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SID Series General Specifications

This series of push-on/pull-off connectors provides a reliable 15 KVDC high voltage connection for use in military and aerospace applications.
A unique interface sealing system allows these connectors to perform well under vibration, shock, altitude and temperature extremes. Mated SID assemblies also have good corona
characteristics.
SID assemblies are especially well suited for interconnecting high voltage system components. The excellent flexibility of the silicone cable makes system cable routing simple and reliable.
A variety of panel connectors are available as well as straight and right angle cable plug assemblies.
SID assemblies are widely used in:

  • Electronic Countermeasure Systems

  • TWT connections

  • Lasers

Interface cleaning

High voltage connectors must always be cleaned prior to mating. The proper cleaning method is to wipe or spray the interface area with isopropyl alcohol and immediately blow an inert gas such as dry nitrogen over the interface area until dry. No other cleaning method should be attempted.
 

WARNING: These connectors should NEVER be handled, mated or unmated when voltage is applied.


Download PDF for all SID Series General Specifications

 

SID Push-on/Pull-off cable assemblies and receptacles, Page 1

SID - 15 KVDC Plug Cable Assemblies

Single-Ended Straight Assembly

Note: Stranded wire shown on single-ended assemblies is for factory testing and is not included in length dimension.

178-6076   SID Series Single Ended Straight Cable Assembly 

Wire Dia. 0.165 (4.1)

178-6075   SID Series Single Ended Straight Cable Assembly

Wire Dia. 0.180 (4.5)

Mating connector: All SID receptacles Mating method: Push-on/Pull-off

Double-Ended Straight assembly

 

178-6078 SID Series Double Ended Straight Cable Assembly

Wire Dia. 0.165 (4.1)
178-6077
SID Series Double Ended Straight Cable Assembly

Wire Dia. 0.180 (4.5)
Mating connector: All SID receptacles Mating method: Push-on/Pull-off

Single-Ended Right Angle Assembly

 

178-6080 SID Series Single Ended Right Angle Cable Assembly

Wire Dia. 0.165 (4.1)
178-6079
SID Series Single Ended Right Angle Cable Assembly

Wire Dia. 0.180 (4.5)
Mating connector: All SID receptacles Mating method: Push-on/Pull-off

Double-Ended Right Angle Assembly

 

178-6082 SID Series Double Ended Right Angle Cable Assembly

Wire Dia. 0.165 (4.1)
178-6081
SID Series Double Ended Right Angle Cable Assembly

Wire Dia. 0.180 (4.5)
Mating connector: All SID receptacles Mating method: Push-on/Pull-off

Double-Ended Hybrid Assembly

 



 

178-6084 SID Series Double Ended Hybrid Cable Assembly

Wire Dia. 0.165 (4.1)
178-6083
SID Series Double Ended Hybrid Cable Assembly

Wire Dia. 0.180 (4.5)
Mating connector: All SID receptacles Mating method: Push-on/Pull-off

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SID Push-on/Pull-off cable assemblies and receptacles, Page 2

SID - 15 KVDC Receptacles

P/N 26RC1031    SID Series Male Solder Flanged Receptacle (Male Contact)

Solder-Flanged Receptacle 15 KVDC
- Mounting: Solder flange
- Terminal type: Exposed solder tube
- Body Material: Molded Plastic
- Mating connectors: Mates all SID cable assemblies
- Maximum Leakage: 1 x 10-6 cc/sec. He

P/N 60RC1031    SID Series Male Flanged Jam Nut Receptacle (Male Contact)

Flanged Jam Nut Receptacle 15 KVDC
- Mounting: Jam nut flange
- Terminal type: Exposed solder tube
- Body Material: Molded Plastic
- Mating connectors: Mates all SID cable assemblies
- Seals: “O” ring flange seal
- Maximum Leakage: 1 x 10-6 cc/sec. He

P/N 29RC1031   SID Series Male Plastic Flanged Receptacle (Male Contact)

Plastic-Flanged Receptacle 15 KVDC
-
Mounting: Designed for encapsulation or bonding
- Terminal type: Flush to recessed solder tube
- Body Material: Molded Plastic
- Mating connectors: Mates all SID cable assemblies

P/N 34RC1031   SID Series Male Plastic 4 Receptacle Block (Male Contact, 4 places)

