Raychem Electrical
Interconnect
Products
SAE AS81824 & SAE AS83519 Series II
Qualified Products Offer Robust
and Highly Reliable Wire Termination
in Demanding Environments
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Electrical Interconnect
Products
Contents
Introduction
3
Typical SolderSleeve Device/Installation
4
Product Selection
5
WIRE-TO-WIRE SPLICING
Introduction
6
SolderSleeve Wire Splices
7
SolderGrip Closed End Connector Splices
13
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Splices
19
Raychem Cold Applied Splices and Ring Terminals
21
MiniSeal High-Performance, Immersion-Resistant
Crimp Splices
23
200˚C MiniSeal High-Performance Crimp Splices
27
.
INSULATED TERMINALS AND DISCONNECTS
Introduction
29
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Terminals and Disconnects
30
SolderGrip Self-Fixturing Insulated Terminals
36
WIRE TERMINATION TO PIN/POST/TAB
Introduction
41
SolderSleeve Discrete Wire Terminators
42
SHIELD TERMINATION
Introduction
46
SolderSleeve Shield Terminators
47
Raychem S200 Shield Terminators
48
COAXIAL CABLE TERMINATION
Introduction
56
SolderSleeve Coaxial Cable Terminators
57
SolderSleeve PCB/Coaxial Cable Terminators
59
RF One Step
61
CABLE-TO-CABLE SPLICING
Introduction
67
SolderShield Shielded and Coaxial Cable Splices
68
Raychem C-Wrap Side Entry Repair Sleeve
71
Rayseal Repair Sleeve
73
D-200 Splice Kit
74
SHIELDED CONTACTS
Introduction
76
SolderTacts Shielded One-Piece Solder Contacts
77
ADDITIONAL REPAIR PRODUCTS
Matched Impedance Splices
84
Raychem Application Tooling
85
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 2
Electrical Interconnect Products
TE Connectivity’s (TE) dependable, economical wire and cable
termination products provide solutions for hundreds of wire and
cable interconnect requirements. All wire termination products
are housed inside transparent heat-shrinkable insulation sleeves,
which provide inspectability and can provide various levels of
environmental protection. Most Raychem brand termination
products incorporate a fluxed solder preform, which is essential
for a highly controlled soldering process. Other products
incorporate controlled crimping or a unique process of combining
a twist-on coil with controlled soldering to provide high-reliability
joints on the widest variety of conductor types and platings.
SolderSleeve technology ensures high-quality electrical and
mechanical performance time after time. Premeasured solder
and flux create repeatable, reliable terminations, reducing rejects
and field failures. When the SolderSleeve device is heated, the
tubing shrinks and the solder preform melts to make a fully
insulated, strain-relieved, protected solder connection. Heatshrinkable tubing provides the benefits of insulation, strain relief,
and protection for our controlled crimp products. Many Raychem
brand interconnect products have earned UL recognition or
SAE AS83159 Mil-Spec approval.
Many SolderSleeve and related devices are made from
polyvinylidene fluoride tubings that meet the requirements of
AMS-DTL-23053/8 (formerly MIL-DTL-23053/8).
Raychem brand interconnect devices combine high-strength
materials with innovative design for consistent, long-life
performance. And because the insulation sleeve is transparent,
operators can easily inspect the connection.
TE 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.
TE 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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 3
Electrical Interconnect Products
Product Selection
Transparent, heat-shrinkable
thermoplastic sleeve
Typical SolderSleeve
Device (illustration
of shield terminator
concept)
Thermoplastic sealing ring
Optional preinstalled wire lead
Fluxed solder
preform
Typical Installation
1. Insert prepared cable
2. Apply heat
Solder preform melts and flows,
Installation quality is fully visible through
transparent sleeve
Sleeve shrinks, conforms to
cable contours, and provides
strain relief
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Sealing rings melt to provide
environmental protection
PAGE 4
Electrical Interconnect Products
Product Selection
Max. Operating
Connection
Page
Application Type
Product Description
Series
Temp.
Type
Number
125°C [257°F]
Solder
SolderSleeve wire splices
B-155-900X
7
CWT
150°C [302°F]
Solder
Wire-to-wire splicing
125°C [257°F]
Coil and solder
SolderSleeve wire splices
SolderGrip closed end
connector splices (stub)
D-110, D-1744
7
SGRP Series X-58, SGRS
13
125°C [257°F]
Crimp
DuraSeal crimp splices
D-406
19
125°C [257°F]
Crimp
Cold applied splices
D-436
22
150°C [302°F]
Crimp
MiniSeal crimp splices
D-436 (M81824)
24
D-200
28
200°C [392°F]
Crimp
125°C [257°F]
Crimp
Terminals and
disconnects
150°C [302°F]
Coil and solder
MiniSeal crimp splices
DuraSeal crimp terminals
and disconnects
SolderGrip terminals
B-106 31
SGRT
36
125°C [257°F]
Solder
SolderSleeve wire terminators
Wire termination
150°C
[302°F]
Solder
SolderSleeve wire terminators
to pin/post/tab
B-155-15XX
43
D-129, D-141,
D-71X 43
125°C [257°F]
Solder
SolderSleeve shield terminators
150°C [302°F]
Solder
SolderSleeve shield terminators
Shield
termination
B-155-X
S01, S02,
M83519, SO63
47
175°C [347°F]
Solder
SolderSleeve shield terminators
SO96, SO175
47
200°C [392°F]
Solder
SolderSleeve shield terminators
S200
47
125°C [257°F]
Solder
SolderSleeve coaxial cable terminators
B-155, D-184
57
150°C [302°F]
Solder
SolderSleeve coaxial cable terminators
B-02X, B-04X, D-181
57
150°C [302°F]
Solder
SolderSleeve PCB/coaxial cable terminators
D-607, B-046
59
135°C [275°F]
Solder
RF one-step BNC/TNC connectors
RBD, RTD
61
Coaxial cable
termination
47
Cable-to-cable splicing
150°C [302°F]
Solder/Crimp
SolderShield cable splices
D-150
68
150°C [302°F]
Solder/Crimp
C-Wrap repair sleeve
D-150
71
260°C [500°F]
Solder/Crimp
Rayseal repair sleeve
D-260
73
200°C [392°F]
Solder/Crimp
D-200 flexible splice
D-200
75
150°C [302°F]
Solder
SolderTacts shielded contacts
D-602
80
Shielded contacts
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 5
Wire-to-Wire
Splicing
Introduction
TE offers many products for wire-to-wire splicing:
SolderSleeve splicing devices; SolderGrip splices; and
DuraSeal and MiniSeal crimp splices.
Like all TE interconnect products, the wire-to-wire splicing
devices are rugged and reliable, yet easy to install.
Designed for applications with temperatures up to 200°C
[302°F], products in this section include:
SolderSleeve splicing devices, which can be used to make
sealed or unsealed splices. In a single step, they solder,
insulate, encapsulate, and strain-relieve a wide range of
wire sizes.
DuraSeal heat-shrinkable nylon crimp splices are easy to
use in factory or repair applications. DuraSeal crimp splices
provide watertight sealing and superior protection against
corrosion, abrasion, and vibration.
Small, lightweight, and low-profile MiniSeal highperformance crimp splices, which substantially reduce
wire bundle size and weight, are QPL-listed to the
SAE AS81824 specification, and are required by the
MIL-W-5088 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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 6
Electrical Interconnect Products
SolderSleeve Wire Splices
Product Selection Process
From the Product Options table below, select the product series
appropriate for your application based on the temperature rating
and sealing performance required.
If the application has only one size of wire per side and no more
than two wires on either side:
1. Determine wire gauge sizes for both sides of splice.
2. Determine number of wires (one or two wires) for each side
of splice.
3. S
elect part numbers from the appropriate table:
RUGGED
• Transparent polyvinylidene fluoride
or polyolefin sleeve provides
encapsulation, inspectability, strain
relief, and insulation
• With one or two wires per end,
the NAS 1744 splices meet 75,000
ft [22,000 m] altitude immersion
requirement
CAPABLE
• Prefluxed solder preform provides a
controlled soldering process
• UL and CUL recognized
(CWT + D-110)
See page 12 specifications
and approvals
EASY TO USE
• One-piece design makes installation
easy and lowers the installed cost
• Thermochromic temperature
indicator in the NAS splices facilitates
termination and inspection
• F
or B-155 and CWT series (low temperature): Use Table A on
page 8.
• For D-110 series (splashproof): Use Table B on page 9.
• F
or D-1744 series (immersion sealed): Use Table C on
page 10.
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. T
urn to “CMA/mm2 Calculation” on page 11 and use
the workspace there to calculate the total cross section to
be spliced.
2. U
se Table E on page 12 to select the sleeve recommended for
that cross section.
Notes:
hile all combinations listed will provide satisfactory solder joints, the degree
W
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 11.
Product Options
Product Series
B-155
CWT
D-110
D-1744 (NAS 1744)
Minimum Wire
Temperature Rating
85°C [185°F]
85°C [185°F]
125°C [257°F]
125°C [257°F]
Maximum Operating
Temperature
125°C [257°F]
125°C [257°F]
150°C [302°F]
150°C [302°F]
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult TE for details.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Intended Application
Environment
(RoHS) Splashproof
Splashproof
Splashproof
Immersion sealed
PAGE 7
Electrical Interconnect Products
Table
A: B-155 Series Selection
Side A: Side B: Size and Number of Conductors
Size and
26 AWG
24 AWG
22 AWG
20 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
26 AWG 1
2
24 AWG
1
2
22 AWG
1
2
20 AWG
1
2
18 AWG
1
2
16 AWG
1
2
14 AWG
1
2
12 AWG
1
2
10 AWG
1
B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002
B-155-9001 B-1559001 B-155-9001 B-155-9002 B-155-9001 B-155-9002 B-155-9002 B-155-9002
B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002
B-155-9001 B-155-9002 B-155-9001 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002
B-155-9001 B-155-9001 B-155-9001 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002
B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003 B-155-9003 B-155-9003
B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003
B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9002 B-155-9003 B-155-9003 B-155-9003
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-1559003 B-155-9003 B-155-9003
B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004
B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-1559005
B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005
26 AWG 1
2
24 AWG
1
2
22 AWG
1
2
20 AWG
1
2
18 AWG
1
2
16 AWG
1
2
14 AWG
1
2
12 AWG
1
2
10 AWG
1
B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9002 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9002 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9005 B-155-9005
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005
B-155-9003 B-155-9003 B-155-9003 B-155-9004 B-155-9003 B-155-9004 B-155-9004 B-155-9005 B-155-9005
B-155-9004 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005 B-155-9005 B-155-9005
B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9004 B-155-9005 B-155-9004 B-155-9005 B-155-9005
B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005
B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005 B-155-9005
Side A: Side B: Size and Number of Conductors
Size and
18 AWG
16 AWG
14 AWG
12 AWG
10 AWG
Number of
1 2 1 2 1 2 1 2 1
Conductors
Table
A: CWT Series Selection
Side A: Side B: Size and Number of Conductors
Size and
26 AWG
24 AWG
22 AWG
20 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
26 AWG 1
2
24 AWG
1
2
22 AWG
1
2
20 AWG
1
2
18 AWG
1
2
16 AWG
1
2
14 AWG
1
2
12 AWG
1
2
10 AWG
1
CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
CWT-9001 CWT9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002
CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
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-9003 CWT-9003 CWT-9003
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-9003 CWT-9003 CWT-9003
CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT9003 CWT-9003 CWT-9003
CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004
CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004
CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT9005
CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
1
26 AWG
2
24 AWG
1
2
22 AWG
1
2
20 AWG
1
2
18 AWG
1
2
16 AWG
1
2
14 AWG
1
2
12 AWG
1
2
10 AWG
1
CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
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-9004 CWT-9004 CWT-9005 CWT-9005
CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
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-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005
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 B-155-9005
Side A: Side B: Size and Number of Conductors
Size and
18 AWG
16 AWG
14 AWG
12 AWG
10 AWG
Number of
1 2 1 2 1 2 1 2 1
Conductors
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 8
Electrical Interconnect Products
Table
B: D-110 Series Selection
Side A: Side B: Size and Number of Conductors
Size and
26 AWG
24 AWG
22 AWG
20 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
26 AWG
2 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41
1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
24 AWG
2 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
1 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
22 AWG
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
D-110-0181
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
20 AWG
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
D-110-0181
D-110-0181
D-110-0181
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
18 AWG
2 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
D-110-0181
D-110-0181
D-110-0181
16 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101
1 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
14 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090
1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101
12 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090
10 AWG
1 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083 D-110-0083
Side A: Side B: Size and Number of Conductors
Size and
18 AWG
16 AWG
14 AWG
12 AWG
10 AWG
Number of
1 2 1 2 1 2 1 2 1
Conductors
1
D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
26 AWG
2
D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
1
D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
24 AWG
2
D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
1
D-110-41 D-110-0181 D-110-41 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
22 AWG
2
D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
1
D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090
20 AWG
2 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
18 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
16 AWG
2 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0083 D-110-0083
1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
14 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
1 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
12 AWG
2 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083
10 AWG
1 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083 D-110-0083
Fine Wire Splices
26 AWG (0.15 mm2)
and Smaller
Part
No.
As Supplied*
D-110-0071
0.9 [0.035]
D-110-0213
0.9 [0.035]
D-110-0214
0.6 [0.025]
D-110-0217
1.0 [0.040]
D-110-40
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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 9
Electrical Interconnect Products
Table
C: D-1744 Series Selection
Side A: Side B: Size and Number of Conductors
Size and
26 AWG
24 AWG
22 AWG
20 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
26 AWG
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
24 AWG
2 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
22 AWG
2 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02
1 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02
20 AWG
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
1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
18 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
16 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
14 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
12 AWG
2
D-1744-04
D-1744-04
D-1744-04 — D-1744-04 —
—
—
Side A: Side B: Size and Number of Conductors
Size and
18 AWG
16 AWG
14 AWG
12 AWG
Number of
1 2 1 2 1 2 1 2
Conductors
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
26 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
24 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03
—
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
22 AWG
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03
—
1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04
—
20 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
—
1 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
—
18 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03
—
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03
—
16 AWG
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
—
1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03
—
14 AWG
2 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04
—
—
—
12 AWG
1 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03
—
D-1744-04
—
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 10
Electrical Interconnect Products
CMA/mm2 Calculation
3. Add together the values
listed in the workspace
below to obtain the
total area.
To calculate the total
circular mil or mm2 area
of the conductors to be
terminated in a single
splice, follow these steps:
4. From Table E on the next
page, select the part
number recommended
for the total CMA or mm2
you have calculated.
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
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
1.50 [.060]
2.50 [.100]
16 AWG (CMA 2426)
[1.21 mm2]
Table D.
Multiwire Splice
1.50 [.060]
3.00 [.120]
22 AWG (CMA 754)
[0.38 mm2]
1.50 [.060]
2.25 [.090]
�
2 at 22 AWG (CMA 1508)
[0.38 mm2]
18 AWG (CMA 1900)
[0.96 mm2]
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)
= B-155-9002, CWT-9002, D-110-41 or D-1744-02.
Correct part number selection from Table E
(based on CMA/mm2 and nominal jacket wire OD)
= B-155-9003, CWT-9003, D-110-0181 or D-1744-03.
CMA of Typical AWG Conductors
AWG
28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm2 0.09 0.15 0.23 0.38 0.62 0.96 1.23 1.44 2.97
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 11
Electrical Interconnect Products
Installation
Requirements
For proper installation of
these devices the correct
heating tool and reflector
attachment must be used.
Any one of the following
TE heating tools is
recommended:
n
n
n
n
Refer to TE installation
procedure RPIP-850-00
for D-1744 Series
and RPIP- 824-00 for
B-155 Series.
HL1920E/HL2020E
IR-1759 MiniRay
AA-400 Super Heater
CV-1981
CMA
mm
Table
E:
Product
Wire Jacket OD
Combined Total Combined Total
Series
Multiwire
Splice
Min.
Max.
Min. Max.
Min. Max.
Selection
B-155-9001
0.4 [0.015]
1.7 [0.066]
450
1500
0.3
0.8
2
Product
Characteristics
Specifications/
Approvals
B-155-9002
B-155-9003
B-155-9004
B-155-9005
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
Material
Insulation (D-110, D-1744)
Insulation (B-155)
Solder and flux (D-110, D-1744)
Solder and flux (B-155)
Solder and flux (CWT)
Meltable inserts (B-155, D-1744)
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating (B-155)
Temperature rating (D-110, D-1744)
Insulation resistance
1.3 [0.05]
1.8 [0.07]
2.8 [0.11]
3.2 [0.125]
0.50 [0.020]
0.80 [0.031]
1.30 [0.050]
2.00 [0.080]
0.51 [0.020]
1.27 [0.050]
1.9 [0.075]
2.41 [0.095]
3.56 [0.140]
4.0 [0.160]
2.7 [0.106]
4.5 [0.18]
6.0 [0.236]
7.0 [0.275]
1.90 [0.075]
2.80 [0.110]
4.57 [0.180]
7.11 [0.280]
1.78 [0.070]
2.54 [1.00]
4.5 [0.177]
4.32 [0.17]
7.11 [0.28]
8.76 [0.345]
1500
4000
7800
12000
350
2000
4000
10000
500
1200
3600
4800
8500
16200
4000
7800
12000
19000
2000
4000
10000
13000
1500
3500
6000
9000
16200
25000
0.8
2.0
4.0
6.0
–
–
–
–
–
–
–
–
–
–
2.0
4.0
6.0
10.0
–
–
–
–
–
–
–
–
–
–
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Radiation-crosslinked, heat-shrinkable polyolefin
Solder: Sn63 Pb37
Flux: ROL1 per ANSI-J-004 (RMA flux)
Solder: Sn42Bi58
Flux: ROM1 per ANSI-J-004 (RA Flux)
Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNI-J-004 (RA flux)
Meltable thermoplastic
2.0 mV
Exceeds strength of conductor
2.0 kV
-55°C to +125°C [-67°F to +257°F]
-55°C to +150°C [-67°F to +302°F]
1000 megohms
Series
B-155
CWT
D-110
D-1744
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Agency
TE
n/a RT-1404
UL E87681
D-5023
UL E87681
RT-1404
NAS-1744 RT-1404
PAGE 12
Electrical Interconnect Products
SolderGrip Closed End Connector Splices
Applications
SolderGrip heat-shrinkable solder-type closed-end connectors are
designed for electrical termination of multiple-wire combinations.
