44A0111-22-0

Wire and Cable, Harnessing and Protection Products Table of Contents Tyco Electronics Embraces the Most Valued Brand Names Worldwide ……………………………ii About Raychem Wire and Cable, Harnessing and Heat-Shrinkable Products ………………………iii How to Use this Catalog ……………………………………………………………………………iv Application Overview Seal It ………………………………………………………………………………………………1-1 Connect It …………………………………………………………………………………………1-2 Insulate It …………………………………………………………………………………………1-3 Protect It …………………………………………………………………………………………1-4 Wire It………………………………………………………………………………………………1-5 Hold It ……………………………………………………………………………………………1-6 Join It ………………………………………………………………………………………………1-7 Beautify It …………………………………………………………………………………………1-8 Reduce It …………………………………………………………………………………………1-9 Repair It …………………………………………………………………………………………1-10 Flex It ……………………………………………………………………………………………1-11 All of It ……………………………………………………………………………………………1-12 Application Guide ………………………………………………………………………………1-13 Electrical Interconnection System Design Harness Design …………………………………………………………………………………2-2 Protection of Harness Components ……………………………………………………………2-5 HarnWare Harness Design Software …………………………………………………………2-6 Integrated Military Harness Systems for Defense and Allied Industries …………………………………………………………………2-15 Product Sections Heat-Shrinkable Tubing ……………………………………………………………………………3 Molded Parts ………………………………………………………………………………………4 Adhesives ……………………………………………………………………………………………5 Adapters ……………………………………………………………………………………………6 Assemblies …………………………………………………………………………………………7 Electrical Interconnect Products …………………………………………………………………8 Wire and Cable ……………………………………………………………………………………9 Application Equipment……………………………………………………………………………10 Supporting Information Equivalents and Conversions …………………………………………………………11-2, 11-3 Temperature Conversion ………………………………………………………………11-4, 11-5 Glossary ………………………………………………………………………………11-6 to 11-18 Part Index ……………………………………………………………………………11-19 to 11-21 i Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products Tyco Electronics Embraces the Most Valued Brand Names Worldwide As a truly global player, Tyco Electronics Corporation has facilities located throughout the world serving customers in a wide range of applications. Tyco Electronics Corporation – the largest unit of Tyco International Ltd.– was established in September 1999 when Tyco acquired Elcon Products and Raychem Corporation, and integrated them with AMP, acquired earlier the same year. Since then, the company has rapidly grown and strengthened its competencies as an electrical and electronic component supplier, with product offerings in 25 passive and active product segments. In the passives field, Tyco Electronics is now the world’s largest supplier. The company has facilities located around the globe serving customers in the aerospace, automotive, commercial electronics/ communications, industrial/energy, marine, medical, military, and rail industries. Tyco Electronics’ product portfolio continues to grow, encompassing connector systems and application tooling, active and passive fiber optic devices, complete power systems, wireless components (including ICs, radar sensors, and complete communications systems), GPS and integrated antenna systems, heatshrink products, circuit protection devices, magnetic components, wire and cable systems, touchscreens, PC boards and backplanes, smart cards, relays, sensors, electronic modules, wire harnessing and labeling products, battery packs, terminal blocks and switches. real benefit to customers, is that Tyco Electronics’ technology leadership becomes even stronger. The synergies of expertise in materials science, product design, and process engineering, coupled with knowledgeable application engineers, sales representatives, and customer service personnel enables you to make your next generation of products successful. A significant result of this continued growth, and a ii Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products About Raychem Wire and Cable, Harnessing, and Heat-Shrinkable Products Tyco Electronics, for its Raychem products, pioneered the application of radiation crosslinking and the development of heat-shrinkable polymer tubing. The Tyco Electronics Raychem brand of heatshrinkable polymer products is recognized worldwide. It is backed by a history of proven performance, reliability, innovation and superior quality. Tyco Electronics manufactures the world’s largest range of heatshrinkable tubing – tubing that provides cable protection offering exceptional insulation, mechanical protection, and strain relief. We are the recognized world leader in heat-shrinkable polymer technology. A broad-based product line of Raychem wire and cable is engineered to meet or exceed the most rigorous technical specifications. Performing from -100°C to +260°C [-148°F to 500°F], the product line encompasses fire-resistant cable, small-size controlled electrical cables, multi-conductor cable, high-performance radiation crosslinked ETFE airframe wire, low fire hazard wire, high-performance automotive and commercial wire, and NASA-spec and other space-application types. Additionally, a variety of low-cost, easy-to-install components for wire harnesses and cable assemblies are available including splices, adapters, low-profile rectangular connectors, and contacts. These components are approved to widely recognized standards and specifications that include UL, SAE, MIL, Defense, DNV, Lloyds, and ABS. Tyco Electronics also provides customized harnessing design supported by a pioneering software package, HarnWare, which enables fast, optimum system design with materials and assembly labor estimates. For over forty-five years customers have recognized the global capabilities of Raychem products. Combining these advanced products with superior technical support and a global sales/service organization, customers with worldwide operations count on Tyco Electronics to supply the knowledge and products they need to solve specific problems and help them take advantage of opportunity, anywhere it arises. This philosophy has earned Tyco Electronics a reputation for leadership in materials science technologies. Developed from these technologies, Raychem products are sold into many industries including aerospace, automotive, electronics, construction, electrical power, utilities, manufacturing, pipeline, process, rail and mass transit, and telecommunications. iii Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable, Harnessing and Protection Products How To Use This Catalog This catalog has four main sections: ■ ■ ■ ■ Application Overview Electrical Interconnection System Design Products Supporting Information Application Overview (Section 1) presents general design ideas based on typical uses for Raychembrand wire and cable, heatshrinkable tubing and protection products. Application photos depict examples of how customers use our products to enhance the performance and improve the reliability of their specific products in one or more of these generic applications; Seal It, Connect It , Wire It, Insulate It, Protect It, Hold It, Join It, Beautify It, Reduce It, Repair It, Flex It, All of It. Electrical Identification System Design (Section 2) describes wire harness components and harness protection issues and provides a step-by-step guide to selecting the right Raychem components for a particular wire harnessing system. Products (Sections 3-10) showcases our product groups. Each section provides: n An overview of the product group. n A table of contents that lets you see at a glance the product families in that product group. n A selection guide to help you determine which product family will satisfy the requirements of your application. n An explanation of the part numbering system for that product group. n Information pages on each product family. The product information pages provide some or all of the following information (depending on the product family): n n Product features/benefits. n Abbreviated installation guidelines. n Specifications and agency approvals. n Part number selection information n Product data (dimensions, properties, and materials). n Ordering information. n Location availability. Supporting Information (Section 11) provides: n Equivalents and conversion tables. n Temperature conversion table. n Glossary. Typical applications for the product family. Market Icons Use these icons to quickly identify market opportunities at-a-glance. They appear on the product information pages. The icons on each page represent, but are not limited to, the markets that currently exist for that particular product. Medical Automotive Commercial Electronics/Communications Industrial Aerospace Marine Military Rail Industries Space iv Catalog 1654025 Revised 12-03 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Seal It 1 Application Overview Advanced materials and product design have resulted in a complete line of products offering the most effective sealing available today: adhesive-lined tubing, molded parts, and a variety of solder and crimp connection devices. These easy-to-use products provide superior waterproofing, resistance to hydrocarbons and other chemicals, protection against corrosion and oxidation, and a barrier against dust and dirt. n n Heat-shrinkable, adhesive-lined products— tubings with high shrink ratios, and molded parts—environmentally protect connector-tocable transitions. Waterblocked and anticapillary wire prevent water and most fluids from wicking between the conductor strands. Bundle sealing products block multiconductor cables. n n Adhesive-lined, heatshrinkable tubing and caps seal and protect electronic components and in-line wire splices from fluids, moisture, and corrosion while also providing strain relief. n Heat-shrinkable, moisture blocking systems are designed to provide reliable sealing of wire bundles preventing fluid ingress. Heat-shrinkable caps lined with an adhesive or encapsulant form a moisture-resistance barrier around stub splices and wire ends. 1-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 : 44-1793-528171 Applications Connect It Raychem electrical interconnect products offer reliable, more cost-effective alternatives to traditional connection methods—such as hand soldering, or crimping and then insulating by taping or overmolding. With our electrical interconnect products, you start with a precisely engineered, fluxed solder preform inside a transparent, heat-shrinkable sleeve. When the product is heated, the solder preform melts, and the sleeve shrinks to create a connection that is fully insulated and strainrelieved. This ease of use expands your options even as it enhances the quality of your end product, as in these applications: n n n Easy and reliable termination of EMI shields to ground, ensuring effective EMI attenuation. Shield termination products are available for computer, data, and instrumentation cable, communications and video cable, and heavy industrial cable. Splicing of one component to another, such as a diode connected to one end of an LED. Coaxial terminations to PCBs and terminals. 1-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Insulate It 1 Application Overview Solving an insulation problem can be easier than you think, especially when you consider the family of Raychem products from Tyco Electronics that can provide superior alternatives to standard methods of insulation such as hand-taping or molding-in-place. n n When heated during installation, our radiationcrosslinked tubings shrink to conform to a variety of shapes, providing dependable insulation. Heat-shrinkable end caps insulate wire or cable terminations, providing protection from dust and dirt. End caps with adhesive or encapsulant lining also provide protection from moisture because the lining, when heated, melts and flows to fill surface irregularities of the substrate. n n General-purpose polyolefin tubing is widely used to insulate and strain-relieve wire terminations and connections. Delicate electrosurgical instruments can be insulated and protected from abrasion by using one of Raychem’s medical-grade, heatshrinkable tubings specially formulated to meet the requirements of USP Class VI for medical use. n Components on a PCB, such as capacitors and fuses, can be insulated with a UL VW-1-approved heat-shrinkable tubing to achieve a specific product rating. 1-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Protect It Designing a brilliant solution is good. Protecting a brilliantly designed solution is even better. A whole family of protection products, made from a wide variety of materials, can provide comprehensive protection: mechanical protection, strain relief, resistance to abrasion and crushing, EMI and noise reduction, fluid resistance, and thermal insulation. n n n Tinel-Lock ring braid terminations can be used for applications where shielding is critical. These shape-memory-metal products attach metal braid shields to backshells and provide 360° protection against EMI and EMP. Heat-shrinkable tubings provide mechanical protection for hoses and pipes, and also reduce problems caused by wire chafing or cable abrasion. Easy-to-install heat-shrinkable tubing and molded parts provide excellent strain relief and electrical insulation for connectorto-cable transitions. n n n A heat-shrinkable molded part can relieve the strain on a multiconductor cable to a D-subminiature connector. Heat-shrinkable feedthroughs relieve the strain on cables entering junction boxes. Highly-flexible, heatshrinkable fabric tubing provides outstanding abrasion protection for components such as rubber hoses, plastic pipes, and harness wiring bundles, recovering easily even over awkward substrates such as bent hoses. n Heat-shrinkable MicroFit tubing is used to provide insulation and strain relief for fine-gauge wire (24 to 42 AWG) and fiber optic cables in such end products as medical devices, computers, communications equipment, and commercial electronic products. 1-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Wire It 1 Application Overview Tyco Electronics is a leader in the development of high-performance wire and cable products for demanding applications, including aerospace, industrial equipment, instrumentation, marine, and automotive applications. Precision extrusion capability, materials expertise, and design knowledge provide wire products that are lightweight; smaller than comparable-performance constructions; highly flexible, yet mechanically tough; flame-retardant and resistant to a variety of industrial fluids. All Raychem products offer outstanding shop-handling characteristics for efficient stripping, wire termination, and bundling. Cable design software is available to create custom multicore cables with unique components, tough but lightweight jacket materials, and optimized shielding. Tyco Electronics can also design complete wiring harnesses for industrial or military applications. n n The FlexLite family of hookup wire provides economical alternatives to fluoropolymers, silicones, and crosslinked polyethylene insulations for applications such as motors, appliances, and lighting, and for applications where thinner walls are needed because of space constraints. n Low-fire-hazard primary wires and cable are made from halogen-free, lowsmoke materials with a low toxicity index. They offer increased safety, with reduced size and weight, over traditional materials in mass transit and similar applications. Raychem high-temperature, dual-wall or singlewall aerospace wire saves space and weight on both military and commercial aircraft and space vehicles. 1-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Hold It To help you arrive at the best way to securely hold and position a component, take a look at the Raychem family of products and consider the many ways that you can use them: to keep components in place, bundle and route wires, create a formed shape for potting, or package components securely before final assembly. n n n n Thin-wall tubings allow bundling of wires to create very flexible, lightweight harnesses that can withstand harsh environments. Fiber and/or copper components can be bundled for a custom multicore cable. Cable legs can be held together with a Y-transition molded part. Multicore and film-bonded cables hold wires together and also provide EMI protection. n n n Tubing can hold a covering (braid or Convolex tubing) onto a substrate. Two components (such as a resistor and fuse) can be held together as a package by enclosing them with heat-shrinkable tubing. Heat-shrinkable fabric tubing will grip substrates, such as harnesses, tightly to provide secure wire bundles without additional fixing. 1-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Join It 1 Application Overview When you have a mechanical connection to make, consider the uniform circumferential recovery force of heat-shrinkable tubing and metals in your designs. n n n Join two dissimilar materials, such as a rubber flapper to the end of a nylon tube, or the handle of a medical instrument to the instrument’s moving parts. Assemble a bellows by covering a spring with heat-shrinkable tubing. Use Tinel ring adapters to provide the even circumferential force necessary to attach a metal braid shield to a backshell. n n Clear, adhesive-lined tubing connects water tubes in appliances to provide a rugged and aesthetically appealing joint which is also inspectable. Heat-shrinkable tubing is used to join polyester cords to heddles in Jacquard weaving loom harnesses. 1-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Beautify It Enhancing the appearance of your brilliantly designed solutions couldn’t be easier, when you use Raychem products. n n n n Heat-shrinkable tubing— instead of tape—can create a smooth covering with no loose ends. Hot-stamp foils (gold or silver) can attractively showcase a company logo. Heat-shrinkable tubing can cover the mechanical attachment of one part to another. n n Tubing or molded parts can be color-matched to the original color of fiber, wire insulation, or other components to enhance the appearance of the final product. Handles of a variety of tools can be covered with colorful, heat-shrinkable tubing to enhance the appearance of the final product. Tubing can attractively cover a metal railing, such as the type used for crowd control. 1-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Reduce It 1 Application Overview With the trend toward miniaturization and higher-density interconnections, products developed for commercial electronics applications must downsize as well. n Versafit V4 tubing—33 percent lighter and smaller than competitive products—is the perfect choice when you need a very-low-profile, thin-wall tubing that installs quickly. In addition to space savings, V4 tubing offers excellent mechanical protection and strain relief for sensitive components. n The MicroFit family of products can be used to connect and insulate finegauge wire (26 to 42 AWG) in such end products as medical devices, computers, and stereo systems. They are easily and quickly installed, thus reducing craft-sensitive labor. MicroFit tubing has a high shrink ratio, up to 3:1, allowing easy installation onto the wire or substrate. SolderSleeve MicroFit devices feature a onestep controlled solder process for splicing and terminating wires up to 36 AWG—a method that is more reliable and less craft-sensitive than hand-soldering. n Tyco Electronics can reliably produce primary Raychem wire insulations as thin as 4 mils. Our design software optimizes component placement and shielding to produce small, lightweight custom multicore cables. These cables can offer size and weight reductions that can range from 10 to 40 percent versus comparable-performance constructions of primary wire or cable. 