BCR2004M METAL SHELL 2000 SERIES

BCR2004M — Metal Shell 2000 Series Bulkhead Connector

The BCR2004M is a Metal Shell 2000 Series hard-shell subsea connector (Shell 20, 4 contacts, male (pins) face) rated to 600 V DC/AC rms and 40 A total (4 × 10 A per contact), qualified to 690 bar (10,000 psi) — approximately 7,000 m water depth — when mated. Unlike rubber-body connectors, the rigid stainless steel outer shell absorbs manipulator impacts, tool-tray collisions and deck-handling abuse while preserving the connector face geometry, making it the preferred choice for high-impact work-class ROV and subsea oil & gas environments.

Metal Shell 2000 (Shell 20) 4 Pins 600 V / 10 A per Contact 40 A Total 690 bar Mated / 7,000 m 480 bar Open Face Wet Matings >500 SubConn Compatible

Key Design Features

• Hard-shell impact protection: the rigid 316 stainless steel outer shell withstands ROV tool-change impacts, drilling-mud exposure and abrasive sand-laden currents that would damage a chloroprene-only body.
• 690 bar / 10,000 psi mated pressure: full work-class depth rating equivalent to the Burton 55 series; every connector is pressure-tested to rated depth before shipment.
• 480 bar open-face rating: the metal shell protects the connector face during deployment without the mating counterpart (approx. 7,000 psi).
• Mixed power and signal in one connector: all contacts rated 600 V DC/AC rms / 10 A each, so power distribution and low-level sensor signals share a single hull penetration.
• BCR mounting: jam-nut bulkhead installs flush to the panel surface — minimal protrusion reduces snagging risk and enables high-density panel layouts.
• Gold-plated beryllium copper contacts: contact resistance < 0.01 Ω, insulation resistance > 200 MΩ; gold plating prevents galvanic corrosion in seawater.
• >500 wet-mate cycles: precision-machined mating face with O-ring wiper seals, rated for standard ROV tool-change and hot-stab operational profiles.
• SubConn Compatible: mates with standard inline and dummy connectors; numbered PTFE pigtail leads and integrated locking-ring thread with stainless steel locking sleeve.

Electrical & Mechanical Specifications

Mechanical Dimensions (per series drawing)

Materials

Mating & Compatibility

Typical Applications

Work-class ROV panel connectors and ROV tooling skid power/signal breakout, subsea junction box (SJB) and flying-lead connector ports, subsea tree (XT) instrumentation and subsea control module (SCM) umbilical terminations, BOP and offshore drilling equipment connections, subsea hydraulic control panels, naval and defence underwater vehicle hard-point ports, and subsea production manifold wiring in high-impact environments.

Notes for Selection

Locking sleeves are mandatory. Always install the POM or stainless steel locking sleeve after mating — the hard shell does not prevent rotation of the coupling nut without it. Each FCR/BCR requires a mating cable plug (CCP) of the same shell size and pin count, sold separately; matched sets with dummy plugs and factory-terminated cable assemblies are available. Rinse with fresh water after every seawater exposure, inspect the rubber-to-metal interface annually for crevice corrosion, and replace O-rings every 2–3 years. Batch or per-unit hydrostatic pressure test certificates to 690 bar are available for oil & gas operator approval programmes.