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Product

10–100 kV DC screened silicone HV cable10 kV – 100 kV DCDual Semicon + Cu BraidHSUS / HSL

HSUS / HSL Screened Silicone High-Voltage Connection Cable10 kV to 100 kV DC coaxial screened silicone HV cable with dual semicon layers (HSUS

Touch-safe coaxial screened high-voltage DC connection cable (10 kV to 100 kV DC) with inner and outer semiconductive silicone stress-control layers, void-free silicone HV dielectric, ≥ 85 % tinned copper earth braid, and PVC/PUR (HSUS) or −60/+180 °C.

Low-EMC design
EMC screen
Flame-retardant
Oil-resistant
Order designation
HSUS-30KV-1.5
Rated DC voltage
30 kV DC
Dielectric OD
6.6 mm
Overall OD
9.4 mm
Capacitance
118 pF/m
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
10 to 100 kV DC
4 kV to 40 kV AC rms (50/60 Hz)
Field confinement
100 % Touch-Safe
Grounded outer braid confines E-field
Stress grading
Dual Semicon
Inner & outer semiconductive layers
HSUS vs HSL
2 Outer Sheaths
HSUS: PVC/PUR · HSL: −60/+180°C SiR
Partial disch.
≤ 5 pC @ 1.2 U0
Corona-free coaxial geometry
Bend radius
6 × OD
Supple coaxial laboratory & rack routing

Typical values for this cable type, based on IEC 60502-2 / IEC 60270 / VDE 0250 — confirmed in the datasheet and quotation for your order.

Application fit

Is HSUS / HSL right for your machine?

Confines the radial electric field completely inside the grounded copper braid so the cable can be touched safely and clamped directly to metal racks.

Switchgear & control cabinet wiring

Suitable

Grounded tinned copper braid and dual semicon layers allow direct clamping to metal walls and bulkhead glands with zero external corona.

Furnace, kiln & high-temp zone

Suitable

HSL all-silicone variant operates from −60 °C to +180 °C in vacuum load-locks, ovens and cryogenic feedthroughs.

VFD inverter to AC motor screened feeder

Suitable

≥ 85 % tinned copper braid shields adjacent low-level instrumentation from HV switching and pulse transients.

Energy chain / drag chain

Not suitable

Designed for laboratory, rack and machine HV interconnects, not high-acceleration C-tracks.

Use EXRAD S200XL Shielded
Typical machinesPrecision High-Voltage Laboratory Power SuppliesIon Beam, Electron Microscope & Mass Spec FeedsIndustrial X-Ray & Capacitor Charger InterconnectsSemiconductor Ion Implantation & Wafer Chuck BiasHigh-Voltage Partial Discharge & Hipot Test Leads

Construction

Layer by layer

True 6-layer coaxial HV architecture: (1) fine tinned Cu center conductor + (2) inner semiconductive silicone + (3) void-free HV silicone insulation + (4) outer strippable semiconductive silicone + (5) ≥ 85 % tinned Cu braid + (6) PVC/PUR (HSUS) or Silicone (HSL) outer jacket.

123456
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Fine-stranded tinned copper HV center conductorStranded tinned copper (IEC 60228 Class 5, 0.75 mm² / 19 AWG to 16 mm² / 6 AWG)Carries HV DC or pulsed current with low bending stiffness
2Inner semiconductive silicone stress-smoothing layerCo-extruded semiconductive silicone layer bonded over the center conductorEliminates strand-gap air voids and smooths inner radial electric stress
3Void-free high-voltage silicone rubber dielectricHigh-purity vacuum-extruded silicone rubber (≥ 30 kV/mm breakdown strength)Provides flexible 10 kV to 100 kV DC insulation
4Outer semiconductive silicone screenExtruded semiconductive silicone layer (or conductive tape) under the metallic braidPrevents partial discharge in the micro-gaps between the HV dielectric and the copper braid wires
5≥ 85 % tinned copper braided earth shieldConcentric tinned copper wire braid (≥ 85 % optical coverage)Confines the electric field, drains capacitive charging current and provides touch-safe earthing
6HSUS (PVC/PUR) or HSL (Silicone) outer sheathHSUS: flame-retardant red/grey/black PVC or PUR (−25 to +80/+90 °C) · HSL: cross-linked silicone rubber (−60 to +180 °C)Protects the ground braid against mechanical abrasion, oils and laboratory handling

HSUS (Silicone HV Core + PVC / PUR Outer Sheath)

Tough, abrasion- and oil-resistant PVC or PUR outer jacket (−25 °C to +90 °C) for HV power supply output cables and industrial racks

HSL (All-Silicone Core + Silicone Outer Sheath, +180 °C)

Ultra-limp all-silicone construction rated −60 °C to +180 °C with halogen-free flame retardancy for thermal chambers and scientific systems

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 60502-2 / IEC 60270 / VDE 0250. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated DC working voltage
10, 15, 20, 30, 40, 50, 60, 75 & 100 kV DC
Rated AC voltage (50/60 Hz)
4 kV to 40 kV AC rms
Factory DC routine test
1.5 × to 2.0 × rated U_DC (core to screen) for 5 min
Jacket spark / dielectric test
3.0 kV AC rms on outer sheath
Nominal capacitance
95 pF/m to 180 pF/m (size & voltage dependent)
Partial discharge level
≤ 5 pC at 1.2 × rated U_AC rms (IEC 60270)

Thermal

Operating temperature (HSUS)
−25 °C to +80 °C (PVC) · −40 °C to +90 °C (PUR)
Operating temperature (HSL)
−60 °C to +180 °C (all-silicone)

