HIGH VOLTAGE MULTI-PIN CONNECTORS. INTRODUCTION Teledyne Reynolds high voltage multi-pin connectors are known industry

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1 HIGH VOLTAGE MULTI-PIN CONNECTORS INTRODUCTION Teledyne Reynolds high voltage multi-pin connectors are known industry of high voltage connectors capable of operating at altitudes of 70,000 feet wide for their reliability in harsh environments, their small size compared to (21.34 km) and above while exposed to temperatures as low as -55 C and up other manufacturer s connector designs for the same voltage rating and their to 5 C. Not all connectors in this catalog are designed to operate at those overall outstanding quality. extremes, but all will perform with a high degree of reliability when operated This catalog contains a selection of multi-pin, high voltage connectors and cable assemblies. These products, some of which have been in production for more than forty years, reflect the legacy of Teledyne Reynolds strong commitment to engineering, quality and customer service. Teledyne Reynolds, Inc. leads the connector industry worldwide in the design as specified. Within this catalog is also the Advanced Group of connectors that use Teledyne Reynolds patented Advanced Interface Sealing. Technologically advanced, these connectors represent the state-of-the-art in high voltage connector design and manufacture.

2 PATENTED ADVANCED INTERFACE SEALING SYSTEM Teledyne Reynolds, Inc. (TRI) pioneered the development of miniature high voltage connectors used within non-pressurized areas of high altitude flying aircraft over forty years ago. This ingenuity is clearly evident in Teledyne Reynolds patented Advanced Interface Sealing System that is used in the Advanced Group of connectors. The Advanced Group consists of a series of nine connector families, four of which are included this brochure. The following are the more significant advantages of selecting from the Advanced Group of high voltage connectors. REPAIRABLE / REPLACEABLE The seals are molded from a proprietary blend of high grade silicone rubber which allows the seal to function over a temperature range of -55 to 5 C. Because the seal is a separate component of the connector, it can be individually inspected, tested and installed. In addition, if necessary a damaged seal can be removed and replaced. This is not the case in conventional high voltage connectors where the insulator is one piece and a failure of any one pin or circuit usually results in the entire connector or, worse yet, a total cable assembly being scrapped or subjected to a costly repair operation. ADVANCED INTERFACE SEAL ENGAGEMENT Contact Pin SCALABILITY The unique design of the Advanced Interface Sealing System permits the size of the seal and the connector to be scaled up or down to accommodate higher or lower operating voltages and larger or smaller mounting spaces. Our largest seal is in the Max and Maxxum series and the smallest in the JR series. This enables a high degree of customization to meet evolving customer needs. MATING Conventional high voltage connectors require very high mating torque levels in order to effect and maintain an axial high voltage seal. In addition, they must continually compensate for the effects of compression set which is common in connectors using a cone shape or axial compression to achieve a seal. Compensating devices are expensive, bulky and often require special tools and even gauges to reliably mate the connectors. Connectors using the Advanced Interface Sealing System require no undue mating forces and no compensation is ever required to maintain the integrity of the mated interface seal. In fact, once these connectors are fully mated, they need only be sufficiently held in place to resist severe vibration and shock. This is due to the use of redundant radial seals in the Advanced Interface Sealing System. Once the hard plastic insulator of the plug engages the radial rings on the receptacle seal, the high voltage interface seal is complete and will remain so until the plug insulator is withdrawn during any subsequent unmating operation. The engagement of the seal is illustrated in Figure 1. One-piece molded silicone rubber seal Cable Hard plastic plug nose engaging and compressing receptacle seal Plastic or ceramic receptacle insulator Encapsulation Figure 1 Sealing points DESIGN FLEXIBILITY Systems and Component Packaging Engineers will find connectors and the appropriate cable in the Advanced Group to satisfy a wide range of voltage and current ratings, shielded or non-shielded, ceramic or plastic, and single or multi-pin configurations. These choices allow the designer to utilize available space and maximize package density. Visit the or speak to one of our Application Engineers to learn about the variety of shapes and contact arrangements that can be assembled from products in the Advanced Group. MULTI-PIN CONNECTOR PRODUCT MATRIX ( = Yes and Blank = No) (kv) At 70,000 ft Number of Contacts Advanced Coupling Method Shielded Ceramic Feedthrough Bag Assembly* Temperature ( C) JR 6 4 & 6 Jack Screw -55 to Bayonet -55 to Bayonet -55 to 5 PeeWee 2 & 8 Jack Screw & Threaded -55 to 5 Magnum 6 Bayonet -55 to 5 Hi/Mate 13.5 Various MIL-DTL to 5 Hi/Mate D 13.5 Various D-Sub -55 to Bayonet & Threaded -55 to Bayonet & Threaded -55 to Bayonet -55 to Bayonet -55 to 5 Teledyne Reynolds welcomes the opportunity to submit alternate design proposals when our standard items do not satisfy your requirements. *Bag assemblies enable customers to build their own cable assemblies using assembly instructions found at Wire is not included in kits and may be ordered separately from Teledyne Reynolds. Although this option is available, Teledyne Reynolds highly recommends purchasing already built cable assemblies because of difficulties customers may experience in assembly and testing. The Magnum is subject to the export jurisdiction of the U.S. Department of State and may require export license or other approval from the U.S. Department of State. 1

