How do I match connectors to my existing cables?

Cable-Connector Matching Guide

Key Matching Factors

1. Cable Outer Diameter (OD)

Most critical dimension! Connector must grip cable properly.

2. Number of Conductors

Must match connector pin count (or use fewer pins than available).

• 2 conductors → 2-pin connector (or larger)
• 4 conductors → 4-pin connector (or larger)
• Cannot use 6-conductor cable with 4-pin connector (waste)
• Can use 4-conductor cable with 6-pin connector (2 pins unused)

3. Conductor Size (Wire Gauge)

Must handle your current without overheating.

4. Jacket Material

Must suit your environment.

Cable Assembly Service

Don’t want to match yourself? We’ll do it for you!

Option 1: Send Us Your Cable

1. Ship 1-2 meters of your cable to us
2. We measure and identify specifications
3. We recommend compatible connectors
4. We can assemble connectors for you

Option 2: Tell Us Your Specs

Email us:

• Cable outer diameter (mm)
• Number of conductors
• Conductor size (AWG or mm²)
• Jacket material (if known)
• Application (ROV, sensor, etc.)

We’ll recommend the right connector.

Option 3: Buy Complete Assembly

We sell pre-assembled cable assemblies:

• Connector already attached
• Pressure tested
• Ready to use
• Custom lengths available

Popular Cable Types for Underwater Use

ROV Tether Cable

• Construction: Multiple conductors + strength members
• Jacket: Polyurethane (high flex, abrasion resistant)
• OD: Typically 8-15mm
• Connector: MCBH series with appropriate gland

Sensor Cable

• Construction: 2-8 conductors, often shielded
• Jacket: TPE or polyurethane
• OD: Typically 4-8mm
• Connector: MCM or MCBH series

Power Cable

• Construction: 2-4 large conductors
• Jacket: Neoprene or polyurethane
• OD: Typically 10-20mm
• Connector: High-current MCBH series

Ethernet Cable (Underwater)

• Construction: 4 twisted pairs + drain wire
• Jacket: Polyurethane
• OD: Typically 6-10mm
• Connector: Ethernet-compatible underwater connector

Cable Preparation Tips

For Connector Installation

1. Strip outer jacket: Carefully, don’t nick conductors
2. Prepare conductors: Strip to correct length
3. Tin conductors: Solder tip for easier insertion
4. Insert into connector: Follow pinout diagram
5. Pot/seal: Use epoxy or potting compound
6. Assemble connector: Follow torque specifications

Common Mistakes to Avoid

• ❌ Cable OD too small (won’t seal properly)
• ❌ Cable OD too large (won’t fit in connector)
• ❌ Conductors too large for contacts
• ❌ Wrong stripping length
• ❌ Damaged conductor insulation
• ❌ Inadequate potting/sealing

Need Help?

Cable matching can be tricky. We’re here to help:

• 📧 Email: sales@hysfsubsea.com
• 📎 Attach: Cable spec sheet or photo
• 📏 Include: Cable OD measurement (most important!)
• ⚡ Specify: Current/voltage requirements

Related: Technical Specifications | Cable Assemblies

Need cable matching help? Email sales@hysfsubsea.com with your cable details.