HD30 & HDP20 Series Technical Manual

Transcription

1 Deutsch Industrial UK Stanier Road St. Leonards On Sea East Sussex T R England Ph. (0) 5 ax (0) 55 industrialuk@deutsch.net Deutsch Industrial Europe raunhoferstrasse b Martinsried Germany Ph. + (0) -0 ax + (0) 5 info.eu@deutsch.net DEUTSH IDUSTRIL Deutsch Industrial US 50 Industrial ve. Hemet, 5 US Ph. +1 (51) 5- ax +1 (51) 5-5 insidesales-ipd@deutsch.net Deutsch Industrial Japan IHO Deutsch Ltd. -, Ohyamakanai-cho Itabashi-ku, Tokyo 1-00 Japan Ph ax rtakemura@nihon-deutsch.co.jp IDUSTRIL HD & HDP Series Technical Manual 50 Industrial venue, Hemet, alifornia 5 Tel.: (51) 5- - ax: (51) 5-5 Web : - Edition 0

2 HD & HDP Series Technical Manual HD & HDP Series Technical Manual HD/HDP Series - Heavy Duty ield - Proven Interconnection Systems Table of ontents Improved Techniques -5 HD/HDP Series onnector eatures Material Specifications Truck pplications Ordering Information Insert rrangements Usable Wire Sizes Envelope Drawings Deutsch HD Series heavy duty, environmentally sealed, multi-pin circular connector, featuring quick connect-disconnect bayonet coupling, single hole bulkhead mounting, silicone seals, with a rear insertion/rear removal contact system. Receptacle Mounting / Mating / Unmating Instructions ssembly Instructions The Deutsch HD Series connector, was developed to meet the needs of the heavy duty equipment and transportation industries for rugged, multi-pin, sealed connector systems. us pplications ontacts 1 HD/HDP ccessories arm Equipment Deutsch HDP Series Designed specifically for the truck, bus and off-highway industry, the HDP Series is a heavy duty rated, environmentally sealed, composite shell, multi-pin connector. The plug features a quick connect-disconnect bayonet style coupling and the receptacle is designed for single hole mounting. Thus reducing assembly line time and installation costs. onstruction Equipment

3 HD & HDP Series Technical Manual HD & HDP Series Technical Manual Electrical onnectors: ritical to System Reliability and Maintainability Recent studies indicate that electrical system failures are a common and constant source of equipment malfunction. major area of electrical system failure is in electrical interconnections. Typical problems include loose and miswired terminals, corrosion, and contamination of terminals. oupled with these problems, the impact of sophisticated safety devices, automated check-out systems, and other increased use of electronics, call for a re-examination of traditional termination techniques. To the operator, termination failures mean excessive down time and maintenance costs. This adds up to slipped production schedules, cost over-runs and user problems. The end result: decreased profits and a loss of share of the market. In today s competitive arena, improved electrical connectors can make the difference between a growing, profitable operation or a losing one. The HD/HDP Series Decreases osts and UP-Grades Performance The Deutsch HD/HDP Series was developed to provide a solution to today s system problems found in the heavy duty trucking, equipment and transportation industries. The HD/ HDP is a cylindrical, multi-pin, sealed device utilizing crimp type contacts that are quickly and easily inserted or removed. Use of the HD/HDP Series eliminates several other common connector problems. Problems associated with assembly and network time, operational breakdowns requiring costly repairs and lengthy out of service time in the field have all been reduced and/or eliminated by the