Wire and Cable, Harnessing and
Protection Products
Table of Contents
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tyco Electronics Embraces the Most Valued Brand Names Worldwide ……………………………ii
About Raychem Wire and Cable, Harnessing and Heat-Shrinkable Products ………………………iii
How to Use this Catalog ……………………………………………………………………………iv
Application Overview
Seal It………………………………………………………………………………………………1-1
Connect It …………………………………………………………………………………………1-2
Insulate It …………………………………………………………………………………………1-3
Protect It …………………………………………………………………………………………1-4
Wire It………………………………………………………………………………………………1-5
Hold It ……………………………………………………………………………………………1-6
Join It ………………………………………………………………………………………………1-7
Beautify It …………………………………………………………………………………………1-8
Reduce It …………………………………………………………………………………………1-9
Repair It …………………………………………………………………………………………1-10
Flex It ……………………………………………………………………………………………1-11
All of It ……………………………………………………………………………………………1-12
Application Guide ………………………………………………………………………………1-13
Electrical Interconnection System Design
Harness Design …………………………………………………………………………………2-2
Protection of Harness Components ……………………………………………………………2-5
HarnWare Harness Design Software …………………………………………………………2-6
Integrated Military Harness Systems for
Defense and Allied Industries …………………………………………………………………2-15
Product Sections
Heat-Shrinkable Tubing ……………………………………………………………………………3
Molded Parts ………………………………………………………………………………………4
Adhesives……………………………………………………………………………………………5
Adapters ……………………………………………………………………………………………6
Assemblies …………………………………………………………………………………………7
Electrical Interconnect Products …………………………………………………………………8
Wire and Cable ……………………………………………………………………………………9
Application Equipment……………………………………………………………………………10
Supporting Information
Equivalents and Conversions …………………………………………………………11-2, 11-3
Temperature Conversion ………………………………………………………………11-4, 11-5
Glossary ………………………………………………………………………………11-6 to 11-18
Part Index ……………………………………………………………………………11-19 to 11-21
i
ii
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire and Cable, Harnessing and
Protection Products
As a truly global player, Tyco Electronics
Corporation has facilities located
throughout the world serving customers
in a wide range of applications.
Tyco Electronics C o r p o r a t i o n
– the largest unit of Tyco
International Ltd.– was
established in September
1999 when Tyco acquired
Elcon Products and
Raychem Corporation, and
integrated them with AMP,
acquired earlier the same
year. Since then, the
company has rapidly grown
and strengthened its
competencies as an
electrical and electronic
component supplier, with
product offerings in 25
passive and active product
segments. In the passives
field, Tyco Electronics is
now the world’s largest
supplier.
The company has facilities
located around the globe
serving customers in the
aerospace, automotive,
commercial electronics/
communications, industri-
al/energy, marine, medical,
military, and rail industries.
Tyco Electronics’ product
portfolio continues to grow,
encompassing connector
systems and application
tooling, active and passive
fiber optic devices,
complete power systems,
wireless components
(including ICs, radar
sensors, and complete
communications systems),
GPS and integrated
antenna systems, heat-
shrink products, circuit
protection devices,
magnetic components,
wire and cable systems,
touchscreens, PC boards
and backplanes, smart
cards, relays, sensors,
electronic modules, wire
harnessing and labeling
products, battery packs,
terminal blocks and
switches.
A significant result of this
continued growth, and a
real benefit to customers,
is that Tyco Electronics’
technology leadership
becomes even stronger.
The synergies of expertise
in materials science,
product design, and
process engineering,
coupled with knowledge-
able application engineers,
sales representatives, and
customer service personnel
enables you to make your
next generation of products
successful.
Tyco Electronics Embraces the Most Valued Brand Names Worldwide
iii
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire and Cable, Harnessing and
Protection Products
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
About Raychem Wire and Cable, Harnessing, and Heat-Shrinkable Products
The Tyco Electronics
Raychem brand of heat-
shrinkable polymer products
is recognized worldwide. It
is backed by a history of
proven performance, relia-
bility, innovation and superi-
or quality. Tyco Electronics
manufactures the world’s
largest range of heat-
shrinkable tubing – tubing
that provides cable protec-
tion offering exceptional
insulation, mechanical
protection, and strain relief.
We are the recognized
world leader in heat-shrink-
able polymer technology.
A broad-based product line
of Raychem wire and cable
is engineered to meet or
exceed the most rigorous
technical specifications.
Performing from -100°C to
+260°C [-148°F to 500°F],
the product line encom-
passes fire-resistant cable,
small-size controlled electri-
cal cables, multi-conductor
cable, high-performance
radiation crosslinked ETFE
airframe wire, low fire
hazard wire, high-perfor-
mance automotive and
commercial wire, and
NASA-spec and other
space-application types.
Additionally, a variety of
low-cost, easy-to-install
components for wire
harnesses and cable
assemblies are available
including splices, adapters,
low-profile rectangular
connectors, and contacts.
These components are
approved to widely recog-
nized standards and speci-
fications that include UL,
SAE, MIL, Defense, DNV,
Lloyds, and ABS.
Tyco Electronics also
provides customized
harnessing design
supported by a pioneering
software package,
HarnWare, which enables
fast, optimum system
design with materials and
assembly labor estimates.
For over forty-five years
customers have recognized
the global capabilities of
Raychem products.
Combining these advanced
products with superior
technical support and a
global sales/service
organization, customers
with worldwide operations
count on Tyco Electronics
to supply the knowledge
and products they need to
solve specific problems
and help them take
advantage of opportunity,
anywhere it arises. This
philosophy has earned
Tyco Electronics a
reputation for leadership
in materials science tech-
nologies. Developed from
these technologies,
Raychem products are
sold into many industries
including aerospace,
automotive, electronics,
construction, electrical
power, utilities, manufactur-
ing, pipeline, process, rail
and mass transit, and
telecommunications.
Tyco Electronics, for its Raychem products, pioneered the application
of radiation crosslinking and the development of heat-shrinkable
polymer tubing.
iv
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-03 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire and Cable, Harnessing and
Protection Products
How To Use This Catalog
Market Icons
Application Overview
(Section 1) presents gener-
al design ideas based on
typical uses for Raychem-
brand wire and cable, heat-
shrinkable tubing and
protection products.
Application photos depict
examples of how customers
use our products to
enhance the performance
and improve the reliability of
their specific products in
one or more of these gener-
ic applications; Seal It,
Connect It , Wire It, Insulate
It, Protect It, Hold It, Join It,
Beautify It, Reduce It,
Repair It, Flex It, All of It.
Electrical Identification
System Design (Section 2)
describes wire harness
components and harness
protection issues and pro-
vides a step-by-step guide
to selecting the right
Raychem components for a
particular wire harnessing
system.
Products (Sections 3-10)
showcases our product
groups. Each section pro-
vides:
nAn overview of the prod-
uct group.
nA table of contents that
lets you see at a glance
the product families in
that product group.
nA selection guide to help
you determine which
product family will satisfy
the requirements of your
application.
nAn explanation of the part
numbering system for
that product group.
nInformation pages on
each product family.
The product information
pages provide some or all
of the following information
(depending on the product
family):
nTypical applications for
the product family.
This catalog has four main
sections:
■Application Overview
■Electrical Interconnection
System Design
■Products
■Supporting Information
Use these icons to quickly
identify market opportunities
at-a-glance. They appear
on the product information
pages. The icons on each
page represent, but are not
limited to, the markets that
currently exist for that
particular product.
nProduct features/benefits.
nAbbreviated installation
guidelines.
nSpecifications and
agency approvals.
nPart number selection
information
nProduct data (dimen-
sions, properties, and
materials).
nOrdering information.
nLocation availability.
Supporting Information
(Section 11) provides:
nEquivalents and conver-
sion tables.
nTemperature conversion
table.
nGlossary.
Medical
Automotive
Commercial Electronics/Communications
Aerospace
Marine
Military
Rail Industries
Industrial
Space
1-1
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 : 44-1793-528171
Seal It
nHeat-shrinkable, adhe-
sive-lined products—
tubings with high shrink
ratios, and molded
parts—environmentally
protect connector-to-
cable transitions.
nWaterblocked and
anticapillary wire prevent
water and most fluids
from wicking between the
conductor strands.
Bundle sealing products
block multiconductor
cables.
nAdhesive-lined, heat-
shrinkable tubing and
caps seal and protect
electronic components
and in-line wire splices
from fluids, moisture, and
corrosion while also
providing strain relief.
nHeat-shrinkable caps
lined with an adhesive
or encapsulant form a
moisture-resistance
barrier around stub
splices and wire ends.
nHeat-shrinkable, moisture
blocking systems are
designed to provide
reliable sealing of wire
bundles preventing fluid
ingress.
A
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1-2
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Connect It
With our electrical intercon-
nect products, you start with
a precisely engineered,
fluxed solder preform inside
a transparent, heat-shrink-
able sleeve. When the
product is heated, the
solder preform melts, and
the sleeve shrinks to create
a connection that is fully
insulated and strain-
relieved.
This ease of use expands
your options even as it
enhances the quality of your
end product, as in these
applications:
nEasy and reliable termina-
tion of EMI shields to
ground, ensuring effective
EMI attenuation. Shield
termination products are
available for computer,
data, and instrumentation
cable, communications
and video cable, and
heavy industrial cable.
nSplicing of one compo-
nent to another, such as
a diode connected to one
end of an LED.
nCoaxial terminations to
PCBs and terminals.
R
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.
1-3
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulate It
nWhen heated during
installation, our radiation-
crosslinked tubings shrink
to conform to a variety of
shapes, providing
dependable insulation.
nHeat-shrinkable end caps
insulate wire or cable
terminations, providing
protection from dust
and dirt. End caps with
adhesive or encapsulant
lining also provide
protection from moisture
because the lining,
when heated, melts and
flows to fill surface
irregularities of the
substrate.
nGeneral-purpose poly-
olefin tubing is widely
used to insulate and
strain-relieve wire termi-
nations and connections.
nDelicate electrosurgical
instruments can be
insulated and protected
from abrasion by using
one of Raychem’s
medical-grade, heat-
shrinkable tubings
specially formulated to
meet the requirements of
USP Class VI for medical
use.
nComponents on a PCB,
such as capacitors and
fuses, can be insulated
with a UL VW-1-approved
heat-shrinkable tubing to
achieve a specific
product rating.
S
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1-4
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Protect It
D
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li
ie
ef
f,
, r
re
es
si
is
st
ta
an
nc
ce
e t
to
o a
ab
br
ra
as
si
io
on
n a
an
nd
d c
cr
ru
us
sh
hi
in
ng
g,
, E
EM
MI
I a
an
nd
d n
no
oi
is
se
e r
re
ed
du
uc
ct
ti
io
on
n,
, f
fl
lu
ui
id
d
r
re
es
si
is
st
ta
an
nc
ce
e,
, a
an
nd
d t
th
he
er
rm
ma
al
l i
in
ns
su
ul
la
at
ti
io
on
n.
.
nTinel-Lock ring braid ter-
minations can be used for
applications where shield-
ing is critical. These
shape-memory-metal
products attach metal
braid shields to back-
shells and provide 360°
protection against EMI
and EMP.
nHeat-shrinkable tubings
provide mechanical
protection for hoses and
pipes, and also reduce
problems caused by wire
chafing or cable abrasion.
nEasy-to-install heat-shrink-
able tubing and molded
parts provide excellent
strain relief and electrical
insulation for connector-
to-cable transitions.
nA heat-shrinkable molded
part can relieve the strain
on a multiconductor cable
to a D-subminiature
connector.
nHeat-shrinkable
feedthroughs relieve the
strain on cables entering
junction boxes.
nHighly-flexible, heat-
shrinkable fabric tubing
provides outstanding
abrasion protection for
components such as
rubber hoses, plastic
pipes, and harness wiring
bundles, recovering
easily even over awkward
substrates such as bent
hoses.
nHeat-shrinkable MicroFit
tubing is used to provide
insulation and strain
relief for fine-gauge wire
(24 to 42 AWG) and fiber
optic cables in such end
products as medical
devices, computers,
communications equip-
ment, and commercial
electronic products.
1-5
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire It
All Raychem products offer
outstanding shop-handling
characteristics for efficient
stripping, wire termination,
and bundling. Cable design
software is available to
create custom multicore
cables with unique compo-
nents, tough but lightweight
jacket materials, and
optimized shielding. Tyco
Electronics can also design
complete wiring harnesses
for industrial or military
applications.
nThe FlexLite family of
hookup wire provides
economical alternatives to
fluoropolymers, silicones,
and crosslinked polyethyl-
ene insulations for appli-
cations such as motors,
appliances, and lighting,
and for applications
where thinner walls are
needed because of
space constraints.
nRaychem high-tempera-
ture, dual-wall or single-
wall aerospace wire
saves space and weight
on both military and
commercial aircraft and
space vehicles.
nLow-fire-hazard primary
wires and cable are made
from halogen-free, low-
smoke materials with a
low toxicity index. They
offer increased safety,
with reduced size and
weight, over traditional
materials in mass transit
and similar applications.
T
Ty
yc
co
o E
El
le
ec
ct
tr
ro
on
ni
ic
cs
s i
is
s a
a l
le
ea
ad
de
er
r i
in
n t
th
he
e d
de
ev
ve
el
lo
op
pm
me
en
nt
t o
of
f h
hi
ig
gh
h-
-p
pe
er
rf
fo
or
rm
ma
an
nc
ce
e w
wi
ir
re
e a
an
nd
d c
ca
ab
bl
le
e p
pr
ro
od
du
uc
ct
ts
s f
fo
or
r d
de
em
ma
an
nd
di
in
ng
g
a
ap
pp
pl
li
ic
ca
at
ti
io
on
ns
s,
, i
in
nc
cl
lu
ud
di
in
ng
g a
ae
er
ro
os
sp
pa
ac
ce
e,
, i
in
nd
du
us
st
tr
ri
ia
al
l e
eq
qu
ui
ip
pm
me
en
nt
t,
, i
in
ns
st
tr
ru
um
me
en
nt
ta
at
ti
io
on
n,
, m
ma
ar
ri
in
ne
e,
, a
an
nd
d a
au
ut
to
om
mo
ot
ti
iv
ve
e a
ap
pp
pl
li
ic
ca
a-
-
t
ti
io
on
ns
s.
. P
Pr
re
ec
ci
is
si
io
on
n e
ex
xt
tr
ru
us
si
io
on
n c
ca
ap
pa
ab
bi
il
li
it
ty
y,
, m
ma
at
te
er
ri
ia
al
ls
s e
ex
xp
pe
er
rt
ti
is
se
e,
, a
an
nd
d d
de
es
si
ig
gn
n k
kn
no
ow
wl
le
ed
dg
ge
e p
pr
ro
ov
vi
id
de
e w
wi
ir
re
e p
pr
ro
od
du
uc
ct
ts
s t
th
ha
at
t
a
ar
re
e l
li
ig
gh
ht
tw
we
ei
ig
gh
ht
t;
; s
sm
ma
al
ll
le
er
r t
th
ha
an
n c
co
om
mp
pa
ar
ra
ab
bl
le
e-
-p
pe
er
rf
fo
or
rm
ma
an
nc
ce
e c
co
on
ns
st
tr
ru
uc
ct
ti
io
on
ns
s;
; h
hi
ig
gh
hl
ly
y f
fl
le
ex
xi
ib
bl
le
e,
, y
ye
et
t m
me
ec
ch
ha
an
ni
ic
ca
al
ll
ly
y
t
to
ou
ug
gh
h;
; f
fl
la
am
me
e-
-r
re
et
ta
ar
rd
da
an
nt
t a
an
nd
d r
re
es
si
is
st
ta
an
nt
t t
to
o a
a v
va
ar
ri
ie
et
ty
y o
of
f i
in
nd
du
us
st
tr
ri
ia
al
l f
fl
lu
ui
id
ds
s.