3 JR SERIES 6 kvdc 70,000 FT -55º TO 5ºC 4 & 6-Pin JR is a series of subminiature high voltage cable assemblies that are ideally designed to interconnect low power, mini-twts to a power supply in Radar or Electronic Countermeasure (ECM) systems. Since their introduction, these high contact density assemblies have also found applications in laser systems, photomultiplier detection systems, night vision systems and other applications where high voltage in a small package with a highly, flexible cable harness is required. JR connectors are only available as pre-assembled plug or receptacle cable assemblies. Each assembly is wired with Teledyne Reynolds Ready-toBond etched or silicone coated, cable. A braided shield or NOMEX woven jacket is optional. The insulator is a thermoplastic on both the plug and receptacle, but the Advanced Interface Seals contained in the receptacle are silicone. The receptacle and plug bodies are nickel plated aluminum. PLUG CABLE ASSEMBLIES (Dimensions shown as in/mm) 4-pin, Single-Ended, Shielded 6-pin, Single-Ended, Shielded Uses Wire Uses Wire Jack Screw (2) 4-40 UNC Allen Type.50 Jack Screw (2) 4-40 UNC Allen Type.50 Polyolefin Jacket Polyolefin Jacket Key For smaller overall size, the 6-pin JR is available without metal housing and shielding. Contact Teledyne Reynolds for more information. RECEPTACLE CABLE ASSEMBLIES 4-pin, Single-Ended, Shielded, Rear Mount 6-pin, Single-Ended, Front Mount Uses Wire Uses Wire Jack Screw (2) 4-40 UNC Allen Type X Threaded Coupling Holes Polyolefin Jacket Standard color is Natural Keyway X Mounting Hole For smaller overall size, the 6-pin JR is available without metal flange. Contact Teledyne Reynolds for more information. PANEL CUTOUT DIMENSIONS AND MOUNTING EXAMPLES 4-pin 6-pin 2X 4-40 UNC Panel ±.003 2X ± ± ±.08 Bulkhead Mount Bulkhead Mount.25± ±.08 2X 4-40 UNC ±.003 2X ±.08.5 Max. Panel Thickness ± ±.08 2X Ø Mounting Hole X Ø Mounting Hole SERIES SPECIFICATIONS JR Panel.88 ± ± ±.003 SQUARE 9.73 ± ± ± ( = Same value as above) Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish 6 70, to 5 5 Plastic Plastic Jack Screw Al/Ni Contact Recept. Contact /Finish /Finish (Socket) (Pin) BeCu/Au with CRES hood Wire Type Shielded or Nonshielded Brass/Au Test Test Wire 70,000 Sea Level Insulation Termination Crimp 9 WIRE SPECIFICATIONS Conductor Insulation Shielding Jacket Part # Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz Strands /36 SPC 0.05 / / 1.48 Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. 3 2

