Hybrid and Electric Vehicle Connection System Portfolio Selected for the Distribution Channel

Transcription

1 Rev DCS Hybrid and Electric Vehicle Connection System Portfolio Selected for the Distribution Channel

2 Rev 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 in HEVs and EVs. There are three standards used throughout the world including SAE J77 in North America and Japan, IEC696 Type II in Europe, and GB/T 034 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. 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. 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. A world of electrification. Delphi has been researching and developing safe, reliable and high performance products for vehicle electrification for more than 0 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. 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. 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 3 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

3 Rev Table of contents AUXILLARY MODULES On-Board Charger Connector Level / Level 6 way Device Connection System AK Class Shield-Pack HV80 Way pass through HVIL (+ way), Way with shunted HVIL, 3 Way APEX HV80 way Connection System with HVIL Shield-Pack HV80 Piece Header with Pluggable Inner Connector APEX 950 On-Board Charger Connector 4 + Way Connection System with HVIL Charging Inlets, Plugs and Couplers POWER CONVERSION AK Class 4 way Connection System with HVIL RCS800 High Voltage Way Connection System with HVIL RCS890 High Voltage Way Right Angle Connection System with HVIL AK passthru High Voltage, & 3 way Panel Mount System Metal passthru way Panel Mount System, 4 AND 48 Volt Solutions Charge Inlet Level & Vehicle Charging Inlet Charge Inlet Type II Vehicle Charging Inlet Charge Coupler Connector Pigtails Power Pack 000 Way Inline Connectors Power Pack 000 Way Device and Pass-Through Connectors 9 0- Charge Plug Mode 3 Jumpers 6 Charge plug mode assembly (with ICCB) 7 Dimensions

4 EV/EV s: Delphi DCS product offering Auxiliary Devices E-Heater, DC Converter, Charger, Air Conditioning, Coolant Heater Control Power Conversion HV battery, E-motor, Inverter, junction box, power electric box Charging Systems Charging inlets and couplers AC on-board charger, 4, 48V Connections 48V Inverter, 48V Battery, Power Distribution boxes, E-charger (e-booster) V battery, DC/DC converter, V Electrical Distribution Center Security Classification

5 SELECTOR GUIDE Auxiliary Modules Solutions Image Page number Temperature/ Vibration Class Shielding Amperage Voltage # Ways / orientation Sections On-board charger female 6-7 On-board charger applications (Level and ) On-board charger male inline Body to Medium Not shielded 3A at 85 C 600V to 4 power lines / 80 to 5 mm² On-board charger header 8 Battery pack (Aux) DC/DC converter On-board charger PTC Electric Heater Electric air conditioning Electric power Steering AK class 3way female (no HVIL) AK class way female (HVIL passthrough) AK class way female (HVIL shunt) Level 4/ Level (LV 5) Shielded multicore cable 30A at 85 C 850V to 3 power lines / 80.5 to 4 mm² 9 APEX80 way plug APEX80 way header Body Peripheral with metal braid 0 Electric air conditioning PTC Electric Heater Charger Inner connector HV80 with inner connector header Body Individual Shielded cable 35A at 70 C 000V power lines / 80.5 to 5 mm² HV80 with inner connector female On-board charger APEX 950 On-Board Charger Connector (HVIL shunt) Body Not shielded 5A at 70 C 750V 4 power lines / 80 0 to 6 mm² power 0.5 to 0.75 mm²

6 Rev On-Board Charger Connector Level / Level 6 way Device Connection System AUXILLARY MODULES High voltage unshielded system for onboard charger applications (Level and ) Performance Current capacity: 3A at 85 C Voltage: 600V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IP6K9K Electrical protection: IPXB 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: mm to 5 mm Capable of multiple keys/indexes Header connector Part number: Mating Part number: DPN Key/index BOM On_board charger connector - (tool required for disconnection) On_board charger connector - (no tool required) Male Terminals Male Terminal.0 HES Gold required.75-.0mm Male Terminal.4 HES Gold required -3mm Male Terminal.4 HES Gold required 4-5mm, 3 or 4 DPN Key/index BOM Level harness connector (+) -.5 mm² Level harness connector (3+) -.5 mm² Level harness connector (4+) -.5 mm² Level harness connector (+) 4-5 mm² Level harness connector (3+) 4-5 mm² Level harness connector (4+) 4-5 mm² Female Terminals Female Terminal.0 HES Gold required.75-.0mm Female Terminal.4 HES Gold required -3mm, 3 or Female Terminal.4 HES Gold required 4-5mm 6

