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.

HES Terminals

HES Circular Connectors

HES Header System

Benefits

  • Terminals
    • 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 Circular Connectors
    • 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
    • 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
    • Interchangeability with industry standard circular products
    • 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 (Less than 4 Nm) torque engage
    • Robust construction to withstand SAE J-2030 Heavy-Duty Electrical Connector Performance Standard
      • Sonic welded seal retainer
      • Wave spring design to maintain face seal compression
  • Header System
    • Virtually eliminates unseats with Delphi’s two stage terminal retainer design
    • High vibration design passes 29 Grms vibration specification
    • Chemical resistant  header face seals with the use of flourosilicone
    • Built-in probing window protect the female terminal during the build process
    • Over-torque bolt design protects the header when too much torque is applied
    • True pin position is one of the tightest in the industry at 0.225 mm, ensuring easy mounting to a circuit board
    • Interchangeability with industry standard products 

    Arrows help simplify pre-engagement of locking collar for simplified mating

Typical Applications

Delphi Harsh Environment Series products are suited for the following industries:

  • 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.

Specifications for Connectors and Terminals

Contacts

Size 20 (1.0 mm)
Size 16 (1.6 mm)
Size 12 (2.4 mm)

Application Tooling Delphi tooling available for each current configuration
Sealing Plugs

Size 20 and 16
Size 12

Operating Temperature - 55°C to + 125°C
Durability
No electrical or mechanical defects after 100 cycles of engagement or disengagement (1000 cycles for the diagnostic connector)
Physical Shock Withstands 50 Gs of mechanical shock in three axes without mechanical failure
Vibration Sinusoidal vibration of 20 GRMS and random vibration of 12.4 GRMS without physical damage of loss of continuity
Sealing Capability

IP67 rating
Withstands high pressure spray of 375 cycles of 1020 psi @ 150 gal/hr.
Withstands water submersion of 3 feet without water intrusion

Cable Range for Optimal Sealing

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

Corrosion Resistance  No corrosion after exposure to 100 hrs of salt fog
Electrical
Contact Current Rating

Contact Size:      Max. Current (Amps):
Size 20               18
Size 16               28
Size 12               40

Contact Resistance
10 mΩ for cable ≤ 18 Ga.
6.7 mΩ for cable > 16 Ga.
Dielectric Withstanding Voltage 1000 V AC
Insulation Resistance Greater than 20 MΩ
Mechanical
Contact Retention to Housing  Contact Size:     Retention Force:
Size 20               160 N
Size 16               270 N
Size 12               365 N
Mating Torque 
Less than 4 Nm
Un-mating Torque
Less than 4 Nm
Physical
Housing Glass filled nylon
Seals 
Silicone
Contact 
Copper alloy
Female Terminal Hood Stainless steel
Plating 
Nickel and gold with tin in crimp area

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 sea)

23 Way
23 size 16
Thinwall (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)
Regular/heavy wall (orange seal)

HES Assembly Part Numbers — Standard Configuration

Description – HES Assembly
New Part Number Old Part Number (backshell, non-backshell) New Mating Part Number
 47 Way M Asm Thin  15544324
 13719103, 13653493  15544892
 47 Way F Asm Thin  15544892
 13719104, 13653492  15544324
 31 Way M Asm Thin   15544325
 13719105, 13667925
 15544893
 31 Way M Asm Thick  15544326  13719107, 13698338  15544894
 31 Way F Asm Thin  15544893  13719106, 13667935
 15544325
 31 Way F Asm Thick  15544894  13719108, 13698339  15544326
 29 Way M Asm Thin  15544327
 13719109, 13697106  15544895
 29 Way M Asm Thick  15544328
 13719111, 13698344
 15544896
 29 Way F Asm Thin  15544895  13719110, 13697107
 15544327
 29 way F Asm Thick  15544896
 13719112, 13698345
 15544328
 23 Way M Asm Thin  15544329
 13719113, 13697104  15544897
 23 Way M Asm Thick  15544330    13719115, 13698342  15544898
 23 Way F Asm Thin
 15544897  13719114, 13697105  15544329
 23 Way F Asm Thick  15544898
 13719116, 13698343
 15544330
 21 Way M Asm Thin
 15544331
 13719117, 13697102  15544899
 21 Way M Asm Thick  15544332  13719119, 13698340  15544901
 21 Way F Asm Thin  15544899
 13719118, 13697103  15544331
 21 Way F Asm Thick  15544901
 13719121, 13698341  15544332
 19 Way M Asm Thin  15544333
 13719123, 13697108  15544902
 19 Way M Asm Thick  15544334  
 13719125, 13698346
 15544903
 19 Way F Asm Thin  15544902 
 13719124, 13697109
 15544333
 19 Way F Asm Thick  15544903
 13719126, 13698347  15544334

