GLOBAL AUTOMOTIVE DIVISION

AUTOMOTIVE WIRE & CABLE

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GLOBAL AUTOMOTIVE DIVISION

AUTOMOTIVE PROTECTION PRODUCTS

Corporate Overview

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Tyco Electronics embraces the most valued brand names worldwide

Tyco Electronics Corporation – thelargest unit of Tyco InternationalLtd. – was established inSeptember 1999 when Tycoacquired Elcon Products andRaychem Corporation, andintegrated them with AMP,acquired earlier the same year.Since then, the company hasrapidly grown and strengthened itscompetencies as an electrical andelectronic component supplier, withproduct offerings in 25 passive andactive product segments. In thepassives field, Tyco Electronics isnow the world’s largest supplier.

The company has facilities locatedaround the globe serving customersin the aerospace, automotive,

commercial electronics/communications, industrial/energy,marine, medical, military and railindustries. Tyco Electronics’ productportfolio continues to grow,encompassing connector systemsand application tooling, active andpassive fibre optic devices,complete power systems, wirelesscomponents (including ICs, radarsensors, and completecommunication systems), GPS andintegrated antenna systems, heat-shrink products, circuit protectiondevices, magnetic components,wire and cable systems,touchscreens, PC boards andbackplanes, smart cards, relays,sensors, electronic modules, wireharnessing and labelling products,

battery packs, terminal blocks andswitches.

A significant result of thiscontinued growth, and real benefitto customers, is that TycoElectronics’ technology leadershipbecomes even stronger. Thesynergies of expertise in materialsscience, product design, andprocess engineering, coupled withknowledgeable applicationengineers, sales representatives,and customer service personnel toenable you to make your nextgeneration of products successful.

IntroductionR

The Tyco Electronics Raychembrand of Automotive Wire andCable products is recognisedworldwide, and is backed by ahistory of proven performance,reliability, innovation and superiorquality.

For over forty-five years, customershave recognised the globalcapabilities of Raychem products.Combining these advancedproducts with superior technicalsupport and a global sales/servicesorganisation, customers withworldwide operations count on

Tyco Electronics to supply theknowledge and products they needto solve specific problems and helpthem take advantage ofopportunities, anywhere they arise.This philosophy has earned TycoElectronics a reputation forleadership in materials sciencetechnologies.

Developed from thesetechnologies, Raychem highperformance Automotive Wires andCables perform from –40°C to200°C. They are engineered tomeet or exceed the most rigorous

automotive specifications, and arethe solution for challengingenvironments and demandingapplications.

This catalogue brings togethersome of the unique, tried andtested technologies pioneered byRaychem. Materials with uniqueproperties, manufacturingtechniques finely honed withexperience and research anddevelopment expertise combine toprovide some of the mostinnovative Automotive Wires andCables today.

Automotive wire market: The Raychem approach

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PVC

FEPPTFE

PFA

XL

TPE

ETFE

125°C

150°C

200°C

Pric

e($

/Km

)

Performance (Temperature Class)P f (TPP

The Raychem brand of TycoElectronics started to produce wiresin the late 50s by introducing twonew technologies in the market:Irradiation cross-linking and dual-wallinsulation systems combining twodifferent polymers to offer the bestbenefits of both.

The ”chem“ in our brand comes fromChemistry, our product developmentteam are continuously looking fornew ways to enhance theperformance of ”off-the-shelf“materials.

Our strategy was, and still is, to addvalue to the market by offeringproducts which outperformcommodities either in cost or inproperties to provide the best valuealternative to a given specification.

This is what the graph above shows:

• 55E is the T6 wire offering thebest balance of cost/performance,in the automotive market and weachieved it by chemicallymodifying the base polymer andthen cross-linking it using an e-beam.

• ACW is the T4 wire offering thebest balance of cost/performance,in the automotive market and weachieved it by creating a dual-wallinsulation system, chemicallymodified and also e-beamirradiated. A key factor in thesuccess of ACW is the fact thatthe two walls are bonded andbehave as a single insulationduring the handling processes inharness shops.

