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Technical FAQ's

  1. Can Delphi-Packard components be used with voltages higher than those found in a 12v nominal electrical system?
  2. How can I find the TPA for a GT sealed connector? How do I know if the TPA is optional?
  3. How can find the terminal & cable seal for a European made connector?
  4. How do I find the crossed DCS/PSG part number with AK item of Reishagen?
  5. How do I find the appropriate clip (Plastic/metal) for the GT and Metri-Pack male connector?
  6. How do I find a mate or determine if one is available?
  7. How can I get a drawing for a part, including 3-D CAD files?
  8. How can I determine if a connector is sealed or unsealed?
  9. Do the parts distributed by Power & Signal Group conform to the RoHS directive?
  10. How do I know which cable seal should be used for various wire gauges?
  11. Where can I find the IP class for your sealed parts?
  12. How can I determine whether a hand crimp tool is available for various terminals?
  13. What is the current rating (amperage) for a connector family or series?
  14. What specifications or standards do Delphi components meet (USCAR, SAE, internal ESA 710)?
  15. What Delphi connectors meet USCAR footprints?
  16. How do silicone parts (cable seals) differ between the US and Europe?
  17. How can I determine if there is a European-made alternative to a part?
  18. What if I need a different gauge terminal?
  19. What are the crimp specifications for a particular terminal?
  20. How many engage/disengage cycles are Delphi connections good for?
  21. Can, or should, grease be used with Delphi-Packard sealed (silicone seals) components?



Can Delphi-Packard components be used with voltages higher than those found in a 12v nominal electrical system? (Back to Top)
Delphi-Packard components are designed, tested and validated for 12v nominal (typically 0 - 16v) electrical systems. The primary concern in using these components with other voltages is not to exceed their amperage ratings. Another obvious consideration is that they should not be mated, or unmated, while under power in these applications. This can result in arcing, which degrades the electrical interface. It can be noted that we have numerous customers using Delphi-Packard components in such applications without any known problems. However, it is the responsibility of the user to obtain any testing and validation that may be required for such applications.

How can I find the TPA for a GT sealed connector? How do I know if the TPA is optional? (Back to Top)
Click here for the GT part number list with available components listed on the spread sheet. All GT TPA's are considered optional unless you are trying to meet a USCAR standard.

How can find the terminal & cable seal for a European made connector? (Back to Top)
Most European drawings do not provide information for mating parts. That information is maintained internally at Delphi Wuppertal. As our European engineering staff maintains resisdent status and full access to the Delphi database any customers looking for mating parts for European-made connectors can email engineeringeurope@powersignal.com for assistance.

How do I find the crossed DCS/PSG part number with AK item of Reishagen? (Back to Top)
Occassionally, the Delphi e-catalog maintains a cross reference to the AK item. If not, the engineering team in Europe can again provide assistance by emailing engineeringeurope@powersignal.com.

How do I find the appropriate clip (Plastic/metal) for the GT and Metri-Pack male connector? (Back to Top)
Consult the taxi prints at www.powerandsignal.com or http://connectors2.delphi.com/dcsgdmcs/homepage.aspx:

How do I find a mate or determine if one is available?  (Back to Top)
Enter the part number you are interested in in the part number search field. A part number list will appear. Click on the part number listed in blue. Click the Prints, Document etc Tab. Click on the PDF or TIF file to view or download the component drawing. Once you have opened the drawing, read the "notes" section of this print, which will detail mating components such as terminals, cable seals and mating connectors. If nothing is listed on the print, as a mating connector and the item you are interested in is not a 3.5mm centerline device connector, then call our Engineering Tech Line for further investigation at 1-800-610-4838.

How can I get a drawing for a part, including 3-D CAD files? (Back to Top)
Enter the part number you are interested in in the part number search field. A part number list will appear. Click on the part number listed in blue. Click the Prints, Document etc Tab. Click on the PDF, TIF or IGES file to view or download.

