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Product

10–100 kV DC PE/XLPE HV equipment wire10 kV – 100 kV DC≥ 60 kV/mm PE/XLPEHXW / HTV

HXW / HTV XLPE High-Voltage DC Equipment Wire10 kV to 100 kV DC compact high-OEM PE / XLPE HV equipment wire (HXW & HTV)

Compact, ultra-high-OEM-strength polyethylene (PE) and cross-linked polyethylene (XLPE) high-voltage DC equipment wire (HXW unjacketed & HTV flame-retardant PVC-jacketed) rated 10 kV to 100 kV DC with co-extruded semiconductive conductor stress.

Flame-retardant
Oil-resistant
Water-resistant
Approved
Order designation
HTV-30KV-1.5-PVC
Rated DC voltage
30 kV DC
Test voltage
60 kV DC
Nominal OD
5.8 mm
Weight
44 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
10 to 100 kV DC
4 kV to 35 kV AC rms (50/60 Hz)
OEM
≥ 60 kV/mm
2× higher breakdown than silicone
Stress control
Semicon Layer
Co-extruded over stranded conductor
HXW / HTV
2 Architectures
HXW bare PE/XLPE · HTV + PVC jacket
Permittivity
εr = 2.25
Ultra-low capacitance (tan δ < 0.0003)
Thermal range
−40 to +105 °C
LDPE (+80°C) · XLPE (+90/+105°C)

Typical values for this cable type, based on UL 3239 / IEC 60502-2 / MIL-DTL-16878 Type J — confirmed in the datasheet and quotation for your order.

Application fit

Is HXW / HTV right for your machine?

Selected when minimum outer diameter, ultra-low OEM loss, and transformer-oil compatibility are required up to 100 kV DC.

Switchgear & control cabinet wiring

Suitable

60 kV/mm OEM strength achieves a 30–40 % smaller outer diameter than equivalent-voltage silicone HV wire.

Immersion & wet locations

Suitable

Cross-linked XLPE core is insoluble in mineral transformer oil and deionized water cooling loops.

VFD inverter to AC motor screened feeder

With conditions

Low permittivity (εr = 2.25) suits high-voltage pulse/flyback leads; use screened HSUS/HSL where grounded outer braid is needed.

Energy chain / drag chain

Not suitable

Semi-rigid PE/XLPE HV insulation is designed for fixed equipment wiring, not dynamic drag chains.

Use HSW / HSX Silicone HV
Typical machinesOil-Immersed X-Ray & Cockcroft-Walton MultipliersPulsed-Power & Marx Generator InterconnectsCRT / Photomultiplier Tube (PMT) Anode LeadsHigh-Voltage Capacitor Bank & Ignition WiringAirborne & Industrial Electrostatic Power Packs

Construction

Layer by layer

Representative HTV construction: stranded tinned copper conductor + extruded semiconductive polyolefin stress-control layer + high-purity natural LDPE or cross-linked XLPE HV OEM + flame-retardant PVC/PUR outer jacket (HXW omits the outer jacket for oil-immersed use).

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Stranded tinned copper conductorStranded tinned copper (IEC 60228 Class 5, 0.50 mm² / 20 AWG to 6.0 mm² / 10 AWG)Provides flexible routing and clean solder/crimp termination
2Co-extruded semiconductive stress-control layerSmooth semiconductive polyolefin layer extruded directly over the stranded wire bundle (on ≥ 20 kV DC grades)Presents a cylindrical equipotential surface to the HV dielectric, eliminating strand-edge corona
3High-purity HV PE / XLPE OEMSuper-clean low-density polyethylene (LDPE) or cross-linked polyethylene (XLPE) insulation (OEM breakdown ≥ 60 kV/mm)Delivers compact OD, ≥ 10¹⁶ Ω·cm volume resistivity and ultra-low 0.0002 dissipation factor
4Flame-retardant PVC outer jacket (HTV series)Extruded red, black or white flame-retardant PVC (or halogen-free PUR) outer sheath on HTV series (HXW series has bare natural PE/XLPE surface)Provides UL VW-1 / IEC 60332-1-2 flame retardancy and mechanical protection in air

HXW (Natural Unjacketed PE / XLPE, Oil-Immersed)

Pure natural translucent PE or XLPE outer surface without plasticisers so it will not contaminate insulating transformer oil

HTV (Flame-Retardant PVC-Jacketed PE / XLPE)

Adds a red, white or black flame-retardant PVC outer jacket over the HV PE/XLPE core for open chassis and rack wiring

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on UL 3239 / IEC 60502-2 / MIL-DTL-16878 Type J. 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 35 kV AC rms
Factory DC routine test
2.0 × rated U_DC for 5 min
OEM breakdown strength
≥ 60 kV/mm (IEC 60243-1)
Volume resistivity
≥ 10¹⁶ Ω·cm at 20 °C
OEM constant / loss
εr = 2.25 · tan δ ≤ 3 × 10⁻⁴ at 1 kHz

Thermal

Operating temperature (PE / XLPE)
−40 °C to +80 °C (LDPE) · −40 °C to +90/+105 °C (XLPE)
Short-circuit conductor temp
+250 °C (XLPE grades)

Mechanical

Conductor cross-sections
0.50 mm², 0.75 mm², 1.0 mm², 1.5 mm², 2.5 mm², 4.0 mm², 6.0 mm²
Min. bend radius
8 × OD (fixed installation)

Resistance

Transformer oil compatibility
HXW natural PE/XLPE is non-leaching in mineral & silicone oil
Flame retardancy (HTV)
UL VW-1 / IEC 60332-1-2 (HTV PVC-jacketed series)
Moisture absorption
< 0.01 % water absorption

Reference standards

Applicable specifications
UL 3239 (HTV flame-retardant) · IEC 60502-2 · MIL-DTL-16878
HV testing standard
IEC 60060-1 / IEC 60270

Identification

Jacket / core colour
Natural Translucent (HXW) · Red, Black or White (HTV)
Surface legend
TEBAOFLEX HXW / HTV [kV DC] XLPE HIGH VOLTAGE
Customs tariff (HS)
8544.49 / 8544.60

Sizes

12 standard HXW & HTV PE/XLPE high-voltage DC wire configurations (10–100 kV DC)

Comparison of unjacketed HXW (oil/potting grade) and PVC-jacketed HTV (flame-retardant chassis grade) dimensions.

