Electrical Interconnect Products Table of Contents Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 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 8 8-1 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Introduction Tyco Electronics' dependable, economical wire and cable termination products provide solutions for hundreds of wire and cable interconnect requirements. All Raychem wire termination products are housed inside transparent heatshrinkable 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 highreliability joints on the widest variety of conductor types and platings. Typical SolderSleeve Device (illustration of shield terminator concept) Transparent, heat-shrinkable thermoplastic sleeve 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, strainrelieved, protected solder connection. Heat-shrinkable tubing provides the benefits of insulation, strain relief, and protection for our controlled crimp products. Many Raychem interconnect products have earned UL recognition or MIL-Spec approval. Raychem interconnect devices combine highstrength 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 sophisticated electronic systems, either sealed or unsealed, and for high- or lowtemperature environments. Thermoplastic sealing ring Optional preinstalled wire lead Fluxed solder preform Typical Installation 1. Insert prepared cable Solder preform melts and flows, Installation quality is fully visible through transparent sleeve 2. Apply heat Sleeve shrinks, conforms to cable contours, and provides strain relief Sealing rings melt to provide environmental protection 8-2 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Product Selection Application Type Wire-to-wire splicing Terminals and disconnects Wire termination to pin/post/tab Shield termination Coaxial cable termination Cable-to-cable splicing Shielded contacts Triax connectors MIL-STD-1553 Data bus connectors MIL-STD-1553 In-line couplers MIL-STD-1533 Max. Operating Temp. 125C [257F] 150C [302F] Connection Type Solder Solder Product Description Series CWT-900X D-110, D-1744 SGRP, SGRS 8-12 D-406 D-436 (M81824) 8-18 8-20 B-106 8-25 Coil and solder Solder SolderSleeve wire splices SolderSleeve wire splices SolderGrip closed end connector splices (stub) DuraSeal crimp splices MiniSeal crimp splices DuraSeal crimp terminals and disconnects SolderGrip terminals SolderSleeve wire terminators Page Number 8-6 8-6 125C [257F] Coil and solder 125C [257F] 150C [302F] Crimp Crimp 125C [257F] Crimp 150C [302F] 125C [257F] 8-31 8-37 150C [302F] Solder SolderSleeve wire terminators 125C [257F] Solder SolderSleeve shield terminators 150C [302F] Solder SolderSleeve shield terminators 175C [347F] 125C [257F] 150C [302F] 150C [302F] 135C [275F] 150C [302F] 150C [302F] 150C [302F] 150C [302F] 150C [302F] Solder Solder Solder Solder Solder Solder/Crimp Solder Solder Solder Solder Solder or connectorized Connectorized SolderSleeve shield terminators SolderSleeve coaxial cable terminators SolderSleeve coaxial cable terminators SolderSleeve PCB/coaxial cable terminators RF one-step BNC/TNC connectors SolderShield cable splices SolderTacts shielded contacts Triax discrete connectors Triax discrete connectors Triax discrete connectors In-line data bus microcoupler Data bus box couplers SGRT CWT-15XX D-129, D-141, D-71X CWT-X S01, S02, M83519, SO63 SO96 CWT-4XXX B-02X, B-04X D-607, B-046 RBD, RTD D-150 D-602 D-621, DK-621 D-621, DK-621 D-621, DK-621 150C [302F] 150C [302F] 8-37 8-42 8-42 8-42 8-49 8-49 8-51 8-53 8-60 8-65 8-85 8-85 8-85 D-500-04 8-77 D-500-025 8-83 Triaxial size 8 contacts 150C [302F] Solder Size 8, triaxial MIL-C-38999 contacts D-602, DK-602 8-92 Data bus cables 150C [302F] 8-75 150C [302F] MIL-STD-1553 B shielded cable MIL-STD-1553 78 and 3000 terminators 1061X Data bus terminators D-621, D-500 8-87 Data bus accessories 150C [302F] Crimp or solder Solder or connectorized Solder or mechanical Dust caps, braid terminators, splices D-600,D-150 8-87 8 8-3 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Product Selection (Continued) Application Type Connection Type Max. Operating Temp. Product Description Series Page Number 125C SolderSleeve wire splices CWT-900X 8-6 150C SolderSleeve wire splices D-110, D-1744 8-6 125C DuraSeal crimp splices D-406 8-18 150C MiniSeal crimp splices D-436 (M81824) 8-20 125C SolderGrip closed end connector splices (stub) SGRP, SGRS 8-12 125C DuraSeal crimp terminals and disconnects B-106 8-25 150C SolderGrip terminals SGRT 8-31 125C SolderSleeve wire terminators CWT-15XX 8-37 150C SolderSleeve wire terminators D-129, D-141, D-71X 8-37 125C SolderSleeve shield terminators CWT-X 8-42 150C SolderSleeve shield terminators S01, S02, M83519, SO63 8-42 175C SolderSleeve shield terminators SO96 8-42 125C SolderSleeve coaxial cable terminators CWT-4XXX 8-49 135C RF one-step BNC/TNC connector RBD, RTD 8-53 B-02X/04X 8-49 SolderSleeve PCB/coaxial cable terminators D-607, B-046 8-51 150C SolderShield cable splices D-150, B-202 8-60 150C SolderTacts shielded contacts D-602 8-65 Solder MIL-STD-1553B data bus components 150C Data bus couplers, connectors, terminators, accessories D-500, D-600, D(K)-621 8-74 Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Solder Wire to wire splicing Crimp Coil and Solder Crimp Terminals and disconnects Wire termination to pin/post/tab Shield termination Coax cable termination Coil and Solder Solder Solder Solder SolderSleeve coaxial cable terminators 150C Cable to cable splicing Shielded contacts Solder/Crimp Solder 8-4 Catalog 1654025 Revised 12-03 www.tycoelectronics.com USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 interconnect products, the wire-towire splicing devices are rugged and reliable, yet easy to install. Designed for applications with temperatures up to 150C [302F], 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 low-profile MiniSeal highperformance crimp splices, which substantially reduce wire bundle size and weight, are QPL-listed to the MIL-S-81824 specification, and are required by the MIL-W5088 specification. SolderGrip splices, which are closed-end connectors 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 8-5 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices 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 Applications In-line wire splices. Product Options Product Series CWT D-110 D-1744 (NAS 1744) Minimum Wire Temperature Rating 85C [185F] 125C [257F] 125C [257F] Maximum Operating Temperature 125C [257F] 150C [302F] 150C [302F] Intended Application Environment Splashproof Splashproof Immersion sealed Note: Cadmium-free option (B-152 series) is available for operating temperature of 125C [257F]. Consult Tyco Electronics for details. 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. Available in: Americas Europe Asia Pacific 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 prefer to work with CMA or mm2 sizes): 1. Turn to "CMA/mm2 Calculation" on page 8-10 and use the workspace 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 diameter 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 having 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. 8-6 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table A: CWT Series Selection Side A: Size and Number of Conductors 1 26 AWG 2 1 24 AWG 2 1 22 AWG 2 1 20 AWG 2 1 18 AWG 2 1 16 AWG 2 1 14 AWG 2 1 12 AWG 2 10 AWG 1 Side B: Size and Number of Conductors 26 AWG 24 AWG 1 2 1 2 1 2 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 Side A: 24 AWG 22 AWG 20 AWG 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG 20 AWG 2 Side B: Size and Number of Conductors Size and Number of Conductors 26 AWG 22 AWG 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG 1 2 1 2 1 2 1 2 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 8 8-7 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table B: D-110 Series Selection Side A: Size and Number of Conductors 1 26 AWG 2 1 24 AWG 2 1 22 AWG 2 1 20 AWG 2 1 18 AWG 2 1 16 AWG 2 1 14 AWG 2 1 12 AWG 2 10 AWG 1 Side A: Size and Number of Conductors 1 26 AWG 2 1 24 AWG 2 1 22 AWG 2 1 20 AWG 2 1 18 AWG 2 1 16 AWG 2 1 14 AWG 2 1 12 AWG 2 10 AWG 1 Side B: Size and Number of Conductors 26 AWG 24 AWG 22 AWG 20 AWG 1 2 1 2 1 2 1 2 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 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-110-0101 D-110-0090 D-110-0083 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 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-110-0083 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181 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-110-0083 Side B: Size and Number of Conductors 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG 1 2 1 2 1 2 1 2 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 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-110-0083 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181 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-110-0083 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101 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 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 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 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 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 D-110-0090 D-110-0090 D-110-0090 D-110-0090 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-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0090 D-110-0090 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-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 Fine Wire Splices 26 AWG (0.15 mm2) and Smaller Part No. D-110-0071 D-110-0213 D-110-0214 D-110-0217 D-110-40 As Supplied* 0.9 [0.035] 0.9 [0.035] 0.6 [0.025] 1.0 [0.040] 0.6 [0.025] Inside Diameter Fully Recovered** 0.6 [0.025] 0.6 [0.025] 0.3 [0.013] 0.6 [0.025) 0.5 [0.021] Length*** 4.7 [0.185] 4.2 [0.165] 6.3 [0.250] 9.1 [0.360] 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. 8-8 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Table C: D-1744 Series Selection Side A: Size and Number of Conductors 1 26 AWG 2 1 24 AWG 2 1 22 AWG 2 1 20 AWG 2 1 18 AWG 2 1 16 AWG 2 1 14 AWG 2 1 12 AWG 2 Side A: Size and Number of Conductors 1 26 AWG 2 1 24 AWG 2 1 22 AWG 2 1 20 AWG 2 1 18 AWG 2 1 16 AWG 2 1 14 AWG 2 12 AWG 1 Side B: Size and Number of Conductors 26 AWG 24 AWG 22 AWG 20 AWG 1 2 1 2 1 2 1 2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 -- D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 -- D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04 -- D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 -- Side B: Size and Number of Conductors 16 AWG 14 AWG 18 AWG 12 AWG 1 2 1 2 1 2 1 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 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04 -- -- D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 -- D-1744-04 D-1744-04 D-1744-04 D-1744-04 -- D-1744-04 -- -- -- -- -- -- -- -- -- -- 8 8-9 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm2 area of the conductors to be terminated in a single splice, follow these steps: 1. Choose either CMA or mm2 as 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 mm2 for each conductor that will go into the same splice. (To assist you, Table D on this page provides the CMA of typical conductors.) Wire Number 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. CMA mm2 1 2 3 4 5 Part Number: Total CMA/mm2 Examples One-to-One Wire Splice Table D. Multiwire Splice Total CMA = 3180 Total mm2 = 1.59 Total CMA = 3408 Total mm2 = 1.71 Correct part number selection from Table E (based on CMA/mm2 and nominal jacket wire OD) = CWT-9002 or D-110-41 or D-1744-02. Correct part number selection from Table E (based on CMA/mm2 and nominal jacket wire OD) = CWT-9003 or D-110-0181 or D-1744-03. CMA of Typical AWG Conductors AWG CMA mm2 28 177 0.09 26 304 0.15 24 475 0.24 22 754 0.38 20 1216 0.61 18 1900 0.95 16 2426 1.21 14 3831 1.92 12 5874 2.94 8-10 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderSleeve Wire Splices (Continued) Installation Requirements Table E: Multiwire Splice Selection 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 Product Series Specifications/Approvals You will find ordering information for these tools in Section 10. Wire Jacket OD Min. Max. 0.4 [0.015] 1.7 [0.066] 1.3 [0.05] 2.7 [0.106] 1.8 [0.07] 4.5 [0.18] 2.8 [0.11] 6.0 [0.236] 3.2 [0.125] 7.0 [0.275] 0.50 [0.020] 1.90 [0.075] 0.80 [0.031] 2.80 [0.110] 1.30 [0.050] 4.57 [0.180] 2.00 [0.080] 7.11 [0.280] 0.51 [0.020] 1.78 [0.070] 1.27 [0.050] 2.54 [1.00] 1.9 [0.075] 4.5 [0.177] 2.41 [0.095] 4.32 [0.17] 3.56 [0.140] 7.11 [0.28] 4.0 [0.160] 8.76 [0.345] CWT-9001 CWT-9002 CWT-9003 CWT-9004 CWT-9005 D-1744-01 D-1744-02 D-1744-03 D-1744-04 D-110-35 D-110-41 D-110-0181 D-110-0101 D-110-0090 D-110-0083 Product Characteristics Refer to Raychem installation procedure RPIP 850-00 for D-1744 Series and RPIP 824-00 for CWT Series. CMA Combined Total Min. Max. 450 1500 1250 3500 2500 7200 6100 19000 12000 25000 350 2000 2000 4000 4000 10000 10000 13000 500 1500 1200 3500 3600 6000 4800 9000 8500 16200 16200 25000 mm2 Combined Total Min. Max. 0.3 1.8 0.8 2.0 2.0 4.0 4.0 6.0 6.0 10.0 - - - - - - - - - - - - - - - - - - - - 8 Material Insulation (D-110, D-1744) Insulation (CWT) Solder and flux (D-110, D-1744) Solder and flux (CWT) Meltable inserts (CWT, D-1744) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAflux) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNS-J-004 (RAflux) Meltable thermoplastic Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating (CWT) Temperature rating (D-110, D-1744) Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to +125C [-67F to +257F] -55C to +150C [-67F to +302F] 1000 megohms Series CWT D-110 D-1744 Agency ULE87681 ULE87681 NAS-1744 Raychem D-5023 RT-1404 RT-1404 8-11 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices Product Facts Soldered connection Electrical insulation Sealed for immersion (SGRS) Excellent strain relief Simple installation 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 wire fixturing and controlledsoldering technology provides dependable electrical termination of multiple wire combinations. SolderGrip terminators consist of a heat-shrinkablethermoplastic 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 hightemperature insulation. The termination is environmentally protected and strain relieved. SolderGrip splice terminators are color-coded for easy identification. Product Options Available in: Americas Europe Asia Pacific Product Series SGRP SGRS Environmental Protection Splashproof Sealed Max. Operating Temp. 125C [257F] 125C [257F] 8-12 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Product Selection Process 1. From the Product Options table on the previous page, select the product series appropriate for your application. Example: For connecting a bundle with one 12 AWG wire (1 #12) and two 14 AWG wires (+2 #14), you need an SGRP3 connector. For sealed parts, select the SGRS series. 2. Determine the wire combination (number of wires and size) of the wire bundle you wish to splice. *If the wire combination is not listed in Table C, use the CMA (mm2) method of determining wire bundle size (see "CMA/ mm2 Calculation" on page 8-14). Using Table B (page 8-14, select the smallest size connector that will fit your total wire CMA(mm2) value. 3. Use Table C (page 8-15) to select the correct connector for AWG wire combinations.