Electrical Interconnect Products
Table of Contents
8-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Typical Solder Sleeve Device/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3, 8-4
Wire-to-Wire Splicing
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Solder Sleeve Wire Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 to 8-11
SolderGrip Closed End Connector Splices . . . . . . . . . . . . . . . . . . . . . . . . .8-12 to 8-17
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18 , 8-19
MiniSeal High-Performance, Immersion-Resistant Crimp Splices . . . . . . . .8-20 to 8-23
Insulated Terminals and Disconnects
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-24
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Terminals and Disconnects . . . . . . . . . . . . . . . . .8-25 to 8-30
SolderGrip Self-Fixturing Insulated Terminals . . . . . . . . . . . . . . . . . . . . . . .8-31 to 8-35
Wire Termination to Pin/Post/Tab
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-36
SolderSleeve Discrete Wire Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37 to 8-40
Shield Termination
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-41
SolderSleeve Shield Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42 to 8-47
Coaxial Cable Termination
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-48
SolderSleeve Coaxial Cable Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49, 8-50
SolderSleeve PCB/Coaxial Cable Terminators . . . . . . . . . . . . . . . . . . . . . . . .8-51, 8-52
RF One-Step BNC/TNC Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-53 to 8-58
Cable-to-Cable Splicing
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-59
SolderShield Sheilded and Coaxial Cable Splices . . . . . . . . . . . . . . . . . . .8-60 to 8-63
Shielded Contacts
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-64
SolderTacts shielded one-piece solder contacts . . . . . . . . . . . . . . . . . . . .8-65 to 8-73
Data Bus (MIL-STD-553B) Components
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-74
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-75, 8-76
In-Line Microcouplers: One- and Two- Stub . . . . . . . . . . . . . . . . . . . . . . . .8-77 to 8-79
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub . . . . . . . . . . . .8-80 to 8-82
Box Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83, 8-84
Discrete Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85, 8-86
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-87 to 8-91
Triaxial Size 8 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-92
Space-Grade Data Bus Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-93 to 8-95
Customer-Specified Harness Assemblies and HarnWare . . . . . . . . . . . . . . . . . . . .8-96
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-96
Other
HexaShield, High Performance EMC Adapters . . . . . . . . . . . . . . . . . . . . .8-97 to 8-102
MTC Crimp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-103 to 8-109
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Electrical Interconnect Products
8-2
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
Typical SolderSleeve
Device (illustration of
shield terminator concept)
Transparent, heat-shrinkable
thermoplastic sleeve Thermoplastic sealing ring
Optional preinstalled wire lead
Fluxed solder preform
Sleeve shrinks, conforms to
cable contours, and provides
strain relief
Solder preform melts and flows,
Installation quality is fully visible
through transparent sleeve
Sealing rings melt to provide
environmental protection
Typical Installation
1. Insert prepared cable
2. Apply heat
Tyco Electronics' depend-
able, economical wire and
cable termination products
provide solutions for
hundreds of wire and cable
interconnect requirements.
All Raychem wire termina-
tion products are housed
inside transparent heat-
shrinkable insulation
sleeves, which provide
inspectability and can
provide various levels of
environmental protection.
Most Raychem termination
products incorporate a
fluxed solder preform,
which is essential for a
highly controlled soldering
process. Other products
incorporate controlled
crimping or a unique
process of combining a
twist-on coil with controlled
soldering to provide high-
reliability joints on the
widest variety of conductor
types and platings.
SolderSleeve technology
ensures high-quality
electrical and mechanical
performance time after time.
Pemeasured solder and flux
create repeatable, eliable
terminations, reducing
rejects and field failures.
When the SolderSleeve
device is heated, the tubing
shrinks and the solder
preform melts to make a
fully insulated, strain-
relieved, protected solder
connection. Heat-shrinkable
tubing provides the benefits
of insulation, strain relief,
and protection for our
controlled crimp products.
Many Raychem intercon-
nect products have earned
UL recognition or MIL-Spec
approval.
Raychem interconnect
devices combine high-
strength materials with
innovative design for
consistent, long-life
performance. And
because the insulation
sleeve is transparent,
operators can easily
inspect the connection.
Raychem shrink-to-fit
technology even helps
reduce inventory, because
one device size will fit a
wide range of wire gauges,
cable diameters, and
component shapes.
Raychem interconnect
products are designed
for many applications,
from simple splices to
terminators for sophisti-
cated electronic systems,
either sealed or unsealed,
and for high- or low-
temperature environments.
8
Electrical Interconnect Products
8-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Selection
Application Type Max. Operating Connection Page
Temp. Type Product Description Series Number
Wire-to-wire splicing
125°C [257°F] Solder SolderSleeve wire splices CWT-900X 8-6
150°C [302°F] Solder SolderSleeve wire splices D-110, D-1744 8-6
125°C [257°F] Coil and solder SolderGrip closed end
connector splices (stub) SGRP, SGRS 8-12
125°C [257°F] Crimp DuraSeal crimp splices D-406 8-18
150°C [302°F] Crimp MiniSeal crimp splices D-436 (M81824) 8-20
Terminals and 125°C [257°F] Crimp DuraSeal crimp terminals
disconnects and disconnects B-106 8-25
150°C [302°F] Coil and solder SolderGrip terminals SGRT 8-31
Wire termination 125°C [257°F] Solder SolderSleeve wire terminators CWT-15XX 8-37
to pin/post/tab 150°C [302°F] Solder SolderSleeve wire terminators D-129, D-141,
D-71X 8-37
Shield termination
125°C [257°F] Solder SolderSleeve shield terminators CWT-X 8-42
150°C [302°F] Solder SolderSleeve shield terminators S01, S02,
M83519, SO63 8-42
175°C [347°F] Solder SolderSleeve shield terminators SO96 8-42
Coaxial cable 125°C [257°F] Solder SolderSleeve coaxial cable terminators CWT-4XXX 8-49
termination 150°C [302°F] Solder SolderSleeve coaxial cable terminators B-02X, B-04X 8-49
150°C [302°F] Solder SolderSleeve PCB/coaxial cable terminators D-607, B-046 8-51
135°C [275°F] Solder RF one-step BNC/TNC connectors RBD, RTD 8-53
Cable-to-cable splicing 150°C [302°F] Solder/Crimp SolderShield cable splices D-150 8-60
Shielded contacts 150°C [302°F] Solder SolderTacts shielded contacts D-602 8-65
Triax connectors 150°C [302°F] Solder Triax discrete connectors D-621, DK-621 8-85
MIL-STD-1553 150°C [302°F] Solder Triax discrete connectors D-621, DK-621 8-85
Data bus connectors 150°C [302°F] Solder Triax discrete connectors D-621, DK-621 8-85
MIL-STD-1553 150°C [302°F] Solder or In-line data bus
In-line couplers connectorized microcoupler D-500-04 8-77
MIL-STD-1533 150°C [302°F] Connectorized Data bus box couplers D-500-025 8-83
Triaxial size 8
contacts 150°C [302°F] Solder Size 8, triaxial MIL-C-38999 contacts D-602, DK-602 8-92
Data bus cables 150°C [302°F] Crimp or solder MIL-STD-1553 B shielded cable 1061X 8-75
Data bus terminators 150°C [302°F] Solder or MIL-STD-1553
connectorized 78° and 3000° terminators D-621, D-500 8-87
Data bus accessories 150°C [302°F] Solder or Dust caps, braid terminators, splices D-600,D-150 8-87
mechanical
Electrical Interconnect Products
8-4
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Selection (Continued)
SolderSleeve wire splices
Application Ty p e Connection Max. P r oduct Description S e r i e s P a g e
Ty p e O p e r a t i n g N u m b e r
Te m p .
Wire to wire
splicing
Terminals
and disconnects
Wire termination
to pin/post/tab
Shield termination
Coax cable
termination
Cable to cable splicing
Shielded contacts
125°C CWT-900X
Solder
Crimp
Coil and
Solder
Coil and
Solder
Crimp
Solder
Solder
Solder
Solder/Crimp
Solder
8-6
8-6
8-18
8-20
8-12
8-25
8-37
8-37
8-42
8-42
8-42
8-49
8-53
8-49
8-51
8-60
8-65
8-74
SolderSleeve wire splices
150°C D-110,
D-1744
DuraSeal crimp splices125°C D-406
MiniSeal crimp splices150°C D - 4 3 6
( M 8 1 8 2 4 )
SolderGrip closed end
connector splices (stub)
125°C SGRP,
SGRS
DuraSeal crimp terminals
and disconnects
125°C B-106
8-31
SolderGrip terminals
150°C SGRT
SolderSleeve wire terminators125°C CWT-15XX
SolderSleeve wire terminators150°C D-129,
D-141,
D-71X
SolderSleeve shield terminators125°C CWT-X
SolderSleeve shield terminators150°C S01, S02,
M83519,
SO63
SolderSleeve shield terminators175°C SO96
SolderSleeve
coaxial cable terminators
125°C CWT-4XXX
SolderTacts shielded contacts150°C D-602
SolderShield cable splices
150°C D-150,
B-202
SolderSleeve
coaxial cable terminators
150°C B-02X/04X
SolderSleeve
PCB/coaxial cable terminators D-607,
B-046
RF one-step BNC/TNC
connector
135°C RBD,
RTD
MIL-STD-1553B
data bus components Solder Data bus couplers, connectors,
terminators, accessories
150°C D-500,
D-600,
D(K)-621
8
8-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
Introduction
Tyco Electronics offers
many products for
wire-to-wire splicing:
Raychem SolderSleeve
splicing devices; SolderGrip
splices; and DuraSeal and
MiniSeal crimp splices.
Like all Raychem intercon-
nect products, the wire-to-
wire splicing devices are
rugged and reliable, yet
easy to install.
Designed for applications
with temperatures up to
150°C [302°F], products
in this section include:
■SolderSleeve splicing
devices, which can be
used to make sealed or
unsealed splices. In a
single step, they solder,
insulate, encapsulate, and
strain-relieve a wide
range of wire sizes.
■DuraSeal heat-shrinkable
nylon crimp splices are
easy to use in factory or
repair applications.
DuraSeal crimp splices
provide watertight sealing
and superior protection
against corrosion,
abrasion, and vibration.
■Small, lightweight, and
l o w - p rofile MiniSeal high-
p e rf o rmance crimp
splices, which substantially
reduce wire bundle size
and weight, are QPL-listed
to the MIL-S-81824
specification, and are
re q u i red by the MIL-W-
5088 specification.
■SolderGrip splices, which
are closed-end connec-
tors utilizing a spiral
copper coil that grips
and compresses the
conductors and allows a
prefluxed solder ring to
flow to the center of the
splicing area, resulting
in a high-reliability,
repeatable solder joint.
8-6
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices
Product Options
Product Series Minimum Wire Maximum Operating Intended Application
Temperature Rating Temperature Environment
CWT 85°C [185°F] 125°C [257°F] Splashproof
D-110 125°C [257°F] 150°C [302°F] Splashproof
D-1744 (NAS 1744) 125°C [257°F] 150°C [302°F] Immersion sealed
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult Tyco Electronics for details.
Product Facts
■Transparent polyvinylidene
fluoride or polyolefin sleeve
provides encapsulation,
inspectability, strain relief,
and insulation
■Prefluxed solder preform
provides a controlled
soldering process
■One-piece design makes
installation easy and lowers
the installed cost
■With one or two wires per
end, the NAS 1744 splices
meet 75,000 ft [22,000 m]
altitude immersion
requirement
■Thermochromic temperature
indicator in the NAS splices
facilitates termination and
inspection
■UL and CUL
recognized
Product Selection Process
From the Product Options
table above, select the
product series appropriate
for your application based
on the temperature rating
and sealing performance
required.
If the application has only
one size of wire per side
and no more than two wires
on either side:
1. Determine wire gauge
sizes for both sides of
splice.
2. Determine number of
wires (one or two wires)
for each side of splice.
3. Select part numbers from
the appropriate table:
■For CWT series (low
temperature): Use
Table A on page 8-7.
■For D-110 series
(splashproof): Use
Table B on page 8-8.
■For D-1744 series
(immersion sealed):
Use Table C on
page 8-9.
If the application has more
than one size of wire per
side or more than two wires
on either side (or if you pre-
fer to work with CMA or mm2
sizes):
1. Turn to “CMA/mm2
Calculation” on page
8-10 and use the work-
space there to calculate
the total cross section to
be spliced.
2. Use Table E on page
8-11 to select the sleeve
recommended for that
cross section.
Notes:
While all combinations listed
will provide satisfactory
solder joints, the degree
of strain relief obtained
depends on the outer diam-
eter of the wires being
joined. Refer to Table E for
the recommended size
ranges for the sleeves.
Wires 16 AWG (1.21 mm2)
and larger, and wires hav-
ing more than 19 strands,
should be pretinned prior
to splicing, to obtain the
optimum solder joint quality.
Part selection for wires
26 AWG (0.15 mm2) and
smaller is covered on page
8-8.
Applications
In-line wire splices.
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002
24 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
22 AWG 1 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
2 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
20 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
18 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
16 AWG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
14 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
2 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004
12 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004
2 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
10 AWG 1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of 121212121
Conductors
26 AWG 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
24 AWG 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
22 AWG 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
20 AWG 1 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
18 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
16 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
14 AWG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005
12 AWG 1 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
2 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
10 AWG 1 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
Table A:
CWT Series Selection
8-8
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 AWG 1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
2 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41
24 AWG 1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
2 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
22 AWG 1 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
20 AWG 1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
18 AWG 1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
2 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
16 AWG 1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101
14 AWG 1 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090
12 AWG 1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090
10 AWG 1 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083 D-110-0083
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of 121212121
Conductors
26 AWG 1 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
24 AWG 1 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
22 AWG 1 D-110-41 D-110-0181 D-110-41 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
20 AWG 1 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
18 AWG 1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
16 AWG 1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
2 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0083 D-110-0083
14 AWG 1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
12 AWG 1 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
2 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083
10 AWG 1 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083
Table B:
D-110 Series Selection
Part Inside Diameter
No. As Supplied* Fully Recovered** Length***
D-110-0071 0.9 [0.035] 0.6 [0.025] 4.7 [0.185]
D-110-0213 0.9 [0.035] 0.6 [0.025] 4.2 [0.165]
D-110-0214 0.6 [0.025] 0.3 [0.013] 6.3 [0.250]
D-110-0217 1.0 [0.040] 0.6 [0.025) 9.1 [0.360]
D-110-40 0.6 [0.025] 0.5 [0.021] 5.1 [0.200]
Note: Micro SolderSleeve terminations are used for splicing wires smaller than 26 AWG [0.15 mm2].
*Minimum. Wire insulation must be smaller than this.
**Maximum. Wire insulation and combined conductor diameters must be greater than this.
***Nominal. Wire strip length must be approximately one-half of this.
Fine Wire Splices 26 AWG
(0.15 mm2) and Smaller
8
8-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 AWG 1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
24 AWG 1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02
22 AWG 1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
2 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02
20 AWG 1 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02
2 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
18 AWG 1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
16 AWG 1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
14 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
12 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
2 D-1744-04 D-1744-04 D-1744-04 — D-1744-04 — — —
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG
Number of 12121212
Conductors
26 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
24 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
22 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
20 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
18 AWG 1 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
16 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
14 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
2 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04 — — —
12 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 — D-1744-04 —
Table C:
D-1744 Series Selection
8-10
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
To calculate the total circu-
lar mil or mm2area of the
conductors to be termi-
nated in a single splice, fol-
low these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue
to use it for all your
selection criteria.
2. In the workspace below,
list the CMA or mm2for
each conductor that will
go into the same splice.
(To assist you, Table D on
this page provides
the CMA of typical
conductors.)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. From Table E on the next
page, select the part
number recommended
for the total CMA or mm2
you have calculated.
5. Refer to the examples on
this page for further
clarification.
Total CMA = 3180 Total CMA = 3408
Total mm2= 1.59 Total mm2= 1.71
Correct part number selection from Table E Correct part number selection from Table E
(based on CMA/mm2and nominal jacket wire OD) (based on CMA/mm2and nominal jacket wire OD)
= CWT-9002 or D-110-41 or D-1744-02. = CWT-9003 or D-110-0181 or D-1744-03.
CMA/mm2Examples
One-to-One Wire Splice Multiwire Splice
Wire Number CMA mm2
1
2
3
4
5 Part Number:
Total
CMA of Typical AWG Conductors
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
CMA/mm2Calculation
Table D.
8
8-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
CMA mm2
Product Wire Jacket OD Combined Total Combined Total
Series Min. Max. Min. Max. Min. Max.
CWT-9001 0.4 [0.015] 1.7 [0.066] 450 1500 0.3 1.8
CWT-9002 1.3 [0.05] 2.7 [0.106] 1250 3500 0.8 2.0
CWT-9003 1.8 [0.07] 4.5 [0.18] 2500 7200 2.0 4.0
CWT-9004 2.8 [0.11] 6.0 [0.236] 6100 19000 4.0 6.0
CWT-9005 3.2 [0.125] 7.0 [0.275] 12000 25000 6.0 10.0
D-1744-01 0.50 [0.020] 1.90 [0.075] 350 2000 – –
D-1744-02 0.80 [0.031] 2.80 [0.110] 2000 4000 – –
D-1744-03 1.30 [0.050] 4.57 [0.180] 4000 10000 – –
D-1744-04 2.00 [0.080] 7.11 [0.280] 10000 13000 – –
D-110-35 0.51 [0.020] 1.78 [0.070] 500 1500 – –
D-110-41 1.27 [0.050] 2.54 [1.00] 1200 3500 – –
D-110-0181 1.9 [0.075] 4.5 [0.177] 3600 6000 – –
D-110-0101 2.41 [0.095] 4.32 [0.17] 4800 9000 – –
D-110-0090 3.56 [0.140] 7.11 [0.28] 8500 16200 – –
D-110-0083 4.0 [0.160] 8.76 [0.345] 16200 25000 – –
Series Agency Raychem
CWT ULE87681 D-5023
D-110 ULE87681 RT-1404
D-1744 NAS-1744 RT-1404
Material
Insulation (D-110, D-1744) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation (CWT) Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux (D-110, D-1744) Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAflux)
Solder and flux (CWT) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNS-J-004 (RAflux)
Meltable inserts (CWT, D-1744) Meltable thermoplastic
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating (CWT) -55°C to +125°C [-67°F to +257°F]
Temperature rating (D-110, D-1744) -55°C to +150°C [-67°F to +302°F]
Insulation resistance 1000 megohms
Installation Requirements
Table E:
Multiwire Splice Selection
Product Characteristics
Specifications/Approvals
For proper installation of
these devices the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
■HL1802E
■IR-1759 MiniRay
■AA-400 Super Heater
■CV-1981
Refer to Raychem installa-
tion procedure RPIP 850-00
for D-1744 Series and RPIP
824-00 for CWT Series.
You will find ordering
information for these tools
in Section 10.
8-12
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices
Applications
SolderGrip heat-shrinkable
solder-type closed-end
connectors are designed
for electrical termination of
multiple-wire combinations.
They provide a reliable
alternative to crimping,
welding, or conventional
twist-on-style closed-end
connectors.
Their unique combination of
w i re fixturing and contro l l e d -
soldering technology pro-
vides dependable electrical
termination of multiple wire
combinations.
SolderGrip terminators
consist of a heat-shrink-
ablethermoplastic sleeve
containing a spiral-wound
copper insert. The insert is
fitted with a prefluxed
solder band.
This innovation design
allows SolderGrip products
to reliably terminate as
many as 10 wires of
different sizes and types in
a single device.
The capability of SolderGrip
terminators encompasses
single or multistranded,
bare or tinned copper
wires with low- or high-
temperature insulation.
The termination is
environmentally protected
and strain relieved.
SolderGrip splice termina-
tors are color-coded for
easy identification.
Product Options
Product Series Environmental Protection Max. Operating Temp.
SGRP Splashproof 125°C [257°F]
SGRS Sealed 125°C [257°F]
Product Facts
■Soldered connection
■Electrical insulation
■Sealed for immersion
(SGRS)
■Excellent strain relief
■Simple installation
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Product Dimensions (Min.) Product Dimensions (Min.)
Part Color L ØA Wire Range (Min.-Max.) L ØA Wire Range (Min.-Max.)
No. Code CMA/mm2CMA/mm2
SGRP-1 Green 1.370 .120 1400 - 4800 SGRS-1 Green 1.370 0.130 1400 - 4800
[34.8] [2.9] [0.7 - 2.4] [34.8] [3.4] [0.7 - 2.4]
SGRP-2 Red 1.350 .150 4000 - 8000 SGRS-2 Red 1.350 0.190 4000 - 8000
[34.2] [3.7] [2.0 - 4.0] [34.2] [4.8] [2.0 - 4.0]
SGRP-3 Blue 1.610 .200 7000 - 18000 SGRS-3 Blue 1.650 0.290 7000 - 16000
[41.0] [5.1] [3.5 - 8.0] [42.0] [7.3] [3.5 - 8.0]
SGRP-4 Yellow 1.650 .270 15000 - 30000 SGRS-4 Yellow 1.630 0.360 15000 - 24000
[42.0] [6.8] [7.5 - 12.0] [41.5] [9.1] [7.5 - 12.0]
1. From the Product Options
table on the previous
page, select the product
series appropriate for
your application.
2. Determine the wire com-
bination (number of wires
and size) of the wire bun-
dle you wish to splice.
3. Use Table C (page 8-15)
to select the correct con-
nector for AWG wire com-
binations.*
For mm2wire combina-
tions use Table A to
select a SolderGrip part
number.
Example: For connecting
a bundle with one 12
AWG wire (1 #12) and
two 14 AWG wires (+2
#14), you need an SGRP-
3 connector. For sealed
parts, select the SGRS
series.
*If the wire combination is not
listed in Table C, use the CMA
(mm2) method of determining
wire bundle size (see “CMA/
m m2Calculation” on page 8-14).
Using Table B (page 8-14, select
the smallest size connector that
will fit your total wire CMA(mm2)
value.
4. Verify that the wire bundle
(with wire insulation) does
not exceed the maximum
diameter allowed for the
connector you selected.
Simply check the bundle’s
diameter against the
maximum diameter that
Table A (below) lists for
that part.
5. Verify that the total
amperage to be applied
does not exceed the
maximum amp rating for
the part as specified in
Table A.
Product Selection Process
Insulated Closed-End Connectors (SGRP series) Insulated and Sealed Closed-End Connectors (SGRS series)
Part Color
No. Code
Table A - Product Dimensions
and Part Number Descriptions
8-14
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
CMA/mm2Example
22 AWG/.38
CMA754 OD Bundle Insulation
Conductor
Bundle diameter must not
exceed 6.0 mm (0.24 in) for
SGRP-2 or 4.5 in (0.18 mm)
for SGRS-2.
Total CMA= 5834
Total mm2 = 2.92
Correct part number (based on CMAof 5834
or mm2of 2.92): SGRP-2or SGRS-2
22 AWG/.38
CMA754
18 AWG/.95
CMA1900
16 AWG/1.21
CMA2426
AWG 30 28 26 24 22 20 18 16 14 12 10 8
CMA 112 177 304 475 754 1216 1900 2426 3831 5874 9354 16983
mm20.05 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94 4.74 8.61
To calculate the total circu-
lar mil or mm2area of the
wire bundle to be termi-
nated, follow these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue to
use it for all your selec-
tion criteria. (Both meas-
ures provide the same
results.)
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Solder Grip Part No.
Total
CMA/mm2Calculation 2. In the workspace below,
list the CMA or mm2for
each conductor in the
bundle. (Table B provides
the CMA of typical con-
ductors.)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. Use Table A to select the
smallest terminator that
will fit the total CMA (mm2) .