• AGP, finally, is a new generation ofpolypropylene based insulationsystem which overcomes all thecompatibility issues shown in themarket by its predecessors. AGP is today the only wire ratedT3 to all European specifications,meeting the toughest compatibilityrequirements, exceeding themechanical expectations, beingfully recyclable and at a price of astandard polypropylene.

Contents

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Core Technologies 4

Cross reference to DIN/ISO part numbering 8

Application Areas 10

Automotive Wire & Cable Application Documents 13

125°C rated wire 14150°C rated wire 16200°C rated wire 18Battery and power cables 20Halogen, fog and high intensity discharge lamp wiring 22Automatic transmission fluid wire 24Diesel injection wire and cables 26Airbag cables and twisted pairs 28Engine sensor cables 30ABS sensor cables 32Databus cables 34

Automotive Wire & Cable Data Sheets 37

AGP Automotive Wire – AGP0119 38AGP Automotive Wire – AGP0129 40AGP Automotive Wire – AGP0219 42AGP Automotive Wire – AGP0229 44ACW Automotive Composite Wire – ACW0219 46ACW Automotive Composite Wire – ACW0229 4855E0119 5055E0219 52ATF*0*11 54Automotive Sensor Cables – ASC 56Power cables 58

Further information 61

Packaging 62Contact Information 64

Core Technologies

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Raychem Wire and CableTechnology: Materials challenges – Leading edge solutions

Since it’s founding in the 1950s,Raychem has pioneered many of thebreakthrough technologies used tocreate today’s most advancedinsulation/protection systems.Raychem products are in servicethroughout the world in automotive,telecommunications, powerdistribution, aerospace and defenceapplications. Renowned for theirunrivalled performance and reliabilityin the most demanding ofenvironments, they include acomprehensive range of AutomotiveWire and Cable products. Combinedwith Tyco’s state-of-the-artmanufacturing facilities andprocesses, these products offer themost cost-effective and robustsolution to all your wiring andinterconnection needs.

Pioneers in Automotive Wire and Cable

Raychem was the first company tocommercialise radiation cross-linkingof insulation, initially for aerospaceapplications. The high-performancetechnologies developed were lateradapted and further developed forhigh-volume automotive applications.Maintaining its position as the pre-eminent force in radiation cross-linked insulation materials to thepresent day. Raychem has sincepioneered new technologies toenable non-cross-linked insulations tobe used in environments where adifferent balance of properties isrequired. Some examples ofRaychem’s pioneering wire and cabletechnologies are explained in thissection.

55E wire: 200°C AutomotiveEngine Compartment wire

First developed by Raychem for theAerospace industry, where ultra-reliability is a must, the predecessorof this wire has been in service incommercial and military aircraft for the past 25 years with anunparalleled safety record. It is a cross-linked fluoropolymerinsulation, and as such, maintains anexcellent balance of properties atextremes of temperature. In itsautomotive version, it possesses superior robustness, markability andovermoulding characteristics to rivalinsulation types, and is essentially immune to all forms of chemicalattack by automotive fluids.

ACW: Automotive Composite Wire – Dual layer bonded insulation technology

Copper conductor Polyolefin innerinsulation

Fluoropolymer outer insulationlayer for outstanding mechanicaland chemical resistance

Core Technologies

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ACW wire: The leader in Dualwall technology for 150°CAutomotive Applications.

In the 1960s, Raychem developed thefirst successful dual-layer insulation,balancing some key performanceadvantages of fluoropolymermaterials, with some of the costadvantages of polyolefin insulation.This was achieved by extruding afluoropolymer outer layer over aninner layer of polyolefin insulation,and cross-linking the resultingproduct.

