LEONI Dacar®

Automotive Cables

The Quality Connection

2 LEONI Dacar® [Link]

About us
Our Automotive Cables business unit is the leading
manufacturer of single-core automotive cables
globally. In the ABS/sensor cable segment we are
number 1 in Europe and North America as we are
Europe-wide with LEONI Dacar data transmission and
coaxial cable products.

Globally we are extending our position as a world market

leader in data cables for vehicles.

Being strategically located near our customers is at the core of

all our Automotive Cables activities. This close proximity allows
to identify requirements and market demand at an early stage
and to develop innovative solutions together with our direct and
indirect customers. The basis for our successful growth lies in
our service as well as in the stability and ongoing optimisation
of our production processes – the proverbial LEONI quality.

International outlook of our Automotive Cables activities and its

worldwide production network is reinforced by the proximity to
customers.

Issue: July 2009

Subject to technical changes.
[Link] LEONI Dacar® 3

Content
About us

Materials LEONI Dacar® 4

Coding Key 6

LEONI Dacar® Data Transmission Cables 8

Probe Cables 10
LVDS + Bus Systems 12
Multimedia 14
LEONI Dacar® Coaxial Cables 16
with foam dielectric 18
with solid dielectric 20
LEONI Dacar® FP Automotive Cables 22

LEONI Roth radio frequency lab 24

Quality management 26
LEONI worldwide / LEONI news 27
 4 LEONI Dacar® [Link]

Materials LEONI Dacar®

Insulation materials

Service
Hardness Shore Tensile Elongation temperatures Dielectric Dielectric
Name A/D strength at break ISO 2578/6722, strength constant
Symbol e.g. DIN ISO 1629 and 7728 Code DIN 53504 DIN 53504 DIN 53504 DIN 0472 DIN 53481 DIN 53483
± 5.0 MPa % °C kV/mm

Thermoplastics
acc. to sample
PVC-P Polyvinyl chloride (plasticized) Y >12,5 >150 –40 up to +90 >10 4–6
(75 A– 95 A)✖
acc. to sample
PVC-P (heat resistant) lead free YW >15 >150 –40 up to +105 >10 4–6
(90 A– 97 A)✖
PE-LD-E Cellular polyethylene 02Y 40D >10 >100 –40 up to +85 >10 1. 2 5 –1.7
PE Polyethylene 2Y 50D >10 >300 –40 up to +85 >30 2. 3
PP Cellular polypropylene 09Y 50 D >15 >100 –40 up to +105 >10 1. 5 –1.7
PP Polypropylene 9Y 70 D >25 >300 –40 up to +125 >30 2. 3
FEP Tetrafluoroethylene/hexafluoropropylene 6Y 55D >15 >200 –65 up to +210 >30 21
ETFE Ethylene/tetrafluoroethylene 7Y 75D >30 >200 –65 up to +180 >30 2.6
Thermoplastic elastomers
TPE-U Thermoplastic polyether polyurethane 11Y 85 A– 95 A >30 > 400 –40 up to +125 >10 7
TPE-O Thermoplastic polyolefin elastomer 91Y 60 A–50 D >10 >300 –40 up to +125 >20 3
Cross-linked plastics
PE-X Polyethylene, crosslinked 2X 95 A >10 >200 –40 up to +125 >20 3–4
✖
depends on recipe
[Link] LEONI Dacar® 5

Conductor materials
Material Elongation
Symbol Number Conductivity at 20 °C Density Tensile strength at break Melting point
Copper acc. to
E-Cu 58 F 21 2.0065 >58.0 m/mm2 8 .9 g /c m 3 >210 M Pa > 21 % 1083 °C
DIN 40500 Part 4
Copper acc. to
Cu-ETP1 >58.58 m/mm2
DIN EN 13602
Copper clad steel 23.2 m/mm2,
Staku 40: Class 40 HS 8 . 2 g /c m 3 >7 70 M Pa <5%
wire >40 % IACS

Galvanic coatings

Tin Silver
Designation Tin 99.90 Designation Fine silver 99.97
Density 7.29 g/cm3 Density 10.5 g/cm3
Melting point 232 °C Melting point 960 °C
Symbol Sn Symbol Ag
 6 LEONI Dacar® [Link]

Coding key
The type designation provides information on the type of wire, the A type designation is made up of several groups. The type of wire is
insulation and sheath materials used and the principle design features specified first and then its construction from inside to outside.
in abbreviated and simplified form.

