Connecting today for a greener tomorrow
Hybrid and Electric Vehicle Connection Systems Portfolio
Innovation for the Real World
About Delphi Delphi Automotive PLC (NYSE: DLPH) is a leading global supplier of technologies for the automotive and commercial vehicle markets. Headquartered in Gillingham, England, Delphi operates major technical centers, manufacturing sites and customer support services in 32 countries, with regional headquarters in Bascharage, Luxembourg; São Paulo, Brazil; Shanghai, China and Troy, Michigan, U.S. Delphi delivers innovation for the real world with technologies that make cars and trucks safer as well as more powerful, efficient and connected. Visit www.delphi.com
A world of electrification Delphi has been researching and developing safe, reliable and high performance products for vehicle electrification for more than 20 years. Delphi believes that in order for hybrid and electric vehicles to become mainstream, they need to be made accessible and practical for the average consumer. Hybrid and electric vehicles present unique challenges when it comes to electrical architecture.
02
They demand performance requirements including shielding to protect against electromagnetic interference, sealing to prevent short circuits, and management of a hazardous voltage interlock loop, or HVIL. To help keep drivers and service technicians safe in High Voltage environments, a number of complex factors in the electrical system must be addressed and engineered for reliability and peak performance.
Delphi is ready when and where you need us
Major Technical Centers
Did you know? Hybrid and electric vehicles are creating a host of challenges, including the demand for a new generation of high performance, high power connectors and charging solutions. Many additional power electronics devices are added to the vehicle architecture including Lithium-ion (Li-ion) batteries, inverters and DC (Direct Current) converters. Their impact on connector design results in handling operating voltages that range from 400V up to 750V and carrying currents as high as 400A.
03
Vehicle electrification is a reality
Driven by rising fuel costs, environmental concerns and a combination of government regulations and incentives, the market for EVs (Electric Vehicles) and HEVs (Hybrid Electric Vehicles) is now becoming a reality. Vehicle specifications and infrastructure deployment have reached a certain level of industrialization. Standards have already been established for vehicle charging interfaces used on plug
Mode 2 cordsets
04
Mode 3 charging cables
in HEVs and EVs. There are three standards used throughout the world including SAE J1772 in North America and Japan, IEC62196 Type II in Europe, and GB/T 20234 in China. In addition, SAE has established a common footprint for DC (Direct Current) fast charging in North America and Europe. Delphi offers a complete line of all global charging standards.
Vehicle inlets
Delphi is currently driving the innovations required for future multivoltage architectures. Our research and development teams have leveraged the lessons learned from the collaboration with OEM’s to focus on technological excellence and to provide real-life electrification performance.
Superior Sealing Performances All our connection systems feature external IP67 sealing performance. To ensure optimum sealing performance, our connectors are designed for the harshest conditions due to a back sealing feature.
With a unique expertise in architecture optimization and systems integration, the company has created one of the most comprehensive portfolios of high power connection systems.
Superior Shielding Performances EV and HEV electrical and electronic systems generate unwanted electromagnetic interference (EMI) which radiate from the interconnecting cables. The connection systems are designed by minimizing the paths which these signals can escape. Our connectors and cabling designs provide high levels of shielding effectiveness to ensure EMI free performance of the complete system.
Superior Safety Performances Our connectors provide finger-proof, touch safe and 2-step disconnection technologies to guarantee optimum safety during all handling operations. They continue to meet with changing requirement of the OEM’s in regard to HVIL on a vehicle system and connection system level. Additionally, the company’s ErgoMateTM axial mating system helps achieve a lower profile solution while reducing mating forces. Once connected, a CPA (Connector Position Assurance) device must be activated to ensure a 100% safe mating. 05
A comprehensive product portfolio High Voltage Auxiliary Modules
p. 09
High Voltage connection systems designed specifically for the voltage and current needs of auxiliary modules, such as A/C compressor, heater, coolant control module, on-board charger, DC converter, and battery accessory output.
High Voltage Power Conversion High Voltage connection systems designed specifically for the voltage and current needs up to 250A. Power conversion modules consist of inverters, drive motors/generators, and High Current/ High Voltage battery outputs.
p. 29 Chargers and Charging Cables
p. 51
Unique technologies to help facilitate a global charging infrastructure, from Delphi’s Portable Electric Vehicle Charger and Charge Coupler pigtails for integration into Electric Vehicle Supply Equipment (EVSE). With Delphi products hybrid and electric vehicles can be powered safely and efficiently at home or away.
Charging Inlets All global standard vehicle interfaces critical for vehicle charging including SAE J1772, IEC62196 Type II, and GB/T 20234.
p. 59 06
Internal Battery Connections Full portfolio of products including Manual Service Disconnects used for safe vehicle service, battery electrical centers, battery interconnects, and High Voltage/Low Voltage wiring assemblies.
p. 67
High Voltage Electrical Centers High Voltage Electrical Centers help provide safe power distribution of High Voltage circuits. Delphi provides electrical centers designed specifically for managing battery power.
p. 71
High Voltage/Low Voltage Wiring Assemblies Delphi’s High Voltage wiring assemblies are developed with the customer to meet their specifications. They are available with both shielded and unshielded cables, addressing the full range of HEV/EV product requirements. Delphi has years of experience in the processing of HV wiring assemblies.