.
1-6
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Hold It
nThin-wall tubings allow
bundling of wires to
create very flexible, light-
weight harnesses that
can withstand harsh
environments.
nFiber and/or copper
components can be
bundled for a custom
multicore cable.
nCable legs can be held
together with a Y-transi-
tion molded part.
nMulticore and film-bonded
cables hold wires togeth-
er and also provide EMI
protection.
nTubing can hold a cover-
ing (braid or Convolex
tubing) onto a substrate.
nTwo components (such as
a resistor and fuse) can
be held together as a
package by enclosing
them with heat-shrinkable
tubing.
nHeat-shrinkable fabric
tubing will grip substrates,
such as harnesses, tightly
to provide secure wire
bundles without additional
fixing.
T
To
o h
he
el
lp
p y
yo
ou
u a
ar
rr
ri
iv
ve
e a
at
t t
th
he
e b
be
es
st
t w
wa
ay
y t
to
o s
se
ec
cu
ur
re
el
ly
y h
ho
ol
ld
d a
an
nd
d p
po
os
si
it
ti
io
on
n a
a c
co
om
mp
po
on
ne
en
nt
t,
, t
ta
ak
ke
e a
a l
lo
oo
ok
k a
at
t t
th
he
e R
Ra
ay
yc
ch
he
em
m
f
fa
am
mi
il
ly
y o
of
f p
pr
ro
od
du
uc
ct
ts
s a
an
nd
d c
co
on
ns
si
id
de
er
r t
th
he
e m
ma
an
ny
y w
wa
ay
ys
s t
th
ha
at
t y
yo
ou
u c
ca
an
n u
us
se
e t
th
he
em
m:
: t
to
o k
ke
ee
ep
p c
co
om
mp
po
on
ne
en
nt
ts
s i
in
n p
pl
la
ac
ce
e,
, b
bu
un
nd
dl
le
e
a
an
nd
d r
ro
ou
ut
te
e w
wi
ir
re
es
s,
, c
cr
re
ea
at
te
e a
a f
fo
or
rm
me
ed
d s
sh
ha
ap
pe
e f
fo
or
r p
po
ot
tt
ti
in
ng
g,
, o
or
r p
pa
ac
ck
ka
ag
ge
e c
co
om
mp
po
on
ne
en
nt
ts
s s
se
ec
cu
ur
re
el
ly
y b
be
ef
fo
or
re
e f
fi
in
na
al
l a
as
ss
se
em
mb
bl
ly
y.
.
1-7
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Join It
nJoin two dissimilar materi-
als, such as a rubber flap-
per to the end of a nylon
tube, or the handle of a
medical instrument to the
instrument’s moving parts.
nAssemble a bellows by
covering a spring with
heat-shrinkable tubing.
nUse Tinel ring adapters to
provide the even circum-
ferential force necessary
to attach a metal braid
shield to a backshell.
nClear, adhesive-lined
tubing connects water
tubes in appliances to
provide a rugged and
aesthetically appealing
joint which is also
inspectable.
nHeat-shrinkable tubing
is used to join polyester
cords to heddles in
Jacquard weaving loom
harnesses.
W
Wh
he
en
n y
yo
ou
u h
ha
av
ve
e a
a m
me
ec
ch
ha
an
ni
ic
ca
al
l c
co
on
nn
ne
ec
ct
ti
io
on
n t
to
o m
ma
ak
ke
e,
, c
co
on
ns
si
id
de
er
r t
th
he
e u
un
ni
if
fo
or
rm
m c
ci
ir
rc
cu
um
mf
fe
er
re
en
nt
ti
ia
al
l r
re
ec
co
ov
ve
er
ry
y
f
fo
or
rc
ce
e o
of
f h
he
ea
at
t-
-s
sh
hr
ri
in
nk
ka
ab
bl
le
e t
tu
ub
bi
in
ng
g a
an
nd
d m
me
et
ta
al
ls
s i
in
n y
yo
ou
ur
r d
de
es
si
ig
gn
ns
s.
.
1-8
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Beautify It
nHeat-shrinkable tubing—
instead of tape—can
create a smooth covering
with no loose ends.
nHot-stamp foils (gold or
silver) can attractively
showcase a company
logo.
nHeat-shrinkable tubing
can cover the mechanical
attachment of one part to
another.
nTubing can attractively
cover a metal railing,
such as the type used
for crowd control.
nTubing or molded parts
can be color-matched to
the original color of fiber,
wire insulation, or other
components to enhance
the appearance of the
final product.
nHandles of a variety of
tools can be covered with
colorful, heat-shrinkable
tubing to enhance the
appearance of the final
product.
E
En
nh
ha
an
nc
ci
in
ng
g t
th
he
e a
ap
pp
pe
ea
ar
ra
an
nc
ce
e o
of
f y
yo
ou
ur
r b
br
ri
il
ll
li
ia
an
nt
tl
ly
y d
de
es
si
ig
gn
ne
ed
d s
so
ol
lu
ut
ti
io
on
ns
s c
co
ou
ul
ld
dn
n’
’t
t b
be
e e
ea
as
si
ie
er
r,
, w
wh
he
en
n y
yo
ou
u u
us
se
e
R
Ra
ay
yc
ch
he
em
m p
pr
ro
od
du
uc
ct
ts
s.
.
1-9
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Reduce It
W
Wi
it
th
h t
th
he
e t
tr
re
en
nd
d t
to
ow
wa
ar
rd
d m
mi
in
ni
ia
at
tu
ur
ri
iz
za
at
ti
io
on
n a
an
nd
d h
hi
ig
gh
he
er
r-
-d
de
en
ns
si
it
ty
y i
in
nt
te
er
rc
co
on
nn
ne
ec
ct
ti
io
on
ns
s,
, p
pr
ro
od
du
uc
ct
ts
s d
de
ev
ve
el
lo
op
pe
ed
d f
fo
or
r
c
co
om
mm
me
er
rc
ci
ia
al
l e
el
le
ec
ct
tr
ro
on
ni
ic
cs
s a
ap
pp
pl
li
ic
ca
at
ti
io
on
ns
s m
mu
us
st
t d
do
ow
wn
ns
si
iz
ze
e a
as
s w
we
el
ll
l.
.
nVersafit V4 tubing—33
percent lighter and
smaller than competitive
products—is the perfect
choice when you need a
very-low-profile, thin-wall
tubing that installs quick-
ly. In addition to space
savings, V4 tubing offers
excellent mechanical
protection and strain relief
for sensitive components.
nThe MicroFit family of
products can be used to
connect and insulate fine-
gauge wire (26 to 42
AWG) in such end prod-
ucts as medical devices,
computers, and stereo
systems. They are easily
and quickly installed, thus
reducing craft-sensitive
labor. MicroFit tubing
has a high shrink ratio, up
to 3:1, allowing easy
installation onto the wire
or substrate.
SolderSleeve MicroFit
devices feature a one-
step controlled solder
process for splicing and
terminating wires up to
36 AWG—a method that
is more reliable and less
craft-sensitive than
hand-soldering.
nTyco Electronics can
reliably produce primary
Raychem wire insulations
as thin as 4 mils. Our
design software optimizes
component placement
and shielding to produce
small, lightweight custom
multicore cables. These
cables can offer size and
weight reductions that
can range from 10 to
40 percent versus
comparable-performance
constructions of primary
wire or cable.
1-10
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Repair It
W
Wh
he
et
th
he
er
r f
fo
or
r r
re
ep
pa
ai
ir
r o
or
r r
re
et
tr
ro
of
fi
it
tt
ti
in
ng
g,
, T
Ty
yc
co
o E
El
le
ec
ct
tr
ro
on
ni
ic
cs
s o
of
ff
fe
er
rs
s a
a w
wh
ho
ol
le
e f
fa
am
mi
il
ly
y o
of
f R
Ra
ay
yc
ch
he
em
m p
pr
ro
od
du
uc
ct
ts
s t
th
ha
at
t c
ca
an
n
p
pr
ro
ov
vi
id
de
e f
fl
le
ex
xi
ib
bl
le
e,
, c
co
os
st
t-
-e
ef
ff
fe
ec
ct
ti
iv
ve
e s
so
ol
lu
ut
ti
io
on
ns
s.
. F
Fo
or
r e
ex
xa
am
mp
pl
le
e,
, m
mo
os
st
t f
fa
ai
il
lu
ur
re
es
s i
in
n e
el
le
ec
ct
tr
ri
ic
ca
al
l w
wi
ir
ri
in
ng
g h
ha
ar
rn
ne
es
ss
se
es
s o
oc
cc
cu
ur
r
w
wi
it
th
hi
in
n t
th
he
e f
fi
ir
rs
st
t s
si
ix
x i
in
nc
ch
he
es
s o
of
f t
th
he
e c
co
on
nn
ne
ec
ct
to
or
r.
. R
Ra
ay
yc
ch
he
em
m p
pr
ro
od
du
uc
ct
ts
s m
ma
ak
ke
e r
re
ep
pa
ai
ir
rs
s i
in
n t
th
hi
is
s a
ar
re
ea
a m
mo
or
re
e r
re
el
li
ia
ab
bl
le
e,
,
l
lo
on
ng
g-
-l
li
iv
ve
ed
d,
, a
an
nd
d c
co
os
st
t-
-e
ef
ff
fe
ec
ct
ti
iv
ve
e.
.
nHigh-shrink-ratio tubing
can be slipped over the
connector without depin-
ning to reinsulate or strain
relieve the connector-to-
cable transition.
nSolderShield repair splice
kits provide the compo-
nents necessary to splice
shielded single-wire or
multicore cables.
nAdapters and Uniboot
molded parts can be
combined to allow reentry
to the back of the connec-
tor area for pin repair.
nSplash-resistant SCL
semirigid heat-shrinkable
tubing, with its meltable
inner wall, can be
stripped off the substrate
without leaving a sticky
residue, thus providing
access to connections
requiring reentry.
nFlexible, adhesive-lined
tubing can be used to
repair damaged wire
insulation, providing a
moisture seal that is
resistant to bending of
the wire substrate.
1-11
Application Overview
1
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Flex It
I
In
n a
ap
pp
pl
li
ic
ca
at
ti
io
on
ns
s w
wh
he
er
re
e f
fl
le
ex
xi
ib
bi
il
li
it
ty
y o
or
r f
fl
le
ex
x l
li
if
fe
e a
ar
re
e i
im
mp
po
or
rt
ta
an
nt
t,
, R
Ra
ay
yc
ch
he
em
m p
pr
ro
od
du
uc
ct
ts
s m
me
ee
et
t t
th
he
e n
ne
ee
ed
d—
—m
ma
an
ny
y
p
pe
er
rf
fo
or
rm
mi
in
ng
g e
ev
ve
en
n a
at
t l
lo
ow
w t
te
em
mp
pe
er
ra
at
tu
ur
re
es
s.
.
nNT tubing, which is
widely used for insulation,
strain relief, and abrasion
protection on cable
harnesses and wire
bundles, remains flexible
at low temperatures (as
low as -70°C [-94°])
without cracking.
nHi-Flex heat-shrinkable
tubing was developed
specifically for sealed
cable-jacketing applica-
tions where cable flexibili-
ty is an important concern.
It is also ideal for situa-
tions where the cable is
subject to motion, such
as in industrial machinery,
transportation equipment,
robotics, and welding.
nFor applications where a
flexible 90° bend right
after the connector is
desired, Uniboot molded
parts can provide the
perfect fit.
nDynaLink wire and cable
is designed specifically
for applications where
flex life is critical: in the
robotics industry; in lifts,
typing machines, and
sewer inspection equip-
ment; and on ships where
wire must be capable of
unwinding from a large
cable reel and then
retracting smoothly
without strain.
1-12
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
All of It
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.
In the pages of this catalog,
you will find literally hun-
dreds of products designed
to provide thousands of
solutions—across a wide
variety of industries.
Although you will find the
catalog features an exten-
sive array of products, keep
in mind that, at Tyco
Electronics Corporation,
we’re always coming up
with new ideas and new
products—so that we can
help you put together the
precise solution you need.
Also, when you choose any
Raychem product, you’re
automatically backed by a
nationwide network of sales
engineers who can provide
application and engineering
assistance as well as on-
site training.
1-13
Application Overview
1
Applications
Application Guide
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tyco Electronics manu-
factures an extensive
selection of Raychem
quality products that hold,
seal, protect, connect, and
insulate. Whatever your
design challenge, take
advantage of the Tyco
Electronics experience
to help you find the right
solution.
Tyco Electronics has led
the way in creating and
supplying high quality,
technologically advanced
products for use in a broad
range of industrial and
commercial applications.
When you choose any
Raychem product, you're
backed by a worldwide
network of sales engineers
who provide application
and engineering assistance
as well as on-site training.
The products shown in
Application Guide
#1654725 (07-03) are just
a sampling of the many
Raychem products Tyco
Electronics offers. Order
your copy today!
Give us a call or visit us at
www.tycoelectronics.com/Raychem
so we can help you put
together the precise
solution you need.
1-14
Applications
Engineering Notes
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Electrical Interconnection System Design
Table of Contents
2-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Harness Design ....................................................2-2 to 2-4
Protection of Harness Components ............................................2-5
HarnWare Harness Design Software .....................................2-6 to 2-14
Integrated Military Harness Systems for Defense and Allied Industries ...........2-15 to 2-25
This section attempts to
provide assistance with
most of the considerations
applicable to the design
of cable and harness
assemblies. Caution must
be used to ensure that the
design is appropriate for a
particular application.
Tyco Electronics provides
this information as a design
aid and assumes no
responsibility for and
makes no representation
regarding the suitability of
adesign for a specific
application.
2
Electrical Interconnection System Design
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Electrical Interconnection System Design
Harness Design
2-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tyco Electronics offers a
range of Raychem compo-
nents for wiring harnesses
and cable assemblies in
commercial, industrial,
automotive, and defense
and allied industries. Our
components are approved
to widely recognized
standards (UL, CSA, CE,
SAE) and to the military
specifications of various
governments.
Avariety of component
material systems can be
used to design a rugged,
reliable, repairable,
shielded, and environmen-
tally sealed harness. We
also offer individual com-
ponents that can be used
independently to meet a
specific sealing, insulation,
strain relief, protection,
identification, or electrical
interconnection need.
Harness Design
Designing wiring harnesses
for demanding applications
such as defense and
aerospace is a complex
business:
nMany different parts need
to be selected while
taking account of various
environmental factors and
mating part conditions.