Table B. CMA of Typical
Copper Conductors
8
8-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Wire S p l a s h - Wire S p l a s h - W i r e S p l a s h -
C o m b i n a t i o n s p ro o f S e a l e d C o m b i n a t i o n s p ro o f S e a l e d C o m b i n a t i o n s p ro o f S e a l e d
1 # 8 + 1 # 12 S G R P - 4 S G R S - 4 1 # 14 + 3 # 20 S G R P - 2 S G R S - 2 2 # 16 + 1 # 18 + 3 # 20 S G R P - 3 S G R S - 3
1 # 8 + 1 # 16 S G R P - 4 S G R S - 4 1 # 14 + 4 # 20 S G R P - 3 S G R S - 3 2 # 16 + 1 # 18 + 2 # 20 S G R P - 3 S G R S - 3
2 # 8 + 2 # 16 S G R P - 4 S G R S - 4 1 # 14 + 1 # 18 S G R P - 2 S G R S - 2 2 # 16 + 1 # 18 + 1 # 20 S G R P - 2 S G R S - 2
1 # 8 + 1 # 14 S G R P - 4 S G R S - 4 1 # 14 + 1 # 18 + 1 # 20 S G R P - 2 S G R S - 2 2 # 16 + 1 # 18 S G R P - 2 S G R S - 2
1 # 8 + 1 # 14 + 1 # 16 S G R P - 4 S G R S - 4 1 # 14 + 2 # 18 S G R P - 2 S G R S - 2 2 # 16 + 4 # 20 S G R P - 3 S G R S - 3
1 # 10 + 1 # 18 S G R P - 3 S G R S - 3 1 # 14 + 3 # 18 S G R P - 3 S G R S - 3 2 # 16 + 3 # 20 S G R P - 3 S G R S - 3
1 # 10 + 2 # 18 S G R P - 3 S G R S - 3 1 # 14 + 4 # 18 S G R P - 3 S G R S - 3 2 # 16 + 2 # 20 S G R P - 2 S G R S - 2
1 # 10 + 3 # 18 S G R P - 3 S G R S - 3 1 # 14 + 5 # 18 SGRP-3 S G R S - 3 2 # 16 + 1 # 20 S G R P - 2 S G R S - 2
1 # 10 + 1 # 16 S G R P - 3 S G R S - 3 1 # 14 + 1 # 16 S G R P - 2 S G R S - 3 2 # 16 S G R P - 2 S G R S - 2
1 # 10 + 1 # 16 + 1 # 18 S G R P - 3 S G R S - 3 1 # 14 + 1 # 16 + 1 # 20 S G R P - 2 S G R S - 2 1 # 16 + 5 # 18 S G R P - 3 S G R S - 3
1 # 10 + 1 # 16 + 2 # 18 S G R P - 3 S G R S - 3 1 # 14 + 1 # 16 + 1 # 18 S G R P - 3 S G R S - 3 1 # 16 + 4 # 18 + 1 # 20 S G R P - 3 S G R S - 3
1 # 10 + 2 # 16 S G R P - 3 S G R S - 3 1 # 14 + 1 # 16 + 2 # 18 S G R P - 3 S G R S - 3 1 # 16 + 4 # 18 S G R P - 3 S G R S - 3
1 # 10 + 3 # 16 S G R P - 4 S G R S - 4 1 # 14 + 1 # 16 + 3 # 18 S G R P - 3 S G R S - 3 1 # 16 + 3 # 18 + 2 # 20 S G R P - 3 S G R S - 3
1 # 10 + 4 # 16 S G R P - 4 S G R S - 4 1 # 14 + 1 # 16 + 4 # 18 S G R P - 3 S G R S - 3 1 # 16 + 3 # 18 + 1 # 20 S G R P - 3 S G R S - 3
1 # 10 + 5 # 16 S G R P - 4 S G R S - 4 1 # 14 + 2 # 16 S G R P - 3 S G R S - 3 1 # 16 + 2 # 18 + 3 # 20 S G R P - 3 S G R S - 3
1 # 10 + 1 # 14 S G R P - 3 S G R S - 3 1 # 14 + 2 # 16 + 1 # 18 S G R P - 3 S G R S - 3 1 # 16 + 2 # 18 + 1 # 20 S G R P - 2 SGRS-2
1 # 10 + 1 # 14 + 1 # 18 S G R P - 3 S G R S - 3 1 # 14 + 2 # 16 + 2 # 18 S G R P - 3 S G R S - 3 1 # 16 + 2 # 18 S G R P - 2 S G R S - 2
1 # 10 + 1 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 14 + 2 # 16 + 3 # 18 S G R P - 3 S G R S - 3 1 # 16 + 1 # 18 + 4 # 20 S G R P - 3 S G R S - 3
1 # 10 + 1 # 14 + 2 # 16 S G R P - 3 S G R S - 3 1 # 14 + 3 # 16 S G R P - 3 S G R S - 3 1 # 16 + 1 # 18 + 3 # 20 S G R P - 2 S G R S - 2
1 # 10 + 1 # 14 + 3 # 16 SGRP-4 S G R S - 4 1 # 14 + 3 # 16 + 1 # 18 S G R P - 3 S G R S - 3 1 # 16 + 1 # 18 + 2 # 20 S G R P - 2 SGRS-2
1 # 10 + 2 # 14 S G R P - 4 S G R S - 4 1 # 14 + 3 # 16 + 2 # 18 S G R P - 3 S G R S - 3 1 # 16 + 1 # 18 + 1 # 20 S G R P - 2 S G R S - 2
1 # 10 + 3 # 14 S G R P - 4 S G R S - 4 1 # 14 + 4 # 16 S G R P - 3 S G R S - 3 1 # 16 + 1 # 18 S G R P - 1 S G R S - 1
1 # 10 + 1 # 12 S G R P - 3 S G R S - 3 1 # 14 + 4 # 16 + 1 # 18 S G R P - 3 S G R S - 3 1 # 16 + 4 # 20 S G R P - 2 S G R S - 2
1 # 10 + 1 # 12 + 1 # 14 S G R P - 4 S G R S - 4 1 # 14 + 5 # 16 S G R P - 3 S G R S - 3 1 # 16 + 3 # 20 S G R P - 2 S G R S - 2
1 # 10 + 2 # 12 S G R P - 4 S G R S - 4 2 # 14 S G R P - 2 SGRS-2 1 # 16 + 1 # 20 + 1 # 22 S G R P - 1 S G R S - 1
2 # 10 S G R P - 4 S G R S - 4 2 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 16 + 1 # 20 S G R P - 1 S G R S - 1
2 # 10 + 1 # 16 S G R P - 4 S G R S - 4 2 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 16 + 3 # 22 S G R P - 1 S G R S - 1
1 # 12 + 1 # 18 S G R P - 2 S G R S - 2 2 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 16 + 2 # 22 S G R P - 1 S G R S - 1
1 # 12 + 2 # 18 S G R P - 3 S G R S - 3 2 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 16 + 1 # 22 S G R P - 1 S G R S - 1
1 # 12 + 3 # 18 S G R P - 3 S G R S - 3 2 # 14 + 2 # 16 S G R P - 3 S G R S - 3 1 # 18 + 1 # 22 S G R P - 1 S G R S - 1
1 # 12 + 4 # 18 S G R P - 3 S G R S - 3 2 # 14 + 2 # 16 S G R P - 3 S G R S - 3 1 # 18 + 2 # 22 S G R P - 1 S G R S - 1
1 # 12 + 5 # 18 S G R P - 3 S G R S - 3 2 # 14 + 3 # 16 S G R P - 3 S G R S - 3 1 # 18 + 3 # 22 S G R P - 1 S G R S - 1
1 # 12 + 1 # 16 S G R P - 3 S G R S - 3 2 # 14 + 4 # 16 S G R P - 4 S G R S - 4 1 # 18 + 1 # 20 S G R P - 1 S G R S - 1
1 # 12 + 1 # 16 + 1 # 18 S G R P - 3 S G R S - 3 3 # 14 S G R P - 3 S G R S - 3 1 # 18 + 1 # 20 + 1 # 22 S G R P - 1 S G R S - 1
1 # 12 + 1 # 16 + 2 # 18 S G R P - 3 S G R S - 3 3 # 14 + 1 # 16 S G R P - 3 S G R S - 3 1 # 18 + 1 # 20 + 2 # 22 S G R P - 1 S G R S - 1
1 # 12 + 1 # 16 + 3 # 18 S G R P - 3 S G R S - 3 3 # 14 + 2 # 16 S G R P - 4 S G R S - 4 1 # 18 + 2 # 20 S G R P - 1 S G R S - 1
1 # 12 + 1 # 16 + 4 # 18 S G R P - 4 S G R S - 4 3 # 14 + 3 # 16 S G R P - 4 S G R S - 4 1 # 18 + 3 # 20 S G R P - 2 S G R S - 2
1 # 12 + 2 # 16 S G R P - 3 S G R S - 3 4 # 14 S G R P - 3 S G R S - 3 1 # 18 + 4 # 20 S G R P - 2 S G R S - 2
Table C. SolderGrip Wire
Combinations
8-16
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Wire S p l a s h - Wire S p l a s h - W i r e S p l a s h -
C o m b i n a t i o n s p ro o f S e a l e d C o m b i n a t i o n s p ro o f S e a l e d C o m b i n a t i o n s p ro o f S e a l e d
1 # 12 + 2 # 16 + 1 # 18 S G R P - 3 S G R S - 3 4 # 14 + 1 # 16 S G R P - 4 S G R S - 4 1 # 18 + 5 # 20 S G R P - 2 S G R S - 2
1 # 12 + 2 # 16 + 2 # 18 S G R P - 3 S G R S - 3 4 # 14 + 2 # 16 S G R P - 4 S G R S - 4 2 # 18 S G R P - 1 S G R S - 1
1 # 12 + 3 # 16 S G R P - 3 S G R S - 3 5 # 14 S G R P - 4 S G R S - 4 2 # 18 + 1 # 22 S G R P - 1 S G R S - 1
1 # 12 + 4 # 16 S G R P - 3 S G R S - 3 5 # 14 + 1 # 16 S G R P - 4 S G R S - 4 2 # 18 + 1 # 20 S G R P - 2 S G R S - 2
1 # 12 + 5 # 16 S G R P - 4 S G R S - 4 1 # 16 + 3 # 18 S G R P - 3 S G R S - 3 2 # 18 + 2 # 20 S G R P - 2 S G R S - 2
1 # 12 + 1 # 14 + 1 # 18 S G R P - 3 S G R S - 3 1 # 16 + 2 # 18 + 2 # 20 S G R P - 3 S G R S - 3 2 # 18 + 3 # 20 S G R P - 2 S G R S - 2
1 # 12 + 1 # 14 + 2 # 18 S G R P - 3 S G R S - 3 1 # 16 + 5 # 20 S G R P - 3 S G R S - 3 2 # 18 + 4 # 20 S G R P - 3 S G R S - 3
1 # 12 + 1 # 14 + 3 # 18 S G R P - 3 S G R S - 3 1 # 16 + 2 # 20 S G R P - 2 S G R S - 2 3 # 18 S G R P - 2 S G R S - 2
1 # 12 + 1 # 14 + 1 # 16 S G R P - 3 S G R S - 3 6 # 16 S G R P - 3 S G R S - 3 3 # 18 + 1 # 20 S G R P - 2 S G R S - 2
1 # 12 + 1 # 14 + 2 # 16 S G R P - 3 S G R S - 3 5 # 16 + 1 # 18 S G R P - 3 S G R S - 3 3 # 18 + 2 # 20 S G R P - 3 S G R S - 3
1 # 12 + 1 # 14 + 3 # 16 S G R P - 4 S G R S - 4 5 # 16 + 1 # 20 S G R P - 3 S G R S - 3 3 # 18 + 3 # 20 S G R P - 3 S G R S - 3
1 # 12 + 1 # 14 + 4 # 16 S G R P - 4 S G R S - 4 5 # 16 S G R P - 3 S G R S - 3 4 # 18 S G R P - 2 S G R S - 2
1 # 12 + 2 # 14 S G R P - 3 S G R S - 3 4 # 16 + 2 # 18 S G R P - 3 S G R S - 3 4 # 18 + 1 # 20 S G R P - 3 S G R S - 3
1 # 12 + 2 # 14 + 1 # 18 S G R P - 3 S G R S - 3 4 # 16 + 1 # 18 + 1 # 20 S G R P - 3 S G R S - 3 4 # 18 + 2 # 20 S G R P - 3 S G R S - 3
1 # 12 + 2 # 14 + 1 # 16 S G R P - 4 S G R S - 4 4 # 16 + 1 # 18 S G R P - 3 S G R S - 3 5 # 18 S G R P - 3 S G R S - 3
1 # 12 + 2 # 14 + 2 # 16 SGRP-4 S G R S - 4 4 # 16 + 2 # 20 S G R P - 3 S G R S - 3 5 # 18 + 1 # 20 S G R P - 3 S G R S - 3
1 # 12 + 2 # 14 + 3 # 16 S G R P - 4 S G R S - 4 4 # 16 + 1 # 20 S G R P - 3 S G R S - 3 6 # 18 S G R P - 3 S G R S - 3
1 # 12 + 3 # 14 S G R P - 4 S G R S - 4 4 # 16 S G R P - 3 S G R S - 3 1 # 20 + 1 # 22 S G R P - 1 S G R S - 1
1 # 12 + 3 # 14 + 1 # 16 S G R P - 4 S G R S - 4 3 # 16 + 3 # 18 S G R P - 3 S G R S - 3 1 # 20 + 2 # 22 S G R P - 1 S G R S - 1
1 # 12 + 4 # 14 S G R P - 4 S G R S - 4 3 # 16 + 2 # 18 + 1 # 20 S G R P - 3 S G R S - 3 1 # 20 + 3 # 22 S G R P - 1 S G R S - 1
2 # 12 S G R P - 4 S G R S - 4 3 # 16 + 2 # 18 S G R P - 3 S G R S - 3 1 # 20 + 4 # 22 S G R P - 1 S G R S - 1
2 # 12 + 1 # 18 S G R P - 3 S G R S - 3 3 # 16 + 1 # 18 + 2 # 20 S G R P - 3 S G R S - 3 2 # 20 S G R P - 1 S G R S - 1
2 # 12 + 1 # 18 S G R P - 3 S G R S - 3 3 # 16 + 1 # 18 + 1 # 20 S G R P - 3 S G R S - 3 2 # 20 + 1 # 22 S G R P - 1 S G R S - 1
2 # 12 + 1 # 16 S G R P - 3 S G R S - 3 3 # 16 + 1 # 18 S G R P - 3 S G R S - 3 2 # 20 + 2 # 22 S G R P - 1 S G R S - 1
2 # 12 + 2 # 16 + 1 # 18 S G R P - 4 S G R S - 4 3 # 16 + 3 # 20 S G R P - 3 S G R S - 3 2 # 20 + 3 # 22 S G R P - 1 S G R S - 1
2 # 12 + 3 # 16 S G R P - 4 S G R S - 4 3 # 16 + 2 # 20 S G R P - 3 S G R S - 3 3 # 20 S G R P - 1 S G R S - 1
2 # 12 + 1 # 14 + 1 # 18 S G R P - 4 S G R S - 4 3 # 16 + 1 # 20 S G R P - 3 S G R S - 3 3 # 20 + 1 # 22 S G R P - 1 S G R S - 1
2 # 12 + 1 # 14 + 1 # 16 S G R P - 4 S G R S - 4 3 # 16 S G R P - 2 S G R S - 2 4 # 20 S G R P - 2 S G R S - 2
3 # 12 + 1 # 14 S G R P - 4 S G R S - 4 2 # 16 + 4 # 18 S G R P - 3 S G R S - 3 5 # 20 S G R P - 2 S G R S - 2
2 # 12 + 2 # 14 S G R P - 4 S G R S - 4 2 # 16 + 3 # 18 + 1 # 20 S G R P - 3 S G R S - 3 6 # 20 S G R P - 2 S G R S - 2
3 # 12 + 1 # 18 S G R P - 4 S G R S - 4 2 # 16 + 3 # 18 S G R P - 3 S G R S - 3 3 # 22 S G R P - 1 S G R S - 1
3 # 12 + 1 # 16 S G R P - 4 S G R S - 4 2 # 16 + 2 # 18 + 2 # 20 S G R P - 3 S G R S - 3 4 # 22 S G R P - 1 S G R S - 1
1 # 14 + 1 # 22 S G R P - 1 S G R S - 1 2 # 16 + 2 # 18 + 1 # 20 S G R P - 3 S G R S - 3 5 # 22 S G R P - 1 S G R S - 1
1 # 14 + 1 # 20 S G R P - 2 S G R S - 2 2 # 16 + 2 # 18 S G R P - 3 S G R S - 3 6 # 22 S G R P - 1 S G R S - 1
1 # 14 + 2 # 20 S G R P - 2 S G R S - 2 — — — — — —
Table C. SolderGrip Wire
Combinations (Continued)
8
8-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Approvals and Reference
Documents
Installation
Agency Approvals UL, CULE 8 7 6 8 1
Reference documents Raychem Specification RB-109 for splices
Specification Control Drawings
Splices—Non Sealed (SGRP-X), Splices—Sealed (SGRS-X)
The SolderGrip product is
pushed onto the conductors
with a twisting motion. With
the product in place, instal-
lation can be completed
with the proper selection
and use of heating tools
and reflectors. Either of the
following Raychem heating
tools is recommended:
■HL1802E
■CV-1981
Material
Insulation Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride
Solder preform with flux Sn 60, Pb 40, ROM1 flux per ANSI-J-STD-004 (RAflux).
Sealing insert (SGRS) Hot melt adhesive
Spiral wound insert Copper alloy
Physical Unit Method of test Requirement
Dimensions inches RB-109 See product dimensions.
Electromechanical Unit Method of test Typical values
Dielectric withstand voltage kilovolts RB-109 2.0
Static heating degrees RB-109 Less than 50°C rise
Environmental* Unit Method of test Requirement
Insulation resistance after water immersion (SGRS only) megohms RB-109 100
Contact resistance after exposure milliohms RB-109 Less than 6 milliohms
Operating condition Unit Method of test Value
Temperature rating — — -55°C to 125°C [-67°F to 257°F]
Voltage rating volts — 600
*Immersion resistance sealing is dependent on the wire combinations used. The user should test specific wire combinations. Refer to RB-109 Raychem
specification for procedures.
Product Characteristics
Refer to Raychem installa-
tion procedure RPIP 820-00
for detailed instructions and
recommended reflector
attachments.
You will find ordering
information for these tools in
Section 10.
8-18
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
DuraSeal Heat-Shrinkable, Environmentally Sealed,
Nylon-Insulated Crimp Splices
Applications
■Automotive/truck wiring
repair and maintenance.
■Automotive accessory
installations.
■OEM automotive/truck/RV
wire harness fabrication.
Specifications/Approvals
Series Agency Raychem
D-406 ULand CULlisted 91J4, File E87681 RB-107
— Lloyd’s listed, File 65 247 HH 02-93 —
Butt Splice Dimensions Wire Dimensions
Part A L Insulation Insulation
No. Min. Nom. Color Conductor O.D. (Max.) O.D. (Min.)
D-406-0001 3.68 [.145] 31.75 [1.25] Red 22–18 3.56 [.140] 1.40 [.055]
D-406-0002 4.57 [.180] 31.75 [1.25] Blue 16–14 4.45 [.175] 2.03 [.080]
D-406-0003 6.35 [.250] 38.10 [1.50] Yellow 12–10 6.22 [.245] 2.79 [.110]
Product Facts
■Protects splices from water,
condensation, salt, and
corrosion
■Provides strain relief
■Protects against vibration in
rugged environments
■Completely insulates and
protects electrical
connections
■Has adhesive lining for
protection that is more
reliable than conventional
splices
■UL, CUL, and
Lloyd’s listed
Product Dimensions
Butt Splices
■Marine electronics.
■Fleet maintenance.
■Commercial wiring
(pumps/pools/spas).
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
DuraSeal Heat-Shrinkable, Environmentally Sealed,
Nylon-Insulated Crimp Splices (Continued)
Wire Size mm2Part No. Color
AWG
22–18 0.38–0.95 D-406-0001 Red
16–14 1.2–2.5 D-406-0002 Blue
12–10 3–6 D-406-0003 Yellow
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Cut-through resistance: 31 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb];
yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 h at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid,
diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 2500 Vac
Insulation resistance: 1000 megohms at 100 Vdc
Installation
1. Select splice of appropri-
ate size. Strip wire 7.5
mm (5/16 in). Insert into
crimp barrel.
2. Crimp using Raychem
AD-1522 crimp tool for
preinsulated crimps.
3. Heat crimped splice with
heat gun until tubing
recovers and adhesive
flows.
Installation Requirements
For proper installation of
these devices, the correct
crimp tool and a heating
tool with a reflector attach-
ment must be used. The
Raychem AD-1522 crimp
tool and HL1802E heating
tool are recommended.
You will find ordering infor-
mation for these tools in
Section 10.
Refer to Raychem installa-
tion procedure RPIP 821-00
for detailed instructions.
Product Selection Process
1. Determine wire size.
2. Select part number.
Product Characteristics
(Typical)
Physical properties
8-20
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices
Applications
MiniSeal wire-to-wire splic-
ing products offer solutions
for hundreds of aerospace
and defense applications.
These environment-resistant
splices provide excellent
reliability, long term per-
formance, MIL-S-81824/1
qualification, and a low
installed cost.
MiniSeal crimp splices con-
sist of a plated copper
crimp barrel and a sepa-
rate, heat-shrinkable, trans-
parent sealing sleeve. They
can be used on a combina-
tion of wires, from 1:1 to
10:10. MiniSeal splices are
one of the smallest, lightest,
and most environment-
resistant splices available.
They preserve the electrical
integrity of the splice by
preventing the penetration
of liquids and the resulting
chemical and galvanic
corrosion.
Product Selection Process
1. Determine the type of
splice required.
■Stub (parallel) splice:
■Butt (in-line) splice:
2. Determine which crimp
barrel plating is required:
■Tin plating,
recommended for tin
or silverplated wire
■Nickel plating,
recommended for
nickel-plated wire, or
silver-plated wire in
applications above
150°C [302°F].
3. Calculate the size of
crimp barrel required.
Using the CMA/mm2
worksheet on the next
page, calculate the total
cross section to be
spliced by adding the
circular mil area (CMA)
or square millimeters
(mm2) of each wire.
Stub splice: Add the
CMA or mm2of all wires
together.
Butt splice: Calculate
each side separately
(see example on the
worksheet).
Table A provides the
CMA of typical conduc-
tors. (Both CMA and mm2
give the same results, so
choose either CMA or
mm2as your unit of
measure for selection
purposes and continue
to use it for all your
selection criteria.)
4. Select the color code for
the size crimp barrel
required. Using Table B
(page 8-21), select the
crimp barrel—color-
coded red, blue, or
yellow—for the CMA or
mm2you calculated.
Stub splice: Select the
barrel that will accommo-
date the total cross
section.
Butt splice: Select the
smallest barrel that will
accommodate the
largest CMA/mm2
required. (Refer to the
example in the work-
sheet for a more specific
description.) If the
CMA/mm2of the smaller
side of a butt splice is
too small for the size
barrel required to fit the
larger side, increase the
CMA/mm2—either by
doubling back one wire
(stripping the conductor
twice the length you
would ordinarily strip it
and then folding it back)
or by adding a filler wire.
5. Determine the type of
sealing sleeve required.
Some wire insulations will
not fit in the holes of the
sealing sleeve inserts, so
be sure to compare the
internal diameter of each
hole with the outer
diameter of the wire(s)
you intend to insert in
that hole. To create a
reliable seal, place a
maximum of two wires
in any hole of the sealing
sleeve.
6. Select the part number.
Turn to the MiniSeal part
number selection tables
(Tables C and D, page
8-21 and 8-22) and find
the table for the type of
splice (stub or butt)
required.
Using the appropriate
table, find the crimp
barrel size range and
the size and number of
wires for your applica-
tion. Then select the
part number for the type
of plating required. The
color code accompany-
ing that part number
should match the color
code you arrived at in
Table B, confirming that
the part number you
have selected is correct.
