Raychem
Application Tooling
The Tools to Make Every Connection Count
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
Raychem Application Tooling
The Tools to Make Every Connection Count
•M
ade from the highest quality
materials for low cost of ownership
TE Connectivity (TE) offers a variety of dependable
hand and bench-mount tools for crimping Raychem
devices and heating heat-shrinkable products. The
tools help give you more accuracy in terminations—
increasing productivity, reducing rework, and taking
the guesswork out of procedures. With easy-to-use
controls and ergonomic design, Raychem tools help
make the job go faster and easier.
EASY TO USE
HAND CRIMPING TOOLS
HIGH QUALITY
•M
anufactured to TE Connectivity’s
strict quality standards
•T
ools are designed to make every job
easy and trouble-free
•D
esigned and developed with the
operator in mind
•C
onvenient, easy to use features
make installations faster and easier
•M
ore choice in tooling, from
simple hand tools to advanced,
automatic operation
APPLICATION SPECIFIC
•T
ools offered by TE are designed
to aid in the installation of
TE wire and cable products
•D
ecades of experience are
applied to the development of all
TE installation tools
•C
hoose from a wide range of tools
for any cable management task
AD-1377 Hand Crimping Tool
3
AD-1522-1 Hand Crimping Tool
4
AD-1381 Hand Crimping Tool
5
INFRARED HEATING TOOLS
IR-550/ED-7 Heating Tool and Controller Kit
6
IR-550 Infrared Heating Tools
8
Mini-Ray MK5 Infrared Heating Tool
10
Mini-Ray MK4 Heating Tool Systems
12
HOT AIR HEATING TOOLS
CV2014 Series ThermoGun Heating Tool
CV1981 and CV1983 Series ThermoGun Heating Tools
HL1920E and HL2020E Heat Guns
15
17
20
COMPRESSED AIR HEATING TOOLS
AA-400 Super Heater Compressed Air Heating Tool
22
HT-900B Compressed Air Nitrogen Heater Tools
24
HEATING TOOLS FOR TINEL-LOCK RING SCREENED TERMINATIONS
AD-5000 Installation Tool
26
AD-5020 Installation Tool
28
RH-396X Tinel-Lock Installation Tool
30
UNDERWATER SPLICE KIT
Underwater Cable Splice (UWCS) Kit
32
ACCESSORIES
AD-1319-9 Holding Fixture for Heat-Shrinkable Devices
PRODUCTS AND RECOMMENDED TOOLING
34
36
TE Components . . . TE Technology . . . TE Know-how . . .
AMP | AGASTAT | CII | HARTMAN | KILOVAC | MICRODOT | NANONICS | POLAMCO | Raychem
SEACON | Rochester | DEUTSCH
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AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 2
Raychem AD-1377
Hand Crimping Tool
VERSATILE
• Crimps MiniSeal splices, covering a
wire range from 26 to 12 AWG
• Ratchet-controlled release handle
•P
re-set crimp depth that provides
the optimum combination of tensile
strength and insulation integrity in
the finished splice
HIGH PERFORMANCE
• Built-in ratchet system ensures
full cycling of the tool and prevents
early release
•D
esigned for an easy and smooth
effort to achieve the crimp
• Inside cavities are polished to
bring maximum reliability to the
crimping operation
QUALIFICATIONS
• Tool: MIL-DTL-22520/37-01
• Calibration Gauge:
MIL-DTL-22520/39-01
AD-1377 Hand Crimping Tool
Tool is used for crimping wire terminations with MiniSeal splices.
AD-1377-CRIMP-TOOL-3-CVTY
MIL-DTL-22520/37-01
The Raychem AD-1377 crimp tool from TE is designed for MiniSeal
splices. It has a pre-set crimp depth that provides the optimum
combination of tensile strength and insulation integrity in the finished
splice. The ratcheted release ensures full closure of the tool to help
prevent undercrimping.
The tool is calibrated with standard gauge pins or with TE calibration
gauge AD-1386. The drawing supplied with the tool defines appropriate
cavity dimensions as diameters for the “Go” and “No Go” conditions.
Specifications
DIMENSION
• Overall Length: 230 mm (9”) approx.
WEIGHT
• 350 g (12.3 oz.)
Ordering Information
AD-1377 Crimp Tool for MiniSeal Splices
Model
Description
Part No.
Mil Spec MiniSeal Splice Crimp Tool AD-1377
AD-1377-CRIMP-TOOL-3-CVTY
992008-000
MiniSeal Splice Crimp Tool
AD-1377-S-SPEC-CRIMP-TOOL
959025-000
Calibration Gauge
AD-1386-CALIBRATION-GAUGE
992013-000
Accessories and Replacement Parts
Parts
Description
Part No.
Crimp Locator
AD-1377-103-CRIMP-LOCATOR
994855-000
Spring
AD-1377-P-E118-TOR-SPRNG
994123-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 3
Raychem AD-1522-1
Hand Crimping Tool
VERSATILE
•C
rimps DuraSeal crimp splices,
covering a range from 22 to 10 AWG
EASY TO USE
• Ratchet-controlled release handle
•P
re-set crimp depth that provides
the optimum combination of tensile
strength and insulation integrity in
the finished splice
HIGH PERFORMANCE
•B
uilt-in ratchet system ensures
full cycling of the tool and prevents
early release
•D
esigned for an easy and smooth
effort to achieve the crimp
• Inside cavities are polished to
bring maximum reliability to the
crimping operation
AD-1522-1 Hand Crimping Tool
Tool is used for completing wire terminations using
DuraSeal splices.
The Raychem AD-1522-1 crimp tool from TE can be used on all
DuraSeal splices. It has a pre-set crimp depth that provides the
optimum combination of tensile strength and insulation integrity
in the finished splice. The ratcheted release ensures full closure
of the tool to help prevent undercrimping.
The tool is calibrated with standard gauge pins or with
TE calibration gauge AE-2245. The drawing supplied with the
tool defines appropriate cavity dimensions as diameters for
the “Go” and “No Go” conditions.
Specifications
DIMENSION
• Overall Length: 230 mm (9") approx.
WEIGHT
• 350 g (12.3 oz.)
PRODUCT RANGE
• DuraSeal Crimp Splices and Terminals
Ordering Information
AD-1522-1 Crimp Tool for DuraSeal Splices
Product
Description
Part No.
Crimp Tool
AD-1522-1-CRIMPING-TOOL
047011-000
Calibration Gauge
AE-2245
020435-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 4
Raychem AD-1381
Hand Crimping Tool
VERSATILE
• Crimps cold-applied gel-filled
splices, covering a wire range from
26 to 12 AWG
EASY TO USE
• Ratchet-controlled release handle
• Pre-set crimp depth that provides
the optimum combination of tensile
strength and insulation integrity in
the finished splice
HIGH PERFORMANCE
• Built-in ratchet system ensures
full cycling of the tool and prevents
early release
• Designed for an easy and smooth
effort to achieve the crimp
QUALIFICATIONS
• Tool: MIL-DTL-22520/44-01
• Calibration Gauge:
MIL-DTL-22520/39-03
AD-1381 Hand Crimping Tool
Tool is used to crimp cold-applied gel-filled splices with wires
ranging from 26 to 12 AWG.
The Raychem AD-1381 crimping tool from TE terminates
cold-applied splices, which are TE’s in-line, sealed, crimp splices
designed for 150°C applications.
The tool has a pre-set crimp depth that provides the optimum
combination of tensile strength and insulation integrity in the finished
splice. The ratcheted release ensures full closure of the tool to help
prevent undercrimping.
The tool is calibrated with standard gauge pins or with the TE
calibration gauge AD-1382. The drawing supplied with the tool
defines appropriate cavity dimensions as diameters for the
“Go” and “No Go” conditions.
Specifications
DIMENSION
• Overall Length: 230 mm (9") approx.
WEIGHT
• 350 g (12.3 oz.)
COLD-APPLIED SPLICE PRODUCT RANGE
• D-436-36-COLD: 26 to 20 AWG wire range
• D-436-37-COLD: 18 to 16 AWG wire range
• D-436-38-COLD: 14 to 12 AWG wire range
Ordering Information
AD-1381 Hand Crimping Tool
Model
Description
Part No.
