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Product

ISO 19642 / LV 216 High-Voltage EV Powertrain CablesISO 19642-9600 V AC / 900 V DC & 1000 V-40 to +180 °C

FHLR2GCB2G Shielded Automotive HV CableISO 19642-9 / LV 216-2 EMC-shielded (foil + braid) double-silicone (2G) orange high-voltag

FHLR2GCB2G is a screened high-voltage automotive traction cable engineered to ISO 19642-9 and German OEM standard LV 216-2 for 600 V AC / 900 V DC and 1000 V AC / 1500 V DC electric vehicle (BEV/HEV) underbody and powertrain harnesses. It combines an extra-fle

Dual Screen C+B
Foil + Cu Braid
-40 to +180 °C
ISO 19642-9 / LV 216-2
Order designation
FHLR2GCB2G 1×25
Nom. OD
12.10 mm
Copper mass
200.1 kg/km
Total mass ≈
345.0 kg/km
Min. bend R
72.6 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 / 900 V
Max 1000 V AC / 1500 V DC
Test voltage
5000 V AC (core-
Dielectric withstand
Operating temp
-40 to +180 °C
Short-circuit +250 °C
Min. bend radius
4 × D
Flexing 6 × D
Primary standard
ISO 19642-9
ISO 19642-9 Class E (+180 °C); LV 216-2
Flame rating
ISO 19642-9 flam
Fire & safety compliance

Typical values for this cable type, based on ISO 19642-9 — confirmed in the datasheet and quotation for your order.

Application fit

Is FHLR2GCB2G right for your machine?

Used across 400 V and 800 V passenger EVs, electric trucks, electric buses, and off-highway e-machinery for EMC-critical high-voltage traction, inverter, and fast-charging harnesses.

Motor stator, traction & converter leads

Suitable

Primary EMC-shielded 3-phase inverter-to-traction-motor and e-axle power cable for 400 V and 800 V EV platforms

Switchgear & control cabinet wiring

Suitable

Connects traction battery pack to inverter, onboard charger (OBC), DC fast-charge inlet, and HV DC/DC converter

Fixed installation

Suitable

Designed for underbody chassis clipping and tight 4 × D routing around suspension and subframe components

Trailing & towing

With conditions

Engineered for on-vehicle HV harnesses; for off-board charging station cords select DC EV Charging Cable

Typical machines800 V Inverter-to-Traction-Motor PhasesBattery-to-Inverter Underbody HV BusOnboard Charger (OBC) & CCS Fast-Charge Inlet Leads

Construction

Layer by layer

Extra-flexible fine-stranded bare or tinned copper (FHL per ISO 19642-9 / IEC 60228 Class 5/6); Reduced-wall halogen-free silicone rubber elastomer (R2G, ISO 19642 Class E, +180 °C); Aluminum/polyester laminate foil tape (B) under tinned copper braid; Tear-resistant halogen-free silicone rubber (2G, Class E +180 °C) in HV safety orange (RAL 2003).

12345
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1ConductorExtra-flexible fine-stranded bare or tinned copper conductor (FHL)ISO 19642-9
2InsulationReduced-wall silicone rubber primary dielectric (R2G)ISO 19642-9
3TapeAluminum-laminated polyester EMC foil screen (B)ISO 19642-9
4ScreenHigh-coverage tinned copper wire braid shield (C, ≥85%)ISO 19642-9
5SheathTear-resistant safety orange silicone rubber outer sheath (2G, RAL 2003)ISO 19642-9

800 V Inverter-to-Traction-Motor Phases

Dual foil + tinned copper braid (CB) suppresses high-frequency SiC/IGBT switching noise (up to 100 MHz+) to meet CISPR 25 Class 5 automotive EMC limits.

Battery-to-Inverter Underbody HV Bus

Routes high-current DC power from the battery pack along the vehicle underbody to front and rear electric drive units.

Onboard Charger (OBC) & CCS Fast-Charge Inlet Leads

Connects the vehicle CCS1/CCS2/NACS charging inlet directly to the traction battery disconnect unit at up to 1500 V DC.