They provide a reliable alternative to crimping, welding, or
conventional twist-on-style closed-end connectors.
Their unique combination of wire fixturing and controlledsoldering technology provides dependable electrical termination
of multiple wire combinations.
RUGGED
• Sealed for immersion (SGRS-X-58,
SGRS)
• Excellent strain relief
EASY TO USE
• Simple installation
CAPABLE
• Soldered connection
• Electrical insulation
SolderGrip terminators consist of a heat-shrinkable thermoplastic
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
multi-stranded, 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
Product Series
SGRP
SGRS-X-58
SGRS
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Environmental Protection
Splashproof
Sealed
Sealed
Max. Operating Temp.
125°C [257°F]
125˚C [257˚F]
125°C [257°F]
PAGE 13
Electrical Interconnect Products
1. From the Product Options
table on the previous
page, select the product
series appropriate for
your application.
Product Selection
Process
2. Determine the wire
combination (number of
wires and size) of the wire
bundle you wish to splice.
3. Use Table C (page 16)
to select the correct
connector for AWG wire
combinations.* For
mm2 wire combinations
use Table A to select a
SolderGrip part number.
Example: For connecting
a bundle with one 12
AWG wire (1 #12) and
two 14 AWG wires
(+2 #14), you need an
SGRP-3 connector. For
sealed parts, select the
SGRS series.
*If the wire combination is not
listed in Table C, use the CMA
(mm2) method of determining
wire bundle size (see “CMA/
mm2 Calculation” on page 15).
Using Table B (page 15,
select the smallest size
connector that will fit your total
wire CMA (mm2) value.
Insulated Closed-End Connectors (SGRP series)
L
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. V
erify that the total
amperage to be applied
does not exceed the
maximum amp rating for
the part.
Insulated and Sealed Closed-End Connectors (SGRS series)
L
ØA
ØA
Sealing insert
Table A - Product
Dimensions and Part
Number Descriptions
Product Dimensions (Min.)
Product Dimensions (Min.)
Part
Color
Part Color
Wire Range (Min.-Max.)
Wire Range (Min.-Max.)
No.
Code
L
ØA
L
ØA
No. Code
CMA/mm2
CMA/mm2
1.370
.120
1400 - 4800
1.370
0.130
1400 - 4800
SGRP-1 Green
SGRS-1
Green
[34.8]
[2.9]
[0.7 - 2.4]
[34.8]
[3.4]
[0.7 - 2.4]
1.350
.150
4000 - 8000
1.350
0.190
4000 - 8000
SGRP-2
Red
SGRS-2
Red
[34.2]
[3.7]
[2.0 - 4.0]
[34.2]
[4.8]
[2.0 - 4.0]
1.610
.200
7000 - 16000
1.650
0.290
7000 - 16000
SGRP-3 Blue
SGRS-3
Blue
[41.0]
[5.1]
[3.5 - 8.0]
[42.0]
[7.3]
[3.5 - 8.0]
1.650
.270
15000 - 24000
1.630
0.360
15000 - 24000
SGRP-4
Yellow
SGRS-4
Yellow
[42.0]
[6.8]
[7.5 - 12.0]
[41.5]
[9.1]
[7.5 - 12.0]
Product Dimensions (Min.)
Part
Color
Wire Range (Min.-Max.)
No.
Code
L
ØA
CMA/mm2
1.370
0.130
1400 - 4800
SGRS-1-58 Green
[34.8]
[3.4]
[0.7 - 2.4]
1.350
0.190
4000 - 8000
SGRS-2-58 Red
[34.2]
[4.8]
[2.0 - 4.0]
1.650
0.290
7000 - 16000
SGRS-3-58 Blue
[42.0]
[7.3]
[3.5 - 8.0]
1.630
0.360
15000 - 24000
SGRS-4-58 Yellow
[41.5]
[9.1]
[7.5 - 12.0]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 14
Electrical Interconnect Products
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.)
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).
Wire Number
CMA
mm
2
1
2
3
4
5
6
7
8
9
10
Solder Grip Part No.
Total
CMA/mm2 Example
22 AWG/.38
CMA 754
OD Bundle
Insulation
22 AWG/.38
CMA 754
18 AWG/.95
CMA 1900
Conductor
16 AWG/1.21
CMA 2426
Total CMA = 5834
Total mm2 = 2.92
Correct part number (based on CMA of 5834
or mm2 of 2.92): SGRP-2, SGRS-2 or SGRS-2-58
Table B. CMA
of Typical Copper
Conductors
Bundle diameter must not exceed 6.0
mm (0.24 in) for SGRP-2 or 0.18 mm
(4.5 in) for SGRS-2 or SGRS-2-58
AWG
30
28 26 24 22 20 18 16 14 12 10 8
CMA
112 177 304 475 754 1216 1900 2426 3831 5874 9354 16983
0.05
0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94 4.74 8.61
mm2
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 15
Electrical Interconnect Products
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
Splash-
Wire
Splash-
Sealed
Sealed
proof
Combinations proof
SGRP-4 SGRS-4-58
1 # 14 + 3 # 20
SGRP-2 SGRS-2-58
SGRP-4 SGRS-4-58
1 # 14 + 4 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
1 # 14 + 1 # 18
SGRP-2 SGRS-2-58
SGRP-4 SGRS-4-58 1 # 14 + 1 # 18 + 1 # 20
SGRP-2 SGRS-2-58
SGRP-4 SGRS-4-58
1 # 14 + 2 # 18
SGRP-2 SGRS-2-58
SGRP-3 SGRS-3-58
1 # 14 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 14 + 4 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 14 + 5 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 14 + 1 # 16
SGRP-2 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 1 # 20
SGRP-2 SGRS-2-58
SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 1 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58 1 # 14 + 1 # 16 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58 1 # 14 + 1 # 16 + 4 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
1 # 14 + 2 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 2 # 16 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 14 + 3 # 16
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58 1 # 14 + 3 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58 1 # 14 + 3 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
1 # 14 + 4 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58 1 # 14 + 4 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
1 # 14 + 5 # 16
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
2 # 14
SGRP-2 SGRS-2 -58
SGRP-4 SGRS-4-58
2 # 14 + 1 # 16
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
2 # 14 + 1 # 16
SGRP-3 SGRS-3-58
SGRP-2 SGRS-2-58
2 # 14 + 1 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
2 # 14 + 1 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
2 # 14 + 2 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
2 # 14 + 2 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
2 # 14 + 3 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
2 # 14 + 4 # 16
SGRP-4 SGRS-4-58
SGRP-3 SGRS-3-58
3 # 14
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
3 # 14 + 1 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
3 # 14 + 2 # 16
SGRP-4 SGRS-4-58
SGRP-4 SGRS-4-58
3 # 14 + 3 # 16
SGRP-4 SGRS-4-58
SGRP-3 SGRS-3-58
4 # 14
SGRP-3 SGRS-3-58
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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-3-58
SGRS-3-58
SGRS-2-58
SGRS-2-58
SGRS-3-58
SGRS-3-58
SGRS-2-58
SGRS-2-58
SGRS-2-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-2 -58
SGRS-2-58
SGRS-3-58
SGRS-2-58
SGRS-2 -58
SGRS-2-58
SGRS-1-58
SGRS-2-58
SGRS-2-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-2-58
SGRS-2-58
PAGE 16
Electrical Interconnect Products
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
Splash-
Wire
Splash-
Sealed
Sealed
proof
Combinations proof
SGRP-3 SGRS-3-58
4 # 14 + 1 # 16
SGRP-4 SGRS-4-58
SGRP-3 SGRS-3-58
4 # 14 + 2 # 16
SGRP-4 SGRS-4-58
SGRP-3 SGRS-3-58
5 # 14
SGRP-4 SGRS-4-58
SGRP-3 SGRS-3-58
5 # 14 + 1 # 16
SGRP-4 SGRS-4-58
SGRP-4 SGRS-4-58
1 # 16 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 16 + 5 # 20
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
1 # 16 + 2 # 20
SGRP-2 SGRS-2-58
SGRP-3 SGRS-3-58
6 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
5 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
5 # 16 + 1 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
5 # 16
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
4 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
4 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
4 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
4 # 16 + 2 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
4 # 16 + 1 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
4 # 16
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
3 # 16 + 1 # 18 + 2 # 20 SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
3 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3-58
SGRP-3 SGRS-3-58
3 # 16 + 1 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 3 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 2 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16 + 1 # 20
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
3 # 16
SGRP-2 SGRS-2-58
SGRP-4 SGRS-4-58
2 # 16 + 4 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
2 # 16 + 3 # 18 + 1 # 20 SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
2 # 16 + 3 # 18
SGRP-3 SGRS-3-58
SGRP-4 SGRS-4-58
2 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3-58
SGRP-1 SGRS-1-58
2 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3-58
SGRP-2 SGRS-2-58
2 # 16 + 2 # 18
SGRP-3 SGRS-3-58
SGRP-2 SGRS-2-58
—
—
—
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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-2-58
SGRS-1-58
SGRS-1-58
SGRS-2-58
SGRS-2-58
SGRS-2-58
SGRS-3-58
SGRS-2-58
SGRS-2-58
SGRS-3-58
SGRS-3-58
SGRS-2-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-3-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-2-58
SGRS-2-58
SGRS-2-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
SGRS-1-58
—
PAGE 17
Electrical Interconnect Products
Product Characteristics
Material
Insulation
Solder preform with flux (SGRS-X-58)
Solder preform with flux (SGRP, SGRS)
Sealing insert (SGRS-X-58, SGRS)
Spiral wound insert
Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride
SN42Bi58, ROM1 flux per ANSI-J-STD-004 (RA flux).
Sn 60 Pb 40, ROM1 flux per ANSI-J-STD-004 (RA flux).
Hot melt adhesive
Copper alloy
Electromechanical
Dielectric withstand voltage
Static heating
Unit
kilovolts
degrees
Physical
Dimensions
Environmental*
Insulation resistance after water immersion (SGRS only)
Contact resistance after testing
Operating condition
Temperature rating
Voltage rating
Unit
inches
Method of test
RB-109
Requirement
See product dimensions.
Unit
megohms
milliohms
Method of test
RB-109
RB-109
Requirement
100
Less than 6 milliohms
Method of test
RB-109
RB-109
Unit
—
volts
Method of test
—
—
Typical values
2.0
Less than 50°C rise
Value
-55°C to 125°C [-67°F to 257°F]
600
*Immersion resistance sealing is dependent on the wire combinations used. The user should test specific wire combinations. Refer to RB-109
TE specification for procedures.
Approvals and
Reference Documents
Agency Approvals
Reference documents
Note: SGRS-X-58 is not UL approved.
Installation
Requirements
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.
UL, CUL E87681
TE Specification RB-109 for splices
Specification Control Drawings
Splices—Non Sealed (SGRP-X), Splices—Sealed (SGRS-X)
Refer to TE installation
procedure RPIP-820-00 for
detailed instructions and
recommended reflector
attachments.
Either of the following
TE heating tools is
recommended:
n
n
HL1920E/HL2020E
CV-1981
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 18
Electrical Interconnect Products
DuraSeal Heat-Shrinkable, Environmentally
Sealed, Nylon-Insulated Crimp Splices
Specifications/Approvals
Series
D-406
Agency
UL and CUL listed 91J4, File E87681
TE
RB-107
Note: D406-0034 is not UL approved.
RUGGED
Product Dimensions
Butt Splices
• Protects splices from water,
condensation,
salt, and corrosion
L
• Provides strain relief
• Protects against vibration in rugged
environments
CAPABLE
• C ompletely insulates and protects
electrical
connections
• Has
adhesive lining for protection
that
is more reliable than
conventional
splices
ØA min.
Butt Splice Dimensions
Wire Dimensions
Part
A
L
Insulation
Insulation
No.
Color Conductor O.D. (Max.)
Min. Nom.
O.D. (Min.)
D-406-0034
3.00 [.118]
31.5 [1.24]
Yellow
26-24
3.00 [.118]
1.40 [.055]
D-406-0001
3.70 [.146]
31.5 [1.24]
Red
22–18
3.70 [.146]
1.40 [.055]
D-406-0002
4.60 [.181]
31.5 [1.24]
Blue
16–14
4.60 [.181]
2.00 [.080]
D-406-0003
6.50 [.255]
37.5 [1.48]
Yellow
12–10
6.50 [.255]
2.80 [.110]
• 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)
• Appliances
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 19
Electrical Interconnect Products
Product Selection
Process
1. Determine wire size.
2. Select part number.
Product
Characteristics
(Typical)
Wire Size
Color
AWG
26-24
22–18
16–14
12–10
Operating temperature
Shrink ratio
Physical properties
Chemical properties
Electrical properties
mm2
0.15-0.25
0.5-1.0
1.2–2.5
3–6
Part No.
D-406-0034
D-406-0001
D-406-0002
D-406-0003
Yellow
Red
Blue
Yellow
-55°C to 125°C [-67°F to 257°F]
Approximately 2:1
Cut-through resistance: 31 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb];
yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 h at 160°C [320°F]
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
For proper installation of
these devices, the correct
crimp tool and a heating
tool with a reflector
attachment must be used.
The AD-1522 crimp tool and
HL1920E/HL2020E heating
tool are recommended.
Refer to TE installation
procedure RPIP-821-00 for
detailed instructions.
Installation
1. S
elect splice of
appropriate size. Strip
wire 7.5 mm (5/16 in).
Insert into crimp barrel.
2. C
rimp using AD-1522
crimp tool for
preinsulated crimps.
3. H
eat crimped splice
with heat gun until
tubing recovers and
adhesive flows.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 20
Electrical Interconnect Products
Raychem Cold Applied Splices and
Ring Terminals
TE Connectivity’s (TE) cold applied splice and terminals
product line is designed as a single-component in-line splice
that requires no heat to install. It seals the termination and
prevents the ingress of moisture which can lead to insulation
failure and breakdown of the electrical connection.
VERSATILE
• Easy installation and application
flexibility
• One-step termination and
environmental protection
• No heating required for
In this product, sealing is achieved by replacing traditional
methods, such as grommets, greases, and tapes with
a novel gel technology. A polymer outer layer provides
electrical isolation.
MECHANICAL/ENVIRONMENTAL
• Tensile Strength: Exceeds that of spliced wire
• Temperature Range: -65°C to 150°C
• Dielectric Strength: 2500 V maximum
• Insulation Resistance: 5000 megohms minimum
installation — safe for use on
• Altitude Immersion: 75,000 feet
fueled aircraft
•F
luid Resistance: MIL-L-7808, MIL-L-3699, MIL-H-5605 (Hydraulic),
MIL-A-8243, MIL-C-59769, and MIL-T-5624 (JP-5)
PROVEN TECHNOLOGY
• Reliable in a wide variety of
environmental conditions
• Prevents water ingress under
permanent pressure/weight
• Achieves environmental performance
while maintaining:
- Small profile
- Electrical performance
•C
urrent Rating: Defined by the size of the crimp, gauge of wire,
and specification
PHYSICAL
•C
ross-Linked Gel Technology:
- Well-established gel sealing system
- Versatile gel closure
- Non-flowing gel
• Protects
and seals on all conventional Mil Spec and commercial wire
insulation systems
MATERIALS
• Insulation Sleeve: Transparent polyvinylidene fluoride
• Metal Crimp Splice or Terminal: Tin-plated copper
• End Caps: Thermoplastic, color coded
• Gel: Clear, flame-retardant silicone-based gel
STANDARDS
• SAE AMS-DTL-23053/8 (Insulation sleeve)
•S
AE AS81824/12 for Splices
SAE AS7928/14 for Terminals
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 21
Electrical Interconnect Products
Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.
WEIGHT
• 350 g (12.3 oz.)
COLD-APPLIED SPLICE PRODUCT RANGE
AD-1381 Hand Crimping Tool
Tool is used to crimp cold-applied
gel-filled splices with wires ranging
from 26 to 12 AWG.
• D-436-36-COLD: 26 to 20 AWG wire range
• D-436-37-COLD: 18 to 16 AWG wire range
• D-436-38-COLD: 14 to 12 AWG wire range
Ordering Information
AD-1381 Hand Crimping Tool
Model
Description
Part No.
