EV, Energy Storage & Equipment Wiring

Custom Battery Wire Harnesses

Battery power and sensing harnesses specified by continuous and peak current, allowable voltage drop, cable length, terminal interface, fuse strategy, flex and operating environment.

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500A

Current Capacity

1200V

DC HV systems built

4/0

AWG Available

Low

Resistance

Power Distribution

Battery Harness Applications

Battery cable solutions across industries.

EV Battery Packs

Cell interconnects, module cables, and main power harnesses

Energy Storage

ESS battery connections and power distribution

Starting Batteries

Automotive and commercial vehicle battery cables

Solar Systems

Battery bank interconnects and charge controller cables

UPS Systems

Backup power battery connections and distribution

Industrial Equipment

Forklift, AGV, and industrial battery harnesses

Power Optimized

Battery Harness Features

Essential capabilities for battery applications.

High Current Capacity

Large gauge cables for battery power requirements

Low Resistance

Optimized connections for minimal power loss

Proper Termination

Crimped and fusion-welded terminals for reliability

Safety Features

Fusing, HVIL, and proper insulation for safe operation

Technical Capabilities

Battery Cable Specifications

Current Capacity

Up to 500A continuous

Voltage Class

400V / 800V EV, up to 1200V DC ESS (built to your cable spec)

Wire Sizes

8 AWG to 4/0 AWG

Terminal Types

Ring, lug, Anderson, custom

Temperature Range

-40°C to +105°C

Insulation

PVC, XLPE, silicone

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EV Battery Specialists

We understand the unique requirements of EV battery systems. From cell interconnects to main power cables, we deliver high-voltage harnesses that meet automotive safety and quality standards.

ISO 9001:2015 certified
HVIL safety circuits
Orange HV identification
Full material traceability

Professional Battery Wire Harness Manufacturing

OurPCB manufactures battery wire harnesses for electric vehicles, energy storage systems, and industrial power applications. Our battery cables handle high currents with low resistance connections for efficient power delivery and minimal losses.

For EV applications, we provide complete battery pack wiring including cell interconnects, module harnesses, and main high-voltage power cables. Our EV harnesses include proper safety features including HVIL circuits and orange jacket identification per automotive standards.

Our battery harnesses use properly sized conductors with fusion-welded or hydraulically crimped terminals for reliable, low-resistance connections. We work with Anderson Power and other premium connectors designed for high-current applications. Compact battery interfaces for cordless tools can also be built as power tool wire harnesses with trigger, motor, LED, and charger wiring in the same controlled assembly.

For industrial battery systems or custom battery harnesses, the drawing should define current, duty cycle, length, allowable voltage drop, terminal interface and environmental exposure rather than relying on a generic cable-size rule.

Energy Storage & High-Voltage DC

600V, 800V & 1200V Energy Storage Battery Wire Harnesses

Grid-scale and commercial energy storage systems (ESS) run at DC bus voltages that keep climbing — 600V and 800V racks are common, and utility and industrial designs increasingly move to 1200V and 1500V DC to cut conduction losses. As a 600V energy storage battery wire harness supplier, we build the module-to-module interconnects, rack busbar cables, and BMS wiring that tie these packs together, matching conductor size and insulation class to each system's working voltage plus safety margin.

For higher-voltage designs we assemble to your specification as a 1200V DC battery cable builder — XLPE or silicone insulation rated for the class, correctly torqued and low-resistance DC power terminations, and creepage/clearance-aware routing. High-voltage builds carry orange HV identification and, where the design requires, HVIL interlock circuits so the pack can detect a disconnected connector.

These harnesses appear in solar-plus-storage installations, data-center backup power, and stationary industrial ESS. Where a project needs finished ring-terminal or lug cables rather than a full harness, we also supply high-current battery cable assemblies and EV charging cable assemblies to the same quality system.

Common Questions

Battery Harness FAQ

Battery cable sizes depend on current requirements. Light-duty applications may use 8-4 AWG, while high-current EV or industrial applications often require 2 AWG to 4/0 AWG. We size cables based on continuous current, voltage drop requirements, and temperature rating.

Yes, we manufacture complete EV battery harnesses including cell interconnects, module cables, main power cables, and BMS (Battery Management System) wiring. Our high-voltage harnesses include proper safety features per automotive standards.

We offer various battery terminals including ring terminals, battery lugs, Anderson connectors, and custom terminals. For high-current applications, we use fusion-welded or hydraulically crimped connections for reliable, low-resistance joints.

Yes, we can integrate fuse holders, fusible links, or battery disconnect switches into battery harness assemblies. Proper overcurrent protection is essential for battery safety and we can recommend appropriate solutions for your application.

Yes. As a battery wire harness supplier for energy storage systems, we build 600V-class ESS harnesses — module-to-module links, rack busbar cables, and BMS wiring — using conductors and insulation rated for the system's working voltage plus margin. We size cable to continuous current and voltage drop, and add HV identification, sealed connectors, and integrated protection where the design calls for it.

We assemble DC battery cables for 400V and 800V EV systems and for 600V, 800V, and 1200V-class energy storage and industrial systems, using cable rated to the appropriate DC working voltage (commonly up to 1500V DC). As an assembler we build to your specified conductor, insulation, and connector — a 1200V DC battery cable uses XLPE or silicone insulation rated for that class with correctly torqued, low-resistance high-current terminations.

Need Battery Cable Assemblies?

From EV battery packs to industrial power systems, we manufacture high-current battery harnesses for reliable power delivery.