4 05 SERIES 7.5 kvdc 70,000 FT -55º TO 105ºC 5-Pin The 05 has been in production since This series has been used extensively in airborne Traveling Wave Tube (TWT) and TWT Amplifier (TWTA) applications. The 05 comes in, both, shielded and non-shielded configurations. The bayonet coupling design provides secure mating. PLUG KIT (Dimensions shown as in/mm) Shielded (shown) Non-shielded Uses Wire: Uses Wire: Ø While plug kits are available for customer-fabricated cable assemblies, Teledyne Reynolds highly recommends purchasing cable assemblies because of difficulties customers may experience in assembly and testing. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering RECEPTACLE Sealed, Front Panel Mount Plastic Mounting: See optional mounting hole Panel Mounting Torque: 48 ± 4 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure Note: Contacts to be soldered to cable, inserted and bonded into insulator. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering. O-Ring P/N P/N P/N Female Contact (5 per assembly kit) Ø See Note Max. Panel 4.78 PLUG CABLE ASSEMBLIES SHIELDED (SHOWN) NON-SHIELDED Strain Relief Adapter SINGLE-ENDED DOUBLE-ENDED WIRE P/N RECEPTACLE CABLE ASSEMBLIES Sealed, Front Panel Mount O-Ring Uses Wire Rubber Mounting: See optional mounting hole Panel Mounting Torque: 48 ± 4 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure SERIES SPECIFICATIONS Altitude (ft) ,000 ( = Same value as above) Temp. (ºC) Current (Amp) -55 to or 8 Silicone Coupling Nut / Finish Coupling Style Silicone Bayonet or Plastic Al/Ni Contact Recept. Contact /Finish /Finish (Pin) (Socket) Brass/Au Wire Type BeCu/Au with CRES hood Shielded or Nonshielded Test Test Wire 70,000 Sea Level Insulation Termination Band 10 WIRE SPECIFICATIONS Conductor Insulation Shielding Jacket Strands /32 TPC / /34 SPC 36 SPC / 2.54 Part # Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz 0.5 / Current value depending on the wire that is selected. Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. 4 3

5 1407 SERIES 10 kvdc 70,000 FT -55º TO 105ºC 7-Pin The 1407 is a ruggedized 7-pin, bayonet coupled connector family. The 1407 is another one of Teledyne Reynolds connector series that has been used extensively in airborne Traveling Wave Tube (TWT) and TWT Amplifier (TWTA) applications. The 1407 comes in, both, shielded and non-shielded configurations. kits are available for customer-fabricated cable assemblies using Teledyne Reynolds wire. PLUG KIT (Dimensions shown as in/mm) Shielded (shown) Non-shielded Uses Wire Uses Wire While plug kits are available for customer-fabricated cable assemblies, Teledyne Reynolds highly recommends purchasing cable assemblies because of difficulties customers may experience in assembly and testing. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering. Ø RECEPTACLE Front, Box Flange Mount Sealed, Rear, Jam Nut Mount (Box Flange) Plastic Mounting: See optional Box Flange mounting 1.13 Square 28.7 Flange Note: Area must be suitably encapsulated for altitude operation Ø TYP. Ø Ø 20.0 See Note O-Ring Silicone.872 Ø 1.39 Mounting: See optional Jam Nut 35.2 Ø 22.2 mounting hole Panel Mounting Torque: 48 ± 4 in-lbs 1.29 Pressure: Sealed for 1 ATM differential 32.9 pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure (Jam Nut).906 TYP Silicone rubber sleeve (7 per assembly kit) Note: Area must be suitably encapsulated for altitude operation Note: Contacts to be soldered to cable, inserted and bonded into insulator. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering PLUG CABLE ASSEMBLIES SHIELDED NON-SHIELDED SINGLE-ENDED DOUBLE-ENDED WIRE P/N RECEPTACLE CABLE ASSEMBLIES Front, Box Flange Mount Sealed, Rear, Jam Nut Mount Uses Wire Uses Wire Plastic Mounting: See optional Box Flange mounting hole Silicone Mounting: See optional Jam Nut mounting hole Panel Mounting Torque: 48 ± 4 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure (Box Flange) Ø TYP. Ø Square 28.7 Flange (Jam Nut) O-Ring Ø TYP SERIES SPECIFICATIONS Approx..500 Tin Dip Altitude (ft) Temp. (ºC) Current (Amp) , to 5 6 or 8 Silicone Coupling Style Silicone Bayonet or Plastic Coupling Nut / Finish Al/Ni Contact Recept. Contact /Finish /Finish (Pin) (Socket) Brass/Au Wire Type Shielded or Nonshielded BeCu/Au ( = Same value as above) Test Test Wire 70,000 Sea Level Insulation Termination Band 15 WIRE SPECIFICATIONS Conductor Insulation Shielding Strands /34 SPC /32 TPC Part # Jacket / SPC Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz 0. / / TBD 30 Current value depending on the wire that is selected. Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. 5 4