1. Type of wire (German abbreviations)

91Y TPE-O (thermopl. polyester elastomer on polyolefin basis)
FL = Automotive wire X PVC-X (polyvinyl chloride crosslinked)
FZL = Automotive ignition wire 2X XLPE (polyethylene crosslinked)
EFL = Automotive wires for electric vehicles 4G EVA (ethylene/vinyl acetate)
10Y PVDF (polyvinylidenfluoride)
2. Special conductor materials (excl. electrolytic copper)
In foamed materials the code is preceded by a “zero”:
M Materials other than E-Cu or resistance conductors e. g. 02Y = foamed or cellular PE.
(e. g. aluminium, steel, steel copper, etc.)
W Resistance conductors 5. Codes for constructional elements
(usually copper alloys with Ni, Cr, Mn, etc.)
Codes for further constructional elements and non-extruded
3. Geometric construction of insulation coverings (where applicable).
B Foil shield
Normal thickness of insulation (equivalent to ISO 6722 “Thick wall”) C Copper wire braiding
is not coded. D Copper wire spiral shield
U Greatly reduced thickness of insulation equivalent to ISO 6722 G Glass fiber braiding
R Reduced thickness of insulation equivalent to ISO 6722✖ P Insulation foil
S Reinforced insulation (thickness bigger than specified T Textile braiding
in ISO 6722)
✖ The code can also be used for other thicknesses. 6. Special design features
The relevant standard or thickness is then also named.

4. Codes for the dielectrics F Flat wire

Z Multi-core wire with separable cores
Code for the dielectrics used for the insulation and sheath.
Y Soft-PVC (polyvinyl chloride) 7. Finally…
YW Soft-PVC, heat-resistant, hot-pressure resistant … the number of cores (except in the case of single core wires) and
YK Soft-PVC, cold-resistant the nominal cross section in mm2 are specified. Especially flexible or
2Y PE (polyethylene) highly flexible stranded conductors are identified by additional specifi-
4Y PA (polyamide) cation of the nominal crosssection of the single wire.
6Y FEP (tetrafluoroethylene/hexafluoropropylene) In some cases the type of metal plating is specified for metal-plated
7Y E/TFE (ethylene/tetrafluoroethylene) copper wires as follows:
9Y PP (polypropylene) SN tin-plated
11Y TPE-U (thermoplastic elastomer on polyurethane basis) NI nickel-plated
12Y TPE-E (thermopl. polyester elastomer on polyether ester basis) AG silver-plated
13Y TPE-E (thermopl. polyester elastomer on polyester ester basis) Bare copper has no special code.
31Y TPE-S (thermopl. polyester elastomer on polystyrene basis) Various components joined by specific structural elements (e. g. inner
41Y TPE-A (thermopl. polyester elastomer on polyamide basis) sheaths or inner shields) are grouped in parentheses in the type code
51Y PFA (perfluoroalkoxy copolymer) (see examples of coding).
[Link] LEONI Dacar® 7

Examples
Multi-core cables

FL R Y 2x 1.5 sn- A FL Y Y 2x 0.5 FL R Y B D YW 2x 0.5

Nominal cross-
Symmetric Nominal cross-section 0.5 mm2 section 0.5 mm2
conductor structure✖ Two cores Two cores
Tinned individual wire PVC sheath Outer sheath
Nominal cross-section 1.5 mm2 PVC insulation (heat-resistant PVC)
Two cores Automotive wire Copper wire spiral shield
PVC insulation Foil shield (static shielding)
Reduced thickness of insulation✖ PVC insulation
Automotive wire Reduced thickness of insulation✖
Automotive wire

FL Y (Y D Y) (Y B Y) C Y 3x0.35+ (1x0.35)+ (2x0.35)

2 cores with
foil shield and inner sheath
1 core with inner shield
(copper wire braiding and inner sheath)
3 cores (without inner shield and inner sheath)
PVC outer sheath for all elements
Complete shield (copper wire braiding) for all elements
PVC inner sheath for the specially grouped elements
Inner sheath (foil tape) for the specially grouped elements
PVC insulation for further specially grouped elements (cores)
PVC inner sheath for the specially grouped element
Inner shield (copper wire spiral shield) for the specially grouped element
PVC insulation for a specially grouped element (core)
PVC insulation
Automotive wire
✖ according to ISO 6722
8 LEONI Dacar ® Data Transmission Cables [Link]

LEONI Dacar®
Data Transmission Cables

Symmetrical data transmission cables

for a wide variety of telematic systems.

