Deep Dive: Glenair Subsea Interconnect Technologies

Glenair QwikConnect Magazine • October 2016 • Volume 20 • Number 4

OCTOBER 2016 NUMBER 4 Qwik Connect n n n VOLUME 20

GLENAIR

Qwik Connect

ROV classes Observation Observation with payload Work class Bottom crawling

ROVs: The Workhorse of Subsea Science and Exploration

Typical work-class ROV systems provide power levels ranging from 100 to 200 horsepower, and even as high as 330 HP. Trenching vehicles are equipped with 1500 HP electrical power for impressive thrust in either vertical or horizontal directions. In the past, ROVs have operated at 120V, but due to growing power requirements the industry is now adopting 270 and 240 VDC full wave rectification of 120/208 three phase AC for manned submersibles. Small inspection-class ROVs continue to operate in the 100–130 VAC range.

Small unmanned submersibles called “marine remotely operated vehicles” or ROVs are deployed throughout the oil & gas industry—and in other industries such as scientific research, fisheries and aquaculture, oceanography, underwater archaeology, ocean exploration, and military/ defense—to perform inspection, repair, and maintenance functions in water too deep or too dangerous for divers. ROVs service sea floor drilling and processing operations with capabilities as diverse as trenching and drill support. The various classes of ROVs are distinguished by their size, maneuverability, methods of propulsion. Regardless of class, all ROVs are cable connected (tethered) to their support platform. In addition, ROVs share two key characteristics: a subsea-to-topside visual feed (typically an HD/SD TV which provides real-time or slow-scan viewing) and the ability to rise or submerge subsea. Autonomous underwater vehicles (AUVs) are a far different class of submersible, and do not employ a support tether.

During operation ROVs are linked to a host ship by a neutrally buoyant tether or, when working in rough conditions or in

deeper water, a load- carrying umbilical cable is used along with a tether management system (TMS). The TMS is either a garage-like device which contains the ROV during lowering through the splash zone or, in the case of larger work-class ROVs, a separate assembly which sits

on top of the ROV. The purpose of the TMS is to lengthen and shorten the tether as needed so that the cable drag effect of underwater currents is minimized. The umbilical is an armored cable that contains a group of electrical conductors and fiber optics that carry electric power, video, and data signals between the operator and the TMS. Some umbilical tethers are equipped with pneumatics to power work-class ROV equipment. Where used, the TMS then relays the signals and power for the ROV down the tether cable to power sonars, magnetometers, still cameras, manipulators, water samplers, cutting arms, or scientific instruments that measure water clarity, temperature, density, sound velocity, and light penetration.

<ROV with tether management system

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Interconnect Technology for ROVs

in elsatomers such as polyurethane and neoprene. Various other techniques and materials are available for front-end and back-end-to-cable sealing in subsea interconnects including: Connector Sealing

ROVs are the backbone of all deepwater offshore operations: From installing assets and bringing wells online, to the complex business of decommissioning end-of- life fields. ROV equipment sets are pressure resistant, making it possible for the submersible to function and operate in harsh and remote depths up to 10,000 feet. In the demanding deep-water operations environment, electrical engineers specifying interconnect technology must consider extremes in temperature, pressure, and corrosion when choosing appropriate cables and connector sets to bring power and data to equipment and tools. Connectors must be evaluated for mating durability and wire-to-connector termination durability by considering working conditions including cathodic delamination, corrosion due to dissimilar metals, and mechanical stress due to cable routing and wave action. Pressure resistant connectors are required on all ROVs for electrical and optical circuits interconnecting payload components and/or for umbilical connectivity topside. 10k psi is the standard for ROV connectors. Connectors typically employ front-end sealing technology that allows for wet underwater mating (not currently supplied by Glenair) and/or open-face exposure of connector halves to subsea pressures (a major Glenair strength—see our revolutionary SeaKing connector series later in this special edition of QwikConnect ).

Technologies Glass-to-Metal Welding/Brazing Metal-to-Metal Seals Rubber-molded connectors Needle valves Tapered threads Potting/Adhesives/Sealants O-rings

O-rings are the unsung hero of sealing, and when properly applied can yield reliable, high pressure sealing results. O-rings are small, cheap, suitable for high-mating cycle applications, easy to inspect, easily serviced and, as mentioned, extremely effective when proper attention is applied to engineering best-practices. These practices focus on gland design (or the relative advantages and disadvantages of axial face seals compared to radial piston or rod seals), as well as careful attention to metal-to-metal extrusion gaps, and O-ring groove widths.

