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Product

150–300 kV DC electron-beam gun HV cable150 – 300 kV DCCathode + Filament + WehneltR24 / R30 / Custom Cone

HXC Electron-Beam High-Voltage Cable150 kV to 300 kV DC 3/4-core electron-beam welding, EBM & accelerator gun HV cable

Ultra-high-voltage multicore electron-beam cable (HXC Electron-Beam) rated 150 kV, 175 kV, 200 kV, 225 kV and 300 kV DC with 3 or 4 central cathode, bombarder filament and Wehnelt grid-bias conductors, stress-graded EPR/silicone HV insulation, and dual.

Low-EMC design
EMC screen
Oil-resistant
Flame-retardant
Order designation
HXC-EB-175KV-2X4+2X1.5
Rated DC voltage
175 kV DC
Wehnelt core U
8.0 kV DC
Overall OD
33.8 mm
Weight
1,510 kg/km
All sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
DC voltage range
150 to 300 kV DC
Negative HV cathode potential
Central cores
3 or 4 Cores
Filament + Bombarder + Wehnelt cup
Wehnelt bias U
Up to 5–8 kV DC
Internal core-to-core isolation
Arc damping
Semicon Graded
Survives gun flashover & crowbar
Cone standard
R24 / R30 / EB
SF6 or oil-insulated gun receptacles
Bend radius
6–8 × OD
Gantry & chamber-lid articulated

Typical values for this cable type, based on IEC 60522 (R24 / R30) / IEC 60502-2 / ISO 14744 — confirmed in the datasheet and quotation for your order.

Application fit

Is HXC Electron-Beam right for your machine?

Engineered for vacuum electron-beam welding (EBW) chambers, electron-beam additive manufacturing (EBM), curing accelerators, and 225–300 kV NDT tubes.

Free-hanging vertical run

Suitable

Supports overhead gantry loop movement on moving-gun vacuum electron-beam welding machines.

Switchgear & control cabinet wiring

Suitable

Double-screened outer braid safely conducts high-peak discharge currents during vacuum gun arc-downs.

VFD inverter to AC motor screened feeder

Suitable

5–8 kV DC internal core insulation isolates fast Wehnelt beam-blanking and pulsing signals at −150 to −300 kV DC.

Energy chain / drag chain

Not suitable

Large-diameter 150–300 kV cable is designed for overhead festoon/catenary loops, not tight drag chains.

Use HXC X-Ray 75–100 kV
Typical machinesVacuum Electron-Beam Welding (EBW) MachinesElectron-Beam Powder-Bed Additive Manufacturing (EBM)Electron-Beam Sterilization & Polymer Cross-Linking225 kV & 300 kV Industrial Cargo / Casting X-RayIon & Electron Accelerator Injector Guns

Construction

Layer by layer

Representative 175–300 kV DC electron-beam cable: 3 or 4 × 2.5–4.0 mm² high-OEM FEP/EPR-insulated triode gun cores (rated 5–8 kV core-to-core) + inner semiconductive stress layer + ultra-thick void-free EPR/HEPR or Silicone HV OEM + outer semiconductive screen + heavy tinned Cu braid + PUR/PVC/Silicone jacket.

123456
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Central cathode filament, bombarder & Wehnelt cores3 or 4 × 2.5 mm² to 4.0 mm² stranded tinned/silver-plated copper conductors insulated with fluoropolymer/EPR for 5.0–8.0 kV DC core-to-core breakdownDelivers 20–40 A cathode heater current, electron-bombardment power and −3 kV Wehnelt beam-current bias at −150 to −300 kV DC
2Inner semiconductive stress-equalising coreCo-extruded semiconductive elastomer filling interstices and forming a smooth cylindrical electrode around the central coresEliminates high-field strand geometry and prevents corona inception up to 300 kV DC
3Ultra-clean 150–300 kV EPR / Silicone HV OEMTriple-extruded void-free high-voltage ethylene propylene rubber (EPR) or high-tear silicone rubberWithstands continuous −150 kV to −300 kV DC plus transient reflections during vacuum gun flashover
4Outer semiconductive stress-control layerExtruded strippable semiconductive elastomer layer bonded over the HV insulationEnsures corona-free transition to the grounded metallic shield
5Low-inductance heavy tinned copper braidHigh-coverage (≥ 90 %) tinned copper braid (or double braid on 225–300 kV grades)Safely carries high-current arc-down surge return pulses to the HV tank ground without shield burn-through
6Heavy-duty PUR, PVC or Silicone outer jacketAbrasion- and oil-resistant black polyether PUR, grey PVC or flexible silicone outer sheathProtects against vacuum-pump oils, gantry rollers and industrial shop floors

