HydroVolt is designed to be the most rugged and reliable, low cost underwater electrical connector available. HydroVolt connectors are only slightly more expensive than other low cost connectors, yet are much more rugged and reliable. Furthermore, we guarantee that they will mate perfectly to the “industry standard” line.

HydroVolt fills a niche between low cost connectors and much more expensive rugged connectors. The line has unique features and benefits only available in much more expensive connector lines. And it has features, such as color-coded receptacle leads, that no other line carries, regardless of cost.

Key Features

Molding Bending Strain Relief
HydroVolt inline connectors have an integrally molded bending strain relief. Frequently the cable is flexed right at the cable/connector joint. This is because of the sharp change in the modulus of flexure between the cable and connector. A bending strain relief spreads this change over a distance ‘relieving” the tendency to bend at one specific point. Image shows comparison between typical competitors connectors and HydroVolt on right.

Color Coded Leads
HydroVolt bulkhead connectors and overmold plugs have color coded leads. The leads are the same color as their mate (the SO cable on the in-line connector). This makes conductor tracing easier and more reliable. Non-HydroVolt connectors use a numbered tag on each conductor (which are all the same color, white).

Bulkhead Pressure Block
HydroVolt bulkhead connectors have a true pressure block machined into the metal shell. In case of a catastrophic failure, such as part of the bulkhead being sheared off, a pressure block, can sometimes prevent water intrusion into the pressure vessel. Image shows comparison between typical competitors connectors and HydroVolt on right.
image overmold comparison

Improved Overmold Connector
HydroVolt has an improved overmold connector which has a much longer sealing area. Additionally, the sealing area has an O-Ring upset to further improve sealing of the boot. Image shows comparison between typical competitors connectors and HydroVolt on right.

Stronger Neck on Bulkhead
A neck is necessary on this style of connector in order to accommodate the industry standard locking sleeve. On non-HydroVolt connectors, it is smaller than necessary. Unfortunately, the head of the bulkhead can therefore be torn off during aggressive disconnection. The neck on the HydroVolt bulkhead, however, is heavier, and stronger. Damage to the neck of the bulkhead is a frequent complaint for non-HydroVolt type connectors. Image shows comparison between typical competitors connectors and HydroVolt on right.

Crimped Contacts
HydroVolt connectors have crimped contacts. Crimped contacts (rather than soldered) are less susceptible to bending fatigue failures. This type of failure occurs because the solder forces the stranded conductor to become a solid conductor at the joint. Connectors are frequently flexed and sometimes pulled by their cable which causes subtle bending and flexing at the contact joint. Crimped joints hold up to flexing better than soldered joints.

Gold Plated Contacts
HydroVolt connectors have gold they reduce the electrical resistance between the pin and socket. Contact resistance can be important in video and digital signal operations. Two, they are not susceptible to normal atmospheric corrosion. Contact corrosion increases contact resistance. Copper and brass contacts corrode right on the shelf. If stored near salt water, such as on a ship, the corrosion can happen quickly. HydroVolt contacts are plated to ASTM B488-01 Type II, which is superceding MIL45204C type II grade C.

Pin Shoulder Radius
The HydroVolt contact pin and insulation shoulder are both radius’ d. This makes it easier to mate in darkness or on rough seas. It also reduces the tendency for the shoulder to fray at the pin/shoulder interface, because there is no sharp edge.