Product Facts
■Immersion-resistant crimp
splices are on QPL for
MIL-S-81824
■MIL-Spec approval
■Small size
■Light weight
■Insulation and strain relief
■Easy installation
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-21
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Strands 7 19 19 19 19 19 19 19 37
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
CMA Range mm2Range 1:1 Splice (AWG Size) Color Code
304–1510 0.15–0.75 26–20 Red
779–2680 0.39–1.34 20–16 Blue
1900–6755 0.95–3.37 18–12 Yellow
Example:
Application: A butt splice
with three AWG 22 wires in
one side and one AWG 18
wire in the other side:
The CMA for AWG 22 wire
in Table A is 754 (0.38 mm2) .
Side one is therefore calcu-
lated as follows:
CMA = 3 x 754 = 2262
(mm2= 3 x 0.38 = 1.14)
The other side, where the
CMA for AWG 18 is 1900, is
calculated as:
CMA = 1 x 1900 = 1900
(mm2= 1 x 0.95 = 0.95)
Using Table B to select the
smallest crimp barrel that
will easily fit 2262 CMA
(0.95 mm2), the blue barrel
is the correct choice.
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Part Number:
Total
Table A. CMA of Typical
Conductors
Table B. Crimp Barrel Color
Code Selection
CMA/mm2Worksheet
Table C. Stub (Parallel) Splices
Crimp Barrel I.D.dimensions
Illustration Part No. Size Range Side 1 Side 2
CMA [mm2]Sealing Max. No. Sealing Max. No.
Tin Plated Nickel Plated Min.–Max. Insert of Wires Insert of Wires
D-436-0128 D-436-0119 304–1510 2 2
Red Red [0.15–0.75]
D-436-58 D-436-75 779–2680 2 2
Blue Blue [0.39–1.34]
D-436-59 D-436-76 1900—6755 2 2
Yellow Yellow [0.95–3.37]
D-436-60 D-436-77 779–2680 10 2
Blue Blue [0.39–1.34] (2 per hole)
D-436-61 D-436-78 1900–6755 10 2
Yellow Yellow [0.95–3.37] (2 per hole)
8-22
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Table D. Butt (in-line) splices
Crimp Barrel I.D.dimensions
Illustration Part No. Size Range Side 1 Side 2
CMA [mm2]Sealing Max. No. Sealing Max. No.
Tin Plated Nickel Plated Min.–Max. Insert of Wires Insert of Wires
D-436-36* D-436-82 304–1510 2 2
Red Red [0.15–0.75]
D-436-37* D-436-83 779–2680 2 2
Blue Blue [0.39–1.34]
D-436-38* D-436-84 1900–6755 2 2
Yellow Yellow [0.95–3.37]
D-436-0110 D-436-85 304–1510 6 2
Red Red [0.15–0.75]
D-436-52 D-436-86 779–2680 6 2
Blue Blue [0.39–1.34] (2 per hole)
D-436-53 D-436-87 1900–6755 6 2
Yellow Yellow [0.95–3.37] (2 per hole)
D-436-0115 D-436-88 304–1510 6 6
Red Red [0.15–0.75] (2 per hole) (2 per hole)
D-436-42 D-436-89 779–2680 6 6
Blue Blue [0.39–1.34] (2 per hole) (2 per hole)
D-436-43 D-436-90 1900–6755 6 6
Yellow Yellow [0.95–3.37] (2 per hole) (2 per hole)
*Qualified to MIL-S-81824/1.
Table E. Crimp Barrel Only
Crimp Barrel Size Range
Type Color Code Tin-Plated Nickel Plated CMA[mm2] Min. - Max.
Butt (in-line) Red D-609-06 D-609-09 304-1510 [0.15-0.75]
Butt (in-line) Blue D-609-07 D-609-10 779-2680 [0.39-1.34]
Butt (in-line) Yellow D-609-08 D-609-11 1900-6755 [0.95-3.37]
Stub (Parrel) Red D-609-03 D-609-12 304-1510 [0.15-0.75]
Stub (Parrel) Blue D-609-04 D-609-13 779-2680 [0.39-1.34]
Stub (Parrel) Yellow D-609-05 D-609-14 1900-6755 [0.95-3.37]
Table F. Sealing Sleeve Only
Part No. Color Code LMax. AMin.
D-436-0096 Red 29.2 [1.15] 2.16 [0.085]
D-436-0097 Blue 29.2 [1.15] 2.8 [0.110]
D-436-0098 Yellow 29.2 [1.15] 4.32 [0.170]
8
8-23
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Crimp barrel Tin- or nickel-plated copper
Meltable inserts Meltable thermoplastic
Typical Performance
Voltage drop 6.9 mV at 4.5 Avs 8.1 mV for an equal length of wire
Tensile strength Exceeds strength of conductor
Dielectric strength 2.5 kV
Temperature rating -55°C to 150°C [-67°F to 302°F]
Insulation resistance 5000 megohms
Series Military
D-436 MIL-S-81824/1 for D-436-36/37/38
For proper installation of
these devices, the correct
crimp tool (Raychem part
number AD-1377) and a
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
■HL1802E
■AA-400 Super Heater
Refer to Raychem installa-
tion procedure RCPS 200-
20 for detailed instructions
and recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
Product Characteristics
Specifications/Approvals
Installation
8-24
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
Introduction
Raychem insulated electrical
terminal products provide
reliable, repeatable, and
rugged examples of termi-
nals available. We start on
the front end with terminal
sizes and configurations
that meet or exceed indus-
try standards in terms of
material selection, surface
treatment, and electrical
performance.
Here the comparison stops.
What separates Raychem
products from the rest of the
industry are the materials
and termination techniques
used on the back end of the
products, which provide
unparalleled value.
Products include:
■DuraSeal heat-shrinkable
nylon crimp products,
which protect against
water, condensation, salt,
and corrosion. Their
tough, heat-shrinkable
nylon tubing resists abra-
sion and cut-through
SolderGrip technology is
a reliable means of termi-
nating more than two
conductors time after
time. SolderGrip terminals
can terminate a variety of
conductor types (solid
and stranded) and
platings. Terminations on
more than eight individual
conductors in a single
joint have been success-
fully demonstrated using
this product.
DuraSeal product delivers
protected electrical joints on
industry standard terminals
and is suitable for harsh
environments.
damage, provides strain
relief, and protects
against vibration damage.
DuraSeal products are
simple and quick to install
using a crimp tool and a
heat source. They accom-
modate a wide range of
wire sizes and are color-
coded for easy identifica-
tion, yet are transparent
for visual inspection of the
finished splice.
■SolderGrip heat-shrinkable
twist-on products, which
utilize a spiral copper
coil that grips and com-
presses the conductors
and allows a prefluxed
solder ring to flow to the
center of the splicing
area, resulting in a highly
reliable, repeatable joint.
SolderGrip terminals use
a durable polyvinylidene
fluoride heat-shrinkable
tubing that protects the
electrical joint and
provides insulation and
strain relief. The
8
8-25
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects
Applications
DuraSeal products insulate
and protect electrical con-
nections from mechanical
abuse, wire pull-out, and
abrasion while resisting
water, salt, and other
contaminants.
DuraSeal devices provide a
tough, environmentally
sealed wire connection.
Their crimp barrel or termi-
nal, encased in rugged,
heat-shrinkable nylon
tubing lined with a special
hot-melt adhesive, resists
damage from abrasions
and cuts.
DuraSeal devices retain
flexibility and impact-
resistance long after similar
products have become
brittle.
DuraSeal devices
accomodate wire gauge
sizes 22 to 10. They are
color-coded for easy
identification of gauge
sizes, yet transparent for
inspection of the finished
splice.
Agency approvals ULlisted component, file E87681, terminals except quick connect terminals;
file E157833, quick connect terminals
Reference documents Raychem specifications RB-108, Specification DuraSeal crimp terminals
DuraSeal selection guide (H54153)
DuraSeal installation guidelines (H54154)
Product Facts
■Resistance to moisture and
abrasion
■Strain relief
■Protection from wire pull-out
■Easy installation
■UL and CUL
listed
Approvals and Reference
Documents
Available in:
Americas ■
Europe ■
Asia Pacific ■
Fork Terminals
Fork Terminal Dimensions Wire Dimensions
Part Insulation Insulation
No. A Stud C L Color Conductor O.D. O.D.
Min. Size Nom. Max. (AWG) (Max.) (Min.)
Metric Imperial
B-106-2401 3.81 [.15] M4 8 7.87 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-2402 4.57 [.18] M4 8 7.87 [.31] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2403 6.35 [.25] M4 8 7.87 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-2502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2503 6.35 [.25] M5 10 9.91 [.39] 40.15 [1.58
]
Yellow 12–10 6.35 [.250] 2.79 [.110]
8-26
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Product Characteristics
Property Unit Requirement Method of Test
Physical Dimensions Inches None See product dimensions
Tensile strength Pounds 8 to 40 lbs depending on AWG UL486C, IEC512-8
Property Unit Typical value Method of Test
Electrical Voltage drop Millivolts Less than equal length of wire MIL-S-81824, IEC512-2
Insulation resistance Megohms 103 min. MIL-STD-202 method 302
Dielectric withstand Kilovolts 2.5 MIL-STD-202F method 301,
voltage IEC512-2
Property Unit Requirement Method of Test
Chemical
Diesel fuel ASTM D 3032, ESA-603D
Brake fluid
Antifreeze — Meet electrical test listed above
5% salt water after conditioning.
Motor oil
Environmental
Humidity MIL-STD-202F method 106, IEC68-2-30
(Fluid)
Immersion MIL-STD-202F condition C, IEC68-2-14 test NC
Vibration Meet electrical test MIL-STD-202F method 201, IEC68-2-6
Bending — listed above after UL486C, IEC512-8
Thermal shock conditioning. MIL-STD-202F method 107, IEC68-2-14 test N
Heat aging (168° @ 85°C [185°F) MIL-STD-202F, IEC68-2-2
Salt spray MIL-STD-202F method 101, IEC68-2-11
Operating Temperature rating -55°C to +125°C [-67°F to -257°F] None
conditions Minimum shrink temperature — 180°C [356°F] None
Voltage rating 600 Volt max None
8
8-27
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Fork Terminal Dimensions Wire Dimensions
Part Insulation Insulation
No. A Stud C L Color Conductor O.D. O.D.
Min. Size Nom. Max. (AWG) (Max.) (Min.)
Metric Imperial
B-106-1401 3.81 [.15] M4 8 7.88 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1501 3.81 [.15] M5 10 9.91 [.39] 34.04 [1.34] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1601 3.81 [.15] M6 1/4 11.94 [.47] 36.07 [1.42] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1801 3.81 [.15] M8 5/16 13.97 [.55] 39.12 [1.54] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1991 3.81 [.15] M10 3/8 17.78 [.70] 43.18 [1.70] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1402 4.57 [.18] M4 8 7.88 [.31] 33.02 [1.30] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1602 4.57 [.18] M6 1/4 11.94 [.47] 36.58 [1.44] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1802 4.57 [.18] M8 5/16 13.97 [.55] 40.13 [1.58] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1992 4.57 [.18] M10 3/8 17.78 [.70] 43.94 [1.73] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1403 6.35 [.25] M4 8 7.88 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1503 6.35 [.25] M5 10 9.91 [.39] 40.13 [1.58] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1603 6.35 [.25] M6 1/4 11.94 [.47] 41.66 [1.64] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1803 6.35 [.25] M8 5/16 13.97 [.55] 45.21 [1.78] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1993 6.35 [.25] M10 3/8 17.78 [.70] 46.99 [1.85] Yellow 12–10 6.35 [.250] 2.79 [.110]
Ring Terminals
8-28
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Push-on Terminal Dimensions Wire Dimensions
Part Tab Color Insulation Insulation
No. Size A B C L Conductor O.D. O.D.
(inches) Min. Nom. Nom. Max. (AWG) (Max.) (Min.)
B-106-3631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.200] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-3632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.260] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-3633 .250 x .032 6.35 [.250] 6.35 [.250] .81 [.032] 33.02 [1.300] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-3281 .110 x .020 3.81 [.150] 2.79 [.110] .51 [.020] 22.86 [.900] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-3481 .187 x .020 3.81 [.150] 4.75 [.187] .51 [.020] 30.48 [1.200] Red 22–18 3.81 [.150] 1.40 [.055]
Tab Terminal Dimensions Wire Dimensions
Part Tab Color Insulation Insulation
No. Size A B C L Conductor O.D. O.D.
(inches) Min. Nom. Nom. Max. (AWG) (Max.) (Min.)
B-106-4631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-4632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.26] Blue 16–14 4.45 [.175] 2.00 [.080]
Push-on Terminals
Tab Terminals
8
8-29
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Pin Terminal Dimensions Wire Dimensions
Part Color Insulation Insulation
No. A B L Conductor O.D. O.D.
Min. Nom. Max. (AWG) (Max.) (Min.)
B-106-6201 3.81 [.150] 2.00 [.080] 30.99 [1.220] Red 22–18 3.81 [.150] 1.40 [.055]
Fig. 1
Fig. 2
Bullet Terminal Dimensions Wire Dimensions
Part Color Conductor Insulation Insulation
No. Fig. Type A B C L (AWG) O.D. O.D.
Min. Nom. Min. Max. (Max.) (Min.)
B-106-7401 1 M 3.81 [.150] 3.81 [.150] — 33.53 [1.32] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-7502 1 M 4.57 [.180] 5.08 [.200] — 34.54 [1.36] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-8401 2 F 3.81 [.150] 3.81 [.150] 5.59 [.220] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-8502 2 F 4.57 [.180] 5.08 [.200] 6.10 [.240] 32.51 [1.28] Blue 16–14 4.45 [.175] 2.00 [.080]
Pin Terminals
Bullet Terminals
8-30
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Physical properties Cut-through resistance: 31.7 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb]; yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 hr at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil,
antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 1000 V
Insulation resistance: 10 megohms
Series Agency Raychem
B-106 ULand CUL91J4, File E87681 RB-108
Lloyd’s listed, File 65 247 HH 02-93
ULand CULE157833
(B-106-3XXX/B-106-4XXX)
1. Select appropriate size.
For terminal and discon-
nect terminations, strip
wire 6.5 mm (1/4 inch).
2. Crimp using Raychem
AD-1522 crimp tool for
preinsulated crimps.
3. Heat terminal or discon-
nect with heat gun until
tubing recovers and
adhesive flows. Avoid
heating ring or fork
metallic parts.
For proper installation of
these devices, the correct
crimp tool and heating tool
with reflector attachment
must be used. The
Raychem AD-1522 crimp
tool and HL1802E heating
tool are recommended. You
will find ordering information
for these tools in Section 10.
Refer to Raychem installa-
tion procedure RPIP 684-00
for detailed instructions.
Product Characteristics
(Typical)
Specifications/Approvals
Installation
8
8-31
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals
Product Facts
■Transparent insulation
sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
■Spiral copper coil grips and
compresses the conductors
for optimum solder
connection
■Prefluxed solder preform
provides a controlled
soldering process.
■One-piece design for easy
installation
■Accommodates a wide
variety of conductor types,
quantities, sizes, and
plating types unmatched by
any other termination
technique
■Parts meet the performance
requirements of
MIL-T-7928G
Product option
Product Series Environmental Protection
SGRT Splashproof
Applications
Used for terminating multi-
ple wires to terminals.
Maximum Maximum Wire Range TypicalSolderGrip Stud Bundle Amp (Min.–Max.) LengthPart No. Size Diameter† Rating CMA [mm2]
SGRT-1-02 2 [2] 4.1 [.161] 12.5 A 1400–5000 38 [1 1/2]
[0.7–2.5]
SGRT-2-03 3 [6] 5.0 [.195] 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-04 4 [8] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-05 5 [10] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-06 6 [1/4] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-3-06 6 [1/4] 6.5 [.255] 33 A 5000–13,200 44.5 [1 3/4]
[2.5–6.6]
SGRT-3-08 8 [5/16] — 33 A 5000–13,200 51.0 [2]
[2.5–6.6]
SGRT-4-06 6 [1/4] 9.0 [.355] 56 A 12,000–22,400 44.5 [1 3/4]
[6.0–11.2]
SGRT-4-08 8 [5/16] — 56 A 12,000–22,400 51 [2]
[6.0–11.2]
†Maximum bundle diameter is measured over wire insulation.
Table A. Part Number
Selection
Product Selection Process
1. Determine the wire com-
bination (number of wires
and size) of the wire bun-
dle you wish to terminate.
2. Use Table C to select the
correct terminal for AWG
wire combination.*
Example: For connecting
a bundle with one 12
AWG wire (1 #12) and
two 18 AWG wires (+ 2
#18) to a terminal, you
need an SGRT-4-XX
terminal.
3. Determine the correct
stud size.
4. Select the correct part
number from Table A for
that stud size in the termi-
nal series and size you
selected in Step 2.
Example: If the stud size
is 1/4, select part number
SGRT-4-06.
5. Verify that the wire bundle
(with wire insulation) does
not exceed the maximum
diameter allowed for the
part you selected. Simply
check the bundle’s
diameter against the
maximum diameter that
Table A lists for that part.
6. Verify that the total
amperage to be applied
does not exceed the
maximum amp rating for
the part as specified in
Table A.
*If the wire combination is
not listed in Table B, use
the CMA (mm2) method of
determining wire bundle
size (see “CMA/mm2
Calculation” on page 8-32).
Using Table B, select the
smallest size part that will fit
your total wire CMA (mm2)
value.
Available in:
Americas ■
Europe ■
Asia Pacific ■
8-32
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals (Continued)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. Use Table A to select the
smallest terminator that
will fit the total CMA
(mm2).
To calculate the total circ u l a r
mil or mm2area of the wire
bundle to be terminated,
follow these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue to
use it for all your selec-
tion criteria. (Both meas-
ures provide the same
results.)
2. In the workspace below,
list the CMA or mm2for
each conductor in the
bundle. (Table B provides
the CMA of typical con-
ductors.)
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Solder Grip Part No.
Total
CMA/mm2Example 22 AWG/.38
CMA754
Total CMA= 5834
Total mm2= 2.92
Correct part number (based on CMA
of 5834 or mm2of 2.92):
SGRT-2-XX if bundle OD is less
than 5.0 mm (0.195 in).
OD Bundle Insulation
Conductor
Bundle diameter must not
exceed 5.0 mm [0.195 in] for
this example
22 AWG/.38
CMA754
18 AWG/.95
CMA1900
16 AWG/1.21
CMA2426
CMA/mm2Calculation
8
8-33
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals (Continued)
Strands 7 19 19 19 19 19 19 19 37
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
Wire Part Wire Part Wire Part
Combinations No. Combinations No. Combinations No.
1 # 8 SGRT-4-XX 1 # 12 + 1 # 16 + 4 # 18 SGRT-4-XX 1 # 14 + 4 # 20 SGRT-3-XX
1 # 8 + 1 # 16 SGRT-4-XX 1 # 12 + 2 # 16 SGRT-3-XX 1 # 14 + 1 # 18 SGRT-2-XX
2 # 8 + 2 # 16 SGRT-4-XX 1 # 12 + 2 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 18 + 1 # 20 SGRT-3-XX
1 # 8 + 1 # 14 SGRT-4-XX 1 # 12 + 2 # 16 + 2 # 18 SGRT-4-XX 1 # 14 + 2 # 18 SGRT-3-XX
1 # 10 SGRT-3-XX 1 # 12 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 18 SGRT-3-XX
1 # 10 + 1 to 3 # 18 SGRT-3-XX 1 # 12 + 4 # 16 SGRT-4-XX 1 # 14 + 4 # 18 SGRT-3-XX
1 # 10 + 2 # 18 SGRT-3-XX 1 # 12 + 5 # 16 SGRT-4-XX 1 # 14 + 5 # 18 SGRT-4-XX
1 # 10 + 3 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 16 SGRT-3-XX
1 # 10 + 1 # 16 SGRT-3-XX 1 # 12 + 1 # 14 + 2 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 20 SGRT-3-XX
1 # 10 + 1 # 16 + 1 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 16 + 2 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 16 + 2 # 18 SGRT-3-XX
1 # 10 + 2 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 3 # 18 SGRT-3-XX
1 # 10 + 3 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 4 # 18 SGRT-4-XX
1 # 10 + 4 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 4 # 16 SGRT-4-XX 1 # 14 + 2 # 16 SGRT-3-XX
1 # 10 + 5 # 16 SGRT-4-XX 1 # 12 + 2 # 14 SGRT-4-XX 1 # 14 + 2 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 14 SGRT-3-XX 1 # 12 + 2 # 14 + 1 # 18 SGRT-4-XX 1 # 14 + 2 # 16 + 2 # 18 SGRT-3-XX
1 # 10 + 1 # 14 + 1 # 18 SGRT-4-XX 1 # 12 + 2 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 2 # 16 + 3 # 18 SGRT-4-XX
1 # 10 + 1 # 14 + 1 # 16 SGRT-4-XX 1 # 12 + 2 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 3 # 16 SGRT-3-XX
1 # 10 + 1 # 14 + 2 # 16 SGRT-3-XX 1 # 12 + 2 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 16 + 1 # 18 SGRT-3-XX
1 # 10 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 12 + 3 # 14 SGRT-4-XX 1 # 14 + 3 # 16 + 2 # 18 SGRT-4-XX
1 # 10 + 2 # 14 SGRT-4-XX 1 # 12 + 3 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 4 # 16 SGRT-4-XX
1 # 10 + 3 # 14 SGRT-4-XX 1 # 12 + 4 # 14 SGRT-4-XX 1 # 14 + 4 # 16 + 1 # 18 SGRT-4-XX
1 # 10 + 1 # 12 SGRT-4-XX 2 # 12 + 1 # 18 SGRT-4-XX 1 # 14 + 5 # 16 SGRT-4-XX
1 # 10 + 1 # 12 + 1 # 14 SGRT-4-XX 2 # 12 + 1 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 10 + 2 # 12 SGRT-4-XX 2 # 12 + 2 # 16 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
2 # 10 SGRT-4-XX 2 # 12 + 3 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
2 # 10 + 1 # 16 SGRT-4-XX 2 # 12 + 1 # 14 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 12 SGRT-3-XX 2 # 12 + 1 # 14 + 1 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
1 # 12 + 1 # 18 SGRT-3-XX 2 # 12 + 2 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 2 # 18 SGRT-3-XX 3 # 12 + 1 # 18 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 3 # 18 SGRT-3-XX 3 # 12 + 1 # 16 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 4 # 18 SGRT-4-XX 3 # 12 + 1 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1 # 12 + 5 # 18 SGRT-4-XX 1 # 14 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1 # 12 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 22 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1 # 12 + 1 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 20 SGRT-2-XX 2 # 14 + 3 # 16 SGRT-4-XX
1 # 12 + 1 # 16 + 2 # 18 SGRT-3-XX 1 # 14 + 2 # 20 SGRT-3-XX 2 # 14 + 4 # 16 SGRT-4-XX
1 # 12 + 1 # 16 + 3 # 18 SGRT-4-XX 1 # 14 + 3 # 20 SGRT-3-XX 3 # 14 SGRT-3-XX
Table B. CMA of Typical
Copper Conductors
Table C. SolderGrip Wire
Combinations (see Table A
for Terminal Size [-XX])
8-34
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals (Continued)
Wire Part Wire Part Wire Part
Combinations No. Combinations No. Combinations No.
