1000V High-Voltage Power Cable Harnesses
Custom EV and industrial high-voltage harnesses built around your system voltage, continuous and peak current, routing, connector, shielding, HVIL and environmental requirements.
Safety First in High-Voltage Applications
High-voltage harnesses require careful design and handling. All our HV assemblies include appropriate safety features and are manufactured by trained technicians following strict safety protocols. Orange jacketing provides clear identification of HV circuits per industry standards.
High-Voltage Applications
Power cable solutions for demanding high-voltage applications.
Electric Vehicles
Battery pack, motor, inverter, and charging system cables
Energy Storage
Battery storage systems, UPS, and power backup cables
Solar/Renewable
PV string cables, inverter connections, DC power cables
Industrial Power
Motor drives, VFDs, power distribution cables
Charging Infrastructure
EV charger cables, DC fast charging connections
Railway & Transit
Traction systems, auxiliary power cables
Safety Features
Essential safety features for high-voltage cable assemblies.
Orange Jacket
High-visibility orange color per SAE J1654 for HV identification
HVIL (Interlock)
High-voltage interlock loop for safe connection/disconnection
EMI Shielding
360° shielding to contain electromagnetic interference
Touch Protection
IPXXB/IPXXD touch-safe connector designs
High-Voltage Specifications
EV Specialists
We understand the unique requirements of electric vehicle applications. From battery pack cables to charging systems, we deliver HV harnesses that meet automotive quality and safety standards.
- ISO 9001:2015 certified
- EV-specific connector expertise
- EMC compliant designs
- Full material traceability
Expert High-Voltage Wire Harness Manufacturing for EV and Power Applications
As a leading high-voltage wire harness manufacturer, OurPCB specializes in engineering and producing HV cable assemblies for electric vehicles, energy storage systems, and industrial power applications. Our wire harness solutions are designed to safely handle voltages up to 1000V DC while incorporating essential safety features including HVIL (High-Voltage Interlock Loop), EMI shielding, and orange jacket identification.
EV battery and motor harness definitions must account for working voltage, fault current, connector touch protection, cable routing and service disconnect strategy. Related automotive harness work can include pack, inverter, motor and charging interfaces, with the acceptance plan stated on the released drawing.
Our shielded wire harness capabilities provide 360° EMI protection essential for electric vehicle applications. We offer braided copper shields with up to 98% coverage, foil+braid combinations for critical applications, and proper backshell terminations for maximum shielding effectiveness. These features ensure EMC compliance and protect sensitive vehicle electronics from HV switching noise.
Beyond automotive, we serve renewable energy applications including solar PV string cables, battery storage interconnects, and industrial power distribution. Our high-voltage cable assemblies feature temperature ratings from -40°C to +150°C, making them suitable for harsh underhood environments and outdoor installations.
Use our design-support process to review connector selection, conductor sizing, bend radius, shielding termination and test requirements. Commercially, no minimum order quantity — prototype reviews start at one piece. Contact us to discuss the released inputs for your high-voltage harness.
High-Voltage Harness FAQ
We manufacture high-voltage cables rated up to 1000V DC for EV applications and 600V AC for industrial power. Voltage rating depends on the specific cable construction, insulation materials, and application requirements. We can recommend appropriate cables based on your system voltage.
Our HV harnesses include safety features per automotive and industrial standards: orange high-visibility jackets (SAE J1654), HVIL (high-voltage interlock loop) circuits, EMI shielding, touch-safe connector designs, and appropriate current interrupt ratings. Specific features depend on application requirements.
Yes, we manufacture battery pack cables including cell interconnects, module cables, and main pack cables. We work with appropriate HV-rated conductors, insulation, and connectors from manufacturers like TE Connectivity, Amphenol, and others specializing in EV applications.
We offer multiple shielding options: braided copper shields (typically 85-95% coverage), foil shields with drain wire, and combination foil+braid for maximum effectiveness. Shielding selection depends on EMC requirements and frequency range of concern.
Real Project Experience
How we've handled similar wire harness and cable assembly projects
See de-identified project scenarios — supplier qualification, connector-shortage recovery, lead-time compression, and engineering spec lockdown — drawn from real production records.
Need High-Voltage Cable Assemblies?
From EV battery cables to industrial power distribution, we manufacture high-voltage harnesses with safety and quality built in.