BENEFITS/PROPERTIES APPLICATIONS
■■ flexible CD changer, multimedia / MP3 player, TFT, rear view
■■ heat resistant camera system, bus systems (Flexray/FireWire/CAN/
■■ very good transmission properties USB), LVDS, mobile phone interface and iPod.
■■ outstanding coupling resistance and shield

attenuation properties PROPERTIES

■■ stable impedance ■■ solid/foam dielectrics

■■ lowest Alien Next ■■ standard temperature range –40 °C up to + 105 °C

■■ superior environmental properties/recyclability ■■ high mechanical strength

■■ flame resistant
[Link] LEONI Dacar ® Data Transmission Cables 9
10 LEONI Dacar ® Data Transmission Cables [Link]

Probe Cables Data transmission cables

Code Part Number Cable structure Conductor Core Shield type Outer
diameter diameter diameter
[mm] [mm] [mm]
LEONI Dacar 540 76841012A 2x2x0.35+(0.35) 0.80 1.30 PETP-AL 6.20
LEONI Dacar 541 76881015A 2x2x0.35+(0.35)+(0.35) 0.80 1.30 PETP-AL 6.20
LEONI Dacar 550 76780000A 1x0.35+(0.35) 0.80 1.25 PVC-AL 4.10
LEONI Dacar 551 76780002A 2x0.35+(0.35) 0.80 1.30 PVC-AL 4.30
 [Link] LEONI Dacar ® Data Transmission Cables 11

Focused on communication.

Insulation Jacket Service temperature Capacity Conductor Weight

material material resistance
[°C] [max. pF/m] [Ω/km] [kg/km]
PVC PVC –40 up to +105 200 52 52
PVC PVC –40 up to +105 200 52 52
PVC TPE-U –40 up to +105 380 52 22
PVC TPE-U –40 up to +105 360 52 25
 12 LEONI Dacar ® Data Transmission Cables [Link]

LVDS + Bus Systems Data Transmission Cables

Code Part number Cable structure Conductor material / shield type Diameter
over shield
nom.
[mm]
LVDS
LEONI Dacar 501 76981008A 4x2x0.22+0.22 Cu bare / PETP-AL / C-shield 5.80
LEONI Dacar 502 76981009A 4x2x0.22+0.22 Cu bare / PETP-AL / C-shield 5.80
LEONI Dacar 503 76981003A 4x2x0.22 Cu bare / PETP-AL / C-shield 5.60
LEONI Dacar 505 76981000A 4x2x0.22+(0.22) Cu bare / AL coated foil / C-shield 5.50
LEONI Dacar 506 76981020A 4x2x0.22+(0.22) Cu tinned / AL coated foil / C-shield 5.50
LEONI Dacar 508 76981006A 5x2x0.22 Cu bare / PETP-AL / C-shield 6.50
LEONI Dacar 509 76981007A 5x2x0.22 Cu bare / PETP-AL / C-shield 6.00
LEONI Dacar 511 76981060A 5x2x0.22 Cu bare / PETP-AL / C-shield 6.00
LEONI Dacar 522 76981035A 2x0.14 Cu tinned / PVC-AL / C-shield 3.10
LEONI Dacar 538 76981056A 4x0.14 Cu tinned / PVC-AL / C-shield 3.40

CAN
LEONI Dacar 520 79116800A 2x0.35 Cu bare / PETP –
LEONI Dacar 560 76731000A 2x0.35 Cu bare –
LEONI Dacar 562 76731010A 2x0.5 Cu bare / PETP –
LEONI Dacar 565 76981030A 2x0.75+(0.75) Cu bare / PETP-AL –

Flexray
LEONI Dacar 533 76981025A 2x0.35+(0.35) Cu bare / PETP-AL –

Fire Wire
LEONI Dacar 536 76981040A 4x0.14 Cu tinned / PVC-AL / C-shield 3.40

USB
LEONI Dacar 516 76981063A (2x0.089)+2x0.24+(0.089) Cu tinned / PETP-AL / C-shield 3.20
LEONI Dacar 518 76981065A (2x0.35)+2x0.35+(0.35) Cu bare / PETP-AL / C-shield 4.10
The table only shows an excerpt of our portfolio – please contact us for further cable designs.
 [Link] LEONI Dacar ® Data Transmission Cables 13

Your way to be connected.

