High-voltage applications are classified as such because they meet at least one of two conditions: they are at high risk of experiencing arcing or causing electrical shock through proximity or contact. In these situations, specialized equipment must be used to accommodate the large electrical load distributed and alleviate the danger posed. That’s where high-voltage cable assemblies come in.

High-Voltage Cable Assembly Capabilities at Connectronics

Interconnection System AssembliesAt Connectronics, we are an AS9100D and ISO 9001:2015 certified designer and manufacturer of reliable electronic components suitable for harsh operating environments. Equipped with over 30 years of experience and access to the full line of Wiremax high-voltage lead wires, we have what it takes to create high-voltage cable assemblies for nearly any industrial application. Our assemblies can handle voltages up to 60 KVDC, elevations up to 70,000 feet, and temperatures ranging from -55° C to 150° C.

Some of the industries we serve with our high-voltage cable assembly products and services include:

  • Aerospace
  • Analytical instruments
  • Avionics
  • Medical
  • Nuclear
  • Oil exploration
  • Radar
  • Stage lighting
  • Underwater

If you need high-voltage cable assemblies for a highly specialized application, we’ve got you covered. Our team can deliver turnkey custom solutions tailored to your unique needs. We handle everything from creating the design to building and testing prototypes to producing, assembling, and validating the final components. Even after you receive the parts, we will continue to provide you with support and service.

What Are High-Voltage Cable Assemblies? 

High-voltage cable assemblies are electrical components that are engineered for use in high-voltage applications. They consist of three main components: cables, high voltage connectors, and accessories. Despite this simple design, they must be carefully constructed. Otherwise, they may not provide adequate performance or protection.

Key Considerations for High-Voltage Cable Assemblies

Given the critical role high-voltage cable assemblies play in electrical and electronic equipment, it is important to choose cables, connectors, and accessories appropriate for the particular application. Below, we highlight some of the key considerations to keep in mind when selecting components for a high-voltage cable assembly.

Cable Considerations

There are many types of cables available, each of which offers distinct advantages that make it suitable for different applications. When choosing a cable for a high-voltage cable assembly, it is vital to consider the cable’s gauge and insulation material. The gauge influences how much operating current it can handle, while the insulation material affects how much operating voltage it can handle. Other elements you may want to add to an assembly depending on the operating and environmental requirements of the application are:

  • Additional conductive/insulation layers. Extruded cables are an excellent choice for high-voltage cable assemblies. They can come in single, double, and extruded variations. Single extruded cables feature a single conductor encased in an insulation layer. Double extruded cables feature a single conductor encased in an extruded semi-conductive layer, both of which are encased in an insulation layer. Triple extruded cables feature a single conductor encased in two extruded semi-conductive layers, all of which are encased in an insulation layer.
  • Shielding/jacket layers. Shielding and jacketing materials add additional layers of protection to a cable assembly. They defend the assembly from various environmental factors, such as heat, cold, moisture, and stress.

Connector Considerations

Connectors come in a wide range of styles and sizes. It is important to choose the options that are appropriate for the cable assembly application. Typical styles available include bulkhead receptacles, inline plugs, inline receptacles, and right-angle plugs. The connector size should be chosen with regard to operating voltage/current requirements and size restrictions.

Accessory Considerations

High-voltage cable assemblies may feature a variety of accessories that help them work. For example:

  • Cable clamps keep the cable in place inside of the connector
  • Strain relief adapters minimize mechanical stress
  • Straps and other restraints ground and secure the cables

Partner With Connectronics for Your High-Voltage Cable Assembly Needs Today

High-voltage cable assemblies play an essential role in many electrical and electronic applications, which is why it vital to source them from a reliable supplier, such as Connectronics. We’ve focused on providing customers with quality products and services since our founding. By continually investing in product and process improvement throughout the years, we’ve ensured we can continue to meet our customers’ demands and expectations.

To learn more about our high-voltage cable assemblies or other products and services, contact us or request a quote today.