HXC-EB-150/175 (150–175 kV DC EBW & EBM Gun Cable)

3-core or 4-core (2.5–4.0 mm²) flexible HV cable for 60 kV, 150 kV and 175 kV electron-beam welding and 3D metal printing guns

HXC-EB-225/300 (225–300 kV DC Accelerator & R30 Cable)

Ultra-heavy OEM wall with R24/R30 or SF6/oil pressure-vessel terminations for 225–300 kV accelerators and high-energy NDT

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 60522 (R24 / R30) / IEC 60502-2 / ISO 14744. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated DC working voltage
150 kV, 175 kV, 200 kV, 225 kV, 250 kV & 300 kV DC
Central core-to-core voltage
5.0 kV DC standard · 8.0 kV DC (high-bias Wehnelt option)
Heater / filament current
Up to 35 A continuous per filament core (4.0 mm²)
Factory DC routine proof test
1.3 × to 1.5 × rated U_DC (up to 400 kV DC) for 15 min
Partial discharge level
≤ 5 pC at rated stress
Nominal capacitance
95 pF/m to 125 pF/m

Thermal

Operating temperature (EPR/PUR)
−25 °C to +85 °C
Operating temperature (Silicone)
−40 °C to +150 °C

Mechanical

Central conductor layout
3×2.5, 4×2.5, 3×4.0 or (2×4.0 + 2×1.5 mm²)
Min. bend radius
6 × OD static · 10 × OD moving-gun gantry

Resistance

Vacuum oil & SF6 compatibility
Compatible with transformer oil & SF6 gun tanks
Flame & abrasion resistance
IEC 60332-1-2 · Tear-resistant PUR outer sheath

Reference standards

EBW machine standard
ISO 14744
HV cone interface
IEC 60522 R24 (160/225 kV) · R30 (300 kV) · Custom EBW cones

Identification

Outer sheath colour
Matte Black or Grey with HV warning legend
Surface legend
TEBAOFLEX HXC ELECTRON-BEAM [kV DC] [CORES] HIGH VOLTAGE
Customs tariff (HS)
8544.60

Sizes

12 standard HXC Electron-Beam 150–300 kV DC high-voltage cable configurations

Dimensions, central triode core layouts, Wehnelt core-to-core voltage rating, capacitance and outer diameter.