p. 73 07
HV Auxiliary Modules HV Power Conversion
HV Auxiliary Modules
Delphi High Voltage Connection Application Guide Device
I/O Detail
Accessories
Electric Air Conditioning Electric Coolant Control
General Specification
Delphi Portfolio
2W < 40A; 750 VDC Shielded
Shield-Pack™ HV280
Electric Heater
APEX® 280
Electric Power Steering
Chargers & Charging Cables
Battery Pack
Charger Input 2W < 40A; 750 VDC Shielded DC/DC Converter Output High Current Charge Input
Charging Inlets Internal Battery Connections
Electric Motor
APEX® 280
2W < 250A; 750 VDC Shielded
Shield-Pack™ HV2000 RCS 890 RCS 800
HV Contact Center
Customer Specific
Delphi Contactor Center
Manual Service Disconnect
< 225A; 600 VDC
Delphi MSD
DC Input
2W < 40A; 750 VDC Shielded
Shield-Pack™ HV280 APEX® 280
14V Output
1W Filtered/1W Unfiltered 200A
Delphi 14V Filtered Output Power Pack 2000
3W < 145A; 600 VAC Shielded
Shield-Pack™ HV1000
< 250A; 600 VAC Shielded
High Voltage Pass-Through
3W < 145A; 600 VAC Shielded
Shield-Pack™ HV1000
< 250A; 600 VAC Shielded
High Voltage Pass-Through
DC Input
2W < 250A; 750 VDC Shielded
Shield-Pack™ HV2000 RCS 890 RCS 800
AC Input
5W < 125A; 400 VAC Unshielded 6W < 40A; 240 VAC Unshielded
APEX® 950 HV150; On-Board Charger
DC Output
2W < 40A; 750 VDC Shielded
Shield-Pack™ HV280 APEX® 280
Portable Cordsets (Mode 2)
< 16A; 120V and 240V
Couplers (Mode 3)
Refer to pages 56 to 57
Vehicle Inlets
Refer to pages 59 to 65
Main Power Output
DC/DC Converter
Shield-Pack™ HV280
AC Input
Inverter AC Output
HV Electrical Centers
On-Board Charger
Vehicle Charging
SAE J1772 IEC62196 Type I IEC62196 Type II
HV/LV Wiring Assemblies
GB/T
08
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules HV Power Conversion
High Voltage Auxiliary Modules
Chargers & Charging Cables
Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LV Wiring Assemblies
HV HV Auxiliary Auxiliary Modules Modules
Shield-Pack™ HV280 With Internal HVIL Shunted in Harness Connector
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13824830
13824784
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application • High voltage accessories connection system
Description • • • •
• • • • •
Sealed connection system Panel mount to device with face seal Internal HVIL (shunt in harness connector) Two options available - Two-stage locking system for HVIL time delay - Tooless mating system Two HV power circuits (2.8 mm terminal) Flange size: 39 mm x 39 mm Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit Three keys/indexes
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV/LV Wiring Assemblies
Mating Information
10
Key/ Index
Header Connector
101
13824830
102
13830171
103
13830172
Mating Device Detail 13837174
HV Connector
HV Connector
(Tool required for disconnect)
(No tool required)
13824784
33107360
13830159
33107347
13830160
33107346
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV280 2 Piece Header with Pluggable Inner Connector
HV Power Conversion
13954108
Chargers & Charging Cables
13824784
Application Charging Inlets
• Ideal for internal battery harnesses/high voltage connection system
Description
15526394
Internal Battery Connections
• Inner Connector with TPA can be plugged into header during device assembly • Sealed connection system • Panel mount to device with face seal • Internal HVIL (shunt in harness connector) • Two options available - Two-stage locking system for HVIL time delay - Tooless mating system • Two HV power circuits (2.8 mm terminal) • Flange size: 38 mm x 43 mm • Finger proof/touch safe • Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Three keys/indexes
Performance HV Electrical Centers
• • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
Mating Information Header Connector
Inner Connector
101
13954108
15526394
102
13954109
15526395
103
13954110
15526396
Mating Device Detail 15508564
Mating HV Connector
HV Connector
(Tool required for disconnect)
(No tool required)
13824784
33107360
13830159
33107347
13830160
33107346
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
11
HV/LV Wiring Assemblies
Key/ Index
HV HVAuxiliary AuxiliaryModules Modules
Shield-Pack™ HV280 PCB Mount or Pluggable Inner Connector
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13954070
13954094
Internal Battery Connections
Charging Inlets
Application • High voltage accessories connection system
Description • Ideal for high corrosion environments with no exposed fasteners on device case • Sealed connection system • Panel mount to device with face seal • Internal HVIL (shunt in harness connector) • Two options available - Two-stage locking system for HVIL time delay - Tooless mating system • Two HV power circuits (2.8 mm terminal) • Flange size: 41 mm • Finger proof/touch safe • Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • One key/index
13824784
HV/LV Wiring Assemblies
HV Electrical Centers
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
Availability • Call for availability
Mating Information
12
Key/ Index
Header Connector
PCB Inner Connector
Mating Device Detail
(Tool required for disconnect)
HV Connector
(No tool required)
HV Connector
101
13954070
13954094
See print for information
13824784
33107360
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV280 With HVIL Shunted in Header
HV Power Conversion
13859931
Chargers & Charging Cables
13859922
Application • High voltage accessories connection system
Charging Inlets
Description Sealed connection system Panel mount to device with face seal Internal HVIL (shunt in header connector) Two-stage locking system for HVIL time delay Two HV power circuits (2.8 mm terminal) Flange size: 42 mm x 42 mm Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Three keys/indexes
Internal Battery Connections
• • • • • • • •
Performance Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV Electrical Centers
• • • • •
Mating Information Header Connector
101
13859931
102
13859932
103
13859933
Mating Device Detail
HV Connector 13859922
13860103
13859923 13859924
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
13
HV/LV Wiring Assemblies
Key/ Index
HV HVAuxiliary Auxiliary Modules Modules
Shield-Pack™ HV280 HVIL Shunt in Header, Bore Seal to Device
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13830674
13861584
Application Description • • • • • • •
Sealed connection system Sealed to device case through bore seal Two HV power circuits (2.8 mm terminal) HVIL shunted in header with five-second time delay Flange size: 43 mm x 49 mm Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Three keys/indexes
13738743
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
• High voltage accessories connection system
14
Mating Information
Key/ Index
Header Connector
101
13830674
102
13830675
103
13830676
Mating Device Detail 13831228
HV Connector
HVIL Connector
13861584
13738743
13861585
13738744
13861586
13766241
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV280 2 Way Connection System without HVIL
HV Power Conversion
13743443
Chargers & Charging Cables
13861584
Application Charging Inlets
• High voltage accessories connection system when no HVIL is required
Description Sealed to device case Two HV power circuits (2.8 mm terminal) Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit One key/index
Internal Battery Connections
• • • • •
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV Electrical Centers
Header Connector
Mating Device Detail
HV Connector
101
13743443
13849778
13861584
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
15
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV HVAuxiliary Auxiliary Modules Modules
Shield-Pack™ HV280 2 Way Connection System with Multiple HVIL Options
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13737767
13861584
• High voltage accessories connection system
Description • Sealed to device case • Two HV power circuits (2.8 mm terminal) • HVIL available in two configurations: pass-through header, shunted in header • HVIL with five-second time delay • Finger proof/touch safe • Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Three keys/indexes
13738743
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
16
Key/ Index
Header with HVIL Shunted
Header with HVIL Pass-Through to Module
101
13756860
13737767
102
13757523
13737768
103
13766024
13766022
Mating Information Mating Device Detail 13739582
