FLR2X Cable for Automotive Wiring

What are FLR2X Cables?

Within the automotive industry, electrical systems are evolving to be more compact, powerful, and thermally demanding, making it crucial for manufacturers to choose the right cable for efficient and reliable processes. As a trusted OEM wire supplier, IEWC provides a wide selection of FLR2X cable options that offer a reliable, space-efficient solution for modern vehicle wiring harnesses and low-voltage power circuits while conforming to automotive manufacturers and ISO 6722 wiring standards and other industry regulations. Curious how FLR2X compares to other automotive wire types? We’ll break it down in the section below.

Key Features and Construction

Designed for use in harsh environments where heat, vibration, fluids, and tight routes are common, FLR2X cables (primary wires) have some variation meeting diverse performance and installation requirements.

• Thick or thin walls: Thin-wall variations help reduce weight and support tight routing, while thick-wall options provide additional protection in rugged environments. Choose the appropriate wall thickness based on space constraints and mechanical durability requirements.
• Stranded bare or tinned copper conductor: Stranded copper ensures flexibility whereas tinned copper offers enhanced corrosion resistance and easier soldering, especially in high-humidity or long-life cycle applications.
• -40°C to 125deg;C temperature range: Designed to operate in extreme weather conditions.
• RoHS compliant: Free of restricted hazardous substances meeting environmental and safety regulations.

Common Applications for FLR2X Cables

FLR2X cables are widely used in low-voltage automotive electrical systems, particularly where compact routing and high thermal resistance are critical. Their flexibility and durability make them well-suited for vehicle wire harnesses, battery ground circuits, and engine compartments — areas that are exposed to fluctuating temperatures, vibration, and potential fluid exposure.

With these cables being useful in both conventional and electric vehicles, including passenger cars, commercial trucks, construction equipment, etc., they are a go-to choice for the industry. FLR2X cables are also used in applications where tight bends, high humidity, or long service life are expected, because of its stranded construction and XLPE insulation options, making it a reliable wire type for cars and commercial vehicles.

What is the Difference Between FLR2X-A and FLR2X-B?

Both types of FLR2X cable types have similar characteristics, like being XLPE insulated and suitable for automotive users. The main difference is in the specific construction of the product and use cases. FLR2X-A cables tend to be more symmetrical, used for low-tension wiring, and suitable for tight spaces. These cables are used for more general-purpose automotive wiring. FLR2X-B cables, on the other hand, tend to have thinner walls and are specifically designed for more demanding, and higher temperature resistance applications, like motor and battery ground circuits, also more popular in European regions.

Which Automotive Wire Type Should I Use?

While FLR2X cable is a leading choice for high-performance automotive wire harnesses — thanks to its XLPE insulation, thermal stability, and compact design — it's not the only option on the market. Understanding how FLR2X compares to other automotive primary wire types such as TXL, GXL, SXL, GPT, TWP, and HDT helps engineers and OEMs choose the most suitable wire for car applications based on insulation type, temperature rating, and environmental exposure.

Compared to traditional PVC-insulated wire, FLR2X and other XLPE automotive cables offer enhanced thermal and chemical resistance for harsh environments like engine compartments or battery ground circuits. However, PVC wires remain a reliable, cost-effective solution in many general and low-voltage automotive applications. Below is a breakdown of how these popular wire types differ in terms of construction and common use cases:

Selecting the Best Automotive Cable for Your Application

Choosing the best wire for high-temperature automotive applications requires careful consideration of factors such as insulation material, conductor type, and wall thickness, especially when operating in demanding environments such as engine compartments and EV battery circuits.

• Environment: Consider the cable’s intended environment, such as under-hood engine compartments or battery circuits. While FLR2X is built for harsh environments, it is still critical to match the insulation and conductor type to the level of exposure.
• Routing space: For tight routing paths or dense harnessing, a thin wall FLR2X option helps reduce bulk and improve flexibility. If mechanical protection is a concern, a thicker wall may be necessary to prevent damage during installation.
• Electrical requirements: Ensure the cable’s voltage rating, current capacity, and insulation type match the circuit’s demands. Tinned copper may be preferred with its enhanced conductivity and corrosion resistance.

Installation Tips

Proper installation of FLR2X is essential to maximize performance in automotive environments. Key things to keep in mind include:

• Avoid over-bending: Always follow the cable’s minimum bend radius, especially in tight routing paths or high-flex zones.
• Secure against vibration: Use wire management tools (like cable ties or convoluted tubing) to secure the cable and minimize movement.
• Protect from sharp edges: Use grommets or protective sleeving to prevent abrasion or cuts.
• Mind fluid exposure: Primarily avoid contact with pooling liquids.
• Maintain proper strip length: When terminating FLR2x cable, strip only as much insulation as needed to avoid nicking the conductor strands.