* For mm2 wire combinations use Table A to select a SolderGrip part number. Insulated Closed-End Connectors (SGRP series) 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. Insulated and Sealed Closed-End Connectors (SGRS series) Table A - Product Dimensions and Part Number Descriptions Part No. Color Code SGRP-1 Green SGRP-2 Red SGRP-3 Blue SGRP-4 Yellow Product Dimensions (Min.) Wire Range (Min.-Max.) OA CMA/mm2 1.370 .120 1400 - 4800 [34.8] [2.9] [0.7 - 2.4] 1.350 .150 4000 - 8000 [34.2] [3.7] [2.0 - 4.0] 1.610 .200 7000 - 18000 [41.0] [5.1] [3.5 - 8.0] 1.650 .270 15000 - 30000 [42.0] [6.8] [7.5 - 12.0] L Part No. Color Code SGRS-1 Green SGRS-2 Red SGRS-3 Blue SGRS-4 Yellow L 1.370 [34.8] 1.350 [34.2] 1.650 [42.0] 1.630 [41.5] Product Dimensions (Min.) Wire Range (Min.-Max.) OA CMA/mm2 0.130 1400 - 4800 [3.4] [0.7 - 2.4] 0.190 4000 - 8000 [4.8] [2.0 - 4.0] 0.290 7000 - 16000 [7.3] [3.5 - 8.0] 0.360 15000 - 24000 [9.1] [7.5 - 12.0] 8 8-13 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm area of the wire bundle to be terminated, follow these steps: 2 1. Choose either CMA or mm2 as your unit of measure for selection purposes and continue to use it for all your selection criteria. (Both measures provide the same results.) Wire Number 2. In the workspace below, list the CMA or mm2 for each conductor in the bundle. (Table B provides the CMA of typical conductors.) 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). CMA mm2 1 2 3 4 5 6 7 8 9 10 Solder Grip Part No. Total CMA/mm2 Example OD Bundle 22 AWG/.38 CMA754 Insulation 22 AWG/.38 CMA754 Conductor 18 AWG/.95 CMA1900 16 AWG/1.21 CMA2426 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 mm2 of 2.92): SGRP-2or SGRS-2 Table B. CMA of Typical Copper Conductors AWG CMA mm2 30 112 0.05 28 177 0.09 26 304 0.15 24 475 0.24 22 754 0.38 20 1216 0.61 18 1900 0.95 16 2426 1.21 14 3831 1.92 12 5874 2.94 10 9354 4.74 8 16983 8.61 8-14 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Table C. SolderGrip Wire Combinations Wire Combinations 1 # 8 + 1 # 12 1 # 8 + 1 # 16 2 # 8 + 2 # 16 1 # 8 + 1 # 14 1 # 8 + 1 # 14 + 1 # 16 1 # 10 + 1 # 18 1 # 10 + 2 # 18 1 # 10 + 3 # 18 1 # 10 + 1 # 16 1 # 10 + 1 # 16 + 1 # 18 1 # 10 + 1 # 16 + 2 # 18 1 # 10 + 2 # 16 1 # 10 + 3 # 16 1 # 10 + 4 # 16 1 # 10 + 5 # 16 1 # 10 + 1 # 14 1 # 10 + 1 # 14 + 1 # 18 1 # 10 + 1 # 14 + 1 # 16 1 # 10 + 1 # 14 + 2 # 16 1 # 10 + 1 # 14 + 3 # 16 1 # 10 + 2 # 14 1 # 10 + 3 # 14 1 # 10 + 1 # 12 1 # 10 + 1 # 12 + 1 # 14 1 # 10 + 2 # 12 2 # 10 2 # 10 + 1 # 16 1 # 12 + 1 # 18 1 # 12 + 2 # 18 1 # 12 + 3 # 18 1 # 12 + 4 # 18 1 # 12 + 5 # 18 1 # 12 + 1 # 16 1 # 12 + 1 # 16 + 1 # 18 1 # 12 + 1 # 16 + 2 # 18 1 # 12 + 1 # 16 + 3 # 18 1 # 12 + 1 # 16 + 4 # 18 1 # 12 + 2 # 16 Splashproof SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 Sealed SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 Wire Combinations 1 # 14 + 3 # 20 1 # 14 + 4 # 20 1 # 14 + 1 # 18 1 # 14 + 1 # 18 + 1 # 20 1 # 14 + 2 # 18 1 # 14 + 3 # 18 1 # 14 + 4 # 18 1 # 14 + 5 # 18 1 # 14 + 1 # 16 1 # 14 + 1 # 16 + 1 # 20 1 # 14 + 1 # 16 + 1 # 18 1 # 14 + 1 # 16 + 2 # 18 1 # 14 + 1 # 16 + 3 # 18 1 # 14 + 1 # 16 + 4 # 18 1 # 14 + 2 # 16 1 # 14 + 2 # 16 + 1 # 18 1 # 14 + 2 # 16 + 2 # 18 1 # 14 + 2 # 16 + 3 # 18 1 # 14 + 3 # 16 1 # 14 + 3 # 16 + 1 # 18 1 # 14 + 3 # 16 + 2 # 18 1 # 14 + 4 # 16 1 # 14 + 4 # 16 + 1 # 18 1 # 14 + 5 # 16 2 # 14 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 2 # 16 2 # 14 + 2 # 16 2 # 14 + 3 # 16 2 # 14 + 4 # 16 3 # 14 3 # 14 + 1 # 16 3 # 14 + 2 # 16 3 # 14 + 3 # 16 4 # 14 Splashproof SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-3 Sealed SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-3 Wire Combinations 2 # 16 + 1 # 18 + 3 # 20 2 # 16 + 1 # 18 + 2 # 20 2 # 16 + 1 # 18 + 1 # 20 2 # 16 + 1 # 18 2 # 16 + 4 # 20 2 # 16 + 3 # 20 2 # 16 + 2 # 20 2 # 16 + 1 # 20 2 # 16 1 # 16 + 5 # 18 1 # 16 + 4 # 18 + 1 # 20 1 # 16 + 4 # 18 1 # 16 + 3 # 18 + 2 # 20 1 # 16 + 3 # 18 + 1 # 20 1 # 16 + 2 # 18 + 3 # 20 1 # 16 + 2 # 18 + 1 # 20 1 # 16 + 2 # 18 1 # 16 + 1 # 18 + 4 # 20 1 # 16 + 1 # 18 + 3 # 20 1 # 16 + 1 # 18 + 2 # 20 1 # 16 + 1 # 18 + 1 # 20 1 # 16 + 1 # 18 1 # 16 + 4 # 20 1 # 16 + 3 # 20 1 # 16 + 1 # 20 + 1 # 22 1 # 16 + 1 # 20 1 # 16 + 3 # 22 1 # 16 + 2 # 22 1 # 16 + 1 # 22 1 # 18 + 1 # 22 1 # 18 + 2 # 22 1 # 18 + 3 # 22 1 # 18 + 1 # 20 1 # 18 + 1 # 20 + 1 # 22 1 # 18 + 1 # 20 + 2 # 22 1 # 18 + 2 # 20 1 # 18 + 3 # 20 1 # 18 + 4 # 20 Splashproof SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-2 SGRP-1 SGRP-2 SGRP-2 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-2 SGRP-2 Sealed SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-2 SGRS-1 SGRS-2 SGRS-2 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-2 SGRS-2 8 8-15 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Table C. SolderGrip Wire Combinations (Continued) Wire Combinations 1 # 12 + 2 # 16 + 1 # 18 1 # 12 + 2 # 16 + 2 # 18 1 # 12 + 3 # 16 1 # 12 + 4 # 16 1 # 12 + 5 # 16 1 # 12 + 1 # 14 + 1 # 18 1 # 12 + 1 # 14 + 2 # 18 1 # 12 + 1 # 14 + 3 # 18 1 # 12 + 1 # 14 + 1 # 16 1 # 12 + 1 # 14 + 2 # 16 1 # 12 + 1 # 14 + 3 # 16 1 # 12 + 1 # 14 + 4 # 16 1 # 12 + 2 # 14 1 # 12 + 2 # 14 + 1 # 18 1 # 12 + 2 # 14 + 1 # 16 1 # 12 + 2 # 14 + 2 # 16 1 # 12 + 2 # 14 + 3 # 16 1 # 12 + 3 # 14 1 # 12 + 3 # 14 + 1 # 16 1 # 12 + 4 # 14 2 # 12 2 # 12 + 1 # 18 2 # 12 + 1 # 18 2 # 12 + 1 # 16 2 # 12 + 2 # 16 + 1 # 18 2 # 12 + 3 # 16 2 # 12 + 1 # 14 + 1 # 18 2 # 12 + 1 # 14 + 1 # 16 3 # 12 + 1 # 14 2 # 12 + 2 # 14 3 # 12 + 1 # 18 3 # 12 + 1 # 16 1 # 14 + 1 # 22 1 # 14 + 1 # 20 1 # 14 + 2 # 20 Splashproof SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-1 SGRP-2 SGRP-2 Sealed SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-1 SGRS-2 SGRS-2 Wire Combinations 4 # 14 + 1 # 16 4 # 14 + 2 # 16 5 # 14 5 # 14 + 1 # 16 1 # 16 + 3 # 18 1 # 16 + 2 # 18 + 2 # 20 1 # 16 + 5 # 20 1 # 16 + 2 # 20 6 # 16 5 # 16 + 1 # 18 5 # 16 + 1 # 20 5 # 16 4 # 16 + 2 # 18 4 # 16 + 1 # 18 + 1 # 20 4 # 16 + 1 # 18 4 # 16 + 2 # 20 4 # 16 + 1 # 20 4 # 16 3 # 16 + 3 # 18 3 # 16 + 2 # 18 + 1 # 20 3 # 16 + 2 # 18 3 # 16 + 1 # 18 + 2 # 20 3 # 16 + 1 # 18 + 1 # 20 3 # 16 + 1 # 18 3 # 16 + 3 # 20 3 # 16 + 2 # 20 3 # 16 + 1 # 20 3 # 16 2 # 16 + 4 # 18 2 # 16 + 3 # 18 + 1 # 20 2 # 16 + 3 # 18 2 # 16 + 2 # 18 + 2 # 20 2 # 16 + 2 # 18 + 1 # 20 2 # 16 + 2 # 18 -- Splashproof SGRP-4 SGRP-4 SGRP-4 SGRP-4 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 -- Sealed SGRS-4 SGRS-4 SGRS-4 SGRS-4 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 -- Wire Combinations 1 # 18 + 5 # 20 2 # 18 2 # 18 + 1 # 22 2 # 18 + 1 # 20 2 # 18 + 2 # 20 2 # 18 + 3 # 20 2 # 18 + 4 # 20 3 # 18 3 # 18 + 1 # 20 3 # 18 + 2 # 20 3 # 18 + 3 # 20 4 # 18 4 # 18 + 1 # 20 4 # 18 + 2 # 20 5 # 18 5 # 18 + 1 # 20 6 # 18 1 # 20 + 1 # 22 1 # 20 + 2 # 22 1 # 20 + 3 # 22 1 # 20 + 4 # 22 2 # 20 2 # 20 + 1 # 22 2 # 20 + 2 # 22 2 # 20 + 3 # 22 3 # 20 3 # 20 + 1 # 22 4 # 20 5 # 20 6 # 20 3 # 22 4 # 22 5 # 22 6 # 22 -- Splashproof SGRP-2 SGRP-1 SGRP-1 SGRP-2 SGRP-2 SGRP-2 SGRP-3 SGRP-2 SGRP-2 SGRP-3 SGRP-3 SGRP-2 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-3 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-1 SGRP-2 SGRP-2 SGRP-2 SGRP-1 SGRP-1 SGRP-1 SGRP-1 -- Sealed SGRS-2 SGRS-1 SGRS-1 SGRS-2 SGRS-2 SGRS-2 SGRS-3 SGRS-2 SGRS-2 SGRS-3 SGRS-3 SGRS-2 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-3 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-1 SGRS-2 SGRS-2 SGRS-2 SGRS-1 SGRS-1 SGRS-1 SGRS-1 -- 8-16 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing SolderGrip Closed End Connector Splices (Continued) Product Characteristics Material Insulation Solder preform with flux Sealing insert (SGRS) Spiral wound insert Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride Sn 60, Pb 40, ROM1 flux per ANSI-J-STD-004 (RAflux). Hot melt adhesive Copper alloy Physical Dimensions Unit inches Method of test RB-109 Requirement See product dimensions. Electromechanical Dielectric withstand voltage Static heating Unit kilovolts degrees Method of test RB-109 RB-109 Typical values 2.0 Less than 50C rise Environmental* Insulation resistance after water immersion (SGRS only) Contact resistance after exposure Unit megohms milliohms Method of test RB-109 RB-109 Requirement 100 Less than 6 milliohms Operating condition Temperature rating Voltage rating Unit -- volts Method of test -- -- Value -55C to 125C [-67F to 257F] 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. Approvals and Reference Documents Agency Approvals Reference documents UL, CUL E87681 Raychem Specification RB-109 for splices Specification Control Drawings Splices--Non Sealed (SGRP-X), Splices--Sealed (SGRS-X) 8 Installation The SolderGrip product is pushed onto the conductors with a twisting motion. With the product in place, installation 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 Refer to Raychem installation procedure RPIP 820-00 for detailed instructions and recommended reflector attachments. You will find ordering information for these tools in Section 10. 8-17 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices 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 Applications Automotive/truck wiring repair and maintenance. Automotive accessory installations. OEM automotive/truck/RV wire harness fabrication. Marine electronics. Fleet maintenance. Commercial wiring (pumps/pools/spas). Specifications/Approvals Series D-406 -- Agency ULand CULlisted 91J4, File E87681 Lloyd's listed, File 65 247 HH 02-93 Raychem RB-107 -- Product Dimensions Butt Splices Part No. Available in: Americas Europe Asia Pacific D-406-0001 D-406-0002 D-406-0003 Butt Splice Dimensions A L Min. Nom. 3.68 [.145] 31.75 [1.25] 4.57 [.180] 31.75 [1.25] 6.35 [.250] 38.10 [1.50] Color Conductor Red Blue Yellow 22-18 16-14 12-10 Wire Dimensions Insulation Insulation O.D. (Max.) O.D. (Min.) 3.56 [.140] 1.40 [.055] 4.45 [.175] 2.03 [.080] 6.22 [.245] 2.79 [.110] 8-18 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing DuraSeal Heat-Shrinkable, Environmentally Sealed, Nylon-Insulated Crimp Splices (Continued) Product Selection Process 1. Determine wire size. 2. Select part number. Product Characteristics (Typical) Wire Size AWG 22-18 16-14 12-10 Operating temperature Shrink ratio Physical properties Chemical properties Electrical properties mm2 Part No. Color 0.38-0.95 1.2-2.5 3-6 D-406-0001 D-406-0002 D-406-0003 Red Blue Yellow -55C to 125C [-67F to 257F] 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 160C [320F] Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water Dielectric strength: 2500 Vac Insulation resistance: 1000 megohms at 100 Vdc Installation Requirements Installation For proper installation of these devices, the correct crimp tool and a heating tool with a reflector attachment must be used. The Raychem AD-1522 crimp tool and HL1802E heating tool are recommended. 1. Select splice of appropriate size. Strip wire 7.5 mm (5/16 in). Insert into crimp barrel. You will find ordering information for these tools in Section 10. Refer to Raychem installation procedure RPIP 821-00 for detailed instructions. 2. Crimp using Raychem AD-1522 crimp tool for preinsulated crimps. 8 3. Heat crimped splice with heat gun until tubing recovers and adhesive flows. 8-19 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices 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 Applications Product Selection Process MiniSeal wire-to-wire splicing products offer solutions for hundreds of aerospace and defense applications. These environment-resistant splices provide excellent reliability, long term performance, MIL-S-81824/1 qualification, and a low installed cost. 1. Determine the type of splice required. MiniSeal crimp splices consist of a plated copper crimp barrel and a separate, heat-shrinkable, transparent sealing sleeve. They can be used on a combination of wires, from 1:1 to 10:10. MiniSeal splices are one of the smallest, lightest, and most environmentresistant splices available. They preserve the electrical integrity of the splice by preventing the penetration of liquids and the resulting chemical and galvanic corrosion. Stub (parallel) splice: 2 2 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 150C [302F]. 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 (mm ) of each wire. 2 Stub splice: Add the CMA or mm of all wires together. 2 Butt splice: Calculate each side separately (see example on the worksheet). Available in: Americas Europe Asia Pacific Table A provides the CMA of typical conductors. (Both CMA and mm give the same results, so choose either CMA or mm as 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--colorcoded red, blue, or yellow--for the CMA or mm you calculated. 2 Stub splice: Select the barrel that will accommodate the total cross section. Butt splice: Select the smallest barrel that will accommodate the largest CMA/mm2 required. (Refer to the example in the worksheet for a more specific description.) If the CMA/mm2 of 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 application. Then select the part number for the type of plating required. The color code accompanying that part number should match the color code you arrived at in Table B, confirming that the part number you have selected is correct. 8-20 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table A. CMA of Typical Conductors Strands AWG CMA mm2 Table B. Crimp Barrel Color Code Selection CMA Range 304-1510 779-2680 1900-6755 7 28 177 0.09 19 26 304 0.15 19 24 475 0.24 19 22 754 0.38 mm2 Range 0.15-0.75 0.39-1.34 0.95-3.37 19 20 1216 0.61 19 18 1900 0.95 19 16 2426 1.21 19 14 3831 1.92 1:1 Splice (AWG Size) 26-20 20-16 18-12 37 12 5874 2.94 Color Code Red Blue Yellow Example: CMA/mm2 Worksheet 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 calculated as follows: CMA = 3 x 754 = 2262 (mm2 = 3 x 0.38 = 1.14) Wire Number 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. CMA mm2 1 2 3 4 5 6 8 7 8 9 10 Part Number: Total Table C. Stub (Parallel) Splices Part No. Illustration Crimp Barrel Size Range CMA [mm2] Min.-Max. I.D.dimensions Side 1 Sealing Insert Side 2 Max. No. of Wires Sealing Insert Max. No. of Wires Tin Plated Nickel Plated D-436-0128 Red D-436-0119 Red 304-1510 [0.15-0.75] 2 2 D-436-58 Blue D-436-75 Blue 779-2680 [0.39-1.34] 2 2 D-436-59 Yellow D-436-76 Yellow 1900--6755 [0.95-3.37] 2 2 D-436-60 Blue D-436-77 Blue 779-2680 [0.39-1.34] 10 (2 per hole) 2 D-436-61 Yellow D-436-78 Yellow 1900-6755 [0.95-3.37] 10 (2 per hole) 2 8-21 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table D. Butt (in-line) splices Illustration Part No. Crimp Barrel Size Range CMA [mm2] Min.-Max. I.D.dimensions Side 1 Side 2 Sealing Insert Max. No. of Wires Sealing Insert Max. No. of Wires Tin Plated Nickel Plated D-436-36* Red D-436-82 Red 304-1510 [0.15-0.75] 2 2 D-436-37* Blue D-436-83 Blue 779-2680 [0.39-1.34] 2 2 D-436-38* Yellow D-436-84 Yellow 1900-6755 [0.95-3.37] 2 2 D-436-0110 Red D-436-85 Red 304-1510 [0.15-0.75] 6 2 D-436-52 Blue D-436-86 Blue 779-2680 [0.39-1.34] 6 (2 per hole) 2 D-436-53 Yellow D-436-87 Yellow 1900-6755 [0.95-3.37] 6 (2 per hole) 2 D-436-0115 Red D-436-88 Red 304-1510 [0.15-0.75] 6 (2 per hole) 6 (2 per hole) D-436-42 Blue D-436-89 Blue 779-2680 [0.39-1.34] 6 (2 per hole) 6 (2 per hole) D-436-43 Yellow D-436-90 Yellow 1900-6755 [0.95-3.37] 6 (2 per hole) 6 (2 per hole) *Qualified to MIL-S-81824/1. Table E. Crimp Barrel Only Type Butt (in-line) Butt (in-line) Butt (in-line) Stub (Parrel) Stub (Parrel) Stub (Parrel) Color Code Red Blue Yellow Red Blue Yellow Tin-Plated D-609-06 D-609-07 D-609-08 D-609-03 D-609-04 D-609-05 Nickel Plated D-609-09 D-609-10 D-609-11 D-609-12 D-609-13 D-609-14 Crimp Barrel Size Range CMA[mm 2] Min. - Max. 