6 PeeWee SERIES kvdc 70,000 FT -55º TO 5ºC 8 & 2-Pin PeeWee is one of a family of subminiature, high-voltage connectors for use in high voltage applications where dense electronic packaging is required. The PeeWee connector uses Teledyne Reynolds patented Advanced Interface method of sealing high voltage at reduced atmospheric pressure, which allows the connector to be rated at kvdc at 70,000 feet with a temperature range of -55 to 5 C. RECEPTACLE (Dimensions shown as in/mm) 8-pin, Front, Box Flange Mount º Ø Apart Key See Note Ø Potting Cavity Coupling Thread 1-1/16 28-UN-2A Ø Ø Note: Contact to be soldered to cable using Sn60 solder. Max. temp. 400º F (204º C) PLUG CABLE ASSEMBLIES 2-Pin Single-ended Single-ended, Right Angle 2-56 UNC-2A x 3/16 Socket Head Cap Screw Bending Point UNC-2A x 3/16 Socket Head Cap Screw Key Key STRAIGHT RIGHT ANGLE WIRE TYPE WIRE P/N Etched Silicone Coated Etched, NOMEX Jacket Silicone Coated, NOMEX Jacket Pin Single-ended Shielded, Single-ended Keyway Crimp Sleeve Ø Max. Polyolefin Jacket NOMEX Jacket 1.40 Max Front Face View Double-ended Shielded, Doube-ended Polyolefin Jacket 6 5 NOMEX Jacket

7 PeeWee SERIES kvdc 70,000 FT -55º TO 5ºC 8 & 2-Pin RECEPTACLE CABLE ASSEMBLIES 2-pin, Single-ended BENDING POINT 2-56 UNC-28 Threaded Insert Keyway SINGLE-ENDED WIRE TYPE WIRE P/N Etched Silicone Coated Etched, NOMEX Jacket Silicone Coated, NOMEX Jacket pin, Single-ended, Front, Box Flange Mount use wire Advanced Interface Seal Ty-Rap Polyolefin, Colored Indent. Sleeve Ø 41.2 Ø ± ± 25.4 Note: Exposed cable insulation on NOMEX covered single-ended cable assembly will be 1/2 inch less the cable length, unless otherwise specified. SERIES SPECIFICATIONS ( = Same value as above) Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish Contact /Finish (Socket) Recept. Contact /Finish (Pin) Wire Type Wire Insulation Braid Termination 70,000 ft Sea Level PeeWee 70, to 5 5 Plastic Plastic Threaded or Jack Screw Al/Ni BeCu/Au with CRES hood Brass/Au Shielded or Non- Shielded Band 18 WIRE SPECIFICATIONS Part # Conductor Insulation Shielding Jacket Strands Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz /36 SPC Etched / Nomex TBD Silicone Coated / Nomex TBD Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Nomex is a registered trademark of DuPont. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. TY-RAP is a registered trademark of Thomas & Betts (T & B) Corporation. 76

8 MAGNUM SERIES kvdc 70,000 FT -55º TO 5ºC 6-Pin Magnum is a quality directed series of multi-pin, high voltage connectors and cable assemblies. The Magnum are mechanical assemblies built-up from pre-tested, detail components, as contrasted to a conventional, one piece, molded in-place cable assembly. The Magnum construction allows the electrical and environment stress testing of details, such as plastic insulators and elastomeric dielectric interface seals, prior to final assembly. This results in a much higher level of quality and reliability. It is also possible, in many cases, to replace damaged receptacle seals and the individual plug leads rather than discarding an entire cable assembly. RECEPTACLE Rear, Jam Nut Mount Sealed, Rear, Jam Nut Mount Contact (6 per assembly) º Master Key Polarization 97º See Note 1.25 Ø Across 28.6 Flats 1.25 Ø 31.8 Master Key Jam nut with lock wire holes Bayonet Pin O-Ring Max. Panel Thickness Mounting Hole (Jam Nut) 30º Mounting: See optional Jam Nut mounting hole Panel Mounting Torque: 20 ± 2 in-lbs Note: Contacts to be soldered to cable, inserted & bonded into insulator. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering. Mounting: See optional Jam Nut mounting hole Panel Mounting Torque: 20 ± 2 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure ø Polarization (Ref.) Polarization (Ref.) º CW º CW º CW º CW º CW º CW º CW º CW Ceramic-to-metal, Brazed, Hermetic, Front Weld Mount º Master Key Polorization 97º Only Ø Master Key Ø 13.2 Mounting: Weld Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-8 cc/s ATM differential pressure 87 The Magnum is subject to the export jurisdiction of the U.S. Department of State and may require export license or other approval from the U.S. Department of State.

