EV Battery Cable XLPE 1500V — Energy Storage Wiring Harness | Oxygen-Free Copper HV Power Cable

Product Overview

Description

The EV High-Voltage Battery Cable is a flagship HV harness built for the electrical heart of modern new energy vehicles, energy storage systems (ESS), photovoltaic inverters, and DC fast-charge stations. The construction pairs oxygen-free pure copper conductor (Class 5 or Class 6 stranded for flexibility) with XLPE — cross-linked polyethylene insulation, the industry standard for HV automotive and ESS applications. XLPE holds up to 90 °C continuous and 130 °C short-circuit operation while maintaining its dielectric strength under partial discharge, repeated voltage stress, and the chemical exposure of battery electrolytes and coolants.

The cable is rated 1500 V DC — the modern standard for traction battery packs in passenger EVs, electric buses and trucks, container-format ESS, and utility-scale PV strings. Standard main-line cross-section is 1×50 mm² (≈ 1/0 AWG), suitable for currents around 200 A continuous; we routinely build 6 mm² to 120 mm² to match your pack architecture. Connectors cover all mainstream HV families — Amphenol RADSOK, TE Connectivity HVA / HVP800, Rosenberger HVS, Yazaki, Sumitomo, and KET — with integrated HV Interlock Loop (HVIL) contacts, IP67 sealing, and silver-plated terminals for the lowest possible contact resistance.

Construction is to ISO 19642 (EV cables), LV 216-2 (German automotive), and GB/T 33594 standards. Every finished assembly passes a 3000 VAC / 1-minute high-voltage withstand test, continuity check, and insulation resistance test (≥ 100 MΩ at 1000 VDC). Each conductor crimp is pull-tested at its rated load. Halogen-free LSZH (low-smoke zero-halogen) jackets are available for cabinet-installed ESS where fire-safety regulations require no halogen emission. Custom lengths, multi-core configurations, overmolded HVIL boots, and corrugated-conduit protection for module-to-module busbar links are all available — send drawing or sample for 1:1 quote.

Key Features

Why This Harness

01

1500 V DC XLPE Rated

Cross-linked PE insulation rated to 1500 V DC continuous — the standard for modern EV traction packs and large ESS.

02

Oxygen-Free Pure Copper

Class 5 / Class 6 OFC stranded conductor for low losses and maximum flexibility — long-term reliability under thermal cycling.

03

6 mm² – 120 mm² Cross-Sections

Standard 1×50 mm² main line; routinely build 6, 10, 16, 25, 35, 70, 95, 120 mm² — sized to your pack current and length.

04

HVIL Ready · IP67

HV Interlock Loop contacts, sealed metal-shell HV connectors (RADSOK, HVA, HVP800, HVS), silver-plated terminals.

05

ISO 19642 · LV 216-2 · GB/T 33594

Built to international EV cable standards. 3000 VAC withstand, IR ≥ 100 MΩ, 100% pull-tested terminals.

06

Halogen-Free LSZH Option

Low-smoke zero-halogen jacket on request — meets indoor ESS cabinet and rail/marine fire-safety requirements.