Glenair SeaKing™ cutaway diagram showing replaceable Nitrile or Buna-N (NBR) O-ring seals that facilitate fast and trouble-free field replacement

Dual O-rings

Back-end sealing technology protects the termination zone for both cable and contact, and is a often a weak point in connector and cable sealing. Glenair brings over 60 years of mission-critical sealing expertise to our subsea interconnect designs, including deep materials science fluency

Dual O-rings

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connector series were originally designed for shallower, lower pressure applications with shorter deployments. But today’s requirements for 10k psi high-pressure performance and deployments measured in weeks, not hours, call for both better mechanical design and harder 90 Shore-rated seals. Many subsea applications utilize electrical and optical Pressure Balanced Oil Filled (PBOF) cables. PBOF cables use a compensating fluid-filled elastomeric tube as a conduit for the electrical and fiber optic lines. The elastomeric conduit allows the ocean pressure to transfer to the compensating fluid, equalizing the pressure differential. PBOF

Clearance Gap

Installed O-Ring

O-Ring Under Pressure

O-Ring Extrusion

Extrusion Failure

^O-rings with proper shore hardness can prevent the extrusion problems shown in this diagram.

Next to mechanical design, the proper application of materials science has the greatest impact on high-pressure sealing. Metallic and non-metallic materials must be evaluated for temperature extremes, fluid compatibility, abrasion resistance, gas decompression, and conductivity. Shore hardness is a particularly critical material selection criterion in high-pressure sealing applications as it directly impacts material performance under pressure. Extrusion gaps in the designed- for clearance between metal sub-assemblies, for example, can be problematic for O-rings with Shore hardness ratings under 90. Many legacy subsea

technology has been widely utilized in ocean science exploration, drilling systems, production

control systems, towed sonar arrays, and most

^NOAA’s Hercules ROV recovers a basalt recruitment block experiment from the sea floor

importantly, for the interconnection of subsea floor structures and equipment. Special PBOF connectors are employed to enable the ROV to connect and disconnect flying lead PBOF cables for maintenance or equipment replacement. Glenair has developed a superior PBOF technology design that allows for faster, easier assembly and ease-of-repair in the field, and the utilization of both straight and sweeping, non-constricting 45° and 90° elbows. These improvements and a host of others are now available in Glenair SeaKing high-pressure connectors and coming soon in our revolutionary SuperG55 series. The SubSea/Marine Team at Glenair invites you to enjoy the rest of this special edition of QwikConnect and to contact the factory for applications and design-in support.

<PBOF cables on Monterey Bay Aquarium Research Institute’s next-generation Doc Ricketts ROV. Photo: Bill Abbott/Flickr

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Forum Engineering Technologies ROV Photo: NOAA

ROV Payloads The equipment that ROVs use to perform their underwater work is known as the “payload.” An ROV’s payload could include sonar, lights, video cameras, gyroscopes, navigation systems, thrusters, manipulators (robotic arms) and occasionally, still cameras and strobes. All of these devices require interconnection to power supplies, communication systems and controllers. Subsea equipment engineers must consider extremes in temperature, pressure, and corrosion when choosing subsea connectors. The ROV’s size and duty range can also influence connector choice. Glenair’s dedicated subsea engineers can work directly with ROV payload designers to select the best interconnect for the application.

SeaKing™ Cable Connector Plug

and Flange Connector Receptacle

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Hydrostatic test lab The Glenair marine/subsea technology team is unique in the industry having the ability to design, produce, validate, and test its complete range of subsea interconnect technologies using 100% in-house resources. Glenair’s hydrostatic lab is a dual-mode pressure test facility equipped with both large form- factor pressure vessels for testing complete cable assemblies, mated cable connectors, and even customer sub-assemblies. In addition, a small pressure vessel cell provides qualification and validation testing on discrete connector inserts and bulkhead connectors. Both the large pressure vessel and small pressure vessel systems can validate and test up to 16.5K psi, or 1 1 / 2 times Glenair’s standard 10,000 psi subsea connector rating.

DISCRETE CONNECTOR TESTING: All Glenair subsea interconnects are subjected to 100% inspection and test

Welcome to the lab, my friends! Lemme show you around.

1. Cable and subassembly staging

2. Large cable and subassembly pressure test bunker

TECHNICAL STAFF: Knowledgable and trained subsea specialists perform both in-house product qualification testing, as well as customer subassemblies.

LARGE PRESSURE VESSELS: Built to accommodate complete cable assemblies, mated connectors, and customer-supplied sub- assemblies. Each unit contains a 12" diameter X 72" depth test chamber accommodating speciment weights up to 1500 lbs.

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CONTROL ROOM: The modular consoles in the control room provide for up to 8 pressure circuits, operating in Manual mode or Automated. Each circuit is capable of a maximum of 16.5K psi. Monitors display: Automated Test Profiles, Data Acquisition, remote viewing of Test rooms and more. System is network connected for access to Profiles and distribution of test reports.

