Confidential and Proprietary – The information contained within this document is the property of

Littelfuse, Inc. It should be considered confidential and proprietary, and shall not be read, copied, or

distributed without the express written consent of Littelfuse, Inc.

Terra Power Systems is now a Littelfuse Company

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distributed without the express written consent of Littelfuse, Inc.

Revision History

Revision Date Description of Change

1.0 2/2/2011 Initial Release

A – Product Requirements, Performance Requirements, & Quality Objectives

Product Variations

Part Number Description

880086 Relay HD 12V 300A with Deutsch DTM

880088 Relay HD 24V 300A with Deutsch DTM

Module Description

The HD Series Bi-Stable Relay (HD Relay) is designed to deliver and remotely switch vehicle loads. The

HD Relay supports remote power switching applications that demand high performance; including high

continuous current passage, large inverter loads, and high ambient temperature situations. The HD

Relay delivers high performance in a compact size, making it a great choice for heavy-duty vehicles,

construction and agriculture equipment, military vehicles, and heavy-duty lifting equipment.

The HD Relay is designed for harsh weather, high shock and vibration environments; typical of those

found in heavy-truck, marine, and emergency vehicle applications. The HD Relay without manual

override is ingress rated to IP67 and all HD Relay products are rated for IP6K9K ingress protection to

support direct high temperature high pressure wash down.

The HD Relay provides significant cost and weight benefits by eliminating the need to route heavy

copper cables to more conveniently located mechanical only disconnects. Cables can instead be routed

directly to loads with the HD Relay positioned close to the battery or in-line with the desired cable

routing. Remote control of the HD Relay can then be located in any convenient location on the vehicle

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with a fine-wire harness linking the HD Relay to the control switch. The HD Relay family of products

provide a host of additional features that add significant value for many typical applications, including:

• Remote LED indication of state of disconnect and warning of imminent disconnect due to

low battery voltage

• Local and remote indication of state of relay (Local indication on Manual Override models

only)

Application Schematic

The HD Relay provides high-current carrying and switching under load. The Remote Battery

Switch/Solenoid Switch is installed close to the battery banks. A single pole double throw (SPDT) Control

Switch Panel, or two momentary push button switches, operate the HD Series Bi-Stable Relay. Control

Switches are often installed in a convenient accessible location.

Module Operation

Remote Operation – Use a momentary (SPDT) (ON)-OFF-(ON) Control Switch (sold separately), as shown

in the application schematic, the HD Relay can be turned ON and OFF by momentarily actuating the

control switch in the desired direction.

Manual Control – Units with the manual control knob can be turned on and off at the device in addition

to remote operation. Using the manual control adds the below additional benefits:

• an added level of safety that allows manual ON-OFF control with or without power

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• LOCK OFF for servicing the electrical system

Manual Operation of units with the Manual Control option:

A remote LED (sold separately) indicates a closed connection between battery bank and load, or

between two battery banks when used as battery cross-connect.

Unit Connections

The HD Relays have two (2) high-amperage 3/8” terminals for connection to a primary power source and

the load connection. The control wire connections are made through a multi-wire control cable

connected to either a 6 position Sealed Deutsch DTM connector, stripped and tinned wires, or a

customer specified connector solution.

The device should be assembled to a flat surface with the four (4) clearance holes counter-bored to

receive pan head #10 or M5 screws.

Local & Remote Indicators

This device has a single remote LED indicator pull-down which is solid ON when the device is closed and

connecting the input and output terminals (A and B), and is OFF when the device is open and isolating

the input and output terminals. The LED indicator will double flash if there is a failure of the device to

open or close.

Product Identification and Marking

All products come with a combination part number / date code label to provide a unique identifier for

testing and warranty purposes. Removal of this label will void the product warranty.

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distributed without the express written consent of Littelfuse, Inc.

The label area on the front of the device is used for identification of the terminal designations and other

critical or custom component information. Contact Terra Power Systems for more details on arranging

custom product variations.

