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Terminal Sizes

CTIS # 29956

Prepared By John Yurtin

Updated 4-25-2005

Connection Systems Training

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The first step in supporting the customer is to clearly know your product. Understanding the reasons for all the different terminal sizes is absolutely necessary to choose the right terminal for any application

This training should help you understand the different terminals we produce, why they exist and how to choose the right product.

Excellence

Focus: Your customer

Method: Innovation and continuous improvement

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“Hello!

Welcome to this terminal systems training

session!

Understanding all the different terminal

systems we produce today is a big challenge. I hope

this session will give you a better knowledge of Delphi’s

various connections.

I plan time for questions at the end of the session,

however, please feel free to ask questions at any time.”

John Yurtin

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Thermo Nalius Ringus

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1946 Chevrolet Wire Harness

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Over 2400 TerminalsOver 2400 TerminalsOver 2400 TerminalsOver 2400 Terminals

Today’s “High End” Vehicle Wiring

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500 to 2400 Terminals / Vehicle

“Over 126 Billion Terminals / Year”

Over 63 Million Vehicles / Year

Automotive Connections “101”

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7,200,000 7,200,000 TerminalsTerminals

2 Hours of Delphi Production

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Pack-Con I

Pack Con II & IV

56 Series

58 Series

59 Series

Com Pack I, II, & III

Edge board (Fork, ECM & Bow Types)

188 Series (4.7mm)

Twin Lock

ACT Series

ES-Kontakt

0.64mm Buchsenkontakt

Pin Grip

Weather-Pack

Metri-Pack 150 - 630

Micro-Pack 100 & 100W

Ducon

Micro-Pack 064

Ring/Spade

Micro-Timer

DS Series

DFK Series

HVF & HVF II

VF Series

SF Series

Faston

AF Series

Pack Con III & IV

Edge board (Pack-Con Types)

Micro 64

Micro HVT (unsealed)

GT

800 Maxi

ATS

MTS 064

DSQ

2.8 BTS

090 II Series

070 Series

040 III Series

250 Series

W Series

Power-Pack

DHD Heavy Duty

ZRT

BFC 1.8

YESC

187 Series

Micro 050 Series (Toyota)

GT 1.5, 2.8 & 6.3 with FBT

Flex-Pack 0.64, 1.2, 1.5 & 2.8

2.8 & 6.3 PCB

1.5 & 2.8 ETS

1.2 Optima

0.64 MTSB

Micro HVT 1.2

090 II with FBT

1mm Deutsch Replacement

.5 mm Blade-on-Beam

.8 mm Blade-on-Beam

6mm vane - Motorola

Develop Introduce and Grow Maintain Exit

Terminal Systems Portfolio

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How many terminal types do we need?

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• Electrical Requirements

Power / Signal / Voltage / Current….

• Mechanical Requirements

• Environmental Requirements

• Mating Devices

• Standards

National / International / OEM / Organization……

• Preferences

Pin / Blade / One Piece / Two Piece…

Materials and plating…

• And Every Combination of These

As many as it takes!!

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Metri-Pack Terminal Proliferation

150, 280,480,630,800 M&F 10

Various Crimp Configurations 50

Sealed and Unsealed 100

Add 150 Pull-To Seat versions 160

280 Slotted Pull to seats 169

Design Variations (e.g. Nose Guards) 287

Material Options 565

Plating Options 680

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Blade / Pin Standards

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ISO Standards

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USCAR Standards

The USCAR organization has standardized on 4 terminal sizes:

– 0.64 X 0.64– 1.5 X 0.8– 2.8 X 0.8– 6.3 X 0.8

USCAR also specifies the material and plating requirements.