3. Hydrostatic test lab control room

4. Production connector staging

5. Small connector pressure test bunker

SeaKing ™ and SuperG55 ™ QUALIFICATION TESTING: Both Glenair Series 70 SeaKing and SuperG55 rugged dry-mate subsea connectors have been tested and qualified to their 10K psi pressure rating—open-face and mated—in Glenair’s state-of-the-art hydrostatic test lab. Additional testing included mating cycles, salt spray, and electrical continuity

Glenair Hydrostatic Test Lab Technical Specifications and Pressure Test Standards

Pressure test profiles Maximum test pressure

Automated or manual

16.5K psi

Pressure, time, temperature, and electrical performance I/R, continuity, insertion loss, and backreflection (optical) All major oil & gas standards Yes, including customer-supplied subassemblies Working volume = 12" diameter x 72" depth; Test specimen weight up to 1500 lbs.

Data acquisition types

Performance monitoring under pressure

Industry profiles

Custom profiles

Capacity (large pressure vessels)

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High-pressure subsea Ruggedized serial and high-speed electrical connectors Glass-sealed high- pressure bulkhead feed-thrus Fiber optic and opto- electronic solutions Hazardous zone ATEx explosion-proof Commercial Oil & Gas and defense industry solutions

High-performance, mission-critical interconnect technologies with proven shipboard and subsea performance

<Crew abord the M/V Independence prepare to launch a Remotely Operated Vehicle (ROV).

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Geo-Marine ®

SeaKing 10K PSI high-density subsea connectors and cables

sneak peek : SuperG55 dry-mate 10K PSI underwater electrical connectors

Series 80 AquaMouse subsea and hermetic connectors

sneak peek : Marine Molded dry mate submersion-zone connectors

Glass-sealed high-pressure to 30K PSI hermetic bulkhead connector feed-thrus and HTHP

Series 22 GeoMarine® 5K PSI transition-zone and subsea connectors and cables

MIL-DTL-28876 qualified Navy fiber optic connectors, termini, and backshells

Harsh environment opto-electronic (photonic) transceivers and media converters

ITS-Ex ATEx-qualified and approved explosive zone connectors

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SERIES 70 SeaKing ™

High density, small form- factor connector Redundant dual O-ring seals ensure high- pressure performance Signal, power, RF Coax, and optical contact arrangements Five shell sizes with 4–109 contacts (#16, #20, and #22) Stainless steel construction with anti-galling marine bronze engaging nut Full-mate inspection ports Easy O-ring replacement Key and keyway polarization

10K PSI / 700 Bar / 7000m open-face or mated, dual O-ring equipped, high-density, high-voltage, fiber optic and hybrid electrical/optical subsea connectors S eaKing is an innovative new connector series that eliminates a broad range of mechanical design weaknesses found in many of today’s high-pressure subsea connector families. From its double O-ring seals and retractable engaging nut, to its multi-keyed mating interface, the SeaKing represents a bold new approach to subsea power and signal connectivity. Ideally suited for offshore oil & gas, military/defense, oceanographic research, and other harsh-environment subsea applications, the dry-mate connector series is built for optimal durability and reliability. Tested to 15,000 PSI (open face and mated), and equipped with integrated dual O-ring seals, marine bronze coupling nuts, corrosion-resistant stainless steel shells and high-pressure contact inserts with gold-plated signal contacts, special RF and fiber optic solutions, the Series 70 SeaKing is today’s most advanced high-density signal and standard-density power subsea connector available.

STANDARD CONFIGURATIONS

Cable Connector Plug (CCP)

Bulkhead Connector Receptacle (BCR)

Flange Connector Receptacle (FCR)

SERIES 70 HIGH-PRESSURE 10K PSI / 700 BAR / 7000 M SeaKing high-density subsea connectors and cable assemblies Key mechanical and environmental features

Sealing: The Series 70 SeaKing is the best sealed subsea connector on the market. All critical interfaces, including bulkhead seals, glass-to-metal insert seals, mating interface bore seals, and face seals are fully redundant ensuring 10K PSI protection, even in the event of a single-seal failure. Mating: SeaKing utilizes a modified UNC (coarse) mating interface with added clearance to reduce bio-fouling and facilitate rapid- advance mating. The marine bronze coupler on the plug is equipped with thread flats as well as knurling and is less susceptible to galling than standard steel engaging nuts. Polarized keys and keyways prevent both thread damage and mismating. Ease-of-Use: Multiple PBOF backshell indexing points, indexable flange FCRs, full-mate inspection ports, retractable engaging nuts, and other features make SeaKing the most user-friendly subsea connector on the market.

SeaKing Flange Connector Receptacles feature a removable spoked body and indexable flange

Retractable engaging nut retention ring for easy O-ring inspection/replacement

Coupling lock set screw (3 places)

Indexable flange

Wrench flats

Disengage flange to rotate body for multiple clocking positions

Accessory thread and overmold features

Multiple PBOF backshell indexing points

Full-mate inspection port

Dual O-rings

Replaceable Nitrile or Buna-N (NBR) O-ring seals facilitate fast and trouble-free field replacement

Available pressure-balanced oil filled (PBOF) back end for use with oil-filled cables

Dual O-rings

BCR showing keyway-assisted mating and polarization feature and wrench flats for reliable, secure attachment to pressure bulkheads

Series 70 SeaKing™ cable assemblies are available from the factory with special 10,000 psi overmolded cable-to-plug connector environmental sealing.

