Kemlon Kemlon

Technical Information

Introduction

Kemlon Products and affiliates have been manufacturing pressure proof components for underwater and subsurface geophysical instuments since 1950. Today, Kemlon manufactures a complete line of pressue proof electrical connectors for carious hostile environments including underwater, subsurface, and high temperature steam.

PB and PC Series Connectors

Connector Underwater Kemlon PB PC Series

The PB Series connectors are bulkhead connectors which utilize a boot to seal the cable and electical contacts from the environment. The boot also contains a contact block and contacts. The contact block ensures proper alignment and further insulates the contacts from the environment. Boot retainers are available which cover the boot and prevent the boot from being inadvertently unplugged. Contact blocks are also availabe which plug onto the back side of the connector in lieu of a solder connection.

The PC Series connectors are the male and female boots which mate to the PB Series bulkhead connectors. In some cases these are bonded directly to the cable and in other cases they are sized to slip onto the wire and can be terminated in the field. The PC Series connectors are availabe in a variety of rubber compounds from neoprene to high temperature fluroelastomers. It is important to choose the appropriate boot material and cable material for your environment

Construction

Kemlon manufactures two versions of the PB Series bulkhead connectors. The first type is an all APK 1000 molded connector. The APK 1000 material is an aromatic polyether. This material represents the latest technology and is superior to glass filled epoxy in strength, shock resistance, and resistance to water absorption. This type of construction is recommended for low to moderate pressure appplications up to 5000 psi when the temperature is -60° C to 140° C. It may also be used to 260° C when the pressures fall to ambient conditions. This type of construction is not recommended for use at moderate or high pressures and high tempuratures for extended periods of time.

The second type of constuction consists of a connector with conductors glass sealed to a metal body with APK 1000 extending the insulation out beyond the body for resistance to arcing. This typre of constuction is recommended for most applications. It provides the best performance for high pressure, high temperature, and extended use at pressure. The internal glass seal also prevents fluid leakage past the connectore if the boot becomes damaged.

PW Series Connectors

Connector Underwater Kemlon PW Series

The PW Series are connectors that when mated form a waterproof connector capable of operating up to 20,000 psi. this series utilizes an "O" ring seal to seal out the environment at the face. Alignment between the plug and receptacle is accomplished using a key and keyway machined into the metal bodies. A metal coupling nut holds the receptacle to the plug after the two are mated. The standard PW Series cable connectors have metal shells with a APK 1000 insert core. This APK 1000 core is bonded into the metal body with epoxy. The PW Series cable connectors are also available with glass sealed pins as an option for high pressure and high temperature applications. This would be recommended when temperatures are over 160° C or pressures over 16,000 psi. Typically, the PW Series cable connectors are sealed to the cable by direct vulcanization, so that a molded cable is furnished. Once again, the type of rubber and cable must be selected that is suited for the application. The PW Series bulkhead connectors are glass sealed high pressure feedthrus capable of withstanding high pressure independent of the female receptacles. This provides additional protection against hydraulic leakage into an instrument in the event the female receptacle is damaged or has a rubber seal failure.

HPW Series Connectors

Connector Underwater Kemlon HPW Series

The HPW Series connectors are very similar to the PW Series except they are designed to operate at higher temperatures and pressures. The HPW Series has a dual "O" ring seal at the mating face between the plug and receptacle. The HPW Series also utilizes a dual "O" ring seal between the bulkhead connector and the bulkhead. This dual "O" ring construction provides better seal reliability than found in the PW Series. All HPW Series cable connectors are glass sealed to provide the highest pressure capability. The HPW Series bulkhead connectors also have glass sealed pins, but in addition they have a heavier construction than the PW Series connectors. The HPW Series connectors would be recommended for high temperature and pressure service, and for service where a dual "O" ring seal is required.

PPW Series Connectors

Connector Underwater Kemlon PPW Series

The PPW Series are waterproof connectors designed to operate at lower pressures similar to those found in most routine subsea applications. The PPW Series form a waterpreoof connection when mated utilizing an "O" ring seal at the mating face. The main body of the PPW Series connector consists of APK 1000. As mentioned before, this material represents the latest technology and is superior to epoxy materials in strength, shock resistance, teperature resistance, and resistance to water absorption.