AD-1381 Hand Crimping Tool
AD-1381-CRIMP-TOOL-3-CVTY
CS1660-000
Calibration Gauge
AD-1382-CALIBRATION-GAUGE
992013-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 5
Raychem IR-550/ED-7
Heating Tool and Controller Kit
COMPREHENSIVE
• Controller and foot-pedal-operated
portable infrared heating tool
• Controller keypad enables the
selection of the operation mode up
to 20 stored programmed sequences
EASY TO USE
• Provides reliable installation of
SolderSleeve and MiniSeal devices,
SolderTacts contacts, and
TE heat-shrinkable products
• Controller can be used in a manual
or automatic mode
FLEXIBLE OPERATION
• Manual Mode: Applies full power
when foot pedal is depressed, and
removed power when the pedal is
released
• Automatic Mode: Controls duration
and level of power according to
a preset sequence stored in
memory when foot pedal is pressed
and released
IR-550/ED-7 Heating Tool and Controller Kit
Kit is used to install SolderSleeve and MiniSeal devices,
SolderTacts contacts, and TE heat-shrinkable products.
The Raychem IR-550/ED-7 from TE provides a convenient
portable electric infrared heating tool and controller. This system
gives fast, reliable installations of SolderSleeve devices, MiniSeal
devices, SolderTacts contacts, and TE heat-shrinkable products.
The foot-pedal-operated, benchtop tool allows both manual
and automatic control of the heating tool. In the manual mode,
the operator uses the foot pedal to start and stop the heating
sequence. In the automatic mode, the power and duration of
heating—including varying levels and times in the sequence—
allow consistent and precise application of heat. The controller
can store up to 20 sequences in memory.
Specifications
INPUT POWER
• IR-550/ED-7-KIT: 220 V, 50 Hz, 7.3 A
• ED-7-001-550 Controller: 220 V, 50 Hz, 2.8 A
• IR-550-MK3-CE-MINUS Heating Tool: 220 V, 50 Hz, 4.5 A
DIMENSIONS
• ED-7-001-550: 160 mm x 120 mm x 250 mm (6.29" x 4.7" x 9.8")
• IR-550-MK3-CE-MINUS: 113.2 mm x 119.3 mm x 250 mm
(4.46” x 4.7” x 9.8”)
WEIGHT
• IR-550/ED-7-KIT: 8.7 kg (19.1 lb.)
• ED-7-001-550: 6.2 kg (13.6 lb.)
• IR-550-MK3-CE-MINUS: 2.5 kg (5.5 lb.)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 6
Application Tooling
Ordering Information
IR-550/ED-7 Heating Tool and Controller Kit
Model
Description
Part No.
IR-550/ED-7 Heating Tool and Controller
IR-550/ED-7-KIT
CV1032-000
Accessories and Replacement Parts
Parts
Description
Part No.
Infrared Heating Tool
IR-550-MK3-CE-MINUS-00
CY8483-000
Controller*
ED-7-001-550
CV2777-000
Lamp 220/230 500 W Lamp
IR-550-303-CE-LAMP
F95965-000
Foot Switch Assembly
IR-550-301-CE-FOOT-SW-ASSY
F91912-000
Viewing Window (frame not included)
IR-550-238-VIEWING-WINDOW
007510-000
RG-2 Reflector, SolderSleeve Reflector, 19 mm (.75")
IR-500-24-RG-2-SLD-SL-REF
993770-000
RG-6 Reflector, Large-Diameter Solder Sleeve
Terminations. Aperture is 25, 4 mm (1.0") wide
IR-550-19-RG-6-NOSECONE
994590-000
Holding Fixture
ED-7-001-550-HOLD-FIX
CV4406-000
PCB for Controller
ED-7-001-550-PCB
CV4408-000
Filter
IR-550-237-FLTR-DUAL-COAT
118902-000
*Controller can be purchased separately.
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 7
Raychem IR-550
Infrared Heating Tools
CAPABLE
• Designed for fast installation of
SolderSleeve terminations, MiniSeal
terminations, SolderTacts contacts,
and heat-shrinkable tubing
• Controls include a power switch, foot
switch, and a handle-mounted switch
• The IR-550-300-MARKIII-CE unit is
CE approved
SAFE OPERATION
IR-550-50-MARKII-HT-TOOL - 120 V
• Fan keeps external surfaces cool and
allows for long-duration heating
• Thermostatic switch helps protect
from overheating
• Optical filter helps reduce glare from
the lamp for safer observation
• A 30-degree base reduces eye strain
and glare to others working nearby
CONVENIENT
• Viewing window enables viewing of
IR-550-300-MARKIII-CE - 230 V
the heating process
• Foot switch or handle switch
operation
• Designed primarily as a benchtop
heating tool
IR-550-50-MARKII-HT-TOOL (120 V)
IR-550-300-MARKIII-CE (230 V)
The Raychem IR-550 heating tool from TE is a portable electric
infrared heating tool designed for fast, reliable installation of
Raychem SolderSleeve terminations, MiniSeal terminations,
SolderTacts contacts, and heat-shrinkable tubing.
The IR-550 heating tool can be used as a hand tool, but is primarily
designed as a bench-top heating tool. As a hand tool, it is operated
using a switch on the handle. As a bench-top heating tool, it can be
operated by either a foot switch or handle switch.
A halogen lamp provides the radiant heat source, and reflectors
focus the heat from the lamp to concentrate it within the work area
of the front reflector. Interchangeable front reflectors are designed
for specific product applications.
An optical filter between the lamp and the work area reduces the
glare from the lamp, allowing the operator to observe the heating
process. The tool also has a viewing window to further reduce glare.
The 30-degree base has been designed to further reduce eye strain
and glare to others working nearby.
The IR-550-50 is a single unit containing both controls and infrared
tool. For the IR-550-300, the control box and infrared tool are
separate units.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 8
Application Tooling
Specifications
IR-550-50
IR-550-300
Input Power
120 V, 50-60 Hz, 4.5 A
230 V, 50–60 Hz, 3 A
Weight
2.5 kg (5.5 lb.)
4.8 kg (10 lb.) approx.
Dimensions
113 x 120 x 249 mm
(4.46" x 4.7" x 9.8")
Control Box: 152 x 120 x 19.mm (6" x 4.7" x .75")
Tool: 114 x 209 x 249 mm (4.5" x 8.2" x 9.8")
Duty Cycle
80%, 90-second max. heating times
Lamp Life
1000+ hours of intermittent use
Ordering Information
IR-550 Infrared Heating Tools
Model
Description
Part No.
IR-550-50 Heating Tool
IR-550-50-MARKII-HT-TOOL
994350-000
IR-550-300 Heating Tool
IR-550-300-MARKIII-CE
C66438-000
Reflectors
Parts
Description
Part No.
RG-2 Reflector for SolderSleeve Terminations
19.0 mm (.75") Wide Aperture
IR-500-24-RG-2-REFLECTOR
993770-000
RG-6 Reflector For Large-Diameter SolderSleeve Terminations
25.4 mm (1.0") Wide Aperture
IR-550-19-RG-6-NOSECONE
994590-000
RG-9 Reflector
9.525 mm (.375") Wide Aperture
IR-550-39-RG-9-REFLECTOR
993693-000
RG-11 Reflector;
12.7 mm (9.5") Wide Aperture
IR-550-41-RG-11-REFLECTOR
993695-000
Accessories and Replacement Parts
Parts Common to Both IR-550-50 and -300
Description
Part No.
