Automotive High Voltage Products

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Automotive High Voltage Products

  1. 1. RoHS Ready Alternative Power Systems (APS) for the Automotive Industry Components for Hybrid, Electric and Fuel Cell Technology
  2. 2. AU TO M OT I V E D I V I S I O N
  3. 3. T H E 5 A P P L I C AT I O N A R E A S I
  4. 4. I N N OVAT I V E TECHNOLOGIES Tyco Electronics Ltd. is a leading global provider of engineered electronic components, network solutions and undersea telecommunication systems. We design, manufacture and market products for customers in industries from automotive, appliance and aerospace and defense to telecommunications, computers and consumer electronics. The automotive division follows the globalization goals of our customers, speeds up the integration of new technologies and enables our customers access to our vast product portfolio and services. TERMINALS & CONNECTORS Tyco Electronics offers a broad range of high quality terminals and connectors. Our electrical/electronic interconnection products and solutions are used to electrically and mechanically join wires and cables, printed circuit boards, integrated circuit packages and batteries. Tyco Electronics expanding capabilities include new copper and fiber-optic connectors, wires, cables/cable management systems that are designed to meet automotive industry demands. Our brands encompass the broadest range of connectors in the world, including high-density, high-speed designs for leading-edge communications equipment. SENSORS Contact-less measuring eliminates interference effects, wear and tear, and provides increased reliability. Tyco Electronics, one of the largest technology providers for the automobile industry, offers contact-less sensors for a variety of applications. As sensor manufacturer and processing partner, Tyco Electronics also provides project planning support for new sensor applications, assistance in the selection of the appropriate sensor technology for the respective application, and assistance with defining the corresponding mechanical, electrical and magnetic interface. Tyco Electronics has a broad electro-mechanical portfolio that includes robust housing technologies, connector systems, and temperature stable designs based on foil and cable networks. This combi- nation of technologies and experience ensures that reliable and cost effective sensor solutions are available for all application types. II
  5. 5. C A B L E A S S E M B LY S Y S T E M S Tyco Electronics is your partner for special cable assemblies. We offer research and development capabilities, prototyping, samples as well as manufacturing facilities for special cable assemblies. This includes overmold technology, semi/fully automatic manufacturing, testing equipment and appliances for handling of high volume production. I N D U C T I V E SYST E M S The Automotive Division is your source for interconnection technologies for automotive, truck and off-highway OEMs and Tier 1 suppliers. With the design competency center in Oostkamp (Belgium), and strategic production centers in Evora (Portugal), Bangalore (India), Shuzhou (China), Oostkamp (Belgium), and others, Tyco Electronics’ Inductive Systems group is ready to offer you any coil module required in the automotive industry. The Inductive System group focus lies on the customer requirement, in order to design to the exact demand. This is achieved by highly technical, intelligent and cost-efficient engineering. In order to be a leader in design, Tyco Electronics’ Inductive Systems group has a vast product portfolio, which consists out of antennas, actuators, resolvers, and integrated coil modules. Next to that, several specific applications are designed. M E C H AT R O N I C S A variety of technical products are designed today by integrating mechanical components and electronic hardware into one packaging unit thus creating true mechatronic solutions. Mechatronic applications offer amazing and versatile potentials related to functionality, cost, space requirements and quality. Tyco Electronics contributes to those applications with its wide range of innovative and cost-effective product and process technologies. Advanced stamping, injection molding and assembly techniques are applied along with highly selective surface plating methods. III
  6. 6. H I G H S P E E D DATA N E T W O R K I N G High speed data networking within the automobile is becoming more predominant. What was till now restricted to the high end of the market utilizing system such as the MOST network, high speed data transmission based on optical fibers, now with the introduction of MP3 player, display screens and cameras results in the need for high speed networking throughout all platforms. MOST IS A TRADEMARK A LT E R N AT I V E P O W E R S Y S T E M S CO M P O N E N TS F O R H Y B R I D, E L E C T R I C A N D FUEL CELL TECHNOLOGY Tyco Electronics is a leader in next-generation transportation technologies and products for hybrid and electric vehicles. The Automotive Division is your source for high voltage power distribution, high current contacts, high voltage connectors and cables, high voltage relays, sensors and temperature protection devices for hybrid and other alternative powered vehicles. T YCO E L E C T R O N I C S O U R C O M M I T M E N T. Y O U R A D VA N TA G E . Tyco Electronics’ businesses operate in thousands of different areas of industry. The products and services we deliver all have one thing in common. They are vital to everyday living. Individuals and companies worldwide have critical needs. And every minute of every day, we satisfy them. IV
