Panel connector 2 - HDP20 24-33 revised to 24-47

Use Deutsche HDP20 24-33 connector

Panel mount receptacle should have male contacts

Size 20 contacts - 33 available

Standard contacts (20, 22AWG)

• Intercom - pilot mic (3 wires + GND), co-pilot mic (3 wires + GND), pilot phones (3 wires + GND), co-pilot phones (3 wires + GND)
• LH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• RH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• gnd consolidated into one wire (-1 wire)
• ap disconnect lines consolidated and joined to servo ap loom disconnect and not passed to connector pin (-2 wires)
• ptt lines consolidated to respective pilot mic lines and not passed to connector pin (-2)
• So LH trim up, LH trim down, LH spare, RH trim up, RH trim down, RH spare, gnd passed to connector - 7 x 20 AWG
• LH fuel sender - 2 x 20AWG (active, gnd)
• RH fuel sender - 2 x 20AWG (active, gnd)
• Consoldated into 3 wires (LH, RH, gnd) 3 x 20 AWG
• oil temperature (Rotax P/N 965531) - 1 wire 18 AWG
• coolant temperature 1 (Rotax P/N 965531) - 1 wire 18 AWG
• coolant temperature 2 (Rotax P/N 965531) - 1 wire 18 AWG
• OAT sensor - 2 wires (22 AWG)
• Pitch and roll servos - 2 x 20 AWG (pos, gnd) + 1 x 22AWG (disconnect)
• disconnect joined to joystick loom - not passed to connector - so only 2 x 20 AWG

Total interconnect wires: 12 (intercom) + 7 (joysticks) + 3 (senders) + 1 (oil temp) + 2 (coolant temp) +2 (OAT) + 2 (servos) = 29 wires

Parts List

• 1 x HDP24-24-33PN receptacle with male contacts
• 1 x HDP26-24-33SN plug with female contacts
• 33 x 0462-201-2031 Sockets (for 20, 22 AWG), gold
• 33 x 0460-202-2031 Pins (for 20, 22 AWG), gold
• 1 x 2414-001-2486 Lockwasher Wave S-Steel Shell Size 24
• 1 x 2411-001-2405 Nut Plastic Shell Size 24

UPDATE 250620:

Use Deutsche HDP20 24-47 connector since the 24-33 is difficult to source.

Blocking pins can be used to prevent inadvertent swapping of plugs

Panel mount receptacle should have male contacts

Size 16 contacts - 5 available

Non-green band contacts (16, 18, 20 AWG) - bought in from connector 3

• Left landing light - 3 x 16AWG downstream
• Right landing light - 3 x 16 AWG downstream
• The shields will be consoldiated, all 5 availiable contacts will be used

Purple-band nickel contacts (16, 18 AWG) - bought in from connector 3

• Fuel pump - 2 wires - 16 AWG (panel mount should be male)
• magneto grounding wires - 3 wires 2x 18 AWG + shield (panel mount ideally should be female, plug only grounds, but could be male on account of the limited flow if shorted to ground)

Standard nickel contacts (20, 22 AWG) - bought in from connector 3

• starter solenoid - 2 wires 20-22 AWG (panel mount should be male)

Merged in with the original connections above

Standard contacts (20, 22AWG)

• Intercom - pilot mic (3 wires + GND), co-pilot mic (3 wires + GND), pilot phones (3 wires + GND), co-pilot phones (3 wires + GND)
• LH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• RH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• gnd consolidated into one wire (-1 wire)
• ap disconnect lines consolidated and joined to servo ap loom disconnect and not passed to connector pin (-2 wires)
• ptt lines consolidated to respective pilot mic lines and not passed to connector pin (-2)
• So LH trim up, LH trim down, LH spare, RH trim up, RH trim down, RH spare, gnd passed to connector - 7 x 20 AWG
• OAT sensor - 2 wires (22 AWG)
• Pitch and roll servos - 2 x 20 AWG (pos, gnd) + 1 x 22AWG (disconnect)
• disconnect joined to joystick loom - not passed to connector - so only 2 x 20 AWG

except for

• LH fuel sender - 2 x 20AWG (active, gnd)
• RH fuel sender - 2 x 20AWG (active, gnd)
• Consoldated into 3 wires (LH, RH, gnd) 3 x 20 AWG
• oil temperature (Rotax P/N 965531) - 1 wire 18 AWG
• coolant temperature 1 (Rotax P/N 965531) - 1 wire 18 AWG
• coolant temperature 2 (Rotax P/N 965531) - 1 wire 18 AWG

which will now be directly connected to the EMS220 from the firewall forward and the wings via its DB connectors

