DEUTSCH INDUSTRIAL
DEUTSCH INDUSTRIAL
3850 Industrial Avenue, Hemet, California 92545 Tel.: (951) 765-2250 - Fax: (951) 765-2255
E-mail : insidesales@deutschipd.net - Web : www.deutschipd.com - Edition 2007
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HD30 & HDP20 Series
Technical Manual
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HD30 & HDP20 Series
Technical Manual
HD/HDP Series - Heavy Duty Field - Proven Interconnection Systems
HD30 & HDP20 Series
Technical Manual
Table of Contents
Improved Techniques
HD/HDP Series Connector Features
Material Specifications
4-5
6
7
8
9
10
11
Truck Applications
Ordering Information
Insert Arrangements
Usable Wire Sizes
Envelope Drawings
Deutsch HD30 Series
A 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.
The Deutsch HD30 Series connector, was developed to meet
the needs of the heavy duty equipment and transportation
industries for rugged, multi-pin, sealed connector systems.
Receptacle Mounting / Mating / Unmating Instructions 12
Assembly Instructions
13
14
15
Bus Applications
Contacts
HD/HDP Accessories
Farm Equipment
Deutsch HDP20 Series
Designed specifically for the truck, bus and off-highway industry,
the HDP20 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.
Construction Equipment
Construction Equipment
2
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HD30 & HDP20 Series
Technical Manual
HD30 & HDP20 Series
Technical Manual
SEALING INTERFACE
“O” RING SEAL
shoulder of the contact, preventing accidental dislodging.
Although securely locked in place, these contacts can be
quickly and easily removed by the use of an inexpensive, non-
conductive removal tool.
The HD/HDP Series
Decreases Costs 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.
WIRE
SEAL
WIRE
SEAL
RECEPTACLE PLUG
LOCKING FINGERS
CONTACT
CONTACT
INSERTION
UNLOCKED POSITION
CONTACT LOCKED
IN POSITION
Corrosion Proof Plastic Shell HDP20 Series Provide
a Cost Effective Alternative
Deutsch plastic shell HDP20 Series provide cost effectiveness
with heavy duty terminations for the truck, bus & off-
highway industries. Other features include: silicone wire and
interfacial seals, visual indication of lock and mated position.
Corrosion proof plastic shells and use of low cost stamped
and formed contacts provides a cost effective solution for your
application.
The HDP20 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.
Electrical Connectors:
Critical to System Reliability and Maintainability
Recent studies indicate that electrical system failures are a
common and constant source of equipment malfunction.
A major area of electrical system failure is in electrical
interconnections. Typical problems include loose and miswired
terminals, corrosion, and contamination of terminals. Coupled
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.
CONTACT
REMOVAL
TOOL INSERTED TO
UNLOCK CONTACT
TOOL AND CONTACT
REMOVED
Sealed Against Moisture and Contaminants
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.
Fabricated 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. Closed wiring also protects maintenance
personnel against accidental shock, yet can be easily checked
for circuit continuity.
Rugged Metal Shell HD30 Series Withstands Years of
Abuse
Deutsch HD30 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 HD30 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.
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
C to
+125
0
C) 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.
Contact Retention Decreases Installation Costs 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. After crimping,
these contacts are easily installed by simply pushing the
contact into place by hand. Contacts are positively secured
by use of “fingers” in the connector which lock behind the
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HD30 & HDP20 Series
Technical Manual
HD30 & HDP20 Series
Technical Manual
Material Specifications
HD30 Plug
Shell: Aluminum
Coupling Ring: Aluminum
Insert Retainer: Thermoplastic
Grommet - Silicone rubber
HDP20 Plug
Shell: Thermoplastic
Coupling Ring: Thermoplastic
Insert Retainer: Thermoplastic
Grommet - Silicone Rubber
HD30 Receptacle
Shell: Aluminum
Insert Retainer: Thermoplastic
Grommet - Silicone rubber
HDP20 Receptacle
Shell: Thermoplastic
Insert Retainer: Thermoplastic
Grommet - Silicone rubber
Vibration
Maintains continuity and exhibits no mechanical or
physical damage during or while subject to a sinusoidal
vibration, having an amplitude of .060 inches double
amplitude and the frequency varied linearly between
limits of 10 to 2000 to 10 Hz with a maximum force
of 20g’s. No electrical discontinuities longer than 1
microsecond.
Moisture Resistance
Water does not penetrate seals when submerged in 3
feet of water.
Corrosion Resistance
Connectors show no evidence of corrosion after
exposure to 48 hours of salt spray per MIL-STD 1344
method 1001.
Fluid Resistance
Connectors show no damage when exposed to most
fluids used in industrial applications.
Dielectric Withstanding Voltage:
Current leakage less than 2 milliamps at 1500 VAC.
Crimp Tensile Strength: (Solid & Stamped)
#20
Size
Contacts
20 lbs.
