in accordance with ISO 19642-5 (formerly ISO 6722-1 and German OEM LV 216) for 600 V AC / 1000 V DC (up to 1500 V DC in extended designs) battery electric vehicle (BEV), hybrid (HEV), and co

ISO 19642 Flame
Automotive Fluids
-40 to +180 °C
ISO 19642-5 / LV 216
Order designation
FHL2G 1×16
Nom. OD
8.20 mm
Copper mass
99.8 kg/km
Total mass ≈
172.0 kg/km
Min. bend R
49.2 mm
All sizes (8)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Rated voltage
600 V AC / 1000
Max 1000 V AC / 1500 V DC
Test voltage
5000 V AC (spark
Dielectric withstand
Operating temp
-40 to +180 °C
Short-circuit +250 °C
Min. bend radius
3 × D
Flexing 5 × D
Primary standard
ISO 19642-5
ISO 19642-5 Class E (+180 °C); LV 216-1
Flame rating
ISO 19642-5 / IS
Fire & safety compliance

Typical values for this cable type, based on ISO 19642-5 — confirmed in the datasheet and quotation for your order.

Application fit

Is FHL2G right for your machine?

Used inside EV traction battery packs, battery disconnect units (BDUs), power distribution units (PDUs), and metallic-conduit-enclosed high-voltage harnesses on electric cars, buses, and trucks.

Switchgear & control cabinet wiring

Suitable

Engineered specifically for internal EV traction battery pack busbars, BDU/PDU interconnects, and shielded enclosures

Motor stator, traction & converter leads

Suitable

Suitable for unshielded auxiliary HV components or connections routed inside metallic braided EMC conduits

Fixed installation

Suitable

Ideal for tight-bend 3 × D fixed routing inside battery modules and fuel-cell stacks

Trailing & towing

With conditions

Designed for on-vehicle HV wiring; for external EV charging station cords select H07BZ5-F or DC EV Charging Cable

Typical machinesInternal EV Traction Battery Pack InterconnectsHigh-Voltage Power Distribution Units (PDU / BDU)Commercial Truck & Bus Fuel-Cell Powertrains

Construction

Layer by layer

Extra-flexible fine-stranded bare or tinned copper (FHL per ISO 19642-5 / IEC 60228 Class 5/6); Halogen-free tear-resistant silicone rubber elastomer (2G, ISO 19642 Class E, -40 °C to +180 °C); Single-layer extruded silicone rubber insulation (unscreened); Integral high-visibility safety orange silicone rubber (2G, RAL 2003 / RAL 2008).

123
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1ConductorExtra-flexible fine-stranded bare or tinned copper conductor (FHL)ISO 19642-5
2InsulationInner zone of tear-resistant silicone rubber (2G) dielectricISO 19642-5
3SheathIntegral high-voltage safety orange silicone rubber (2G) outer wall (RAL 2003)ISO 19642-5

Internal EV Traction Battery Pack Interconnects

Connects cell modules, contactors, pyro-fuses, and BMS current shunts inside grounded aluminum battery enclosures where individual cable screening is unnecessary.

High-Voltage Power Distribution Units (PDU / BDU)

Ultra-supple 2G silicone rubber enables 3 × D bend radii inside compact junction boxes without stressing busbar terminals.

Commercial Truck & Bus Fuel-Cell Powertrains

Handles continuous +180 °C thermal environments around DC/DC converters, air compressors, and PTC cabin heaters.

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 19642-5. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage (U0/U)
600 V AC / 1000 V DC (extended 1000 V AC / 1500 V DC)
Max. operating voltage
1000 V AC / 1500 V DC
Dielectric test voltage
5000 V AC (spark & dielectric withstand per ISO 19642-5)
Insulation resistance
≥ 1000 MΩ·km at +20 °C

Thermal

Operating temperature range
-40 °C to +180 °C
Dynamic / flexing temperature
-40 °C to +180 °C
Max. short-circuit temperature
+250 °C

Mechanical

Min. bend radius (fixed)
3 × D
Min. bend radius (flexing)
5 × D
Max. tensile pulling load
15 N/mm²
Vibration & mechanical duty
Vehicle chassis & battery pack vibration

Resistance

Flame retardancy
ISO 19642-5 / ISO 6722-1 flame propagation self-extinguishing (< 70 s)
Oil & fluid resistance
ISO 19642-5 automotive fluid resistance (ATF, engine oil, brake fluid, coolant, battery electrolyte)
UV, weather & ozone
Ozone, thermal aging (3000 h at +180 °C) & hydrolysis resistant
Chemical & environmental
Halogen-free, acid-gas-free silicone elastomer resistant to automotive fluids and road salt