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SAE Standards

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Terminal Sizes (slide 1 of 3)

0.50 0.64 0.8 1.0 1.2 1.5 1.8Micro 050 Toyota

Micro-Pack .64

Micro-Pack 100W

150Metri-Pack 070 Series

.5 Ducon .64 Ducon .8 Ducon Micro-Pack 100

1.5 Ducon BFC 1.8

Micro 64 040 III 150 GT

Micro HVT Micro HVT Micro HVT Micro HVT DSQ 1.5

.5mm Blade-on-Beam

.8mm Blade-on-Beam

Optima 150 GT (FBT)

MTS/MTSB 1mm P&S BTS 1.5

Buchsen-kontakt

CTS 1.2 CTS 1.5

.64 Kaizan Replacement

1.5 ZRT

.64 Flex-Pack 1.2 Flex-Pack 1.5 Flex-Pack

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2.0 2.3 2.8 3.0 3.75 4.8 5.2Weather-Pack 090 II Series 280 Metri-Pack Pack-Con I 187 Series Pack-Con II

090 II (FBT) DS Series 188 Series

DSQ Series 188 Pack-Con

ZRT 2.8 480 Metri-Pack

HVF Series 4.8 Ducon

2.8 Ducon

2.8 Flex-Pack

280 GT

280 GT (FBT)

ATS

2.8 BTS

2.8 CTS

Terminal Sizes (slide 2 of 3)

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5.7 6.3 8.0 9.5 15 20Pack-Con III,

IV & V56 Series 59 Series 9.5 Ducon Power Pack

1500 SeriesPower Pack 2000 Series

58 Series 800 Maxi

SF Series Maxi-Fuse

630 Metri-Pack

800 Metri-Pack

6.3 Ducon

630 GT

630 GT (FBT)

VF Series

Terminal Sizes (slide 3 of 3)

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0.50 Ducon

0.5 mm Terminals

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Micro-Pack 0.64

MTS

MTS B

Buchsenkontakt

Micro-64

Micro HVT

0.64 mm Terminals

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Ducon 0.8 Micro HVT

0.8 mm Terminals

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040-III

Micro-Pack 100

Micro-Pack 100W

Micro HVT

1.0 mm Terminals

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CTS 1.5BTS 1.5

DSQ 1.5

Micro HVT

1.2 mm Terminals

Optima 1.2

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CTS 1.5BTS 1.5

DSQ 1.5

Ducon 1.5150 GTMetri-Pack 150

1.5 mm Terminals

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1.8 mm Terminals

BFC 1.8

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090-II

2.3 mm Terminals

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DSQ 2.8

ATS 2.8

Ducon 2.8Metri-Pack 280

280 GT

DS Series

VF 2.8

2.8 mm Terminals

BTS2.8

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Ducon 4.8187 Series480 Metri-Pack

4.8 mm Terminals

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56 Series

VF SeriesDucon 6.3SF Contact

630 Metri-Pack58 Series

6.3 mm Terminals

GT

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59 Series Maxi Fuse800 Metri-Pack

8.0 mm Terminals

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Ducon 9.5

9.5 mm Terminals

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15 mmPower-Pack

20 mmPower-Pack

15 & 20 mm Terminals

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One-Piece, Tangless, Non-Oriented Terminal

Square Peg in a Round HoleMinimum 3 point contact is maintained

in all terminal orientations by design

Internal contact arms are protected by outer barrelTerminal-to-connector locking accomplished on outer barrelNon-oriented design facilitates harness manufacture

Mating Pin• USCAR or ISO Standard 0.64mm

Square or 0.8mm Round

Production Crimp• Mechanically and electrically

validated• 0.35mm²/0.50mm² and 0.80mm²

2 Moving Contacts

Stationary Contact

Female Terminal• 0.007” thick, CDA 425 hard

•Palladium/gold flash electroplate

Micro-64 Terminal SystemMicro-64 Terminal SystemMicro-64 Terminal SystemMicro-64 Terminal System

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Application

•FFC/FPC Connection•Device Connection

Features

•Two piece female terminal design•Mating part: 0.64 x 0.64 male terminal•FPC Crimp •MQS (Tyco) cavity compatible

Target Customers•OPEL, VOLVO, PSA,FIAT, RENAULT, TIER 1

Expected Volumes per Year•SOP: August 2001•2002 5 Mio. parts •2003 20 Mio. parts•2004 20 Mio. parts

Stage of Development•Parts available and validated

MMicro icro TTerminal erminal SSystem 0.64ystem 0.64MMicro icro TTerminal erminal SSystem 0.64ystem 0.64

