RB-107
TE Connectivity
6801 Kaiser Drive
Fremont, CA 94555
USA
26 JUN 20 Rev 4
RB-107 Specification DuraSeal Splices
1.0
INTRODUCTION
1.1
Scope
This specification covers a series of one-piece pre-insulated crimp splices having a
heat-shrinkable sleeve lined with a meltable adhesive coating.
1.2
Classification
The Duraseal Device shall be as specified in the applicable Raychem Specification
Control Drawing (SCD).
1.3
Temperature Rating The continuous operating temperature range shall be from -67F
to 257F (-55C to 125C).
2.0
APPLICABLE DOCUMENTS
The latest issue of those specifications and standards referenced below or in the
applicable Raychem SCD shall form part of this document to the extent specified.
Furnished Documents
ASTM D-471
ASTM B-187
P-D-410
MIL-STD-129
MIL-STD-202
ANSI/ASQC Z1.4-1993
SAE-J-1128
3.0
REQUIREMENTS
3.1
Detail Requirements
Standard Test Method for Rubber Property- Effect of Liquids
Standard Specification for Copper Rods, Bars and Shapes
Detergent, synthetic, anionic (Alkyl Benzene Sulfonate)
Marking for Shipment and Storage
Test Methods for Electronics and Electrical Components Parts
Sampling Procedures and Tables for Inspection by Attributes
Low Tension Primary Cable, Standard
Detail requirements or exceptions applicable to a particular style of Duraseal splice
shall be as specified on the applicable Raychem SCD. In the event of any conflict
between requirements of this specification and the SCD, the latter shall take
precedence.
3.2
Qualification
A DuraSeal splice furnished under this specification shall be one which has passed,
or is a minor modification of a part which has passed, the qualification test specified
herein or on the applicable Raychem SCD. A minor modification shall be one which
uses the same materials as the qualified part in a different size.
© 2020 TE Connectivity Ltd. family of companies.
All Rights Reserved.
| Indicates Change
*Trademark. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
1 of 11
RB-107
3.3
Material
The material used in the construction of a Duraseal Splice shall be as specified on the
applicable SCD and shall meet the requirements set forth herein.
3.3.1 Insulation Sleeve
The insulation sleeve shall be a tubing of the type and color specified in the applicable
SCD and shall be free from functional defects.
3.3.2 Metals
The metal crimp splice shall be fabricated from copper conforming to ASTM B-187.
3.3.3 Plating
Unless otherwise specified, the metal crimp splice shall be tin-plated ETP copper.
3.3.4 Sealing Material
The sealing material shall be a thermally stabilized thermoplastic, homogenous and
essentially free from flaws, defects, pinholes, seams, cracks and inclusions. The
material shall have a melt viscosity suitable to meet the performance requirements
when using the recommended installation tooling.
3.4
Design and Construction.
The splice shall consist of a metal crimp, insulated with pre-installed sealing sleeve.
The splice shall conform an all respects to the design, dimension and construction
specified herein and on the applicable SCD. Each splice size shall be designed for
attachment to the wire size range specified on the applicable SCD by having the metal
crimp splice reshaped around the conductor and the sealing sleeve recovered over the
splice assembly. It shall be possible to perform these operations by means of tooling
as specified on the applicable SCD. The splice shall be capable of being crimped in
any radial plane and shall exhibit no evidence of fracturing, spalling, or protruding
sharp edges as a result of the reshaping operation.
3.4.1 Wire Acceptance
Each size splice shall be designed for attachment to the conductor diameter range
specified on the applicable specification sheet. The wire insertion shall be facilitated by
a bell mount or chamfer on the metal crimp barrel.
3.4.2 Insulation
The sealing sleeve shall exhibit no evidence of splitting or cracking as a result of
crimping or heating.
Rev 4
2 of 11
RB-107
3.5
Performance
The splice shall conform to the following requirements:
3.5.1 Sealing Sleeve
The sealing sleeve component of the splice assembly shall conform to the dimensions
of the applicable SCD.
