High-Voltage Wire Harness
ORANGE JACKET.
800 V ARCHITECTURE.
100% HIPOT.
EV battery, traction inverter and DC fast-charge harnesses from Cavite. 6 mm² to 95 mm² cross- sections, Lapp Olflex EV and Coroplast 9-2611 cable, Amphenol Radsok and TE HVA-630 termination. Every harness 1,500 V AC HiPot 100% tested with a 0.3 mA leakage gate.
1000 V
Max DC Rating
1500 V
AC HiPot Test
200 A
Max Continuous
0.3 mA
Leakage Gate
Orange Jacket
ISO 6469-3 ready
1,500 V AC
100% HiPot
UL 758
Verified material
Class 3
IPC-A-620 default
Why HV Is Different
VOLTAGE BREAKS
THE EASY ASSUMPTIONS.
A 12 V signal harness can survive a marginal crimp, a misrouted shield, or a wrong cable-seal size — performance degrades quietly. A 600 V battery harness cannot. The same defect arcs to ground, trips a contactor, and bricks a vehicle in the field. Every cell in the Cavite HV bay is laid out with that asymmetric failure cost in mind: lug-crimp cross-section every shift, Cirris HiPot 100% serial, shield continuity below 5 mΩ before sign-off.
If your harness is HV but the dominant constraint is sealing (EV charging gun, marine BESS), see waterproof harness — we stack both specs. For lower-voltage signal and chassis runs, see custom wire harness. For HV that requires a TPE strain-relief overmold (EV charge connector boot), see overmolded harness.
HV Capability Block
WHAT THE HV BAY
ACTUALLY DOES.
600 V to 1,000 V DC Orange-Jacket
EV-grade orange-jacket cable from Lapp Olflex EV, Coroplast 9-2611 and TE Raychem ZH series. UL 758 / UL 1581 / ISO 6469-3 references on file. Cross-sections from 6 mm² to 95 mm² (AWG 10 to 4/0) routinely built.
Up to 200 A Continuous
Battery interconnect and traction-inverter feeds rated to 200 A continuous, 350 A 30-second peak. Lug crimp on 70 mm² uses 95 kN hydraulic press with calibrated die set. Cross-section verified each shift, IPC Class 3.
1,500 V AC HiPot 100%
Every HV harness through Cirris CR / HiPot tester at 1,500 V AC for 60 seconds with a 0.3 mA leakage gate. Insulation resistance test at 500 V DC, 100 MΩ minimum. Failures arc-trip and quarantine the assembly automatically.
EMI Shielding & HVIL
Tinned-copper braid (JIS C 3406) and aluminum-PET foil shield, 360-degree termination via Amphenol Radsok or TE HVA series. HVIL (High-Voltage InterLock) detection circuit integrated where the customer specifies.
HV Connector Library
Active stock: Amphenol Radsok PowerLok, TE HVA-280 / HVA-630, Rosenberger HVR series, Hirose RF40, JAE MX97. Compatible with Tesla, BYD, BMW iX and Volvo EX battery-pack interface specs on quote.
Partial Discharge Tested
PD testing on request per IEC 60270 — 5 pC discharge gate at 1.2 × U_n. Required for 800 V architecture programs (Porsche Taycan, Hyundai E-GMP class). Test bench rated to 5 kV AC, calibrated quarterly.
Specification Sheet
HV ENVELOPE.
DC Voltage Rating
300 V, 600 V, 800 V, 1,000 V DC system rated
Cable Cross-Section
6 mm² to 95 mm² (AWG 10 to 4/0)
Current Rating
30 A to 200 A continuous · 350 A 30-second peak
Cable Vendors
Lapp Olflex EV, Coroplast 9-2611, TE Raychem ZH, Belden Hybrid
HV Connectors
Amphenol Radsok PowerLok, TE HVA-280/630, Rosenberger HVR, Hirose RF40
Jacket Color
Orange RAL 2003 (HV) per ISO 6469-3 · custom on quote
Operating Temperature
−40 °C to +150 °C (XLPE) · +200 °C (silicone)
HiPot Test
1,500 V AC / 60 s / 0.3 mA leakage · 100% of units
Insulation Resistance
500 V DC test, 100 MΩ minimum, 100% of units
Partial Discharge
IEC 60270, 5 pC at 1.2 × U_n on request (800 V architecture)
EMI Shielding
Tinned-copper braid 85% coverage + aluminum-PET foil
Acceptance Class
IPC/WHMA-A-620 Class 3 default
Lead Time
Sample 5-7 days · Production 12-18 days
MOQ
1 piece (NPI) · 200 (production tier) · 2,000 (volume tier)
HV-Specific Flow
SINGLE-LINE TO
FOB MANILA.
HV Spec Review
Send single-line, system voltage, peak current, HVIL requirement and connector mating spec. Engineering replies in 12 h with quote and PD-test recommendation.
Material Approval
Cable, terminal, and shield braid lot certified to UL 758 / UL 1581 / ISO 6469-3. Customer-portal MDS upload supported when required by the program.
