EV & Renewable Energy Cable Assembly Requirements in Australia 2026
Australia's electric vehicle and renewable energy markets are experiencing unprecedented growth. Learn the critical cable assembly requirements, safety standards, and testing protocols for high-voltage EV systems, battery packs, charging infrastructure, and solar/wind installations.
Australia is at the forefront of the global energy transition. The Electric Vehicle Council reports that EV sales reached record highs in 2025, while the Clean Energy Council confirms Australia now leads the world in rooftop solar adoption per capita.
2026 Market Reality
With Australia targeting net-zero emissions by 2050 and the rapid expansion of electric vehicles and renewable energy infrastructure, demand for high-voltage cable assemblies has increased 340% since 2023. This guide covers everything you need to know about cable requirements for these critical applications.
Whether you're designing EV charging stations, battery electric vehicles, solar installations, or wind farms, understanding the specific cable assembly requirements is essential for safety, performance, and regulatory compliance.
EV & Renewable Energy Growth in Australia
Electric Vehicles
- 87,000+ EVs sold in Australia in 2025 (8.3% market share)
- 800V architecture now standard in premium EVs (Hyundai Ioniq 6, Kia EV6, Porsche Taycan)
- 6,500+ public charging stations across Australia as of January 2026
- CCS2 (Combined Charging System) is the Australian DC fast charging standard
Renewable Energy
- 3.7 million Australian homes with rooftop solar (38% of households)
- 40% of electricity from renewable sources in 2025 (target: 82% by 2030)
- Large-scale battery storage projects (Hornsdale Power Reserve expanded to 194MW/389MWh)
- Wind farms supplying 11% of national electricity generation
Impact on Cable Assembly Manufacturers
This explosive growth creates unprecedented demand for specialized cable assemblies that can safely handle high voltages (up to 1500V DC), high currents (up to 500A for fast charging), extreme temperatures, and decades of outdoor exposure. Traditional automotive and electrical cables are not suitable for these applications.
EV Cable Assembly Requirements
Modern electric vehicles use three distinct cable systems, each with specific requirements:
1. High Voltage (HV) Cables (400V - 800V)
Technical Requirements
- • Voltage rating: 450V - 1000V DC nominal
- • Current capacity: 150A - 400A continuous
- • Conductor: Stranded copper (class 5 or 6 per IEC 60228)
- • Insulation: XLPE or silicone (-40°C to +150°C)
- • Shielding: Braided or wrapped shield for EMI protection
- • Outer jacket: Orange color (HV identification per ISO 6469)
Safety Features
- • Double insulation system (primary + secondary)
- • Insulation resistance: >100MΩ @ 500V DC test
- • High voltage interlock (HVIL) integration
- • Flame retardant per ISO 6722-2
- • Color coding: Orange for HV positive, Blue for HV negative
- • Breakaway protection and strain relief
Typical Applications: Battery to inverter, inverter to motor, DC-DC converter connections, onboard charger wiring
2. Low Voltage (LV) Cables (12V / 48V)
Technical Requirements
- • Voltage rating: 12V or 48V DC systems
- • Current capacity: 5A - 150A depending on circuit
- • Conductor: Stranded copper per ISO 6722
- • Insulation: PVC or XLPE (-40°C to +105°C)
- • Wire gauge: 0.35mm² to 6mm² typical
Applications
- • 12V auxiliary systems (lights, wipers, HVAC)
- • 48V mild hybrid systems
- • Battery management system (BMS) communication
- • CAN bus, LIN bus networks
- • Sensor and actuator connections
3. Signal & Communication Cables
Requirements
- • Shielded twisted pair for CAN/LIN bus
- • Impedance-controlled for high-speed data
- • EMI/EMC protection (shielding effectiveness >70dB)
- • Low capacitance for sensor signals
- • Temperature sensors (thermocouples, RTDs)
Common Protocols
- • CAN bus (battery management, motor control)
- • LIN bus (sensors, switches)
- • Ethernet (in-vehicle infotainment, ADAS)
- • High voltage interlock loop (HVIL)
- • Temperature monitoring (PT100, NTC)
High Voltage Safety Considerations
Critical Safety Warning
Per AS/NZS 5139, any voltage above 60V DC or 30V AC is classified as high voltage and requires qualified personnel, specialized tools, and strict safety protocols. Most EVs operate at 400V or 800V—more than capable of causing fatal electric shock. Improper cable design or installation can result in death, fire, or vehicle damage.