7 Rev On-Board Charger Connector Level / Level 6 way Inline Connection System AUXILLARY MODULES Inline between inlet and on-board charger for cable routing (Level and )) Performance Current capacity: 3A at 85 C Voltage: 600V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IP6K9K Electrical protection: IPXB 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: mm to 5 mm Capable of multiple keys/indexes Header connector Part number: Mating Part number: DPN Key/index BOM Level harness connector (+) Level harness connector (3+) Level harness connector (4+) Level harness connector (+) Level harness connector (3+) Level harness connector (4+) Male Terminals Male Terminal.0 HES Gold required.75-.0mm Male Terminal.4 HES Gold required -3mm, 3 or Male Terminal.4 HES Gold required 4-5mm DPN Key/index BOM Level harness connector (+) -.5 mm² Level harness connector (3+) -.5 mm² Level harness connector (4+) -.5 mm² Level harness connector (+) 4-5 mm² Level harness connector (3+) 4-5 mm² Level harness connector (4+) 4-5 mm² Female Terminals Female Terminal.0 HES Gold required.75-.0mm Female Terminal.4 HES Gold required -3mm, 3 or Female Terminal.4 HES Gold required 4-5mm 7

8 Rev Shield-Pack HV80 AK CLASS female connector AUXILLARY MODULES High voltage accessories connection system Performance Current capacity: 30 A at 85 C Voltage: 850V DC Temperature range: -40 C to +40 C Sealing protection: IP6K9K Electrical protection: IPXB unmated, IPXD mated Sealed connection system Two or three HV power circuits (.8 mm terminal) Way: HVIL shunted in harness connection and pass-through HVIL options available 3 Way: No HVIL Finger proof/touch safe Cable range:.5 & 4mm multi-core circuit; 0.5 mm HVIL circuit ( way only) Four keys/indexes Female connector: Receptacle Housing Subassembly, Way, Code A Receptacle Housing Subassembly, Way, Code B Receptacle Housing Subassembly, Way, Code C Receptacle Housing Subassembly, Way, Code D Receptacle Housing Subassembly, Way, Code E Terminals DCK.8 FEMALE TERMINAL 4 mm² DCK.8 FEMALE TERMINAL.5 mm² Duo Twin 0,64 MALE TERMINAL 0,5 mm² (HVIL passthrough version only) Components: DPN Way, HVIL shunt Bill Of Material Way, HVIL passthrough Spacer Shielding ASM Strain Relief for 3X.5sqmm Cable Seal for 3X.5sqmm Inner Housing, Way ASM Strain Relief for X4.0sqmm Cable Seal for X4.0sqmm Inner ferrule Outer ferrule Inner Housing Subassembly Inner Housing, 3Way TPA (Terminal Position Assurance) 3 way 8

9 Rev APEX HV80 way Connection System with HVIL AUXILLARY MODULES High voltage peripheral equipment connection system: Air conditioning, PTC, Charger Performance Current capacity: 35 A at 70 C Voltage: 000V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IPX9K Electrical protection: IPXB 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 (.8 mm terminal) Flange size: 46 mm x 53 mm IPXB Finger proof/touch safe Cable range:.5 to 4 mm power circuit; 0.5 to 0.75 mm HVIL circuit Two keys/indexes Header connector Part number: Mating Part number: DPN MPN Key/index BOM F8730 APEX-80 WAY HEADER CODE BLACK F9730 APEX-80 WAY HEADER CODE BROWN Male Terminals DPN MPN BOM NA APEX 80 MALE TERMINAL 4 mm² NA APEX 80 MALE TERMINAL.5 mm² HVIL- Interlock DCS.5 gold-plated MALE TERMINAL 0,5-,0 mm² HVIL- Interlock DCS.5 gold-plated MALE TERMINAL 0,-0,35 mm² Seal DPN MPN BOM C30400 APEX.8 MALE & FEMALE SWS Red 4 mm² C0400 APEX.8 MALE & FEMALE SWS.5 mm² DCS.5 MALE RED SWS 0, - 0,5 mm² DCS.5 MALE GREY SWS 0,75 -,0 mm² DPN MPN Key/index BOM F0830 APEX-80 WAY PLUG CODE BLACK F830 APEX-80 WAY PLUG CODE BROWN Female Terminals APEX.8 FEMALE TERMINAL 4 mm² APEX.8 FEMALE TERMINAL.5 mm² Seal DPN MPN BOM C30400 APEX.8 MALE & FEMALE SWS Red 4 mm² C0400 APEX.8 MALE & FEMALE SWS.5 mm² 9