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] Table F. Sealing Sleeve Only Part No. D-436-0096 D-436-0097 D-436-0098 Color Code Red Blue Yellow LMax. 29.2 [1.15] 29.2 [1.15] 29.2 [1.15] Catalog 1654025 Revised 12-03 Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. AMin. 2.16 [0.085] 2.8 [0.110] 4.32 [0.170] 8-22 www.tycoelectronics.com Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Product Characteristics Specifications/Approvals Installation Material Insulation Crimp barrel Meltable inserts Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Tin- or nickel-plated copper Meltable thermoplastic Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance 6.9 mV at 4.5 Avs 8.1 mV for an equal length of wire Exceeds strength of conductor 2.5 kV -55C to 150C [-67F to 302F] 5000 megohms Series D-436 Military 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 You will find ordering information for these tools in Section 10. Refer to Raychem installation procedure RCPS 20020 for detailed instructions and recommended reflector attachments. 8 8-23 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects Introduction Raychem insulated electrical terminal products provide reliable, repeatable, and rugged examples of terminals available. We start on the front end with terminal sizes and configurations that meet or exceed industry 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 abrasion and cut-through 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 accommodate a wide range of wire sizes and are colorcoded for easy identification, 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 compresses 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 SolderGrip technology is a reliable means of terminating 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 successfully demonstrated using this product. DuraSeal product delivers protected electrical joints on industry standard terminals and is suitable for harsh environments. 8-24 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects Product Facts Resistance to moisture and abrasion Strain relief Protection from wire pull-out Easy installation UL and CUL listed Applications DuraSeal products insulate and protect electrical connections 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 terminal, encased in rugged, heat-shrinkable nylon tubing lined with a special hot-melt adhesive, resists damage from abrasions and cuts. Approvals and Reference Documents Agency approvals Reference documents Available in: Americas Europe Asia Pacific DuraSeal devices retain flexibility and impactresistance 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. 8 ULlisted component, file E87681, terminals except quick connect terminals; file E157833, quick connect terminals Raychem specifications RB-108, Specification DuraSeal crimp terminals DuraSeal selection guide (H54153) DuraSeal installation guidelines (H54154) 8-25 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Product Characteristics Physical Electrical Chemical Environmental (Fluid) Operating conditions Property Dimensions Tensile strength Unit Inches Pounds Requirement None 8 to 40 lbs depending on AWG Method of Test See product dimensions UL486C, IEC512-8 Property Voltage drop Insulation resistance Dielectric withstand voltage Unit Millivolts Megohms Kilovolts Typical value Less than equal length of wire 103 min. 2.5 Method of Test MIL-S-81824, IEC512-2 MIL-STD-202 method 302 MIL-STD-202F method 301, IEC512-2 Property Diesel fuel Brake fluid Antifreeze 5% salt water Motor oil Humidity Immersion Vibration Bending Thermal shock Heat aging (168 @ 85C [185F) Salt spray Temperature rating Minimum shrink temperature Voltage rating Unit Requirement Method of Test ASTM D 3032, ESA-603D -- Meet electrical test listed above after conditioning. -- Meet electrical test listed above after conditioning. -- -55C to +125C [-67F to -257F] 180C [356F] 600 Volt max MIL-STD-202F method 106, IEC68-2-30 MIL-STD-202F condition C, IEC68-2-14 test NC MIL-STD-202F method 201, IEC68-2-6 UL486C, IEC512-8 MIL-STD-202F method 107, IEC68-2-14 test N MIL-STD-202F, IEC68-2-2 MIL-STD-202F method 101, IEC68-2-11 None None None Fork Terminals Fork Terminal Dimensions Part No. B-106-2401 B-106-2402 B-106-2403 B-106-2502 B-106-2503 A Min. 3.81 4.57 6.35 4.57 6.35 [.15] [.18] [.25] [.18] [.25] Stud Size Metric Imperial M4 8 M4 8 M4 8 M5 10 M5 10 C Nom. 7.87 [.31] 7.87 [.31] 7.87 [.31] 9.91 [.39] 9.91 [.39] L Max. 32.00 35.05 38.10 35.05 40.15 [1.26] [1.38] [1.50] [1.38] [1.58] Color Insulation Conductor (AWG) Red Blue Yellow Blue Yellow 22-18 16-14 12-10 16-14 12-10 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 4.45 6.35 4.45 6.35 [.150] [.175] [.250] [.175] [.250] 1.40 2.00 2.79 2.00 2.79 [.055] [.080] [.110] [.080] [.110] 8-26 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Ring Terminals Part No. B-106-1401 B-106-1501 B-106-1601 B-106-1801 B-106-1991 B-106-1402 B-106-1502 B-106-1602 B-106-1802 B-106-1992 B-106-1403 B-106-1503 B-106-1603 B-106-1803 B-106-1993 A Min. 3.81 3.81 3.81 3.81 3.81 4.57 4.57 4.57 4.57 4.57 6.35 6.35 6.35 6.35 6.35 [.15] [.15] [.15] [.15] [.15] [.18] [.18] [.18] [.18] [.18] [.25] [.25] [.25] [.25] [.25] Fork Terminal Dimensions Stud C Size Nom. Metric Imperial M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] M4 8 7.88 [.31] M5 10 9.91 [.39] M6 1/4 11.94 [.47] M8 5/16 13.97 [.55] M10 3/8 17.78 [.70] L Max. 32.00 34.04 36.07 39.12 43.18 33.02 35.05 36.58 40.13 43.94 38.10 40.13 41.66 45.21 46.99 [1.26] [1.34] [1.42] [1.54] [1.70] [1.30] [1.38] [1.44] [1.58] [1.73] [1.50] [1.58] [1.64] [1.78] [1.85] Color Insulation Conductor (AWG) Red Red Red Red Red Blue Blue Blue Blue Blue Yellow Yellow Yellow Yellow Yellow 22-18 22-18 22-18 22-18 22-18 16-14 16-14 16-14 16-14 16-14 12-10 12-10 12-10 12-10 12-10 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 3.81 3.81 3.81 3.81 4.45 4.45 4.45 4.45 4.45 6.35 6.35 6.35 6.35 6.35 [.150] [.150] [.150] [.150] [.150] [.175] [.175] [.175] [.175] [.175] [.250] [.250] [.250] [.250] [.250] 1.40 1.40 1.40 1.40 1.40 2.00 2.00 2.00 2.00 2.00 2.79 2.79 2.79 2.79 2.79 [.055] [.055] [.055] [.055] [.055] [.080] [.080] [.080] [.080] [.080] [.110] [.110] [.110] [.110] [.110] 8 8-27 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Push-on Terminals Push-on Terminal Dimensions Part No. B-106-3631 B-106-3632 B-106-3633 B-106-3281 B-106-3481 Tab Size (inches) .250 x .032 .250 x .032 .250 x .032 .110 x .020 .187 x .020 A Min. 3.81 4.57 6.35 3.81 3.81 [.150] [.180] [.250] [.150] [.150] B Nom. 6.35 6.35 6.35 2.79 4.75 C Nom. [.250] [.250] [.250] [.110] [.187] .81 .81 .81 .51 .51 L Max. [.032] [.032] [.032] [.020] [.020] 30.48 32.00 33.02 22.86 30.48 [1.200] [1.260] [1.300] [.900] [1.200] Color Red Blue Yellow Red Red Wire Dimensions Insulation Insulation Conductor O.D. O.D. (AWG) (Min.) (Max.) 22-18 3.81 [.150] 1.40 [.055] 16-14 4.45 [.175] 2.00 [.080] 12-10 6.35 [.250] 2.79 [.110] 22-18 3.81 [.150] 1.40 [.055] 22-18 3.81 [.150] 1.40 [.055] Tab Terminals Tab Terminal Dimensions Part No. B-106-4631 B-106-4632 Tab Size (inches) .250 x .032 .250 x .032 A Min. B Nom. C Nom. L Max. Color Insulation Conductor (AWG) 3.81 [.150] 4.57 [.180] 6.35 [.250] 6.35 [.250] .81 [.032] .81 [.032] 30.48 [1.20] 32.00 [1.26] Red Blue 22-18 16-14 Wire Dimensions Insulation O.D. O.D. (Min.) (Max.) 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 8-28 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Pin Terminals Wire Dimensions Insulation O.D. (Max.) 3.81 [.150] Pin Terminal Dimensions Part No. B-106-6201 A Min. B Nom. L Max. Color Conductor (AWG) 3.81 [.150] 2.00 [.080] 30.99 [1.220] Red 22-18 Insulation O.D. (Min.) 1.40 [.055] Bullet Terminals Fig. 1 Fig. 2 Bullet Terminal Dimensions Part No. Fig. Type B-106-7401 B-106-7502 B-106-8401 B-106-8502 1 1 2 2 M M F F A Min. 3.81 4.57 3.81 4.57 [.150] [.180] [.150] [.180] B Nom. 3.81 5.08 3.81 5.08 [.150] [.200] [.150] [.200] C Min. -- -- 5.59 [.220] 6.10 [.240] L Max. 33.53 34.54 30.48 32.51 [1.32] [1.36] [1.20] [1.28] Color Conductor (AWG) Red Blue Red Blue 22-18 16-14 22-18 16-14 Wire Dimensions Insulation Insulation O.D. O.D. (Max.) (Min.) 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 3.81 [.150] 1.40 [.055] 4.45 [.175] 2.00 [.080] 8 8-29 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects DuraSeal Heat-Shrinkable Environmentally Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued) Product Characteristics (Typical) Operating temperature Shrink ratio Physical properties -55C to 125C [-67F to 257F] Approximately 2:1 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 160C [320F] Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water Dielectric strength: 1000 V Insulation resistance: 10 megohms Chemical properties Electrical properties Specifications/Approvals Series Agency ULand CUL91J4, File E87681 Lloyd's listed, File 65 247 HH 02-93 ULand CULE157833 (B-106-3XXX/B-106-4XXX) B-106 Installation Raychem RB-108 1. Select appropriate size. For terminal and disconnect terminations, strip wire 6.5 mm (1/4 inch). 2. Crimp using Raychem AD-1522 crimp tool for preinsulated crimps. 3. Heat terminal or disconnect 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 installation procedure RPIP 684-00 for detailed instructions. 8-30 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 SGRT Environmental Protection Splashproof Product Selection Process 1. Determine the wire combination (number of wires and size) of the wire bundle you wish to terminate. Applications Used for terminating multiple wires to terminals. 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. Table A. Part Number Selection Available in: Americas Europe Asia Pacific 4. Select the correct part number from Table A for that stud size in the terminal 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. SolderGrip Part No. Stud Size Maximum Bundle Diameter Maximum Amp Rating SGRT-1-02 2 [2] 4.1 [.161] 12.5 A SGRT-2-03 3 [6] 5.0 [.195] 15 A SGRT-2-04 4 [8] -- 15 A SGRT-2-05 5 [10] -- 15 A SGRT-2-06 6 [1/4] -- 15 A SGRT-3-06 6 [1/4] 6.5 [.255] 33 A SGRT-3-08 8 [5/16] -- 33 A SGRT-4-06 6 [1/4] 9.0 [.355] 56 A SGRT-4-08 8 [5/16] -- 56 A 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). 8 Using Table B, select the smallest size part that will fit your total wire CMA (mm2) value. Wire Range (Min.-Max.) CMA [mm2] 1400-5000 [0.7-2.5] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 2400-6000 [1.2-3.0] 5000-13,200 [2.5-6.6] 5000-13,200 [2.5-6.6] 12,000-22,400 [6.0-11.2] 12,000-22,400 [6.0-11.2] Typical Length 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 38 [1 1/2] 44.5 [1 3/4] 51.0 [2] 44.5 [1 3/4] 51 [2] Maximum bundle diameter is measured over wire insulation. 8-31 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) CMA/mm2 Calculation To calculate the total circular mil or mm2 area of the wire bundle to be terminated, follow these steps: 1. Choose either CMA or mm2 as your unit of measure for selection purposes and continue to use it for all your selection criteria. (Both measures provide the same results.) 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). 2. In the workspace below, list the CMA or mm2 for each conductor in the bundle. (Table B provides the CMA of typical conductors.) Wire Number CMA mm2 1 2 3 4 5 6 7 8 9 10 Solder Grip Part No. Total CMA/mm2 Example OD Bundle 22 AWG/.38 CMA754 Insulation 22 AWG/.38 CMA754 Conductor 18 AWG/.95 CMA1900 16 AWG/1.21 CMA2426 Total CMA= 5834 Total mm2 = 2.92 Correct part number (based on CMA of 5834 or mm2 of 2.92): SGRT-2-XX if bundle OD is less than 5.0 mm (0.195 in). Bundle diameter must not exceed 5.0 mm [0.195 in] for this example 8-32 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) Table B. CMA of Typical Copper Conductors Strands AWG CMA mm2 7 28 177 0.09 19 26 304 0.15 19 24 475 0.24 19 22 754 0.38 19 20 1216 0.61 19 18 1900 0.95 19 16 2426 1.21 19 14 3831 1.92 37 12 5874 2.94 Table C. SolderGrip Wire Combinations (see Table A for Terminal Size [-XX]) Wire Combinations 1#8 1 # 8 + 1 # 16 2 # 8 + 2 # 16 1 # 8 + 1 # 14 1 # 10 1 # 10 + 1 to 3 # 18 1 # 10 + 2 # 18 1 # 10 + 3 # 18 1 # 10 + 1 # 16 1 # 10 + 1 # 16 + 1 # 18 1 # 10 + 1 # 16 + 2 # 18 1 # 10 + 2 # 16 1 # 10 + 3 # 16 1 # 10 + 4 # 16 1 # 10 + 5 # 16 1 # 10 + 1 # 14 1 # 10 + 1 # 14 + 1 # 18 1 # 10 + 1 # 14 + 1 # 16 1 # 10 + 1 # 14 + 2 # 16 1 # 10 + 1 # 14 + 3 # 16 1 # 10 + 2 # 14 1 # 10 + 3 # 14 1 # 10 + 1 # 12 1 # 10 + 1 # 12 + 1 # 14 1 # 10 + 2 # 12 2 # 10 2 # 10 + 1 # 16 1 # 12 1 # 12 + 1 # 18 1 # 12 + 2 # 18 1 # 12 + 3 # 18 1 # 12 + 4 # 18 1 # 12 + 5 # 18 1 # 12 + 1 # 16 1 # 12 + 1 # 16 + 1 # 18 1 # 12 + 1 # 16 + 2 # 18 1 # 12 + 1 # 16 + 3 # 18 Part No. SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX Wire Combinations 1 # 12 + 1 # 16 + 4 # 18 1 # 12 + 2 # 16 1 # 12 + 2 # 16 + 1 # 18 1 # 12 + 2 # 16 + 2 # 18 1 # 12 + 3 # 16 1 # 12 + 4 # 16 1 # 12 + 5 # 16 1 # 12 + 1 # 14 + 1 # 18 1 # 12 + 1 # 14 + 2 # 18 1 # 12 + 1 # 14 + 3 # 18 1 # 12 + 1 # 14 + 1 # 16 1 # 12 + 1 # 14 + 2 # 16 1 # 12 + 1 # 14 + 3 # 16 1 # 12 + 1 # 14 + 4 # 16 1 # 12 + 2 # 14 1 # 12 + 2 # 14 + 1 # 18 1 # 12 + 2 # 14 + 1 # 16 1 # 12 + 2 # 14 + 2 # 16 1 # 12 + 2 # 14 + 3 # 16 1 # 12 + 3 # 14 1 # 12 + 3 # 14 + 1 # 16 1 # 12 + 4 # 14 2 # 12 + 1 # 18 2 # 12 + 1 # 16 2 # 12 + 2 # 16 + 1 # 18 2 # 12 + 3 # 16 2 # 12 + 1 # 14 + 1 # 18 2 # 12 + 1 # 14 + 1 # 16 2 # 12 + 2 # 14 3 # 12 + 1 # 18 3 # 12 + 1 # 16 3 # 12 + 1 # 14 1 # 14 1 # 14 + 1 # 22 1 # 14 + 1 # 20 1 # 14 + 2 # 20 1 # 14 + 3 # 20 Part No. SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX Wire Combinations 1 # 14 + 4 # 20 1 # 14 + 1 # 18 1 # 14 + 1 # 18 + 1 # 20 1 # 14 + 2 # 18 1 # 14 + 3 # 18 1 # 14 + 4 # 18 1 # 14 + 5 # 18 1 # 14 + 1 # 16 1 # 14 + 1 # 16 + 1 # 20 1 # 14 + 1 # 16 + 1 # 18 1 # 14 + 1 # 16 + 2 # 18 1 # 14 + 1 # 16 + 3 # 18 1 # 14 + 1 # 16 + 4 # 18 1 # 14 + 2 # 16 1 # 14 + 2 # 16 + 1 # 18 1 # 14 + 2 # 16 + 2 # 18 1 # 14 + 2 # 16 + 3 # 18 1 # 14 + 3 # 16 1 # 14 + 3 # 16 + 1 # 18 1 # 14 + 3 # 16 + 2 # 18 1 # 14 + 4 # 16 1 # 14 + 4 # 16 + 1 # 18 1 # 14 + 5 # 16 2 # 14 2 # 14 2 # 14 2 # 14 2 # 14 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 1 # 16 2 # 14 + 2 # 16 2 # 14 + 2 # 16 2 # 14 + 3 # 16 2 # 14 + 4 # 16 3 # 14 Part No. SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-3-XX 8 8-33 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Insulated Terminals and Disconnects SolderGrip Self-Fixturing Insulated Terminals (Continued) Table C. SolderGrip Wire Combinations (see Table A for Terminal Size [-XX]) (Continued) Wire Combinations 3 # 14 + 1 # 16 3 # 14 + 2 # 16 3 # 14 + 3 # 16 4 # 14 4 # 14 + 1 # 16 4 # 14 + 2 # 16 5 # 14 5 # 14 + 1 # 16 1 # 16 1 # 16 + 1 # 22 1 # 16 + 2 # 22 1 # 16 + 3 # 22 1 # 16 + 1 # 20 1 # 16 + 1 # 20 + 1 # 22 1 # 16 + 2 # 20 1 # 16 + 3 # 20 1 # 16 + 4 # 20 1 # 16 + 5 # 20 1 # 16 + 1 # 18 1 # 16 + 1 # 18 + 1 # 20 1 # 16 + 1 # 18 + 2 # 20 1 # 16 + 1 # 18 + 3 # 20 1 # 16 + 1 # 18 + 4 # 20 1 # 16 + 2 # 18 1 # 16 + 2 # 18 + 1 # 20 1 # 16 + 2 # 18 + 2 # 20 1 # 16 + 2 # 18 + 3 # 20 1 # 16 + 3 # 18 1 # 16 + 3 # 18 + 1 # 20 1 # 16 + 3 # 18 + 2 # 20 1 # 16 + 4 # 18 1 # 16 + 4 # 18 + 1 # 20 1 # 16 + 5 # 18 2 # 16 2 # 16 + 1 # 20 2 # 16 + 2 # 20 2 # 16 + 3 # 20 Part No. SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX Wire Combinations 2 # 16 + 4 # 20 2 # 16 + 1 # 18 2 # 16 + 1 # 18 + 1 # 20 2 # 16 + 1 # 18 + 2 # 20 2 # 16 + 1 # 18 + 3 # 20 2 # 16 + 2 # 18 2 # 16 + 2 # 18 + 1 # 20 2 # 16 + 2 # 18 + 2 # 20 2 # 16 + 3 # 18 2 # 16 + 3 # 18 + 1 # 20 2 # 16 + 4 # 18 3 # 16 3 # 16 + 1 # 20 3 # 16 + 2 # 20 3 # 16 + 3 # 20 3 # 16 + 1 # 18 3 # 16 + 1 # 18 + 1 # 20 3 # 16 + 1 # 18 + 2 # 20 3 # 16 + 2 # 18 3 # 16 + 2 # 18 + 1 # 20 3 # 16 + 3 # 18 4 # 16 4 # 16 + 1 # 20 4 # 16 + 2 # 20 4 # 16 + 1 # 18 4 # 16 + 1 # 18 + 1 # 20 4 # 16 + 2 # 18 5 # 16 5 # 16 + 1 # 20 5 # 16 + 1 # 18 6 # 16 1 # 18 + 1 # 22 1 # 18 + 2 # 22 1 # 18 + 3 # 22 1 # 18 + 1 # 20 1 # 18 + 1 # 20 + 1 # 22 -- Part No. SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-4-XX SGRT-3-XX SGRT-4-XX SGRT-4-XX SGRT-4-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX -- Wire Combinations 1 # 18 + 1 # 20 + 2 # 22 1 # 18 + 2 # 20 1 # 18 + 3 # 20 1 # 18 + 4 # 20 1 # 18 + 5 # 20 2 # 18 2 # 18 + 1 # 22 2 # 18 + 1 # 20 2 # 18 + 2 # 20 2 # 18 + 3 # 20 2 # 18 + 4 # 20 3 # 18 3 # 18 + 1 # 20 3 # 18 + 2 # 20 3 # 18 + 3 # 20 4 # 18 4 # 18 + 1 # 20 4 # 18 + 2 # 20 5 # 18 5 # 18 + 1 # 20 6 # 18 1 # 20 + 2 # 22 1 # 20 + 3 # 22 1 # 20 + 4 # 22 2 # 20 2 # 20 + 1 # 22 2 # 20 + 2 # 22 2 # 20 + 3 # 22 3 # 20 3 # 20 + 1 # 22 4 # 20 5 # 20 6 # 20 4 # 22 5 # 22 6 # 22 -- Part No. SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX SGRT-3-XX SGRT-3-XX SGRT-2-XX SGRT-2-XX SGRT-2-XX -- 8-34 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Solder Style SolderGrip Self-Fixturing Insulated Terminals (Continued) Installation The SolderGrip product is pushed onto the conductors with a twisting motion. With the product in place, installation can be completed with the proper selection and use of heating tools and reflectors. Refer to Raychem installation procedure RPIP 820-01 for detailed instructions and recommended reflector attachments. You will find ordering information for these tools in Section 10. Either of the following Raychem heating tools is recommended: Product Characteristics HL1802E CV-1981 Material Insulation Solder and flux Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar) Sn60 Pb40 with RAflux Typical Performance Tensile strength Temperature rating Voltage Drop Dielectric Withstanding Voltage Exceeds strength of individual wires -55C to +150C [-67F to +302F] Not to exceed that of equivalent length of wire by more than 1 mV Current leakage less than 2 mA(1.5 kV) 8 8-35 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 150C [302F], the products in this section include SolderSleeve discrete wire terminators, which are heat-shrinkable thermoplastic sleeves containing a precisely engineered fluxed solder preform. SolderSleeve terminators are also available on carrier tape, spaced precisely to match connector terminal spacing, enabling termination of an entire row of wires at one time. SolderSleeve wire-to-pin, wire-to-post, and wire-to-tab terminators, like all Raychem termination products, provide reliability and economical installation for greater productivity. They can be supplied either in bulk or on carrier tape. 8-36 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators 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 Applications Installation Used for terminating wires to component terminals, such as motor tabs, connector pins, and switch terminals. Product selection process 5. Optional: Select tape carrier center-to-center spacing (D-71X series only). This should match center spacing of component terminals. 1. Determine the application operating temperature. 6. Select part number from the appropriate table: 2. From the Product Options table on the next page, select the product series appropriate for the application, based on the temperature required. 3. Determine your component connection point type (pin, post, or tab) and dimensions. For CWT series (applications with lowtemperature wires-- below 125C [257F]), use Table A. For D-129/141/71X series (applications with wires rated higher than 125C [257F]), use Table B. 4. Determine your wire gauge. Available in: Americas Europe Asia Pacific 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 installation procedure RCPS 20012 (for D-129, D-141, D-71X) or RPIP 824-00 (for CWT) for detailed instructions and recommended reflector attachment. 8 You will find ordering information for these tools see section 10. 8-37 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Product Options Product Series CWT D-129, D-141, D-71X Max. Operating Temperature 125C [257F] 150C [302F] Min. Wire Temperature Rating 85C [185F] 125C [257F] Note: Cadmium-free option (B-152 series) is available for operating temperature of 125C [257F]. Consult Tyco Electronics for details. Table A. CWT Series (125C [257F] rated) Connection-point Type and Size W pin W post Terminal Dimensions Wire AWG/mm2 Part No. W = up to 0.63 [.025] 24 [0.24] 20 [0.61] CWT-1501 CWT-1502 W = 0.63 [.025] to 0.89 [0.035] 24 [0.24] 22 [0.38] 20 [0.61] CWT-1501 CWT-1502 CWT-1503 W = 0.89 [0.035] to 1.14 [.045] 24-22 [0.24-0.38] 20-18 [0.61-0.95] CWT-1502 CWT-1503 W = 1.14 [.045] to 1.52 [.060] 24-22 [0.24-0.38] 20-18 [0.61-0.95] CWT-1503 CWT-1504 W = up to1.52 [.060] 24-20 [0.24-0.61] CWT-1501 W = 1.27 [.050] to 2.28 [.090] 24-18 [0.24-0.95] CWT-1502 W = 1.77 [.070] to 2.79 [.110] 24-18 [0.24-0.95] CWT-1503 W = 2.54 [.100] to 3.80 [.150] 24-18 [0.24-0.95] CWT-1504 W = 2.28 [.090] to 4.70 [.187] 22-16 [0.38-1.21] CWT-1505 W tab 8-38 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Table B. D-129/141/71X Series (up to 150C [302F] rated) Connection-point Type and Size Tape Carrier Spacing of Sleeves (Center-to-Center) 1.27 2.54 3.17 4.0 [0.050] [0.100] [0.125] [0.156] Wire Terminal Dimensions AWG mm2 None 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 0.81 [.032] 20 [0.61] D-141-31 -- D-711-04 D-711-07 D-711-08 W = 0.76 [.030] to 1.27 [.050] 24-20 [0.24-0.61] D-141-56 -- -- -- -- W = up to 1.52 [.060] 24-20 [0.24-0.61] D-129-05 -- D-714-01 -- -- W W = 1.27 [.050] to 2.28 [.090] 24-20 [0.24-0.61] D-129-03 -- -- -- D-714-00 tab W = 2.28 [.090] to 3.55 [.140] 24-20 [0.24-0.61] D-129-0043 -- -- -- -- W W = up to 0.61 [.024] pin W post For Fine Wire Terminations 0.15 mm2 (26 AWG) and Smaller* Part No.* D-110-0062 D-110-0217 D-141-13 D-141-22 D-141-30 Inside Diameter As Supplied** 1.0 [0.040] 1.0 [0.040] 0.75 x 1.65 [0.030 X 0.065] 0.75 x 1.65 [0.030 X 0.065] 0.75 x 1.65 [0.030 X 0.065] Fully Recovered 0.6 [0.025] 0.6 [0.025] 0.75 [0.030] 0.75 [0.030] 0.75 [0.030] Length 16.0 [0.630] 9.0 [0.360] 4.7 [0.185] 6.0 [0.240] 9.5 [0.375] 8 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 combined 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. 8-39 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire Termination to Pin/Post/Tab SolderSleeve Discrete Wire Terminators (Continued) Product Characteristics Specifications/Approvals Material Insulation [D-129, D-141, D-71X] Insulation [CWT] Solder and flux [D-129, D-141, D-71X] Solder and flux [CWT] Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI -J - 004 [RMA flux] Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI -J - 004 [RAflux] Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating [CWT] Temperature rating [D-129, D-141, D-71X] Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] 1000 megohms Series CWT D-129, D-141 Agency ULand CULE87681 ULand CULE87681 Raychem D-5023 RT-1404 8-40 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination Introduction Raychem SolderSleeve shield grounding terminators provide an environmentally 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 -65C to 200C [-85F to 392F], the products in this section include: CWT-X SolderSleeve terminators, designed for low-temperature cables with operating temperatures up to 125C [257F] 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 8-41 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators 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 Product Selection Process Used for shield-to-ground termination. 1. Select product series from the Product Options table below. 4. Select part number (use the selection table indicated for your product series in the Product Options table below). 2. Determine cable dimensions. 5. Refer to Table H on page 8-47 for cross-reference information. 3. Optional: Select preinstalled wire lead type (see Table G on page 8-45 for type descriptions). Jacket OD (max.) Shield OD (min.) Product Options (Refer to Table G on Page 8-45 for Additional Information) Product Series CWT SO63* S01/S02**, S03 SO96*** SO175**** System Oper. Temperature (Max.) 125C [257F] 150C [302F] 150C [302F] 175C [347F] 175C [347F] Used on Cables Rated (Min.) 85C [185F] 125C [257F] 125C [257F] 150C [302F] 150C [302F] Environmental Protection Solder Alloy Flux Type Insulation Material Splash resistant Immersion resistant Immersion resistant Immersion resistant Immersion resistant Cd18 Sn63 Sn63 Sn96 Sn96 RA RMA RMA RA RA Polyolefin Polyvinylidene fluoride Polyvinylidene fluoride Polyvinylidene fluoride Polyvinylidene fluoride Part No. Selection Table A B C, D E 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 125C [257F]. Consult Tyco Electronics for details. Available in: Americas Europe Asia Pacific 8-42 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table A. CWT Series (125C [257F] rated) Cable OD Jacket OD Max. 1.7 [.065] 1.95 [.075] 2.7 [.105] 4.5 [.180] 6.0 [.235] 7.0 [.275] 8.7 [.340] 10.7 [.420] 13.0 [.510] Part Nos. Shield OD Min. 0.9 [.035] 1.1 [.043] 1.5 [.059] 2.0 [.079] 3.3 [.130] 3.3 [.130] 4.5 [.177] 4.5 [.177] 7.0 [.276] No Preinstalled Lead CWT-3801 CWT-3802 CWT-3 CWT-5 CWT-6 CWT-7 CWT-9 CWT-11 CWT-13 With Preinstalled Lead (22AWG/0.38 mm2 green) -- -- CWT-3-W122-5 CWT-5-W122-5 CWT-6-W122-5 CWT-7-W122-5 CWT-9-W122-5 CWT-11-W122-5 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 85C [185F] to 125C [257F]) with bare copper or tin plating. Table B. SO63 Series BiAlloy Temperature Indication System This system greatly enhances the reliability and repeatability of SO63 series terminators while reducing installed cost. The heat-shrinkable thermoplastic sleeve contains a precisely 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. Cable OD Jacket OD Max. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.90 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] 8 Part Nos. No Preinstalled Lead SO63-1-00 SO63-2-00 SO63-3-00 SO63-4-00 SO63-5-00 Preinstalled Lead Option* 20 AWG 22 AWG SO63-1-55-20-90 SO63-2-55-20-90 SO63-3-55-20-90 SO63-4-55-20-90 SO63-5-55-20-90 SO63-1-55-22-90 SO63-2-55-22-90 SO63-3-55-22-90 SO63-4-55-22-90 SO63-5-55-22-90 24 AWG SO63-1-55-24-90 SO63-2-55-24-90 SO63-3-55-24-90 SO63-4-55-24-90 SO63-5-55-24-90 Braid Strap 26 AWG Nickel Plated Tin Plated SO63-1-55-26-90 SO63-2-55-26-90 SO63-3-55-26-90 SO63-4-55-26-90 SO63-5-55-26-90 SO63-1-01 SO63-2-01 SO63-3-01 SO63-4-01 SO63-5-01 SO63-1-9030 SO63-2-9030 SO63-3-9030 SO63-4-9030 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) . 8-43 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table C. S01/S02 M83519 Series 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. Cable OD Part No. (MIL Part Number and Raychem Part No.) by Lead Option Preinstalled Lead Option* No Preinstalled Lead Jacket OD Max Shield OD Min MIL Raychem MIL Raychem MIL Raychem 1.95 [0.075] 2.7[0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] M83519/1-1 M83519/1-2 M83519/1-3 M83519/1-4 M83519/1-5 S01-01-R S01-02-R S01-03-R S01-04-R S01-05-R M83519/2-1 M83519/2-2 M83519/2-3 M83519/2-4 M83519/2-5 S02-01-R S02-02-R S02-03-R S02-04-R S02-05-R M83519/2-6 M83519/2-7 M83519/2-8 M83519/2-9 M83519/2-10 S02-06-R S02-07-R S02-08-R S02-09-R S02-10-R Jacket OD Max. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3[0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] 20 AWG 22 AWG Preinstalled Lead Option* 24 AWG M83519/2-11 M83519/2-12 M83519/2-13 M83519/2-14 M83519/2-15 26 AWG M83519/2-16 S02-16-R M83519/2-17 S02-17-R M83519/2-18 S02-18-R M83519/2-19 S02-19-R M83519/2-20 S02-20-R S02-11-R S02-12-R S02-13-R S02-14-R S02-15-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 termination and inspection. The Raychem part number is permanently marked on the sleeve. Table D. S03 Series Thermochromic Temperature Indicator The S03 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. Cable OD Part No. Jacket OD Max. Preinstalled Lead Option* Shield OD Min. Tin plated Braid Strap Nickel plated Braid Strap 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] S03-01-R S03-02-R S03-03-R S03-04-R S03-05-R S03-06-R S03-07-R S03-08-R S03-09-R S03-10-R *See Table G for lead description. 8-44 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Table E. SO96 Series (175C [347F] rated) Thermochromic Temperature Indicator The SO96 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. Cable OD Part No. Jacket OD Max. Shield OD Min. No Preinstalled Lead 22 AWG Preinstalled Lead Option* Braid Strap 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.9 [.035] 1.40 [.055] 2.15 [.085] 3.30 [.130] 4.30 [.170] SO96-1-00 SO96-2-00 SO96-3-00 SO96-4-00 SO96-5-00 SO96-1-55-22-90 SO96-2-55-22-90 SO96-3-55-22-90 SO96-4-55-22-90 SO96-5-55-22-90 SO96-1-01 SO96-2-01 SO96-3-01 SO96-4-01 SO96-5-01 *See Table G for lead description. The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200C [392F]. This series features a thermochromic 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 F. SO175 Series (175C [347F] 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. Cable OD Part No. Jacket OD Max. Shield OD Min. 1.95 [0.075] 2.7 [0.105] 4.3 [0.170] 6.0 [0.235] 7.0 [0.275] 0.90 [0.035] 1.40 [0.055] 2.15 [0.085] 3.30 [0.130] 4.30 [0.170] 8 Preinstalled Lead Option* No Preinstalled Lead 22 AWG Braid Strap SO175-1-00 SO175-2-00 SO175-3-00 SO175-4-00 SO175-5-00 SO175-1-1-55-22-90 SO175-2-1-55-22-90 SO175-3-1-55-22-90 SO175-4-1-55-22-90 SO175-5-1-55-22-90 SO175-1-01 SO175-2-01 SO175-3-01 SO175-4-01 SO175-5-01 *See Table G for lead description. Table G. Preinstalled Lead Description Series M83519, SO63 SO96, SO175 SO63, SO96, S03 CWT SO63, S03 Lead Type 55A0111 55A0813 Braid strap XLpolyethylene Braid Strap Remarks MIL-W-22759/32 MIL-W-22759/41 Uninsulated ULListed Uninsulated Plating Tin Nickel Nickel Tin Tin Stranding Stranded Stranded 40 x 38 AWG Stranded (W1) Stranded Min. Length 150 [6.00] 150 [6.00] 150 [6.00] 150 [6.00] 150 [6.00] 8-45 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shield Termination SolderSleeve Shield Terminators (Continued) Product Characteristics Material Insulation SO, M83519 CWT Solder and flux SO63, M83519, S03 SO96, SO175 series CWT Ground lead CWTseries SO, M83519, SO175 Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating CWT SO63/M83519/S03 SO96/SO175 series Insulation resistance Specifications/Approvals Series CWT SO63* M83519** SO96*** SO175 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Solder: Sn96 Ag4 Solder: Sn50 Pb32 Cd18 Flux: ROL1 per ANSI - J - 004 (RMAFlux) Flux: ROM1 per ANSI - J - 004 (RAFlux) Flux: ROM1 per ANSI - J - 004 (RAFlux) XLpolyethylene MIL-W-22759/32 or /41 2.5 mV Exceeds strength of ground lead 1.0 kV immersed -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] -55C to 175C [-67F to 347F] 1000 megohms Agency -- NAS 1747 MIL-S-83519/1&/2 NAS 1747 Raychem D-5023 RT-1404 RT-1404 RT-1404 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. 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: 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 HL1802E M83519 (S01/S02) RCPS 100-70 AA-400 Super Heater SO96 RCPS 100-70 CV-1981 S03 RCPS 100-70 MiniRay SO175 RCPS-100-70 IR-1759 You will find ordering information for these tools in section 10. 