D-436-43CS246

CUSTOMER DRAWING MATERIALS 1. INSULATION SLEEVE: Heat-shrinkable, transparent blue, radiation cross-linked modified polyvinylidene flouride. 2. INTEGRAL MULTI-WIRE SEAL: Low outgassing immersion resistant thermoplastic fluoroelastomer. Color: BLUE. 3. SEPARATE MULTI-WIRE SEAL: Low outgassing immersion resistant thermoplastic fluoroelastomer. Color: BLUE. 4. CRIMP SPLICER: Base Metal: Copper Alloy 101 or 102 per ASTM B-75. Plating: Tin per MIL-T-10727, Type 1. Color Code: See table below. Part Name D-436-42 D-436-43 Prod. Rev. F A Dimensions: Crimp Splice I.D.±0.05 O.D.±0.08 Color (I.D.±0.002) (O.D.±0.003) Code 1.70 (0.067) 2.62 (0.103) Blue 2.54 (0.100) 3.81 (0.150) Yellow Installation Data: Wire Size Range of Crimp Splicer Two Wires Three Wires Minimum Maximum Minimum Maximum 2 x 24 2 x 20 3 x 24 3 x 22 2 x 22 2 x 16 3 x 22 3 x 18 APPLICATION 1. These parts are designed to provide an immersion resistant in-line splices of 2 or 3 to 2 or 3 wires falling within the size range listed above, having insulations rated for at least 135C. 2. Parts are available only as an assembly of one of each Item #1 and Item #2. 3. Crimp splicer may be installed with Raychem AD-1377 crimp tool or equivalent. 4. Inside diameter and outside diameter of splice are to be measured in crimp area, 2.54 to 5.08 (0.100 to 0.200) from ends of part. Slight burr permitted on parted surfaces. 5. Acceptance sampling shall be in accordance with paragraph 4.6.1 of MIL-T-7928. 6 . Packing and packaging shall be in accordance with Section 5, Level C, of MIL-T-7928. 7. This document takes precedence over documents referenced herein. TITLE : Raychem Devices UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. INCHES DIMENSIONS ARE BETWEEN BRACKETS. TE CONNECTIVITY (TE) RESERVES THE RIGHT TO ANGLES: N/A TOLERANCES: CHANGE THIS DRAWING AT ANYTIME. USER SHOULD 0.00 N/A EVALUATE THE SUITABILITY OF THE PRODUCT FOR ROUGHNESS IN 0.0 N/A THEIR APPLICATION. MICRON 0 N/A DRAWN BY: ECO APPROVED: ECO NUMBER: M. FORONDA L. RODRIGUEZ IN-LINE SPLICE SEALING SYSTEM, MULTI-WIRE DOCUMENT NO.: D-436-42/-43 DATE: REVISION: June 26, 2015 SCALE: 15-009842 ©2015 TE CONNECTIVITY LTD. FAMILY OF COMPANIES. ALL RIGHT RESERVED. If this document is printed it becomes uncontrolled. Check for the latest revision. C SIZE: None A SHEET: 1 of 4 CUSTOMER DRAWING 1.0 TEST ASSEMBLIES The test assemblies for qualification testing shall be 3 to 3 in-line splices made in wire conforming to MIL-W-81044/12 or MIL-W-16878/4. The assemblies shall be divided equally between the maximum and minimum wire size as shown below: Assembly D-436-42 D-436-43 Minimum 24 22 Maximum 22 18 The qualification sample shall consists of 35 assemblies and 8 uninstalled sleeves. 1.1 Acceptance Testing: Acceptance sampling shall be in accordance with ANSI/ASQC Z1.4, Inspection Level S-4. The Acceptable Quality Level shall be 4.0 for all defects. Acceptance tests shall consist of visual and dimensional examination. 