Lug Crimp + Cross-Section
70 mm²+ on 95 kN hydraulic press, calibrated die. Cross-section every shift verifies void-free crimp at IPC Class 3 acceptance.
Shielded Assembly
360-degree braid termination on the Radsok or HVA backshell. Continuity from shield to chassis < 5 mΩ. Operator IPC-620 Class 3 plus HV addendum.
1,500 V HiPot + IR
Cirris CR HiPot 1,500 V AC / 60 s / 0.3 mA gate, plus 500 V DC insulation resistance 100 MΩ minimum. Both 100%, both serialized.
Pack & Ship
Anti-static bag, vacuum-sealed, foam-padded carton. FOB Manila MICT; qualifying Philippine-origin product (HS 8544.30 / 8544.42) is outside the China Section 301 tariffs.
Application Map
SIX HV USE
CASES.
EV Battery Pack Interconnect
Module-to-module and module-to-BMS bus bars and harnesses. 70 mm² to 95 mm² (AWG 2/0 to 4/0), 1,000 V system, Amphenol Radsok PowerLok or TE HVA-630 termination.
Traction Inverter / Motor Feed
3-phase shielded HV harness for permanent-magnet and induction traction motors. 800 V architecture supported, partial-discharge tested per IEC 60270.
DC Fast-Charge Stations
150 kW to 350 kW CCS / CHAdeMO charge cabinet harnesses. UL 2251, IEC 62196 sealing geometry, liquid-cooled cable variants on quote.
Battery Energy Storage (BESS)
Stationary BESS DC strings 600 V to 1,500 V, NEC 690 compliant. UL 4703 PV cable on solar-side, EV cable on battery-side, copper bus bars in between.
PV Inverter & Combiner
1,500 V DC string and combiner harnesses for utility-scale solar. MC4 / Stäubli connectorization, 25-year UV + humidity validated.
eVTOL & Industrial Mobility
Aerospace-leaning HV harness for eVTOL battery and industrial AGVs. MIL-DTL-38999 + Radsok hybrid backshells.
Founder Note
“800 V architecture is where most contract manufacturers stumble — not because the assembly is harder, but because partial-discharge testing requires a 5 kV AC bench and a quarterly calibration. We added that bench in 2022 because the EV programs we wanted demanded it. It is now a competitive moat.”
Mr. Fei Bo Hu
President · Xudong Group · XUDONG
HV FAQ
SIX QUESTIONS
HV BUYERS ASK.
Q.01What voltage range counts as “high voltage” here?
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What voltage range counts as “high voltage” here?
Q.02Do you support 800 V EV architecture programs?
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Do you support 800 V EV architecture programs?
Q.03How do you handle EMI shielding and 360-degree termination?
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How do you handle EMI shielding and 360-degree termination?
Q.04Can you build harnesses for both EV traction and BESS in the same line?
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Can you build harnesses for both EV traction and BESS in the same line?
Q.05What is the lead time and MOQ for HV builds?
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What is the lead time and MOQ for HV builds?
Q.06Are HV harnesses from Cavite outside the China Section 301 tariffs?
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Are HV harnesses from Cavite outside the China Section 301 tariffs?
Related Services
ADJACENT HV
CAPABILITIES.
Waterproof Harness
Stack IP67 / IP68 / IP69K sealing on top of HV. Required for EV charging guns and marine BESS.
Read moreOvermolded Harness
TPE liquid-injection overmold for HV strain relief and HVIL connector boots. strain-relief flex validation by program.
Read moreTesting & Inspection
Cirris HiPot 1,500 V AC, 5 kV AC PD bench, four-wire Kelvin shield continuity. All on site.
Read moreWhere It Ships
HV HARNESS
VERTICALS.
Automotive & EV
EV battery, traction inverter, on-board charger. 800 V architecture supported with PD testing.
See industrySolar & Energy
1,500 V DC string and BESS harnesses, MC4 / Stäubli, NEC 690 grounding compliant.
See industryAerospace & Defense
eVTOL battery, ground-support HV, MIL-DTL-38999 + Radsok hybrid backshells.
See industryHV Examples
High-Voltage Harnesses · 600 V - 1500 V Programs.
Orange HV jacket coding, sealed terminations, paired LV companion cables — recent EV and energy-storage builds.
HV battery cable + LV companion
Orange sleeving, sealed LV pigtail
Conduit main cable + Deutsch breakout
Yellow sleeving, sealed DT 4-pin
ECU controller harness
Yellow conduit, 25-pin OEM connector
Reviewed by Hommer Zhao- Cavite-based wire harness engineer at XUDONG, IPC/WHMA-A-620 Class 3 trained, 8+ years in automotive & medical harness manufacturing.
Next Step
Send The Single-Line. We HiPot Every Unit.
600 V to 1,000 V DC, 200 A continuous, 1,500 V AC HiPot 100%, partial discharge on request. UL 758 cable library on site. Quote returned within 12 hours. NDA on file. No obligation.