Plastic 4-Receptacle Block 15 KVDC (each)
- Mounting: Designed for encapsulation or bonding
- Terminal type: Flush solder tube (4 places)
- Body Material: Molded Plastic
- Mating connectors: Mates all SID cable assemblies
- Seals: None
- Note Block can be precision cut by customer to convert to single, double or triple connector

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Index by Part Number
 

2R1030 (KIT)
2R1030-XLX

2R1031 (KIT)
2R1031-XLX

2R1032 (KIT)
2R1032-XLX

2R1033 (KIT)
2R1033-XLX
2R1530
2R1540
2R1560
2RC1046
2RC1059

2RC1500
2RC1505

2RC1510
2RC1515

2RC1530
2RC1540
2RC1545

2RC1560
2RC1565

2RT1007
2RT1008

3R1033-XLX
3R1500
3R1550
3R1560
3RC1505
3RC1525
3RC1550
4R1032 (KIT)
4R1032-XLX
4R1550
4RC1063
4RT1007
4RT1008
5R1032 (KIT)
5R1032-XLX
5R1033 (KIT)
5R1033-XLX
6R1033 (KIT)
6R1033-XLX
7RC1500
7RC1510
10RC1565
13RC1515
17R1500
17R1510
21RC1520
26RC1031
29RC1031
34RC1031
60RC1031
167-0669
167-1615
167-1617

167-2669
167-2896

167-3305
167-3306
167-3516
167-3516-1
167-3517
167-3638
167-3770
167-3771
167-4078
167-4356
167-4358
167-4360
167-4450
167-4534
167-4534-1
167-4569
167-4596
167-7058-1
167-7058-2
167-7058-3
167-7624-1
167-7624-2
167-7624-3
167-7628
167-7667
167-7792
167-7793
167-7794
167-7825-1
167-7825-2
167-7825-3
167-7826-1
167-7826-2
167-7826-3
167-7864-1
167-7864-2
167-7864-3
167-7903-1
167-7903-2
167-7903-3
167-7904-1
167-7904-2
167-7904-3
167-7905-1
167-7905-2
167-7905-3
167-8603
167-8626
167-8721
167-8793
167-8794
167-8794
167-8795
167-8796
167-8798
167-8804
167-8805
167-8810
167-8811
167-8812
167-8813
167-8814
167-8815
167-8816
167-8817
167-8818
167-8841
167-8842
167-8842
167-8850
167-8851
167-8854
167-8855
167-8920
167-9149
167-9150
167-9151
167-9157
167-9158
167-9163
167-9164
167-9169
167-9180
167-9193
167-9201
167-9203
167-9210
167-9213
167-9219
167-9227
167-9228
167-9263
167-9275
167-9293
167-9294
167-9296
167-9330
167-9332
167-9333
167-9336
167-9337
167-9363
167-9364
167-9391
167-9449
167-9487
167-9610
167-9611
167-9634
167-9785
167-9803
167-9833
167-9872
167-9875
167-9876
167-9879
167-9916
167-9917
167-9957
178-6027
178-6028
178-6075
178-6076
178-6077
178-6078
178-6079
178-6080
178-6081
178-6082
178-6083
178-6084
178-6090
178-6092
178-6093
178-6094
178-6142
178-6143
178-6144
178-6153
178-6154
178-7023
178-7024
178-7025
178-7026
178-7027
178-7028
178-7032
178-7033
178-7034
178-7110
178-7111
178-7113
178-7115
178-7139
178-7140
178-7141
178-7142
178-7143
178-7144
178-7146
178-7152
178-7157
178-7158
178-7162
178-7163
178-7370
178-7371
178-7372
178-7375
178-7376
178-7377
178-7435
178-7631-1
178-7631-2
178-7631-3
178-8210
178-8315
178-8781
178-9578
467-7094
R790-2518
R790-3516
R790-4516
R790-6014
R1006-1
R1030 (KIT)
R1030-XLX
R1031 (KIT)
R1031-XLX
R1032 (KIT)
R1032-XLX
R1033 (KIT)
R1046-1
R1059-1
R1520
R1530
R1540
RC1046
RC1060
RC1061
RC1062
RC1500
RC1505
RC1510
RC1515
RC1520
RC1525
RC1530
RC1535
RC1540
RC 1545
RC1550
RC1560
RG 213/U
RT1007
RT 1008


AWG wire data

 

