Equipment Wiring Harness

Our equipment wiring harness is a customized low-voltage DC power distribution cable designed to connect one DC power input to two separately terminated output branches. The standard configuration uses a DC female barrel connector on the input side and two white 2P plug terminals on the output side.

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Description

Our equipment wiring harness is a customized low-voltage DC power distribution cable designed to connect one DC power input to two separately terminated output branches. The standard configuration uses a DC female barrel connector on the input side and two white 2P plug terminals on the output side. It allows one compatible DC adapter to supply two low-voltage loads without requiring on-site soldering, making equipment assembly, replacement, and maintenance more efficient. The molded Y-split junction reinforces the branching area, while the red and black conductors provide clear positive and negative polarity identification. DC splitter cable structures are commonly used to distribute one compatible power source to several low-voltage devices, but they do not convert voltage or provide electrical isolation.

This equipment wiring harness is suitable for LED modules, monitoring equipment, small industrial control boards, low-voltage motors, vehicle accessories, instrument modules, and other electronic assemblies. Rather than supplying a generic adapter lead, we configure the main cable length, two branch lengths, connector size, conductor gauge, current capacity, terminal housing, and jacket color around the customer's installation drawing. The two branches can be produced at equal or different lengths, allowing the harness to follow the actual routing inside an enclosure or machine. The standard cable uses a black PVC jacket, a molded strain-relief structure at the DC connector, and an integrated molded splitter that helps prevent internal conductor damage caused by repeated pulling.

Specifications

Product Type	One-input, two-output DC equipment wiring harness
Input Connector	DC female barrel connector
Optional DC Size	5.52.1mmor 5.52.5mm
Output Connector	Two independent 2P male plug terminals
Circuit Structure	Parallel power distribution branches
Voltage Conversion	None
Electrical Isolation	None
Rated Voltage	DC 12V or DC 24V
Maximum Reference Voltage	DC 36V
Standard Conductor Gauge	24AWG or 22AWG copper wire
Standard Reference Current	Up to 3A per branch and 6A total under validated configuration
Higher-Current Option	Upgraded conductor and connector configuration available
Polarity	Red wire positive; black wire negative
Cable Jacket	Black PVC as standard
Operating Temperature	-20℃ to +70℃
Storage Temperature	-30℃ to +80℃

Applications

LED Lighting Assemblies

Connects one DC adapter to two LED strips, light boards, display modules, or cabinet-lighting groups.

CCTV and Security Equipment

Provides organized low-voltage power distribution for cameras, sensors, access-control modules, and monitoring accessories.

Industrial Control Equipment

Suitable for small controllers, control boards, indicators, relay modules, and low-voltage machine accessories.

Vehicle Electronics

Applicable to low-voltage vehicle accessories, display equipment, auxiliary lighting, and other compatible electronic modules.

Instrument and Test Systems

Supports removable power connections for laboratory instruments, test fixtures, and modular electronic devices.

Customization Capability

Every equipment wiring harness can be configured according to a wiring diagram, physical sample, equipment layout, or bill of materials. The length from the DC connector to the molded splitter can be specified independently from the two branch lengths. The branches may be equal in length or produced with different dimensions to match the location of each load.

Available customization covers DC barrel size, terminal pitch, connector housing, wire gauge, jacket color, polarity, branch quantity, current capacity, labels, identification sleeves, and molded junction shape. For longer cable runs, we review current, voltage drop, conductor size, and connector capacity before confirming the final specification.

Our development process normally begins with application review, drawing confirmation, material selection, sample production, and electrical verification. Customers can approve the sample before bulk production, reducing the risk of installation mismatches during final equipment assembly.

Quality Control

The input connector, output terminals, conductor polarity, crimping condition, soldering quality, cable dimensions, and electrical continuity are inspected during production. Pull-force testing is used to verify that the terminal and conductor remain secured, while bending tests are performed at the DC connector and terminal roots.

The standard reference design includes an axial pull resistance of at least 50N on each branch, at least 5,000 terminal insertion cycles, and at least 8,000 bending cycles at reinforced cable exits under specified test conditions. The molded branch junction is also inspected for cracking, separation, and internal conductor movement.

Our production process covers wire cutting, conductor stripping, terminal crimping, soldering, injection molding, assembly, and finished-product inspection. By keeping these operations within our factory, we can trace quality problems to the relevant material, machine, process, and production batch.

After-Sales Service

Before production, our sales and engineering personnel confirm the connector definition, polarity, cable lengths, voltage, current, conductor gauge, and installation requirements. During production, order progress and important specification changes are communicated to the customer.

Finished products can be supplied with outgoing inspection records and relevant reliability reports according to the order requirement. If a customer discovers damage, incorrect wiring, dimensional deviation, or functional problems after receipt, our dedicated after-sales personnel review photographs, videos, product labels, and batch information before providing a corresponding solution.

Depending on the verified cause, the solution may include technical guidance, replacement of affected products, repair evaluation, or production correction for subsequent batches. This process gives equipment manufacturers and overseas purchasing teams a clear contact point after delivery rather than leaving them to resolve technical issues alone.