Upgrade Kit: Filter, Viewing Window,
Inner Reflector-Outer Reflector
IR-550-240-Refurb-KIT
529600-000
Filter
IR-550-237-FLTR-DUAL-COAT
118902-000
Button, Large, Black
AES-IR550-C23-BUTTON
C33802-000
Viewing Window (Frame Not Included)
IR-550-238-VIEWING-WINDOW
007510-000
Lamp (120 V)
IR-1000-P-N-13-LAMP
993020-000
Foot Switch Assembly
IR-550-216-FOOT-SWITCH-ASSY
994375-000
Lamp (220-230 V), 500 W
IR-550-303-CE-LAMP
F95965-000
Foot Switch Assembly
IR-550-301-CE-FOOT-SW-ASSY
F91912-000
PC Board
AES-IR550-63-PC-BRD
576297-000
Parts for IR-550-50 Only
Parts for IR-550-300 Only
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 9
Raychem Mini-Ray MK5
Infrared Heating Tool
CONVENIENT
• Portable, lightweight and
convenient for use where workspace
is constrained
• Product being installed is visible
during the heating cycle
• Available as a complete kit,
comprised of manual control box,
hand tool, AT3130 reflector and
spare bulb
SAFE AND EFFICIENT
• Heat energy is derived from a
tungsten halogen lamp and focused
onto the product with a reflector
• Optical filter eliminates unwanted UV
emissions and excess visible light,
reducing glare for the operator
Mini-Ray MK5 Infrared Heating Tool
Tool is designed for installing SolderSleeve termination products
up to 9 mm diameter.
• UL Approved
IR1759-MK5-AT3130-ED-CONT
EASY TO USE
The Raychem Mini-Ray MK5 tool from TE is a hand-held infrared
heating tool designed for use in installing TE’s SolderSleeve
termination products. The tool is portable, lightweight and
convenient for use where workspace is constrained.
• Hand-held unit with simple
trigger operation
• Options available for products up to
9 mm diameter
• Tool can be used with either 230 V
or 110 V (nom.) power supply
ROHS Information can be found at the following
website: http://www.te.com/customersupport/
productcompliance/
This product must not be disposed of as
municipal waste.
The hand tool is fan cooled and has low heat emission, as the
lamp is only energized on demand. The heat energy is derived
from a halogen lamp and is focused onto the product by means
of the reflector design.
The IR1759-MK5 standard aperture is recommended for products
up to 6 mm diameter, and the IR-3104-MK4/A large aperture for
installing products up to 9 mm diameter. This version of the tool
will accept larger diameter components, but uniform heating
cannot be assured.
The Raychem ED-7 controller is a simple unit, with no variable
time or variable power memory functions. It maintains power
to the lamp for as long as the tool’s trigger switch remains
depressed. The controller can be used with either 230 V or 110 V
supply voltage.
NOTE: Control unit ED-7-CONT-230/110V-MK5 is used with
the IR-1759-MK5-GUN and cannot be used with or fitted to
other existing Mini-Ray systems (such as 1759-MK4/A and
IR-3104-Mk4/A hand tool).
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 10
Application Tooling
Specifications
CONTROLLER
HEATING TOOL
•
•
•
•
•
•
•
Supply Voltage: 24.0 VAC Nom.
Typical Operating Temperature: 600°C @ 10-second operation
Typical Heating Time: 15 to >70 seconds
Lamp: 250 W tungsten halogen, 800 cycles
Noise: 51 dB (A)
Weight: 1.1 kg (2.4 lb.)
Power Cord Length: 3.1 m
•
•
•
•
•
Supply Voltage: 230 V, 50 Hz or 110 V, 50-60 Hz
Input Current: 6.3 A
Output Voltage: 24.0 VAX
Weight: 8.0 kg (17.6 lb.)
Dimension: 160 x 120 x 250 mm
Ordering Information
IR-1759 Infrared Heating Tools
Model
Description
Part No.
Mini-Ray Infrared Heating Tool
IR1759-MK5-AT3130-EDCont
(With manual control box, hand tool,
AT3130 reflector and spare bulb)
CV3948-000
Accessories and Replacement Parts
Part
Description
Part No.
Heating Tool
IR-1759-MK5-GUN*
CV4411-000
Controller
ED-7-CONT-230/110V-MK5*
CV4409-000
AT-3130
988299-000
Reflector for SolderTacts Contacts
AT-3131
988300-000
Reflector With Clamps
AT-3132
988301-000
Reflector With Clamps and 5 mm Mask
AT-3132 -MK31
879865-000
Reflector With Special Vee Block
AT-3191
588701-000
Linear Reflector
AE-205
988596-000
Reflectors for Standard Aperture
Reflector With Vee Block
Reflectors For Large Aperture (Requires Conversion Kit AE-897)
Conversion Kit From Standard To Large Aperture
AE-897
966953-000
Reflector With Clamps
AT-3134
988303-000
Reflector With Clamps
AT-3147
988328-000
Linear Reflector
AE-206
988314-000
For Standard Aperture
AE-424 Standard IR-1759
547918-000
For Large Aperture
AE-153 3104
988285-000
Inner Reflectors
Replacement Parts
PCB For Trigger/Handle
IR-1759-MK5-TRIGGER-PCB
CV4416-000
Thermal Switch With Plate/Tubing
IR-1759-MK5-THRMSW-PLT
CV4418-000
Dual Filter
AES-IR1759-100- FILTER-DUL
431468-000
Main PCB
ED-7-CONT-MK5-PCB
CV4414-000
Filter Spring IE-1759
AE-900
277774-000
Bulb, 250 W, 24 V IR1759/3104
NAE-143-3
988208-000
Replacement Connector, De-Pin Tool, and Instructions
IR1759-MK5-REPCON-DEPINTL
EG2846-000
Cable, Trigger PCB, Lamp Holder, and Thermal Switch
IR-1759-MK5-CABLE-ASY
CV4412-000
*Note: Heating tool and controller not sold separately.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 11
Raychem Mini-Ray MK4
Heating Tool Systems
SAFE AND EFFICIENT
• Product being installed is visible
during the heating cycle
• Optical filter eliminates unwanted UV
emissions and excess visible light,
reducing glare for the operator
• Heat energy from a tungsten
halogen lamp is focused onto the
product with a reflector
VERSATILE
• Controller can be used in a manual
mode with the trigger switch or by
pre-set time and power
• Up to 20 memory locations are
available for the storage of time/
power values
COMPONENTS
• The ED-7-Cont-230 V/110 V
controller is a simple unit, with no
variable time or variable power
memory functions
• The ED-7-001/002 control units
provide controls for both power
and time, and are suitable where the
use of pre-set installation conditions
is required
• The ED-7-Batterybox controller is
designed for remote areas, and can
install approximately 50 x 30 second
installations before recharging
COMPLETE
• A kit product is available, comprising
manual control box, hand tool,
Mini-Ray MK4 Infrared Heating Tool
Designed for installing SolderSleeve termination products
up to 9 mm diameter.
IR-1759-MK4/A, IR-3104-MK4/A
ED-7-001/002, ED-7-CONT-230 V/110 V
ED-7-BATTERYBOX-230 V/110 V
The Raychem Mini-Ray MK4 tool from TE is a hand held
infrared heating tool designed for use in installing SolderSleeve
termination products. The tool is portable, lightweight and
convenient for use where workspace is restricted.
The hand tool is fan cooled and has low heat emission as the
lamp is only energized on demand. A duty cycle up to 50% is
permissible with a maximum heating time of 50 seconds. With
the ED-7-Cont and ED-7-Batterybox, this duty cycle is fixed
within the controller software.
The controllers have a new software feature that improves
filter and bulb life. The heat energy is derived from a halogen
lamp and is focused onto the product by means of the reflector
design. The IR-1759-MK4/A standard aperture is recommended
for products up to 6 mm diameter and the IR-3104-MK4/A large
aperture for products up to 9 mm diameter. This version of
the tool will accept larger diameter components, but uniform
heating is not then assured.
AT3130 reflector and bulb
Note: Current optical filters still fit the older MK III tools.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 12
Application Tooling
Specifications
Mini-Ray MK4 Heating Tool System
Hand Tool
Control Units
IR-1759/IR-3104
ED-7-001/002
ED-7-Cont
ED-7-Batterybox
Supply Voltage
21.5 VAC nom.
230 VAC,
50 Hz and
110 V, 50-60 Hz
230 VAC, 50 Hz or
110 V, 50-60 Hz
Input Current
—
4 A/10 A
6.3 A
2 x 12 V
batteries, not
supplied
Output Voltage
—
16-22 VAC
(dependent on
program)
21.5 VAC
22 VDC nominal
Weight
1.1 kg (2.4 lb.)
6.2 kg
(13.6 lb.)
8.0 kg (17.6 lb.)
8.5 kg, 160
(18.7 lb.)