HV Connector
HVIL Connector
13861584
13738743
13861585
13738744
13861586
13766241
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV280 2 Way Inline Connection System with HVIL Shunt
HV Power Conversion
13966949
Chargers & Charging Cables
13859922
Application • Inline connection system for high voltage accessories
Charging Inlets
Description • • • • •
Internal Battery Connections
Sealed connection system Two HV power circuits (2.8 mm terminal) Two-stage locking system for HVIL time delay Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Two keys/indexes
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV Electrical Centers
Male Connector
Female Connector
101
13966949
13859922
102
13966948
13859923
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
17
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV HVAuxiliary Auxiliary Modules Modules
Shield-Pack™ HV280 2 Way Inline Connection System with HVIL Shunt
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13737736
13861584
• Inline connection system for high voltage accessories
Description • • • • •
Sealed connection system Two HV power circuits (2.8 mm terminal) HVIL with five-second time delay Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit; 0.5 mm2 HVIL circuit • Two keys/indexes
13738743
Performance • • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
18
Mating Information
Key/ Index
Male Connector
Female Connector
HVIL Connector
101
13737736
13861584
13738743
102
13737737
13861585
13738744
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
APEX® HV280 2 Way Connection System with HVIL 46.4
53
56
15.8
56
HV Power Conversion
46.4
15.8
53
F873110
35.4
57.3
Chargers & Charging Cables
43.9
43.9
57.3
35.4
F083110
Application
Description • • • •
• • • • •
• • • • •
HV Electrical Centers
Performance Current capacity: 35 A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
Header Connector
Mating Information HV Connector
1
F873110
F083110
2
F973110
F183110
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
19
HV/LV Wiring Assemblies
Key/ Index
Internal Battery Connections
• •
Bundle shielding with external braid Dual sealing connection system: mated and unmated header Panel mount to device with face seal Unique integrated electric interlock - HVIL shunted in harness connector Two-stage disconnect for safe unmating ErgoMate™ Axial Mating Assist System on harness connector Two HV power circuits (2.8 mm terminal) Flange size: 46 mm x 53 mm IP2XB Finger proof/touch safe Cable range: 2.5 to 4 mm2 power circuit; 0.5 to 0.75 mm2 HVIL circuit Two keys/indexes
Charging Inlets
• High voltage peripheral equipment connection system: Air conditioning, PTC, Charger
HV HVAuxiliary Auxiliary Modules Modules
High Voltage Unshielded Connection System 2 Way and 3 Way
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13848288
15530997
• High voltage connection internal to modules requiring unsealed/unshielded cable such as battery electrical centers
Description • • • • •
Cavity isolation for high voltage applications Unsealed/unshielded connection system Finger proof/touch safe Cable range: 2 mm2 to 5 mm2 power circuit Hinged terminal secondary lock
Performance • • • •
Current capacity: 40A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
20
Circuits
Female Connector
2
13848288
3
15530997 Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
On-Board Charger Connectors Level 1/Level 2 6 Way Device Connection System
HV Power Conversion
13879038
Chargers & Charging Cables
13879047
Application Charging Inlets
• High voltage unshielded system for on-board charger applications (Level 1 and 2)
Description
Internal Battery Connections
• Sealed connection system • Capability for four power circuits and two signal circuits • Unshielded with terminal spacing for HV applications • Two-stage locking system for electrical protection • One-stage locking system also available • Finger proof/touch safe • Cable range: 2 mm2 to 5 mm2 • Capable of multiple keys/indexes
Performance • Current capacity: 30A at 85°C • Voltage: 600V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IP6K9K • Electrical protection: IP2XB
Header Connector
(Tool required for disconnect)
(No tool required)
13879038
15543396
Mating Information Level 1 Connector
Level 2 Connector
13879051 (2+2)
13879048 (2+2)
15525754 (3+0)
15525753 (3+0)
13879050 (3+2)
13879047 (3+2)
13879049 (4+2)
13879046 (4+2)
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
21
HV/LV Wiring Assemblies
101
Header Connector
HV Electrical Centers
Key/ Index
HV HV Auxiliary Auxiliary Modules Modules
On-Board Charger Connectors Level 1/Level 2 6 Way Inline Connection System
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13990590
13879048
• Inline between inlet and on-board charger for cable routing (Level 1 and 2)
Description • Sealed connection system • Capability for four power circuits and two signal circuits • Unshielded with terminal spacing for HV applications • Two-stage locking system for electrical protection • Finger proof/touch safe • Cable range: 2 mm2 to 5 mm2 • Capable of multiple keys/indexes
Performance • Current capacity: 30A at 85°C • Voltage: 600V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IP6K9K • Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
22
Mating Information
Male Connector Level 1
Male Connector Level 2
13990593 (2+2)
13990590 (2+2)
13879051 (2+2)
13879048 (2+2)
13990592 (3+2)
13990589 (3+2)
13879050 (3+2)
13879047 (3+2)
13990591 (4+2)
13990588 (4+2)
13879049 (4+2)
13879046 (4+2)
Female Connector Level 1
Female Connector Level 2
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
HV150 On-Board Charger Connectors 3 Way High Voltage Unshielded Connection System
HV Power Conversion
13863040
Chargers & Charging Cables
13861587
Application Charging Inlets
• High voltage unshielded system for on-board charger applications (Level 1)
Description
Internal Battery Connections
• Sealed connection system • 1.5 mm terminal • Unshielded with terminal spacing for HV applications • Finger proof/touch safe • Cable size: 2 mm2 • One key/index
Performance • Current capacity: 16A at 85°C • Voltage: 600V • Temperature range: -40°C to + 125°C • Sealing protection: IP67, IP6K9K • Electrical protection: IP2XB
HV Electrical Centers
Header Connector
Mating Device Detail
HV Connector
101
13863040
See print for information
13861587
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
23
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV HVAuxiliary Auxiliary Modules Modules
HV150 On-Board Charger Connectors 3 Way Unshielded Connection System with HVIL
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
13737769
13861587
• High voltage unshielded system for on-board charger applications (Level 1)
Description • • • • • •
Sealed connection system 1.5 mm terminal Unshielded with terminal spacing for HV applications Finger proof/touch safe Cable size: 2 mm2 Two keys/indexes
Performance • • • • •
Current capacity: 16A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
24
Key/ Index
Header Connector
101
13737769
102
13757521
Mating Device Detail 13739582
Mating Information HV Connector
Signal Connector
13861587
13738743
13861588
13738744
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
APEX® 950 On-Board Charger Connector 4 + 1 Way Connection System with HVIL
HV Power Conversion
33402137
Chargers & Charging Cables
33402139
Application Charging Inlets
• High voltage unshielded system for on-board charger applications
Description
Internal Battery Connections
• Sealed in mated or unmated position • Unshielded 4 + 1 way connector • Panel mount to device with face seal to module • Unique integrated electric interlock - HVIL shunted in harness connector • ErgoMate™ slider for easy handling and reduced mating force • 5 HV power circuits (four 9.5 mm and one 2.8 mm terminals) • Flange size: 111 mm x 52 mm • IP2XB Finger proof/touch safe • Cable range: 10 to 16 mm2 power circuit; 0.5 to 0.75 mm2 electric interlock • 1 key/index
HV Electrical Centers
Performance • Current capacity: 125A at 70°C • Voltage: 750V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IPX9K • Electrical protection: IP2XB
Header Connector
HV Connector
1
33402137
33402139
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
25