There can be a large
number of alternative
design solutions to
analyze and the
constraints imposed
upon harness design
arebecoming more
demanding.
nWeight and space are
especially important in
missile and aerospace
applications. With the
additional electrical
equipment now in prod-
ucts such as cars, these
factors arebecoming a
bigger issue in these
industries.
nElectromagnetic interfer-
ence (EMI). Harnesses
can either radiate
interference to, or pick up
interference from, nearby
equipment. With the
increasing use of
sensitive electronics in
cars, aircraft and military
equipment this is a major
problem.
Harnessing system
components include:
nHeat-shrinkable tubing
nHeat-shrinkable molded
shapes
nAdhesives
nAdapters
nAssemblies
nElectrical interconnect
components
nWire and cable
nSolder termination
devices
nApplication equipment
In many cases, properly
selected components can
raise the performance of a
harness to acceptable
levels compatible with even
very demanding environ-
ments wherecables are
exposed to water, tempera-
ture extremes, EMI-radiated
fields, or fluids.
Tyco Electronics is the
established leader in auto-
motive, aerospace, marine,
mass transit, industrial, and
military harnessing. Call us
for ideas on protecting your
harness—whether it’s a
typical UL wiring system or
aharness assembly for
demanding environments.
nResistance to environ-
mental hazards including
corrosion, high tempera-
ture or fire, chemical
and nuclear agents. The
additional costs of totally
sealed wiring harness
systems are becoming
easier to justify as
products and the lives
of those who use them,
become more dependent
upon the fault free
operation of electrical
systems.
nRepair and maintainability.
Electrical and electronic
systems in military
vehicles and naval
vessels now need to be
upgraded or modified
several times during
the life of the main
mechanical platform.
There are now parts
and harness design
techniques that make
this work easier to
accomplish.
ARaychem molded part provides strain relief on the back end of a connector.
Electrical Interconnection System Design
Harness Design (Continued)
2-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
This section provides
information about the basic
components in a harness
design, the factors to
consider in designing a
harness, and the Tyco
Electronics HarnWare
Harness Design CAD
software. With this informa-
tion and the selection tables
that follow, you will be able
tochoose from this catalog
the right components for an
integrated military or high-
performance industrial
harnessing system.
The checklist on page 2-4
covers some of the factors
to consider in the design of
aharness.
Harness Components
Connectors and wires are
the two basic components
of a harness that need to be
specified. Once they have
been chosen, compatible
protection, shielding and
identification follow.
Connectors
Connectors come in two
opposite types: plugs and
receptacles. Both contain
contacts, usually made of
plated copper. The
contacts, called pins or
sockets, arejoined to the
conductors and are
designed to mate or join
with contacts of the
opposite type.
The front or joining end of
the connector is designed
to mate only with a connec-
tor having the right configu-
ration. The back end of the
connector is where the
wires are terminated to the
metal contacts.
Connectors for indoor or
internal use are generally
not designed to resist mois-
ture. Connectors that will be
exposed to moisture are
generally sealed to meet a
specific requirement.
Wires
In this discussion, a wire is
defined as an insulated
conductor and a cable is
defined as two or more
wires with or without a
common jacket or shield.
Conductors are usually
made from copper.
Acopper conductor can be
solid or, when flexibility is
important, can consist of
smaller strands of copper
wire twisted together. The
strands can be coated with
tin, nickel, or silver to make
them easier to terminate or
more resistant to corrosion.
Conductors are sized in
metric units (mm2)or by
AWG (American Wire
Gauge), a holdover from
the days when wire was
made of steel in steel mills.
The AWG refers to the
number of passes it takes to
draw the wire down to the
required size - the larger the
AWG, the smaller the wire.
Making a 26 AWG wire, for
example, requires more
passes through reduction
dies than are required for a
4AWG wire.
A26 AWG stranded wire,
however, is made of many
smaller wires, such as
seven strands of 32 AWG
wire (sometimes shown as
7/32 or 7x32).
The choice of insulation for
aconductor depends on a
number of factors:
nOperating, design, and
excursion temperatures
of the system
nSize and weight
limitations
nMechanical performance
desired
nFlexibility requirements
nResistance to various
fluids
nSpecialized requirements,
such as:
-low firehazardor low
halogen
-low outgassing
Electrical Interconnection System Design
Harness Design (Continued)
2-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Connectors
Sealed or unsealed? Mating frequency?
Made of plastic or metal? Keyway angle?
Crimp or solder contacts? Exposed to electrical noise (EMI)?
Pins or sockets?
Geometry
Dimensions?
Point to point or branched?
Configuration of ends - straight, 90°, 45°?
Environment
Exposed to sunlight? Exposed to dust?
Exposed to moisture? Exposed to corrosive fluids?
Immersed? Exposed to flexing?
Temperature extremes? Repairable?
Temperature cycling? Circuit identification?
Normal operating temperature? Cable identification?*
Exposed to abrasion? Shielding effectiveness?
Exposed to mechanical abuse? Magnetic-field–induced signals?
Circuit
Voltage?
Current?
Signal transmission (impedance, velocity, frequency, etc.)?
Circuit layout?
Is circuit integrity critical? What if the circuit fails?
*Tyco Electronics Identification products information available at www.tycoelectronics.com
Harness Design Checklist
ences and moremust be
considered when choosing
the termination protection
method.
Shielding and Shield
Termination
Step 3 of the component
selection process dis-
cussed later in this section
gives advice on choosing
the appropriate shielding
products for the gross
shield. Consideration must
also be given to the individ-
ual cable shield termina-
tions. Can they be pigtailed
together with a common
termination to a contact or
to earth, or should they have
individual terminations?
If using a solder device, the
correct choice is based,
not only on size, but also
temperature rating or
compatibility with the cable
braid.
Protection
Once the connectors and
wires have been specified,
the method of protection
must be considered.
Various jacket materials are
available to protect the
wires and these can be
extruded or heat-shrink.
Jacket material formulations
arecompounded to meet a
wide range of environmental
demands.
Similarly, protection for the
wire termination must be
considered. In general, the
wires will be terminated to
connector contacts.
Protection products must
protect the joints from dam-
age caused by mechanical
stress such as flex, torque
and tensile load, and corro-
sion or electrical breakdown
from fluid ingress, while
retaining the ability to be
repaired. All these influ-
Identification
Circuit identification is
important, both in manufac-
ture, where an assembly
operator must ensure
correct wire to contact
termination, and in repair,
whereadamaged
connector may need
replacing in difficult
circumstances and contact
positions have to be easily
identified. Individual wire
markers help with these
two circumstances. Where
acable is severed and
access to the ends is
prevented, unique identifi-
cation on the wires, or wire
color coding aids repair.
Consideration given to the
identification of harness
legs is also important.
Connectors will normally be
chosen with unique keying
to prevent incorrect mating
but end identification will
speed up plugging,
particularly for multi-
connector harnesses.
It is also good practice to
label the harness with its
partnumbers and other
relevant information for
traceability purposes.
The Tyco Electronics
Identification Products
Group offers a variety of
products that arecompati-
ble to the HarnWare soft-
ware design process.
For complete information
regarding these products
visit our website at
www.tycoelectronics.com.
Electrical Interconnection System Design
Protection of Harness Components
2-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Harness components are
vulnerable to corrosion,
stress, strain, and electro-
magnetic interference
(EMI).
Corrosion
Humidity, moisture, salt, and
corrosive fluids can corrode
conductors and contacts.
What is worse, the corrosion
can take place well beyond
the point of penetration
because of the small tube-
like voids—capillaries—
between the individual
strands of copper that make
up the conductor. Called
“capillary action,” the pene-
tration of a fluid can “wick”
many feet in a relatively
short time (see photo
above), depending on the
specific characteristics of
the affected wire. As the
copper in the conductor is
depleted by corrosion, the
conductor can no longer
sustain mechanical or elec-
trical loads and the metal
will fail. Mechanical failure
can thus occur anywherein
the wiring system.
Even beforemechanical
failure occurs, electrical
A salt deposit can be seen beneath
the end of this 18-AWG, 19-strand
wire. The other end of the wire has
been immersed in salt water for 24
hours.
performance can be
adversely affected by the
presence of nonconductive
by-products from galvanic
or aqueous corrosion.
Moisture within a connector
body may cause an imped-
ance mismatch, increase
noise in a signal circuit, or
modify the waveform. Even
small amounts of corrosion
orother contaminants can
have a significant impact on
contact surfaces and the
efficiency with which signals
flow through them.
If a chemical solution
contacting the electrical
connection is itself conduc-
tive it can cause a short
circuit between conductors.
Pure water, not itself a
conductor,can also
facilitate a short circuit by
providing a medium into
which conductive salts can
dissolve. These salts may
be the by-products of
corrosion or the result of
earlier contamination.
High humidity and
temperaturecycling in
some situations cause
condensation, the accumu-
lation of which can also
result in a short circuit.
Depending on circum-
stances, the resulting short
circuit may be intermittent,
significantly complicating
the process of identifying
the underlying cause.
To prevent corrosion,
sealing may have to meet
the performance require-
ments of applicable military
specifications or the
International Protection
(IP) Code.
Stress and Strain
Wires that are attached to
the connector pins need
help to withstand stresses
and strain from the cable,
which could break the wires
from the pins. It is almost
always necessary to pre-
vent strain from occurring in
aweak spot, such as where
the wire is attached to the
contact. This is called strain
relief and can be provided
in a variety of ways, from
mechanical devices, such
as adapters, to molded
boots and heat-shrinkable
tubings.
EMI (Electromagnetic
Interference)
EMI is similar to the noise
heard on an AM radio when
the radio is close to high-
voltage lines. EMI causes
the wire or cable to act like
an antenna and pick up
electrical signals, which
interfere with the signals
on the wire and can cause
malfunctions in sensitive
electronic circuits.
Wiring systems are suscep-
tible to two types of EMI:
nRadiated emissions (the
electromagnetic energy a
wiring system radiates to
its surrounding environ-
ment), such as the EMI a
high-voltage line radiates
to its surroundings.
(There are regulations on
the amount of radiated
energy a circuit is allowed
to produce.)
nExternal radiated
emissions (the electro-
magnetic energy in the
environment), such as the
EMI an AM radio picks up
from a high-voltage line,
causing distortions in the
conducted signal.
Conducted EMI is noise
carried by the cable into
the receiving circuit and
needs to be filtered.
To reduce susceptibility to
radiated emissions from the
cable or from external
sources, the harness must
be grounded, shielded,
and/or filtered, depending
on the sensitivity of the
equipment and the strength
and frequency of the EMI.
Electrical Interconnection System Design
HarnWare Harness Design Software
2-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Some HarnWare Software
Outputs
The following are some
examples of the outputs that
HarnWare software can
generate:
nHigh quality engineering
drawings. Clear and
reliable drawings play a
crucial role in the success
of any design project.
nPoint-to-point wiring lists,
including calculated wire
lengths.
nFully detailed parts lists.
HarnWare software
automatically generates
the parts list table and
adds item number
balloons into the drawing.
Parts lists can also be
exported to a spread
sheet, database
or word processor.
nAssembly time estimates.
HarnWaresoftware
automatically adds the
design details into a
‘spread sheet’ containing
standard assembly time
synthetics.
nWiring schematics and
schedules are quickly
produced using connec-
tor plan formdata and
wiring details from the
wirelist.
nLists of codes of practice
describing harness
assembly techniques
and other issues that are
relevant to the parts
included in the design.
nFiles containing cable
marker details can be
exported ready for use
in marker printing
systems such as the
Tyco Electronics WinTotal*
system. A drawing page
showing these cable
marker details can also
be generated.
Asample set of documents
produced by HarnWare
software is shown at the
end of this section.
*Tyco Electronics Identification
product information available at
www.tycoelectronics.com
Select
optimum
parts
Check for
problems &
deviations from
'best practice'
Generate
parts lists &
assembly
time estimates
Determine
best cable lays,
diameters
& construction
Determine
most suitable
wire gauge
Determine
wire routes
& lengths
Generate
wiring
schematics &
schedules
HarnWare
Software
HarnWareDesign Software
is Tyco Electronics’ harness
design CAD software.
Originally developed for
use by our own harness
designers it is now offered
to our customers so they
can benefit from this
powerful tool.
From a simple input of
geometry, dimensions,
connector and wiring
details, HarnWare software
can suggest a design
sequence and help with
many aspects of wiring
harness design (see
diagram).
HarnWaresoftware is used
interactively by harness
design engineers. The
choices and calculations
made by the system can
always be modified to suit
specific requirements.
Design data is saved with
each shape in the harness
drawing. This data can be
reviewed simply by moving
the mouse over the parts
listed in the Design Wizard.
It is, therefore, very easy
to incorporate design
changes, modify design
constraints or analyze
alternative design solutions.
Moreover a design checker
can be used to search
for deviations from ‘best
practice’.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
System Building Blocks
Some key features of
HarnWare software are:
nRuns under Microsoft
Windows on affordable
PC’s.
nThe user interface is
similar to that of common-
ly used software such as
Microsoft Word and
Excel.
nUses the Visio drag and
drop drawing system for
creating harness draw-
ings more quickly and
more easily than with
other computer aided
design (CAD) systems.
nAgrowing library of 400
intelligent drawing shapes
and a 110,000 record
design database which
can generate 100,000s of
partdescriptions for
Raychem wiring harness
products in their various
material and finish
permutations.
nSoftware that traces wire
routes through harnesses
and automatically creates
wiring schematics and
calculates wire lengths.
nAnalysis options to deter-
mine the optimum lay of
cables containing mixed
diameter wires and to
suggest the most appro-
priate wire gauge for
specified current and
temperaturerise limits.
HarnWare
Software
Database
Visio
HarnWare
Software
Help Marker Page
LabourEstimate
Design Notes
Parts List
CableXSections
Wiring Schematic
Wiring Schedule
Wire List
Drawing
HarnWare
Software
nSoftware to help identify
the parts most suitable for
use within the given
design constraints and to
fit the mating parts,
cables, etc.
nOn-line help systems for
guidance on using the
system and on Raychem
wiring harness products.
Designing a Harness With
HarnWare Software
Shapes, representing
Raychem harnessing
products, are dragged and
dropped into the harness
assembly drawing. The
shapes automatically snap
and glue together and it
takes very little time to
produce a high quality
drawing. Pages from a
sample HarnWare software
document set can be seen
on page 2-14. Dimensions
and connector references
are entered by clicking a
shape and typing in the
numbers and references.
The HarnWare Software
Design Wizard analyzes the
drawing and lists the parts
and operations in the sug-
gested design sequence.
The wizard also provides
quick access to details on
each partin the harness
and the connections
between parts. When the
mouse is moved over the
parts listed by the wizard,
HarnWare software outputs
such details as partdimen-
sions, materials, finishes,
etc.
HarnWare software
indicates the Raychem
harness material system
that is most suited to the
given application, operating
temperature range and
required defense
specifications.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Selection
The wiremost suited to the
particular environment and
service conditions is select-
ed using design rules
encoded in the HarnWare
software and database. If
the wire selected is a non-
preferred option, alternative
types and colors can be
identified which may also
suit the design require-
ments and be available on
shorter deliverytimes.
Guidance is also available
for choosing the wire gauge
most suited to given current
loading, ambient tempera-
ture, length, number of
conductors, etc. For each
available wire size
HarnWare software
estimates temperature
rises, operating tempera-
tures and voltage drops.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Wire Selection (Continued)
From-To connector refer-
ences are specified to form
apoint-to-point wiring list.