  7. 7. R E S T R I C T I O N O N T H E U S E O F H A Z A R D O U S S U B S TA N C E S ( R O H S ) At Tyco Electronics, we’re ready to support your RoHS requirements. We’ve assessed more than 1.5 million end items/components for RoHS compliance, and issued new part numbers where any change was required to eliminate the restricted materials. Part numbers in this catalog are identified as: RoHS Compliant Part numbers in this catalog are RoHS Compliant, unless marked otherwise. These products comply with European Union Directive 2002/95/EC as amended 1 January 2006 that restricts the use of lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE in certain electrical and electronic products sold into the EU as of 1 July 2006. Note: For purposes of this Catalog, included within the definition of RoHS Compliant are products that are clearly “Out of Scope” of the RoHS Directive such as hand tools and other non-electrical accessories. Non-RoHS Compliant These part numbers are identified with a “ ” symbol. These products do not comply with the material restrictions of the European Union Directive 2002/95/EC. 5 of 6 Compliant A “ ” symbol identifies these part numbers. These products do not fully comply with the European Union Directive 2002/95/EC because they contain lead in solderable interfaces (they do not contain any of the other five restricted substances above allowable limits). However, these products may be suitable for use in RoHS applications where there is an application-based exception for lead in solders, such as the server, storage, or networking infrastructure exemption. Note: Information regarding RoHS compliance is provided based on reasonable inquiry of our suppliers and represents our current actual knowledge based on the information provided by our suppliers. This information is subject to change. For latest compliance status, refer to our website referenced below. Getting the Information You Need Our comprehensive on-line RoHS Customer Support Center provides a forum to answer your questions and support your RoHS needs. A RoHS FAQ (Frequently Asked Questions) is available with links to more detailed information. You can also submit RoHS questions and receive a response within 24 hours during a normal work week. The Support Center also provides: ■ Cross-Reference from Non-compliant to Compliant Products ■ Ability to browse RoHS Compliant Products in our on-line catalog: RoHS http://ecommas.tycoelectronics.com/commerce/alt/RohsAltHome.do Customer ■ Downloadable Technical Data Customer Information Presentation Support ■ More detailed information regarding the definitions used above Center So whatever your questions when it comes to RoHS, we’ve got the answers at www.tycoelectronics.com/leadfree V
  8. 8. “AT YO U R S E RV I C E ” Tyco Electronics Online The Tyco Electronics website is an innovative and interactive source for application information, product updates and technical solutions. Our step-by-step software makes our website intuitive and user-friendly to better serve you! Please contact us at: www.tycoelectronics.com/automotive Internet www.tycoelectronics.com www.tycoelectronics.com/automotive www.tycoelectronics.com/automotive/sensors www.tycoelectronicsmost.com Electronic Internet Catalog www.tycoelectronics.com/components www.tycoelectronics.com/automotive www.tycoelectronics.com/automotive/sensors www.tycoelectronicsmost.com VI
  9. 9. “AT YO U R S E RV I C E ” Product and Machine Literature Tyco Electronics offers a variety of product specific catalogs, brochures and high impact flyers to help better serve you! For more information on literature for Tyco Electronics’ Automotive Division, please contact your local Tyco Electronics organization or go to www.tycoelectronics.com/automotive Product Information Center (PIC) You can rely on Tyco Electronics’ PIC Team to provide you support for answers to your general information or technical questions in an efficient and effective manner. To reach our PIC staff, please contact your local Tyco Electronics organization. See our Global Contacts page. VII
  10. 10. AU TO M OT I V E D I V I S I O N Page Alternative Power Systems (APS) Creating “A Green Advantage” 12-10 ✓ Introduction 12-20 ✓ 2 Position HVA 280 Connector System 12-30 ✓ 3 Position HVA 280 Connector System 12-40 ✓ 2 Position HVA 400 Connector System 12-50 ✓ 2 Position Auxiliary Power Terminal (APT) 12-60 ✓ 2 Position Low Voltage (LV) 800 Connector 12-70 ✓ 2 Position High Voltage (HV) 800 Connector 12-80 ✓ 3 Position High Voltage (HV) 800 Connector 12-90 ✓ 1 Position IPT Shielded Ring Tongue 12-10 ✓ EV 200 Contactor 12-12 ✓ LEV 100 Contactor 12-13 ✓ Power Resistor 12-14 ✓ Typical Make / Break Application 12-15 ✓ High Current Relay (HCR) 200 12-16 ✓ High Current Relay (HCR) 150 12-17 ✓ Battery Disconnect Switch (BDS)-A 12-18 ✓ High Voltage Cable Assemblies 12-19 ✓ Multi-Coil Resolver (MCR) 12-20 ✓ Clutch Position Sensor 12-21 ✓ Dual Clutch Position Sensor 12-22 ✓ Neutral Position Sensor 12-23 ✓ Brake Pedal Position Sensor 12-24 ✓ Thermal Indicator 12-25 ✓ HFT 5000 12-26 ✓ Application Tooling 12-27 ✓ Numerical Index 12-28 ✓ VIII
  11. 11. THE PRODUCTS ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ IX
  12. 12. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Engineering Notes X All specifications subject to change. Consult Tyco Electronics for latest specifications.
