Wire Processing and Testing for Data Center Equipment Manufacturers

Data Centers

Data Center Boom Reaches the Production Floor
Because miles of processed wire go into every data center, automated wire processing and testing turn rising demand into a chance to scale.
  • High Power Density and Advanced Cooling
    The massive power demands and high thermal loads of data center infrastructure drive more power distribution and increasingly complex cooling systems. Automation and integrated testing help meet these demands under time pressure.
  • High Complexity for Low Lot Sizes
    Customized power distribution units (PDUs), switchgear cabinets, and cooling systems mean thousands of unique wire configurations. A digital workflow from ECAD to wire processing and testing makes production more flexible, more productive, and cost-effective.
  • End-to-End Quality with 100% Testing
    Every processed cable must be tested and documented, from power distribution to cooling, and above all in the high-speed networking layer that ties the data center together. Automated testing verifies every connection at scale, not just samples.
  • Skilled Labor Shortage and Time Pressure
    Data center suppliers face severe challenges like the scarcity of skilled technicians, coupled with aggressive delivery deadlines. These challenges can be overcome through gradual automation, without losing sight of ROI.

Power Distribution

The Power Core of Every Data Center

Power distribution reaches every part of a data center, from medium-voltage switchgear and Uninterruptible Power Supply (UPS) systems to low-voltage switchgear, PDUs, and busway tap-offs. The cables involved span a wide range, from small single-core control wires to heavy-duty multi-conductor power cables. Building this equipment is a highly customized process: wire-intensive panels, made to order in small volumes, with thousands of connections per system, are still largely wired by hand at a time when skilled staff are scarce and deadlines are tight.

Control Cabinet and Switchgear Wiring

Low-voltage switchgear and control cabinets hold the highest density of discrete single-core wires, typically in the 0.5 to 6 mm² (20 to 10 AWG) range. A single cabinet can contain several thousand wires with thousands of individual connection points, and because routing, marking, and crimping are performed manually based on an electrical schematic, even a skilled technician can spend up to 20 minutes on a single complex wire.

This is where the Komax Group shows significant strength, as data is becoming a key element of productivity. Rather than re-entering wire lists by hand, the engineering data generated in ECAD is converted into a production-ready and optimized wire set. The WIRE Mind platform automates the data preparation, assists with wire-length determination if needed, and manages the Zeta workload, which cuts, marks, strips, and crimps the wires in a single cycle and delivers them in installation order. WIRE Mind and Zeta work as one system, and it is this combination that makes the highest output possible. An even higher automation level is reached with our fully automated pre-assembly on the Omega machine, which wires connectors and terminal rails directly.

The same process and machines cover low-voltage switchgear, PDUs, and busway tap-offs alike. With a unique configuration in almost every system, this data-driven approach is often the fastest automation investment to pay off.

Heavy-Gauge Power Cables for MV Switchgear, UPS, and Generators

Medium-voltage switchgear, UPS systems, generators, and primary distribution rely on heavier single-core power cables and larger terminations that carry load around the clock. Here too, Komax offers proven solutions: our Automatic Crimpring lines produce terminated power assemblies up to 95 mm² (3/0 AWG) with consistent, repeatable quality, while our Semi-Autoamtion machines cut and strip wires or cables with cross-sections up to 300 mm² (MCM 600).

Multi-conductor power whips, on the other hand, are still assembled largely by hand in most plants. No single supplier automates every step, so the real value lies in applying automation where it makes the biggest difference.

Whatever the cross-section, power connections must meet standards such as IPC/WHMA-A-620, with crimp force monitoring and full documentation, covered in the Testing and Quality Assurance Section.

Cooling Systems

Multi-Conductor Wiring at the Heart of Thermal Management

Cooling systems are among the most electrical-cable-intensive parts of a data center. In a typical chiller unit, about 60% of the electrical connections are single-conductor wires, and 40% are multi-conductor cables, typically unshielded 3G1.5 (3x14AWG), running to fans, dampers, valves, and other actuators or sensors. In processing terms, this multi-conductor cables are prepared much like control-cabinet wiring, so the same automation applies. The cables are laid into each unit by hand, and preparing and assembling the wiring for a single system can take a production team up to two weeks, at a time when demand is growing faster than teams can expand.