150–300 kV DC ratings, core layouts & OD
Order designationCentral Gun ConductorsRated U_DC
kV DC		Core-Core
kV DC		OEM OD
mm		Overall OD
mm		Capacitance
pF/m		Weight
kg/km		Enquiry
150 kV to 200 kV DC Electron-Beam Welding (EBW) & EBM Additive Gun Cables
HXC-EB-150KV-3X2.53 × 2.5 mm² (5 kV Core-Core)1505.023.529.01151,120
HXC-EB-150KV-4X2.54 × 2.5 mm² (5 kV Core-Core)1505.024.229.81181,185
HXC-EB-150KV-2X4+2X1.52×4.0 + 2×1.5 mm² (8 kV Grid)1508.025.030.81221,270
HXC-EB-175KV-3X2.53 × 2.5 mm² (5 kV Core-Core)1755.026.532.51081,390
HXC-EB-175KV-2X4+2X1.52×4.0 + 2×1.5 mm² (8 kV Grid)1758.027.533.81121,510
HXC-EB-200KV-4X2.54 × 2.5 mm² (8 kV Core-Core)2008.030.036.51051,760
225 kV to 300 kV DC Industrial Accelerator & R30 High-Energy Cables
HXC-EB-225KV-3X2.5-R243 × 2.5 mm² (R24/R30 Cone)2255.032.539.21022,040
HXC-EB-225KV-2X4+2X1.52×4.0 + 2×1.5 mm² (8 kV Grid)2258.033.540.51052,190
HXC-EB-250KV-4X2.5-R304 × 2.5 mm² (8 kV Core-Core)2508.036.043.5982,520
HXC-EB-300KV-1X10-COAX1 × 10 mm² Coaxial HV Bus3000.038.546.0952,840
HXC-EB-300KV-3X2.5-R303 × 2.5 mm² (5 kV Core-Core)3005.040.548.5963,150
HXC-EB-300KV-2X4+2X1.52×4.0 + 2×1.5 mm² (8 kV Grid)3008.041.549.8983,340
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Custom vulcanised R24, R30 and proprietary electron-beam welding gun boots with integrated damping resistors are assembled to customer drawing.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Ultra-high-voltage DC proof test (200 kV to 400 kV DC)15-minute DC hold test between central conductor bundle and outer copper braid100 % of manufactured lengths
8.0 kV / 12.0 kV DC core-to-core Wehnelt isolation testVerify OEM integrity between filament, bombarder and Wehnelt grid cores100 % of manufactured lengths
Sample tests
Impulse flashover & partial-discharge testVerify robustness under simulated gun crowbar discharge and PD ≤ 5 pCQualification lot

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

ISO 14744 Electron-Beam Welding HV Supply CompliantIEC 60522 R24 / R30 High-Voltage Cone Compatible

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HXC ELECTRON-BEAM HIGH VOLTAGE CABLE [150-300 kV DC]
Delivery form
Heavy wooden drums or factory-terminated double-ended gun assemblies
Terminations
R24, R30, epoxy/silicone conical gun plugs & SF6 tank feedthroughs
Lead time
4–6 weeks ex-works

Technical documents

Downloads

PDFHXC Electron-Beam High-Voltage Cable – technical datasheet12 sizes · construction, technical data, approvalsXLSXHXC Electron-Beam spec data (Excel)All 12 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

How does an HXC Electron-Beam cable differ from a standard 75–160 kV medical X-ray cable?
Electron-beam welding (EBW) and additive manufacturing (EBM) guns operate at much higher unipolar voltages (−150 kV to −300 kV DC), require higher cathode heater/bombarder currents (up to 35 A via 4.0 mm² cores), require higher internal core-to-core insulation (5–8 kV DC for the Wehnelt beam-control cup), and must survive frequent vacuum-chamber metal-vapour flashovers (gun arc-downs) without puncturing the HV wall.
What happens inside the cable when an electron gun arcs over in the vacuum chamber?
When metal vapour triggers a vacuum arc inside the electron gun, the cable's capacitance discharges rapidly, launching a travelling voltage wave that reflects between the gun and the HV tank. HXC Electron-Beam cables use high-impulse-strength EPR/silicone insulation, bonded semiconductive stress layers, and a heavy low-inductance double copper braid to damp reflected transients.
Why are 4 central cores used in triode electron guns?
In a directly or indirectly heated triode electron gun, two heavy cores (2 × 4.0 mm²) carry the high-current filament heater power, a third core provides the cathode/bombarder reference, and the fourth core (insulated for 5–8 kV DC against the other three) carries the negative Wehnelt grid voltage that modulates beam current from 0 to 1,000 mA.
Can you supply complete factory-terminated electron-beam cables with R30 or custom conical boots?
Yes. We mould and vulcanise R24 (160/225 kV), R30 (300 kV), and OEM-specific stepped or conical elastomer terminations complete with spring-loaded contact pins and routine 200–400 kV DC test certificates.

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