judicious application of the HD/HDP Series. Deutsch HD/HDP Series provide the widest selection of interconnections for critical circuits requiring heavy-duty environmental terminations. Together, the HD and HDP offer common layouts, common tooling, the same adaptability to backshells and both meet the performance standards for heavy duty applications. So whether you are looking for rugged HD metal shells or cost effective HDP plastic shells, Deutsch offers the best product for your applications while holding the line on hidden inventory and assembly costs. Some of the benefits of the Deutsch HD/HDP Series include: Quick, fool-proof assembly, decreasing time on the assembly line and eliminating miswiring. Simple and easy to rework, decreasing down time and increasing profits to the operator. Sealed against moisture and contaminants, eliminating open wiring system. Operation under severe shock and vibration, reducing break down and out of commission loss due to rugged operating conditions. Performance over a wide temperature range (-55 0 to +1 0 ) meaning continuous operation in all environments, from arctic to desert conditions. Human factors engineered to assure that assembly and rework can be reliably handled by unskilled personnel. SELIG ITERE O RIG SEL shoulder of the contact, preventing accidental dislodging. lthough securely locked in place, these contacts can be quickly and easily removed by the use of an inexpensive, nonconductive removal tool. orrosion Proof Plastic Shell HDP Series Provide a ost Effective lternative Deutsch plastic shell HDP Series provide cost effectiveness with heavy duty terminations for the truck, bus & offhighway industries. Other features include: silicone wire and interfacial seals, visual indication of lock and mated position. orrosion proof plastic shells and use of low cost stamped and formed contacts provides a cost effective solution for your application. The HDP uses a bayonet coupling system to provide a vibration resistant locking mechanism. This shell provides a multiple keying system that positively prevents mismating and makes plug and receptacle coupling quick and easy. Receptacles mount with a single hole using a flat to prevent the connector from rotating. Rugged Metal Shell HD Series Withstands Years of buse Deutsch HD Series features a lightweight, yet compact and rugged metal shell to protect contacts and sealing grommets. This shell provides a multiple keying system that positively prevents mismating and makes plug and receptacle coupling quick and easy. The HD Series uses a bayonet coupling system that provides a positive vibration resistant locking mechanism with visual indication of proper mate and lock. This quick disconnect system requires only a quarter turn to operate. Easy installation to structure is provided by a single one-hole mounting system using a flat to prevent the connector from rotating during assembly or service. by use of fingers in the connector which lock behind the 5 WIRE SEL OTT ISERTIO OTT REMOVL REEPTLE LOKIG IGERS OTT ULOKED POSITIO TOOL ISERTED TO ULOK OTT PLUG OTT LOKED I POSITIO TOOL D OTT REMOVED Sealed gainst Moisture and ontaminants WIRE SEL Unlike terminal strips, binding posts and other open-wiring systems, the Deutsch HD/HDP Series is a completely sealed unit. The rear of the connector features an integral grommet wire seal that automatically seals each contact as it is locked into place during installation. There is no extra hardware to fasten or tighten or potting operation to achieve this seal. abricated from