3.5.2 Splice Assemblies
The splice assemblies shall conform to the following requirements when attached to
each of the specified wire sizes with the applicable tooling specified (see 3.4).
Maximum tensile values will be attained with a controlled action (ratchet-type) crimping
tool.
3.5.2.1
Voltage Drop
The millivolt drop across the splice shall no exceed the millivolt drop of an
equivalent length of wire by more than the value specified in Table I (see 4.8.1).
3.5.2.2
Room Temperature Flex Test
A room temperature flex test is included in the sequence to ensure that the splice
will remain sealed when the harness encounters bending such as in packaging or
routing through the vehicle.
3.5.2.3
Insulation Resistance
The insulation resistance shall be not less than 1000 Mega ohms (see 4.8.3.).
3.5.2.4
Dielectric Withstanding Voltage
The splice shall show no sign of evidence of damage, arcing, or breakdown and the
leakage current shall be less than that 2 milliamperes (see 4.8.4).
3.5.2.5
Tensile Strength
The wire shall not break or separate from the splice to which it is attached, nor shall
the splice break, before the minimum tensile strength specified in Table I is reached
(see 4.8.5).
Rev 4
3 of 11
RB-107
TABLE I. TEST REQUIREMENTS
Wire
section
nominal
Test
current
(Amperes
)
mm2
0.25
0.35
0.50
0.75
1.00
1.50
2.50
4.00
6.00
Wire
Gauge
3
4.5
9
11
16
22
32
41
50
Test
current
(Amperes
)
AWG
26
24
22
20
18
16
14
12
10
Rev 4
3
4.5
9
11
16
22
32
41
50
A) Metric System
Tensile
Tensile
strength strength
Pounds Newton
minimu
m
12
15
18
27
36
45
56
79
112
minimum
55
70
80
120
160
200
250
350
500
Maximum voltage drop
(mV) millivolt drop of
equivalent length of wire
plus
Initial
After test
2
2
2
2
2
2
2
2
2
4
4
4
4
4
4
4
4
4
B) AWG System
Tensile
Tensile
Maximum voltage drop
strength strength
(mV) millivolt drop of
Pounds Newton
equivalent length of wire
plus
minimu
minimu
Initial
After test
m
m
7
31
2
4
10
45
2
4
14
61
2
4
22
99
2
4
35
154
2
4
40
178
2
4
44
195
2
4
63
282
2
4
84
374
2
4
4 of 11
RB-107
3.5.2.6
Environmental Conditioning
Splice assemblies shall meet the applicable performance requirements listed, when
tested in groups and sequences shown in Table III. Discoloration of the sealing
sleeve materials during these tests shall not be cause for rejection (see 4.8.6).
3.5.2.7
Salt Spray (Corrosion)
Splice assemblies shall show no evidence of exposure of the base metal or
blistering of the plated surfaces. After salt spray, the voltage drop and tensile
strength shall be in accordance withTable I. For voltage drop, the “after test”
requirements shall apply.
3.5.2.8
Vibration
When tested according to the method specified in 4.8.6.5, there shall be no
evidence of cracking, breaking, or loosing of the Duraseal splice assembly.
3.5.2.9
Cold Temperature Flex Test
A cold temperature flex test is included in the sequence to take into account the
change in flexibility that may occur. A sealing material that becomes too brittle will
crack and fail during the test.
3.5.2.10 Fluid Compatibility
Visually inspect for splice insulation integrity. The cross sectional dimensions of
applied sealant may not increase by more than 50% due to swell.
3.6
Identification of Product
The splice shall be color coded in accordance with the applicable SCD for identification
purposes.
3.7
Workmanship
The metal crimp splice shall be free from blistering, pitting, or peeling of plating,
cracks, or other defects which may affect serviceability. Slight burr is permitted
on parted surfaces. The metal crimp shall be held within the sleeve with sufficient
force to withstand dislodging during normal installation.
