Understanding the Metri-Pack 280 Series Connectors

In the world of automotive and industrial electrical connections, few components have earned the trust and widespread adoption of the Metri-Pack 280 Series connectors. These versatile connectors have become an industry standard for medium-current applications, offering a perfect balance of performance, reliability, and ease of use. Whether you're an automotive engineer, a repair technician, or a DIY enthusiast, understanding the capabilities and applications of Metri-Pack 280 connectors is essential for creating robust electrical systems.

Introduction to Metri-Pack 280 Series Connectors

Overview of Metri-Pack Connectors

Metri-Pack connectors, developed by Delphi (now Aptiv), represent one of the most comprehensive families of automotive-grade electrical connectors available today. The Metri-Pack series includes various sizes, with the 280 Series positioned as the medium-current solution within the lineup. These connectors have become ubiquitous in automotive wiring harnesses, with applications spanning from powertrain components to body electronics.

The 280 Series specifically caters to applications requiring current handling capabilities between 14 and 30 amps, filling the important middle ground between the smaller 150 Series and the larger 480, 630, and 800 Series connectors. This positioning has made the 280 Series an ideal choice for many vehicle systems, including lighting, HVAC controls, power accessories, and sensor networks.

Key Features

The Metri-Pack 280 Series stands out with several distinctive features that contribute to its popularity:

• Current Handling: Rated for up to 30 amps continuous current

• Voltage Rating: Designed for automotive 12V/24V systems

• Terminal Design: Features the signature Metri-Pack modular terminal design with male blade terminals set at a standard ISO 2.8mm width

• Sealing Options: Available in both sealed and unsealed configurations for different environmental needs

• Wire Compatibility: Accommodates wire gauges from 22 to 10 AWG

• Modularity: Available in standard 1 to 7 cavity configurations, plus specialty configurations to support various circuit requirements

• Connection Security: Incorporates Terminal Position Assurance (TPA) and Connector Position Assurance (CPA) features

• Connector Keying: Uses key-mated connector pairings for easier identification and proper mating

These features combine to create a robust connector system that meets the demanding requirements of modern automotive and industrial applications, where reliability under harsh conditions is non-negotiable.

Technical Specifications

Electrical Performance and Ratings

The Metri-Pack 280 Series delivers impressive electrical performance characteristics that make it suitable for a wide range of applications:

• Current Rating: 14-30 amps continuous

• Contact Resistance: Less than 10 milliohms at 20 millivolts

• Operating Temperature: -40°C to +125°C (-40°F to +257°F)

• Voltage Drop: <10 millivolts per amp

Material and Construction

The durability and performance of Metri-Pack 280 connectors stem from careful material selection and design:

• Housing Material: High-temperature thermoplastic, typically Polyamide 66 (PA66)

• Terminal Material: Typically tin brass with tin plating

• Seal Materials: Silicone rubber for cable seals and interfacial seals in sealed versions

• Environmental Protection: Sealed versions provide superior protection against dust and water

• Light Resistance: Housing material formulated to resist degradation from UV light exposure

• Chemical Resistance: Designed to withstand automotive fluids, including oils, coolants, and cleaning solutions

Components

Connectors

• Cavity Counts: Available in 1, 2, 3, 4, 5, 6, and 7 cavity versions for standard, in-line connections

• Mounting Options: Includes panel mount and free-hanging styles

• Locking Mechanisms: Features positive locking systems providing audible and tactile feedback

Terminals

• Types: Male blade-style and female box-shaped receptacles

• Wire Size Compatibility: Available for 22 to 10 AWG wire

• Platin: Tin plated for resistance to corrosion and improved conductivity

Seals

• Types: Cable seals, interfacial seals, and cavity plugs

• Material: Primarily silicone rubber

• Environmental Protection: Triple ribbed for enhanced protection against moisture

Locks

• Primary Lock: Ensures full and complete mating

• Terminal Position Assurance (TPA): Prevents terminal back-out

• Connector Position Assurance (CPA): Prevents accidental disconnection

CustomConnectorKits Pro Wiring Kits

• Service Kits: Smaller kits that contain commonly used terminal sizes, seals, and connector housings

• Stock Kits: Larger kits with a wider range of connector designs included inside

Advantages of Using Metri-Pack 280 Series Connectors

Durability and Reliability

• Vibration Resistance: Maintains contact integrity under harsh conditions

• Temperature Stability: Performs across extreme temperature ranges

• Moisture and Corrosion Protection: Sealed versions provide environmental protection

Ease of Installation and Maintenance

• Tooling Compatibility: Can be crimped with many standard crimping tools

• Modular Design: Supports flexible configurations

• Repairable: Individual terminals can be replaced

Installation Guidelines

Step-by-Step Installation Process

1. Slide the cable seal onto the wire (sealed versions)

2. Strip the wire to the recommended 0.25” length

3. Align the cable seal and stripped wire strands into the terminal wings

4. Crimp the terminal using a crimper

5. Push the terminal into the connector housing

6. Lock in place using TPA and CPA mechanisms

Common Installation Mistakes to Avoid

• Improper Wire Stripping: Damaging conductor strands

• Incorrect Terminal Selection: Mismatching wire gauge and terminal

• Incomplete Terminal Insertion: Failing to fully seat terminals

What Tools You Need to Install a 280 Series Connector

• Wire Stripper

• Ratcheting or Hand Operated Crimper

• Terminal Extraction Tool

Metri-Pack 280 vs 150 Series vs 150.2 Series

Frequently Asked Questions

Q: Are Metri-Pack 280 connectors waterproof?

A: Sealed versions can withstand temporary, shallow immersion, but shouldn’t be left submerged continuously.

Q: Can I repair damaged Metri-Pack 280 connectors?

A: While individual terminals can be replaced, damaged housings should be replaced entirely.

Conclusion

The Metri-Pack 280 Series offers a robust, reliable solution for medium-current automotive and industrial applications. With a variety of configurations and sealing options, these connectors provide superior electrical performance, durability, and ease of maintenance.