AD-1381 Hand Crimping Tool
AD-1381
CS1660-000
Calibration Gauge
AD-1382
992013-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
ORDERING INFORMATION
Mini-Seal Crimp Wire Splices – Cold Applied (Gel Filled)
TE Description
TE RPN
QPL P/N
Specification
D-436-36-COLD
CN1020-000
M81824/12-1
SAE AS81824
D-436-37-COLD
CN1021-000
M81824/12-2
SAE AS81824
D-436-38-COLD
CN1022-000
M81824/12-3
SAE AS81824
Ring Tongue Terminal – Cold Applied (Gel Filled)
TE Description
TE RPN
QPL P/N
Specification
D-436-1101-COLD
CW8662-000
M7928/14-004
SAE AS7928
D-436-1102-COLD
CW0419-000
M7928/14-008
SAE AS7928
D-436-1103-COLD
CW0421-000
M7928/14-016
SAE AS7928
D-436-1122-COLD
TBD
M7928/14-012
SAE AS7928
D-436-1123-COLD
TBD
M7928/14-020
SAE AS7928
D-436-1142-COLD
TBD
M7928/14-009
SAE AS7928
D-436-1143-COLD
TBD
M7928/14-017
SAE AS7928
D-436-1162-COLD
TBD
M7928/14-010
SAE AS7928
D-436-1163-COLD
TBD
M7928/14-018
SAE AS7928
D-436-1382-COLD
TBD
M7928/14-011
SAE AS7928
D-436-1383-COLD
TBD
M7928/14-019
SAE AS7928
D-436-1401-COLD
TBD
M7928/14-001
SAE AS7928
SAE AS7928
D-436-1402-COLD
TBD
M7928/14-005
D-436-1403-COLD
TBD
M7928/14-013
SAE AS7928
D-436-1601-COLD
TBD
M7928/14-002
SAE AS7928
SAE AS7928
D-436-1602-COLD
TBD
M7928/14-006
D-436-1603-COLD
TBD
M7928/14-014
SAE AS7928
D-436-1801-COLD
CW8661-000
M7928/14-003
SAE AS7928
D-436-1802-COLD
CW0418-000
M7928/14-007
SAE AS7928
D-436-1803-COLD
CW0420-000
M7928/14-015
SAE AS7928
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 22
Electrical Interconnect Products
MiniSeal High-Performance, ImmersionResistant Crimp Splices
Applications
MiniSeal wire-to-wire splicing
products offer solutions for
hundreds of aerospace and defense
applications. These environmentresistant splices provide excellent
reliability, long term performance,
MIL-S-81824/1 qualification, and a
low installed cost.
RUGGED
• Insulation and strain relief
CAPABLE
• MIL-Spec approval
• Small size
• Light weight
EASY TO USE
• Immersion-resistant crimp splices are
on QPL for SAE-AS81824
• Easy installation
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 environment-resistant splices
available. They preserve the
electrical integrity of the splice by
preventing the penetration of liquids
and the resulting chemical and
galvanic corrosion.
Product Selection Process
1. D
etermine the type of
splice required.
• Stub (parallel) splice:
• Butt (in-line) splice:
2. Determine which crimp barrel
plating is required:
• T
in plating, recommended for
tin or silverplated wire
• N
ickel plating, recommended
for nickel-plated wire, or silverplated wire in applications
above 150°C [302°F].
3. Calculate the size of crimp
barrel required.
Using the CMA/mm2 worksheet on
the next page, calculate the total
cross section to be spliced by
adding the circular mil area (CMA)
or square millimeters (mm2) of
each wire.
Stub splice: Add the CMA or mm2
of all wires together.
Butt splice: Calculate each
side separately (see example on
the worksheet).
Table A provides the CMA of
typical conductors. (Both CMA
and mm2 give the same results,
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
so choose either CMA or mm2 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 24), select the crimp
barrel—color-coded red, blue, or
yellow—for the CMA or mm2
you calculated.
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
24 and 25) and find the table for
the type of splice (stub or butt)
required.
sing the appropriate table, find
U
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.
PAGE 23
Electrical Interconnect Products
Table A. CMA of
Typical Conductors
Strands 7 19 19 19 19 19
19 19 37
AWG 28 26 24 22 20 18
16 14 12
CMA 177 304 475 754 1216 1900
2426 3831 5874
1.21 1.92 2.94
mm2 0.09 0.15 0.24 0.38 0.61 0.95
Table B. Crimp Barrel
Color Code Selection
CMA Range
304–1510
1058–2680
2375–6755
CMA/mm2 Worksheet
Example:
Color Code
Red
Blue
Yellow
The other side, where the
CMA for AWG 18 is 1900, is
calculated as:
Application: A butt splice
with three AWG 22 wires in
one side and one AWG 18
wire in the other side:
CMA = 1 x 1900 = 1900
The CMA for AWG 22 wire
in Table A is 754.
Using Table B to select the
smallest crimp barrel that
will easily fit 2262 CMA,
the blue barrel is the
correct choice.
Side one is therefore
calculated as follows:
CMA = 3 x 754 = 2262
Wire Number
1:1 Splice (AWG Size)
26–20
20–16
16–12
CMA
mm2
1
2
3
4
5
6
7
8
9
10
Part Number:
Total
Table C. Stub (Parallel) Splices
Part No.
Illustration
Tin
Plated
Nickel Plated
Crimp Barrel
Size Range
Side 1
CMA
Sealing
Min.–Max.
Insert
I.D.dimensions
Max. No.
of Wires
Sealing
Insert
Side 2
Max. No.
of Wires
D-436-0128 D-436-0119
Red Red
304–1510 2
1.01 [.040]
2.16 [.085]
2
D-436-58
D-436-75
Blue Blue
1058–2680
4.56 [.180]
2
2
D-436-59
D-436-76
Yellow Yellow
2375—6755
4.56 [.180]
2
D-436-60
D-436-77
Blue Blue
D-436-61
D-436-78
Yellow Yellow
2.28 [.090]
2.28 [.090]
2
1058–2680
2.03
[.080]
10
2
(2 per hole)
6.35 [.250]
2375–6755
2.03
[.080]
10
2
(2 per hole)
6.35 [.250]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 24
Electrical Interconnect Products
Table D. Butt (in-line) splices
Part No.
Illustration
Tin
Plated
Nickel Plated
D-436-82
D-436-36*
D-200-82
Red
Red
D-436-83
D-436-37*
D-200-83
Blue
Blue
D-436-84
D-436-38*
D-200-84
Yellow
Yellow
Crimp Barrel
Size Range
Side 1
CMA
Sealing
Min.–Max.
Insert
I.D.dimensions
Max. No.
of Wires
Sealing
Insert
Side 2
Max. No.
of Wires
304–1510 2
2
1058–2680 2
2.79 [.110]
2.79 [.110]
2
2375–6755 2
2
D-436-0110
D-436-85
2.36
Red Red 304–1510 6
4.06 [.160]
[.093]
2
D-436-52
D-436-86
1058–2680
Blue Blue
2
D-436-53
D-436-87
2375–6755 6
2.36
Yellow Yellow
4.06 [.160]
[.093]
(2 per hole)
D-436-0115
D-436-88
6
2.36
2.36
Red Red 304–1510 6
[.093]
[.093]
(2 per hole)
(2 per hole)
D-436-42 D-436-89
1058–2680 6
6
2.36
2.36
Blue
Blue
[.093]
[.093]
(2 per hole)
(2 per hole)
D-436-43
D-436-90
2375–6755 6
6
2.36
2.36
Yellow Yellow
[.093]
[.093]
(2 per hole)
(2 per hole)
2.16 [.085]
2.16 [.085]
4.32 [.170]
4.32 [.170]
6
(2 per hole)
2.36
[.093]
4.06 [.160]
2
*Qualified to MIL-S-81824/1.
Table E. Crimp Barrel Only
Type
Color Code
Tin-Plated
Nickel Plated
Butt (in-line)
Red
D-609-06
D-609-09
Butt (in-line)
Blue
D-609-07
D-609-10
Butt (in-line)
Yellow
D-609-08
D-609-11
Stub (Parrel)
Red
D-609-03
D-609-12
Stub (Parrel)
Blue
D-609-04
D-609-13
Stub (Parrel)
Yellow
D-609-05
D-609-14
Crimp Barrel Size Range
CMA Min. - Max.
304-1510
1058-2680
2350-6755
304-1510
1058-2680
2350-6755
Table F. Sealing Sleeve Only
L max.
∅A min.
Part No.
D-436-0096
D-436-0097
D-436-0098
Color Code
Red
Blue
Yellow
L Max.
29.2 [1.15]
29.2 [1.15]
29.2 [1.15]
A Min.
2.16 [0.085]
2.8 [0.110]
4.32 [0.170]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 25
Electrical Interconnect Products
Material
Insulation
Crimp barrel
Meltable inserts
Product
Characteristics
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (D-436)
Tin- or nickel-plated copper
Meltable thermoplastic (D-436)
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating
Insulation resistance
Specifications/
Approvals
Series
D-436
Installation
Requirements
For proper installation of
these devices, the correct
crimp tool (TE part number
AD-1377) and a heating tool
and reflector attachment
must be used.
6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire
Exceeds strength of conductor
2.5 kV
-55°C to 150°C [-67°F to 302°F] (D-436 Series)
5000 megohms
Military
SAE-AS-81824/1 for D-436-36/37/38
Any one of the following
TE heating tools is
recommended:
n
n
HL1920E/HL2020E
AA-400 Super Heater
Refer to TE installation
procedure RCPS-200-20 for
detailed instructions and
recommended reflector
attachments.
Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.
WEIGHT
• 350 g (12.3 oz.)
AD-1377 Hand Crimping Tool
Tool is used for crimping wire
terminations with MiniSeal splices.
Ordering Information
AD-1377 Crimp Tool for MiniSeal Splices
Model
Description
Part No.
AD-1377 Crimp Tool
AD-1377-CRIMP-TOOL-3-CVTY
992008-000
Commercial Crimp Tool
AD-1377-S-SPEC-CRIMP-TOOL
959025-000
Calibration Gauge
AD-1386-CALIBRATION-GAUGE
992013-000
Accessories and Replacement Parts
Parts
Description
Part No.
Crimp Locator
AD-1377-103-CRIMP-LOCATOR
994855-000
Spring
AD-1377-P-E118-TOR-SPRNG
994123-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 26
Electrical Interconnect Products
200˚ MiniSeal High-Performance,
Immersion-Resistant Crimp Splices
In-line nickel plated sealed crimp splices for 200˚C applications
were developed for the growing needs of high temperature
applications in the aerospace and defense industry.
200˚C MiniSeal crimp splices provides the smallest, lightest,
and the most environmental-resistant splices available, while
meeting all requirements of SAEAS81812/11.
Applications
RUGGED
• Transparent heat-shrinkable insulation
sleeve provides environmental
protection and strain relief
EASY TO USE
MiniSeal wire-to-wire splicing products are ideal for aerospace
and defense applications where performance, reliability or size
reduction is essential.
Designed to provide an immersion resistant in-line splice on 1:1
wires for the following: wire range from 26 AWG to 12 AWG;
nickel-plated conductors and insulation rated for at least 135˚C.
• No need to staffer wire splices
VERSATILE
• Small size
• Light weight
• Immersion-resistant crimp splices
while meeting all requirements
of SAE AS81824/11
• Splices provide sealing to unetched
wire insulations
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 27
Electrical Interconnect Products
Product
Characteristics
Material
Insulation
Crimp splicer
Meltable rings
Heat-shrinkable, transparent blue, radiation cross-linked
modified fluoropolymer
Base Metal: Copper alloy 101 or 102 per ASTM B75
Plating: Nickel per SAE AMS-QQ-N-290
Color Code: see table below
Environment resistant modified thermoplastic fluoroelastomer
Color: Light blue
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating
Insulation resistance
Specifications/
Approvals
Part Numbers
6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire
Exceeds strength of conductor
2.5 kV
-55˚C to 200°C [-67°F to 392°F]
5000 megohms
Series
D-200
Military
Meets the requirements of SAE AS81824/11
Part No.
Color Code
D-200-82 Red
D-200-83 Blue
D-200-84 Yellow
Part Number
D17660-000
A36675-000
C60253-000
Product Dimensions
Product Product
Name Rev.
D-200-82 A
D-200-83 A
D-200-84 A
I.D.*
Crimp Splicer
a. min
øA øB C D
b. max
2.16 (0.085)
1.27 (0.050) 2.03 (0.080) 12.95 (0.510) 6.22 (0.245)
0.64 (0.025)
1.14 (0.045) 1.91 (0.075) 12.45 (0.490) 5.72 (0225)
2.79 (0.110)
1.75 (0.069) 2.70 (0.106) 14.86 (0.585) 7.11 (0.280)
0.64(0.025)
1.63 (0.064) 2.57 (0.101) 14.35 (0.565) 6.60 (0.260)
4.32 (0.170)
2.60 (0.102) 3.89 (0.153) 14.86 (0.585) 7.11 (0.280)
0.64 (0.025)
2.46 (0.097) 3.73 (0.147) 14.35 (0.565) 6.60 (0.260)
E
max.
0.38
(0.015)
0.51
(0.020)
1.27
(0.050)
Color
Code
Red
Blue
Yellow
*I.D.: a- As received; b- After unrestricted recovery thru meltable insert.
Product
MIL Spec
Name
Equivalent Size
D-200-82 M81824/11-1
D-200-83 M81824/11-2
D-200-84 M81824/11-3
Wire
Range
26-20
20-16
16-12
Wgt. Lbs/Mpc
max.
1.02
1.61
2.72
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 28
Insulated Terminals
and Disconnects
Introduction
TE 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
brand 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 color-coded 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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 29
Electrical Interconnect Products
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals
and Disconnects
Applications
DuraSeal products insulate and protect electrical connections
from mechanical abuse, wire pull-out, and abrasion while
resisting water, salt, and other contaminant’s.
DURABLE
• Resistance to moisture and abrasion
• Strain relief
CAPABLE
• Protection from wire pull-out
• UL and CUL listed
EASY TO USE
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.
DuraSeal devices retain flexibility and impact-resistance long
after similar products have become brittle.
DuraSeal devices accommodate wire gauge sizes 22 to 10.
They are color-coded for easy identification of gauge sizes, yet
transparent for inspection of the finished splice.
• Easy installation
Approvals and Reference Documents
Agency approvals
Reference documents
UL listed component, file E87681, terminals except quick connect terminals;
file E157833, quick connect terminals
TE specifications RB-108,
Specification DuraSeal crimp terminals
DuraSeal selection guide (H54153)
DuraSeal installation guidelines (H54154)
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 30
Electrical Interconnect Products
Product Characteristics
Physical
Electrical
Property
Dimensions
Tensile strength
Unit
Inches
Pounds
Requirement
None
8 to 40 lbs depending on AWG
Property
Unit
Typical value
Voltage drop
Millivolts
Less than equal length of wire
Insulation resistance
Megohms
103 min.
Dielectric withstand
Kilovolts
2.5
voltage
Chemical
Environmental
(Fluid)
Property
Unit
Requirement
Diesel fuel
Brake fluid
Meet electrical test listed above
Antifreeze
—
after conditioning.
5% salt water
Motor oil
Humidity
Immersion
Vibration
Meet electrical test
Bending
—
listed above after
Thermal shock
conditioning.
Heat aging (168h @ 85°C [185°F)
Salt spray
Operating
conditions
Temperature rating
Minimum shrink temperature
—
Voltage rating
Method of Test
See product dimensions
UL486C, IEC512-8
Method of Test
MIL-S-81824, IEC512-2
MIL-STD-202 method 302
MIL-STD-202F method 301,
IEC512-2
Method of Test
ASTM D 3032, ESA-603D
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
-55°C to +125°C [-67°F to -257°F] None
180°C [356°F]
None
600 Volt max
None
Fork Terminals
L max.
ØA min.
ØB nom. C nom.
Wire Dimensions
Fork Terminal Dimensions
Insulation
Part
Insulation
Color
Conductor
O.D.
A Stud
C
L
No.
O.D. (Min.)
Min. Size
Nom.
Max. (AWG) (Max.)
Metric Imperial
B-106-2401
3.81 [.15] M4
8
7.87 [.31]
32.00 [1.26]
Red
22–18
3.81 [.150]
1.40 [.055]
B-106-2402
4.57 [.18] M4
8
7.87 [.31]
35.05 [1.38]
Blue
16–14
4.45 [.175]
2.00 [.080]
B-106-2403
6.35 [.25] M4
8
7.87 [.31]
38.10 [1.50]
Yellow
12–10
6.35 [.250]
2.79 [.110]
B-106-2502
4.57 [.18] M5
10
9.91 [.39]
35.05 [1.38]
Blue
16–14
4.45 [.175]
2.00 [.080]
Yellow
12–10
6.35 [.250]
2.79 [.110]
B-106-2503
6.35 [.25] M5
10
9.91 [.39]
40.15 [1.58]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 31
Electrical Interconnect Products
Ring Terminals
L max.
ØA min.
B nom.
ØC nom.
Ring Terminal Dimensions
Wire Dimensions
Insulation
Part
Insulation
Color
Conductor
A Stud
C
L
O.D.
No.
(AWG) O.D. (Min.)
Min. Size
Nom.
Max.
(Max.)
Metric Imperial
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
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]
M4
M5
M6
M8
M10
M4
M5
M6
M8
M10
M4
M5
M6
M8
M10
8
10
1/4
5/16
3/8
8
10
1/4
5/16
3/8
8
10
1/4
5/16
3/8
7.88
9.91
11.94
13.97
17.78
7.88
9.91
11.94
13.97
17.78
7.88
9.91
11.94
13.97
17.78
[.31]
[.39]
[.47]
[.55]
[.70]
[.31]
[.39]
[.47]
[.55]
[.70]
[.31]
[.39]
[.47]
[.55]
[.70]
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]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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
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]
PAGE 32
Electrical Interconnect Products
Push-on Terminals
L max.
C nom.
A min.
B nom.
Wire Dimensions
Push-on Terminal Dimensions
Insulation
Part
Tab
Insulation
Color
Conductor
O.D.
A B C L
No.
Size
O.D.
(AWG)
(Min.)
Min. Nom. Nom. Max.
(inches)
(Max.)
