Industry Platform
EVSE wire harnesses and cable assemblies for Level 2 AC stations and DC fast-charge cabinets — charge-gun leads, liquid-cooled high-power DC cable and ISO 15118 comms wiring. Built to CCS, NACS, CHAdeMO and Type 2, up to 1000V DC and 500A+.
Application Context
An EV charging harness is not ordinary power cable cut to length. A charge cable gets plugged, bent and dragged hundreds of times a year at the curbside, while carrying high current at 600–1000V DC and feeding back the control and communication signals that govern the charge. That demands a flexible TPU/TPE jacket that is oil-, UV- and abrasion-resistant, fine-stranded copper that survives the bend cycles, and a shielded comms pair built into the same assembly. For the highest-power DC fast chargers, the conductor itself is liquid-cooled high-voltage cable so a 350kW+ station can deliver 500A+ without overheating.
Across an EVSE the wiring changes job at every stage: the contactor, RCD and control board inside a Level 2 AC station; the DC power-module bus, AC mains input and charge-gun lead inside a DC fast-charge cabinet; the PLC-over-CP, CAN and ISO 15118 comms that run the logic; and the grid-side power and metering wiring back to the panel or energy-storage buffer. We build all of these as custom, pre-terminated and tested assemblies to CCS1/CCS2, NACS, CHAdeMO and Type 2, including commercial EV truck harnesses, EV HVAC adapter cables and IP67 waterproof assemblies for outdoor charging hardware.
Applications
Custom EVSE cable assemblies for every stage of an AC or DC charging station.
Internal power and control harnesses for Level 2 AC EVSE — wall boxes, pedestals and commercial AC posts. We wire the contactor, RCD/RCM, control board and the captive Type 2 / J1772 charge-cable assembly, with the CP/PP control-pilot signaling built to IEC 61851 and SAE J1772.
High-current cabinet and dispenser harnesses for DC fast chargers and HPC cabinets — power-module DC bus, AC mains input, and the charge-gun lead. Liquid-cooled high-power DC cable carries 500A+ for 350kW+ stations while the conductor stays within temperature.
Shielded comms and control harnesses for charger logic — PLC over the CP line, CAN between power modules and the controller, and the ISO 15118 high-level communication that enables Plug & Charge and smart-charging.
AC input, metering and grid-side power wiring connecting the charger to the panel, transformer or energy-storage buffer. High-ampacity power assemblies and lug terminations for the cabinet busbar and breaker landings.
Construction
Fine-stranded copper sized for ampacity and flex life — from heavy liquid-cooled DC conductors carrying 500A+ down to the shielded comms pair, each chosen for current, voltage drop and the bend cycles a charge cable sees daily.
Dielectric rated for 600–1000V DC service with the spacing and wall thickness a high-power EVSE charge cable demands, plus a shielded twisted pair for the CP/PLC and CAN signaling so power and comms share one assembly without coupling noise.
Flexible TPU/TPE charge-cable jacket that is oil-, UV- and abrasion-resistant for outdoor curbside duty, rated -40°C to +90°C, with a liquid-cooled high-power DC option for HPC cabinets that holds conductor temperature at 350kW+.
Charge-gun and inlet assemblies built to CCS1, CCS2, NACS, CHAdeMO and Type 2 per IEC 62196 / SAE J1772, terminated, sealed to IP67 and electrically tested in-house — no field crimping on the dispenser.
Technical Capabilities
High-power DC and AC construction built to CCS / NACS / IEC 61851, validated for 600–1000V DC, 500A+ liquid-cooled current and IP67 outdoor service.
Manufacturing Process
Quality & Testing
Every EV charging assembly gets continuity, hi-pot and contact-resistance verification before it ships, built under our ISO 9001 quality system to IPC/WHMA-A-620 workmanship and documented for lot-level traceability.
Why WHP
EVSE cable assemblies that pass inspection and survive years of daily plug cycles.
TPU/TPE oil-, UV- and abrasion-resistant charge-cable jackets and fine-stranded flexible copper engineered for daily plug cycles and curbside abuse — not repurposed general-purpose wire.
Charge-gun assemblies and station harnesses manufactured to the connector and signaling standards your charger must meet — CCS1/CCS2, NACS, CHAdeMO and Type 2 per IEC 62196, with CP/PP control to IEC 61851 and SAE J1772.
Liquid-cooled DC cable, 600–1000V dielectric design and 500A+ conductor sizing validated for 350kW+ HPC cabinets, alongside the ISO 15118 / PLC / CAN comms wiring that runs the charger.
Built under our ISO 9001 quality system to IPC/WHMA-A-620 workmanship, with continuity, hi-pot and contact-resistance testing on every assembly before it ships.
Charge-gun assemblies and station harnesses manufactured to the connector and signaling standards your charger must meet, under our ISO 9001 quality system and IPC/WHMA-A-620 workmanship.
FAQ
OEM Program Entry
EVSE cable built to CCS / NACS / Type 2, liquid-cooled for high-power DC and 100% electrically tested, with 7–10 day samples. Talk to our EV charging specialists.
Related Capabilities
Custom cable assembly and harness services that pair with EV charging programs.