1-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Repair It Whether for repair or retrofitting, Tyco Electronics offers a whole family of Raychem products that can provide flexible, cost-effective solutions. For example, most failures in electrical wiring harnesses occur within the first six inches of the connector. Raychem products make repairs in this area more reliable, long-lived, and cost-effective. n n n High-shrink-ratio tubing can be slipped over the connector without depinning to reinsulate or strain relieve the connector-tocable transition. SolderShield repair splice kits provide the components necessary to splice shielded single-wire or multicore cables. Adapters and Uniboot molded parts can be combined to allow reentry to the back of the connector area for pin repair. n n Splash-resistant SCL semirigid heat-shrinkable tubing, with its meltable inner wall, can be stripped off the substrate without leaving a sticky residue, thus providing access to connections requiring reentry. Flexible, adhesive-lined tubing can be used to repair damaged wire insulation, providing a moisture seal that is resistant to bending of the wire substrate. 1-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Flex It 1 Application Overview In applications where flexibility or flex life are important, Raychem products meet the need—many performing even at low temperatures. n n NT tubing, which is widely used for insulation, strain relief, and abrasion protection on cable harnesses and wire bundles, remains flexible at low temperatures (as low as -70°C [-94°]) without cracking. Hi-Flex heat-shrinkable tubing was developed specifically for sealed cable-jacketing applications where cable flexibility is an important concern. It is also ideal for situations where the cable is subject to motion, such as in industrial machinery, transportation equipment, robotics, and welding. n n For applications where a flexible 90° bend right after the connector is desired, Uniboot molded parts can provide the perfect fit. DynaLink wire and cable is designed specifically for applications where flex life is critical: in the robotics industry; in lifts, typing machines, and sewer inspection equipment; and on ships where wire must be capable of unwinding from a large cable reel and then retracting smoothly without strain. 1-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications All of It At Tyco Electronics Corporation, we like the word “multitasking.” So it should come as no surprise that Raychem products are designed to help you integrate several tasks—seal, connect, insulate, protect, wire, hold, join, beautify, reduce, repair, and flex. In the pages of this catalog, you will find literally hundreds of products designed to provide thousands of solutions—across a wide variety of industries. Although you will find the catalog features an extensive array of products, keep in mind that, at Tyco Electronics Corporation, we’re always coming up with new ideas and new products—so that we can help you put together the precise solution you need. Also, when you choose any Raychem product, you’re automatically backed by a nationwide network of sales engineers who can provide application and engineering assistance as well as onsite training. 1-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Application Guide Tyco Electronics manufactures an extensive selection of Raychem quality products that hold, seal, protect, connect, and insulate. Whatever your design challenge, take advantage of the Tyco Electronics experience to help you find the right solution. 1 Application Overview Tyco Electronics has led the way in creating and supplying high quality, technologically advanced products for use in a broad range of industrial and commercial applications. When you choose any Raychem product, you're backed by a worldwide network of sales engineers who provide application and engineering assistance as well as on-site training. The products shown in Application Guide #1654725 (07-03) are just a sampling of the many Raychem products Tyco Electronics offers. Order your copy today! Give us a call or visit us at www.tycoelectronics.com/Raychem so we can help you put together the precise solution you need. 1-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Applications Engineering Notes 1-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Table of Contents This section attempts to provide assistance with most of the considerations applicable to the design of cable and harness assemblies. Caution must be used to ensure that the design is appropriate for a particular application. Harness Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 to 2-4 Protection of Harness Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 HarnWare Harness Design Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 to 2-14 Integrated Military Harness Systems for Defense and Allied Industries . . . . . . . . . . .2-15 to 2-25 2 Electrical Interconnection System Design Tyco Electronics provides this information as a design aid and assumes no responsibility for and makes no representation regarding the suitability of a design for a specific application. Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 2-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design A Raychem molded part provides strain relief on the back end of a connector. Tyco Electronics offers a range of Raychem components for wiring harnesses and cable assemblies in commercial, industrial, automotive, and defense and allied industries. Our components are approved to widely recognized standards (UL, CSA, CE, SAE) and to the military specifications of various governments. A variety of component material systems can be used to design a rugged, reliable, repairable, shielded, and environmentally sealed harness. We also offer individual components that can be used independently to meet a specific sealing, insulation, strain relief, protection, identification, or electrical interconnection need. Harnessing system components include: n Heat-shrinkable tubing n Heat-shrinkable molded shapes n Adhesives n Adapters n Assemblies n n n n Harness Design n Electrical interconnect components Wire and cable Solder termination devices Application equipment In many cases, properly selected components can raise the performance of a harness to acceptable levels compatible with even very demanding environments where cables are exposed to water, temperature extremes, EMI-radiated fields, or fluids. Tyco Electronics is the established leader in automotive, aerospace, marine, mass transit, industrial, and military harnessing. Call us for ideas on protecting your harness—whether it’s a typical UL wiring system or a harness assembly for demanding environments. n Designing wiring harnesses for demanding applications such as defense and aerospace is a complex business: n n Many different parts need to be selected while taking account of various environmental factors and mating part conditions. There can be a large number of alternative design solutions to analyze and the constraints imposed upon harness design are becoming more demanding. Weight and space are especially important in missile and aerospace applications. With the additional electrical equipment now in products such as cars, these factors are becoming a bigger issue in these industries. n Resistance to environmental hazards including corrosion, high temperature or fire, chemical and nuclear agents. The additional costs of totally sealed wiring harness systems are becoming easier to justify as products and the lives of those who use them, become more dependent upon the fault free operation of electrical systems. Repair and maintainability. Electrical and electronic systems in military vehicles and naval vessels now need to be upgraded or modified several times during the life of the main mechanical platform. There are now parts and harness design techniques that make this work easier to accomplish. Electromagnetic interference (EMI). Harnesses can either radiate interference to, or pick up interference from, nearby equipment. With the increasing use of sensitive electronics in cars, aircraft and military equipment this is a major problem. 2-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design (Continued) The front or joining end of the connector is designed to mate only with a connector having the right configuration. The back end of the connector is where the wires are terminated to the metal contacts. The checklist on page 2-4 covers some of the factors to consider in the design of a harness. Wires Harness Components Connectors and wires are the two basic components of a harness that need to be specified. Once they have been chosen, compatible protection, shielding and identification follow. Connectors Connectors come in two opposite types: plugs and receptacles. Both contain contacts, usually made of plated copper. The contacts, called pins or sockets, are joined to the conductors and are designed to mate or join with contacts of the opposite type. Connectors for indoor or internal use are generally not designed to resist moisture. Connectors that will be exposed to moisture are generally sealed to meet a specific requirement. In this discussion, a wire is defined as an insulated conductor and a cable is defined as two or more wires with or without a common jacket or shield. Conductors are usually made from copper. A copper conductor can be solid or, when flexibility is important, can consist of smaller strands of copper wire twisted together. The strands can be coated with tin, nickel, or silver to make them easier to terminate or more resistant to corrosion. Conductors are sized in metric units (mm2) or by AWG (American Wire Gauge), a holdover from the days when wire was made of steel in steel mills. The AWG refers to the number of passes it takes to draw the wire down to the required size - the larger the AWG, the smaller the wire. Making a 26 AWG wire, for example, requires more passes through reduction dies than are required for a 4 AWG wire. 2 Electrical Interconnection System Design This section provides information about the basic components in a harness design, the factors to consider in designing a harness, and the Tyco Electronics HarnWare Harness Design CAD software. With this information and the selection tables that follow, you will be able to choose from this catalog the right components for an integrated military or highperformance industrial harnessing system. A 26 AWG stranded wire, however, is made of many smaller wires, such as seven strands of 32 AWG wire (sometimes shown as 7/32 or 7x32). The choice of insulation for a conductor depends on a number of factors: n n n n n n Operating, design, and excursion temperatures of the system Size and weight limitations Mechanical performance desired Flexibility requirements Resistance to various fluids Specialized requirements, such as: - low fire hazard or low halogen - low outgassing 2-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Harness Design (Continued) Harness Design Checklist Connectors Sealed or unsealed? Made of plastic or metal? Crimp or solder contacts? Pins or sockets? Mating frequency? Keyway angle? Exposed to electrical noise (EMI)? Geometry Dimensions? Point to point or branched? Configuration of ends - straight, 90°, 45°? Environment Exposed to sunlight? Exposed to moisture? Immersed? Temperature extremes? Temperature cycling? Normal operating temperature? Exposed to abrasion? Exposed to mechanical abuse? Exposed to dust? Exposed to corrosive fluids? Exposed to flexing? Repairable? Circuit identification? Cable identification?* Shielding effectiveness? Magnetic-field–induced signals? Circuit Voltage? Current? Signal transmission (impedance, velocity, frequency, etc.)? Circuit layout? Is circuit integrity critical? What if the circuit fails? *Tyco Electronics Identification products information available at www.tycoelectronics.com Protection Once the connectors and wires have been specified, the method of protection must be considered. Various jacket materials are available to protect the wires and these can be extruded or heat-shrink. Jacket material formulations are compounded to meet a wide range of environmental demands. Similarly, protection for the wire termination must be considered. In general, the wires will be terminated to connector contacts. Protection products must protect the joints from damage caused by mechanical stress such as flex, torque and tensile load, and corrosion or electrical breakdown from fluid ingress, while retaining the ability to be repaired. All these influ- ences and more must be considered when choosing the termination protection method. Shielding and Shield Termination Step 3 of the component selection process discussed later in this section gives advice on choosing the appropriate shielding products for the gross shield. Consideration must also be given to the individual cable shield terminations. Can they be pigtailed together with a common termination to a contact or to earth, or should they have individual terminations? If using a solder device, the correct choice is based, not only on size, but also temperature rating or compatibility with the cable braid. Identification Circuit identification is important, both in manufacture, where an assembly operator must ensure correct wire to contact termination, and in repair, where a damaged connector may need replacing in difficult circumstances and contact positions have to be easily identified. Individual wire markers help with these two circumstances. Where a cable is severed and access to the ends is prevented, unique identification on the wires, or wire color coding aids repair. speed up plugging, particularly for multiconnector harnesses. It is also good practice to label the harness with its part numbers and other relevant information for traceability purposes. The Tyco Electronics Identification Products Group offers a variety of products that are compatible to the HarnWare software design process. For complete information regarding these products visit our website at www.tycoelectronics.com. Consideration given to the identification of harness legs is also important. Connectors will normally be chosen with unique keying to prevent incorrect mating but end identification will 2-4 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Protection of Harness Components A salt deposit can be seen beneath the end of this 18-AWG, 19-strand wire. The other end of the wire has been immersed in salt water for 24 hours. Harness components are vulnerable to corrosion, stress, strain, and electromagnetic interference (EMI). Corrosion Humidity, moisture, salt, and corrosive fluids can corrode conductors and contacts. What is worse, the corrosion can take place well beyond the point of penetration because of the small tubelike voids—capillaries— between the individual strands of copper that make up the conductor. Called “capillary action,” the penetration of a fluid can “wick” many feet in a relatively short time (see photo above), depending on the specific characteristics of the affected wire. As the copper in the conductor is depleted by corrosion, the conductor can no longer sustain mechanical or electrical loads and the metal will fail. Mechanical failure can thus occur anywhere in the wiring system. Even before mechanical failure occurs, electrical If a chemical solution contacting the electrical connection is itself conductive it can cause a short circuit between conductors. Pure water, not itself a conductor, can also facilitate a short circuit by providing a medium into which conductive salts can dissolve. These salts may be the by-products of corrosion or the result of earlier contamination. High humidity and temperature cycling in some situations cause condensation, the accumulation of which can also result in a short circuit. Depending on circumstances, the resulting short circuit may be intermittent, significantly complicating the process of identifying the underlying cause. To prevent corrosion, sealing may have to meet the performance requirements of applicable military specifications or the International Protection (IP) Code. Stress and Strain Wires that are attached to the connector pins need help to withstand stresses and strain from the cable, which could break the wires from the pins. It is almost always necessary to prevent strain from occurring in a weak spot, such as where the wire is attached to the contact. This is called strain relief and can be provided in a variety of ways, from mechanical devices, such as adapters, to molded boots and heat-shrinkable tubings. 