B-106-3631
.250 x .032
3.81 [.150]
6.35 [.250]
.81 [.032]
30.48 [1.200]
Red
22–18
3.81 [.150] 1.40 [.055]
B-106-3632
.250 x .032
4.57 [.180]
6.35 [.250]
.81 [.032]
32.00 [1.260]
Blue
16–14
4.45 [.175] 2.00 [.080]
B-106-3633
.250 x .032
6.35 [.250]
6.35 [.250]
.81 [.032]
33.02 [1.300]
Yellow
12–10
6.35 [.250] 2.79 [.110]
B-106-3281
.110 x .020
3.81 [.150]
2.79 [.110]
.51 [.020]
22.86 [.900]
Red
22–18
3.81 [.150] 1.40 [.055]
B-106-3481
.187 x .020
3.81 [.150]
4.75 [.187]
.51 [.020]
30.48 [1.200]
Red
22–18
3.81 [.150] 1.40 [.055]
Tab Terminals
L max.
C nom.
ØA min.
B nom.
Wire Dimensions
Tab Terminal Dimensions
Insulation
Part
Tab
Insulation
Color Conductor
O.D.
A B C L
No.
Size
O.D.
(AWG)
(Min.)
(inches) Min. Nom. Nom. Max.
(Max.)
B-106-4631
.250 x .032
3.81 [.150]
6.35 [.250]
.81 [.032]
30.48 [1.20]
Red
22–18
3.81 [.150]
1.40 [.055]
B-106-4632
.250 x .032
4.57 [.180]
6.35 [.250]
.81 [.032]
32.00 [1.26]
Blue
16–14
4.45 [.175]
2.00 [.080]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 33
Electrical Interconnect Products
Pin Terminals
L max.
ØA min.
ØB
Wire Dimensions
Pin Terminal Dimensions
Part
Insulation
Insulation
Color
Conductor
A B L
No.
O.D. O.D.
(AWG)
Min. Nom. Max.
(Max.) (Min.)
B-106-6201
3.81 [.150]
2.00 [.080]
30.99 [1.220]
Red
22–18
3.81 [.150]
1.40 [.055]
Bullet Terminals
Fig. 1
L max.
B nom.
ØA min.
L max.
Fig. 2
ØA min.
ØB
ØC min.
Bullet Terminal Dimensions
Wire Dimensions
Part
Conductor
Insulation
Insulation
Color
A B C
L
(AWG) O.D. O.D.
No.
Fig. Type
Min. Nom.
Min.
Max.
(Max.) (Min.)
B-106-7401
1
M
3.81 [.150] 3.81 [.150]
—
33.53 [1.32]
Red
22–18
3.81 [.150]
1.40 [.055]
B-106-7502
1
M
4.57 [.180] 5.08 [.200]
—
34.54 [1.36]
Blue
16–14
4.45 [.175]
2.00 [.080]
B-106-8401
2
F
3.81 [.150] 3.81 [.150]
5.59 [.220]
30.48 [1.20]
Red
22–18
3.81 [.150]
1.40 [.055]
B-106-8502
2
F
4.57 [.180] 5.08 [.200]
6.10 [.240]
32.51 [1.28]
Blue
16–14
4.45 [.175]
2.00 [.080]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 34
Electrical Interconnect Products
Product Characteristics
(Typical)
Operating temperature
Shrink ratio
Physical properties
Chemical properties
Electrical properties
-55°C to 125°C [-67°F to 257°F]
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 160°C [320°F]
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
Specifications/
Approvals
Series
B-106
Installation
Requirements
Agency
UL and CUL 91J4, File E87681
Lloyd’s listed, File 65 247 HH 02-93
UL and CUL E157833
(B-106-3XXX/B-106-4XXX)
1. Select appropriate
size. For terminal
and disconnect
terminations, strip wire
6.5 mm (1/4 inch).
TE
RB-108
For proper installation of
these devices, the correct
crimp tool and heating tool
with reflector attachment
must be used. The AD-1522
crimp tool and HL1920E/
HL2020E heating tools are
recommended. Refer to
TE installation procedure
RPIP-684-00 for detailed
instructions.
2. Crimp using 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.
Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.
WEIGHT
• 350 g (12.3 oz.)
PRODUCT RANGE
AD-1522-1 Hand Crimping Tool
Tool is used for completing wire
terminations using DuraSeal splices.
• DuraSeal Crimp Splices and Terminals
Ordering Information
AD-1522-1 Crimp Tool for DuraSeal Splices
Product
Description
Part No.
Crimp Tool
AD-1522-1
047011-000
Calibration Gauge
AE-2245
020435-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 35
Electrical Interconnect Products
SolderGrip Self-Fixturing Insulated Terminals
Product Selection Process
1. D
etermine the wire combination (number of wires and size) of
the wire bundle you wish to terminate.
2. U
se 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.
RUGGED
• Transparent insulation sleeve
provides encapsulation,
inspectability, strain relief, and
insulation
VERSATILE
• Spiral copper coil grips and
compresses the conductors for
optimum solder connection
• Prefluxed solder preform provides a
controlled soldering process
• Accommodates a wide variety of
conductor types, quantities, sizes,
and plating types unmatched by any
other termination technique
HIGH PERFORMANCE
• Parts meet the performance
requirements of MIL-T-7928G
EASY TO USE
• One-piece design for easy
installation
APPLICATIONS
• Used for terminating
multiple wires to terminals
4. S
elect 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. V
erify that the wire bundle (with wire insulation) does not
exceed the maximum diameter allowed for the part you
selected. Simply check the bundle’s diameter against the
maximum diameter that Table A lists for that part.
6. V
erify 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 37).
Using Table B, select the smallest size part that will fit your total
wire CMA (mm2) value.
Product Option
Product Series
SGRT
Environmental Protection
Splashproof (not RoHS compliant)
Table A. Part Number Selection
Maximum
Maximum
Wire Range
SolderGrip Stud
Typical
Bundle
Amp
(Min.–Max.)
Part No.
Size
Length
Diameter†
Rating
CMA [mm2]
1400–5000
SGRT-1-02
2 [2]
4.1 [.161]
12.5 A
38 [1 1/2]
[0.7–2.5]
2400–6000
SGRT-2-03
3 [6]
5.0 [.195]
15 A
38 [1 1/2]
[1.2–3.0]
2400–6000
SGRT-2-04
4 [8]
—
15 A
38 [1 1/2]
[1.2–3.0]
2400–6000
SGRT-2-05
5 [10]
—
15 A
38 [1 1/2]
[1.2–3.0]
2400–6000
SGRT-2-06
6 [1/4]
—
15 A
38 [1 1/2]
[1.2–3.0]
5000–13,200
SGRT-3-06
6 [1/4]
6.5 [.255]
33 A
44.5 [1 3/4]
[2.5–6.6]
5000–13,200
SGRT-3-08
8 [5/16]
—
33 A
51.0 [2]
[2.5–6.6]
12,000–22,400
SGRT-4-06
6 [1/4]
9.0 [.355]
56 A
44.5 [1 3/4]
[6.0–11.2]
12,000–22,400
SGRT-4-08
8 [5/16]
—
56 A
51 [2]
[6.0–11.2]
†Maximum bundle diameter is measured over wire insulation.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 36
Electrical Interconnect Products
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.)
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. A
dd together the
values listed in the
workspace below to
obtain the total area.
4. U
se Table A to select
the smallest terminator
that will fit the total
CMA (mm2).
Wire Number
CMA
mm2
1
2
3
4
5
6
7
8
9
10
Solder Grip Part No.
Total
CMA/mm2 Example
22 AWG/.38
CMA 754
OD Bundle
Insulation
22 AWG/.38
CMA 754
18 AWG/.95
CMA 1900
Conductor
16 AWG/1.21
CMA 2426
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).
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Bundle diameter must not
exceed 5.0 mm [0.195 in] for
this example
PAGE 37
Electrical Interconnect Products
Table B. CMA of Typical
Copper Conductors
Strands
7 19 19 19 19 19 19 19 37
AWG
28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm2 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 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
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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
PAGE 38
Electrical Interconnect Products
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
—
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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
—
PAGE 39
Electrical Interconnect Products
Installation
Requirements
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 TE installation
procedure RPIP-820-01 for
detailed instructions and
recommended reflector
attachments.
Either of the following
TE heating tools is
recommended:
n
n
Product
Characteristics
HL1920E/HL2020E
CV-1981
Material
Insulation
Solder and flux
Typical Performance
Tensile strength
Temperature rating
Voltage Drop
Dielectric Withstanding Voltage
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar®)
Sn60 Pb40 with RA flux
Exceeds strength of individual wires
-55°C to +150°C [-67°F to +302°F]
Not to exceed that of equivalent length of wire by more than 1 mV
Current leakage less than 2 mA (1.5 kV)
Kynar is a trademark of Arkema, Inc.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 40
Wire Termination to
Pin/Post/Tab
Introduction
TE SolderSleeve terminators offer easy, one-step
solutions for wire connections to pins, posts, and tabs and
for mass wire terminations.
Designed for applications with temperatures up to 150°C
[302°F], the products in this section include SolderSleeve
discrete wire terminators, which are heat-shrinkable
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 TE termination products, provide
reliability and economical installation for greater
productivity. They can be supplied either in bulk or on
carrier tape.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 41
Electrical Interconnect Products
SolderSleeve Discrete Wire Terminators
Product Selection Process
1. Determine the application operating temperature.
2. F
rom 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.
DURABLE
• Transparent polyvinylidene
fluoride or polyolefin insulation
sleeve provides encapsulation,
inspectability, strain relief,
and insulation
CAPABLE
• Prefluxed solder preform offers a
controlled soldering process
HIGH PERFORMANCE
4. Determine your wire gauge.
5. O
ptional: Select tape carrier center-to-center spacing
(D-71X series only). This should match center spacing of
component terminals.
6. Select part number from the appropriate table:
•F
or B-155 and CWT series (applications with lowtemperature wires—below 125°C [257°F]), use Table A.
•F
or D-129/141/71X series (applications with wires rated higher
than 125°C [257°F]), use Table B.
Installation Requirements
EASY TO USE
For proper installation of these devices, the correct heating tool
and reflector attachment must be used. Either of the following
TE heating tools is recommended:
• One-piece design means easy
• HL1920E/HL2020E
• UL and CUL Recognized
installation and low installed cost
• Optional tape carrier provides
convenience and ease of installation
APPLICATIONS
• AA-400 Super Heater
Refer to TE installation procedure RCPS-200-12 (for D-129,
D-141, D-71X) or RPIP-824-00 (for B-155 and CWT) for detailed
instructions and recommended reflector attachment.
• Used for terminating wires to
component terminals, such as
motor tabs, connector pins, and
switch terminals
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 42
Electrical Interconnect Products
Product Options
Product Series
B-155, CWT
D-129, D-141, D-71X
Max. Operating Temperature
125°C [257°F]
150°C [302°F]
Min. Wire Temperature Rating
85°C [185°F]
125°C [257°F]
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult TE for details.
Table A. B-155 Series
(125°C [257°F] rated)
Connection-point
2
Terminal Dimensions
Wire AWG/mm
Type and Size
24 [0.24]
W = up to 0.63 [.025]
20 [0.61]
W
B-155-1501
B-155-1502
24 [0.24]
W = 0.63 [.025] to
22 [0.38]
0.89 [0.035]
20 [0.61]
pin
B-155-1501
B-155-1502
B-155-1503
W
post
Part No.
W = 0.89 [0.035] to
1.14 [.045]
24–22 [0.24–0.38]
20–18 [0.61–0.95]
B-155-1502
B-155-1503
W = 1.14 [.045] to
1.52 [.060]
24–22 [0.24–0.38]
20–18 [0.61–0.95]
B-155-1503
B-155-1504
W = up to1.52 [.060]
24–20 [0.24–0.61]
B-155-1501
W = 1.27 [.050] to
24-18 [0.24–0.95]
B-155-1502
2.28 [.090]
W
tab
W = 1.77 [.070] to
24-18 [0.24–0.95]
B-155-1503
2.79 [.110]
W = 2.54 [.100] to
24-18 [0.24–0.95]
B-155-1504
3.80 [.150]
W = 2.28 [.090] to
22-16 [0.38–1.21]
B-155-1505
4.70 [.187]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 43
Electrical Interconnect Products
Table B. D-129/141/71X Series (up to 150°C [302°F] rated)
Connection-point
Type and Size
Wire Tape Carrier Spacing of Sleeves (Center-to-Center)
Terminal
2
1.27 2.54 3.17 4.0
None
Dimensions
AWG mm
[0.050] [0.100] [0.125] [0.156]
30–26 [0.05–0.15] D-141-30 D-713-03
—
—
—
W
W = up to 0.61 [.024]
24–22 [0.24–0.38] D-141-07 — D-711-00 —
—
pin
W
post
W
tab
W = 0.63 [.025] to
[0.61]
D-141-31
—
D-711-04 D-711-07
20
0.81 [.032]
W = 0.76 [.030] to
24–20
[0.24–0.61]
D-141-56 —
1.27 [.050]
W = up to 1.52 [.060]
24–20
W = 1.27 [.050] to
2.28 [.090]
24–20 [0.24–0.61]
W = 2.28 [.090] to
3.55 [.140]
For Fine Wire
Terminations
0.15 mm2 (26 AWG)
and Smaller*
— — —
D-129-05
—
D-129-03
—
—
— D-714-00
24–20 [0.24–0.61] D-129-0043 —
—
—
Part
No.*
D-110-0062
D-110-0217
D-141-13
D-141-22
D-141-30
[0.24–0.61]
D-711-08
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]
D-714-01
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]
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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 44
Electrical Interconnect Products
Product
Characteristics
Material
Insulation [D-129, D-141, D-71X]
Insulation [B-155, CWT]
Solder and flux [D-129, D-141, D-71X]
Solder and flux [B-155]
Solder and flux [CWT]
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating [B-155, CWT]
Temperature rating [D-129, D-141, D-71X]
Insulation resistance
Specifications/
Approvals
Series
B-155
CWT
D-129, D-141
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Radiation-crosslinked, heat-shrinkable polyolefin
Solder: Sn63 Pb37
Flux: ROL1 per ANSI-J-004 [RMA flux]
Solder: Sn42Bi58
Flux: ROM1 per ANSI-J-004 [RA flux]
Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI-J-004 [RA flux]
2.0 mV
Exceeds strength of conductor
2.0 kV
-55°C to 125°C [-67°F to 257°F]
-55°C to 150°C [-67°F to 302°F]
1000 megohms
Agency
RoHS
UL and CUL E87681
UL and CUL E87681
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
TE
RT-1404
D-5023
RT-1404
PAGE 45
Shield
Termination
Introduction
TE 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 -65°C to 200°C [-85°F to 392°F], the
products in this section include:
•B
-155-X and CWT-X SolderSleeve terminators,
designed for low-temperature cables with operating
temperatures up to 125°C [257°F] and suitable for most
commercial environments.
• MIL-S-83519 SolderSleeve terminators, which are
immersion resistant and available with or without a
preinstalled ground lead.
• SO Series SolderSleeve terminators, which also
are immersion resistant and feature the TE BiAlloy
temperature indication system.
• S200 Shield terminators are offered in various sizes
and ground lead configurations.
All SolderSleeve products are reliable, versatile, and easy
to install, resulting in lower installed costs.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 46
Electrical Interconnect Products
SolderSleeve Shield Terminators
Product Selection Process
1. Select product series from the Product Options table below.
2. Determine cable dimensions.
3. Optional: Select preinstalled wire lead type (see Table G on
page 53 for type descriptions).
4. S
elect part number (use the selection table indicated for your
product series in the Product Options table below).
RUGGED
5. Refer to Table H on page 53 for cross-reference information.
• Transparent insulation sleeve
provides encapsulation,
inspectability, strain relief, and
insulation
VERSATILE
• Prefluxed solder preform provides a
controlled soldering process
Jacket OD (max.)
Shield OD (min.)
EASY TO USE
• One-piece design means easy
installation and lower installed cost
• Optional preinstalled ground
leads provide convenience and
ease of installation
APPLICATIONS
• Used for shield-to-ground
termination
Product Options (Refer to Table G on Page 53 for Additional Information)
System Oper.
Used on
Part No.
Product
Environmental
Solder Flux
Insulation
Temperature Cables Rated
Selection
Series
Protection
Alloy Type
Material
(Max.) (Min.)
Table
B-155
125°C [257°F]
85°C [185°F]
Splash resistant
Bi58
PA
Polyolefin
A
CWT
125°C [257°F]
85°C [185°F]
Splash resistant
Cd18
RA
Polyolefin
A
SO63*
150°C [302°F] 125°C [257°F]
Immersion resistant
Sn63
RMA
Polyvinylidene fluoride
B
S01/S02**, S03 150°C [302°F] 125°C [257°F]
Immersion resistant
Sn63
RMA
Polyvinylidene fluoride
C, D
SO96***
175°C [347°F] 150°C [302°F]
Immersion resistant
Sn96
RA
Polyvinylidene fluoride
E
SO175****
175˚C [347°F] 150˚C [302°F]
Immersion resistant
Sn96
RA
Polyvinylidene fluoride
F
S200****
200°C [392°F] 150˚C [302°F]
Immersion resistant
Sn96
RA
Fluoropolymer
G
*Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with BiAlloy temperature indicator.
**Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with thermochromic temperature indicator.
****Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519), supplied with BiAlloy temperature indicator.
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F]. Consult TE for details.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 47
Electrical Interconnect Products
Raychem S200 Shield Terminators
HIgh-Performance, High-Temperature Cable Terminators
An important extension of the Raychem SolderSleeve family,
S200 shield termination devices were developed specifically
to address the need for high-temperature connecting,
insulating, and sealing for applications in the aerospace and
defense industry.