10 Rev Shield-Pack HV80 Piece Header with Pluggable Inner Connector AUXILLARY MODULES Ideal for internal battery harnesses/high voltage connection system Performance Current capacity: 40A at 85 C Voltage: 000V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IP6K9K Electrical protection: IPXB 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 - Tool-less mating system Two HV power circuits (.8 mm terminal) Finger proof/touch safe Cable range: mm to 5 mm power circuit; 0.5 mm HVIL circuit 0 Header & Inner connector Part number: DPN Key/index BOM Shield-Pack HV80 piece header with Loose Inner connector Shield-Pack HV80 piece header with Loose Inner connector Inner connector Inner connector Male Terminals Male terminal cable OD - mm Male terminal cable OD / 3 mm-5mm solder rqd Male terminal cable OD / 4-5 mm HVIL terminal TPA TPA (Terminal Position Assurance) Ferrule (for female connector only) Inner ferrule cable OD / 4 gage (mm) Inner ferrule cable OD / gage (3mm) Inner ferrule cable OD / 0 ga (5mm) Outer Ferrule Mating Part number: Female Terminals Seal Cable seal LSR 0ga Cable seal LSR ga Cable seal LSR 4ga Cable seal LSR 4mm EU TPA DPN Key/index BOM Shield-Pack HV80 Internal HVIL Shunted - (tool required for disconnection) Shield-Pack HV80 Internal HVIL Shunted - (tool required for disconnection) Shield-Pack HV80 Internal HVIL Shunted - (no tool required) Shield-Pack HV80 Internal HVIL Shunted - (no tool required) Female terminal 3-4-5mm Female terminal mm TPA/seal retainer Cable 4 ga TPA/seal retainer Cable ga TPA/seal retainer Cabe 0 ga

11 Products presentation Rev APEX 950 On-Board Charger Connector 4 + Way Connection System with HVIL HV Auxiliary Modules Header connector Part number: DPN Key/index BOM APEX 950 Header connector Code Male Terminals High voltage unshielded system for onboard charger applications Performance Current capacity: 5A at 70 C Voltage: 750V Temperature range: -40 C to +5 C Sealing protection: IP67, IPX9K Electrical protection: IPXB F APEX 950 Male Terminal 0 to 6mm APEX 80 MALE TERMINAL 4 mm² HVIL - Interlock DCS.5 Male Terminal AU Sealed 0.5 to mm Seals F8900 APEX 950 SWS wire size 6 mm F08900 APEX 950 SWS wire size 0 mm 4 C30400 APEX.8 SWS DCS.5 SWS red 0. to 0.5 mm Sealed in mated or unmated position Unshielded 4 + 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.8 mm terminals) Flange size: mm x 5 mm IPXB Finger proof/touch safe Cable range: 0 to 6 mm power circuit; 0.5 to 0.75 mm electric interlock key/index Mating Part number: DPN Key/index BOM APEX 950 connector black Code Female Terminals F08900 APEX 950 Female Terminal 0 to 6mm APEX.8 FEMALE TERMINAL 4 mm² Seals F8900 APEX 950 SWS wire size 6 mm F08900 APEX 950 SWS wire size 0 mm 4 C30400 APEX.8 SWS DCS.5 SWS red 0. to 0.5 mm

12 SELECTOR GUIDE Power Conversion Solutions Image Page number Temperature/ Vibration Class Shielding Amperage Voltage # Ways / orientation Sections 3 AK class 4 header AK class 4 female plug Level 4/ Level 3 (LV 5) Shielded cable 80A at 40 C (50 mm²) 850V ways / 90 5 to 50 mm² 4 RCS890 female terminal RCS890 way header RCS-890 way plug Body Peripheral with metal braid 0A at 85 C (50 mm²) 000V ways / to 50 mm² RCS890 female terminal Inverter DC/DC Converter Battery junction box power electric box High Voltage Power Distribution RCS890 way header RCS-890 way plug RCS890 female terminal Plastic AK pass through way Plastic AK pass through way Plastic AK pass through 3way Metal pass through 5 mm² Metal pass through 35 mm² Metal pass through 50 mm² Body to Medium Level 4/ Level 3 (LV 4) Volvo truck class 5 & 6 Peripheral with metal braid Shielded cable Shielded cable 0A at 85 C (50 mm²) 80A at 40 C (50 mm²) 50A at 85 C (50 mm²) 000V ways / V 000V to 3 ways / 80 way with indexes / to 50 mm² 6 to 50 mm² 5 to 50 mm²