2 Electrical Interconnection System Design performance can be adversely affected by the presence of nonconductive by-products from galvanic or aqueous corrosion. Moisture within a connector body may cause an impedance mismatch, increase noise in a signal circuit, or modify the waveform. Even small amounts of corrosion or other contaminants can have a significant impact on contact surfaces and the efficiency with which signals flow through them. EMI (Electromagnetic Interference) EMI is similar to the noise heard on an AM radio when the radio is close to highvoltage lines. EMI causes the wire or cable to act like an antenna and pick up electrical signals, which interfere with the signals on the wire and can cause malfunctions in sensitive electronic circuits. Wiring systems are susceptible to two types of EMI: n n Radiated emissions (the electromagnetic energy a wiring system radiates to its surrounding environment), such as the EMI a high-voltage line radiates to its surroundings. (There are regulations on the amount of radiated energy a circuit is allowed to produce.) External radiated emissions (the electromagnetic energy in the environment), such as the EMI an AM radio picks up from a high-voltage line, causing distortions in the conducted signal. Conducted EMI is noise carried by the cable into the receiving circuit and needs to be filtered. To reduce susceptibility to radiated emissions from the cable or from external sources, the harness must be grounded, shielded, and/or filtered, depending on the sensitivity of the equipment and the strength and frequency of the EMI. 2-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software Select optimum parts Check for problems & deviations from 'best practice' Generate parts lists & assembly time estimates Generate wiring schematics & schedules HarnWare Software Determine best cable lays, diameters & construction HarnWare Design Software is Tyco Electronics’ harness design CAD software. Originally developed for use by our own harness designers it is now offered to our customers so they can benefit from this powerful tool. From a simple input of geometry, dimensions, connector and wiring details, HarnWare software can suggest a design sequence and help with many aspects of wiring harness design (see diagram). HarnWare software is used interactively by harness design engineers. The choices and calculations made by the system can always be modified to suit specific requirements. Design data is saved with each shape in the harness drawing. This data can be reviewed simply by moving the mouse over the parts listed in the Design Wizard. It is, therefore, very easy to incorporate design changes, modify design constraints or analyze alternative design solutions. Moreover a design checker can be used to search for deviations from ‘best practice’. Determine wire routes & lengths Determine most suitable wire gauge Some HarnWare Software Outputs The following are some examples of the outputs that HarnWare software can generate: n n n n High quality engineering drawings. Clear and reliable drawings play a crucial role in the success of any design project. Point-to-point wiring lists, including calculated wire lengths. Fully detailed parts lists. HarnWare software automatically generates the parts list table and adds item number balloons into the drawing. Parts lists can also be exported to a spread sheet, database or word processor. Assembly time estimates. HarnWare software automatically adds the design details into a ‘spread sheet’ containing standard assembly time synthetics. n n n Wiring schematics and schedules are quickly produced using connector plan form data and wiring details from the wire list. Lists of codes of practice describing harness assembly techniques and other issues that are relevant to the parts included in the design. Files containing cable marker details can be exported ready for use in marker printing systems such as the Tyco Electronics WinTotal* system. A drawing page showing these cable marker details can also be generated. A sample set of documents produced by HarnWare software is shown at the end of this section. *Tyco Electronics Identification product information available at www.tycoelectronics.com 2-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) n System Building Blocks Some key features of HarnWare software are: n n The user interface is similar to that of commonly used software such as Microsoft Word and Excel. n On-line help systems for guidance on using the system and on Raychem wiring harness products. Uses the Visio drag and drop drawing system for creating harness drawings more quickly and more easily than with other computer aided design (CAD) systems. HarnWare Software Database HarnWare Software HarnWare Software Help Drawing Wire List Wiring Schedule Wiring Schematic Cable X Sections Parts List Design Notes Labour Estimate Marker Page Visio n n n A growing library of 400 intelligent drawing shapes and a 110,000 record design database which can generate 100,000s of part descriptions for Raychem wiring harness products in their various material and finish permutations. Software that traces wire routes through harnesses and automatically creates wiring schematics and calculates wire lengths. Designing a Harness With HarnWare Software Shapes, representing Raychem harnessing products, are dragged and dropped into the harness assembly drawing. The shapes automatically snap and glue together and it takes very little time to produce a high quality drawing. Pages from a sample HarnWare software document set can be seen on page 2-14. Dimensions and connector references are entered by clicking a shape and typing in the numbers and references. 2 Electrical Interconnection System Design n Runs under Microsoft Windows on affordable PC’s. Software to help identify the parts most suitable for use within the given design constraints and to fit the mating parts, cables, etc. The HarnWare Software Design Wizard analyzes the drawing and lists the parts and operations in the suggested design sequence. The wizard also provides quick access to details on each part in the harness and the connections between parts. When the mouse is moved over the parts listed by the wizard, HarnWare software outputs such details as part dimensions, materials, finishes, etc. HarnWare software indicates the Raychem harness material system that is most suited to the given application, operating temperature range and required defense specifications. Analysis options to determine the optimum lay of cables containing mixed diameter wires and to suggest the most appropriate wire gauge for specified current and temperature rise limits. 2-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) Wire Selection The wire most suited to the particular environment and service conditions is selected using design rules encoded in the HarnWare software and database. If the wire selected is a nonpreferred option, alternative types and colors can be identified which may also suit the design requirements and be available on shorter delivery times. Guidance is also available for choosing the wire gauge most suited to given current loading, ambient temperature, length, number of conductors, etc. For each available wire size HarnWare software estimates temperature rises, operating temperatures and voltage drops. 2-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) SK1 60 0 2 480 SK2 500 450 Electrical Interconnection System Design PL1 900 + SK3 WIRE LIST ITEM NO QTY FROM TO PART NO DIA LENGTH 1 2 4 PL1 SK1 44A1121-20-0/9-9 3.76 1800.00 2 2 5 PL1 SK2 44A1121-20-0/9-9 3.76 1668.00 3 1 19 PL1 SK3 44A0111-20-9 1.40 1590.00 SHELL = SK1 A B C D E F G H J WIRE NO SHELL PL1 A B C D E F G H t. J K L M N P R S T U s. V W X Y Z a. b. c. d. e. 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black SHELL 20 AWG White A B C D E F G H J K L 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White SK2 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White SHELL A B C D E F G H J K SK3 Wire Selection (Continued) From-To connector references are specified to form a point-to-point wiring list. Wiring schematics can be generated automatically from the information included in the wire list. These schematic diagrams show the pin to pin wiring for all the connectors and wires in a harness design. n n HarnWare software automatically: n Traces the route of each wire in the point-to-point wire list through the harness geometry contained in the drawing. n Calculates wire lengths by summing the lengths of the harness legs through which each wire is routed. Adjustments are applied based on a variety of design rules relating to the parts through which wires pass. Determines the cable sub-assembly structure that would save the maximum amount of labor in assembling the harness. diameter and most even construction. In the example below, the listbox contains the quantity of each wire diameter for which HarnWare software has automatically developed 29 alternative design solutions. The minimum diameter alternative is shown which is 17.72 [.698] diameter and uses 2 fillers to achieve a sufficiently round lay. Determines the optimum lay of wires in each harness leg and produces a cable cross-section drawing. Alternative lays of cables containing mixed diameter wires are automatically analyzed to identify the smallest 2-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) Part Selection All the parts in a harness can be specified. The key steps in selecting parts include: n n Clicking a shape in the harness drawing or the design wizard. HarnWare software automatically obtains design data and dimensions from the shape and from mating parts in the harness assembly drawing. In the case of a Raychem boot, for example, HarnWare software extracts the required style of boot from the shape and the diameters from the mating harness leg and adapter. n The database is searched for parts suited to the dimensional constraints. The choice is further refined by the service conditions which determine the best materials, finishes and adhesives. When alternative parts are found in the database, HarnWare software offers the best option first, which the designer can compare with the other alternatives. The on-line help systems contain details and advice on the various types of parts, materials and finishes and their suitability to different service conditions. Among the parts that HarnWare software helps to select are: n Adapters n Braid n Connectors n Databus couplers, etc. n Feedthroughs n Heat-shrinkable tubing n Marker sleeves* n Molded parts n Adhesives n Solder sleeves n Wire *Tyco Electronics Identification product information available at www.tycoelectronics.com 2-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) PARTS LIST ITEM DESCRIPTION PART NUMBER SPEC/REMARKS QTY UNIT 1 Wire 44A0111-20-9 Raychem 30.3 M 2 Wire 44A1121-20-0/9-9 Raychem 15.6 M 3 Filler 2.75-MM-SZF Raychem 0.5 M 4 Filler 3.50-MM-SZF Raychem 0.5 M 5 Braid RAY-101-10.0 Raychem 1.2 M 6 Braid RAY-101-12.5 Raychem 1.2 7 Braid RAY-101-7.5 Raychem 1 M 8 Tubing AT099-43 Raychem 2 Pc 9 Tubing DR-25-1/2-0 Raychem 1.6 M 10 Tubing DR-25-1/2-0-50MM Raychem 1 Pc 11 Tubing DR-25-1-0 Raychem 1 12 Tubing DR-25-3/4-0 Raychem 0.6 M 13 Tubing RNF-100-3/16-0-15MM Raychem 4 Pc 14 Tubing RNF-100-1/2-0-20MM Raychem 3 Pc 15 Tubing RNF-100-1-0-20MM Raychem 1 Pc 16 Tubing RT-375-1/2-X-65MM Raychem 1 Pc 17 Tubing RT-375-1-X-65MM Raychem 3 Pc 18 Tubing RT-375-3/4-X-65MM Raychem 1 Pc 19 Insulation Cap TC4001-9 Raychem 18 20 Adaptor TXR40AB00-1208AI Raychem 21 Adaptor TXR40AB00-1410AI Raychem 22 Adaptor TXR40AB00-2014AI Raychem Pc PL1 1 Pc 1 MATES Pc WITH 1 CPU Pc- SK1 23 Adaptor TXR76AB90-1208AI Raychem 1 Pc 24 Moulded Part 202K142-25/225-0 Raychem 2 Pc 25 Moulded Part 202K153-25/225-0 Raychem 1 Pc 26 Moulded Part 202K163-25/225-0 Raychem 1 Pc 27 Moulded Part 382A034-25/225-0 Raychem 2 Pc 28 Solder Device B-051-01-01 Raychem 1 29 Solder Device B-051-02-01 Raychem 1 30 Solder Device ST63-3-55-20-90 Raychem 14 Pc 31 Marker Sleeve TMS-NR501-NR19-4-CS-65571 Raychem 4 KT 32 Marker Sleeve TMS-NR501-NR19-4-CS-65572 Raychem 1 KT 33 Marker Sleeve TMS-SCE-1/2-2.0-4 Raychem 1 Pc 34 Marker Sleeve TMS-SCE-1-2.0-4 Raychem 2 Pc 35 Marker Sleeve TMS-SCE-3/4-2.0-4 Raychem 2 Pc 36 Connector 62GB-56T12-10P Amphenol 1 Pc 37 Connector D38999/26WC98PN MIL-C-38999 1 Pc 38 Connector D38999/26WD18SA MIL-C-38999 1 Pc 39 Connector D38999/26WG41PN MIL-C-38999 1 Pc 40 Filler Plug MS27488-20 - 20 Pc 2 M Electrical Interconnection System Design PL1 M Pc Pc 22 19 13 9 26 17 34 2 31 30 7 39 32 HARNESS PROPOSAL DRAWING TITLE: Printed 13/03/01, 13:16:41 BRANCHED HARNESS ASSEMBLY 40 CREATOR: D Hammond FILENAME: PicHarn.vsd 13/03/01 DATE: 12 Page 3 of 8 Parts Listing Other Features During the parts listing process HarnWare software automatically: Among the other HarnWare software features and options are: n n n n Extracts part details from the drawing Generates a sorted and totalized parts list table Adds item number balloons to the drawing cross referencing the parts to the parts list table. HarnWare software parts list data can be written to a structured text file ready for use in a variety of other systems including spread sheets, databases or word processors. The parts lists for a number of harnesses can also be combined to form a composite parts list that totalizes all the parts for a set of harnesses on a project. Other parts listing options include the ability to: n n n Retain existing item numbers when a design is modified. Include gaps in the item numbering sequence. n n 3D modelling system for visualizing harness designs. HarnWare software automatically generates to-scale 3D models which provide virtual prototypes of harnesses designed. The user can see what a harness will look like with lengths, diameters and parts shown to scale thus reducing the potential for errors. Lay-up (nail) board designs. Harness lay-up board design can be modeled with pegs automatically positioned along the harness legs. Drawn output can be used on the lay-up board. Weight calculation. Most components weights are stored in the HarnWare software database and this enables the software to estimate the weight of the harness. Convert part numbers to customer numbers or to VG or other industry standard numbers. 2-11 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) phrases, rather than individual words, are translated in order to achieve more meaningful and grammatically correct results. Other Features (Continued) n n n Labor estimator. Harness drawings can be analyzed and details automatically added to a spread sheet containing assembly time standards. While estimating harness assembly times can never be an exact science, the estimates produced are sufficiently accurate for such purposes as comparing the cost effectiveness of alternative design solutions. A labor estimate is contained in the attached sample HarnWare software document set. Cable analyzer. This option analyzes the harness topology, wire lengths, etc. in order to suggest where machine, rather than hand, built cable sub-assemblies could result in the maximum cost savings. Drawing translator. Drawings can be translated into a number of foreign languages, including French and some Asian languages such as Korean and Japanese. Harnessing n n n Design checker. This analyzes the contents and structure of a harness design against a set of rules. Where potential problems or deviations from 'best practice' are found, HarnWare software outputs a warning. The relevant parts in the harness design drawing can be flagged and the warning messages can also be listed in a table for use in design reviews. The warning flags and the messages are all linked to an on-line help system which contains further details on each specific problem. Codes of practice. A list can be generated of the codes of practice that are relevant to the parts included in the design. These describe harness assembly techniques and other issues. system covers system operating procedures and details on many aspects of harness design procedures and Raychem products. The help system is context sensitive and extensively cross-referenced using hyperlinks including links to the on-board manual or the Tyco Electronics website. n User parts library for non-standard parts. A database to allow identification and retrieval of regularly used parts. n Multi-core cable database. A database to allow selection of standard or regularly used cables. n Databus module. Software for the design of MIL-C-1553 databus harness assemblies using Tyco Electronics components. n Conduit module. Software for the design of Tyco Electronics conduit harnesses. On-line help system. An extensive on-line help 2-12 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) y ar ts st Mo eff ect ive re fer Pre System Integration Benefits HarnWare software can be linked to many other computer systems using a variety of interfaces including: The five key benefits of using HarnWare software are: n n n n Parts list data can be exported in structured text files suitable for reading by such systems as spread sheets, databases and word processors. Drawings can be imported and exported using industry standard formats such as DXF and IGES. Cable marker data can be transferred to marker printing systems such as Tyco Electronics WinTotal* system. Wiring connectivity data export for test equipment. Electrical Interconnection System Design HarnWare Software co st n 2 ter Fas Ensures com pa tib ilit More detailed dp 1) More detailed and accurate design. 2) Up to 20 times faster design and quotation. 3) Preferred part selection, to ensure best delivery and price. HarnWare Software Document Set The following partial set of drawings and associated documents is a simple example of what can be produced using HarnWare software. *Tyco Electronics Identification product information available at www.tycoelectronics.com 4) More cost effective design. 5) Ensures parts are compatible with the intended service conditions and with mating parts. Hundreds of users around the world can confirm the benefits of using HarnWare. X, Y coordinates of nail positions on lay-up (nail) board for NC drilling. 2-13 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design HarnWare Harness Design Software (Continued) 1 2 3 SERVICE DRAWING NO./RAYCHEM DRAWING NO. 3 SHEET NO OF 4 5 6 7 0 1 8 8 50 9 100 150 10 11 200 12 13 OF 3 11 4 8 9 100 10 150 11 200 12 13 14 250 250 MILLIMETRES FULL SIZE SK1 A B B 24 60 0 2 2 SHELL 2 18 35 A B C D E F G H t. J K L M N P R S T U s. V W X Y Z a. b. c. d. e. SK1 CABLE SECTION C 38 40 8 SK2 MATES WITH BOX 1 - PL2 A-A CABLE SECTION 28 27 14 7 25 21 13 30 31 4 2 SK2 500 D 29 27 A 15 14 450 7 50 20 11 MAIN MARKER ISSUE # SERIAL No. 6 0 - A 9 5 6 6 PL1 MATES WITH CPU - SK1 5 3rd ANGLE PROJECTION UNCLASSIFIED USED ON SK1 31 30 13 PL1 CABLE SECTION 4 1 8 SECURITY CLASSIFICATION 40 37 250 MILLIMETRES FULL SIZE 1 SHEET NO HBJC4/37-18/18652K 14 250 3rd ANGLE PROJECTION UNCLASSIFIED - A B C D E F G H J 2 HBJC4/37-18/18652K USED ON SHELL 1 SERVICE DRAWING NO./RAYCHEM DRAWING NO. SECURITY CLASSIFICATION 1 ITH 1 SK S W PL E AT 1 M OX B General Assembly, Wiring Schematic, Parts List, Labor Estimate, Marker Sleeve and Codes of Practice Pages 480 PL1 PL1 17 35 E A MA SK3 TE BO S WI X1 TH - PL 3 5 2 F 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black C 20 AWG White 20 AWG Black SHELL 20 AWG White A B C D E F G H J K L 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White 20 AWG Black 20 AWG White D SK2 20 AWG White 20 AWG White E 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White 20 AWG White F 20 AWG White 19 13 22 9 26 17 34 34 17 20 AWG White 24 8 2 20 AWG White 12 31 30 20 AWG White 3 20 AWG White 10 7 20 AWG White 39 32 20 AWG White 40 1 23 900 9 20 AWG White SK2 CABLE SECTION 12 33 16 G 20 AWG White G 7 19 31 36 Q.C. APP'D 9 SK3 CABLE SECTION Q.C. APP'D - A B C D E F G H J K - H TECH APP'D SK3 45 SK3 - - PRODAPP'D CERTIFIED UNCONTROLLED COPY,CHECK REVISION BEFORE USE CHECKED - THIS DRAWING IS C.A.D. GENERATED AND MUST NOT BE MODIFIED MANUALLY DRAWN D.E.H. 1 17.06.99 --- - ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CONTINUITY AND INSULATION RESISTANCE TESTS SHALL BE IN ACCORDANCE WITH MVEE 773 SECTIONS 7.1.2, 7.1.3 AND 7.1.4. CHK'D N.T.S. SCALE (ORIGINAL) DRAWING TO BE READ IN CONJUNCTION WITH B.S.308 AND DEF. STAN. 05-10 - TITLE TOLERANCES,UNLESS OTHERWISE STATED >50 - 50 - 150 - 300 - 1000 - 2000 - 4000 ANGULAR +5 +10 +15 +25 +50 +75 +100 ±5˚ N.S.N. CERTIFIED - UNCLASSIFIED K 1 0 HARNESSING SYSTEMS CHENEY MANOR INDUSTRIAL ESTATE, SWINDON MOD ESTABLISHMENT/CUSTOMER 1 0 RAYCHEM DRAWING NO. HBJC4/37-18/18652K SERVICE DRAWING NO. - SHEET NO OF 1 8 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 SHEET NO OF - UNCONTROLLED COPY,CHECK REVISION BEFORE USE CHECKED - THIS DRAWING IS C.A.D. GENERATED AND MUST NOT BE MODIFIED MANUALLY A 2 78 79 80 N.T.S. SCALE (ORIGINAL) DRAWING TO BE READ IN CONJUNCTION WITH B.S.308 AND DEF. STAN. 05-10 SECURITY CLASSIFICATION DRAWN 1 1 H - RESPONSIBLE AUTHORITY BRANCHED HARNESS ASSEMBLY DIMENSIONS IN MILLIMETRES THIS DRAWING AND THE INFORMATION SET FORTH HEREON ARE THE PROPERTY OF RAYCHEM AND ARE TO BE HELD IN TRUST AND CONFIDENCE. PUBLICATION, DUPLICATION, DISCLOSURE, OR USE FOR ANY OTHER PURPOSE NOT EXPRESSLY AUTHORISED IN WRITING BY RAYCHEM IS PROHIBITED. SHELL TECH APP'D PRODAPP'D 17.06.99 --- CONTINUITY AND INSULATION RESISTANCE TESTS SHALL BE IN ACCORDANCE WITH MVEE 773 SECTIONS 7.1.2, 7.1.3 AND 7.1.4. - D.E.H. ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D >50 - 50 - 150 - 300 - 1000 - 2000 - 4000 ANGULAR +5 +10 +15 +25 +50 +75 +100 ±5˚ DESCRIPTION SPEC/REMARKS QTY UNIT Wire 44A0111-20-9 Raychem 30.3 M 2 Wire 44A1121-20-0/9-9 Raychem 15.6 M 3 Filler 2.75-MM-SZF Raychem 0.5 M 4 Filler 3.50-MM-SZF Raychem 0.5 M 5 Braid RAY-101-10.0 Raychem 1.2 M 6 Braid RAY-101-12.5 Raychem 7 Braid RAY-101-7.5 Raychem 1 M 8 Tubing AT099-43 Raychem 2 Pc 9 Tubing DR-25-1/2-0 Raychem 1.6 M 10 Tubing DR-25-1/2-0-50MM Raychem 1 Pc 11 Tubing DR-25-1-0 Raychem 1 12 Tubing DR-25-3/4-0 Raychem 0.6 M 13 Tubing RNF-100-3/16-0-15MM Raychem 4 Pc 14 Tubing RNF-100-1/2-0-20MM Raychem 3 Pc 15 Tubing RNF-100-1-0-20MM Raychem 1 Pc 16 Tubing RT-375-1/2-X-65MM Raychem 1 Pc 17 Tubing RT-375-1-X-65MM Raychem 3 Pc 18 Tubing RT-375-3/4-X-65MM Raychem 1 Pc 19 Insulation Cap TC4001-9 Raychem 18 Pc 1.2 M Adaptor TXR40AB00-1208AI Raychem 1 Pc 21 Adaptor TXR40AB00-1410AI Raychem 1 Pc 22 Adaptor TXR40AB00-2014AI Raychem 1 Pc 23 Adaptor TXR76AB90-1208AI Raychem 1 Pc 24 Moulded Part 202K142-25/225-0 Raychem 2 Pc 25 Moulded Part 202K153-25/225-0 Raychem 1 Pc 26 Moulded Part 1 Pc 27 Moulded Part 382A034-25/225-0 Raychem 2 Pc 28 Solder Device B-051-01-01 Raychem 1 Pc 29 Solder Device B-051-02-01 Raychem 1 Pc 30 Solder Device ST63-3-55-20-90 Raychem 14 Pc 31 Marker Sleeve TMS-NR501-NR19-4-CS-65571 Raychem 4 KT 32 Marker Sleeve TMS-NR501-NR19-4-CS-65572 Raychem 1 KT 33 Marker Sleeve TMS-SCE-1/2-2.0-4 Raychem 1 Pc 34 Marker Sleeve TMS-SCE-1-2.0-4 Raychem 2 Pc 35 Marker Sleeve TMS-SCE-3/4-2.0-4 Raychem 2 Pc 36 Connector 62GB-56T12-10P Amphenol 1 37 Connector D38999/26WC98PN MIL-C-38999 1 Pc 38 Connector D38999/26WD18SA MIL-C-38999 1 Pc 39 Connector D38999/26WG41PN MIL-C-38999 1 Pc 202K163-25/225-0 Raychem MS27488-20 - Element Time (mins) Unpack Check Kit Cut EPD to Length Jacket Stripping for Con. Ends Remove EPD Jacket Identify Wires Strip/Crimp/Insert 15 1 5 5 1.3 2.5 Qty / Length Total mins UNCLASSIFIED K 1 0 1 0 RAYCHEM DRAWING NO. HARNESSING SYSTEMS HBJC4/37-18/18652K CHENEY MANOR INDUSTRIAL ESTATE, SWINDON MOD ESTABLISHMENT/CUSTOMER SERVICE DRAWING NO. 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 SHEET NO OF 1 8 SHEET NO OF - A 78 79 80 per end per metre per wire per cont. 4 20 0 60 50 0 78 125 Solder Wires Up to 16AWG (Tin/Strip/Insulate) 14 to 12AWG (Tin/Strip/Insulate) Power Cable 3.5 per term 10 35 5 per term 0 0 15 per term 0 0 Lugs Crimp Lugs Solder 10 per term per term 0 0 15 0 0 0.5 0.75 per wire per wire 60 0 30 0 Pc 20 Pc Repair Loops Up to 55 Way Con. Above 55 Way Con. Soldertact 4 3 6 per term per term per term 0 0 14 0 42 0 Insulating Screens Filler Plugs 2 1 per term per f/plug 4 20 8 20 Spare Wires 0.5 per wire 18 9 Ring Tags Crimp Ring Tags Solder RF one-step 2 2.5 8 per term per term per term 0 0 0 0 0 0 Adaptors (includes Braid Term / Torque) Spin Coupling Braided Adaptor Tinel Whipping/Soldering 7.5 12 10 5 0 0 4 0 0 0 40 0 per metre per metre per metre per metre } Enter } 0 for No }1 for Yes 0 1.50 1.43 0 0 0 0 0 10.5 14.3 0 0 0 0 per metre 2.93 5.86 per term per term per term per term 4 7 10 15 0.25 -.25 -.25 Tubing Installation on Multi-Leg Harness 2 0 0 0 0 0 0 Standard 11 to 42 52 to 63 74 85 12 15 20 25 per piece per piece per piece per piece 2 2 0 0 24 30 0 0 Uniboot 611 to 621 632 to 642 653 to 663 10 12 15 per piece per piece per piece 0 0 0 0 0 0 KTKK Small Medium Large 5 6 7 per piece per piece per piece 0 0 0 0 0 0 3 Outlets 11 to 19 22 to 48 56 to 91 4 Outlets 11 to 19 22 to 48 56 to 91 5 Outlets 11 to 19 22 to 48 56 to 91 Viton +50% Precoated -25% Potting +50% Packing Piece/Ext. Atum/Htat Straight Branch Transition Overlap Bandage 3.5 5 8 33 Protection Cap Installation Marker Sleeves Protection Sleeves Wire Cutting Qty / Length Total mins 16 20 23 per piece per piece per piece 0 2 0 0 40 0 21 25 29 per piece per piece per piece 0 0 0 0 0 0 25 per piece 28 per piece 33 per piece .50 } Enter -.25 } 0 for No .5 } 1 for Yes 5 per piece per piece 3 0 0 0 0 1 0 3 0 0 0 0 0 -23.5 0 15 0 per metre per metre per piece per piece 0 2.93 2 0 0 14.65 16 0 5 per piece 0 0 4 1 per piece per piece 5 5 20 5 1 per wire 37 37 Unravel / Count Cut Wires Wire Layup Legs 30 wires Legs >4 Metres < 20 wires 20 - 30 wires > 30 wires per piece per piece per piece Raybraid / Install Tubing DR25 < 1/4 1/4 to 1/2 3/4 to 1 1 1/2 + Viton, VPB +25% ZHTM -25% CGPT & Versafit Time (mins) 17 25 30 Transitions Screen Termination Individual Term. Coaxial Term. Element Rayaten 121 to 142 152 to 163 174 Moulded Parts 0 0 0 0 per kit per metre M 20 Filler Plug SECURITY CLASSIFICATION - LABOUR ESTIMATE PART NUMBER 1 40 3 N.S.N. Wiring Schematic PARTS LIST ITEM 2 - BRANCHED HARNESS ASSEMBLY TOLERANCES,UNLESS OTHERWISE STATED 1 General Assembly RESPONSIBLE AUTHORITY TITLE DIMENSIONS IN MILLIMETRES THIS DRAWING AND THE INFORMATION SET FORTH HEREON ARE THE PROPERTY OF RAYCHEM AND ARE TO BE HELD IN TRUST AND CONFIDENCE. PUBLICATION, DUPLICATION, DISCLOSURE, OR USE FOR ANY OTHER PURPOSE NOT EXPRESSLY AUTHORISED IN WRITING BY RAYCHEM IS PROHIBITED. Common Size Mixed Sizes 1 1.5 2 27.38 12.60 0 27.38 18.9 0 1.5 2 2.5 0 0 0 0 0 0 Enter 1 to add 30% for mixed wire sizes 0.1 0.3 per wire per wire 37 0 3.7 0 Enter 1 to add 5% allowance for QC Special Requirements (mins) Total Labour Time (mins) 0 0 679.67 Total Labour Time (hours) 11.33 Labour rate per hour Total Labour Cost 1 0.00 0.00 £ Enter 1 to Add Allowances for Prototypes: HARNESS PROPOSAL DRAWING 20% for Straight or Branched < 4 Ends 0 35% for Branched 4+ Ends 0 BRANCHED HARNESS ASSEMBLY TITLE: Printed 13/03/01, 13:16:41 CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: 13/03/01 Page 3 of 8 MARKER PAGE Printed 13/03/01, 13:16:41 HARNESS PROPOSAL DRAWING TITLE: BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd 13/03/01 DATE: Page 5 of 8 CODES OF PRACTICE, FAX-ON-DEMAND AND DRAWING NOTES PL1 MATES WITH CPU - SK1 SK1 MATES WITH BOX 1 - PL1 Item:34 Quantity:1 Part Number:TMS-SCE-1-2.0-4 Colour:Yellow Font:10 cpi Standard Item:35 Quantity:1 Part Number:TMS-SCE-3/4-2.0-4 Colour:Yellow Font:10 cpi Standard MAIN MARKER ISSUE # SERIAL No. SK2 MATES WITH BOX 1 - PL2 Item:34 Quantity:1 Part Number:TMS-SCE-1-2.0-4 Colour:Yellow Font:10 cpi Standard Item:35 Quantity:1 Part Number:TMS-SCE-3/4-2.0-4 Colour:Yellow Font:10 cpi Standard Codes of Practice: Code Description 251 End stripping primary wire and cable Stripping wire and cable jackets 254 256 Laying hand laid sections of harnesses Applying Kevlar binder to hand-laid sections of harnesses 257 261 Preparing shielded and jacketed wire 301 Looping wire gauges 18 and below Terminating a primary wire to a cable shield using a solder sleeve with a pre-installed lead 368 361 Applying a single layer of braid to a hand laid cable Terminating overall shields formed by single layers of braid at a transition 363 551 Installing heat shrinkable tubing Preparing cable jackets for the installation of pre-coated tubings 610 Installing Tinel-Lock rings with a resistance heater 359 366 Positioning Tinel-Lock rings 451 Applying Loctite sealants to Raychem adaptors 452 Torque tightening Raychem adaptors 553 Installing medium and large transitions 554 Installing straight lipped boots 557 Under jacket packing for moulded parts 559 Installing moulded parts using Unicure adhesive 603 Preparing cable jackets and adaptors for installing moulded parts 609 Preparing non-shielded moulded parts 556 Installing marker sleeves 454 Checking the retention of pins or sockets within a connector SK3 MATES WITH BOX 1 - PL3 Item:33 Quantity:1 Part Number:TMS-SCE-1/2-2.0-4 Colour:Yellow Font:10 cpi Standard HARNESS PROPOSAL DRAWING TITLE: Printed 13/03/01, 13:16:41 HARNESS PROPOSAL DRAWING BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: TITLE: 13/03/01 Page 6 of 8 Printed 13/03/01, 13:16:41 BRANCHED HARNESS ASSEMBLY CREATOR: D Hammond FILENAME: PicHarn.vsd DATE: 13/03/01 Page 8 of 8 2-14 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 2 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries 2 Raychem integrated harness systems have been developed for a wide range of defense and industrial applications. Each system consists of compatible components, including cable jackets, heatshrinkable components, and adhesives. Performance of these parts is assured because all components are tested separately and as part of an assembled system (see photo top left). 1. Primary wire and cable 2. Heat-shrinkable tubing 3. Backshell adapter 4. Molded part 5. Adhesive 6. Cable jacket 7. Marker sleeve* Military harness system components. Additional components for harnessing systems include the following: n n n n A typical designed harness consists of seven component parts (pictured at right): Electrical Interconnection System Design Assembled military harness. A wide range of special devices, such as SolderSleeve devices for primary wire interconnection. A selection of electrical shielding (screening) options, including braids and termination assemblies. Multiconductor (multicore) cables. Specialty adhesives and sealants for complete environmental sealing.** Table 1 on the next page serves as both a summary of Raychem products for specific harnessing systems and a selection table for harnessing system components. An explanation of how to select components for a harness system follows. *Tyco Electronics Identification products information available at www.tycoelectronics.com **Tyco Electronics Sealant product information available at www.tycoelectronics.com 2-15 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 1. Raychem Harnessing Systems and Their Components Components Wire System 10 System 20 System 25 System 30 System 100 System 200 System 300 44 44 44 55 99, 100A, 100G 55 55 ZHTM Viton® RT555 Versafit NT-FR DR25 VPB Tubing Adapter material and plating finish chosen for compatibility with the connectors. Molded part -3, -4, -71 -51 -25 -50 -100 -12 -55/-125 -35 — -25S — -100S — — S1017, S1030 S1124, S1048 S1048, S1125 S-1125, S-1255-04 S1030, S1125, S1125, S1255 S1255-04 /42, /180 — /164,/86 — /86, /225 S1184 — — /180 S1184 — — — — Cable jacket Thermorad NT-FR Viton® RT555 Marker sleeve* TMS-SCE HT-SCE HT-SCE Preinstalled Rayaten molded part Adhesive Precoated adhesive Conductive adhesive FDR-25 Thermorad Zerohal VPB TMS-SCE TMS-SCE TMS-SCE HX-SCE *Tyco Electronics Identification products information available at www.tycoelectronics.com. Selection Process Selecting the components for a harnessing system is a four-step process: Step 1: Select the material system appropriate for the operating conditions and environment to which the harness will be exposed. Step 2: Select the adhesive system appropriate for the material system you select in Step 1. Step 3: Determine the level of EMI shielding required. Step 4: Select the components. Step 1. Select the Material System. Detailed in Table 2 on the next page are the major material systems for use in a wide range of operating conditions and environments. Choose a material system that: n n Has the physical characteristics your harness requires. Will accommodate the operating temperature and the fluids and abuse to which the harness will be exposed. Each step is described on the pages that follow. A selection table accompanies each step. You can also use HarnWare software to design your harness. VITON is a trademark of Dupont Dow Elastomers LLC 2-16 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 2. Material System Selection Operating temperature Physical characteristics Flammability Typical applications Operating temperature Physical characteristics Flammability System 20 -55°C to +121°C [-67°F to +250°F] • Environmentally sealed • Tough • Flexible • Low profile • Flame-retarded • Self-extinguishing • Resists most commonly used military fuels, oils, and greases • Used in high-performance industrial applications, and in military communication and test equipment. • Specially suited to military vehicles and engine compartments, low profile shapes save space and weight. System 25 -75°C to +150°C* [-103°F to +302°F] • Environmentally sealed • Rugged • Abrasion-resistant • Very flexible • Flame-resistant • Self-extinguishing • Resists most common military fuels, oils, and greases. up to 70°C [158°F]. • Specially suited to military vehicles, aerospace and marine applications, and communication and test equipment. System 30 System 100 System 200 -55°C to +150°C [-67°F to +302°F] • Environmentally sealed • Tough • Flexible • Low profile -30°C to +105°C [-22°F to +221°F] • Environmentally sealed • Flexible -55°C to +200°C [-67°F to +392°F] • Environmentally sealed • Very flexible • Flame-retarded • Self-extinguishing Fluid resistance • Resists most of commonly used military fuels, oils, and greases. Typical applications • Specifically suited to military vehicles and engine compartments for higher temperature applications, low profile shapes save space and weight. • Low toxicity index (as defined by NES-13) • Low smoke emission (as defined by NES-711) • Low corrosive gas evolution • Resistant to a range of military fuels, oils, and greases. • Specially suitable for confined habitat areas in military and civil applications. • Extensively used in surface and submarine vessels and underground railways • Highly flame-retardant • Resists long-term immersion in military fuels, oils, and greases at elevated temperatures. Used where there is prolonged exposure to high temperatures. Used where a harness may be permanently immersed in difficult fuels, such as in fuel tanks. • • 2 Electrical Interconnection System Design Fluid resistance System 10 -20°C to +60°C [-4°F to +140°F] • Environmentally sealable • Lightweight • Small diameter • Flexible • Flame-retardant • Self-extinguishing • Resists common industrial and military cleaning solvents and degreasers. System 300 Operating temperature -55°C to +200°C [-67°F to +392°F] Physical characteristics • Environmentally sealed • Highly abrasion resistant • Low profile Flammability • Highly flame-retardant Fluid resistance Typical applications • Performs in aggressive fluids at extremely high temperatures • Permanent immersion in aggressive fluids *Per VG 95343. 2-17 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Raychem Harnessing Systems and Their Components — NBC Survivable Systems* w NeProduct System System 780 770 44 55 Wire RT-770 RT-780 Tubing -770 -780 Molded part S-1264 S-1255-04 Adhesive RT-375 RT-375 Marker sleeve cover Marker sleeve** TMS-SCE NBC-SCE **Tyco Electronics Identification products information available at www.tycoelectronics.com. Components System 790 55 RT-790 -790/-791 S-1255-04 RT-375 NBC-SCE 2005 Material System Selection Operating temperature Physical characteristics Flammability Fluid resistance Typical applications Adhesive Selection System 770 -55°C to +125°C [-67°F to +257°F] • Environmentally sealed • NBC resistant • Flexible • Flame retarded • Self-extinguishing • Resistant to NBC uptake and decontamination • Base-line system for NBC resistant applications System 780 -65°C to +175°C [-85°F to +347°F] • Environmentally sealed • NBC resistant • Flexible • Flame retarded • Self-extinguishing • Resistant to NBC uptake and decontamination • High temperature system for NBC resistant applications System 790 -65°C to 200°C [-85°F to +392°F] • Environmentally sealed • NBC resistant • Flexible • Flame retarded • Self-extinguishing • Resistant to NBC uptake and decontamination • Extreme high temperature system for NBC resistant applications Material System System 770 Adhesive Type Two-part Epoxy Component Adhesive S-1264 Precoated Adhesive Designation — Service Temperature 150°C System 780 Thermoset tape S-1255-04 — 200°C System 790 Thermoset tape S-1255-04 — 200°C *Under Development - contact Tyco Electronics for additional information 2-18 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Step 2. Select the Adhesive System. Two types of adhesives are used to bond heat-shrinkable boots and transitions to tubing or wire jacketing: n n Thermosets, which include epoxies and other two-part systems. 2 Electrical Interconnection System Design Thermoplastics, which include pre-coated meltable adhesives applied to parts during manufacture and those applied as meltable tapes during assembly. Table 3 below outlines the differences between thermosets and thermoplastics. Table 4 shows which adhesive type is appropriate for each harness material system. Table 3. Comparison of Adhesive Types Method of adhesion Application Cure time Strength Disassembly Repair/reassembly Table 4. Adhesive Selection Thermoset Cures through chemical reaction. Two-part types require mixing and application at assembly. Varies with cure temperature. Oven cure usually desirable. Retains most strength at elevated temperatures. Items can be forcibly peeled apart when heated sufficiently. Requires new adhesive or hot rollback to reenter behind connector without affecting adhesive bonds. Material System Adhesive Type System 10 Thermoplastic System 20 System 25 System 30 System 100 System 200 Thermoplastic Component Adhesive S-1030 Thermoplastic Melts, flows, and solidifies. Precoated types require no preparation at assembly. Not required. Adhesive functional when cooled to room temperature. Loses strength as melt temperature is approached. Items can be separated when heated to temperature of the adhesive. Can be reheated to form new bond if sufficient adhesive remains. Precoated Adhesive Designation /180 Service Temperature 80°C S-1017 /42 60°C S-1124 /164 105°C S-1048 /86 120°C Thermoplastic S-1048 /86 120°C Two-part thermoset S-1125 /225 150°C Thermoset Tape S-1255-04 — 200°C 150°C Two-part thermoset Thermoplastic S-1125 — S-1030 /180 80°C S-1048 /86 120°C Two-part thermoset S-1125 — 150°C Two-part thermoset S-1125 — 150°C Thermoset tape S-1255-04 — 200°C System 300 Thermoset tape S-1255-04 — 200°C System 770 — S-1264 — — System 780 Thermoset tape S-1255-04 — 200°C System 790 Thermoset tape S-1255-04 — 200°C 2-19 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Step 3. Determine the Level of EMI Shielding Required. Tyco Electronics offer several methods and technologies for controlling electromagnetic interference (EMI) and noise in cable harnesses. Developed in response to well-established threats in military and other harsh environments, these technologies can be employed in compatible shielding (screening) systems to achieve the level of shielding required for a harness system. Table 5 on page 2-22 outlines the shielding requirements for various types of threat and levels of interference. Introduction This section is intended as a guide for the use of harness designers who are required to achieve a level of EMI control in their design practices. It is not intended that it should be a definitive statement on all aspects of EMI control for harnesses. In case of difficulty contact us for further clarification or consultancy. For well-designed EMI control of electrical systems it is essential that a detailed knowledge of the system requirements and susceptibility be obtained. The chosen level of shielding will be dependent on the: n n n n n Susceptibility of electrical system. For the most cost effective design of harnesses, which offer a long-term stability in performance, the system should be designed to achieve a balance of component characteristics. Components should only be used if they are qualified to a minimum level of EMI performance and the performance and test method should be applicable to the design technique being used. For quality assurance purposes minimum EMI characteristics should always be specified and for critical harnesses the complete performance should be measured. The technique to be adopted should always be specified. Finally the inter-relationship between harnesses and the protection, termination and grounding of equipment boxes is vital for good system performance against EMI. All components form part of the external shield on the system and therefore should be considered in the overall EMI design process. Subjects covered in this topic are: n n Harness Types - point to point and branched Shielding Levels calculations Types of components used. Harness Types Harnesses are divided into two types, point-to-point and branched. The advantages and disadvantages of each from an EMI control standpoint are described below. No attempt has been made to analyze their relative merits in mechanical or installation terms. Point To Point: The three major components of this type of harness are: connectors, cable, and connector accessories. Connectors There are many different types of circular military connectors. However, for a well-shielded harness only those connectors having a guaranteed performance level should be used e.g. MIL-C-26482 Series II and MIL-C-38999 series 1 and 2, and series 3 and 4. Cable Cable used in this type of harness is generally machine made. Hand laid cables may also be used but generally the shields incorporated in these harnesses vary in consistency of performance. In the case of machine made cables all shields should be designed for optimum shielding effectiveness at radio frequency. Physical layout of the system. Equipment practices adopted. Anticipated EMI threat. 