2.0 QUALIFICATION TESTING: .1 2.2 All sleeves shall be tested for compliance with Sheet 1 in regard to: Property Test Method Material and Appearance Dimensions Visual Examination MIL-I-23053, Paragraph 4.6.3 Test Group A: Ten assemblies shall pass the post conditioning tests after conditioning in the sequence shown: Post Conditioning Requirement Test Method Insulation Resistance Altitude Immersion Insulation Resistance Dielectric Withstanding 5000 M @500V d-c 75,000 ft. 5000 M @500V d-c 2.5Kv (rms) for 1 min. Conditioning Parameters Altitude Immersion Immersion Temperature Cycling Moisture Resistance Fluid Immersion Heat Aging 75,000 ft. Condition C -65C to 150C (5 cycles) Step 7b not required MIL-H-5606, MIL-L-7808 96 hours @200C MIL-W-81044, Par. 4.7.5.2 MIL-C-26500, Par. 4.7.21 MIL-W-81044, Par. 4.7.5.2 MIL-W-81044, Par. 4.7.5.1 Test method MIL-C-26500, Par. 4.7.21 Method 104* Method 102* Method 106* MIL-T-7928, Par. 4.8.8 Method 108* TITLE : Raychem Devices UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. INCHES DIMENSIONS ARE BETWEEN BRACKETS. TE CONNECTIVITY (TE) RESERVES THE RIGHT TO ANGLES: N/A TOLERANCES: CHANGE THIS DRAWING AT ANYTIME. USER SHOULD 0.00 N/A EVALUATE THE SUITABILITY OF THE PRODUCT FOR ROUGHNESS IN 0.0 N/A THEIR APPLICATION. MICRON 0 N/A DRAWN BY: ECO APPROVED: ECO NUMBER: M. FORONDA L. RODRIGUEZ IN-LINE SPLICE SEALING SYSTEM, MULTI-WIRE DOCUMENT NO.: D-436-42/-43 DATE: REVISION: June 26, 2015 SCALE: 15-009842 ©2015 TE CONNECTIVITY LTD. FAMILY OF COMPANIES. ALL RIGHT RESERVED. If this document is printed it becomes uncontrolled. Check for the latest revision. C SIZE: None A SHEET: 2 of 4 CUSTOMER DRAWING 2.3 Test Group B: Ten Assemblies: Test Sequence Requirement Test Method Insulation Resistance Vibration Insulation Resistance Altitude Immersion Insulation Resistance Voltage Drop** 5000 M @500V d-c MIL-STD-202, Method 201 5000 M @500V d-c 75,000 ft. (1 cycle) 5000 Megaohms Wire Equivalent + 2.0 millivolts (maximum) Table II MIL-W-81044, Par. 4.7.5.2 MIL-T-7928, Par. 4.8.6 MIL-W-81044, Par. 4.7.5.2 MIL-C-26500, Par. 4.7.21 MIL-W-81044, Par. 4.7.5.2 MIL-T-7928, Par. 4.8.1 Tensile Strength MIL-T-7928, Par. 4.8.7 * Test methods are per MIL-STD-202. ** Test current shall be equal to 3X the rated current fot the smallest gauge wire used. 2.4 Test Group C: Ten Assemblies: Test Sequence Requirement Test Method Insulation Resistance Salt Spray (Corrosion)*** Insulation Resistance Altitude Immersion Insulation Resistance Voltage Drop** 5000 M @500V d-c MIL-W-81044, Par. 4.7.5.2 MIL-T-7928, Par. 4.8.4 MIL-W-81044, Par. 4.7.5.2 MIL-C-26500, Par. 4.7.21 MIL-W-81044, Par. 4.7.5.2 MIL-T-7928, Par. 4.8.1 Tensile Strength 5000 M @500V d-c 75,000 ft. (1 cycle) 5000 M @500V d-c Wire Equivalent + 2.0 millivolts (maximum) Table II MIL-T-7928, Par. 4.8.7 *** Lead ends to be sealed prior to exposure. 