Technical Data

Specifications

Product Code	EV-01 · WHW-EV-BATTERY-CABLE
Product Series	EV Battery Cable & Energy Storage Wiring Harness
Application Field	EV / NEV traction battery, BMS, ESS cabinets, PV inverters, EV charging
Voltage Rating	1500 V DC continuous (Uo/U)
Withstand Voltage	3000 VAC / 1 min · IR ≥ 100 MΩ at 1000 VDC
Conductor	Oxygen-free pure copper — Class 5 / Class 6 stranded
Insulation	XLPE — cross-linked polyethylene
Jacket	Orange TPU / PVC standard · halogen-free LSZH on request
Standard Cross-Section	1×50 mm² (≈ 1/0 AWG)
Custom Cross-Sections	6 / 10 / 16 / 25 / 35 / 50 / 70 / 95 / 120 mm²
Multi-Core	3+1 / 4+1 HV power + HVIL/CAN signal (custom)
Operating Temperature	90 °C continuous · 130 °C short-circuit
Bend Radius	≥ 6× outer diameter (fixed) · ≥ 12× (flex)
Variant A	Main HV power cable — ring terminals both ends
Variant B	Branched HV harness — multi-connector with HVIL
Variant C	Busbar 3-way cable — corrugated conduit, parallel module link
Variant D	Custom full HV assembly — HVIL boot, shielding, sealed connectors
HV Connectors	Amphenol RADSOK · TE HVA / HVP800 · Rosenberger HVS · Yazaki · Sumitomo · KET
Terminal Options	Closed-barrel ring lugs M5/M6/M8/M10/M12 · HV silver-plated pins
Ingress Protection	Up to IP67 (sealed HV connectors)
Standards	ISO 19642 · LV 216-2 · GB/T 33594
Quality System	IATF 16949 · ISO 9001
Packing Dimensions	40 × 30 × 20 cm carton · ~6 kg per pc (depends on length/gauge)
MOQ	10 pcs (prototype) · 50+ pcs (mass production)
Sample Lead Time	10–15 days
Mass Production Lead Time	20–30 days after artwork approval

FAQ

Frequently Asked Questions

What is the voltage rating and what does "1500V XLPE" mean?

The cable is rated 1500V DC, the standard for modern EV traction battery packs and large energy storage systems (ESS). XLPE — cross-linked polyethylene — is a thermoset insulation that retains its dielectric strength up to 90 °C continuous and 130 °C short-circuit, with excellent partial-discharge resistance and chemical stability against battery electrolytes and coolants. Compared with PVC, XLPE handles higher temperatures, lower losses, and meets EV HV requirements per ISO 19642 and LV 216-2.

What cross-sections are available?

Standard main-line cross-section is 1×50 mm² (≈ 1/0 AWG). We routinely build 6, 10, 16, 25, 35, 50, 70, 95, and 120 mm² — sized to your pack current and length. Multi-core configurations (3+1, 4+1) are available for combined HV power and HVIL/CAN signal in one jacket. Conductor stranding is Class 5 or Class 6 oxygen-free copper for flexibility.

Which connector and terminal types do you support?

All mainstream EV HV connector families — Amphenol RADSOK, TE Connectivity HVA / HVP800, Rosenberger HVS, Yazaki, Sumitomo, KET. Terminal options include closed-barrel ring lugs (M5 / M6 / M8 / M10 / M12), HV silver-plated pins, and HVIL (HV Interlock Loop) integrated boots. We can match your existing battery pack / inverter mating face — send drawing or sample for 1:1 quote.

Is the cable suitable for energy storage systems (ESS) and PV inverters?

Yes. This is one of the most common applications. The same XLPE 1500V construction is used in battery storage cabinets, container ESS, residential and utility-scale PV inverter strings, DC fast-charge stations, and grid-tied battery banks. Halogen-free, low-smoke (LSZH) jacket options are available for indoor cabinet installations where fire-safety regulations require zero halogen emission.

What certifications and quality testing do you provide?

Cable construction is built to ISO 19642 (EV cables), LV 216-2 (Germany), GB/T 33594, and UL AVSS-style standards. Every finished assembly passes 100% high-voltage withstand test (3000 VAC / 1 minute for 1500V-rated cables), continuity, and insulation resistance (≥ 100 MΩ at 1000 VDC). Each conductor crimp is pull-tested at rated load. SGS and TÜV pre-shipment inspection available on request.

Applications

Where It's Installed

01

EV traction battery packs

02

NEV BMS interconnects

03

Energy storage cabinets (ESS)

04

Container ESS systems

05

PV string inverters

06

DC fast-charge stations

07

Electric bus & truck HV runs

08

EV High-Voltage Battery Cable — XLPE 1500V Oxygen-Free Copper Energy Storage Wiring Harness for NEV & ESS Systems

Description