3 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 4 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 2 # 22 SGRT-2-XX
3 # 14 + 2 # 16 SGRT-4-XX 2 # 16 + 1 # 18 SGRT-3-XX 1 # 18 + 2 # 20 SGRT-2-XX
3 # 14 + 3 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 3 # 20 SGRT-2-XX
4 # 14 SGRT-4-XX 2 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 1 # 18 + 4 # 20 SGRT-3-XX
4 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 3 # 20 SGRT-3-XX 1 # 18 + 5 # 20 SGRT-3-XX
4 # 14 + 2 # 16 SGRT-4-XX 2 # 16 + 2 # 18 SGRT-3-XX 2 # 18 SGRT-2-XX
5 # 14 SGRT-4-XX 2 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 1 # 22 SGRT-2-XX
5 # 14 + 1 # 16 SGRT-4-XX 2 # 16 + 2 # 18 + 2 # 20 SGRT-3-XX 2 # 18 + 1 # 20 SGRT-2-XX
1 # 16 SGRT-2-XX 2 # 16 + 3 # 18 SGRT-3-XX 2 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 1 # 22 SGRT-2-XX 2 # 16 + 3 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 3 # 20 SGRT-3-XX
1 # 16 + 2 # 22 SGRT-2-XX 2 # 16 + 4 # 18 SGRT-3-XX 2 # 18 + 4 # 20 SGRT-3-XX
1 # 16 + 3 # 22 SGRT-2-XX 3 # 16 SGRT-3-XX 3 # 18 SGRT-2-XX
1 # 16 + 1 # 20 SGRT-2-XX 3 # 16 + 1 # 20 SGRT-3-XX 3 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 1 # 20 + 1 # 22 SGRT-2-XX 3 # 16 + 2 # 20 SGRT-3-XX 3 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 2 # 20 SGRT-2-XX 3 # 16 + 3 # 20 SGRT-3-XX 3 # 18 + 3 # 20 SGRT-3-XX
1 # 16 + 3 # 20 SGRT-3-XX 3 # 16 + 1 # 18 SGRT-3-XX 4 # 18 SGRT-3-XX
1 # 16 + 4 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 4 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 5 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 4 # 18 + 2 # 20 SGRT-3-XX
1 # 16 + 1 # 18 SGRT-2-XX 3 # 16 + 2 # 18 SGRT-3-XX 5 # 18 SGRT-3-XX
1 # 16 + 1 # 18 + 1 # 20 SGRT-2-XX 3 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 5 # 18 + 1 # 20 SGRT-3-XX
1 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 3 # 16 + 3 # 18 SGRT-3-XX 6 # 18 SGRT-3-XX
1 # 16 + 1 # 18 + 3 # 20 SGRT-3-XX 4 # 16 SGRT-3-XX 1 # 20 + 2 # 22 SGRT-2-XX
1 # 16 + 1 # 18 + 4 # 20 SGRT-3-XX 4 # 16 + 1 # 20 SGRT-3-XX 1 # 20 + 3 # 22 SGRT-2-XX
1 # 16 + 2 # 18 SGRT-3-XX 4 # 16 + 2 # 20 SGRT-3-XX 1 # 20 + 4 # 22 SGRT-2-XX
1 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 4 # 16 + 1 # 18 SGRT-3-XX 2 # 20 SGRT-2-XX
1 # 16 + 2 # 18 + 2 # 20 SGRT-3-XX 4 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 2 # 20 + 1 # 22 SGRT-2-XX
1 # 16 + 2 # 18 + 3 # 20 SGRT-3-XX 4 # 16 + 2 # 18 SGRT-4-XX 2 # 20 + 2 # 22 SGRT-2-XX
1 # 16 + 3 # 18 SGRT-3-XX 5 # 16 SGRT-3-XX 2 # 20 + 3 # 22 SGRT-2-XX
1 # 16 + 3 # 18 + 1 # 20 SGRT-3-XX 5 # 16 + 1 # 20 SGRT-4-XX 3 # 20 SGRT-2-XX
1 # 16 + 3 # 18 + 2 # 20 SGRT-3-XX 5 # 16 + 1 # 18 SGRT-4-XX 3 # 20 + 1 # 22 SGRT-2-XX
1 # 16 + 4 # 18 SGRT-3-XX 6 # 16 SGRT-4-XX 4 # 20 SGRT-2-XX
1 # 16 + 4 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 22 SGRT-2-XX 5 # 20 SGRT-3-XX
1 # 16 + 5 # 18 SGRT-3-XX 1 # 18 + 2 # 22 SGRT-2-XX 6 # 20 SGRT-3-XX
2 # 16 SGRT-2-XX 1 # 18 + 3 # 22 SGRT-2-XX 4 # 22 SGRT-2-XX
2 # 16 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 20 SGRT-2-XX 5 # 22 SGRT-2-XX
2 # 16 + 2 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 1 # 22 SGRT-2-XX 6 # 22 SGRT-2-XX
2 # 16 + 3 # 20 SGRT-3-XX — — — —
Table C. SolderGrip Wire
Combinations (see Table A
for Terminal Size [-XX])
(Continued)
8
Solder Style
8-35
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderGrip Self-Fixturing Insulated Terminals (Continued)
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar)
Solder and flux Sn60 Pb40 with RAflux
Typical Performance
Tensile strength Exceeds strength of individual wires
Temperature rating -55°C to +150°C [-67°F to +302°F]
Voltage Drop Not to exceed that of equivalent length of wire by more than 1 mV
Dielectric Withstanding Voltage Current leakage less than 2 mA(1.5 kV)
The SolderGrip product is
pushed onto the conductors
with a twisting motion. With
the product in place, instal-
lation can be completed
with the proper selection
and use of heating tools
and reflectors.
Either of the following
Raychem heating tools is
recommended:
■HL1802E
■CV-1981
Product Characteristics
Installation Refer to Raychem installa-
tion procedure RPIP 820-01
for detailed instructions and
recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
8-36
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
Introduction
Raychem SolderSleeve
terminators offer easy,
one-step solutions for wire
connections to pins, posts,
and tabs and for mass wire
terminations.
Designed for applications
with temperatures up to
150°C [302°F], the products
in this section include
SolderSleeve discrete wire
terminators, which are
heat-shrinkable thermoplas-
tic sleeves containing a
precisely engineered fluxed
solder preform.
SolderSleeve terminators
are also available on carrier
tape, spaced precisely to
match connector terminal
spacing, enabling termina-
tion of an entire row of wires
at one time.
SolderSleeve wire-to-pin,
wire-to-post, and wire-to-tab
t e rminators, like all Raychem
termination products, pro-
vide reliability and economi-
cal installation for greater
productivity. They can be
supplied either in bulk or
on carrier tape.
8
8-37
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators
Applications
Used for terminating wires
to component terminals,
such as motor tabs, con-
nector pins, and switch
terminals.
Product selection process
1. Determine the application
operating temperature.
2. From the Product Options
table on the next page,
select the product series
appropriate for the appli-
cation, based on the tem-
perature required.
3. Determine your compo-
nent connection point
type (pin, post, or tab)
and dimensions.
4. Determine your wire
gauge.
5. Optional: Select tape
carrier center-to-center
spacing (D-71X series
only). This should match
center spacing of com-
ponent terminals.
6. Select part number from
the appropriate table:
■For CWT series
(applications with low-
temperature wires—
below 125°C [257°F]),
use Table A.
■For D-129/141/71X
series (applications with
wires rated higher than
125°C [257°F]), use
Table B.
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Either of the following
Raychem heating tools are
recommended:
■HL1802E
■AA-400 Super Heater
Refer to Raychem installa-
tion procedure RCPS 200-
12 (for D-129, D-141, D-71X)
or RPIP 824-00 (for CWT)
for detailed instructions and
recommended reflector
attachment.
You will find ordering infor-
mation for these tools see
section 10.
Product Facts
■Transparent polyvinylidene
fluoride or polyolefin
insulation sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
■Prefluxed solder preform
offers a controlled soldering
process
■One-piece design means
easy installation and low
installed cost
■Optional tape carrier
provides convenience and
ease of installation
■UL and CUL
Recognized
Available in:
Americas ■
Europe ■
Asia Pacific ■
8-38
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Connection-point
Type and Size Terminal Dimensions Wire AWG/mm2Part No.
W = up to 0.63 [.025] 24 [0.24] CWT-1501
20 [0.61] CWT-1502
W = 0.63 [.025] to 24 [0.24] CWT-1501
0.89 [0.035] 22 [0.38] CWT-1502
20 [0.61] CWT-1503
W = 0.89 [0.035] to 24–22 [0.24–0.38] CWT-1502
1.14 [.045] 20–18 [0.61–0.95] CWT-1503
W = 1.14 [.045] to 24–22 [0.24–0.38] CWT-1503
1.52 [.060] 20–18 [0.61–0.95] CWT-1504
W = up to1.52 [.060] 24–20 [0.24–0.61] CWT-1501
W = 1.27 [.050] to 24-18 [0.24–0.95] CWT-1502
2.28 [.090]
W = 1.77 [.070] to 24-18 [0.24–0.95] CWT-1503
2.79 [.110]
W = 2.54 [.100] to 24-18 [0.24–0.95] CWT-1504
3.80 [.150]
W = 2.28 [.090] to 22-16 [0.38–1.21] CWT-1505
4.70 [.187]
Product Series Max. Operating Temperature Min.Wire Temperature Rating
CWT 125°C [257°F] 85°C [185°F]
D-129, D-141, D-71X 150°C [302°F] 125°C [257°F]
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult Tyco Electronics for details.
Product Options
Table A. CWT Series
(125°C [257°F] rated)
pin
W
post
W
tab
W
8
8-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Wire Tape Carrier Spacing of Sleeves (Center-to-Center)
Terminal 1.27 2.54 3.17 4.0
Dimensions AWG mm2None [0.050] [0.100] [0.125] [0.156]
W = up to 0.61 [.024] 30–26 [0.05–0.15] D-141-30 D-713-03 — — —
24–22 [0.24–0.38] D-141-07 — D-711-00 — —
W = 0.63 [.025] to 20 [0.61] D-141-31 — D-711-04 D-711-07 D-711-08
0.81 [.032]
W = 0.76 [.030] to 24–20 [0.24–0.61] D-141-56 — — — —
1.27 [.050]
W = up to 1.52 [.060] 24–20 [0.24–0.61] D-129-05 — D-714-01 — —
W = 1.27 [.050] to 24–20 [0.24–0.61] D-129-03 — — — D-714-00
2.28 [.090]
W = 2.28 [.090] to 24–20 [0.24–0.61] D-129-0043 — — — —
3.55 [.140]
Part Inside Diameter Fully
No.* As Supplied** Recovered† Length††
D-110-0062 1.0 [0.040] 0.6 [0.025] 16.0 [0.630]
D-110-0217 1.0 [0.040] 0.6 [0.025] 9.0 [0.360]
D-141-13 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 4.7 [0.185]
D-141-22 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 6.0 [0.240]
D-141-30 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 9.5 [0.375]
Note: Micro SolderSleeve terminators are used for attaching leads smaller than 26 AWG (0.15 mm2) to terminals less
than 0.6 [.025] wide.
*The D-110 series sleeves are primarily for single wire terminations and do not have a wire stop. The D-141 series will
accept either one or two wires; the parts have a built-in wire stop that will locate the wire approximately 0.76 [0.03]
from bottom of terminal.
**Minimum. Wire insulation must be smaller than this. When using the D-141 parts for two-wire terminations, the com-
bined wire insulation diameters must be less than 1.5 [.060].
†Maximum. The combination of conductor diameter and terminal width and the wire insulation must be greater than
this.
††The terminal length should be at least 1.2 [0.05] shorter than this. The wire strip length must be adjusted so that,
when terminated, the exposed conductor is covered by the sleeve.
pin
W
post
W
tab
W
For Fine Wire Terminations
0.15 mm2(26 AWG) and
Smaller*
Table B. D-129/141/71X Series
(up to 150°C [302°F] rated)
Connection-point
Type and Size
8-40
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Material
Insulation [D-129, D-141, D-71X] Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation [CWT] Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux [D-129, D-141, D-71X] Solder: Sn63 Pb37 Flux: ROL1 per ANSI -J - 004 [RMA flux]
Solder and flux [CWT] Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI -J - 004 [RAflux]
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating [CWT] -55°C to 125°C [-67°F to 257°F]
Temperature rating [D-129, D-141, D-71X] -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Series Agency Raychem
CWT ULand CULE87681 D-5023
D-129, D-141 ULand CULE87681 RT-1404
Product Characteristics
Specifications/Approvals
8
8-41
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
Introduction
Raychem SolderSleeve
shield grounding termina-
tors provide an environmen-
tally sealed, insulated,
and encapsulated solder
connection for a variety of
applications. SolderSleeve
terminators are available in
many styles.
Designed for a wide variety
of temperature applications
ranging from -65°C to
200°C [-85°F to 392°F], the
products in this section
include:
■CWT-X SolderSleeve
terminators, designed for
low-temperature cables
with operating
temperatures up to 125°C
[257°F] and suitable for
most commercial
environments.
■MIL-S-83519
SolderSleeve terminators,
which are immersion
resistant and available
with or without a
preinstalled ground lead.
■SO Seies SolderSleeve
terminators, which also
are immersion resistant
and feature the Raychem
BiAlloy temperature
indication system.
All SolderSleeve products
are reliable, versatile, and
easy to install, resulting in
lower installed costs.
8-42
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators
Product Selection Process
1. Select product series
from the Product Options
table below.
2. Determine cable
dimensions.
3. Optional: Select p re i n -
stalled wire lead type
(see Table G on page
8-45 for type
descriptions).
4. Select part number (use
the selection table indi-
cated for your product
series in the Product
Options table below).
5. Refer to Table H on page
8-47 for cross-reference
information.
Product Options (Refer to Table G on Page 8-45 for Additional Information)
System Oper. Used on Part No.
Product Temperature Cables Rated Environmental Solder Flux Insulation Selection
Series (Max.) (Min.) Protection Alloy Type Material Table
CWT 125°C [257°F] 85°C [185°F] Splash resistant Cd18 RA Polyolefin A
SO63* 150°C [302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride B
S01/S02**, S03 150°C [302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride C, D
SO96*** 175°C [347°F] 150°C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride E
SO175**** 175˚C [347°F] 150˚C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride F
*Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with BiAlloy temperature indicator.
**Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with thermochromic temperature indicator.
****Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519), supplied with BiAlloy temperature indicator.
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F]. Consult Tyco Electronics for details.
Jacket OD (max.) Shield OD (min.)
Product Facts
■Transparent insulation
sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
■Prefluxed solder preform
provides a controlled
soldering process
■One-piece design offers
easy installation and lower
installed cost
■Optional preinstalled ground
leads provide convenience
and ease of installation
Applications
Used for shield-to-ground
termination.
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-43
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Table A. CWT Series
(125°C [257°F] rated)
Cable OD Part Nos.
Jacket Shield No Preinstalled With Preinstalled Lead
OD Max. OD Min. Lead (22AWG/0.38 mm2green)
1.7 [.065] 0.9 [.035] CWT-3801 —
1.95 [.075] 1.1 [.043] CWT-3802 —
2.7 [.105] 1.5 [.059] CWT-3 CWT-3-W122-5
4.5 [.180] 2.0 [.079] CWT-5 CWT-5-W122-5
6.0 [.235] 3.3 [.130] CWT-6 CWT-6-W122-5
7.0 [.275] 3.3 [.130] CWT-7 CWT-7-W122-5
8.7 [.340] 4.5 [.177] CWT-9 CWT-9-W122-5
10.7 [.420] 4.5 [.177] CWT-11 CWT-11-W122-5
13.0 [.510] 7.0 [.276] CWT-13 CWT-13-W122-5
*See Table G on page 8-45 for lead description.
Note: The CWTseries is suitable for applications using low-temperature wires (typically rated at 85°C [185°F] to 125°C [257°F]) with bare copper or tin plating.
Cable OD Part Nos.
No Preinstalled Lead Option* Braid Strap
Jacket OD Shield OD Preinstalled
Max. Min. Lead 20 AWG 22 AWG 24 AWG 26 AWG Nickel Plated Tin Plated
1.95 [0.075] 0.90 [.035] SO63-1-00 SO63-1-55-20-90 SO63-1-55-22-90 SO63-1-55-24-90 SO63-1-55-26-90 SO63-1-01 SO63-1-9030
2.7 [0.105] 1.40 [.055] SO63-2-00 SO63-2-55-20-90 SO63-2-55-22-90 SO63-2-55-24-90 SO63-2-55-26-90 SO63-2-01 SO63-2-9030
4.3 [0.170] 2.15 [.085] SO63-3-00 SO63-3-55-20-90 SO63-3-55-22-90 SO63-3-55-24-90 SO63-3-55-26-90 SO63-3-01 SO63-3-9030
6.0 [0.235] 3.30 [.130] SO63-4-00 SO63-4-55-20-90 SO63-4-55-22-90 SO63-4-55-24-90 SO63-4-55-26-90 SO63-4-01 SO63-4-9030
7.0 [0.275] 4.30 [.170] SO63-5-00 SO63-5-55-20-90 SO63-5-55-22-90 SO63-5-55-24-90 SO63-5-55-26-90 SO63-5-01 SO63-5-9030
*See Table G on page 8-45 for lead description. Color of wire lead is denoted by the last two digits of the part number as follows:
90 = White with a black stripe 9 = White 0 = Black 6 = Blue (24 AWG only) 5 = Green (20, 22, 24 AWG)
The SO63 series is immersion resistant, features the Raychem BiAlloy temperature indication system, and meets the performance requirements of
SAE-AS83519 (formerly MIL-S-83519) .
BiAlloy Temperature
Indication System
This system greatly enhances the reliability and repeatabil-
ity of SO63 series terminators while reducing installed cost.
The heat-shrinkable thermoplastic sleeve contains a pre-
cisely engineered, fluxed solder band that is visible through
the sleeve. The band provides exactly the amount of solder
and flux required to terminate the ground lead to the cable
shield. Encircling the band is a small temperature indicator
ring. This ring melts only when the surfaces to be joined
have reached the correct soldering temperature, thus
ensuring a properly soldered connection. Process control is
built into each sleeve.
Table B. SO63 Series
8-44
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Cable OD Part No. (MIL Part Number and Raychem Part No.) by Lead Option
Preinstalled Lead Option*
Jacket OD Shield OD No Preinstalled Lead 20 AWG 22 AWG
Max Min MIL Raychem MIL Raychem MIL Raychem
1.95 [0.075] 0.9 [.035] M83519/1-1 S01-01-R M83519/2-1 S02-01-R M83519/2-6 S02-06-R
2.7[0.105] 1.40 [.055] M83519/1-2 S01-02-R M83519/2-2 S02-02-R M83519/2-7 S02-07-R
4.3 [0.170] 2.15 [.085] M83519/1-3 S01-03-R M83519/2-3 S02-03-R M83519/2-8 S02-08-R
6.0 [0.235] 3.30 [.130] M83519/1-4 S01-04-R M83519/2-4 S02-04-R M83519/2-9 S02-09-R
7.0 [0.275] 4.30 [.170] M83519/1-5 S01-05-R M83519/2-5 S02-05-R M83519/2-10 S02-10-R
Jacket OD Shield OD Preinstalled Lead Option*
Max. Min. 24 AWG 26 AWG
1.95 [0.075] 0.9 [.035] M83519/2-11 S02-11-R M83519/2-16 S02-16-R
2.7 [0.105] 1.40 [.055] M83519/2-12 S02-12-R M83519/2-17 S02-17-R
4.3[0.170] 2.15 [.085] M83519/2-13 S02-13-R M83519/2-18 S02-18-R
6.0 [0.235] 3.30 [.130] M83519/2-14 S02-14-R M83519/2-19 S02-19-R
7.0 [0.275] 4.30 [.170] M83519/2-15 S02-15-R M83519/2-20 S02-20-R
*See Table G for lead description.
M83519 is the qualified product listed in SAE-AS83519 (formerly MIL-S-83519) . The series features a thermochromic temperature indicator to assist in termi-
nation and inspection. The Raychem part number is permanently marked on the sleeve.
Thermochromic Temperature Indicator
The M83519 (S01 and S02) series terminators contain
a colored thermochromic temperature indicator that
exhibits a distinct color change when surfaces have
reached wetting temperature. This color change gives both
manufacturing and Quality Control an aid in the inspection
of the completed termination.
Table C. S01/S02 M83519
Series
Thermochromic Temperature Indicator
The S03 series terminators contain a colored ther-
mochromic temperature indicator that exhibits a
distinct color change when surfaces have reached wetting
temperature. This color change gives both Manufacturing
and Quality Control an aid in the inspection of the
completed termination.
Table D. S03 Series
Cable OD Part No.
Preinstalled Lead Option*Jacket OD Shield OD
Max. Min. Tin plated Braid Strap Nickel plated Braid Strap
1.95 [0.075] 0.9 [.035] S03-01-R S03-06-R
2.7 [0.105] 1.40 [.055] S03-02-R S03-07-R
4.3 [0.170] 2.15 [.085] S03-03-R S03-08-R
6.0 [0.235] 3.30 [.130] S03-04-R S03-09-R
7.0 [0.275] 4.30 [.170] S03-05-R S03-10-R
*See Table G for lead description.
8
8-45
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Cable OD Part No.
Preinstalled Lead Option*Jacket OD Shield OD No
Max. Min. Preinstalled Lead 22 AWG Braid Strap
1.95 [0.075] 0.9 [.035] SO96-1-00 SO96-1-55-22-90 SO96-1-01
2.7 [0.105] 1.40 [.055] SO96-2-00 SO96-2-55-22-90 SO96-2-01
4.3 [0.170] 2.15 [.085] SO96-3-00 SO96-3-55-22-90 SO96-3-01
6.0 [0.235] 3.30 [.130] SO96-4-00 SO96-4-55-22-90 SO96-4-01
7.0 [0.275] 4.30 [.170] SO96-5-00 SO96-5-55-22-90 SO96-5-01
*See Table G for lead description.
The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200°C [392°F]. This series features a ther-
mochromic temperature indicator and meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) . The solder is Sn96 with RAflux compatible
with nickel-plated shields.
Table G. Preinstalled Lead
Description
Series Lead Type Remarks Plating Stranding Min. Length
M83519, SO63 55A0111 MIL-W-22759/32 Tin Stranded 150 [6.00]
SO96, SO175 55A0813 MIL-W-22759/41 Nickel Stranded 150 [6.00]
SO63, SO96, S03 Braid strap Uninsulated Nickel 40 x 38 AWG 150 [6.00]
CWT XLpolyethylene ULListed Tin Stranded (W1) 150 [6.00]
SO63, S03 Braid Strap Uninsulated Tin Stranded 150 [6.00]
Cable OD Part No.
Preinstalled Lead Option*Jacket OD Shield OD No
Max. Min. Preinstalled Lead 22 AWG Braid Strap
1.95 [0.075] 0.90 [0.035] SO175-1-00 SO175-1-1-55-22-90 SO175-1-01
2.7 [0.105] 1.40 [0.055] SO175-2-00 SO175-2-1-55-22-90 SO175-2-01
4.3 [0.170] 2.15 [0.085] SO175-3-00 SO175-3-1-55-22-90 SO175-3-01
6.0 [0.235] 3.30 [0.130] SO175-4-00 SO175-4-1-55-22-90 SO175-4-01
7.0 [0.275] 4.30 [0.170] SO175-5-00 SO175-5-1-55-22-90 SO175-5-01
*See Table G for lead description.
Thermochromic
Temperature Indicator
The SO96 series terminators contain a colored ther-
mochromic temperature indicator that exhibits a
distinct color change when surfaces have reached
wetting temperature. This color change gives both manu-
facturing and Quality Control an aid in the
inspection of the completed termination.
Table E. SO96 Series
(175°C [347°F] rated)
BiAlloy Temperature Indication System
This system greatly enhances the reliability and
repeatability of SO175 series terminators while reducing
installed cost. The temperature indicator ring, encircling the
solder preform, melts to indicate the very minimum amount
of heat.
Table F. SO175 Series
(175°C [347°F] rated)
8-46
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Material
Insulation
SO, M83519 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
CWT Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux
SO63, M83519, S03 Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMAFlux)
SO96, SO175 series Solder: Sn96 Ag4 Flux: ROM1 per ANSI - J - 004 (RAFlux)
CWT Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI - J - 004 (RAFlux)
Ground lead
CWTseries XLpolyethylene
SO, M83519, SO175 MIL-W-22759/32 or /41
Typical Performance
Voltage drop 2.5 mV
Tensile strength Exceeds strength of ground lead
Dielectric strength 1.0 kV immersed
Temperature rating
CWT -55°C to 125°C [-67°F to 257°F]
SO63/M83519/S03 -55°C to 150°C [-67°F to 302°F]
SO96/SO175 series -55°C to 175°C [-67°F to 347°F]
Insulation resistance 1000 megohms
Series Agency Raychem
CWT — D-5023
SO63* NAS 1747 RT-1404
M83519** MIL-S-83519/1&/2 RT-1404
SO96*** NAS 1747 RT-1404
SO175 RT-1404
* Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747,
supplied with BiAlloy temperature indicator.
** Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with
thermochromic temperature indicator.
Shield Termination
SolderSleeve Shield Terminators (Continued)
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
■HL1802E
■AA-400 Super Heater
■CV-1981
■MiniRay
■IR-1759
Product Characteristics
Specifications/Approvals
Installation For detailed instructions and recommended reflector
attachments, refer to the appropriate Raychem
installation procedure:
Series Procedure
CWT RPIP 655-00-D
SO63 RCPS 100-70
M83519 (S01/S02) RCPS 100-70
SO96 RCPS 100-70
S03 RCPS 100-70
SO175 RCPS-100-70
You will find ordering information for these tools
in section 10.
8
8-47
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Table H. NAS, M83519, and
Raychem Cross-Reference NAS Raychem D Series NAS
Part No. Part No. Comment
1744-1 D-1744-01
1744-2 D-1744-02
1744-3 D-1744-03
1744-4 D-1744-04
1744-5 D-1744-05
1744-6 D-1744-06
1744-7 D-1744-07
1744-8 D-1744-08
1745-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-2 D-100-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1745-3 D-101-00 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-4 D-103-00 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-5 D-144-26
1745-6 D-100-31
1745-7 D-101-31
1745-8 D-103-31
1745-9 Obsolete - Use NAS1745-13
1745-10 Obsolete - Use NAS1745-14
1745-11 Obsolete - Use NAS1745-15
1745-12 Obsolete - Use NAS1745-16
1745-13 D-142-83 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-14 D-142-50 Inactive, Use SAE-AS83519/1-2(formerly MIL-S-83519)
1745-15 D-142-51 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-16 D-142-52 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-17 D-107-00 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-18 D-104-00
1745-19 D-105-00
1745-20 D-107-31
1745-21 D-104-31
1745-22 D-105-31
1745-23 D-142-56 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-24 D-142-65
1745-25 D-142-66
1746-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1746-2 D-144-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1746-3 D-144-01 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1746-4 D-144-02 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1746-5 D-144-26
1746-6 D-144-03
1746-7 D-144-04
1746-8 D-144-05
1746-9 D-144-46 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1746-10 D-144-37
Military Raychem S01/S02 Series* Raychem SO63 Series**
Part No. Part No. Part No.
M83519/1-1 S01-01-R SO63-1-00
M83519/1-2 S01-02-R SO63-2-00
M83519/1-3 S01-03-R SO63-3-00
M83519/1-4 S01-04-R SO63-4-00
M83519/1-5 S01-05-R SO63-5-00
M83519/2-1 S02-01-R SO63-1-55-20-90
M83519/2-2 S02-02-R SO63-2-55-20-90
M83519/2-3 S02-03-R SO63-3-55-20-90
M83519/2-4 S02-04-R SO63-4-55-20-90
M83519/2-5 S02-05-R SO63-5-55-20-90
M83519/2-6 S02-06-R SO63-1-55-22-90
M83519/2-7 S02-07-R SO63-2-55-22-90
M83519/2-8 S02-08-R SO63-3-55-22-90
M83519/2-9 S02-09-R SO63-4-55-22-90
M83519/2-10 S02-10-R SO63-5-55-22-90
M83519/2-11 S02-11-R SO63-1-55-24-90
M83519/2-12 S02-12-R SO63-2-55-24-90
M83519/2-13 S02-13-R SO63-3-55-24-90
M83519/2-14 S02-14-R SO63-4-55-24-90
M83519/2-15 S02-15-R SO63-5-55-24-90
M83519/2-16 S02-16-R SO63-1-55-26-90
M83519/2-17 S02-17-R SO63-2-55-26-90
M83519/2-18 S02-18-R SO63-3-55-26-90
M83519/2-19 S02-19-R SO63-4-55-26-90
M83519/2-20 S02-20-R SO63-5-55-26-90
* QPLlisted to SAE-AS83519 (formerly MIL-S-83519)
** Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519)
8-48
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
Introduction
Raychem SolderSleeve
coaxial cable terminators
allow reliable, easy termina-
tions in a variety of coaxial
cable applications, includ-
ing printed circuit boards
(PCBs). The insulating and
strain-relieving capabilities
of SolderSleeve terminators
provide the ideal solution to
center-conductor breakage
problems.
Designed for applications
with temperatures up to
150°C [302°F], the products
in this section include:
■SolderSleeve coaxial
cable terminators, which
allow reliable, economical
attachment of coaxial
cable to connector
terminals, printed wiring
assemblies, or solderless
wrap terminals.
■One-piece SolderSleeve
PCB coaxial cable termi-
nators, which permit
quick, easy, and cost-
effective terminations of
coaxial cable to printed
circuit boards.
■RF one-step BNC/TNC
connectors, which are sin-
gle-piece assemblies for
terminating the center
conductor and the braid
of a broad range of coax-
ial cables. They are fully
intermateable with MIL-C-
39012C connectors and
are available in 50-ohm
and 75-ohm versions
(refer to pages 8-53 to
8-58 for product informa-
tion).
With precisely measured
solder and flux, SolderSleeve
products provide exact
process control of termina-
tions. The SolderSleeve
method means strong
connections with the lowest
possible voltage drop. Small,
lightweight SolderSleeve
t e rminators are also the ideal
solution for high-density
packaging problems.
8
8-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve Coaxial Cable Terminators
Product Facts
■Transparent polyvinylidene
fluoride or polyolefin
insulation sleeve provides
encapsulation,
inspectability, strain relief
(eliminates center conductor
breakage), and insulation.
■Prefluxed solder preform
provides a controlled
soldering process
■One-piece design provides
easy installation and lower
installed cost
■Preinstalled termination
leads provide convenience
and ease of installation
Product Options
Product Series Max. Operating Temp. Use on Cables Rated (Min) Cable Shield Plating Part No. Selection Table Design
CWT 125°C [257°F] 85°C [185°F] Tin, copper A 2-pc.
B-02X/B-04X 150°C [302°F] 125°C [257°F] Tin, silver B 1-pc.
D-181 150°C [302°F] 125°C [257°F] Tin, silver C 2-pc.
D-184 125°C [257°F] 85°C [185°F] Tin D 2-pc.
Preinstalled Lead Descriptions
Series Lead Type Plating Stranding AWG Length Color
CWT XLpolyethelene Tin Stranded (W1) 22 150 [6.000] White (cntr), green (grnd)
B-021 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-041 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-043 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-020 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-040 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-044 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
D-181-12XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-22XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-32XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-18XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-181-28XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-184 55A0111 (MIL-W-22759/32) Tin Stranded 20 – 26 150 [6.000] White (cntr), white w/black stripe (grnd)
Applications
Used for terminating coaxial
cable to component termi-
nals, contacts, printed cir-
cuit boards, and solderless
wrap terminals.
Product Selection Process
1. Select product series
from the product options
table below.
2. Select preinstalled lead
type from the table below.
3. Determine cable RG
number or dimensions.
4. Select part number from
Table A (CWT series) or
Table B (B-02X/B-04X
series) on the next page.
Product Characteristics
Material
Insulation (B-02X/B-04X, D-181, D-184) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar)
Insulation (CWTseries) Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux (B-02X/B-04X, D-181) Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAFlux)
Solder and flux (CWTseries, D-184) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI-J-004 (RAFlux)
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating (CWT, D-184) -55°C to 125°C [-67°F to 257°F]
Temperature rating (B-02X/B-04X, D-181) -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Available in:
Americas ■
Europe ■
Asia Pacific ■
8-50
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve Coaxial Cable Terminators (Continued)
Part 1: Coaxial Product Group Selection
Typical Compatible
Part No. Dimension Range
Raychem One-Piece
RG Cable Cable Jacket OD (Max.) Shield OD Dielectric Conductor Coaxial Product
Number Description OD OD Group
RG178, RG404 5030A13XX 3.40 1.30–2.30 0.50–1.70 0.30–0.80 Group 1
5028A13XX [.134] [.051–.091] [.019–.067] [.011–.032]
5024A13XX
RG179, RG316 7530A13XX 4.40 1.50–2.80 1.20–2.50 0.30–1.60 Group 2
7526A13XX [.173] [.060–.110] [.047–.100] [.011–.063]
9530A13XX
RG180, RG302, 9527A13XX 6.30 2.40–4.60 1.40–4.30 0.30–2.80 Group 3
RG303 9528A13XX [.248] [.094–.181] [.055–.169] [.011–.110]
Part 2: Product Part Number Selection
One-Piece Preinstalled Wire Size
Coaxial Preinstalled 20 22 24 26 28 30
Product Group Wire Type AWG AWG AWG AWG AWG AWG
Stranded — B-044-22-N B-044-24-N B-044-26-N — —
Group 1 (M22759)
Solid — — B-043-24-N B-043-26-N B-043-28-N B-043-30-N
(M81822)
Stranded B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N
Group 2 (M22759)
Solid — — B-041-24-N B-041-26-N B-041-28-N B-041-30-N
(M81822)
Stranded B-020-20-N B-020-22-N B-020-24-N B-020-26-N — —
Group 3 (M22759)
Solid — — — B-021-26-N — —
(M81822)
1. The B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125°C minimum.
2. Using Part 1 of this table, select the appropriate coaxial product group (1, 2, or 3) based on your RG cable number, Raychem cable
description, or cable dimensions.
3. Using Part 2 of this table, select the product part number based on the coaxial product group you selected in Part 1 and the appropriate
preinstalled lead type you selected on the previous page.
Table B. B-02X/B-04X
Series Part Numbers
Table A. CWT Series
Part Numbers
Table C. D-181 Series
Part Numbers
Product Dimensions
Product A B C D E F L1 L2 Wire
Name min. min. min. min. min. min. max. max. AWG
D-181-1220-90/9 20
D-181-1222-90/9 22
D-181-1224-90/9 3.7 3.2 2.7 2.4 2.3 0.71 17 21.5 24
D-181-1226-90/9 [0.145] [0.125] [0.105] [0.095] [0.09] [0.028] [0.67] [0.85] 26
D-181-1826-6/9 26
D-181-1830-6/9 30
D-181-2220-90/9 20
D-181-2222-90/9 22
D-181-2224-90/9 4.5 4 3.45 2.9 3 1.1 17 22.7 24
D-181-2226-90/9 [0.18] [0.16] [0.135] [0.115] [0.12] [0.045] [0.67] [0.895] 26
D-181-2826-6/9 26
D-181-2830-6/9 30
D-181-3220-90/9 20
D-181-3222-90/9 ] 22
D-181-3224-90/9 5.2 4.7 4.45 3.95 4 1.3 17 21.5 24
D-181-3226-90/9 [0.205] [0.185] [0.175] [0.155] [0.16] [0.055] [0.67] [0.85] 26
D-181-3826-6/9 26
D-181-3830-6/9 30
Table D. D-184 Series
Part Numbers
Product Dimensions
Product ∅A∅B∅C∅D∅E∅F L1 L2 Wire
Name min. min. min. min. min. min. max. max. AWG
D-184-1220-90/9 20
D-184-1222-90/9 3.7 3.2 2.7 2.4 2.3 0.71 17 21.5 22
D-184-1224-90/9 [0.145] [0.125] [0.105] [0.095] [0.09] [0.028] [0.67] [0.85] 24
D-184-1226-90/9 26
D-184-2220-90/9 20
D-184-2222-90/9 4.5 4 3.45 2.9 3 1.1 17 22.7 22
D-184-2224-90/9 [0.18] [0.16] [0.135] [0.115] [0.12] [0.045] [0.67] [0.895] 24
D-184-2226-90/9 26
Dimensions Part No.
Cable RG Number Dielectric OD Jacket OD With Preinstalled Lead
AWG/0.38 mm2Green/White)
174 0.80–2.30 [.032–.091] 1.30–2.80 [.051–.110] CWT-4174-W122-5/9
58, 122 2.00–2.80 [.079–.110] 2.50–4.40 [.100–.173] CWT-4058-W122-5/9
59 2.80–3.30 [.110–.130] 3.20–6.00 [.125–.235] CWT-4059-W122-5/9
8
8-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve PCB/Coaxial Cable Terminators
Product Options
Product Series Typical Application Performance Shield Method Part No. Selection Table
D-607 Matched impedance up to 2.3 GHz Metal body A
B-046 Effective transmission up to 100 MHz Pin to ground B
Product Selection Process
1. Select product series
from the Product Options
table below.
2. Determine cable RG
number or outside diame-
ter dimensions.
3. Select the appropriate
part number from Table A
(D-607 series) or Table B
(B-046 series).
■For D-607 (matched
impedance) series, deter-
mine straight or right-
angle entry to PCB and
grid pattern, then select
the appropriate part num-
ber from Table A on the
next page.
■For B-046 (PinPak, or pin
to ground) series, deter-
mine hole spacing and
diameter. Refer to Table B
for product selection (see
illustration below for cable
dimensions).
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
■HL1802E
■AA-400 Super Heater
■IR-1759 MiniRay
■CV-1981
Refer to Raychem installa-
tion procedure ES61139 for
detailed instructions and
recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
Product Facts
■Provides a completely
shielded, low-resistance,
matched-impedance
termination with very low
VSWR (D-607 series only)
■Transparent polyvinylidene
fluoride insulation sleeve
provides encapsulation,
inspectability, strain relief,
and insulation
■Prefluxed solder preform
provides a controlled
soldering process
■One-piece design offers
easy installation and lower
installed cost
■Preinstalled PCB
termination body provides
convenience and ease of
installation
Applications
Used for terminating coaxial
cable to printed circuit
boards.
Available in:
Americas ■
Europe ■
Asia Pacific ■
8-52
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve PCB/Coaxial Cable Terminators (Continued)
Table A. D-607 Series
Part Numbers
Cable Dimensions (mm/in) Part No.
RG Cable No. Max. Outside Diameter Entry to PCB
Straight Right-Angle Straight
Jacket Shield Dielectric grid 5.08 [.200] Grid 5.08 [.200] Grid 2.54 [.100]
174, 178, 179, 1.5–3.55 1.1–3.15 0.60–2.25 D-607-09 D-607-10 D-607-40*
316, 404 [.060–.140] [.045–.125] [.025–.090]
Table B. B-046 Series
Part Numbers
Cable Dimensions Part No.
RG Cable No. A B C D Pin Diameter Spacing Between Pins
Max. 2.54 [.100] 5.08 [.200] 6.35 [.250]
178, 404 0.30–0.80 0.5–1.7 1.3–2.3 3.4 0.6 [.023] B-046-14-N B-046-10-N B-046-12-N
[.011–.032] [.019–.067] [.050–.091] [.134] 0.8 [.031] B-046-11-N B-046-13-N
179, 316 0.3–1.6 1.2–2.5 .1.5–2.8 4.4 0.6 [.023] B-046-15-N B-046-66-N B-046-16-N
[.011–.063] [.047–.100] [.060–.110] [.173] 0.8 [.031] B-046-68-N B-046-18-N
Product Characteristics
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Solder and flux Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMAflux)
Termination body/pin Copper alloy, solder-plated
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Electrical Performance (typical) D-607 Series Only
Frequency VSWR (D-607-09, -40) VSWR (D-607-10)
350 MHz 1.04 max. 1.04 max.
700 MHz 1.05 max. 1.09 max.
2.3 GHz 1.09 max. 1.12 max.
Specifications/Approvals
Series Raychem
D-607 RT-1404
B-046 RT-1404
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors
8-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Applications
One-Step BNC/TNC con-
nectors are single-piece
assemblies for terminating
the center conductor and
the braid of a broad range
of coaxial cables.
The connectors are fully
intermateable with
MIL-C-39012 connectors
and are available in 50-ohm
and 75-ohm versions.
Specifications Installation
For proper installation of these devices,
the correct heating tool and reflector
Raychem attachment must be used. Refer to Raychem installation procedure
RB-115 Any one of the following Raychem RPIP683-00 for detailed instructions.
heating tools is recommended:
• Steinel Model HL1802E
• CV-1981
Product Facts
■Easy, quick installation
■Outstanding cable-retention
force
■Solder-solder connection
type (center conductor and
braid)
■One-step termination for
easy, quick installation and
lower installed cost
■Exceptional cable retention
force to withstand high
vibration and frequent mates
and unmates
■Fully soldered center
conductor and braid
■Excellent built-in strain
relief against vibration and
excessive handling
■Long-term reliability
■Controlled soldering
termination
■Use with standard RG/U
cables and Raychem
Cheminax cables
■Three product sizes to
accommodate a wide range
of cables
■Meets performance
requirements of
MIL-C-39012 up to 2.8 GHz
Available in:
Americas ■
Europe ■
Asia Pacific ■
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-54
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Connector Style
Dash No. Style Connector Type
RXX - XX - X - XX
-XX TNC BNC
-00 Straight plug
-01 Right-angle plug
-02 Straight bulkhead jack
-03 Straight jack
-04 Straight panel jack
Connector size
L = Large
M = Medium
S = Small
50 = 50 ohms
75 = 75 ohms
D = Nickel-plated brass body, gold-plated brass pin
B = BNC
T= TNC
Example: RBD-50-L-00 is a BNC connector, 50 ohms, large size, with straight plug body.
Female
Male
Product Options and Part
Numbering System
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Part Selection Process
1. From Product Options and Dimensions on page 7035, select the connector style you need
(BNC or TNC, plug or jack, male or female contacts).
2. From the tables that follow, find the appropriate table for the connector style you selected.
3. From the appropriate table, select the connector part number based on the RG cable type or
Raychem cable part number. For cable types not shown use the cable dimensions.
Note: The cable dimensions in each table are keyed to the diagram below.
Product Characteristics
Material
Center contact Gold-plated beryllium copper (female)
Gold-plated brass (male)
Dielectric insulator PTFE
Transition Silver-plated brass
Connector body Nickel-plated brass
Solder and flux Sn63Pb37, RMAflux
Braided shield Tin-plated copper wire per ASTM B3
Insulation sleeve Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue
Strain relief/sealing sleeve Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black
Typical Performance
Dielectric withstand voltage 1500 V
Insulation resistance 5000 megohms
Temperature rating -55˚C to 150˚C [-67˚F to 302˚F]
Contact resistance-straight Inner = 1.5 milliohms, outer = 1.0 milliohm
Contact resistance — right-angle Inner = 2.5 milliohms, outer = 1.5 milliohms
Cable retention force 295N (66 lb) to 822N (196 lb)
Voltage rating 500 V RMS
Connector durability 500 mating cycles minimum
Electrical Performance
Nominal impedance 50 and 75 ohms
Frequency range Up to 2.8 GHz
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-56
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable Type Cable Dimensions
Impedance RG Cables Raychem Cables D E F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
BNC Straight Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-00
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-00
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-00
75 RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-00
75 —7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.126] [.050] RBD-75-M-00
75 RG-6, RG-11, RG-12, RG-59 —5.00–.12.50 4.10–9.50 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-00
BNC Right-Angle Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-01
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-01
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.1–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.9-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-01
75 — 524A1311, 7528A1317 3.50–7.00 2.1–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.1–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-01
BNC Straight Bulkhead Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-02
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-02
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-02
75 RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-02
75 75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
—[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 —5.00-12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-02
BNC Straight Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-03
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-03
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-03
75 — 75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-03
BNC Straight Panel Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-04
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-04
75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
—[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.5o 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-04
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Cable Type Cable Dimensions
Impedance RG Cables Raychem Cables D E F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
TNC Straight Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-00
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-00
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-00
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-00
75 — 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-00
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-00
TNC Straight Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-03
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-03
75 RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-03
75 — 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-03
TNC Straight Panel Jacks,Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-04
75 RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-04
75 — 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-04
TNC Coaxial Connectors
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-58
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable Type Cable Dimensions
Impedance RG Cables Raychem Cables D E F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
TNC Straight Bulkhead Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-02
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-02
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-02
75 RG-179, RG-187 7530A1317 1.5–5.5 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-02
75 — 7524A1311, 7528A1317 3.5–7.0 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-02
TNC Right-Angle Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RTD-50-S-01
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-01
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-01
75 — 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-01
TNC Coaxial Connectors
8
8-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
Introduction
The question is, how to
meet growing performance
requirements for shielded
cable system fabrication
and maintenance while
minimizing electromagnetic
interference (EMI). The
answer is Raychem
SolderShield cable splices.
SolderShield devices are
one-piece products consist-
ing of a flux-coated, solder-
impregnated copper shield
braid encased in a heat-
shrinkable insulation sleeve.
SolderShield cable-to-cable
splice kits, designed for
single-conductor or multi-
conductor shielded cables,
are ideal for fabrication/
repair/rework while restoring
the electrical integrity of
the cable.
SolderShield devices
perform even in demanding
environments. They are
reliable, versatile, and easy
to install.
8-60
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices
Applications
Used for splicing a wide
range of cables, including
coaxial and multiconductor
cables.
SolderShield devices can
be used to repair or splice
shielded or coaxial cables.
These products consist of
a MiniSeal crimp splice
plus a flux-coated, solder-
impregnated copper shield
encased in a heat-shrinkable
sealing sleeve, for splicing
the shields. SolderShield
kits terminate single- or
multiple-conductor cables,
eliminate EMI problems at
the splice, and provide
strain relief for the cable.
Product Selection Process
For splicing multiconductor
cables refer to Table A.
For splicing coaxial cables
refer to Table B.
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
■HL1802E
■IR-1759 MiniRay
■CV-1981
Specifications/Approvals
Series Military Raychem
D-150 US: M81824 (conductor splice only) RT-1404
UK: RAF AP1130-2008-1
Product Facts
■Flux-coated, solder-
impregnated copper shield
braid encased in a
transparent heat-shrinkable
insulation sleeve provides a
controlled soldering
process, encapsulation,
inspectability, strain relief,
and insulation
■One-piece design provides
easy installation and lower
installed cost
■Circumferential (360°)
shielding results in EMI
protection and shield
continuity equal to or better
than the original cable
■Conductor splices are made
using Raychem MiniSeal
crimp products, which are
recognized by MIL-S-81824
and MIL-W-5088
Refer to Raychem installa-
tion procedure RCPS 150-
02 (D-150 series) and RPIP
699-00 (B-202 series) for
detailed instructions and
recommended reflector
attachment.
You will find ordering infor-
mation for most of these
tools in Section 10.
Available in:
Americas ■
Europe ■
Asia Pacific ■
8
8-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
SolderShield Product Dimensions Conductor Splice
Part No. Dimensions Size Range Color Quantity
L1 L2 L3 ID CMA [mm2] Code Per Kit
Tin Plated Nickel Plated Max. Nom. Min. Min. Min.–Max.
D-150-0168 D-150-0228 80.50 50.00 10.20 3.00 304–1510 Red 1
[3.17] [1.97] [.400] [.118] [0.15–0.75]
D-150-0169 D-150-0229 80.50 50.00 10.20 4.00 779–2680 Blue 1
[3.17] [1.97] [.400] [.157] [0.39–1.34]
D-150-0170 D-150-0230 80.50 50.00 10.20 5.00 1900–6755 Yellow 1
[3.17] [1.97] [.400] [.197] [0.95–3.37]
D-150-0174 D-150-0231 10.60 75.00 10.20 4.00 304–1510 Red 2
[4.17] [2.95] [.400] [.157] [0.15–0.75]
D-150-0175 D-150-0232 10.60 75.00 10.20 5.00 779–2680 Blue 2
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0176 D-150-0233 10.60 75.00 10.20 6.00 1900–6755 Yellow 2
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0177 D-150-0234 10.60 75.00 10.20 9.00 304–1510 Yellow 2
[4.17] [2.95] [.400] [.356] [0.15–0.75]
D-150-0178 D-150-0235 10.60 75.00 10.20 4.00 304–1510 Red 4
[4.17] [2.95] [.400] [.157 ] [0.15–0.75]
D-150-0179 D-150-0236 10.60 75.00 10.20 5.00 779–2680 Red 4
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0180 D-150-0237 10.60 75.00 10.20 6.00 1900–6755 Blue 4
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0181 D-150-0238 10.60 75.00 10.20 9.00 1900–6755 Yellow 4
[4.17] [2.95] [.400] [.353] [0.95–3.37]
Note: The SolderShield splice kits listed in this table are for 1:1 cable splices. The kits can be used on cables with tin-, silver-, and nickel-plated copper con-
ductors. All the kits have environmental-sealing capability. The cable temperature rating must be 125°C minimum.
