PowerTube Connectors FAQs

Q: What are the differences between the PowerTube HVP-HD 1000 and HVP-HD 1400?

A: The primary differences between the PowerTube HVP-HD 1000 and HVP-HD 1400 series are their current capacity and wire size compatibility:

• Current Capacity: The HVP-HD 1000 supports up to 300 A continuous current, while the HVP-HD 1400 supports up to 580 A continuous current.
• Wire Size Compatibility: The HVP-HD 1000 accommodates wire sizes ranging from 35 mm² to 70 mm². In contrast, the HVP-HD 1400 can handle larger wire sizes, from 70 mm² to 150 mm².
• Terminal Size: The HVP-HD 1000 uses a 10 mm round pin, whereas the HVP-HD 1400 uses a 14 mm round pin.
• Application Scope: Due to the higher current capacity and larger wire size compatibility, the HVP-HD 1400 is suitable for more demanding high-power applications.

Q: When should I use the PowerTube HVP-HD 1000 and when should I use the HVP-HD 1400?

A: The choice between the PowerTube HVP-HD 1000 and HVP-HD 1400 depends on your specific power and current requirements:

• PowerTube HVP-HD 1000: Use this series when your application requires up to 300 A continuous current and wire sizes between 35 mm² to 70 mm². It is suitable for medium-power applications such as smaller electric motors, battery packs, and auxiliary power systems.
• PowerTube HVP-HD 1400: Opt for this series when your application demands higher current, up to 580 A, and larger wire sizes from 70 mm² to 150 mm². This series is suitable for high-power applications, including large electric motors, extensive battery packs, and heavy-duty power distribution systems.

Q: Why should I use a PowerTube Connector?

A: PowerTube Connectors offer several advantages:

• High Performance: Designed to handle high current and high voltage, enabling reliable power delivery in demanding applications.
• Enhanced Safety: Equipped with High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA), which help prevent accidental disconnections and provide secure connections.
• Robust Construction: Built to withstand harsh environmental conditions, including dust, water ingress, and engine-level vibrations, making them durable for long-term use.
• Versatility: Available in various configurations and sizes, accommodating different wire sizes and application needs.
• High EMC Performance: 360° shielding protects against electromagnetic interference, enabling reliable signal integrity.

Q: What parts do I need to build a PowerTube Connector?

A: To build a PowerTube Connector, you will need several key components to enable reliable and secure high-voltage connections for industrial and commercial transportation applications. Here's a detailed breakdown of the necessary parts:

Connector Housing:

• HVP-HD 1000 or HVP-HD 1400 Housing for Female Terminals: Choose based on your current and voltage requirements (HVP-HD 1000 for up to 300 A, HVP-HD 1400 for up to 580 A).
• Features: Durable plastic construction, IP67 and IP6K9K protection, and designed to withstand harsh environmental conditions.

Headers:

• 180º or 90º Headers: Select the orientation that best suits your installation needs. Both 1000 and 1400 series offer these options.
• Features: High current capacity (up to 300 A for 1000 series, up to 580 A for 1400 series), robust design, and compatibility with larger wire sizes (up to 70 mm² for 1000 series, up to 150 mm² for 1400 series).

Terminals:

• Female Terminals: These metal contacts make the electrical connection within the housing.
• Contact Size: 10 mm round pin for HVP-HD 1000, 14 mm round pin for HVP-HD 1400.
• Plating Material: Silver plating for reliable electrical performance.

Seals and Gaskets:

• Environmental Seals: Provide IP67 and IP6K9K protection against dust and water ingress, enabling durability in harsh conditions.

High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA):

• HVIL: Prevents high voltage circuits from engaging unless the connector is properly mated, enhancing safety.
• CPA: Provides secure connections and helps prevent accidental disconnections.

Cable and Wire Components:

• Wire Sizes: Compatible wire sizes range from 35 mm² to 70 mm² for the HVP-HD 1000 series and 70 mm² to 150 mm² for the HVP-HD 1400 series.
• Shielding: 360° shielding to protect against electromagnetic interference, supporting reliable signal integrity.

Mounting Accessories:

• Boardlock or Mounting Hole: Depending on the specific header, you may need boardlock or mounting holes for secure installation.
• Tool and Finger Access: Provides ease of assembly and maintenance.