4.0
QUALITY ASSURANCE PROVISIONS
4.1
Responsibility for Inspection
Unless otherwise specified in the contract or purchase order, the supplier is
responsible for the performance of all inspection requirements as stated. Except
as otherwise specified, the supplier may utilize his own facilities or any other
commercial laboratory.
4.2
Classification of Inspection
The examination and testing of Duraseal splices shall be classified as follows:
Component-Materials inspection (see 4.3) Qualification inspection (see 4.5)
Quality conformance inspection (see 4.6)
4.3
Component-Materials Inspection
Component-materials inspection shall consists of verification that the component
materials listed in Table II used in fabricating the splices are in accordance with
the applicable specifications or requirements prior to such fabrication.
Rev 4
5 of 11
RB-107
TABLE II. COMPONENTS-MATERIALS INSPECTION
Component Material
Metals
Insulation Sleeve
Sealing Inserts
4.4
Requirement
Paragraph
3.3.2, 3.3.3
3.3.1
3.3.4
Applicable Specification
or Requirement
ASTM B-187, ASTM B-545
As listed
As listed
Inspection Conditions
Unless otherwise specified herein, all inspections shall be made at ambient
temperature, and humidity as specified in the general requirements of MIL-STD202.
4.4.1 Assembly to Conductors
The splices shall be attached to wire conforming to SAE J1128 SXL, having a
temperature rating of 125C, by the testing activity using the specified tooling
(see 3.4). The test specimens shall be one to one inline splice made in
accordance with the specified assembly technique. This specified number of
sample units for testing shall be selected and divided between the minimum and
maximum wire size within the wire range listed on the applicable SCD for he
sizes to be qualified. Unless otherwise specified, the leads shall be at least 12
inches in length.
4.4.2 Temperature Stabilization
Voltage drop measurements shall be made after the temperature of the wire has
stabilized. Temperature stabilization shall be determined by three consecutive
readings with 1C at intervals of 3 minutes each. All tests performed after
exposure to high or low temperature shall be conducted after the splices have
been conditioned for at least one hour at the inspection conditions specified (see
4.4).
4.4.3 Water Bath
Unless otherwise specified in the applicable test method, a water bath containing
0.5% of an anionic wetting agent (P-D-410) and 5.0% sodium chloride shall be
used whenever immersion is specified. Free ends of the leads shall be a
minimum of 4 inches from the top surface of the water.
4.5
Qualification Inspection
4.5.1 Sample
24 splices for each size of each specification sheet (see 3.1) for which
qualification is sought shall be submitted for qualification testing.
4.5.2 Test Routine
Sample units shall be subjected to the qualification inspection specified in Table
III in the order shown. All sample units shall be subjected to the inspection of
Group I. The samples shall then be divided into Groups II through V as shown in
Table III and subjected to the inspection for their particular group.
Rev 4
6 of 11
RB-107
4.5.3 Qualification Test Reports
The Qualification Test Report shall be forwarded to the activity requesting
qualification.
4.5.4 Failures
Any failure shall be cause for refusal to grant qualification
4.5.5 Retention of Qualification
A Duraseal splice, once qualified under this specification, shall remain qualified as
long as no significant change is made in the materials or design of the splice(see
6.3)
4.6
Quality Conformance Inspection
4.6.1 Inspection of Product for Delivery
Inspection of product for delivery shall consist of visual and dimensional
examination.
4.6.1.1
Inspection Lot
An inspection lot, as far as is practical, shall consist of all Duraseal splices of
a single size and type, manufactured under essentially the same conditions
and offered for inspection at one time.
4.6.1.2
Sampling Plan
Quality conformance sampling shall be in accordance with ANSI/ASQC Z1.4
for normal inspection. The inspection level shall be Level I and the acceptable
quality level (AQL) shall be 4.0 for all defects.
4.6.1.3
Non-conforming Lots
Disposition of non-conforming lots shall be in accordance with ANSI/ASQC
Z1.4.