  13. 13. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Creating “A Green Advantage” Tyco Electronics Ltd. is a We design, manufacture With worldwide engineering, Global Automotive Division leading global provider of and market products for manufacturing, sales and engineered electronic com- customers in a broad array customer service capabilities, ALTERNATIVE ponents, network solutions, of industries including auto- Tyco Electronics’ commit- POWER SYSTEMS specialty products and motive; data communication ment is our customers’ (APS) undersea telecommunication systems and consumer elec- advantage. systems, with customers in tronics; telecommunications; Tyco Electronics is a leader more than 150 countries. aerospace, defense and in next-generation trans- marine; medical; energy; portation technologies and and lighting. products for hybrid and electric vehicles. The Global Automotive Division is your source for high voltage power distribution, high current contacts, high voltage connectors and cables, high voltage relays, sensors and temperature protection devices for hybrid and other alternative powered vehicles. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-1
  14. 14. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Introduction High-Power Automotive Electrical Systems for Hybrid and Electrical Vehicles Alternative powered vehicles, Electrical systems on conven- Tyco Electronics offers a wide such as hybrid electric tional vehicles are typically range of components and vehicles (HEV’s), can reduce designed for 12 volts, with subsystems for HEV’s, harmful pollutants and exhaust the majority of loads less than including: emissions. Recent interest in 30 amps. In contrast, hybrid ■ High power electrical alternative powered vehicles and electric vehicles have connectors and cables, creates a new challenge for electrical systems with voltage vehicle electrical systems levels between 300–800 volts ■ High power contactors because of the need for and currents from 200–1000 for battery switching and high power electrical system amps. High power environ- control, technology. ments require design and ■ Circuit protection devices, packaging solutions for power like Raychem PolySwitch™ The demand for high power switching, circuit protection, PPTC’s, electrical components has electrical power distribution ■ Power Distribution Units. accelerated due to the and interconnection systems. constant development of alternative powered vehicles, high power electrical com- ponents for “drive by wire” electromechanical systems and high-power systems on vehicles with conventional voltage levels. 12-2 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  15. 15. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 2 Position HVA 280 Connector System 2 Position HVA 280 Connector System Application ■ High voltage accessory (HVA) / device interconnect Description ■ Sealed ■ Touch safe ■ 2.8 mm AMP MCP Box/ Blade Contact System ■ Wire Range: 2.0–4.0 mm2 ■ Individually Shielded Cable ■ Wire-to-device ■ Internal safety interlock ■ 360° EMC shielding ■ Finger actuated two-stage latch ■ Multiple indexes available Performance ■ Rated Voltage: 600 V DC ■ Current Carrying Capacity: 40 A continuous @ +85 °C on Ordering Information 4.0 mm2 wire in connector Connector No. of Product Overview 27 A continuous @ +125 °C on Type Positions Description Part Number 4.0 mm2 wire in connector Plug Housing 1587819-x ■ Operating Temperature: HVA 280 2 Header Housing 1587831-x –40 °C to +125 °C ■ Degree of Protection: IP6K9K, IPX7 mated, IP2XB unmated ■ Vibration Profile: USCAR-2 (Body Profile) All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-3
  16. 16. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 3 Position HVA 280 Connector System 3 Position HVA 280 Connector System Application ■ High voltage accessory (HVA) / device interconnect Description ■ Sealed ■ Touch Safe ■ 2.8 mm AMP MCP Box/ Blade Contact System ■ Multicore shielded cable ■ Wire Range: 2 x 2.5–4.0 mm2, 3 x 2.5–3.0 mm2 ■ Wire-to-device ■ 360° EMC shielding ■ Tool actuated latch ■ Multiple indexes available Performance ■ Rated Voltage: 600 V DC ■ Current Carrying Capacity: 30 A continuous @ +125 °C on Ordering Information 3 x 2.5 mm2 wire in connector Connector No. of Product Overview ■ Operating Temperature: Type Positions Description Part Number –40 °C to +125 °C Plug Housing 1587715-x ■ Degree of Protection: HVA 280 3 IP6K9K, IPX7 mated, Header Housing 1587727-x IP2XB unmated ■ Vibration Profile: USCAR-2 (Body Profile) 12-4 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  17. 17. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 2 Position HVA 400 Connector System 2 Position HVA 400 Connector System Application ■ High voltage accessory (HVA) / device interconnect Description ■ Sealed ■ Touch safe ■ 4.0 mm pin/socket contact system ■ Wire Range: 3.0–6.0 mm2 ■ Individually shielded cable ■ Wire-to-wire ■ External safety interlock ■ 360° EMC shielding ■ Tool actuated latch Performance ■ Rated Voltage: 600 V DC ■ Current Carrying Capacity: 33 A continuous @ +125 °C on 3.0 mm2 Wire (free in air) ■ Operating Temperature: Ordering Information –40 °C to +125 °C Connector No. of Product Overview ■ Degree of Protection: Type Positions Description Part Number IP6K9K, IPX7 mated, IP2XB unmated Plug Housing 1587517-x HVA 400 2 ■ Vibration Profile: Cap Housing 1587777-x USCAR-2 (Body Profile) All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-5
  18. 18. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 2 Position Auxiliary Power Terminal (APT) 2 Position Auxiliary Power Terminal (APT) Application ■ High voltage accessory (HVA) / device interconnect Description ■ Auxiliary pigtail system ■ Sealed ■ Touch safe ■ Wire Range: 2.5–6.0 mm2 ■ Individually shielded cable ■ Wire-to-device ■ Non-serviceable fixed device interface ■ 360° EMC shielding Performance ■ Rated Voltage: 600 V DC ■ Current Carrying Capacity: 30 A continuous @ +125 °C on 4.0 mm2 Wire ■ Operating Temperature: Ordering Information –40 °C to +125 °C Connector No. of Product Overview ■ Degree of Protection: Type Positions Description Part Number IP6K9K APT 2 Kit 1587833-x ■ Vibration Profile: USCAR-2 (on Engine) 12-6 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  19. 19. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 2 Position LV 800 Connector 2 Position Low Voltage (LV) 800 Connector Application ■ Accessory/main interconnect Description ■ 2 positions ■ Sealed ■ 8.0 mm socket contact system ■ Wire Range: 25.0–50.0 mm2 ■ Wire-to-device Performance ■ Rated Voltage: 12 V DC ■ Current Carrying Capacity: 210 A continuous @ +85 °C on 50.0 mm2 wire ■ Operating Temperature: –40 °C to +130 °C ■ Degree of Protection: IP6K9K, IPX7 mated Ordering Information Connector No. of Product Overview Type Positions Description Part Number Plug Housing 1670564-x LV 800 2 Pin Header 1670559-x All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-7
  20. 20. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 2 Position HV 800 Connector 2 Position High Voltage (HV) 800 Connector Application ■ Accessory/main interconnect Description ■ 2 positions ■ Sealed ■ Touch safe ■ 8.0 mm socket contact system ■ Wire Range: 25.0–50.0 mm2 ■ Wire-to-device ■ Full integrated interlock ■ 360° EMC shielding Performance ■ Rated Voltage: 800 V DC ■ Current Carrying Capacity: 210 A continuous @ +85 °C on 50.0 mm2 wire ■ Operating Temperature: –40 °C to +130 °C ■ Degree of Protection: IP6K9K, IPX7 mated, Ordering Information IP2XB unmated Connector No. of Product Overview Type Positions Description Part Number Plug Housing 1719822-x HV 800 2 Pin Header 1719833-x 12-8 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  21. 21. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 3 Position HV 800 Connector 3 Position High Voltage (HV) 800 Connector Application ■ Accessory/main interconnect Description ■ 3 positions ■ Sealed ■ Touch safe ■ 8.0 mm socket contact system ■ Wire Range: 25.0–50.0 mm2 ■ Wire-to-device ■ Full integrated interlock ■ 360° EMC shielding Performance ■ Rated Voltage: 800 V DC ■ Current Carrying Capacity: 210 A continuous @ +85 °C on 50.0 mm2 wire ■ Operating Temperature: –40 °C to +130 °C ■ Degree of Protection: IP6K9K, IPX7 mated, Ordering Information IP2XB unmated Connector No. of Product Overview Type Positions Description Part Number Plug Housing 1563425-x HV 800 3 Pin Header 1563315-x All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-9