To find the splice kit part number for your application:
1. Determine the number of conductors in the cable to be spliced.
2. Determine the gauge of each conductor or the maximum jacket OD.
3. Determine the conductor plating.
4. Select the appropriate part number from the table above.
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers of
conductor splices.
SolderShield Splice Crimp Splice
Table A. Multiconductor
Cable Splices
8-62
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
RG Cable No. Raychem Conductor Part SolderShield Dimensions
Cable Description Splice Qty/Kit No. L1 Max L2 Min ID Min
8A, 9B, 11 5012A3311
13, 26, 31 5012E1339
115, 144, 149 7518A1311 1 D-150-0214 80.50 50.00 12.00
165, 213, 214 — [3.170] [1.970] [.472]
216, 235, 391 —
393, 397 —
178, 196, 5028A1317
179, 187, 188, 7528A1317 1 D-150-0094 80.50 50.00 3.00
316, 404, M17/138-00001, 5030A1317 [3.170] [1.970] [.118]
M17/136-00001 7530A1317
180, 195 5024A1311
M17/137-00001 7526A1311 1 D-150-0095 80.50 50.00 4.00
M17/139-00001 9527A1318 [3.170] [1.970] [.157]
— 9530E1014
124, 140, 141 5020A1311
159, 302, 303 5022A1311 1 D-150-0096 80.50 50.00 5.00
— 7522A1311 [3.170 ] [1.970] [.236]
— 7523D1331
— 7524A1311
29, 30, 55B 5019D3318 1 B-202-81* 56.00 23.00 7.00
58, 223 5021D1331 [2.200] [.900] [.275]
— 5022A1311
59, 62, 71 7523D1331 1 B-202-82* 56.00 23.00 7.00
— 7524A1311 [2.200 ] [.900] [.275]
— 9524A1311
*These kits use solder to terminate the center conductors. All other kits use crimp.
All kits are for one-to-one coaxial cable splices, and all kits have environmental sealing capability. Each kit contains products to splice conductors, build up
dielectric, splice the shield, and provide insulation.
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers of
conductor splices.
SolderShield Splice Crimp Splice
Table B. Coaxial Cable
Splices
8
8-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
Product Characteristics
Materials
Insulation sleeve Radiation-crosslinked polyvinylidene fluoride
Meltable inserts Fluorocarbon-based thermoplastic
MiniSeal crimp splice Base metal: Copper alloy C10200 per ASTM B75
Plating: Tin per MIL-T-10727 or nickel per QQ-N-290
SolderShield shield splice Base metal: Tin-plated copper wire braid per ASTM B3
Solder and flux coating: Type Sn63 Pb37. Flux: ROM1 per ANSI - J - STD - 004 (RAflux)
Parameter Test Method Requirement
Electromechanical Performance
Dielectric strength (shield connection) — No breakdown or arcing at 1000 Vac (RMS)
Dielectric strength (conductor connection) — 2.5 kV
Voltage drop MIL-S-81824 Less than 2.0-millivolt increase
Insulation resistance (shield connection) — 1000 megohms minimum at 500 Vdc
Insulation resistance (conductor connection) — 5000 megohms
Tensile strength for MiniSeal MIL-S-81824 Exceed yield strength (pounds) of wire.
Tensile strength for SolderShield MIL-S-81824 75% of strength (pounds) of unspliced cable
Temperature rating — -55°C to 150°C [-67°F to 302°F]
Environmental Resistance
Salt spray MIL-STD-202 M101 Meet voltage drop requirement.
Heat aging 750 hours at 150°C [302°F] Meet all electromechanical requirements.
Temperature cycling MIL-STD-202 M107C Meet all electromechanical requirements.
Altitude immersion Immersion at 22,860m [75,000 ft] Meet insulation-resistance requirement.
Corrosion resistance — No evidence of corrosion after testing in accordance
with MIL-STD-202, Method 101, Test Condition A
Shielded Contacts
8-64
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
Raychem SolderTacts
shielded contacts are
designed to provide
reliable, one-piece solder
terminations for use with
circular and rectangular
connectors. These con-
trolled soldering contacts
help speed installation
and reduce installed costs
while eliminating the
variables associated
with hard-to-handle
crimped terminations.
With Tyco Electronics’
controlled soldering
technology, the connections
typically exceed the
strength of the wire.
Transparent insulation
and inspection windows
permit fully inspectable
terminations.
S o l d e r Tacts products are
available to terminate coaxial
cable and twisted wire
pairs in both military and
c o m m e r cial applications.
Shielded Contacts
8-65
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
SolderTacts Shielded One-Piece Solder Contacts
Applications
One-piece controlled-sol-
dering SolderTacts contacts
connectors are designed to
terminate coaxial cables,
shielded wires, and twisted
pairs faster and more reli-
ably than any other method.
SolderTacts contacts elimi-
nate the variables associat-
ed with hard-to-handle
crimping. Their one-step
installation accelerates
production while reducing
handling and installed
costs.
Controlled Soldering
SolderTacts contacts pro-
vide the optimum amount
and type of solder and flux
in prefluxed solder preforms
to control soldering and
reduce operator sensitivity.
The geometry of the coaxial
cable is carried through the
connector to eliminate
separate pins, help reduce
cross talk, and improve
shielding effectiveness and
signal transmission.
SolderTacts contacts pro-
vide simultaneous electrical
connection and strain relief.
Heat-shrinkable tubing
insulations eliminate stress
concentration on the wire
within the contact. Because
the insulation is transparent
and inspection windows are
provided, terminations are
fully inspectable.
Compatibility
The design versatility of
SolderTacts contacts makes
them exceptionally well suit-
ed to military applications,
along with commercial
aerospace, instrumentation
and computers. SolderTacts
products are compatible
with most standard connec-
tor cavities. SolderTacts
contacts are intermateable
and intermountable with
contacts qualified to the
indicated specification.
SolderTacts shielded
contacts can be terminated
with standard Raychem
heating tools. Once termi-
nated, they can be installed
into connector cavities with
standard insertion and
extraction tools. They are
replaceable without cutting
and restripping or shorten-
ing the cable.
Specifications/Approvals
Series Raychem
D-602 D-6002
Product Facts
■Reliable one-piece solder
contacts: through-connector
shielding reduces cross-
talk, and improves signal
transmission
■One-step installation
■Solder joints are strong and
reliable
■Terminations are fully
inspectable
■Termination for coax cables,
shielded wires, twisted
pairs, triaxial cables, for a
variety of commercial and
military connectors
Available in:
Americas ■
Europe ■
Asia Pacific ■
Shielded Contacts
8-66
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter Raychem
Military Wire SolderTacts Size Polarity Cable Type
Specification JOD SOD DOD COD (AWG) Part No.
MIS-20067/5-001† 1.78–4.70 1.65–2.79 .76–2.03 .23–.51 24–32 D-602-16 12 S Coaxial
[.070–.185] [.065–.110] [.030–.080] [.009–.020]
MIS-20067/6-001† 1.78–4.70 1.65–2.79 .76–2.03 .23–.51 24–32 D-602-17 12 P Coaxial
[.070–.185] [.065–.110] [.030–.080] [.009–.020]
— 1.52–3.30 1.68–2.13 .91–1.75 .30–.66 24–30 D-602-46 16 P Coaxial
[.060–.130] [.066–.089] [.036–.069] [.012–.026]
— 1.52–3.30 1.68–2.13 .91–1.75 .30–.66 26–32 D-602-47 16 S Coaxial
[.060–.130] [.066–.089] [.036–.069] [.012–.026]
— — — .76–1.24 .28–.79 24–30 D-602-56 16 P Twinax
[.030–.049] [.011–.031]
— — — .76–1.24 .28–.79 24–30 D-602-57 16 S Twinax
[.030–.049] [.011–.031]
†These SolderTacts contacts are on qualified parts list for indicated specification.
Engineering Convection
Standard (Hot Air) Heating IR1004 Infrared Contact Contact
(Termination AT-1319 Repair Semiautomatic Insertion RemovalPart Numbers
Instructions) Adapter Wand Heater Tool Set Tool Tool
D-602-46/47 ES61137 AT-1319-17 * * AD-1525 AD-1526
D-602-56/57 ES61138 — — — (M81969/17-04) (M81969/19-08)
D-602-16/17 ES61161 — — — — —
*Could be developed.
SolderTacts Product Construction, MIL-C-26482 Series
SolderTacts Series:
MIL-C-26482
Tooling Selection Guide
Shielded Contacts
8-67
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter Raychem
Military Wire SolderTacts Size Polarity Cable Type
Specification JOD SOD DOD COD (AWG) Part No.
MIS-20067/2-002a1.52–3.35 1.68–2.13 .91–1.78 .23–.89 26–32 D-602-44 16 P Coaxial
[.060-.132] [.066-.084] [.036-.070] [.009-.035]
MIS-20067/1-001a1.52–3.35 1.68–2.13 .91–1.78 .23–.89 26–32 D-602-45 16 S Coaxial
[.060-.132] [.066-.084] [.036-.070] [.009-.035]
MIS-20067/4-001a— — .76–1.24 .28–.79 24–30 D-602-54 16 P Twisted pair
[.030-.049] [.011-.031]
MIS-20067/3-001a— — .76–1.24 .28–.79 24–30 D-602-55 16 S Twisted pair
[.030-.049] [.011-.031]
M39029/79b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-72 16 P Coaxial
[.060-.132] [.066-.084] [.036-.066] [.012-.026]
M39029/80b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-73 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
M39029/40b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-76 16 P Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
M39029/41b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-77 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
— — — .76–1.24 .28–.79 24–30 D-602-0126 16 P Twisted pairc
[.030-.049] [.011-.031]
— — — .76–1.24 .28–.79 24–30 D-602-0127 16 S Twisted pairc
[.030-.049] [.011-.031]
—1.52–3.35 1.68–2.13 .91–1.78 .23–.46 28–32 D-602-0172 16 P Coaxial
[.060-.132] [.066-.084 ] [.036-.070] [.009-.018]
MIS-20067/2-001, 003a1.52–3.35 1.68–2.13 .91–1.78 .23–.46 28–32 D-602-0173 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.070] [.009-.018]
MIS-20067/8-001a— — 1.40–3.15 .64–1.57 16–20 D-610-09 16 P Power
[.055-.124] [.025-.062]
MIS-20067/7-001a— — 1.40–3.15 .64–1.57 16–20 D-610-10 16 S Power
[.055-.124] [.025-.062]
a These SolderTacts contacts are on the qualified parts list for indicated specification.
b These SolderTacts contacts are intermateable and intermountable with contacts qualified to the indicated specification; they replace crimp-style termination.
c These SolderTacts contacts are designed for twisted-pair cable per MIL-STD-1553B.
SolderTacts product construction, MIL-C-28748 Series
SolderTacts Series:
MIL-C-28748 Series
Shielded Contacts
8-68
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Convection (Hot Air) Heating IR1004 Infrared
SolderTacts Part Engineering Standard AT-1319 Repair Semiautomatic
Series No. (Termination Instructions) Adapter Wand Heater Tool Set
D-602-44/45 ES61133 AT-1319-14 AD-1480 Tool Set #2
D-602-0172/0173 ES61240 — — —
D-602-54/55 ES61132 — — —
D-602-0126/0127 ES61199 — — —
748 D-610-09/10 ES61187 AT-1319-15 AD-1571 Tool Set #10
(AT-1044-12)
D-602-72/73 ES61135 AT-1319-18 AD-1486 Tool Set #5
(AT-1044-63)
D-602-76/77 ES61164 AT-1319-20 AD-1554 Tool Set #6
(AT-1044-64)
Contact Contact
SolderTacts Series Insertion Tool Removal Tool Special Tools
AD-1457A AD-1464 AD-1496
748 *AD-1447 (bushing tool) (flex tip (twisted pair cut-to-
removal tool) length tool)
*Not applicable.
Tooling Selection Guide:
MIL-C-28748 Series
Shielded Contacts
8-69
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact United States Cable Diameter Raychem
Military Air Force Wire SolderTacts Size Polarity Cable Type
Specification Drawing No. JOD SOD DOD COD (AWG) Part Number
Series I, I I I , and IV
M 3 9 0 2 9 / 6 0a—3 . 8 1 – 5 . 9 4 3 . 1 0 – 4 . 3 2 1 . 5 2 – 3 . 8 4 . 4 8 – 1 . 0 9 22–24 D-602-0122 8 P C o a x i a l
[ . 1 5 0 - . 2 3 4 ] [ . 1 5 0 - . 1 7 0 ] [ . 0 6 0 - . 1 5 1 ] [ . 0 1 9 - . 0 4 3 ]
M 3 9 0 2 9 / 5 9a—3 . 8 1 – 5 . 9 4 3 . 1 0 – 4 . 3 2 1 . 5 2 – 3 . 8 4 . 4 8 – 1 . 0 9 22–24 D-602-0123 8 S C o a x i a l
[ . 1 5 0 - . 2 3 4 ] [ . 1 5 0 - . 1 7 0 ] [ . 0 6 0 - . 1 5 1 ] [ . 0 1 9 - . 0 4 3 ]
M 3 9 0 2 9 / 7 6a915304-1 1 . 2 7 – 2 . 6 2 1 . 6 8 – 2 . 1 3 . 9 1 – 1 . 7 3 . 2 3 – . 5 8 26–30 D-602-0140 16 P C o a x i a l
[ . 0 5 0 - . 1 0 3 ] [ . 0 6 6 - . 0 8 4 ] [ . 0 3 6 - . 0 6 8 ] [ . 0 0 9 - . 0 2 3 ]
M 3 9 0 2 9 / 7 7a915305-1 1 . 2 7 – 2 . 6 2 1 . 6 8 – 2 . 1 3 . 9 1 – 1 . 7 3 . 2 3 – . 5 8 26–30 D-602-0141 16 S C o a x i a l
[ . 0 5 0 - . 1 0 3 ] [ . 0 6 6 - . 0 8 4 ] [ . 0 3 6 - . 0 6 8 ] [ . 0 0 9 - . 0 2 3 ]
M 3 9 0 2 9 / 7 6a915304-2 — — . 6 4 – 1 . 0 9 . 2 3 – . 5 8 26–30 D-602-0142 16 P Twisted pair
[ . 0 2 5 - . 0 4 3 ] [ . 0 0 9 - . 0 2 3 ]
M 3 9 0 2 9 / 7 7a915305-2 — — . 6 4 – 1 . 0 9 . 2 3 – . 5 8 26–30 D-602-0143 16 S Twisted pair
[ . 0 2 5 - . 0 4 3 ] [ . 0 0 9 - . 0 2 3 ]
M 3 9 0 2 9 / 2 8a915307-1 1 . 4 7 – 3 . 1 0 1 . 6 8 – 2 . 3 9 1 . 1 2 – 2 . 0 3 . 4 8 – . 8 9 24–32 D-602-0144 12 P C o a x i a l
[ . 0 5 8 - . 1 2 2 ] [ . 0 6 6 - . 0 9 4 ] [ . 0 4 4 - . 0 8 0 ] [ . 0 1 9 - . 0 3 5 ]
M 3 9 0 2 9 / 7 5a915308-1 1 . 4 7 – 3 . 1 0 1 . 6 8 – 2 . 3 9 1 . 1 2 – 2 . 0 3 . 4 8 – . 8 9 24–32 D-602-0145 12 S C o a x i a l
[ . 0 5 8 - . 1 2 2 ] [ . 0 6 6 - . 0 9 4 ] [ . 0 4 4 - . 0 8 0 ] [ . 0 1 9 - . 0 3 5 ]
M 3 9 0 2 9 / 2 8a915307-3 — — . 7 4 – 1 . 4 5 . 4 8 – . 8 9 22–26 D-602-0146 12 P Twisted pair
[ . 0 2 9 - . 0 5 7 ] [ . 0 1 9 - . 0 3 5 ]
M 3 9 0 2 9 / 7 5a915308-3 — — . 7 4 – 1 . 4 5 . 4 8 – . 8 9 22–26 D-602-0147 12 S Twisted pair
[ . 0 2 9 - . 0 5 7 ] [ . 0 1 9 - . 0 3 5 ]
M 3 9 0 2 9 / 2 8a915307-2 1 . 9 0 – 3 . 8 1 2 . 5 4 – 2 . 9 7 1 . 2 7 – 2 . 6 2 . 4 8 – . 8 9 22, 28 D-602-0150 12 P C o a x i a l
[ . 0 7 5 - . 1 5 0 ] [ . 1 0 0 - . 11 7 ] [ . 0 5 0 - . 1 0 3 ] [ . 0 1 9 - . 0 3 5 ]
M 3 9 0 2 9 / 7 5a9 1 5 3 0 8 - 2 1 . 9 0 – 3 . 8 1 2 . 5 4 – 2 . 9 7 1 . 2 7 – 2 . 6 2 . 4 8 – . 8 9 22, 28 D-602-0151 12 S C o a x i a l
[ . 0 7 5 - . 1 5 0 ] [ . 1 0 0 - . 11 7 ] [ . 0 5 0 - . 1 0 3 ] [ . 0 1 9 - . 0 3 5 ]
—8340712-OS-01 2 . 4 9 – 3 . 4 2 1 . 6 8 – 3 . 0 5 . 7 6 – 1 . 2 4 . 2 7 – . 7 9 24–26 D - 6 0 2 - 1108 8 S Twisted pairb
[ . 0 9 8 - . 1 3 5 ] [ . 0 6 6 - . 1 2 0 ] [ . 0 3 0 - . 0 4 9 ] [ . 0 11 - . 0 3 1 ]
—8340713-OS-01 2 . 4 9 – 3 . 4 2 1 . 6 8 – 3 . 0 5 . 7 6 – 1 . 2 4 . 2 7 – . 7 9 24–26 D - 6 0 2 - 1109 8 P Twisted pairb
[ . 0 9 8 - . 1 3 5 ] [ . 0 6 6 - . 1 2 0 ] [ . 0 3 0 - . 0 4 9 ] [ . 0 11 - . 0 3 1 ]
— — 2 . 4 9 – 3 . 7 6 1 . 6 8 – 3 . 3 0 . 9 1 – 1 . 7 8 . 2 3 – . 8 9 22–26 D - 6 0 2 - 1110 8 S Tr i a x i a l
[ . 0 9 8 - . 1 4 8 ] [ . 0 6 6 - . 1 3 0 ] [ . 0 3 6 - . 0 7 0 ] [ . 0 0 9 - . 0 3 5 ]
— — 2 . 4 9 – 3 . 7 6 1 . 6 8 – 3 . 3 0 . 9 1 – 1 . 7 8 . 2 3 – . 8 9 22–26 D - 6 0 2 - 1111 8 P Tr i a x i a l
[ . 0 9 8 - . 1 4 8 ] [ . 0 6 6 - . 1 3 0 ] [ . 0 3 6 - . 0 7 0 ] [ . 0 0 9 - . 0 3 5 ]
—8340712-OL-01 2 . 4 9 – 3 . 4 2 1 . 6 8 – 3 . 0 5 . 7 6 – 1 . 2 4 . 2 7 – . 7 9 24–26 D - 6 0 2 - 1112 8 S Twisted pairb
[ . 0 9 8 - . 1 3 5 ] [ . 0 6 6 - . 1 2 0 ] [ . 0 3 0 - . 0 4 9 ] [ . 0 11 - . 0 3 1 ]
—8340713-OL-01 2 . 4 9 – 3 . 4 2 1 . 6 8 – 3 . 0 5 . 7 6 – 1 . 2 4 . 2 7 – . 7 9 24–26 D - 6 0 2 - 1113 8 P Twisted pairb
[ . 0 9 8 - . 1 3 5 ] [ . 0 6 6 - . 1 2 0 ] [ . 0 3 0 - . 0 4 9 ] [ . 0 11 - . 0 3 1 ]
M 3 9 0 2 9 / 9 0a8912020-OS-01 3.68 —. 6 4 – 1 . 2 9 . 2 7 – . 7 4 24–26 DK-602-0156-N-1 8 P Tw i n a x i a lc
[.145 ] Max. [ . 0 2 9 - . 0 5 1 ] [ . 0 11 - . 0 2 9 ]
M 3 9 0 2 9 / 9 0a8912020-DL-01 4 . 11 —. 6 4 – 1 . 2 9 . 2 7 – . 7 4 24–26 DK-602-0156-N-2 8 P Tw i n a x i a lc
[.162] Max. [ . 0 2 9 - . 0 5 1 ] [ . 0 11 - . 0 2 9 ]
a These SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination.
b These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B.
c These SolderTacts contacts are designed for databus contacts per MIL-STD-1553B.
SolderTacts Product Construction, MIL-C-38999 Series
SolderTacts Series:
MIL-C-38999, Series I, II,
III, IV Circular Connectors
Shielded Contacts
8-70
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact United States Cable Diameter (in inches) Raychem
Military Air Force Wire SolderTacts Size Polarity Cable Type
Specification Drawing No. JOD SOD DOD COD (AWG) Part Number
Series I, I I I , and IV
M 3 9 0 2 9 / 9 0a8912020-EL-01 4.50 max. — .74-1.30 . 2 4 - . 7 4 24–26 DK-602-0156-N-3 8 P Tw i n a x i a lc
[. 1 7 7 ] [ . 0 2 9 – . 0 5 1 ] [ . 0 11 – . 0 2 9 ]
M 3 9 0 2 9 / 9 1a8912019-OS-01 3.68 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-1 8 S Tw i n a x i a lc
[. 1 4 5 ] [ . 0 2 9 – . 0 5 1 ] [ . 0 11 – . 0 2 9 ]
M 3 9 0 2 9 / 9 1a8912019-DL-01 4.12 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-2 8 S Tw i n a x i a lc
[. 1 6 2 ] [ . 0 2 9 – . 0 5 1 ] [ . 0 11 – . 0 2 9 ]
M 3 9 0 2 9 / 9 1a8912019-EL-01 4.50 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-3 8 S Tw i n a x i a lc
[. 1 7 7 ] [ . 0 2 9 – . 0 5 1 ] [ . 0 11 – . 0 2 9 ]
M 3 9 0 2 9 / 9 0a8912020-OL-01 4.67 max. — — — 20 DK-602-0169-1 8 P Tw i n a x i a lc
[. 1 8 4 ]
M 3 9 0 2 9 / 9 1a8912019-OL-01 4.67 max. — — — 20 DK-602-0170-1 8 S Tw i n a x i a lc
[. 1 8 4 ]
Series II
M 3 9 0 2 9 / 7 6a915304-1 1.27-2.62 1.68-2.13 .91-1.73 .23-.58 26–30 D-602-0140 16 P C o a x i a l
[ . 0 5 0 – . 1 0 3 ] [ . 0 6 6 – . 0 8 4 ] [ . 0 3 6 – . 0 6 8 ] [ . 0 0 9 – . 0 2 3 ]
M 3 9 0 2 9 / 7 7a915306-1 1.27-2.62 1.68-2.13 .91-1.73 . 2 3 - . 5 8 26–30 D-602-0171 16 S C o a x i a l
[ . 0 5 0 – . 1 0 3 ] [ . 0 6 6 – . 0 8 4 ] [ . 0 3 6 – . 0 6 8 ] [ . 0 0 9 – . 0 2 3 ]
M 3 9 0 2 9 / 7 6a915304-2 — — . 6 4 - 1 . 0 9 .23-.58 26–30 D-602-0142 16 P Twisted pair
[ . 0 2 5 – . 0 4 3 ] [ . 0 0 9 – . 0 2 3 ]
M 3 9 0 2 9 / 7 7a915306-2 — — . 6 4 - 1 . 0 7 .23-.58 26–30 D-602-0174 16 S Twisted pair
[ . 0 2 5 – . 0 4 2 ] [ . 0 0 9 – . 0 2 3 ]
a These SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination.
b These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B.
c These SolderTacts contacts are designed for databus contacts per MIL-STD-1553B.
