1. Introduction
This manual provides comprehensive instructions for the proper use, assembly, and maintenance of the Deutsch HDP20 Bulkhead 47-pin Connector Kit. This kit is designed for robust electrical connections in demanding environments, featuring 14 and 20 AWG solid contacts. Adherence to these instructions will ensure optimal performance and longevity of the connector system.
2. Product Components
The Deutsch HDP20 Bulkhead 47-pin Connector Kit includes the following components:
- HDP20 Bulkhead Connector Shells (Male and Female)
- 47-pin Solid Contacts (14 AWG and 20 AWG)
- Wedge Locks (for contact retention)
- Sealing Plugs (for unused cavities)
- Contact Removal/Insertion Tools
- Mounting Nut
Figure 2.1: Overview of the Deutsch HDP20 Bulkhead 47-pin Connector Kit components, including connector shells, contacts, wedge locks, and tools.
3. Setup and Assembly
Proper assembly is critical for the performance of Deutsch HDP20 connectors. Follow these steps carefully:
- Wire Preparation: Strip approximately 4mm (0.16 inches) of insulation from the wire end. Ensure the wire strands are not frayed.
- Crimping Contacts: Select the appropriate solid contact (14 AWG or 20 AWG) for your wire gauge. Using a suitable crimping tool (not included in this kit), crimp the contact onto the stripped wire. Ensure a secure, gas-tight crimp.
- Contact Insertion: Hold the connector shell with the mating face pointing away from you. Insert the crimped contact into the correct cavity on the wire side of the connector. Push the contact straight in until a distinct "click" is felt, indicating the contact is locked into place. Gently pull on the wire to verify it is securely seated.
- Wedge Lock Installation: Once all contacts are inserted, install the appropriate wedge lock into the connector. The wedge lock provides additional contact retention and environmental sealing. Ensure it is fully seated.
- Bulkhead Mounting: For bulkhead applications, insert the connector through the panel opening. Secure it with the provided mounting nut, tightening it to the recommended torque specifications (refer to Deutsch specifications for exact values, typically hand-tight plus a quarter turn).
Figure 3.1: Detail of the male HDP20 connector face, showing pin cavities and Deutsch branding.
Figure 3.2: Detail of the female HDP20 connector face, showing socket cavities and part markings.
4. Operating Instructions
Once assembled and mounted, connecting and disconnecting the HDP20 series connectors is straightforward:
- Connecting: Align the male and female connector halves, ensuring the keyways are correctly oriented. Push the connectors together firmly until the locking mechanism engages. A distinct click or positive resistance indicates a secure connection.
- Disconnecting: To disconnect, pull back on the coupling ring (if present) or apply firm, steady pressure to separate the connector halves. Avoid pulling directly on the wires.
5. Maintenance
Deutsch HDP20 connectors are designed for durability and require minimal maintenance. However, periodic inspection is recommended:
- Cleaning: If exposed to dirt or debris, clean the connector surfaces with a lint-free cloth and a mild, non-conductive cleaning solution. Ensure connectors are dry before re-mating.
- Inspection: Check for any signs of physical damage, corrosion on contacts, or degradation of sealing components. Replace damaged connectors or components as necessary.
- Contact Removal: If a contact needs to be replaced, use the appropriate Deutsch contact removal tool. Insert the tool into the contact cavity from the mating face side, push until resistance is felt, and gently pull the wire from the wire side.
6. Troubleshooting
This section addresses common issues encountered during assembly or use:
- Contacts Not Locking:
- Ensure the contact is fully inserted until a "click" is heard/felt.
- Verify the correct contact size for the cavity.
- Check for debris in the cavity preventing full insertion.
- Ensure the wedge lock is not installed prematurely.
- Difficulty Inserting Contacts:
- Confirm the wire is properly crimped and the contact is not deformed.
- Use gentle, direct force. Avoid bending the contact.
- Damaged Removal Tool:
- The plastic removal tools can be fragile. Apply force carefully and ensure the tool is correctly aligned with the contact. Replacement tools are available.
- Intermittent Connection:
- Inspect contacts for corrosion or damage.
- Verify proper crimp quality.
- Ensure wedge locks are fully seated.
7. Specifications
Key technical specifications for the Deutsch HDP20 Bulkhead 47-pin Connector Kit:
| Feature | Detail |
|---|---|
| Brand | Deutsch |
| Model Number | HDP47-WNS-1620-KIT |
| Connector Type | Pin (Circular) |
| Connector Gender | Male and Female |
| Number of Pins | 47 |
| Wire Gauge Compatibility | 14 AWG, 20 AWG (Solid Contacts) |
| Contact Material | Brass |
| Insulation Material | Nylon |
| Temperature Rating | -55°C to +125°C (221°F) |
| Specification Met | UL |
| Resistance | 1000 MΩ minimum at 25°C |
| Current Leakage | < 2 mA at 1500 VAC |
| Vibration Resistance | Resistant to 3D Vibration of 20G's at 10-2000Hz |
| Shock Resistance | Resistant to 3D Physical Shocks at 50 G's |
| Immersion Rating | Withstand immersion under 3ft of water |
| Durability | No defect after 100 Cycles of Connect & Disconnect |
| Package Dimensions | 4.65 x 4.57 x 2.17 inches |
| Item Weight | 5.1 ounces |
Figure 7.1: Manufacturer's performance specifications and guarantees.
8. Warranty and Support
For specific warranty information or technical support regarding your Deutsch HDP20 Bulkhead 47-pin Connector Kit, please refer to the official Deutsch website or contact their customer service department. Keep your purchase receipt for warranty claims.
Figure 8.1: TE Connectivity, the manufacturer of Deutsch products.