#16
Size
Contacts
25 lbs.
#12
Size
Contacts
70 lbs.
#8
Size
Contacts
90 lbs.
#4
Size
Contacts
300 lbs.
HD/HDP Mounting Hardware
Panel Nut: Aluminum, Plastic
Lockwasher: Spring Steel - Tin over Nickle
Solid Contacts
Pin: Copper Alloy
Socket: Copper Alloy
Finish: Nickel plating
Optional: Gold plating is
available for dry circuit applications
Sealing Plugs
Thermoplastic: Size 20 thru 8
Elastomer: Size 4
Stamped & Formed Contact
Pin: Copper Alloy
Socket: Copper Alloy
Finish: Nickel plating
Optional: Gold plating is
available for dry circuit applications
HD/HDP Series Connector Features
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.
E. Redundant wire seals prevent contamination from
entering from rear of connector.
F. Sealing plug to fill unused cavities to keep
environmental sealing characteristics intact.
III. Shell
A. Rugged, all metal shell to withstand years of abuse
(HD30) Corrosion resistant all plastic shell (HDP20)
has same features (item C).
B. Positive shell keying prevents mismating.
C. Simple, one quarter turn coupling.
1. Free rotating, captivated coupling ring for fast
assembly.
2. Coupling ring designed to insure proper
environmental sealing with minimum mating
forces.
3. Audio and visual indications of positive locked
condition.
D. Available in a straight plug and single hole mounting
receptacle for easy installation to structure.
I. Contacts
A. Solid copper alloy construction withstands continuous
current overload without degradation.
Cost effective stamped and formed contacts provide
high reliability and low cost.
B. Range of contact and acceptable wire sizes
1. Size #4 AWG 6 (13.0 mm
2
)
2. Size #8 AWG 8 & 10 (8.0 – 5.0 mm
2
)
3. Size #12 AWG 12 & 14 (4.0 – 2.0 mm
2
)
4. Size #16 AWG 14 & 20 (0.5 – 2.0 mm
2
)
5. Size #20 AWG 16 & 22 (0.5 – 1.5 mm
2
)
C. Closed entry socket contact design assures positive
conductivity and eliminates probe damage.
D. Simplified pin contact design limits possibility of
bending.
Performance Specifications
Temperature
Operating at temperatures from -55
0
C to + 125
0
C.
Continuous at rated current
Durability
No electrical or mechanical defects after 100 cycles of
engagement or disengagement.
Physical Shock
No unlocking unmating or other unsatisfactory result during
or after 50 g’s in each of three mutually perpendicular planes.
No electrical discontinuities longer than 1 microsecond.
MIL-STD 202. Method 213, Condition “C”.
Contact Current Rating @ 125
0
C
(continuous)
Contact Size
Max. Current
#20
7.5 amps
#16
13 amps
#12
25 amps
#8
60 amps
#4
100 amps
Insulation Resistance
1000 megohms min. at 25
0
C.
CONTACT RESISTANCE
CONTACT WIRE GAUGE Test Current
AWG(mm
2
}
SIZE
(Amps)
Resistance (mV)
Solids
Resistance (mV)
Stamped & Formed
20
20
(.50)
18
(.80)
16
(1.0)
7.5
7.5
7.5
7.5
10
13
13
18
25
60
60
100
60
60
60
60
60
60
60
60
60
60
60
60
100
100
100
100
100
100
100
100
100
N/A
N/A
N/A
16
20
(.50)
18
(.80)
16
(1.0)
14
(2.0)
IV. Application Tooling
A. Standard crimp tool or semi-automated, high-speed
crimping tool is available.
1. Fast, reliable, uniform results.
2. Simplified procedures mean that only average skill
is required for assembly.
3. No soldering heat means:
a. No chance of heat damage to parts.
b. No wicking to contribute to vibration failure.
B. Inexpensive plastic removal tool designed to eliminate
hidden internal insert damage.
1. Removal tool designed to break rather than injure
connector.
2. Dielectric tool construction prevents shocks to
personnel.
II Inserts
A. The hard plastic insert and closed contact interface
captivate the contacts to prevent “float” and “splay”.
B. Positive contact retention is provided through the use of
plastic locking fingers which snap closed behind the
shoulder of the contact.
C. Interfaces
1. Lead-ins on socket interface properly align bent pins.
2. Hard plastic prevents pins from penetrating dielectric
material.
D. Available in several insert arrangements*.
1. Five in shell size 18 (HD30 or HDP20).
2. Fourteen in shell size 24 (HD30 or HDP20).
*See Page 9
12
8
4
14
(2.0)
12
(3.0)
8
(8.60)
10
(5.60)
6
(13.0)
6
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HD30 & HDP20 Series
Technical Manual
HD30 & HDP20 Series
Technical Manual
HD30 & HDP20 Series Insert Arrangements
All insert arrangements show socket rear insert.