8-46 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 8-47 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination Introduction Raychem SolderSleeve coaxial cable terminators allow reliable, easy terminations in a variety of coaxial cable applications, including 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 150C [302F], 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 terminators, which permit quick, easy, and costeffective terminations of coaxial cable to printed circuit boards. RF one-step BNC/TNC connectors, which are single-piece assemblies for terminating the center conductor and the braid of a broad range of coaxial cables. They are fully intermateable with MIL-C39012C connectors and are available in 50-ohm and 75-ohm versions (refer to pages 8-53 to 8-58 for product information). With precisely measured solder and flux, SolderSleeve products provide exact process control of terminations. The SolderSleeve method means strong connections with the lowest possible voltage drop. Small, lightweight SolderSleeve terminators are also the ideal solution for high-density packaging problems. 8-48 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 Applications Product Selection Process Used for terminating coaxial cable to component terminals, contacts, printed circuit boards, and solderless wrap terminals. 1. Select product series from the product options 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. 2. Select preinstalled lead type from the table below. Product Options Product Series CWT B-02X/B-04X D-181 D-184 Max. Operating Temp. 125C [257F] 150C [302F] 150C [302F] 125C [257F] Use on Cables Rated (Min) 85C [185F] 125C [257F] 125C [257F] 85C [185F] Cable Shield Plating Tin, copper Tin, silver Tin, silver Tin Part No. Selection Table A B C D Design 2-pc. 1-pc. 2-pc. 2-pc. Preinstalled Lead Descriptions Series CWT B-021 B-041 B-043 B-020 B-040 B-044 D-181-12XX D-181-22XX D-181-32XX D-181-18XX D-181-28XX D-184 Lead Type XLpolyethelene M81822/13 (solderless wrap) M81822/13 (solderless wrap) M81822/13 (solderless wrap) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) 55A0111 (MIL-W-22759/32) M81822/13 M81822/13 55A0111 (MIL-W-22759/32) Plating Tin Silver Silver Silver Tin Tin Tin Tin Tin Tin Silver Silver Tin Stranding Stranded (W1) Solid-OFHC Solid-OFHC Solid-OFHC Stranded Stranded Stranded Stranded Stranded Stranded Solid Solid Stranded AWG 22 24--30 24--30 24--30 20--30 20--30 20--30 20--30 20--30 20--30 26 - 30 26 - 30 20 - 26 Length 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] 150 [6.000] Color White (cntr), green (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), white w/black stripe (grnd) White (cntr), white w/black stripe (grnd) White (cntr), white w/black stripe (grnd) White (cntr), blue (grnd) White (cntr), blue (grnd) White (cntr), white w/black stripe (grnd) 8 Product Characteristics Available in: Americas Europe Asia Pacific Material Insulation (B-02X/B-04X, D-181, D-184) Insulation (CWTseries) Solder and flux (B-02X/B-04X, D-181) Solder and flux (CWTseries, D-184) Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating (CWT, D-184) Temperature rating (B-02X/B-04X, D-181) Insulation resistance Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar) Radiation-crosslinked, heat-shrinkable polyolefin Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAFlux) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI-J-004 (RAFlux) 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 125C [-67F to 257F] -55C to 150C [-67F to 302F] 1000 megohms 8-49 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve Coaxial Cable Terminators (Continued) Table A. CWT Series Part Numbers 174 58, 122 59 Table B. B-02X/B-04X Series Part Numbers Part No. With Preinstalled Lead AWG/0.38 mm2 Green/White) CWT-4174-W122-5/9 CWT-4058-W122-5/9 CWT-4059-W122-5/9 Dimensions Cable RG Number Dielectric OD Jacket OD 0.80-2.30 [.032-.091] 2.00-2.80 [.079-.110] 2.80-3.30 [.110-.130] 1.30-2.80 [.051-.110] 2.50-4.40 [.100-.173] 3.20-6.00 [.125-.235] Part 1: Coaxial Product Group Selection Typical Compatible Part No. Raychem RG Cable Cable Jacket OD (Max.) Number Description Dimension Range Shield OD Dielectric OD One-Piece Conductor Coaxial Product OD Group RG178, RG404 5030A13XX 5028A13XX 3.40 [.134] 1.30-2.30 [.051-.091] 0.50-1.70 [.019-.067] 0.30-0.80 [.011-.032] Group 1 RG179, RG316 5024A13XX 7530A13XX 7526A13XX 9530A13XX 4.40 [.173] 1.50-2.80 [.060-.110] 1.20-2.50 [.047-.100] 0.30-1.60 [.011-.063] Group 2 RG180, RG302, RG303 9527A13XX 9528A13XX 6.30 [.248] 2.40-4.60 [.094-.181] 1.40-4.30 [.055-.169] 0.30-2.80 [.011-.110] Group 3 Part 2: Product Part Number Selection One-Piece Coaxial Product Group Group 1 Group 2 Group 3 Preinstalled Wire Type Preinstalled Wire Size 24 26 AWG AWG 20 AWG 22 AWG 28 AWG 30 AWG Stranded (M22759) -- B-044-22-N B-044-24-N B-044-26-N -- -- Solid (M81822) -- -- B-043-24-N B-043-26-N B-043-28-N B-043-30-N Stranded (M22759) B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N Solid (M81822) -- -- B-041-24-N B-041-26-N B-041-28-N B-041-30-N Stranded (M22759) B-020-20-N B-020-22-N B-020-24-N B-020-26-N -- -- Solid (M81822) -- -- -- B-021-26-N -- -- 1. The B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125C 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 C. D-181 Series Part Numbers Product Name D-181-1220-90/9 D-181-1222-90/9 D-181-1224-90/9 D-181-1226-90/9 D-181-1826-6/9 D-181-1830-6/9 D-181-2220-90/9 D-181-2222-90/9 D-181-2224-90/9 D-181-2226-90/9 D-181-2826-6/9 D-181-2830-6/9 D-181-3220-90/9 D-181-3222-90/9 D-181-3224-90/9 D-181-3226-90/9 D-181-3826-6/9 D-181-3830-6/9 Table D. D-184 Series Part Numbers Product Name D-184-1220-90/9 D-184-1222-90/9 D-184-1224-90/9 D-184-1226-90/9 D-184-2220-90/9 D-184-2222-90/9 D-184-2224-90/9 D-184-2226-90/9 Product Dimensions C D E min. min. min. A min. B min. F min. L1 max. L2 max. 3.7 [0.145] 3.2 [0.125] 2.7 [0.105] 2.4 [0.095] 2.3 [0.09] 0.71 [0.028] 17 [0.67] 21.5 [0.85] 4.5 [0.18] 4 [0.16] 3.45 [0.135] 2.9 [0.115] 3 [0.12] 1.1 [0.045] 17 [0.67] 22.7 [0.895] 5.2 [0.205] 4.7 [0.185] 4.45 [0.175] 3.95 [0.155] 4 [0.16] 1.3 [0.055] 17 [0.67] ] 21.5 [0.85] A B min. min. F min. L1 max. L2 max. 3.7 [0.145] 3.2 [0.125] 2.7 [0.105] 2.4 [0.095] 2.3 [0.09] 0.71 [0.028] 17 [0.67] 21.5 [0.85] 4.5 [0.18] 4 [0.16] 3.45 [0.135] 2.9 [0.115] 3 [0.12] 1.1 [0.045] 17 [0.67] 22.7 [0.895] Product Dimensions D E min. min. min. C Wire AWG 20 22 24 26 26 30 20 22 24 26 26 30 20 22 24 26 26 30 Wire AWG 20 22 24 26 20 22 24 26 8-50 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve PCB/Coaxial Cable Terminators 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 Installation Product Selection Process Used for terminating coaxial cable to printed circuit boards. 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: 1. Select product series from the Product Options table below. HL1802E AA-400 Super Heater IR-1759 MiniRay CV-1981 2. Determine cable RG number or outside diameter 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, determine straight or rightangle entry to PCB and grid pattern, then select the appropriate part number from Table A on the next page. For B-046 (PinPak, or pin to ground) series, determine hole spacing and diameter. Refer to Table B for product selection (see illustration below for cable dimensions). Refer to Raychem installation procedure ES61139 for detailed instructions and recommended reflector attachments. You will find ordering information for these tools in Section 10. Available in: Americas Europe Asia Pacific 8 Product Options Product Series D-607 B-046 Typical Application Performance Matched impedance up to 2.3 GHz Effective transmission up to 100 MHz Shield Method Metal body Pin to ground Part No. Selection Table A B 8-51 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination SolderSleeve PCB/Coaxial Cable Terminators (Continued) Specifications/Approvals Series D-607 B-046 Raychem RT-1404 RT-1404 Table A. D-607 Series Part Numbers Cable Dimensions (mm/in) Max. Outside Diameter Jacket Shield Dielectric Straight grid 5.08 [.200] Part No. Entry to PCB Right-Angle Grid 5.08 [.200] 1.5-3.55 [.060-.140] 1.1-3.15 [.045-.125] 0.60-2.25 [.025-.090] D-607-09 D-607-10 RG Cable No. 174, 178, 179, 316, 404 Straight Grid 2.54 [.100] D-607-40* Table B. B-046 Series Part Numbers Cable Dimensions RG Cable No. Part No. A B C D Max. Pin Diameter Spacing Between Pins 2.54 [.100] 178, 404 0.30-0.80 [.011-.032] 0.5-1.7 [.019-.067] 1.3-2.3 [.050-.091] 3.4 [.134] 0.6 [.023] 0.8 [.031] B-046-14-N 179, 316 0.3-1.6 [.011-.063] 1.2-2.5 [.047-.100] .1.5-2.8 [.060-.110] 4.4 [.173] 0.6 [.023] 0.8 [.031] B-046-15-N 5.08 [.200] 6.35 [.250] B-046-10-N B-046-11-N B-046-66-N B-046-68-N B-046-12-N B-046-13-N B-046-16-N B-046-18-N Product Characteristics Material Insulation Solder and flux Termination body/pin Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMAflux) Copper alloy, solder-plated Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance 2.0 mV Exceeds strength of conductor 2.0 kV -55C to 150C [-67F to 302F] 1000 megohms Electrical Performance (typical) D-607 Series Only Frequency 350 MHz 700 MHz 2.3 GHz VSWR (D-607-09, -40) 1.04 max. 1.05 max. 1.09 max. VSWR (D-607-10) 1.04 max. 1.09 max. 1.12 max. 8-52 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors 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 Applications One-Step BNC/TNC connectors 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. 8 Specifications 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: * Steinel Model HL1802E * CV-1981 Raychem RB-115 Available in: Americas Europe Asia Pacific Refer to Raychem installation procedure RPIP683-00 for detailed instructions. 8-53 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) Product Options and Part Numbering System RXX - XX - X - XX Connector Style Dash No. Style -XX Connector Type TNC -00 Straight plug -01 Right-angle plug -02 Straight bulkhead jack -03 Straight jack BNC Male Female -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. 8-54 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) Product Characteristics Material Gold-plated beryllium copper (female) Gold-plated brass (male) PTFE Silver-plated brass Nickel-plated brass Sn63Pb37, RMAflux Tin-plated copper wire per ASTM B3 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black Center contact Dielectric insulator Transition Connector body Solder and flux Braided shield Insulation sleeve Strain relief/sealing sleeve Typical Performance Dielectric withstand voltage Insulation resistance Temperature rating Contact resistance-straight Contact resistance -- right-angle Cable retention force Voltage rating Connector durability 1500 V 5000 megohms -55C to 150C [-67F to 302F] Inner = 1.5 milliohms, outer = 1.0 milliohm Inner = 2.5 milliohms, outer = 1.5 milliohms 295N (66 lb) to 822N (196 lb) 500 V RMS 500 mating cycles minimum Electrical Performance Nominal impedance Frequency range 50 and 75 ohms Up to 2.8 GHz 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. 8-55 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.00 [.060-.217] 3.50-7.00 [.138-.276] 5.00-.12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 5 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.126] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.1-9.50 [.161-.375] 0.9-3.00 [.035-.118] 2.1-5.00 [.083-.197] 4.1-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.00 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 5 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.5o [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables BNC Straight Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 Raychem Cables 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Right-Angle Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Straight Bulkhead Jacks, Female Contacts RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 50 RG-196,RG-316 5030A1317 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 50 RG-303, RG-400 5020A1311 RG-165, RG-215, RG-213, 50 5012F3332, 5012A3311 RG-225, RG-214 75 RG-179, RG-187 7530A1317 75 -- 75 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Straight Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 75 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- BNC Straight Panel Jacks, Female Contacts RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 50 RG-196,RG-316 5030A1317 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 50 RG-303, RG-400 5020A1311 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 50 RG-225, RG-214 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RBD-50-S-00 RBD-50-M-00 RBD-50-L-00 RBD-75-S-00 RBD-75-M-00 RBD-75-L-00 RBD-50-S-01 RBD-50-M-01 RBD-50-L-01 RBD-75-S-01 RBD-75-M-01 RBD-75-L-01 RBD-50-S-02 RBD-50-M-02 RBD-50-L-02 RBD-75-S-02 RBD-75-M-02 RBD-75-L-02 RBD-50-S-03 RBD-50-M-03 RBD-50-L-03 RBD-75-S-03 RBD-75-M-03 RBD-75-L-03 RBD-50-S-04 RBD-50-M-04 RBD-50-L-04 RBD-75-S-04 RBD-75-M-04 RBD-75-L-04 8-56 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) TNC Coaxial Connectors D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 1.55 [.060] 3.0 [.118] 7.3 [.287] 1.55 [.060] 3.7 [.146] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 0.9-3.0 [.035-.118] 2.1-5.0 [.083-.197] 4.1-9.5 [.161-.375] 1.55 [.060] 3.0 [.118] 7.3 [.287] 1.55 [.060] 3.7 [.146] 7.3 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables TNC Straight Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 Raychem Cables 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- TNC Straight Jacks, Female Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- TNC Straight Panel Jacks, Female Contacts RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 50 RG-196,RG-316 5030A1317 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 50 RG-303, RG-400 5020A1311 RG-165, RG-215, RG-213, 50 5012F3332, 5012A3311 RG-225, RG-214 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RTD-50-S-00 RTD-50-M-00 RTD-50-L-00 RTD-75-S-00 RTD-75-M-00 RTD-75-L-00 RTD-50-S-03 RTD-50-M-03 RTD-50-L-03 RTD-75-S-03 RTD-75-M-03 RTD-75-L-03 RTD-50-S-04 RTD-50-M-04 RTD-50-L-04 RTD-75-S-04 RTD-75-M-04 8 RTD-75-L-04 8-57 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Coaxial Cable Termination RF One-Step BNC/TNC Connectors (Continued) TNC Coaxial Connectors D (Min.-Max.) Cable Dimensions E F (Min.-Max.) (Max.) G (Max.) 1.50-5.50 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 1.5-5.5 [.060-.217] 3.5-7.0 [.138-.276] 5.0-12.5 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.00-12.50 [.197-.500] 1.50-5.50 [.060-.217] 3.50-7.00 [.138-.276] 5.0-12.5 [.197-.500] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 0.90-3.00 [.035-.118] 2.10-5.00 [.083-.197] 4.10-9.50 [.161-.375] 1.55 [.060] 3.00 [.118] 7.30 [.287] 1.55 [.060] 3.70 [.146] 7.30 [.287] 0.65 [.025] 1.25 [.050] 2.45 [.100] 0.65 [.025] 1.25 [.050] 2.45 [.100] Cable Type Impedance (ohms) RG Cables Raychem Cables TNC Straight Bulkhead Jacks, Female Contacts RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 50 RG-196,RG-316 5030A1317 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 50 RG-303, RG-400 5020A1311 RG-165, RG-215, RG-213, 50 5012F3332, 5012A3311 RG-225, RG-214 75 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- TNC Right-Angle Plugs, Male Contacts RG-174, RG-178, RG-188, 50 RG-196,RG-316 RG-58, RG-141, RG-142, 50 RG-303, RG-400 RG-165, RG-215, RG-213, 50 RG-225, RG-214 75 5026A1311, 5028A1317, 5030A1317 5019D3318, 5021D1331, 5020A1311 5012F3332, 5012A3311 RG-179, RG-187 7530A1317 75 -- 7524A1311, 7528A1317 75 RG-6, RG-11, RG-12, RG-59 RG-144, RG-216 -- Part No. RTD-50-S-02 RTD-50-M-02 RTD-50-L-02 RTD-75-S-02 RTD-75-M-02 RTD-75-L-02 RTD-50-S-01 RTD-50-M-01 RTD-50-L-01 RTD-75-S-01 RTD-75-M-01 RTD-75-L-01 8-58 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 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 consisting of a flux-coated, solderimpregnated copper shield braid encased in a heatshrinkable insulation sleeve. SolderShield cable-to-cable splice kits, designed for single-conductor or multiconductor 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 8-59 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices Product Facts Flux-coated, solderimpregnated 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 Applications Product Selection Process Used for splicing a wide range of cables, including coaxial and multiconductor cables. For splicing multiconductor cables refer to Table A. 