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Product

Screened XLFE 1,500 V DC EV traction cableISO 19642 / LV 2161,000 V AC / 1,500 V DC−70 to +200 °C XLFE

EXRAD S200XL Shielded Screened XLFE Automotive High-Voltage CableISO 19642 / LV 216-2 −70 to +200 °C screened XLFE 1,000 V AC / 1,500 V DC EV power cable

Q: How does e-beam cross-linked XLFE (EXRAD S200XL) compare with silicone rubber on 800–1,000 V EV platforms?

Silicone rubber is flexible and rated to +180/+200 °C, but it has low tear strength, poor pinch/cut-through resistance, and swells in hydrocarbon fluids. Electron-beam cross-linked fluoropolymer elastomer (XLFE) provides rubber-like flexibility down to −70 °C while delivering 4× higher pinch and scrape-abrasion resistance, enabling thinner walls and tighter bend radii without mechanical conduit.

Q: Why does S200XL Shielded combine both an aluminised polyester tape and a ≥ 85 % tinned copper braid?

High-voltage SiC and IGBT traction inverters generate both low-frequency switching currents (10 kHz–10 MHz) and high-frequency dV/dt ringing (30–300 MHz). The ≥ 85 % tinned copper braid provides low DC/LF transfer impedance and mechanical 360° crimp strength, while the 100 % foil blocks high-frequency RF leakage through braid optical windows.

Q: Can EXRAD S200XL Shielded be used on 800 V and 1,000 V battery architectures?

Yes. It is rated for 1,000 V AC rms and 1,500 V DC continuous service per ISO 19642 Voltage Class B2 and SAE J1654, providing full voltage margin for 800 V–1,000 V passenger EVs and commercial electric trucks.

Q: Does XLFE insulation shrink back or melt during ultrasonic welding or high-current lug crimping?

No. Because the fluoropolymer elastomer is permanently cross-linked by high-energy electron-beam irradiation, it is thermoset and will not melt, flow, or shrink back during ultrasonic busbar welding or thermal overload.

Extra-flexible electron-beam cross-linked fluoropolymer elastomer (XLFE) shielded high-voltage EV traction cable (EXRAD S200XL Shielded) rated 1,000 V AC / 1,500 V DC from −70 °C to +200 °C with 100 % foil plus ≥ 85 % tinned copper braid EMC screening.

Low-EMC design

EMC screen

Oil-resistant

Flame-retardant

EXRAD S200XL Size

Order designation: S200XL-SH-1/0AWG-50
Gauge (mm²): 1/0 AWG (50 mm²)
Overall OD: 15.80 mm
Weight: 745 kg/km
Ampacity (+85°C): 430 A

All sizes (12)

Request a quote Datasheet WhatsApp

Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum

Voltage rating: 1000V AC / 1500V
Thermal class: −70 to +200 °C
Cross-section: 2.5–120 mm²
EMC shielding: Foil + ≥85% Cu
Insulation: E-Beam XLFE
Bend radius: 3–5 × OD

Typical values for this cable type, based on ISO 19642-5 / ISO 19642-9 / LV 216-2 / SAE J1654 — confirmed in the datasheet and quotation for your order.

Application fit

Is EXRAD S200XL Shielded right for your machine?

Engineered for tight routing between high-voltage traction battery packs, SiC inverters, e-axles, onboard chargers (OBC), and DC fast-charge inlets.

VFD inverter to AC motor screened feeder

Suitable

100 % aluminised polyester tape plus ≥ 85 % tinned copper braid suppresses SiC/IGBT inverter switching noise from 150 kHz to 108 MHz.

Motor stator, traction & converter leads

Suitable

E-beam cross-linked XLFE combines silicone-like cold flexibility (−70 °C) with superior cut-through, pinch and fluid resistance at +200 °C.

Switchgear & control cabinet wiring

Suitable

Resists ATF transmission fluid, battery glycol coolant, brake fluid and salt spray along vehicle underbodies.