  22. 22. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 1 Position IPT Shielded Ring Tongue 1 Position IPT Shielded Terminal, Screwed, 25.0–50.0 mm2 Application ■ Accessory/main interconnect Description ■ 1 position ■ Sealed ■ Ring tongue ■ Wire Range: 25.0–50.0 mm2 ■ Wire-to-device ■ 360° EMC shielding Performance ■ Rated Voltage: 800 V DC ■ Current Carrying Capacity: 200 A continuous @ +105 °C on 50.0 mm2 wire ■ Operating Temperature: –40 °C to +130 °C ■ Degree of Protection: IP6K9K, IPX7 mated Ordering Information Connector Wire Size Range Product Overview Type (mm2) Description Part Number IPT 20.0– 50.0 IPT Shielded Terminal 1991227-x 12-10 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  23. 23. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. 1 Position IPT Shielded Ring Tongue 1 Position IPT Shielded Terminal, Screwed, 70.0–120.0 mm2 Application ■ Accessory/main interconnect Description ■ 1 position ■ Sealed ■ Ring tongue ■ Wire Range: 70.0–120.0 mm2 ■ Wire-to-device ■ 360° EMC shielding Performance ■ Rated Voltage: 800 V DC ■ Current Carrying Capacity: 420 A continuous @ +105 °C on 120.0 mm2 wire ■ Operating Temperature: –40 °C to +130 °C ■ Degree of Protection: IP6K9K, IPX7 mated Ordering Information Connector Wire Size Range Product Overview Type (mm2) Description Part Number IPT 70.0–120.0 IPT Shielded Terminal 1670904-x All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-11
  24. 24. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break EV 200 Contactor Application ■ Main relay ■ Accessory relay ■ High speed pre-charge relay Description ■ Form X ■ Available with and without Economizer (see application note) ■ Hermetically sealed Performance ■ 500 A DC continuous carry ■ 2,000 A, 320 V DC emergency interrupt ■ 900 V DC contact maximum ■ Capacitive make switching • 50,000 cycles, 360 amps peak • 50 Cycles, 650 amps Peak ■ 9 to 95 V DC coil voltage ■ 1.6 watts coil power Ordering Information Product Description Part Number ✱✱ EV200AAANA- (with Economizer) 2098190-1 EV200A1ANA-✱✱ (without Economizer) 2098372-1 12-12 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  25. 25. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break LEV 100 Contactor Application ■ Low cost 135 A sealed contactor ■ Side or bottom mount – not position sensitive ■ Multiple coil options available Application ■ Main relay ■ Accessory relay ■ High speed pre-charge relay Description ■ SPST – no form X ■ Hermetically sealed Performance ■ 135 A DC continuous carry ■ 200 A DC (>3 minutes carry) ■ 1000 A, 400 V DC emergency Ordering Information Interrupt Product Description Part Number ■ 900 V DC contact maximum LEV100A4BNG01 5-1618389-5 ■ 12, 24 and 48 V DC coil voltage ■ 5.5 watts coil power All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-13
  26. 26. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break Power Resistor Application ■ Filter capacitor pre-charge Description ■ Thick film isotop (shown) ■ Cement encased wirewound ■ Aluminum housed ■ Ceramic housed Performance ■ Typical 700 joules (360 V, 7 mF) ■ 3 charges at 5 second intervals ■ 500 V DC ■ 2000 V AC flash tested Available up to 5000 joules Terminals: Faston, screw Mounting: Screw, clip Ordering Information Product Description Part Number Power Resistor SQBW40 1879068-x 12-14 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  27. 27. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break Typical Make / Break Application Pre-Charge Relay and Resistor Motor Controller B+ +A1 –A2 Main Relay Filter Caps From Source (Fuel cell, batteries, generator etc.) –A2 +A1 To Load B– Vehicle Start Sequence ■ Pre-charge relay closes into resistor ■ Positive main propulsion relay closes into partially ■ Capacitors charge under current-limit conditions charged capacitors ■ Contact welds are prevented ■ In-rush current is limited due to pre-charge conditions Capacitive Switching Test Protocols Test Protocol 1 Test Protocol 2 Make/break life capacitive and resistive loads at 320 V DC 1), 2) Make/break life capacitive and resistive loads at 320 V DC 1), 2) Cycles Cycles @ 90% capacitive pre-charge (make only) see charts below 50,000 @ 90% capacitive pre-charge (make only) see charts below 50,000 @ 80% capacitive pre-charge (make only) see charts below 50 @ 70% capacitive pre-charge (make only) see charts below 50 @ 200 A make/break 2 consecutive, reverse polarity 1) 12 @ 250 A, 320 V make/break 2 consecutive, reverse polarity 1) 10 @ 2000 A break only (1700 A for auxiliary contact model 1) 1✱ @ Interrupt current maximum, 320 V break only 4✱ (1700 A for auxiliary contact model) 1) Capacitive Make Test Curves for Pre-Charged Capacitive Make Test Curves for Pre-Charged Motor Controller (Test Protocol 1) Motor Controller (Test Protocol 2) 80% Pre-Charge 80% Pre-Charge Current (Amps) Current (Amps) 90% Pre-Charge 90% Pre-Charge Time (ms) Time (ms) 1) 2) Resistive load includes inductance L = 25 µH. Load @ 2500 A tested @ 200 µH. Life based on projected Weibull Life with 95% Reliability. ✱) Does not meet dielectric and IR after test. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-15