2-20 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Transitions Connector accessories, such as Raychem adapters, are available in many styles and therefore their performance varies with construction. For a level of consistency in performance it is essential that, as with connectors, a guarantee in performance level be achieved. Fittings not specified in this way may significantly degrade the overall system performance. Transitions, as with accessories, are very susceptible to performance variability with construction type. Branched In addition to those components described above, branched harnesses include transitions. This type of harness is usually made by hand and it is therefore difficult to incorporate accurately made machine fabricated shields. The implications of this are: Shields Cable shields may be put on by hand or by feeding through a braiding machine. However, as braid optimization depends on all the constructional parameters of the braid being accurately specified, unless braid is well constructed the shielding performance can suffer dramatically. Reductions in shield performance of 20-40 dB have been measured on badly made branched harnesses. The alternative method is to use pull on braids. If the cable bundle diameter is known the braid may be designed for optimized performance. For high performance harnesses these components should also have a guaranteed performance. In general the use of techniques such as hand soldering or the use of butted tape wraps are not recommended except where only a low performance of less that 40dB is required. Shield performance is specified in two ways, either as a power relationship in decibels (dB) or as an absolute measurement of the shield performance in terms of the surface transfer impedance. Except for very specific low frequency problems it is general to specify the performance at frequencies in the range 0.1MHz to 100MHz. 2 Electrical Interconnection System Design Connector Accessories Shielding Levels and Component Performance System Performance To specify the overall requirements of a complete electronic system in terms of its EMI characteristics it is necessary to consider the performance of the individual components parts. The harnesses form one of the major entry points for interference and this as such can degrade a complete system performance by a significant amount. In general terms, assuming that a shielded harness system is used, with the available components on the market the overall harness system performance and typical applications may be as below. n n n n n 40 to 50 dB Standard shielded systems for insensitive systems. 50 to 60 dB Military standard shielded systems for general applications. 60 to 80 dB As above but where full threat EMP & TEMPEST protection is required. 80 to 100 dB Severe TEMPEST and very sensitive systems. Over 100 dB Exceptional shielding requirements only. 2-21 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Safety Margins Connectors As with all designs EMI system design should not be performed to the “limit of performance safety margin should always be incorporated when determining the minimum shielding level appropriate for consistent operation of the system. A study of those connector specifications having an EMI test shows that they are generally specified in the frequency band 100MHz to 1GHz. For an assessment at lower frequencies the low frequency performance as dictated by the d.c. resistance of the connector is required. These two parameters enable the EMI characteristic to be made of the complete connector performance. Typical values for standard connectors are 65dB (MIL-C-26482 Series II) and 90dB (MIL-C-38999 Series III) connectors. The inter-relationship of shielding effectiveness measured in decibels and the surface transfer impedance in ohms presents the designer with a conversion difficulty. External harness circuits vary, as do the coupling characteristics and it is therefore only possible to give an approximate conversion. The normal conversion from decibels to ohms and vice versa is to a reasonable approximation: Screening Effectiveness (dB) = 36 – 20 log 10 (ZT (Ohms)) The constant term is developed from the expressions for the characteristic impedance of the line formed by the harness shield and the ground plane and the internal characteristic impedance of the inside of the harness. The translation from shielding effectiveness to surface transfer impedance is shown below in Table 5 for S.E. from 20 to 105dB. Table 5 - Screening Effectiveness (SE)/Surface Transfer Impedance (Zt) Relationships S.E. (dB) ZT (ohms) S.E. (dB) ZT (ohms) 20 25 30 35 40 45 50 55 60 6.309 3.548 1.995 1.122 0.631 0.355 0.200 0.112 0.063 65 70 75 80 85 90 95 100 105 0.0355 0.0200 0.0112 0.0063 0.0036 0.0020 0.0011 0.0006 0.0004 2-22 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Connector Accessories and Transitions In constructional terms the performance of the connector accessory includes both the resistive terminations to the cable shield and the connector. However, it is most unusual to specify the performance of an accessory and this is a distinct weakness in the design of harnesses. The reason is that the performance is extremely variable as accessories have to fit a variety of different cable sizes and shapes. Where specified at all the relationship between the test method and the coupling mechanism for the EMI must be considered. Table 6 - Cable Performances Type of Screen Single optimized braid Double optimized braid Superscreened (2 braids + 1 wrap) 2 Electrical Interconnection System Design Cable In accordance with most common cable specification the shielding performance of a cable is specified at 30MHz. It is also well into the band where inductive leakage is the primary penetration characteristic. For frequencies above or below 30Mhz, approximations, as for connectors, must be made. It should be noted that the performance specified at 30MHz in Table 6 for different cable types is the maximum that is allowed using Tyco Electronics’ standard Q.C. values. Actual performance may be up to 20dB better. Diameter under screen Surface transfer Impedance Zt (mm) Up to 7.5 7.6 and up Up to 7.5 7.6 and up Up to 7.5 7.6 and up @ 30 Mhz (maximum) 100 milli ohms/metre 50 milli ohms/metre 10 milli ohms/metre 5 milli ohms/metre 100 micro ohms/metre 50 micro ohms/metre 2-23 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Connector Terminator Splice Transition Feedthrough Cable Braid Complete Harness When considering the complete harness the coupling calculations are relatively simple. In general terms they are the addition of all the individual leakages within the system from connector to connector. The analysis route is therefore as follows: 1. Convert all decibel values at the desired frequency to surface transfer impedance. 2. Choose components for a ‘balanced’ system, i.e. the components should have approximately the same performance. 3. Add the values determined for surface transfer impedance of the components at the frequency chosen. 4. Reconvert to decibels if necessary. (Table 5 can be used for this purpose) As a guide to the shielding performance that can be expected from a harness that is constructed using Raychem components, Table 7 on the next page has been compiled to help in the product selection process. For branched harnesses it is necessary to determine whether every branch has the same susceptibility requirements or carries the same signals of power. The performance requirement of each branch is then determined and the matrix for the harness established. This is a more complex subject and not discussed here. System improvements may be achieved by changing either the connectors or cable. In general terms changing from a single to a double optimized braid improves the performance of that component by 20-25 dB. A similar advantage is achieved by changing from MIL-C-26482 Series II to MIL-C-38999 Series I connectors. However, the relative significance, as part of the system, of each component must be considered to determine the true weighting effect. For the optimum in system design a balance of component performances should be achieved wherever possible such that each of the components is of similar performance level. General Considerations Although cables and harnesses are considered to be the most significant in terms of coupling into systems the construction of equipment boxes can play an important part in the overall EMI performance of a system. With the increasing use of high speed digital circuits and the generation of harmonics having high energy content relatively short printed circuit board tracks can radiate or pick up energy as efficiently as cables. If the boxes themselves are not adequately protected these circuits may constitute an EMI threat. There is a further area of significance in the EMI protection of the boxes and this is the connector/ box interface. The junction may be considered to be a part of the harness system and any degradation in it may cause an overall harness degradation. 2-24 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnection System Design Integrated Military Harness Systems for Defense and Allied Industries (Continued) Table 7 - Screen System Guide Adapter Styles Harness System Components Termination Cable Braid (max. length in m/ft) TinelRayaten (by cable construction) Lock Assembly SO DO SSS System NO Connector 1,000,000 hours n 8 Electrical Interconnect Products Applications The low-profile configuration of these couplers enables avionics system designers to plan for optimum coupler locations. Microcouplers are supplied with Raychem SPEC 55 data bus cables, Specifications/Approvals Available in: Americas Europe Asia Pacific including EMP-hardened versions. They are also available assembled with other components into a complete data bus harness. Series D-500-04 Military MIL-STD-1553B Raychem D-6020 n n n 8-79 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Product Selection Single Stub Double Stub D-500-0455-1-YYY-ZZZ D-500-0455-2-YYY-ZZZ D-500-0465-1-YYY-ZZZ D-500-0465-2-YYY-ZZZ D-500-0456-1-YYY-ZZZ D-500-0456-2-YYY-ZZZ D-500-0466-1-YYY-ZZZ D-500-0466-2-YYY-ZZZ D-500-0457-1-YYY-ZZZ D-500-0457-2-YYY-ZZZ D-500-0467-1-YYY-ZZZ D-500-0467-2-YYY-ZZZ D-500-0458-1-YYY-ZZZ D-500-0458-2-YYY-ZZZ D-500-0468-1-YYY-ZZZ D-500-0468-2-YYY-ZZZ Note: 1. Bus cable 2. Stub cable 8-80 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components In-Line Microcouplers: One- and Two-Stub (Continued) Microcoupler Part Numbering System D-500-04 W W - X- YYY - ZZZ Standard Cable Length 012 = 12 in (1 ft) 078 = 78 in (6.5 ft) 079 = 79 in (2 m) 120 = 120 in (10 ft) 236 = 236 in (6 m) 240 = 240 in (20 ft) 360 = 360 in (30 ft) Cable Type 612 = 1061224 AWG single optimized shield 613 = 1061324 AWG double optimized shield 614 = 1061424 AWG EMP hardened H06 = 7724H0664 (24 AWG Flat Wire Unfilled) Number of Stubs 1 or 2 Design 5 = Without internal terminator 6 = Same as 5 but with reverse bus 7 = With internal terminator 8 = Same as 7 but with reverse bus Boot 5 = Without mounting eyelet 6 = With mounting eyelet 8 Electrical Interconnect Products 8-81 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub Product Facts n Environmental sealing No connectors n Very small size n Ultra Light weight (1 stub: 6.5 g max.; 2 stubs: 9.5 g max.) n In-line profile that makes wire bundle mounting possible n 360° continuous lowimpedance cable-shield terminations n Reliable solder termination of all components n Potted circuit elements for maximum durability and in-use reliability n Ease of installation n Altitude immersion resistance n Mean time between failures > 1,000,000 hours n Applications Building on over 20 years of experience and continuous improvement in data bus, including pioneering in-line microcouplers, Tyco Electronics introduces a new family of ultra lightweight In-line Raychem Microcouplers, available in 1- through 6-stub configurations. These couplers offer the same high performance and reliability as Raychem current microcouplers, but their weight is further reduced. They are available in configurations up to 6stub, and minimize weight there is no option with a mounting eyelet. Combined with Raychem 24 AWG data bus cables, these ultra light couplers allow designers to significantly reduce weight. An unfilled flat braid cable is available for additional weight savings. They are also available assembled with other customer specified components into a complete factory-built and tested data bus harness. Specifications/approvals Series D-500-L4xx Available in: Americas Europe Asia Pacific Military MIL-STD-1553B Raychem D-6020 (same as current microcouplers) n n n 8-82 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Lightweight In-Line Couplers Part Numbering System D-500-L4 5 W -X -YYY -ZZZ Cable Length 012 = 12 in 079 = 79 in 078 = 78 in 120 = 120 in 236 = 236 in 240 = 240 in 360 = 360 in Cable Type 612 = 10612 (24 AWG single optimized shield) 613 = 10613 (24 AWG double optimized shield) 614 = 10614 (24 AWG EMP hardened) H06 = 7724H0664 (24 AWG flat shield, unfilled) Lightest cable Number of Stubs 1, 2, 3, 4, 5 or 6 Design 5 = Without internal terminator 7 = With internal terminator Style 5 = Without eyelet 8 Electrical Interconnect Products 8-83 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued) Product Selection D-500-L455-X-YYY-ZZZ End View Left Side D-500-L456-X-YYY-ZZZ End View Right Side End View Left Side End View Right Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub D-500-L457-X-YYY-ZZZ End View Left Side D-500-L458-X-YYY-ZZZ End View Right Side End View Right Side End View Left Side 1 stub 1 stub 2 stub 2 stub 3 stub 3 stub 4 stub 4 stub 5 stub 5 stub 6 stub 6 stub Legend Bus cable Stub cable 8-84 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Box Couplers Product Facts n Light, robust coupler modules with connector versatility n Up to eight stub connectors can be arrayed on the “face” of the box coupler. Bus connectors can also be on the “face” or on the “side” of the box n Designed with Raychem D-621 series corrosionresistant threaded-type or bayonet-type connectors Applications The multiport capability of these couplers (up to eight stubs) enables avionics system designers to interconnect black boxes with minimum wire runs. Box couplers are supplied with Raychem triaxial threaded or bayonet connectors. 8 Electrical Interconnect Products Note: Tyco Electronics also designs and manufactures customized Raychem data bus box couplers. Specifications/Approvals Available in: Americas Europe Asia Pacific Series D-500-0255 Military MIL-STD-1553 Raychem D-6021 n n n 8-85 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Box Couplers (Continued) Product Selection Coupler Type Part No. Face - 1 Stub Face - 2 Stub Face - 3 Stub Face - 4 Stub Face - 5 Stub Face - 6 Stub Face - 7 Stub Face - 8 Stub Threaded D-500-0255-511-1 D-500-0255-521-1 D-500-0255-531-1 D-500-0255-541-1 D-500-0255-551-1 D-500-0255-561-1 D-500-0255-571-1 D-500-0255-581-1 Bayonet A* D-500-0255-513-1 D-500-0255-523-1 D-500-0255-533-1 D-500-0255-543-1 D-500-0255-553-1 D-500-0255-563-1 D-500-0255-573-1 D-500-0255-583-1 Bayonet B* D-500-0255-515-1 D-500-0255-525-1 D-500-0255-535-1 D-500-0255-545-1 D-500-0255-555-1 D-500-0255-565-1 D-500-0255-575-1 D-500-0255-585-1 Bayonet C* D-500-0255-517-1 D-500-0255-527-1 D-500-0255-537-1 D-500-0255-547-1 D-500-0255-557-1 D-500-0255-567-1 D-500-0255-577-1 D-500-0255-587-1 Side - 1 Stub Side - 2 Stub Side - 3 Stub Side - 4 Stub Side - 5 Stub Side - 6 Stub Side - 7 Stub Side - 8 Stub D-500-0255-512-1 D-500-0255-522-1 D-500-0255-532-1 D-500-0255-542-1 D-500-0255-552-1 D-500-0255-562-1 D-500-0255-572-1 D-500-0255-582-1 D-500-0255-513-2 D-500-0255-523-2 D-500-0255-533-2 D-500-0255-543-2 D-500-0255-553-2 D-500-0255-563-2 D-500-0255-573-2 D-500-0255-583-2 D-500-0255-515-2 D-500-0255-525-2 D-500-0255-535-2 D-500-0255-545-2 D-500-0255-555-2 D-500-0255-565-2 D-500-0255-575-2 D-500-0255-585-2 D-500-0255-517-2 D-500-0255-527-2 D-500-0255-537-2 D-500-0255-547-2 D-500-0255-557-2 D-500-0255-567-2 D-500-0255-577-2 D-500-0255-587-2 *The bayonet polarization listed is for the bus connector. All stub connectors are Bayonet D polarization. Polarizations are depicted as follows (jack view): 1=A 2=B 3=C 4=D 8-86 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Discrete Connectors Product Facts n Compliance with MIL-STD-1553B hardware requirements n Light weight n Removable pin or socket contacts n Termination with Raychem MIL-STD-1553B data bus cables, including EMPhardened versions n Continuous 360° shield coverage n Rugged constructions n Termination time of 1 to 2 minutes n Inspectable solder terminations n Low-skill assembly n Reworkable and repairable terminations n Strain relief built into the design n Low-voltage drop and high reliability because of precisely controlled solder terminations n Threaded and bayonet coupling styles n Low total installed cost n 1000-hour salt spray resistance n Lower-cost connectors, for benchtop and mock-up Available in: Americas Europe Asia Pacific Designed specifically for MIL-STD-1553B data bus applications, the D-621 connector is intended to be a perfect match for the Raychem airworthy data bus cable. Together they provide durable, reliable, and reworkable interconnection hardware for the MIL-STD-1553B market. Series DK-621 8 Military MIL-STD-1553B Electrical Interconnect Products Specifications/Approvals Applications Raychem D-6025 n n n 8-87 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Discrete Connectors (Continued) Connector Kit Part Numbering System DK-621-04 XX-XX Contact (supplied in DK-621 kits only) P = Pin S = Socket Polarization (bayonet styles only) (jack view) 1=A 2=B 4=D 3=C Basic Connector Configurations Threaded styles 11 = Plug 12 = Jack Bayonet styles 33 = Plug, A polarization 34 = Jack, A polarization 35 = Plug, B polarization 36 = Jack, B polarization 37 = Plug, C polarization 38 = Jack, C polarization 39 = Plug, D polarization 40 = Jack, D polarization D-621 connector, kitted with accessories Example: DK-621-0434-1P = D-621 connector, kitted with accessories, jack bayonet style with A polarization and pin contact. 8-88 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories Product Facts n A single source for all harness components n Products designed to work together 8 Available in: Americas Europe Asia Pacific n n n Electrical Interconnect Products These include: Applications Tyco Electronics manufactures all the products needed to build a MIL-STD1553B data bus network. In addition to the main components (couplers, connectors, contacts, and cables), Tyco Electronics supplies the accessory components that may be necessary to complete a data bus system. n n n n n Bus and stub terminators (spliced-in and connectorized D-621 series). Cable splice kits. EMI/environment-resistant connector caps. Braid terminators and strain relief tubing (for rework applications). Cable marking materials. 