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Designing Heat Pumps for Heating, Ventilation and Air Conditioning (HVAC)

Developing efficient heat pumps for HVAC systems poses a unique set of challenges, from ensuring electrical performance to supporting ease of installation and maintenance while balancing space constraints, cost efficiency and long-term reliability. Molex addresses these challenges with compact and robust connectors that simplify assembly and maximize space savings while delivering safe and reliable performance.

High Performance HVAC Heat Pumps

Heat pump systems demand high-voltage power connectors and control boards that can accommodate a wide range of modular features. They must deliver optimal electrical performance in a compact design, while also being cost-effective, reliable, safe and simple to install and maintain. 

Molex connectors are specifically engineered to address these challenges. With features like latches, potting-capable headers and low mating forces, these connectors, purpose built for high voltages, are easy to install and won’t un-mate, even in high-vibration environments. 

To fit the tight confines of heat pump units, Molex provides interconnect solutions for printed circuit boards (PCBs) with reduced footprints to help reliably and safely manage a wide array of sensor inputs and actuator outputs that adhere to international safety standards such as V-0 / Glow Wire.

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Featured Products

High-Voltage Power Solutions

Managing the trade-offs between electrical performance, ease of installation and maintenance, and overall system cost remains a key challenge for designers of heat pump systems. Molex connectors for high-voltage applications offer easy termination through low insertion force without the need of special tools, greatly simplifying assembly and disassembly without sacrificing electrical performance.

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  Circuits Max. Current Rating Max. Voltage Wire Size
Barrier and Terminal Strips 2 to 12 63.0A 600V 12 to 26 AWG
Quixon Quick Disconnects   20.4A 600V 10 to 22 AWG

Sensor, Valve and Switch Connectors

Heat pump sensors, valves and switches require compact and durable components that can withstand regular mechanical stresses such as vibration and shock, without increasing footprint or cost. Molex miniaturized connectors with ruggedized features like friction or positive locks support secure connections in high-vibration settings. With tapeless connectors or components with surface-mount technology (SMT), Molex interconnect solutions can help reduce manual labor and overall production costs.

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  Configuration Pitch Circuits Max. Current Rating
OneBlade Connectors Wire-to-board 1.00mm 2 to 8 2.5A
Pico-Clasp Connectors Wire-to-board 1.00mm 2 to 50 2.0A

Main Power and Control Board Connectors

To optimize board space to fit within the physical confines of the heat pump unit, design engineers need to choose components with smaller PCB footprints, without sacrificing robust connections. Miniaturized, rugged connectors from Molex feature positive locks and latching, as well as potting-capable headers to minimize the connector footprint while still ensuring durability.

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  Configuration Pitch Circuits Max. Current Rating
Micro-One Connectors Wire-to-board 2.00mm 2 to 8 4.0A
Mini-Fit Connectors Wire-to-wire 
Wire-to-board 
Board-to-board		 4.20mm 2 to 24 20.5A
Micro-Lock Plus Connectors Wire-to-board 1.25mm 
2.00mm		 2 to 42 4.7A
KK Plus Connectors Wire-to-board 2.50mm 
3.00mm 
3.96mm		 2 to 8 11.0A
CP-6.5 Connectors Wire-to-wire 
Wire-to-board		 6.50mm 2 to 6 12.5A
Mini-Lock Connectors Wire-to-board 2.50mm 2 to 15 3.5A
  Type Orientation Tab Thickness Tab Width
PCB Tabs Quick disconnects

PCB flag tab

PCB straight tab

0.51mm

0.81mm

2.79mm

4.75mm

6.35mm
  Max. Current Rating Max. Voltage Wire Size
Quixon Quick Disconnects 20.4A 600V

10 to 22 AWG

Sensor Connectors

Heat pumps must function in both extreme cold and intense heat, requiring sensor connectors that maintain precision and reliability across this broad temperature spectrum without malfunctioning. Molex connectors are designed with reliability in mind, delivering optimal performance under extreme operating conditions. 

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  Configuration Pitch Circuits Max. Current Rating Operating Temperatures
Mini-Lock Connectors Wire-to-board 2.50mm 2 to 15 3.5A -40 to +105°C
Micro-One Connectors  
Wire-to-board 
 		 2.00mm 2 to 8 4.0A -40 to +105°C