  28. 28. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Carry / Break High Current Relay (HCR) 200 Features ■ Normally closed contact ■ Limiting continuous current 120 A @ +110 °C Customized Versions on Request ■ Integrated components (e.g. resistor, diode) ■ Special marking Typical Applications ■ Energy management ■ Battery coupling ■ Start-stop Design ■ ELV/RoHS/WEEE compliant ■ Splash-water and dust-tight; protection class IP64 to ISO 20653 (DIN 40050-9) Ordering Information ■ Weight: approx. 230 g Product Description Part Number ■ Nominal voltage: 12 V ■ Terminals HCR 200 V23230-D2001-B200 1-1414995-0 Quick connect terminals (coil) Screw terminals (load) Conditions All parametric, environmental and endurance tests are performed according to EIA Standard RS-407-A at standard test con- ditions unless otherwise noted: 23 °C ambient temperature, 20–50 % RH, 29.5 ±1.0 Hg (998.9 ±33.9 hPa). 12-16 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  29. 29. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break High Current Relay (HCR) 150 Application Main relay Accessory relay High speed pre-charge relay Description Form A, X, C Sealed Performance 200 A DC continuous carry 300 A DC emergency interrupt To 200 V DC contact maximum 12 V DC, 24 V DC coil voltage 3.3 watts coil power Ordering Information Product Description Part Number HCR 150 V23132-A2001-A100 1416010-1 All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-17
  30. 30. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break Battery Disconnect Switch (BDS)-A Application ■ High current loads (heaters, pumps) ■ Dual power network ■ Dual battery systems ■ Energy management Description ■ Compact high current relay for multivalent applications, sealed, mono and bi-stable Performance ■ 190 A DC continuous current @85 °C ■ 40 mOhm voltage drop at 100 A (Initial) ■ 1500 A interrupt ■ 15 ms operating time (approx. @14 V) ■ Up to 60 V contact voltage Ordering Information Product Description Part Number BDS-A V23130-C2021-A412 1-1414939-4 12-18 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  31. 31. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. High Voltage Cable Assemblies High Voltage Cable Assemblies High voltage cable assemblies for connections of high voltage systems that provide reliability and robustness to meet the safety requirements of the electric vehicle market. ■ System integration of high voltage harnesses from Battery Power Distribution Systems Contactor Boxes Inverters to E-machines ■ Multi-core and individually shielded cable capability ■ Capability to process cables from 2.5 mm2 to 120 mm2 in conductor size ■ Design and process competence in contact and shield crimp technology ■ Capable of end of line reliability testing For ordering information please contact your local sales representative. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-19
  32. 32. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Position Sensors Multi-Coil Resolver (MCR) Application ■ Rotary position sensor for E-Motor Description ■ Analog output ■ Platform product based on speed numbers Performance Wide Temperature Range: –40 °C to +130 °C Robust for harsh environments High rotational speed Connection technology delivered in package High reliability, low number of components Sensing absolute position and velocity By connecting the MCR to an AVD converter analog output signals are converted to digital position signals. For ordering information please contact your local sales representative. 12-20 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  33. 33. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Sensor Solutions for Alternative Powered Vehicles Clutch Position Sensor Application ■ Alternative powertrain solutions Function ■ Measuring piston position at concentric slave cylinder Technology ■ Permanent magnetic linear contact-less displacement sensor (PLCD) Product Features ■ Small design in ■ Measurement Range: 22.0 mm absolute ■ Highly temperature stable (up to +180 °C) ■ Redundancy possible For ordering information please contact your local sales representative. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-21