Warranty

All HD Relay devices are warranted free from manufacturing defects or product failure within prescribed

environmental limitations for a period of one (1) year.

Traceability

Date code labelling of products is performed to improve lot traceability.

Packaging

Aftermarket products are provided in single-pack packaging suitable for commercial distribution. OEM

bulk pack large orders shall be packaged in a corrugated cardboard box with corrugated cardboard

dividers, designed for effective pallet loading and stacking and to minimize environmental impact.

Smaller OEM standard pack quantities are also available. Contact Terra Power Systems for additional

packaging details and options.

Life, Reliability, Durability

All HD Relay variations are designed to withstand operation for 10 years and 1,000,000 miles in a heavy-

duty truck environment. The product is also designed to withstand a minimum of 10 years of regular use

within a harsh and corrosive marine environment.

Customized Options

Contact Terra Power Systems for custom variations with unique delay features or auxiliary contact logic.

Variations to control switch logic and inclusion of voltage sensing, automatic relay operation, and CAN

based communication protocols may be added to customized variations of this product.

Maintainability

The product is designed to accept regular high pressure, high temperature pressure washing (IP 9K)

without collecting water inside or electrically shorting. No maintenance of the product is required during

its service life. Regular inspection of control connector integrity and terminal nut torque is

recommended to ensure optimal system up-time.

Electrical Description

The HD Relay electrically consists of two input/output terminals each with an embedded silver alloy

contact. One heavy-duty primary internal relay is utilized to provide low contact resistance while

connecting and disconnecting a large moveable copper bus bar with embedded silver alloy contacts.

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distributed without the express written consent of Littelfuse, Inc.

Mechanical Description

See outline drawings at end of document.

Electrical Power Specifications

Parameter Value

Maximum Continuous Current

(4/0 Input / Output Cables) 300 A

Maximum Intermittent Current, 30 Second Duration

(4/0 Input / Output Cables) 1,000 A

Maximum Inrush Current, 1 Second Duration

(4/0 Input / Output Cables) 2,000 A

Miscellaneous Electrical Specifications

Parameter Value

Live Switching Current

(12Vdc, 3,000 operations max)

500 A Make / 250 A

Break

Live Switching Current

(12Vdc, 10,000 operations max)

250 A Make / 150 A

Break

Live Switching Current

(12Vdc, 3,000 operations max)

500 A Make / 250 A

Break

Dielectric Breakdown Withstand 1100 VDC, 2 min

External Remote LED Max Fwd V-drop TBD

24Hr Protected Tachograph Output Max Current 1 A

Emergency Break Current, 12V DC nominal 1,500 A / 10 times

Emergency Break Current, 24V DC nominal 750 A / 10 times

Power Consumption – Steady-State (On or Off) 15 mA

Power Consumption – Changing State to On or Off 7 A Max

I/O Connections

Connection Gauge Function Max Current

“A” Max 4/0 AWG High Current I/O - A 300 A (4/0 Cable)

“B” Max 4/0 AWG High Current I/O - B 300 A (4/0 Cable)

Control Connections Wire

Color Wire Gauge Max Current

De

uts

ch

DT

M

Co

nn

ect

or

Pin

#

Ground, Reference for Source Battery Black 22 – 16 AWG 7 A (momentary) 1

+VDC, 24 Hour Red 22 – 16 AWG 50 mA 2

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+VDC, to Close Brown 22 – 16 AWG 50 mA 3

LED Output Yellow 22 – 16 AWG 50 mA 4

Not Used - - - 5

+VDC, to Open Orange 22 – 16 AWG 50 mA 6

Mechanical Specifications

* Special modifications are available depending on customer requirements. No polarization on standard product.

† Quantity depends on optional wire connections. The total number of pins and sealing plugs is 6.

‡ Required for hand assembly of wires and terminal pins.