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Networking

High-Speed Data at Scale

Networking is where a data center's connections multiply. From the internet service provider (ISP) through firewalls, switches, and spines down to the server racks, data travels across copper, coax, and fiber, with copper handling the short links and fiber carrying the longer, high-speed runs. AI has changed the scale: traditional cloud traffic runs north-south and is limited by the internet connection, while AI workloads generate east-west traffic across leaf-spine networks as Graphics Processing Units (GPUs) communicate with each other. That multiplies the number of connections exponentially and pushes speeds to 800G and beyond, making networking by far the most connection-dense part of any data center. Many of these high-speed assemblies, from DAC and twinax links to complete NVLink spines, are built by specialized interconnect manufacturers in a process far removed from conventional wire processing.

Processing the Cables Behind the Network

At these speeds, there is no room for variation. With millions of connections in a single facility, reliable networking starts with precise cable and wire processing. Optical fiber and RJ45 cables are two examples of how processing requirements can vary: depending on the cable construction, preparation can involve cutting and stripping as well as the processing of jackets, shields, and multiple layers.

This is where Komax contributes. For optical fiber applications, the required fiber lengths can be planned as production orders in the WIRE Flow Software and sent directly to the E300 for processing. This connects digital production planning with the machine, reducing manual touchpoints in production preparation and making different fiber lengths easier to manage. For RJ45 processing, different cable constructions call for flexibility in production. The Komax Group cut and strip and wire stripping solutions cover these changing needs, while quick setup makes it easier to move from one application to the next. The result is the flexibility to handle changing cable requirements with consistent processing, which is precisely what the networking layer demands at scale.

Testing and Quality Assurance

Compliance with Strict Zero-Defect Tolerances and 100% Electrical Testing

Every electrical system for data centers, whether it's a switchgear cabinet, a chiller control panel, or a high-speed copper link, requires 100% electrical and safety testing with full documentation. High-reliability standards such as IPC/WHMA-A-620 Class 3 leave no room for sampling. Every connection has to be tested, and every result has to be documented in an audit-proof way. At several thousand connections per system, this is not something manual checks can keep up with.

Does It Work, and Can You Prove It

Every data center operator needs these two questions answered. Because a data center's enforcement of zero-failure tolerance is non-negotiable, complying with this means building quality into three stages rather than inspecting for it at the end.

Testing in the Production Process
Quality starts inside the production process, where crimp force monitoring, cross-section analysis, and pull-out testing confirm the integrity of each termination before an assembly ever leaves the machine.
Testing the Finished Assembly
Continuity testing confirms every connection is present, correct, and within its resistance limits, while funktional testing verifies that the finished cabinet actually operates as intended. Harness and cable assemblies add high-voltage (hipot) testing. Every connection is checked instead of samples and operator variance removed.
Full Audit-Proof Documentation
Good quality control ends with documentation. Every result is recorded and tied to its assembly for complete traceability, giving operators and general contractors the audit-proof documentation they require.

On a comparable switching cabinet, functional testing that used to take nearly four hours by hand was completed in under three minutes with an adaptronic NT 600. At the volumes a data center demands, that is what turns 100% testing from a bottleneck into a standard step. The test systems below cover every stage, from continuity and functional testing to complete rack final tests.

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FAQ

Still Got Questions?

Got questions about automating wire processing, handling heavy-gauge power cables, wiring cooling systems, or testing and traceability for data center assemblies? Here you'll find answers to the questions we hear most often from the manufacturers who build this equipment.

What cables, harnesses, and connections are used in a data center?

A modern data center relies on cabling in three areas: power distribution, cooling, and networking. A wide variety of cables are used, ranging from thick-walled power cables and single-conductor control cables to multi-conductor cooling cables, as well as high-speed copper and fiber-optic cables.

Power Distribution

Single-conductor control cables (often of the SIS and MTW types in the U.S.), thick-walled power cables ranging from 6 AWG to 500 MCM, busbars, as well as PDU cables and power connection cables are used. Connections are made using crimp connectors and wire end ferrules, which are processed on machines such as the Zeta 640, Alpha 560, and MegaStrip 9680.

Cooling Systems

The cabling consists of a mix of single-conductor control cables inside the control panels and multi-conductor cables leading to fans, pumps, and sensors, which are typically terminated with printed heat-shrink tube marking and wire end ferrules. These are processed on the PowerStrip 9580 and the Zeta product family.

Network and Server Infrastructure

Copper, coaxial, and twinax cable assemblies, including DAC (Direct Attach Copper Cable) and ACC (All Aluminum Conductor) for short, high-speed connections, connect servers within and between racks, while fiber-optic cable assemblies cover longer distances with higher bandwidth, and Cat6A powers the management network. Whatever the type, every connection must be electrically tested and documented, using systems such as the Cirris 8250 and adaptronic NT 700.