Typical Operating
Temperature
500°C @ 10 second operation
—
—
—
Typical Heating Time
15 seconds
—
—
—
Halogen Lamp. Power/
Live, Typical Values
250 W x 24 V average life 10,000
cycles @ 50% duty cycle
—
—
—
Noise
41 dB (A)
—
—
—
Power Cord Length
3.1 m
—
—
—
Dimensions
—
Timer A
Memory Locations
(001 and 002 only)
—
NP7-12FR
Yuasa 12 V 7 Ah
6.3" x 4.7" x 9.8"
1-250 secs
20 Memory
—
—
*Note: Current optical filters still fit the older MK III tools.
Ordering Information
IR-1759 Infrared Heating Tools
Model
Description
Part No.
Mini-Ray MK4 Heating Tool System
IR1759-MK4-AT3130-EDCont
Hand tool/Reflector/Control Box
CF0024-000
IR-1759-MK4/A (1)
Hand tool, standard aperture
CF0025-000
IR-3104-MK4/A (1)
Hand tool large aperture
CF5497-000
IR1759-MK4AT3130-ED-7-001
Hand tool/standard aperture/
Timed 230 V Control Box
EG3472-000
ED-7-001-MK4-230V-50HZ
Control Box with time control-230 V
CF0199-000
ED-7-002-MK4-110V-60HZ
Control Box with time control-110 V
CF0201-000
ED-7-CONT-230/11OV-MK4
Control Box manual control 110/230
CF0026-000
ED-7-BATTBOX-MK4-230/110V
Battery Box†
CF0200-000
†Battery box takes 2X12V batteries, type NP7-12FR. Please note that TE does not supply replacement batteries.
(1) Note: No control box or reflector supplied. Hand tool only.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 13
Application Tooling
Ordering Information (continued)
Accessories and Replacement Parts
Model
Description
Part No.
AE-153
Inner reflector for large aperture (3104)*
988285-000
AE-424
Inner reflector for standard aperture*
547918-000
AES-IR1759-100- FILTER-DUL
Standard filter*
431468-000
AES-IR1759-300-FLT-LRG
Large filter
F52511-000
ED-7-CONT-PCB
PCB*
CA3022-000
AE-900
Filter spring IR-1759*
277774-000
AE-897
Conversion kit for standard to Large aperture*
966953-000
AT-3130
Reflector to fit standard aperture standard Vee block*
988299-000
AT-3131
Reflector to fit standard aperture for SolderTacts contacts*
988300-000
AT-3132
Reflector to fit standard aperture*
988301-000
AT-3132-MK31/1
Reflector to fit standard aperture with clamps*
879865-000
AT-3134
Reflector to fit large aperture with standard Vee block*
988303-000
AT-3147
Reflector to fit large aperture with clamps*
988328-000
AT-3191
Reflector to fit standard aperture special Vee block*
588701-000
ED-7-CONT-TRANSFORMER
Transformer
139128-000
ED-7-BATT-FRONT-PANEL
Comes complete with PCB
132692-000
IR-1759/3104-CABLE-ASSY
Trigger PCB/cable/fan/lamp holder*
585643-000
NAE-143-3
Bulb 250 W, 24 V IR1759/3104*
988208-000
AE-205
Linear reflector for standard aperture
988596-000
AE-226
Linear reflector for large aperture
988314-000
AT-3134/AE-897
Reflector and conversion kit (see above)
934630-000
NAE-109-02
Lamp support
988382-000
NAE-152-1
Fan
988204-000
MINIRAY-GUN-CASE
Mini-Ray heat gun case
CM8837-000
*Items marked with an asterisk are compatible and can be used with MK2/MK3 IR1759.
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 14
Raychem CV2014 Series
ThermoGun Heating Tool
SPACE AND WEIGHT EFFICIENT
• Ultra compact design
• Lightweight: 600 g (1.32 lb.)
POWERFUL
• Produces temperatures to 650°C
•E
lectronic steplessly controlled
temperature
•E
lectronic steplessly controlled
airflow
•E
lectronic heating element
protection
SAFE
• Low noise
• Built in stand
• UL Approved
CV2014 Series ThermoGun Heating Tool
Tool is used for installing TE heat-shrink tubing and SolderSleeve
terminations, and for making cable repairs.
CV2014-JETS-120V460W-UL
CV2014-JETS-230V460W-EU
CV2014-JETS-230V460W-UK
The small, but powerful Raychem CV2014 hot air gun is
capable of producing temperatures of up to 600°C. It can be
used for installing heat-shrink tubing, SolderSleeve devices,
and cable repair products.
PR Reflectors as shown below can be used with a
reflector adapter.
Specifications
POWER
• Voltage: 120 V (US models) or 230 V (UK/EU models)
• Power Consumption: 460 W
AIR
• Air Flow (@ 20°C): 20 to 80 l/min
TEMPERATURE
• Temperature Range: 40°C to 650°C
DIMENSIONS
•S
ize (L x ø): 235 mm L × 70 mm dia., 9.25" L x 2.75 dia.
Handle is 40 mm (1.6") dia.
WEIGHT
• 0.6 kg (1.3 lb.) (with 3 m cord)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 15
Application Tooling
Ordering Information
CV2014 Series ThermoGun Heating Tools
Model
Plug
Description
Part No.
Hot Jet S 120 V/460 W
UL (US)
CV2014-JETS-120V460W-UL
EG2900-000
Hot Jet S 230 V/460 W
Schuko (EU)
CV2014-JETS-230V460W-EU
EG2902-000
Reflectors
Reflector/Application
Description
Part No.
PR Reflector adaptor
CV2014-PR-ADAPTOR
EG3417-000
PR-38: Large cable repair
PR-38-REFLECTOR
EG2498-000
PR-13: Tubing up to 6 mm dia.
PR-13-REFLECTOR
991963-000
PR-13-C: Tubing 6 to 12 mm dia.
PR-13C-REFLECTOR
991974-000
PR-25: SolderSleeve products up to 6 mm dia.
PR-25-REFLECTOR
991965-000
PR-25-D: SolderSleeve products 6 to 12 mm dia.
PR-25D-REFLECTOR
989523-000
PR-26: Miniature SolderSleeve products and small products
PR-26-REFLECTOR
991967-000
PR-33: For SolderSleeve products 20 to 27 mm dia.
PR-33-REFLECTOR
997768-000
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 16
Raychem CV1981 and CV1983 Series
ThermoGun Heating Tools
VERSATILE
•H
eavy-duty bench or hand held hot
air tool
• Intelligent e-Drive operating unit
•D
igital temperature indicator
(AT models) for easy adjustment to
product requirements
CAPABLE
•W
ide temperature range:
40°C to +650°C
•P
recise temperature control on AT
models allows tool temperature
to be matched to the heat-shrink
product’s requirements
• Closed-loop controlled temperature
• Open-loop controlled air volume
SAFE
• Ergonomic handling
• Modern design
• Safety guard
CV1981 and CV1983 Series ThermoGun Heating Tools
ThermoGun heating tools are used for installation of TE heatshrink products, molded parts, and SolderSleeve terminations.
CV1981 Series ThermoGun Heating Tool
CV1983 Series ThermoGun Heating Tool
Raychem CV1981 and CV1983 Series ThermoGun heating tools
from TE are intelligent, robust, double insulated heavy-duty
tools. The tools use an internal thermocouple to ensure accurate
output temperature.
CV1981 AT model use closed-loop control to ensure that
the set value is achieved even while supply voltage varies
slightly. The digital display shows set temperature and
measured temperature simultaneously. AT models also feature
adjustable airflow.
A motor-driven fan forces air through the heating element,
which is enclosed in a stainless steel barrel and safety guard.
The tool is fitted with power control, to allow for adjustment
of output temperature. An integral stand allows the tool to be
used as a bench tool.
The heating tool is available in a variety of models and is
suited to a wide range of heat-shrink applications. The various
PR Series push-on reflectors are easily and quickly attached
to the gun.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 17
Application Tooling
Specifications
Power Consumption
CV1981
CV1983
1600 W
2300 W/2400 W/3400 W
Voltage
120 V or 230 V
Temperatures
40°C to 650°C
Air Flow (20°C)
240 l/min max.
Dimensions
Tool: 338 mm L x 90 mm dia. (13.3" L x 3.5" dia.)