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV HV Auxiliary Auxiliary Modules Modules
Filtered High Current Headers
HV Power Conversion
HV Auxiliary Modules
High Voltage Auxiliary Modules
Chargers & Charging Cables
28115977
• High current filtered pass-through header
Description • Panel mount to device with bore ground contact to case • Horizontal M6 stud for external ring terminal attachment • M5 captive nut for internal electrical attachment • Filter capacitance 60µF, 25V
Performance • Current capacity: 170A at 85°C • Voltage: 14V • Temperature range: -40°C to +105°C • Insertion loss: 40dB at 200kHz
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
Mating Information
26
Header Connector
Mating Device Detail
RingTerminal
Ferrule
28115977
See print for information
12146425
28105377
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Filtered High Current Headers Sealed to Device
HV Power Conversion
28105350
Chargers & Charging Cables
Application • High current filtered header on DC converter
Charging Inlets
Description • Panel mount to device with bore seal and ground to case • Vertical M8 stud for external ring terminal attachment • M5 captive nut for internal electrical attachment • Filter capacitance 60µF, 25V • Cover with multiple cable dress
Internal Battery Connections
Performance • Current capacity: 250°A at 85°C • Voltage: 14V • Temperature range: -40°C to +105°C • Insertion loss: 40dB at 200kHz
HV Electrical Centers
Header Connector
Mating Device Detail
RingTerminal
Ferrule
28105350
See print for information
12146429
28105377
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
27
HV/LV Wiring Assemblies
Mating Information
HV Auxiliary Modules HV Power Conversion
High Voltage Power Conversion
Chargers & Charging Cables Charging Inlets Internal Battery Connections
• High voltage shielded/sealed connections • Shielded ring terminal pass-through systems
HV Electrical Centers
Products include:
• High current sealed connection systems HV/LV Wiring Assemblies
HV Auxiliary Modules
Shield-Pack™ HV2000 1 Way Right Angle Connection System with Internal or External HVIL
HV Power Conversion
HV Auxiliary Modules
High Voltage Shielded/Sealed Connections
Chargers & Charging Cables
13928223
13928224
• High voltage/high current modules: inverter, battery
Description • • • • • • • • •
Panel mount to device with face seal to module Terminal provided as part of header Lever arm for mechanical advantage Internal HVIL shunt in harness connector Two-stage lever for HVIL time delay External HVIL blocks lever from moving Finger proof/touch safe Cable range: 25 mm2 to 50 mm2 One key/index
13936492
Performance • • • • •
Current capacity: 250A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB harness connector only
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
Mating Information
Terminal
30
(Device Side)
Header withTerminal
Straight
13928223
90°
13928224
Mating Device Detail
HV Connector
See print for information
13936492
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV2000 2 Way Connection System with Internal or External HVIL, Inline Mating Direction
HV Power Conversion
15514006
Chargers & Charging Cables
15512757
Application • High voltage/high current modules: inverter, battery
Charging Inlets
Description
Internal Battery Connections
• Panel mount to device with face seal to module • Terminal provided as part of header • Anti-rotation for attachment to terminal in three orientations • Internal HVIL shunt in harness connector • Two-stage locking system for HVIL time delay • External HVIL blocks lever from moving • Finger proof/touch safe • Cable range: 25 mm2 to 50 mm2 • Multiple keys/indexes
Performance Current capacity: 250A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB
HV Electrical Centers
• • • • •
Header withTerminal
101
15514006
102
15514007
Mating Device Detail See print for information
HV Connector 15512757 15512758
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
31
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV Auxiliary Modules
Shield-Pack™ HV2000 2 Way Right Angle Connection System with Internal HVIL; IP2XB Harness Connector Only
HV Power Conversion
HV Auxiliary Modules
High Voltage Shielded/Sealed Connections
Chargers & Charging Cables
13986175
13986176
• High voltage/high current modules: inverter, battery
Description • • • • • • •
Panel mount to device with face seal to module Header available with or without terminals Internal HVIL Harness connector mates in right angle direction Finger proof/touch safe harness connector only Cable size: 35 mm2 One key/index
15515644
Performance • • • • •
Current capacity: 250A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB harness connector only
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
32
Mating Information
Key/ Index
Header without Terminal
Header with Terminal
Mating Device Detail
HV Connector
101
13986175
13986176
See print for information
15515644
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
2 Way Right Angle Connection System with Internal HVIL; IP2XB Harness Connector Only
HV Auxiliary Modules
Shield-Pack™ HV2000
HV Power Conversion
13832577
Chargers & Charging Cables
13959810
Application Charging Inlets
• High voltage/high current modules: inverter, battery
Description
13832576
Panel mount to device with face seal to module Header available with or without terminals Internal HVIL Harness connector mates in right angle direction Finger proof/touch safe harness connector only Cable size: 35 mm2 One key/index
Internal Battery Connections
• • • • • • •
Performance • • • • •
Current capacity: 250A at 85°C Voltage: 600V Temperature range: -40°C to +85°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB harness connector only
HV Electrical Centers
Header without Terminal
Header with Terminal
Mating Device Detail
HV Connector
101
13832577
13959810
See print for information
13832576
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
33
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV Auxiliary Modules
RCS800 High Voltage 2 Way Connection System with HVIL
HV Power Conversion
HV Auxiliary Modules
High Voltage Shielded/Sealed Connections
83
68.5
83
13.5
53
68.5 13.5
53
Chargers & Charging Cables
F473110 69
74.3
69
48.8
48.8
F673110
Internal Battery Connections
Charging Inlets
Application • High voltage/high current modules: inverter, battery, junction box, power electric box
Description • • • • • • • • • •
HV/LV Wiring Assemblies
HV Electrical Centers
•
Bundle shielding with external braid Dual sealing connection system: mated and unmated header Panel mount to device with face seal to module Unique integrated electric interlock - HVIL shunted in harness connector Two-stage disconnect for safe unmating ErgoMate™ Axial Mating Assist System on harness connector Two HV power circuits (8.0 mm round terminal) Flange size: 53 mm x 83 mm IP2XB Finger proof/touch safe Cable range: 35 to 50 mm2 power circuit; 0.5 to 0.75 mm2 HVIL circuit Two keys/indexes
Performance • • • • •
34
Current capacity: 230 A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
Mating Information
Key/ Index
Header Connector
HV Connector
1
F473110
F673110
2
F573110
F773110
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
74.3
HV Auxiliary Modules
RCS890 High Voltage 2 Way Right Angle Connection System with HVIL 54.5 54.5 13.113.1
85
HV Power Conversion
85
55.9 55.9
F722210
Chargers & Charging Cables
71.471.4
49.149.1
89
89
F922210
Application
Description • • • •
•
Internal Battery Connections
• • • • • •
Bundle shielding with external braid Dual sealing connection system: mated and unmated header Panel mount to device with face seal to module Unique integrated electric interlock - HVIL shunted in harness connector Two-stage disconnect for safe unmating Slider Mating Assist System on harness connector Two HV power circuits (8.0 mm round terminal) Flange size: 51 mm x 62 mm IP2XB Finger proof/touch safe Cable range: 35 to 50 mm2 power circuit; 0.5 to 0.75 mm2 HVIL circuit One key/index
Charging Inlets
• High voltage/high current modules: inverter, battery, junction box, power electric box
Performance Current capacity: 230A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
HV Electrical Centers
• • • • •
Header Connector
HV Connector
1
F722210
F922210
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
