WIXLIB

Packard Electrical/Electronic ArchitectureHybrid & Electric Vehicle PortfolioConnection Systems, Electrical Centers,Wiring Assemblies and Charging Solutions

Delphi’s extensiveHEV/EV product portfolioHybrid and electric vehicles present unique challengeswhen it comes to electrical/electronic (E/E) architecture.They demand performance requirements including shieldingto protect against electromagnetic interference, sealing toprevent short circuits and arcing, and the incorporationof a hazardous voltage interlock loop, or HVIL. To helpkeep drivers and service technicians safe in high-voltageenvironments, a number of complex factors in the electricalsystem must be addressed and engineered for reliability andpeak performance.Power Pack UnshieldedHigh-CurrentConnection SystemsShield-Pack HighPower ConnectionSystemsDelphi’s extensive HEV/EV product portfolio offers a completerange of E/E architecture systems and components for everyhigh-power, high-voltage application, whether off-the-shelfor customized. Delphi has E/E architecture technologiesspecific for battery-powered transportation, including harnessprotection systems such as bent aluminum tubes or moldedchannels, battery monitoring devices, plug-in charging,and a new series of connection systems that incorporatethe shielding, sealing, and high-voltage safety interconnectsrequired for high-voltage/high-power applications.Delphi’s vast systems knowledge, innovative automotivecomponent design and integration skills helps reduce costs,provide peak performance and offer a robust portfolio ofhybrid and electric vehicle components and systems.We are where you need us to beDelphi has a strong global engineering team with GlobalHybrid Development Centers dedicated to Electrical/ElectronicArchitecture in Champion, OH USA, Wuppertal, Germanyand Shanghai, China. Our exclusive Velocity Tool Suite ofproprietary analysis, design and simulation tools allow us tolook at all the options, seamlessly import customer data, andspeed development through virtual testing and validation,wherever we are around the globe.We have custom, optimized E/E architecture solutions thatoffer significant benefits for today’s hybrid and electricvehicles, including: 2Greater functionalityReduced mass and packaging spaceCost savingsImproved reliabilityEnvironmental friendlinessHigh-Voltage ElectricalCentersconnectors.delphi.comApplication SpecificHigh-Power Products

Shield-Pack SeriesTable of ContentsHybrid & Electric Vehicle Charging Systems& Components . . . . . . . . . . . . . . . . . . 35High-Voltage Battery Systems. . . . . . . . . . . 39High-Voltage Electrical Centers . . . . . . . . . . . . 43High-Voltage Wiring Assemblies . . . . . . . . . . 45At Delphi, we recognize the importance of vehiclemanufacturers offering more comfort, more efficiency, morefuel economy and more environmentally friendly cars andtrucks accessible to more consumers. We believe in workingtogether to create the most value for our customers. Oursystems knowledge, innovative automotive componentdesign and integration skills extend through our entireorganization. This helps us reduce costs, provide peakperformance and offer a robust portfolio of hybrid andelectric vehicle components and systems including:Charging SystemsEnergy Storage SystemsThermal SystemsConnection SystemsPower ElectronicsService SolutionsElectrical CentersPowertrain SystemsWiring AssembliesHV Electrical Centers For more information, visit www.delphi.com/hybridElectric VehicleCharging Systems &ComponentsPart numbers, specifications, dimensions and performance data in this catalog are for general reference only andare subject to change without notice. To verify product information, please contact a Delphi representative.connectors.delphi.com3HV Wiring AssembliesHigh-VoltageBattery SystemsApplication SpecificApplication Specific High-Power Products. . . . . . 25High-Voltage WiringAssembliesEV Charging SystemsPower Pack Unshielded High-CurrentConnection Systems . . . . . . . . . . . . . . . . 19HV Battery SystemsDelphi Shield-Pack High-PowerConnection Systems . . . . . . . . . . . . . . . . . . 5Power Pack SeriesDelphi Shield-Pack Application Guideline . . . . . . 4

Delphi Shield-Pack Application GuidelineDeviceI/O DetailGeneralDelphi PortfolioSpecificationBatteryPack2W 250A; 600 VDC ShieldedMain Power OutputHigh-Current Charge InputShield-Pack HV20002W 200A; 600 VDC ShieldedCharger Input2W 40A; 600 VDC ShieldedDC/DC Converter Output2W 40A; 600 VDC ShieldedHV Contactor CenterCustomer SpecificDelphi Contactor CenterManual Service Disconnect 225A; 600 VDCDelphi MSDDC Input2W 250A; 600 VDC ShieldedShield-Pack HV20003W 145A; 600 VAC ShieldedShield-Pack HV1000 250A 600; VAC ShieldedHigh-Voltage Pass-ThroughDC/DCConverterDC Input2W 40A; 600 VDC ShieldedShield-Pack HV28014V Output1W Filtered/1W Unfiltered 200ADelphi 14V Filtered OutputAC Input3W 40A; 240 VAC UnshieldedHV150; On-Board ChargerDC Output2W 40A; 600 VDC ShieldedShield-Pack HV2803W 145A; 600 VAC ShieldedShield-Pack HV1000 250A; 600 VAC ShieldedHigh-Voltage Pass-ThroughShield-Pack HV280InverterAC OutputOn-BoardChargerElectricMotorAC InputAccessoriesElectric Air ConditioningElectric Heater2W 40A; 600 VDC ShieldedShield-Pack HV280Electric Power SteeringElectric Coolant ControlVehicleLevel 1, Level 2 30A; 120VAC, 240 VACChargingDelphi Charging Cordset, InletsPart 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.4connectors.delphi.com