In the late 1990’s, Raychem took thistechnology to the next level,inventing a way to bond theseseemingly incompatible layerstogether, to create a true compositeinsulation structure for the first time -In fact the name “ACW” stands for“Automotive Composite Wire”This patented breakthrough enabledRaychem to provide the automotiveindustry with an outstandingly robustand cost-effective product, with somecritical advantages over competing technologies (includingnon-bonded “lookalike” products). In addition to meeting the mostdemanding 150°C specifications, the product possesses superbautomated handling and strippingcharacteristics. As a result of thesebenefits, ACW has quickly becomethe dominant 150°C wire in usetoday by European OEMs, and its usecontinues to grow.

Uncross-linked polymer chains in insulation immediately after extrusion:Long chain molecules are free to slide over each other – polymer can be melted

To cross-link the insulation, high energy electrons are fired at it in a special chamber:

The resulting structure is a network of linked molecules: This acts as a single giant molecule. Because the chains are no longer free to move over one another, the cross-linked molecules will not melt

Reactive sites are created on thepolymer chains. These sites may combine with other sites on adjacent polymer chains, linking them together

What is Radiation Cross-linking?

Core Technologies

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AGP wire: A breakthrough in125°C rated wire technology

In recent years, polypropylene hasachieved widespread market successwithin the automotive and otherindustries in a wide range of injectionmoulded and extruded products. It isvalued for its combination ofexcellent mechanical properties, lowcost, and easy recyclability. As athermoplastic material, it can be re-melted and re-processed into newcomponents at the end of a vehicle’slife, making a significant contributionto increasingly stringent requirementsfor recyclability of vehicles. It haslong been the goal of wiremanufacturers to incorporate theseadvantageous properties ofpolypropylene into a viableautomotive wire for applications upto 125°C. These efforts have hithertobeen hampered by technicaldifficulties in achieving the requiredthermal stability and materialcompatibility in the aggressiveenvironment of a vehicle enginecompartment. Tyco has, however,succeeded in developing proprietaryformulations which overcome theselimitations, thus creating a newgeneration of polypropylene insulatedwires which combine low cost with asuperb balance of mechanical,thermal, and chemical/environmentalbenefits.

Tyco’s Product Design Philosophy

• Innovation is key: We don’tfocus on “me too” products. We concentrate instead on addingsignificant technology, cost, andquality benefits to our customers. We achieve this by taking a radicalapproach to product design, focussingon the optimum solution for theapplication, rather than on thecharacteristics of existing solutions.

• Testing products to their limitsand beyond: We ensure therobustness of our products byextensive testing, not just tocustomers specificationrequirements, but well beyond them,to ensure that we fully understandthe performance envelope of ourproducts. Thus we ensure that theclaims we make for the reliability andperformance of our wire and cableproducts can be backed up by hard experimental data.

• Meeting the customer’s realneeds: We have long recognisedthat to be a product which ourcustomers want to use, as opposedto one which simply meets the formalspecification, a whole range ofadditional performancecharacteristics may be required. We have done extensive work with a range of customers to define thesecharacteristics, and in conjunctionwith them, have developed our own“handling specification”, an internalrequirement which we ensure ourproducts pass before we releasethem commercially. This documentcomprises a rigorous series of tests,often under extreme conditions. It assesses a wire’s ability to passsuccessfully through all the majoroperations (e.g. cutting, stripping,termination, welding) to which it islikely to be subjected during themanufacture of harnesses, orinstallation into a vehicle.

As part of our advanced productdevelopment facility we have acomprehensive suite of analyticalequipment that aids product design.

Picture: Scanning electronmicroscope.

During product development wires aretested against many requirementsoutside of the OEMs specification. Theway the wire behaves in the manyharness shop processes is critical tothe design.

Picture: Ultrasonic welding machine.

Core Technologies

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• Continuous improvement: We visit our customers frequently, to ensure their ongoing satisfactionwith our products, and are alwayskeen to listen to their views on anyfurther refinements they would like tosee. We also continuously review the performance andcompetitiveness of our products, and introduce efficiency, quality,and/or technical improvements withevery iteration. Thus we ensure thatour customers are able to benefitfrom the most advanced productsavailable, and we aim always toprovide products with the leadingprice/performance ratio in eachtemperature class.