How can I determine if a connector is sealed or unsealed? (Back to Top)
There are some visual clues that indicate a connector is sealed. When viewing the connector from the cable entry end, the cavity shape will be round. This will also indicate that our round cable seals and cavity plugs would be required. You may also see a 1-piece cable seal in place with multiple cable holes. This is a sealed Pull to Seat device connector. Unsealed connectors will have a squared cavity appearance form the cable entry end.

To be certain if a connector is sealed, you should also examine the print. The notes section will identify the seal code of the part. Seal codes are as follows:

  • 0-Unsealed
  • Dust Protected
  • Dust and Splash Protected
  • Sealed (can be submerged in water).



Do the parts distributed by Power & Signal Group conform to the RoHS directive? (Back to Top)
Delphi Connection Systems (DCS) and Power & Signal Group have identified its products affected by the EU's RoHS directive and customers have been notified via the Production Trial Run notification process that measures are being taken to bring the companies into compliance with the Directive. To learn more about the EU directive and actions taken by Delphi and Power & Signal Group click here.

How do I know which cable seal should be used for various wire gauges? (Back to Top)
It is strongly recommended that customer's reference Delphi's ES- A-605 Crimping Specification/Supplement when determining what cable seal should be used for a given terminal/wire gauge combination. The ES-A-605 Supplement lists all Delphi Packard terminals and what wire gauge, wire type and cable seal combinations have been validated to Delphi Packard crimp tooling. If the ES-A-605 Supplement cannot be referenced, a customer would need to determine what the O.D. (outside diameter) of their cable is. Cable seal reference material generally specifics what cable diameter (min./max.) each cable seal can accept.

Where can I find the IP class for your sealed parts? (Back to Top)
Delphi Connection Systems does not validate and test their components, sealed or unsealed, to IP ratings/classifications. Components are designed, tested and validated to classifications below. Use these "Sealing Codes" to determine to the closest corresponding "IP Code".

  • Sealing Code 0 - Unsealed
  • Sealing Code 1 - Design has limited sealing capability.
  • Sealing Code 2 - Design will pass salt fog test after conditioning as specified in ESA-644 (Weather-Pack), ESA-710 (Metri- Pack), ESA-650 (under hood Micro-Pack), C-4006 (World Connector), etc. when mated to mating part or equivalent
  • Sealing Code 3 - Design will pass salt fog and immersion test after conditioning as specified in ESA-644 (Weather-Pack), ESA- 710 (Metri-Pack), ESA-650 (under hood Micro-Pack), C-4006 (World Connector), etc. when mated to mating part or equivalent
  • Sealing Code 4 - Design will meet requirements of SAE/USCAR-2 Connector System Environmental Test Flowchart (pressure/vacuum and submersion).
  • Sealing Code Y- Sealed purchased component (non Delphi Packard design) sealing capability undefined.



How can I determine whether a hand crimp tool is available for various terminals? (Back to Top)
Delphi Packard offers a terminal hand crimp tool (HCT) for almost all of their terminals. It should be noted that hand crimp tools are designed for repair, prototype or low volume usage. Solder to guarantee crimp integrity. For your convenience, reference this Hand Crimp Cross Reference sheet. PSG has developed their own HCT that can be used with a number of different Delphi Packard terminals. Reference this PSG HCT cross-reference information.

What is the current rating (amperage) for a connector family or series? (Back to Top)
Current Rating will vary depending on the Connection System Series/Family. Current rating (amperage) for Delphi Components can be found in the Connection System Catalog on pg. 6 titled ‘Product Family Features’. This same information can be found throughout the catalog in each Connection System Section under information titled ‘Application Information’.

What specifications or standards do Delphi components meet (USCAR, SAE, internal ESA 710)? (Back to Top)
Delphi components are tested and validated to ESA Specifications, which is an internal Delphi Specification. The ESA specification varies among product series/family.