Essential HV Safety Features
Double Insulation System
HV cables must have two independent layers of insulation. If the primary insulation fails, the secondary layer prevents electric shock.
- • Primary: XLPE or silicone insulation (2-4mm thick)
- • Secondary: Outer jacket with 1-2mm minimum thickness
- • Total insulation: Typically 3-6mm for 400V/800V systems
- • Dielectric strength: >20kV/mm test voltage
High Voltage Interlock (HVIL)
HVIL is a low-voltage signal loop that detects connector disconnection and immediately shuts down HV power. Mandatory in Australia.
- • Integrated into HV connector housings
- • Detects connector mating status in real-time
- • Triggers HV contactor shutdown (<100ms)
- • Prevents accidental live disconnection
Temperature Monitoring
HV cables carry high current and can overheat if undersized or damaged. Integrated temperature sensors prevent thermal runaway.
- • PT100 or NTC thermistors embedded in cable
- • Monitors cable temperature in real-time
- • Triggers derating or shutdown at 105-125°C
- • Essential for fast-charging applications (350kW+)
EMI Shielding
High-frequency switching in inverters creates electromagnetic interference. Shielding is mandatory to meet CISPR 25 EMC standards.
- • Braided copper or aluminum shield (85-95% coverage)
- • 360° bonding at both cable ends
- • Shielding effectiveness: >60dB @ 1GHz
- • Prevents interference with radio, GPS, sensors
Color Coding Per ISO 6469-3
Orange: HV Positive (+)
Main HV power cables
Blue: HV Negative (-)
HV return path
Yellow/Green: PE Ground
Chassis/safety ground
Battery Pack Wiring Harnesses
The battery pack is the heart of any EV, and its wiring harness is one of the most critical—and complex—assemblies in the vehicle. A typical EV battery contains 200-400 individual cells organized into modules, requiring extensive wiring for power distribution, monitoring, and safety.
Battery Pack Harness Components
Power Distribution
- HV busbar assemblies: Copper or aluminum busbars (10-20mm wide) connecting cell modules in series/parallel
- Main HV cables: 35-70mm² stranded copper for pack output (400A+ current capacity)
- Fusing/protection: High voltage fuses (500A-800A) with sense wiring
Battery Management System (BMS)
- Cell voltage sensing: 0.35-0.5mm² wires to each cell (200-400 wires total)
- Temperature sensors: NTC thermistors (10-30 per pack) with twisted pair wiring
- CAN bus communication: Shielded twisted pair to vehicle ECU
- Current sensing: Hall effect or shunt-based measurement
Critical Design Considerations
Vibration & Mechanical Stress
Battery packs are typically mounted under the vehicle floor, exposing them to constant vibration, shock, and mechanical stress. Harness must survive 15+ years / 300,000+ km.
- • ISO 16750-3 vibration testing (10-2000 Hz)
- • Mechanical shock: 50g peak acceleration
- • Strain relief at all connection points
- • Flexible routing to accommodate thermal expansion
- • P-clips and cable ties rated for automotive use
- • Protection from sharp edges (chafe protection)
Thermal Management
Battery packs can reach 55-60°C during fast charging and -30°C in Australian winter (Tasmania, alpine regions). Cables must function across this entire range.
- • Operating range: -40°C to +125°C minimum
- • Silicone insulation for extreme flexibility
- • Derating calculations for high-temp operation
- • Thermal runaway protection (fire barriers)
- • Integration with battery cooling system
- • Flame retardant per UL 94 V-0
Serviceability & Modularity
Battery modules may need replacement during vehicle lifetime. Harness design must allow module R&R without complete disassembly.