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, solderimpregnated 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. 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 Refer to Raychem installation procedure RCPS 15002 (D-150 series) and RPIP 699-00 (B-202 series) for detailed instructions and recommended reflector attachment. You will find ordering information for most of these tools in Section 10. Specifications/Approvals Series Military US: M81824 (conductor splice only) UK: RAF AP1130-2008-1 D-150 Available in: Americas Europe Asia Pacific Raychem RT-1404 8-60 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) SolderShield Splice Table A. Multiconductor Cable Splices Crimp Splice 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 Product Dimensions Dimensions Part No. Tin Plated Nickel Plated L1 Max. L2 Nom. L3 Min. ID Min. D-150-0168 D-150-0228 D-150-0169 D-150-0229 D-150-0170 D-150-0230 D-150-0174 D-150-0231 D-150-0175 D-150-0232 D-150-0176 D-150-0233 D-150-0177 D-150-0234 D-150-0178 D-150-0235 D-150-0179 D-150-0236 D-150-0180 D-150-0237 D-150-0181 D-150-0238 80.50 [3.17] 80.50 [3.17] 80.50 [3.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 10.60 [4.17] 50.00 [1.97] 50.00 [1.97] 50.00 [1.97] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 75.00 [2.95] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 10.20 [.400] 3.00 [.118] 4.00 [.157] 5.00 [.197] 4.00 [.157] 5.00 [.197] 6.00 [.236] 9.00 [.356] 4.00 [.157 ] 5.00 [.197] 6.00 [.236] 9.00 [.353] Conductor Splice Size Range CMA [mm2] Min.-Max. 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 304-1510 [0.15-0.75] 304-1510 [0.15-0.75] 779-2680 [0.39-1.34] 1900-6755 [0.95-3.37] 1900-6755 [0.95-3.37] Color Code Quantity Per Kit Red 1 Blue 1 Yellow 1 Red 2 Blue 2 Yellow 2 Yellow 2 Red 4 Red 4 Blue 4 Yellow 4 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 conductors. All the kits have environmental-sealing capability. The cable temperature rating must be 125C 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. 8 8-61 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) Table B. Coaxial Cable Splices SolderShield Splice Crimp Splice 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. RG Cable No. Raychem Cable Description 8A, 9B, 11 13, 26, 31 115, 144, 149 165, 213, 214 216, 235, 391 393, 397 178, 196, 179, 187, 188, 316, 404, M17/138-00001, M17/136-00001 180, 195 M17/137-00001 M17/139-00001 -- 124, 140, 141 159, 302, 303 -- -- -- 29, 30, 55B 58, 223 -- 59, 62, 71 -- -- 5012A3311 5012E1339 7518A1311 -- -- -- 5028A1317 7528A1317 5030A1317 7530A1317 5024A1311 7526A1311 9527A1318 9530E1014 5020A1311 5022A1311 7522A1311 7523D1331 7524A1311 5019D3318 5021D1331 5022A1311 7523D1331 7524A1311 9524A1311 SolderShield Dimensions L2 Min ID Min Conductor Splice Qty/Kit Part No. 1 D-150-0214 80.50 [3.170] 50.00 [1.970] 12.00 [.472] 1 D-150-0094 80.50 [3.170] 50.00 [1.970] 3.00 [.118] 1 D-150-0095 80.50 [3.170] 50.00 [1.970] 4.00 [.157] 1 D-150-0096 80.50 [3.170 ] 50.00 [1.970] 5.00 [.236] 1 B-202-81* 56.00 [2.200] 23.00 [.900] 7.00 [.275] 1 B-202-82* 56.00 [2.200 ] 23.00 [.900] 7.00 [.275] L1 Max *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. 8-62 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Cable-to-Cable Splicing SolderShield Shielded and Coaxial Cable Splices (Continued) Product Characteristics Materials Insulation sleeve Meltable inserts Radiation-crosslinked polyvinylidene fluoride Fluorocarbon-based thermoplastic Base metal: Copper alloy C10200 per ASTM B75 Plating: Tin per MIL-T-10727 or nickel per QQ-N-290 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) MiniSeal crimp splice SolderShield shield splice Parameter Electromechanical Performance Dielectric strength (shield connection) Dielectric strength (conductor connection) Voltage drop Insulation resistance (shield connection) Insulation resistance (conductor connection) Tensile strength for MiniSeal Tensile strength for SolderShield Temperature rating Environmental Resistance Salt spray Heat aging Temperature cycling Altitude immersion Test Method Requirement -- -- MIL-S-81824 -- -- MIL-S-81824 MIL-S-81824 No breakdown or arcing at 1000 Vac (RMS) 2.5 kV Less than 2.0-millivolt increase 1000 megohms minimum at 500 Vdc 5000 megohms Exceed yield strength (pounds) of wire. 75% of strength (pounds) of unspliced cable -- MIL-STD-202 M101 750 hours at 150C [302F] MIL-STD-202 M107C Immersion at 22,860m [75,000 ft] Corrosion resistance -- -55C to 150C [-67F to 302F] Meet voltage drop requirement. Meet all electromechanical requirements. Meet all electromechanical requirements. Meet insulation-resistance requirement. No evidence of corrosion after testing in accordance with MIL-STD-202, Method 101, Test Condition A 8 8-63 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts Introduction Raychem SolderTacts shielded contacts are designed to provide reliable, one-piece solder terminations for use with circular and rectangular connectors. These controlled 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. SolderTacts products are available to terminate coaxial cable and twisted wire pairs in both military and commercial applications. 8-64 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts Product Facts Reliable one-piece solder contacts: through-connector shielding reduces crosstalk, 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 Applications One-piece controlled-soldering SolderTacts contacts connectors are designed to terminate coaxial cables, shielded wires, and twisted pairs faster and more reliably than any other method. SolderTacts contacts eliminate the variables associated with hard-to-handle crimping. Their one-step installation accelerates production while reducing handling and installed costs. Controlled Soldering SolderTacts contacts provide 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 provide 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 suited to military applications, along with commercial aerospace, instrumentation and computers. SolderTacts products are compatible with most standard connector cavities. SolderTacts contacts are intermateable and intermountable with contacts qualified to the indicated specification. 8 SolderTacts shielded contacts can be terminated with standard Raychem heating tools. Once terminated, they can be installed into connector cavities with standard insertion and extraction tools. They are replaceable without cutting and restripping or shortening the cable. Specifications/Approvals Available in: Americas Europe Asia Pacific Series D-602 Raychem D-6002 8-65 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Product Construction, MIL-C-26482 Series SolderTacts Series: MIL-C-26482 Contact Military Specification Cable Diameter JOD SOD DOD COD 1.78-4.70 [.070-.185] 1.78-4.70 [.070-.185] 1.52-3.30 [.060-.130] 1.52-3.30 [.060-.130] 1.65-2.79 [.065-.110] 1.65-2.79 [.065-.110] 1.68-2.13 [.066-.089] 1.68-2.13 [.066-.089] -- -- -- -- -- -- .76-2.03 [.030-.080] .76-2.03 [.030-.080] .91-1.75 [.036-.069] .91-1.75 [.036-.069] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .23-.51 [.009-.020] .23-.51 [.009-.020] .30-.66 [.012-.026] .30-.66 [.012-.026] .28-.79 [.011-.031] .28-.79 [.011-.031] MIS-20067/5-001 MIS-20067/6-001 -- -- Wire (AWG) Raychem SolderTacts Part No. Size Polarity Cable Type 24-32 D-602-16 12 S Coaxial 24-32 D-602-17 12 P Coaxial 24-30 D-602-46 16 P Coaxial 26-32 D-602-47 16 S Coaxial 24-30 D-602-56 16 P Twinax 24-30 D-602-57 16 S Twinax These SolderTacts contacts are on qualified parts list for indicated specification. Tooling Selection Guide Part Numbers D-602-46/47 D-602-56/57 D-602-16/17 Engineering Standard (Termination Instructions) ES61137 ES61138 ES61161 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-17 -- -- Repair Wand IR1004 Infrared Semiautomatic Heater Tool Set Contact Insertion Tool Contact Removal Tool * -- -- * -- -- AD-1525 (M81969/17-04) -- AD-1526 (M81969/19-08) -- *Could be developed. 8-66 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-28748 Series SolderTacts product construction, MIL-C-28748 Series Contact Military Specification MIS-20067/2-002a MIS-20067/1-001a MIS-20067/4-001a Cable Diameter JOD SOD DOD COD 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084] -- -- .91-1.78 [.036-.070] .91-1.78 [.036-.070] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .91-1.68 [.036-.066] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.78 [.036-.070] .91-1.78 [.036-.070] 1.40-3.15 [.055-.124] 1.40-3.15 [.055-.124] .23-.89 [.009-.035] .23-.89 [.009-.035] .28-.79 [.011-.031] .28-.79 [.011-.031] .30-.66 [.012-.026] .30-.66 [.012-.026] .30-.66 [.012-.026] .30-.66 [.012-.026] .28-.79 [.011-.031] .28-.79 [.011-.031] .23-.46 [.009-.018] .23-.46 [.009-.018] .64-1.57 [.025-.062] .64-1.57 [.025-.062] MIS-20067/3-001a -- -- M39029/79b 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] -- -- -- -- -- -- -- 1.52-3.35 [.060-.132] 1.52-3.35 [.060-.132] 1.68-2.13 [.066-.084 ] 1.68-2.13 [.066-.084 ] MIS-20067/8-001a -- -- MIS-20067/7-001a -- -- M39029/80b M39029/40b M39029/41b MIS-20067/2-001, 003a Wire (AWG) Raychem SolderTacts Part No. Size Polarity Cable Type 26-32 D-602-44 16 P Coaxial 26-32 D-602-45 16 S Coaxial 24-30 D-602-54 16 P Twisted pair 24-30 D-602-55 16 S Twisted pair 26-32 D-602-72 16 P Coaxial 26-32 D-602-73 16 S Coaxial 26-32 D-602-76 16 P Coaxial 26-32 D-602-77 16 S Coaxial 24-30 D-602-0126 16 P Twisted pairc 24-30 D-602-0127 16 S Twisted pairc 28-32 D-602-0172 16 P Coaxial 28-32 D-602-0173 16 S Coaxial 16-20 D-610-09 16 P Power 16-20 D-610-10 16 S Power 8 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. 8-67 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) Tooling Selection Guide: MIL-C-28748 Series SolderTacts Series 748 SolderTacts Series 748 D-602-44/45 D-602-0172/0173 D-602-54/55 D-602-0126/0127 ES61133 ES61240 ES61132 ES61199 Convection (Hot Air) Heating AT-1319 Repair Adapter Wand AT-1319-14 AD-1480 -- -- -- -- -- -- D-610-09/10 ES61187 AT-1319-15 AD-1571 D-602-72/73 ES61135 AT-1319-18 AD-1486 D-602-76/77 ES61164 AT-1319-20 AD-1554 Part No. Contact Insertion Tool Engineering Standard (Termination Instructions) Contact Removal Tool * AD-1447 IR1004 Infrared Semiautomatic Heater Tool Set Tool Set #2 -- -- -- Tool Set #10 (AT-1044-12) Tool Set #5 (AT-1044-63) Tool Set #6 (AT-1044-64) Special Tools AD-1457A (bushing tool) AD-1464 (flex tip removal tool) AD-1496 (twisted pair cut-tolength tool) *Not applicable. 8-68 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-38999, Series I, II, III, IV Circular Connectors Contact United States Military Air Force Specification Drawing No. SolderTacts Product Construction, MIL-C-38999 Series Cable Diameter JOD SOD DOD COD 3.81-5.94 [.150-.234] 3.81-5.94 [.150-.234] 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] 3.10-4.32 [.150-.170] 3.10-4.32 [.150-.170] 1.68-2.13 [.066-.084] 1.68-2.13 [.066-.084] -- -- 1.52-3.84 [.060-.151] 1.52-3.84 [.060-.151] .91-1.73 [.036-.068] .91-1.73 [.036-.068] .64-1.09 [.025-.043] .64-1.09 [.025-.043] 1.12-2.03 [.044-.080] 1.12-2.03 [.044-.080] .74-1.45 [.029-.057] .74-1.45 [.029-.057] 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .91-1.78 [.036-.070] .91-1.78 [.036-.070] .76-1.24 [.030-.049] .76-1.24 [.030-.049] .64-1.29 [.029-.051] .64-1.29 [.029-.051] .48-1.09 [.019-.043] .48-1.09 [.019-.043] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .48-.89 [.019-.035] .27-.79 [.011-.031] .27-.79 [.011-.031] .23-.89 [.009-.035] .23-.89 [.009-.035] .27-.79 [.011-.031] .27-.79 [.011-.031] .27-.74 [.011-.029] .27-.74 [.011-.029] Wire (AWG) Raychem SolderTacts Part Number Size Polarity Cable Type 22-24 D-602-0122 8 P Coaxial 22-24 D-602-0123 8 S Coaxial 26-30 D-602-0140 16 P Coaxial 26-30 D-602-0141 16 S Coaxial 26-30 D-602-0142 16 P Twisted pair 26-30 D-602-0143 16 S Twisted pair 24-32 D-602-0144 12 P Coaxial 24-32 D-602-0145 12 S Coaxial 22-26 D-602-0146 12 P Twisted pair 22-26 D-602-0147 12 S Twisted pair 22, 28 D-602-0150 12 P Coaxial 22, 28 D-602-0151 12 S Coaxial 24-26 D-602-1108 8 S Twisted pairb 24-26 D-602-1109 8 P Twisted pairb 22-26 D-602-1110 8 S Triaxial 22-26 D-602-1111 8 P Triaxial 24-26 D-602-1112 8 S Twisted pairb 24-26 D-602-1113 8 P Twisted pairb 24-26 DK-602-0156-N-1 8 P Twinaxialc 24-26 DK-602-0156-N-2 8 P Twinaxialc Series I, III, and IV M39029/60 M39029/59 M39029/76 M39029/77 M39029/76 M39029/77 M39029/28 M39029/75 M39029/28 M39029/75 M39029/28 M39029/75 a a a a a a a a a a a a -- -- -- -- -- -- M39029/90 M39029/90 a a -- -- 915304-1 915305-1 915304-2 915305-2 -- -- 915307-1 1.47-3.10 [.058-.122] 1.47-3.10 [.058-.122] 1.68-2.39 [.066-.094] 1.68-2.39 [.066-.094] 915307-3 -- -- 915308-3 -- 915308-1 1.90-3.81 915307-2 [.075-.150] 1.90-3.81 915308-2 [.075-.150] 8340712-OS-01 2.49-3.42 [.098-.135] 8340713-OS-01 2.49-3.42 [.098-.135] 2.49-3.76 -- [.098-.148] 2.49-3.76 -- [.098-.148] 8340712-OL-01 2.49-3.42 [.098-.135] 8340713-OL-01 2.49-3.42 [.098-.135] 3.68 8912020-OS-01 [.145 ] Max. 4.11 8912020-DL-01 [.162] Max. -- 2.54-2.97 [.100-.117] 2.54-2.97 [.100-.117] 1.68-3.05 [.066-.120] 1.68-3.05 [.066-.120] 1.68-3.30 [.066-.130] 1.68-3.30 [.066-.130] 1.68-3.05 [.066-.120] 1.68-3.05 [.066-.120] -- -- 8 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. 8-69 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-38999, Series I, II, III, IV Circular Connectors (Continued) Contact Military Specification United States Air Force Drawing No. Cable Diameter (in inches) Wire (AWG) Raychem SolderTacts Part Number Size 24-26 DK-602-0156-N-3 8 P Twinaxialc 24-26 DK-602-0157-N-1 8 S Twinaxialc 24-26 DK-602-0157-N-2 8 S Twinaxialc 24-26 DK-602-0157-N-3 8 S Twinaxialc Polarity Cable Type JOD SOD DOD COD 4.50 max. [.177] 3.68 max. [.145] 4.12 max. [.162] 4.50 max. [.177] 4.67 max. [.184] 4.67 max. [.184] -- .74-1.30 [.029-.051] .74-1.30 [.029-.051] .74-1.30 [.029-.051] .74-1.30 [.029-.051] .24-.74 [.011-.029] .24-.74 [.011-.029] .24-.74 [.011-.029] .24-.74 [.011-.029] -- -- -- 20 DK-602-0169-1 8 P Twinaxialc -- -- -- 20 DK-602-0170-1 8 S Twinaxialc .