CONNECTION SYSTEMS Delphi Harsh Environment Series (HES) Connection Systems The Delphi Harsh Environment Series (HES) Connection Systems include circular connectors, terminals, and a rectangular 50 and 60 way header. The 24 shell size industry standard connector includes six terminal configurations (47, 31, 29, 23, 21, and 19). Delphi's circular connection systems are available with straight and right angle conduit wire dress covers on both receptacle and plug assemblies. The HES Connection Systems provide higher current capability, improved sealing, higher terminal retention and a significant cost advantage compared to standard pin-and-sleeve systems. Delphi HES Connection Systems are also compatible with existing systems in the commercial and agricultural vehicle markets. Benefits * Terminals o o o o o o * High current performance is realized through the selection of high conductive materials Robust design with a stainless steel sleeve that provides stability and protection to contact interface area Overlapping wing design provides exceptional strain relief and larger outside diameter cable range capability Crimp stability over the terminal life with the use of tin in the crimp area Wide range of cable sizes accommodated with Delphi's crimp design Interchangeability with industry standard terminal products HES Connection Systems HES Terminals HES Circular Connectors o Sealing performance exceeds expectations with recessed 3-rib design that will maintain sealing properties even if a tight wire dress is applied, providing better sealing capability up to 30% compared to existing designs o Superior contact (terminal) retention performance virtually eliminates terminal unseats with a specialized finger design that results in better retention up to 40% when compared to existing designs o Interchangeability with industry standard circular products o Ergonomic design for ease of assembly and to maintain quality: Arrows help simplify pre-engagement of locking collar for simplified mating Visual lock engagement window Color coded seals to distinguish between various cable diameters as well as terminal gender Low torque engage o Robust construction through sonic welding the seal retainer construction and using wave spring design that ensures the connection system maintains face seal compression, even when subjected to the high vibration commercial vehicle SAE J-2030 standard www.delphi.com | (c) Delphi. All rights reserved. | 1 Delphi Harsh Environment Series (HES) Connection Systems * Header System o Virtually eliminates unseats with Delphi's two stage terminal retainer design o High vibration design passes 29 Grms vibration specification o Chemical resistant header face seals with the use of flourosilicone o Built-in probing window protect the female terminal during the build process o Over-torque bolt design protects the header when too much torque is applied o True pin position is one of the tightest in the industry at 0.225 mm, ensuring easy mounting to a circuit board o Interchangeability with industry standard products Typical Applications Delphi Harsh Environment Series products are suited for the following industries: * * * * * HES Circular Connectors Agriculture Commercial vehicle Construction Marine Other harsh environment applications The HES circular design is ideally suited for making connections in a vehicle sheet metal firewall pass-through locations. Because of the rugged connection system design, they are well suited for engine compartments. HES headers are an ideal choice for high density device I/Os that are mounted directly to the engine. HES Header System Arrows help simplify pre-engagement of locking collar for simplified mating www.delphi.com | (c) Delphi. All rights reserved. | 2 Delphi Harsh Environment Series (HES) Connection Systems Specifications for Connectors and Terminals Contacts Application Tooling Sealing Plugs Operating Temperature Durability Physical Shock Vibration Sealing Capability Cable Range for Optimal Sealing Corrosion Resistance Electrical Contact Current Rating Contact Resistance