D-436-84

Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices Product Facts Immersion-resistant crimp splices are on QPL for SAE-AS-81824 ■ MIL-Spec approval ■ Small size ■ Light weight ■ Insulation and strain relief ■ Easy installation ■ Applications Product Selection Process MiniSeal wire-to-wire splicing products offer solutions for hundreds of aerospace and defense applications. These environment-resistant splices provide excellent reliability, long term performance, MIL-S-81824/1 qualification, and a low installed cost. 1. Determine the type of splice required. MiniSeal crimp splices consist of a plated copper crimp barrel and a separate, heat-shrinkable, transparent sealing sleeve. They can be used on a combination of wires, from 1:1 to 10:10. MiniSeal splices are one of the smallest, lightest, and most environmentresistant splices available. They preserve the electrical integrity of the splice by preventing the penetration of liquids and the resulting chemical and galvanic corrosion. ■ Table A provides the CMA of typical conductors. (Both CMA and mm give the same results, so choose either CMA or mm as your unit of measure for selection purposes and continue to use it for all your selection criteria.) 2 Stub (parallel) splice: 2 ■ Butt (in-line) splice: 2. Determine which crimp barrel plating is required: ■ Tin plating, recommended for tin or silverplated wire ■ Nickel plating, recommended for nickel-plated wire, or silver-plated wire in applications above 150°C [302°F]. 4. Select the color code for the size crimp barrel required. Using Table B (page 8-23), select the crimp barrel—colorcoded red, blue, or yellow—for the CMA or mm you calculated. 3. Calculate the size of crimp barrel required. Using the CMA/mm2 worksheet on the next page, calculate the total cross section to be spliced by adding the circular mil area (CMA) or square millimeters (mm ) of each wire. 2 Stub splice: Add the CMA or mm of all wires together. 2 Butt splice: Calculate each side separately (see example on the worksheet). Available in: Americas Europe Asia Pacific ■ ■ ■ 2 Stub splice: Select the barrel that will accommodate the total cross section. Butt splice: Select the smallest barrel that will accommodate the largest CMA/mm2 required. (Refer to the example in the worksheet for a more specific description.) If the CMA/mm2 of the smaller side of a butt splice is too small for the size barrel required to fit the larger side, increase the CMA/mm2 —either by doubling back one wire (stripping the conductor twice the length you would ordinarily strip it and then folding it back) or by adding a filler wire. 5. Determine the type of sealing sleeve required. Some wire insulations will not fit in the holes of the sealing sleeve inserts, so be sure to compare the internal diameter of each hole with the outer diameter of the wire(s) you intend to insert in that hole. To create a reliable seal, place a maximum of two wires in any hole of the sealing sleeve. 6. Select the part number. Turn to the MiniSeal part number selection tables (Tables C and D, page 8-23 and 8-24) and find the table for the type of splice (stub or butt) required. Using the appropriate table, find the crimp barrel size range and the size and number of wires for your application. Then select the part number for the type of plating required. The color code accompanying that part number should match the color code you arrived at in Table B, confirming that the part number you have selected is correct. 8-24 Catalog 1654025 Revised 5-12 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 (800) 522-6752 Canada: +1 (905) 475-6222 Mexico/C. Am.: +52 (0) 55-1106-0800 Latin/S. Am.: +54 (0) 11-4733-2200 Germany: +49 (0) 6251-133-1999 UK: +44 (0) 800-267666 France: +33 (0) 1-3420-8686 Netherlands: +31 (0) 73-6246-999 China: +86 (0) 400-820-6015 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table A. CMA of Typical Conductors 7 28 177 0.09 Strands AWG CMA mm2 Table B. Crimp Barrel Color Code Selection 19 26 304 0.15 19 24 475 0.24 CMA Range 304–1510 1058–2680 2375–6755 19 22 754 0.38 19 20 1216 0.61 19 18 1900 0.95 19 16 2426 1.21 1:1 Splice (AWG Size) 26–20 20–16 16–12 19 14 3831 1.92 37 12 5874 2.94 Color Code Red Blue Yellow Example: CMA/mm2 Worksheet The other side, where the CMA for AWG 18 is 1900, is calculated as: Application: A butt splice with three AWG 22 wires in one side and one AWG 18 wire in the other side: CMA = 1 x 1900 = 1900 The CMA for AWG 22 wire in Table A is 754. Using Table B to select the smallest crimp barrel that will easily fit 2262 CMA, the blue barrel is the correct choice. Side one is therefore calculated as follows: CMA = 3 x 754 = 2262 Wire Number CMA mm2 1 2 3 4 5 6 8 7 8 10 Electrical Interconnect Products 9 Part Number: Total Table C. Stub (Parallel) Splices Part No. Illustration Crimp Barrel Size Range CMA Min.