13 Rev HV890 AK Class 4 Way Connection System with HVIL POWER CONVERSION 3 Header: High voltage/high current modules: inverter, battery, junction box, power electric box Performance Current capacity: 70A at 40 C Voltage: 850V DC Temperature range: -40 C to +40 C IP Rating: IPX7, IP6K9K Vibration severity 3 LV AK Way Pin Header-Code A AK Way Pin Header-Code B AK Way Pin Header-Code C AK Way Pin Header-Code D HVIL terminal (Interlock) MCON. Male terminal (TE connectivity) Insulation & socket: (for female connector) Outer insulation Deep Drawn Socket, Pin Assy Number of ways: Number of indexes: 4 Terminal Size/Style: Ø8mm Pin Sleeve Wire range: 5mm to 50mm Fully interchangeable with other AK productz Female connector: AK CLASS 4 FEMALE CODE A AK CLASS 4 FEMALE CODE B AK CLASS 4 FEMALE CODE C AK CLASS 4 FEMALE CODE D 5 mm²: Female Terminal Assy.5mm Inner Ferrule 5mm Outer Ferrule 5mm,Ni plated ASM Strain Relief 5 mm Cable Seal 5mm 35 mm²: Female Terminal Assy.35/50mm Inner Ferrule 35mm Outer Ferrule 35mm,Ni plated ASM Strain Relief 35 mm Cable Seal 35mm 50 mm²: Female Terminal Assy.35/50mm Inner Ferrule for 50mm Outer Ferrule 50mm,Ni plated ASM Strain Relief 50 mm Cable Seal 50mm

14 Rev RCS800 High Voltage Way Connection System with HVIL POWER CONVERSION High voltage/high current modules: inverter, battery, junction box, power electric box Performance Current capacity: 30 A at 70 C Voltage: 000V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IPX9K Electrical protection: IPXB 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 IPXB Finger proof/touch safe Cable range: 35 to 50 mm power circuit; 0.5 to 0.75 mm HVIL circuit Two keys/indexes Header connector Part number: Mating Part number: DPN MPN Key/index BOM F4730 RCS-800 WAY HEADER CODE BLACK F5730 RCS-800 WAY HEADER CODE BBROWN Male Terminals DPN MPN BOM F RCS 800 MALE Bus Bar TERMINAL Silver version standard length F76600 RCS 800 MALE Bus Bar TERMINAL Silver version V length F76600 RCS 800 MALE Bus Bar TERMINAL Silver version V length HVIL- Interlock DCS.5 gold-plated MALE TERMINAL 0,5-,0 mm² Seal DPN MPN BOM DCS.5 MALE RED SWS 0, - 0,5 mm² DCS.5 MALE GREY SWS 0,75 -,0 mm² DPN MPN Key/index BOM F6730 RCS-800 WAY PLUG CODE BLACK F7730 RCS-800 WAY PLUG CODE BROWN Female Terminals DPN MPN BOM F RCS 800 FEMALE TERMINAL silver version 35 to 50 MM² F57600 RCS 800 FEMALE RETAINER (PLUG) Seal DPN MPN BOM F47600 RCS 800 FEMALE SWS MM² (PLUG) F37600 RCS 800 FEMALE SWS 50 MM² (PLUG) 4