9
7
6
1
2
3
21
7
6
17
8
1
5 4
15
1
3
4
2
C
B
H
D
C
G
E
N
M
C
P
D
A
B
E
F
G
H
8
20
19
10
11
12
19
20
9
F
L
PART NUMBERING SYSTEM
HD X 36 - 24-21 SN - XXX
Designates Deutsch Heavy
Duty Cylindrical Connector
B = Breakaway plug option
N= Non-environmental option
Special Modifications
-072 = Threaded adapter
-059 = Cable clamp/adapter
Wire Seal Options
N = Normal position and wire seals
(Green Ring)
T = Thin wall wire seals option (Grey
Ring)
E = Extra thin wall seal (Blue Ring)
Contact Style
P = Pin (Male) type
S = Socket (Female) type
(Consult factory for options and special
modifications available.)
Shell size and insert layout
5
6
K
L
18
13
5 4
17
14
16 15
18
16
10
2 11
3 12
13
14
2 size 4, 4 size 16**
N, E***
T
S
Z
Y
X
R
U
V
W
18-6*
8 size 12
N, E
14
13
12
11
10
7
9
8
1
2
3
4
18-8
14 size 16
N, E, T
S
R
5
6
N
P
E
D
18-14
2 size16 & 18 size 20
N, E
F
A
B
C
K
M
L
G
H
J
18
17
16
15
5
4
14
6
18-20
21 size 20
N
7
1
2
3
13
12
8
9
10
11
18-21
Type
3 = Standard Commercial - Bulk packed
without contacts or accessories
4 = Kit - Individually packaged with
contacts, sealing plugs, mounting hardware
and removal tool
Style
4 = Receptacle - Jam nut type mounting
6 = Plug
1 size 4, 2 size 8
& 6 size 12**
N, E***
19
18
17
6
16
15
5
14
7
1
4
13
8
2
3
12
X
9
10
11
W
24-9*
1 size 4, 1 size 12
& 12 size 16
N, E
H
G
V
U
T
S
F
A
E
R
B
C
3
D
P
J
K
L
M
N
U
T
S
W
V
H
G
F
R
X
J
A
E
Q
D
P
B
K
24-14
16 size 12
N, E
24-16
1 size 8, 3 size 12
& 14 size 16
N, E
29 17
5
1
6 18
7
2
19
8 20
20
8
19 1 9 21
2
10
29 18
22
7
3
17
1
11
28
23
4
6
5
12
16
15
13
27
14
24
26
25
30
31
24-18
L
C
O
M
N
28 16
27
15
26
4 G
14
25
13
24
12
9 21
3 10
22
23
11
PART NUMBERING SYSTEM
HDP 26 - 24-21 SN - XXXX
Designates Deutsch Heavy
Duty Plastic Connector
Type
2 = Standard Commercial - Bulk
packed without contacts or
accessories
Style
4 = Receptacle - Jam nut type mounting
6 = Plug
Special Modifications
-L015 Threaded Adapter
-L017 Backshell Adapter
N = Normal postion and wire seals (Green Ring)
T = Thin wall wire seals option (Grey Ring)
E = Extra thin wall wire seals (Blue Ring)
Contact Style
P = Pin (Male) type
S = Socket (Female) type
Shell size and insert layout
Deutsch HD30 Series contacts, sealing plugs and tooling are
specified for use in the HDP20 Series. Consult factory for
additional options and special modifications available.
6 size 12
& 13 size 16
N, E
18
6
19
31 15
7
20
1
30 14 5
8
13 4
2
21
29
3
9
12
28
22
10
27 11
23
26 25
24
32
33
16
17
24-19
4 size 12
& 17 size 16
N, E
34
33
9
22 10
23
34
24
21 8
2 11
25
32
7 13
12
20 6
4
5
19 17
15 13 26
31
18 16 14
30
29 28
27
24-21
23 size 16
N,T, E
18 19
7
24-23
4 size12, 19 size 16
& 6 size 20
E
34
47
46
20 35
33
32
8
36
31
21
19
22
18
2
9
10
30
23
45
3
7
1
29
11
37
17
44
24
16 6
5 4
38
12
14 13 25 39
43 28 15
42 27
41
26 40
24-29
31 size 16
T, E
24-31
35
17
20
8
21
+3
2
1
4
9 22
16 6
1 2 10 23
32 15
5
3
31
4
11 24
30 14
25
13 12
29
26
28
27
33
9
8
7
+6
5
33 size 20
N
* Arrangement
** Description
*** Rear Seal
24-33
12 size 12 &
22 size 20
N
24-34
3 size 16
& 32 size 20
N,E
24-35
5 size16
& 42 size 20
E
24-47
2 size 8, 2 size 12
& 5 size 16
N,E
9
24-91
8
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