ECONOMICAL
• One-piece design allows for a singlestep, simplified installation and a low
total installed cost
• Bi-alloy or thermochromic
temperature indicator works as a
process control aid and simplifies
operator training
• Offered in various sizes and ground
lead configurations
CAPABLE
• Provides a completely soldered,
strain-relieved termination
• Heat-shrinkable sleeve helps
provide insulation, inspectability, and
strain relief
• Designed for high-temperature
applications up to 200°C
• Sealing inserts helps ensure reliable,
environmental protection
Wide Selection
Offered in various sizes and ground lead configurations, our
S200 shield termination devices provide environmentally
protected shield termination on cables with a minimum
temperature rating of 150°C, and silver or nickel-plated shields.
They are also available with bi-alloy or thermochromic indicators
Fast Installation and Lower Costs
Convenient to use, the one-piece design of S200 shield
termination devices help ensure reliable environmental
protection and greatly simplified installation for a lower total
installed cost.
MATERIALS
• Solder: Tin 96%/Silver 4% bi-alloy solder
• Tubing: Heat-shrinkable modified fluoropolymer
• Inserts: Thermoplastic fluoropolymer
STANDARDS AND SPECIFICATIONS
• I ndustry Standards:
SAE-AMS-DTL-23053/13 (applies to heat-shrinkable insulation sleeve only)
SAE-AS83519 (modified for 200°C applications)
EU RoHS/ELV compliant
•T
E Instruction Sheet: RCPS-100-71
• TE Qualification and Test Report: Available on request
MECHANICAL/ENVIRONMENTAL
• Operating Temperature: 150°C to 200°C
APPLICATIONS
• Shield termination of cables
•D
urability: Heat-shrinkable sleeve adheres and seals to provide a completely
soldered, strain-relieved termination
subjected to a minimum temperature
rating of 150°C and maximum
operating temperature of 200°C
• Protecting and sealing for BMS 13-60
PTFE wrapped cables and M27500
cables with PTFE/polyimide jackets
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 48
Electrical Interconnect Products
ORDERING INFORMATION (TC indicates that this part has a thermochromic indicator)
Without ground lead
Jacket OD (mm) Shield (mm)
1.90
0.90
1.90
0.90
2.67
1.40
2.67
1.40
4.32
2.15
4.32
2.15
5.97
3.30
5.97
3.30
6.98
4.30
6.98
4.30
Product Description
S200-1-00
S200-1-00-TC
S200-2-00
S200-2-00-TC
S200-3-00
S200-3-00-TC
S200-4-00
S200-4-00-TC
S200-5-00
S200-5-00-TC
Raychem Part Number
F92583-000
CN5417-000
F94898-000
CN5418-000
A65903-000
CN5419-000
E32454-000
CN5420-000
D12074-000
CN5421-000
SAE AS83519
With pre-installed braid: Nickel-plated copper strands in accordance to AA59569F36N0031. (6 Inches)
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.32
2.15
5.97
3.30
6.98
4.30
Product Description
S200-1-01
S200-2-01
S200-3-01
S200-4-01
S200-5-01
Raychem Part Number
CS5526-000
D08259-000
A77145-000
F26506-000
A18826-000
SAE AS83519
M83519/5-1
M83519/5-2
M83519/5-3
M83519/5-4
M83519/5-5
With pre-installed braid: Ni-plated copper strands per ASTM B355, Class 4. CMA = 1200. (6 Inches)
Jacket OD (mm) Shield (mm)
1.90
0.90
1.90
0.90
2.67
1.40
2.67
1.40
4.32
2.15
4.32
2.15
5.97
3.30
5.97
3.30
6.98
4.30
6.98
4.30
Product Description
S200-1-9020
S200-1-9020-TC
S200-2-9020
S200-2-9020-TC
S200-3-9020
S200-3-9020-TC
S200-4-9020
S200-4-9020-TC
S200-5-9020
S200-5-9020-TC
Raychem Part Number
CJ1037-000
CP7589-000
CJ1039-000
CP4262-000
CJ1041-000
CP6063-000
CJ1042-000
CP6893-000
CJ1043-000
CP7313-000
SAE AS83519
M83519/5-11
M83519/5-16
M83519/5-12
M83519/5-17
M83519/5-13
M83519/5-18
M83519/5-14
M83519/5-19
M83519/5-15
M83519/5-20
With pre-installed braid: Ni-plated copper strands per ASTM B355, Class 4. CMA = 1800. (6 Inches)
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.32
2.15
5.97
3.30
6.98
4.30
6.98
4.30
Product Description
S200-1-9030
S200-2-9030
S200-3-9030
S200-4-9030
S200-5-9030
S200-5-9030-TC
Raychem Part Number
CA7639-000
CA7640-000
CA7641-000
CA7642-000
CA7643-000
CP7417-000
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
SAE AS83519
PAGE 49
Electrical Interconnect Products
With pre-installed braid: High nickel-plated copper strands per ASTM-B355 Class 7. CMA = 640. (10 Inches)
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.30
2.15
5.95
3.30
6.90
4.30
Product Description
S200-1-01-100HN
S200-2-01-100HN
S200-3-01-100HN
S200-4-01-100HN
S200-5-01-100HN
Raychem Part Number
D89883-000
A87947-000
A59779-000
C69495-000
D92195-000
SAE AS83519
With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.30
2.15
5.95
3.30
6.90
4.30
Product Description
S200-1-55-22-9
S200-2-55-22-9
S200-3-55-22-9
S200-4-55-22-9
S200-5-55-22-9
Raychem Part Number
EH1934-000
EH1935-000
EH1936-000
EH1938-000
EH1939-000
SAE AS83519
With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.30
2.15
5.95
3.30
6.90
4.30
Product Description
S200-1-55-20-9
S200-2-55-20-9
S200-3-55-20-9
S200-4-55-20-9
S200-5-55-20-9
Raychem Part Number
EH1940-000
EH1941-000
EH1942-000
EH1943-000
EH1944-000
SAE AS83519
With pre-installed braid: Stranded nickel-plated copper wire in accordance with SAE-AS22759/41.
Jacket OD (mm) Shield (mm)
1.90
0.90
2.67
1.40
4.30
2.15
5.95
3.30
6.90
4.30
Product Description
S200-1-55-18-9
S200-2-55-18-9
S200-3-55-18-9
S200-4-55-18-9
S200-5-55-18-9
Raychem Part Number
EH1945-000
EH1946-000
EH1948-000
EH1949-000
EH1950-000
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
SAE AS83519
PAGE 50
Electrical Interconnect Products
Table A. B-155 Series
(125°C [257°F] rated)
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]
Cable OD
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
B-155-3801
B-155-3802
B-155-3
B-155-5
B-155-6
B-155-7
B-155-9
B-155-11
B-155-13
Part Nos.
With Preinstalled Lead
(22AWG/0.38 mm2 green)
—
—
B-155-03-35-22-5
B-155-05-35-22-5
B-155-06-35-22-5
B-155-07-35-22-5
B-155-09-35-22-5
B-155-11-35-22-5
B-155-13-35-22-5
*See Table G on page 53 for lead description.
Note: The B-155 series is suitable for applications using low-temperature wires (typically rated at 85°C [185°F] to 125°C [257°F]) with bare copper or tin plating.
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
No
Jacket OD
Shield OD
Preinstalled
Max. Min.
22 AWG
Lead 20 AWG
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]
SO63-1-00
SO63-2-00
SO63-3-00
SO63-4-00
SO63-5-00
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
Part Nos.
Preinstalled Lead Option*
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
26 AWG
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
Braid Strap
Nickel Plated Tin Plated
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 53 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 TE BiAlloy temperature indication system, and meets the performance requirements of SAE-AS83519
(formerly MIL-S-83519) .
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 51
Electrical Interconnect Products
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 TE Part No.) by Lead Option
Preinstalled Lead Option*
No Preinstalled Lead
Shield OD
Jacket OD
20 AWG
22 AWG
Max Min
MIL TE
MIL TE MIL
TE
1.95 [0.075]
0.9 [.035]
M83519/1-1
S01-01-R
M83519/2-1
S02-01-R
M83519/2-6
S02-06-R
2.7[0.105]
1.40 [.055]
M83519/1-2
S01-02-R M83519/2-2 S02-02-R M83519/2-7
S02-07-R
4.3 [0.170]
2.15 [.085]
M83519/1-3
S01-03-R
M83519/2-3
S02-03-R
M83519/2-8
S02-08-R
6.0 [0.235]
3.30 [.130]
M83519/1-4
S01-04-R
M83519/2-4
S02-04-R
M83519/2-9
S02-09-R
7.0 [0.275]
4.30 [.170]
M83519/1-5
S01-05-R
M83519/2-5
S02-05-R
M83519/2-10
S02-10-R
Jacket OD
Preinstalled Lead Option*
Shield OD
Max. Min.
24 AWG
26 AWG
1.95 [0.075]
0.9 [.035]
M83519/2-11
S02-11-R
M83519/2-16
S02-16-R
2.7 [0.105]
1.40 [.055]
M83519/2-12
S02-12-R
M83519/2-17
S02-17-R
4.3[0.170]
2.15 [.085]
M83519/2-13 S02-13-R M83519/2-18
S02-18-R
6.0 [0.235]
3.30 [.130]
M83519/2-14
S02-14-R
M83519/2-19
S02-19-R
7.0 [0.275]
4.30 [.170]
M83519/2-15
S02-15-R
M83519/2-20
S02-20-R
*See Table G for lead description.
M83519 is the qualified product listed in SAE-AS83519 (formerly MIL-S-83519) . The series features a thermochromic temperature indicator to assist in
termination and inspection. The 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.
These parts now have qualification to /3
SOLDER SLEEVE SHIELD TERMINATORS
S03-01-R 257305-000 M83519/3-1 SAE AS83519
S03-02-R 065762-000 M83519/3-2 SAE AS83519
S03-03-R 676516-000 M83519/3-3 SAE AS83519
S03-04-R 689088-000 M83519/3-4 SAE AS83519
S03-05-R 531872-000 M83519/3-5 SAE AS83519
S03-06-R 022926-000 M83519/3-6 SAE AS83519
S03-07-R 101273-000 M83519/3-7 SAE AS83519
S03-08-R 587725-000 M83519/3-8 SAE AS83519
S03-09-R 751586-000 M83519/3-9 SAE AS83519
S03-10-R 621833-000 M83519/3-10 SAE AS83519
Cable OD
Part No.
Jacket OD
Preinstalled
Lead Option*
Shield OD
Min.
Tin
plated
Braid
Strap
Nickel plated Braid Strap
Max.
1.95 [0.075]
0.9 [.035]
S03-01-R
S03-06-R
2.7 [0.105]
1.40 [.055]
S03-02-R
S03-07-R
4.3 [0.170]
2.15 [.085]
S03-03-R
S03-08-R
6.0 [0.235]
3.30 [.130]
S03-04-R
S03-09-R
7.0 [0.275]
4.30 [.170]
S03-05-R
S03-10-R
*See Table G for lead description.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 52
Electrical Interconnect Products
Table E. SO96 Series
(175°C [347°F] 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.
Preinstalled Lead Option*
Jacket OD
No
Shield OD
Min.
Preinstalled Lead
22 AWG
Braid Strap
Max.
1.95 [0.075]
0.9 [.035]
SO96-1-00
SO96-1-55-22-90
SO96-1-01
2.7 [0.105]
1.40 [.055]
SO96-2-00
SO96-2-55-22-90
SO96-2-01
4.3 [0.170]
2.15 [.085]
SO96-3-00
SO96-3-55-22-90
SO96-3-01
6.0 [0.235]
3.30 [.130]
SO96-4-00
SO96-4-55-22-90
SO96-4-01
7.0 [0.275]
4.30 [.170]
SO96-5-00
SO96-5-55-22-90
SO96-5-01
*See Table G for lead description.
The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200°C [392°F]. This series features a
thermochromic temperature indicator and meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) . The solder is Sn96 with RA flux compatible
with nickel-plated shields.
Table F. SO175 Series
(175°C [347°F] rated)
BiAlloy Temperature Indication System
This system greatly enhances the reliability and repeatability of SO175 series terminators
while reducing installed cost. The temperature indicator ring, encircling the solder preform,
melts to indicate the very minimum amount of heat.
Cable OD
Part No.
Preinstalled Lead Option*
Jacket OD
No
Shield OD
Min.
Preinstalled Lead
22 AWG
Braid Strap
Max.
1.95 [0.075]
0.90 [0.035]
SO175-1-00
SO175-1-55-22-90
SO175-1-01
2.7 [0.105]
1.40 [0.055]
SO175-2-00
SO175-2-55-22-90
SO175-2-01
4.3 [0.170]
2.15 [0.085]
SO175-3-00
SO175-3-55-22-90
SO175-3-01
6.0 [0.235]
3.30 [0.130]
SO175-4-00
SO175-4-55-22-90
SO175-4-01
7.0 [0.275]
4.30 [0.170]
SO175-5-00
SO175-5-55-22-90
SO175-5-01
*See Table H for lead description.
Table G. S200 Series
(200°C [392°F] rated)
BiAlloy Temperature Indication System
This system greatly enhances the reliability and repeatability of S200 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
Preinstalled Lead Option*
No
Shield OD
Min.
Preinstalled Lead
22 AWG
Braid Strap
Max.
1.95 [0.075]
0.90 [0.035]
S200-1-00
S200-1-55-22-9
S200-1-01
2.7 [0.105]
1.40 [0.055]
S200-2-00
S200-2-55-22-9
S200-2-01
4.3 [0.170]
2.15 [0.085]
S200-3-00
S200-3-55-22-9
S200-3-01
6.0 [0.235]
3.30 [0.130]
S200-4-00
S200-4-55-22-9
S200-4-01
7.0 [0.275]
4.30 [0.170]
S200-5-00
S200-5-55-22-9
S200-5-01
*See Table H for lead description.
Table H. Preinstalled Lead Description
Series
S200
M83519, SO63
SO96, SO175
SO63, SO96, S03
B-155
CWT
SO63, S03
Lead Type
M22759/91
55A0111
55A0813
Braid strap
XL polyethylene
XL polyethylene
Braid Strap
Remarks
MIL-W-22759/91
MIL-W-22759/32
MIL-W-22759/41
Uninsulated
RoHS
UL Listed
Uninsulated
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Plating
Silver
Tin
Nickel
Nickel
Tin
Tin
Tin
Stranding
Stranded
Stranded
Stranded
40 x 38 AWG
Stranded (W2)
Stranded (W1)
Stranded
Min. Length
150 (6.00)
150 [6.00]
150 [6.00]
150 [6.00]
150 [6.00]
150 [6.00]
150 [6.00]
PAGE 53
Electrical Interconnect Products
Product
Characteristics
Specifications/
Approvals
Material
Insulation
S200
SO, M83519
B-155
Solder and flux
SO63, M83519, S03
S200, SO96, SO175 series
B-155
Ground lead
B-155 series
S200 series
SO, M83519, SO175
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating
B-155
SO63/M83519/S03
SO96/SO175 series
S200
Insulation resistance
Radiation-crosslinked, heat-shrinkable, modified fluoropolymer
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Radiation-crosslinked, heat-shrinkable polyolefin
Solder: Sn63 Pb37
Solder: Sn96 Ag4
Solder: SN42Bi58
Flux: ROL1 per ANSI - J - 004 (RMA Flux)
Flux: ROM1 per ANSI - J - 004 (RA Flux)
Flux: ROM1 per ANSI - J - 004 (RA Flux)
XL polyethylene
MIL-C-22759/91 or /87
MIL-W-22759/32 or /41
2.5 mV
Exceeds strength of ground lead
1.0 kV immersed
-55°C to 125°C [-67°F to 257°F]
-55°C to 150°C [-67°F to 302°F]
-55°C to 175°C [-67°F to 347°F]
-55°C to 200°C [-67°F to 392°F]
1000 megohms
Series Agency
TE
B-155
—
RT-1404
SO63*
NAS 1747
RT-1404
M83519**
MIL-S-83519/1&/2
RT-1404
SO96***
NAS 1747
RT-1404
SO175
RT-1404
S200**
—
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
Requirements
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
TE heating tools
is recommended:
For detailed instructions and recommended reflector
attachments, refer to the appropriate TE installation
procedure:
n
SO63 RCPS-100-70
n
n
n
n
HL1920E/HL2020E
AA-400 Super Heater
CV-1981
MiniRay
IR-1759
Series Procedure
B-155 RPIP-824-000
CWT RPIP-655-00-D
M83519 (S01/S02) RCPS-100-70
SO96 RCPS-100-70
S03 RCPS-100-70
SO175 RCPS-100-70
S200 RCPS-100-71
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 54
Electrical Interconnect Products
Table H. NAS,
M83519, and
TE Cross-Reference
NAS
TE 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
TE
TE
Military
S01/S02 Series*
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
* QPL listed to SAE-AS83519 (formerly MIL-S-83519)
** Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519)
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 55
Coaxial Cable
Termination
Introduction
TE 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 150°C
[302°F], the products in this section include:
•S
olderSleeve coaxial cable terminators, which allow
reliable, economical attachment of coaxial cable to
connector terminals, printed wiring assemblies, or
solderless wrap terminals.
•O
ne-piece SolderSleeve PCB coaxial cable terminators,
which permit quick, easy, and cost-effective
terminations of coaxial cable to printed circuit boards.
•R
F 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-C-39012C connectors and are available in 50-ohm
and 75-ohm versions).
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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 56
Electrical Interconnect Products
SolderSleeve Coaxial Cable Terminators
Product Selection Process
1. Select product series from the product options table below.
2. Select preinstalled lead type from the table below.
3. Determine cable RG number or dimensions.
4. S
elect part number from Table A (B-155, CWT series) or
Table B (B-02X/B-04X series) on the next page.