35
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV Auxiliary Modules
HV Auxiliary Modules
High Voltage Shielded/Sealed Connections
RCS890 High Voltage 1 Way Right Angle Connection System with HVIL 51
HV Power Conversion
51
50.1
9.1
50.1
9.1
62
Chargers & Charging Cables
62
46.2
46.1
46.2
115.9
46.1
115.9
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application • High voltage/high current modules: inverter, battery, junction box, power electric box
Description • Sealed in mated or unmated position • Panel mount to device • Unique integrated electric interlock - HVIL shunted in header • Two-step disconnect for safe unmating • One HV power circuit (8.0 mm terminal) • Flange size: 50 mm x 75 mm • Finger proof/touch safe • Cable range: 16 mm2 (other wire section possible) power circuit; 0.5 mm2 to 0.75 mm2 electric interlock • Seven keys/indexes
Performance • • • • •
Current capacity: 230A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
Availability • Call for availability
36
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Pin & Sleeve HV800 2 Way Connection System with Electric Interlock
HV Power Conversion
Header
Chargers & Charging Cables
HV Connector
Application Charging Inlets
• High voltage/high current modules: inverter, battery, junction box, power electric box
Description Single wire shielding Sealing connection system: mated header Header mount to device with face seal Unique integrated electric interlock Two-stage disconnect for safe unmating Axial Mating Assist System on harness 2 HV power circuits (8.0 mm round terminal) Flange size: 50 mm x 70 mm IP2XB Finger proof/touch safe Modular design for different cable size as module unit Cable range: 16 to 50 mm2 power circuit; 0.5 to 0.75 mm2 electric interlock • Multiple keys/indexes available
Internal Battery Connections
• • • • • • • • • • •
Performance Current capacity: 230A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
HV Electrical Centers
• • • • •
Availability • Call for availability
37
HV/LV Wiring Assemblies
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Pin & Sleeve HV800 3 Way Connection System with Electric Interlock
HV Power Conversion
HV Auxiliary Modules
High Voltage Shielded/Sealed Connections
Chargers & Charging Cables
Header
HV Connector
Internal Battery Connections
Charging Inlets
Application • High voltage/high current modules: inverter, battery, junction box, power electric box
Description • • • • • • • • • • •
Single wire shielding Sealing connection system: mated header Header mount to device with face seal Unique integrated electric interlock Two-stage disconnect for safe unmating Axial Mating Assist System on harness 3 HV power circuits (8.0 mm round terminal) Flange size: 70 mm x 102 mm IP2XB Finger proof/touch safe Modular design for different cable size as module unit Cable range: 16 to 50 mm2 power circuit; 0.5 to 0.75 mm2 electric interlock • Three keys/indexes
HV Electrical Centers
Performance • • • • •
Current capacity: 230A at 70°C Voltage: 750V Temperature range: -40°C to +125°C Sealing protection: IP67, IPX9K Electrical protection: IP2XB
Availability
HV/LV Wiring Assemblies
• Call for availability
38
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Shield-Pack™ HV1000 Connection System 3 Way Panel Mount Connection System
HV Power Conversion
13879064
Chargers & Charging Cables
13879062
Application • High voltage/high current devices (inverters)
Charging Inlets
Description
13738743
Internal Battery Connections
• High voltage panel mount connection system • Three high voltage power circuits (Power Pack 1000 terminal) • HVIL with five-second time delay • Cable range: 16 mm2 to 25 mm2 power circuit; 0.5 mm2 HVIL circuit • Two keys/indexes
Performance • • • • •
Current capacity: 145A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K Electrical protection: IP2XB female connector only
HV Electrical Centers
Header Connector
Mating Device Detail
Female Connector
HVIL Connector
101
13879064
13879066
13879062
13738743
102
13879065
13879067
13879063
13738744
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
39
HV/LV Wiring Assemblies
Mating Information
Key/ Index
HV Auxiliary Modules
High Voltage Pass-Through Bolted Pass-Through Connections
HV Power Conversion
HV Auxiliary Modules
Shielded Ring Terminal Pass-Through Systems
Chargers & Charging Cables
13888001
• High voltage/high vibration connections for motors or power electronics
Description • • • • •
HV/LV Wiring Assemblies
1 Way sealed and shielded Ring terminal bolted to device Shield bolted to device case Cable range: 25 mm2 to 50 mm2 Multiple keys/indexes
Performance • • • •
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
40
Current capacity: 250A at 85°C Voltage: 600V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
Key/ Index
25 mm2 Cable Size
35 mm2 Cable Size
50 mm2 Cable Size
1
-
-
-
2
13888001
13888009
33112598
3
-
13888010
33112599
4
-
13888011
-
5
-
-
-
6
-
-
-
7
-
-
-
8
-
15504147
-
9
-
15504148
-
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
High Voltage Pass-Through Single Bolt Pass-Through Connections
HV Power Conversion
13957033
Chargers & Charging Cables
Application Charging Inlets
• High voltage/high vibration connections for motors or power electronics
Description
Internal Battery Connections
• 1 Way sealed and shielded • Ring terminal bolted to device • Shield bolted to device case • Cable size: 35 mm2 • One key/index available • Capable of multiple indexes
Performance • Current capacity: 250A at 85°C • Voltage: 600V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IP6K9K
HV Electrical Centers
35 mm2 Cable Size
1
13957033
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
41
HV/LV Wiring Assemblies
Key/ Index
HV Auxiliary Modules
High Voltage Pass-Through 1 Way Pass-Through Connection System
HV Power Conversion
HV Auxiliary Modules
Shielded Ring Terminal Pass-Through Systems
Chargers & Charging Cables
Pass-Through Header
Female Connector
• High voltage/high vibration connections for motors or power electronics
Description • 1 Way sealed and shielded • Pluggable design -- easy to plug in and pull out • Cable range: 50 mm2 to 70 mm2 • One key/index
Performance • Current capacity: 350A at 85°C • Voltage: 600V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IP6K9K
Available Options • Call for availability
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
42
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
High Voltage Pass-Through 2 Way Bolted Pass-Through Connections
HV Power Conversion
13957217
Chargers & Charging Cables
Application Charging Inlets
• High voltage/High vibration connections for motors or power electronics
Description
Internal Battery Connections
• 2 Way sealed and shielded • Ring terminal bolted to device • Bundle Shield bolted to device case • Cable size: 35 mm2 • Two keys/indexes
Performance • Continuous current: 180A continuous at 85°C • Voltage: 600V • Temperature range: -40°C to +125°C • Sealing protection: IP67, IP6K9K
Availability • Call for additional configurations
HV Electrical Centers
35 mm2 Cable Size
1
13957217
2
13957216
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
43
HV/LV Wiring Assemblies
Key/ Index
HV Auxiliary Modules
Power Pack 1000 1 Way Inline Connectors
HV Power Conversion
HV Auxiliary Modules
High Current Sealed Connection Systems
Chargers & Charging Cables
13952702
13882980
• High current wiring harness inline
Description • • • • •
Sealed connection system Silver-plated, multi-contact terminal system Cable range: 6 mm2 to 25 mm2 One key/index Capable of additional indexes
Performance • • • •
Current capacity: 145A at 85°C Voltage: 12V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
Availability • Call for availability
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
44
Female 1 Way
Male 1 Way
13952702
13882980
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Power Pack 1000 2 Way Inline Connectors
HV Power Conversion
13849756
Chargers & Charging Cables
13849747
Application • High current wiring harness inline
Charging Inlets
Description • • • •
Sealed connection system Silver-plated, multi-contact terminal system Cable range: 6 mm2 to 25 mm2 Two keys/indexes
• • • •
Internal Battery Connections