Energy chain / drag chain

Not suitable

Designed for automotive and heavy-duty vehicle chassis routing, not industrial factory drag chains.

Use M23 Servo Assembly

Typical machinesBattery Electric Vehicles (800 V / 1,000 V BEV)Heavy-Duty Electric Trucks, Buses & Mining HaulersSiC Traction Inverter to E-Axle Motor LeadsDC Fast-Charge (CCS1 / CCS2 / MCS) Internal BusAerospace & Marine Hybrid-Electric Propulsion

Construction

Layer by layer

Single-core (and 2-core LV 216) screened XLFE construction: extra-fine rope-lay tinned copper conductor + e-beam cross-linked XLFE primary insulation + 100 % Al/PET foil + ≥ 85 % tinned copper braid + Safety Orange (RAL 2003/2008) XLFE outer jacket.

Schematic, not to scale — generated from the layer data

#	Layer	Material & reference
1	Extra-flexible rope-lay tinned copper conductor	Fine-stranded annealed tinned copper to ISO 19642-2 / ASTM B33 (19× to 2,109× stranding, 14 AWG to 4/0 AWG / 2.5 mm² to 120 mm²)Provides low contact resistance and vibration fatigue immunity on e-axle mounts
2	E-beam cross-linked XLFE dielectric	Irradiation cross-linked fluoropolymer elastomer (XLFE) primary insulation rated −70 °C to +200 °CWill not melt, flow or shrink back during high-current overload or short-circuit events
3	100 % aluminised polyester EMC foil	Helically applied aluminium/PET foil screen with overlapProvides 100 % high-frequency RF shielding coverage up to 1 GHz
4	≥ 85 % tinned copper braided shield	High-coverage tinned copper wire braid over the foil screenDelivers low surface transfer impedance (≤ 15 mΩ/m) and 360° HV connector shield termination
5	Safety Orange e-beam XLFE outer sheath	Extruded high-visibility HV Orange (RAL 2003 / RAL 2008) cross-linked fluoropolymer elastomer outer jacketResists stone chip abrasion, battery electrolyte, road salt and +200 °C engine-bay heat

S200XL-1C (Single-Core Screened HV Traction)

2.5 mm² (14 AWG) to 120 mm² (4/0 AWG) single-core screened XLFE for 800–1,000 V battery, inverter and e-axle phases

S200XL-2C (Twin-Core Screened HV Auxiliary)

2 × 2.5 mm² to 2 × 6.0 mm² twisted screened XLFE pair for electric HVAC compressor, PTC heater and DC/DC converter feeds

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 19642-5 / ISO 19642-9 / LV 216-2 / SAE J1654. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage: 600 V / 1,000 V AC rms · 1,500 V DC (ISO 19642 / SAE J1654)
AC spark test voltage: 8.0 kV to 10.0 kV AC rms in-line
Dielectric withstand test: 5.0 kV AC rms for 5 min
Shielding effectiveness: ≥ 80 dB (150 kHz to 108 MHz CISPR 25 Class 5)
Volume resistivity: ≥ 10¹⁴ Ω·cm at 20 °C

Thermal

Operating temperature range: −70 °C to +200 °C (ISO 6722 Class F)
Short-term overload / solder heat: +300 °C pinch resistance without flow
Cold-bend flexibility: No cracking at −70 °C (4 h mandrel bend)

Mechanical

Size range: 14 AWG to 4/0 AWG (2.5 mm² to 120 mm²)
Min. bend radius: 3 × OD static · 5 × OD dynamic routing
Scrape abrasion & pinch: Exceeds ISO 19642-5 / SAE J1128 thin-wall requirements

Resistance

Automotive fluid resistance: ISO 6722 gasoline, diesel, ATF, DOT4, glycol & battery acid
Flame retardancy: ISO 6722-1 self-extinguishing (< 5 s) · UL VW-1
Ozone & UV stability: Zero cracking after 192 h at 200 pphm ozone