- • Modular connectors per battery module
- • Clear labeling and identification
- • Service loops for connector access
- • HVIL integration for safe disconnection
- • Torque-limited fasteners to prevent over-tightening
- • Documentation per AS/NZS 3000 requirements
EV Charging Infrastructure Cables
Australia has standardized on CCS2 (Combined Charging System Type 2) for DC fast charging, while AC charging uses Type 2 (IEC 62196-2) connectors. Understanding the different charging levels and their cable requirements is essential.
| Charging Level | Power | Voltage/Current | Connector Type | Cable Requirements |
|---|---|---|---|---|
| Level 1 AC (Home) | 2.4 kW | 240V / 10A | Type 2 or standard 10A plug | 2.5mm² standard cable per AS/NZS 3000 |
| Level 2 AC (Home/Public) | 7-22 kW | 240V / 32A (single-phase) or 400V / 32A (3-phase) | Type 2 (IEC 62196-2) | 6-10mm² cable, rated 105°C, TPE jacket |
| DC Fast (50kW) | 50 kW | 200-500V / 125A | CCS2 (Combo 2) | 35mm² HV cable, liquid-cooled optional |
| DC Ultra-Fast (150kW) | 150 kW | 200-500V / 350A | CCS2 (Combo 2) | 70mm² HV cable, liquid-cooled recommended |
| DC Ultra-Fast (350kW) | 350 kW | 200-1000V / 500A | CCS2 (Combo 2) | 95-120mm² or liquid-cooled cable (mandatory) |
Charging Cable Design Requirements
AC Charging Cables (Type 2)
- Cable construction: 4-core (3-phase + PE) or 2-core (single-phase + PE)
- Conductor size: 6mm² (32A) to 10mm² (63A) per AS/NZS 3000
- Insulation: TPE or rubber (not PVC—too stiff in cold weather)
- Temperature rating: -40°C to +90°C (Australian climate range)
- Flexibility: Minimum bend radius 5× cable diameter when cold
- Signal wires: Control pilot (CP) and proximity detection (PP) per SAE J1772
- Typical length: 5-7.5 meters (balance between usability and voltage drop)
DC Fast Charging Cables (CCS2)
- Cable construction: 2× HV DC cables + multiple signal/control wires
- Conductor size: 35-95mm² (air-cooled) or liquid-cooled for 350kW+
- Insulation: Double-insulated XLPE or silicone (1000V DC rated)
- Temperature monitoring: Integrated PT100 or thermistor at connector
- CAN communication: High-speed CAN (500 kbps) for PLC/ISO 15118
- Cable weight: 2-4 kg for 50kW, 6-10 kg for 350kW (ergonomic challenge)
- Typical length: 3-5 meters (shorter to reduce weight and voltage drop)
Liquid-Cooled Charging Cables (350kW+)
At 350kW charging power (500A @ 700V), conventional air-cooled cables become impractically heavy (>12 kg) and difficult to handle. Liquid-cooled cables solve this problem by circulating coolant (water/glycol mix) through the cable to remove heat, allowing smaller conductor sizes.
Conductor Size Reduction
95mm² air-cooled → 35mm² liquid-cooled (same 500A capacity)
Weight Reduction
12 kg air-cooled → 4-5 kg liquid-cooled (much easier to handle)
Complexity Trade-off
Requires cooling system (pump, radiator, hoses) in charging station
Solar & Wind Energy Cable Requirements
Renewable energy systems present unique challenges: decades of outdoor exposure, extreme temperature cycling, UV radiation, and high DC voltages (up to 1500V for solar). Cable selection is critical for system reliability and safety.
Solar PV Cable Requirements
Australian Solar Conditions (Extreme)
Australian rooftops are among the harshest environments for cables: UV index up to 16, roof surface temperatures reaching 75-80°C in summer, thermal cycling from -5°C (winter nights) to +90°C (summer peak), and expected lifetime of 25-30 years. Standard electrical cables will fail within 3-5 years under these conditions.