VERSATILE
• 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
EASY TO USE
• One-piece design means easy
installation and lower installed cost
• Optional preinstalled ground
leads provide convenience and
ease of installation
Product Characteristics
Material
Insulation
(B-02X/B-04X, D-181, D-184)
Insulation (B-155, CWT series)
Solder and flux
(B-02X/B-04X, D-181)
Solder and flux
(CWT series, D-184)
Solder and flux (B-155)
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating
(B-155, CWT, D-184)
Temperature rating
(B-02X/B-04X, D-181)
Insulation resistance
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 Cd18
Flux: ROM1 per ANSI-J-004 (RA Flux)
Solder: Sn42Bi58
Flux: ROM1 per ANSI-J-004 (RA Flux)
2.0 mV
Exceeds strength of conductor
2.0 kV
-55°C to 125°C [-67°F to 257°F]
-55°C to 150°C [-67°F to 302°F]
1000 megohms
APPLICATIONS
• Used for terminating coaxial cable
to component terminals, contacts,
printed circuit boards, and solderless
wrap terminals.
Product Options
Product Series
B-155, CWT
B-02X/B-04X
D-181
D-184
Max. Operating Temp.
125°C [257°F]
150°C [302°F]
150°C [302°F]
125°C [257°F]
Use on Cables Rated (Min)
85°C [185°F]
125°C [257°F]
125°C [257°F]
85°C [185°F]
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
B-155, 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
XL polyethelene
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
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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)
PAGE 57
Electrical Interconnect Products
Table A. B-155 Series
Part Numbers
Table B. B-02X/B-04X
Series Part Numbers
Dimensions
Cable RG Number
Dielectric
OD
Jacket OD
174
0.80–2.30 [.032–.091] 1.30–2.80 [.051–.110]
58, 122
2.00–2.80 [.079–.110] 2.50–4.40 [.100–.173]
59
2.80–3.30 [.110–.130] 3.20–6.00 [.125–.235]
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
Part 1: Coaxial Product Group Selection
Typical Compatible
Dimension Range
Part No.
TE
One-Piece
RG Cable
Dielectric Conductor
Cable
Jacket OD (Max.) Shield OD
Coaxial Product
Number
OD OD
Description
Group
RG178, RG404
5030A13XX
5028A13XX
3.40
[.134]
1.30–2.30 0.50–1.70 0.30–0.80
Group 1
[.051–.091] [.019–.067] [.011–.032]
5024A13XX
7530A13XX
RG179, RG316
7526A13XX
9530A13XX
4.40
1.50–2.80 1.20–2.50 0.30–1.60
[.173]
[.060–.110] [.047–.100] [.011–.063]
Group 2
6.30
[.248]
Group 3
RG180, RG302,
RG303
9527A13XX
9528A13XX
Part 2: Product Part Number Selection
2.40–4.60 1.40–4.30 0.30–2.80
[.094–.181] [.055–.169] [.011–.110]
Preinstalled Wire Size
One-Piece
Preinstalled
Coaxial
20 22 24 26 28 30
Wire Type
Product Group
AWG AWG AWG AWG AWG AWG
Stranded
(M22759)
Group 1
Solid
(M81822)
—
B-044-22-N B-044-24-N B-044-26-N
— —
—
—
B-043-24-N B-043-26-N B-043-28-N B-043-30-N
Stranded B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N
(M22759)
Group 2
Solid
— —
B-041-24-N B-041-26-N B-041-28-N B-041-30-N
(M81822)
Stranded
(M22759)
Group 3
Solid
(M81822)
B-020-20-N B-020-22-N B-020-24-N B-020-26-N
— —
—
—
B-021-26-N —
—
—
1. T
he B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125°C minimum.
2. U
sing Part 1 of this table, select the appropriate coaxial product group (1, 2, or 3) based on your RG cable number, TE cable
description, or cable dimensions.
3. U
sing 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
∅E min.
∅F min.
L1 max.
L2 max.
∅A min.
∅D min.
∅B min.
∅C min.
Table D. D-184 Series
Part Numbers
∅E min.
∅F min.
L1 max.
L2 max.
∅A min.
∅D min.
∅B min.
∅C min.
Product Dimensions
Product
A B C D E F L1
L2
Wire
Name
min. min. min. min. min. min. max.
max.
AWG
D-181-1220-90/9
20
D-181-1222-90/9
22
D-181-1224-90/9
3.7 3.2 2.7 2.4 0.71 2.3 17 21.5 24
D-181-1226-90/9 [0.145] [0.125] [0.105] [0.095] [0.028] [0.09] [0.67] [0.85] 26
D-181-1826-6/9
26
D-181-1830-6/9
30
D-181-2220-90/9
20
D-181-2222-90/9
22
D-181-2224-90/9
4.5 4
3.45
2.9 1.1 3 17
22.7
24
D-181-2226-90/9 [0.18] [0.16] [0.135] [0.115] [0.045] [0.12] [0.67] [0.895] 26
D-181-2826-6/9
26
D-181-2830-6/9
30
D-181-3220-90/9
20
D-181-3222-90/9
]
22
D-181-3224-90/9 5.2 4.7 4.45 3.95 1.3
4
17 21.5 24
D-181-3226-90/9 [0.205] [0.185] [0.175] [0.155] [0.055] [0.16] [0.67] [0.85] 26
D-181-3826-6/9
26
D-181-3830-6/9
30
Product Dimensions
Product
∅A
∅B
∅C
∅D
∅E
∅F L1 L2 Wire
Name
min. min. min. min. min. min. max.
max.
AWG
D-184-1220-90/9
20
D-184-1222-90/9
3.7 3.2 2.7 2.4 0.71 2.3 17 21.5 22
D-184-1224-90/9 [0.145] [0.125] [0.105] [0.095] [0.028] [0.09] [0.67] [0.85] 24
D-184-1226-90/9
26
D-184-2220-90/9
20
D-184-2222-90/9
4.5 4
3.45
2.9 1.1 3 17
22.7
22
D-184-2224-90/9 [0.18] [0.16] [0.135] [0.115] [0.045] [0.12] [0.67] [0.895] 24
D-184-2226-90/9
26
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 58
Electrical Interconnect Products
SolderSleeve PCB/Coaxial Cable Terminators
Installation Requirements
For proper installation of these devices, the correct heating
tool and reflector attachment must be used. Any one of the
following TE heating tools is recommended:
• HL1920E/HL2020E
• AA-400 Super Heater
• IR-1759 MiniRay
VERSATILE
• CV-1981
• Transparent polyvinylidene
fluoride or polyolefin insulation
sleeve provides encapsulation,
inspectability, strain relief
(eliminates center conductor
breakage), and insulation.
Refer to TE installation procedure ES-61139 for detailed
instructions and recommended reflector attachments.
• Prefluxed solder preform provides
a controlled soldering process
2. Determine cable RG number or outside diameter dimensions.
Product Selection Process
1. Select product series from the Product Options table below.
3. Select the appropriate part number from Table A
(D-607 series) or Table B (B-046 series).
EASY TO USE
• One-piece design means easy
installation and lower installed cost
•F
or D-607 (matched impedance) series, determine straight
or right-angle entry to PCB and grid pattern, then select the
appropriate part number from Table A on the next page.
• Optional preinstalled ground
leads provide convenience and
ease of installation
•F
or 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).
APPLICATIONS
• Used for terminating coaxial cable
to component terminals, contacts,
printed circuit boards, and solderless
wrap terminals.
A
B
C
D
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
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Part No. Selection Table
A
B
PAGE 59
Electrical Interconnect Products
Specifications/Approvals
Series
D-607
B-046
TE
RT-1404
RT-1404
Table A. D-607 Series
Part Numbers
Cable Dimensions (mm/in)
Part No.
Max. Outside Diameter
Entry to PCB
RG Cable No.
Straight
Right-Angle
Straight
Jacket
Shield
Dielectric
grid 5.08 [.200]
Grid 5.08 [.200]
Grid 2.54 [.100]
174, 178, 179,
1.5–3.55
1.1–3.15
0.60–2.25
D-607-09 D-607-10 D-607-40*
316, 404
[.060–.140]
[.045–.125]
[.025–.090]
Table B. B-046 Series
Part Numbers
Cable Dimensions
Part No.
RG Cable No.
D
Pin Diameter Spacing Between Pins
A B C
5.08 [.200]
6.35 [.250]
Max. 2.54 [.100]
B-046-10-N B-046-12-N
0.30–0.80 0.5–1.7 1.3–2.3
3.4
0.6 [.023]
178, 404
B-046-14-N
[.011–.032] [.019–.067] [.050–.091] [.134]
0.8 [.031]
B-046-11-N B-046-13-N
B-046-66-N B-046-16-N
0.3–1.6
1.2–2.5
.1.5–2.8
4.4
0.6 [.023]
179, 316
B-046-15-N
[.011–.063]
[.047–.100]
[.060–.110]
[.173]
0.8 [.031]
B-046-68-N B-046-18-N
Product Characteristics
Material
Insulation
Solder and flux
Termination body/pin
Typical Performance
Voltage drop
Tensile strength
Dielectric strength
Temperature rating
Insulation resistance
Electrical Performance (typical) D-607 Series
Only Frequency
350 MHz
700 MHz
2.3 GHz
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Solder: Sn63 Pb37
Flux: ROL1 per ANSI - J - 004 (RMA flux)
Copper alloy, solder-plated
2.0 mV
Exceeds strength of conductor
2.0 kV
-55°C to 150°C [-67°F to 302°F]
1000 megohms
VSWR (D-607-09, -40)
1.04 max.
1.05 max.
1.09 max.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
VSWR (D-607-10)
1.04 max.
1.09 max.
1.12 max.
PAGE 60
RF One Step BNC/TNC
Connectors
Applications
DURABLE
• Outstanding cable-retention force
• Exceptional cable retention force
to withstand high vibration and
frequent mates and unmates
• Excellent built-in strain relief against
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.
vibration and excessive handling
CAPABLE
• Long-term reliability
• Meets performance requirements of
MIL-C-39012 up to 2.8 GHz
• Solder-solder connection type
(center conductor and braid)
• Fully soldered center conductor
and braid
VERSATILE
• Three product sizes to accommodate
a wide range of cables
• Use with standard RG/U cables and
TE Cheminax cables
EASY TO USE
• One-step termination for easy, quick
installation and lower installed cost
Specifications
TE
RB-115
Installation
For proper installation of these devices,
the correct heating tool and reflector
attachment must be used.
Any one of the following TE
heating tools is recommended:
• Steinel ® Model HL-2010E-230V
• CV-1981
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Refer to TE installation procedure
RPIP-683-00 for detailed instructions.
PAGE 61
Electrical Interconnect Products
Product Options and
Part Numbering System
RXX - XX - X - XX
Connector Style
Dash No.
Style
-XX
TNC
Connector Type
BNC
24.5 Max.
[.965]
-00
24.5 max.
[.965]
Straight plug
31.5 max.
[1.23]
33.5 Max.
[1.32]
-01
Right-angle plug
28 [1.09]
25.4 max.
[1.0]
-02
-03
Male
25.4 Max.
[1.0]
Straight bulkhead jack
25.4 max.
[1.0]
Male
28 [1.09]
25.4 Max.
[1.0]
Straight jack
25.4 Max.
[1.0]
-04
Connector size
L = Large
M = Medium
S = Small
50 = 50 ohms
75 = 75 ohms
D = Nickel-plated brass body, gold-plated brass pin
25.4 Max.
[1.0]
Female
Female
Straight panel jack
4 x M2.5 x 0.45
4 x M2.5 x 0.45
B = BNC
T = TNC
Example: RBD-50-L-00 is a BNC connector, 50 ohms, large size, with straight plug body.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 62
Electrical Interconnect Products
Product Characteristics
Solder
Insulation
Sleeve
Material
Center contact
Dielectric insulator
Transition
Connector body
Solder and flux
Braided shield
Insulation sleeve
Strain relief/sealing sleeve
Transition
Shield
Center
Contact
Dielectric
Insulator
Connector
Body
Insulation Sleeve
and Solder
Gold-plated beryllium copper (female)
Gold-plated brass (male)
PTFE
Silver-plated brass
Nickel-plated brass
Sn63Pb37, RMA flux
Tin-plated copper wire per ASTM B3
Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue
Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black
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
-55˚C to 150˚C [-67˚F to 302˚F]
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
Part Selection Process
1. From Product Options and Part Numbering System, 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
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.
D
E
F
G
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 63
Electrical Interconnect Products
Impedance
(ohms)
Cable Type
RG Cables
D
Cables
(Min.–Max.)
BNC Straight Plugs, Male 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
BNC Right-Angle Plugs, Male 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
—
524A1311, 7528A1317
RG-6, RG-11, RG-12, RG-59
75
—
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
—
RG-6, RG-11, RG-12, RG-59
75
—
RG-144, RG-216
BNC Straight 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
—
75 7524A1311, 7528A1317
75 RG-6, RG-11, RG-12, RG-59
—
RG-144, RG-216
BNC Straight Panel Jacks, Female Contacts
5026A1311, 5028A1317,
50 RG-174, RG-178, RG-188,
RG-196,RG–316
5030A1317
RG-58,
RG-141,
RG-142,
5019D3318,
5021D1331,
50
RG-303, RG-400
5020A1311
5012F3332, 5012A3311
50 RG-165, RG-215, RG-213,
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
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]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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
PAGE 64
Electrical Interconnect Products
TNC Coaxial Connectors
Impedance
(ohms)
Cable Type
D
RG Cables
Cables
(Min.–Max.)
TNC Straight Plugs, Male 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
RG-6, RG-11, RG-12, RG-59
75
—
RG-144, RG-216
TNC Straight 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 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
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]
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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
RTD-75-L-04
PAGE 65
Electrical Interconnect Products
TNC Coaxial
Connectors
Panel thickness: 3.2 [.125] max.
RBD-XX-X -02
RTD-XX-X -02
RBD-XX-X-04
RTD-XX-X-04
12.7 [.5]
12.7
[.5]
= =
12 [.47]
∅11.2 [.44]
=
=
∅3 [.12]
∅12.9 [.51]
18 [.7] min.
Impedance
(ohms)
20.5 [.8] min.
Cable Type
D
Cables
(Min.–Max.)
E
(Min.–Max.)
F
(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]
RG Cables
TNC Straight Bulkhead Jacks, Female Contacts
5026A1311, 5028A1317,
50 RG-174, RG-178, RG-188,
RG-196,RG–316
5030A1317
RG-58,
RG-141,
RG-142,
5019D3318,
5021D1331,
50
RG-303, RG-400
5020A1311
50 RG-165, RG-215, RG-213,
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
5026A1311, 5028A1317,
50 RG-174, RG-178, RG-188,
RG-196,RG–316
5030A1317
RG-58, RG-141, RG-142,
5019D3318, 5021D1331,
50
RG-303, RG-400
5020A1311
50 RG-165, RG-215, RG-213,
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
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Cable Dimensions
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
PAGE 66
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 TE SolderShield
cable splices. SolderShield devices are one-piece
products consisting of a flux-coated, solder-impregnated
copper shield braid encased in a heat-shrinkable
insulation sleeve.
SolderShield cable-to-cable splice kits, designed for
single-conductor or 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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 67
Electrical Interconnect Products
SolderSleeve Shielded and Coaxial
Cable Splices
Product Selection Process
1. Select product series from the Product Options table below.
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).
VERSATILE
• Flux-coated, solder-impregnated
copper shield braid encased in
a transparent heat-shrinkable
insulation sleeve provides a
controlled soldering process,
encapsulation, inspectability, strain
•F
or D-607 (matched impedance) series, determine straight
or right-angle entry to PCB and grid pattern, then select the
appropriate part number from Table A on the next page.
•F
or 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).
Installation Requirements
EASY TO USE
For proper installation of these devices, the correct heating
tool and reflector attachment must be used. Any one of the
following TE heating tools is recommended:
• One-piece design means easy
• HL1920E/HL2020E
relief, and insulation
installation and lower installed cost
• IR-1759 MiniRay
CAPABLE
• CV-1981
• Circumferential (360°) shielding
Refer to TE installation procedure RCPS-150-02 (D-150 series)
and RPIP-699-00 (B-202 series) for detailed instructions and
recommended reflector attachment.
results in EMI protection and shield
continuity equal to or better than the
original cable
• Conductor splices are made using
MiniSeal crimp products, which are
recognized by MIL-S-81824 and
MIL-W-5088
Applications
Used for splicing a wide range of cables, including coaxial and
multiconductor cables.
SolderShield devices can be used to repair or splice shielded or
coaxial cables. These products consist of a MiniSeal crimp splice
plus a flux-coated, solder-impregnated copper shield encased
in a heat-shrinkable sealing sleeve, for splicing the shields.
SolderShield kits terminate single- or multiple-conductor cables,
eliminate EMI problems at the splice, and provide strain relief
for the cable.
Specifications/Approvals
Series
D-150
Military
US: M81824 (conductor splice only)
UK: RAF AP 1130-2008-1
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
TE
RT-1404
PAGE 68
Electrical Interconnect Products
SolderShield Splice
Table A. Multiconductor
Cable Splices
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.
L1
L3
L2
Crimp Splice
L1
L3
L2
I.D.
SolderShield Product Dimensions
Conductor Splice
Dimensions
Part No.
Size Range
Color
Quantity
L1
L2
L3
ID
CMA [mm2]
Code
Per Kit
Tin Plated
Nickel Plated
Max.
Nom.
Min.
Min.
Min.–Max.