By carefully selecting and assembling these components, you can build a PowerTube Connector that offers robust performance, enhanced safety, and reliable connectivity tailored to your industrial and commercial transportation needs.

Q: What are the key safety features of the PowerTube HVP-HD 1000 180º Headers?

A: The PowerTube HVP-HD 1000 180º Headers include High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA) to enhance safety. HVIL confirms that high voltage circuits are not engaged unless the connector is properly mated, while CPA provides additional security by helping prevent accidental disconnections.

Q: What protection ratings do the PowerTube HVP-HD 1000 180º Headers have?

A: The PowerTube HVP-HD 1000 180º Headers are rated with IP67 and IP6K9K protection. This means they are highly resistant to dust and water ingress, making them suitable for use in harsh environmental conditions commonly encountered in industrial and commercial vehicles.

Q: What wire sizes are compatible with the PowerTube HVP-HD 1000 180º Headers?

A: The PowerTube HVP-HD 1000 180º Headers are compatible with wire sizes ranging from 35 mm² to 70 mm². This flexibility allows them to be used in a variety of high-power applications, providing secure and efficient connections in industrial and commercial vehicles.

Q: What advantages does the 90º orientation of the PowerTube HVP-HD 1000 90º Headers offer?

A: The 90º orientation provides several advantages, including space-saving benefits and more efficient cable management. It simplifies cable routing, reducing bending and potential strain on wires, which can enhance the durability and reliability of the connections in compact or constrained spaces.

Q: What safety features are included in the PowerTube HVP-HD 1000 90º Headers?

A: The PowerTube HVP-HD 1000 90º Headers are equipped with High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA) features. HVIL confirms that high-voltage circuits are not engaged unless the connector is properly mated, while CPA prevents accidental disconnections, enhancing overall safety.

Q: In what applications are the PowerTube HVP-HD 1000 90º Headers most commonly used?

A: These headers are suitable for a variety of high-power applications, including e-motor connectivity, battery pack integration, power distribution systems, on-board chargers, and high power auxiliaries. They are well-suited for use in industrial and commercial vehicles, such as electric and hybrid vehicles, construction and agricultural equipment, public transport vehicles, heavy-duty trucks, and marine vessels.

Q: What safety features does the PowerTube HVP-HD 1000 Plug Pre-Assemblies include?

A: The PowerTube HVP-HD 1000 Plug Pre-Assemblies includes High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA) features. HVIL helps prevent high voltage circuits from engaging unless the connector is properly mated, while CPA helps secure the connection to prevent accidental disconnections.

Q: What environmental protection ratings does the PowerTube HVP-HD 1000 Plug Pre-Assemblies have?

A: This plug is rated with IP67 and IP6K9K protection, offering strong resistance to dust and water ingress. These ratings make it suitable for use in harsh environmental conditions, enabling reliable performance in industrial and commercial transportation applications.

Q: What wire sizes are compatible with the PowerTube HVP-HD 1000 Plug Pre-Assemblies?

A: The PowerTube HVP-HD 1000 Plug Pre-Assemblies is compatible with wire sizes of 35 mm², 50 mm², and 70 mm². This flexibility allows it to be used in various high-power applications, supporting reliable and efficient connections in industrial and commercial vehicles.

Q: What types of accessories are available for the PowerTube HVP-HD 1000 series?

A: The PowerTube HVP-HD 1000 series includes a range of accessories such as dust caps, spacers, cable exit covers, EMC shielding ferrules, plugs, cable covers, and crimp ferrules. These components enhance the protection, stability, and performance of high voltage connections in industrial and commercial vehicles.

Q: What materials are used in the PowerTube HVP-HD 1000 Accessories, and how do they contribute to durability?

A: The accessories are made from durable materials including copper alloy, PA 66 GF, PA GF, PC/PET, and steel. These materials offer robust protection and longevity, enabling the accessories perform reliably in harsh environmental conditions and maintain secure connections over time.

Q: How do the PowerTube HVP-HD 1000 Accessories improve the performance and reliability of high voltage connections?

A: The accessories provide enhanced protection against dust, debris, and electromagnetic interference, enabling long-term reliability. Spacers and crimp ferrules help maintain stable and secure connections, while cable exit covers and clips simplify cable management, reducing installation time and potential points of failure.