Revolutionary PBOF swivel assembly features kink-proof hose swivel, straight, 45° and 90° routing, and superfast assembly

SERIES 70 HIGH-PRESSURE 10K PSI / 700 BAR / 7000 M SeaKing high-density subsea connectors and cable assemblies Available connectors and cable assemblies

SeaKing™ CONNECTOR SERIES OVERVIEW

700-001 SeaKing™ Cable Connector Plug (CCP), 10,000 psi rated (mated condition), subsea environment, solder termination

700-006 SeaKing™ Flange Connector Receptacle (FCR), 10,000 psi rated (open face and mated), subsea environment, solder termination, indexable flange

700-007 SeaKing™ Bulkhead Connector Receptacle (BCR), 10,000 psi rated (open face and mated), subsea environment, solder termination

TURNKEY OVERMOLDED AND REPAIRABLE CABLE ASSEMBLIES AND SPECIAL CONFIGURATIONS

Transparent overmold test sample demonstrates Glenair’s harsh-environment,

high-pressure cable overmolding and cable termination expertise (no voids, 360° material adhesion and cosmetic perfection)

10K psi overmolded CCP assembly

10K psi overmolded 75 Ohm Coax hybrid assembly

Repairable wire mesh grip- equipped topside CCP cable

Cabled bulkhead connector receptacle (BCR) assembly

FCR assembly with flange mounting points and indexed flange

Special Oil & Gas industry NE 606 overmolded cable

SERIES 70 HIGH-PRESSURE 10K PSI / 700 BAR / 7000 M SeaKing high-density subsea connectors and cable assemblies PBOF cable attachment accessories

REVOLUTIONARY PBOF SWIVEL HOSE ATTACHMENT ACCESSORIES Hose barb fittings for PBOF cable assemblies are the perennial weak link in subsea oil & gas applications. Kinked and twisted hoses, leaky fittings, corroded hose clamps, and general poor performance characterize most existing solutions. The Glenair PBOF swivel hose attachment for SeaKing connectors solves these problems and more. Designed from the sea floor up to perform flawlessly and reliably, this revolutionary attachment puts an end to the long list of field maintenance problems associated with oil-filled cable applications. Straight, 45°, and 90° “full radius” angle and profile hose routing Hose angle adjustment feature eliminates risk of oil leakage Corrosion-resistant materials used throughout Threaded couplers with safety set-screws for fail-safe leak and decoupling protection—no special tools required for assembly Compact PBOF compression fitting with 340° hose swivel action Support for the broad range of hose diameters and wall thicknesses

interlocking teeth

Interlocking teeth on SeaKing plug connectors interface with corresponding teeth on the PBOF swivel hose attachment to facilitate easy indexing and routing of hose assemblies

Elastomer Tubing

hose barb swivel attachment

Optional Fill Port

Revolutionary swivel hose barb compression attachment eliminates twisting and damage in PBOF assemblies

S Straight

M 45°

The complete range of SeaKing PBOF hose compression fittings includes straight, 45°, and 90° full radius profile versions; with and without integrated oil fill ports

N 90°

SeaKing Performance Specifications

threaded couplings

Pressure Rating Plug: 10,000 psi, mated condition

per ISO 13628-6

Receptacles: 10,000 psi mated and open face 600 V typical 5 GOhm insulation resistance at 500 VDC

Electrical

per MIL-STD-202, Method 301 per MIL-STD-202, Method 302 MIL-STD-202, Method 101 MIL-STD-202, Method 103 ISO 13628-6

Threaded PBOF compression nut and connector coupling nut (with additional safety set screw) provide for fast and easy assembly and prevent leaks and assembly decoupling

Materials

Salt Spray (corrosion) Humidity (steady state) Thermal Cycle 30G Mechanical Shock

Shock

per ISO 13628-6 per ISO 13628-6

Vibration

5G Vibration

Photo: NOAA

Bulkhead Connector Receptacle (BCR)

SuperG55 T he SuperG55 family of dry-mate underwater connectors is a revolutionary new design of the popular industry-standard marine interconnect used in countless ROV, underwater camera, diver communications, lights, pan and tilts, and other subsea applications. Available in 3 shell sizes, the SuperG55 is manufactured from 316L Stainless Steel with insert molded contact assemblies designed for pressure-sealed applications up to 10K psi mated and unmated. Intermateable and intermountable with other “55” series connectors, the Glenair solution introduces a long list of product innovations designed RUGGED UNDERWATER DRY MATE ELECTRICAL Factory- terminated overmolded Cable Connector Plug (CCP)

Flange Connector Receptacle (FCR)

10,000 psi mated/ unmated (approx. 22,500ft/7,000m) Recessed plug socket contacts for safety Intermateable and intermountable with other “55” series connectors 3 shell sizes — 15, 20 and 24, with 3 to 21 contacts PBOF versions available 600 VDC, 5 to 18 Amps (dependent on conductor and cable size and make-up) Retractable, anti-galling coupling nuts prevent mismating and improve durability

to improve performance and durability. Our PBOF versions, for example, utilize easy-to- assemble threaded fittings which deliver both superior sealing performance while reducing installation time. Other innovations include full-mate inspection windows, improved solder cup contact design, improved potting and sealing, and more. Cable plugs and receptacles are available in attachable (user- terminatable) versions or factory overmolded single- ended whips.