Performance Current capacity: 145A at 85°C Voltage: 12V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
HV Electrical Centers
Female 2 Way
Mating Information Male 2 Way
Index Right
13849756
13849747
Index Left
13849757
13849748
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
45
HV/LV Wiring Assemblies
Key/ Index
HV Auxiliary Modules
Power Pack 1000 2 Way Device and Pass-Through Connectors
HV Power Conversion
HV Auxiliary Modules
High Current Sealed Connection Systems
Chargers & Charging Cables
13849756
13849758
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application • High current device applications • Sealed pass-through panel mount system
Description • • • •
Sealed connection system Sealed panel mount prestages prior to fastening Panel mount secures in place through self tapping screws Pass-through connection accepts both straight and right angle connectors • Silver- plated, multi-contact terminal system • Cable range: 6 mm2 to 25 mm2 • Two keys/indexes
13959822
Performance • • • •
Current capacity: 145A at 85°C Voltage: 12V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
Availability • Call for pass-through availability
46
Mating Information
Key/ Index
Female Right Angle
Female Straight
Header
Index Right
13849758
13849756
13959822
Index Left
13849759
13849757
13959823
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Power Pack 2000 1 Way Inline Connectors
HV Power Conversion
13520909
Chargers & Charging Cables
13520916
Application • Inline connections up to 250A
Charging Inlets
Description • • • •
Sealed system Silver-plated, multi-contact terminal system Cable range: 19 mm2 to 62 mm2 One key/index
• • • •
Internal Battery Connections
Performance Current capacity: 250A at 85°C Voltage: 12V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
HV Electrical Centers
Male 1 Way
Mating Information Female 1 Way
Index 0
13520909
13520916
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
47
HV/LV Wiring Assemblies
Key/ Index
HV Auxiliary Modules
Power Pack 2000 1 Way Device and Pass-Through Connectors
HV Power Conversion
HV Auxiliary Modules
High Current Sealed Connection Systems
Chargers & Charging Cables
13520386
13520916
• Device connections up to 250A • Sealed pass-through header
Description • • • •
Sealed system Silver-plated, multi-contact terminal system Cable range: 19 mm2 to 62 mm2 One key/index
Performance • • • •
Current capacity: 250A at 85°C Voltage: 12V Temperature range: -40°C to +125°C Sealing protection: IP67, IP6K9K
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
48
Mating Information
Key/ Index
Female 1 Way
Header
Index 0
13520916
13520386
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Filtered High Current Connection Systems 1 Way Sealed Hand Mateable Connectors
HV Power Conversion
28257913
Chargers & Charging Cables
13520916
Application Charging Inlets
• High current filtered pass-through header
Description
Internal Battery Connections
• Panel mount to device with bore seal and ground to case • Pluggable mating Power Pack 2000 connector • Silver-plated multi-contact terminal system • M5 captive nut for internal electrical attachment • Filter capacitance 60µF, 25V • Three keys/indexes
Performance • Current capacity: 250A at 85°C • Voltage: 14V • Temperature range: -40°C to +105°C • Insertion loss: 40dB at 200kHz • Sealing protection: IP67, IP6K9K • Electrical protection: IP2XB female connector only
HV Electrical Centers
Mating Information Header Connector
101
28257913
103
28257912
104
28259497
Mating Device Detail
PP2000 Connector
Ferrule
13520916 See print for information
13817280
28105377
13817281
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
49
HV/LV Wiring Assemblies
Key/ Index
HV Auxiliary Modules HV Power Conversion
Chargers and Charging Cables
Chargers & Charging Cables Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LV Wiring Assemblies
HV Auxiliary Modules
Chargers & Charging Cables
Portable Electric Vehicle Charger
HV Power Conversion Chargers & Charging Cables Charging Inlets
Application • Portable Electric Vehicle Supply Equipment (EVSE) for electric vehicle charging
Description
Internal Battery Connections
• Vehicle interface through three global standards • EVSE provides restart in the event of power grid fault • Programmable for multiple charge currents • NEMA 4 construction • UL/CE certified
Available Options • 120V/12A • 240V/10A,13A, or 16A • SAE J1772/IEC62196 Type I, IEC62196 Type II, and GB/T 20234 vehicle interface • Grid cord as required by country of use • Call for additional configurations
HV Electrical Centers
53
HV/LV Wiring Assemblies
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Charge Coupler Connector Pigtails
1 Type I – Rubber Overmold
2 Type I – Plastic Handle
3 Type II – Rubber Overmold
4 Type II – Plastic Handle
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Chargers & Charging Cables
HV Power Conversion
HV Auxiliary Modules
Chargers & Charging Cables
Application • Cable assemblies for integration into charging stations or portable cordsets per customer requirements
Description • SAE J1772/IEC62196 Type I, IEC62196 Type II, and GB/T 20234 compliant connections • Wiring crimps sealed from environment • Rubber overmold and plastic grip options available
Performance • • • •
54
Current capacity: 15A to 32A Voltage range: 120V to 480V Temperature range: -40°C to +50°C Validation: See part number information
5 GB/T – Rubber Overmold
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Charge Coupler Connector Pigtails
HV Power Conversion
2 Type I – Plastic handle
3 33155747: Type II – Rubber overmold
4 33400850: Type II – Plastic handle
Chargers & Charging Cables
1 33105172: Type I – Rubber overmold
Charging Inlets
5 13960876: GB/T – Rubber overmold
Charge Coupler
Handle Picture
33105172 33105194 33105183
Rubber overmold
Plastic
2
33155747 33155746 Call for availability
IEC62196
Rubber overmold
3
Type II
13960876 13937383
Plastic GB/T 20234
Rubber overmold
15A, 120 VAC
3 - 2.0 mm2 + 1 - 0.8 mm2 UL cable
6.20 m/20.33 ft
UL, CE
16A, 240 VAC
3 - 2.5 mm2 + 1 - 0.75 mm2 IEC cable
6.20 m/20.33 ft
UL, CE
20A, 240 VAC
3 - 3.0 mm2 + 1 - 0.8 mm2 UL cable
7.725 m/25.00 ft
UL, CE
30A, 240 VAC
3 - 5.0 mm2 + 1 - 0.8 mm2 UL cable
7.725 m/25.00 ft
UL, CE
16A, 240 VAC
3 - 2.5 mm2 + 1 - 0.75 mm2 IEC cable
6.5 m/21.3 ft
CE
20A - 1-Phase, 240 VAC
3 - 2.5 mm² + 1 - 0.5 mm² IEC cable
5.0 m/16.4 ft
CE
20A - 3-Phase, 480 VAC
5 - 2.5 mm² + 1 - 0.5 mm² IEC cable
5.0 m/16.4 ft
CE
20A - 3-Phase, 480 VAC
5 - 2.5 mm² + 1 - 0.5 mm² Spiral cable
5.0 m/16.4 ft
CE
32A - 3-Phase, 480 VAC
5 - 6.0 mm² + 1 - 0.5 mm² IEC cable
5.0 m/16.4 ft
CE
4
32A - 3-Phase, 480 VAC
5 - 4.0 mm² + 1 - 0.75 mm² IEC cable
6.5 m/21.3 ft
CE
16A - 1-Phase, 250 VAC
3 - 2.5 mm2
5
5.0 m/16.4 ft
N/A
16A - 1-Phase, 250 VAC
3 - 2.5 mm2 + 1 - 0.5 mm2 IEC cable
2.7 m/8.86 ft
N/A
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
55
HV/LV Wiring Assemblies
33155745 33400850
Cable Certifications/ Length (m/ft) Approvals
1
33105199 Call for availability
Cable Description
HV Electrical Centers
SAE J1772/ IEC62196 Type I
Electrical Rating
Internal Battery Connections
Assembly Part Number
HV Auxiliary Modules
Mode 3 Charging Cable Assemblies
Charging Inlets
Chargers & Charging Cables
HV Power Conversion
HV Auxiliary Modules
Chargers & Charging Cables
1 Type I to Type II – Plastic Handle
3 Type II to Type II – Rubber Overmold
5 Type II to Type III – Plastic Handle
2 Type I to Type III – Plastic Handle
4 Type II to Type II – Plastic Handle
6 GB/T to GB/T – Rubber Overmold
Application Description • Vehicle to infrastructure connection • Wiring crimps sealed from environment • Rubber overmold and plastic handle options available • Single-phase and three-phase charging
Performance • Current capacity: up to 32A • Voltage range: 240V to 480V • Temperature range: -40°C to +50°C • Validation: See part number information
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
• Cable assemblies for plugging to charging station
56
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Mode 3 Charging Cable Assemblies Infrastructure Drawings
HV Power Conversion
59.2
210.1
105.5
210.1
GB/T – Rubber Overmold
Type II – Plastic Handle
Type III – Plastic Handle
Chargers & Charging Cables
Type II – Rubber Overmold
*Please reference page 55 for the vehicle interface drawings.
