Terminal Sizes

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Terminal Sizes
Connection Systems Training

• CTIS 29956
• Prepared By John Yurtin
• Updated 4-25-2005

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Excellence
Method Innovation and continuous improvement
Focus Your customer
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.
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John Yurtin
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 Delphis various
connections. I plan time for questions at the
end of the session, however, please feel free to
ask questions at any time.
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1946 Chevrolet Wire Harness
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Todays High End Vehicle Wiring

• Over 2400 Terminals

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Automotive Connections 101

• 500 to 2400 Terminals / Vehicle

• Over 63 Million Vehicles / Year

Over 126 Billion Terminals / Year
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2 Hours of Delphi Production
7,200,000 Terminals
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Terminal Systems Portfolio
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How many terminal types do we need?
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As many as it takes!!

• 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

Over 2000 Part Numbers
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Metri-Pack Terminal Proliferation

• 150, 280,480,630,800 MF 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 1.8
Micro 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 PS 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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Terminal Sizes (slide 2 of 3)
2.0 2.3 2.8 3.0 3.75 4.8 5.2
Weather-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
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Terminal Sizes (slide 3 of 3)
5.7 6.3 8.0 9.5 15 20
Pack-Con III, IV V 56 Series 59 Series 9.5 Ducon Power Pack 1500 Series Power 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
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0.5 mm Terminals
0.50 Ducon
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0.64 mm Terminals
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0.8 mm Terminals
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1.0 mm Terminals
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1.2 mm Terminals
Micro HVT
Optima 1.2
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1.5 mm Terminals
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1.8 mm Terminals
BFC 1.8
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2.3 mm Terminals
090-II
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2.8 mm Terminals
DSQ 2.8
BTS2.8
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4.8 mm Terminals
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6.3 mm Terminals
GT
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8.0 mm Terminals
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9.5 mm Terminals
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15 20 mm Terminals
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Micro-64 Terminal System

• Female Terminal
• 0.007 thick, CDA 425 1/2 hard
• Palladium/gold flash electroplate

• Production Crimp
• Mechanically and electrically validated
• 0.35mm²/0.50mm² and 0.80mm²

• Mating Pin
• USCAR or ISO Standard 0.64mm Square or 0.8mm Round

2 Moving Contacts
Stationary Contact
One-Piece, Tangless, Non-Oriented Terminal
Internal contact arms are protected by outer
barrel Terminal-to-connector locking accomplished
on outer barrel Non-oriented design facilitates
harness manufacture
Square Peg in a Round Hole Minimum 3 point
contact is maintained in all terminal
orientations by design
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Micro Terminal System 0.64

• 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

MTS 0.64
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Micro Terminal System 0.64

• 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

MTS 0.64
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Micro Terminal System Blockseal 0.64

• 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

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Micro HVT 1.2 mm

• 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 terminal
• 0.80 x 0.64 male terminal
• 1.00 x 0.64 male terminal
• 1.20 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
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High Value Terminal System (Sealed)

• Application
• Engine Compartment Connection
• In-Line Device Connection
• Features
• One piece terminal designs
• Female terminal mates to
• 0.64 x 0.64 male terminal
• 0.80 x 0.64 male terminal
• 1.00 x 0.64 male terminal
• 1.20 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

HVT Sealed Female
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GT Standard Terminal System 1.5
Tangless Design In conformance with
SAE/USCAR design guidelines
Indexing Tab
Secondary Contact Support Supports the primary
contact, giving the advantages of a two-piece
terminal in a one-piece design
Closed Box Terminal Contact gap is optimized for
0.64 mm thick blade, but mates to a 0.8 mm thick
blade (devices)
-40C to 125C operating range (USCAR Class
III) 155C terminal exists for high temp
applications (Class IV)

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

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GT USCAR Device Terminal System 1.5
Tangless Design Same basic geometry as
the standard GT female terminal
Closed Box Terminal Contact gap is optimized for
0.8 mm thick blade on USCAR-standard devices
Indexing Tab Unique 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

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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.

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Flex Beam Technology

• 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 housing

Integrated Blade Lead In
Cantilever Lock (Flexible)
Conn Housing
Conn Housing
Rigid Lock
Blade Lead In on PLR
PLR or Secondary Piece
Flex Beam Technology
Typical Tangless Terminal Cavity
Flex Beam (Spring)
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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

Terminal to Pin contact 90 from axis of plug
Build Holder
Ring Out Pins
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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 ESDs in design
• Basic electrical contact remains same

Wedge Feature added to increase terminal
retention
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Flex Beam TechnologyNext Generation- Flex Pack

• 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

Ring out pin cavities
Blade Lead In 100 enclosed
Hold Down Beam
Built in Interference between Terminal and Beam
Terminal Lock
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Flex Beam Cavity Enhanced Cavity Design

• One piece female connector housing, NO spacer or
  secondary lock required
• Superior terminal retention. Retention force
  averages above 120Ns (Toyota Spec 100N min)
• Packaging advantage
• Adapts to European device footprint
• Mating blade lead in integral to connector housing

Integrated Blade Lead In
Terminal Lock
Hold Down Beam
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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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DSQ 1.5 (Double Spring Quadlock)

• 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

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BTS 1.5 (Block Seal Terminal System)

• 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

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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 Female
• Customer All
• Application Standard
• Status Development
• Innovation 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, Female Customer PSA /
Renault Status 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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CTS 2.8 (Compact Terminal System)

• 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

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ETS 1.5 2.8 (European Terminal System)

• 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

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DSQ 2.8 (Double Spring Quadlock)

• 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

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ATS 2.8 (Active Terminal System)

• 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
• Production

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Maxi Fuse 8.0

• 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

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PCB Terminals
PCB Terminals

• Features
• One piece terminal system
• Soldering Terminal

• Version 2,8 and 6,3 mm
• Customer All
• Application IBEC
• Stage of Development Concept
• Innovation status Patent application
• Availability of parts No

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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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Power-Pack Terminals

• 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
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Power-Pack Terminals

• Passed Current Cycling
• 400A for 12s
• 200A for 12s
• 50A for 12s
• 20 Cycles
• Successfully used at 230A continuously

8 vane Insert
1500 Series
10 vane Insert
2000 Series