In the above the original intercom wires

• Intercom - pilot mic (3 wires + GND), co-pilot mic (3 wires + GND), pilot phones (3 wires + GND), co-pilot phones (3 wires + GND)

have now been removed and replaced, since the Dynon intercom wiring loom will now be mounted in the aircraft and will not be removeable with the panel. The mic and phone lines will run all the way from the DB connector to the jacks. So it is the remaining wires in this loom that might have to be passed through the midsection connector. These lines are

• Radio audio input
• Radio mic output
• Muting input
• EFIS
• power and gnd
• Non-muting input
• Music In

But if the radio is mounted in the fuselage and not on the panel, then its DB25 connector could have wired into it the following

• Radio audio input (3 wires)
• input high
• input low
• shield (N/C to radio??)
• Radio mic output
• output high
• output low
• PTT
• shield (N/C to radio??)

The following would need to be routed by the midsection connector

• EFIS lines (4 wires)
• Audio left
• Audio Right
• Audio GND
• Dimming Input

Which leaves

Music In (4 wires)

• not connected

Muting Input (3 wires)

• not connected

Non muting input (3 wires, high, low and shield)

• connect to FLARM audio output

The flarm fusion is mounted in the fuselage. It has interface wire

• Pin 1: Audio Out Yellow
• Pin 2: TX, Fusion sends (RS-232) Green
• Pin 3: RX, Fusion receives (RS-232) Brown
• Pin 5: GND Red
• Pin 7: +12 to +32 V DC power supply

The 4 wires pins 2-7 should pass via the midsection interconnect

Pin 1 can be connected directly to the Non-muting input of the intercom

The results is:

Size 16 contacts - 5 available

Non-green band contacts (16, 18, 20 AWG) - bought in from connector 3

• Left landing light - 3 x 16AWG downstream
• Right landing light - 3 x 16 AWG downstream
• The shields will be consoldiated, all 5 availiable contacts will be used

All contacts used, more are used than strictly needed (the gnds and pos could also be consolidated)

Size 20 contacts - 42 available

Purple-band nickel contacts (16, 18 AWG)

• Fuel pump - 2 wires - 16 AWG (panel mount should be male)
• magneto grounding wires - 3 wires 2x 18 AWG + shield (panel mount ideally should be female, plug only grounds, but could be male on account of the limited flow if shorted to ground)

Standard nickel contacts (20, 22 AWG)

• Radio (5 wires)
• pwr, gnd
• enable
• data rx
• data tx
• Intercom (6 wires)
• pwr, gnd
• EFIS Audio left
• EFIS Audio Right
• EFIS Audio GND
• EFIS Dimming Input
• Flarm fusion (4 wires)
• pwr, gnd
• data tx
• data rx
• starter solenoid - 2 wires 20-22 AWG (panel mount should be male)
• LH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• RH joystick - trim up, trim down, gnd, ptt, ap disconnect, spare - 6 x 24AWG
• gnd consolidated into one wire (-1 wire)
• ap disconnect lines consolidated and joined to servo ap loom disconnect and not passed to connector pin (-2 wires)
• ptt lines consolidated to respective pilot mic lines and not passed to connector pin (-2)
• So LH trim up, LH trim down, LH spare, RH trim up, RH trim down, RH spare, gnd passed to connector - 7 x 20 AWG
• OAT sensor - 2 wires (22 AWG) - this eliminated the need to have to connect/disconnect the small 2-way connector at the ADAHRS when removing the panel
• Pitch and roll servos - 2 x 20 AWG (pos, gnd) + 1 x 22AWG (disconnect)
• disconnect joined to joystick loom - not passed to connector - so only 2 x 20 AWG

33 used

Parts List

• 1 x HDP24-24-47PE receptacle with male contacts, E-seal
• 1 x HDP26-24-47SE plug with female contacts, E-seal
• 5 x 0460-202-16141 Pins (for 16, 18, 20 AWG), nickel
• 5 x 0462-201-16141 Sockets (for 16, 18, 20 AWG), nickel
• 33 x 0460-202-2031 Pins (for 20, 22 AWG), gold
• 33 x 0462-201-2031 Sockets (for 20, 22 AWG), gold
• 5 x 0460-010-20141 purple band Pins (for 16,18AWG), nickel
• 5 x 0462-005-20141 purple band Sockets (for 16, 18AWG), nickel
• 1 x 2414-001-2486 Lockwasher Wave S-Steel Shell Size 24
• 1 x 2411-001-2405 Nut Plastic Shell Size 24