To facilitate 360° indexing of the bulkhead keyway, SuperG55 FCR designs are now equipped with removable, spoked-body and indexable flange—a proven

innovation borrowed from Glenair Series 70 SeaKing

To improve assembly speed and electrical performance, the SuperG55 CCP is equipped with extended- length solder cups and an auxiliary potting cap for post-soldering wire-to- contact sealing

RUGGED UNDERWATER DRY-MATE ELECTRICAL SuperG55 Tested and qualified for intermateability with popular “55” type interconnects

SuperG55 Performance Specifications

SUPERG55 FLANGE CONNECTOR RECEPTACLE (FCR)

Mating Cycles 500 Operating Temperature -20°C to +90°C Voltage Rating 600 VDC / 440 VAC

5 to 18 Amps (dependant on contact and cable conductor sizes)

Current (max.)

SuperG55 Material/Finish

316L Stainless Steel/ Passivated

Shells

Insulator

PEEK

Insert

Neoprene

Copper alloy, gold plated

Contacts

O-rings

Nitrile

Overmold and Cable

Polyurethane or Neoprene

UNIVERSAL CCP SUPERG55 FOR EITHER MOLDED OR PRESSURE- BALANCED OIL-FILLED CABLE CONFIGURATIONS

55XX-2004 * 4#10 NON-STANDARD MATERIALS: Other material options are available as part of our non-catalog offerings including Anodized aluminium, Titanium, and Aluminium Bronze. Glenair is also able to supply SuperG55 interconnects in composite thermoplastic (PEEK) to meet application requirements for reduced cathodic corrosion as well as weight reduction without affecting connector performance. HIGH-SPEED ETHERNET: The SuperG55 Ethernet option is available in the 1508, 2013 and 2021 contact configurations and provides both high speed (Up to 1GB) and power (600Volts) in a full subsea environment (10,000PSI). Gigabit speed data transfer up to a distance of 75mtrs. 55XX-1503 3#12 55XX-1504 * 4#16

Locking ring and grub screw

Filler cap and seal

Retaining ring and washers

O-ring seal

Hose RR pbofbp

CONTACT CON

Shortened coupling nut allows positive

SIZE

RR pbofbp CONTACT CONFIGURATIONS AVA

visual alignment of connector keyways

Innovative universal threaded PBOF back end eliminates low- tech hose collet 15

55XX-1502 2#12

55X 6

CONTACT CONFIGURATIONS

pbofbp RR pbofbp

Oil-filled shell

SIZE

RR pbofbp CONTACT CONFIGURATIONS AVAILABLE (CCP FACE VIEW ONLY - NOT TO SCALE) RR pbofbp CONTACT CONFIGURATIONS AVAILABLE (CCP FACE VIEW ONLY - NOT TO SCALE)

Female contact with hood and solder buckets

55XX-1608 8#16

55XX-1506 6#16 Extended shell

55XX-1504 * 4#16

55XX-1502 2#12

55XX-1506 6#16

55XX-1503 3#12

55XX-1508 * 8#16

Insert

3 full-mate viewing ports

55XX-2003 3#10

55XX-2006 6#10

55XX-1608 8#16

AVAILABLE CONTACT ARRANGEMENTS CONTACT CONFIGURATIONS CONTACT CONFIGURATIONS

R pbofbp

SIZE TACT CONFIGURATIONS AVAILABLE (CCP FACE VIEW ONLY - NOT TO SCALE)

RR pbofbp CONTACT CONFIGURATIONS AVAILABLE (CCP FACE VIEW ONLY - NOT TO SCALE)

55XX-1508 * 8#16 1508 8 #16

55XX-1503 3#12 1503 3 #12

55XX-2008 * 8#12 2008 8 #12

55XX-2013 * 13#16 2013 13 #16

2021 21#16

55XX-2412 12#12 2412 12 #12

55XX-1502 2#12 55XX-1504 * 4#16 55XX-2003 3#10

55XX-1504 * 4#16

55XX-1506 6#16

55XX-1508 * 8#16

55XX-2004 * 4#10

55XX-2008 * 8#12

55XX-2013 * 13#16

55XX-2003 3#10

55XX-2006 6#10

55XX-2004 1#8/3#10 (4)