9 MAGNUM SERIES kvdc 70,000 FT -55º TO 5ºC 6-Pin PLUG CABLE ASSEMBLIES Shielded, Single-ended, Right Angle Polarization (Ref.) Mating Handle Shielded, Double-ended, Right Angle 97º CW 1º CW 8º CW 143º CW Mating Handle Silicone Shrink Tube Jacket 97º CW 1º CW 8º CW 143º CW Silicone Shrink Tube Jacket Overall Shield Overall Shield Indent, Shrink Boot Polarization (Ref.) Indent, Shrink Boot Shield Terminator Flange Ø Ø º Apart 4X Ø 3.18 Shield Terminator Flange Rear View RECEPTACLE CABLE ASSEMBLIES Rear, Jam Nut Mount 30º Uses wire Polarization 97º Silicone Shrink Tube Jacket Silicone Rubber Potting Mounting: See optional Jam Nut mounting hole Front Face View Master Key See Tab Block Ø Mounting Hole (Jam Nut) Polarization (Ref.) º 97º CW 1º CW 8º CW 143º CW Ø SERIES SPECIFICATIONS Magnum ( = Same value as above) Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish 70, to 5 6 Plastic Plastic Bayonet CRES / Passivate Contact Recept. Contact /Finish /Finish (Socket) (Pin) BeCu/Au with CRES hood Brass/Au Wire Type Shielded Test Test Wire 70,000 Sea Level Insulation Termination Silicone Coated Yes 18 WIRE SPECIFICATIONS Conductor Insulation Shielding Jacket Part # Strands /32 SPC.09 / 2.29 Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. The Magnum is subject to the export jurisdiction of the U.S. Department of State and may require export license or other approval from the U.S. Department of State. 9 8

10 Hi/Mate SERIES 13.5 kvdc 70,000 FT -55º TO 5ºC Various Pins The Hi/Mate are miniature insertable/removeable high voltage contact assemblies for use in MIL-C I, III and IV off-the-shelf connectors having a gauge, rear release, contact retention cavity. Hi/Mate Hi/Mate expands the capability of MIL-C I, III and IV connectors, by adapting them to carry 13.5 kvdc from sea level to airborne applications up to 70,000 feet altitude over a temperature range of -55 to 5 C. The MIL-C compatible high voltage interface Hi/Mate contact assemblies are insertable into four standard shell sizes and eight insert arrangements in accordance with MILSTD These contact assemblies are, in actuality, independent high voltage connectors, and do not rely upon the dielectric properties of the MIL-C insert. This fact makes the Hi/Mate ideally suited to be combined in inserts with fiber optic, co-axial or low voltage pins. The insert is merely a holder for the Hi/Mate contact and Advanced Interface Seal. The Advanced Interface Seal was patented by Teledyne Reynolds and has been highly successful in numerous connectors designed for use in the harshest of environments from sea level to Deep Space. INSERT ARRANGEMENTS Any gauge cavity in the insert arrangements shown below, can be converted to a 13.5 kvdc high voltage circuit without modification to the insert, by installing a Hi/Mate contact assembly in the appropriate pin and socket combination. Insert arrangements are in accordance with MIL-STD gauge cavities are identified in the Contact Legend. Contact Legend D Front face of pin inserts illustrated Insert Arrangement Service Number of Contacts Contact Size D M Note: Custom inserts are available for high voltage, low voltage, fiber optic and coaxial pins, as well as combinations of these pins Front face of pin inserts illustrated Insert Arrangement Service Number of Contacts Contact Size N I Twinax Coax I Coax PLUG AND RECEPTACLE CONTACT ASSEMBLY DIMENSIONS Contact Assembly Standard wire color is Red.16 Ø 4.09 Approx..500 Tin Dip Contact Assembly.08 Ø 2.04 Standard wire color is Red Approx..500 Tin Dip