Dielectric Withstanding Voltage Insulation Resistance Mechanical Contact Retention to Housing Mating Torque Un-mating Torque Physical Housing Seals Contact Female Terminal Hood Plating www.delphi.com | (c) Delphi. All rights reserved. | Size 20 (1.0 mm) Size 16 (1.6 mm) Size 12 (2.4 mm) Delphi tooling available for each current configuration Size 20 and 16 Size 12 - 55C to + 125C No electrical or mechanical defects after 100 cycles of engagement or disengagement (1000 cycles for the diagnostic connector) Withstands 50 Gs of mechanical shock in three axes without mechanical failure Sinusoidal vibration of 20 GRMS and random vibration of 12.4 GRMS without physical damage of loss of continuity IP67 rating Withstands high pressure spray of 375 cycles of 1020 psi @ 150 gal/hr. Withstands water submersion of 3 feet without water intrusion Contact size: Blue Seal: Orange Seal: Size 20 (1.0) 1.10 - 2.40 mm 1.80 - 3.05 mm Size 16 (1.6) 1.30 - 2.85 mm 2.25 - 3.70 mm Size 12 (2.4) 2.45 - 3.60 mm 2.90 - 4.30 mm No corrosion after exposure to 100 hrs of salt fog Contact Size: Max. Current (Amps): Size 20 18 Size 16 28 Size 12 40 10 m for cable 18 Ga. 6.7 m for cable > 16 Ga. 1000 V AC Greater than 20 M Contact Size: Size 20 Size 16 Size 12 Less than 4 Nm Less than 4 Nm Retention Force: 160 N 270 N 365 N Glass filled nylon Silicone Copper alloy Stainless steel Nickel and gold with tin in crimp area 3 Delphi Harsh Environment Series (HES) Connection Systems HES 24 Shell Terminal Patterns 47 Way 42 size 20 5 size 16 Thin wall (blue seal) 23 Way 23 size 16 Thin wall (blue seal) Regular/heavy wall (orange seal) www.delphi.com | (c) Delphi. All rights reserved. | 31 Way 31 size 16 Thin wall (blue seal) Regular/heavy wall (orange seal) 21 Way 17 size 16 4 size 12 Thin wall (blue seal) Regular/heavy wall (orange seal) 29 Way 6 size 20 19 size 16 4 size 12 Thin wall (blue seal) Regular/heavy wall (orange seal) 19 Way 13 size 16 6 size 12 Thin wall (blue seal) 4 Delphi Harsh Environment Series (HES) Connection Systems HES Assembly Part Numbers -- Standard Configuration Description - HES Assembly 47 Way M Asm Thin 47 Way F Asm Thin 31 Way M Asm Thin 31 Way M Asm Thick 31 Way F Asm Thin 31 Way F Asm Thick 29 Way M Asm Thin 29 Way M Asm Thick 29 Way F Asm Thin 29 way F Asm Thick 23 Way M Asm Thin 23 Way M Asm Thick 23 Way F Asm Thin 23 Way F Asm Thick 21 Way M Asm Thin 21 Way M Asm Thick 21 Way F Asm Thin 21 Way F Asm Thick 19 Way M Asm Thin 19 Way M Asm Thick 19 Way F Asm Thin 19 Way F Asm Thick New Part Number 15544324 15544892 15544325 15544326 15544893 15544894 15544327 15544328 15544895 15544896 15544329 15544330 15544897 15544898 15544331 15544332 15544899 15544901 15544333 15544334 15544902 15544903 Old Part Number (backshell, non-backshell) 13719103, 13653493 13719104, 13653492 13719105, 13667925 13719107, 13698338 13719106, 13667935 13719108, 13698339 13719109, 13697106 13719111, 13698344 13719110, 13697107 13719112, 13698345 13719113, 13697104 13719115, 13698342 13719114, 13697105 13719116, 13698343 13719117, 13697102 13719119, 13698340 13719118, 13697103 13719121, 13698341 13719123, 13697108 13719125, 13698346 13719124, 13697109 13719126, 13698347 New Mating Part Number 15544892 15544324 15544893 15544894 15544325 15544326 15544895 15544896 15544327 15544328 15544897 15544898 15544329 15544330 15544899 15544901 15544331 15544332 15544902 15544903 15544333 15544334 HES Assembly Part Numbers -- Reverse Configuration Description - HES Assembly 31 Way M Asm Thin 31 Way M Asm Thick 31 Way F Asm Thin 31 Way F Asm Thick 19 Way M Asm Thin 19 Way M Asm Thick 19 Way F Asm Thin 19 Way F Asm Thick New Part Number 15544343 15544344 15544348 15544349 15544345 15544346 15544350 15544351 Old Part Number (backshell, non-backshell) 13765454, 13765449 13765455, 13765450 13765456, 13765452 13765457, 13765453 13765458, 13752444 13765459, 13765447 13765460, 13752445 13765461, 13765451 New Mating Part Number 15544348 15544349 15544343 15544344 15544350 15544351 15544345 15544346 Light seal color represents female/sleeve terminal Dark seal color