• Commitment to Quality: Our plant in Valls, Spain was one of the first in Europe to gain ISOTS16949 approval. Along with ourother manufacturing plants, also ISOTS approved, we are able to provideguaranteed quality products,manufactured to the most demandingperformance and dimensionalspecifications on precision extrusionand processing equipment.

Summary

Tyco – Technical leadership inthe Wire and Cable industry

• We were the original pioneersof radiation cross-linking, andare the leading supplier ofsuch products worldwide

• We are rapidly attainingleadership in some key non-cross-linked insulationtechnologies, where they aremost appropriate for theapplication

• All our major product lines useinsulation formulationsdeveloped in-house, andtailored to give optimumperformance for each specificneed

• When we develop any newproduct, we test it well beyondthe limits of international andOEM specifications, to ensurethat it will not only exceedexpectations in service, butwill be as easy to process andinstall as possible

• We employ state-of-the-artmanufacturing techniques toensure that consistent productquality is achieved

• We provide comprehensivehandling guidelines with ourproducts, and our experttechnical support team isalways on hand to respond toany technical queries that mayarise

Quality/Environment

End of Life Vehicles Directive

All of our products (in this catalogue– must be specific and must bechecked) meet the requirements ofthe published EC Directive on “End of Life Vehicles”, 2000/53/EC, inthat they do not contain cadmium,mercury, lead or hexavalentchromium.

According to amendment reference2002/525/EC of Directive2000/53/EC, we do not declarematerials below a maximumconcentration value up to 0.1% byweight for lead, hexavalent chromiumand mercury and up to 0.01% byweight for cadmium, if thesesubstances are not intentionallyintroduced.

Declarable and RestrictedMaterials Reporting

Our standard electronic reportingmethod for product material content,including declarable or restrictedmaterials, is via the InternationalMaterial Data System (IMDS), bymeans of Material Data Sheet (MDS)submissions to our customers uponrequest or new part approval.

IMDS is a joint development of Audi,BMW, DaimlerChrysler, Ford, Opel,Porsche, VW and Volvo. In the IMDS, all materials used for carmanufacture are archived andmaintained. Only in this way is itpossible to meet the obligationsplaced on car manufacturers, andthus on their suppliers, by nationaland international standards, laws andregulations.

Compliance with other OEM’smaterial reporting requirements ismaintained by submission of relevantdeclaration forms as required againstindividual OEM specifications.

RCross reference to DIN/ISO part numbering

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AGP0219 AGP0229 ACW0219 ACW0229 55E0219 ASCsSingle core wiresunshieldedFLR9YFLR7YFLR6YFLR2XFLR13YFLRY

Multi coreFLR7Y 2XFLR13Y 2XFLR2X..2XFLR 33X33XFLR7Y33X

DIN classificationsFLR = low voltage cable with reduced wall thickness of insulation

Construction codesB Foil screen (usually aluminium)C Woven copper braidD Spiral copper braid

Material code Material descriptionY PVCX Cross-linked PVC2Y Polyethylene2X Cross-linked polyethylene4Y Polyamide5Y PTFE6Y FEP7Y ETFE9Y PP11Y PUR2G Silicone3G EPR/EPDM4G EVA

RCross reference to DIN/ISO part numbering

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Colour coding chart0 Black1 Brown2 Red2L Pink3 Orange4 Yellow45 Yellow/Green5 Green6 Blue7 Violet8 Grey9 White

*These colours are an indication only

The ‘*’ in the part number shall bereplaced by a standard numericalcolour code designator as perabove.

Additional number after base colourindicates stripe. e.g. ACW0219-0.50-54 is a greenbase colour with yellow stripe. Where stripes are required the wirecarries two co-extruded longitudinalstripes of the same colour.

The individual stripe width is aminimum of 10% of the wirecircumference with an overall stripecoverage of 30% maximum.

ACW0219: Ordering example:

ACW0219-0.50-54

RApplication Areas

DriverInformation

Safety

Body

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Convenience

Powertrain

Security

Chassis Systems

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