How do AI data centers differ from traditional data centers in wiring and power distribution?

AI data centers are not simply larger then conventional data centers, they require massive parallel computing, higher power density, more advanced cooling, ultra-fast internal communication, and purpose-built infrastructure.

For suppliers, this shift has three practical consequences:

  • Power cables get heavier, with larger cross-sections up to 500 MCM and terminations that must stay consistent under continuous load.
  • Liquid cooling replaces much of the air cooling, adding far more multi-conductor cabling to pumps, fans, and sensors.
  • And the sheer cable volume, combined with zero tolerance for failure, raises the bar for 100% electrical testing and audit-proof documentation.

How can a wire harness or cabinet manufacturer become a data center supplier?

We have good news: the data center boom needs exactly the skills wire harness and cabinet manufacturers already have. Companies with wire processing and panel-building experience, including those diversifying from automotive or machine building, are well positioned to move into switchgear, power distribution, and cooling equipment.

When it comes to supplying data centers, three things are crucial: delivering the required performance (despite labor shortages), meeting tight delivery deadlines, and —most importantly — fulfilling the quality requirements expected by data center operators (100% inspection and audit-ready documentation in accordance with IPC/WHMA-A-620 and UL). Automation and integrated testing procedures can help avoid bottlenecks in data center supply.

How can automation help data center suppliers deal with the skilled labor shortage?

The skilled-labor shortage is one of the biggest constraints on data center suppliers. Automation helps not by replacing experienced staff but by taking the repetitive, physically demanding steps off their hands, so their expertise goes where it matters most.

It works on several fronts:

  • Automated processing delivers consistent quality regardless of the operator or shift, which is critical where manual crimping today can take up to 20 minutes per complex wire, or where wiring a single cooling unit ties up a team for two weeks.
  • A continuous data path, feeding digital wire lists straight into the machine, reduces the dependence on scarce specialists and shortens onboarding for new staff.
  • Automated testing checks thousands of connections that no team could verify by hand.

Do not be alarmed: Automation is a journey, not a single leap. If you're interested in scaling through automation, get in contact. We analyze your current production setup and find the right fit from our broad portfolio.

What wire processing can be automated for switchgear and control cabinets?

The short answer: Almost all steps.

The long answer: From cutting and marking to stripping, crimping, and applying wire end ferrules, all of these steps can be performed in a single machine cycle instead of as separate manual steps.

Two factors make the biggest difference here:

  • The cables can be manufactured in the exact order in which they will be installed, so that assembly is carried out using a ready-to-install set rather than loose cables, and the order data can be transferred directly from ECAD, 3D, or even Excel cable lists to the machine, instead of being entered manually. For this purpose, software such as WIRE Mind or DLW transfer data directly to the processing machines.
  • For fully automated control panel cable production, the Zeta 640 cuts, marks, strips, and crimps the cables with wire end ferrules in a single pass. For partially automated processes, cutting and stripping machines handle individual steps, and benchtop presses process loose contacts and connectors, including straight and bent versions.

Since control cabinets contain a wide variety of cables and connectors, the appropriate level of automation depends on your specific cable configuration and batch sizes – feel free to contact us for a no-obligation consultation.

Can I automate wire processing if my wiring lists are still in Excel?

Yes. Excel wiring lists are an excellent starting point, and you do not need a full-fledged ECAD or 3D system right away. Many manufacturers of switchgear and control panels start out exactly this way.

Software such as WIRE Mind and DLW can import the data from your Excel lists and send it directly to the processing machines, eliminating the need for manual re-entry and the errors that come with it.

The more structured your data becomes, the more you can automate: the transition to ECAD or 3D design data unlocks more comprehensive benefits, such as automatic sequencing and seamless traceability. The key point is that you can start with the data you have today and transition step by step to a more integrated process, for example on machines like the Zeta 640.

What automation is available for heavy-gauge wires and large cross-sections up to 500 MCM?

Heavy-gauge power cables appear mainly in medium-voltage switchgear, UPS systems, generators, and primary distribution. For these, the Alpha 560 produces crimp-to-crimp assemblies with consistent, repeatable quality, while the MegaStrip 9680 cuts and strips large cross-sections up to around 300 mm² (600 MCM).

Crimp force monitoring keeps every termination repeatable. The very largest cross-sections and multi-conductor power whips remain semi-automated or manual, so the value lies in automating the steps that carry the highest volume and load.