15 Rev RCS890 High Voltage Way Right Angle Connection System with HVIL POWER CONVERSION High voltage/high current modules: inverter, battery, junction box, power electric box Performance Current capacity: 0A at 70 C Voltage: 000V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IPX9K Electrical protection: IPXB 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: 5 mm x 6 mm IPXB Finger proof/touch safe Cable range: 35 to 50 mm power circuit; 0.5 to 0.75 mm HVIL circuit One key/index Header connector Part number: Mating Part number: DPN MPN Key/index BOM F70 RCS-890 -WAY HEADER CODE BLACK Male Terminals Seal DPN MPN BOM F RCS 800 MALE Bus Bar TERMINAL Silver version standard length F76600 RCS 800 MALE Bus Bar TERMINAL Silver version V length F76600 RCS 800 MALE Bus Bar TERMINAL Silver version V length DCS.5 gold-plated FEMALE TERMINAL 0.5 to.0 mm² DPN MPN BOM DCS.5 MALE RED SWS 0, - 0,5 mm² DCS.5 MALE GREY SWS 0,75 -,0 mm² DPN MPN Key/index BOM F90 RCS-890 -WAY PLUG CODE BLACK Female Terminals DPN MPN BOM F6000 RCS 890 FEMALE TERMINAL silver version 35 to 50 MM² Seal & retainer DPN MPN BOM F30 RCS 890 -WAY FEMALE SWS & RETAINER (PLUG) 50 mm² F30 RCS 890 -WAY FEMALE SWS & RETAINER (PLUG) mm² Clamp DPN MPN BOM F8500 RCS890 -WAY HALF CLAMP 5

16 Rev AK passthru High Voltage, & 3 way Panel Mount System POWER CONVERSION High voltage/high current modules: inverter, battery, junction box, power electric box Performance Current capacity: 90A at 40 C Voltage: 850V DC Temperature range: -40 C to +40 C IP Rating: IPX7, IP6K9K Vibration: LV4, Vibration Severity 3, Temperature Severity 4 Possible configurations:, or 3 ways Main Housing Material: Plastic Terminal Size/Style: Ring-Tongue Wire range: 6mm to 50mm Shielding principle: 360 Individually Shielded Housing Body Component: ASM AK passthrough -way ASM AK passthrough -way ASM AK passthrough 3-way Peripheral Seal, or ASM Shield Terminal, or 3 6 mm²: 35 mm²: Single Wire Seal fo 6 mm² cable, or Protection Cover Assy for 6mm², or Shielding Outer Ferrule for 6sqmm² cable, or 3 5 mm² : Single Wire Seal fo 5 mm² cable,, or Protection Cover Assy for 5mm², or Shielding Outer Ferrule for 5 mm² cable, or Single Wire Seal fo 35 sqmm^ cable,, or Protection Cover Assy for 35mm^, or Shielding Outer Ferrule for 35sqmm^ cable, or 3 50 mm² : Single Wire Seal fo 50 sqmm^ cable,, or Protection Cover Assy for 50 mm^, or Shielding Outer Ferrule for 50sqmm^ cable, or 3 6

17 Rev Metal passthru way Panel Mount System POWER CONVERSION 7 5 mm² Metal Passthru Part number: High voltage/high current modules: inverter, battery, junction box, power electric box Performance Current capacity: up to 50A at 85 C Voltage: 000V DC Temperature range: -40 C to +5 C Sealing protection: IP67, IP6K9K High robustness against vibration DPN Key/index BOM Metal passthru 5 mm² Metal passthru 5 mm² Metal passthru 5 mm² Metal passthru 5 mm² Metal passthru 5 mm² Metal passthru 5 mm² 35 mm² Metal Passthru Part number: DPN Key/index BOM Metal passthru 35 mm² Metal passthru 35 mm² Metal passthru 35 mm² Metal passthru 35 mm² Metal passthru 35 mm² Metal passthru 35 mm² 50 mm² Metal Passthru Part number: DPN Key/index BOM Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² Metal passthru 50 mm² High voltage panel mount system One way sealed and shielded Ring terminal bolted to device Cable range: 5 to 50 mm Six to eight keys/indexes depending on wire sections Very compact dimensions 5 mm² Accessories mm² Seal retainer mm² Seal O-ring seal mm² Ferrule 35 mm² Accessories mm² Seal retainer mm² Seal O-ring seal mm² Ferrule 50 mm² Accessories mm² Seal retainer mm² Seal O-ring seal mm² Ferrule

18 SELECTOR GUIDE, 4 and 48 Volt Solutions Image Page number Temperature / Vibration Class Shielding Amperage Voltage # Ways / orientation Sections Power Pack 000 way male inline Power Pack 000 way header High current module mates Power Pack 000 way female right angle Electrical center mate Power Pack 000 way female 9- Front Wall/Sheet metal Power Pass-thru Power Pack 000 way male inline Power Pack 000 way female inline Class 3/ Class No 45A at 85 C 48V to ways / 90 & 80 8 to 5 mm² Electric Power Steering High Current inline Male terminal Power Pack 000 Female terminal Power Pack 000