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] .23-.58 [.009-.023] 26-30 D-602-0140 16 P Coaxial 26-30 D-602-0171 16 S Coaxial 26-30 D-602-0142 16 P Twisted pair 26-30 D-602-0174 16 S Twisted pair Series I, III, and IV M39029/90 M39029/91 M39029/91 M39029/91 M39029/90 M39029/91 a a a a a a 8912020-EL-01 8912019-OS-01 8912019-DL-01 8912019-EL-01 8912020-OL-01 8912019-OL-01 -- -- -- Series II M39029/76 M39029/77 M39029/76 M39029/77 a a a a 915304-1 915306-1 1.27-2.62 [.050-.103] 1.27-2.62 [.050-.103] 915304-2 -- 915306-2 -- 1.68-2.13 .91-1.73 [.066-.084] [.036-.068] 1.68-2.13 .91-1.73 [.066-.084] [.036-.068] .64-1.09 -- [.025-.043] .64-1.07 -- [.025-.042] 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. Tooling Selection Guide SolderTacts Series 999 Size 16 999 Size 12 999 Size 8 Part Numbers (D-602-) 0140/0141 0142/0143 0171 0174 0144/0145 0146/0147 0150/0151 0122/0123 1108/1109 1110/1111 1112/1113 0156/0157-X 0169/0170-X Engineering Standard (Termination Instructions) ES61226 ES61224 ES61226 ES61224 ES61206 ES61218 ES61223 ES61179 ES61172 ES61172 ES61184 ES61231 ES61235 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-78 -- AT-1319-27 -- AT-1319-24 -- -- AT-1319-22 AT-1319-22 and AT-1319-14 Repair Wand IR1004 Infrared Semiautomatic Heater Tool Set AD-1565 -- AD-1572 -- AD-1566 -- -- AD-1568 -- AT-1044-70 (P) AT-1044-69 (S) -- -- AT-1044-72 (P) AT-1044-71 (S) -- AD-1568 and AD-1480 -- Contact Insertion Tool Contact Removal Tool* M81969/8-07 or M81969/14-03 M81869/8-08 or M81969/14-03 M81969/8-09 or M81969/14-04 M81969/8-10 or M81969/14-04 -- M81969/14-06 or Astro ATBX-2277 *Tyco Electronics does not provide this tool. See connector manufacturer. 8-70 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: Subminiature* SolderTacts Product Construction, Submin Series Raychem Cable Diameter SolderTacts Size Polarity Cable Type D-602-0278 16 P Coaxial D-602-0279 16 S D-602-0288 16 D-602-0289 16 Coaxial JOD 1.52-2.92 [.060-.115] 1.52-2.92 [.060-.115] SOD 1.85-2.18 [.073-.086] 1.85-2.18 [.073-.086] P Twisted pair -- -- S Twisted pair -- -- Cable Diameter DOD .64-1.91 [.025-.075] .64-1.91 [.025-.075] .74-1.40 [.029-.055] .74-1.40 [.029-.055] COD .23-.74 [.009-.029] .23-.74 [.009-.029] .23-.74 [.009-.029] .23-.74 [.009-.029] (AWG) 24-32 24-32 24-32 24-32 *These SolderTacts contacts belong to the Raychem "Subminiature" series of contacts, which are designed for use in commercial connectors. 8 Tooling Selection Guide SolderTacts Series Part Numbers (D-602-) Submin -- 0278/0279 0288/0289 Engineering Standard (Termination Instructions) ES61170 ES61414 Convection (hot air) Heating AT-1319 Adapter AT-1319-12 -- Repair Wand IR1004 infrared Semiautomatic Heater Tool Set Contact Insertion Tool Contact Removal Tool Special Tools AD-1481 -- Tool Set #9 (AT-1044-11) * -- AD-1447 -- AA-400-140 (magnifier) *Not applicable. 8-71 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: MIL-C-83723 Contact Military Specification* Cable Diameter JOD SOD DOD COD 2.39-3.56 [.094-.140] 2.39-3.56 [.094-.140] 1.96-2.49 [.077-.098] 1.96-2.49 [.077-.098] M39029/74-401 -- -- M39029/73-398 -- -- M39029/74-399 3.05-3.68 [.120-.145] 3.05-3.68 [.120-.145] 3.10-3.15 [.122-.124] 3.10-3.15 [.122-.124] 1.32-2.06 [.052-.081] 1.32-2.06 [.052-.081] .74-1.45 [.029-.057] .74-1.45 [.029-.057] 2.36-2.67 [.093-.105] 2.36-2.67 [.093-.105] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] .28-.74 [.011-.029] M39029/74-400 M39029/73-397 M39029/73-396 Wire (AWG) Raychem SolderTacts Size Polarity Cable Type 24-32 D-602-0094 12 P Coaxial 24-32 D-602-0095 12 S Coaxial 24-32 D-602-0104 12 P Twisted pair 24-32 D-602-0105 12 S Twisted pair 24-32 D-602-0106 12 P Large coaxial 24-32 D-602-0107 12 S Large coaxial * These SolderTacts contacts are on qualified parts list for indicated specification. Tooling Selection Guide Raychem SolderTacts Part Number D-602-0094/0095 D-602-0106/0107 D-602-0104/0105 Engineering Standard (Termination Instructions) ES61128 ES61134 ES61129 Convection (Hot Air) Heating AT-1319 Adapter AT-1319-19 Rev. D -- Repair Wand IR1004 infrared Semiautomatic Heater Tool Set Contact Insertion Tool Contact Removal Tool Special Tools AD-1494 Rev. C -- AT-1044-67 (P) AT-1044-68 (S) -- AD-1527 (M81969/14-04) -- AD-1527 (M81969/14-04) -- AD-1496 (twisted) -- SolderTacts Series: DOD-C-83527 Raychem SolderTacts Reference D-602-0185 D-602-0094 D-602-0093 D-602-0106 D-602-0189 Size Polarity Cable Type 16 12 12 12 12 socket pin socket pin socket Coaxial Coaxial Coaxial Coax (large) Coax (large) Size Polarity Cable Type 8 8 8 8 pin socket pin socket Twisted pair Twisted pair Sh. twisted pair Sh. twisted pair Contact Military Specification -- M39029/74 M39029/73 M39029/74 M39029/73 SolderTacts Series: DOD-C83527 (data bus contacts)* Raychem SolderTacts Reference D-602-0186 D-602-0187 DK-602-0186-2 DK-602-0187-2 Contact Military Specification M39029/96 M39029/95 M39029/96 M39029/95 * These SolderTacts contacts are on designed for shielded twisted pair cable per MIL-STD-1553B. 8-72 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Shielded Contacts SolderTacts Shielded One-Piece Solder Contacts (Continued) SolderTacts Series: Grommets Raychem SolderTacts Reference D-600-0071 D-600-0116 D-600-0125 Performance Size -- For size 8 DOD-C-83527 series For size 8 MIL-C-38999 series, for twisted pair Polarity For shielded twisted pair -- -- The performance of SolderTacts contacts is defined by the applicable Raychem specification control drawing (SCD) and Raychem Specification D-6002. Products on qualified 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. 8 8-73 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Introduction The full line of Raychem data bus products offers a complete system of interconnection 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 contacts 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) Raychem MIL-STD-1553B data bus components are also specified in the Air Force drawings listed in Air Force Drawing 8340707. Tyco Electronics also supplies 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. All Raychem data bus components offer: High packaging density and weight savings Design flexibility High performance (to 150C [302F] rating) 8-74 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Cables Product Facts Light weight Highly flexible Flame resistant Chemical resistant to all aircraft fluids Solder iron resistant Defined shielding levels Applications Tyco Electronics manufactures a line of Raychem SPEC 55 data bus cables that meet or exceed the performance requirements of MIL-STD-1553B. 8 SPEC 55 insulation is a high-temperature, radiationcrosslinked, modified ETFE material that can be used in wire constructions rated up to 200C [392F]. Note: Tyco Electronics will build harnesses with any customer specified cables and/or connectors. 8-75 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Cables (Continued) Specifications/Approvals Product Selection Series SPEC 55 insulation Military MIL-W-22759/32-/35 MIL-W-22759/41-/46 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 8-76 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components 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 lowimpedance cable-shield terminations Reliable solder termination of all components Potted circuit elements for maximum durability and inuse reliability Ease of installation Altitude immersion resistance Optional eyelet configurations for bulkhead mounting Mean time between failures > 1,000,000 hours 8 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. Series D-500-04 Military MIL-STD-1553B Raychem D-6020 8-77 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Product Selection 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 8-78 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Microcoupler Part Numbering System 8 8-79 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub 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 lowimpedance 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 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 lightweight 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 6stub, 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 significantly reduce weight. An unfilled flat braid cable is available for additional weight savings. They are also available assembled with other customer specified components into a complete factory-built and tested data bus harness. Specifications/approvals Series D-500-L4xx Available in: Americas Europe Asia Pacific Military MIL-STD-1553B Raychem D-6020 (same as current microcouplers) 8-80 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Lightweight In-Line Couplers Part Numbering System 8 8-81 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Product Selection D-500-L455-X-YYY-ZZZ End View Left Side D-500-L456-X-YYY-ZZZ End View Right Side End View Left Side End View Right Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub D-500-L457-X-YYY-ZZZ End View Left Side D-500-L458-X-YYY-ZZZ End View Right Side End View Right Side End View Left Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub Bus cable Stub cable 8-82 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components 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 corrosionresistant threaded-type or bayonet-type connectors Applications The multiport capability of these couplers (up to eight stubs) enables avionics system designers to interconnect black boxes with minimum wire runs. Box couplers are supplied with Raychem triaxial threaded or bayonet connectors. 8 Note: Tyco Electronics also designs and manufactures customized Raychem data bus box couplers. Specifications/Approvals Available in: Americas Europe Asia Pacific Series D-500-0255 Military MIL-STD-1553 Raychem D-6021 8-83 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Box Couplers (Continued) Product Selection Face - 1 Stub Face - 2 Stub Face - 3 Stub Face - 4 Stub Face - 5 Stub Face - 6 Stub Face - 7 Stub Face - 8 Stub Threaded D-500-0255-511-1 D-500-0255-521-1 D-500-0255-531-1 D-500-0255-541-1 D-500-0255-551-1 D-500-0255-561-1 D-500-0255-571-1 D-500-0255-581-1 Part No. Bayonet A* Bayonet B* D-500-0255-513-1 D-500-0255-515-1 D-500-0255-523-1 D-500-0255-525-1 D-500-0255-533-1 D-500-0255-535-1 D-500-0255-543-1 D-500-0255-545-1 D-500-0255-553-1 D-500-0255-555-1 D-500-0255-563-1 D-500-0255-565-1 D-500-0255-573-1 D-500-0255-575-1 D-500-0255-583-1 D-500-0255-585-1 Bayonet C* D-500-0255-517-1 D-500-0255-527-1 D-500-0255-537-1 D-500-0255-547-1 D-500-0255-557-1 D-500-0255-567-1 D-500-0255-577-1 D-500-0255-587-1 Side - 1 Stub Side - 2 Stub Side - 3 Stub Side - 4 Stub Side - 5 Stub Side - 6 Stub Side - 7 Stub Side - 8 Stub D-500-0255-512-1 D-500-0255-522-1 D-500-0255-532-1 D-500-0255-542-1 D-500-0255-552-1 D-500-0255-562-1 D-500-0255-572-1 D-500-0255-582-1 D-500-0255-513-2 D-500-0255-523-2 D-500-0255-533-2 D-500-0255-543-2 D-500-0255-553-2 D-500-0255-563-2 D-500-0255-573-2 D-500-0255-583-2 D-500-0255-517-2 D-500-0255-527-2 D-500-0255-537-2 D-500-0255-547-2 D-500-0255-557-2 D-500-0255-567-2 D-500-0255-577-2 D-500-0255-587-2 Coupler Type D-500-0255-515-2 D-500-0255-525-2 D-500-0255-535-2 D-500-0255-545-2 D-500-0255-555-2 D-500-0255-565-2 D-500-0255-575-2 D-500-0255-585-2 *The bayonet polarization listed is for the bus connector. All stub connectors are Bayonet D polarization. Polarizations are depicted as follows (jack view): 8-84 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components 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 EMPhardened 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 Specifications/Approvals Available in: Americas Europe Asia Pacific 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 interconnection hardware for the MIL-STD-1553B market. Series DK-621 8 Military MIL-STD-1553B Raychem D-6025 8-85 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components 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. 8-86 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories Product Facts A single source for all harness components Products designed to work together 8 Available in: Americas Europe Asia Pacific Applications These include: Tyco Electronics manufactures all the products needed to build a MIL-STD1553B data bus network. In addition to the main components (couplers, connectors, contacts, and cables), Tyco Electronics supplies the accessory components that may be necessary to complete a data bus system. Bus and stub terminators (spliced-in and connectorized D-621 series). Cable splice kits. EMI/environment-resistant connector caps. Braid terminators and strain relief tubing (for rework applications). Cable marking materials. 8-87 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Product Selection D-621 Plug D-621 Jack Splice-in Bus and Stub Terminators Spliced-in 77-ohm 10612 cable 77-ohm 10613 cable 77-ohm 10614 cable 77-ohm 7724H0664 cable 12-inch Cable D-500-0463-612 D-500-0463-613 D-500-0463-614 D-500-0463-H06 D-621 Series--Plug 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact Threaded D-621-0413 D-621-0415 D-621-0417 D-621-0407 Bayonet A D-621-0453 D-621-0469 D-621-0457 D-621-0473 Bayonet B D-621-0454 D-621-0470 D-621-0458 D-621-0474 Bayonet C D-621-0455 D-621-0471 D-621-0459 D-621-0475 Bayonet D D-621-0456 D-621-0472 D-621-0476 D-621-0460 D-621 Series--Jack 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact Threaded D-621-0418 D-621-0406 D-621-0423 D-621-0424 Bayonet A D-621-0477 D-621-0461 D-621-0481 D-621-0465 Bayonet B D-621-0478 D-621-0462 D-621-0482 D-621-0466 Bayonet C D-621-0479 D-621-0463 D-621-0483 D-621-0467 Bayonet D D-621-0480 D-621-0464 D-621-0484 D-621-0468 D-621 Series--L Lanyard 7" -- -- -- -- Connector Caps D-621 Series Plug cap for jack connector Supplied with 7" Lanyard Threaded Bayonet A Bayonet B Bayonet C Bayonet D D-600-0083 D-600-0068 D-600-0068 D-600-0068 D-600-0065 Cable Splice Kits Cables All data bus cables Flexible Crimp D-150-0708-5 8-88 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Terminator and Connector and Compatibility -- Bayonet and Threaded Connectors Panel Thickness Connector Contact Terminator Reference Standard Connector Mate with Long ReachConnector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0453(-L) D-621-0469(-L) D-621-0477(-L) D-621-0461(-L) D-621-0457(-L) D-621-0473(-L) D-621-0481(-L) D-621-0465(-L) DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0550-1S DK-621-0550-1P -- -- DK-621-0550-1S DK-621-0550-1P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0454-(-L) D-621-0470-(-L) D-621-0478-(-L) D-621-0462-(-L) D-621-0458-(-L) D-621-0474-(-L) D-621-0482-(-L) D-621-0466-(-L) DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0548-2S DK-621-0548-2P -- -- DK-621-0548-2S DK-621-0548-2P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0455(-L) D-621-0471(-L) D-621-0479(-L) D-621-0463(-L) D-621-0459(-L) D-621-0475(-L) D-621-0483(-L) D-621-0467(-L) DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0546-3S DK-621-0546-3P -- -- DK-621-0546-3S DK-621-0546-3P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0456(-L) D-621-0472(-L) D-621-0480(-L) D-621-0464(-L) D-621-0460(-L) D-621-0476(-L) D-621-0468(-L) D-621-0484(-L) DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0551-4S DK-621-0551-4P -- -- DK-621-0551-4S DK-621-0551-4P -- -- Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0413(-L) D-621-0415(-L) D-621-0418(-L) D-621-0406(-L) D-621-0417(-L) D-621-0407(-L) D-621-0423(-L) D-621-0424(-L) DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0512-S DK-621-0512-P -- -- DK-621-0512-S DK-621-0512-P -- -- Bayonet Connectors Polarity A 77 Ohm bus terminator 3K Ohm stub terminator Polarity B 77 Ohm bus terminator 3K Ohm stub terminator Polarity C 77 Ohm bus terminator 3K Ohm stub terminator 8 Polarity D 77 Ohm bus terminator 3K Ohm stub terminator Threaded Connectors 77 Ohm bus terminator 3K Ohm stub terminator 8-89 