Delphi Connection Systems for Commercial Vehicles

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) and is offered with and without backshells. 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 nut for simplified mating
  
• Visual lock engagement window
• Color coded seals to distinguish between various cable diameters as well as terminal gender
• Low torque engage
• 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

• 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
  

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

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 Circular Connector Assemblies — Standard Configuration

HES Circular Connector Assemblies — Reverse Configuration

*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

HES plugs

Cavity Seal Plugs

Miscellaneous Accessories

Specifications for the 50/60 Way Header Connections

HES 50-way Header System

Miscellaneous HES 50/60-Way Header System

HES Header Accessory

Miscellaneous HES 50/60 Way Header Accessories

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.