Reference standards

Automotive HV cable standards: ISO 19642-5 · ISO 19642-9 · LV 216-2 · SAE J1654
Thermal & test standard: ISO 6722-1 Class F (200 °C)

Identification

Outer sheath colour: High-Voltage Safety Orange (RAL 2003 / RAL 2008)
Inner insulation colour: Natural / White or Red / Black (2-core)
Customs tariff (HS): 8544.49 / 8544.30

Sizes

12 standard EXRAD S200XL Shielded automotive HV cable sizes (14 AWG to 4/0 AWG)

Dimensions, stranding, conductor resistance, outer diameter, weight and free-air ampacity at +85 °C ambient (+200 °C conductor).

AWG / metric sizes, OD & ampacity
Order designation	AWG (Metric mm²)	Stranding N × mm	Max R @20°C mΩ/m	Core OD mm	Overall OD mm	Weight kg/km	Ampacity A (+85°C)
HV Auxiliary & Charger Sizes — 14 AWG to 4 AWG (2.5–25 mm²)
S200XL-SH-14AWG-2.5	14 AWG (2.5 mm²)	41 × 0.254	8.71	3.10	5.20	52	54
S200XL-SH-12AWG-4.0	12 AWG (4.0 mm²)	65 × 0.254	5.48	3.65	5.85	72	72
S200XL-SH-10AWG-6.0	10 AWG (6.0 mm²)	105 × 0.254	3.40	4.45	6.75	104	98
S200XL-SH-8AWG-10	8 AWG (10 mm²)	133 × 0.287	2.10	5.60	8.10	156	138
S200XL-SH-6AWG-16	6 AWG (16 mm²)	133 × 0.361	1.32	6.85	9.50	228	185
S200XL-SH-4AWG-25	4 AWG (25 mm²)	133 × 0.455	0.83	8.40	11.30	342	245
HV Traction Battery & Inverter Sizes — 2 AWG to 4/0 AWG (35–120 mm²)
S200XL-SH-2AWG-35	2 AWG (35 mm²)	665 × 0.254	0.52	10.10	13.20	495	325
S200XL-SH-1AWG-42	1 AWG (42 mm²)	817 × 0.254	0.43	11.15	14.40	598	370
S200XL-SH-1/0AWG-50	1/0 AWG (50 mm²)	1045 × 0.254	0.34	12.30	15.80	745	430
S200XL-SH-2/0AWG-70	2/0 AWG (70 mm²)	1330 × 0.254	0.27	13.80	17.50	935	505
S200XL-SH-3/0AWG-95	3/0 AWG (95 mm²)	1672 × 0.254	0.21	15.40	19.30	1,165	585
S200XL-SH-4/0AWG-120	4/0 AWG (120 mm²)	2109 × 0.254	0.17	17.20	21.40	1,455	680

Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
Continuous current ratings are shown for single cable in free air at +85 °C engine-bay ambient and +200 °C conductor temperature per ISO 19642.

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.

ConductorClass 5 stranding
Spark test100 % in-line
Lay-upCores, earth, fillers
SheathingInner, braid / screen, outer
Electrical testsAC voltage, resistance
DimensionsOD, wall thickness
Inspection documents & dispatchDrum & dispatch

Testing & inspection	Test value / reference	Frequency
Routine tests
100 % in-line spark test & 5.0 kV AC dielectric withstand	Zero breakdown at 8.0–10.0 kV AC spark and 5.0 kV AC 5 min immersion test	Every production reel
Sample tests
Surface transfer impedance & triaxial shielding attenuation	Z_T ≤ 15 mΩ/m and ≥ 80 dB shielding effectiveness (0.15–108 MHz)	Production lot
3,000-hour +200 °C thermal ageing & −70 °C cold-wind test	Zero cracks after mandrel bend and 1.0 kV AC post-ageing wet dielectric	Type approval