PV Cable Standards & Specs
- Standard: AS/NZS 5033:2021 (Installation and safety requirements for PV arrays)
- Voltage rating: 1000V DC (residential) to 1500V DC (commercial)
- Temperature rating: -40°C to +120°C (130°C for premium cables)
- Insulation: Cross-linked PE (XLPE) or Electron Beam Cross-linked (EBXL)
- Sheath: UV-stabilized LSZH (Low Smoke Zero Halogen) compound
- UV resistance: Must pass 720-hour UV aging test per IEC 60216
- Conductor: Tinned copper (corrosion resistance) class 5 stranded
Common PV Cable Sizes
- 4mm² (12 AWG)Up to 30A / 7kW residential
- 6mm² (10 AWG)Up to 50A / 12kW residential
- 10mm² (8 AWG)Up to 70A / 20kW commercial
- 16mm² (6 AWG)Up to 100A / 30kW+ commercial
Note: Sizing per AS/NZS 3008.1.1, accounting for ambient temperature, installation method, and voltage drop (<3% recommended)
PV String vs. Main Array Cables
DC String Cables (Module to Combiner)
- • Single-core PV cables (positive and negative separate)
- • 4-6mm² typical for residential (15-20 modules per string)
- • MC4 or MC3 connectors (rated IP67 minimum)
- • Exposed on roof—maximum UV/weather exposure
- • Must be secured to prevent wind damage
DC Main Array Cables (Combiner to Inverter)
- • Multi-core or bundled single-core cables
- • 10-25mm² typical for 10-30kW systems
- • Usually run in conduit (UV protected)
- • Requires DC-rated disconnectors/isolators
- • Shorter runs (5-30m typical) with lower voltage drop
Wind Turbine Cable Requirements
Wind turbines present unique cable challenges: constant movement (yaw, blade flexing), extreme environmental exposure (coastal salt spray, UV, temperature cycling), and long cable runs (tower height + underground to substation). Cable failure means costly crane rental and downtime.
Tower Internal Cables (Nacelle to Base)
- Power cables: 3-core + earth, 35-185mm² (690V AC typical)
- Flexibility: Class 5 or 6 stranded (millions of flex cycles)
- Flame retardant: IEC 60332-3-24 (limited flame propagation in vertical run)
- Temperature: -40°C to +90°C (tower interior can freeze in winter)
- Control cables: Shielded pairs for sensors, encoders, safety systems
Yaw & Pitch Cables (High-Flex)
- Application: Continuous rotation (yaw) and blade pitch control
- Construction: Ultra-flexible PUR or TPE jacket, very fine stranding
- Flex rating: 5-10 million cycles minimum (20-year design life)
- Bend radius: 7.5-10× cable diameter (extremely flexible)
- Cost: 3-5× standard cable (specialized manufacturing)
Battery Energy Storage Systems (BESS)
Large-scale battery storage (like the Hornsdale Power Reserve in South Australia) and residential home batteries (Tesla Powerwall, Enphase, etc.) require similar cable assemblies to EV battery packs: high voltage DC, extensive BMS wiring, and thermal management.
Residential (5-15 kWh)
400-800V DC, 6-16mm² cables, integrated BMS, wall-mounted or floor-standing
Commercial (50-500 kWh)
600-1000V DC, 25-70mm² busbars, modular design, container or rack-mounted
Utility-scale (1-400 MWh)
1000-1500V DC, 95-300mm² busbars, extensive fire suppression, 40-ft container modules
Australian Standards & Compliance
Compliance with Australian and international standards is mandatory for EV and renewable energy installations. Non-compliant installations can be rejected by network operators, void insurance, and pose serious safety risks.
