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Packed Up and Ready to Go

Delphi's Power Pack Connectors are among the industry's most comprehensive high-current/high-power connection systems.

As vehicle manufacturers seek new ways to meet the increasing demands placed on electrical systems, additional strain is placed on connection systems. Commercial vehicle manufacturers have the toughest task, as their connection systems have to meet increased electrical demand and also stand up to harsh operating conditions.

Delphi is helping its customers meet these challenges head on with its Power Pack Connectors. Consisting of the Power Pack 1000 and the Power Pack 2000, this extensive lineup of connection systems is an ideal option for direct mating of high-power, on-board devices and modules.

"Our versatile Power Pack portfolio offers an extremely broad range of current-carrying capabilities," said Don Bizon, Delphi Connection Systems product manager. "It also provides one of the widest cable ranges, a unique combination of sealed solutions, and both in-line and right-angle box-and-blade connections for easy mating."

Delphi Power Pack Connectors—1000 and 2000 product families

Delphi Power Pack's most unique feature is the ability to provide a sealed connection system that mates in the in-line or right-angle direction to provide original equipment manufacturers a routing advantage for large-gage cables. This mating direction is managed through the two-piece design of the female terminal. The female terminal has multiple contact points and uses beryllium copper with silver plating to manage the heat generated in high-current applications.

Amped up

One of the main reasons Delphi's patented Power Pack Connector portfolio is attracting attention is its high current-carrying capabilities: 145 amps for the Power Pack 1000 and 250 amps for the Power Pack 2000. But there are plenty of other reasons for taking a closer look. For example, their versatile terminal system allows Power Pack Connectors to mate in either in-line or right-angle directions, enabling easy routing of the large cables that are often found in high-current applications. And both feature a cable range capability equal to its robust current carrying capability: 6 mm² to 25 mm² for the Power Pack 1000 and 13 mm² to 62 mm² for the Power Pack 2000.

Both are designed for operating in temperatures ranging from -40°C to 150°C. And both are designed to resist vibration transmitted by large-gage cables. They are easily engaged and disengaged by hand, eliminating the need for tools, mechanical assists, and fasteners, and their indexed configurations prevent plugging misalignment during installation.

"Using Power Pack Connectors can also help manufacturers enhance plant efficiencies by eliminating labor steps associated with ring terminal systems," said Bizon.

Power Pack 1000 Portfolio

A—Terminal Position Assurance (TPA) provides extra strain relief for cables. TPA and seal cover a 6 mm² to 25 mm² cable range.

B—Connection systems feature sealed and isolated cavities, integrated Connector Position Assurance (CPA) and connector seal retainer. Pictured is the two-way in-line and two-way right-angle with flange mounted connection.

C—Terminal system can mate in the in-line or right-angle direction with a 6 mm² to 25 mm² cable range.

Note: The terminal contact is shown outside of the female terminal, but is only supplied as an assembly.

Power Pack 2000 Portfolio

A—Terminal Position Assurance (TPA) ensures seal and terminal are held in place. TPA and seal cover a 13 mm² to 62 mm² cable range.

B—Connection systems feature integrated Connector Position Assurance (CPA) and connector seal retainer. One-way female mates with panel mount or in-line male connection. One-way right-angle mates with panel mount header.

C—Terminal system can mate in the in-line or right-angle direction with a 13 mm² to 62 mm² cable range.
Note: The terminal contact is shown outside of the female terminal, but is only supplied as an assembly.

Sealing the deal

Commercial vehicles, particularly construction and agricultural equipment, operate in some of the harshest conditions imaginable. That can expose their electrical systems to materials that can compromise function, making sealed connections a must. Both the Power Pack 1000 and Power Pack 2000 are available in sealed versions, making them an ideal option for systems that will be subject to rugged use.

"The design criteria used throughout the development of the Power Pack Connector family address the rigorous power requirements and robust performance necessary in extreme in-vehicle environments," said Bizon. "The special needs of these markets require advanced connection systems technology capable of meeting diverse design criteria. The Power Pack series hits these targets with a highly reliable, cost-effective product that is well tailored for passenger car, hybrid, commercial and off-road vehicles as well as industrial applications."

And within that framework, the advanced characteristics of Delphi Power Pack Connectors make them ideal for a wide range of applications, noted Bizon.

"Their sealed-system configurations, along with their high-voltage, high-current capabilities make Power Pack strong candidates in applications such as sealed electrical centers, electric power steering modules, front wall power pass-through, battery cable in-line connections, and hybrid vehicle modules," he said.

As with all of Delphi's Electrical/Electronic (E/E) architecture products, the Power Pack Connectors are designed using proprietary design tools and software to create a virtual model of a vehicle's E/E architecture, including each connector, electrical center, electronic module, and wiring harness. Delphi engineers use this information to evaluate the impact of various tradeoffs to deliver a fully optimized E/E architecture system, backed by Delphi technical centers and manufacturing facilities in 31 countries.

For more information about Delphi's Power Pack Connectors, click here.