Engineering Convection
SolderTacts Part Numbers Standard (Hot Air) Heating Repair IR1004 Infrared Contact Contact
Series (D-602-) (Termination AT-1319 Wand Semiautomatic Insertion Removal
Instructions) Adapter Heater Tool Set Tool Tool*
999 0140/0141 ES61226 AT-1319-78 AD-1565 AT-1044-70 (P) M81969/8-07 M81869/8-08
Size 16 0142/0143 ES61224 — — AT-1044-69 (S) or or
0171 ES61226 AT-1319-27 AD-1572 — M81969/14-03 M81969/14-03
0174 ES61224 — — —
999 0144/0145 ES61206 AT-1319-24 AD-1566 AT-1044-72 (P) M81969/8-09 M81969/8-10
Size 12 0146/0147 ES61218 — — AT-1044-71 (S) or or
0150/0151 ES61223 — — — M81969/14-04 M81969/14-04
999
0122/0123 ES61179 AT-1319-22 AD-1568
Size 8
1108/1109 ES61172 — M81969/14-06
1110/1111 ES61172 AT-1319-22 AD-1568 or
1112/1113 ES61184 and and — — Astro ATBX-2277
0156/0157-X ES61231 AT-1319-14 AD-1480
0169/0170-X ES61235
*Tyco Electronics does not provide this tool. See connector manufacturer.
SolderTacts Series:
MIL-C-38999, Series I, II,
III, IV Circular Connectors
(Continued)
Tooling Selection Guide
Shielded Contacts
8-71
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Cable Diameter
SolderTacts Size Polarity Cable Type JOD SOD DOD COD (AWG)
D-602-0278 16 P Coaxial 1.52–2.92 1.85–2.18 .64–1.91 .23–.74 24–32
[.060-.115] [.073-.086] [.025-.075] [.009-.029]
D-602-0279 16 S Coaxial 1.52–2.92 1.85–2.18 .64–1.91 .23–.74 24–32
[.060-.115] [.073-.086] [.025-.075] [.009-.029]
D-602-0288 16 P Twisted pair — — .74–1.40 .23–.74 24–32
[.029-.055] [.009-.029]
D-602-0289 16 S Twisted pair — — .74–1.40 .23–.74 24–32
[.029-.055] [.009-.029]
*These SolderTacts contacts belong to the Raychem “Subminiature” series of contacts, which are designed for use in commercial connectors.
Tooling Selection Guide
Engineering Convection IR1004 infrared Contact Contact
SolderTacts Part Numbers Standard (hot air) Heating Removal Special
Series (D-602-) (Termination AT-1319 Repair Semiautomatic Insertion Tool Tools
Instructions) Adapter Wand Heater Tool Set Tool
Submin 0278/0279 ES61170 AT-1319-12 AD-1481 Tool Set #9 * AD-1447 AA-400-140
— 0288/0289 ES61414 — — (AT-1044-11) — — (magnifier)
*Not applicable.
SolderTacts Product Construction, Submin Series
SolderTacts Series:
Subminiature*
Raychem Cable Diameter
Shielded Contacts
8-72
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter
Military Wire Raychem Size Polarity Cable Type
Specification* JOD SOD DOD COD (AWG) SolderTacts
M39029/74-400 2.39–3.56 1.96–2.49 1.32–2.06 .28–.74 24–32 D-602-0094 12 P Coaxial
[.094-.140] [.077-.098] [.052-.081] [.011-.029]
M39029/73-397 2.39–3.56 1.96–2.49 1.32–2.06 .28–.74 24–32 D-602-0095 12 S Coaxial
[.094-.140] [.077-.098] [.052-.081] [.011-.029]
M39029/74-401 — — .74–1.45 .28–.74 24–32 D-602-0104 12 P Twisted pair
[.029-.057] [.011-.029]
M39029/73-398 — — .74–1.45 .28–.74 24–32 D-602-0105 12 S Twisted pair
[.029-.057] [.011-.029]
M39029/74-399 3.05–3.68 3.10–3.15 2.36–2.67 .28–.74 24–32 D-602-0106 12 P Large coaxial
[.120-.145] [.122-.124] [.093-.105] [.011-.029]
M39029/73-396 3.05–3.68 3.10–3.15 2.36–2.67 .28–.74 24–32 D-602-0107 12 S Large coaxial
[.120-.145] [.122-.124] [.093-.105] [.011-.029]
* These SolderTacts contacts are on qualified parts list for indicated specification.
Tooling Selection Guide
Engineering Convection
Raychem Standard (Hot Air) Heating Repair IR1004 infrared Contact Contact Special
SolderTacts (Termination AT-1319 Wand Semiautomatic Insertion Removal Tools
Part Number Instructions) Adapter Heater Tool Set Tool Tool
D-602-0094/0095 ES61128 AT-1319-19 AD-1494 AT-1044-67 (P) AD-1527 AD-1527 AD-1496
D-602-0106/0107 ES61134 Rev. D Rev. C AT-1044-68 (S) (M81969/14-04) (M81969/14-04) (twisted)
D-602-0104/0105 ES61129 — — — — — —
Raychem SolderTacts Size Polarity Cable Type Contact Military
Reference Specification
D-602-0185 16 socket Coaxial —
D-602-0094 12 pin Coaxial M39029/74
D-602-0093 12 socket Coaxial M39029/73
D-602-0106 12 pin Coax (large) M39029/74
D-602-0189 12 socket Coax (large) M39029/73
Raychem SolderTacts Size Polarity Cable Type Contact Military
Reference Specification
D-602-0186 8 pin Twisted pair M39029/96
D-602-0187 8 socket Twisted pair M39029/95
DK-602-0186-2 8 pin Sh. twisted pair M39029/96
DK-602-0187-2 8 socket Sh. twisted pair M39029/95
* These SolderTacts contacts are on designed for shielded twisted pair cable per MIL-STD-1553B.
SolderTacts Series:
MIL-C-83723
SolderTacts Series:
DOD-C-83527
SolderTacts Series: DOD-C-
83527 (data bus contacts)*
Shielded Contacts
8-73
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Raychem SolderTacts Size Polarity
Reference
D - 6 0 0 - 0 0 7 1 — For shielded twisted pair
D - 6 0 0 - 0 11 6 For size 8 DOD-C-83527 series —
D - 6 0 0 - 0 1 2 5 For size 8 MIL-C-38999 series, for twisted pair —
Performance
The performance of
SolderTacts contacts is
defined by the applicable
Raychem specification con-
trol drawing (SCD) and
Raychem Specification
D-6002. Products on quali-
fied product lists meet the
requirements of the base
specification.
Termination
Termination of SolderTacts
contacts is defined in the
appropriate Raychem
Engineering Standard.
To obtain a copy, contact
Tyco Electronics.
SolderTacts Series:
Grommets
Data Bus (MIL-STD-1553B) Components
8-74
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
The full line of Raychem
data bus products offers a
complete system of inter-
connection hardware for all
MIL-STD-1553B multiplexing
needs.
Available components
include:
■Couplers (micros, boxes,
flat packs)
■Data bus cables
■Triax connectors and
contacts with strain relief
■One-piece triaxial con-
tacts for MIL-C-38999
connectors (size 8 cavity)
■Bus and stub terminators
■Cable marker sleeves
(TMS)
■Lightweight couplers
(see pages 8-80 to 8-82)
■Space components
(see pages 8-93 to 8-95)
■Harness design
(HarnWare)
All Raychem data bus
components offer:
■High packaging density
and weight savings
■Design flexibility
■High performance
(to 150°C [302°F] rating)
Raychem MIL-STD-1553B
data bus components are
also specified in the
Air Force drawings listed in
Air Force Drawing 8340707.
Tyco Electronics also sup-
plies complete Raychem
data bus networks in
accordance with customer
harness drawings. Using
factory-built harnesses
eliminates unnecessary
splices and connectors,
reducing the cost and
increasing the reliability of
the networks. Factory-built
harnesses are pre-tested
and ready for installation.
8
Data Bus (MIL-STD-1553B) Components
8-75
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cables
Product Facts
■Light weight
■Highly flexible
■Flame resistant
■Chemical resistant to all
aircraft fluids
■Solder iron resistant
■Defined shielding levels
Applications
Tyco Electronics manufac-
tures a line of Raychem
SPEC 55 data bus cables
that meet or exceed the
performance requirements
of MIL-STD-1553B.
SPEC 55 insulation is a
high-temperature, radiation-
crosslinked, modified ETFE
material that can be used in
wire constructions rated up
to 200°C [392°F].
Note: Tyco Electronics will build
harnesses with any customer
specified cables and/or connectors.
Data Bus (MIL-STD-1553B) Components
8-76
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cables (Continued)
Cable Type Part No.
24 AWG Single Optimized Shield 10612
24 AWG Double Optimized Shield 10613
24 AWG EMPHardened 10614
24 AWG Flat Shield, Unfilled 7724 H 0664
Series Military
SPEC 55 insulation MIL-W-22759/32–/35
MIL-W-22759/41–/46
Specifications/Approvals
Product Selection
8
Data Bus (MIL-STD-1553B) Components
8-77
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub
Product Facts
■Environmental sealing
■No connectors
■Very small size
■Light weight (1 stub: 10 g
max.; 2 stubs: 15 g max.)
■In-line profile that makes
wire bundle mounting
possible
■360° continuous low-
impedance cable-shield
terminations
■Reliable solder termination
of all components
■Potted circuit elements for
maximum durability and in-
use reliability
■Ease of installation
■Altitude immersion
resistance
■Optional eyelet
configurations for bulkhead
mounting
■Mean time between failures
> 1,000,000 hours
Series Military Raychem
D-500-04 MIL-STD-1553B D-6020
Applications
The low-profile configuration
of these couplers enables
avionics system designers
to plan for optimum coupler
locations. Microcouplers are
supplied with Raychem
SPEC 55 data bus cables,
Specifications/Approvals
Available in:
Americas ■
Europe ■
Asia Pacific ■
including EMP-hardened
versions. They are also
available assembled with
other components into a
complete data bus harness.
Data Bus (MIL-STD-1553B) Components
8-78
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub (Continued)
Single Stub Double Stub
D-500-0455-1-YYY-ZZZ D-500-0455-2-YYY-ZZZ
D-500-0465-1-YYY-ZZZ D-500-0465-2-YYY-ZZZ
D-500-0456-1-YYY-ZZZ D-500-0456-2-YYY-ZZZ
D-500-0466-1-YYY-ZZZ D-500-0466-2-YYY-ZZZ
D-500-0457-1-YYY-ZZZ D-500-0457-2-YYY-ZZZ
D-500-0467-1-YYY-ZZZ D-500-0467-2-YYY-ZZZ
D-500-0458-1-YYY-ZZZ D-500-0458-2-YYY-ZZZ
D-500-0468-1-YYY-ZZZ D-500-0468-2-YYY-ZZZ
Note:
1. Bus cable
2. Stub cable
Product Selection
8
Data Bus (MIL-STD-1553B) Components
8-79
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub (Continued)
Microcoupler Part
Numbering System
Data Bus (MIL-STD-1553B) Components
8-80
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub
Applications
Building on over 20 years of
experience and continuous
improvement in data bus,
including pioneering
in-line microcouplers,
Tyco Electronics introduces
a new family of ultra light-
weight In-line Raychem
Microcouplers, available in
1- through 6-stub
configurations.
These couplers offer the
same high performance
and reliability as Raychem
current microcouplers, but
their weight is further
reduced. They are available
in configurations up to 6-
stub, and minimize weight
there is no option with a
mounting eyelet.
Combined with Raychem
24 AWG data bus cables,
these ultra light couplers
allow designers to signifi-
cantly reduce weight. An
unfilled flat braid cable is
available for additional
weight savings.
They are also available
assembled with other
customer specified compo-
nents into a complete
factory-built and tested
data bus harness.
Product Facts
■Environmental sealing
■No connectors
■Very small size
■Ultra Light weight
(1 stub: 6.5 g max.; 2 stubs:
9.5 g max.)
■In-line profile that makes
wire bundle mounting
possible
■360° continuous low-
impedance cable-shield
terminations
■Reliable solder termination
of all components
■Potted circuit elements for
maximum durability and
in-use reliability
■Ease of installation
■Altitude immersion
resistance
■Mean time between failures
> 1,000,000 hours
Specifications/approvals
Series Military Raychem
D-500-L4xx MIL-STD-1553B D-6020 (same as current microcouplers)
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-81
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued)
Lightweight In-Line
Couplers Part Numbering
System
Data Bus (MIL-STD-1553B) Components
8-82
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued)
D-500-L455-X-YYY-ZZZ D-500-L456-X-YYY-ZZZ
End View End View End View End View
Left Side Right Side Left Side Right Side
D-500-L457-X-YYY-ZZZ D-500-L458-X-YYY-ZZZ
End View End View End View End View
Left Side Right Side Left Side Right Side
1 stub
2 stub
3 stub
4 stub
5 stub
6 stub
1 stub
2 stub
3 stub
4 stub
5 stub
6 stub
1 stub
2 stub
3 stub
4 stub
5 stub
6 stub
1 stub
2 stub
3 stub
4 stub
5 stub
6 stub
Bus cable
Stub cable
Product Selection
Data Bus (MIL-STD-1553B) Components
8-83
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Box Couplers
Product Facts
■Light, robust coupler
modules with connector
versatility
■Up to eight stub connectors
can be arrayed on the “face”
of the box coupler. Bus
connectors can also be on
the “face” or on the “side”
of the box
■Designed with Raychem
D-621 series corrosion-
resistant threaded-type or
bayonet-type connectors
Series Military Raychem
D-500-0255 MIL-STD-1553 D-6021
Applications
The multiport capability of
these couplers (up to eight
stubs) enables avionics
system designers to inter-
connect black boxes with
minimum wire runs. Box
couplers are supplied with
Raychem triaxial threaded
or bayonet connectors.
Note: Tyco Electronics also designs
and manufactures customized
Raychem data bus box couplers.
Specifications/Approvals
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-84
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Box Couplers (Continued)
Part No.
Coupler Type Threaded Bayonet A* Bayonet B* Bayonet C*
Face - 1 Stub D-500-0255-511-1 D-500-0255-513-1 D-500-0255-515-1 D-500-0255-517-1
Face - 2 Stub D-500-0255-521-1 D-500-0255-523-1 D-500-0255-525-1 D-500-0255-527-1
Face - 3 Stub D-500-0255-531-1 D-500-0255-533-1 D-500-0255-535-1 D-500-0255-537-1
Face - 4 Stub D-500-0255-541-1 D-500-0255-543-1 D-500-0255-545-1 D-500-0255-547-1
Face - 5 Stub D-500-0255-551-1 D-500-0255-553-1 D-500-0255-555-1 D-500-0255-557-1
Face - 6 Stub D-500-0255-561-1 D-500-0255-563-1 D-500-0255-565-1 D-500-0255-567-1
Face - 7 Stub D-500-0255-571-1 D-500-0255-573-1 D-500-0255-575-1 D-500-0255-577-1
Face - 8 Stub D-500-0255-581-1 D-500-0255-583-1 D-500-0255-585-1 D-500-0255-587-1
Side - 1 Stub D-500-0255-512-1 D-500-0255-513-2 D-500-0255-515-2 D-500-0255-517-2
Side - 2 Stub D-500-0255-522-1 D-500-0255-523-2 D-500-0255-525-2 D-500-0255-527-2
Side - 3 Stub D-500-0255-532-1 D-500-0255-533-2 D-500-0255-535-2 D-500-0255-537-2
Side - 4 Stub D-500-0255-542-1 D-500-0255-543-2 D-500-0255-545-2 D-500-0255-547-2
Side - 5 Stub D-500-0255-552-1 D-500-0255-553-2 D-500-0255-555-2 D-500-0255-557-2
Side - 6 Stub D-500-0255-562-1 D-500-0255-563-2 D-500-0255-565-2 D-500-0255-567-2
Side - 7 Stub D-500-0255-572-1 D-500-0255-573-2 D-500-0255-575-2 D-500-0255-577-2
Side - 8 Stub D-500-0255-582-1 D-500-0255-583-2 D-500-0255-585-2 D-500-0255-587-2
*The bayonet polarization listed is for the bus connector. All stub connectors are Bayonet D polarization. Polarizations
are depicted as follows (jack view):
Product Selection
Data Bus (MIL-STD-1553B) Components
8-85
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Discrete Connectors
Product Facts
■Compliance with
MIL-STD-1553B hardware
requirements
■Light weight
■Removable pin or socket
contacts
■Termination with Raychem
MIL-STD-1553B data bus
cables, including EMP-
hardened versions
■Continuous 360° shield
coverage
■Rugged constructions
■Termination time of 1 to 2
minutes
■Inspectable solder
terminations
■Low-skill assembly
■Reworkable and repairable
terminations
■Strain relief built into the
design
■Low-voltage drop and high
reliability because of
precisely controlled solder
terminations
■Threaded and bayonet
coupling styles
■Low total installed cost
■1000-hour salt spray
resistance
■Lower-cost connectors, for
benchtop and mock-up
Series Military Raychem
DK-621 MIL-STD-1553B D-6025
Applications
Designed specifically for
MIL-STD-1553B data bus
applications, the D-621
connector is intended to be
a perfect match for the
Raychem airworthy data
bus cable. Together they
provide durable, reliable,
and reworkable intercon-
nection hardware for the
MIL-STD-1553B market.
Specifications/Approvals
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-86
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Discrete Connectors (Continued)
Connector Kit Part
Numbering System
Example:
DK-621-0434-1P = D-621
connector, kitted with
accessories, jack bayonet
style with A polarization and
pin contact.
Data Bus (MIL-STD-1553B) Components
8-87
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Accessories
Applications
Tyco Electronics manufac-
tures all the products
needed to build a MIL-STD-
1553B data bus network. In
addition to the main compo-
nents (couplers, connec-
tors, contacts, and cables),
Tyco Electronics supplies
the accessory components
that may be necessary to
complete a data bus
system.
These include:
■Bus and stub terminators
(spliced-in and connec-
torized D-621 series).
■Cable splice kits.
■EMI/environment-resistant
connector caps.
■Braid terminators and
strain relief tubing (for
rework applications).
■Cable marking materials.