Outer cable Insulation material Jacket material Service temperature Impedance Weight
diameter
nom.
[mm] 1 2 [°C] [Ω] [kg/km]

6.80 PE – PVC –40 up to +90 100 56.0

6.80 PP – PVC –40 up to +105 100 55.0
6.80 cellular PP – PVC –40 up to +105 100 56.0
6.30 PE – TPE-U –40 up to +90 100 51.0
6.30 FEP – TPE-U –40 up to +110 100 61.0
7.40 PE – PVC –40 up to +90 100 63.5
7.40 PP – PVC –40 up to +105 100 71.0
7.00 cellular PP – PVC –40 up to +105 100 69.0
4.60 PP – PVC –40 up to +105 100 27.0
4.60 PP – PVC –40 up to +105 100 34.0

4.90 cellular PP – TPE-U –40 up to +105 120 22.0

5.00 TPE-O-X – TPE-U –40 up to +125 120 28.5
5.40 TPE-O-X – TPE-U –40 up to +120 120 31.0
8.00 cellular PP – PVC –40 up to +105 120 62.0

4.80 cellular PP – PVC –40 up to +105 100 28.0

4.60 cellular PP – PVC –40 up to +105 110 32.0

4.30 PP PVC PVC –40 up to +105 90 29.0

5.80 cellular PP PVC PVC –30 up to +105 90 54.0
 14 LEONI Dacar ® Data Transmission Cables [Link]

Multimedia Data Transmission Cables

Code Part number Cable structure Conductor material / shield type

Multimedia
LEONI Dacar 594 76981103A (3x0.14)+4x0.14+2x0.5+Z50+(0.14) Cu bare / Copper clad steel conductor bare / PETP / C-shield
LEONI Dacar 805 76981108A (2x0.055)+((2x0.14)+(0.14))+4xZ53 Cu bare / PETP-AL / D-shield

Car phone
LEONI Dacar 590 76981090A 8x0.22+2x0.35+Z50 Cu tinned / Cu bare / PETP-AL / C-shield
LEONI Dacar 514 76981080A 5x2x0.14+2x0.5 Cu tinned / Cu bare / AL-PETP-AL / C-shield

iPod
LEONI Dacar 533 76981025A 2x0.35+(0.35) Cu bare / PETP-AL
LEONI Dacar 592 76981025A ((2x0.089)+2x0.22+(0.22))+2x(3x0.089) Cu tinned / AL-PETP-AL / C-shield
 [Link] LEONI Dacar ® Coaxial Cables 15

Pioneering digital entertainment.

Diameter Outer Insulation material Jacket Service Impedance Weight

over shield cable diameter material temperature
nom. nom.
[mm] [mm] 1 2 3 4 [°C] [Ω] [kg/km]

5.50 6.70 PVC PVC PP – PVC –40 up to +105 50 70

5.50 5.80 PP PP PP – PVC –25 up to +90 53 54

5.60 6.70 ETFE ETFE PE – TPE-U –40 up to +85 50 104

4.60 5.80 TPE-E TPE-E – – PVC –40 up to +105 – 60

– 4.80 cellular PP – PVC –40 up to +105 100 28.0

5.40 7.10 PP PVC PVC PVC PVC –40 up to +105 90 75
16 LEONI Dacar ® Coaxial Cables [Link]

LEONI Dacar®
Coaxial Cables

Coaxial cables for antennas made for

special and standard applications.

BENEFITS/PROPERTIES APPLICATIONS
■■ fits all standard components GSM, GPS/Galileo, DVB, Radio, WCDMA, HSPDA,
■■ excellent properties for processing WLAN, WUSB, WiMAX, mobile broadcast, Car to Car
■■ approvals from all major OEMs Communication
■■ outstanding coupling resistance and shield

attenuation properties CUSTOMISED OPTIMISATIONS OF

■■ stable impedance ■■ high frequency properties such as

■■ low signal attenuation ➔ EMC properties

■■ best environmental properties/recyclability ➔ Impedance
■■ solid / foam dielectrics ➔ Reflection and transmission parameters
■■ standard temperature range ■■ mechanical properties

–40 up to +85 °C / –65 up to +205 °C ■■ chemical and thermal parameters based on

■■ standard diameter ranging from 1.6 to 6.7 mm inhouse material design and radio frequency
■■ standard impedances of 50/75/120/125/130 Ω laboratories
available
[Link] LEONI Dacar ® Coaxial Cables 17
18 LEONI Dacar ® Coaxial Cables [Link]

Coaxial Cables with foam dielectric

Code Part number Cross section Diameter of conductor Conductor material Diameter of core

nom. nom. nom.