Wiring schematics can be
generated automatically
from the information includ-
ed in the wire list. These
schematic diagrams show
the pin to pin wiring for all
the connectors and wires in
aharness design.
HarnWare software auto-
matically:
nTraces the route of each
wirein the point-to-point
wire list through the
harness geometry
contained in the drawing.
450
600
480
500
PL1
SK1
SK2
SK3
900
1 2 4 PL1 SK1
2 2 5 PL1 SK2
3 1 19 PL1 SK3
WIRE ITEM QTY FROM TO
NO NO
3.76 1800.00
3.76 1668.00
1.40 1590.00
WIRE LIST
44A1121-20-0/9-9
44A1121-20-0/9-9
44A0111-20-9
PART NO DIA LENGTH
A
B
C
D
E
F
G
H
J
K
L
SHELL
SK2
A
B
C
D
E
F
G
H
t.
J
K
L
M
N
P
R
S
T
U
s.
V
W
X
Y
Z
a.
b.
c.
d.
e.
SHELL
PL1
A
B
C
D
E
F
G
H
J
SHELL
SK1
A
B
C
D
E
F
G
H
J
K
SHELL
SK3
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG Black
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
20 AWG White
+
=
nCalculates wirelengths
by summing the lengths
of the harness legs
through which each wire
is routed. Adjustments are
applied based on a vari-
ety of design rules relat-
ing to the parts through
which wires pass.
nDetermines the cable
sub-assembly structure
that would save the maxi-
mum amount of labor in
assembling the harness.
nDetermines the optimum
lay of wires in each har-
ness leg and produces a
cable cross-section draw-
ing. Alternative lays of
cables containing mixed
diameter wires are auto-
matically analyzed to
identify the smallest
diameter and most even
construction. In the exam-
ple below, the listbox
contains the quantity of
each wirediameter for
which HarnWare software
has automatically devel-
oped 29 alternative
design solutions. The
minimum diameter alter-
native is shown which is
17.72 [.698] diameter and
uses 2 fillers to achieve a
sufficiently round lay.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Part Selection
All the parts in a harness
can be specified. The key
steps in selecting parts
include:
nClicking a shape in the
harness drawing or the
design wizard.
nHarnWare software
automatically obtains
design data and dimen-
sions from the shape and
from mating parts in the
harness assembly draw-
ing. In the case of a
Raychem boot, for exam-
ple, HarnWare software
extracts the required style
of boot from the shape
and the diameters from
the mating harness leg
and adapter.
nThe database is searched
for parts suited to the
dimensional constraints.
The choice is further
refined by the service
conditions which deter-
mine the best materials,
finishes and adhesives.
When alternative parts
arefound in the data-
base, HarnWare software
offers the best option first,
which the designer can
compare with the other
alternatives. The on-line
help systems contain
details and advice on the
various types of parts,
materials and finishes
and their suitability to dif-
ferent service conditions.
Among the parts that
HarnWare software helps
to select are:
nAdapters
nBraid
nConnectors
nDatabus couplers, etc.
nFeedthroughs
nHeat-shrinkable tubing
nMarker sleeves*
nMolded parts
nAdhesives
nSolder sleeves
nWire
*Tyco Electronics Identification
product information available at
www.tycoelectronics.com
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Parts Listing
During the parts listing
process HarnWare software
automatically:
nExtracts part details from
the drawing
nGenerates a sorted and
totalized parts list table
nAdds item number
balloons to the drawing
cross referencing the
parts to the parts list
table.
HarnWare software parts list
data can be written to a
structured text file ready for
use in a variety of other
systems including spread
sheets, databases or word
processors. The parts lists
for a number of harnesses
can also be combined to
form a composite parts list
that totalizes all the parts
for a set of harnesses on a
project. Other parts listing
options include the ability to:
nRetain existing item
numbers when a design
is modified.
nInclude gaps in the item
numbering sequence.
nConvert part numbers to
customer numbers or to
VG or other industry
standardnumbers.
1 Wire 44A0111-20-9 Raychem 30.3 M
PARTS LIST
ITEM DESCRIPTION PART NUMBER SPEC/REMARKS QTY UNIT
Printed 13/03/01, 13:16:41
HARNESS PROPOSAL DRAWING
TITLE:
FILENAME: Page 3 of 8
CREATOR: DATE:
BRANCHED HARNESS ASSEMBLY
D Hammond
PicHarn.vsd
13/03/01
2 Wire 44A1121-20-0/9-9 Raychem 15.6 M
3Filler 2.75-MM-SZF Raychem 0.5 M
4 Filler 3.50-MM-SZF Raychem 0.5 M
5 Braid RAY-101-10.0 Raychem 1.2 M
6Braid RAY-101-12.5 Raychem 1.2 M
7 Braid RAY-101-7.5 Raychem 1 M
8 Tubing AT099-43 Raychem 2 Pc
9 Tubing DR-25-1/2-0 Raychem 1.6 M
10 Tubing DR-25-1/2-0-50MM Raychem 1 Pc
11 Tubing DR-25-1-0 Raychem 1 M
12 Tubing DR-25-3/4-0 Raychem 0.6 M
13 Tubing RNF-100-3/16-0-15MM Raychem 4 Pc
14 Tubing RNF-100-1/2-0-20MM Raychem 3 Pc
15 Tubing RNF-100-1-0-20MM Raychem 1 Pc
16 Tubing RT-375-1/2-X-65MM Raychem 1 Pc
17 Tubing RT-375-1-X-65MM Raychem 3 Pc
18 Tubing RT-375-3/4-X-65MM Raychem 1 Pc
19 Insulation Cap TC4001-9 Raychem 18 Pc
20 Adaptor TXR40AB00-1208AI Raychem 1 Pc
21 Adaptor TXR40AB00-1410AI Raychem 1 Pc
22 Adaptor TXR40AB00-2014AI Raychem 1 Pc
23 Adaptor TXR76AB90-1208AI Raychem 1 Pc
24 Moulded Part 202K142-25/225-0 Raychem 2 Pc
25 Moulded Part 202K153-25/225-0 Raychem 1 Pc
26 Moulded Part 202K163-25/225-0 Raychem 1 Pc
27 Moulded Part 382A034-25/225-0 Raychem 2 Pc
28 Solder Device B-051-01-01 Raychem 1 Pc
29 Solder Device B-051-02-01 Raychem 1 Pc
30 Solder Device ST63-3-55-20-90 Raychem 14 Pc
31 Marker Sleeve TMS-NR501-NR19-4-CS-65571 Raychem 4 KT
32 Marker Sleeve TMS-NR501-NR19-4-CS-65572 Raychem 1 KT
33 Marker Sleeve TMS-SCE-1/2-2.0-4 Raychem 1 Pc
34 Marker Sleeve TMS-SCE-1-2.0-4 Raychem 2 Pc
35 Marker Sleeve TMS-SCE-3/4-2.0-4 Raychem 2 Pc
36 Connector 62GB-56T12-10P Amphenol 1 Pc
37 Connector D38999/26WC98PN MIL-C-38999 1 Pc
38 Connector D38999/26WD18SA MIL-C-38999 1 Pc
39 Connector D38999/26WG41PN MIL-C-38999 1 Pc
40 Filler Plug MS27488-20 - 20 Pc
PL1
MA TES WITH
CPU - SK1
PL1
40
12
39
34
30
7
26
22
19
9
17
13
2
31
32
Other Features
Among the other HarnWare
softwarefeatures and
options are:
n3D modelling system for
visualizing harness
designs. HarnWare
softwareautomatically
generates to-scale 3D
models which provide
virtual prototypes of
harnesses designed.
The user can see what a
harness will look like with
lengths, diameters and
parts shown to scale thus
reducing the potential for
errors.
nLay-up (nail) board
designs. Harness lay-up
board design can be
modeled with pegs auto-
matically positioned along
the harness legs. Drawn
output can be used on
the lay-up board.
nWeight calculation. Most
components weights are
stored in the HarnWare
software database and
this enables the software
to estimate the weight of
the harness.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Other Features (Continued)
nLabor estimator. Harness
drawings can be
analyzed and details
automatically added to a
spread sheet containing
assembly time standards.
While estimating harness
assembly times can never
be an exact science, the
estimates produced are
sufficiently accurate for
such purposes as com-
paring the cost effective-
ness of alternative design
solutions. A labor estimate
is contained in the
attached sample
HarnWare software
document set.
nCable analyzer. This
option analyzes the
harness topology, wire
lengths, etc. in order to
suggest where machine,
rather than hand, built
cable sub-assemblies
could result in the
maximum cost savings.
nDrawing translator.
Drawings can be trans-
lated into a number of
foreign languages,
including French and
some Asian languages
such as Korean and
Japanese. Harnessing
phrases, rather than
individual words, are
translated in order to
achieve moremeaningful
and grammatically correct
results.
nDesign checker. This
analyzes the contents
and structure of a harness
design against a set of
rules. Where potential
problems or deviations
from 'best practice' are
found, HarnWare software
outputs a warning. The
relevant parts in the
harness design drawing
can be flagged and the
warning messages can
also be listed in a table
for use in design reviews.
The warning flags and the
messages areall linked
to an on-line help system
which contains further
details on each specific
problem.
nCodes of practice. Alist
can be generated of the
codes of practice that are
relevant to the parts
included in the design.
These describe harness
assembly techniques and
other issues.
nOn-line help system. An
extensive on-line help
system covers system
operating procedures
and details on many
aspects of harness
design procedures and
Raychem products. The
help system is context
sensitive and extensively
cross-referenced using
hyperlinks including links
to the on-board manual
or the Tyco Electronics
website.
nUser parts libraryfor
non-standardparts. A
database to allow identifi-
cation and retrieval of
regularly used parts.
nMulti-corecable data-
base. Adatabase to allow
selection of standard or
regularly used cables.
nDatabus module.
Software for the design
of MIL-C-1553 databus
harness assemblies using
Tyco Electronics compo-
nents.
nConduit module. Software
for the design of Tyco
Electronics conduit
harnesses.
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
System Integration
HarnWare software can be
linked to many other com-
puter systems using a vari-
ety of interfaces including:
nParts list data can be
exported in structured text
files suitable for reading
by such systems as
spread sheets, databases
and word processors.
nDrawings can be import-
ed and exported using
industry standard formats
such as DXF and IGES.
nCable marker data can
be transferred to marker
printing systems such as
Tyco Electronics WinTotal*
system.
nWiring connectivity data
export for test equipment.
nX, Y coordinates of nail
positions on lay-up (nail)
board for NC drilling.
HarnWare Software
Document Set
The following partial set of
drawings and associated
documents is a simple
example of what can be
produced using HarnWare
software.
HarnWare
Software
M
os
t
co
st
ef
fe
cti
ve
En
s
ure
s
co
m
p
ati
bi
lit
y
Mo
re
d
et
ail
ed
F
as
ter
Pr
efe
rr
ed
p
ar
ts
Benefits
The five key benefits of
using HarnWare software
are:
1)Moredetailed and accu-
rate design.
2)Up to 20 times faster
design and quotation.
3)Preferred part selection,
to ensurebest delivery
and price.
4)More cost effective
design.
5)Ensures parts are com-
patible with the intended
service conditions and
with mating parts.
Hundreds of users around
the world can confirm the
benefits of using HarnWare.
*Tyco Electronics Identification
product information available at
www.tycoelectronics.com
Electrical Interconnection System Design
HarnWare Harness Design Software (Continued)
2-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
General Assembly, Wiring
Schematic, Parts List,
Labor Estimate, Marker
Sleeve and Codes of
Practice Pages
Unpack Check Kit per kit
Cut EPD to Length per metre
Jacket Stripping per
for Con. Ends end
Remove EPD Jacket per metre
Identify Wires per wire
Strip/Crimp/Insert per cont.
Up to 16AWG per term
(Tin/Strip/Insulate)
14 to 12AWG per term
(Tin/Strip/Insulate)
Power Cable per term
Lugs Crimp per term
Lugs Solder per term
Repair Loops
Up to 55 Way Con. per wire
Above 55 Way Con. per wire
Soldertact per term
Individual Term. per term
Coaxial Term. per term
Insulating Screens per term
Filler Plugs per f/plug
Spare Wires per wire
Ring Tags Crimp per term
Ring Tags Solder per term
RF one-step per term
Spin Coupling per term
Braided Adaptor per term
Tinel per term
Whipping/Soldering per term
DR25 < 1/4 per metre
1/4 to 1/2 per metre
3/4 to 1 per metre
1 1/2 + per metre
Viton, VPB +25% } Enter
ZHTM -25% } 0 for No
CGPT & Versafit }1 for Yes
Tubing Installation per
on Multi-Leg Harness metre
Legs <=4 Metres
<20 wires
20 - 30 wires
>30 wires
Legs >4 Metres
<20 wires
20 - 30 wires
> 30 wires
Rayaten
121 to 142 per piece
152 to 163 per piece
174 per piece
Standard
11 to 42 per piece
52 to 63 per piece
74 per piece
85 per piece
Uniboot
611 to 621 per piece
632 to 642 per piece
653 to 663 per piece
KTKK
Small per piece
Medium per piece
Large per piece
3 Outlets
11 to 19 per piece
22 to 48 per piece
56 to 91 per piece
4 Outlets
11 to 19 per piece
22 to 48 per piece
56 to 91 per piece
5 Outlets
11 to 19 per piece
22 to 48 per piece
56 to 91 per piece
Viton +50% } Enter
Precoated -25% } 0 for No
Potting +50% } 1 for Yes
Packing Piece/Ext. per piece
Atum/Htat per piece
Straight per metre
Branch per metre
Transition Overlap per piece
Bandage per piece
Protection Cap per piece
Installation
Marker Sleeves per piece
Protection Sleeves per piece
Wire Cutting per wire
Common Size per wire
Mixed Sizes per wire
Time (mins)Element Qty / Length Total mins
LABOUR ESTIMATE
Printed 13/03/01, 13:16:41
TITLE:
FILENAME: Page 5 of 8
CREATOR: DATE:
BRANCHED HARNESS ASSEMBLY
D Hammond
PicHarn.vsd
13/03/01
0015 001
4205
00560781.3 50 1252.5
10353.5
005
0015
0010
0015
60 300.5 000.75
004
14 423
482 20 201
18 90.5
002 002.5
007.5 0012 44010 005
0041.50 10.57 1.43 14.310 0015 000.25 00-.25 00-.25
2.93 5.862
006
008
Solder Wires
Screen Termination
Adaptors (includes Braid Term / Torque)
Tubing
0017 0025 0030
22412 23015 0020 0025
0010 0012 0015
005006007
0016 24020 0023
00
21 0025 0029
0025 0028 0033 00
.50 1 -23.5
-.25
.5
5
3
003.5 2.93 14.655 2168 0033
005
5204
37371
37 3.70.1 000.3
551
127.38 27.38
Enter 1 to add 30%
for mixed wire sizes 1
1.5 12.60 18.9
200
1.5 0 0
200
2.5 0
Wire Layup
Time (mins)Element Qty / Length Total mins
Moulded Parts
Raybraid / Install
Unravel / Count Cut Wires
Transitions
Enter 1 to add 5% allowance for QC 0
Total Labour Time (mins) 679.67
Labour rate per hour 0.00
Total Labour Time (hours) 11.33
£
Total Labour Cost 0.00
00
315
00
20% for Straight or Branched < 4 Ends 0
35% for Branched 4+ Ends 0
Enter 1 to Add Allowances for Prototypes:
0
Special Requirements (mins) 0
HARNESS PROPOSAL DRAWING
MARKER PAGE
Printed 13/03/01, 13:16:41
TITLE:
FILENAME: Page 6 of 8
CREATOR: DATE:
BRANCHED HARNESS ASSEMBLY
D Hammond
PicHarn.vsd
13/03/01
HARNESS PROPOSAL DRAWING
Item:34 Quantity:1
Part Number:TMS-SCE-1-2.0-4
Colour:Yellow Font:10 cpi Standard
PL1
MA TES WITH
CPU - SK1
Item:34 Quantity:1
Part Number:TMS-SCE-1-2.0-4
Colour:Yellow Font:10 cpi Standard
MAIN MARKER
ISSUE #
SERIAL No.
