XLPE / PE-X High Voltage Wire, 3–50 kV DC

XLPE high voltage wire provides a compact, unshielded connection inside high voltage equipment. This family covers two distinct constructions: single-insulated HXW reference configurations at 3, 6 and 10 kV DC, and PE-X-insulated, PVC-jacketed HTV reference configurations at 20, 30 and 50 kV DC. Select the voltage and construction together before choosing the termination.

HXW uses a flexible, tinned copper 24 AWG conductor and irradiation-cross-linked polyethylene insulation. Its 1.60–1.90 mm outside diameters suit equipment layouts where lead size and routing space are important. The insulation is the external surface of the wire; this construction has no separate jacket or metallic screen.

HTV adds a red PVC jacket around the PE-X dielectric and a tinned copper 22 AWG conductor. Its dielectric and outside diameters increase with the selected DC voltage. Separate moving and fixed bend-radius values are provided for each configuration, so the lead can be matched to the available entry, support and service-loop space.

The AC figures in the HTV table describe production spark-test conditions. They are separate from the DC operating ratings. For continuous operation, specify the operating voltage, duty duration and equipment environment so the appropriate operating-voltage derating can be set. Use the construction tables to match insulation diameter, overall diameter, colour and terminal preparation to the equipment drawing.

Explore the high voltage DC and test cable range for related configurations.

For related flexible silicone-insulated DC wires and chemically inert fluoropolymer HV hook-up leads, compare: High Voltage Silicone Wire, 3–60 kV DC (for extra-flexible -60 °C to +200 °C silicone-insulated 3–60 kV DC leads); FEP High Voltage Wire, 18–30 kV DC (for thin-wall 18–30 kV DC FEP fluoropolymer wires resistant to transformer oils, solvents, and vacuum outgassing). Confirm continuous operating temperature, minimum static bend radius, and rated DC voltage before ordering.

Construction

The illustration represents the HTV-50-22-2 reference configuration: one small tinned copper conductor, a concentric PE-X dielectric and a red PVC jacket. HXW is a separate single-insulated construction with no outer jacket.

Applications

Use these single-conductor designs for internal high voltage equipment wiring, with the insulation system and routing selected for the equipment and operating duty.

• Internal DC high voltage connections in power supplies, test equipment and electronic equipment.
• Compact internal leads where the 24 AWG HXW construction and small outside diameter suit the available routing space.
• Jacketed internal leads where HTV PE-X dielectric dimensions and the additional PVC jacket match the equipment entry and support arrangement.
• Observe the configuration-specific bend radius and provide strain relief at terminations. Moving bend-radius data do not specify a continuous-flex service life.
• Coordinate DC voltage, continuous-operation duty, temperature and termination clearances with the equipment design.

For custom high-voltage silicone cable assemblies and braided-shield PE-X coaxial leads, review these engineering pages: High Voltage Silicone Cable Manufacturer (for custom elastomer HV leads when tight routing radii or extreme ambient temperatures exceed XLPE limits); High Voltage Coaxial Cable — PE-X, FEP and PE Configurations (for screened PE-X, FEP, and PE coaxial cables where grounded outer shielding and controlled impedance are required). Verify potting-compound adhesion, creepage distance, and flame rating (UL 3239 / UL 3173 style) during layout.

Specifications

Model references identify the compared constructions. Include the required DC rating, conductor size, colour and length with the enquiry.

XLPE and PE-X both denote cross-linked polyethylene. The HXW and HTV insulation systems remain separate configurations, with their own dimensions and test references.

The HTV AC spark-test values are production-test conditions, not AC working-voltage ratings. Set the continuous-duty operating voltage with the equipment design and the required derating.

The * in an HXW model reference is the insulation colour suffix. HTV references listed here use a red jacket, approximately RAL 3000.

Standards

UL 758 scope: Appliance Wiring Material