D-150-0168
80.50
50.00
10.20
3.00
304–1510
D-150-0228
Red
1
[3.17]
[1.97]
[.400]
[.118]
[0.15–0.75]
D-150-0169
80.50
50.00
10.20
4.00
779–2680
D-150-0229
Blue
1
[3.17]
[1.97]
[.400]
[.157]
[0.39–1.34]
D-150-0170
80.50
50.00
10.20
5.00
1900–6755
D-150-0230
Yellow 1
[3.17]
[1.97]
[.400]
[.197]
[0.95–3.37]
D-150-0174
10.60 75.00 10.20 4.00
304–1510
D-150-0231
Red
2
[4.17]
[2.95]
[.400]
[.157]
[0.15–0.75]
D-150-0175
10.60
75.00
10.20
5.00
779–2680
D-150-0232
Blue
2
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0176
10.60
75.00
10.20
6.00
1900–6755
D-150-0233
Yellow
2
[4.17]
[2.95]
[.400]
[.236]
[0.95–3.37]
D-150-0177
10.60
75.00
10.20
9.00
304–1510
D-150-0234
Yellow 2
[4.17] [2.95] [.400] [.356] [0.15–0.75]
D-150-0178 D-150-0235
10.60
75.00
10.20
4.00
304–1510
Red
4
[4.17]
[2.95]
[.400]
[.157 ]
[0.15–0.75]
D-150-0179
10.60
75.00
10.20
5.00
779–2680
D-150-0236
Red 4
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0180
10.60
75.00
10.20
6.00
1900–6755
D-150-0237
Blue 4
[4.17]
[2.95]
[.400]
[.236]
[0.95–3.37]
D-150-0181
10.60 75.00 10.20 9.00
1900–6755 Yellow
D-150-0238
4
[4.17]
[2.95]
[.400]
[.353]
[0.95–3.37]
Note: The SolderShield splice kits listed in this table are for 1:1 cable splices. The kits can be used on cables with tin-, silver-, and nickel-plated copper conductors. All the kits have environmental-sealing capability. The cable temperature rating must be 125°C minimum.
To find the splice kit part number for your application:
1. Determine the number of conductors in the cable to be spliced.
2. Determine the gauge of each conductor or the maximum jacket OD.
3. Determine the conductor plating.
4. Select the appropriate part number from the table above.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 69
Electrical Interconnect Products
L1
L3
Table B. Coaxial
Cable Splices
SolderShield 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.
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
—
—
L2
Crimp Splice
L1
L3
L2
I.D.
Cable Description
Conductor
Splice Qty/Kit
SolderShield Dimensions
Part
No.
L1 Max
L2 Min
ID Min
5012A3311
5012E1339
7518A1311
1 D-150-0214
—
—
—
5028A1317
7528A1317
1 D-150-0094
5030A1317
7530A1317
5024A1311
7526A1311
1 D-150-0095
9527A1318
9530E1014
5020A1311
5022A1311
1 D-150-0096
7522A1311
7523D1331
7524A1311
5019D3318
5021D1331
1 B-202-81*
5022A1311
7523D1331
7524A1311
1 B-202-82*
9524A1311
80.50
[3.170]
50.00
[1.970]
12.00
[.472]
80.50
[3.170]
50.00
[1.970]
3.00
[.118]
80.50
50.00
4.00
[3.170] [1.970] [.157]
80.50 50.00 5.00
[3.170 ]
[1.970]
[.236]
56.00
23.00
7.00
[2.200] [.900] [.275]
56.00 23.00 7.00
[2.200 ]
[.900]
[.275]
*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.
Product Characteristics
Materials
Insulation sleeve
Meltable inserts
MiniSeal crimp splice
SolderShield shield splice
Parameter
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 (RA flux)
Test Method
Electromechanical Performance
Dielectric strength (shield connection)
—
Dielectric strength (conductor connection)
—
Voltage drop
MIL-S-81824
Insulation resistance (shield connection)
—
Insulation resistance (conductor connection)
—
Tensile strength for MiniSeal
MIL-S-81824
Tensile strength for SolderShield
MIL-S-81824
Temperature rating
—
Environmental Resistance
Salt spray
MIL-STD-202 M101
Heat aging
750 hours at 150°C [302°F]
Temperature cycling
MIL-STD-202 M107C
Altitude immersion
Immersion at 22,860m [75,000 ft]
Corrosion resistance
—
with MIL-STD-202, Method 101, Test Condition A
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
Requirement
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
-55°C to 150°C [-67°F to 302°F]
Meet voltage drop requirement.
Meet all electromechanical requirements.
Meet all electromechanical requirements.
Meet insulation-resistance requirement.
No evidence of corrosion after testing in accordance
PAGE 70
Electrical Interconnect Products
Raychem C-Wrap Side Entry Repair Sleeve
TE Connectivity’s (TE) C-Wrap repair sleeve is a side-entry
sleeve designed to repair and seal a damaged wire jacket that is
either chafed or has a radial crack or cut on the insulation.
It consists of two pieces: the outer tubing and an adhesive
inner layer.
MECHANICAL/ENVIRONMENTAL
• Environmental resistant
EASY INSTALLATION
• Easy to install: saves time,
manpower, and cost
• Color-coded to ensure proper sizing
for each application
• Low profile (small diameter and
short length)
• Side entry for easy access to
damaged wire
• Ideal for use on insulations rated at 135˚C or higher
• Temperature range: -65˚C to +150˚C
MATERIALS
• Meltable Adhesive: Modified thermoplastic fluoroelastomer
• Insulation Sleeve: Radiation cross-linked modified fluoropolymer
STANDARDS
• SAE AS81824 (fluid and sealing requirements)
• TE Performance Specification: D-6201
• TE Application Specification: RPIP-1101
• TE Qualification Test Reports: ISTR-1134 and ISTR-1206
MECHANICALLY ROBUST
APPLICATION TOOLING
• 150˚C rated
• General Purpose Heat Gun: Steinel HL19XX or HL20XX
• Long-term performance provides a
permanent repair
• Wrap-around design eliminates
de-pinning of connector for repair
• SolderSleeve Reflector: Steinel HL1802E-074616
•M
il Spec installation tools:
D-150-C-11: M81969/8-08
D-150-C-12: M81969/8-08
D-150-C-13: M81969/8-10
D-150-C-14: M81969/8-10
Contact TE for details on installation tooling
APPLICATIONS
• Used as a side-entry repair kit
•R
epair of nicks, chafed and radial cracks on the wire in most Aerospace,
Defense and Marine applications
• Prevents galvanic corrosion on center conductor
• RoHS compliant
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 71
Electrical Interconnect Products
ORDERING INFORMATION
Product Dimension
Part
Description
Color
Code
D-150-C-11
I.D. (A)
Conductor
Cut Length (B)
Adhesive
±.05 (.002)
Sleeve
±.05 (.002)
Adhesive
±.5 (.02)
Sleeve
±.5 (.02)
AWG
Wire OD
(Note*)
Green
1.11
(.044)
2.29
(.090)
21.59
(.85)
19.05 (.75)
26 - 24
0.80 - 1.10
(.031 - .043)
D-150-C-12
Red
1.68
(.066)
2.74
(.108)
21.59
(.85)
19.05 (.75)
22 - 20
1.10 - 1.50
(.043 - .029)
D-150-C-13
Blue
2.13
(.084)
3.43
(.135)
21.59
(.85)
19.05 (.75)
18 - 16
1.50 - 2.30
(.059 - .090)
D-150-C-14
Yellow
3.34
(.133)
4.80
(.189)
21.59
(.85)
19.05 (.75)
14 - 12
2.30 - 2.80
(.090 - .110)
MATERIALS
• Meltable Adhesives: Environment-resistant modified
thermoplastic fluoroelastomer. Color coded.
• Insulation Sleeve: Heat-shrinkable, transparent, radiation
cross-linked modified fluoropolymer. Color coded.
•T
emperature range: -65°C to +150°C.
APPLICATION
• Parts are designed to provide an environment-resistant
repair to damaged primary wire that has a radial crack up
to 360°, nicks/scrapes not longer than 1/4” on insulations
rated for 135°C minimum with no damage to the wire
conductor. For insulation procedures, refer to RPIP 1101.
D-150-C-11
(Part No. CX2001-000)
NSN 5970-01-611-8609
• Install using TE approved convection or infrared
heating tools in accordance with TE. When installed
with approved convection or infrared heating tools,
assemblies will meet the performance requirements
of TE D-6201 specification. Infrared tools are not
recommended for use with black cable jackets.
D-150-C-12
(Part No. CX2096-000)
NSN 5970-01-611-8596
Note*: If the O.D. of the wire is out of the range that is specified in
the Table, use the next size of C-Wrap up or down
D-150-C-13
(Part No. CX2097-000)
NSN 5970-01-611-8600
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
D-150-C-14
(Part No. CX2098-000)
NSN 5970-01-611-8586
PAGE 72
Electrical Interconnect Products
Rayseal High-Performance, Large-Gauge
Cable Repair
The Rayseal large gauge cable repair sleeve is a high-performance
side-entry repair product for large gauge and power feeder cables
(8 AWG to 4/0 AWG) with chafed or cracked insulation.
RUGGED PERFORMANCE
• Designed for 8 AWG to
4/0 AWG cable
• Abrasion-resistant fluoropolymer
• Resists aerospace fuels and fluids
COST SAVINGS
• Easy to install: helps save manpower
and cost
• Permanent, tough and robust repair
• Side entry helps reduce repair times
Its tough fluoropolymer material has been specially formulated by
TE to give greater resistance to mechanical abrasion and common
aerospace fuels and fluids. The high-temperature adhesive lining,
by sealing around the underlying damage to the cable jacket,
maintains the cable jacket properties as close as possible to its
original specification.
The operating temperature range from -65°C to +260°C helps
ensure excellent high-temperature performance.
ENVIRONMENTAL/MECHANICAL
• Operating temperatures: -65°C to +260°C
• Durability: Adheres and seals for permanent repair
• Fluid resistance: Resists aggressive fluids used in military and aerospace platforms
MATERIALS
VERSATILE
• Sleeve: Fluoropolymer, black
• Make permanent repairs to chafed
and cracked cable insulation
• Adhesive: Fluoropolymer
• High-temperature adhesive lining
seals around repair
TOOLING
• -65°C to +260°C temperature range
APPLICATIONS
• Military Aerospace and Defense
• Commercial Air
•H
eat gun: CV2014-JETS-120V460W-UL (US plug)
CV2014-JETS-230V460W-EU (European plug)
CV2014-JETS-230V460W-UK (UK plug)
PR-38-B-REFLECTOR
EACH KIT ALSO CONTAINS:
• Military Ground Systems
• Abrasive Cleaning Pad, 2” x 2”
• Wet/Dry Cleaning Wipes, 2-Package Kit
• PTFE Tape, 2 Mils Thick, 1” Wide, 30” Long
Cable
Sleeve Dimensions
Part
Description
Kit Part No.
Wire Size (AWG)
Cable OD
L
L1
10, 8
.137-203 [3.48-5.16]
1.40 [35.6]
1.00 [24.5]
D-260-C-A
EF7428-000
6, 4
.225-.308 [5.72-7.82]
1.70 [43.2]
1.25 [31.8]
D-260-C-B
EF7429-000
2, 1/0
.356-.465 [9.04-11.81]
2.20 [55.9]
1.75 [44.5]
D-260-C-C
EF7430-000
2/0, 3/0
.485-.590 [14.99-12.32]
2.67 [67.8]
2.10 [53.3]
D-260-C-D
EF7431-000
4/0
.590-.640 [14.99-16.26]
3.10 [78.8]
2.50 [63.5]
D-260-C-E
EF7432-000
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 73
Electrical Interconnect Products
Raychem D-200 Flexible Splice Kit
Our D-200 flexible splice kit features environmentally resistant,
high-temperature splices with EMI protection and flexibility.
In-Line Splicing for Harsh Aerospace and
Defense Applications
An important extension of the Raychem family of termination
devices, the D-200 splice kit is specially designed for
use in demanding high temperature aerospace and defense
applications.
DURABLE SPLICING
• Resistant to most common
aerospace fluids
• Flexible splice for long-term
performance
• Immersion resistant, sealed cable
splice with 360° shielding
HIGH PERFORMANCE
Fast Installation and Lower Costs
Make in-line splices fast and easy with the D-200 flexible splice
kit. Whether splicing shielded single, twisted pair, or trio cables,
the D-200 splice kit creates a permanent, flexible, immersionresistant splice for long-term reliable performance in the
harshest environments. Easy installation with existing crimp and
heating tools results in a lower total installed cost.
• Rated for 200°C continuous
operating temperature
• Resists vibration and mechanical
shock without loss of signal
• Splice allows bending without
insulation cracking
VERSATILE
• Cables can be spliced with existing
heating and crimping tools
• Additional sealing rings allow
splicing 1 to 1, 2 to 1, and 2 to 2
constructions
• Works with shielded single, paired,
and triple cables
• 26 AWG to 10 AWG wire range
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 74
Electrical Interconnect Products
D-200-0232-RT
D-200-0233-RT
D-200-0237-RT
STANDARDS AND TEST REPORT
•
•
•
•
PHYSICAL PROPERTIES
SAE AMS-DTL-23053/13 (applies to insulation sleeve only)
SAE AS81824/11
TE Performance Specification: D-6203
TE Qualification Test Report: ISTR-1404
•T
ensile Strength: 75% min. of an unspliced cable
• Vibration and Mechanical Shock: Resistant without
loss of signal
• Temperature Range: -55°C to 200°C
MATERIALS
CHEMICAL PROPERTIES
• Cable Sealing Sleeve
Insulation Sleeve: Heat-shrinkable fluoropolymer, black
Meltable Inserts: Environment-resistant thermoplastic
fluoroelastomer, light blue
• SolderSleeve Device
Insulation Sleeve: Heat-shrinkable fluoropolymer,
transparent blue
Solder Preform with Flux: 96% tin per ANSI/J-STD-006.
ROM1 per ANSI/J-STD-004
Meltable Insert: Thermoplastic, blue
• Crimp Splice: Nickel-plated copper alloy
• Sealing Splice Sleeve: Heat-shrinkable fluoropolymer,
containing two environment-resistant sealing rings,
transparent blue
• Meltable Insert: Environment-resistant thermoplastic
fluoroelastomer, light blue
• I mmersion Resistance: Resists most common aerospace
fluids (e.g., fuels, oils, MPK, etc.)
• Immersion Resistance Altitude: 75,000 feet
Number of Conductors
1
2
3
ELECTRICAL PROPERTIES
•V
oltage Drop: Voltage drop across spliced conductors and
shield do not exceed equivalent length of unspliced cable
• Dielectric Strength: 2500 V
• Insulation Resistance: 100 V
TOOLING
• Steinel HL20XXE heat gun
• TE IR-550 infrared tool
• TE AD-1377 crimp tool
• TE 46447 crimp tool
Wire Range (AWG)
Color Code
Part Description
Part Number
26 – 20
Red
D-200-0228-RT
CV7712-000
20 – 16
Blue
D-200-0230-RT
EG4031-000
16 – 12
Yellow
D-200-0232-RT
EG4032-000
12 – 10
None
D-200-0242-RT
EG3869-000
26 – 20
Red
D-200-0233-RT
EG3678-000
20 – 16
Blue
D-200-0234-RT
CU1642-000
16 – 12
Yellow
D-200-0235-RT
EG3865-000
12 – 10
None
D-200-0249-RT
CW7956-000
20 – 16
Blue
D-200-0237-RT
EG3867-000
16 – 12
Yellow
D-200-0238-RT
EG3868-000
12 – 10
None
D-200-0243-RT
CW7949-000
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 75
Shielded
Contacts
Introduction
TE 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 TE’s 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.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 76
Electrical Interconnect Products
SolderTacts Shielded One-Piece
Solder Contacts
One-piece controlled-reflow-solder SolderTacts contacts are
designed to terminate coaxial cables, shielded wires and twisted
pairs faster and more reliably than other methods. SolderTacts
contacts help eliminate the variables of crimping. The one-step
installation process helps cut down on production time while
reducing handling and installed costs.
ECONOMICAL
• One-piece contact design with
integrated soldering technology
• One-step installation process
• One contact fits multiple cable sizes
• No special tools required
RELIABLE
• 360° shielding reduces crosstalk
and improves signal transmission
• Reflow solder joints are strong
and reliable
• Controlled reflow soldering
process yields reliable,
consistent terminations
• Terminations are fully inspectable
VERSATILE
• Compatible with a variety of
commercial and military connectors
• Termination available for coax
cables, shielded pairs, twisted pairs,
and triaxial cables
• 150°C temperature rating
Controlled Soldering and Strain Relief
SolderTacts contacts provide the optimum amount and type
of solder and flux in a prefluxed solder preform that controls
soldering and reduces operator sensitivity. The geometry of
the coaxial cable is carried through the connector to eliminate
separate pins, help reduce crosstalk, and supports improved
shielding effectiveness and signal transmission.
These contacts contain two SolderSleeve terminations.
One terminator connects the cable’s signal conductor to the
contact’s inner pin. The other terminator connects the shield or
ground lead to the contact body. When the contact is heated, the
solder melts to provide a precise solder connection. SolderTacts
contacts provide a simultaneous electrical connection and strain
relief. Heat shrinkable tubing insulations help eliminate stress
concentration on the wire within the contact.
Improved Signal Integrity
For digital and RF signals, SolderTacts contacts offer better
signal transmission than obtained with crimp contacts. They
reduce crosstalk, signal attenuation, and reflections, while
providing excellent protection against outside noise.