How can multi-conductor cable processing for cooling systems be automated?

Much of this process can now be automated today. Control-panel single-core wiring runs fully automatically on the Zeta 640, while multi-conductor cables to fans, pumps, and sensors are cut and stripped on the MultiStrip 9480, with a CableCoiler 1300 coiling the finished cable and benchtop presses handling loose contacts.

Job data can flow directly from ECAD or Excel to the machines using software such as WIRE Mind.

Fully automated one-pass processing that combines stripping, printed heat-shrink tubing marking, and ferrule installation in a single pass, is an area we are actively developing in collaboration with manufacturers in the HVAC/cooling industry. The best next step is therefore to take a look at your specific range of cables.

How can 100% testing of data center cable assemblies be implemented efficiently?

Electrical systems for data centers differ from many other electrical systems in one crucial respect: they have thousands of connections per system, and every single one must be tested, not just on a random basis, as is common in many other industries. Efficiency is therefore not just helpful, it is the only way to ensure 100% testing given the time pressures associated with today’s high demand for data center equipment.

The most efficient approach is to automate the testing process and carry it out in two steps: first the sub-assemblies, then the final assembly.

Automated testers check each connection within seconds and simultaneously log the result. Detecting a fault as early as the sub-assembly phase is far more cost-effective than discovering it only after the cabinet or rack has been fully assembled. The Cirris Easy-Touch Pro covers assemblies with up to 512 connections, the Cirris 8250 is suitable for larger cable harnesses and the final testing of complete racks, and the adaptronic NT 700 handles complex cable harnesses and high-voltage testing.

Each device tests continuity, resistance, and insulation in a single pass, ensures that every wire is in the correct position, and logs the results for audit-proof documentation. This makes testing a quick, repeatable step that no longer creates a bottleneck.

What traceability and documentation options are available for data center cable production?

Data center operators do not just want to know that a cable assembly works, they want proof of it – often down to the individual connection and its serial number. That is why traceability is built into the entire process, from the first cut to the final test, rather than being added only at the end.

Several options work together in this process:

  1. During production, crimp force monitoring records the quality of each individual connection as soon as it is made. And since job data can flow from ECAD or Excel, for example with software such as WIRE Mind or DLW, through processing all the way to testing, every recorded result can be traced back to the original wire list.
  2. Cable assemblies can be serialized with unique IDs, and in many networking applications, even individual pins and connectors are tracked. Test systems such as the Cirris 8250, the Cirris Easy-Touch Pro, and the adaptronic NT 700 record the actual measured values for each connection, such as resistance, insulation, and higher-voltage test results, rather than just a “Pass” or “Fail.”

The result is audit-proof documentation that satisfies operators, general contractors, and standards such as IPC/WHMA-A-620.

Do Komax machines support IPC/WHMA-A-620 (Class 3) and UL — including pull testing and crimp force monitoring?

Yes. Both the processing machines and the test systems are built to support IPC/WHMA-A-620, up to Class 3, as well as UL requirements, including the specific checks mentioned here.

Quality is confirmed at two points:

Quality Assurance During Production

Crimp force monitoring checks every crimp as it is made and flags any deviation, which is the basis for the crimp repeatability that Class 3 demands. Pull testing and cross-section analysis then validate the mechanical integrity of the terminations to the same standard.

Testing of the Assembly

⁠On the electrical side, the test systems, the Cirris 8250, Cirris Easy-Touch Pro, and adaptronic NT 700, run continuity, resistance, and high-voltage (hipot) tests and can be set to the exact acceptance limits a standard requires, including UL dielectric levels of twice the rated voltage plus 1,000 V.

From the first crimp to the final test, compliance is both enforced and documented.

Which test systems suit harnesses with hundreds to thousands of connections?

The right system depends mainly on two things: the number of connections and the voltage level. Automated test systems scale from a few hundred points into the thousands and check every connection in a single run, which is the only practical way to test a harness or cabinet with that many terminations.

A Rough Guide by Connection Count
  • The Cirris Easy-Touch Pro covers assemblies up to 512 connections, making it a good fit for mid-sized harnesses and panels.
  • The Cirris 8250 scales beyond that into the thousands and up to a complete rack final test, which suits large switchgear cabinets and server racks.
  • The adaptronic NT 700 and NT 600 cover complex harnesses and functional testing, and the KT 211 offers guided continuity testing with probes.

All of them run continuity, resistance, and high-voltage (hipot) tests in one automated pass and record the measured values for each connection, so documentation is produced as you test.