The PPW Series cable female connectors are available as a molded cable or field attchable kit which is designed to be potted. The simple constuction and high quality of materials used in the PPW Series translate into a highly reliable low cost underwater connector.

Electrical Specifications

Insulation resistance

The insulation resistance of a connector is a function of the temperature and test voltage. The minimum values of insulation resistance for the PB Series and PW Series connector are shown in Table 1. Note that the insulation resistance at room temperature is greater than 5000 megaohms at 500 V.D.C. This specification applies to pin to shell or pin to pin measurements.

Table 1 - General Specifications
Series Temperature Voltage Insulation Resistance
PB,PC Series 20° C 500 VDC 5000 Megaohms
PBM, PBFL, PBPM, PBFLS 140° C 500 VDC 500 Megaohms
PBMG, PBFLG, PBFLGS, PBPMG, PBMGSS 220° C 500 VDC 100 Megaohms
PCM, PCF, PCFA, PCFB, PCFD, PBF 162° C 500 VDC 100 Megaohms
PW Series 20° C 500 VDC 5000 Megaohms
PWM, PWMF, PWMFL, PWFFL, PWMD, PWFF, PWF 220° C 500 VDC 100 Megaohms
PWCM, PWCF, PWCFR, PWCFA, PWCFAO, PWCMA, PWCMAO 162° C 500 VDC 200 Megaohms
HPW Series 20° C 500 VDC 5000 Megaohms
HPWMD, HPWMFL, HPWCFAO, HPWCMAO 200° C 500 VDC 200 Megaohms
HPWCF, HPWCFA, HPWCMA 200° C 500 VDC 100 Megaohms
PPW Series 20° C 500 VDC 5000 Megaohms
PPWM, PPWMF 200° C 500 VDC 100 Megaohms
PPWCM, PPWCF, PPWCFA, PPWCMA 162° C 500 VDC 100 Megaohms

Current Capacity

The current capacity of a multipin connector is a function of four conditions. These are (1) the pin diamerer, (2) the type of pin material, (3) the operating temperature, and (4) the ability to dissipate heat that is generated by current flowing through the pins (resistance heating).

Table 2 - Specific Resistivities of Pin Materials @ 20° C
Pin Material Standard Optional Ohms per Circulas Mil Foot Micro Ohm cm Magnetic
Beryllium-Copper yes no 43 7.1 no
Kovar® yes no 294 48 yes
Nickel-Iron yes no 260 43 yes
Molybdenum no yes 34 5.7 no
Inconel® X-750 no yes 731 121 no
Nickel-Iron/Copper no yes 70.5 11.7 yes

Pins with a larger diamerter and a lower specific resistance will conduct more current. Therefore, beryllium copper pins have a higher current capacity than Kovar pins of the same size. See Table 2 for specific resistivities of standard and optional Kemlon pin materials.

The current capacity of a single pin has been set by Kemlon as the current which produces a 40° C temperature rise. The current carrying capacity of a multipin connector is complicated by its inability to dissipate heat, because the inner rows of pins dissipate heat more slowly that the outer rows. therfore, Kemlon has reduced the current copacity of the multipin connector load. In the case where only a few pins need to carry a high current, the current capacity would more closely apporximate that of a single pin. See Table 3

Table 3 - Current Capacities For Standard Pin Materials - Amps @ 20° C
Pin Size Diameter Kovar Single Kovar® Multipin Nicke/iron Single Nickel/Iron Multipin Beryllium Copper Single Beryllium Copper Multipin
#20 0.0400 5.5 3.3 5.9 3.5 14.5 .8.7
#16 0.0625 9.4 5.6 10.0 6.0 24.5 14.7
#12 0.0938 15.6 9.4 16.6 10.0 40.8 24.5
#10 0.1250 23.0 13.8 24.5 14.7 60.2 36.0
#8 0.1410 26.0 15.6 27.0 16.2 66.0 39.0

Since the specific resistance of pin materials increases with increasing temperature, the current capacity is lower at higher temperature than at 25° C. See Table 4 for the current capacities at 200° C.