[mm²] [mm] [mm]
50 Ohm
LEONI Dacar 031 85120003A 0.40 0.81 Cu bare 2.10
LEONI Dacar 037 85120030D 0.75 1.11 Cu bare 2.95
LEONI Dacar 302 85120380D 0.40 0.81 Cu bare 2.10
LEONI Dacar 380 85120385A 0.22 0.60 Cu bare 1.53

75 Ohm
LEONI Dacar 360 85120370A 0.089 0.385 Cu bare 1.68
LEONI Dacar 362 85120381D 0.141 0.48 Cu tinned 2.10

120 Ohm
LEONI Dacar 077 85120035D 0.055 0.32 Copper clad steel conductor bare 3.10

Code Impedance Capacity Conductor Velocity of Weight

at 1kHz resistance propagation
at 20 °C
[Ω] [pF/m] [Ω/km] [%] [kg/km] 0.1 0.2 0.5 0.8
50 Ohm
LEONI Dacar 031 50.00 85.00 48.50 77 23.00 20.5 25.9 – 48.3
LEONI Dacar 037 50.00 88.50 25.50 78 39.00 11.2 16.1 26 33.5
LEONI Dacar 302 50.00 85.00 48.50 78 23.00 – 21.1 30.3 43.7
LEONI Dacar 380 50.00 90.00 85.00 78 12.00 22.7 33.7 54.4 69.7

75 Ohm
LEONI Dacar 360 75.00 61.00 208.00 – 11.00 22.8 – – –
LEONI Dacar 362 75.00 58.00 126.00 – 13.50 15.6 22.2 35.9 46.2

120 Ohm
LEONI Dacar 077 120.00 37.00 850.00 – 23.00 14.2 20.3 32.7 42.1
 [Link] LEONI Dacar ® Coaxial Cables 19

Connecting the world.

Foil shield Shield optical Diameter over Shield material Outer diameter Material jacket Material dielectric Service temperature
coverage shield
nom. nom. nom.
[%] [mm] [mm] [°C]

AL-PP-AL 92.00 2.65 Cu tinned 3.20 PVC cellular PE –40 up to +85

PETP-AL 95.00 3.58 Cu tinned 4.95 PVC cellular PP –40 up to +105
AL-PETP-AL 90.00 2.50 Cu tinned 3.20 PVC cellular PP –40 up to +105
AL-PETP-AL 80.00 2.03 Cu tinned 2.60 PVC cellular PP –40 up to +105

– 90.00 2.08 Cu tinned 2.70 PVC cellular PP –40 up to +105

– 89.00 2.50 Cu tinned 3.10 PVC cellular PP –40 up to +105

– 75.00 3.50 Cu bare 4.80 PVC cellular PE –40 up to +85

Attenuation [dB/100 m]

Frequency [GHz]
1 1.2 1.5 1.8 2 2.2 2.8 3 3.5 4 4.5 5 5.5 5.60 6

53.5 58.6 65.3 72.4 76.7 81.7 95 99.1 110.0 120.0 131.0 141.3 151.2 153.5 161.1
38 41.8 47.8 53.3 56.6 60 69.3 72.4 80.1 87.9 95.3 103.1 110.7 112.6 119.6
48.9 53.6 60.5 66.3 70.5 74 84.4 88.1 96.6 104.2 112.3 120.4 127.8 129.3 134.9
78.7 86.2 97.8 107.9 113.9 118.4 134.4 138.7 150.0 160.4 171.2 182.0 192.9 – 203.0

74.50 – – – – – – – – – – – – – –
52.1 57.5 65.1 – – – – – – – – – – – –

47.5 52.5 59.4 65.7 69.7 73.6 84.4 87.8 – – – – – – –

 20 LEONI Dacar ® Coaxial Cables [Link]

Coaxial cables with solid dielectric

Code Part number Cross section Diameter Conductor Diameter

of conductor material of core
nom. nom. nom.
[mm²] [mm] [mm]
50 Ohm
LEONI Dacar 100 85020350D 0.14 0.48 copper clad steel conductor 1.50
LEONI Dacar 110 85020610D 0.50 0.9 Cu tinned 2.95
LEONI Dacar 300 85120355D 0.14 0.5 copper clad steel conductor 1.52
LEONI Dacar 310 85122990D 0.50 0.9 Cu tinned 2.95
LEONI Dacar 400 85022050A 0.14 0.51 Copper clad steel conductor silver plated 1.48
LEONI Dacar 403 85022055A 0.15 0.51 Cu tinned 1.48
LEONI Dacar 410 85021080A 0.057 0.31 Copper clad steel conductor silver plated 0.81