8-89 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Product Selection D-621 Plug D-621 plug D-621 Jack D-621 jack Splice-in Splice-in Bus and Stub Terminators Spliced-in 77-ohm 10612 cable 77-ohm 10613 cable 77-ohm 10614 cable 77-ohm 7724H0664 cable 12-inch Cable D-500-0463-612 D-500-0463-613 D-500-0463-614 D-500-0463-H06 D-621 Series—Plug 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact 1 = A 2 = B 3 = C 4 = D Threaded D-621-0413 D-621-0415 D-621-0417 D-621-0407 Bayonet A D-621-0453 D-621-0469 D-621-0457 D-621-0473 Bayonet B D-621-0454 D-621-0470 D-621-0458 D-621-0474 Bayonet C D-621-0455 D-621-0471 D-621-0459 D-621-0475 Bayonet D D-621-0456 D-621-0472 D-621-0476 D-621-0460 D-621 Series—Jack 77-ohm pin contact 77-ohm socket contact 3000-ohm pin contact 3000-ohm socket contact Threaded D-621-0418 D-621-0406 D-621-0423 D-621-0424 Bayonet A D-621-0477 D-621-0461 D-621-0481 D-621-0465 Bayonet B D-621-0478 D-621-0462 D-621-0482 D-621-0466 Bayonet C D-621-0479 D-621-0463 D-621-0483 D-621-0467 Bayonet D D-621-0480 D-621-0464 D-621-0484 D-621-0468 D-621 Series—L Lanyard 7” — — — — Connector Caps D-621 Series Plug cap for jack connector Supplied with 7” Lanyard Threaded Bayonet A Bayonet B Bayonet C Bayonet D D-600-0083 D-600-0068 D-600-0068 D-600-0068 D-600-0065 Cable Splice Kits Cables All data bus cables Flexible Crimp D-150-0708-5 8-90 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Terminator and Connector and Compatibility — Bayonet and Threaded Connectors Panel Thickness Connector Contact Terminator Reference Standard Connector Mate with Long Reach Connector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0453(-L) D-621-0469(-L) D-621-0477(-L) D-621-0461(-L) D-621-0457(-L) D-621-0473(-L) D-621-0481(-L) D-621-0465(-L) DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0550-1S DK-621-0550-1P — — DK-621-0550-1S DK-621-0550-1P — — Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0454-(-L) D-621-0470-(-L) D-621-0478-(-L) D-621-0462-(-L) D-621-0458-(-L) D-621-0474-(-L) D-621-0482-(-L) D-621-0466-(-L) DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0548-2S DK-621-0548-2P — — DK-621-0548-2S DK-621-0548-2P — — Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0455(-L) D-621-0471(-L) D-621-0479(-L) D-621-0463(-L) D-621-0459(-L) D-621-0475(-L) D-621-0483(-L) D-621-0467(-L) DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0546-3S DK-621-0546-3P — — DK-621-0546-3S DK-621-0546-3P — — Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0456(-L) D-621-0472(-L) D-621-0480(-L) D-621-0464(-L) D-621-0460(-L) D-621-0476(-L) D-621-0468(-L) D-621-0484(-L) DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0551-4S DK-621-0551-4P — — DK-621-0551-4S DK-621-0551-4P — — Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket D-621-0413(-L) D-621-0415(-L) D-621-0418(-L) D-621-0406(-L) D-621-0417(-L) D-621-0407(-L) D-621-0423(-L) D-621-0424(-L) DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0512-S DK-621-0512-P — — DK-621-0512-S DK-621-0512-P — — Bayonet Connectors Polarity A 77 Ohm bus terminator 3K Ohm stub terminator Polarity B 77 Ohm bus terminator 3K Ohm stub terminator Polarity C 77 Ohm bus terminator 3K Ohm stub terminator 8 Polarity D 3K Ohm stub terminator Electrical Interconnect Products 77 Ohm bus terminator Threaded Connectors 77 Ohm bus terminator 3K Ohm stub terminator 8-91 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility — Bayonet and Threaded Connectors Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0433-1P DK-621-0433-1S DK-621-0434-1P DK-621-0434-1S DK-621-0550-1P DK-621-0434-1S DK-621-0434-1P DK-621-0433-1S DK-621-0433-1P DK-621-0433-1S D-621-0461(-L) D-621-0477(-L) D-621-0461(-L) D-621-0453(-L) D-621-0469(-L) D-621-0465 (-L) D-621-0481(-L) D-621-0473(-L) D-621-0457(-L) D-621-0473(-L) 12.5mm max. Jack Socket DK-621-0550-1S DK-621-0433-1P D-621-0453(-L) D-621-0457(-L) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0435-2P DK-621-0435-2S DK-621-0436-2P DK-621-0436-2S DK-621-0448-2P DK-621-0436-2S DK-621-0436-2P DK-621-0435-2S DK-621-0435-2P DK-621-0435-2S D-621-0462(-L) D-621-0478(-L) D-621-0470(-L) D-621-0454(-L) D-621-0470(-L) D-621-0474 (-L) D-621-0458(-L) D-621-0474(-L) D-621-0458(-L) D-621-0467(-L) 12.5mm max. Jack Socket DK-621-0448-2S DK-621-0435-2P D-621-0454(-L) D-621-0483(-L) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0437-3P DK-621-0437-3S DK-621-0438-3P DK-621-0438-3S DK-621-0446-3P DK-621-0438-3S DK-621-0438-3P DK-621-0437-3S DK-621-0437-3P DK-621-0437-3S D-621-0463(-L) D-621-0479(-L) D-621-0471(-L) D-621-0455(-L) D-621-0471(-L) D-621-0467(-L) D-621-0483(-L) D-621-0475(-L) D-621-0459(-L) D-621-0475(-L) 12.5mm max. Jack Socket DK-621-0446-3S DK-621-0437-3P D-621-0455(-L) D-621-0459(-L) Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0439-4P DK-621-0439-4S DK-621-0440-4P DK-621-0440-4S DK-621-0551-4P DK-621-0440-4S DK-621-0440-4P DK-621-0439-4S DK-621-0439-4P DK-621-0439-4S D-621-0464(-L) D-621-0480(-L) D-621-0472(-L) D-621-0456(-L) D-621-0472(-L) D-621-0468(-L) D-621-0484(-L) D-621-0476(-L) D-621-0460(-L) D-621-0476(-L) Jack Socket DK-621-0551-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L) Standard 2.4mm max. Long Reach Plug Plug Jack Jack Jack Pin Socket Pin Socket Pin DK-621-0411-P DK-621-0411-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0412-S DK-621-0412-P DK-621-0411-S DK-621-0411-P DK-621-0411-S D-621-0406(-L) D-621-0418(-L) D-621-0415(-L) D-621-0413(-L) D-621-0415(-L) D-621-0424(-L) D-621-0423(-L) D-621-0407(-L) D-621-0417(-L) D-621-0407(-L) 12.5mm max. Jack Socket DK-621-0412-S DK-621-0411-P D-621-0413(-L) D-621-0417(-L) 3K Ohm Stub Terminator Bayonet Connectors Polarity A Polarity B Polarity C Polarity D Standard 2.4mm max. Long Reach 12.5mm max. Threaded Connectors 8-92 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Accessories (Continued) Triaxial Connectors and Terminator Compatibility — to European norme 3716 Panel Thickness Connector Contact Connector Reference Connector Mate with 77 Ohm Bus Terminator 3K Ohm Stub Terminator Plug Plug Plug Plug Jack Jack Jack Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket Pin DK-3716-F101-TP DK-3716-F101-TS DK-3716-F201-TP DK-3716-F201-TS DK-3716-E102-TP DK-3716-E102-TS DK-3716-E202-TP DK-3716-E202-TS DK-3716-E112-TP DK-621-E102-TS DK-621-E102-TP DK-621-E202-TS DK-621-E202-TP DK-621-F101-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP DK-621-F101-TS D-621-E077-S D-621-E077-P D-621-E077-S D-621-E077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-F077-P D-621-F077-S D-621-E03K-S D-621-E03K-P D-621-E03K-S D-621-E03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S D-621-F03K-P D-621-F03K-S Jack Jack Jack Socket Pin Socket DK-3716-E112-TS DK-3716-E212-TP DK-3716-E212-TS DK-621-F101-TP DK-621-F201-TS DK-621-F201-TP D-621-F077-P D-621-F077-S D-621-F077-P D-621-F03K-P D-621-F03K-S D-621-F03K-P Triaxial Connectors Standard 2.4mm max. Long Reach 12.5mm max. Panel Thickness Mate with Connector Contact Terminator Reference Standard Connector Long Reach Connector Plug Plug Jack Jack Plug Plug Jack Jack Pin Socket Pin Socket Pin Socket Pin Socket DK-3716-F077-P DK-3716-F077-S DK-3716-F077-P DK-3716-F077-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E03K-P DK-3716-E03K-S DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP DK-3716-E#02-TS DK-3716-E#02-TP DK-3716-E#01-TS DK-3716-E#01-TP DK-3716-E#12K-TS DK-3716-E#12K-TP — — DK-3716-E#12K-TS DK-3716-E#12K-TP — — Terminators 77 Ohm bus terminator 3K Ohm stub terminator 8 Electrical Interconnect Products 8-93 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Triaxial Size 8 Contacts Product Facts n One-step termination Termination time of 1 to 2 minutes n No requirements for special termination tools n No requirements for special skills n Reworkable and repairable terminations n Strain relief n Continuous 360° shield coverage n Triaxial mating face for least susceptibility to damage n Rugged construction, because only two parts are being soldered together n Inspectable solder terminations n Low voltage drop and high reliability due to precisely controlled solder termination n Applications Contacts provide full shield coverage with a simple, quick, and reliable termination system. 24 AWG twisted-pair data bus cables are terminated with triaxial SolderTacts contacts, which fit size 8 cavities of MIL-C-38999, Series 1, 3, or 4 connectors. Specifications/Approvals Product Selection Available in: Americas Europe Asia Pacific Raychem size 8 triaxial data bus contacts for MIL-C-38999 connectors have interfaces that comply with MIL-C-39029/90 and /91 to provide ease of termination, and intermateability with more cumbersome crimp contacts. Series Size 8 These contacts provide a fast and convenient method of implementing MIL-STD-1553B connections in MIL-STD-1760 applications. Raychem D-6002 Cable Type 10612 10613 10614 Pin DK-602-0156-N-1 DK-602-0156-N-2 DK-602-0156-N-3 Socket DK-602-0157-N-1 DK-602-0157-N-2 DK-602-0157-N-3 n n n 8-94 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components Product Facts n Complete line of spacequalified MIL-STD-1553B components n Low outgassing levels that meet NASA requirements n Light weight n Rugged construction Figure 1. In-line couplers and terminators Applications Figure 2. Threaded triaxial connectors Figure 3. Bayonet triaxial connectors Raychem space-grade components are designed in a variety of configurations and are currently available either as discrete items or as Raychem- assembled harnesses. Using factorybuilt harnesses eliminates unnecessary splices and connectors, reducing the cost and increasing the reliability of the networks. Figure 4. Splice kit Specification control drawings describe the design Available in: Americas Europe Asia Pacific features and performance characteristics of Raychem space-grade couplers, terminators, connectors, and splices. The spacegrade data bus couplers, terminators, and connectors have tin/nickel-plated metallic parts and baked silicone rubber components. For strain relief they include low-outgassing tubing. Unlike parts intended for aircraft applications, these components do not have polymeric environmental covers. 8 Electrical Interconnect Products Tyco Electronics full line of Raychem data bus products includes space-grade couplers, terminators, triaxial connectors, and SolderShield splices. These space-grade components meet the low outgassing requirements of NASA specification SP-R-0022A and can be used in outerspace applications. The table on the next page lists Raychem standard space-grade data bus components with their part numbers and descriptions. New components will become available per customer request. n n n 8-95 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Specifications/Approvals Series Space-grade data bus components Raychem D-6022 Space-Grade In-Line Coupler Part Numbering System D-500-94 W W -X -YYY -ZZZ Cable Length 012 = 12 in 078 = 78 in 079 = 79 in 120 = 120 in 236 = 236 in 240 = 240 in 360 = 360 in Cable Type S16 = 7724S1664 (24 AWG single optimized shield) S36 = 7724S3664 (24 AWG double optimized shield) S86 = 7724S8664 (24 AWG EMP hardened) H06 = 7742H0664 flat shield, unfilled (lightest cable) Number of Stubs 1, 2, 3, or 4 Design 5 = Without internal terminator 6 = Same as 5 but with reverse bus 7 = With internal terminator 8 = Same as 7 but with reverse bus Style 5 = Without mounting eyelet 6 = With mounting eyelet 8-96 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Space-Grade Data Bus Components (Continued) Space-Grade Connectors Part Numbering System DK-621 -09 XX -X X Contact (installed, DK-621 kits only) P = Pin* S = Socket* *May be ordered separately as D-602-0126 (pin) and D-602-0127 (socket) Polarization (bayonet styles only) (jack view) 1=A 2=B 4=D 3=C Basic Connector Configurations Threaded styles: 11 = Plug 12 = Jack Bayonet styles: 33 = Plug, A polarization 34 = Jack, A polarization 35 = Plug, B polarization 36 = Jack, B polarization 37 = Plug, C polarization 38 = Jack, C polarization 39 = Plug, D polarization 40 = Jack, D polarization D-621 Connector, Kitted with Accessories 8 Electrical Interconnect Products Space-Grade Terminators Part Numbering System D-500-9463- ZZZ Cable Type 612 = 10612 (24 AWG single optimized shield) 613 = 10613 (24 AWG double optimized shield) 614 = 10614 (24 AWG EMP hardened) H06 = 7724H0664 flat shield, unfilled (lightest cable) Space-Grade Splice Kit = D-150-9708-5 8-97 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Data Bus (MIL-STD-1553B) Components Customer-Specified Harness Assemblies and HarnWare Harness Design Software Tyco Electronics supplies complete Raychem data bus networks in accordance with customer harness drawings, with any customer-specified cables and/or connectors. Using factory-built harnesses eliminates unnecessary splices and connectors, reducing the cost and increasing the reliability of the networks. Factory-built harnesses are pre-tested and ready for installation. HarnWare Harness Design Software allows designers to draw a data bus harness in a matter of minutes, while selecting Raychem or others’ components; a bill of materials is automatically generated. Sample Drawing WHEELBAY 10 WHEEL BAY 2 1 12 D-600-XXXX ISSUE x LOT N˚ XXXX 4 1 3 NOSE 12 1 NOSE DATA BUS COUPLER Raychem Raychem Raychem DATA BUS COUPLER DATA BUS COUPLER 2 5 12 11 6 2 12 CMC1 2 12 12 8 STBD CMC2 CMC 1 7 9 CMC 2 STBD Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Description Data bus Cable Data bus Cable Data bus Coupler Data bus Coupler Data bus Coupler Data bus Terminator Data bus Contact Data bus Contact Data bus Connector Data bus Connector Data bus Connector Marker Sleeve Part No. 10613-9 10613-96 D-500-0455-1 D-500-0455-2 D-500-0457-1 D-621-0469-L DK-602-0156-N-2 DK-602-0157-N-2 DK-621-0411-P DK-621-0412-P DK-621-0434-1P TMS-SCE-3/16-2.0-9 Spec/Remarks Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Raychem Qty 5.3 7 1 1 1 1 1 1 1 1 1 6 Unit M M Pc Pc Pc Pc Pc Pc Pc Pc Pc Pc 8-98 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Introduction Product Facts n Superior EMC/EMI Shielding Performance n Simple installation n Easy reentry n Simplified maintenance and repair n Excellent mechanical and environmental resistance n Efficient strain relief n Flexibility n Versatility Applications Tyco Electronics, a longtime leader in harnessing technology, has written a new chapter in EMC shielding with the introduction of the Raychem HexaShield EMC adapter. n n n HexaShield adapters are simple to install, easy to Designed to corresponding connector specifications. Principal points and features n n n n n Easy reentry: To insert or remove ferrules from the HexaShield adapter, simply loosen the back nut. Superior protection: No degradation of shielding performance. Up to four shielded cables accommodated by each ferrule. Mechanical and environmental protection equal to backshells complying with MIL-C-85049 Category 3B. Strain relief on each individual cable. Two Platings Available Electroless nickel (MIL-DTL-26074) Olive drab cadmium (QQ-P-416 Type II Class 3) n n n Weight reduction, by possibly eliminating the need for overall shielding. Compact size - not exceeding outer diameter of connector. Available in straight, 45° and 90° angles, as well as swept and long bodies. 8 Simple assembly and installation 1. Solder cable or wire shield to a ferrule with a Raychem heat-shrinkable SolderShield terminator. 2. Clip ferrule into one of the grounding star cavities. 3. Secure the back nut of the HexaShield adapter so that the conic ring assembly automatically compresses the ferrules. Electrical Interconnect Products Available in: Americas Europe Asia Pacific Designed to provide EMC protection solutions for both commercial and military applications, HexaShield adapters represent a significant improvement over pigtail termination methods. By providing 360-degree EMC shielding on the termination area of each individual cable, HexaShield adapters provide outstanding shielding effectiveness. maintain, and dependably resistant to mechanical and environmental stresses. Raychem Product Specifications RB-110 and RB-114 — *Contact Tyco Electronics for additional platings. Installation Procedures Installation procedure for HET-A-02X and HET-A-04X (RPIP-696-00) Installation procedure for HET-03X (RPIP-696-03) General procedure for ARINC 600 Size II General procedure for cylindrical connectors (RPIP-696-01) connectors, straight body (RPIP-696-04) General procedure for ARINC 600 Size III — connectors (RPIP-696-02) General procedure for cylindrical connectors, right-angle body (RPIP-696-07) — — 8-99 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC/EMI Adapters Kit Descriptions Hexashield Adapters for Circular Connectors: Straight, 45°and 90° Assemblies Item 1 2 3 4 5 6 7 8 Description Straight adapter assembly Conic ring assembly Star Plain (Standard) Drilled (Option) Split (Option) _ Straight adapter assembly - “L” version - nominally 0.5" [12.7] longer body 45° adapter assembly - welded 45° adapter assembly - swept 90° adapter assembly - welded 90° adapter assembly - swept Standard products shown. Variants available on request. 1 1 2 2 3 3 c 4 Split star assemblies are shown on relevant S.C.D’s where applicable. Item -1 -2 -3 -C HexaShield Version Back Nut Tinel adapter assembly Tinel-Lock ring for single braid Bandstrap adapter assembly Conduit adapter 5 6 7 8 HexaShield Adapters for ARINC 404/600 Connectors: Sizes 1, 2, 3 and 4 Assemblies Item 1 2 3 4 5 6 7 Description Left side support Right side support Retention bars Body assemblies Body Holding nut Conic ring assembly Star _ Back nut Cavity plug assemblies Plug Holding nut Pan head screws - 4-40 UNC Spring washers ARINC 600 Size 2 shown Stars are available as plain, drilled or split. See relevant S.C.D’s for further information 8-100 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters Ordering Information Part Numbering for Standard Products HexaShield Adapter for Circular Connectors HEXYY L -AY -00 S -YY -AY -Y -DS Drilled Star: See applicable SCD for star options Type of Back Nut: 1 = Standard back nut 2 = Clamping nut for tinel ring (for overbraid protection) 3 = Clamping nut with bandstrap C = Clamping nut for conduit applicator Max. number of ferrules that can be accommodated See applicable SCD for options Hexashield Size Code: See applicable SCD for order number (shell size) S = Swept version Configuration: 00 = Straight body 45 = 45 degree angle body 90 = 90 degree angle body 8 Electrical Interconnect Products Type of Plating: B = Cadmium plated C = Electroless nickel L = Long body See applicable SCD for availability Connector Code Number: 21 = MIL-C-26482 Series 1 40 = MIL-DTL-38999 Series 3 and 4 41 = MIL-DTL-38999 Series 1 and 2 54 = MIL-DTL-38723 Series 1 and 3 MIL-C-25482 Series 2 8-101 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters Ordering Information (Continued) HexaShield Adapter for Collins Connectors HEXDB-AC-00-A9-1 00 = Straight body 90 = Right-angle body HexaShield Adapter for ARINC 600 Connectors HEXA6-AY-00-YY-AY-Y Clamping nut version: 1 = Clamping nut alone 2 = Clamping nut for tinel ring Number of ferrules: 18 for ARINC 600 size II (A and B cavities) 25 for ARINC 600 size II (A, B and C cavities) 18 for ARINC 600 size III (A and B cavities) See applicable SCD for options ARINC Connector Size: 02 = ARINC 600 size II 03 = ARINC 600 size III Configuration: 00 = Straight body 90 = Right-angle body Plating: B = Cadmium plated C = Electroless nickel Drilled Stars are standard on ARINC 600 adapters. Part Numbering of Ferrule Kits* HET-A-02X for small-size cable with SolderShield terminator HET-A-03X for connection of unshielded cables ferrules with heat-shrinkable tubing (no shield) HET-A-04X for large-size cables with SolderShield terminator Type of Plating: B = Cadmium plated C = Electroless nickel HEX07-AX ferrule - solid blank for use when a HET-A is not needed Type of Plating: B = Cadmium plated C = Electroless nickel *Not all part numbers are standard; your local Tyco Electronics representative will assist you in selecting the appropriate standard product 8-102 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance Product Facts Transfer Impedance n 75 10 85 95 Zt (mΩ/m) 1.0 105 115 .1 125 .01 .01 .1 1.0 10 Frequency (MHz) 100 Shielding effectiveness (dB) Outperforms traditional pigtail termination, especially in HIRF performance n Withstands 10-kA peak current lightning transients of SAE AE4L-87-3 135 1000 HexaShield size: 23 Cable: Raychem 5024H8424 (one cable installed) Test method: CEI 96-1 Protection Level Generalized system performance (Actual system performance in any one test method may differ.) 