Voltage ratings, core OD & overall OD
Order designationConstructionConductor
mm² (AWG)		Rated U_DC
kV DC		Rated U_AC
kV rms		Test U_DC
kV DC		Nominal OD
mm		Weight
kg/km		Enquiry
HXW Series — Unjacketed Natural PE / XLPE HV DC Wire (10 kV to 100 kV DC)
HXW-10KV-0.75-XLPEHXW Natural XLPE0.75 (19 AWG)104202.611
HXW-20KV-1.0-XLPEHXW Semicon + XLPE1.0 (18 AWG)208403.518
HXW-30KV-1.5-XLPEHXW Semicon + XLPE1.5 (16 AWG)3012604.628
HXW-50KV-1.5-XLPEHXW Semicon + XLPE1.5 (16 AWG)5020906.546
HXW-75KV-2.5-XLPEHXW Semicon + XLPE2.5 (14 AWG)75281309.286
HXW-100KV-2.5-XLPEHXW Semicon + XLPE2.5 (14 AWG)1003516512.0135
HTV Series — Flame-Retardant PVC-Jacketed PE / XLPE HV DC Wire (15 kV to 100 kV DC)
HTV-15KV-1.0-PVCHTV XLPE + PVC Jacket1.0 (18 AWG)156304.024
HTV-30KV-1.5-PVCHTV Semicon + XLPE + PVC1.5 (16 AWG)3012605.844
HTV-40KV-1.5-PVCHTV Semicon + XLPE + PVC1.5 (16 AWG)4016756.858
HTV-50KV-2.5-PVCHTV Semicon + XLPE + PVC2.5 (14 AWG)5020908.078
HTV-75KV-2.5-PVCHTV Semicon + XLPE + PVC2.5 (14 AWG)752813010.8126
HTV-100KV-4.0-PVCHTV Semicon + XLPE + PVC4.0 (12 AWG)1003516514.2210
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • For potting in epoxy or polyurethane HV modules, HXW surface can be factory corona-etched or flame-treated to promote resin adhesion.

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
100 % DC water-tank OEM proof test20 kV DC to 165 kV DC hold for 5 min with zero breakdownEvery spool
Sample tests
Partial discharge test (IEC 60270)PD ≤ 3 pC at 1.2 × rated AC rms voltage on semicon-graded buildsProduction lot
UL VW-1 vertical flame test (HTV series)Self-extinguishing within 60 s without flaming dropletsType approval

Inspection certificate

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

Product approvals

UL 3239 Flame-Retardant HV Style (HTV Series)IEC 60243-1 ≥ 60 kV/mm OEM Verified

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HXW / HTV XLPE HIGH VOLTAGE DC WIRE [kV DC]
Delivery form
100 m / 500 m spools or cut leads
Surface treatment
Optional corona-discharge surface treatment on HXW for epoxy potting
Test documentation
Lot-traceable DC hipot & PD test certificate
Lead time
2–3 weeks ex-works

Technical documents

Downloads

PDFHXW / HTV XLPE High-Voltage DC Equipment Wire – technical datasheet12 sizes · construction, technical data, approvalsXLSXHXW / HTV 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.

When should HXW / HTV (PE/XLPE) be chosen instead of HSW / HSX (silicone) high-voltage wire?
Choose HXW / HTV when space is tight, when the wire is submerged in mineral transformer oil, or in high-frequency pulsed/flyback circuits. PE/XLPE has double the intrinsic OEM breakdown strength of silicone (≥ 60 kV/mm vs 30 kV/mm), allowing a 35 % smaller OD, and has a dissipation factor 10× lower than silicone (tan δ ≤ 0.0003). Choose HSW/HSX when you need rubber-like limpness or temperatures above +105 °C.
What is the difference between HXW and HTV?
HXW is unjacketed: its outer surface is pure additive-free natural LDPE or XLPE so it will not leach plasticisers into transformer oil or vacuum potting resins. HTV adds a flame-retardant PVC (or PUR) outer sheath over the PE/XLPE OEM so the wire passes UL VW-1 / IEC 60332-1-2 flame tests for open air routing.
Why isXLPE preferred over standard LDPE in high-power HV modules?
Standard LDPE softens above +80 °C and can deform under mechanical pressure or soldering heat. Electron-beam or silane cross-linked polyethylene (XLPE) converts the polymer into a thermoset network rated to +90/+105 °C continuous and +250 °C short-circuit temperature without melting during soldering.
Why is a semiconductive layer extruded over the copper conductor on ≥ 20 kV DC ratings?
Stranded copper wires have small radii of curvature along the outer strands that locally intensify the radial electric field (E_max) and trap microscopic air pockets during extrusion. A smooth co-extruded semiconductive polyolefin layer equalises the potential and bonds molecularly to the XLPE insulation.

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HXW / HTV XLPE High-Voltage DC Equipment Wire

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