Hi/Mate is a miniature, high voltage contact rated at 13.5 KVDC and precisely dimensioned to fit into a 12 gauge cavity of a 38999 insert. It is installed and removed in the same manner as a 12 gauge, low voltage contact. Same tools. Same procedures.
Hi/Mate contains its own dielectric and environmental seals and simply uses the 38999 insert as a holder and retainer. Hi/Mate can:
Add a high voltage capability to new or existing 38999 connectors
Be operated at 70,000 feet at temperature extremes with excellent corona characteristics
Be combined in inserts with fiber optic, co-axial or low voltage pins because Hi/Mate is independently sealed
Be installed without potting compounds or adhesives. Interface seals assure 13.5 KVDC operation at altitude
Be purchased tested and ready to install at your facility, a depot or in the field
Be assembled at Reynolds using your 38999 connectors by MIL-STD 2000 approved solderers
Be assembled to your specifications and have group ‘B’ testing performed at Reynolds
Hi/Mate uses the interface sealing system developed by Reynolds for its
proven, highly successful Advanced series of connectors. Illustrations
not to scale.
When mated, the hard plastic nose of the plug assembly creates four sealing points as it engages the receptacle seal. Female contact in plug engages male receptacle pin
Receptacle body with seal in place
Hard plastic receptacle body with male contact
Molded silicone rubber seal with inner and outer protrusions
Design Verification Testing In-house verification testing has been conducted using 4 high voltage contact assemblies in each of two mated pairs of MIL-C-38999 series III connectors. A 25-24 insert arrangement was used. The contacts were installed in four of the available 12 gauge insert cavities. The 16 gauge cavities were filled with contacts. The chart to the left depicts the tests and the results . Corona attributes are shown in red.
Group 'A' Tests (100%)
Mechanical and visual examination
Continuity and Resistance.
Dielectric withstanding:16 KVDC for 3 minutes at 70,000 feet simulated altitude at room ambient temp.
Group 'B' Tests (optional)
Thermal Shock. MIL-STD 1344. Method 107
Hot and cold cycling. Dielectric withstanding 16 KVDC at 70,000 feet (simulated) .
Corona inception and extinction levels
EMI testing to customer requirements.
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