55XX-2410 8#10/2#12 (10)

55X 2

55XX-1608 8#16

Fill in the randomly numbered blanks to solve this sea song puzzle

1. ___th___ C____ 2. _______’s _a____ 3. ___k ______r 4. ___ W____ __ ___ _____d _________d 5. (______’ __) ___ ____ o_ ___ __y 6. W____ _____s/ ____gg_ 7. _____ o_ t__ _____ 8. ________b _______a___ ___m_ 9. O____ __n 10. __l___ __b______ 11. _____ t__ __a 12. A_______ 13. ____k __ ___ ____r 14. ____ _y __e ___s___ 15. _a__ __, _a____ 16. ___e __i_ _w__ 17. __o__ _o__ _ 18. _e____ ___ ___ 19. _h_ _r_____ __i_ 20. _ _m ___ S__

Solution posted November 15 th www.glenair.com/qwikconnect

Qwik Connect n October 2016

Photo: Subsea production systems by jasonwoodhead23

AquaMouse SERIES 802 Ultraminiature high-pressure O riginally developed for petroleum pipeline inspection equipment, Series 802 connectors are available in ten sizes from 1 to 130 contacts and equipped with Viton® O-rings to withstand exposure to corrosive chemicals and high temperature environments. These connectors feature high density crimp Mighty Mouse inserts, 316 stainless steel or marine bronze shells and a piston O–ring for hydrostatic sealing. Series 802 insulated wire, panel mount receptacles can be ordered as square flange, in–line or jam–nut versions. Choose integral shield termination platform or accessory thread for use with a variety of strain relief options. Crimp style gold–plated crimp contacts accept #12–30 wire. Connectors are backfilled with epoxy potting compound. Hermetic glass–sealed connectors come with solder cup contacts (non-removable) or PC tails. 100% tested to meet 1 x 10 -7 cc/sec helium leakage. Open face pressure rating 3500 PSI.

3500 psi pressure rated High-temperature and corrosive chemical- resistant Viton® or Nitrile O-rings Ultraminiature #23 contacts Size #20, #20HD, #16, #12, #8 signal, power, fiber optic and shielded contacts Discrete connectors and turnkey cable assemblies

Tooled Contact Arrangements 

Contact Legend

#20 #20HD

#16 #12

#23

AQUAMOUSE CONNECTOR CONFIGURATIONS AND CLASSES

Series 802 Plugs

Series 802 BCR

Series 802 FCR

Series 802 Hermetic BCR

Series 802 Hermetic Bulkhead Feed-Thru

5-3 6-1 6-23 6-4 6-6

6-7

7-25 7-10

6-7

7-25 7-10

8-2

2 1

3 10

19 18

8-28 8-13 8-200 9-4

8-13 8-200 9-4

9-210

9-19

9-200

9 8

9-201

10-2

9-200

9-201

10-2

10-5

10-26

10-200

10-201

20 11 12

4 7

8 7

10-202 10-200 10-201 10-202

12-2

12-3

12-7

12-220

2 1

1 2

20 11 12

8 7

10 9

12 11

12-37

12-7

12-220

12-37

12-200

12-201

12-202

12-203

2 1

1 2

10 9

12 11

12-201

12-202

12-203

12-204

12-205

14-5

14-12

1 2

2 4

1 2

20 10

5 6

6 7

31 32

11 15 14 12

10 9

12 11

35 36

14-235

14-55

14-204

14-205

14-206

14-207

15-7

15-14

15-241

15-85

15-203

15-204

2 3 4

27 28 29

45 46 47 48

59 60 61

71 59 48

49 60 72

42 43

55 54

105

36 39 38 37

106

115

116

124

17 16

125

130

21-12

21-22

21-269

21-130

Marine Molded Underwater Interconnect Assemblies SERIES GLA 20 G lenair Marine Molded series connectors are used in remotely operated vehicles, underwater lighting systems, underwater video monitoring systems and other subsea applications. Available in both rubber molded cable and inline versions, as well as glass- filled epoxy bulkhead versions, the Marine Molded series is a reliable and cost-effective interconnect technology for high-pressure subsea applications up to 10K psi mated condition. Available in a wide range of high-pressure insert molded contact arrangements, with size #16 to size #0 contacts, and from two to eight circuits.