11 Hi/Mate SERIES 13.5 kvdc 70,000 FT -55º TO 5ºC Various Pins PLUG CONTACT ASSEMBLIES Single-Ended Double-Ended RECEPTACLE CONTACT ASSEMBLIES Single-Ended Double-Ended PLUG - RECEPTACLE CONTACT ASSEMBLY Double-Ended SERIES SPECIFICATIONS ( = Same value as above) Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish Contact /Finish (Socket) Recept. Contact /Finish (Pin) Wire Type Wire Insulation Test 70,000 ft Termination Sea Level Hi/Mate , to 5 4 Plastic Plastic MIL-DTL MIL-DTL BeCu/Au Brass/Au Nonshielded 18 NA WIRE SPECIFICATIONS Part # Conductor Insulation Shielding Jacket Strands Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz /36 SPC Silicone Coated.058 / 1.48 Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied

12 Hi/Mate D SERIES 13.5 kvdc 70,000 FT -55º TO 5ºC Various Pins The Hi/Mate D of high voltage insertable/removeable contact assemblies are rated at 13.5 kvdc and can be fitted into a Subminiature-D (Sub-D) 8 gauge insert cavity. The assemblies are ideal for airborne applications up to 70,000 feet altitude over a temperature range of -55 to 5 C. Hi/Mate D is fully compatible with signal lines, co-axial, fiber optic and power contacts in the same Sub-D connector. These contact assemblies are independent high voltage connectors, and do not rely upon the dielectric properties of the Sub-D insert. Complete cable assemblies with Hi/Mate D high voltage contact assemblies installed into Positronic CBD Subminiature-D connectors, are available from Teledyne Reynolds as fully tested units. INSERT ARRANGEMENTS Any 8 gauge cavity in the insert arrangements shown below, can be converted to a 13.5 kvdc high voltage circuit simply by installing a Hi/Mate D contact assembly into the appropriate male or female cavity. 8 Gauge Cavity for Hi/Mate D installation Size 20 fixed contacts SHELL SIZE 1 5 W 1 Positronic CBD series Subminiature-D Insert Arrangemets Face view of Male - Rear view of Female SHELL SIZE 3 SHELL SIZE 2 3 W 3 7 W 2 11 W 1 5 W 5 9 W 4 13 W 3 17 W 2 21 W 1 SHELL SIZE 4 8 W 8 13 W 6 17 W 5 21 W A 4 25 W 3 27 W 2 SHELL SIZE 5 To view shell dimensions courtesy of Positronic Industries please go to: Notes: 1. Shell drawings are not to scale. 24 W 7 46 W 4 PLUG AND RECEPTACLE CONTACT ASSEMBLY DIMENSIONS 36 W 4 43 W 2 47 W 1 2. Care must be taken to observe Male/Female gender of both the Hi/Mate D contact assembly and the Sub-D Shell/Insert arrangement. Contact Assembly SHELL SIZE 6 Standard wire color is Natural Contact retention clip Approx..500 Tin Dip Contact Assembly Contact retention clip Standard wire color is Natural Approx..500 Tin Dip Note: assembly can only be installed into a Sub-D female insert. s can only be installed into a male insert. 11

13 Hi/Mate D SERIES 13.5 kvdc 70,000 FT -55º TO 5ºC Various Pins PLUG CONTACT ASSEMBLIES Single-Ended Double-Ended RECEPTACLE CONTACT ASSEMBLIES Single-Ended Double-Ended PLUG-RECEPTACLE CONTACT ASSEMBLY Double-Ended SERIES SPECIFICATIONS Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish Contact /Finish (Socket) Recept. Contact /Finish (Pin) Hi/Mate D , to 5 4 Plastic Plastic D-Sub D-Sub BeCu/Au Brass/Au WIRE SPECIFICATIONS Wire Type Nonshielded Wire Insulation ( = Same value as above) Braid Termination 70,000 ft Sea Level 18 NA Part # Conductor Insulation Shielding Jacket Strands Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz /32 SPC.06 / 1.53 Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied. 13

