Appliance & Lighting
Home Appliance Wiring Harness
- Up to 300 V; 80 °C and 105 °C PVC styles cover most internal wiring
- 1 to 30 circuits, dominated by single and double-ended leads
Appliance & Lighting Wire Harness
Domestic appliance and luminaire harnesses at volume, with high-temperature leads at the hot end and sealed entries on outdoor fixtures.
2harness lines
7application groups
This is volume work with a quality trap in it. At tens of thousands of leads a week, the only way to hold a crimp together is process control rather than inspection: applicator tooling dedicated to the terminal series, crimp height measured on a schedule, and a pull-test on every terminal.
The second trap is temperature. A lead that runs close to a heating element or across an LED board is not the same lead as the one beside it, even though both terminate in the same housing. The lines in this group separate those two duties explicitly, and every wire named carries its published temperature rating.
Practically, that means two bills of materials inside one appliance. The general internal wiring is 105 °C PVC or SRPVC — UL1007, UL1015, UL10002 — which crimps predictably on automatic equipment. The leads that sit near a heater, a lamp holder or a driver board come from a different set: 150 °C XLPE fixture wire such as UL3485, ETFE at 150 °C in UL1671 or UL10086, and FEP at 200 °C in UL1330 and UL1332 where the lead is both hot and chemically exposed.
Volume changes the tooling conversation. A terminal series used at hundreds of thousands of pieces justifies a dedicated applicator and a crimp-height check on a fixed interval; a series used at a few hundred pieces does not, and it is quoted with hand tooling and a pull-test regime instead. Saying which is which is part of the quotation, because it is the difference between a programme that holds its crimp height and one that drifts.
Market variants are the last variable. The same luminaire harness built to UL 758 AWM for North America will normally be built to H05V2V2-F or H05VV-F for a European version, and to a JIS construction such as VCTFK or VFF for Japan, on one assembly drawing with the wire line and the colour code called out per destination. Outdoor fixtures add sealed entries and moulded grommets, which are specified with the housing rather than with the wire.
Appliance & Lighting harness lines
Each line states the wire it is built on, the conductor range, the termination style and the inspection method.
Appliance & Lighting
LED Lighting & Fixture Harness
- 300 V to 600 V; 105 °C to 200 °C depending on proximity to the board
- 1 to 12 circuits per luminaire, plus dimming and control pairs
Other harness application groups
Appliance & Lighting harness questions
What buyers ask before they send a drawing for this group.
Which leads in an appliance or luminaire need a high-temperature wire?
Any lead whose route passes within the radiant envelope of a heater, a lamp holder, a driver or a motor winding. The practical test is the temperature at the point of the route, not the rated temperature of the appliance, so a lead crossing an LED board can run hotter than one beside a 60 W element. Those leads are drawn from the 150 °C and 200 °C lines rather than from general 105 °C PVC.
How is crimp quality held across a high-volume programme?
By tooling and by measurement rather than by looking at parts. Each terminal series gets its own applicator, the crimp height is measured on a fixed interval against the terminal maker’s specification, and a pull-test is performed on every terminal rather than on a sample. The records are kept against the lot, so a question about a specific delivery can be answered with data.
Can the same harness be supplied in a UL version and a JIS version?
Yes, from one assembly drawing with the wire line and colour code called out per destination. The terminal and the housing are normally common; the conductor and its insulation are not — UL 758 AWM for North America, the harmonised H05 or H07 lines for Europe, a JIS construction for Japan. Building both variants on the same drawing is what keeps them from drifting apart.
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