Inspection certificate

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

Product approvals

ISO 19642-5 / ISO 19642-9 & LV 216-2 Class F CompliantSAE J1654 High-Voltage & ISO 6722-1 200 °C Verified

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX EXRAD S200XL SHIELDED 1000V AC / 1500V DC ISO 19642 200C [AWG/MM2]

Delivery form: Non-returnable plywood reels (250 m / 500 m) or cut-and-stripped HV harnesses
Standard stock sizes: 14 AWG (2.5 mm²) through 4/0 AWG (120 mm²) in Safety Orange
Quality documentation: PPAP Level 3, IMDS material declaration & routine HV test certificate
Lead time: 2–4 weeks ex-works

Technical documents

Downloads

PDFEXRAD S200XL Shielded Screened XLFE Automotive High-Voltage Cable – technical datasheet12 sizes · construction, technical data, approvals XLSXEXRAD S200XL Shielded spec data (Excel)All 12 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 does e-beam cross-linked XLFE (EXRAD S200XL) compare with silicone rubber on 800–1,000 V EV platforms?

Silicone rubber is flexible and rated to +180/+200 °C, but it has low tear strength, poor pinch/cut-through resistance, and swells in hydrocarbon fluids. Electron-beam cross-linked fluoropolymer elastomer (XLFE) provides rubber-like flexibility down to −70 °C while delivering 4× higher pinch and scrape-abrasion resistance, enabling thinner walls and tighter bend radii without mechanical conduit.

Why does S200XL Shielded combine both an aluminised polyester tape and a ≥ 85 % tinned copper braid?

High-voltage SiC and IGBT traction inverters generate both low-frequency switching currents (10 kHz–10 MHz) and high-frequency dV/dt ringing (30–300 MHz). The ≥ 85 % tinned copper braid provides low DC/LF transfer impedance and mechanical 360° crimp strength, while the 100 % foil blocks high-frequency RF leakage through braid optical windows.

Can EXRAD S200XL Shielded be used on 800 V and 1,000 V battery architectures?

Yes. It is rated for 1,000 V AC rms and 1,500 V DC continuous service per ISO 19642 Voltage Class B2 and SAE J1654, providing full voltage margin for 800 V–1,000 V passenger EVs and commercial electric trucks.

Does XLFE insulation shrink back or melt during ultrasonic welding or high-current lug crimping?

No. Because the fluoropolymer elastomer is permanently cross-linked by high-energy electron-beam irradiation, it is thermoset and will not melt, flow, or shrink back during ultrasonic busbar welding or thermal overload.

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01Selected sizes

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Reel typeDrum core diameter (mm)Cable length on drum (m)Travel speed (m/min)Max. accelerationCycles per hourLength and quantityAmbient temperatureExposure (outdoor, water, oil, abrasion)Destination countryEquipment and operating conditions

03Message for our engineers

EXRAD S200XL Shielded Screened XLFE Automotive High-Voltage Cable

Selected sizes:


Reel & motion:
- Reel type: 
- Drum core diameter (mm): 
- Cable length on drum (m): 
- Travel speed (m/min): 
- Max. acceleration: 
- Cycles per hour: 
- Length and quantity: 
- Ambient temperature: 
- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
- Equipment and operating conditions:

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Datasheet Request a quote

EXRAD S200XL Shielded Screened XLFE Automotive High-Voltage CableISO 19642 / LV 216-2 −70 to +200 °C screened XLFE 1,000 V AC / 1,500 V DC EV power cable

VFD inverter to AC motor screened feeder

Motor stator, traction & converter leads

Switchgear & control cabinet wiring

Energy chain / drag chain

S200XL-1C (Single-Core Screened HV Traction)

S200XL-2C (Twin-Core Screened HV Auxiliary)

Electrical

Thermal

Mechanical

Resistance

Reference standards

Identification

Inspection certificate

Product approvals

Company certificates

01Selected sizes

02Reel & motion

03Message for our engineers

HSW / HSX / HST

HSUS / HSL

CGAU

M81044