Table 4 - Current Capacities - Amps @ 200° C
Pin Size Diameter Kovar Single Kovar® Multipin Nicke/iron Single Nickel/Iron Multipin Beryllium Copper Single Beryllium Copper Multipin
#20 0.0400 3.6 2.2 3.8 2.2 9.4 5.6
#16 0.0625 6.2 3.7 6.6 3.7 16.0 9.6
#12 0.0938 10.3 6.2 11.0 6.2 26.0 15.0
#10 0.1250 15.2 9.1 16.2 9.1 39.0 23.0
#8 0.1410 17.0 10.2 18.1 10.2 43.0 26.0

Kemlon offers some optional pin materials as shown in table 2. These materials may be requested depending upon the application. The Nickel Alloy/Copper is an optional material for Kemlon's glass sealed connectors and offers a higher current capacity. Molybdenum also offers higher current capacity and low magnetic permeability, but has lower mechanical strength than the Nickel Alloy/Copper material.

Continuity

Kemlon connectors are capable of maintaining electrical continuity between the male plug and female receptacle due to the use of heat treated spring contacts. Each contact is set for a minimum pin engagement force shown in the table below. Continuity is further enhanced by 100% gold plating of all contact surfaces. The maximum voltage drop across a contact is measured from the end of the contact to the engaged pin which is specified in Table 5. Also shown in Table 5 is the maximum voltage drop from the end of a 2" long pin to the end of a 2" long contact, which approximates the voltage drop across mated connector pair with beryllium copper pins and inserts.

Kemlon's standard spring insert material is beryllium copper. For operating temperatures greater than 200° C our option nickel alloy insert is recommended. However, unless requested all connectors will be supplied with gold plated copper alloy inserts.

Table 5 - Electrical Continuity
Contact Size Contact Diameter Minimum Contact Engagement Force in Ounces Conact Resistance - Voltage Drop BeCu Pin - BeCu Contact
Max Voltage Drop Contact Only Millivolts @ 25° C Max Voltage Drop Contact With 2" Long Pins Millivolts @25° C Test Current Amps
#20 0.0400 2 55 74 7.5
#16 0.0625 4 49 60 13.0
#12 0.0938 6 42 50 23.0
#10 0.1250 8 33 39 33.0
#8 0.1410 16 33 39 39.0

Kemlon Rubber Materials

Kemlon compounds a variety of rubber materials in house. These materials are carefully weighed and then mixed using Banbury mixer and Calendar mill. Each batch is given a batch number and is tested by our quality control department to ensure that is meets our specifications. Extensive testing has gone into the development of many of the formulations so the specific applications could be satisfied. Table 6 summarizes the compounds which cover the majority of application needs.

The low values shown for the temperature range represent the point where the rubber no longer has any flexibility. Molded boots and connectors operating near or below this teperature will not flex and should best be left undisturbed. The high values for the temperature range represent the maximum operating temperature of the material.

Table 6 - Kemlon Elastomer Chart
Compound Classification Durometer Shore A Temperature Range °C Recommended Uses
KN-01 Neoprene® 65 -55 to 162 General Purpose Compound. Underwater applications. Good insulator
KN-02 Nitrile 80 -16 to 180 Downhole oil wells. Inexpensive. Slightly conductive electrically.
KN-34 Fluoroelastomer 80 -20 to 260 For high temperature appllication. Excellant electrical insulator at temperature. Excellant resistance to water/steam.
KN-38 Viton® A 84 -14 to 230 General purpose high temperaure applications.
KN-42 Fluoroelastomer 82 -20 to 260 Excellant chemical resistance. High temperature downgole well service. Excellant resistance to water, water based and oil based drilling fluids.
KN-53 Fluoroelastomer 78 -20 to 250 Excellant gas resistance. High temperature downhole oil well service.Limited oil based drilling fluid resistance.
KN-55 Fluoroelastomer 67 -20 to 260 Similar to KN-34 except lower durometer. Better flexibility.
KN-62 Fluoroelastomer 65 -35 to 260 Similar to KN-42. better low temperature flexibility. More expensive.
KN-61 Polyurethane 75 -55 to 130 Compatible with polyurethane and neoprene cables. Pressure molded compound.Water resistant, but not recommended for oil well service.
KN-63 Polyurethane 80 -56 to 140 Compatible with neoprene and polyurethane cables. Castable compound meets MIL-M240441-C category A.

