CIRCULAR & RECTANGULAR

CONNECTOR CABLE ASSEMBLIES

SCOPE: Rugged military style and industrial connectors & options

This document will provide the reader with a rudimentary understanding of typical
industrial and military grade circular and rectangular connectors and aspects of the cable
and ancillary functions that contribute to the performance and function of the complete
assembly. It is our goal to provide ideal fit, custom cable with every assembly. The
Overmolding of connector backshells should also be stressed but is not mandatory.

CIRCULAR CONNECTORS MATERIALS & CONSTRUCTION DETAILS .

CONNECTORS MANUFACTURERS / CIRCULAR MIL-SPEC & INDUSTRIAL GRADE

Amphenol, Pyle, Matrix, ITT Cannon, VEAM, Deutsch, Glenair, FCI, Tyco
COMMON NOMENCLATURE FOR MIL-SPEC
MIL-DTL-38999, MIL-C-27599, MIL-C-81511, MIL-C-26482, MIL-C-26500, MIL-C-5015,
MIL-C-83723, MIL-C-22992
COMMON TRADENAMES FOR COMMERCIAL / INDUSTRIAL
GT SERIES (AMPHENOL) SOCAPEX (AMPHENOL) TRIDENT NEPTUNE (ITT) CPP (DEUTSCH) CPC (TYCO)

Listing of available Manufactures & Mil-Spec. connector documents on last page on last page

The following segment is to make you aware of Rectangular connectors where the more
common geometry is of Circular connectors.
RECTANGULAR CONNECTORS MANUFACTURERS AND POPULAR MODELS .

Deutsch corp. Thomas & Betts LAPP.

CONNECTOR MANUFACTURERS / RECTANGULAR INDUSTRIAL

Deutsch, Thomas & Betts, LAPP, Tyco, Amphenol-Tuchel

COMMON TRADENAMES & STANDARDS

DRC series (Deutsch), V.35 (Tyco), EPIC (LAPP), Pos-E-Con (T&B), HMC series
(Molex), C146 series (Amphenol-Tuchel), HD 10 series (Deutsch),
 SECTION B: CIRCULAR CONNECTOR ANATOMY
MATING OPTIONS
Below left are the most common Mating interface options that are available to the
designer.
CONTACT INSERT OPTIONS
This is but an example of the hundreds of insert arrangements that are available.

Mating options Contact insert arrangement option “examples”

Illustrations courtesy of Amphenol Corp.

Typical contact size service rating
Contact Size Wire AWG accepted Test Current Amps
#16 22 5
#16 20 7.5
#16 18 10
#16 16 13
#12 14 17
#12 12 23
#8 10 33
#8 8 46
#4 6 60
#4 4 80
#0 2 100
#0 1 125
#0 0 150

Actual rating of continuous current can be impacted by Switching surges, transients, Peak Voltages etc. terror
designer is responsible to building necessary safety margins when selecting the proper contact for the
application.
 CONNECTOR FACTS
How is connector gender determined? Typically a plug (male) has pins and is terminated
to the ends of a cable. The Female or receptacle is terminated to the hardware or
equipment panel. Contact gender is not limited by the gender of the connector housing.
Plugs and receptacles can contain pins or sockets.

The choices for the receptacle connector are: Wall or panel mount, in-line or Jam-nut
receptacles. Again they may hold pins or sockets.
The wall mount has a flange with holes for mounting to the face of equipment panel. They
can be mounted from the front or rear of the panel. Gaskets may be included to improve
environmental or EMI shielding.
The in line receptacle is used to direct connect to a cable plug, as one might do when
daisy chaining multiple lengths of cable assemblies.
The Jam-nut is designed to pass thru a bulkhead or equipment panel from the rear of the
panel where a nut is threaded to the front of the connector to secure it to the panel or
bulkhead. Again, gaskets are available to improve environmental or EMI shielding.

POSITIONING AND COUPLING ELEMENTS

The following diagram depicts options for positioning the bayonet interface to eliminate cross
plugging of like connectors.

Bayonet Coupling: Pins are utilized on the receptacle body and ramps on the plug body to
provide a quick-connect and disconnect coupling.
Reverse Bayonet: This feature puts the pins on the plug and the ramps on the receptacle. This
role reversal allows for easier cleaning of the grooves.
Scoop Proof: Where the shell length of the receptacle prevents damage to the exposed contact
pins during mating. The external coupling mechanism is first engaged thus aligning the pins
correctly before the socket and pin meet.
Hermetic vs. Water Proof vs. Water Resistant: A true hermetic connector is one, which
provides an airtight seal between the contacts, connector insert and body thus can support and
maintain positive pressure or a vacuum. Waterproof connectors are ones where ingress of water
below 3 feet or more of water is prevented. There are methods such as molding, potting and
encapsulating which can prevent water intrusion at very high hydrostatic pressures. Water resistant
suggests that a terminated junction will prevent water ingress that can lead to shorting in shallow
standing water or rain. This is achieved by inserting rubber gaskets and compression seals at the
contract region as well as at the cable entry.
Right Angle Connector Bodies: Where a tight bend is needed housings can be provided that
forms a rigid 90-degree bend at the cable plug connector.
 STANDARD CABLE ENTRY OPTIONS VS. OVERMOLDING
There are a number of cable entry options available but vary by connector series or
mil-spec. and also by manufacturers.