75 Ohm
LEONI Dacar 200 85023015D 0.182 0.55 Cu tinned 3.10
LEONI Dacar 450 85020360A 0.055 0.31 Copper clad steel conductor silver plated 1.60
LEONI Dacar 210 85040320D 0.22 0.58 Copper clad steel conductor bare 3.70

Code Impedance Capacity Conductor resistance Velocity of Weight

at 1kHz at 20 °C propagation
[Ω] [pF/m] [Ω/km] [%] [kg/km]
50 Ohm
LEONI Dacar 100 50.00 106.00 317.00 66 13.00
LEONI Dacar 110 50.00 105.00 41.00 66 39.00
LEONI Dacar 300 50.00 106.00 317.00 66 13.00
LEONI Dacar 310 50.00 105.00 41.00 66 39.00
LEONI Dacar 400 50.00 106.00 317.00 70 17.00
LEONI Dacar 403 50.00 98.00 125.00 67 14.00
LEONI Dacar 410 50.00 105.00 800.00 70 9.00

75 Ohm
LEONI Dacar 200 75.00 70.00 97.00 – 36.00
LEONI Dacar 450 75.00 75.00 802.00 – 17.00
LEONI Dacar 210 75.00 73.00 157.00 – 56.00
 [Link] LEONI Dacar ® Coaxial Cables 21

Your link to mobile communication.

Shield Diameter Shield material Outer Material jacket Material dielectric Service temperature
optical coverage over shield diameter
nom. nom. nom.
[%] [mm] [mm] [°C]

86.00 1.90 Cu tinned 2.80 PVC PE –40 up to +85

94.00 3.50 Cu tinned 4.95 PVC PE –40 up to +85
85.00 1.92 Cu tinned 2.80 PVC PP –40 up to +85
95.00 3.45 Cu tinned 4.95 PVC PP –40 up to +85
96.00 1.90 Cu silver plated 2.50 FEP FEP –65 up to +205
96.00 1.90 Cu tinned 2.50 TPE-E FEP –40 up to +125
96.00 1.25 Cu silver plated 1.80 FEP FEP –65 up to +205

95.00 3.70 Cu tinned 4.60 PVC PE –40 up to +85

92.00 2.00 Cu silver plated 2.60 FEP FEP –65 up to +205
94.00 4.35 Cu tinned 6.15 PVC PE –40 up to +85

Attenuation [dB/100 m]
frequency [GHz]
0.1 0.2 0.5 0.8 1 1.2 1.5 1.8 2 2.2 2.5 2.8 3

31.3 43.8 69.3 85.9 96.7 105.9 121.1 134.5 141.8 152.5 162.6 172.1 180.9
20.3 27.2 43.0 53.5 60.4 66.2 77.8 87.9 92.7 103.8 110.6 122.1 126.3
29.7 41.8 66.2 81.9 91.9 100.8 115.5 128.5 135.5 145.5 155.1 165.9 171.7
20.3 27.2 43.0 53.5 60.4 66.2 77.8 87.9 92.7 103.8 110.6 122.1 126.3
29.5 42.0 67.7 86.6 97.5 108.0 121.0 134.0 142.0 149.0 160.0 170.0 177.0
29.4 – 61.7 92.8 106.4 – 137.7 – 163.9 – 189.2 – –
50.4 71.3 112.8 152.6 173.5 198.7 222.1 247.0 260.4 285.7 304.5 328.6 340.1

16 22.5 37.0 48.0 55.0 62.0 72.0 81.0 88.0 94.0 103.0 112.0 117.0
27.6 38.1 59.3 75.0 84.1 92.3 103.7 114.2 120.7 127.0 136.0 144.6 150.1
12.4 17.9 29.3 37.9 42.9 – – – – – – – –
22 LEONI Dacar ® FP Automotive Cables [Link]

LEONI Dacar® FP
Automotive Cables

For Data communication between audio

devices and airbag management in
vehicles.