Product Facts
■A single source for all
harness components
■Products designed to work
together
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-88
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Accessories (Continued)
Spliced-in 12-inch Cable
77-ohm 10612 cable D-500-0463-612
77-ohm 10613 cable D-500-0463-613
77-ohm 10614 cable D-500-0463-614
77-ohm 7724H0664 cable D-500-0463-H06
D-621 Series—Plug Threaded Bayonet A Bayonet B Bayonet C Bayonet D
77-ohm pin contact D-621-0413 D-621-0453 D-621-0454 D-621-0455 D-621-0456
77-ohm socket contact D-621-0415 D-621-0469 D-621-0470 D-621-0471 D-621-0472
3000-ohm pin contact D-621-0417 D-621-0457 D-621-0458 D-621-0459 D-621-0476
3000-ohm socket contact D-621-0407 D-621-0473 D-621-0474 D-621-0475 D-621-0460
D-621 Series—Jack Threaded Bayonet A Bayonet B Bayonet C Bayonet D
77-ohm pin contact D-621-0418 D-621-0477 D-621-0478 D-621-0479 D-621-0480
77-ohm socket contact D-621-0406 D-621-0461 D-621-0462 D-621-0463 D-621-0464
3000-ohm pin contact D-621-0423 D-621-0481 D-621-0482 D-621-0483 D-621-0484
3000-ohm socket contact D-621-0424 D-621-0465 D-621-0466 D-621-0467 D-621-0468
D-621 Series—L Lanyard 7” — — — —
D-621 Series Threaded Bayonet A Bayonet B Bayonet C Bayonet D
Plug cap for jack connector D-600-0083 D-600-0068 D-600-0068 D-600-0068 D-600-0065
Supplied with 7” Lanyard
Cables Flexible Crimp
All data bus cables D-150-0708-5
D-621 Plug D-621 Jack
Splice-in
Bus and Stub Terminators
Product Selection
Connector Caps
Cable Splice Kits
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-89
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Panel Connector Contact Terminator Mate with
Thickness Reference Standard Connector Long ReachConnector
Bayonet Connectors
Polarity A Plug Pin D-621-0453(-L) DK-621-0434-1S DK-621-0550-1S
77 Ohm bus Plug Socket D-621-0469(-L) DK-621-0434-1P DK-621-0550-1P
terminator Jack Pin D-621-0477(-L) DK-621-0433-1S —
Jack Socket D-621-0461(-L) DK-621-0433-1P —
Plug Pin D-621-0457(-L) DK-621-0434-1S DK-621-0550-1S
3K Ohm stub Plug Socket D-621-0473(-L) DK-621-0434-1P DK-621-0550-1P
terminator Jack Pin D-621-0481(-L) DK-621-0433-1S —
Jack Socket D-621-0465(-L) DK-621-0433-1P —
Polarity B Plug Pin D-621-0454-(-L) DK-621-0436-2S DK-621-0548-2S
77 Ohm bus Plug Socket D-621-0470-(-L) DK-621-0436-2P DK-621-0548-2P
terminator Jack Pin D-621-0478-(-L) DK-621-0435-2S —
Jack Socket D-621-0462-(-L) DK-621-0435-2P —
Plug Pin D-621-0458-(-L) DK-621-0436-2S DK-621-0548-2S
3K Ohm stub Plug Socket D-621-0474-(-L) DK-621-0436-2P DK-621-0548-2P
terminator Jack Pin D-621-0482-(-L) DK-621-0435-2S —
Jack Socket D-621-0466-(-L) DK-621-0435-2P —
Polarity C Plug Pin D-621-0455(-L) DK-621-0438-3S DK-621-0546-3S
77 Ohm bus Plug Socket D-621-0471(-L) DK-621-0438-3P DK-621-0546-3P
terminator Jack Pin D-621-0479(-L) DK-621-0437-3S —
Jack Socket D-621-0463(-L) DK-621-0437-3P —
Plug Pin D-621-0459(-L) DK-621-0438-3S DK-621-0546-3S
3K Ohm stub Plug Socket D-621-0475(-L) DK-621-0438-3P DK-621-0546-3P
terminator Jack Pin D-621-0483(-L) DK-621-0437-3S —
Jack Socket D-621-0467(-L) DK-621-0437-3P —
Polarity D Plug Pin D-621-0456(-L) DK-621-0440-4S DK-621-0551-4S
77 Ohm bus Plug Socket D-621-0472(-L) DK-621-0440-4P DK-621-0551-4P
terminator Jack Pin D-621-0480(-L) DK-621-0439-4S —
Jack Socket D-621-0464(-L) DK-621-0439-4P —
Plug Pin D-621-0460(-L) DK-621-0440-4S DK-621-0551-4S
3K Ohm stub Plug Socket D-621-0476(-L) DK-621-0440-4P DK-621-0551-4P
terminator Jack Pin D-621-0468(-L) DK-621-0439-4S —
Jack Socket D-621-0484(-L) DK-621-0439-4P —
Threaded Connectors Plug Pin D-621-0413(-L) DK-621-0412-S DK-621-0512-S
77 Ohm bus Plug Socket D-621-0415(-L) DK-621-0412-P DK-621-0512-P
terminator Jack Pin D-621-0418(-L) DK-621-0411-S —
Jack Socket D-621-0406(-L) DK-621-0411-P —
Plug Pin D-621-0417(-L) DK-621-0412-S DK-621-0512-S
3K Ohm stub Plug Socket D-621-0407(-L) DK-621-0412-P DK-621-0512-P
terminator Jack Pin D-621-0423(-L) DK-621-0411-S —
Jack Socket D-621-0424(-L) DK-621-0411-P —
Terminator and Connector
and Compatibility —
Bayonet and Threaded
Connectors
Panel Connector Contact Connector Mate with
Thickness Reference Connector 77 Ohm Bus Terminator 3K Ohm Stub Terminator
Bayonet Connectors
Polarity A Plug Pin DK-621-0433-1P DK-621-0434-1S D-621-0461(-L) D-621-0465 (-L)
Plug Socket DK-621-0433-1S DK-621-0434-1P D-621-0477(-L) D-621-0481(-L)
Standard Jack Pin DK-621-0434-1P DK-621-0433-1S D-621-0461(-L) D-621-0473(-L)
2.4mm max. Jack Socket DK-621-0434-1S DK-621-0433-1P D-621-0453(-L) D-621-0457(-L)
Long Reach Jack Pin DK-621-0550-1P DK-621-0433-1S D-621-0469(-L) D-621-0473(-L)
12.5mm max. Jack Socket DK-621-0550-1S DK-621-0433-1P D-621-0453(-L) D-621-0457(-L)
Polarity B Plug Pin DK-621-0435-2P DK-621-0436-2S D-621-0462(-L) D-621-0474 (-L)
Plug Socket DK-621-0435-2S DK-621-0436-2P D-621-0478(-L) D-621-0458(-L)
Standard Jack Pin DK-621-0436-2P DK-621-0435-2S D-621-0470(-L) D-621-0474(-L)
2.4mm max. Jack Socket DK-621-0436-2S DK-621-0435-2P D-621-0454(-L) D-621-0458(-L)
Long Reach Jack Pin DK-621-0448-2P DK-621-0435-2S D-621-0470(-L) D-621-0467(-L)
12.5mm max. Jack Socket DK-621-0448-2S DK-621-0435-2P D-621-0454(-L) D-621-0483(-L)
Polarity C Plug Pin DK-621-0437-3P DK-621-0438-3S D-621-0463(-L) D-621-0467(-L)
Plug Socket DK-621-0437-3S DK-621-0438-3P D-621-0479(-L) D-621-0483(-L)
Standard Jack Pin DK-621-0438-3P DK-621-0437-3S D-621-0471(-L) D-621-0475(-L)
2.4mm max. Jack Socket DK-621-0438-3S DK-621-0437-3P D-621-0455(-L) D-621-0459(-L)
Long Reach Jack Pin DK-621-0446-3P DK-621-0437-3S D-621-0471(-L) D-621-0475(-L)
12.5mm max. Jack Socket DK-621-0446-3S DK-621-0437-3P D-621-0455(-L) D-621-0459(-L)
Polarity D Plug Pin DK-621-0439-4P DK-621-0440-4S D-621-0464(-L) D-621-0468(-L)
Plug Socket DK-621-0439-4S DK-621-0440-4P D-621-0480(-L) D-621-0484(-L)
Standard Jack Pin DK-621-0440-4P DK-621-0439-4S D-621-0472(-L) D-621-0476(-L)
2.4mm max. Jack Socket DK-621-0440-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L)
Long Reach Jack Pin DK-621-0551-4P DK-621-0439-4S D-621-0472(-L) D-621-0476(-L)
12.5mm max. Jack Socket DK-621-0551-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L)
Threaded Connectors Plug Pin DK-621-0411-P DK-621-0412-S D-621-0406(-L) D-621-0424(-L)
Plug Socket DK-621-0411-S DK-621-0412-P D-621-0418(-L) D-621-0423(-L)
Standard Jack Pin DK-621-0412-P DK-621-0411-S D-621-0415(-L) D-621-0407(-L)
2.4mm max. Jack Socket DK-621-0412-S DK-621-0411-P D-621-0413(-L) D-621-0417(-L)
Long Reach Jack Pin DK-621-0412-P DK-621-0411-S D-621-0415(-L) D-621-0407(-L)
12.5mm max. Jack Socket DK-621-0412-S DK-621-0411-P D-621-0413(-L) D-621-0417(-L)
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-90
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Triaxial Connectors and
Terminator Compatibility —
Bayonet and Threaded
Connectors
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-91
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Triaxial Connectors and
Terminator Compatibility —
to European norme 3716
Panel Connector Contact Connector Mate with
Thickness Reference Connector 77 Ohm Bus Terminator 3K Ohm Stub Terminator
Triaxial Connectors Plug Pin DK-3716-F101-TP DK-621-E102-TS D-621-E077-S D-621-E03K-S
Plug Socket DK-3716-F101-TS DK-621-E102-TP D-621-E077-P D-621-E03K-P
Plug Pin DK-3716-F201-TP DK-621-E202-TS D-621-E077-S D-621-E03K-S
Plug Socket DK-3716-F201-TS DK-621-E202-TP D-621-E077-P D-621-E03K-P
Jack Pin DK-3716-E102-TP DK-621-F101-TS D-621-F077-S D-621-F03K-S
Standard Jack Socket DK-3716-E102-TS DK-621-F101-TP D-621-F077-P D-621-F03K-P
2.4mm max. Jack Pin DK-3716-E202-TP DK-621-F201-TS D-621-F077-S D-621-F03K-S
Jack Socket DK-3716-E202-TS DK-621-F201-TP D-621-F077-P D-621-F03K-P
Jack Pin DK-3716-E112-TP DK-621-F101-TS D-621-F077-S D-621-F03K-S
Long Reach Jack Socket DK-3716-E112-TS DK-621-F101-TP D-621-F077-P D-621-F03K-P
12.5mm max. Jack Pin DK-3716-E212-TP DK-621-F201-TS D-621-F077-S D-621-F03K-S
Jack Socket DK-3716-E212-TS DK-621-F201-TP D-621-F077-P D-621-F03K-P
Panel Connector Contact Terminator Mate with
Thickness Reference Standard Connector Long ReachConnector
Terminators Plug Pin DK-3716-F077-P DK-3716-E#02-TS DK-3716-E#12K-TS
77 Ohm bus Plug Socket DK-3716-F077-S DK-3716-E#02-TP DK-3716-E#12K-TP
terminator Jack Pin DK-3716-F077-P DK-3716-E#01-TS —
Jack Socket DK-3716-F077-S DK-3716-E#01-TP —
Plug Pin DK-3716-E03K-P DK-3716-E#02-TS DK-3716-E#12K-TS
3K Ohm stub Plug Socket DK-3716-E03K-S DK-3716-E#02-TP DK-3716-E#12K-TP
terminator Jack Pin DK-3716-E03K-P DK-3716-E#01-TS —
Jack Socket DK-3716-E03K-S DK-3716-E#01-TP —
Data Bus (MIL-STD-1553B) Components
8-92
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Triaxial Size 8 Contacts
Applications
Contacts provide full shield
coverage with a simple,
quick, and reliable termina-
tion system. 24 AWG twist-
ed-pair data bus cables
are terminated with triaxial
SolderTacts contacts,
which fit size 8 cavities of
MIL-C-38999, Series 1, 3,
or 4 connectors.
Raychem size 8 triaxial
data bus contacts for
MIL-C-38999 connectors
have interfaces that comply
with MIL-C-39029/90 and
/91 to provide ease of termi-
nation, and intermateability
with more cumbersome
crimp contacts.
Product Facts
■One-step termination
■Termination time of 1 to 2
minutes
■No requirements for special
termination tools
■No requirements for special
skills
■Reworkable and repairable
terminations
■Strain relief
■Continuous 360° shield
coverage
■Triaxial mating face for least
susceptibility to damage
■Rugged construction,
because only two parts are
being soldered together
■Inspectable solder
terminations
■Low voltage drop and high
reliability due to precisely
controlled solder
termination
Series Raychem
Size 8 D-6002
Cable Type Pin Socket
10612 DK-602-0156-N-1 DK-602-0157-N-1
10613 DK-602-0156-N-2 DK-602-0157-N-2
10614 DK-602-0156-N-3 DK-602-0157-N-3
Specifications/Approvals
Product Selection
These contacts provide
a fast and convenient
method of implementing
MIL-STD-1553B connec-
tions in MIL-STD-1760
applications.
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-93
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Space-Grade Data Bus Components
Applications
Tyco Electronics full line of
Raychem data bus prod-
ucts includes space-grade
couplers, terminators,
triaxial connectors, and
SolderShield splices. These
space-grade components
meet the low outgassing
requirements of NASA
specification SP-R-0022A
and can be used in outer-
space applications.
Raychem space-grade
components are designed
in a variety of configurations
and are currently available
either as discrete items or
as Raychem- assembled
harnesses. Using factory-
built harnesses eliminates
unnecessary splices and
connectors, reducing the
cost and increasing the
reliability of the networks.
Specification control draw-
ings describe the design
features and performance
characteristics of Raychem
space-grade couplers,
terminators, connectors,
and splices. The space-
grade data bus couplers,
terminators, and connectors
have tin/nickel-plated metal-
lic parts and baked silicone
rubber components. For
strain relief they include
low-outgassing tubing.
Unlike parts intended for
aircraft applications, these
components do not have
polymeric environmental
covers.
The table on the next page
lists Raychem standard
space-grade data bus
components with their part
numbers and descriptions.
New components will
become available per
customer request.
Figure 1. In-line couplers and
terminators
Figure 2.Threaded triaxial
connectors
Figure 3. Bayonet triaxial
connectors
Figure 4. Splice kit
Product Facts
■Complete line of space-
qualified MIL-STD-1553B
components
■Low outgassing levels that
meet NASA requirements
■Light weight
■Rugged construction
Available in:
Americas ■
Europe ■
Asia Pacific ■
Data Bus (MIL-STD-1553B) Components
8-94
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Space-Grade Data Bus Components (Continued)
Series Raychem
Space-grade data bus components D-6022
Space-Grade In-Line Coupler
Part Numbering System
Specifications/Approvals
Data Bus (MIL-STD-1553B) Components
8-95
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Space-Grade Data Bus Components (Continued)
Space-Grade Connectors
Part Numbering System
Space-Grade Terminators
Part Numbering System
Space-Grade Splice Kit =
D-150-9708-5
Data Bus (MIL-STD-1553B) Components
8-96
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Customer-Specified Harness Assemblies and HarnWare Harness Design Software
Sample Drawing
Tyco Electronics supplies
complete Raychem data
bus networks in accordance
with customer harness
drawings, with any cus-
tomer-specified cables
and/or connectors. Using
factory-built harnesses
eliminates unnecessary
splices and connectors,
reducing the cost and
increasing the reliability of
the networks. Factory-built
harnesses are pre-tested
and ready for installation.
HarnWare Harness Design
Software allows designers
to draw a data bus harness
in a matter of minutes, while
selecting Raychem or oth-
ers’ components; a bill of
materials is automatically
generated.
Parts List
Item Description Part No. Spec/Remarks Qty Unit
1 Data bus Cable 10613-9 Raychem 5.3 M
2 Data bus Cable 10613-96 Raychem 7 M
3 Data bus Coupler D-500-0455-1 Raychem 1 Pc
4 Data bus Coupler D-500-0455-2 Raychem 1 Pc
5 Data bus Coupler D-500-0457-1 Raychem 1 Pc
6 Data bus Terminator D-621-0469-L Raychem 1 Pc
7 Data bus Contact DK-602-0156-N-2 Raychem 1 Pc
8 Data bus Contact DK-602-0157-N-2 Raychem 1 Pc
9 Data bus Connector DK-621-0411-P Raychem 1 Pc
10 Data bus Connector DK-621-0412-P Raychem 1 Pc
11 Data bus Connector DK-621-0434-1P Raychem 1 Pc
12 Marker Sleeve TMS-SCE-3/16-2.0-9 Raychem 6 Pc
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC/EMI Adapters
8-97
8
Introduction
Applications
Tyco Electronics, a longtime
leader in harnessing tech-
nology, has written a new
chapter in EMC shielding
with the introduction of the
Raychem HexaShield EMC
adapter.
Designed to provide EMC
protection solutions for both
commercial and military
applications, HexaShield
adapters represent a signifi-
cant improvement over pig-
tail termination methods. By
providing 360-degree EMC
shielding on the termination
area of each individual
cable, HexaShield adapters
provide outstanding shield-
ing effectiveness.
HexaShield adapters are
simple to install, easy to
■Weight reduction, by pos-
sibly eliminating the need
for overall shielding.
■Compact size - not
exceeding outer diameter
of connector.
■Available in straight, 45°
and 90° angles, as well as
swept and long bodies.
Simple assembly and installa-
tion
1. Solder cable or wire
shield to a ferrule with a
Raychem heat-shrinkable
SolderShield terminator.
2. Clip ferrule into one of the
grounding star cavities.
3. Secure the back nut of
the HexaShield adapter
so that the conic ring
assembly automatically
compresses the ferrules.
maintain, and dependably
resistant to mechanical and
environmental stresses.
Principal points and features
■Easy reentry: To insert or
remove ferrules from the
HexaShield adapter, sim-
ply loosen the back nut.
■Superior protection: No
degradation of shielding
performance.
■Up to four shielded
cables accommodated
by each ferrule.
■Mechanical and environ-
mental protection equal to
backshells complying
with MIL-C-85049
Category 3B.
■Strain relief on each
individual cable.
Two Platings Available Raychem Product Specifications
Electroless nickel (MIL-DTL-26074) RB-110 and RB-114
Olive drab cadmium —
(QQ-P-416 Type II Class 3)
*Contact Tyco Electronics for additional platings.
Installation procedure for HET-A-02X Installation procedure for HET-03X General procedure for cylindrical
and HET-A-04X (RPIP-696-00) (RPIP-696-03) connectors, right-angle body
(RPIP-696-07)
General procedure for ARINC 600 Size II General procedure for cylindrical
connectors (RPIP-696-01) connectors, straight body (RPIP-696-04) —
General procedure for ARINC 600 Size III — —
connectors (RPIP-696-02)
Product Facts
■Superior EMC/EMI Shielding
Performance
■Simple installation
■Easy reentry
■Simplified maintenance and
repair
■Excellent mechanical and
environmental resistance
■Efficient strain relief
■Flexibility
■Versatility
Designed to corresponding
connector specifications.
Installation Procedures
Available in:
Americas ■
Europe ■
Asia Pacific ■
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC/EMI Adapters
8-98
Kit Descriptions
Item Description
1 Straight adapter assembly
2 Conic ring assembly
Star
3Plain (Standard)
Drilled (Option)
Split (Option) _
4Straight adapter assembly - “L” version
- nominally 0.5" [12.7] longer body
5 45° adapter assembly - welded
6 45° adapter assembly - swept
7 90° adapter assembly - welded
90° adapter assembly - swept
8 Standard products shown.
Variants available on request.
Split star assemblies are shown
on relevant S.C.D’s where applicable.
Item HexaShield Version
-1 Back Nut
-2 Tinel adapter assembly
Tinel-Lock ring for single braid
-3 Bandstrap adapter assembly
-C Conduit adapter
Item Description
1 Left side support
2 Right side support
3 Retention bars
Body assemblies
Body
4Holding nut
Conic ring assembly
Star _
Back nut
Cavity plug assemblies
5 Plug
Holding nut
6 Pan head screws - 4-40 UNC
7 Spring washers
ARINC 600 Size 2 shown
Stars are available as plain, drilled or split.
See relevant S.C.D’s for further information
Hexashield Adapters for
Circular Connectors:
Straight, 45°and 90°
Assemblies
HexaShield Adapters for
ARINC 404/600 Connectors:
Sizes 1, 2, 3 and 4
Assemblies
1
2
3
c
1
2
3
4
56
78
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-99
8
Ordering Information
Part Numbering for
Standard Products
HexaShield Adapter for
Circular Connectors
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-100
Ordering Information (Continued)
HexaShield Adapter for
Collins Connectors
HexaShield Adapter for
ARINC 600 Connectors
Part Numbering of Ferrule
Kits*
*Not all part numbers are standard; your local Tyco Electronics representative will assist you in selecting the
appropriate standard product
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-101
8
EMC Performance
Transfer Impedance
Protection Level
Generalized system per-
formance (Actual system
performance in any one
test method may differ.)
HexaShield size: 23
Cable: Raychem 5024H8424
(one cable installed)
Test method: CEI 96-1
Product Facts
■Outperforms traditional
pigtail termination,
especially in HIRF
performance
■Withstands 10-kA peak
current lightning transients
of SAE AE4L-87-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-102
EMC Performance (Continued)
Civilian and military aircraft
Avionics
Fighter aircraft
Missiles and launch support systems
Armored and military support vehicles
Navy ships (total shipboard hardening)
Military communications
Engines (FADEC harness hardening)
Accommodates the following connector types*:
MIL-C-26482 Series 1
MIL-DTL-38999 Series 1, 2, 3, and 4
MIL-C-26482 Series 2
MIL-DTL-83723 Series 1 and 3
DBAD
ARINC 600
ARINC 404
*Please contact Tyco Electronics for other connector types and special
requests.
Typical HexaShield
Applications
HexaShield Product Range
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-103
8
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
System
The Raychem MTC product
line is a complete modular
connector system consist-
ing of lightweight, environ-
mentally sealed miniature
rectangular connectors
(shell housings with remov-
able inserts) and individually
removable rear-release
contacts.
Components
MTC connectors are
now available with quick-
disconnect mating hard-
ware, EME shielding acces-
sories, and modular inserts
that can accommodate a
mix of signal and power
crimp contacts and coaxial
contacts. The need for spe-
cial termination tooling has
been minimized, while the
ease of manufacturing and
maintenance has been
improved.
Configurations
MTC rectangular connectors
using jack screws or quick-
disconnect hard w a re can be
stacked or panel-mounted
next to each other without
any provision for grip
space, a feature that can
save significant panel area.
MTC connectors are avail-
able in 1-inch and 2-inch
configurations. Modular
removable inserts with size
22 and/or size 16 contact
cavities can be combined
into the 1-inch and 2-inch
MTC housings.
Inserts
MTC inserts are available
in 20-cavity and 5-cavity
versions. The 20-cavity
insert accepts size 20-22
(24 AWG to 20 AWG wire)
crimp contacts. The
5-cavity insert accepts size
16–14 crimp contacts.
Insertion/extraction of the
contacts is rear release.
Note:
Other configurations are available
in the MTC family (size 12 contacts;
50 mil spacing for double density;
accessories). Please contact
Tyco Electronics.
Product Facts
■Low-profile rectangular
design for high packaging
density
■Environmental sealing for
aerospace applications
■Modular components for
design versatility and
logistics savings
■Lightweight materials for
weight savings
■Quick-disconnect mating
hardware
Available in:
Americas ■
Europe ■
Asia Pacific ■
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-104
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
20-Cavity Inserts
Pin Insert Socket Insert
MTCP-122-20P1 MTCP-122-20S1
MTCP-122-20P2 MTCP-122-20S2
2-inch shell with inserts
MTCP-122-20 inserts are used with MTC100 1-inch and 2-inch shells.
The 1-inch shell takes:
■One MTCP-122-20P (pin contact) or
■One MTCP-122-20S (socket contact)
The 2-inch shell takes:
■One MTCP-122-20P1 and one MTCP-122-20P2 (pin contact) or
■One MTCP-122-20S1 and one MTCP-122-20S2 (socket contact)
2 x 20 Cavity Inserts
(Size 20–22)—2-Inch Shell
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-105
8
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
20-Cavity Inserts (Continued)
Pin Insert Socket Insert
MTCP-122-20P MTCP-122-20S
Contacts for 20-Cavity Inserts
The contacts for 20-cavity inserts must be ordered separately. They are:
■CTA-0166—pin contact
■CTA-0165—socket contact
Contacts accept 24 AWGto 20 AWGwires.
Tools Tools
Positioner for pin contact CE-1605900 Positioner for socket contact CE-1606000
Installation process ES-61413 Installation process ES-61413
Contact removal tool (plastic) CTA-1160 Contact removal tool (plastic) CTA-1160
Extraction tool for MTCPinserts CTA-0161 Extraction tool for MTCPinserts CTA-0161
1-inch shell with insert
1 x 20 Cavity Inserts (Size
20–22)—1-Inch Shell
Pin Contact
CTA-0166 Socket Contact
CTA-0165
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-106
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
5-Cavity Inserts
5-Cavity Inserts (Size 16)
Pin Insert Socket Insert
MTCP-116-05P1 MTCP-116-05S1
MTCP-116-05P2 MTCP-116-05S2
The contacts for 5-cavity inserts must be ordered separately. They include:
■CTA-0079 - pin contact (MS 27493-16) (MIL-C-39029/58 intermateable)
■CTA-0078 - socket contact (MS 27491-16) (MIL-C-39029/57 intermateable)
■D-602-0140 - coaxial pin contact (MIL-C-39029/76 intermateable)
■D-602-0171 - coaxial socket contact (MIL-C-39029/78 intermateable)
Other contacts designed for M38999 Series II connectors can be used.
Pin Contact Socket Contact
D-602-0140 (coaxial) D-602-0171 (coaxial)
CTA-0079 (power) CTA-0078 (power)
MTCP-116-05 inserts are used with MTC100 1-inch and 2-inch shells.
The 1-inch shell takes:
■One MTCP-116-05-P1 (pin contact) or
■One MTCP-116-05-S1 (socket contact)
The 2-inch shell takes:
■One MTCP-116-05P1 and one MTC-116-05P2 (pin contact) or
■One MTCP-116-05-S1 and one MTCP-116-05-S2 (socket contact)
5-Cavity Inserts (Size 16)
Contacts for 5-Cavity
Inserts
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-107
8
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Hybrid Inserts
Hybrid insert combinations of size 22 and size 16 contact cavities are also possible.
2-Inch Shell—Hybrid Assembly
Power and signal
Shells
MTC connector housing
shells are available with
nickel plating (48-hr salt
spray performance) or
cadmium over nickel
plating (500-hr salt spray
performance).
MTC connector housings
are offered with quick-
disconnect or jack-screw
mating hardware. Each
connector shell is polarized
and has 64 user-defined
keying combinations.
Lightweight, low-profile
EME backshells are also
available for increased
shielding effectiveness of
the connector.
ReceptaclePlug
Hybrids
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-108
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
MTC Shells Ordering Information
*Some combinations of shells, mating hardware and EMEshielding accessories are not available.
Contact Tyco Electronics for product information.
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-109
8
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Accessories
Low-Profile EME Backshells
Lightweight rectangular
EME backshells connect
the overall bundle shield to
the MTC connector hous-
ing. Individual cable shields
can also be terminated to
the backshell braid by
using Raychem
SolderSleeve devices.
The backshell is mounted
on the MTC housing via the
cable clamp screws.
MTC backshell features
include a low profile, light
weight, and Level II EME
performance.
EME Backshell Adapters
CHA-0275 2-inch adapter
(plug or recep-
tacle)
CHA-0276 1-inch adapter
(plug or recep-
tacle)
MTC Shield-Grounding
BusBars
Raychem MTC shield-
grounding busbars allow for
simple, cost-effective termi-
nation of cable shielding to
MTC aluminum housings.
Two-inch shield-grounding
busbars terminate up to 20
shielded twisted pairs on a
2-inch MTC connector. The
individual shields are termi-
nated to “fingers” on the
busbar with Raychem
SolderSleeve devices.
The busbar is mounted on
the MTC housing via cable
clamp screws.
MTC busbar features
include a simple termina-
tion, cost effectiveness, light
weight, and Level I EME
performance.
EME Shielding Accessories for
MTC Connectors
Grounding Block
Allows for cable shield ter-
mination grounding on the
MTC shell housing via
crimp-removable contacts.
This grounding scheme
allows individual cables to
be removed from the con-
nector without cutting a
ganged ground connection.
Sufficient ground contacts
are available to handle
shielded twisted-pair
cables.
Grounding Block
CHA-0301 1-inch ground-
ing block recep-
tacle shell
CHA-0302 2-inch ground-
ing block recep-
tacle shell
CHA-0303 1-inch ground-
ing block plug
shell
CHA-0304 2-inch ground-
ing block plug
shell
Shield-Grounding Busbars
CTA-0022 1-inch busbar
(with 5
SolderSleeve
terminators)
CTA-0023 2-inch busbar
(with 10
SolderSleeve
terminators)
8-110
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Electrical Interconnect Products
Engineering Notes