Compatibility
SolderTacts contacts are compatible with a wide range of circular
and rectangular military and commercial connectors, including
MIL-DTL-38999, MIL-DTL-83723 and MIL-DTL-28748. Compatible
with most standard connector cavities, SolderTacts contacts are
intermateable and intermountable with contacts qualified to the
above connector specifications. They use standard insertion and
extraction tools.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 77
Electrical Interconnect Products
APPLICATION TOOLING
•
•
•
•
•
Steinel HL1920E or HL2020E
Steinel HL1802E-074616
Raychem CV-1981
Raychem CV-1983
Raychem AA-400
For more details, please see TE Application Tooling
brochure 1-1773872-1
SPECIFICATION
• D-6002: SolderTacts Military-Grade Electrical Contacts for
Solder Termination
APPLICATIONS
•
•
•
•
•
•
•
•
Commercial Aerospace
Military Aerospace
C4ISR
Ground Defense
Military Marine
Missile Defense
Offshore/Civil Marine
Space
The outer SolderSleeve termination is a
cross-linked heat-shrinkable insulating
sleeve supplied in the expanded state.
Cables insert easily, with no spacers or
other parts required.
The inner SolderSleeve
termination is a heat-shrinkable
sleeve with a precisely
prefluxed solder preform
conforming to QQ-S-571.
The outer solder preform
contains precise amounts of
solder and flux conforming
to QQ-S-571.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
The precision outer body meets
electrical engagement and
contact retention requirements of
individual connector systems.
Inner pin and socket contacts
are permanently fixed within
the assembly to provide proper
setback and concentricity.
PAGE 78
Electrical Interconnect Products
SolderTact
Series
Submin
748
723
No. 12
482
999
Size 16
999
Size 12
Part No.
(D-602-)
Engineering Standard
(Termination Instructions)
0218, 0219
ES-61170
0238, 0239
ES-61169
44, 45
ES-61133
0172, 0173
ES-61240
54, 55
ES-61132
0126, 0127
ES-61199
D-610-09, -10
ES-61187
0094, 0095
ES-61128
0106, 0107
ES-61134
0104, 0105
ES-61129
16, 17
ES-61161
46, 47
ES-61137
56, 57
ES-61138
0140, 0141
ES-61226
0142, 0143
ES-61224
0171
ES-61226
0174
ES-61124
0144, 0145
ES-61206
0146, 0147
ES-61218
0159/0151
ES-61223
1108/1109
999
Size 8
1110/1111
Part No.
Repair Wand
Part Description
959014-000
AD-1481-SUBMN-SLDTK-HOLDR
994040-000
AD-1480
551737-000
AD-1571-1-POWERTACT-HOLDR
994057-000
AD-14940723-SLTC-HLD-ASY
966800-000
AD-1508-REP-FOR-12-CONT
181779-000
AD-1565-1-SLDTCT-HLDR-ASY
859747-000
AD-1572-1-SOLD-HOLDER-ASY
122917-000
AD-1566-1-HOLDER-ASSEMBLY
635308-000
AD-1568-1-SOLDERTACT-HLDR
ES-61172
1112/1113
ES-61184
0156/0157-X
ES-61231
0169/0170-X
ES-61235
In the terminated signal lead, the
heat-shrink tubing shrinks tightly around
the termination to insulate and strain
relieve the connection. The tensile
strength of the soldered terminations
exceeds that of the cable itself.
The dielectric between inner and outer
contacts provides concentricity, electrical
integrity, precise mating dimensions, and
closed entry at the inner socket.
The shield termination
can be inspected through
the viewing port.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 79
Electrical Interconnect Products
Table I: SolderTacts Contacts-to-Cable Cross Reference
Submin
Series
D-602-0278
D-602-0279
723 Series
Size 12
D-602-0094
D-602-0095
723 Series
Size 12
D-602-0106
D-602-0107
748 Series
Size 16
D-602-44
D-602-45
748 Series
Size 16
D-602-0172
D-602-0173
847 Series
Size 16
D-602-72
D-602-73
748 Series
Size 16
D-602-76
D-602-77
4
4
4
4
Cheminax Coaxial Cables
5021K1X1X
5022A1X1X
5024A1X1X
5026A1X1X
5026D1X2X
5028A1X1X
5028A1X2X
5030A1X1X
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1
4
4
4
4
4
847 Series
Size 16
D-602-74
D-602-75
748 Series
Size 16
7522A1X1X
7524A1X1X
7528A1X1X
7530A1X1X
7530D1X2X
9526A1X1X
9528A1X1X
4
4
9528D1X2X
9530A1X1X
9530H1X1X
9532A1X1X
RG/U Coaxial Cables
RG-58
RG-174
RG-178
RG-179
RG-180
1
4
4
RG-195
RG-316
1
4
4
Submin
Series
D-602-0288
D-602-0289
723 Series
Size 12
D-602-0104
D-602-0105
4
Twisted Pair Cables
723 Series
Size 12
—
748 Series
Size 16
D-602-54
D-602-55
22-26
—
4
24-26
24-303
748 Series
Size 16
D-602-0126
D-602-0127
4
4
2
4
4
26-303
1. Requires use of barrier.
2. .048” maximum insulation diameter.
3. Smaller cables can be accommodated. Consult product management.
4. These cables can be accommodated by D-602-44 and D-602-45. However, the D-602-0172 and the D-602-0173 are preferred for these cables.
The cross reference list above is not intended to be exhaustive. Please consult TE.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 80
Electrical Interconnect Products
Table I: SolderTacts Contacts-to-Cable Cross Reference
482 Series
Size 16
No. 12
Size 12
999 Series
Size 8
999 Series
Size 12
999 Series
Size 12
D-602-46
D-602-47
D-602-16
D-602-17
D-602-0122
D-602-0123
D-602-0144
D-602-0145
D-602-0150
D-602-0151
999 Series
Size 16
D-602-0140
D-602-0141
D-602-0171
Cheminax Coaxial Cables
5021K1X1X
4
4
5022A1X1X
5024A1X1X
5026A1X1X
5026D1X2X
4
4
4
4
4
4
4
4
4
4
4
4
4
4
5028A1X1X
5028A1X2X
5030A1X1X
7522A1X1X
4
4
7524A1X1X
7528A1X1X
7530A1X1X
4
4
4
7530D1X2X
4
4
4
9526A1X1X
4
4
4
4
4
9528A1X1X
9528D1X2X
9530A1X1X
9530H1X1X
9532A1X1X
4
4
4
4
4
4
4
4
4
4
RG/U Coaxial Cables
RG-58
RG-174
RG-178
RG-179
4
4
4
4
1
4
4
RG-180
4
4
4
4
4
RG-195
RG-316
4
4
4
482 Series
Size 16
D-602-56
D-602-57
No. 12
Size 12
999 Series
Size 8
—
—
4
4
4
Twisted Pair Cables
22-26 AWG
999 Series
Size 12
D-602-0146
D-602-0147
999 Series
Size 12
999 Series
Size 16
—
—
4
24-26
24-303
4
26-303
4
1. Requires use of barrier.
2. .048” maximum insulation diameter.
3. Smaller cables can be accommodated. Consult product management.
4. These cables can be accommodated by D-602-44 and D-602-45. However, the D-602-0172 and the D-602-0173 are preferred for these cables.
The cross reference list above is not intended to be exhaustive. Please consult TE.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 81
Electrical Interconnect Products
Table II: Connector Accommodation: SolderTacts Shielded Contacts
Military
Specification
NAS 1599
MIL-DTL-26482
Series II
SAE-AS81703
Series III
MIL-DTL-83723
Series I & III
MIL-DTL-83733
MiL-DTL-26482
Series I
MIL-DTL-26500
MIL-PRF-81733
Series II
MIL-DTL28748/3,4,9,10
MIS-20065 (Army)
SolderTacts Contacts
Series/Contact Size
Cable Type
AS39029/74
Small Coaxial
AS39029/74
Large Coaxial
AS39029/74
Twisted Pair
AS39029/73
723 Series
Size 12 Contact
No. 12 Series
Size 12 Contact
748 Series
Size 16 Contact
999 Series
Size 12 Contact
999 Series
Size 8 Contact
Submin Series
Size 16
Part No.
Pin
D-602-0094
Pin
D-602-0106
Socket
Large Coaxial
Socket
AS39029/73
Twisted Pair
Socket
D-602-0105
MIS-20067
(Army)
Coaxial
Coaxial
Coaxial
Coaxial
Twisted Pair
Twisted Pair
Coaxial
Coaxial
Twisted Pair
Twisted Pair
Power
Power
Coaxial
Coaxial
Twisted Pair (MIL-STD-1553)
Twisted Pair
Coaxial
Coaxial
Coaxial*
Twisted Pair
Twisted Pair
Twisted Pair*
Coaxial
Coaxial
Twisted Pair
Twisted Pair
Large Coaxial
Large Coaxial
Coaxial
Coaxial
Shielded Twisted Pair (MIL-STD-1553)
Shielded Twisted Pair (MIL-STD-1553)
Shielded Twisted Pair (MIL-STD-1553)
Shielded Twisted Pair (MIL-STD-1553)
Triaxial
Triaxial
Coaxial
Coaxial
Twisted Pair
Twisted Pair
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Socket
Pin
Socket
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Pin
Socket
Socket
Pin
Socket
Pin
Socket
Pin
Pin
Socket
Pin
Socket
D-602-17
D-602-16
D-602-46
D-602-47
D-602-56
D-602-57
D-602-44
D-602-45
D-602-54
D-602-55
D-610-09
D-610-10
D-602-0173
D-602-0172
D-602-0126
D-602-0127
D-602-0140
D-602-0141
D-602-0171
D-602-0142
D-602-0143
D-602-0174
D-602-0144
D-602-0145
D-602-0146
D-602-0147
D-602-0150
D-602-0151
D-602-0122
D-602-0123
D-602-1108
D-602-1109
D-602-1112
D-602-1113
D-602-1110
D-602-1111
D-602-0278
D-602-0279
D-602-0288
D-602-0289
AS39029/73
MIS20067
(Army)
AS39029/76
AS39029/77
AS39029/77
AS39029/76
AS39029/77
AS39029/77
AS39029/28
AS39029/75
AS39029/28
AS39029/75
AS39029/28
AS39029/75
AS39029/60
AS39029/59
USAF8340712-1^
USAF8340713-1^
USAF8340712-2^
USAF8340713-2^
—
Contact
Type
Small Coaxial
482 Series
Size 16 Contact
999 Series
Size 16 Contact
MIL-DTL-38999
Series I, ll*, III, IV
Specification
Pin
D-602-0095
D-602-0107
D-602-0104
* Size 16 contacts only for use with MTCP and MIL-DTL-38999 Series II connectors only.
^ Intermountable and intermatable, replaces crimp style termination.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 82
Electrical Interconnect Products
Table III: SolderTacts Contact Compatibility
Contact Military
Specification
M39029/73-396
M39029/73-397
M39029/73-398
M39029/73-555
M39029/74-399
M39029/74-400
M39029/74-401
M39029/28
M39029/59
M39029/60
M39029/75
M39029/76
M39029/77
M39029/90
M39029/91
USAF8340712-1
USAF8340712-2
USAF8340713-1
USAF8340713-2
M39029/25
M39029/26
MIS20067/5
MIS20067/6
M39029/40
M39029/41
M39029/42
M39029/43
M39029/79
M39029/80
MIS20067/1
MIS20067/2
MIS20067/3
MIS20067/4
MIS20067/7
MIS20067/8
TE
Equivalent*
Part Numbers
D-602-0107
D-602-0095
D-602-0105
D-602-0093
D-602-0106
D-602-0094
D-602-0104
D-602-0144
D-602-0146
D-602-0150
D-602-0123
D-602-0122
D-602-0145
D-602-0147
D-602-0151
D-602-0140
D-602-0142
D-602-0141
D-602-0143
D-602-0171
D-602-0174
DK-602-0156-N-X
DK-602-0169-N-X
DK-602-0157-N-X
DK-602-0170-N-X
D-602-1108
D-602-1112
D-602-1109
D-602-1113
D-602-17
D-602-16
D-602-16
D-602-17
D-602-76
D-602-77
D-602-77
D-602-76
D-602-72
D-602-74
D-602-73
D-602-75
D-602-45
D-602-44
D-602-55
D-602-54
D-610-10
D-610-09
D-602-77
D-602-76
D-602-76
D-602-77
D-602-0278
D-602-0279
D-602-0288
D-602-0289
Nature of Compatibility
SolderTacts - Compatible
Connector Specifications
SolderTact
Series
Equivalent product.
TE is a qualified vendor.
MIL-DTL-26482 Series II
MIL-DTL-81703 Series III
MIL-DTL-83723 Series I, III
MIL-DTL-83733
NAS-1599
723
Series
MIL-DTL-38999 Series I, II*, III, IV
*Size 16 only
999
Series
Intermountable and intermatable.
Replaces crimp-style termination.
Equivalent product.
TE is a qualified vendor.
MIL-DTL-26482 Series I
MIL-DTL-26500
MIL-DTL-81703 Series II
No. 12
Series
Intermountable and intermatable.
Replaces crimp-style termination.
MIL-DTL-28748/3, /4, /9, /10
748
Series
Intermountable and intermatable.
Replaces crimp-style termination.
Intermountable and intermatable.
Replaces crimp-style termination.
Equivalent product.
TE is a qualified vendor.
Intermountable and intermatable.
Replaces crimp-style termination.
Equivalent products.
TE is a qualified vendor.
847
Series
MIS-20065 (Army)
Intermountable and intermatable.
Replaces crimp-style termination.
Intermountable and intermatable.
Replaces crimp-style termination.
748
Series
748
Series
Souriau Trim Trio Connector Family
Submin
Series
* SolderTacts contacts are intermatable and interchangeable with existing MIL-spec contacts.
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 83
Additional Repair
Products
Raychem Matched Impedance Splices
With the matched impedance splice, TE Connectivity (TE)
solves the problem of costly removal and replacement of
damaged coaxial cable. Not only does the new splice allow fast,
easy repair of the cable in situ, it maintains the characteristic
impedance and other electrical properties. System performance
is not affected by the repair.
MATCHED IMPEDANCE
•M
aintains cable’s electrical
properties
• Meets MIL-PRF-32517 performance
requirements
• Matches cable’s impedance
+10%/-3%
TIME AND COST SAVING
• Repairs made in situ
• No need to remove or replace cable
SEALED
•H
eat-shrinkable outer layer plus
thermoplastic adhesive for sealing
and strain relief
ROBUST
•
•
•
•
•
Withstands high vibration
Corrosion resistant
Wide temperature range
Excellent fluid resistance
Suitable for high EMI environments
Save Time and Money
Removing and replacing a damaged coaxial cable can be
time consuming and expensive. The matched impedance
splice’s ability to be applied without removing the cable can
significantly speed the repair, saving time and cost.
Simple and Effective
The splice contains three components: a hexagonal crimp
barrel for the center conductors, a dielectric shell that helps
maintain cable geometry for impedance control, and a
SolderShield splice that both terminates the cable’s shield and
provides sealing to protect the splice environmentally.
The SolderShield splice uses a flux-coated, solder-impregnated
copper shield inside an adhesive-lined, heat-shrinkable sleeve.
The completed assembly provides an environmentally sealed
termination and strain relief.
Part Numbers
Cable Type
Part Number
D-150-Z393
RG-393
APPLICATIONS
• Military Aerospace
• Commercial Aerospace
Hexagonal Crimp Barrel
Dielectric Shell
SolderShield Splice
Specifications
Electrical
Impedance:
Insertion Loss:
Return Loss:
Insulation Resistance:
Cable Compatibility
MIL-PRF-32517
MIL-PRF-32517
MIL-PRF-32517
5000 MΩ
RG-393
TE Specifications
Environmental/Mechanical
Altitude Immersion:
Heat Aging:
Temperature Range:
Cable Types:
75,000 ft
750 hr. at +165°C
-55° C to 150°C
Application Specification:
Product Specification:
Qualification Test Reports:
Installation Instructions:
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
D-6204
D-6204
HT4203 (for D-150-Z393)
RPIP-1108
PAGE 84
Raychem Application Tooling
Lit #1-1773872-1
Raychem
Application Tooling
The Tools to Make Every Connection Count
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 85
Electrical Interconnect Products
Notes
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 86
Electrical Interconnect Products
Notes
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
PAGE 87
LET’S CONNECT
We make it easy to connect with our experts and are ready to
provide all the support you need. Just call your local support number or visit
www.te.com/industrial to chat with a Product Information Specialist.
Technical Support
te.com/support-center
North America
+1 800 522 6752
Asia Pacific
+86 400 820 6015
North America (Toll)
+1 717 986 7777
Japan
+81 044 844 8180
EMEA/South Africa
+800 0440 5100
Australia
+61 2 9554 2695
EMEA (Toll)
+31 73 624 6999
New Zealand
+64 (0) 9 634 4580
India (Toll-Free)
+800 440 5100
te.com/devices
AMP, AGASTAT, CII, DEUTSCH, DuraSeal, HARTMAN, KILOVAC, MICRODOT, MiniSeal, NANONICS, POLAMCO,
Raychem, Rayseal, SEACON, SolderGrip, SolderSleeve, SolderTacts, TE, TE Connectivity and the TE connectivity
(logo) are trademarks owned or licensed by TE Connectivity. Other products, logos, and company names
mentioned herein may be trademarks of their respective owners.
While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information herein,
nothing herein constitutes any guarantee that such information is error-free, or any other representation, warranty
or guarantee that the information is accurate, correct, reliable or current. The TE entity issuing this publication
reserves the right to make any adjustments to the information contained herein at any time without notice. All
implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of
merchantability or fitness for a particular purpose are expressly disclaimed. The dimensions herein are for reference
purposes only and are subject to change without notice. Specifications are subject to change without notice.
Consult TE for the latest dimensions and design specifications.
© 2019 TE Connectivity All Rights Reserved.
2347480-1 01-19
AEROSPACE, DEFENSE & MARINE /// ELECTRICAL INTERCONNECT PRODUCTS
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