AWGSTRANDINGAPPROX. DIA.CROSS SECTIONDC RESISTANCECURRENT RATING
MMINCHESOHMS/1000M (amps) Free air. 80°C*
3041/460.30.0120.051337.30.4
2951/460.350.0140.064271.30.5
2841/440.370.0150.081212.30.6
26SOLID0.40.0160.13133.91
26111390.480.0190.141122.41
26119620.510.020.127136.21
2619/380.50.020.151113.81
2651/420.560.0220.16107.31
2666/440.480.0190.131131.91
24SOLID0.510.020.20584.31.6
24104090.610.0240.22476.81.6
24112310.640.0250.20185.61.6
2416/360.610.0240.203851.6
2419/360.640.0250.24171.51.6
2441/400.590.0230.205841.6
22SOLID0.640.0250.32652.82.5
22349090.760.030.35648.22.5
2219/340.80.0320.38344.92.5
2226/360.750.030.32952.52.5
2265/400.780.0310.32652.52.5
20SOLID0.810.0320.51833.54
20349070.960.0380.56730.54
20350011.020.040.50933.84
2019/321.010.040.60928.24
2026/340.940.0370.52432.84
20105/400.990.0390.52632.84
18SOLID1.020.040.823218
18349051.210.0480.901198
1816/301.230.0480.815218
1819/301.270.050.96817.78
1841/341.190.0470.826218
1865/361.250.0490.823218
18168/401.340.0530.84220.38
16SOLID1.290.0511.30913.110
16349031.530.061.43312.110
1619/291.430.0561.2214.110
1626/301.50.0591.32413.110
1641/321.50.0591.32613.310
1665/341.570.0621.30913.110
16260/401.730.0681.30313.110
14SOLID1.630.0642.0818.215
14349011.850.0732.2857.615
1419/271.80.0711.948.915
1441/301.890.0752.0888.215
12348992.440.0963.664.920
1219/252.270.093.0855.620

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Application guide for product selection


Criterion

Guide

Voltage Rating

Reynolds rates voltage as the “maximum operating voltage.” Ratings are for steady state DC The user should define the maximum DC voltage of the proposed circuit and select a connector rated at least 25% above the maximum circuit operating voltage. If the circuit contains voltage with an AC component or is pulsed DC, the user should consult with Reynolds engineering department before choosing a connector.

Altitude Operation

If a proposed application involves operation at a reduced pressure equivalent to 15,000 ft. or higher, the user should refer to p. 42 for background on the relationship of voltage stand off and atmospheric pressure. Connectors presented in this catalog are clearly rated concerning operation at altitude. Reynolds altitude-rated connectors use precision elastomeric seals
to effect an altitude seal and requires no silicone grease to operate reliably at their rated voltage.

Operating Temperature

The user should accurately establish the operating temperature range of any application for high voltage connectors. This
is very important for sea level applications and becomes critical for altitude operation. The user should be realistic in evaluating the temperature range. Connectors designed to operate over a range of -55°C to +125°C are considerably more expensive than those designed for room ambient operation or even -40°C to +70°C. The operating temperature is clearly indicated for all connectors in this catalog.

Plugs

Plugs, the ends that are attached to cable assemblies, are available in some cases as a bag assembly for installation by the user. Reynolds generally discourages the purchase and installation of these connectors by the user, especially if the final assembly is to be used at altitude and/or extremely cold temperature, for several reasons. (1) Extreme cleanliness must be observed to preclude conductive contamination. (2) If the connector requires bonding (most do), only an experienced person with all the necessary potting room equipment should attempt the installation. (3) Assemblies must be voltage–stress tested and, when destined for use at altitude, in an altitude chamber capable of simulating the equivalent of 70,000 ft.

Receptacles

Receptacles also must be kept clean, particularly in the interface area. If the rear portion of the receptacle requires encapsulation, it is best to have this done and tested by Reynolds prior to shipment. However, the potting of a receptacle
is usually straightforward and can be accomplished by following the material manufacturer’s printed instructions.