14 1804 SERIES 15 kvdc 70,000 FT -55º TO 5ºC 1807 SERIES 4-Pin 7-Pin The 1804 and 1807 of ruggedized 4 and 7-pin, connectors have been used in applications ranging from military vehicle electric reactive armor to airborne Synthetic Aperture Radar. The 1807 has even been used on the Ion Propulsion systems that have propelled some of NASA s most successful spacecraft into Deep Space. Both the 1804 and 1807 use the same connector housings which come in, shielded and non-shielded configurations with either threaded or bayonet coupling nuts. kits are available for customer-fabricated cable assemblies using Teledyne Reynolds specified wire. PLUG KITS Bayonet, Shielded (shown) Threaded, Shielded (shown) Lockwire Holes Ø Ø SERIES BAYONET, SHIELDED BAYONET, NON-SHIELDED THREADED, SHIELDED THREADED, NON-SHIELDED Shielded Kits use wire Non-shielded Kits use wire While plugs kits are available for customer-fabricated cable assemblies, Teledyne Reynolds highly recommends purchasing cable assemblies because of difficulties customers may experience in assembly and testing. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering. RECEPTACLE Bayonet, Front, Box Flange Mount with Contact Kit Threaded, Front, Box Flange Mount 1807: : : Mounting: See optional Box Flange mounting hole Ø (Box Flange) Contact (7 per assembly kit) Ø. 3.0 Ø Square 33.8 Flange Ø Silicone rubber sleeve (7 per assembly kit) Square 33.4 Flange Area must be suitably encapsulated for altitude operation TYP Mounting: See optional Box Flange mounting hole Note: Contacts to be soldered to cable, inserted & bonded into insulator. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering. Bayonet, Front, Box Flange Mount with Molded-in Contacts 1804: : Mounting: See optional Box Flange mounting hole Area must be suitably encapsulated for altitude operation Sealed, Bayonet, Rear, Jam Nut Mount 1804: : Panel Mounting Torque: 84 ± 2 in-lbs Mounting: See optional Jam Nut mounting hole Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure (Jam Nut) O-Ring 1.33 Square 33.8 Flange 1.56 Across Ø Flats Area must be suitably encapsulated for altitude operation

15 1804 SERIES 15 kvdc 70,000 FT -55º TO 5ºC 1807 SERIES 4-Pin 7-Pin PLUG CABLE ASSEMBLIES 1804 SINGLE-ENDED DOUBLE-ENDED WIRE SINGLE-ENDED DOUBLE-ENDED WIRE BAYONET, SHIELDED BAYONET, NON-SHIELDED THREADED, SHIELDED THREADED, NON-SHIELDED 1807 BAYONET, SHIELDED BAYONET, NON-SHIELDED THREADED, SHIELDED THREADED, NON-SHIELDED RECEPTACLE CABLE ASSEMBLIES Non-sealed, Bayonet, Front, Box Flange Mount Non-sealed, Threaded, Front, Box Flange Mount 1804: Uses wire : Uses wire Plastic Mounting: See optional Box Flange mounting hole 1804: Uses wire : Uses wire Plastic Mounting: See optional Box Flange mounting hole (Box Flange) Approx..500 Tin Dip TYP. Ø Square 33.8 Flange 1.33 Square 33.8 Flange Ø Ø Approx..500 Tin Dip Ø TYP Sealed, Rear, Jam Nut Mount 1804: Uses wire : Uses wire Plastic Panel Mounting Torque: 84 ± 2 in-lbs Mounting: See optional Jam Nut mounting hole Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure.500 Max. O-Ring (Jam Nut) Approx..500 Tin Dip SERIES SPECIFICATIONS Altitude (ft) ( = Same value as above) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish Contact Recept. Contact /Finish /Finish (Pin) (Socket) 70, to Plastic Silicone Bayonet or Threaded Al/Ni Brass/Au BeCu/Au with CRES hood Shielded or Nonshielded Clamp 22 N /A Wire Type Test Test Wire 70,000 Sea Level Insulation Termination WIRE SPECIFICATIONS Conductor Insulation Shielding Jacket Strands /32 TPC / /34 SPC 36 SPC / 2.54 Part # Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz 0.5 / Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied

16 155 SERIES 20 kvdc 70,000 FT -55º TO 105ºC 5-Pin The 155 is a 5-pin, bayonet coupled connector. At 20 kvdc between pins and shell, the 155 is one of Teledyne Reynolds highest rated multi-pin connectors. The 155 is a non-shielded connector. kits are available for customer-fabricated cable assemblies using Teledyne Reynolds wire. PLUG KIT (Dimensions shown as in/mm) Includes Strain Relief Adapter Uses wire While plug kits are available for customer-fabricated cable assemblies, Teledyne Reynolds highly recommends purchasing cable assemblies because of difficulties customers may experience in assembly and testing. Assembly instructions can be found at or by contacting Teledyne Reynolds Engineering Ø 45.2 RECEPTACLE Sealed, Rear, Jam Nut Mount Mounting: See optional mounting hole Panel Mounting Torque: 96 ± 6 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure O-Ring Max. Panel Thickness PLUG CABLE ASSEMBLIES Ø Single-Ended Uses wire Double-Ended Uses wire Ident. Shrink Boot Ident. Shrink Boot SERIES SPECIFICATIONS ( = Same value as above) Altitude (ft) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish Contact /Finish (Socket) Recept. Contact /Finish (Pin) , to Plastic Plastic Bayonet Al/Ni BeCu/Au Brass/Au Wire Type Nonshielded Wire Insulation Test 70,000 ft Termination Sea Level PE WIRE SPECIFICATIONS Part # Conductor Insulation Shielding Jacket Strands Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz /30 TPC PE. / 3.05 Vinyl.15 / 3.81 Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied

17 403 SERIES 35 kvdc 70,000 FT -55º TO 5ºC 3-Pin The 403, at the time of this writing, is the highest voltage rating in Teledyne Reynolds family of multi-pin connector products. It is a high reliability, ruggedized 3-pin, bayonet coupled connector. The 403 is designed to minimize any generation of corona or partial discharges, both, at sea level and at the reduced pressures found at 70,000 feet. This connector series has been extremely successful in high power Naval Radar applications. The 403 is offered as, either, a shielded or non-shielded cable assembly. RECEPTACLE Sealed, Rear, Jam Nut Mount Uses wire , O-Ring Max. Panel Thickness Mounting: See optional mounting hole Panel Mounting Torque: 96 ± 6 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure Ø Ø Area must suitably encapsulated for altitude operation PLUG CABLE ASSEMBLIES SINGLE-ENDED DOUBLE-ENDED WIRE SHIELDED NON-SHIELDED Ø RECEPTACLE CABLE ASSEMBLIES Sealed, Rear, Jam Nut Mount Uses wire Mounting: See optional mounting hole Panel Mounting Torque: 96 ± 6 in-lbs Pressure: Sealed for 1 ATM differential pressure Max. Leak Rate: 1x10-6 cc/s ATM differential pressure Ø Max Panel 6.35 Thickness O-Ring SERIES SPECIFICATIONS Altitude (ft) ,000 ( = Same value as above) Temp. (ºC) Current (Amp) Coupling Style Coupling Nut / Finish -55 to 5 Plastic Plastic Bayonet CRES / Passivate Contact Recept. Contact /Finish /Finish (Socket) (Pin) Brass / Au Wire Type BeCu/Au with CRES hood Shielded or Nonshielded Test Test Wire 70,000 Sea Level Insulation Termination WIRE SPECIFICATIONS Conductor Insulation Shielding Jacket Part # Impedance Ω Attenuation db/ MHz Capacitance pf/ft 1 khz Strands /32 TPC / TPC 0.18 / / / Cable Assembly Ordering Information: All cable assembly cable lengths are to be specified in inches only. For example, to order part number with a cable length of 10 feet 8 inches the cable assembly part number would be specified as N. Note: Product numbers and specs subject to change without notice. Products listed represent only a small selection of Teledyne Reynolds products please visit for the most up to date product information. Contact Teledyne Reynolds Engineering to discuss custom designs. WARNING: Connectors should NEVER be handled mated or unmated when voltage is applied

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