Industry Platform
Custom UPS and battery-backup harnesses for rolling stock, trackside signaling and transit substations — low-smoke halogen-free cable built to EN 45545-2 fire safety and EN 50155 / IEC 60571 rolling-stock requirements, rated -40°C to +90°C and engineered for rail shock and vibration.
Application Context
A rail UPS harness is not ordinary battery cable cut to length. It lives inside an enclosed passenger vehicle or an unconditioned trackside cabinet, carries the backup power that keeps emergency lighting, doors, brakes, signaling and passenger-information systems alive when traction or grid power drops, and does it for decades of constant shock and vibration. That is why rolling-stock and transit backup harnesses use rail-grade fire-safety cable — built to EN 45545-2 and NFPA 130 as low-smoke, halogen-free constructions — instead of repurposed industrial wire that would feed smoke and toxic gas into an onboard fire. We pair that cable with vibration-resistant fine-stranded copper from battery interconnect cable up through high-voltage assemblies for traction-side feeds.
Across a rail or transit system the backup wiring changes job at every point: onboard auxiliary-power and battery interconnects tying the battery box to DC/DC converters, trackside signaling and interlocking cabinets that must ride through outages, level-crossing controls, transit traction-substation battery banks, and the low-current BMS sense harnesses that watch each cell string. We build all of these as custom, pre-terminated, tested assemblies — using Anderson SB power connectors, sealed lugs and waterproof sealed constructions where enclosures see moisture — so depot and substation crews install one labeled harness instead of field-terminating power lugs trackside. Cell-monitoring runs use our CAN bus sense cabling where the BMS talks over a data bus.
Applications
Fire-safe, vibration-rated harnesses for every backup-power point in a rail system.
Onboard uninterruptible-power and battery-backup harnesses for trains, metros, light-rail and trams — keeping emergency lighting, doors, brakes and passenger-information systems alive when traction power drops. Built to EN 50155 rolling-stock electronics requirements with fire-safety cable that meets EN 45545-2.
UPS and battery-bank interconnect harnesses for wayside signaling cabinets, interlocking systems and level-crossing controls that must ride through grid outages without dropping a safety-critical circuit. Sealed, abrasion-resistant constructions survive years in unconditioned trackside enclosures.
High-ampacity battery interconnects and auxiliary-converter cabling that tie the onboard battery box to DC/DC converters, chargers and the auxiliary bus. Anderson SB power connectors and sealed lugs handle repeated connect/disconnect and constant rail vibration without contact fatigue.
Battery-backup interconnects for transit traction substations plus low-current BMS sense harnesses that monitor each cell string. Power and sense lines are built and tested as one assembly so substation crews install a single, labeled, verified harness.
Engineering Challenges
Low-smoke halogen-free cable selection built to EN 45545-2 and NFPA 130 so an onboard UPS harness inside an enclosed passenger space limits smoke density and toxic gas in a fire.
Constructions, temperature class and vibration tolerance built to the EN 50155 rolling-stock electronics standard and IEC 60571 rail requirements your vehicle and signaling specs call out.
Fine-stranded conductors, strain relief, sealed lugs and rail-rated circulars validated for the continuous shock and vibration profile of rolling stock and trackside enclosures.
Continuity and dielectric (Hi-Pot) testing plus crimp-pull and contact checks planned to IPC/WHMA-A-620 Class 3 workmanship under our ISO 9001 quality system before shipment.
Technical Capabilities
EN 45545-2 / IEC 60571 fire-safe, low-smoke halogen-free construction with vibration-resistant fine-stranded copper, validated for onboard and trackside backup-power service.
Manufacturing Process
Quality & Testing
Every backup harness gets continuity and dielectric (Hi-Pot) testing plus crimp-pull and contact checks, built to IPC/WHMA-A-620 Class 3 workmanship under our ISO 9001 quality system — all documented for lot-level traceability before it ships.
Why WHP
Backup harnesses that pass rail fire-safety inspection and last as long as the vehicle.
Low-smoke halogen-free cable built to EN 45545-2 and NFPA 130 fire-safety requirements — not repurposed industrial wire — because an onboard UPS harness sits inside an enclosed passenger space.
Constructions, temperature class and vibration tolerance are built to the EN 50155 rolling-stock electronics standard and IEC 60571 rail requirements your vehicle and signaling specs call out.
Fine-stranded conductors, strain relief, sealed lugs and rail-rated circulars validated for the continuous shock and vibration profile of rolling stock and trackside enclosures.
Every backup harness gets continuity and dielectric (Hi-Pot) testing plus crimp-pull and contact checks, built to IPC/WHMA-A-620 Class 3 workmanship under our ISO 9001 quality system before it ships.
Our backup harnesses are built to the railway fire-safety and rolling-stock standards transit authorities and rail integrators require, under ISO 9001 and IPC/WHMA-A-620 workmanship.
FAQ
OEM Program Entry
EN 45545-2 fire-safe cable, Anderson SB and rail-rated terminations, 100% electrically tested, with 7–10 day samples. Talk to our rail specialists.
Related Capabilities
Custom cable assembly and harness services that pair with rail and transit UPS programs.