  34. 34. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Sensor Solutions for Alternative Powered Vehicles Dual Clutch Position Sensor Application ■ Dual clutch transmission for hybrid cars Function ■ Measuring the position of the clutch actuators Technology ■ Permanent magnetic linear contact-less displacement sensor (PLCD) Product Features ■ Two PLCD in one housing concept ■ PWM interface ■ Small, very flat design For ordering information please contact your local sales representative. 12-22 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  35. 35. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Sensor Solutions for Alternative Powered Vehicles Neutral Position Sensor Application ■ Start-stop application (mild hybrid) Function ■ Measuring neutral position of the transmission Technology ■ Active permanent magnetic linear contact-less displacement (PLCD) sensor (moving magnet) Product Features ■ Contact-less measurement through transmission wall ■ Measurement Range: 28 mm absolute ■ Neutral position <2% over travel, temperature, life time, etc. ■ Optional redundancy possible For ordering information please contact your local sales representative. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-23
  36. 36. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Sensor Solutions for Alternative Powered Vehicles Brake Pedal Position Sensor Application ■ Regenerative brake for hybrid cars Function ■ Brake pedal position detection Technology ■ Permanent magnetic linear contact-less displacement sensor (PLCD) Product Features ■ Optional travel or rotational measurement possible ■ PWM or analogue output ■ Optional redundancy possible ■ High linearity (<2% over travel, temperature, life time, etc.) ■ Optional sensor location pedal works or brake master cylinder For ordering information please contact your local sales representative. 12-24 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  37. 37. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Make / Break Thermal Indicator Thermal Indicator for Over-Temperature Detection Thermal indicator with very steep R-T curve “Close to digital” resistance response Direct input into FET of BJT No comparator necessary Built-in hysteresis to avoid cycling Different temperatures possible from 70 °C up to 165 °C Flexible Design: can be located wherever the potential heat might appear Can be put in series to protect several cells or places with one controller Tyco Electronics’s thermal They also feature a temperature Finally, the “near digital” indicators (RTI’s) are used for hysteresis response that can resistance response allows for over-temperature (OT) signaling. minimize signal oscillation multiple devices to be placed They provide “silicon-like” traditionally achieved using in series on the same circuit performance (in a passive active components. without significant dilution in component), reduce footprint The steep resistance response system measurement accuracy. needs and support simple and hysteresis also allow for This allows for a simple, low distributed monitoring. a reduction in support com- cost implementation of multi- In contrast to ceramic PTC ponents. RTI devices require point distributed monitoring. devices, RTI devices provide only one ballasting resistor to clear, “near digital”, OT signals directly control power FET’s and due to a steep resistance BJT’s. Solutions using ceramic change with temperature (~10 x PTC’s might require a resistor resistance change per 2 °C). network and comparator to offer similar functionality. This reduction in support com- ponents translates directly to lower system cost and reduced board area requirements. For ordering information please contact your local sales representative. All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-25
  38. 38. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Mechanical Protection for Power Cables HFT 5000 Description ■ Heat Shrinkable Fabric Tubing (HFT) ■ Polyester/polyethylene construction Features ■ Temperature rating 125 °C (3000 h), 150 °C (1000 h) ■ 2:1 shrink ratio ■ High performance polyester fibers ■ Highly flexible ■ Halogen free ■ Available in many sizes ■ Low shrink temperature Benefits ■ Excellent mechanical protection for power cables even at high temperatures ■ Fits perfectly to all cables therefore minimum space consumption ■ Highly flexible thus no constraints regarding routing of power cables For ordering information please contact your local sales representative. 