Wire and Cable

There is no single wire or cable suitable for all applications and conditions. Following are comparisons:

FEP Advantages:

Silicone Rubber Advantages:

High dielectric

Fair dielectric strength

Abrasion resistant

Good flexibility

Good corona characteristics

Easy to bond and encapsulate with silicone rubber

Can be etched and silicone–rubber coated

Disadvantages:

Resistant to most fluids including Coolanol™

Relatively large diameter compared to FEP

Disadvantages:

Susceptible to pinholes and wire migration

Must be etched for bonding or encapsulation

Incompatible with Coolanol™ and some other oil dielectrics

FEP Wire & Cable Etching -Coating

FEP wire can be etched and coated with silicone rubber for encapsulation using silicone rubber compounds or bonding to molded silicone rubber components using approved elastomeric bonding materials. FEP wire that has been etched but not coated can also be used for encapsulation or bonding to most epoxy materials. These processes give FEP wire a versatility found in no other high voltage wire or cable and make it an excellent choice for most high voltage applications

Cable Routing and Bend Radius

In routing cable, the user should take care to avoid making sharp bends. Sharp bends put added stress on the wire strands and can create a corona stress point. Sharp or rough metal edges in the routing area should also be eliminated, especially when using silicone cable. Torquing a cable excessively during routing should be avoided.

Liquid Dielectrics

Reynolds connectors use silicone rubber seals and “O” rings to effect dielectric and pressure sealing. Silicone rubber, including silicone rubber cable, is incompatible with many dielectric oils and Coolanol™ dielectric. While these are excellent dielectric mediums they can cause silicone rubber to swell. Some Reynolds connectors offer fluorsilicone seals and/or insulators for use with these dielectrics. Only FEP or PFA cable should be used where these dielectrics are present.

Loss Line Cable

Reynolds manufactures a complete line of high voltage loss line or distributed loss R.F. attenuation cable. The user requiring R.F. attenuation should consider using loss line. Reynolds engineers are available for application consultation.

Corona

Users with concerns about corona should consult Reynolds engineering department before making a high voltage connector choice. Reynolds is extremely knowledgeable concerning the origins of corona and its effects and and possible remedies. Reynolds makes no claim to manufacturing “corona-free” connectors, cable or cable assemblies. Reynolds does, however, maintain extensive corona research and test data on its products with the objective of manufacturing connectors as resistant to the effects of corona as possible. Reynolds is noted in the industry for its corona detection equipment and technical competence to analyze the existence and level of corona in a connector or circuit.


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Paschen curve: Voltage arc level vs atmospheric pressure


Paschen’s results
In the 19th century, Paschen, a German scientist, conducted experiments to determine electrical arc char-acteristics when ambient pressure changed. He spaced two spherical electrodes at a constant 3/8 inch (1cm). He then reduced the ambient pressure in increments from sea level (760 mm Hg.) to 260,000 ft. (0.01 mmHg.). At each selected pressure increment he increased the voltage across the electrodes until a low-energy arc occurred.

The curve on the chart above tells the story. At sea level, about 30,000 VDC is required to initiate an arc across the electrode gap. At 47,000 ft. the arc level drops to about 1200 VDC. Accordingly, the worst altitude is 150,000 ft., where only about 300 VDC will arc across the electrodes. Electronic Countermeasure Systems (ECM) and other radar and electronic systems aboard aircraft require high voltage connectors and cable assemblies to function at altitudes up to 70,000 ft. with 1,500 to 40,000 volts applied. Missile-borne ECM systems raise the requirement to 150,000 ft..

The problem
In low voltage electrical connector applications (less than 500 volts DC), reduced air pressure presents little concern or special design considerations. But to take one example, a high voltage connector operating requirement of 10,000 volts DC, the creep path (arc distance) between two conductors at sea level would be 1/2 inch (12.7mm), and at 70,000 ft. it would be 5 inches (127mm) minimum.

The extended creep path solution
If no design solution were possible other than the lengthening of the creep path, then aerospace high voltage connectors would occupy unreasonable volume and would be extremely heavy.

Elastomer seals
To eliminate the need for a lengthened creep path, all connectors manufactured by Reynolds that are rated for altitude operation have precision elastomer seals incorporated into the design. These seals block high voltage creep at reduced air pressure.

Temperature swing effect
Temperature swings from -55°C to +125°C can cause elastomer materials to exhibit compression set or loss of memory between hot and cold cycles. This can result in voltage creep past the seals and subsequent failure of the connector. Through the use of select elastomer materials and seal geometry, Reynolds altitude rated connectors will operate reliably when exposed to reduced pressure and hot and cold cycling.

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上次更新日期: 2016年04月13日。