BENEFITS / PROPERTIES The core jacket always consists of two polyamide layers:
■■ easy and cost-efficient assembly a black inner jacket to rule out possible interference from
■■ very good processing properties outside light and a coloured outer sheath (blue, green,
■■ insusceptibility to interference from yellow or orange).
electromagnetic radiation
■■ low weight The fibre consists of a PMMA core and optimised double
■■ large bandwidths cladding.
■■ direct assembly of sockets

■■ length 5,000 m The design significantly reduces the attenuation that

■■ where subject to heavy mechanical strain and occurs when the fibre optic cable is bent compared with
in highly flexible applications with small standard polymer optical fibre.
bending radii

Coding LEONI Dacar® FP:

Colour Code Number Part Number

orange 17 84A00500S262
green C7 84A00500S666
blue C8 84A00500S519
yellow C9 84A00500S201
 [Link] LEONI Dacar ® FP Automotive Cables 23

Diagram:
Dependance attenuation to bending radius (standard POF compared to LEONI Dacar® FP)

5
4
LEONI Dacar ® FP
3
Standard POF
2
Attenuation [dB]

1
0
–1
20 40 60 80 100
Bending radius [mm]
 24 LEONI Dacar® [Link]

LEONI Roth radio frequency lab

LEONI cables are used in various sectors and applications. They are (constant or cyclical changes) or humidity as well as various kinds
therefore subject to differing mechanical, electrical and climatic of mechanical strain such as flex cycles and torsion are of increasing
requirements, which are specified and published in our data sheets. importance. This enables making predictions about the long-term
Radio frequency properties are significant especially when it comes behaviour and useful life of the cables in the various areas of use.
to the coaxial and data cables of the LEONI Dacar® line. To meet
these different requirements, we integrated a laboratory within the The characteristic impedance (wave impedance) of a cable can
test lab at our facility in Roth fitted with state-of-the-art equipment be ascertained by various measurement methods. Time domain
for measuring and ascertaining the radio frequency properties of reflectrometry (TDR) determines and shows the pattern of a cable’s
our cables. To guarantee a high level of production quality at all wave resistance over time. The impedance pattern is scrutinised for
plants that are producing LEONI data cables the necessary measur- irregularities, i.e. for reflections in the cable’s make-up. This makes
ing devices were installed and specialised staff in laboratories and it possible to identify and correct for example discontinuities or
quality management has been trained. damage caused in the manufacturing process or during fitting. A
network analyser makes it possible to ascertain all the key param-
Scope of the RF lab’s activity eters of a cable. The wave impedance is determined indirectly by
The tasks of the lab for radio frequency measurements are wide means of two reflection measurements set off against each other.
ranging. In addition to development and production-related meas- This complex process makes sure that the measured impedance of
urements and analysis, the lab measures, evaluates and assures the the cable is only marginally affected by the properties of the meas-
cables’ radio frequency properties pursuant to the pertinent nation- uring instrument and the measuring set-up. Due to the modern
al and international test standards as well as customer specifications equipment that, besides different standard network analysers also
in the context of qualification and re-qualification tests. The proper- comprises a symmetric network analyser, measurements become
ties of cables under different ambient conditions such as cold, heat
[Link] LEONI Dacar® 25

possible that go far beyond the limitations of usual baluns (sym- Radio frequency properties of cables
metric transmitters).
Transfer parameters:
Rather like four-terminal attenuation, the parameter of wave at- Impedance
tenuation describes the transmission property of a cable depending Structured return loss
on its length and is usually quoted in the unit [dB/100m] on data Attenuation
sheets and in specifications. Either wave or four-terminal attenu- Shield attenuation
ation enables determining the maximum length of a cable along Transfer impedance
which reliable and faultless data transmission is possible. Cross-talk (NEXT, FEXT, PSNEXT, Alien NEXT)
In the case of cables with either a foil or braided shield, or a combi-
nation of the two, the quality of the shield is determined by measur- Primary cable parameters:
ing the electromagnetic radiation of the cable by means of line in- R‘ / G‘
jection or triaxial measuring methods. Both measuring methods can C‘
be performed in the radio frequency lab at LEONI. Measurements of L‘
shield attenuation values beyond –100dB can be carried out using
the shield attenuation chamber set up for the line injection method.

Besides the desired effect, the transmission of signals, all methods LEONI has invested repeatedly over the past few years to bring
of transmitting data involve unwanted noise transmission. These ef- the RF laboratory within the LEONI group to such a high level it is
fects are defined by several different terms like NEXT, FEXT, PSNEXT, currently at. With their automated measuring systems, the produc-
ELFEXT, ALIENNEXT, etc. When an electrical signal, such as a data tion plants are able to record all RF parameters that are relevant to
signal, is transmitted via a core pair that is fed through a cable with the production. This guarantees a stable and high level of quality
several other core pairs (for instance star quad cables), this signal is of the transmission parameters. The facility of Roth, as develop-
coupled to other core pairs. The intensity of coupling the signal to ment and competence centre, has been equipped with additional
another core pair is described, depending on the end at which the high-precision measurement devices. This equipment allows us to
interfering signal is received, by the parameters of either near-end respond to the highest quality and performance requirements from
crosstalk (NEXT) or far-end crosstalk (FEXT). the development phase to serial production.