100 HexaShield terminated, shielded, twisted pairs without overbraid 80 8 dB 60 40 20 0 Frequency spectrum of threats Electrical Interconnect Products Pigtailed, shielded twisted pairs Pigtailed, shielded twisted pairs with overbraid 0 10 100 MHz 1000 10,000 Lightning EMP Cross talk HIRF Frequency spectrum of test methods Lightning Surface transfer impedance Bulk cable injection Radiated susceptibility Stirred mode 8-103 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 HexaShield High-Performance EMC Adapters EMC Performance (Continued) Typical HexaShield Applications Civilian and military aircraft Avionics Fighter aircraft Missiles and launch support systems Armored and military support vehicles Navy ships (total shipboard hardening) Military communications Engines (FADEC harness hardening) HexaShield Product Range Accommodates the following connector types*: MIL-C-26482 Series 1 MIL-DTL-38999 Series 1, 2, 3, and 4 MIL-C-26482 Series 2 MIL-DTL-83723 Series 1 and 3 DBAD ARINC 600 ARINC 404 *Please contact Tyco Electronics for other connector types and special requests. 8-104 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Introduction Product Facts n Low-profile rectangular design for high packaging density n Environmental sealing for aerospace applications n Modular components for design versatility and logistics savings n Lightweight materials for weight savings n Quick-disconnect mating hardware 8 The Raychem MTC product line is a complete modular connector system consisting of lightweight, environmentally sealed miniature rectangular connectors (shell housings with removable inserts) and individually removable rear-release contacts. Components Available in: Americas Europe Asia Pacific n n n MTC connectors are now available with quickdisconnect mating hardware, EME shielding accessories, and modular inserts that can accommodate a mix of signal and power crimp contacts and coaxial contacts. The need for special termination tooling has been minimized, while the ease of manufacturing and maintenance has been improved. Configurations MTC rectangular connectors using jack screws or quickdisconnect hardware can be stacked or panel-mounted next to each other without any provision for grip space, a feature that can save significant panel area. MTC connectors are available in 1-inch and 2-inch configurations. Modular removable inserts with size 22 and/or size 16 contact cavities can be combined into the 1-inch and 2-inch MTC housings. Electrical Interconnect Products System Inserts MTC inserts are available in 20-cavity and 5-cavity versions. The 20-cavity insert accepts size 20-22 (24 AWG to 20 AWG wire) crimp contacts. The 5-cavity insert accepts size 16–14 crimp contacts. Insertion/extraction of the contacts is rear release. Note: Other configurations are available in the MTC family (size 12 contacts; 50 mil spacing for double density; accessories). Please contact Tyco Electronics. 8-105 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts 2-inch shell with inserts 27 max. Raychem A2 Raychem 20 A1 15 1 10 5 27 max. Raychem A2 15 10 5 20 1 MTCP-122-20 inserts are used with MTC100 1-inch and 2-inch shells. The 1-inch shell takes: n One MTCP-122-20P (pin contact) or n One MTCP-122-20S (socket contact) The 2-inch shell takes: 2 x 20 Cavity Inserts (Size 20–22)—2-Inch Shell n One MTCP-122-20P1 and one MTCP-122-20P2 (pin contact) or n One MTCP-122-20S1 and one MTCP-122-20S2 (socket contact) Pin Insert MTCP-122-20P1 MTCP-122-20P2 Socket Insert MTCP-122-20S1 MTCP-122-20S2 8-106 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 20-Cavity Inserts (Continued) 1 x 20 Cavity Inserts (Size 20–22)—1-Inch Shell 1-inch shell with insert 27 max. 27 max. Raychem A Raychem 10 3 A 1 1 Pin Insert MTCP-122-20P 5 10 Socket Insert MTCP-122-20S Contacts for 20-Cavity Inserts The contacts for 20-cavity inserts must be ordered separately. They are: n CTA-0166—pin contact n CTA-0165—socket contact 8 Contacts accept 24 AWG to 20 AWG wires. Tools Positioner for pin contact Installation process Contact removal tool (plastic) Extraction tool for MTCP inserts Electrical Interconnect Products Socket Contact CTA-0165 Pin Contact CTA-0166 CE-1605900 ES-61413 CTA-1160 CTA-0161 Tools Positioner for socket contact Installation process Contact removal tool (plastic) Extraction tool for MTCP inserts CE-1606000 ES-61413 CTA-1160 CTA-0161 8-107 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts 5-Cavity Inserts 5-Cavity Inserts (Size 16) A B C D E 27 max. 27 max. A1 A B C D E A B C D E F G H J K A2 A2 A B C D E A B C D E F G H J K F G H J K MTCP-116-05 inserts are used with MTC100 1-inch and 2-inch shells. The 1-inch shell takes: n One MTCP-116-05-P1 (pin contact) or n One MTCP-116-05-S1 (socket contact) The 2-inch shell takes: n One MTCP-116-05P1 and one MTC-116-05P2 (pin contact) or n One MTCP-116-05-S1 and one MTCP-116-05-S2 (socket contact) 5-Cavity Inserts (Size 16) Pin Insert MTCP-116-05P1 MTCP-116-05P2 Contacts for 5-Cavity Inserts Socket Insert MTCP-116-05S1 MTCP-116-05S2 The contacts for 5-cavity inserts must be ordered separately. They include: n CTA-0079 - pin contact (MS 27493-16) (MIL-C-39029/58 intermateable) n CTA-0078 - socket contact (MS 27491-16) (MIL-C-39029/57 intermateable) n D-602-0140 - coaxial pin contact (MIL-C-39029/76 intermateable) n D-602-0171 - coaxial socket contact (MIL-C-39029/78 intermateable) Other contacts designed for M38999 Series II connectors can be used. Pin Contact D-602-0140 (coaxial) CTA-0079 (power) Socket Contact D-602-0171 (coaxial) CTA-0078 (power) 8-108 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Hybrid Inserts 1 A1 10 1 B1 10 A B C D E Plug F G H J K 11 A2 20 11 B2 20 Receptacle 1" = 2.00 2" = 3.00 1" = 1.75 2" = 2.75 .39 max. A Raychem 1.09 .34 MTC100-JH1-P32 XXXX MTC100-JH1-R32 XXXX .34 1.09 Raychem A .394 max. flangeless .60 max. flanged 1" = 1.75 2" = 2.75 1" = 1.75 flanged 2" = 2.75 1" = 2.06 flangeless 2" = 3.06 Hybrids Hybrid insert combinations of size 22 and size 16 contact cavities are also possible. 2-Inch Shell—Hybrid Assembly Power and signal Shells MTC connector housing shells are available with nickel plating (48-hr salt spray performance) or cadmium over nickel plating (500-hr salt spray performance). 8 Electrical Interconnect Products MTC connector housings are offered with quickdisconnect or jack-screw mating hardware. Each connector shell is polarized and has 64 user-defined keying combinations. Lightweight, low-profile EME backshells are also available for increased shielding effectiveness of the connector. 8-109 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts MTC Shells Ordering Information MT C 1 0 0 X - X H X - X X 2 2 = Nickel plating. 48-hr salt spray test performance 3 = Cadmium over nickel plating.* 500-hr salt spray test performance P = Plug housing R = Receptacle housing, flangeless F = Receptacle housing, flanged 1 = 1" 2 = 2" J = Standard housing S = EMI housing Q = Quick-disconnect mating hardware (connector performance per Raychem specification C-6114) Blank = Jack-screw mating hardware (connector performance per Raychem specification C-6115) *Some combinations of shells, mating hardware and EME shielding accessories are not available. Contact Tyco Electronics for product information. 8-110 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 MTC High-Performance Modular Rectangular Connectors with Removable Contacts Accessories Low-Profile EME Backshells EME Backshell Adapters Lightweight rectangular EME backshells connect the overall bundle shield to the MTC connector housing. Individual cable shields can also be terminated to the backshell braid by using Raychem SolderSleeve devices. CHA-0275 2-inch adapter (plug or receptacle) CHA-0276 1-inch adapter (plug or receptacle) The backshell is mounted on the MTC housing via the cable clamp screws. MTC backshell features include a low profile, light weight, and Level II EME performance. MTC Shield-Grounding BusBars Raychem MTC shieldgrounding busbars allow for simple, cost-effective termination of cable shielding to MTC aluminum housings. Two-inch shield-grounding busbars terminate up to 20 shielded twisted pairs on a 2-inch MTC connector. The individual shields are terminated to “fingers” on the busbar with Raychem SolderSleeve devices. Shield-Grounding Busbars CTA-0022 1-inch busbar (with 5 SolderSleeve terminators) CTA-0023 2-inch busbar (with 10 SolderSleeve terminators) 8 The busbar is mounted on the MTC housing via cable clamp screws. EME Shielding Accessories for MTC Connectors Grounding Block Allows for cable shield termination grounding on the MTC shell housing via crimp-removable contacts. This grounding scheme allows individual cables to be removed from the connector without cutting a ganged ground connection. Sufficient ground contacts are available to handle shielded twisted-pair cables. Electrical Interconnect Products MTC busbar features include a simple termination, cost effectiveness, light weight, and Level I EME performance. Grounding Block CHA-0301 1-inch grounding block receptacle shell CHA-0302 2-inch grounding block receptacle shell CHA-0303 1-inch grounding block plug shell CHA-0304 2-inch grounding block plug shell 8-111 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Electrical Interconnect Products Engineering Notes 8-112 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 High-Performance Wire and Cable SPEC 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3 to 9-9 SPEC 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10 to 9-18 RCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19 to 9-24 FlexLine (SPEC 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-25, 9-26 Low-Fire-Hazard Wire and Cable FR-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27 to 9-34 Type 99M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-35 to 9-38 Zerohal 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-39 to 9-41 Zerohal 100G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-42 to 9-44 Commercial Wire Family FlexLite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-45, 9-46 FlexLite DW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47, 9-48 FlexLite TW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-49, 9-50 FlexLite MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-51, 9-52 FlexLite HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-53, 9-54 FlexLite TX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-55, 9-56 FLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-57 to 9-59 Thermocouple Extension Cable Thermocouple Extension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-60 to 9-62 Controlled Electrical Cables Electroloss FilterLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-63 to 9-67 Cheminax Coaxial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-68 to 9-70 Cheminax High-Performance Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-71, 9-72 Cheminax Twin Axial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-73, 9-74 Multiconductor (Multicore) Cables Custom Designed and Standard Multiconductor Cables . . . . . . . . . . . . . . . . . . . . . . .9-75 Multicore Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-76 Cable Jacket Materials 9 Properties and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-77, 9-78 FDR 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-79, 9-80 Wire and Cable Zerohal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-81 to 9-83 Thermorad HTF/Fluoroelastomer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-84 Thermorad/Thermorad F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-85 Raythane, Neoprene, Rayolin, and AFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-86 Miscellaneous Electrical Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-87, 9-88 Computer-Aided Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-89 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-90 to 9-93 Conductor Sizes, Strandings, and Resistance Values . . . . . . . . . . . . . . . . . . . .9-94, 9-95 Fiber Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-96 to 9-99 Note: Users should independently evaluate the suitability of the product for their application. Before ordering, check with Tyco Electronics for most current data. 9-1 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Wire and Cable Introduction Tyco Electronics provides wire and cable solutions for challenging environments and demanding applications. The Raychem product range includes highperformance insulated wires, coaxial and data bus cables, power cables, electronics wire, and multicore cables. n n n SPEC 44 wire is an economical yet rugged dual-wall insulation system rated at 150°C [221°F], with consistently low cost and reliable performance. SPEC 55 wire insulation provides high reliability in harsh environments from -65°C to +200°C [-85°F to +392°F]. Resistant to electrical arc tracking, it combines the easy handling of a flexible wire with excellent resistance to scrapes, abrasion, and cutthrough. RCW is a small size, ultra light weight insulated wire with a temperature rating of -65°C to +260°C [-85°F to +500°F]. It is resistant to electrical arc tracking in wet or dry conditions and has excellent cut-through resistance. n n n n Type 99T dual-wall insulation system is a 105°C [221°F] rated wire that combines excellent chemical and mechanical resistance with limited fire hazard performance. ElectroLoss Filterline wire reduces the vulnerability of critical circuits to high-frequency electromagnetic interference. Cheminax coaxial and data bus cables allow system designers to optimize minimum size and weight with impedance and attenuation characteristics. Multiconductor (multicore) cables organize a variety of Raychem wire and cable products in controlled geometries for specific applications. Using a computer-aided design system, Tyco Electronics can quickly design multicore cables to meet your needs. A variety of cable jackets are available to suit most applications. Raychem wire and cable products can meet your specific application needs. Here are just a few examples: n n n n n n n Limited-fire-hazard wire and cable for mass transit and marine applications. High-performance, high temperature automotive wiring. Small, light hookup wires for high-temperature applications in commercial appliances, tools, and devices. Very flexible, rugged, thin-wall insulated power cables. Low-outgassing spacevehicle wiring. Lightweight, shielded wire and cable constructions for aerospace applications. Thermocouple extension cables with a range of our high-performance insulations materials. Contact Tyco Electronics to find out more about wire and cable and our associated interconnection products. 9-2 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 Product Facts n Dual wall construction 600, 1000 and 2500 voltage rating n Small size, light weight n Low smoke and low corrosive gas generation n Resistant to most chemicals and electrical arc tracking n Applications SPEC 44 wire has a dual wall construction which combines the outstanding physical and electrical characteristics of radiation crosslinked polyalkene with the excellent mechanical and chemical properties of radiation cross-linked polyvinylidene fluoride (PVDF). The result is a wire insulation system that offers a 150°C [302°F] temperature rating, small size, light weight, solder iron resistance, and resistance to most solvents, fuels and lubricants. SPEC 44 wire and cable is highly flame retardant, nonmelting, does not cold flow, and though mechanically very tough, is easy to handle and install using conventional tools. replacement for PVC/Nylon/ Glass braid type wire and cables. SPEC 44 wire is offered in a wide range of sizes in stranded conductors, standard materials available being tin or silver-plated copper and high strength copper alloy. Voltage ratings of 600, 1000 and 2500 volts are available as standard. Shielded and jacketed versions include single and multi-conductor constructions and flat braid shields where further size and weight savings are achieved. Originally developed for aerospace and military requirements in applications of high density and complex circuitry, SPEC 44 wire and cable now finds Conductor wide use throughout industry, in commercial and military electronics, avionics, on satellites, aircraft, helicopters, ships, trains, and offshore platforms where environmental conditions demand consistently reliable performance. In airPrimary frame applications SPEC 44Insulation Radiation Crosslinked, constructions can offerExtruded a Polyalkene modern dimensional Jacket Radiation Crosslinked, Modified PVDF 9 Wire and Cable Conductor Primary Insulation Radiation Crosslinked, Extruded Polyalkene Available in: Jacket Radiation Crosslinked, Modified PVDF Americas Europe Asia Pacific n n n 9-3 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Physical Characteristics Small Size General Handling Lengths SPEC 44 equipment wire, 600 volt rated has a 0.19 [.008] nominal wall thickness compared to 0.25 [.010] and 0.38 [.015] for equivalent PTFE and PVC wires in MIL-W-16878, MILW-22759 or BS G210. The flexibility of SPEC 44 and the ease with which it takes a 'set' makes it one of the easiest of the 'high performance' wires to install. Stripping is done with conventional die blade strippers. SPEC 44 is available in long continuous lengths and can be supplied for use on automatic cut and strip wire preparation machines. Light Weight For details of appropriate tools see separate wire handling guide. The tin-plated conductor usually specified is easily soldered or crimped. The insulation may be hot stamp marked or printed and does not need etching before potting. Because of the thin wall and low density of the insulation materials considerable weight savings are made over similarly rated PTFE wires, eg:- 44A0111-22AWG equipment wire 4.62 grams/meter max 22 AWG PTFE equipment wire, MIL-W-81044 5.54 grams/meter max Specifications/Approvals MIL-W-81044, NEMA-WC-27500 (Cables) Def Stan. 61-12 Part 18 Issue 4 - Type 1 pliable (Maintenance Range) Def Stan. 61-12 Part 26 Issue 3 Type 2, 3, 8 & 9 & METS VG 95218 Parts 20, 21, 22, 23 and 1000 NATO Stock Numbers (NSN's) exist for most standard constructions Civil Aviation Authority Accessory Approval E11623 Lloyds Register of Shipping NASA Preferred Product List Raychem Specification 44 Typical Properties Temperature rating Voltage rating (thin wall) Voltage rating (thick wall) Tensile strength and elongation of insulation Notch propagation, 0.05mm notch Solder iron resistance (370°C, 1 minute) Shrinkage, 200°C Low temperature bend Voltage withstand (thin wall) Resistance: fuels, oils, solvents -65°C to +150°C [-85°F to +302°F] 600 V 2500 V 28 N/mm2 , 230%, 4000 PSI Pass Pass 300°C [572°F] 9 Wire and Cable Smoke/Toxicity Index Solder Iron/Overload Resistance 9-5 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Part Numbering System 44 X X X X X- AWG- X/X- X Basic Product Number Temperature Rating: / - 135˚C (XL-PVF2 cable jacket) A - 150˚C (XL-PVF2 cable jacket) AC - 150˚C (same as 44AM with 90% min. shield coverage) AM - 150˚C (M27500, shielded and/or XL-PVF2 jacketed cable) B - 150˚C (XL-ETFE cable jacket) Construction 0 - Primary wire; or unshielded & unjacketed cable 1 - Round braid shielded and jacketed cable** 2 - Tin-coated copper flat braid shielded & jacketed cable 3 - Round braid shielded cable, no jacket** 4 - Jacketed cable, no shield 5 - Spiral braid shielded & jacketed cable** 7-9 - Special constructions Class of Wire 1 - 600 V, general purpose 2 - 1000 V, general purpose 3 - 2500 V, general purpose 4 - 600 V, outerspace* 5 - 1000 V, outerspace* 6 - 2500 V, outerspace* 7 - 600 V, airframe 8 - 600 V, medium weight Number of Conductors 1 through 10 (designator for 10 conductor = 0) Conductor Type 1 - Tin-coated copper 2 - Silver-coated copper 3 - Nickel-coated copper 4 - Silver-coated high strength copper alloy 5 - Aluminum 6 - Nickel-coated high strength copper alloy A - Silver-coated CS95 C - Silver-coated high strength copper alloy (cadmium-free) D - Nickel-coated high strength copper alloy (cadmium-free) Conductor Size (AWG) Primary Wire Insulation Color (code per MIL-STD-681) 0 - Black 5 - Green 1 - Brown 6 - Blue 2 - Red 7 - Violet 3 - Orange 8 - Gray 4 - Yellow 9 - White Jacket Color (codes same as for Primary Wire Insulation Color) * Classes 4, 5 and 6 available only as “44/” constructions. 