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Hook-up & equipment wiresEXRAD S200XL · ISO 19642 / SAE J16541000 V AC / 1500 V DC EV−70…+200 °C Safety Orange XLFE

EXRAD S200XL Unscreened XLFE Automotive High-Voltage CableEXRAD S200XL −70…+200 °C 600/1000 V AC (1500 V DC) unscreened XLFE EV high-voltage cable

Ultra-flexible unscreened high-voltage EV/HEV power cable (`EXRAD S200XL`) rated 600/1000 V AC and 1500 V DC from −70 °C to +200 °C (ISO 19642-5 / ISO 6722-1 Class F / SAE J1654), combining finely stranded copper (4–120 mm²) with safety-orange XLFE insulation.

Flame-retardant

Oil-resistant

Water-resistant

Ozone, UV & moisture

Cores × cross-section

Order designation: EXRAD S200XL 2 AWG (35 mm²)
Outer Ø min: 10.3 mm
Outer Ø max: 11.2 mm
Weight ≈: 392 kg/km
Min. bend R: 45 mm

Check against my drum All sizes (10)

Request a quote Datasheet WhatsApp

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

Voltage rating: 1 kV AC / 1.5 kV
Temp. range: −70…+200 °C
Dielectric type: E-beam XLFE
Bending radius: 3–4 × OD
Jacket colour: HV Safety Orange
Size range: 12–4/0 AWG

Typical values for this cable type, based on ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654 — confirmed in the datasheet and quotation for your order.

Application fit

Is EXRAD S200XL right for your machine?

Silicone high-voltage EV cables are flexible at +200 °C but tear easily during assembly and swell in ATF/coolants. `EXRAD S200XL` electron-beam cross-linked fluoropolymer-elastomer (`XLFE`) matches silicone's limp flexibility while delivering superior tear, pinch, abrasion and fluid resistance.

Fixed installation

Suitable

EV/HEV battery-pack internal module links, PDU interconnects, fuel-cell buses and conduit-shielded HV trunks.

VFD inverter to AC motor screened feeder

With conditions

Unscreened HV core designed for routing inside shielded battery enclosures, metallic conduits or braided harnesses.

Trailing & towing

Not suitable

Automotive EV/HEV high-voltage vehicle cable; not for industrial ground drag.

Use EN 50264-2-2

Energy chain / drag chain

Not suitable

For submerged low-voltage +180 °C transmission valve-body wiring, select EXRAD 180B.

Use EXRAD 180B

Typical machinesEV / HEV traction battery-pack internal interconnectsHigh-voltage PDU, DC/DC converter & OBC harnessesCommercial electric truck, bus & off-highway HV busesHydrogen fuel-cell stack & compressor power leads48 V mild-hybrid & 800 V e-axle phase jumpers

Construction

Layer by layer

Shown: EXRAD S200XL 35 mm² (2 AWG) — extra-flexible rope-lay stranded bare or tinned annealed copper conductor (30/36 AWG fine strands) and single-wall safety-orange (RAL 2003) electron-beam cross-linked fluoropolymer-elastomer (XLFE) insulation.

Schematic, not to scale — generated from the layer data

#	Layer	Material & reference
1	Extra-flexible rope-lay copper	Ultra-fine 30 AWG / 36 AWG rope-stranded bare or tinned annealed copper (12 AWG / 4 mm² to 4/0 AWG / 120 mm²) for tight battery-pack bendsISO 19642-2 · SAE J1654 · ASTM B33
2	200 °C cross-linked XLFE dielectric	Electron-beam irradiated fluoropolymer-elastomer rated 600/1000 V AC & 1500 V DC from −70 °C to +200 °CISO 19642-5 · ISO 6722-1 Class F · SAE J1654
3	Safety-orange tear-resistant XLFE finish	UV-stabilised high-voltage orange (RAL 2003 / 2008) outer surface resisting tear propagation, connector-seal cold flow and battery coolantsISO 6469-3 · LV 216

EXRAD S200XL Unscreened HV Safety Orange (12 AWG–4/0 AWG / 4–120 mm²)

1000 V AC / 1500 V DC unscreened XLFE power cable for inside battery packs, PDUs and overall-braided HV harnesses

EXRAD S200XL Black / Red Polarity Cores (48 V & DC Busbar Jumpers)