MTS 0.64

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Application

•Inline Connection

Features

•Three piece male terminal design•Mating part: 0.64 x 0.64 female terminal•Unsealed •MQS (Tyco) cavity compatible

Target Customers•OPEL, VOLVO, DC, FIAT, RENAUT, PSA, TIER 1

Expected Volumes per Year•SOP: Oct. 2002•2003 40 Mio. parts •2004 80 Mio. parts•2005 80 Mio. parts

Stage of Development

•Tooling in process

MMicro icro TTerminal erminal SSystem 0.64ystem 0.64MMicro icro TTerminal erminal SSystem 0.64ystem 0.64

MTS 0.64

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Application

•Engine Compartment Connection•Device Connection

Features

•Two piece female terminal design•Mating part: 0.64 x 0.64 male terminal•Clean body for blocksealing systems

Target Customers•OPEL, FIAT, VOLVO, PSA, RENAULT, VW, DC

Expected Volumes per Year•SOP Oct. 2002•2003 120 Mio. parts •2004 200 Mio. parts•2005 200 Mio. parts

Stage of Development

•Prototypes available

MMicro icro TTerminal erminal SSystem Blockseal 0.64ystem Blockseal 0.64MMicro icro TTerminal erminal SSystem Blockseal 0.64ystem Blockseal 0.64

MTS 0.64 B

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Application

•In-Lines and Device Connection•2.54 mm Centerlines

Features

•One piece terminal designs•Female terminal mates to:

0.64 x 0.64 male terminal0.80 x 0.64 male terminal1.00 x 0.64 male terminal1.20 x 0.64 male terminal

Target Customers•First Application GMT201 Headlamp Conn

•Stage of Development•Female in Production•Male terminal in development (1.0 x 0.64)•Validation Complete to USCAR

HVT Unsealed Female

HVT Unsealed Male

Micro HVT 1.2 mm

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Application

•Engine Compartment Connection•In-Line & Device Connection

Features

•One piece terminal designs•Female terminal mates to:

0.64 x 0.64 male terminal0.80 x 0.64 male terminal1.00 x 0.64 male terminal1.20 x 0.64 male terminal

•Clean body for blocksealing systems•Cavity compatable with Kostal MLK 1.2

Target Customers•First application Daimler Chrysler ECM

Stage of Development

•Production Tooling Near Completion

HHighigh V Valuealue T Terminal erminal SSystem (Sealed)ystem (Sealed)HHighigh V Valuealue T Terminal erminal SSystem (Sealed)ystem (Sealed)

HVT Sealed Female

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Closed Box TerminalContact gap is optimized for 0.64 mm thick blade,

but mates to a 0.8 mm thick blade (devices)

Secondary Contact Support Supports the primary contact, giving the

advantages of a two-piece terminal in a one-piece design

Tangless DesignIn conformance with SAE/USCAR

design guidelines

-40°C to 125°C operating range (USCAR Class III)155°C terminal exists for high temp applications (Class IV)

Indexing Tab

Approximately 10.4 billion 150 GT terminals with this interface are currently in service

GT Standard Terminal System 1.5GT Standard Terminal System 1.5GT Standard Terminal System 1.5GT Standard Terminal System 1.5

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Closed Box TerminalContact gap is optimized for 0.8 mm thick blade on USCAR-standard devices

Tangless DesignSame basic geometry as thestandard GT female terminal

Indexing TabUnique from that on standard GT female terminal- Terminal will not plug to a connector designed for standard female terminal

This interface geometry has been in production since MY02– Used on GMT360/370

» 40 places – BEC to BCM flex circuit jumper

GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5GT USCAR Device Terminal System 1.5

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Flex-Pack Connection System Proposal

– New low cost connection system that performs to USCAR and Toyota 1000G requirements

Goal– Reduce connection system cost by 15% to 20% from current systems cost.

– Offer innovation- closer centerlines with larger cable, high terminal retention forces with one piece plastic, optimize normal force on contacts while maintaining engage force requirements, mating blade lead-in.