2.5 Test Group D: Five Assemblies: Test Requirement Test Method Flammability Self Extinguishing within 15 seconds MIL-T-7928, Par. 4.8.10 2.6 Test Group E: Three Sleeves: Test Requirement Test Method Corrosive Effect Non-Corrosive MIL-I-23053, Par. 4.6.10.2 TITLE : Raychem Devices UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. INCHES DIMENSIONS ARE BETWEEN BRACKETS. TE CONNECTIVITY (TE) RESERVES THE RIGHT TO ANGLES: N/A TOLERANCES: CHANGE THIS DRAWING AT ANYTIME. USER SHOULD 0.00 N/A EVALUATE THE SUITABILITY OF THE PRODUCT FOR ROUGHNESS IN 0.0 N/A THEIR APPLICATION. MICRON 0 N/A DRAWN BY: ECO APPROVED: ECO NUMBER: M. FORONDA L. RODRIGUEZ IN-LINE SPLICE SEALING SYSTEM, MULTI-WIRE DOCUMENT NO.: D-436-42/-43 DATE: REVISION: June 26, 2015 SCALE: 15-009842 ©2015 TE CONNECTIVITY LTD. FAMILY OF COMPANIES. ALL RIGHT RESERVED. If this document is printed it becomes uncontrolled. Check for the latest revision. C SIZE: None A SHEET: 3 of 4 CUSTOMER DRAWING 2.7 Test Group F: Five Sleeves: Test Requirement Test Method Insulation Shrinkage Sheet 1 Longitudinal Change ±10% MIL-I-23053, Par. 4.6.3.2.2 (5 minutes @ 300C) MIL-I-23053, Par. 4.6.5.1 (5 minutes @ 300C) TEHRMOFIT ASSEMBLY PROCEDURE: 1.0 SCOPE This document outlines the procedure to be followed to obtain immersion resistant multiple wire butt splices using Thermofit Multi-Wire In-Line Splice Sealing System D-436-42/-43. 2.0 PROCEDURE a) Pass the wires to be attached to one barrel through the separate three wire seal. (Item 3) Pass the wires to be attached to the other barrel through the sealing sleeve from the three hole insert end. b) Strip wires 5/16” to 11/32” and crimp into splicer using one of the approved crimping tools (see below). Care must be taken that the wires remain untwisted between the splice and the three wire seals or the sealing sleeve cannot be positioned properly. c) Position the separate seal as close as possible to the splicer. Hold this piece in position by squeezing the wires directly behind it, and slide the sealing sleeve over the assembly so that the separate seal is as far inside the sleeve as possible. d) Apply heat, using the recommended heat source, first to the “separate” seal end, and then the other. Heat should be applied until insert melts and flows axially along the wires. 3.0 RECOMMENDED TOOLS a. Crimp Tools Manufacturer Raychem Buchanan Electric Products Daniels manufacturing Company Model Number AD-1377 614080 OT-609 b. Heat Tools Heater Thermogun #500A Shop Air Heater #CV-4504 Mini-Gun #CV-5300 Reflector TG-14 991180 991319 Heater should be operated to give an air stream temperature of at least 550F. TITLE : Raychem Devices UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MILLIMETERS. INCHES DIMENSIONS ARE BETWEEN BRACKETS. TE CONNECTIVITY (TE) RESERVES THE RIGHT TO ANGLES: N/A TOLERANCES: CHANGE THIS DRAWING AT ANYTIME. USER SHOULD 0.00 N/A EVALUATE THE SUITABILITY OF THE PRODUCT FOR ROUGHNESS IN 0.0 N/A THEIR APPLICATION. MICRON 0 N/A DRAWN BY: ECO APPROVED: ECO NUMBER: M. FORONDA L. RODRIGUEZ IN-LINE SPLICE SEALING SYSTEM, MULTI-WIRE DOCUMENT NO.: D-436-42/-43 DATE: REVISION: June 26, 2015 SCALE: 15-009842 ©2015 TE CONNECTIVITY LTD. FAMILY OF COMPANIES. ALL RIGHT RESERVED. If this document is printed it becomes uncontrolled. Check for the latest revision. C SIZE: None A SHEET: 4 of 4