Handle: 56 mm (2.2" dia.)
Weight
990 g (2 lb.)
1.3 kg (2.9 lb.)
Ordering Information
Heating Tools
Model
Description
Part No.
CV1981 AT Series (with Controlled Temperature, Adjustable Air Volume, and Digital Display)
230 V, 1600 W, EU Plug
CV1981-ATPID-230V1600W-EU
EG1106-000
230 V, 1600 W, UK Plug
CV1981-ATPID-230V1600W-UK
EG1108-000
120 V, 1600 W, US Plug
CV1981-ATPID-120V1600W-US
EG1110-000
120 V, 1600 W, CEE Plug
CV1981-ATPID120V1600W-CEE
EG1112-000
CV1981 ST Series†
230 V, 1600 W, EU Plug
CV1981-ST-230V1600W-EU
EG1114-000
230 V, 1600 W, Swiss Plug
CV1981-ST-230V1600W-CH*
EG1115-000
230 V, 1600 W, UK Plug
CV1981-ST-230V1600W-UK*
EG1116-000
120 V, 1600 W, US Plug
CV1981-ST-120V1600W-US*
EG1118-000
120 V, 1600 W, CEE Plug
CV1981-ST-120V1600W-CEE*
EG1120-000
230 V, 3400 W, EU Plug
CV1983-ST-230V3400W-EU
EG0998-000
230 V, 2300 W, EU Plug
CV1983-ST-230V2300W-EU
EG1100-000
CV1983 ST Series†
120 V, 2400 W, CEE Plug
CV1983-ST-120V2400W-CEE
EG1102-000
230 V, 3400 W, CEE Plug
CV1983-ST-230V3400W-CEE
EG1104-000
*Note: Refer to TE installation guides and Codes of Practice for appropriate temperature settings.
† ST tooling does not feature digital display.
Accessories and Replacement Parts
Spare/replacement elements for CV1981 and CV1983
Description
Part No.
CV1981-ATSTELEM-230V1600W
EG8165-000
CV1981-ATSTELEM-120V1600W
EG8166-000
CV1983-STELEM-230V3400W
EG8167-000
CV1983-STELEM-230V3400W
EG8168-000
CV1983-STELEM-120V2400W
EG8169-000
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 18
Application Tooling
Accessories and Replacement Parts (continued)
Spares for CV1981MK2-PID, CV1983M2
Description
Part No.
CV-1981-PID-ELEM-120V
179178-000
CV-1981-PID-ELEM-230V
091282-000
CV-1983-M2-230V-2200W-ELE
D40442-000
CV-1983-M2-230V-3060W-ELE
123906-000
Reflectors
Part
Description
Part No.
AD-1962-CV1648-PR.RFL-ADP
Adaptor to CV1983 for PR Series Reflectors
989172-000
AD-1999-Temp-Meas-Rflt
Temperature Measurement Reflector
932525-000
PR-12-REFLECTOR
For Tubing 6 to 25 mm Dia.
991973-000
PR-13-REFLECTOR
For Tubing up to 6 mm Dia.
991963-000
PR-13C-REFLECTOR
For Tubing 6 - 12 mm Dia.
991974-000
PR-21-REFLECTOR
For Tubing 6 - 25 mm Dia.
991984-000
PR-24-REFLECTOR
For Small Molded Parts and Tubing 25 to 35 mm Dia.
991964-000
PR-24-A-REFLECTOR
For Small Molded Parts and Tubing 35 to 60 mm Dia.
991989-000
PR-25-REFLECTOR
For SolderSleeve Products up to 6 mm Dia.
991965-000
PR-25-D-REFLECTOR
For SolderSleeve Products 6 to 12 mm Dia.
989523-000
PR-26-REFLECTOR
For Miniature SolderSleeve Products and Small Products
991967-000
PR-27-REFLECTOR
Special
997858-000
997768-000
PR-33-REFLECTOR
For SolderSleeve Products 20 to 27 mm Dia.
PR-34-REFLECTOR
For SolderSleeve Products 12 to 20 mm Dia.
989111-000
PR-ATUM-HTAT-16/4-32/8
For HTAT 16/4 - 32/8
463664-000
AD-7-025
Unicure Heat Shield (HS1)
121629-000
Accessories and Replacement Parts
Reflectors
Applications
Description
Part No.
A-160-HG
Up to 19 mm (0.75") Dia. Tubing
TG-12/A-160-HG-RFL-SMALL
991017-000
A-170-HG
19 to 51 mm (0.75" to 2") Dia. Tubing
A-170-HG
991018-000
TG-23
44 to 51 mm (1.75") Dia. Tubing
TG-23/A-205-HG
991026-000
TG-24
Molded Parts
TG-24-RFL-LGE-BOOT
991027-000
TG-23 and TG-24 reflectors will fit
CV-1981 and CV-1983 heat guns
using adaptor part 989172-000
AD-1962-CV1648-PR.RFL-ADP
A-160-HG Reflector
A-170-HG Reflector
TG-23 Reflector
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 19
Heat Guns for
Raychem Products
HL1920E
CONVENIENT
• Electronic temperature control
• Hand-held and self-resting
• Industrial grade rubber power cord
RELIABLE
• Thermal fuse
• Dual air vents
• Ergonomic soft grip handle
HL2020E
ADVANCED
• Electronically controlled hot air tool
with LCD display
• Adjustable by joystick from 80°C to
630°C in 10°C steps
• Current working temperature and
airflow rate is indicated on the display
SAFE, COMFORTABLE
• Residual heat indicator to
prevent burns
• Ergonomic soft grip handle
Raychem Heat Guns
Tools are designed for installation of TE heat-shrink products
and SolderSleeve devices.
HL1920E
HL2020E
HL1920E
The HL1920E heat gun is a powerful, electronically controlled
hot air gun with temperature control and cool air stage.
The switch, located on the grip handle, is used for setting
temperature and airflow. The heat gun can be conveniently
operated using one hand.
Temperature range 50°C to 600°C @150/300/500 l/min.
Both tools are suited for heat-shrink products and
SolderSleeve devices.
HL2020E
ROHS Information can be found at the following
website: http://www.te.com/customersupport/
productcompliance/
This product must not be disposed of as
municipal waste.
The HL2020E heat gun from TE is a microprocessor-controlled,
high-end heat gun with temperature control, LCD display, and
cold air stage. The heat gun features a joystick for making
temperature adjustments, and the current working temperature
is identified on an LCD display.
Temperature range: 80°C to 630°C in 10°C steps @150/300/
500 l/min.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 20
Application Tooling
Specifications
TEMPERATURE
HEATER ELEMENT POWER
• HL2020E: 80°C to 630°C
• HL1920E: 50°C to 600°C
• 120 V, 2000 W
• 230 V, 2000 W
POWER
WEIGHT
• 120 V - 60 Hz, 12.5 A
• 230 V - 50 Hz, 8.7 A
• 900 g (2.0 lb.)
CORD LENGTH
Ordering Information
• 2.2 m (7.2') approx.
Heat Guns
Models
Description
Part No.
230 V, UK Plug
HL1920E-230V-UK
EG8160-000
230 V, EU Plug
HL1920E-230V-EURO
EG8162-000
Kit, 230 V, EU Plug
HL1920E-KIT-230V-EURO
EG8164-000
HL1920E Tools
Kit, 120 V, US Plug
--
CJ2086-000
HL2020E Tools
230 V, UK Plug
HL2020E-230V-UK
EG6424-000
230 V, EU Plug
HL2020E-230V-EURO
EG6422-000
Kit, 230 V, EU Plug
HL2020E-KIT-230V-EURO
EG6426-000
Kit, 120 V, US Plug
--
CJ2087-000
Description
Part No.
Note: Kit contains heating tool plus SolderSleeve reflector EH0600-000.
