Have you ever looked at a large structure and wondered how it's powered? The Sycor team, believe it or not, does this with every single application. From simple appliance wiring to extremely high-voltage applications, our team consistently deals with applications on all kinds of different power levels, for a wide range of different industries. This blog will breakdown some of the most important information about some of the most durable and well-protected cabling products.

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High-Voltage WireHigh-Voltage Cable Copper Tape Shielded

A high-voltage wire, commonly known as an HV cable, is used for electrical power transmission at an extremely high voltage level. These extremely durable cables typically come in two different constructions. The first type of construction involves underground cables that typically have insulation, which is in contrast to the overline head cables that do not.


High-voltage wiring applications are one of the more difficult types of applications to source for. Some of these applications include instruments, direct current power transmission and ignition systems. The biggest issue that arises from these types of applications is the deterioration of a cable's insulation, which is caused by high-voltage stress, ozone or tracking.


High-Voltage Wire Shielding

Shielding is one of the most important factors within the application and these shields typically come in two standard configurations. These constructions are the popular copper tape shield and the less known wire shielded cables (metallic shield).

Each shield is relied on for different purposes, and when these shields are combined with various types of insulations and jackets, it provides even greater protection. Wire shielding gets tricky when it reaches higher voltages as its main purpose is to stop EMI, but typically that's only used for data and communication applications.

When high-voltage wires over 2kv come in contact with the earth or a grounded object, it inevitably causes discharge and the deterioration of the insulation. This issue is why it's an industry standard for all cables over 2kv to have a required shield, for obvious safety precautions. These shields, as mentioned above, can come in many different styles and serve multiple purposes.

 Copper Tape Shield

Copper Tape Shields

The copper tape shield creates an electric field and helps transmit unbalanced currents. When the cable is short-circuited, it can then be used as a loop, which helps to discharge the cable. The main function is to equalize the electric field. Copper tape shielding also plays a role in the grounding of the short circuit current. Lastly, the copper tape shielding on the high-voltage cables is a measure used to help improve the electric field distribution.


Metallic Shields

The metallic portion of the high-voltage construction is necessary for providing low resistance between the flow of the current and the ground. With such high voltages becoming increasingly difficult to handle, there's a number of issues that may arise, especially within shields, as these cables typically can't handle more than a few milliamperes of current flow.

Another important aspect to remember about metallic shields is the amount of metal required. The metal is a type of back-up protection that helps preserve the cable's integrity in the event of any faults over the life of the cable. This is a deciding factor for many people in the industry as the more metal within the shield will inevitably increase the price of the cable and overall the flow of the current.


Different Types of High-Voltage Wire Shielding Constructions:

  1. XLPE-PVC Wire Shield
  2. XLPE-PVC Copper Tape Shield
  3. EPR-CPE Copper Tape Shield
  4. EPR PVC Copper Tape Shield

These different combinations are also available with multiple conductors and different temperature ratings (90C & 105C). The different variations make the high-voltage wiring category extremely reliable, as they provide the customers with such a large selection of different products that they'll be able to find a solution to their application, and potentially even a reliable alternative.


High-Voltage Construction Comparison

XLPE-PVC Wire Shield

 MV90 XLPE Insulated PVC Jacketed Wire-Shielded Cable 5kV - 35kV

EPR-CPE Copper Tape Shield

High-Voltage Cable Copper Tape Shielded
  • Soft annealed bare copper compacted conductor, Class B per ASTM B496.
  • Semiconducting cross-linked polyethylene (XLPE) conductor shield.
  • Solid soft annealed uncoated copper per ASTM B3, helically applied and uniformly spaced.
  • Semiconducting cross-linked polyethylene (XLPE) insulation.
  • Black Oil sunlight resistant and flame retardant Polyvinyl Chloride (PVC) compound jacket.
  • Soft annealed bare copper conductor, Class B per ASTM B496
  • Semiconducting cross-linked polyethylene (XLPE) conductor shield.
  • Thermoset ethylene-propylene rubber (EPR) insulation.
  • XLPE Insulation shield
  • Soft annealed bare copper tape, 5 mils thick, 25% minimum overlap + suitable binder tape.
  • Oil Resistant, Black flame retardant thermosetting chlorinated polyethylene (CPE) compound jacket.

Danger high-voltage

High-Voltage Wire Applications

  • Primary power and distribution circuits in industrial, utility and commercial installations.
  • True Triple extrusion system and closed handling raw materials system, to eliminate any contact with ambient, until the extrusion process ends.
  • Power circuits in generating plants where the line to ground fault current are within shield capabilities.
  • May be used in wet or dry locations, installed in cable trays, raceways, ducts and open-air, aerially or directly buried as permitted by NEC.


High-voltage wire and cable are one of the most diverse and powerful electrical products on the market. With multiple configurations available for some of the most demanding applications in any industry, the high voltage wiring products are consistently some of the most reliable cables currently accessible. Our team has been supplying high-voltage wire and cable for a number of years and can help answer any questions or concerns you may have.



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