19 Rev Power Pack 000 Way Inline Connectors, 4 AND 48 Volt Solutions High current wiring harness inline Performance Current capacity: 45A at 85 C Voltage: 48V Temperature range: -40 C to +5 C IP Rating: IP67, IP6K9K Sealed connection system Silver-plated, multi-contact terminal system Cable range: 8 mm to 5 mm One key/index Capable of additional indexes Male connector Part number: Power Pack 000 male in-line connector Male terminal Part number: PP000 Male Silver Terminal 8-0 mm PP000 Male Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²) Mating Part number: Power Pack 000 female in-line connector Female terminal Part number: PP000 Female Silver Terminal 8-0 mm PP000 Female Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²) 9

20 Rev Power Pack 000 Way Device Connectors, 4 AND 48 Volt Solutions Header connector Part number: Straight exit High current device applications Sealed pass-through panel mount system Performance Current capacity: 45A at 85 C Voltage: 48V Temperature range: -40 C to +5 C IP Rating: IP67, IP6K9K Power Pack 000 male header connector Straight exit PP000 Male Silver Terminal 8-0 mm PP000 Male Silver Terminal 9-5 mm Header connector Part number: Right angle exit 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: 8 mm to 5 mm Mating Part number: Straight exit Power Pack 000 female straight exit PP000 Female Straight Silver Terminal 8-0 mm PP000 Female Straight Silver Terminal 9-5 mm Mating Part number: Right angle exit Power Pack 000 male header connector Right angle exit PP000 Male Silver Terminal 8-0 mm PP000 Male Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²) Power Pack 000 female right angle exit PP000 Female Right angle Silver Terminal 8-0 mm PP000 Female Right angle Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²)

21 Rev Power Pack 000 Way inline Connectors, 4 AND 48 Volt Solutions High current wiring harness inline Performance Current capacity: 45A at 85 C Voltage: 48V Temperature range: -40 C to +5 C IP Rating: IP67, IP6K9K Sealed connection system Female connection accepts both straight and right angle connectors Silver-plated, multi-contact terminal system Cable range: 8 mm to 5 mm One key/index Male connector Part number: Power Pack 000 male header connector Straight exit PP000 Male Silver Terminal 8-0 mm PP000 Male Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²) Mating Part number: Power Pack 000 female straight exit PP000 Female Straight Silver Terminal 8-0 mm PP000 Female Straight Silver Terminal 9-5 mm Cable seal: Cable seal PP dia cable (gray) (8-0mm²) Cable seal PP dia cable (blue) (9-5mm²) Cable seal retainer: Cable seal retainer PP000 (8-0mm²) Cable seal retainer PP000 (9-5mm²)

22 SELECTOR GUIDE Charging Solutions Image Page number Design Life Phase Amperage Voltage Wire Sections/ Cable length 3 Plug-in hybrid and electric vehicle AC charge inlet (Male) SAE J77, Type I Vehicle Charging Inlet 0,000 + Mating cycles Phase 5A 30A 0V 40V to 5 mm² 4 Plug-in hybrid and electric vehicle AC charge inlet (Male IEC696 type II Vehicle Charging Inlet 0,000 + Mating cycles Phase 3 Phase 6A 63A 30V 480V.5 to 6 mm² 5 Cable assemblies for integration into charging stations (female) Type (NA) Type (EMEA) GBT (China) Charge Coupler Connector Pigtails 0,000 + Mating cycles Phase Phase & 3 Phase Phase & 3 Phase 6A 8A 0A 5A 3A 0V 480V 6.5m 7m 5m 7.6m 7.6m & 5m 6 Charging between Vehicle and Charge Station Type to Type Type to Type Type to Type 3 Charge Coupler Connector Mode 3 Jumpers 0,000 + Mating cycles 3 Phase Phase Phase Phase 0A (T-T) 3A (T-T) 0A (T-T) 3A (T-T) 0A (T-T3) 0V - 40V 6.5m 6m 6m 6m 7 Portable Electric Vehicle Supply Equipment (EVSE) for electric vehicle charging (female) Charge Coupler Connector mode assembly (with ICCB) 0,000 + Mating cycles Phase 8A - 0A 0V-40V 5m Security Classification