tear resistant, high temperature silicone, this rear grommet protects the contact from moisture, sand, dust, lubricating oils, road salt, hydraulic fluid, grease, mud and other contaminants encountered in heavy duty use. The elimination of open-wiring systems does away with such common hazards as short circuits due to metallic objects across the terminals. This is especially important during loading or refueling operation when a spark could cause a serious explosion. losed wiring also protects maintenance personnel against accidental shock, yet can be easily checked for circuit continuity. ontact Retention Decreases Installation osts and Increases Reliability The HD/HDP Series uses crimp type, solid copper alloy contacts for damage proof performance and stamped & formed copper alloy contacts for cost effectiveness. Each style has the ability to carry continuous high operating current loads without overheating. The contacts or terminals are crimp terminated using automatic tooling for production and inexpensive readily available hand tools for field maintenance. fter crimping, these contacts are easily installed by simply pushing the contact into place by hand. ontacts are positively secured

4 HD & HDP Series Technical Manual HD & HDP Series Technical Manual HD/HDP Series onnector eatures Deutsch HD/HDP Series environmental connectors offer the advantages of decreased costs and upgraded performance. Designed to withstand years of abuse, the Deutsch HD/HDP Series is setting the pace in the Heavy Equipment Industry. Key features common to the HD/HDP Series are itemized below. I. ontacts. Solid copper alloy construction withstands continuous current overload without degradation. ost effective stamped and formed contacts provide high reliability and low cost.. Range of contact and acceptable wire sizes 1. Size # WG (.0 mm ). Size # WG & ( mm ). Size # WG & 1 (.0.0 mm ). Size # WG 1 & (0.5.0 mm ) 5. Size # WG & ( mm ). losed entry socket contact design assures positive conductivity and eliminates probe damage. D. Simplified pin contact design limits possibility of bending. II Inserts. The hard plastic insert and closed contact interface captivate the contacts to prevent float and splay.. Positive contact retention is provided through the use of plastic locking fingers which snap closed behind the shoulder of the contact.. Interfaces 1. Lead-ins on socket interface properly align bent pins.. Hard plastic prevents pins from penetrating dielectric material. D. vailable in several insert arrangements*. 1. ive in shell size 1 (HD or HDP).. ourteen in shell size (HD or HDP). *See Page E. Redundant wire seals prevent contamination from entering from rear of connector.. Sealing plug to fill unused cavities to keep environmental sealing characteristics intact. III. Shell. Rugged, all metal shell to withstand years of abuse (HD) orrosion resistant all plastic shell (HDP) has same features (item ).. Positive shell keying prevents mismating.. Simple, one quarter turn coupling. 1. ree rotating, captivated coupling ring for fast assembly.. oupling ring designed to insure proper environmental sealing with minimum mating forces.. udio and visual indications of positive locked condition. D. vailable in a straight plug and single hole mounting receptacle for easy installation to structure. IV. pplication Tooling. Standard crimp tool or semi-automated, high-speed crimping tool is available. 