Mechanical

Center conductor sizes
0.75, 1.0, 1.5, 2.5, 4.0, 6.0, 10 & 16 mm²
Min. bend radius
6 × OD static · 10 × OD flexing

Resistance

Touch safety
Fully grounded concentric screen (EN 50191 / IEC 61010)
Flame retardancy
IEC 60332-1-2 · HSL zero-halogen IEC 60754-1

Reference standards

Design & test standards
IEC 60502-2 · IEC 60270 · DIN VDE 0250
HV connector compatibility
Redel-HV Redel/HV, HV-Lock, OEM, HV-Plug & Claymount HV plugs

Identification

Outer sheath colour
Red (RAL 3000/3013), Grey (RAL 7001) or Black
Surface legend
TEBAOFLEX HSUS / HSL SCREENED HV CABLE [kV DC]
Customs tariff (HS)
8544.60

Sizes

12 standard HSUS & HSL screened silicone HV connection cable configurations (10–100 kV DC)

Coaxial dimensions across core, dielectric, copper braid screen and outer sheath, with capacitance and DC test voltage.

Voltage ratings, coaxial diameters & capacitance
Order designationConductor
mm² (AWG)		Rated U_DC
kV DC		Test U_DC
kV DC		Dielectric OD
mm		Overall OD
mm		Capacitance
pF/m		Weight
kg/km		Enquiry
HSUS Series — Silicone HV Core + Tough PVC/PUR Outer Sheath (10–100 kV DC)
HSUS-10KV-1.01.0 (18 AWG)10203.86.215558
HSUS-20KV-1.51.5 (16 AWG)20405.27.813588
HSUS-30KV-1.51.5 (16 AWG)30556.69.4118124
HSUS-40KV-2.52.5 (14 AWG)40708.011.0122168
HSUS-50KV-2.52.5 (14 AWG)50859.412.6110215
HSUS-65KV-2.52.5 (14 AWG)6511011.214.8102285
HSUS-100KV-4.04.0 (12 AWG)10016015.819.896490
HSL Series — All-Silicone −60/+180 °C Screened HV Cable (15–100 kV DC)
HSL-15KV-1.5-SIR1.5 (16 AWG)15304.67.214576
HSL-30KV-1.5-SIR1.5 (16 AWG)30556.69.6118128
HSL-50KV-2.5-SIR2.5 (14 AWG)50859.412.8110220
HSL-75KV-2.5-SIR2.5 (14 AWG)7512512.616.498345
HSL-100KV-6.0-SIR6.0 (10 AWG)10016016.520.8105545
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • When terminating HSUS / HSL cables, always strip back the outer semiconductive layer cleanly to the manufacturer stress-cone dimension so it does not bridge the HV termination creepage path.

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
Core-to-screen DC high-voltage proof test20 kV DC to 160 kV DC applied between center conductor and grounded copper braid for 5 min100 % of finished reels
Partial discharge measurement (IEC 60270)PD ≤ 5 pC at 1.2 × rated AC rms voltageEvery production length ≥ 20 kV
Sample tests
Outer sheath 3 kV AC dielectric & transfer impedance checkVerify outer jacket isolation and ≥ 85 % braid coverageProduction lot

Inspection certificate

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

Product approvals

IEC 60270 Partial-Discharge Tested (≤ 5 pC)DIN VDE 0250 & EN 50191 Touch-Safe Screened HV

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HSUS / HSL SCREENED HIGH VOLTAGE CABLE [kV DC]
Delivery form
50 m / 100 m / 250 m reels or pre-terminated HV plug assemblies
Termination service
Factory-moulded HV silicone stress cones & coaxial HV connectors
Quality report
Individual DC hipot & IEC 60270 partial-discharge test certificate
Lead time
2–4 weeks ex-works

Technical documents

Downloads

PDFHSUS / HSL Screened Silicone High-Voltage Connection Cable – technical datasheet12 sizes · construction, technical data, approvalsXLSXHSUS / HSL 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.

Why are both an inner and an outer semiconductive layer required in a screened high-voltage cable?
If a woven metal braid is applied directly over high-voltage silicone insulation, thousands of microscopic air wedges exist between the round braid wires and the insulation surface. At voltages above 10 kV, the high dielectric constant of silicone forces intense electric stress across those air wedges, causing continuous partial discharge (corona) that erodes the insulation. Co-extruding inner and outer semiconductive layers bonds directly to the dielectric and confines 100 % of the electric field inside solid void-free rubber.
What is the difference between HSUS and HSL?
Both share the exact same coaxial high-voltage silicone core, dual semiconductive stress-grading layers, and ≥ 85 % tinned copper braid. HSUS uses a rugged PVC or polyurethane (PUR) outer jacket for mechanical abrasion and oil resistance in laboratory/industrial environments (−25/+90 °C), whereas HSL uses a silicone rubber outer jacket for extreme −60 °C to +180 °C flexibility and halogen-free safety.
How must the outer semiconductive layer be handled when stripping the cable for a high-voltage plug?
After stripping back the outer sheath and folding back the tinned copper braid, the black outer semiconductive layer MUST be peeled or shaved back to the specified creepage distance (typically 25–150 mm depending on kV rating) with a smooth, nick-free chamfer before sliding on the HV silicone stress-relief boot.
When should I upgrade from coaxial HSUS/HSL to triaxial HSC Low-Noise cable?
Use coaxial HSUS/HSL for power delivery (HV power supplies, lasers, ion sources). Upgrade to triaxial HSC Low-Noise when measuring picoampere leakage currents, photomultiplier pulses, or < 1 pC partial discharges where triboelectric cable noise and ground-loop currents must be guarded out.

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HSUS / HSL Screened Silicone High-Voltage Connection Cable

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