23 Rev Charge Inlet Level & Vehicle Charging Inlet AUXILLARY MODULES Plug-in hybrid and electric vehicle charge inlet Performance Supports: AC Level (5A, 0V) and AC Level (30A, 40V) Voltage: 600V maximum rating Temperature range: -40 C to +85 C Validation: UL recognized, Delphi GTP Electrical protection: IPXB Design life: 0,000 mating cycles Interface complies with SAE J77 and IEC696 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 Part number: Grommet: TPA Cover opens left Grommet wire protection Terminals DPN AWG Gauge Wire section mm² BOM mm pin 8 GA ( mm ) 0.75 mm² mm pin 4 GA (-.5 mm ).5 mm mm pin 0 GA (5 mm ) 5 mm mm pin 4 GA (-.5 mm ).5 mm mm pin 0 GA (5 mm ) 5 mm TPA 3

24 Rev Charge Inlet Type II Vehicle Charging Inlet AUXILLARY MODULES 4 Part number: Grommet: TPA Plug-in hybrid and electric vehicle charge inlet Performance Supports single-phase or three-phase power supply Supports: (6A, 30V) and (63A, 400V) Voltage: 400V maximum rating Temperature range: -40 C to +50 C Electrical protection: IPXB Sealing protection: IP44 (connector/inlet mated) Design life: 0,000+ mating cycles Inlet sub-assy - INLET Type II Right open cover, Left wire exit Rear Cover, Left wire exit Rear grommet tube DPN MPN BOM F5040 TPA Screw Inlet sub-assy - INLET Type II Left open cover, Right wire exit Rear Cover,Right wire exit DPN MPN BOM F0800 Screw 3 Thermo sensor DPN MPN BOM F37340 Thermo sensor set (see note) Interface complies with IEC696 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 Terminals for 6A version (-ph) DPN MPN Designation Wire BOM section (-phase) NA Male terminal 6mm diameter with cap Ag - N & L.5 mm² F6340 Male terminal 6mm diameter w/o cap Ni - PE.5 mm² F8340 Male terminal 3mm diameter - 3mm length - CP 0.5 mm² F7340 Male terminal 3mm diameter - 5mm length - PP 0.5 mm² Terminals for 3A version (-ph or 3-ph)* DPN MPN Designation Terminals for 63A version (-ph or 3-ph)* Wire section BOM (-phase) BOM (3-phase) NA Male terminal 6mm diam with cap Ag - N,L,L & L3 6 mm² NA Male terminal 6mm diam w/o cap Ag - PE 6 mm² F8340 Male terminal 3mm diameter - 3mm length -CP 0.5 mm² F7340 Male terminal 3mm diameter - 5mm length - PP 0.5 mm² DPN MPN Designation Wire BOM BOM section (-phase) (3-phase) NA Male terminal 6mm diam with cap Ag - L,L,L3,N 6 mm² 3 or NA Male terminal 6mm diameter with cap Ag - N 4 mm² or NA Male terminal 6mm diameter w/o cap Ag - PE 6 mm² F8340 Male terminal 3mm diameter - 3mm length -CP 0.5 mm² F7340 Male terminal 3mm diameter - 5mm length - PP 0.5 mm² * Compulsory usage of thermo sensor set

25 Rev Charge Coupler Connector Pigtails AUXILLARY MODULES Cable assemblies for integration into charging stations or portable cordsets per customer requirements Performance Current capacity: 5A to 3A Voltage range: 0V to 480V Temperature range: -40 C to +50 C Validation: See part number information SAE J77/IEC696 Type I, IEC696 Type II,and GB/T 034 compliant connections Wiring crimps sealed from environment Rubber overmold and plastic grip options available cable length Manufacturing DPN MPN Type (veh / wall) Current # phase Design Cable sections Certification (m/ft) plant NA Type / SAE J77 8 A -phase Plastic handle 7.0/3 3G AWG UL Warren, USA NA Type / SAE J77 5 A -phase Plastic handle 7.6/5 3G AWG UL Warren, USA NA Type / SAE J77 3 A -phase Plastic handle 7.6/5 3G AWG UL Warren, USA NA Type 0A -phase Rubber overmold 5.0 / G CE Tatabanya, Hu NA Type 0A -phase Rubber overmold 5.0 / G CE Tatabanya, Hu NA Type 0A 3-phase Rubber overmold 5.0 / G CE Tatabanya, Hu NA Type 3A 3-phase Rubber overmold 5.0 / G6+0.5 CE Tatabanya, Hu F3330 Type 6A -phase Plastic handle 6.5 /.3 3G CE Tatabanya, Hu NA GBT 0A -phase Rubber overmold 5.0 / G CCC & CQC Tatabanya, Hu Type cap Tatabanya, Hu Type cap Tatabanya, Hu GBT cap Tatabanya, Hu 5