Flex Beam Cavity

Develop Flex-Pack 0.64 Terminal

Develop Flex-Pack 1.2 Terminal

Develop Flex-Pack 1.5 Terminal

Develop Flex-Pack 2.8 Terminal

For 4.8, 6.3, and 9.5, use existing GT/MP and Ducon. (low volumes)

Develop

Optimize

Modify existing GT 1.5 Terminal

Modify existing GT 2.8 Terminal

Modify existing GT 6.3 Terminal

Interim Step ADP

ADPPDP

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One piece female connector housing, NO spacer/PLR or secondary lock required (tangless terminal system)

Superior terminal to connector retention

– No flexible lock features

Good tactile and audible plug: Inertia style plug

Tighter row to row packaging than typical tangless terminal systems- Works in Europe

Mating blade lead in integral to connector housingIntegrated Blade Lead In

Flex Beam (Spring)

Cantilever Lock(Flexible)

Flex Beam Technology

Typical Tangless Terminal Cavity Flex Beam Technology

Rigid Lock

PLR or SecondaryPiece

Blade Lead Inon PLR

Conn HousingConn Housing

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Flex Beam Technology

Marrying Product/Process Build Holder utilizes two ring out pins

– Terminal contacts pins 90° with respect to plugging direction

– One or two ring out pins can be used depending on build process

Ring Out PinsBuild Holder

Terminal to Pin contact 90° from axis of plug

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GT Terminal with Flex Beam Technology

GT 150 Terminal Redesign (first step)» Smoothing box to evaluate matt seal applications

» Wedge feature for added terminal retention

» Evaluating contact

280 and 630 ESD’s in design

Basic electrical contact remains same

Wedge Featureadded to increase terminal retention

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100% closed mating blade lead in integral to connector housing

Non-orienting terminal, symmetric

to blade

Plug through matte (block) seal

New double spring terminal contact

Roll out– 1.2, 1.5, 2.8, 6.3/8.0

– 0.64 being evaluated

Blade Lead In100% enclosed

Hold Down Beam

Terminal Lock

Flex Beam TechnologyNext Generation- Flex Pack

Built in Interferencebetween Terminal and Beam

Ring out pin cavities

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Integrated Blade Lead In

Hold Down Beam

Terminal Lock

Flex Beam Cavity – “Enhanced Cavity Design”

One piece female connector housing, NO spacer or secondary lock required

Superior terminal retention. Retention force averages above 120N’s (Toyota Spec: 100N min)

Packaging advantage–Adapts to European device footprint

Mating blade lead in integral to connector housing

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VF Series Terminals ( Vier Feder) Description

– Terminal System 1.5, 2.8, 6.3 (4.8) Series

– Sealed and unsealed available

– Brand Names

» DS (Double Spring)

» VF (Vier-Feder)

» HVF (Hochleistungs Vier-Feder)

» DSQ (Double Spring Quadlock)

» ATS (Active Terminal System)

– HVF available with FPC Crimp Value

– Cavity compatible with Industry standard connectors

– Good electrical and mechanical performance combination

– ATS with high vibration performance due to S-Spring element

– 1,5 Male Terminal is universally usable Status

– All Terminal Versions in production including several connector systems

– New connector developments in process

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Application

•Inline Connection•Device Connection

Features

•Two piece female terminal design•Mating part: 1.2/1.5 x 0.8 male terminal•Unsealed and Sealed•Cavity compatible to Tyco Micro-Timer

Target Customers•OPEL, FIAT

Status•In Production

DSQ 1.5

DSQ 1.5 (Double Spring Quadlock)

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Application

•Device Connection•Inline Connection

Features

•Two piece female terminal design•Mating part: 1,5 x 0.8 blade •Sealed and Unsealed•Sicma 2 & 3 (FCI) cavity compatible

Target Customers•PSA, Renault, FIAT

Stage of Development

•Tooling in process

BTS 1.5

BTS 1.5 (Block Seal Terminal System)

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Optima 1.2

Features:•2 Piece Terminal System•Blockseal /Unsealed and Single Wire•Cavity compatible to MLK & MCP•Centerline 2,54 mm, two rows•One Part for 2 Gap Sizes 0.6 & 0.8 mm

Version: 1.2 mm FemaleCustomer: AllApplication: StandardStatus: DevelopmentInnovation: Patent application

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BTS 2.8 (Block Seal Terminal System)

Features:•2 Piece Terminal System•Blockseal / Unsealed Terminal•Cavity compatible to FCI Sicma

Version: 2,8 mm, FemaleCustomer: PSA / RenaultStatus: Patent Filed

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BFC 1.8 Terminal

Application

• Inline Connections• 0.5mm2 - 2.5mm2 versions• Unsealed versions only

Features

• One piece female terminal design• Mating part: 1.8 x 0.8 male terminal

• Cavity Compatable with Tyco 070 Series Micro-Lock or Mini-MIC terminals

• (BFC is Portuguese for "Baixa Força de Conexão" (Low Engage Force).

