• HeavyBOS
  • Feature & Benefits
  • Product Range
  • Technical
  • Dimensions

Our HeavyBOS connectors are designed for maximum ruggedness. These are heavy connectors with thick cross sections. They are best for fixed locations where weight is not an issue, but ruggedness is necessary.

The BOS acronym started out as an internal light hearted name that meant bulkhead-on-steroids, due to their massively heavy and strong shells. Eventually customers started calling them BOS as well, so we stuck with that name.

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.
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.
HeavyBOS Product Range
Bulkhead connector receptacles are designed to be mounted to your pressure vessel. They are capable of handling 10,000 psi pressure differential (open face). Bulkheads are available in aluminum, brass, or stainless steel. Other materials can be made by special request.
Inline connector plugs are available as pigtails or can be molded onto your cable. The standard pigtail length is 1 meter. However, you may specify any length. Inline connectors plug into a bulkhead receptacle or another inline connector.
Dummy connectors are used to blank off either a bulkhead receptacle or an inline connector to prevent salt water from touching the gold plated contacts.
Locking Sleeves
Although not necessary for operations, locking sleeves can make sure that connectors will not disengage due to pulling loads on the cable. Locking sleeves are available in Delrin, Aluminum, or Stainless Steel.

Part Numbers Key



(310) 762-1600





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