10,000 psi (mated) pressure rating

7.5 Amps to 200 Amps Two to eight contacts Catalog and custom cable options Chemically resistant

Gold-Plated Pins

Molded O-Ring

Neoprene Body

Neoprene Jacket

Gold-Plated Socket Contacts

Neoprene Body

Neoprene Jacket

Male Cable Assembly

Glass-Filled Epoxy Body

O-Ring

Stainless Steel Nut and Washer

Solder Cup Pins

Gold-Plated Pins

Female Cable Assembly

Male Bulkhead Connector

SERIES GLA20 Marine Molded Underwater Interconnect Assemblies Specifications, contact arrangements and accessories

Specifications

Contacts O-Rings

Copper Alloy, Gold-Plated

Nitrile

Nut, Washer

Stainless Steel

Cable

Neoprene insulation, Stranded Copper Conductor

Bulkhead Connector Body

Glass-Filled Epoxy

Voltage Rating Current Rating

600 VDC

See Contact Arrangements

Male Bulkhead Connector

Temperature Rating

-55 o C to +105 o C

Contact Arrangements and Current Rating

2 contacts 1 #10 Contact 1 #12 Contact 10 Amps G2

3 contacts 1 #10 Contact 2 #12 Contact 10 Amps G3

4 contacts

1 #12 Contact 3 #16 Contacts 7.5 Amps G4

1 #10 Contact 3 #12 Contacts 7.5 Amps K4

5 contacts

6 contacts

8 contacts

1 #10 Contact 4 #16 Contacts 7.5 Amps K5

1 #10 Contact 5 #16 Contacts 7.5 Amps K5

1 #10 Contact 7 #16 Contacts 6 Amps K8

ACCESSORIES

Locking Sleeves Locking Sleeves enable a mated pair of cable assemblies to be locked together, preventing accidental unmating. Material: Delrin.

Replacement O-Rings for bulkhead connectors. Material: Nitrile O-Rings

Male

Female

Cable Part No.

Type Male Male

Sleeve Part No.

GL20G*P GL20K*P GL20G*S GL20K*S

GL20G401 GL20K403 GL20G402 GL20K404

Cable Part No.

O-Ring

Female Female

GL30G GL30K

2-213 2-217

VITREOUS GLASS TECHNOLOGY ADVANTAGES Superior pressure resistance to 32,000+ PSI Hundreds of designs, including long-length bulkhead feed-thrus and penetrators Higher resistance to extreme operating temperatures to 260°+ C Superior mechanical strength No material breakdown or aging over time Helium leak rate <1X10 -7 cc/sec to 1X10 -10

HIGH-RELIABILITY Glass-sealed Hermetic Connectors

Resolve gas, moisture and particle ingress problems with advanced-performance glass- sealed hermetic connectors

CIRCULAR GLASS-SEALED HERMETIC CONNECTORS AVAILABLE WITH ACCELERATED LEAD TIMES

MIL-DTL-26482

MIL-DTL-83723

MIL-DTL-38999 (QPL)

MIL-DTL-5015

Series 80 Mighty Mouse

MIL-DTL-38999 AND OTHER Glass-Sealed Hermetic Connectors

GEOPHYSICAL AND OFFSHORE CONFIGURATIONS

GeoMarine® double- start hermetic connector

Hermetic power connector

Single-way tool joint hermetic connector

Hermetic probe connector

Hermetic bulkhead penetrator

HIGH-SPEED/SHIELDED DESIGNS

Hybrid coax/signal hermetic

Quadrax hermetic

Hybrid coax/signal hermetic

Triax hermetic

MT ribbon fiber optic hermetic

RECTANGULAR PACKAGES

ALSO AVAILABLE:

MIL-DTL-24308 QPL hermetic

Series 79 Micro-Crimp hermetic

MIL-DTL-83513 type micro-D hermetics

Sealed panel-mount micro-D hermetic

Well-Master™ 260° high-temperature Micro-D

MIL-DTL-38999 QPL PIN AND SOCKET HERMETICS

Series I Scoop-proof 3 Point Bayonet Coupling

Series II Low-profile 3 Point Bayonet Coupling

Series III Scoop-proof Triple Start, Self-Locking

Series IV Scoop-proof Breech Lock

Geo-Marine ® SERIES 22

D esigned for use in oceanographic, geophysical and other severe industrial environments, Glenair Series 22 Geo-Marine® Connectors and Cables are the ultimate harsh-environment power and signal connector solution. Built to withstand hydrostatic pressures up to 5,000 PSI and exposure to extreme temperatures and corrosives, the Series 22 Geo-Marine® is ideally suited for applications such as US Navy towed array sonar systems, military land vehicles, submersibles and ROV’s, offshore-oil drilling equipment, seabed exploration, pipeline inspection systems, well monitoring equipment, and digital seismic streamers. High-pressure harsh-environment connectors and overmolded cables for towed array and other high-pressure/submersible applications

Geo-Marine ® 5000 psi pressure rated Marine Grade 316 stainless steel machined shells and Naval Bronze coupling rings High-pressure environmental and hermetically sealed receptacles for field applications Power and signal contact arrangements from 2 to 128 contacts Anti-vibration ratcheted

Geo-Marine® plugs are equipped with arctic coupling nuts—made from marine-grade naval bronze— with easy-to-grip castellated knurling and a powerful ratcheted anti-decoupling mechanism which guarantees reliable mating and demating performance in even the harshest environments. Supplied as discrete connectors— or more typically in build-to-print overmolded cable assemblies.

