UPS battery cables

Built for Performance, Reliability & Scale in Power Backup Systems

In a world where power reliability is non-negotiable, **Celestix Industries **stands as a trusted manufacturer of custom UPS and battery cable wiring harnesses, delivering dependable, application-specific solutions for critical infrastructure, industrial UPS systems, data centers, energy storage, and telecommunications.

With over a decade of experience and certified manufacturing rooted in ISO 9001, IATF 16949, and ISO 14001, Celestix brings a commitment to quality, flexibility, and long-term reliability into every custom wiring harness we build.

Why Celestix?

• Rigorous Quality Control: End-to-end testing for continuity, insulation, and functionality.

• Scalable Production: Agile manufacturing with capacity to meet fluctuating demand for scalable UPS wiring and OEM battery cable harness solutions.

• Global Compliance: Harnesses designed to align with UL-approved UPS cable, BIS-compliant battery harness, RoHS UPS wiring harness, and other international standards.

• Collaborative Engineering: Design support from early development through prototype UPS cable builds to full production.

• Reliable Materials: Options tailored to your needs, including flame-retardant jackets, shielded UPS harness configurations, and moisture-resistant connectors.

• In-House Testing & Trained Staff: IPC-certified operators and internal validation of mechanical and electrical performance.

Engineered for Versatility

Conductor Options:

• Copper variants (pure, tinned, stranded)

• Aluminum or copper-clad options available for weight- or cost-sensitive applications

Insulation & Jacket Materials:

• Materials selected based on thermal, chemical, and mechanical needs

• PVC, XLPE, silicone, and Teflon options available for heat-resistant UPS harness and durable UPS cable needs

Shielding Solutions:

• Braided, foil, or hybrid shielding for EMI protection and smart battery wiring harness configurations

Connector Integration:

• Wide range of industry-standard or custom connectors for UPS inverter cable harness, battery terminal wiring, or UPS control cable harness applications

• Sealed and vibration-resistant configurations for demanding environments

Power & Thermal Capabilities:

• Designed to match voltage, current, and temperature needs as defined by the system and use-case

Environmental Design Elements:

• Protection options include overmolding, potting, sealed terminals, and strain relief systems

Application Coverage

• UPS Systems (Modular, Line-Interactive, Online): We support a broad range of UPS topologies, from small modular units to enterprise-grade online double-conversion systems. Our harnesses are tailored for input/output connectivity, battery banks, control systems, inverters, bypass circuits, and alarm signal lines—ensuring seamless power transitions and fail-safe backup performance.

• Battery Energy Storage Systems (BESS): Celestix designs custom battery cable harnesses for large-scale and decentralized energy storage solutions. Whether you're managing a grid-tied lithium-ion system or a hybrid lead-acid configuration, our assemblies support high-current distribution, thermal resistance, sensor wiring, and secure battery terminal connections.

• Data Center & Edge Computing Infrastructure: High-density rack configurations, power distribution units (PDUs), and redundant UPS banks require compact, thermally stable, and EMI-shielded harnesses. We build to spec for server farms, co-location centers, and micro data facilities where uptime and wiring traceability are non-negotiable.

• Telecom, Solar-Hybrid & Industrial Power Units: For telecom base stations, hybrid solar-inverter systems, and industrial backup panels, Celestix harnesses are built to withstand vibration, environmental ingress, and variable load conditions. Solutions include solar-to-battery cabling, inverter interfaces, and dual-source UPS wiring with strain relief, ruggedized jackets, and flexible layout configurations.

Our cable harnesses are deployed across a wide spectrum of applications where power integrity, system-level compliance, and physical reliability are mission-critical.

We support a broad range of electrical harness assembly requirements across industries, including battery backup cable, UPS power supply cable, battery charger harness, and battery sensor wiring harness use cases.

Built for Reliability

Every harness undergoes validation protocols aligned with application expectations:

• Electrical integrity and visual quality checks

• Environmental and mechanical stress simulations as needed

• Customized testing to customer-defined criteria

Failures in wiring harnesses can cause anything from intermittent malfunctions to full system outages. At Celestix, we proactively mitigate risks such as:

• Connector failures due to poor mating, corrosion, or vibration

• Wire fatigue and breakage from routing strain or mechanical stress

• Insulation degradation from heat, abrasion, or chemical exposure

• Manufacturing defects from poor crimping, materials, or incorrect assembly

By integrating failure mode analysis into our design and production stages, we prevent issues before they reach the field.