HES Assembly Part Numbers — Reverse Configuration

Description – HES Assembly
New Part Number Old Part Number (backshell, non-backshell) New Mating Part Number
 31 Way M Asm Thin
 15544343  13765454, 13765449
 15544348
 31 Way M Asm Thick  15544344 
 13765455, 13765450 
 15544349
 31 Way F Asm Thin  15544348
 13765456, 13765452
 15544343
 31 Way F Asm Thick
 15544349
 13765457, 13765453   15544344
 19 Way M Asm Thin
 15544345 
 13765458, 13752444  15544350
 19 Way M Asm Thick  15544346 
 13765459, 13765447
 15544351
 19 Way F Asm Thin  15544350 
 13765460, 13752445  15544345
 19 Way F Asm Thick  15544351  13765461, 13765451
 15544346

Light seal color represents female/sleeve terminal
Dark seal color represents male/pin terminal

Mounting specification for the HES size 24 rceptacle

HES non-threaded backshell conduit adaptors

Conduit Backshell Wire Dress

 Part Number 
 Conduit Size   Configuration
13767802 19 Wire dress straight
13767803
22
13667839
25
13767805 19 Wire dress right angle
13767806 22
13667840 
25

HES plugs

Cavity Seal Plugs

Part Number Terminal Cavity
13756464 Size 20 and 16
13756465 Size 12

Miscellaneous Accessories

Part Number
Description
13780240
Gasket
13813956 
Gasket with adhesive
13752446
Shipping cover (reverse pin cover)
13668988 
Shipping cover (standard pin cover)
15417623 Nut
13840220 Lock washer

Specifications for the 50/60 Way Header Connections

Contacts
Size 20 (1.0 mm)
Sealing Plugs
Size 20 (Note: Different part number than HES circulars)
Operating Temperature
- 55°C to + 125°C
Physical Shock Withstands 50 Gs of mechanical shock in three axes without mechanical failure
Vibration 29.4 Grms
Sealing Capability IPX7
Corrosion Resistance

No corrosion after exposure to 100 hours of salt fog
Chemical resistant flourosilicon face seal on the header

Electrical
Contact Current Rating Size 20: 18 amps maximum current
Contact Plating

Selective gold with tin in crimp area on the female contact
Gold flash palladium on the header pins

 Mechanical
Contact Retention to Housing   

Contact size:     Retention force:
Size 20               90 N

Physical  
Housing
High temperature, glass filled nylon
Seals
Flourosilicone face seals
Silicone cable seals
Contact
Copper alloy
Plating
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
13837191 1
13836627
13837192 2
13836628
13837193
3
13836629
13837194 4
13836630
13837195
5
13936631 13837196
6
13636632 13837197
7
13636633
13837198 8
13836634 13837199 9
13836635
13837200 10

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
13836616
13837180 1
Available upon request 13836617 13837181 2
Available upon request 13836618 13837182
3
Available upon request 13836619
13837183
4
13806063
13836620
13837184 5
13806064 13836621
13837185
6
13806065 13836622 13837186 7
Available upon request 13836623
13837187
8
Available upon request 13836624 13837188 9
Available upon request 13836625
13837189 10

HES Header Accessory

Miscellaneous HES 50/60 Way Header Accessories

Part Number
Description
 15475969
 Backshell 60-way
 15475968  Backshell 50-way
 12129557  Cavity plug

The Delphi Advantage

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.