represents male/pin terminal www.delphi.com | (c) Delphi. All rights reserved. | 5 Delphi Harsh Environment Series (HES) Connection Systems Mounting specification for the HES size 24 rceptacle Conduit Backshell Wire Dress Part Number 13767802 13767803 13667839 13767805 13767806 13667840 Conduit Size 19 22 25 19 22 25 Configuration Wire dress straight Wire dress right angle HES non-threaded backshell conduit adaptors Cavity Seal Plugs Part Number 13756464 13756465 Terminal Cavity Size 20 and 16 Size 12 Miscellaneous Accessories Part Number 13780240 13813956 13752446 13668988 15417623 13840220 Description Gasket Gasket with adhesive Shipping cover (reverse pin cover) Shipping cover (standard pin cover) Nut Lock washer www.delphi.com | (c) Delphi. All rights reserved. | HES plugs 6 Delphi Harsh Environment Series (HES) Connection Systems Specifications for the 50/60 Way Header Connections Contacts Sealing Plugs Operating Temperature Physical Shock Vibration Sealing Capability Corrosion Resistance Electrical Contact Current Rating Contact Plating Mechanical Contact Retention to Housing Physical Housing Seals Contact Plating Size 20 (1.0 mm) Size 20 (Note: Different part number than HES circulars) - 55C to + 125C Withstands 50 Gs of mechanical shock in three axes without mechanical failure 29.4 Grms IPX7 No corrosion after exposure to 100 hours of salt fog Chemical resistant flourosilicon face seal on the header Size 20: 18 amps maximum current Selective gold with tin in crimp area on the female contact Gold flash palladium on the header pins Contact size: Size 20 Retention force: 90 N High temperature, glass filled nylon Flourosilicone face seals Silicone cable seals Copper alloy Female: Gold with tin in crimp area Male: Gold flash palladium HES 50-way Header System Top Mount Header Part Number Female Plug Connector Part Number Index 13836626 13836627 13836628 13836629 13836630 13936631 13636632 13636633 13836634 13836635 13837191 13837192 13837193 13837194 13837195 13837196 13837197 13837198 13837199 13837200 1 2 3 4 5 6 7 8 9 10 www.delphi.com | (c) Delphi. All rights reserved. | 7 Delphi Harsh Environment Series (HES) Connection Systems HES 60-Way Header System Bottom Flange Mount Header Part Number Top Mount Header Part Number Female Plug Connector Part Number Index Available upon request Available upon request Available upon request Available upon request 13806062 13806064 13806065 Available upon request Available upon request Available upon request 13836616 13836617 13836618 13836619 13836620 13836621 13836622 13836623 13836624 13836625 13837180 13837181 13837182 13837183 13837184 13837185 13837186 13837187 13837188 13837189 1 2 3 4 5 6 7 8 9 10 Miscellaneous HES 50/60 Way Header Accessories Part Number 15475969 15475968 12129557 Description Backshell 60-way Backshell 50-way Cavity plug The Delphi Advantage HES Header Accessory Delphi is one of the world's leading automotive suppliers of advanced terminals, connectors, sealing, wiring and cable products. Delphi's deep understanding of various connection system technologies and the company's vast research and development capabilities have enabled continuing innovation. Delphi is a source for high value solutions and our expertise is built into every product. Delphi has a thorough understanding of markets around the world and a global network of resources. Delphi relies on its global capabilities, consistent processes, and extensive testing to develop and manufacture a comprehensive offering of terminals, connectors, sealing, wiring and cable products. The result is that Delphi provides customers with robust, reliable products and world-class quality. www.delphi.com | (c) Delphi. All rights reserved. | 8 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Delphi Connection Systems: 13719108-B 13719112-B 13719111-B 13719110-B 13719115-B 13719107-B 13719106-B 13719105-B 13719104-B 13719126-B 13719125-B 13719124-B 13719123-B 13719119-B 13719118-B 13719117-B 13719116B 13697104-B 13697109-B 13667925-B 13653493-B 13698346-B 13698343-B 13698341-B 13698340-B 13697105-B