4.7
Examination
4.7.1 Duraseal Splice Uninstalled
The splice shall be examined to verify that the materials design construction, and
physical dimensions are in accordance with the applicable SCD.
4.7.2 Visual Examination of Assemblies
Each assembly shall be examined to check that the crimping of the splice has
been achieved without damage to the insulation sleeve and that the desired
degree of shrinkage of the tubing has been obtained.
4.8
Rev 4
Test Methods, Assemblies
7 of 11
RB-107
TABLE III: QUALIFICATION INSPECTION
Examination or Test Group
GROUP I
24 uninstalled splices
Visual and dimensional
examination
GROUP II
24 splice assemblies
(from Group I)
Visual examination
Insulation resistance
GROUP III
4 splice assemblies
(from Group II)
Dielectric withstanding voltage
Voltage drop initial
Tensile strength
GROUP IV
4 splice assemblies
(from Group II)
Salt spray (Corrosion)
Voltage drop (after test)
Tensile strength
GROUP V
12 splice assemblies
(from Group II)
Environmental conditioning
Room temperature flex test
Heat ageing
Thermal shock
Temperature humidity cycling
Vibration
Cold flexion
Fluid compatibility
Insulation resistance
Dielectric withstanding voltage
Tensile strength
GROUP VI
4 splice assemblies
(from Group II)
Immersion
Insulation resistance
Rev 4
Requirement Paragraph
Method Paragraph
3.4
4.7.1
3.5.2.3
4.7.2
4.8.3
3.5.2.4
3.5.2.1
3.5.2.5
4.8.4
4.8.1
4.8.5
3.5.2.7
3.5.2.1
3.5.2.5
4.8.6.6
4.8.1
4.8.5
3.5.2.2
3.5.2.6
3.5.2.6
3.5.2.8
3.5.2.9
3.5.2.10
3.5.2.3
3.5.2.4
3.5.2.5
4.8.2
4.8.6.1
4.8.6.2
4.8.6.3
4.8.6.5
4.8.2.1
4.8.6.4
4.8.3
4.8.4
4.8.5
3.5.2.6
3.5.2.3
4.8.6.7
4.8.3
8 of 11
RB-107
4.8.1
Voltage Drop
Splices shall be tested as follows:
Test points: Measurements shall be made by puncturing the insulation of the current
carrying conductor on each end of splice 1/16 inch back from the ends of the sealing
sleeve.
The distance between the two test points shall be noted. Measurement of the
current carrying conductor shall be made by puncturing the conductor insulation
the same distance between test points as that noted for the splice measurement.
The millivolt drop of the equivalent length of wire may be determined by
averaging four readings taken on 10 inch lengths of wire selected at random
throughout the supply of wire to be used for subsequent tests.
Measurements: The millivolt drop through the crimp termination and the current
carrying conductor shall be measured while the specified test current (see Table
I) is being applied, and after the temperature of the wire has stabilized. (see
4.4.2)
4.8.2 Flex Test
While at room temperature warp samples around a 2-inch diameter mandrel,
bending clockwise. Wrap each sample 5 times in each direction.
4.8.2.1
Cold Flex Test
Wrap each sample around a four-inch mandrel and place samples in a cold
chamber at –10C for a period of three hours.
4.8.3 Insulation Resistance
Splices shall be tested in accordance with Method 302 of MIL-STD-202. The
flowing details shall apply:
Test condition: A 100 Volts
Conditioning of splices: Splices shall be immersed as specified for at least 1-hour
(see 4.4.3) Points of measurement: Between splice leads and water bath.
Electrification time: 1 minute.
4.8.4 Dielectric Withstanding Voltage
Splices shall be tested in accordance with Method 301 of MIL-STD-202. The
following details shall apply:
Conditioning of splices: Splices shall be immersed as specified (see 4.4.3)
Magnitude and nature of potential: 2500 VAC (RMS) Points of measurement:
Between splice leads and water bath.