Wire clamp, no grommet With Cable clamp &

No grommet or clamp
. Moisture grommet

For heat shrink & suitable Water seal strain relief

for over molding Basket weave strain relief and compression grip

SELECTING THE RIGHT CABLE ENTRY OPTION

Cable entry clamp selection is driven by the assembly’s exposure to harsh or wet
environment and where connector retention is a concern. Connectors without an
adjustable cable clamp or rubber compression grip, are often used for discrete wire
bundles, in protected environments. The connector with the knurled tail can accommodate
water resistant shrink tubing which provides some moisture protection but minimal
connector retention benefit. Connectors with the positive clamping system can provide
some protection against water leakage, however the best protection is provided by direct
molding the backshell to the cable and connector. Regardless of which cable entry system
is used, proper anchoring of a tensile strength threads or cords, or tensile load bearing
braids is recommended to enhance connector retention.

OVERMOLDING BENEFITS

Definition of Overmolding: In the over-molding process the backshell of the connector and
its cable entry options are eliminated in favor of a single homogenous molded unit.

Why mold when so may standard back shell options are available? These are some of the
advantages offered by replacing fixed mechanical backshells with a molded body.
• Reduced cost
• Improved cable retention
• Can integrate a strain relief feature
• Virtually water proof even with increased hydrostatic pressure
• Reduced size
• Visual appeal - chose a color to match equipment, the cable, or blend in.
• Infinite shape, contour or routing options: 30°, 45°, 90°, 110° gradual taper, abrupt end

Form – Fit – Function: The shape, length, taper, texture of the molded section are all design elements
that a customer can specify. Where there exists inventory of a specific connector mold tool, a customer
can elect to go with that design to eliminate a tooling expense.
 What’s it made of? The most widely used plastic compounds are polyurethane and PVC. Compounds
compatible with the cable jacket are the first choice so as to provide a superior bond and environmental
seal. Other compounds options are available as needed to satisfy special environmental or functional
requirements. {TPR, TPV, Nylon, etc.}

Tooling costs: Tooling costs vary with complexity of the connector body shape and features such as a
complex integral strain relief. A general rule of thumb is that a new tool unique to a customer or one where
Storm has not already purchased a tool can run from $3,000 to $8,000 dollars.

Molded version: When molding a connector we choose versions that accommodate shrink tubing or are
designed for molding. An example is shown below left. If grooves or some other textured feature is not
standard with the part, the designer may have to alter the aft section to improve mold material adhesion
that improves bonding and increases retention strength.

ACCESSORIES / OPTIONS

Special contacts will accommodate and maintain unique electrical or transmission properties.
Thermocouple functions can be supported by installing Thermocouple contact layouts containing
special alloys of iron, alumel, chromel, constantan, etc. and special wire must be used in the cable.
Optical fiber contacts provide reasonably good mating and transmission characteristics. Typically
multimode fiber is supported where return loss and insertion loss degradation is higher than one sees
with discrete fiber terminations but is often acceptable for industrial and military applications.
Coaxial cables can be terminated thru circular connectors with the use of special contacts however the
“typical” transmission performance is limited. Most coax contacts are designed to mate to generic mil-
spec coax cables, such as RG142, RG178, or RG316. Storm can provide proprietary, higher
performance coaxial contacts that are compatible with specific mil-spec circular connectors.

EMI and environmental gaskets: Provide additional moisture barrier or improve the electrical ground
between the receptacle and hardware frame.

Dust Caps: Shown with Lanyards; can be attached to the cable or hardware so it is available to
protect the interface of the otherwise exposed contacts.
Dust caps Gaskets
Plug cap Jack cap
 Typical part number scheme Material and ratings
table

Connector physical dimensions specification table

Cable features and performance attributes

Conductor:
• Collect mechanical characteristics: Gauge of wire, high tensile load (use special alloy
wire) high flex life or low flex torque (high stranding), temperature range, chemical or
water resistant, abrasion resistant coating, matte finish UV resistant jacket?
• Collect critical electrical characteristics: low capacitance, inductance, impedance, low
DC resistance (large gauge wire), knowing what voltage drop they can tolerate that
will drive the conductor, current carrying capacity
• Unique properties: Thermocouple wire, differentially driven pair, optical fibers

Insulation:
• Mechanical: Temperature, small size, chemical resistance, cut resistant, flexible,
Flame retardant, zero halogen, UL or other certification
• Electrical: Insulation resistance, dielectric strength, current carrying capacity

Shielding and other internal components:

• Mechanical: Low weight, flexibility, tensile strength
• Electrical: excellent noise rejection, triboelectric static dissipative coatings

Other mechanical features:

• Water blocking
• Aramid rope or braids to increase tensile strength

Jacket:
• Mechanical performance priorities: Flexibility, small size, temperature, abrasion
resistance, UV protection, hydrocarbon water, or chemical resistance, flame &
smoke resistance characteristics, V0, riser, plenum {UL, CSA, CE}

This training document is presented by Storm Products Company.

Storm referenced numerous trade journal articles, connector manufacturers literature, and other resources to
compile this comprehensive connector assembly-training document. To obtain a complete list please write to
Storm Products Cable Solutions Group.

CABLE SOLUTIONS GROUP – WWW.STORMPRODUCTS.COM

1400 Memorex Drive Contact: Jack Sanford

Santa Clara, CA 95050 Ph: 408-565-9810 x255