Key Australian/New Zealand Standards
Electrical Installation Standards
- AS/NZS 3000Wiring Rules (the foundation—covers all electrical installations)
- AS/NZS 3008Cable sizing and selection (derating factors, voltage drop calculations)
- AS/NZS 3012Electrical installations in vehicles (applies to EVs and mobile equipment)
- AS/NZS 5139Electrical installations—Safety of battery systems (lithium-ion, lead-acid)
Renewable Energy Specific
- AS/NZS 5033Installation and safety requirements for photovoltaic (PV) arrays
- AS/NZS 4777Grid connection of energy systems via inverters (grid compliance)
- AS/NZS 4755Demand response capabilities (smart charging, load management)
- AS 60529IP ratings (ingress protection for outdoor equipment)
Internationally Referenced Standards
EV-Specific Standards
- • SAE J1772: AC Level 1/2 charging connector (Type 1, common in USA)
- • IEC 62196: Type 2 connector standard (European/Australian AC charging)
- • ISO 15118: Vehicle-to-grid communication (V2G, smart charging)
- • ISO 6469: EV safety specifications (HV systems, crash safety)
- • ISO 16750: Environmental conditions and testing for automotive equipment
- • CISPR 25: EMC limits and test methods for automotive components
Cable & Component Standards
- • IEC 60228: Conductors of insulated cables (stranding classes)
- • IEC 60332: Tests on electric cables under fire conditions
- • IEC 60754: Test on gases evolved during combustion (LSZH testing)
- • IEC 60811: Insulation and sheath materials tests
- • ISO 6722: Road vehicles—60V and 600V single-core cables
- • UL 94: Flammability testing (V-0, V-1, V-2 ratings)
Clean Energy Council Accreditation
In Australia, only Clean Energy Council (CEC) accredited installers can install solar PV systems eligible for government rebates (Small-scale Technology Certificates). CEC accreditation requires:
- • Completion of CEC-approved training courses
- • Demonstrated knowledge of AS/NZS 5033 and AS/NZS 3000
- • Use of CEC-approved components (inverters, modules, mounting systems)
- • Compliance with cable assembly best practices and AS/NZS standards
Material Selection for EV & Renewable Cables
Cable material selection is critical for long-term reliability in harsh Australian conditions. The wrong material choice can lead to premature failure, safety hazards, and costly replacements.
Insulation Materials
XLPE (Cross-Linked Polyethylene)
Best for: Solar PV cables, high-voltage EV cables, underground installations
- • Temperature range: -40°C to +120°C (130°C for XLPE-2)
- • Excellent UV resistance (with proper additives)
- • Superior dielectric strength (25-30 kV/mm)
- • Moisture resistant, flame retardant
- • 30+ year lifespan in outdoor applications
- • Not suitable for high-flex applications (stiffens over time)
Silicone Rubber
Best for: EV HV cables, high-flex applications, extreme temperature environments
- • Temperature range: -60°C to +180°C (extreme flexibility maintained)
- • Remains flexible even when frozen
- • Excellent ozone and UV resistance
- • Self-extinguishing flame properties
- • More expensive than XLPE (2-3×)
- • Can be damaged by some oils and solvents
TPE (Thermoplastic Elastomer)
Best for: EV charging cables (Type 2, CCS2), high-flex applications
- • Temperature range: -40°C to +105°C
- • Excellent flexibility and cold-weather performance
- • Abrasion resistant, suitable for frequent handling
- • Recyclable (unlike PVC or XLPE)
- • UV resistance inferior to XLPE (not ideal for permanent outdoor)
- • Lower voltage rating than XLPE or silicone
Shielding & Conductor Materials
EMI/EMC Shielding Options
Braided Copper Shield (85-95% coverage)
Best shielding effectiveness (>80dB), most expensive, used in HV EV cables and signal cables
Aluminum/Polyester Foil Tape (100% coverage)
Good shielding (60-70dB), lightweight, cost-effective, common in BMS and CAN bus cables
Spiral/Wrapped Shield (60-80% coverage)
Moderate shielding (40-60dB), flexible, used in motor phase cables
Note: CISPR 25 EMC testing is mandatory for all automotive cables. Shielding must provide >60dB attenuation at 1 GHz to prevent interference with vehicle electronics.
Conductor Materials
Bare Copper (Standard)
Most common, excellent conductivity (100% IACS), cost-effective. Use for indoor/protected applications.