44/7xxx and 44A7xxx will be available as indicated on the applicable SCD. **Shield coating same as conductor coating except: - for Conductor Type 4, 6, C and D, shield shall be tin-coated copper Typical ordering example Ordering information 3 conductors, brown, yellow with green stripe, blue, white jacket. If 600 volt, round braid, 20 AWG tinned conductor, 44A1131-20-1/45/6-9. Other constructions and custom designed wire and cable are available on request. 9-6 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) NEMA WC-27500 Cable Part Numbering System M27500 X AWG XX X X XX Basic Specification Number Component Wire ID/Shield Coverage Code Shield Coverage 85% 90% - C A B F D E H G K L P S J M N R T Component Wire Identification Colored Stripes on White Wire (9/96/93/95/92/90/94/97/98/91... etc.) Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.) Band Marks on Solid Colors (by AWG) Alternate Colored Stripes (92/96/94/95/9/90/91/93/97/98...etc) Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.) Number Marking on Solid Colors (by AWG) Number Marking on White Wires Band Marks on Colored Stripes (by AWG) Band Marks on White Wires Conductor Size (AWG) Basic Wire Spec Code (MIL-W-81044) and Slash Sheet MD - M81044/5 (44A0712) ME - M81044/6 (44A0711) MF - M81044/7 (44A0714) MG - M81044/8 (44A0812) MH - M81044/9 (44A0811) MJ - M81044/10 (44A0814) MK - M81044/11 (44A0112) ML - M81044/12 (44A0111) MM - M81044/13 (44A0114) Number of Component Wires Shield Material and Style Code U - No shield T - Tin-coated copper, round J - Tin-coated copper, flat S - Silver-coated copper, round G - Silver-coated copper, flat N - Nickel-coated copper, round 9 Wire and Cable Jacket Material and Style Code 00 - No jacket 08 - Crosslinked, white PVDF 23 - Crosslinked, white Modified ETFE Example: M27500-22ML3T08 = 44AM1131-22-9/96/93-9 Raychem Part No. Military Part No. 9-7 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Primary Wires/Twisted Pair 44A011X (600 V) Primary Wire Stranding Wire Size (AWG) 30 28 26* 24 22 20 18 16 14 12 10 8 #/AWG (mm) 7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32 37/0.40 133/0.29 7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28 37/26 133/29 CSA (mm2) 0.06 0.09 0.15 0.25 0.40 0.60 1.00 1.25 2.00 3.00 5.00 — 44A011X (600 V) Max. Weight (g/m) lb/kft 0.68 [0.027] 1.06 [0.71] 0.76 [0.030] 1.43 [0.96] 0.86 [0.034] 2.08 [1.4] 1.02 [0.040] 2.98 [2.0] 1.19 [0.047] 4.46 [3.0] 1.40 [0.055] 6.70 [4.5] 1.65 [0.065] 10.12 [6.8] 1.83 [0.072] 12.80 [8.6] 2.26 [0.089] 19.64 [13.2] 2.74 [0.108] 30.06 [20.0] 3.28 [0.129] 46.28 [31.1] — — Nom. OD 44A021X (1000 V) Primary Wire 44A021X (1000 V) Max. Weight (g/m) lb/kft — — — — 1.02 [0.040] 2.38 [1.6] 1.17 [0.046] 3.57 [2.4] 1.37 [0.054] 5.20 [3.5] 1.57 [0.062] 7.59 [5.1] 1.85 [0.073] 11.46 [7.7] 2.06 [0.081] 14.58 [9.8] 2.49 [0.098] 21.88 [14.7] 2.97 [0.117] 32.89 [22.1] 3.71 [0.146] 52.98 [35.6] 5.23 [0.206] 91.97 [61.8] Nom. OD *For 44A0211-26 the stranding is 7/0.16mm 7/34 AWG 44A031X (2500 V) Primary Wire 44A081X (600 V) Airframe Wire 44A031X (2500 V) Max. Weight (g/m) lb/kft — — — — 1.35 [0.053] 3.13 [2.1] 1.44 [0.057] 4.46 [3.0] 1.75 [0.069] 6.40 [4.3] 1.98 [0.078] 9.08 [6.1] 12.95 [8.7] 2.23 [0.088] 2.46 [0.097] 16.22 [10.9] 2.92 [0.115] 24.10 [16.2] 3.32 [0.131] 36.01 [24.2] 4.09 [0.161] 54.32 [36.5] 96.20 [0.219] 96.73 [65.0] 44A081X (600 V) Max Weight (g/m) lb/kft — — — — 1.22 [0.048] 2.98 [2.0] 3.87 [2.6] 1.37 [0.054] 1.57 [0.062] 5.65 [3.8] 1.78 [0.070] 8.04 [5.4] 2.03 [0.080] 11.91 [8.0] 2.26 [0.089] 14.73 [9.9] 2.74 [0.108] 22.17 [14.9] 3.20 [0.126] 32.59 [21.9] 3.94 [0.155] 52.08 [35.0] 92.94 [0.214] 93.46 [62.8] Nom. OD Nom. OD 44A012X (600 V) Twisted Pair 44A012X (1000 V) Max. Weight (g/m) lb/kft 1.37 [0.054] 2.38 [1.6] 1.52 [0.060] 3.13 [2.1] 1.73 [0.068] 4.47 [3.0] 2.03 [0.080] 6.69 [4.5] 2.38 [0.094] 9.82 [6.6] 2.79 [0.110] 14.73 [9.9] 22.32 [15.0] 3.30 [0.130] 3.65 [0.144] 28.42 [19.1] 4.52 [0.178] 44.35 [29.8] 5.48 [0.216] 69.00 [46.5] — — — — Nom. OD 9-8 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 44 (Continued) Shielded and Jacketed Cable 44A121X (600 V) 1 Conductor 44A111X (600 V) 1 Conductor Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 Stranding (mm) #/AWG 7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32 7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28 44A111X (600 V) Max. Weight (g/m) lb/kft 1.47 [0.058] 5.20 [3.5] 1.55 [0.061] 5.80 [3.9] 1.57 [0.065] 6.84 [4.6] 1.83 [0.072] 8.63 [5.8] 2.01 [0.079] 10.71 [7.2] 2.26 [0.089] 14.73 [9.9] 2.62 [0.103] 20.68[13.9] 2.79 [0.110] 24.55 [16.5] 3.22 [0.127] 34.08 [22.9] 3.70 [0.146] 47.77 [32.1] 44A121X (600 V) Nom. OD Nom. OD — 1.60 [0.063] 1.73 [0.068] 1.98 [0.078] 2.24 [0.088] 2.54 [0.100] 2.82 [0.111] 3.02 [0.119] 3.45 [0.136] 4.14 [0.155] Max. Weight (g/m) lb/kft — 5.65 [3.8] 6.85 [4.6] 9.67 [6.5] 12.35 [8.3] 17.41 [11.7] 22.62 [15.2] 26.64 [17.9] 36.16 [24.3] 49.56 [33.3] Other sizes are also available in some constructions depending on conductor type and construction required. 44A112X (600 V) 2 Conductor 44A181X (600 V) 1 Conductor 44A181X (600 V) Max. Weight (g/m) lb/kft — — — — — — 2.26 [0.089] 11.76 [07.9] 2.57 [0.101] 15.48 [10.4] 2.77 [0.109] 19.19 [12.9] 3.02 [0.119] 24.11 [16.2] 3.25 [0.128] 28.13 [18.9] 3.73 [0.147] 38.69 [26.0] 4.19 [0.165] 52.38 [35.2] Nom. OD 44A112X (600 V) Nom. OD 2.23 [0.088] 2.38 [0.094] 2.59 [0.102] 2.99 [0.118] 3.35 [0.132] 3.76 [0.148] 4.32 [0.170] 4.67 [0.184] 5.53 [0.218] 6.50 [0.256] Max. Weight (g/m) lb/kft 8.63 [5.8] 9.82 [6.6] 12.05 [8.1] 16.82 [11.3] 21.57 [14.5] 27.97 [18.8] 38.24 [25.7] 44.94 [30.2] 64.28 [43.2] 91.51 [61.5] 9 Wire and Cable Wire Size (AWG) 30 28 26 24 22 20 18 16 14 12 Other sizes are also available in some constructions depending on conductor type and construction required. 9-9 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 by hot stamp, ink jet or laser, and can be potted without pre-etching. Product Facts n Resistant to electrical arc tracking in wet or dry conditions n Single or dual wall constructions n Small size, ultra light weight n Exceptional chemical resistance n -65°C to 200°C [-85°F to 392°F] SPEC 55PC Wire and Cable Insulation System Applications SPEC 55 wire is insulated with modified radiation cross-linked ETFE polymer. It has a temperature rating of -65°C to 200°C [-85°F to 392°F] continuous using a silver plated copper conductor, and combines the easy handling of a flexible wire with excellent scrape abrasion and cut-through characteristics. Available in: Americas Europe Asia Pacific n n n The dual wall airframe construction of SPEC 55 wire is currently used on numerous aircraft programs. It has a choice of two total wall thicknesses, 0.25 [.010] (55A08XX 10 mil) and 0.2 [.008] (55A02XX 8 mil). Both have a contrasting core color to act as a damage indicator. Chosen for its balance of properties, SPEC 55 wire has outstanding resistance to chemicals and solvents, excellent electrical arc track resistance, and is not susceptible to UV and moisture degradation. Single wall equipment wire constructions are available in 0.10 [.004] (55/03XX 4 mil) and 0.15 [.006] (6 mil) wall thicknesses for use inside black boxes where flexibility and solderiron resistance make it a wire which is very easy to install reliably. Both single and dual wall insulated wires are available in twisted pairs, triples, etc., and as shielded and jacketed cables. Physical Characteristics Size and Weight SPEC 55 wire provides one of the most comprehensive wiring product ranges for aerospace users, with a wide choice of conductor sizes and insulation wall thicknesses.The dual wall airframe wire has an insulation wall thickness of either 0.2 [.008] or 0.25 [.010] for robustness in unprotected harnesses and has excellent wire to wire abrasion properties. The single wall equipment wire has a 0.15 [.006] wall thickness for use inside equipment and protected harnesses. For high density, interconnect wiring, the 450 volt 55M041X series of equipment wire has a nominal 0.1 [.004] wall and provides considerable weight and size savings over other comparable wires. This product was originally developed to meet Boeing’s material standard BMS1348 for the 777 airliner. SPEC 55PC provides lightweight, compact insulation that matches the proven performance of our SPEC 55 wire. Today, 55PC is specified and utilized on the majority of aerospace platforms worldwide. Tyco Electronics’ rigorous, statistical-process-controlled manufacturing has produced Raychem wiring that is rugged and versatile enough for a wide range of commercial and defense aerospace applications, including electronic hookups in harsh, open airframe environments. SPEC 55PC wire and cable systems feature an 8-mil airframe wire that is lighter and smaller than typical 10-mil wire, with little reduction in key mechanical performance features. SPEC 55PC wire offers flame resistance superior to FAA standards and also resists scrape abrasion, notch, propagation, cut-through, and electrical arc tracking. n n Meets Boeing material standard BMS 13-48. Exceeds FAR 25 test requirements for flame resistance and smoke density. Handling The excellent flexibility and handleability makes SPEC 55 the ideal wire to install, both in new aircraft and equipment and for maintenance purposes. The wire is easily stripped with conventional tooling. The insulation is readily marked 9-10 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 High Performance Wire and Cable SPEC 55 (Continued) Specifications Conductor Conductor Insulation Radiation Crosslinked, Modified ETFE SPEC 55 insulation system - single wall Insulations Radiation Crosslinked, Modified ETFE Inner layer colored blue SPEC 55 insulation system - dual wall MIL-W-22759/32-35 and /41 to /46 and NEMA-WC-27500 (Cables) Defense Standard 61-12 Part 33 Issue 4 Part 1001 and Part 1002 VDE 9426, 9427, 9428 British Standard 3G233 Civil Aviation Authority Accessory Approval E11749 Boeing BMS 13-48 Airbus ABS 0820 to 0826 NASA preferred product list European Space Agency 3901/012, 3901/020 and 3901/022 Raychem Specification 55 Typical Properties -65°C to +150°C [-85°F to +302°F] -65°C to +200°C [-85°F to +392°F] 200 °C [392°F], 10000 h >100 cycles at 150°C [302°F] >1000 cycles 600 V, 450V (Dual wall wire) 35 N/mm2, 125% min. (Dual wall wire) 35 N/mm2, 75% min. Pass Pass 260°C [500°F] (BS2782). Smoke index 260°C (BS2782), Smoke index 260°C [482°F] (BS2782), Smoke index 260°C [500°F] (BS2782), Smoke index 935°C [1715°F], gases dissolved in water) Ordering Information Conductor Wire Size AWG Stranding No x AWG Dia (mm) 24 22 20 18 16 14 12 10 19x36 19x34 19x32 19x30 19x29 19x27 37x28 37x26 Diameter Min. 0.550 [0.022] 0.735 [0.029] 0.940 [0.037] 1.170 [0.046] 1.321 [0.052] 1.650 [0.065] 2.080 [0.082] 2.690 [0.106] Max. 0.63 [0.025] 0.79 [0.031] 1.01 [0.040] 1.26 [0.050] 1.37 [0.054] 1.79 [0.070] 2.24 [0.088] 2.83 [0.111] Finished Wire Maximum Resistance at 20°C /kft/km 25.7 [84.32] 15.9 [52.2] 9.9 [32.4] 6.2 [20.4] 4.8 [15.8] 3.1 [10.0] 2.0 [6.63] 1.3 [4.13] Diameter Min. Max. Maximum Weight lbs/kft kg/km 1.09 [0.043] 1.26 [0.050] 1.46 [0.057] 1.69 [0.067] 1.84 [0.072] 2.27 [0.089] 2.71 [0.107] 3.33 [0.131] 1.19 [0.047] 1.33 [0.052] 1.54 [0.061] 1.79 [0.071] 1.94 [0.076] 2.39 [0.094] 2.86 [0.113] 3.51 [0.138] 2.41 [3.59] 3.34 [4.98] 4.98 [7.42] 7.31 [10.89] 9.19 [13.70] 14.45 [21.53] 21.03 [31.33] 33.27 [49.58] Part No. 100A0111-24-* 100A0111-22* 100A0111-20* 100A0111-18* 100A0111-16* 100A0111-14* 100A0111-12* 100A0111-10* 9-40 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100A (Continued) Environmental Properties Fire Hazard Characteristics Flammability Fluid Resistance Zerohal 100A is a halogen free insulation system and does not contain phosphorus or sulphur. It meets the toxicity, smoke density, halogen content, corrosivity and flammability requirements of major recognized agencies. Zerohal 100A meets the flammability/burning behavior requirements of major recognized agencies. Zerohal 100A wire demonstrates an outstanding balance of resistance to a wide range of commonly used solvents, fluids and lubricants. Voltage Rating Zerohal 100A wire is a 600 volt rated wire. Fire Hazard Properties Test Method Flammability - small scale IEC 332-1 Flammability - large scale IEC 332-3 Flammability IEEE 383 Smoke - small scale ISO 5659-2 Smoke - small scale ASTM E662 Toxicity Halogen Content Copper Mirror Corrosion IMO FTPC IEC 684-2 ASTM D2671 Acid Gas Detection IEC 754-2 Typical Value Charring confined between 50mm and 540mm from lower edge of top support. (Single vertical wire, 60 s flame) 2.5m maximum burn length. (Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame) Pass Ds1.5 of 100 max., Ds4 of 150 max., Dmax of 150 max., VOF4 of 300 max. (‘NBS’ smoke box with cone heater, 1.8m of wire 50 kW/m2 heat flux with and without a pilot flame) Smoke density - Ds4 (Max.) Flaming - 200 Non-Flaming - 75 Toxicity index < 1 (Test conditions as in smoke - small scale) Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis) 5% maximum etched area. (0.4g sample, 200°C [392°F], 16hr.) pH greater than 4.3 10 µS/mm maximum (1g sample, tube furnace, T > 935°C [715°F], gases dissolved in water) Part Numbering System 100 A X X X X- Size- X Primary Wire Insulation Color 0 - Black 4 - Yellow 1 - Brown 5 - Green 2 - Red 6 - Blue 3 - Orange 7 - Violet 8 - Gray 9 - White 9 Wire and Cable Conductor Size Conductor Type 1 - Tin-plated copper Number of Conductors 1 to 9 Class of Wire 1 - 600 V equipment wire Construction 0 - Primary wire and unscreened, unjacketed cables 1 - Roundbraid, screened and jacketed 4 - Jacketed, no screen Wire Type A - AWG construction (US Specification) Basic Specification Number 9-41 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G Product Facts n Qualified to VG 95218-20, Type E n Halogen free, low smoke n Highly flame retardant n Flexible, easy to install n Small size, lightweight (thin wall construction) Applications System Zerohal 100G wire has been developed to meet the requirements of German Specification VG 95218-20, Type E primary wire. The construction is a dual wall combination of Raychem formulated polymer blends developed to meet the specification requirements while maintaining the desirable features of small size, lightweight, flexibility, nonwrinkling, ease of stripping, compatibility with standard stripping equipment, lack of recoil and mechanical robustness. n System 100 Physical Characteristics Handleability Zerohal 100G wire has been designed for minimum recoil during harnessing operations, to be readily handleable by modern wiring and harnessing techniques and to be easily stripped with standard equipment and tools. Insulation - dual wall modified polymer blend Conductor - tin plated copper Available in: Americas Europe Asia Pacific n n n 9-42 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G (Continued) Approvals VG 95218-20, Type E (Electrical cables and insulated wires for low frequency - Part 20: Single core insulated wires.) Typical Properties Test Max. operating temperature Insulation shrinkage (160°C) Low temperature bend Pressure test at high temperature Heat aging (150°C, 6 h) (140°C, 120 h) Voltage rating Abrasion resistance Insulation blocking (125°C) Voltage withstand (23°C, 2.5 kV rms) Insulation resistance Chemical resistance Grease (G-354)* Hydraulic fluid (H-515, H-544)* Brake fluid (H-542)* De-icing fluid (S-745)* Method VG 95218-20, ASTM D 3032 DIN VDE 0472 Pt 628, IEC 811-1-3 VG 95218 - Pt 2 DIN VDE 0472 Pt 609, IEC 811-3-1 DIN VDE 0472 Pt 303, IEC 811-1-2 VG 95218-20 VG 95218 - Pt 2 VG 95218 - Pt 2 DIN VDE 0472 pt 509 < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown < 5% diameter change, no dielectric breakdown VG 95218 - Pt 2, 23°C 1h Elongation at break No cracking, no dielectric breakdown 750/1300 V AC Pass Pass Pass VG 95218 - Pt 2, 70°C 24h VG 95218 - Pt 2, 23°C 24h Tensile strength -55°C [-67 °F] 125°C [257°F] < 30% indentation > 500 M ohms. km (20°C [68°F]) > 0.5 M ohms. km (90°C [194°F]) VG 95218 - Pt 2, 23°C 24h 70/30 ISO-Octane/ Toluene Insulation < 0.5% DIN VDE 0472 pt 502, IEC 885-1 VG 95218 - Pt 2, 50°C 24h MEK Typical Value 125°C [257°F] (20,000 h) VG 95218 - Pt 2, 23°C 24h DIN VDE 0472 pt 602, IEC 811-1-1 DIN VDE 0472 pt 602, IEC 811-1-1 > 20 MPa > 200% *NATO code. For further details please consult the German Standard VG 95218-20, Type E. Part Numbering System 100 G X X X X- Size- X 7 8 9 - 9 Violet Gray White Wire and Cable Primary Wire Insulation Color 0 - Black 3 - Orange 1 - Brown 4 - Yellow 2 - Red 5 - Green 2L - Pink 6 - Blue NB. VG 95218 T020-EXXX wire only available in colors 0, 1, 45, 6, 9 Conductor Size Conductor Type 1 - Tin-plated copper Number of Conductors 1 Class of Wire 1 - 750 V equipment wire Construction 0 - Primary wire Wire Type G - Meeting the performance requirements of German Specification VG 95218-20, Type E Basic Specification Number 9-43 Catalog 1654025 Revised 12-04 www.tycoelectronics.com Dimensions are in millimeters and inches unless otherwise specified. Values in brackets are U.S. equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Japan: 81-44-900-5102 Singapore: 65-4866-151 UK: 44-1793-528171 Low-Fire-Hazard Wire and Cable Zerohal 100G (Continued) Environmental Properties Fire Hazard Characteristics Flammability Fluid Resistance Zerohal 100G is a halogen free insulation system and does not contain phosphorus or sulphur. It meets the toxicity, smoke density, halogen content, corrosivity and flammability requirements of VG 95218-20, Type E. Zerohal 100G meets the flammability/burning behavior requirements of VG 95218-20, Type E. Method NES 713 IEC 1034 Pt 1 and 2 DIN VDE 0472 pt 815 DIN VDE 0472 pt 813, IEC 754-2 Typical value 3.5 95% light transmittance Non-detected 5.0 pH,