Available in Black, Red or Blue for 48 V mild-hybrid starters, supercapacitors and enclosed DC links

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage: 600 V / 1000 V AC RMS · 1500 V DC (ISO 19642-5 Voltage Class B2)
AC dielectric test voltage: 5.0 kV to 10.0 kV AC RMS for 5 min · 10–15 kV spark test
Max. DC conductor resistance (20 °C): 4 mm² (12 AWG): ≤ 4.71 Ω/km · 10 mm² (8 AWG): ≤ 1.82 Ω/km · 25 mm² (4 AWG): ≤ 0.727 Ω/km · 35 mm² (2 AWG): ≤ 0.524 Ω/km · 50 mm² (1/0 AWG): ≤ 0.368 Ω/km · 70 mm² (2/0 AWG): ≤ 0.259 Ω/km · 95 mm² (3/0 AWG): ≤ 0.196 Ω/km

Thermal

Operating temperature range: −70 °C cold bend to +200 °C continuous (3,000 h Class F rating)
Overload & thermal runaway margin: Withstands +250 °C short-circuit spikes without thermoplastic melt-through

Mechanical

Min. bending radius: 3 × OD (up to 25 mm²) · 4 × OD (35 to 120 mm²) — silicone-like limpness for tight EV battery bus routing
Tear, pinch & abrasion vs Silicone: Up to 5× higher tear strength and 10× higher scrape/pinch resistance than 200 °C silicone rubber (VMQ)

Resistance

EV battery coolants & oils: Resists water-glycol coolants, dielectric immersion fluids, ATF, brake fluid, battery electrolyte and salt spray
Flame retardance: Passes ISO 6722-1 / ISO 19642-5 flame propagation and UL VW-1 / horizontal burn tests

Reference standards

Primary EV standards: ISO 19642-5 (1000 V AC / 1500 V DC Road Vehicles HV Cable), ISO 6722-1 Class F & SAE J1654
High-voltage colour standard: Safety Orange (RAL 2003 / 2008) per ISO 6469-3 & FMVSS 305
RoHS, ELV & REACH: 2000/53/EC (ELV), 2011/65/EU (RoHS 2), siloxane-free & IMDS registered

Identification

Insulation colour: High-Voltage Safety Orange (RAL 2003 / 2008) — or Black / Red on request
Surface marking: EXRAD S200XL [AWG / mm²] 1000V AC / 1500V DC 200C ISO 19642 SAE J1654 TEBAOFLEX
Customs tariff (HS): 8544.49 (insulated conductors ≤ 1000 V) / 8544.60 (> 1000 V DC)

Sizes

10 standard EXRAD S200XL configurations

Typical ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654 outer diameter limits, copper content and cable weight.

Dimensions & weights
Order designation	Cores × mm² / AWG	AWG ≈	Outer Ø min mm	Outer Ø max mm	Copper kg/km	Weight ≈ kg/km	Min. bend R mm
Auxiliary HV — OBC, DC/DC, PTC Heater & Compressor (4–16 mm² / 12–6 AWG)
EXRAD S200XL 12 AWG (4 mm²)	1×4.0 (12 AWG)	12	4.0	4.3	38	52	17
EXRAD S200XL 10 AWG (6 mm²)	1×6.0 (10 AWG)	10	4.7	5.1	57	76	20
EXRAD S200XL 8 AWG (10 mm²)	1×10 (8 AWG)	8	6.0	6.5	96	122	26
EXRAD S200XL 6 AWG (16 mm²)	1×16 (6 AWG)	6	7.3	7.9	153	188	32
Traction HV — Battery Pack, PDU, Inverter & E-Axle (25–120 mm² / 4–4/0 AWG)
EXRAD S200XL 4 AWG (25 mm²)	1×25 (4 AWG)	4	9.0	9.8	240	286	39
EXRAD S200XL 2 AWG (35 mm²)	1×35 (2 AWG)	2	10.3	11.2	336	392	45
EXRAD S200XL 1/0 AWG (50 mm²)	1×50 (1/0 AWG)	1/0	12.1	13.2	480	550	53
EXRAD S200XL 2/0 AWG (70 mm²)	1×70 (2/0 AWG)	2/0	14.1	15.3	672	760	61
EXRAD S200XL 3/0 AWG (95 mm²)	1×95 (3/0 AWG)	3/0	16.2	17.6	912	1,020	70
EXRAD S200XL 4/0 AWG (120 mm²)	1×120 (4/0 AWG)	4/0	18.0	19.6	1,152	1,275	78

Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
Dimensions and weights are typical values per ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654. Minimum fixed bending radius shown is 4 × OD.