26 Rev Charge Plug Mode 3 Jumpers AUXILLARY MODULES Portable Electric Vehicle Supply Equipment (EVSE) for electric vehicle charging Available options 0V/A 40V/0A,3A, or 6A SAE J77/IEC696 Type I, IEC696 Type II, and GB/T 034 vehicle interface Grid cord as required by country of use Call for additional configurations 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 marking Part numbers: Part number Type (veh / wall) Current # phase Design cable length Manufacturing Cable sections Marking (m/ft) plant Jumper T -T 0A 3-phase All plastic grip 6.5 /.3 5G CE Tatabanya, Hu Jumper T -T 3A 3-phase All plastic grip 4.0 / 3. 5G CE Tatabanya, Hu Jumper T -T 3A 3-phase All plastic grip 6.5 /.3 5G CE Tatabanya, Hu Jumper T -T 0A -phase All plastic grip 6.0 / G CE Tatabanya, Hu Jumper T -T 3A -phase All plastic grip 6.0 / G CE Tatabanya, Hu Jumper T T3 0A -phase All plastic grip 6.0 / G CE Tatabanya, Hu 6

27 Rev Charge plug mode assembly (with ICCB) AUXILLARY MODULES Portable Electric Vehicle Supply Equipment (EVSE) for electric vehicle charging Available options 0V/A 40V/0A,3A, or 6A SAE J77/IEC696 Type I, IEC696 Type II, and GB/T 034 vehicle interface Grid cord as required by country of use Call for additional configurations 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 marking Part numbers: Part number Type (veh / wall) Current # phase Design cable length Manufacturing Countries Marking (m/ft) plant Type 0A -phase Soft grip 5.0 / 6.40 Europe CE Tatabanya, Hu Type 0A -phase Soft grip 5.0 / 6.40 UK, Ireland, Cyprus, Malta CE Tatabanya, Hu Type 8A -phase Soft grip 5.0 / 6.40 Denmark CE Tatabanya, Hu Type 8A -phase Soft grip 5.0 / 6.40 Switzerland CE Tatabanya, Hu Type 0A -phase Soft grip 5.0 / 6.40 Norway CE Tatabanya, Hu 7

28 Rev Dimensions Shown in millimeters. Shield-Pack HV80 Piece Header with Pluggable Inner Connector APEX HV80 way Connection System with HVIL 8

29 Rev Dimensions Shown in millimeters. AK Class Way pass through HVIL (+way), Way with shunted HVIL, 3 Way On-Board Charger Connector Level / Level 6 way Device Connection System 9

30 Rev Dimensions Shown in millimeters. RCS800 High Voltage Way Connection System with HVIL RCS890 High Voltage Way Right Angle Connection System with HVIL 30

31 Rev Dimensions Shown in millimeters. AK Class 4 way Connection System with HVIL Metal passthru way Panel Mount System 3

32 Rev Dimensions Shown in millimeters. AK passthru High Voltage, & 3 way Panel Mount System 3

33 Rev Dimensions Shown in millimeters. Power Pack 000 Way Inline Connectors Power Pack 000 Way Device and Pass-Throught Connectors 33

34 Rev Dimensions Shown in millimeters. Charge Inlet Type II Vehicle Charging Inlet Charge Inlet Level & Vehicle Charging Inlet 34

35 Products presentation Rev Dimensions Shown in millimeters. Charge Coupler Connector Pigtails 35

36 Rev Dimensions Shown in millimeters. Charge Plug Mode 3 Jumpers 36

37 Rev Notes

38 Rev Contact Information Asia Pacific Regional Operations 60 Yuanguo Road Anting, Jiading District Shanghai, 084 China Tel: (86) Fax: (86) North America Customer Center 575 Delphi Drive Troy, Michigan USA Tel: () Fax: () Europe Regional Operations Customer Technology Center Delphiplatz 49 Wuppertal, Germany Tel: (49) Fax: (49) South America Regional Operations Delphi Automotive Systems do Brasil Ltda. Rod. dos Tamoios, Km,8 Jambeiro, São Paulo Brazil Tel: (55) Fax: (55) Delphi reserves the right to improve, enhance and modify the design specifications and construction of Delphi products without prior notification. For additional product and engineering information visit our website at