1. ast, reliable, uniform results.. Simplified procedures mean that only average skill is required for assembly.. o soldering heat means: a. o chance of heat damage to parts. b. o wicking to contribute to vibration failure.. Inexpensive plastic removal tool designed to eliminate hidden internal insert damage. 1. Removal tool designed to break rather than injure connector.. Dielectric tool construction prevents shocks to personnel. Material Specifications HD Plug Shell: luminum oupling Ring: luminum Insert Retainer: Thermoplastic Grommet - Silicone rubber HD Receptacle Shell: luminum Insert Retainer: Thermoplastic Grommet - Silicone rubber HD/HDP Mounting Hardware Panel ut: luminum, Plastic Lockwasher: Spring Steel - Tin over ickle Solid ontacts Pin: opper lloy Socket: opper lloy inish: ickel plating Optional: Gold plating is available for dry circuit applications Sealing Plugs Thermoplastic: Size thru Elastomer: Size Performance Specifications Temperature Operating at temperatures from to ontinuous at rated current Durability o electrical or mechanical defects after 0 cycles of engagement or disengagement. Physical Shock o unlocking unmating or other unsatisfactory result during or after 50 g s in each of three mutually perpendicular planes. o electrical discontinuities longer than 1 microsecond. MIL-STD. Method, ondition. ontact urrent 1 0 (continuous) ontact Size Max. urrent #.5 amps # amps # amps # 0 amps # 0 amps Insulation Resistance 00 megohms min. at 0. HDP Plug Shell: Thermoplastic oupling Ring: Thermoplastic Insert Retainer: Thermoplastic Grommet - Silicone Rubber HDP Receptacle Shell: Thermoplastic Insert Retainer: Thermoplastic Grommet - Silicone rubber Stamped & ormed ontact Pin: opper lloy Socket: opper lloy inish: ickel plating Optional: Gold plating is available for dry circuit applications Vibration Maintains continuity and exhibits no mechanical or physical damage during or while subject to a sinusoidal vibration, having an amplitude of.00 inches double amplitude and the frequency varied linearly between limits of to 00 to Hz with a maximum force of g s. o electrical discontinuities longer than 1 microsecond. Moisture Resistance Water does not penetrate seals when submerged in feet of water. orrosion Resistance onnectors show no evidence of corrosion after exposure to hours of salt spray per MIL-STD method 01. luid Resistance onnectors show no damage when exposed to most fluids used in industrial applications. Dielectric Withstanding Voltage: urrent leakage less than milliamps at 00 V. rimp Tensile Strength: (Solid & Stamped) # Size ontacts lbs. # Size ontacts lbs. # Size ontacts 0 lbs. # Size ontacts 0 lbs. # Size ontacts 0 lbs. OTT OTT RESISTE WIRE GUGE WG(mm } (.50) 1 (.0) (1.0) (.50) 1 (.0) (1.0) Test urrent (mps) Resistance (mv) Solids Resistance (mv) Stamped & ormed (.0) (.0) (.0) 0 0 (.0) (5.0) / 0 / (.0) 0 0 /

5 HD & HDP Series Technical Manual HD & HDP Series Technical Manual HD & HDP Series Insert rrangements ll insert arrangements show socket rear insert. Designates Deutsch Heavy Duty ylindrical onnector = reakaway plug option = on-environmental option Type = Standard ommercial - ulk packed without contacts or accessories = Kit - Individually packaged with contacts, sealing plugs, mounting hardware and removal tool Style = Receptacle - Jam nut type mounting = Plug PRT UMERIG SYSTEM HD X - -1 S - XXX (onsult factory for options and special modifications available.) Special Modifications -0 = Threaded adapter -05 = able clamp/adapter Wire Seal Options = ormal position and wire seals (Green Ring) T = Thin wall wire seals option (Grey Ring) E = Extra thin wall seal (lue Ring) ontact Style P = Pin (Male) type S = Socket (emale) type Shell size and insert layout 1 P 1 D E E D M H G L G K H 1 1 L * size, size ** *** Z Y S T X R W U -* 1 size, size & size ** *** V 1- size size, 1 size & size size, T 5 P R S D 1- size & 1 size E M L G - size K H J size size, size & 1 size Designates Deutsch Heavy Duty Plastic onnector Type = Standard ommercial - ulk packed without contacts or accessories Style = Receptacle - Jam nut type mounting = Plug PRT UMERIG SYSTEM HDP - -1 S - XXXX Deutsch HD Series contacts, sealing plugs and tooling are specified for use in the HDP Series. onsult factory for additional options and special modifications available. Special Modifications -L0 Threaded dapter -L01 ackshell dapter = ormal postion and wire seals (Green Ring) T = Thin wall wire seals option (Grey Ring) E = Extra thin wall wire seals (lue Ring) ontact Style P = Pin (Male) type S = Socket (emale) type Shell size and insert layout size & size size * rrangement ** Description *** Rear Seal V U W T X H J W X K K 1 5 G V J L 1 H 1 L U 1 M M G G T E D 1 S E D 1 O S R P R Q P -1 size & 1 size size & size - size,t, E size & size,e - size, 1 size & size E size & size E size T, E size, size & 5 size,e 5

6 HD & HDP Series Technical Manual HD & HDP Series Technical Manual ISERT RRGEMET SEL TYPE T E USLE WIRE OTT # # # # # REOMMEDED WIRE ISULTIO O.D. OR: -SEL Green Ring (1.0-.1).0-. (.5-.0).-.10 (.0-.) (.-.).0-. (.-.) T-SEL Grey Ring (1.0-.1).0-. (.-.0) (.-.) (.-.).1-. (.-.) E-SEL lue Ring (1.0-.1) ( ).0-. (.-.01).5-. (.-5.5).1-. (.-.) MI POLRIZIG KEY 1 0 SHELL 1 MX DI 1 0 Series Plug 1. (.) 1. (.) EVELOPE DRWIGS OR HD/HDP SERIES MX. DI. OVER KURL POLRIZIG IDITOR DI (. +0.) 1.0 (. +0.).05 MX DI. METL PLSTI METL PLSTI OLOR ODE RIG PRT UMER 1-0* * METL Panel ut* SHELL 1.1 (.5+.) +.0 THRED (.0 +.) 1.5 (. +.) PLSTI (.0) THRED THRED 1-1/ - 1 UE- 1 /-1 UE *1 * * * *1 Modified T Seal. See envelope print * Modified E Seal. See envelope print DI MI POLRIZIG KEY ( ) (.+.0) PEL UT MOUTIG TORQUE 0-0 I. L. HD 1 SHELL (.-1..M.) 5-55 I. L. HDP 1 SHELL ( M.) HD SHELL 50-5 I. L. (.5-..M.) 5-5 I. L. HDP SHELL (.-..M.).0+.0 (.5+0.) onnector Identification ( ) OLOR ODED RIG MX.DI DI DI olor code is visible from the rear of the receptacle or plug. MTIG SLOT POSITIOS Green: ormal Seal Grey: Thin Wall Seal lue: Extra Thin Seal UTIO: Undersize wire insultation is a major cause for leakage. Shrink tubing SHOULD OT E USED. SHELL (. +0.) 1.5 (0. +0.) Series Receptacle (.5 +0.).000 ( ) (1. +0.) 1.5 (. +0.) THRED 1 1/-1 UE 1 /-1 UE PRT O. 1* ** 1* ** Panel Lockwasher* SHELL DI (.0 +.) 1.0 (.1 +.) * Metal Panel uts are used on HD only. ** or use on HDP. DI (.0 +.).0 (5. +.) RE (1.5+.).0 (0.51+.).0 (1.5+.).0 (1.5 +.)

7 HD & HDP Series Technical Manual HD & HDP Series Technical Manual Receptacle Mounting OTT ISERTIO SSEMLY ISTRUTIOS OTT REMOVL LT ULOKIG IGERS OTT PEL UT LOKWSHER ULOKED POSITIO ontact Insertion OTT LOKED I POSITIO TOOL ISERTED TO ULOK OTT TOOL D OTT REMOVED OETOR REEPTLE STRUTURE REOMMEDED O MOUTIG HOLE (0.) +.0 (0.) (0.00) SHELL (.) 1. (.0) 1. (.) 