4.8.5 Tensile Strength
The splice shall be placed in a standard tensile-testing machine so that
the
splice is centered between, and at least 3 inches from the jaws. Sufficient force
shall be applied to pull the wire out of the splice or break the wire or the splice.
The travel speed of the head shall be 1inch per minute. The clamping surfaces of
the jaws may be serrated to provide sufficient force.
Rev 4
9 of 11
RB-107
4.8.6
Environmental Conditioning
The splice shall be exposed to each condition in the sequence shown in
Table III.
4.8.6.1
Heat Ageing
The specimens shall be conditioned in an air circulatory oven at the maximum
operating temperature for 168 hours.
4.8.6.2
Thermal Shock
The splices shall be tested in accordance with Method 107, Test condition F
of MIL-STD-202. The samples shall be heated to 125C for ½ hour, followed
by -55C for ½ hour. This will constitute one cycle. The samples shall be
submitted to five cycles in total.
4.8.6.3
Temperature Humidity Cycling
The splices shall be tested in accordance with Method 106 of MIL-STD-202
except subcycle 7b shall not be required.
4.8.6.4
Fluid Compatibility
Test 12 samples, 3 in each fluid. Immerse samples for 3 seconds in each fluid
at intervals of 30 minutes for 24 hours at 23±3C to simulate a splash
environment. Allow samples to drain between immersions.
Use the following fluids:
ASTM D-471 Fuel C
4.8.6.5
Diesel fuel
SAE J 1703 Brake fluid
Gunk brand (engine degreaser)
Vibration
The splices shall be vibrated in accordance with Method 201A of MIL-STD202F for 2 hours on each of two axes mutually perpendicular to each other
and to the axis of the wire.
4.8.6.6
Salt Spray (Corrosion)
The salt spray test shall be in accordance with Method 101, Test condition B of MILSTD-202. Splices shall be crimped to 12 inch minimum lengths of wire. Adjoining
samples shall be separated by at least ¼ inch. During this test, the samples shall not
come in contact with wooden or metallic objects, and the salt spray solution shall be a
salt solution concentration of 5% and shall have free access to the samples. The
samples shall be removed from the salt spray, washed with distilled water and air
dried.
4.8.6.7
Immersion
The splices shall be tested in accordance with Method 104, Test condition C
of MIL-STD-202.
Rev 4
10 of 11
RB-107
5.0
PREPARATION FOR DELIVERY
5.1
Packaging and Packing
Duraseal splices shall be packaged and packed in accordance with standard
commercial practices.
5.2
Marking
Packages shall be identified in accordance with MIL-STD-129 with the following
information:
Raychem part number
Lot control number
Quantity
6.0
NOTES
6.1
Intended Use
Splices covered by this specification are for use in making one-to-one
environmentally protected permanent joints on conductors falling within the size
range listed on the applicable SCD having insulations compatible with the sealing
material. They may be used in applications where the total temperature of the
wire insulation does not exceed 125C.
6.2
Ordering Data
Procurement documents should specify:
6.3
Raychem part number
Quantity
Any special marking or packaging requirements
Design Modification
Raychem reserves the right to make minor product design modifications which
do not affect the from, fit, or primary function of a Duraseal splice as measured
by his specification and the appropriate SCD, without notification.
6.4
Storage Recommendations
Raychem Duraseal splices may be stored for a period of up to 5 years after the
date of manufacture indicated on the label, provided the following conditions are
satisfied:
The products should be kept, unopened, in their original packages.
Recommended storage temperatures should not exceed +50C, nor fall
below +5C; relative humidity should not exceed 80%.
If storage exceeds 5 years, or storage conditions are not as described above, the
user should carry out tests on installed products to ensure joints have acceptable
mechanical and electrical characteristics. Note, application of the product should
always conform with Raychem Selection Guide and installation with the
recommended installation procedures.
Rev 4
11 of 11
工商网监
湘ICP备2023018690号
