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 for Tier-1 EV programs.
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, tariff-free under HS 8544.30 / 8544.42.
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. AS9100-aware build, 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?
+
What voltage range counts as “high voltage” here?
Q.02Do you support 800 V EV architecture programs?
+
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?
+
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?
+
What is the lead time and MOQ for HV builds?
Q.06Do HV harnesses ship tariff-free from Cavite to the US?
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Do HV harnesses ship tariff-free from Cavite to the US?
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. 50K-cycle flex life.
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
Real Project Snapshot · US · marine · 2026-Q1
A Build We Already Shipped In This Lane.
Scenario
A US high-end boat manufacturer needed to move from design validation to physical prototypes for custom audio and harness systems.
Challenge
The customer needed prototypes quickly to validate the design before committing to mass production, but tooling development typically delays this process.
Outcome
Customer confidently placed the tooling PO, accelerating the transition from a 9-month evaluation phase to a confirmed prototype and pre-mass-production stage.
Anonymized customer detail. Concrete numbers preserved verbatim.
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.