New Energy Power truck parts High voltage distribution box to water-cooled unit high voltage cable assembly 2105095-KT2A1

Built to deliver stable power to water-cooled units (critical for NEV thermal management), this cable assembly boasts exceptional electrical efficiency. The conductor uses 99.9% pure oxygen-free copper (OFC) with a 40mm² cross-section and 7×16 strand structure, minimizing DC resistance to ≤0.00045Ω/m. This low resistance reduces voltage drop to ≤1.2V at 200A load, cutting energy loss by 22% compared to copper-clad aluminum alternatives. The cable’s 200A continuous current capacity (400A peak for 8s) supports the power demands of 250kW water-cooled units, ensuring consistent cooling performance during high-load operations (e.g., climbing, heavy hauling). The twisted conductor design enhances electromagnetic compatibility (EMC), reducing interference with the vehicle’s BMS and complying with CISPR 25 Class 2 standards

Engineered as a safety-critical component, the cable assembly integrates comprehensive protections for high-voltage and wet environments. The conductor is insulated with cross-linked polyethylene (XLPE) material, offering 12kV/mm dielectric strength and resisting 150℃ continuous temperature—preventing insulation breakdown. A tinned copper braid shielding layer (coverage ≥96%) isolates EMI and acts as a ground path, while the flame-retardant EPDM outer sheath (UL94 V-0 rating) inhibits fire spread. The connectors feature triple-seal design (Viton O-rings + silicone gaskets) for IP68 waterproofing, critical for water-cooled unit proximity. Integrated high-voltage interlock (HVIL) pins trigger system shutdown if connectors are disconnected, eliminating electric shock risks for maintenance personnel

Designed for the rigorous demands of commercial NEVs—especially near water-cooled units—the cable assembly exhibits exceptional durability. The XLPE insulation maintains flexibility at -40℃ (northeast China winters) and resists aging at 90℃ (engine bay heat), passing 3000-hour thermal cycle testing (-30℃ to 100℃) without cracking. The EPDM sheath resists water, glycol (coolant), road salt, and diesel, with no swelling after 72-hour immersion in coolant. The assembly passes 500,000 vibration cycles (5-2000Hz, ISO 16750-3) with no connector loosening and 1200-hour salt spray testing (ASTM B117) with no shielding corrosion. Its abrasion-resistant sheath (wear resistance ≥120,000 cycles) withstands chassis friction, ensuring 8-year/400,000km service life—matching NEV lifecycle expectations

Optimized for efficient fleet maintenance, the cable assembly features a pre-assembled plug-and-play design that cuts installation time by 55%. It comes fully terminated with connectors pre-tightened to OE torque (12-18N·m) and equipped with pre-installed nylon mounting clips matching the chassis’s original holes—requiring only a cable tie gun for routing. The connectors’ keyed design and color-coding (red for positive, blue for negative) prevent reverse installation. A 120mm service loop at the midpoint allows easy disassembly during water-cooled unit maintenance, and printed length markers facilitate precise routing. The lightweight design (1.8kg) simplifies handling, enabling a single technician to complete installation in 20 minutes or less—minimizing truck downtime and labor costs