Some of Delphi components do meet USCAR or Approved USCAR Specifications. If the component meets the USCAR specification it means that components meet the USCAR electrical and functional characteristics. If the component is USCAR approved this means that the components meet USCAR electrical, functional and also footprint. Contact the PSG Engineering Tech Line to determine.

SAE- Delphi does meet some SAE Standards. Contact the PSG Engineering Tech Line to determine.


What Delphi connectors meet USCAR footprints? (Back to Top)
USCAR Footprints are determined from USCAR. GT Series is typically used for USCAR applications. USCAR’s website must be used to determine if a component meets the footprint. In some cases this information can be found on the Delphi Component drawing.

How do silicone parts (cable seals) differ between the US and Europe? (Back to Top)
In general American seals are oiled with 4% oil, while European seals are oiled with 2% oil

How can I determine if there is a European-made alternative to a part?  (Back to Top)
There are cross-reference lists available between European and American components. These lists are available only for PSG associates.

What if I need a different gauge terminal? (Back to Top)
Most Delphi terminals can be found on Taxi drawings, which are simply drawings that contain similar parts. To look for a terminal that accommodates a different gauge size, go to www.powerandsignal.com and enter the terminal part number that is currently being used in the "Part Number Search" field and click "Submit". Once the search matches appear, click on the active link part number that corresponds to the terminal part number. A new screen will pop-up with the product attributes. Click on the tab that says "Prints, Documents, etc". The available drawing formats will be shown, usually PDF format and tif format. Select the format you would prefer and then click "Go" to open the drawing. After the drawing is open, look in the chart at the bottom of the Taxi drawing for the cable diameter and gauge size for the desired application.

What are the crimp specifications for a particular terminal? (Back to Top)
To look for the crimp specifications for a particular terminal, go to www.powerandsignal.com and enter the terminal part number in the "Part Number Search" field and click "Submit". Once the search matches appear, click on the active link part number that corresponds to the terminal part number. A new screen will pop-up with the product attributes. At the bottom of the Attributes page, there will be an active link for crimp specification that says "Click Here to View Crimp Specifications for (part number)". Click on the link and a new window will appear with the matching Crimp Applicator Specifications. Click on the "Crimp Specs" button next to your corresponding Crimp Applicator Type.

How many engage/disengage cycles are Delphi connections good for? (Back to Top)
In general, Delphi components are validated to perform to specification after 10 engage/disengage cycles. Some components may have a slightly higher number of cycles specified in their individual design specifications. We need to know which component family, or families, the customer is referring to in order to be more specific. However, in actuality you probably wouldn't see any degradation of the electrical interface of Delphi connection system components until beyond about 50 engage/disengage cycles (barring any physical damage). Some newer product families may have even higher engage/disengage cycle durability; these may primarily be designed specifically for the Commercial Vehicle market.

In summary, most Delphi Connection Systems are not intended for applications that necessitate multiple numbers of engage/disengage. Please contact us to discuss your application for more information.


Can Delphi-Packard components be used with voltages higher than those found in a 12v nominal electrical system? (Back to Top)
Delphi-Packard components are designed, tested and validated for 12v nominal (typically 0 - 16v) electrical systems. The primary concern in using these components with other voltages is not to exceed their amperage ratings. Another obvious consideration is that they should not be mated, or unmated, while under power in these applications. This can result in arcing, which degrades the electrical interface. It can be noted that we have numerous customers using Delphi-Packard components in such applications without any know problems. However, it is the responsibility of the user to obtain any testing and validation that may be required for such applications.



Can, or should, grease be used with Delphi-Packard sealed (silicone seals) components?  (Back to Top)
Delphi-Packard recommends NOT to grease their sealed components. These components are designed, tested and validated to withstand environmental exposure. Adding grease can cause various problems. Incompatible grease can degrade and/or distort silicone seals. Too much grease can cause mating issues and/or displace the seals.