Multi-Conductor Cable

Kemlon offers a variety of rubber jacketed Teflon® insulated cables for pressure applications. These are available in 100 foot minimum lengths with blown jackets and 1000 foot minimum lengths with extruded jackets. Optional wire conductor sizes, jacket thickness, and materials also available upon request.

Table 7 - Neoprene Jacket over PTFE Wrap over Tin-Plated Copper Shield over PTFE Wrap over Individual PTFE Insulated Wire: 600 volt, .008-.010 Teflon®, 19 Strand Silver-Plated Wire
Part Number Conductor # / Size AWG Current Amps* Max Voltage Cable Dia Max Temp °C
16-A-7035-1 3 - #20 6.5 600 0.250 162
16-A-7035-2 4 - #20 6.5 600 0.265 162
16-A-7035-3 5 - #20 6.5 600 0.285 162
16-A-7035-4 7 - #20 6.5 600 0.300 162
16-A-7035-5 10 - #20 6.5 600 0.360 162
16-A-7036-1 2 - #16 11.0 600 0.300 162
16-A-7036-2 3 - #16 11.0 600 0.315 162
16-A-7036-3 4 - #16 11.0 600 0.335 162
16-A-7036-4 5 - #16 11.0 600 0.335 162
16-A-7036-5 7 - #16 11.0 600 0.380 162
16-A-7036-6 10 - #16 11.0 600 0.465 162
16-A-7036-7 14 - #16 11.0 600 0.500 162
16-A-7037-1 3 - #12 21.0 600 0.415 162
16-A-7037-2 4 - #12 21.0 600 0.440 162
16-A-7037-3 7 - #12 21.0 600 0.510 162
16-A-7038-1 4 - #8 40.0 600 0.695 162
Table 8 - Polyurethane Jacket over PTFE Wrap over Tin-Plated Copper Shield over PTFE Wrap over Individual PTFE Insulated Wire: 600 volt, .008-.010 Teflon®, 19 Strand Silver-Plated Wire
Part Number Conductor # / Size AWG Current Amps* Max Voltage Cable Dia Max Temp °C
16-A-7031-1 3 - #20 6.5 600 0.250 90
16-A-7031-2 4 - #20 6.5 600 0.265 90
16-A-7031-3 5 - #20 6.5 600 0.285 90
16-A-7031-4 7 - #20 6.5 600 0.300 90
16-A-7031-5 10 - #20 6.5 600 0.360 90
16-A-7032-1 2 - #16 11.0 600 0.300 90
16-A-7032-2 3 - #16 11.0 600 0.315 90
16-A-7032-3 4 - #16 11.0 600 0.335 90
16-A-7032-4 5 - #16 11.0 600 0.335 90
16-A-7032-5 7 - #16 11.0 600 0.380 90
16-A-7032-6 10 - #16 11.0 600 0.465 90
16-A-7032-7 14 - #16 11.0 600 0.500 90
16-A-7033-1 3 - #12 21.0 600 0.415 90
16-A-7033-2 4 - #12 21.0 600 0.440 90
16-A-7033-3 7 - #12 21.0 600 0.510 90
16-A-7034-1 4 - #8 40.0 600 0.695 90
Table 9 - Viton Jacket over PTFE Wrap over Tin-Plated Copper Shield over PTFE Wrap over Individual PTFE Insulated Wire: 600 volt, .008-.010 Teflon®, 19 Strand Silver-Plated Wire
Part Number Conductor # / Size AWG Current Amps* Max Voltage Cable Dia Max Temp °C
16-A-7023-1 3 - #20 6.5 600 0.250 200
16-A-7023-2 4 - #20 6.5 600 0.265 200
16-A-7023-3 5 - #20 6.5 600 0.285 200
16-A-7023-4 7 - #20 6.5 600 0.300 200
16-A-7023-5 10 - #20 6.5 600 0.360 200
16-A-7024-1 2 - #16 11.0 600 0.300 200
16-A-7024-2 3 - #16 11.0 600 0.315 200
16-A-7024-3 4 - #16 11.0 600 0.335 200
16-A-7024-4 5 - #16 11.0 600 0.335 200
16-A-7024-5 7 - #16 11.0 600 0.380 200
16-A-7024-6 10 - #16 11.0 600 0.465 200
16-A-7024-7 14 - #16 11.0 600 0.500 200
16-A-7025-1 3 - #12 21.0 600 0.415 200
16-A-7025-2 4 - #12 21.0 600 0.440 200
16-A-7025-3 7 - #12 21.0 600 0.510 200
16-A-7026-1 4 - #8 40.0 600 0.695 200
Table 10 - PTFE Jacket over Tin-Plated Copper Shield over PTFE Wrap over Individual PTFE Insulated Wire: 600 volt, .008-.010 Teflon®, 19 Strand Nickel-Plated Wire
Part Number Conductor # / Size AWG Current Amps* Max Voltage Cable Dia Max Temp °C
16-A-7027-1 3 - #20 6.5 600 0.250 260
16-A-7027-2 4 - #20 6.5 600 0.265 260
16-A-7027-3 5 - #20 6.5 600 0.285 260
16-A-7027-4 7 - #20 6.5 600 0.300 260
16-A-7027-5 10 - #20 6.5 600 0.360 260
16-A-7028-1 2 - #16 11.0 600 0.300 260
16-A-7028-2 3 - #16 11.0 600 0.315 260
16-A-7028-3 4 - #16 11.0 600 0.335 260
16-A-7028-4 5 - #16 11.0 600 0.335 260
16-A-7028-5 7 - #16 11.0 600 0.380 260
16-A-7028-6 10 - #16 11.0 600 0.465 260
16-A-7028-7 14 - #16 11.0 600 0.500 260
16-A-7029-1 3 - #12 21.0 600 0.415 260
16-A-7029-2 4 - #12 21.0 600 0.440 260
16-A-7029-3 7 - #12 21.0 600 0.510 260
16-A-7030-1 4 - #8 40.0 600 0.695 260