coupling nuts with castellated knurling

Available Viton®

overmolded cable assemblies

SERIES 22 Geo-Marine ® Connectors High-pressure environmental and hermetic connectors

Geo-Marine ®

Range of Offerings Series 22 Geo-Marine® connectors are supplied with either fused-glass (“H” hermetic class) or high grade thermoplastic (“E” environmental class) insulators. Both classes of

connectors are supplied with rugged, corrosion-resistant

materials. Low-profile and scoop- proof cable plugs and receptacles, as well as bulkhead feed-thrus are available. Specially-designed cable sealing

backshells as well as EMI/RFI shield termination backshells and environmentally-sealed protective covers complete the range of discrete product offerings. 35 insert arrangements (contact sizes #12, #16, #20 and #22) are tooled and fully available.

WIDE RANGE OF PLUG CONFIGURATIONS WITH ANTI-GALLING ARCTIC COUPLING NUTS

Cable plug with overmold adapter

Panel-mounted plug

Factory overmolded plug

Cable plug with accessory threads

HIGH-PRESSURE ENVIRONMENTAL AND HERMETIC RECEPTACLE CONFIGURATIONS

Jam Nut

In-Line

Square Flange

Solder-Mount

Bulkhead Feed-Through

RUGGEDIZED STAINLESS STEEL BACKSHELLS AND OTHER CONNECTOR ACCESSORIES

Environmental strain relief backshell

Overmolding adapter

Right-angle strain relief backshell

Environmentally sealed protective covers

D esigned for safe operation in petrochemical refineries, oil & gas drilling platforms, and other explosion zone applications, the Glenair ITS-Ex series connector is optimized for life-of-system durability and reliability. Qualified by the globally-recognized IEC and IECEx standards bodies, the connector series is suitable for use in application areas where flammable gases and vapors are present as a normal condition of operation (group IIC) and with temperature classes T6 and T5, zones 1 and 2; and for applications where potentially flammable dust is present as a normal condition of operation (group IIIC) and with temperature classes T80°C and T95°C in zone 21 and 22. Series ITS-Ex is designed for easy and repeatable termination of armored and unarmored cables built to IEEE 45, IEC, BS, DIN, and JIC standards. A full range of power and signal contacts, from size #16 to size #0 in over 40 insert arrangements are available to address all common voltage, wire size and connector service class ratings. Special Ex design attributes of the series include an integral labyrinth flame path cooling zone, 2-part epoxy potting well, fixed in-line receptacles for attachment of cables to cable management brackets and trays, set screw (grub screw) secured protective safety covers, and durable life-of-system Ex marking labels. Industrial-strength power and signal connector series qualified for use in hazardous zone interconnect applications SERIES ITS-Ex

Utilizes all standard features of 5015 inserts, contacts, tools, etc. Grub nuts (set screw) to lock coupling nut Long plug barrels provide cooling zone Labyrinth gas exit port/ pathway augments cooling Accessory accommodation for potted glands Increased wall thickness Stainless steel and Marine Bronze available

SERIES ITS-EX IECEx/ATEx Qualified Explosive Zone Connectors

Automotive refuelling or petrol stations Oil & gas extraction Oil refineries Gas pipelines and distribution Chemical processing plants Aircraft refuelling and hangars Transportation Pharmaceuticals Food processing Metal surface grinding Sugar refineries Grain handling and storage Coal mining RANGE OF APPLICATIONS

ATEX Marking

2460 II 2 G Ex db IIC T6, T5 Gb II 2 D Ex tb IIIC T80°C, T95°C Db IP68 -40ºC ≤ Tamb ≤ +40°C (T6, T80°C) or +55°C (T5, T95°C)

IECEx Marking

Ex db IIC T6, T5 Gb Ex tb IIIC T80°C, T95°C Db IP68 -40ºC ≤ Tamb ≤ +40°C (T6, T80°C) or +55°C (T5, T95°C)

Glenair ITS-Ex series encompasses both in-line cable plugs and receptacles as well as fixed bulkhead-mountable designs

MIL-PRF-28876 Fiber optic connection system QPL AND COMMERCIAL Qualified MIL-PRF-28876 fiber optic connectors and MIL-PRF-29504 termini— Navy approved, in stock, and ready for immediate shipment

Connectors qualified to the complete requirements of MIL-PRF-28876 including plugs, wall-mount receptacles, jam-nut mount receptacles and in-line receptacles Multiple shell sizes and insert arrangements, including 2, 4, 6, 8, 18 and 31 channel layouts Backshells in straight, 45° and 90° configurations Corrosion-resistant and environmentally sealed Qualified MIL-PRF-29504/14 and /15 pin and socket termini and /3 dummy terminus Connectors, backshells and protective covers available for immediate, same-day shipment

M28876/2 receptacle with backshell

M28876/7 plug with backshell

M28876/11 jam nut receptacle

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