12-26 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  39. 39. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Application Tooling Tyco Electronics Tooling for the Automotive Industry Tyco Electronics’ Global Application Tooling Division (GATD) is dedicated to providing high quality equipment options to meet all levels of your connector product specifications. We are also able to provide a broad range of equipment for other manufacturer’s products. Our equipment range is vast and unmatched by others operating in the same industry segments, as is our global presence and support network in the form of field service engineers and product managers. You will see from browsing this catalog; we supply everything from simple hand tools to the most complex automated systems – you name it, we supply it! Equipment is segregated into two categories: Generic Equipment Where we can supply you with sufficient information referenced by Part Number such that you can identify and order what you need yourself. Specialized Equipment Where you will need help from our specialist product managers to identify what’s just right for your application. Finding Equipment Online Powerful search functions are available to identify appropriate tooling: ● Applicators — www.tooling.tycoelectronics.com/europe/applicator.asp ● Hand Tools — www.tooling.tycoelectronics.com/europe/handtools.asp All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-27
  40. 40. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Numerical Index Part Number Page Part Number Page Part Number Page 1-1414939-4 12-18 1-1414995-0 12-16 0-1416010-1 12-17 5-1618389-5 12-13 0-2098190-1 12-12 0-2098372-1 12-12 Disclaimer While Tyco Electronics and its affiliates referenced herein have made every reasonable effort to ensure the accuracy of the information contained in this catalog, Tyco Electronics cannot assure that this information is error free. For this reason, Tyco Electronics does not make any representation or offer any guarantee that such information is accurate, correct, reliable or current. Tyco Electronics reserves the right to make any adjustments to the information at any time. Tyco Electronics expressly disclaims any implied warranty regarding the information contained herein, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose. Tyco Electronics' only obligations are those stated in Tyco Electronics’ Standard Terms and Conditions of Sale. Tyco Electronics will in no case be liable for any incidental, indirect or consequential damages arising from or in connection with, including, but not limited to, the sale, resale, use or misuse of its products. Users should rely on their own judgment to evaluate the suitability of a product for a certain purpose and test each product for its intended application. In case of any potential ambiguities or questions, please don’t hesitate to contact us for clarification. www.tycoelectronics.com www.tycoelectronics.com/automotive AMP, AMP MCP, KILOVAC, POLYSWITCH, RAYCHEM, TE (logo) and Tyco Electronics are trademarks of the Tyco Electronics group of companies and its licensors. USCAR is a trademark of United States Council for Automotive Research. Other product names, logos, and company names mentioned herein may be trademarks of their respective owners. 12-28 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  41. 41. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Engineering Notes All specifications subject to change. Consult Tyco Electronics for latest specifications. 12-29
  42. 42. Section Catalog 1654294-3. Revised 5-2010. Alternative Power Systems (APS) Main Catalog 1654400-1 for the Automotive Industry Chapter 12 – Issued 4-2010. Engineering Notes 12-30 All specifications subject to change. Consult Tyco Electronics for latest specifications.
  43. 43. 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  44. 44. Tyco Electronics AMP GmbH AMPèrestr. 12–14 64625 Bensheim / Germany Phone: +49-(0)6251-133-0 Fax: +49-(0)6251-133-1600 www.tycoelectronics.com www.tycoelectronics.com/automotive www.tycoelectronics.com/automotive/sensors www.tycoelectronicsmost.com TE (logo) and Tyco Electronics are trademarks of the Tyco Electronics group of companies and its licensors. Tyco Electronics AMP GmbH certified acc. ISO 14001 and ISO/TS 16949:2002 © 2010 Tyco Electronics Ltd. 1654294-3 Revised 5-2010 5M ST

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