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 19642-9. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage (U0/U)
600 V AC / 900 V DC & 1000 V AC / 1500 V DC
Max. operating voltage
1000 V AC / 1500 V DC
Dielectric test voltage
5000 V AC (core-to-screen dielectric withstand per ISO 19642-9)
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)
4 × D
Min. bend radius (flexing)
6 × D
Max. tensile pulling load
15 N/mm²
Vibration & mechanical duty
E-axle & chassis dynamic movement

Resistance

Flame retardancy
ISO 19642-9 flame propagation self-extinguishing (< 70 s)
Oil & fluid resistance
ISO 19642-9 automotive fluid resistance (ATF, gear oil, brake fluid, coolant, diesel, road salt)
UV, weather & ozone
Ozone, UV, stone-chip abrasion & 3000 h +180 °C thermal aging resistant
Chemical & environmental
Halogen-free silicone elastomer inner and outer layers resistant to hydrolysis and underbody chemicals

Reference standards

Governing standard
ISO 19642-9 (2019) — Road vehicles — Automotive cables — Part 9: Dimensions and requirements for 600 V a.c. or 900 V d.c. and 1000 V a.c. or 1500 V d.c. round, sheathed, screened or unscreened multicore and single-core copper conductor cables
Applicable clauses
ISO 19642-9 Class E (+180 °C); LV 216-2
Secondary reference
LV 216-2 — Electric and electronic components in motor vehicles — Screened high-voltage cables

Identification

Core identification
Natural or colored inner silicone core; high-voltage orange outer sheath
Outer sheath colour
High-Voltage Safety Orange (RAL 2003 / RAL 2008)
Surface print legend
TEBAOFLEX — FHLR2GCB2G — ISO 19642-9 / LV 216-2 — 1×<size> mm² — 1000V AC / 1500V DC — 180°C

Sizes

8 standard configurations (FHLR2GCB2G)

Nominal dimensions, copper weight, total mass and electrical parameters for FHLR2GCB2G per ISO 19642-9.

Dimensions & masses
DesignationSize / ConfigurationStranding · WallNom. OD
mm		Copper
kg/km		Total mass ≈
kg/km		Min. bend R
mm		Enquiry
FHLR2GCB2G size schedule
FHLR2GCB2G 1×61×60.15 · 0.9 mm7.4060.9105.044.4
FHLR2GCB2G 1×101×100.20 · 1.0 mm8.9094.0162.053.4
FHLR2GCB2G 1×161×160.20 · 1.0 mm10.30136.3235.061.8
FHLR2GCB2G 1×251×250.20 · 1.1 mm12.10200.1345.072.6
FHLR2GCB2G 1×351×350.20 · 1.2 mm13.60266.8460.081.6
FHLR2GCB2G 1×501×500.20 · 1.3 mm15.80368.3635.094.8
FHLR2GCB2G 1×701×700.20 · 1.4 mm17.90495.9855.0107.4
FHLR2GCB2G 1×951×950.20 · 1.6 mm20.40661.21,140.0122.4
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Dimensions and tolerances conform to ISO 19642-9.

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 (core-to-screen dielectric withstand per ISO 19642-9)100 % of production lengths
Sample tests
Insulation wall thickness, hot-set / pinch & cold bendConforms to ISO 19642-9 sample scheduleEvery production batch
Fluid immersion, flame propagation & thermal agingISO 19642-9 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 19642-9 Class E (+180 °C); LV 216-2LV 216-2 (2014)RoHS 3 & REACH Compliant

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX — FHLR2GCB2G — ISO 19642-9 / LV 216-2 — 1×<size> mm² — 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

PDFFHLR2GCB2G Shielded Automotive HV Cable – technical datasheet8 sizes · construction, technical data, approvalsXLSXFHLR2GCB2G 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.

How do you decode the designation FHLR2GCB2G?
'FHL' = automotive wire with extra-fine flexible copper stranding; 'R' = reduced wall thickness; '2G' = silicone rubber insulation; 'C' = tinned copper wire braid screen; 'B' = aluminum/PET foil screen; '2G' = silicone rubber outer sheath.
Why does FHLR2GCB2G use both foil (B) and copper braid (C) shielding?
The tinned copper braid (C) provides low transfer impedance at low-to-medium frequencies and mechanical termination strength in 360° HV connectors, while the aluminum/PET foil (B) provides 100% optical coverage to block high-frequency electromagnetic interference from fast-switching SiC inverters.
Is FHLR2GCB2G compatible with 800 V EV architectures?
Yes. Compliant with ISO 19642-9 and LV 216-2 up to 1000 V AC / 1500 V DC, it provides full voltage margin for both 400 V and 800 V–900 V electric vehicle architectures.
What voltage and temperature ratings apply to FHLR2GCB2G under ISO 19642-9?
FHLR2GCB2G is rated for 600 V AC / 900 V DC & 1000 V AC / 1500 V DC (maximum operating voltage 1000 V AC / 1500 V DC, dielectric test voltage 5000 V AC (core-to-screen dielectric withstand per ISO 19642-9)) and continuous operation from -40 °C to +180 °C (short-circuit up to +250 °C) per ISO 19642-9.

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FHLR2GCB2G Shielded Automotive HV Cable

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