Item:35 Quantity:1
Part Number:TMS-SCE-3/4-2.0-4
Colour:Yellow Font:10 cpi Standard
SK2
MA TES WITH
BOX 1 - PL2
Item:33 Quantity:1
Part Number:TMS-SCE-1/2-2.0-4
Colour:Yellow Font:10 cpi Standard
SK3
MA TES WITH
BOX 1 - PL3
Item:35 Quantity:1
Part Number:TMS-SCE-3/4-2.0-4
Colour:Yellow Font:10 cpi Standard
SK1
MA TES WITH
BOX 1 - PL1
1 Wire 44A0111-20-9 Raychem 30.3 M
PARTS LIST
ITEM DESCRIPTION PART NUMBER SPEC/REMARKS QTY UNIT
Printed 13/03/01, 13:16:41
HARNESS PROPOSAL DRAWING
TITLE:
FILENAME: Page 3 of 8
CREATOR: DATE:
BRANCHED HARNESS ASSEMBLY
D Hammond
PicHarn.vsd
13/03/01
2Wire 44A1121-20-0/9-9 Raychem 15.6 M
3 Filler 2.75-MM-SZF Raychem 0.5 M
4Filler 3.50-MM-SZF Raychem 0.5 M
5 Braid RAY-101-10.0 Raychem 1.2 M
6Braid RAY-101-12.5 Raychem 1.2 M
7Braid RAY-101-7.5 Raychem 1 M
8 Tubing AT099-43 Raychem 2 Pc
9 Tubing DR-25-1/2-0 Raychem 1.6 M
10 Tubing DR-25-1/2-0-50MM Raychem 1 Pc
11 Tubing DR-25-1-0 Raychem 1 M
12 Tubing DR-25-3/4-0 Raychem 0.6 M
13 Tubing RNF-100-3/16-0-15MM Raychem 4 Pc
14 Tubing RNF-100-1/2-0-20MM Raychem 3 Pc
15 Tubing RNF-100-1-0-20MM Raychem 1 Pc
16 Tubing RT-375-1/2-X-65MM Raychem 1 Pc
17 Tubing RT-375-1-X-65MM Raychem 3 Pc
18 Tubing RT-375-3/4-X-65MM Raychem 1 Pc
19 Insulation Cap TC4001-9 Raychem 18 Pc
20 Adaptor TXR40AB00-1208AI Raychem 1 Pc
21 Adaptor TXR40AB00-1410AI Raychem 1 Pc
22 Adaptor TXR40AB00-2014AI Raychem 1 Pc
23 Adaptor TXR76AB90-1208AI Raychem 1 Pc
24 Moulded Part 202K142-25/225-0 Raychem 2 Pc
25 Moulded Part 202K153-25/225-0 Raychem 1 Pc
26 Moulded Part 202K163-25/225-0 Raychem 1 Pc
27 Moulded Part 382A034-25/225-0 Raychem 2 Pc
28 Solder Device B-051-01-01 Raychem 1 Pc
29 Solder Device B-051-02-01 Raychem 1 Pc
30 Solder Device ST63-3-55-20-90 Raychem 14 Pc
31 Marker Sleeve TMS-NR501-NR19-4-CS-65571 Raychem 4 KT
32 Marker Sleeve TMS-NR501-NR19-4-CS-65572 Raychem 1 KT
33 Marker Sleeve TMS-SCE-1/2-2.0-4 Raychem 1 Pc
34 Marker Sleeve TMS-SCE-1-2.0-4 Raychem 2 Pc
35 Marker Sleeve TMS-SCE-3/4-2.0-4 Raychem 2 Pc
36 Connector 62GB-56T12-10P Amphenol 1 Pc
37 Connector D38999/26WC98PN MIL-C-38999 1 Pc
38 Connector D38999/26WD18SA MIL-C-38999 1 Pc
39 Connector D38999/26WG41PN MIL-C-38999 1 Pc
40 Filler Plug MS27488-20 - 20 Pc
CODES OF PRACTICE, FAX-ON-DEMAND AND DRAWING NOTES
Printed 13/03/01, 13:16:41
TITLE:
FILENAME: Page 8 of 8
CREATOR: DATE:
BRANCHED HARNESS ASSEMBLY
D Hammond
PicHarn.vsd
13/03/01
Codes of Practice:
Code Description
251 End stripping primary wire and cable
254 Stripping wire and cable jackets
256 Laying hand laid sections of harnesses
257 Applying Kevlar binder to hand-laid sections of harnesses
261 Preparing shielded and jacketed wire
301 Looping wire gauges 18 and below
368 Terminating a primary wire to a cable shield using a solder sleeve with a pre-installed lead
361 Applying a single layer of braid to a hand laid cable
363 Terminating overall shields formed by single layers of braid at a transition
551 Installing heat shrinkable tubing
610 Preparing cable jackets for the installation of pre-coated tubings
359 Installing Tinel-Lock rings with a resistance heater
366 Positioning Tinel-Lock rings
451 Applying Loctite sealants to Raychem adaptors
452 Torque tightening Raychem adaptors
553 Installing medium and large transitions
554 Installing straight lipped boots
557 Under jacket packing for moulded parts
559 Installing moulded parts using Unicure adhesive
603 Preparing cable jackets and adaptors for installing moulded parts
609 Preparing non-shielded moulded parts
556 Installing marker sleeves
454 Checking the retention of pins or sockets within a connector
HARNESS PROPOSAL DRAWING
A
B
C
D
E
F
G
H
J
K
L
SHELL
SK2
A
B
C
D
E
F
G
H
t.
J
K
L
M
N
P
R
S
T
U
s.
V
W
X
Y
Z
a.
b.
c.
d.
e.
SHELL
PL1
A
B
C
D
E
F
G
H
J
SHELL
SK1
A
B
C
D
E
F
G
H
J
K
SHELL
SK3
20AWG Black
20 AWG White
20AWG Black
20AWG White
20AWG Black
20 AWG White
20AWG Black
20AWG White
20 AWG Black
20AWG White
20AWG Black
20AWG White
20AWG Black
20 AWG White
20 AWG Black
20AWG White
20AWG Black
20AWG White
20AWG White
20AWG White
20AWG White
20 AWG White
20 AWG White
20AWG White
20 AWG White
20 AWG White
20AWG White
20 AWG White
20AWG White
20 AWG White
20 AWG White
20AWG White
20 AWG White
20AWG White
20AWG White
20 AWG White
20 AWG White
SHEET
NO
OF
SHEET
NO
OF
1
8
-
-
A
2
CHENEY MANOR INDUSTRIAL ESTATE, SWINDON
MOD ESTABLISHMENT/CUSTOMER
K1010
N.S.N.
TITLE RESPONSIBLE AUTHORITY
SECURITY CLASSIFICATION
RAYCHEM DRAWING NO.
SCALE (ORIGINAL)
DIMENSIONS IN MILLIMETRES
TOLERANCES,UNLESS OTHERWISE STATED
>50 - <=50
>50 - <=150
>150 - <=300
>300 - <=1000
>1000 - <=2000
>2000 - <=4000
>4000
ANGULAR
+5
+10
+15
+25
+50
+75
+100
±5˚
H
G
F
E
D
C
B
A
1413121110987654321
0 50 100 150 200 250
250 MILLIMETRES FULL SIZE
USED ON
SECURITY CLASSIFICATION
SHEET
NO
OF
1
8
SERVICE DRAWING NO./RAYCHEM DRAWING NO.
SERVICE DRAWING NO.
Q.C. APP'D
TECH APP'D
PRODAPP'D
CERTIFIED
CHECKED
DRAWN
ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D
DRAWING TO BE READ IN CONJUNCTION WITH
B.S.308 AND DEF. STAN. 05-10
UNCONTROLLED COPY,CHECK REVISION BEFORE USE
THIS DRAWING IS C.A.D. GENERATED AND MUST
NOT BE MODIFIED MANUALLY
CONTINUITY AND INSULATION RESISTANCE TESTS
SHALL BE IN ACCORDANCE WITH MVEE 773
SECTIONS 7.1.2, 7.1.3 AND 7.1.4.
THIS DRAWING AND THE INFORMATION
SET FORTH HEREON ARE THE
PROPERTY OF RAYCHEM AND ARE
TO BE HELD IN TRUST AND CONFIDENCE.
PUBLICATION, DUPLICATION,
DISCLOSURE, OR USE FOR ANY OTHER
PURPOSE NOT EXPRESSLY AUTHORISED
IN WRITING BY RAYCHEM IS
PROHIBITED.
-
UNCLASSIFIED
HBJC4/37-18/18652K
-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 807978
HBJC4/37-18/18652K
UNCLASSIFIED
-
-
-
-
-
-
D.E.H.
N.T.S.
BRANCHED HARNESS
ASSEMBLY
-
3rd ANGLE PROJECTION
HARNESSING SYSTEMS
1 17.06.99 --- -
SK2
PL1
MATES WITH
CPU - SK1
MAIN MARKER
ISSUE #
SERIAL No.
SK2
MATESWITH
BOX 1-PL2
SK3
MATESWITH
BOX1-PL3
SK1
MATESWITH
BOX 1 - PL1
SHEET
NO
OF
SHEET
NO
OF
1
8
-
-
A
2
HARNESSING SYSTEMS
CHENEY MANOR INDUSTRIAL ESTATE, SWINDON
MOD ESTABLISHMENT/CUSTOMER
K1010
N.S.N.
TITLE RESPONSIBLE AUTHORITY
SECURITY CLASSIFICATION
RAYCHEM DRAWING NO.
SCALE (ORIGINAL)
DIMENSIONS IN MILLIMETRES
TOLERANCES,UNLESS OTHERWISE STATED
>50 - <=50
>50 - <=150
>150 - <=300
>300 - <=1000
>1000 - <=2000
>2000 - <=4000
>4000
ANGULAR
+5
+10
+15
+25
+50
+75
+100
±5˚
H
G
F
E
D
C
B
A
1413121110987654321
0 50 100 150 200 250
250 MILLIMETRES FULL SIZE
USED ON
SECURITY CLASSIFICATION
SHEET
NO
OF
1
8
SERVICE DRAWING NO./RAYCHEM DRAWING NO.
SERVICE DRAWING NO.
Q.C. APP'D
TECH APP'D
PRODAPP'D
CERTIFIED
CHECKED
DRAWN
ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D ISSUE DATE CHANGE NO CHK'D
DRAWING TO BE READ IN CONJUNCTION WITH
B.S.308 AND DEF. STAN. 05-10
UNCONTROLLED COPY,CHECK REVISION BEFORE USE
THIS DRAWING IS C.A.D. GENERATED AND MUST
NOT BE MODIFIED MANUALLY
CONTINUITY AND INSULATION RESISTANCE TESTS
SHALL BE IN ACCORDANCE WITH MVEE 773
SECTIONS 7.1.2, 7.1.3 AND 7.1.4.
THIS DRAWING AND THE INFORMATION
SET FORTH HEREON ARE THE
PROPERTY OF RAYCHEM AND ARE
TO BE HELD IN TRUST AND CONFIDENCE.
PUBLICATION, DUPLICATION,
DISCLOSURE, OR USE FOR ANY OTHER
PURPOSE NOT EXPRESSLY AUTHORISED
IN WRITING BY RAYCHEM IS
PROHIBITED.
-
UNCLASSIFIED
HBJC4/37-18/18652K
-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 807978
HBJC4/37-18/18652K
UNCLASSIFIED
-
-
-
-
-
-
D.E.H.
N.T.S.
BRANCHED HARNESS
ASSEMBLY
-
3rd ANGLE PROJECTION
1 17.06.99 --- -
PL1
CABLE SECTION
SK3
CABLE SECTION
SK2
CABLE SECTION
SK1
CABLE SECTION
A-A
CABLE SECTION
A
A
450
600
900
480
500
PL1
SK1
45 SK3
40
7
40
12
40
39
38
37
36
35
35
34
34
33
30
4
30
7
30
3
29
28
27
27
26
25
24
24
23
22
21
20
19
9
19
9
18
17
17
17
16
15
14
14
2
13
13
2
13
12
11
10
9
9
8
7
65
5
4
3
2
2
1
2
11
6
2
1
8
31
32
31
31
31
General Assembly Wiring Schematic
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries
2-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Raychem integrated
harness systems have been
developed for a wide range
of defense and industrial
applications. Each system
consists of compatible
components, including
cable jackets, heat-
shrinkable components,
and adhesives. Perfor-
mance of these parts is
assured because all
components are tested
separately and as partof
an assembled system
(see photo top left).
Atypical designed harness
consists of seven compo-
nent parts (pictured at right):
1. Primary wire and cable
2. Heat-shrinkable tubing
3. Backshell adapter
4. Molded part
5. Adhesive
6. Cable jacket
7. Marker sleeve*
Additional components for
harnessing systems include
the following:
nAwide range of special
devices, such as
SolderSleeve devices
for primary wire
interconnection.
nAselection of electrical
shielding (screening)
options, including braids
and termination
assemblies.
nMulticonductor (multi-
core) cables.
nSpecialty adhesives and
sealants for complete
environmental sealing.**
Table 1 on the next page
serves as both a summary
of Raychem products for
specific harnessing sys-
tems and a selection table
for harnessing system
components. An explana-
tion of how to select
components for a harness
system follows.
*Tyco Electronics Identification products information available at
www.tycoelectronics.com
**Tyco Electronics Sealant product information available at
www.tycoelectronics.com
Assembled military harness. Military harness system components.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Selection Process
Selecting the components
for a harnessing system is a
four-step process:
Step 1: Select the material
system appropriate for the
operating conditions and
environment to which the
harness will be exposed.
Step 2: Select the adhe-
sive system appropriate for
the material system you
select in Step 1.
Step 3: Determine the level
of EMI shielding required.
Step 4: Select the
components.
Each step is described on
the pages that follow. A
selection table accompa-
nies each step. You can
also use HarnWare software
to design your harness.
Step 1. Select the Material
System.
Detailed in Table 2 on the
next page arethe major
material systems for use in
awide range of operating
conditions and environ-
ments.
Choose a material system
that:
nHas the physical charac-
teristics your harness
requires.
nWill accommodate the
operating temperature
and the fluids and abuse
to which the harness will
be exposed.
System System System System System System System
Components 10 20 25 30 100 200 300
Wire 44 44 44 55 99, 100A, 5555
100G
Tubing Versafit NT-FR DR25 VPB ZHTM Viton®RT555
Adapter material and plating finish chosen for compatibility with the connectors.