Charging Inlets
33403378
Infrastructure Picture
Grip
SAE J1772/ IEC62196 Type I
Plastic
33401185 Call for availability 33401404
IEC62196 Type II
Call for availability
20234
16A - 1-Phase, 240 VAC
3 - 2.5 mm2 + 1 - 0.75 mm2 IEC cable
6.0 m/15.7 ft
CE
32A - 1-Phase, 240 VAC
3 - 6.0 mm² + 1 - 0.75 mm² IEC cable
6.0 m/15.7 ft
CE
IEC62196 Type III
2
16A - 1-Phase, 240 VAC
3 - 2.5 mm2 + 1 - 0.5 mm2 IEC cable
6.0 m/15.7 ft
CE
3
16A - 3-Phase, 480 VAC
5 - 2.5 mm² + 1 - 0.75 mm² IEC cable
4.0 m/13.1 ft
CE
32A - 3-Phase, 480 VAC
5 - 4.0 mm² + 1 - 0.75 mm² IEC cable
6.5 m/21.3 ft
CE
32A - 3-Phase, 480 VAC
5 - 4.0 mm² + 1 - 0.75 mm² IEC cable
4.0 m/13.1 ft
CE
32A - 3-Phase, 480 VAC
5 - 4.0 mm² + 1 - 0.75 mm² IEC cable
6.5 m/21.3 ft
CE
16A - 1-Phase, 250 VAC
3 - 2.5 mm² + 1 - 0.5 mm² IEC cable
5.0 m/16.4 ft
N/A
32A - 1-Phase, 250 VAC
3 - 6.0 mm² + 1 - 0.75 mm² IEC cable
5.0 m/16.4 ft
N/A
IEC62196 Type II
Plastic
Rubber overmold
Cable Certifications/ Length (m/ft) Approvals
1
IEC62196 Type III GB/T
Cable Description
IEC62196 Type II
4
33401403
Electrical Rating
GB/T 20234
5
6
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
57
HV/LV Wiring Assemblies
33403734
Rubber overmold
Interface
HV Electrical Centers
33401184
Internal Battery Connections
Assembly Part Vehicle Number Interface
HV Auxiliary Modules
Charging Inlets
HV Power Conversion
Chargers & Charging Cables
Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LV Wiring Assemblies
HV Auxiliary Modules
Charge Inlet Level 1 & 2 Vehicle Charging Inlet
Chargers & Charging Cables
HV Power Conversion
HV Auxiliary Modules
Charging Inlets
SAE J1772/IEC62196 Type I
IEC62196 Type I
• Plug-in hybrid and electric vehicle charge inlet
Description
• Interface complies with SAE J1772 and IEC62196 Type I standard • Panel mounts to vehicle • Protective grommet/wire dress mounts to inlet • Available with latching cover or without cover • Cover mounting features allow latch to open left or right
HV/LV Wiring Assemblies
13826395
Performance • Supports: AC Level 1 (15A, 120V) and AC Level 2 (30A, 240V) • Voltage: 600V maximum rating • Temperature range: -40°C to +85°C • Validation: UL recognized, Delphi GTP • Electrical protection: IP2XB • Design life: 10,000 mating cycles
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
13829165
Inlet with Upper Plate
Mating Information
60
Configuration
Assembly Part Number
No cover
13829165
Cover opens left
13826395
Cover opens right, with upper plate
Call for availability
Cover opens left, with upper plate
Call for availability
Cover opens right, without upper plate
Call for availability
Vehicle Mounting Detail 13827259
-
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Charge Inlet Type II Vehicle Charging Inlet
HV Power Conversion
33402098
Chargers & Charging Cables
Application Charging Inlets
• Plug-in hybrid and electric vehicle charge inlet
Description
Internal Battery Connections
• Interface complies with IEC62196 Type II standard • Panel mounts to vehicle • Integrated thermal circuit breaker to prevent abnormal temperature increase inlet connector only • Cover provides dust protection • Designed to drain fluid if introduced to inlet • Holes provided for coupler lock actuator • Available with cover opening right or left
Performance
Assembly Part Number
Right open cover, wires exit left
33402098
Left open cover, wires exit right
33402097
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
61
HV/LV Wiring Assemblies
Configuration
HV Electrical Centers
• Supports single-phase or three-phase power supply • Supports: (16A, 230V) and (63A, 480V) • Voltage: 400V maximum rating • Temperature range: -40°C to +85°C • Electrical protection: IP2XB • Sealing protection: IP44 (connector/inlet mated) • Design life: 10,000+ mating cycles
HV Auxiliary Modules
Charge Inlet GB/T 20234 Level 1 & 2 Vehicle Charging Inlet
HV Power Conversion
HV Auxiliary Modules
Charging Inlets
Chargers & Charging Cables
13947629
13937834
• Plug-in hybrid and electric vehicle charge inlet
Description • Interface complies with GB/T 20234 standard • Optional electrical lock and emergency release function • Optional cover for cable routing • Available with latching cover, plugging cover or without cover • Cover mounting features allow latch to open left or right
Performance • Supports: AC 220V/50Hz, 10A/16A/32A • Voltage: 600V maximum rating • Temperature range: -40°C to +85°C • Validation: CCC recognized, Delphi GTP • Electrical protection: IP2XB • Sealing protection: IP6X4, IP6X5 • Design life: 10,000 mating cycles
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
62
Configuration
Assembly Part Number
No cover
13947629
With latching cover, opens right
13937834
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
Combo 1 AC/DC Vehicle Charging Inlet High Voltage/High Current Power Charging for SAE 74.1
98
15.5
Type I eet EE
15.5
141.3 119.5
HV Power Conversion
74.1
Chargers & Charging Cables
232.4
93.1
15.5
98
93.1
• COMBO 1 charging interface for slow AC (Type I) and fast DC charging applications
34.5 15.5
Description
Internal Battery Connections
pe I et EE ap and Cord)
• Interface complies with SAE J1772 and IEC62196 • Combined charging system for electrical vehicle • AC/DC: slow + fast charge (600V, 125A) • Actuator pin for locking connector to inlet during charging 141.3 • Optional thermistor for additional thermal protection 119.5 during DC charging • Wire Cross Section: Contact Pin/Present Pin (0.5 mm²), PE (16 mm²), L1/N (6.0 mm²), DC+/-(40 mm²)
Performance
HV Electrical Centers
• Temperature range: -40°C to +80°C • Voltage: 600V DC • Max. current capacity: 32A AC/ 125A DC • Sealing Protection: IP55 with cover, IP44 when mated • Connector/Inlet mating and unmating force < 100N • Number of mating cycles > 10,000
Availability • Call for availability
63
HV/LV Wiring Assemblies
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
Charging Inlets
34.5
Application
HV Auxiliary Modules
HV Auxiliary Modules
Charging Inlets
Combo 2 AC/DC Vehicle Charging Inlet
HV Power Conversion
High Voltage/High Current Power Charging for IEC 76.4
98
Charge Inlet IEC62196-3 Type II Standard Sheet FF
141.9 119.5
Chargers & Charging Cables
141.9 119.5
98
7
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application 98
239.9 • COMBO 2 charging interface for slow AC (Type II) and fast DC charging applications
239.9
95.1 25.7
98
7