Accessories and Replacement Parts
Part/Application
Reflectors
Adaptor for PR Series Reflectors
*HL-ADPT-PR-REFLECTORS
EH0598-000
Reflector For Tubing
HL-GEN-TUBE-REFLECTOR
EH0599-000
Reflector for SolderSleeve Products
HL-SOLDER-SLV-REFLECTOR
EH0600-000
9 mm Nozzle For Small-to-Medium Tubing
HL-9MM-REDUCTION-NOZ
EH0601-000
14 mm Medium Nozzle
HL-14MM-REDUCTION-NOZ
EH0602-000
20 mm Medium-to-Large Nozzle
*PR-12-REFLECTOR
991973-000
HL-BENCH-STAND
EH0603-000
Reduction Nozzles
Stands
Bench Stand for Fixed Position Environments
Note - Reflector: SolderSleeve reflector comes with the kit only.
*HL-ADPT-PR-REFLECTORS required for use with PR-12-REFLECTOR.
SolderSleeve Reflector
20 mm Reduction Nozzle
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
Small to Medium Tubing
Reflector Tubing
PAGE 21
Raychem AA-400 Super Heater
Compressed-Air Heating Tool
APPLICATIONS
• For installing heat-shrinkable tubing
in confined spaces
• Small SolderSleeve devices
• Devices (wire-to-pin applications)
• SolderTacts contacts
VERSATILE
• Very focused heat
• Wide variety of reflectors available
• Excellent tool for small items and
confined areas
EASY TO USE
• Automatic power cut-off switch to
protect heating element if air flow is
interrupted
• Pressure regulator and gauge for
AA-400 Super Heater Compressed-Air Heating Tool
Tool is used for installing heat-shrinkable tubing and devices.
AA-400-32-Mk3 (120V)
AA-400-200-CE-SUPERHTR (230V) CE
adjusting air flow and temperature
• Indicator light to show when power
is applied to heating element
Specifications
POWER
• 120 V model: 120 VAC, 4 A, 50–60 Hz
• 240 V model: 240 VAC, 2 A, 50–60 Hz
AIR
• 60 psi /413 kPa /4 bar minimum, 5 cfm, oil free
DIMENSION
• 152 x 108 x 89 mm (6 x 4.25 x 3.5") with regulator
WEIGHT
• 1kg (2.2 lb.)
TEMPERATURES
• Standard Tool as Supplied: 375°C to 400°C
• Tool with Needlepoint Tip: 283°C to 306°C
• Tool with Mini SolderSleeve Reflector: 347°C to 459°C
(Temperatures achieved within the specified pressure switch operating
range as shown on the front of controller.)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 22
Application Tooling
Ordering Information
AA-400 Super Heater
Model
Voltage AC
Description
Part No.
120
AA-400-32-Mk3 (120 V)
582602-000
240 CE
AA-400-200-CE-SUPERHTR
281917-000
AA-400 Super Heater
(With stand, needlepoint tip,
Mini SolderSleeve reflector,
and input air filter
Note: Controller is not sold separately.
Accessories and Replacement Parts
Parts
Description
Part No.
NSN Stock No.
SolderSleeve Reflector
AA-400-94-SLD-SLV-TIP-KIT
979646-000
4940-00-609-4993
*Needlepoint Tip
AA-400-96
979647-000
4940-00-148-9847
Boot And Tubing Tip
AA-400-101
979691-000
4940-00-148-9848
*Mini SolderSleeve Reflector
AA-400-102
979663-000
4940-01-043-7634
3439-01-173-8810
Low-Flow Tip
AA-400-103
979672-000
Heating Element Replacement Kit, 120 V
AA-400-128
013750-000
Heating Element Replacement Kit, 240 V (CE)
AA-400-228-EL-KT-240V-CE
444179-000
*Stand
AA-400-09
979649-000
*Input Air Filter
AA-400-P-Y-92-Filter
979673-000
Air Hose Replacement Kit
AA-400-136
156553-000
Gun And Air Hose Replacement Kit
AA-400-229-GUN-HSE-KIT
238231-000
*Indicates parts that come with the Super Heater
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 23
Raychem HT-900B Compressed Air
Nitrogen Heater Tools
CAPABLE
• 290°C to 495°C temperature range
• Compressed air/nitrogen 80 to
200 psi
• Regulated air/nitrogen through
the hose
• Air/nitrogen monitored by small
sensing hose
EASY TO USE
• Temperature is controlled by
the controller setting and on
thermo-couple feedback
• On/Off power switch handle with
overload protection controls
electrical supply
SAFE
• Automatic shutdown if air supply
falls below 5.0 psi
• Compressed air/nitrogen runs
through four orifices to cool handle
of tool
• Power on light for unit
• Heated air light for heating element
HT-900B Compressed Air Nitrogen Heater Tools
(Available in the US only)
Tools are used for the field installation of heat-shrinkable
insulation and termination products.
HT-900B-1-HT-TOOL-YELLOW (115 V)
HT-900B-30-HT-TOOL-OLIVE (115 V)
HT-920B-10-HT-TOOL-YELLOW (230 V)
HT-920B-1-HT-TOOL-OLIVE (230 V)
The Raychem HT900B compressed air/nitrogen heating
tool from TE supplies a stream of heated air or nitrogen to aid
in the field installation of heat-shrinkable insulation and
termination products.
The heating tool consists of a heat gun and a control module.
The tool comes with hot air reflectors, a spare heating
element, thermocouple, and operating instructions. The heat
gun is permanently attached to the control module by a hose
assembly, which contains air hoses and electrical wires.
The compressed air/nitrogen heating tool operates by passing
a stream of air or nitrogen through an electrical heated element
located in the body of the heat gun.
Specifications
ELECTRICAL
• HT-900B: 115 VAC, 50-400 Hz, single-phase, 7 A
• HT-920B: 220 VAC, 50-400 Hz, single-phase, 3.5 A
WEIGHT
• 9 kg (20 lb.)
DIMENSION
• Tool Case: 246 x 440 x 292 mm (9.7" x 17.3" x 11.5")
OUTPUT TEMPERATURE
• 290°C to 495°C
COMPRESSED AIR/NITROGEN
• 80 to 200 psi, 4 SCFM (Dry and oil-free)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 24
Application Tooling
Ordering Information
HT-900B Compressed Air Nitrogen Heater Tools (Available in the US only)
Model
Voltage
Description
Case Color
Part No.
HT-900B
115
HT-900B-1-HT-TOOL-YELLOW
Yellow
910987-000
HT-900B
115
HT-900B-30-HT-TOOL-OLIVE
Olive Drab
837097-000
HT-920B
230
HT-920B-10-HT-TOOL-YELLOW
Yellow
303754-000
HT-920B
230
HT-920B-1-HT-TOOL-OLIVE
Olive Drab
712121-000
Accessories and Replacement Parts
Part
Description
Part No.
Heating Element
HT-900A-112-SPAR-ELE-115V
252997-000
Thermocouple
HT-900A-114-TC-RPLMT-KIT
729711-000
1. Boot and Tubing Reflector
AA400-101-STAINLESS-BOOT
979691-000
2. Miniature Termination Sleeve Reflector
AA-400-102-MINI-SOLD-TIP
979663-000
3. Termination Sleeve Reflector
HT-900A-103-REFL-RPLMT-KT
491878-000
Supplied with HT-900B and HT-920B tools, and as replacement parts
4. Needle Point Reflector
AA-400-96-NED-PNT-TIP-KIT
979647-000
5. Large Boot and Tubing Reflector
HT-900A-100-LBT-RPLMT-KIT
444100-000
Heater Element, 120 V
HT-900A-123-HTR-RPLMT-KIT
508744-000
Heating Element, 230 V
HT-920A-124-HTELE-RPL-KIT
011349-000
Additional Replacement Parts
1
2
Handle Kit 115 V
HT-900A-32-HNDLE-KIT-115V
980123-000
Handle Assembly
HT-900A-34-HANDLE-ASSMBLY
074594-000
3
4
5
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 25
Raychem AD-5000
Installation Tool
EASY TO USE
• Designed specifically to install
Tinel-Lock ring screened
terminations in the correct position
• Tinel-Lock rings have thermochromic
patch to aid in consistent installation
• Thermochromic patch color changes
to black to provide visual verification
of correct installation
• Tool switches off when pressure on
jaws is released
FAST
• 5 to 15-second typical installation
time for a Tinel-Lock ring
• Simple line-up and squeeze-handle
installation
AD-5000 Installation Tool
Tool is used to correctly position and install size TR04 to TR24
Raychem Tinel-Lock rings in screened terminations.