1. (1.5) 1 Grasp contact approximately (. mm) one inch behind the contact crimp barrel. Hold connector with rear grommet facing you. OTE: or unused wire cavities, insert sealing plugs for full environmental sealing. Push contact straight into connector grommet until a positive stop is felt. slight tug will confirm that it is properly locked in place.. (.).0 (1.5) ontact Removal D Hole Punches available from: LDD Industrial Sales. Mating / Unmating Instructions To mate the plug and the receptacle, line up the index groove on the plug with the flat surface on the receptacle, turn 1/ turn clockwise. You will feel and hear the pieces snap into the locked position. To unmate the plug and receptacle, reverse the above procedure. VISULLY ISPETLE OR PROPER MTIG POLRIZIG IDITOR HDP SERIES & HD SERIES MTE 1 With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. Slide tool along into the insert cavity until it engages contact and resistance is felt. OTE: Do not twist or insert tool at an angle. Pull contact-wire assembly out of connector. UMTE Removal Tools Sealing Plugs ORML WIRE SELS () EXTR THI WLL WIRE SELS (E) SELIG PLUG UTIO: When mating or unmating plug and receptacle, disassemble by hand. DO OT use pliers or any other tool. PRT O WIRE RGE WG THI WLL WIRE SELS (T) PRT O WIRE RGE WG OTT - PRT O

8 HD & HDP Series Technical Manual HD & HDP Series Technical Manual OTTS D PPLITIO DT Solid ontacts PI SOLID OTT PRT UMERS SOKET 00--** 0-1-** 0--** 0-1-** 00--** 0--** 00--** 0--** 00--0** 0--0** 00--0** 0--0** WIRE WG (mm ) (0.50) - ( ) 1 (.0) -1 (.0 -.0) - (.0-5.0) (.0) REOMMEDED STRIP LEGTH IHES (mm).-.1 ( ).0 -. (.5 -.).0 -. (.5 -.). -. (5. -.1). -. (. -.50).-. (.-.50) MI OTT RETETIO LS () () () 5 () 5 () RE RIMP TESILE LS () * See Envelope Print onsult factory for alternate finishes. Solid ontacts Stamped and ormed ontacts MX RTED MPS T 1 0 OTIUOUS.5 () 5- (-) 0 () 5-0 ( - ) 1-0 (55-00) 0 0 () 0 onnector P/ *HDP*--****-LO vailable in plugs and receptacles onnecting hardware available through distribution HD/HDP ESSORIES HDP Straight ackshell P/ Locking tabs ensure closure Socket ISPETIO HOLE Pin Socket Pin ISPETIO HOLE Locking tabs ensure closure Stamped & ormed ontacts ** or proper dies and stamped & formed crimp dimensions - See Envelope Size onsult factory for alternate finishes Size Size , Size Size Size 1 STMPED & ORMED OTT PRT UMERS PI SOKET 0--01** --01** 0--0** --0** / --0** ** -1-01** 0-1-** -1-** 0--01** --01** 0--0** --0** 0--0** --0** 0--0** --0** 0--** --** / --1** 0--01** --01** 0--0** --0** RRIER STRIP IDETIITIO WIRE WG (mm) - ( ) - ( ) - ( ) 1-1 (.0 -.5) 1-1 (.0 -.5) 1-1 (.0 -.5) - ( ) 1-1 (.0 -.5) 1-1 (.0 -.5) - (.5-1.0) - (.5-1.0) - 1 (.0 -.0) - (.0 -.0) WIRE ISULTIO O.D. RGE (1.1 -.) (1. -.) (1.1 -.) (.1 -.1) (.1 -.1) ( ) ( ) ( ) ( ) ( ) ( ) (. -.). -. (.5-5.1) REOMMEDED STRIP LEGTH IHES (mm) (.1-5.0) (.1-5.0) (.1-5.0) (.1-5.0) (.1-5.0) ( (.1-5.0) (.1-5.0) (.1-5.0). -. (.5-5.). -. (.5-5.). -.5 (5. -.1). -.5 (5. -.) MI OT. RETETIO LS () () () () () () RE RIMP TESILE LS () - ( - 5) - ( - 5) - ( - 5) - (1 - ) 0 () 0 () MX RTED MPS T 1 0 OTIUOUS *HDP*--****-LO1 HDP*-1-****-L01 vailable in plugs and receptacles able lamp* *Metal Shells Only -0 DPTOR OLY -05 WITH DRI HOLES -L00 WITHOUT DRI HOLES Designed to interconnect with the HD Series receptacles and provide an emergency disconnect between farm tractors and implements requiring power connections. HD - reakaway Plugs can be specified with pin or socket contacts and cable clamps (-05 mod). Minimum force required to emergency disconnect is 50 lbs. Maximum force required is 0 lbs. Mate with HD Series Only. PRT O. HD --XXS-05 1 HD -1-XXS Straight Strain Relief (luminum) PRT O. WHDS--1 1 WHDS-1-1 PRT O. WITHOUT MTG HI (DD) HD - -1 E 1 HD -1-1 E 0 0 Strain Relief (luminum) PRT O. WHDS-- 1 WHDS-1- (onnector shown for reference only.) HD - HD Series Only reakaway Plug Protective aps Protective aps Plug cap for receptacle protection (luminum) Receptacle cap for plug protection (luminum) PRT O. WITHOUT MTG HI (DD) HD - -1 E 1 HD -1-1 E