Molded part -3, -4, -71 -51 -25 -50 -100 -12 -55/-125
Preinstalled Rayaten molded part -35 — -25S — -100S — —
Adhesive S1017, S1124, S1048, S-1125, S1030, S1125, S1255-04
S1030 S1048 S1125 S-1255-04 S1125, S1255
Precoated adhesive /42, /180 /164,/86 /86, /225 — /180 — —
Conductive adhesive — — S1184 — S1184 — —
Cable jacket Thermorad NT-FR FDR-25 Thermorad Zerohal Viton®RT555
VPB
Marker sleeve* TMS-SCE TMS-SCE TMS-SCE TMS-SCE HX-SCE HT-SCE HT-SCE
Table 1. Raychem
Harnessing Systems and
Their Components
*Tyco Electronics Identification products information available at www.tycoelectronics.com.
VITON is a trademark of
Dupont Dow Elastomers LLC
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Table 2. Material System Selection
System 10 System 20 System 25
Operating temperature -20°C to +60°C [-4°F to +140°F] -55°C to +121°C [-67°F to +250°F] -75°C to +150°C* [-103°F to +302°F]
Physical characteristics •Environmentally sealable • Environmentally sealed • Environmentally sealed
•Lightweight • Tough • Rugged
•Small diameter • Flexible • Abrasion-resistant
•Flexible • Low profile • Very flexible
Flammability •Flame-retardant • Flame-retarded • Flame-resistant
•Self-extinguishing • Self-extinguishing • Self-extinguishing
Fluid resistance •Resists common industrial • Resists most commonly • Resists most common
and military cleaning used military fuels, oils, military fuels, oils,
solvents and degreasers. and greases and greases. up to 70°C
[158°F].
•Used in high-performance • Specially suited to • Specially suited to
Typical applications industrial applications, and military vehicles and military vehicles,
inmilitary communication engine compartments, aerospace and marine
and test equipment. low profile shapes applications, and
save space and weight. communication and
test equipment.
System 30 System 100 System 200
Operating temperature -55°Cto +150°C[-67°F to +302°F] -30°C to +105°C [-22°F to +221°F] -55°C to +200°C [-67°F to +392°F]
Physical characteristics • Environmentally sealed • Environmentally sealed • Environmentally sealed
•Tough • Flexible • Very flexible
•Flexible
• Low profile
Flammability • Flame-retarded • Low toxicity index • Highly flame-retardant
• Self-extinguishing (as defined by NES-13)
•Low smoke emission
(as defined by NES-711)
•Low corrosive gas evolution
Fluid resistance • Resists most of commonly • Resistant to a range of • Resists long-term
used military fuels, oils, military fuels, oils, immersion in military
and greases. and greases. fuels, oils, and greases
at elevated temperatures.
Typical applications
• Specifically suited to military • Specially suitable for • Used where there is
vehicles and engine compartments confined habitat areas prolonged exposure to
for higher temperature in military and civil high temperatures.
applications, low profile shapes applications. • Used where a harness
save space and weight. • Extensively used in surface may be permanently
and submarine vessels immersed in difficult
and underground railways fuels, such as in fuel tanks.
System 300
Operating temperature -55°C to +200°C [-67°F to +392°F]
Physical characteristics •Environmentally sealed
•Highly abrasion resistant
• Low profile
Flammability • Highly flame-retardant
Fluid resistance •Performs in aggressive
fluids at extremely high
temperatures
Typical applications •Permanent immersion in
aggressive fluids
*Per VG 95343.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Raychem Harnessing
Systems and Their
Components —
NBC Survivable Systems*
System System System
Components 770 780 790
Wire 44 55 55
Tubing RT-770 RT-780 RT-790
Molded part -770 -780 -790/-791
Adhesive S-1264 S-1255-04 S-1255-04
Marker sleeve cover RT-375 RT-375 RT-375
Marker sleeve** TMS-SCE NBC-SCE NBC-SCE
**Tyco Electronics Identification products information available at www.tycoelectronics.com.
*Under Development - contact Tyco Electronics for additional information
Material System Selection
System 770 System 780 System 790
Operating temperature -55°Cto +125°C[-67°Fto +257°F] -65°C to +175°C [-85°F to +347°F] -65°C to 200°C [-85°F to +392°F]
•Environmentally sealed • Environmentally sealed • Environmentally sealed
Physical characteristics • NBC resistant • NBC resistant • NBC resistant
• Flexible • Flexible • Flexible
Flammability • Flame retarded • Flame retarded • Flame retarded
• Self-extinguishing • Self-extinguishing • Self-extinguishing
Fluid resistance • Resistant to NBC uptake • Resistant to NBC uptake • Resistant to NBC uptake
and decontamination and decontamination and decontamination
Typical applications •Base-line system for • High temperature system for • Extreme high temperature
NBC resistant applications NBC resistant applications system for NBC resistant
applications
New
Product
2005
Material Adhesive Component Precoated Service
System Type Adhesive Adhesive Designation Temperature
System 770 Two-part Epoxy S-1264 — 150°C
System 780 Thermoset tape S-1255-04 — 200°C
System 790 Thermoset tape S-1255-04 — 200°C
Adhesive Selection
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Two types of adhesives are
used to bond heat-shrink-
able boots and transitions
to tubing or wire jacketing:
nThermosets, which
include epoxies and other
two-part systems.
nThermoplastics, which
include pre-coated
meltable adhesives
applied to parts during
manufacture and those
applied as meltable tapes
during assembly.
Table 3 below outlines
the differences between
thermosets and thermo-
plastics.
Table 4 shows which adhe-
sive type is appropriate for
each harness material
system.
Thermoset Thermoplastic
Method of adhesion Cures through chemical reaction. Melts, flows, and solidifies.
Application Two-part types require mixing and Precoated types require no preparation
application at assembly. at assembly.
Cure time Varies with cure temperature. Not required. Adhesive functional when
Oven cure usually desirable. cooled to room temperature.
Strength Retains most strength at Loses strength as melt temperature is
elevated temperatures. approached.
Disassembly Items can be forcibly peeled apart Items can be separated when heated
when heated sufficiently. to temperature of the adhesive.
Repair/reassembly Requires new adhesive or hot rollback Can be reheated to form new bond if
to reenter behind connector without sufficient adhesive remains.
affecting adhesive bonds.
Table 3. Comparison of
Adhesive Types
Material Adhesive Component Precoated Service
System Type Adhesive Adhesive Designation Temperature
System 10 Thermoplastic S-1030 /180 80°C
S-1017 /42 60°C
System 20 Thermoplastic S-1124 /164 105°C
S-1048 /86 120°C
System 25 Thermoplastic S-1048 /86 120°C
Two-part thermoset S-1125 /225 150°C
System 30 Thermoset Tape S-1255-04 — 200°C
Two-part thermoset S-1125 — 150°C
Thermoplastic S-1030 /180 80°C
System 100 S-1048 /86 120°C
Two-part thermoset S-1125 — 150°C
System 200 Two-part thermoset S-1125 — 150°C
Thermoset tape S-1255-04 — 200°C
System 300 Thermoset tape S-1255-04 — 200°C
System 770 —S-1264 — —
System 780 Thermoset tape S-1255-04 — 200°C
System 790 Thermoset tape S-1255-04 — 200°C
Table 4. Adhesive Selection
Step 2. Select the Adhesive
System.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tyco Electronics offer
several methods and
technologies for controlling
electromagnetic interfer-
ence (EMI) and noise in
cable harnesses. Developed
in response to well-estab-
lished threats in military and
other harsh environments,
these technologies can be
employed in compatible
shielding (screening)
systems to achieve the level
of shielding required for a
harness system. Table 5 on
page 2-22 outlines the
shielding requirements for
various types of threat and
levels of interference.
Introduction
This section is intended as a
guide for the use of harness
designers who are required
to achieve a level of EMI
control in their design prac-
tices. It is not intended that
it should be a definitive
statement on all aspects of
EMI control for harnesses.
In case of difficulty contact
us for further clarification or
consultancy.
For well-designed EMI
control of electrical systems
it is essential that a detailed
knowledge of the system
requirements and suscepti-
bility be obtained. The
chosen level of shielding
will be dependent on the:
nSusceptibility of electrical
system.
nTypes of components
used.
nPhysical layout of the
system.
nEquipment practices
adopted.
nAnticipated EMI threat.
For the most cost effective
design of harnesses, which
offer a long-term stability in
performance, the system
should be designed to
achieve a balance of com-
ponent characteristics.
Components should only
be used if they are qualified
to a minimum level of EMI
performance and the per-
formance and test method
should be applicable to
the design technique
being used.
For quality assurance
purposes minimum EMI
characteristics should
always be specified and
for critical harnesses the
complete performance
should be measured. The
technique to be adopted
should always be specified.
Finally the inter-relationship
between harnesses and the
protection, termination and
grounding of equipment
boxes is vital for good sys-
tem performance against
EMI. All components form
partof the external shield
on the system and therefore
should be considered in the
overall EMI design process.
Subjects covered in this
topic are:
nHarness Types - point
to point and branched
nShielding Levels -
calculations
Harness Types
Harnesses are divided into
two types, point-to-point
and branched. The advan-
tages and disadvantages of
each from an EMI control
standpoint are described
below. No attempt has been
made to analyze their rela-
tive merits in mechanical or
installation terms.
Point To Point:
The three major compo-
nents of this type of harness
are: connectors, cable, and
connector accessories.
Connectors
There are many different
types of circular military
connectors. However, for a
well-shielded harness only
those connectors having a
guaranteed performance
level should be used e.g.
MIL-C-26482 Series II and
MIL-C-38999 series 1 and
2, and series 3 and 4.
Cable
Cable used in this type
of harness is generally
machine made. Hand laid
cables may also be used
but generally the shields
incorporated in these
harnesses vary in consis-
tency of performance. In
the case of machine made
cables all shields should be
designed for optimum
shielding effectiveness at
radio frequency.
Step 3. Determine the
Level of EMI Shielding
Required.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-21
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Connector Accessories
Connector accessories,
such as Raychem adapters,
are available in many styles
and therefore their perform-
ance varies with construc-
tion. For a level of consis-
tency in performance it
is essential that, as with
connectors, a guarantee
inperformance level be
achieved. Fittings not speci-
fied in this way may signifi-
cantly degrade the overall
system performance.
Branched
In addition to those compo-
nents described above,
branched harnesses
include transitions. This
type of harness is usually
made by hand and it is
therefore difficult to incorpo-
rate accurately made
machine fabricated shields.
The implications of this are:
Shields
Cable shields may be put
on by hand or by feeding
through a braiding machine.
However,as braid optimiza-
tion depends on all the con-
structional parameters of
the braid being accurately
specified, unless braid is
well constructed the shield-
ing performance can suffer
dramatically. Reductions in
shield performance of 20-40
dB have been measured on
badly made branched har-
nesses. The alternative
method is to use pull on
braids. If the cable bundle
diameter is known the braid
may be designed for opti-
mized performance.
Transitions
Transitions, as with acces-
sories, are very susceptible
to performance variability
with construction type.
For high performance har-
nesses these components
should also have a guaran-
teed performance.
In general the use of tech-
niques such as hand sol-
dering or the use of butted
tape wraps are not recom-
mended except where only
alow performance of less
that 40dB is required.
Shielding Levels and
Component Performance
System Performance
Tospecify the overall
requirements of a complete
electronic system in terms
of its EMI characteristics it
is necessaryto consider the
performance of the individ-
ual components parts. The
harnesses form one of the
major entrypoints for inter-
ference and this as such
can degrade a complete
system performance by a
significant amount. In gen-
eral terms, assuming that a
shielded harness system is
used, with the available
components on the market
the overall harness system
performance and typical
applications may be as
below.
n40 to 50 dB Standard
shielded systems for
insensitive systems.
n50 to 60 dB Military stan-
dard shielded systems for
general applications.
n60 to 80 dB As above but
wherefull threat EMP &
TEMPEST protection is
required.
n80 to 100 dB Severe
TEMPEST and very
sensitive systems.
nOver 100 dB Exceptional
shielding requirements
only.
Shield performance is
specified in two ways,
either as a power relation-
ship in decibels (dB) or as
an absolute measurement
of the shield performance in
terms of the surface transfer
impedance. Except for very
specific low frequency
problems it is general to
specify the performance at
frequencies in the range
0.1MHz to 100MHz.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Safety Margins
Aswith all designs EMI sys-
tem design should not be
performed to the “limit of
performance safety margin
should always be incorpo-
rated when determining the
minimum shielding level
appropriate for consistent
operation of the system.
The inter-relationship of
shielding effectiveness
measured in decibels and
the surface transfer imped-
ance in ohms presents the
designer with a conversion
difficulty. External harness
circuits vary, as do the cou-
pling characteristics and it
is therefore only possible to
give an approximate con-
version. The normal conver-
sion from decibels to ohms
and vice versa is to a rea-
sonable approximation:
Screening Effectiveness
(dB) = 36 – 20 log 10 (ZT(Ohms))
The constant termis devel-
oped from the expressions
for the characteristic imped-
ance of the line formed by
the harness shield and the
ground plane and the inter-
nal characteristic imped-
ance of the inside of the
harness. The translation
from shielding effectiveness
to surface transfer imped-
ance is shown below in
Table 5 for S.E. from 20 to
105dB.
Connectors
Astudy of those connector
specifications having an
EMI test shows that they are
generally specified in the
frequency band 100MHz to
1GHz. For an assessment at
lower frequencies the low
frequency performance
asdictated by the d.c.
resistance of the connector
is required. These two
parameters enable the EMI
characteristic to be made
of the complete connector
performance. Typical values
for standard connectors are
65dB (MIL-C-26482 Series II)
and 90dB (MIL-C-38999
Series III) connectors.
S.E. (dB) ZT(ohms) S.E. (dB) ZT(ohms)
20 6.309 65 0.0355
25 3.548 70 0.0200
30 1.995 75 0.0112
35 1.122 80 0.0063
40 0.631 85 0.0036
45 0.355 90 0.0020
50 0.200 95 0.0011
55 0.112 100 0.0006
60 0.063 105 0.0004
Table 5 - Screening
Effectiveness (SE)/Surface
Transfer Impedance (Zt)
Relationships
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-23
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Diameter under screen Surface transfer Impedance Zt
Type of Screen (mm) @30 Mhz (maximum)
Single optimized braid Up to 7.5 100 milli ohms/metre
7.6 and up 50 milli ohms/metre
Double optimized braid Up to 7.5 10 milli ohms/metre
7.6 and up 5milli ohms/metre
Superscreened Up to 7.5 100 micro ohms/metre
(2 braids + 1 wrap) 7.6 and up 50 micro ohms/metre
Table 6 - Cable Performances
Cable
In accordance with most
common cable specification
the shielding performance
of a cable is specified at
30MHz. It is also well into
the band where inductive
leakage is the primary pen-
etration characteristic. For
frequencies above or below
30Mhz, approximations, as
for connectors, must be
made. It should be noted
that the performance speci-
fied at 30MHz in Table 6 for
different cable types is the
maximum that is allowed
using Tyco Electronics’
standardQ.C. values.
Actual performance may
be up to 20dB better.