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility -- Bayonet and Threaded Connectors Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator 3K Ohm Stub Terminator Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0433-1P DK-621-0433-1S DK-621-0434-1P DK-621-0434-1S DK-621-0550-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0433-1S D-621-0461(-L) D-621-0477(-L) D-621-0461(-L) D-621-0453(-L) D-621-0469(-L) D-621-0465 (-L) D-621-0481(-L) D-621-0473(-L) D-621-0457(-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) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0435-2P DK-621-0435-2S DK-621-0436-2P DK-621-0436-2S DK-621-0448-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0435-2S D-621-0462(-L) D-621-0478(-L) D-621-0470(-L) D-621-0454(-L) D-621-0470(-L) D-621-0474 (-L) D-621-0458(-L) D-621-0474(-L) D-621-0458(-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) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0437-3P DK-621-0437-3S DK-621-0438-3P DK-621-0438-3S DK-621-0446-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0437-3S D-621-0463(-L) D-621-0479(-L) D-621-0471(-L) D-621-0455(-L) D-621-0471(-L) D-621-0467(-L) D-621-0483(-L) D-621-0475(-L) D-621-0459(-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) Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0439-4P DK-621-0439-4S DK-621-0440-4P DK-621-0440-4S DK-621-0551-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0439-4S D-621-0464(-L) D-621-0480(-L) D-621-0472(-L) D-621-0456(-L) D-621-0472(-L) D-621-0468(-L) D-621-0484(-L) D-621-0476(-L) D-621-0460(-L) D-621-0476(-L) Jack Socket DK-621-0551-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0411-P DK-621-0411-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0411-S D-621-0406(-L) D-621-0418(-L) D-621-0415(-L) D-621-0413(-L) D-621-0415(-L) D-621-0424(-L) D-621-0423(-L) D-621-0407(-L) D-621-0417(-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) Bayonet Connectors Polarity A Polarity B Polarity C Polarity D Standard 2.4mm max. Long Reach 12.5mm max. Threaded Connectors 8-90 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility -- to European norme 3716 Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator 3K Ohm Stub Terminator Plug Plug Plug Plug Jack Jack Jack Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket Pin DK-3716-F101-TP DK-3716-F101-TS DK-3716-F201-TP DK-3716-F201-TS DK-3716-E102-TP DK-3716-E102-TS DK-3716-E202-TP DK-3716-E202-TS DK-3716-E112-TP DK-621-E102-TS DK-621-E102-TP DK-621-E202-TS DK-621-E202-TP DK-621-F101-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP DK-621-F101-TS D-621-E077-S D-621-E077-P D-621-E077-S D-621-E077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-E03K-S D-621-E03K-P D-621-E03K-S D-621-E03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S Jack Jack Jack Socket Pin Socket DK-3716-E112-TS DK-3716-E212-TP DK-3716-E212-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP D-621-F077-P D-621-F077-S D-621-F077-P D-621-F03K-P D-621-F03K-S D-621-F03K-P Triaxial Connectors Standard 2.4mm max. Long Reach 12.5mm max. Panel Thickness Connector Contact Terminator Reference Standard Connector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket DK-3716-F077-P DK-3716-F077-S DK-3716-F077-P DK-3716-F077-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP Mate with Long ReachConnector Terminators 77 Ohm bus terminator 3K Ohm stub terminator DK-3716-E#12K-TS DK-3716-E#12K-TP -- -- DK-3716-E#12K-TS DK-3716-E#12K-TP -- -- 8 8-91 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Triaxial Size 8 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 Applications Contacts provide full shield coverage with a simple, quick, and reliable termination system. 24 AWG twisted-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. Specifications/Approvals Product Selection Available in: Americas Europe Asia Pacific 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 termination, and intermateability with more cumbersome crimp contacts. Series Size 8 These contacts provide a fast and convenient method of implementing MIL-STD-1553B connections in MIL-STD-1760 applications. Raychem D-6002 Cable Type 10612 10613 10614 Pin DK-602-0156-N-1 DK-602-0156-N-2 DK-602-0156-N-3 Socket DK-602-0157-N-1 DK-602-0157-N-2 DK-602-0157-N-3 8-92 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components Product Facts Complete line of spacequalified MIL-STD-1553B components Low outgassing levels that meet NASA requirements Light weight Rugged construction Figure 1. In-line couplers and terminators Applications Tyco Electronics full line of Raychem data bus products 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 outerspace applications. Figure 2. Threaded triaxial connectors Figure 3. Bayonet triaxial connectors 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 factorybuilt harnesses eliminates unnecessary splices and connectors, reducing the cost and increasing the reliability of the networks. Figure 4. Splice kit Specification control drawings describe the design Available in: Americas Europe Asia Pacific features and performance characteristics of Raychem space-grade couplers, terminators, connectors, and splices. The spacegrade data bus couplers, terminators, and connectors have tin/nickel-plated metallic 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. 8 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. 8-93 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Specifications/Approvals Series Space-grade data bus components Raychem D-6022 Space-Grade In-Line Coupler Part Numbering System 8-94 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Space-Grade Connectors Part Numbering System 8 Space-Grade Terminators Part Numbering System Space-Grade Splice Kit = D-150-9708-5 8-95 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Customer-Specified Harness Assemblies and HarnWare Harness Design Software Tyco Electronics supplies complete Raychem data bus networks in accordance with customer harness drawings, with any customer-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 others' components; a bill of materials is automatically generated. Sample Drawing Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Description Data bus Cable Data bus Cable Data bus Coupler Data bus Coupler Data bus Coupler Data bus Terminator Data bus Contact Data bus Contact Data bus Connector Data bus Connector Data bus Connector Marker Sleeve Part No. 10613-9 10613-96 D-500-0455-1 D-500-0455-2 D-500-0457-1 D-621-0469-L DK-602-0156-N-2 DK-602-0157-N-2 DK-621-0411-P DK-621-0412-P DK-621-0434-1P TMS-SCE-3/16-2.0-9 Spec/Remarks Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Qty 5.3 7 1 1 1 1 1 1 1 1 1 6 Unit M M Pc Pc Pc Pc Pc Pc Pc Pc Pc Pc 8-96 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Introduction 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 Applications Tyco Electronics, a longtime leader in harnessing technology, has written a new chapter in EMC shielding with the introduction of the Raychem HexaShield EMC adapter. Available in: Americas Europe Asia Pacific Designed to provide EMC protection solutions for both commercial and military applications, HexaShield adapters represent a significant improvement over pigtail termination methods. By providing 360-degree EMC shielding on the termination area of each individual cable, HexaShield adapters provide outstanding shielding effectiveness. HexaShield adapters are simple to install, easy to Designed to corresponding connector specifications. maintain, and dependably resistant to mechanical and environmental stresses. Weight reduction, by possibly eliminating the need for overall shielding. Principal points and features Compact size - not exceeding outer diameter of connector. Available in straight, 45 and 90 angles, as well as swept and long bodies. Easy reentry: To insert or remove ferrules from the HexaShield adapter, simply loosen the back nut. Superior protection: No degradation of shielding performance. Up to four shielded cables accommodated by each ferrule. Mechanical and environmental protection equal to backshells complying with MIL-C-85049 Category 3B. Strain relief on each individual cable. Two Platings Available Electroless nickel (MIL-DTL-26074) Olive drab cadmium (QQ-P-416 Type II Class 3) 8 Simple assembly and installation 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. Raychem Product Specifications RB-110 and RB-114 -- *Contact Tyco Electronics for additional platings. Installation Procedures Installation procedure for HET-A-02X and HET-A-04X (RPIP-696-00) Installation procedure for HET-03X (RPIP-696-03) 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) General procedure for cylindrical connectors, right-angle body (RPIP-696-07) -- -- 8-97 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Kit Descriptions Hexashield Adapters for Circular Connectors: Straight, 45and 90 Assemblies Item 1 2 3 4 5 6 7 8 Description Straight adapter assembly Conic ring assembly Star Plain (Standard) Drilled (Option) Split (Option) _ Straight adapter assembly - "L" version - nominally 0.5" [12.7] longer body 45 adapter assembly - welded 45 adapter assembly - swept 90 adapter assembly - welded 90 adapter assembly - swept Standard products shown. Variants available on request. 1 1 2 2 3 3 c 4 Split star assemblies are shown on relevant S.C.D's where applicable. Item -1 -2 -3 -C HexaShield Version Back Nut Tinel adapter assembly Tinel-Lock ring for single braid Bandstrap adapter assembly Conduit adapter 5 6 7 8 HexaShield Adapters for ARINC 404/600 Connectors: Sizes 1, 2, 3 and 4 Assemblies Item 1 2 3 4 5 6 7 Description Left side support Right side support Retention bars Body assemblies Body Holding nut Conic ring assembly Star _ Back nut Cavity plug assemblies Plug Holding nut Pan head screws - 4-40 UNC Spring washers ARINC 600 Size 2 shown Stars are available as plain, drilled or split. See relevant S.C.D's for further information 8-98 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters Ordering Information Part Numbering for Standard Products HexaShield Adapter for Circular Connectors 8 8-99 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters 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 8-100 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance Product Facts Transfer Impedance Outperforms traditional pigtail termination, especially in HIRF performance Withstands 10-kA peak current lightning transients of SAE AE4L-87-3 HexaShield size: 23 Cable: Raychem 5024H8424 (one cable installed) Test method: CEI 96-1 Protection Level Generalized system performance (Actual system performance in any one test method may differ.) 8 8-101 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance (Continued) Typical HexaShield Applications 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) HexaShield Product Range 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. 8-102 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Introduction 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 8 System The Raychem MTC product line is a complete modular connector system consisting of lightweight, environmentally sealed miniature rectangular connectors (shell housings with removable inserts) and individually removable rear-release contacts. Components Available in: Americas Europe Asia Pacific MTC connectors are now available with quickdisconnect mating hardware, EME shielding accessories, and modular inserts that can accommodate a mix of signal and power crimp contacts and coaxial contacts. The need for special termination tooling has been minimized, while the ease of manufacturing and maintenance has been improved. Configurations MTC rectangular connectors using jack screws or quickdisconnect hardware 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 available 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. 8-103 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts 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: 2 x 20 Cavity Inserts (Size 20-22)--2-Inch Shell One MTCP-122-20P1 and one MTCP-122-20P2 (pin contact) or One MTCP-122-20S1 and one MTCP-122-20S2 (socket contact) Pin Insert MTCP-122-20P1 MTCP-122-20P2 Socket Insert MTCP-122-20S1 MTCP-122-20S2 8-104 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts (Continued) 1 x 20 Cavity Inserts (Size 20-22)--1-Inch Shell 1-inch shell with insert Pin Insert MTCP-122-20P Socket Insert 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 8 Contacts accept 24 AWGto 20 AWGwires. Pin Contact CTA-0166 Tools Positioner for pin contact Installation process Contact removal tool (plastic) Extraction tool for MTCPinserts Socket Contact CTA-0165 CE-1605900 ES-61413 CTA-1160 CTA-0161 Tools Positioner for socket contact Installation process Contact removal tool (plastic) Extraction tool for MTCPinserts CE-1606000 ES-61413 CTA-1160 CTA-0161 8-105 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 5-Cavity Inserts 5-Cavity Inserts (Size 16) 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) Pin Insert MTCP-116-05P1 MTCP-116-05P2 Contacts for 5-Cavity Inserts Socket Insert MTCP-116-05S1 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 D-602-0140 (coaxial) CTA-0079 (power) Socket Contact D-602-0171 (coaxial) CTA-0078 (power) 8-106 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Hybrid Inserts Plug Hybrids Receptacle 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). 8 MTC connector housings are offered with quickdisconnect 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. 8-107 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts MTC Shells Ordering Information *Some combinations of shells, mating hardware and EMEshielding accessories are not available. Contact Tyco Electronics for product information. 8-108 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Accessories Low-Profile EME Backshells EME Backshell Adapters Lightweight rectangular EME backshells connect the overall bundle shield to the MTC connector housing. Individual cable shields can also be terminated to the backshell braid by using Raychem SolderSleeve devices. CHA-0275 2-inch adapter (plug or receptacle) CHA-0276 1-inch adapter (plug or receptacle) 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. MTC Shield-Grounding BusBars Raychem MTC shieldgrounding busbars allow for simple, cost-effective termination 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 terminated to "fingers" on the busbar with Raychem SolderSleeve devices. Shield-Grounding Busbars CTA-0022 1-inch busbar (with 5 SolderSleeve terminators) CTA-0023 2-inch busbar (with 10 SolderSleeve terminators) 8 The busbar is mounted on the MTC housing via cable clamp screws. MTC busbar features include a simple termination, cost effectiveness, light weight, and Level I EME performance. EME Shielding Accessories for MTC Connectors Grounding Block Allows for cable shield termination grounding on the MTC shell housing via crimp-removable contacts. This grounding scheme allows individual cables to be removed from the connector without cutting a ganged ground connection. Sufficient ground contacts are available to handle shielded twisted-pair cables. Grounding Block CHA-0301 1-inch grounding block receptacle shell CHA-0302 2-inch grounding block receptacle shell CHA-0303 1-inch grounding block plug shell CHA-0304 2-inch grounding block plug shell 8-109 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Engineering Notes 8-110 Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171