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
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
o
o
o
o
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
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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:
•
•
•
•
•
Agriculture
Commercial vehicle
Construction
Marine
Other harsh environment applications
HES Circular Connectors
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
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Delphi Harsh Environment Series (HES) Connection Systems
Specifications for Connectors and Terminals
Contacts
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
- 55° to + 125°
C
C
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
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
Glass filled nylon
Silicone
Copper alloy
Stainless steel
Nickel and gold with tin in crimp area
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Delphi Harsh Environment Series (HES) Connection Systems
HES 24 Shell Terminal Patterns
47 Way
42 size 20
5 size 16
Thin wall (blue seal)
31 Way
31 size 16
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)
23 Way
23 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)
19 Way
13 size 16
6 size 12
Thin wall (blue seal)
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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
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