VERSATILE
AD-5000-TINEL-ASSY
• Accommodates Tinel-Lock rings
The AD-5000 tool is a manually operated resistance-heating
tool designed to install Raychem Tinel-Lock rings in screened
terminations. Intended for small batches, the tool makes it easy
to consistently and quickly install Tinel-Lock rings. Machine cycle
time is typically 5 to 15 seconds, depending on ring size and
braid type on the termination.
from size TR04 to TR24 inclusive
• Various electrode types can be used
to install other Tinel-Lock ring sizes
and types
The tool accommodates Tinel-Lock rings from size TR04 to
TR24. Various electrode (jaws) types can be used to install other
ring sizes and types.
Specifications
POWER
• Supply: 220–240 V, 50 Hz
• Main Fuse: 240 V, 2 A (Type T) Anti-surge
• System Noise: Silent operation
DIMENSION
• 340 x 320 x 170 mm (13.4" x 13" x 6.7")
WEIGHT
• 4.2 kg (9.5 lb.)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 26
Application Tooling
Ordering Information
A complete tool includes the hand tool assembly and electrodes. Three types of electrodes are available:
• Standard electrodes are used for Tinel-Lock rings, sizes TR04 through TR24
• Conduit electrodes are used when terminating Tinel-Lock rings on conduit or double braids
• Square profile electrodes are used with TC02 and TC03 rings
Tinel installation tool AD-5000-TINEL-ASSY includes both the hand tool assembly
(AD-5000-TINEL-HAND-TOOL) and standard electrodes (AD-5000-TINEL-STD-ELECT).
AD-5000 Installation Tool
Model
Description
Part No.
AD-5000 Installation Tool
AD-5000-TINEL-ASSY
411993-000
Parts
Description
Part No.
Hand Tool Assembly
AD-5000-TINEL-HAND-TOOL
795257-000
Standard Electrodes
AD-5000-TINEL-STD-ELECT
180245-000
Conduit Electrodes
AD-5000-TINEL-COND-ELECT
747235-000
Square Profile Electrodes
AD-5000-TINEL-SQ-EXT-ELEC
065583-000
Accessories and Replacement Parts
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 27
Raychem AD-5020
Installation Tool
CONVENIENT
• Designed specifically to install
Tinel-Lock ring screened
terminations in the correct position
• Foot pedal operated on and off
• Controller “POWER OUTPUT” is
adjustable from 80% to 100%
EASY TO USE
• Ring’s thermochromic patch color
changes to black to provide visual
verification of correct installation
• Tool switches off when foot pedal
is released
FAST
• 5 to 15-second typical installation
time for a Tinel-Lock ring
• Simple line-up and press foot pedal
switch installation
AD-5020 Installation Tool for Tinel-Lock Rings
Tool is used to correctly position and install size TR04 through
TR24 Raychem Tinel-Lock rings in screened terminations.
AD-5020-TINEL-HAND-TOOL-230V
EG1245-000
The AD-5020 tool is a manually operated resistance-heating
tool designed to install Tinel-Lock rings in screened
terminations. Intended for small batches, the tool makes it easy
to consistently and quickly install Tinel-Lock rings. Machine cycle
times typically 5 to 15 seconds, depending on ring size and
braid type on the termination.
The tool accommodates Tinel-Lock rings from size TR04
through TR24. A foot pedal is used to cycle the tool on and off.
Specifications
POWER
• Supply: 220–240 V, 50 Hz
• Main Fuse: 230 V, 4 A (Type T) Anti-surge
• System Noise: Silent operation
DIMENSIONS
• 160 x 120 x 250 mm (6.3" x 4.7" x 9.8")
• Power Lead: 1.3 m (51”)
• Foot Pedal Lead: 2 m (78”)
WEIGHT
• 7.9 kg (17.4 lb.)
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 28
Application Tooling
Ordering Information
AD-5020 Installation Tool
Model
Description
Part No.
AD-5020 Hand Tool
AD-5020-TINEL-HAND-TOOL
EG1245-000
Model
Description
Part No.
Standard Electrodes
AD-5020-TINEL-ELECTRODE
EG7238-000
Jaws
AD-5020-TINEL-JAWS
EG7239-000
PCB for Controller
AD-5020-TINEL-PCB
EG7240-000
Accessories and Replacement Parts
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 29
RH-3960 and RH-3965
Tinel-Lock Installation Tools
EASY TO USE
• Designed specifically to install
Tinel-Lock ring screened
terminations in the correct position
• Tinel-Lock rings have thermochromic
patch to aid in consistent installation
• Thermochromic patch color changes
to black to provide visual verification
of correct installation
• Tool switches off when pressure on
jaws is released
FAST
• 5 to 15-second typical installation
time for a Tinel-Lock ring
• Simple line-up and
squeeze-handle installation
VERSATILE
• Accommodates Tinel-Lock rings
from size TR04 to TR24 inclusive
RH-396X Tinel-Lock Installation Tool
Tool is designed specifically to install TE Connectivity’s
Tinel-Lock rings for screened terminations.
RH-3960-1-TINEL-KIT-120V
RH-3965-1-TINEL-KIT-220V
The RH-396X manually operated resistance heating tool is
designed specifically to install TE Connectivity’s Tinel-Lock rings
for screened terminations. Available in 120 V and 220 V versions,
it is designed to accommodate our Tinel-Lock rings from size
TR04 through TR24 inclusive.
The tool makes it easy to install Tinel-Lock rings consistently
and quickly. The operator uses the hand-held tool to install the
Tinel-Lock ring in its correct position on screened terminations.
The ring has a patch of thermochromic paint, which turns to a
black color upon successful installation.
The operator positions the ring on the termination, ensuring
that the patch of thermochromic color is visible. The jaws
of the installation tool are then clamped onto the ring to start
the installation. When the thermochromic paint turns black,
installation is complete.
The RH-396X Tinel-Lock ring installation tool is available in
North America and Asia Pacific only.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 30
Application Tooling
Specifications
POWER
• Supply: 250 W/2.8 VAC
TRANSFORMER DIMENSIONS
• 260 mm x 210 mm x 165 mm (10.25" x 8.25" x 6.5")
WEIGHT
• 3.18 kg (7.0 lb.)
Ordering Information
Recommended for installing Tinel-Lock rings TC series and TR04 thru TR20.
A complete tool includes the hand tool assembly and electrodes.
• Standard electrodes are used for Tinel-Lock rings, sizes TR04 through TR24
• Resistance Heating Tool: 915088-01
• Use with American Beauty Transformer 105-A12 (110 V) or 105-A12-220V (220 V) and Foot Switch 10519
TH-3960 and TH-3965 Installation Tools
Model
Description
Part No.
TH-3960 Installation Tool (120 VAC)
RH-3960-1-TINEL-KIT-120V
173643-000
TH-3965 Installation Tool (220 VAC)
RH-3965-1-TINEL-KIT-220V
859855-000
Parts
Description
Part No.
Hand Tool Assembly
915088-01-TINI-RING-HEATR
170224-000
Foot Switch
IR-500-P-FOOT-SWITCH
993702-000
120 VAC Transformer
AES-RH3960-TRNSFMR-120V
9951119-000
220 VAC Transformer
TRNSFMR-220V-105-A12-250W
574557-000
Accessories and Replacement Parts
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 31
Raychem Underwater
Cable Splice (UWCS) Kit
CONVENIENT
• Portable
• Available in 110 V and 240 V
• Full range of spares available
FOR INSTALLING HIGH
PERFORMANCE SPLICES
• Splices tested to 86 bar
(on specified cables)
• Splices operating temperature range:
-55°C to +95°C
• Kit: NATO Codified (110 V option)
Raychem Underwater Cable Splice Kit
Tool is used for jointing of TE specified polyethylene
jacketed cables.
ROHS Information can be found at the following
website: http://www.te.com/customersupport/
productcompliance/
This product must not be disposed of as
municipal waste.
UWCS-AT3535-110V
UWCS-AT3535-220V
The Raychem underwater cable splice (UWCS) from
TE is suitable for jointing of TE specified polyethylene jacketed
cables, which are subject to water immersion and pressure.