Q:What makes the PowerTube HVP-HD 1400 180º Headers suitable for high-current applications?

A:The PowerTube HVP-HD 1400 180º Headers are designed to handle up to 580 A continuous current, accommodating larger wire sizes (70 mm² to 150 mm²). This makes them suitable for high-current applications in industrial and commercial vehicles.

Q:How do the safety features of the PowerTube HVP-HD 1400 180º Headers enhance their reliability?

A:The headers include High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA). HVIL helps prevent high voltage circuits from engaging unless the connector is properly mated, while CPA prevents accidental disconnections, enhancing overall safety and reliability.

Q:In what environments can the PowerTube HVP-HD 1400 180º Headers be used?

A:With IP67 and IP6K9K protection ratings, the PowerTube HVP-HD 1400 180º Headers are designed to withstand harsh environments, including exposure to dust and water. This makes them suitable for various applications in industrial and commercial transportation, such as construction equipment, public transport vehicles, and marine applications.

Q: What benefits does the 90º orientation of the PowerTube HVP-HD 1400 90º Headers provide?

A: The 90º orientation offers space-saving benefits, making it suitable for compact installations. It also simplifies cable routing, reducing bending and potential strain on wires, which can enhance the durability and reliability of the connections in tight or constrained spaces.

Q: How do the safety features of the PowerTube HVP-HD 1400 90º Headers improve connection security?

A: The headers include High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA). HVIL helps prevent high voltage circuits from engaging unless the connector is properly mated, while CPA prevents accidental disconnections, enhancing overall safety and reliability.

Q: In what environments can the PowerTube HVP-HD 1400 90º Headers be used?

A: With IP67 and IP6K9K protection ratings, the PowerTube HVP-HD 1400 90º Headers are designed to withstand harsh environments, including exposure to dust and water. This makes them suitable for various applications in industrial and commercial transportation, such as construction equipment, public transport vehicles, and marine applications.

Q: What makes the PowerTube HVP-HD 1400 HVP-HD 1400 suitable for high current applications?

A: The PowerTube HVP-HD 1400 HVP-HD 1400 is designed to handle up to 580 A continuous current, accommodating larger wire sizes (70 mm² to 150 mm²). This makes it suitable for demanding high-power applications in industrial and commercial vehicles.

Q: How do the safety features of the PowerTube HVP-HD 1400 Plug enhance connection security?

A: The plug includes High Voltage Interlock Loop (HVIL) and Connector Position Assurance (CPA). HVIL helps prevent high voltage circuits from engaging unless the connector is properly mated, while CPA helps prevent accidental disconnections, enhancing overall safety and reliability.

Q: In what environments can the PowerTube HVP-HD 1400 HVP-HD 1400 be used?

A: With IP67 and IP6K9K protection ratings, the PowerTube HVP-HD 1400 HVP-HD 1400 is designed to withstand harsh environments, including exposure to dust and water. This makes it suitable for various applications in industrial and commercial transportation, such as construction equipment, public transport vehicles, and marine applications.

Q: What types of accessories are available for the PowerTube HVP-HD 1400 series?

A: The PowerTube HVP-HD 1400 series includes a range of accessories such as C-clips, caps, cable exit covers, EMC shielding ferrules, spacers, and crimp ferrules. These components enhance the protection, stability, and performance of high current, high voltage connections in industrial and commercial vehicles.

Q: What materials are used in the PowerTube HVP-HD 1400 Accessories, and how do they contribute to durability?

A: The accessories are made from durable materials including copper alloy, PA 66 GF, PA GF, and PC/PET. These materials offer robust protection and longevity, enabling the accessories perform reliably in harsh environmental conditions and maintain secure connections over time.

Q: How do the PowerTube HVP-HD 1400 Accessories improve the performance and reliability of high voltage connections?

A: The accessories provide enhanced protection against dust, debris, and electromagnetic interference. They provide secure and stable connections with spacers and crimp ferrules, improve cable management with covers and C-clips, and maintain reliable connections with robust caps and ferrules. Additionally, they support higher current capacities and larger wire sizes, making them suitable for demanding high-power applications.