Connector Accessories and
Transitions
In constructional terms the
performance of the connec-
tor accessory includes both
the resistive terminations to
the cable shield and the
connector. However, it is
most unusual to specify
the performance of an
accessory and this is a
distinct weakness in the
design of harnesses. The
reason is that the perform-
ance is extremely variable
as accessories have to fit a
variety of different cable
sizes and shapes. Where
specified at all the relation-
ship between the test
method and the coupling
mechanism for the EMI
must be considered.
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Complete Harness
When considering the com-
plete harness the coupling
calculations are relatively
simple. In general terms
they arethe addition of all
the individual leakages
within the system from
connector to connector.The
analysis route is therefore
as follows:
1. Convert all decibel
values at the desired
frequency to surface
transfer impedance.
2. Choose components for
a‘balanced’ system, i.e.
the components should
have approximately the
same performance.
3. Add the values deter-
mined for surface
transfer impedance of
the components at the
frequency chosen.
4. Reconvert to decibels if
necessary. (Table 5 can
be used for this purpose)
As a guide to the shielding
performance that can be
expected from a harness
that is constructed using
Raychem components,
Table 7 on the next page
has been compiled to help
in the product selection
process.
For branched harnesses it
is necessary to determine
whether every branch has
the same susceptibility
requirements or carries the
same signals of power.The
performance requirement
of each branch is then
determined and the matrix
for the harness established.
This is a morecomplex
subject and not discussed
here. System improvements
may be achieved by chang-
ing either the connectors or
cable. In general terms
changing from a single to a
double optimized braid
improves the performance
of that component by 20-25
dB. A similar advantage is
achieved by changing from
MIL-C-26482 Series II to
MIL-C-38999 Series I
connectors. However, the
relative significance, as
part of the system, of each
component must be consid-
ered to determine the true
weighting effect. For the
optimum in system design
abalance of component
performances should be
achieved wherever possible
such that each of the
components is of similar
performance level.
General Considerations
Although cables and har-
nesses are considered to
be the most significant in
terms of coupling into sys-
tems the construction of
equipment boxes can play
an important part in the
overall EMI performance of
asystem. With the increas-
ing use of high speed digital
circuits and the generation of
harmonics having high
energy content relatively
shortprinted circuit board
tracks can radiate or pick
up energy as efficiently as
cables. If the boxes them-
selves are not adequately
protected these circuits
may constitute an EMI
threat. There is a further
area of significance in the
EMI protection of the boxes
and this is the connector/
box interface. The junction
may be considered to be a
part of the harness system
and any degradation in it
may cause an overall
harness degradation.
Connector Terminator Splice Transition Feedthrough
Cable Braid
Electrical Interconnection System Design
Integrated Military Harness Systems for Defense and Allied Industries (Continued)
2-25
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
2
Electrical Interconnection System Design
Harness System Components
Adapter Styles Termination Cable Braid
Shielding Tinel- (max. length in m/ft)
Level Band Lock Rayaten (by cable construction) Feed-
Required Connector Strap Braided System Assembly NOSO DO SSS DSS
Transition Splice through
<60 dB VG95328 nn n — <2/6.5 15/49 100/328 — —
Shield Solder- Tinel or
VG95234
tape & Sleeve solder
Solder- device devices
Sleeve
device
60 to 80 dB
MIL-C-26482
—— n— — <2/6.5 7/22.9 100/328 —
Shield Solder- Tinel or
Series 2 tape & Sleeve Rayaten
VG96912 Solder- device assembly
Series 1 Sleeve
device
>80 dB MIL-C-38999 — — — n— — <0.5/1.6 50/164 65/213 Not Solder- Tinel or
recom- Sleeve Rayaten
mended device assembly
Table 7 - Screen System Guide
NO = Non Optimized, SO = Single Optimized, DO = Double Optimized, SSS = Single Super Shield, DSS = (TYCO must provide info)
Note:
1.The cable lengths are to be used as a guide.
Outside 30 MHz, the lengths that can be used will vary. For specific harness design outside 30 MHz, please consult Tyco Electronics.
2.Tinel-Lock use at shielding levels of 60–80 dB depends on the adapter entry, cable braid size, and design. For further details, contact Tyco Electronics.
3.Connectors commonly used but not mentioned in the table may not have a stated shielding performance in their specification. Contact the manufacturer for
guidance.
4.This guide makes no allowance for the possible effects of resonance. Tyco Electronics should be consulted for advice on compensating for resonance.
Step 4. Select Components Using the previous sections, you can now select all of the
components for an integrated harness assembly.
Please refer to the sections listed for more detailed
component information:
Molded Parts . . . . . . . . . . . . . . . . . . . . . . . . .Section 4
Wireand Cable . . . . . . . . . . . . . . . . . . . . . . .Section 9
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7
Electrical Interconnect Products . . . . . . . . . .Section 8
Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3
Electrical Interconnection System Design
Engineering Notes
2-26 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Table of Contents
3-1
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
Overview .....................................................3-3
Tubing Categories .....................................................3-3
Tubing Selection Guide .................................................3-4, 3-5
Specification Cross-Reference Guide ..........................................3-6
Single Wall Tubing
CGPE-105 Brightly colored, shiny, non-flame-retardant polyolefin tubing .3-7, 3-8
CGPT General purpose, flame-retardant, polyolefin tubing . . . . . . . .3-9, 3-10
CRN Semirigid, flame-retardant, polyolefin tubing . . . . . . . . . . . . .3-11, 3-12
DCPT Flexible, flame-retardant, dual-color, polyolefin tubing . . . . .3-13, 3-14
LSTT Low-shrink-temperature, non-flame-retardant,
heat-shrinkable, polyolefin tubing . . . . . . . . . . . . . . . . . . . . .3-15, 3-16
RNF-100 Flexible, flame-retardant, general purpose,
polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17, 3-18
RNF-3000 Flexible, high-shrink-ratio, flame-retardant,
general purpose, polyolefin tubing . . . . . . . . . . . . . . . . . . . .3-19, 3-20
RP-4800 High-shrink-ratio, flame-retardant, polyolefin tubing . . . . . . .3-21, 3-22
RT-3 Semirigid, flame-retardant, polyolefin tubing . . . . . . . . . . . . .3-23, 3-24
TUGA-GP Brightly colored, shiny, non-flame-retardant, polyolefin
tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25, 3-26
Versafit Highly flame-retardant, very flexible,
low-shrink-temperature, polyolefin tubing . . . . . . . . . . . . . . .3-27, 3-28
Versafit V2 Highly flame-retardant, very flexible,
low-shrink temperature, polyolefin tubing . . . . . . . . . . . . . . .3-29, 3-30
Versafit V4 Very-thin-wall, very flexible, highly flame-retardant,
polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31, 3-32
Dual Wall Tubing (Adhesive and Encapsulant-Lined)
ATUM High-shrink-ratio, adhesive-lined polyolefin tubing . . . . . . . .3-33, 3-34
DWP-125 Flexible, high-shrink-ratio, adhesive-lined,
polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35, 3-36
ES1000 Clear, high-shrink-ratio, adhesive-lined, semirigid
polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37, 3-38
ES2000 Flame-retardant, high-shrink-ratio, adhesive-lined,
semirigid polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . .3-39, 3-40
FL2500 Fully flame-retardant, adhesive-lined, polyolefin
heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41, 3-42
HTAT Semiflexible, dual wall, moisture-resistant,
heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43, 3-44
RPPM Flexible, dual wall, moistureproof,
heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45, 3-46
SCL Semirigid, encapsulant-lined, polyolefin tubing . . . . . . . . . .3-47, 3-48
SCT Flame-retardant, adhesive-lined, semirigid polyolefin,
heat-shrinkable tubing (extended temperature range) . . . . .3-49, 3-50
TAT-125 Adhesive-lined, flexible polyolefin tubing . . . . . . . . . . . . . . .3-51, 3-52
Heavy Duty Tubing
BSTS/BSTS-FR General purpose, heat-shrinkable tubing . . . . . . . . . . . . . . .3-53, 3-54
HF High-flex, heavy-wall, heat-shrinkable tubing . . . . . . . . . . . .3-55, 3-56
HRHF/HRNF/ High-ratio, heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . .3-57, 3-58
HRSR
RHW Rugged, heavy wall, adhesive-lined, polyolefin
heat-shrinkable tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59, 3-60
RMW Medium wall, polyolefin heat-shrinkable tubing . . . . . . . . . .3-61, 3-62
SST/SST-FR Self-sealing, heat-shrinkable tubing . . . . . . . . . . . . . . . . . . .3-63, 3-64
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
3-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
Table of Contents (Continued)
Special Purpose Tubing
DR-25 Heat-shrinkable, flexible, chemical and abrasion
resistant tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65, 3-66
ES Caps High-shrink-ratio, adhesive-lined, semirigid
polyolefin caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67, 3-68
HCTE Helical convolex tubing with a high crush resistance . . . . . .3-69, 3-70
HFT5000 Heat-shrinkable fabric tubing . . . . . . . . . . . . . . . . . . . . . . . .3-71, 3-72
MicroFit Small-diameter, high-shrink-ratio tubing . . . . . . . . . . . . . . . .3-73, 3-74
MT1000 Altera medical-grade, USP Class VI, high-temperature,
semirigid, fluoropolymer tubing . . . . . . . . . . . . . . . . . . . . . . .3-75, 3-76
MT2000 Altera medical-grade, USP Class VI, lubricious,
thin-wall, polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77, 3-78
MT3000 Altera medical-grade, USP Class VI, high-temperature
flexible, fluoropolymer tubing . . . . . . . . . . . . . . . . . . . . . . . .3-79, 3-80
MT5000 Altera medical-grade, USP Class VI, flexible,
polyolefin tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81, 3-82
NT Flexible, general purpose modified elastomeric tubing . . . .3-83, 3-84
NT-MIL Flexible, rugged, modified elastomeric heat-shrinkable
tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85, 3-86
NTFR Very flexible, rugged neoprene elastomer tubing . . . . . . . . .3-87, 3-88
PD Caps Semirigid, encapsulant-lined, polyolefin caps . . . . . . . . . . .3-89, 3-90
RayBlock 85 Heat-shrinkable water-blocking system . . . . . . . . . . . . . . . .3-91, 3-92
RayBlock 105 Heat-shrinkable water-blocking system . . . . . . . . . . . . . . . .3-93, 3-94
Rayflex PET and PFR expandable, braided, polyester sleeving . . . .3-95, 3-96
Rayflex PETM Expandable, braided, polyester sleeving . . . . . . . . . . . . . . .3-97, 3-98
Rayrim Commercial protective, self-adhering, edging material . . .3-99, 3-100
RNF-150 High-performance, flame-resistant, flexible,
fluoropolymer tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-101, 3-102
RT-375 Clear, flame-resistant, flexible, fluoropolymer tubing . . . . .3-103, 3-104
RT555 Fluid-resistant, chemical-resistant, crosslinked
fluoropolymer tubing with extended temperaturerange . .3-105, 3-106
RW-175 High temperature, chemical-resistant, polyvinylidene
fluoride tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107, 3-108
SFR Very flexible, flame-retardant, silicone elastomer tubing . .3-109, 3-110
SRFR Highly flexible, silicone rubber tubing . . . . . . . . . . . . . . . .3-111, 3-112
TFE and TFE-R High-temperature, chemically inert, modified
tubing made of Teflon®Fluoropolymer . . . . . . . . . . . . . . .3-113, 3-114
Viton®/Viton®-HW/ Heat-shrinkable, chemical-resistant, high-temperature
Viton®-E/ tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115, 3-116
Viton®-TW
XFFR Halogen-free, flame-retardant, heat-shrinkable tubing . . .3-117, 3-118
ZH-100 Flexible, thin-wall, low-fire-hazard tubing . . . . . . . . . . . . .3-119, 3-120
ZHTM Heat-shrinkable, flexible tubing with low toxicity for
fire safety applications . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-121, 3-122
TEFLON is a trademark of E.I. du Pont
de Nemours and Company
VITON is a trademark of
Dupont Dow Elastomers LLC
Heat-Shrinkable Tubing
3-3
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Overview
Tyco Electronics Raychem
brand of tubing was devel-
oped when our scientists
pioneered the application
of radiation crosslinking
and the development of
heat-shrinkable polymer
products. Today Tyco
Electronics is recognized
worldwide for its expertise
in these areas.
The Raychem brand of
tubings are made of
polyolefins, fluoropolymers,
and elastomers enhanced
by radiation crosslinking
and heat-shrinkability. When
heated during installation,
our tubings shrink to
conform to virtually any
shape. They provide
dependable insulation,
mechanical protection,
and strain relief, as well
as aesthetic appeal.
Single wall tubings are
available in thin-wall,
medium-wall, and thick-wall
versions. With dual wall
tubings, an inner wall —
either an encapsulant or
an adhesive — melts and
flows during installation
heating, to protect against
environmental damage.
Encapsulants protect
connections and compo-
nents from splashes and
corrosion. Adhesives go a
step further, sealing to
plastic, metal, rubber, or
other substrates.
You can choose from tubings
that are highly flexible or
semirigid, designed for
operation in high- or low-
temperature environments,
and halogen-free and
flame-retardant to meet a
range of industry standards.
Tubing Categories
Single Wall
Dual Wall
Heavy Duty
Special Purpose
Very Flexible LSTT
Versafit Versafit V2
Versafit V4
Flexible CGPE-105
CGPT
DCPT
RNF-100
RNF-3000
RP-4800
TUGA
BSTS
HF HRHF/HRNF/HRSR
RMW RHW
SST
DR-25
NT
NT-MIL
NTFR
SFR
SRFR
Viton®
Viton®-HW
Viton®-E
Viton®-TW
Semirigid
Semi-flexible ATUM DWP-125 HTAT
CRN RT-3
Flexible RPPM TAT-125
Semirigid
Elastomers
RNF-150
RT-375 RT555
RW-175 TFE and TFE-R
Fluoropolymers
ES1000
ES2000 FL2500
SCL SCT
MT1000
MT2000 MT3000
MT5000
Medical-grade
MFT-RW-175 MFT-MT1000 MFT-MT2000
MicroFit
ES Caps
PD Caps
Caps
HCTE
Conduit
RayBlock 85 RayBlock 105
Kits
XFFR ZH-100 ZHTM
Low toxicity
Rayrim
Edging material
HFT5000
Fiber and fabric
RF-PET RF-PFR RF-PETM
Braid
Available in many sizes,
constructions, lengths,
and colors to meet both
commercial and military
specifications, our tubings
can also be customized for
special applications.
Installation is fast and easy
with handheld heating tools
or bench-mounted heaters.
Arange of automatic and
semi-automatic installation
equipment is available for
high-volume applications.