Overview of the RF lab’s equipment Neither the ongoing expansion nor further development of meas-
Digital Sampling Oscilloscope 20GHz/tr=17.5 ps urement methods in the area of high frequency measuring is just for
Symmetric Network Analyser 300 kH up to 8 GHz internal purposes, but rather also important to serve the interests of
Network analyser 300 kHz to 8.5 GHz our customers.
Precision LCR meter 10 Hz to 1 MHz
Shield attenuation chamber with measuring space
for the line injection method
Network analyser 30 kHz to 4 GHz
Triaxial measurement tube 1–3 m, climate chamber for
measurements under climatic conditions with temperatures
ranging from –40 °C to +180 °C
26 LEONI – The Quality Connection [Link]

Quality management
Automotive Cables

LEONI quality management

We are able to satisfy the exceptionally high standards of our cus-
tomers from the automobile industry. The quality management at all
the LEONI Wire and Cable locations throughout the world is certified
as complying with ISO 9001:2002; locations producing automotive
cables are also certified according to ISO/TS 16949:2002. Our efforts
are concentrated on preventive quality assurance involving fault-
inhibiting instruments such as FMEA or machine and process capabil-
ity analysis.

We use state-of-the-art systems to continuously measure, monitor

and control the diameter and dielectric strength of our cables and
wires during the production process. Regular testing of random sam-
ples guarantees product compliance with the required limit values.
With these tests conducted directly alongside the production line it
is possible to respond quickly to any faults.

Product properties are tested in accordance with our customers‘ LEONI environmental management
own specifications and/or German and international standards. For us, business success with ecological responsibility is not a contra-
They include: diction in terms. As a globally active producer we acknowledge our
cable and wire behaviour under extreme temperature co-responsibility in protecting the world‘s natural resources and basis
conditions of life. It is our objective to strike a harmony between nature‘s needs
functionality after artificial ageing and our company‘s interests. As such, environmental protection is an
resistance to fuels, lubricants and environmental intrinsic element of our corporate activities. We motivate our contrac-
influences tual partners to follow environmental guidelines that are equivalent
resistance of the insulated covering to stretching, to our own and advise our customers on how to use and dispose our
abrasion and tearing products in an environmentally responsible manner.
mechanical and electrical properties of the conductor
alternate bending strength and resistance to torsion Our environmental management system is certified as complying
with DIN EN ISO 14001, confirming that our environmental policy is
Through the combined efforts of these quality assurance activities effectively implemented.
we are able to continuously optimize our ambitious quality goals.
[Link] LEONI – The Quality Connection 27

LEONI worldwide LEONI news

Cable facilities of the LEONI group

Germany ➔ LEONI Kabel GmbH, LEONI HighTemp Solutions GmbH Our regularly updated information services such as the
China ➔ LEONI Cable (Changzhou) Co. Ltd. customer publication “LEONI inTeam” keep you abreast of
Hungary ➔ LEONI Kábelgyár Hungaria Kft. recent developments at LEONI and on the market, either by
Poland ➔ LEONI Kabel Polska S.p.z.o.o. mail or by e-mail. So that we can tailor our choice of topics
Mexico ➔ LEONI Cable Mexico S.A. de C.V. even more closely to your requirements and interests, we would
Turkey ➔ LEONI Kablo ve Teknolojileri San. ve Tic. Ltd. Sti. be delighted to receive your suggestions and comments.
Slovakia ➔ LEONI Slowakia spol. s.r.o.

Sales offices of the Automotive Cables business unit

Production facilities of the Automotive Cables business unit

Polen
USA Slowakei
Deutschland
Ungarn Türkei
Mexiko China

Proximity to our customers is a core element of our corporate policy. Visit our website
LEONI is a dependable partner to its customers – all over the world. [Link]
We also regard maintaining, as well as raising quality and service at
the same high level everywhere in the world as a sign of proximity.

We support efficient operating as well as our customers’ power of

innovation and market position on the basis of our own international
positioning, standardised methods and clearly defined processes.
No matter where we apply and realise our know-how, commitment
and ideas: we want confident customers around the world.
LEONI Kabel GmbH Stieberstrasse 5
Automotive Cables 91154 Roth
Germany
Phone +49 (0)9171-804-2218
Fax +49 (0)9171-804-2232
E-mail cable-info@[Link]
[Link]