Kemlon Plastics

Kemlon provides a wide variety of molded connectors, sensors and related intruments for downhole applications. The following materials are aromatic polyether ketones and find widespread acceptance in environments with temperatures to 500° F and pressures to 30,000 psi.

Table 11 - Kemlox® High Temperature Plastics
Property Units Kemlox® APK 1000 Kemlox® APK 1000G30 Kemlox® APK 5000 Kemlox® APK 6000
Unfilled PEEK 30% Glass Filled PEEK PEK UberPEK
Density, Crystalline gm/cu. cm 1.32 1.5 1.32 ~1.32
Density, Anamorphous gm/cu. cm 1.26 ~ 1.27 ~1.27
Typical Crystallinity % 35 30~35 35 35
Water Absorption %~24hrs @ 73° F 0.50 0.11 0.50 ~0.50
Water Absorption %~Equil @ 73° F 0.50 ~ ~ ~
Melting Point ° F 644 644 705 723
Glass Transition Temperature ° F 289 289 315 327
Heat Distortion Tempurature ° F 306 ~ 329 347
Tensile Strength psi @ 73 °F 14065 22600 15950 16679
Tensile Strength psi @ 302° F ~ ~ 6962 ~
Tensile Strength psi @ 482° F 1740 4930 2466 ~
Dialectric Strength Volts/mil 480 444 440 ~430

Chemical Resistance of Kemlox® APK Thermoplastics

These plastic materials are all aromatic polyether ketones and exhibit similar and excellent chemical resistance to many materials. The following descriptions provide general guidelines to chemical resistance. Please inquire for materials not specifically listed below.