Reference standards

Governing standard
ISO 19642-5 (2019) — Road vehicles — Automotive cables — Part 5: Dimensions and requirements for 600 V a.c. or 900 V d.c. and 1000 V a.c. or 1500 V d.c. single core copper conductor cables
Applicable clauses
ISO 19642-5 Class E (+180 °C); LV 216-1
Secondary reference
ISO 6722-1 — Road vehicles — 60 V and 600 V single-core cables — Class E

Identification

Core identification
Single-core high-voltage safety orange conductor
Outer sheath colour
High-Voltage Safety Orange (RAL 2003 / RAL 2008)
Surface print legend
TEBAOFLEX — FHL2G — ISO 19642-5 — <size> mm² — 600V AC / 1000V DC (1000V AC / 1500V DC) — 180°C

Sizes

8 standard configurations (FHL2G)

Nominal dimensions, copper weight, total mass and electrical parameters for FHL2G per ISO 19642-5.

Dimensions & masses
DesignationSize / ConfigurationStranding · WallNom. OD
mm		Copper
kg/km		Total mass ≈
kg/km		Min. bend R
mm		Enquiry
FHL2G size schedule
FHL2G 1×2.51×2.50.15 · 0.9 mm3.9019.734.023.4
FHL2G 1×61×60.15 · 1.0 mm5.3039.468.031.8
FHL2G 1×101×100.20 · 1.2 mm6.9066.1114.041.4
FHL2G 1×161×160.20 · 1.3 mm8.2099.8172.049.2
FHL2G 1×251×250.20 · 1.5 mm10.00152.0262.060.0
FHL2G 1×351×350.20 · 1.5 mm11.30205.9355.067.8
FHL2G 1×501×500.20 · 1.8 mm13.60292.9505.081.6
FHL2G 1×701×700.20 · 1.8 mm15.50403.1695.093.0
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Dimensions and tolerances conform to ISO 19642-5.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Dielectric voltage withstand & conductor DC resistance5000 V AC (spark & dielectric withstand per ISO 19642-5)100 % of production lengths
Sample tests
Insulation wall thickness, hot-set / pinch & cold bendConforms to ISO 19642-5 sample scheduleEvery production batch
Fluid immersion, flame propagation & thermal agingISO 19642-5 / ISO 6722-1 flame propagation self-extinguishing (< 70 s)Type qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

ISO 19642-5 Class E (+180 °C); LV 216-1ISO 6722-1 (2011)RoHS 3 & REACH Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX — FHL2G — ISO 19642-5 — <size> mm² — 600V AC / 1000V DC (1000V AC / 1500V DC) — 180°C
Delivery form
Non-returnable wooden drums, export reels or shrink-wrapped coils
Standard drum lengths
100 m · 250 m · 500 m · 1000 m
MOQ
200 m (stock sizes) · 500 m (custom lengths)
Lead time
2–3 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFFHL2G Automotive High-Voltage Cable – technical datasheet8 sizes · construction, technical data, approvalsXLSXFHL2G spec data (Excel)All 8 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

What does the designation FHL2G stand for?
Under German VDE / LV 216 nomenclature, 'FL' denotes an automotive low/high-voltage wire, 'H' indicates extra-fine stranding for high flexibility (FHL), and '2G' specifies silicone rubber insulation rated up to +180 °C.
When is unscreened FHL2G used instead of shielded FHLR2GCB2G?
FHL2G is used inside already-shielded metal enclosures (such as inside the traction battery pack or PDU) or inside overall metal braided conduits. For exterior underbody HV harnesses connecting the inverter, e-motor, and onboard charger, EMC-shielded FHLR2GCB2G is required.
Why is FHL2G colored bright orange?
International EV safety standards (ISO 6469-3, FMVSS 305, UN ECE R100) mandate high-visibility orange for all high-voltage (>60 V DC / >30 V AC) automotive cables so service technicians and first responders can immediately identify live HV circuits.
What voltage and temperature ratings apply to FHL2G under ISO 19642-5?
FHL2G is rated for 600 V AC / 1000 V DC (extended 1000 V AC / 1500 V DC) (maximum operating voltage 1000 V AC / 1500 V DC, dielectric test voltage 5000 V AC (spark & dielectric withstand per ISO 19642-5)) and continuous operation from -40 °C to +180 °C (short-circuit up to +250 °C) per ISO 19642-5.

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FHL2G Automotive High-Voltage Cable

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