Description • Interface complies with IEC62196 • Combined charging system for electrical vehicle Charge Inlet IEC62196-3 Type II • AC/DC: slow + fast charge (600V, 125A) Standard Sheet FF • Actuator pin for locking connector to inlet during charging 141.9 (with AC/DC Cap and Cord) • Optional thermistor for additional thermal protection during 119.5 DC charging • Wire Cross Section: Contact Pin/Present Pin (0.5 mm²), PE (16 mm²), L1/N (6.0 mm²), DC+/-(40 mm²)
119
Performance • Temperature range: -40°C to +80°C • Voltage: 600V DC • Max. current capacity: 32A AC/ 125A DC • Sealing Protection: IP55 with cover, IP44 when mated • Connector/Inlet mating and unmating force < 100N • Number of mating cycles > 10,000
107.6
Availability • Call for availability
64
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
DC Charge Inlet Level 1 & Level 2 Vehicle Charging Inlet
HV Power Conversion
33103831
Chargers & Charging Cables
Application Charging Inlets
• Plug-in hybrid and electric vehicle DC Charge inlet
Description • Interface complies with GB/T 20234 standard • Optional Shielding function • Optional 90° Adapter • Latching cover • Cover mounting features allow latch to open left
Internal Battery Connections
Performance • Supports: 125A/250A • Voltage: 600V maximum rating • Temperature range: -40°C to +85°C • Validation: CCC recognized, Delphi GTP • Electrical protection: IP2XB • Sealing protection: IP6X4, IP6X5 • Design life: 10,000 mating cycles
HV Electrical Centers
Assembly Part Number
With latching cover, opens left
33103831
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
65
HV/LV Wiring Assemblies
Configuration
HV Auxiliary Modules HV Power Conversion
Internal Battery Connections
Chargers & Charging Cables
Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LV Wiring Assemblies
HV Auxiliary Modules
Sealed Battery Manual Service Disconnect (MSD) Sealed for Protection from the Environment
HV Power Conversion
HV Auxiliary Modules
Internal Battery Connections
Chargers & Charging Cables
Base Assembly
Fuse Assembly
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application • Sealed battery manual service disconnect used for servicing HV system
Description • Panel mount to device with face seal to case • Base mounts from inside with threaded inserts to attach to battery • Optional splash proof base • Two-stage lever provides HVIL time delay • Integrated HVIL with shunt in MSD portion • High speed fuse with various ratings in same package size • MSD keyed/indexed per fuse rating
Performance • Current capacity: Call to discuss application • Voltage: 690V • Temperature range: -40°C to +85°C • Sealing protection: IP67, IP6K9K (N.A. to splash version) • Electrical protection: IP2XB
Availability • Call for availability
68
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Auxiliary Modules
High Voltage Battery I/O Junction Block Custom 2 Way, 3 Way Bolted Connection
HV Power Conversion Chargers & Charging Cables
13658746
Application • High voltage/unshielded bolted connections for battery I/O
Charging Inlets
Description • Custom 2 Way and/or 3 Way high voltage • Fit to device case per customer requirements • Ability to fasten direct to PCB • Isolation between HV circuits through isolation towers • Insert molded terminals and/or studs
Internal Battery Connections
Performance • Continuous current: Per customer requirements • Voltage: 600V • Temperature range: -40°C to +125°C
HV Electrical Centers
3 Way System
13658746
28115976
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
69
HV/LV Wiring Assemblies
2 Way System
HV Auxiliary Modules HV Power Conversion
High Voltage Electrical Centers
Chargers & Charging Cables
Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LV Wiring Assemblies
HV Auxiliary Modules
High Voltage Battery Electrical Center
High Voltage Electrical Center
Chargers & Charging Cables
HV Power Conversion
HV Auxiliary Modules
High Voltage Electrical Centers
• High voltage battery electrical center
Description • Battery pack mounted contactor and sensing device • Provides galvanic isolation of the high voltage battery • Pre-charge protects contactors from high current in-rush • Sensing of battery current and voltage • Provides circuit protection for auxiliary loads • Size: 268 mm L x 200 mm W x 78 mm H
Application • High voltage electrical center
Description • • • •
Custom solutions to system requirements Integration of terminal, contactor, and/or HV fuses Shielded and sealed system Harness connections through Shield-Pack™ connection systems • Venting for pressure variations
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
72
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
HV Power Conversion
Chargers & Charging Cables
Charging Inlets
Internal Battery Connections
HV Electrical Centers
HV/LVWiring WiringAssemblies Assemblies HV/LV
www.delphi.com/connect
HV Auxiliary Modules
High Voltage/Low Voltage Wiring Assemblies
HV Auxiliary Modules
High Voltage/Low Voltage Wiring Assemblies
Chargers & Charging Cables
HV Power Conversion
HV Auxiliary Modules
High Voltage/Low Voltage Wiring Assemblies
• High voltage wiring assemblies for hybrid/electric vehicles
Description • High voltage wiring assemblies pigtailed to modules • Full vehicle high voltage assemblies • Ability to process Delphi Shield-PackTM and/or industry HV connections • Quality systems for high voltage safety concerns • High potential, pressure, and seal testing of wiring assemblies • Delphi customer support for high voltage wire harness design
HV/LV Wiring Assemblies
HV Electrical Centers
Internal Battery Connections
Charging Inlets
Application
74
Part numbers, specifications, dimensions and performance data in this catalog are for general reference only and are subject to change without notice. To verify product information, please contact a Delphi representative.
For more information:
delphi.com/highpower
Innovation for the Real World
Asia Pacific Regional Operations 60 Yuanguo Road Anting, Jiading District Shanghai, 201814 China Tel: (86) 21. 5956.3300 Fax: (86) 21. 6957.3797
North America Customer Center 5725 Delphi Drive Troy, Michigan 48098-2815 USA Tel: [1] 248.813.2000 Fax: [1] 248.813.2673
Europe Regional Operations Customer Technology Center Delphiplatz 1 42119 Wuppertal, Germany Tel: (49) 202.291.0 Fax: (49) 202.291.2777
South America Regional Operations Delphi Automotive Systems do Brasil Ltda. Rod. dos Tamoios, Km 21,8 Jambeiro, São Paulo 12290-000 Brazil Tel: (55) 12.3978.2005 Fax: (55) 12.3978.2077
DEEAen140212
Innovation for the Real World
