A connector sourcing checklist covering mating interfaces, voltage and current, cable size, HVIL, CPA, touch safety, shielding, ingress protection, environment, drawings and validation samples.
A high-voltage connector is a system of matched components, not just an orange housing. A reliable RFQ identifies the complete mating interface, electrical duty, cable construction, environmental requirements and validation evidence. This checklist helps buyers prepare that information without assuming compatibility from appearance.
1. Identify the complete interface
Provide manufacturer and full part numbers for the header/receptacle, plug housing, terminals, seals, backshell, secondary lock, HVIL components and accessories. State which components are already installed. Similar-looking families can use different keys, terminal sizes, sealing systems or revisions.
2. Define electrical duty and cable range
- Nominal and maximum voltage.
- Continuous and peak-current profile.
- High-voltage poles and low-voltage/HVIL circuits.
- Copper or aluminium conductor and cable area.
- Shielded or unshielded construction.
- Approved temperature-rise or derating criteria.
Ask for rating conditions from the exact datasheet. Manufacturer current figures are tied to a specific family, cable size and temperature.
3. Confirm safety and locking features
If the application requires a High Voltage Interlock Loop, specify the circuit and sequence. TE describes HVIL as a low-voltage loop used to monitor high-voltage circuit integrity. Also identify CPA, terminal position assurance, touch-safe protection and staged mating requirements. One feature does not prove the complete assembly satisfies the application.
4. Specify sealing and environment precisely
State the required ingress rating and condition: mated, unmated, capped, after vibration or after thermal cycling. List temperature, vibration, fluids, salt spray, altitude and mounting orientation. IEC 60529 defines IP coding, while automotive product specifications may add tests. Request evidence for the exact configuration.
5. Check shielding and EMC interfaces
For shielded systems, provide cable shield construction and termination method. Confirm whether shielding continues through connector and header. A shielded housing alone does not guarantee system-level EMC performance.
6. Request drawings and processing documents
- Customer drawing and revision.
- Application specification for stripping, crimping, assembly and inspection.
- Approved terminal and seal combinations.
- Tooling and inspection requirements.
- Mating connector and keying information.
- Packaging and traceability.
TE's HVA 1200 application specification includes assembly and inspection steps for HVIL contacts. Request the processing document for the exact connector family, not a generic crimp instruction.
7. Validate samples
Check identity, fit, locking, terminal retention, seals, cable compatibility and project tests. Acceptance limits must come from approved drawings, manufacturer specifications or a validated control plan.
FAQ
Can a photo confirm compatibility?
No. Keying, terminals, seals, revisions and dimensions may differ.
Does an IP rating apply when unplugged?
Not necessarily. Documentation should state the configuration and whether a cap is required.
Is HVIL the main high-voltage circuit?
No. It is typically a low-voltage monitoring loop associated with the high-voltage connection.
Primary references
- TE Connectivity HVA HD400 and HVIL overview
- TE Connectivity HVP 1100
- TE Connectivity HVA 1200 application specification
Next step: send the existing connector/header part number, cable size, quantity, destination and alternative policy for RFQ review.