Shield-Pack SeriesDelphi Shield-Pack High-Power ConnectionSystemsDelphi Shield-Pack connection systems have beenspecifically designed for high-voltage applications usedon hybrid and electric vehicles. They provide powerterminal isolation for 600V applications, finger proof/touch safe protection, and HVIL circuit integrationinto the connection system design. The Shield-Pack family comes in three series to cover high-voltageapplications up to 250 amps. The HV280 series issuitable for applications up to 40 amps, HV1000 up to145 amps, and HV2000 up to 250 amps. The DelphiShield-Pack family provides customers with one of thelargest globally available connection systems portfoliosfor HEV/EV system optimization.Special attention is required for high-voltage connectionsystems. All applications of Delphi Shield-PackTM seriesshould be discussed with Delphi to ensure properapplication of the connection system. Please consult Delphifor technical support.connectors.delphi.com5

Shield-Pack SeriesShield-Pack HV280With Internal HVIL Header13824830ApplicationHigh-voltage accessories connection system13824784Description Sealed connection system Panel mount to device with face seal Internal HVIL (shunt on harness connector) Two-stage locking system for HVIL time delay Two HV power circuits (2.8mm terminal) Flange size: 39mm x 39mm Finger proof/touch safe Cable range: 2mm2 to 5mm2 power circuit; 0.5mm2 HVIL circuit Three keys/indexesPerformance Current capacity: 40A continuous at 85 C Voltage: 600V Temperature range: -40 C to 125 C Sealing protection: IP67, IP6K9K Electrical protection: IP2XBPart Number InformationKey/IndexHeader ConnectorMating InformationMating Device DetailHV 138301721383717413830160Part 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.6connectors.delphi.com

Shield-Pack SeriesShield-Pack HV280HVIL Shunt in Header, Face Seal to Device13829178ApplicationHigh-voltage accessories connection system13861584 (13737728)*Description Sealed connection system Panel mount to device with face seal Two HV power circuits (2.8mm terminal) HVIL shunted-in header with five-second time delay Flange size: 43mm x 49mm Finger proof/touch safe Cable range: 2mm2 to 5mm2 power circuit; 0.5mm2 HVIL circuit Three keys/indexes13738743Performance Current capacity: 40A continuous at 85 C Voltage: 600V Temperature range: -40 C to 125 C Sealing protection: IP67, IP6K9K Electrical protection: IP2XBPart Number InformationKey/IndexHeader ConnectorMating InformationMating Device DetailHV ConnectorHVIL Connector1011382917813861584 (13737728)*137387431021382917913861585 (13737729)*137387441031382918013861586 (13766034)*1376624113834720*Part numbers in parentheses to be replaced in 2011. Contact Delphi for details.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.connectors.delphi.com7

Shield-Pack SeriesShield-Pack HV280HVIL Shunt in Header, Bore Seal to Device13830674ApplicationHigh-voltage accessories connection system13861584 (13737728)*Description Sealed connection system Sealed to device case through bore seal Two HV power circuits (2.8mm terminal) HVIL shunted-in header with five-second time delay Flange size: 43mm x 49mm Finger proof/touch safe Cable range: 2mm2 to 5mm2 power circuit; 0.5mm2 HVIL circuit Three keys/indexes13738743Performance Current capacity: 40A continuous at 85 C Voltage: 600V Temperature range: -40 C to 125 C Sealing protection: IP67, IP6K9K Electrical protection: IP2XBPart Number InformationKey/IndexHeader ConnectorMating Device ing InformationHV ConnectorHVIL Connector13861584 (13737728)*1373874313861585 (13737729)*1373874413861586 (13766034)*13766241*Part numbers in parentheses to be replaced in 2011. Contact Delphi for details.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.8connectors.delphi.com

Shield-Pack SeriesShield-Pack HV2802 Way Connection System Without HVIL13743443Application High-voltage accessories connection system when no HVIL is requiredDescription13861584 (13737728)* Sealed to device case Two HV power circuits (2.8mm terminal) Finger proof/touch safe Cable range: 2mm2 to 5mm2 power circuit One key/indexPerformance Current capacity: 40A continuous at 85 C Voltage: 600V Temperature range: -40 C to 125 C Sealing protection: IP67, IP6K9K Electrical protection: IP2XBPart Number InformationMating InformationKey/IndexHeader ConnectorMating Device Detail1011374344313849778HV Connector13861584 (13737728)**Part numbers in parentheses to be replaced in 2011. Contact Delphi for details.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.connectors.delphi.com9