Customers• Ford and Fiat

Status:

• In Production (Brazil)

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CTS 1.5 (Compact Terminal System)

Product Description

– 1,5 Terminal size, sealed and unsealed

– Successor of the Timer terminals

– Terminal is cavity compatible with QKK (VW) and MCP (rest of the world)

Value Proposition

– One terminal part number for mating tab 0,6 and 0,8 mm

– highest vibration performance and low insertion force based on 2 piece CTS terminal design

Status

– In Production

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Application

•Inline Connections

Features

•Two piece female terminal design•Mating part: 2.8 x 0.8/0.6 male terminal

•Support spring from the front•Spacer at the body terminal to define the gap size•Soft spring rate

Target Customers•All

Stage of Development

•Concept Only

CTS 2.8 (Compact Terminal System)

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Application

•Inline and Devices

Features

•Two piece female terminal design•1.) Mating part: 1.5 x 0.8 male terminal•2.) Mating part: 2.8 x 0.8 male terminal

• Cavity compatible to GT-System

Target Customers•European Customers

Expected Volumes per Year•SOP: tbd

Stage of Development

•Concept study in process

ETS 2.8

ETS 1.5 & 2.8 (European Terminal System)

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Application

•Inline Connection•Bus Electrical Centers (BEC)

Features

•Two piece female terminal design•Mating part: 2.8 x 0.8 male terminal•Unsealed•4-side-shoulder for secondary locking•Cavity Compatible with Tyco Junior Power Timer

Target Customers•OPEL

Status

•In Production

DSQ 2.8

DSQ 2.8 (Double Spring Quadlock)

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Application•Engine Compartment Device Connections•High Vibration Applications

Features•Two piece female terminal design•Mating part: 2.8 x 0.8 male terminal•Fretting Corrosion Resistant•Flewxible section between core crimp and body absorbs vibrations.•Sealed System

Target Customers•OPEL, FIAT

Status•ProductionATS S-Spring performance

ATS 2.8 (Active Terminal System)

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Application

•Terminal for Maxi Fuses•Unsealed terminal

Features

•Two piece female terminal design•Mating part: 8,0 x 0.8 fuse blade

Target Customers•VW, Audi

Stage of Development•Development on hold

Maxi Fuse 8.0

Maxi Fuse 8.0

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Features:

– One piece terminal system

– Soldering Terminal

PCB Terminals

Version: 2,8 and 6,3 mm

Customer: All

Application: IBEC

Stage of Development: Concept

Innovation status: Patent application

Availability of parts: No

PCB Terminals

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Ducon Series Terminals

Description– High performing terminal system

– Sealed and unsealed

– Blade sizes 0.64, 0.8, 1.5, 2.8, 4.8, 6.3, 9.5, and 9.5 HT

Status– In production since 1989

– Copied by Kostal SLK

– Plan to optimize the manufacturing process during 2005 for cost reduction

Value Proposition High electrical performance

High energy, high voltage capability

Excellent temperature and vibration

resistance

Robust two piece design

Multiple contact point technology

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– Silver Plated Copper Alloy

» 2 Piece Terminals

» Offers Low Electrical Resistivity and High Thermal Conductivity

» Uses “Vane” contacts

» Designed for straight or Right Angle Mating

Inline connection

Right angle connection

Power-Pack Terminals

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1500 Series

2000 Series

10 vane Insert

8 vane Insert

Power-Pack Terminals

– Passed Current Cycling

» 400A for 12s

» 200A for 12s

» 50A for 12s

» 20 Cycles

– Successfully used at 230A continuously