New Energy Power parts DCDC output power cord assembly 3724750-TE810

Built to handle the high-current output demands of DCDC converters (typically 50-100A), this power cord assembly delivers exceptional electrical performance with minimal energy loss. The conductor core is made of 99.99% pure stranded copper (252 individual strands, 0.32mm diameter each) with a conductivity rating of ≥98% IACS, minimizing DC resistance (≤0.007Ω/m at 20℃). This low resistance reduces power loss by 30% compared to standard copper-clad aluminum conductors, ensuring the DCDC converter’s full output (e.g., 12V/100A=1200W) reaches on-board loads without voltage drops (≤0.5V under full load). The 25mm² cross-sectional area supports continuous current of 120A (short-term peak: 150A), exceeding the maximum output of most commercial DCDC converters—preventing overheating and ensuring stable power for critical systems like the vehicle’s BMS (Battery Management System) and HVAC

Designed with comprehensive safety features to address the risks of high-current power transmission, the power cord assembly integrates multiple protective mechanisms. The conductor is insulated with a 3mm-thick cross-linked polyethylene (XLPE) layer that withstands dielectric strength of 15kV/mm, preventing insulation breakdown and electric shock. The outer jacket is made of flame-retardant PVC (UL94 V-0 rating), which self-extinguishes within 10 seconds of ignition—reducing fire risks from short circuits. Terminals are plated with 10μm-thick tin, providing corrosion resistance and low contact resistance (≤0.001Ω) to avoid arcing. Additionally, the cord includes a built-in temperature sensor (optional for high-end models) that triggers an alert if the cord temperature exceeds 80℃, preventing thermal damage. These features comply with IEC 60245 and ISO 6469-3 standards, ensuring safe operation in new energy vehicles

Engineered to endure the harsh operating environment of new energy truck engine bays and undercarriages, the power cord assembly offers long-lasting durability. The XLPE insulation tolerates continuous temperatures of -40℃ to 125℃ (short-term peak: 150℃) without hardening or cracking, maintaining flexibility in freezing winters and resistance to heat in summer. The outer PVC jacket resists abrasion (≥1000 cycles of rubbing against steel per ISO 6722), road salt, diesel fuel, and coolant—preventing jacket degradation and conductor exposure. Connectors are sealed with IP67-rated rubber gaskets, blocking water and dust intrusion even in heavy rain or dusty construction sites. In accelerated aging tests, the cord maintains 95% of its electrical performance after 6000 hours of use—equivalent to 8 years of commercial operation—ensuring reliability in diverse conditions

Designed for efficient installation and maintenance, the power cord assembly features a user-friendly pre-assembled structure. It comes with pre-crimped terminals (equipped with lock washers) and 6 nylon mounting clips (pre-sized for OE chassis holes), eliminating the need for on-site crimping tools or custom drilling. The cord is marked with length indicators and polarity labels (“+” for positive, “-” for negative) to prevent reverse connection—reducing installation errors by 70%. The terminals’ ring design allows easy attachment to DCDC output terminals and load connection points, with a recommended torque of 18-22N·m for secure fastening. A professional technician can complete installation in 20 minutes or less, and the cord’s flexible structure (minimum bend radius: 50mm) simplifies routing around engine bay components. This design reduces labor costs and minimizes truck downtime for fleet operators