Tinned Copper (Recommended for EV/Solar)
Corrosion resistant, essential for marine/coastal areas, solar applications. +15-20% cost vs bare copper.
Aluminum (Large Cable Only)
1/3 the weight of copper, 60% conductivity. Used in utility-scale solar (50mm²+). Requires special termination.
Testing Requirements for HV Cable Assemblies
High voltage cable assemblies for EV and renewable energy applications require comprehensive testing and validation to ensure safety and reliability. Our CNAS & ISO 17025 certified laboratory performs all required tests to Australian and international standards.
Electrical Testing
High Voltage Insulation Test (Hipot)
Test voltage: 2× operating voltage + 1000V for 1 minute (e.g., 2800V for 400V system). Detects insulation defects. Must show no breakdown or flashover.
Insulation Resistance (IR) Test
500V DC megger test. Must achieve >100MΩ (typically 500-1000MΩ for new cable). Test before and after environmental conditioning.
High Current Test
Pass 125% of rated current for 1 hour. Monitor temperature rise (<50K above ambient). Verifies conductor sizing and termination quality.
Voltage Drop Test
Measure voltage drop at rated current. Must be <3% for power cables per AS/NZS 3008. Detects undersized conductors or poor connections.
Contact Resistance
4-wire Kelvin measurement at all terminations. Must be <1mΩ for HV power connections. Detects poor crimps or oxide buildup.
Environmental Testing
Temperature Cycling
-40°C to +125°C, 100-500 cycles (per ISO 16750-4). Simulates Australian climate extremes. Check for insulation cracking, seal failure.
Humidity/Moisture Resistance
85°C / 85% RH for 1000 hours (per IEC 60068-2-78). Detects moisture ingress that can cause tracking and insulation failure.
UV Aging Test
720-2000 hours UV exposure (340nm wavelength) per AS/NZS 5033. Critical for solar cables. Measure tensile strength retention (>80%).
Salt Spray / Corrosion
ASTM B117 salt spray test (5% NaCl solution, 35°C, 96-1000 hours). Essential for coastal installations and marine applications.
IP Rating Verification
IP67/IP68 testing per AS 60529. Dust chamber (8 hours) and water immersion tests. Critical for outdoor connectors and enclosures.
Mechanical Testing
Vibration Testing
ISO 16750-3 random vibration (10-2000 Hz, 8 hrs per axis). Simulates vehicle operation. Check for connector loosening, chafing, fatigue.
Mechanical Shock
50g peak, 11ms half-sine pulse (ISO 16750-3). Simulates potholes, curbs, off-road use. Must maintain electrical continuity.
Flex/Bend Testing
50,000-5,000,000 flex cycles (per application). Critical for charging cables and EV doors/hatches. Monitor resistance change <10%.
Pull-Out / Retention Force
Axial load test on connectors and crimps. HV connectors: >200N retention. Crimps: >80% of wire breaking strength per IEC 60352.
Abrasion Resistance
IEC 60811-4-1 abrasion test. Simulates cable routing against vehicle body/sharp edges. Jacket must not expose insulation.
EMC/EMI Testing
Radiated Emissions (CISPR 25)
150 kHz to 2.5 GHz emission limits. HV cables must not interfere with AM/FM radio, GPS, cellular, ADAS systems. Requires anechoic chamber.
Conducted Emissions
150 kHz to 108 MHz per CISPR 25. Measures noise injected back into 12V system. Critical for BMS and signal cables on HV harness.
Shielding Effectiveness
Transfer impedance measurement per IEC 62153-4-3. HV cables require >60dB attenuation at 1 GHz. Verifies shield coverage and bonding.
ESD Immunity
±8kV contact / ±15kV air discharge per ISO 10605. Ensures HV interlock and BMS signals survive electrostatic discharge events.
Our Testing Capabilities
As a leading automotive and energy sector cable assembly manufacturer, we maintain a fully equipped testing laboratory certified to CNAS and ISO 17025 standards. We can perform all tests listed above in-house, ensuring rapid turnaround and complete traceability. Our test reports are accepted by major Australian and international OEMs.