The splice consists of molded polyethylene inserts, which are
encased in a heat recoverable sleeve. The joint is placed in a
purpose-made oven, which melts the joint components with
the cable jacket and, when cooled, gives a water- and
pressure-tight joint with the insulated conductor connections
embedded within it.
Specifications
ELECTRIC
• 110 V
• 240 V
TOOL KITS
Voltage
Description
Part No.
110 V
UWCS-AT3535-110V
921209-000
240 V
UWCS-AT3535-220V
866776-000
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 32
Application Tooling
Product Range
Cable Description
(Diameter first)
EPD No.
Splice Kit
End Cap
6.8 mm, 6 mm2 unscreened
26732C
UCWS-1U/6.8
UWCS-END-CAP/6.8
unscreened
26732C
UCWS-1U/10.9-1U/6.8
6.8 mm, 6
mm2
TO
10.9 mm, 25 mm2 unscreened
UCWS-2U/7.6
7.6 mm, 2 core unscreened
21735F
7.6 mm, 2 core unscreened
21735F
UCWS-2U/7.6-1C/5.8
UWCS-END-CAP/7.6
5.8 mm, 25 mm Coaxial
26640A
UCWS-2S/8.3
8.3 mm, 2 core screened
21291G
UCWS-2S/8.3
UWCS-END-CAP/8.3
TO
8.3 mm, 3 core screened
24171E
UCWS-3S/8.3
UWCS-END-CAP/8.3
8.3 mm, 4 core screened
21736E
UCWS-4S/8.3
UWCS-END-CAP/8.3
10.3 mm
45572Q
10.9 mm, 25
mm2
unscreened
UWCS-END-CAP/8.3
31451A
UCWS-1U/10.9
11.2 mm, 50’Ω Coaxial
25984G
UCWS-1C/11.2
12.7 mm, 3 core unscreened
36892C
UCWS-3U/12.7
UWCS-END-CAP/11.2
* Please contact TE for more details
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 33
Raychem AD-1319-9
Holding Fixture
EASY TO USE
• Holding fixture simplifies and
speeds installation of terminations
and splices
• Two lateral clamps, simple to adjust
and align
• Fixture secures wire or cable for
consistent installation
VERSATILE
• Designed for use with Raychem
heat-shrinkable devices
• Adjustable jaws set distance
between clamps
AD-1319-9 Holding Fixture
Tool is used to quickly and accurately install Raychem
heat-shrinkable devices.
AD-1319-9
The AD-1319-9 holding fixture is a tool that simplifies and speeds
installation of Raychem devices. The fixture contains two wire
clamps that are easily adjusted to center and secure the wire or
cable for installation.
Specifications
DIMENSION
• 180 x 150 mm (7" x 6") approx.
WEIGHT
• 300 g (.67 lb.)
PRODUCT RANGE
•
•
•
•
•
•
SolderSleeve splices
DuraSeal splices
MiniSeal splices
One-Step BNC/TNC connectors
Shield terminators: D-100-XX, D-144-XX, SO63, SO96
SolderTacts contacts: D-602-XX
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 34
Application Tooling
Ordering Information
AD-1319-9 Holding Fixture
Model
Description
Part No.
AD-1319-9 Holding Fixture
AD-1319-9
993850-000
Note: For holding fixtures for our SolderTacts products, please refer to TE’s SolderTacts brochure, 1-1773722-5.
Accessories and Replacement Parts
Parts
Description
Part No.
38999 Size 8 Contact
AT-1319-22
395241-000
38999 Size 16 Contact
AT-1319-78
413186-000
Subminiature Contact
AT-1319-12
993872-000
748 Contact
AT-1319-14
993877-000
723 Contact
AT-1319-19
993938-000
482 Size 16 Contacts
AT-1319-17
993917-000
SolderTacts Adapters
ROHS Information can be found at the following website: http://www.te.com/customersupport/productcompliance/
This product must not be disposed of as municipal waste.
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 35
Application Tooling
Selecting the Equipment Needed To Install TE Connectivity
Heat-Shrinkable Products
Selecting the proper tool is very important in order to ensure correct and efficient installation.
Our application equipment has been designed, selected, and engineered for maximum production
efficiency, providing optimal heating temperatures, performance and control features.
TE has developed installation Codes of Practice and Product Installation Procedures that give
instructions to our customers in the correct methods for successfully installing our heat-shrinkable
products. These are either available as stand-alone documents, or are incorporated into the product
drawings themselves.
Below are listed some of our heat-shrinkable products along with the recommended tooling that can be
found within this catalog. Please note that there are some tools that can be used for the installation of
several of our product families, such as our various types of heat gun.
In order to ensure the correct and focused delivery of heat, reflectors are recommended and available
in a variety of sizes. For more details, see the Codes of Practice and Product Installation Guides, or
contact your TE representative.
Product Family
Recommended Application Tooling
Page
AD-1377 Hand Crimping Tool
3
UL Approved MK5 Infrared Hand-Held Tooling
10-11
Mini-Ray MK4 Infrared Hand-Held Tooling
12-13
CV2014 Series ThermoGun Heating Tool
15-16
AA-400 Super Heater
22-23
AD-1522-1 Hand Crimping Tool
4
CV1981/CV1983 Series ThermoGun Heating Tools
17-19
Reflectors for CV1981/CV1983 Tools
19
Heat Guns
20-21
Reflectors for Heating Guns
21
MiniSeal Crimp Splices
DuraSeal Crimp Splices
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 36
Application Tooling
Product Family
Recommended Application Tooling
Page
Heat-Shrinkable Molded
Boots and Shapes
CV1981/CV1983 Series ThermoGun Heating Tools
17-19
Reflectors for CV1981/CV1983 Tools
19
Heat Guns
20-21
Reflectors for Heat Guns
21
CV1981/CV1983 Series ThermoGun Heating Tools
17-19
Reflectors for CV1981/CV1983 Tools
19
Heat Guns
20-21
Reflectors for Heat Guns
21
Heat-Shrinkable Tubing
(For example DR-25, RNF-100 Tubing)
Tinel-Lock Rings for TXR Backshells
AD-5000 Installation Tool
26-27
AD-5020 Installation Tool
28-29
RH-3960/RH-3965 Tinel-Lock Installation Tool
30-31
Please note that our infrared tools are not suitable for installation
of black-colored tubing.
The above are recommendations only. Please consult your
TE representative for further details on our tooling or any of our
Raychem heat-shrink tubing and molded shapes
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 37
Application Tooling
Notes
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 38
Application Tooling
Notes
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
PAGE 39
LET’S CONNECT
We make it easy to connect with our experts and are ready to
provide all the support you need. Just call your local support number or visit
www.te.com/industrial to chat with a Product Information Specialist.
Technical Support
te.com/support-center
North America
+1 800 522 6752
Asia Pacific
+86 400 820 6015
North America (Toll)
+1 717 986 7777
Japan
+81 044 844 8180
EMEA/South Africa
+800 0440 5100
Australia
+61 2 9554 2695
EMEA (Toll)
+31 73 624 6999
New Zealand
+64 (0) 9 634 4580
India (Toll-Free)
+800 440 5100
te.com/Raychem-tooling
AMP, AGASTAT, CII, DEUTSCH, DuraSeal, HARTMAN, KILOVAC, LL ROWE, MICRODOT, MiniSeal, NANONICS,
POLAMCO, Raychem, SEACON, SolderSleeve, SolderTacts, ThermoGun, Tinel-Lock, TE, TE Connectivity and the
TE connectivity (logo) are trademarks of TE Connectivity. Other products, logos, and company names mentioned
herein may be trademarks of their respective owners.
While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information herein,
nothing herein constitutes any guarantee that such information is error-free, or any other representation, warranty
or guarantee that the information is accurate, correct, reliable or current. The TE entity issuing this publication
reserves the right to make any adjustments to the information contained herein at any time without notice. All
implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of
merchantability or fitness for a particular purpose are expressly disclaimed. The dimensions herein are for reference
purposes only and are subject to change without notice. Specifications are subject to change without notice.
Consult TE for the latest dimensions and design specifications.
© 2018 TE Connectivity All Rights Reserved.
1-1773872-1 08/18
AEROSPACE, DEFENSE & MARINE /// APPLICATION TOOLING
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