Resistance is outstanding to alcohols, aldehydes, ketones, bases such as ammonia, ammonium hydroxide, potassium hydroxide and sodium hydroxide. Furthermore, these plastics are unaffected by esters, ethers and a wide variety of halogenated organics such as freon, trichloroethylene and methylene chloride.

Most hydrocarbons show no attack, including benzene, crude oil, diesel oil, gasoline, kerosene, motor oil, vegetable oil, toluene, and transformer oil. Many inorganic reagents show little attack. Included in this group is bleach, calcium hypochlorite, copper cyanide, hydrogen sulfide, lime, mercury, nickel chloride, ozone, potassium nitrate, sodium chloride, sulfur, steam, sea water, and sulphur dioxide. However, a few inorganic materials should be avoided including bromine, flourine, chlorine, and some salts of halogens.

Acid resistance is outstanding with little or no attack by such chemicals as acetic acid, acrylic acid, boric acid, chromic acid, oxalic acid, hydrochloric acid, nitric acid, and phosphoric acid. The Kemlox® APK plastics are attacked by aqua regia, concentrated hydroflouric acid (70%), concentrated nitric acid (50%), and concentrated sulfuric acid (40%).

Plating

All pins, solder cups, and socket contacts found in this catalog are gold over nickel plated for maximum electrical contact. All gold plating is done in house to Kemlon's strict procedures, which meet or exceed MIL-G-45204-C, Type I, Class 1 specification of 50 microinches minimum thickness unless specified othewise. Plating thickness is carefully monitored with Beta Back Scatter instruments.

Helium Leakage

Kemlon glass sealed connectors are fabricated to meet or exceed a helium leak test of 10 ^-8 cc/sec at 15 psi differential pressure. Representative samples are inspected using a mass spectrometry helium leak detector to insure product integrity. 100% batch inspection can be performed at an additional charge.

Pin Termination

In most cases Kemlon connectors are shown with straight pins. However, solder cups may be shown on some connectors to aid in soldering or may be requested as an option.

Table 12 - Standard Solder Cup Dimensions
Pin Size Wire Size Cup I.D.
#20 20 Awg 0.047
#16 16 Awg 0.073
#12 12 Awg 0.113
#8 8 Awg 0.16

Quality Control

Kemlon maintains a quality control program with complete manufacturing documentation and traceability. Kemlon's program exceeds the system requirements of MIL-I-45208-A. In addition a written schedule for calibrating gauges, measuring and test equipment is strictly followed in accordance with MIL-C-45662. Kemlon inspects all "first parts" and samples of all sub-assembly components prior to final assembly. During final inspection, and electric test for insulation resistance and dielectric withstanding voltage are performed on 100% of the final assemblies prior to shipment. Kemlon also routinely performs pressure tests and maintains vessels for testing in water and oil to 25,000 psi and 260° C

Table 13 - Pressure Equivalents
PSI Feet Seawater Meters Seawater Bars Kilograms per Cm² Kilo Pascals
1 2.25 0.69 0.069 0.07 6.89
10 22.5 6.86 0.69 0.7 68.9
100 225 68.6 6.9 7.0 689
500 1125 343 34.5 35.2 3447
1000 2250 686 69 70.3 6890
5000 11250 3429 345 352 34470
10000 22500 6858 690 703 68900
Table 14 - Material Specifications
Materials Specification Tensile Strength
Nitronic 50® AMS-5764 135,000
APK 1000 MIL-P-46183 26,000
Beryllium Copper QQ-C-530 175,000
Inconel® X-150 AMS 5667 95,000
Kovar® AMS 7727 65,000
316 S.S. ASTM-A-276 55,000
Aluminum Bronze QQ-C-450 85,000
Nickel alloy 50% nickel MIL-I-23011 70,000