CNAS Accredited Lab
ISO 17025 certified testing
Full EMC Chamber
CISPR 25 radiated/conducted
Environmental Chambers
-70°C to +200°C range
Frequently Asked Questions
What voltage is considered high voltage in EV applications?
Per AS/NZS 5139, high voltage (HV) is defined as any voltage above 60V DC or 30V AC. Most modern EVs operate at 400V or 800V nominal, making them high voltage systems requiring specialized cable assemblies, safety interlocks, and qualified installers. The 800V architecture is becoming standard in premium EVs (Hyundai Ioniq 6, Kia EV6, Porsche Taycan) for faster charging capabilities.
What cable standards apply to EV charging infrastructure in Australia?
Australian EV charging installations must comply with AS/NZS 3000 Wiring Rules, AS/NZS 3012 for electrical installations in vehicles, and AS/NZS 4755 for demand response capabilities. For the charging cable itself, SAE J1772 (Type 1) and IEC 62196 (Type 2) are the recognized connector standards, with CCS2 (Combined Charging System) becoming the Australian standard for DC fast charging.
How do solar cable requirements differ from standard electrical cables?
Solar PV cables must withstand decades of UV exposure, extreme temperature cycling (-40°C to +90°C in Australian rooftop conditions), and maintain electrical safety with up to 1500V DC systems. AS/NZS 5033 requires solar cables to be dual-insulated with UV-stabilized materials (typically XLPE or cross-linked PE). Standard electrical cables lack the UV resistance and temperature rating needed for long-term rooftop solar installations and will fail within 3-5 years.
What testing is required for high voltage EV cable assemblies?
HV EV cable assemblies require comprehensive testing including: high voltage insulation testing (typically 2× operating voltage + 1000V for 1 minute), high current testing to verify thermal performance, mechanical durability testing (flexing, vibration per ISO 16750), environmental testing (temperature cycling, humidity, salt spray), and EMC/EMI testing per CISPR 25. All assemblies must maintain insulation resistance >100MΩ throughout testing to ensure safety.
Can I use standard automotive wire for EV high voltage applications?
Absolutely not. Standard automotive wire (per ISO 6722) is rated for 60V maximum. EV HV systems operate at 400-800V and require specialized double-insulated cables with XLPE or silicone insulation, EMI shielding, high-voltage interlocks, and orange color coding per ISO 6469. Using standard wire in HV applications will result in insulation breakdown, electric shock hazard, and catastrophic failure. This is a critical safety issue—never substitute standard wire for HV-rated cable.
What's the difference between Type 1 and Type 2 EV charging connectors?
Type 1 (SAE J1772) is a 5-pin single-phase connector common in North America and Japan, supporting up to 7.4kW (240V × 32A). Type 2 (IEC 62196-2) is a 7-pin connector supporting both single-phase and three-phase charging up to 22kW (400V 3-phase × 32A), and is the European and Australian standard. Type 2 is preferred in Australia because our 400V 3-phase grid allows faster AC charging. CCS2 (Combo 2) adds two additional DC pins to the Type 2 connector for DC fast charging up to 350kW.
Partner with Australia's EV & Renewable Energy Cable Assembly Experts
With 18 years of experience manufacturing high-voltage cable assemblies for electric vehicles, renewable energy, and battery storage systems, we understand the unique challenges of the Australian market. Our CNAS & ISO 17025 certified laboratory ensures every assembly meets the stringent safety and performance requirements of AS/NZS standards.
HV cable assemblies up to 1500V DC (400V/800V EV systems)
AS/NZS 3000, AS/NZS 5033, AS/NZS 5139 compliant designs
Complete testing per ISO 16750, CISPR 25, IEC 60068
Solar PV, wind turbine, and BESS cable assemblies
EV charging cables (Type 2, CCS2) with liquid cooling option
Battery pack harnesses with integrated BMS and HVIL
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