termination 



Figure 6. Prototype dry connector schematic. 



which had been recently recovered from the 

 long-term immersion test. The assembly was placed in 

 the NCEL 72-inch pressure vessel and pressurized at 

 100 psi per minute to 3,000 psi (6,750 feet), held for 

 one hour, depressurized, and recycled at the same 

 rate to 500 psi for 15 minutes. There was no 

 electrical degradation of either connector half during 

 the test. Because of the difficulty of adapting seals to 

 the existing housing seams, the prototype housing 

 leaked and the compensating mineral oil was found to 

 contain 1 5% seawater upon disassembly. Since there 

 was no electrical degradation, the test confirmed the 

 effectiveness of the heat-shrink seals around the 

 individual conductors and splices; the design is 

 genuinely redundant and will tolerate at least partial 

 contamination. 



The strength of the cable termination 

 (Dyna-Grip) was tested by mating one prototype half 

 with one experimental half of a dry connector and 

 attempting to lift a 21,000-pound concrete clump as 

 described in the discussion of the experimental test 

 program. Although the experimental termination 

 failed, the Dyna-Grip showed no ill effects at all. 

 Further testing for fatigue, corrosion and other 

 effects will have to await employment in larger-scale 

 systems at sea. 



The entire dry connector prototype in its 

 present form can be assembled and attached to a 

 cable end by two men in about six to eight hours. 

 This is a major improvement over the one-to-two days 

 required to install even small connectors utilizing 

 potting techniques. The NCEL prototype design also 

 requires no special tools or controlled conditions for 

 installation. 



The contacts and penetrator pins are the same as 

 those in the experimental model (fused glass) which 

 showed no degradation after five months of shallow- 

 submerged continuous operation and one year of 

 submerged (600 feet) intermittent operation. 

 Glass-filled epoxy pins developed later for use in the 

 wet connector should be used for applications 

 requiring less stringent open-face pressures (such as 

 for in-line operation rather than as a structural 

 penetration). 



Evaluation. The NCEL high-power 

 electromechanical connector (dry) is now ready for 

 final design to fit whatever specific applications may 

 arise. With the exception of the penetrator pins and 

 cable termination, production of the entire dry 

 connector is well within the capacity of any user with 

 access to a machine shop. Costs may be expected to 

 vary considerably with the desired mechanical 

 strength because of the termination, housing and 

 resultant machining effort. The cost would also 

 increase if fused-glass pins were used. The connector 

 depth rating is exclusively a function of the com- 

 pensator volume, and the life is principally a function 

 of the choice of housing materials. Performance has 

 been demonstrated to a simulated depth of 6,750 feet 

 and over a sustained immersion of one year at 600 

 feet. 



Prototype Wet Connector 



Modifications. A set of experimental wet 

 connectors was disassembled for analysis of failed 

 internal components and for modification as 



10 