Technical Partnership & Engineering Depth

We understand that for engineers, a wiring harness is not just a component—it’s a mission-critical system element that affects uptime, thermal performance, signal integrity, and safety. At Celestix, our engineering-first approach is built to support rapid development cycles, design resilience, and long-term field performance.

Here's what engineering teams can expect from Celestix:

• Early Engagement & Design Reviews: We collaborate from the schematic phase—advising on conductor types, connector pinouts, routing pathways, and thermal mitigation techniques.

• Design for Manufacturability (DFM): We optimize every detail—from wire gauge standardization and bundle routing to connector orientation and strain relief—all aimed at making assembly faster and more repeatable.

• Design for Assembly (DFA): Engineering input extends to labeling, service loop design, mounting tolerances, and ease of access for in-field service and maintenance.

• Prototyping & Iteration: Whether you’re in concept validation or pilot builds, we provide iterative prototyping with fast turnaround times—so you can test, revise, and scale confidently.

• Failure Mode Avoidance: Through lessons learned from other OEMs, we proactively prevent common faults like insulation cuts, crimp pullout, thermal cycling failures, and EMI noise ingress.

• Software Compatibility: We work with native CAD formats, maintain revision control protocols, and align with your BOM management ecosystem.

• Full Documentation: You’ll receive complete harness drawings, testing protocols, PPAP documentation (if needed), and traceability logs—aligned with IPC, IATF, and application-specific standards.

• Agile Engineering Support: We respond quickly to ECRs, spec modifications, or urgent reroutes—because your design timeline doesn’t pause.

Engineers count on Celestix not just for wiring—but for thinking. We embed technical intelligence into every harness we build.

Commercial Partnership Confidence

Purchasing professionals operate in a high-stakes environment where a single supplier misstep can ripple across production lines, brand reputation, and bottom lines. At Celestix, we recognize what buyers look for:

• Risk Mitigation: We understand buyer psychology—risk aversion drives supplier selection. That’s why we maintain consistent quality, stable lead times, and full traceability.

• Trust Through Reputation: Buyers trust proven suppliers. With over a decade of on-time delivery, strong references, and global certifications, Celestix has earned that trust.

• Total Cost of Ownership: It's not just unit price. We help buyers reduce hidden costs through quality assurance, design optimization, and dependable delivery.

• Supply Chain Resilience: Our domestic manufacturing presence, vetted sub-suppliers, and robust planning systems keep your line moving even under global disruptions.

• Emotional Drivers: We address the anxiety that comes with high-involvement technical purchases. Our clear documentation, proactive communication, and reliable support provide peace of mind.

• Value Beyond Price: We help buyers achieve long-term operational reliability and cost efficiency through component traceability, tailored engineering, and consistent documentation.

For complex cable harness assembly or contract battery harness requirements, buyers want a supplier they don’t have to second-guess. That’s Celestix.

Addressing UPS-Specific Material and Engineering Challenges

Wiring harnesses for UPS and battery applications face unique challenges:

• High Current Loads: Proper conductor sizing and material selection prevent voltage drop and overheating

• Thermal Stress: Use of heat-resistant insulations like XLPE, silicone, or PTFE ensures safe long-term operation

• EMI Shielding: Braided, foil, or hybrid shielding plus low-resistance grounding minimizes interference

• Mechanical Protection: Reinforced jackets, abrasion-resistant wraps, and durable overmolds protect against environmental wear

• Stationary System Durability: Material selection emphasizes long-term resistance to chemical, thermal, and mechanical stress

We engineer each custom battery cable or harness to the specific current, voltage, temperature, and spatial profile required by your UPS or battery backup system. Whether you need a rugged battery wiring solution or a compact battery cable layout for space-constrained setups, we deliver with precision.

Compliance & Commercial Assurance

At Celestix, we recognize that every cable harness we deliver must meet not only performance standards, but also procurement, compliance, and regulatory expectations. That’s why we embed our quality-first approach into both manufacturing and customer collaboration.

Compliance Protocols:

• Fully aligned with IEC, UL, SAE, and BIS certification pathways

• Committed to RoHS and REACH materials compliance for sustainability

• Adaptable to customer-defined standards, drawings, and quality plans

Commercial Confidence:

• Clear documentation packages: harness drawings, PPAP files, and traceability logs

• Agile, responsive RFQ and design communication workflows

• Volume flexibility and scalable batch management for OEM procurement cycles

• Proactive design for manufacturability (DFM) guidance to reduce cost and lead time

As established cable and harness manufacturers, we align regulatory confidence with business agility—ensuring peace of mind across sourcing, compliance, and field performance.