Material Specifications

Parameter Value

Base 10% GF Polycarbonate

Power Terminal Insulators, Internal Insulators 30% GF Valox 420 SEO

High-Amp Conductors C11000 Oxygen Free

ETP Copper 99% IACS,

Bright Tin Plate for

External Conductors

Base/Cover Seal Silicone

Hardware Fasteners (Nuts, Studs, Screws, etc.) 18-8 Stainless Steel

Internal Electrical Power Contacts Silver Alloy

Cover Label Back-Printed Polyester

Parameter Value

Recommended Cable Terminal Nut Torque 10 N-m

Maximum Cable Terminal Nut Torque 15 N-m

Overall Product Size (see outline drawing) N/A

Mounting Hole Pattern (see outline drawing) N/A

Mounting Hardware (counter-bore mounting holes) M5 or #10

Recommended Mounting Bolt Torque 10 N-m

Maximum Mounting Bolt Torque 15 N-m

High-Amp Terminal Hardware

3/8” Heavy Hex Nut

(3/4” Hex Socket)

Harness Connector (select models) Value

Installed Connector Deutsch DTM Series

DTM-06-6S*

Mating Part Requirements:

Receptacle Shell DTM-04-6P

Wedgelock WM-6P

Terminal Pins 1060-20-0122†

Sealing Plugs 0413-204-2005†

Hand Crimp Tooling DTT-20-0‡

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or Polycarbonate

Environmental Specifications

Parameter (Reference Standards) Value

Temperature, Operational (SAE J1455, Sec 4.1.3.1) -50 C to 85 C

Temperature, Non-Operational (SAE J1455, Sec 4.1.3.1) -55 C to 105 C

Temperature Shock (SAE J1455, Sec 4.1.3.2) -40 C to 85 C

Humidity Cycle (SAE J1455, Sec 4.2.3, Fig 4a) 0 – 95% RH

Dust Bombardment (SAE J1455, Sec 4.7.3) Pass

Salt Spray (SAE J1455, Sec 4.3) 1,000 Hours

Operational Shock - Operational (MIL-STD-202-F, Method

213B, Condition J) 10 G*

Handling Shock – (SAE J1455, Sec 4.10.3.1) See Spec

Transit Drop (SAE J1455, Sec 4.10.3.2.2) See Spec

Operational Vibration, 3 Axis, Power Density Level of 0.2535

G^2/Hz @ 5-100 Hz, 3db per octave roll-off to 500 Hz 8 G†

Steam Cleaning & Pressure Wash (SAE J1455, Sec 4.5) Pass

Ingress Protection (DIN 40050-9) IP 67 (non-knob

versions only) & IP6K9K

(all versions)

Chemicals and Oils Withstand, Immersion and Splash (SAE

J1455, Sec 4.4, all listed elements) Pass

UV Exposure (ASTM G155) 50 days

* Minimum Operational Shock Values for shock in line with solenoid action and parallel to terminal stud. Operational

Shock value in orientations perpendicular to terminal studs and solenoid action is 50 G.

† Minimum Operational Vibration Values for shock in line with solenoid action and parallel to terminal stud.

Operational Vibration value in orientations perpendicular to terminal studs and solenoid action is 20 G.

Electrical Environmental Specifications

Parameter Standard(s) Met

Steady State - Normal Operation SAE J1455, Sec 4.11.1

Steady State - Reverse Polarity -24V SAE J1455, Sec 4.11.1

Steady State - Jump Start +24V SAE J1455, Sec 4.11.1

Steady State - Cold Cranking 0-6V SAE J1455, Sec 4.11.1

Steady State - Series Charging +48V SAE J1455, Sec 4.11.1

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Transients: +300V Mutual Coupling SAE J1455, Sec 4.11.2

Transients: -300V Mutual Coupling () SAE J1455, Sec 4.11.2

Electrostatic Discharge SAE J1455, Sec

4.11.2.2.5.1, SAE

J1113-13

Short to Gnd on all Ctrl Lines Pass

Short to Vcc on all Ctrl Lines Pass

EMI Susceptibility SAE J1812, J1113-21

EMI Emissions SAE J1113-41

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Module Outline Drawing