Mwrf 11940 Promo Dept3fig1
Mwrf 11940 Promo Dept3fig1
Mwrf 11940 Promo Dept3fig1
Mwrf 11940 Promo Dept3fig1
Mwrf 11940 Promo Dept3fig1

Custom Solutions Connect in Harsh Environments

Nov. 14, 2019
When standard connectors don’t fit, these connectors can be customized to meet the mechanical/electrical requirements of the most demanding military and commercial applications.

Cables and connectors are often an afterthought—until they fail. Whether as a loss of power, phase distortion in a receiver, or irregular signal transfers, seasoned system designers have learned the importance of making the best connections possible, which can be difficult at times depending on the mechanical and electrical configuration of a radar, electronic warfare (EW), or electronic countermeasures (ECM) systems. However, at least one source—Connectronics Corp.—offers custom cables and connectors for high-voltage, high-current, and even underwater applications targeting military, industrial, and commercial markets.

For many systems, standard high-voltage and high-current connectors will provide the performance levels needed to meet electronic defense specifications. For example, the Dual HVL series high-voltage connectors are available in panel-mount or in-line configurations for maximum voltages from 10 to 20 kV and for use at altitudes to 70,000 ft. The corona-resistant, radiation-resistant connectors handle operating temperatures from −55 to +125°C. The connectors can be assembled at the factory or in the field.

For high-voltage applications through 15 kV dc where corona effects are a concern, the company’s CMC-715 Series high-voltage connectors (Fig. 1) incorporate tapered interfaces designed for high altitudes (to 70,000 ft.) and high temperatures (from −55 to +125°C). They can be used with AWG-16 through AWG-24 stranded wire, with knurled- or hex-nut threaded coupling, and supplied as parts of kits for customer assembly or terminated at the factory, complete with straight or right-angle overmolding. 

1. High-voltage connectors like the CMC-715 devices can be used to 15 kV dc at altitudes to 70,000 ft. and temperatures to +125°C.

Channeling Current

High-current connectors include the Safety Lock Series for safe and reliable interconnections, available in 200- and 400-A versions for three-phase service use at voltages to 600 V. The single-pin connectors employ a ground configuration that makes it difficult to improperly connect any power until the ground and neutral connections are made. For safety, including in emergency-service applications, ground and neutral connections cannot be disconnected until all other power lines are disconnected.

These high-current connectors can be installed in stationary panel boards (with standard size of 3.5 × 19.0 in. for input and output boards) for rack-mounted setups or used in the field. The connectors feature a large self-wiping contact area and silver-plated construction. They can be assembled with standard tools and require no special maintenance. The UL-listed and patent-protected safety lock system features machined aluminum shells with a corrosion-resistant anodized finish. The connectors are designed for operating temperatures from −65 to +125°C and for altitude to 10,000 ft.

For applications requiring custom connectors and/or cable assemblies, the firm offers examples of its engineering and in-house test capabilities in the forms of specialized connectors, such as O-ring-sealed, stainless-steel-overmolded connectors for underwater use, and its hermetic connectors (Fig. 2). Hermetic connectors, for example, are 100% helium leak tested prior to shipping.

2. Specialized connectors such as these hermetic options are well-suited for high-vacuum and high-current aerospace systems.

Specialized and custom connectors can be developed with thermocouple functions for currents beyond 1 kA, for low-outgassing applications, and for temperatures as high as +250°C in the most demanding applications (e.g., in x-ray equipment and nuclear systems). The company backs all of its designs with extensive engineering experience, a well-equipped CNC machining facility, and well-stocked test laboratory, along with the people who know how to use those instruments. 

Connectronics Corp., 2745 Avondale Ave., Toledo, OH 43607-3732; (800) 965-0020, (419) 537-0007

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