–Max. Tin Plated Nickel Plated D-436-0128 Red D-436-0119 Red 304–1510 D-436-58 Blue D-436-75 Blue 1058–2680 D-436-59 Yellow D-436-76 Yellow 2375—6755 D-436-60 Blue D-436-77 Blue 1058–2680 D-436-61 Yellow D-436-78 Yellow 2375–6755 I.D.dimensions Side 1 Sealing Insert 2.16 [.085] 4.56 [.180] 4.56 [.180] 2.03 [.080] 2.03 [.080] Side 2 Max. No. of Wires Sealing Insert 2 2 1.01 [.040] 2.28 [.090] 2 Max. No. of Wires 2 2 2 2.28 [.090] 10 (2 per hole) 10 (2 per hole) 2 6.35 [.250] 2 6.35 [.250] 8-25 Catalog 1654025 Revised 5-12 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 (800) 522-6752 Canada: +1 (905) 475-6222 Mexico/C. Am.: +52 (0) 55-1106-0800 Latin/S. Am.: +54 (0) 11-4733-2200 Germany: +49 (0) 6251-133-1999 UK: +44 (0) 800-267666 France: +33 (0) 1-3420-8686 Netherlands: +31 (0) 73-6246-999 China: +86 (0) 400-820-6015 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Table D. Butt (in-line) splices Illustration Part No. Crimp Barrel Size Range CMA Min.–Max. Tin Plated Nickel Plated D-436-36* Red D-436-82 D-200-82 Red D-436-83 D-200-83 Blue D-436-84 D-200-84 Yellow 1058–2680 D-436-0110 Red D-436-85 Red 304–1510 D-436-52 Blue D-436-86 Blue 1058–2680 D-436-53 Yellow D-436-87 Yellow 2375–6755 D-436-0115 Red D-436-88 Red 304–1510 D-436-42 Blue D-436-89 Blue 1058–2680 D-436-43 Yellow D-436-90 Yellow 2375–6755 D-436-37* Blue D-436-38* Yellow I.D.dimensions Side 1 Sealing Insert Side 2 Max. No. of Wires 304–1510 Sealing Insert 2 2.16 [.085] Max. No. of Wires 2 2.16 [.085] 2 2.79 [.110] 2375–6755 2.79 [.110] 2 4.32 [.170] 2 2 4.32 [.170] 6 2.36 [.093] 2 4.06 [.160] 2.36 [.093] 6 (2 per hole) 4.06 [.160] 2 2.36 [.093] 6 (2 per hole) 4.06 [.160] 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2.36 [.093] 6 (2 per hole) 2 *Qualified to MIL-S-81824/1. Table E. Crimp Barrel Only Type Butt (in-line) Butt (in-line) Butt (in-line) Stub (Parrel) Stub (Parrel) Stub (Parrel) Color Code Red Blue Yellow Red Blue Yellow Tin-Plated D-609-06 D-609-07 D-609-08 D-609-03 D-609-04 D-609-05 Nickel Plated D-609-09 D-609-10 D-609-11 D-609-12 D-609-13 D-609-14 Crimp Barrel Size Range CMA Min. - Max. 304-1510 1058-2680 2350-6755 304-1510 1058-2680 2350-6755 Table F. Sealing Sleeve Only L max. ∅A min. Part No. D-436-0096 D-436-0097 D-436-0098 Color Code Red Blue Yellow L Max. 29.2 [1.15] 29.2 [1.15] 29.2 [1.15] A Min. 2.16 [0.085] 2.8 [0.110] 4.32 [0.170] 8-26 Catalog 1654025 Revised 5-12 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 (800) 522-6752 Canada: +1 (905) 475-6222 Mexico/C. Am.: +52 (0) 55-1106-0800 Latin/S. Am.: +54 (0) 11-4733-2200 Germany: +49 (0) 6251-133-1999 UK: +44 (0) 800-267666 France: +33 (0) 1-3420-8686 Netherlands: +31 (0) 73-6246-999 China: +86 (0) 400-820-6015 Wire-to-Wire Splicing MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued) Product Characteristics Specifications/Approvals Installation Material Insulation Crimp barrel Meltable inserts Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (D-436) Tin- or nickel-plated copper Meltable thermoplastic (D-436) Typical Performance Voltage drop Tensile strength Dielectric strength Temperature rating Insulation resistance 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire Exceeds strength of conductor 2.5 kV -55°C to 150°C [-67°F to 302°F] (D-436 Series) 5000 megohms Military SAE-AS-81824/1 for D-436-36/37/38 Series D-436 For proper installation of these devices, the correct crimp tool (TE part number AD-1377) and a heating tool and reflector attachment must be used. Any one of the following TE heating tools is recommended: ■ HL1910E/HL2010E ■ AA-400 Super Heater You will find ordering information for these tools in Section 10. Refer to TE installation procedure RCPS-200-20 for detailed instructions and recommended reflector attachments. 8 Electrical Interconnect Products 8-27 Catalog 1654025 Revised 5-12 www.te.com Dimensions are shown for reference purposes only. Specifications subject to change. Dimensions are in millimeters unless otherwise specified. USA: +1 (800) 522-6752 Canada: +1 (905) 475-6222 Mexico/C. Am.: +52 (0) 55-1106-0800 Latin/S. Am.: +54 (0) 11-4733-2200 Germany: +49 (0) 6251-133-1999 UK: +44 (0) 800-267666 France: +33 (0) 1-3420-8686 Netherlands: +31 (0) 73-6246-999 China: +86 (0) 400-820-6015