Electrical & current ratings
Cross-section mm²	AWG ≈	Max. DC resistance 20 °C, Ω/km	Single wire in air 30 °C, A	Multi-core bundle 30 °C, A
4	12	5.09	41	30
6	10	3.39	53	38
10	8	1.95	75	53
16	6	1.24	100	71
25	4	0.795	135	94
35	2	0.565	169	117
50	1/0	0.393	215	148
70	2/0	0.277	270	185
95	3/0	0.21	330	225
120	4/0	0.164	385	260

Current ratings at 30 °C ambient in free air. Apply temperature and bundle grouping factors per applicable equipment standard.

Reel check

Will it fit your machine?

A first screen using datasheet values. Engineering confirms drum geometry, acceleration and tension with your quotation.

Cable sizeDrum core diameter (mm)

Cable length on drum (m)

Drum core 300 mm ≥ 90 mmBending radius OK (4 × OD 11.2 mm)

Minimum bending radius: 45 mm
Min. drum core diameter: ≈ 90 mm
Cable weight on drum: 19.6 kg
Copper content: 16.8 kg

Indicative only: based on the datasheet outer diameter and 4 × OD bending radius. Current derating for wound layers per DIN VDE 0298-4 is assessed separately.

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
AC dielectric voltage test	5.0 kV AC (50/60 Hz)	Every manufactured length
Conductor DC resistance	IEC 60228 / ASTM (tinned copper)	Every manufactured length
Sample tests
Flame propagation test	IEC 60332-1-2 / UL VW-1 / ISO 6722-1	Per production batch
Insulation & sheath material physical properties	ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654	Type approval

Inspection certificate

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

Product approvals

ISO 19642-5 / ISO 6722-1 Class F (+200 °C) · SAE J1654CE · RoHS 2 (2011/65/EU) · REACH

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

EXRAD S200XL [Size] 1000V AC / 1500V DC 200C ISO 19642 SAE J1654 TEBAOFLEX

Delivery form: Export wooden drums, reels or coils, cut-to-length on request
Packaging: Heat-treated ISPM-15 timber drums or spools with sealed ends
Conductor / colour options: Custom core counts, stripe combinations or cut harnesses on request

Technical documents

Downloads

PDFEXRAD S200XL Unscreened XLFE Automotive High-Voltage Cable – technical datasheet10 sizes · construction, technical data, approvals XLSXEXRAD S200XL spec data (Excel)All 10 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 EXRAD S200XL (XLFE) compare with 200 °C silicone rubber (VMQ) EV high-voltage cables?

While silicone EV cables are very flexible and rated +180/+200 °C, silicone has poor tear resistance (nicking easily during harness pulling), swells in ATF and dielectric oils, and releases low-molecular-weight siloxanes. EXRAD S200XL electron-beam cross-linked fluoropolymer-elastomer (XLFE) provides silicone-like flexibility with 5× higher tear strength, smaller wall thickness, zero siloxane outgassing and full oil/coolant immunity.

Where are unscreened high-voltage EV cables used instead of individually shielded HV cables?

Unscreened EXRAD S200XL is used inside metal-enclosed traction battery packs (module-to-module, BDU/PDU links), inside corrugated metallic conduits, or inside multi-core HV harnesses enclosed in an overall braided EMC sleeve, eliminating the weight, stiffness and termination cost of individual cable shields.

What is the voltage rating of EXRAD S200XL for 800 V EV architectures?

EXRAD S200XL is rated 600 V / 1000 V AC RMS and 1500 V DC (ISO 19642 Voltage Class B2), providing ample dielectric margin for both 400 V and 800 V passenger and commercial electric vehicle platforms.

How cold can EXRAD S200XL operate without cracking?

Its fluoropolymer-elastomer matrix passes cold-bend testing down to −70 °C while maintaining +200 °C continuous thermal endurance.

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01Selected sizes

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02Reel & motion

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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 Unscreened 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: 
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