Type Product Name
VITON is a trademark of Dupont Dow Elastomers LLC
Heat-Shrinkable Tubing
3-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tubing Selection Guide
Polyolefin
Fluoropolymer
Elastomer
Shrink ratio
Min. shrink
temperature
(˚C)
Min. full
recovery
temperature
(˚C)
Operating
Temperature
˚C / [˚F]
PRODUCT
Single Wall Very flexible LSTT l-40 to 125 [-40 to 257] 65 110 2:1
Versafit l-55 to 135 [-67 to 275] 70 90 2:1
Versafit V2 l-30 to 125 [-22 to 257] 70 90 2:1
Versafit V4 l-30 to 125 [-22 to 257] 70 90 2:1
Flexible CGPE-105 l-70 to 105 [-94 to 221] 85 110 2:1
CGPT l-40 to 135 [-40 to 275] 80 120 2:1
DCPT l-55 to 135 [-67 to 275] 95 120 2:1
RNF-100 l-55 to 135 [-67 to 275] 95 121 2:1
RNF-3000 l-55 to 135 [-67 to 275] 80 120 3:1
RP-4800 l-55 to 135 [-67 to 275] 95 121 4:1
TUGA l-55 to 125 [-67 to 257] 85 110 2:1
Semirigid CRN l-55 to 135 [-67 to 275] 110 135 2:1
RT-3 l-55 to 135 [-67 to 275] 110 135 2.5:1
Dual wall Semiflexible ATUM l-55 to 110 [-67 to 230] 80 110 3:1
[adhesive-and 4:1
encapsulant-lined] DWP-125 l-40 to 110 [-40 to 230] 80 125 3:1
HTATl-55 to 125 [-67 to 257] 80 110 4:1
Flexible RPPM l-40 to 85 [-40 to 185] 6080 4:1
TAT-125 l-55 to 110 [-67 to 230] 95 121 2:1
Semirigid ES1000 l-40 to 130 [-40 to 266] 110 135 4:1
ES2000 l-40 to 130 [-40 to 266] 110 135 4:1
FL2500 l-40 to 135 [-40 to 275] 110 135 4:1
SCL l-55 to 110 [-67 to 230] 125 135 3:1
SCT l-40 to 150 [-40 to 302] 110 135 4:1
Heavy Duty BSTS l-55 to 90 [-67 to 194] 90 121 3:1
HF l-55 to 90 [-67 to 194] 80 121 3:1
HRHF/HRNF/HRSR l-55 to 90 [-67 to 194] 80 121 5.6:1
RHW l-55 to 110 [-67 to 230] 110 125 3:1
RMW l-55 to 110 [-67 to 230] 110 125 3:1
SST l-55 to 90 [-67 to 194] 90 121 3:1
Special Elastomers DR-25 l-75 to 150 [-103 to 302] 150 175 2:1
Purpose NT l-55 to 90 [-67 to 194] 90 135 2:1
NT-MIL l-70 to 121 [-94 to 250] 90 135 2:1
NTFR l-70 to 121 [-94 to 250] 90 135 2:1
SFR l-75 to 180 [-103 to 356] 135 175 1.75:1
SRFR l-75 to 200 [-103 to 392] 135 175 1.5:1
Viton®l-40 to 200 [-40 to 392] 100 175 2:1
Viton®-HW l-40 to 200 [-40 to 392] 100 175 2:1
Viton®-E l-55 to 200 [-67 to 392] 100 175 2:1
Viton®-TW l-40 to 200 [-40 to 392[ 100 175 2:1
Fluoropolymers RNF-150 l-55 to 150 [-67 to 302] 110 150 2:1
RT-375 l-55 to 150 [-67 to 302] 125 150 2:1
RT555 l-65 to 200 [-85 to 392] 150 220 2:1
RW-175 l-55 to 175 [-67 to 347] 155 175 2:1
TFE and TFE-R l-67 to 250 [-89 to 482] 330 340 1.8:1/
3.2:1
Medical-grade MT1000 l-55 to 175 [-67 to 347] 155 175 2:1
MT2000 l-40 to 105 [-40 to 221] 110 140 2.5:1
MT3000 l-55 to 150 [-67 to 302] 110 150 2:1
MT5000 l-70 to 105 [-94 to 221] 90 110 2:1
MicroFit MFT-RW-175 l-55 to 175 [-67 to 347] 155 175 2.5:1
MFT-MT1000 l-55 to 125 [-67 to 257] 155 175 2.5:1
MFT-MT2000 l-40 to 105 [-40 to 221] 110 140 2.5:1
Caps ES Caps l-40 to 105 [-40 to 221] 100 135 4:1
PD Caps l-55 to 110 [-67 to 230] 125 135 3:1
Conduit HCTE l-55 to 200 [-67 to 392] N/A N/A N/A
Kits RayBlock 85 l-40 to 85 [-40 to 185] 80 110 4:1
RayBlock 105 l-40 to 105 [-40 to 221] 80 110 4:1
Low Toxicity XFFR l-55 to 105 [-67 to 221] 70 121 3:1
ZH-100 l-30 to 105 [-22 to 221] 80 120 2:1
ZHTM l-30 to 105 [-22 to 221] 80 121 2:1
Edging Matl Rayrim l-55 to 80 [-67 to 176] 120 150 N/A
Fiber & Fabric HFT5000 -40 to 125 [-40 to 257] 80 110 2:1
Braids RF-PET -50 to 150 [-58 to 302] N/A N/A N/A
RF-PFR -50 to 150 [-58 to 302] N/A N/A N/A
RF-PETM -50 to 150 [-58 to 302] N/A N/A N/A
*For specific MIL-Spec information for each product, refer to individual product pages or the Tubing Cross-Reference Guide on page 3-6.
**Sizes 9/3 through 70/21 only. †Clear is not flame-retardant VITON is a trademark of Dupont Dow Elastomers LLC.
Heat-Shrinkable Tubing
3-5
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tubing Selection Guide (Continued)
Flame-
retardant
UL 224
Clear
CSA
ABS
UL D486**
VW-1 (UL/CSA)
MIL Spec*
USP Class VI
Colored
Size range
(inside
diameter as
supplied)
DESCRIPTION
1.6 mm to 38 mm ll Non-flame-retardant polyolefin
3/64" to 4" llllll Highly flame-retardant, multi-spec polyolefin
1mm to 30 mm lllll Highly flame-retardant polyolefin
3/64" to 1" lllll Very-thin-wall, highly flame-retardant polyolefin
1mm to 10 mm lllll
3/64" to 2" ll Brightly colored, general purpose polyolefin
1.6 mm to 38 mm lllll General purpose, flame-retardant polyolefin†
3mm to 38 mm llll Green and yellow striped polyolefin
3/64" to 5" lllll l High-performance flexible polyolefin†
1.5 mm to 39 mm lllll l 3:1 shrink ratio general-purpose polyolefin†
3/4" to 4.5" lll l 4:1 shrink ratio polyolefin
1.2 mm to 38 mm ll Brightly colored, tough polyolefin
3/64" to 3/4" lllll l Flame-retardant polyolefin†
.240" to .485" llll Semirigid polyolefin for terminal insulation
3mm to 40 mm llll l 3:1 and 4:1 shrink ratio adhesive-lined polyolefin†
4mm to 52 mm lll
1/8" to 1" llll 3:1 shrink ratio adhesive-lined polyolefin
4mm to 48 mm llHigh-temperatureadhesive-lined polyolefin
4mm to 16 mm llDual wall, moisture-proof polyolefin
1/8" to 1 1/2" llll l 2:1 adhesive-lined polyolefin†
.225" to .700" ll Clear high-shrink-ratio adhesive-lined polyolefin
.225" to .700" lll Flame-retardant adhesive-lined polyolefin
.300" to .700" ll Fully flame-retardant, adhesive-lined polyolefin
1/8" to 1" lll3:1 shrink ratio encapsulant-lined polyolefin
.300" to .700" llHigh-temperatureadhesive-lined polyolefin
.3" to 4.5" ll lRugged, general purpose, thick-wall polyolefin
.4" to 2.7" ll lHighly flexible, thick-wall polyolefin
.6" to 4" lllHigh-shrink-ratio repair sleeve
9mm to 180 mm l l Heavy wall adhesive-lined polyolefin
10 mm to 180 mm lMedium wall polyolefin
.3" to 4.5" ll l lSelf-sealing, dual wall polyolefin
1/8" to 3" ll l Diesel-resistant elastomer
1/8" to 4" llll Flexible general-purpose modified elastomer
1/8" to 4" lllFlexible rugged modified elastomer
1/8" to 3" ll l Very flexible rugged neoprene
1/4" to 2" ll l Very flexible silicone
2.9 mm to 51 mm llll Very flexible silicone rubber
1/8" to 2" ll l High-temperature flexible elastomer
1/8" to 2" ll l Heavy-walled Viton®elastomer
1/8" to 2" ll l High-temperature flexible elastomer
1/8" to 2" ll High-temperature flexible elastomer
3/64" to 1" lllll High-performance flexible fluoropolymer
3/64" to 1 1/2" l lll lll Clear high-performance flexible fluoropolymer
1/8" to 2" lll l Fluid- and chemical-resistant fluoropolymer
3/64" to 1 1/2" lllllllHigh-performance fluoropolymer
0.8 mm to 11.9 mm/ ll lHigh-temperature Teflon®fluoropolymer resin
2 mm to 32 mm
1/16" to 1" ll lAutoclavable semirigid fluoropolymer
1mm to 10 mm ll lLubricious thin-wall polyolefin
1/16" to 1" l l High-temperature flexible fluoropolymer
1/16" to 1" lllFlexible polyolefin
.014" to .045" lllHigh performance fluoropolymer microtubing
.014" to .045" ll lSemirigid medical-grade fluoropolymer microtubing
.014" to .045" lllLubricious medical-grade polyolefin microtubing
.225" to .427" llll High-ratio, adhesive-lined caps
1/8" to 1/2" ll Semirigid encapsulant-lined polyolefin caps
.187" to 2" ll Modified ETFE, helically convoluted tubing
12 mm to 32 mm ll Heat-shrinkable water blocking system
12 mm to 32 mm ll Heat-shrinkable water blocking system
.4" to 3" ll l Halogen-free, flame-retardant polyolefin
1/8" to 2" llThin-wall, low-fire-hazardpolyolefin
3mm to 40 mm ll Low toxicity, flexible polyolefin
0.8 mm to 4.5 mm lProtective self-adhering edging material
12 mm to 80 mm lHeat-shrinkable, fabric tubing
1/8" to 2" lExpandable, braided polyester sleeving
1/8" to 2" lllll Expandable, braided polyester sleeving
3mm to 50 mm lExpandable, braided polyester sleeving
TEFLON is a trademark of E. I. du Pont de Nemours and Company. VITON is a trademark of Dupont Dow Elastomers LLC.
Heat-Shrinkable Tubing
3-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Specification Cross-Reference Guide
Product UL CSA AMS-DTL-23053* MIL-PRF-46846 Raychem Page
Type File File Sheet Class Type Class Specification No.
ATUM E85381** /4 3 RW-2063 & RK-6024 3-33
BSTS RW-2017 3-53
BSTS-FR /15 1 & 2*** RW-2017 3-53
CGPE-105 CGPE-105 SCD 3-7
CGPT E35586 LR31929 RW-2059 3-9
CRN Type 1 (colors) E35586 LR31929† /6 1 RT-360, Type 1 3-11
CRN Type 2 (clear) /6 2 RT-360, Type 2 3-11
DCPT E35586 LR31929 RW-2056 3-13
DR-25 /16 RT-1116 3-65
DWP-125 E35586 LR31929 DWP-125 SCD 3-35
ES1000 E85381 RT-1113 3-37
ES2000 E85381 RT-1112 3-39
ESCaps E85381 RW-3006 3-67
FL2500 FL2500 SCD 3-41
HCTE RT-1162 3-69
HF /15 1*** RW-2023 3-55
HFT5000 E199379 RW-2060 3-71
HRSR RW-2013 3-57
HRNF RW-2013 3-57
HRHF RW-2013 3-57
HTAT RW-2052 3-43
LSTT RW-2051 3-15
MFT-MT1000 Altera MicroFit SCD 3-73
MFT-MT2000 Altera MicroFit SCD 3-73
MFT-RW-175 RW-175 MicroFit SCD 3-73
MT1000*** MT1000 SCD 3-75
MT2000*** MT2000 SCD 3-77
MT3000 MT3000 SCD 3-79
MT5000*** MT5000 SCD 3-81
NT E35586 LR31929 RT-510 3-83
NT-MIL /1 1 & 2 RW-3030 3-85
NTFR RT-511 3-87
PD Caps E85381 PD Caps SCD 3-89
RayBlock 85 RW-2101 3-91
RayBlock 105 RW-2102 3-93
Rayrim RK-6182 3-99
RF-PETM 3-97
RF-PET RW-2069 3-95
RF-PFR 3-95
RHW E115664 RHW SCD 3-59
RMW RMW SCD 3-61
RNF-100 Type 1 (colors) E35586 LR31929 /5 1 RT -350, Type 1 3-17
RNF-100 Type 2 (clear) /5 2 RT-350, Type 2 3-17
RNF-150 E35586 VW-1 /18 2 RT-370 3-101
RNF-3000 E35586 LR31929 RW-2053 3-19
RPPM RK-6214 3-45
RP-4800 E35586 /5 1†† RT-1122 3-21
RT-3 E35586 LR31929† RT-360††† 3-23
RT-375 E35586 VW-1 LR31929 VW-1 /18 2 RT-375 3-103
RT555 E85381 RT-555 3-105
RW-175 E35586 VW-1 LR31929 VW-1 /8 RW-3029 3-107
SCL E85381 /4 1 RT-1301 3-47
SCT SCT SCD 3-49
SFR /10 ll 1 RT-1140 3-109
SRFR E85381 VW-1 RT-1142/RW-2057 3-111
SST RW-20113-63
SST-FR /15 1 & 2 RW-2011 3-63
TAT-125 Type 1 (colors) E85381 /4 2 TAT-125 SCD 3-51
TAT-125 Type 2 (clear) TAT-125 SCD 3-51
TFE/TFE-R RW-2054, RW-2055 3-113
TUGA-GP RW-2201 3-25
Versafit E35586 VW-1 LR31929 VW-1 /5 1 & 3 RW-3009 3-27
Versafit V2 E35586 VW-1 LR31929 VW-1 RW-3023 3-29
Versafit V4 E85381 VW-1 LR31929 VW-1 RW-3023 3-31
Viton®/13 RT-1146 3-115
Viton®-HW III 1 RT-1145 3-115
Viton®-E RK-6014/1 3-115
Viton®-TW RK-6014/2 3-115
XFFR RW 2016 3-117
ZH-100 RW-2031 3-119
ZHTM RW-2058 3-121
*Formerly MIL-I-23053 and MIL-DTL-23053 **Black only, except sizes 3/1 and 4/1. ***Without adhesive
†Black only †† Overexpanded †††With exception to dimensions and longitudinal change. VITON is a trademark of Dupont Dow Elastomers LLC.
Single Wall Tubing
CGPE-105
3-7
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Brightly Colored, Shiny,
Non-Flame-Retardant
Polyolefin Tubing
Product Facts
nBright, shiny surface; clear
version offers exceptional
clarity
nCan be easily hot-stamped
nEconomical, yet offers the
improved performance of a
crosslinked material
nConforms to substrates more
uniformly and with less
longitudinal change than
most PVC-based materials
Applications
Attractive covering for many
automotive, appliance,
and consumer-goods
applications. Commercial
grade tubing for applica-
tions where a flame-retar-
dant product is not needed.
Provides both insulation and
protection of components
and wires while also
providing a smooth, glossy
finish with a choice of five
standard colors as well
as clear. Exceptional
transparency of clear
CGPE-105 makes it an
ideal choice for protecting
marked surfaces.
Installation
Minimum shrink
temperature: 85°C [185°F]
Minimum full recovery
temperature: 110°C [230°F]
for black; 100°C[212°F] for
all other colors and clear
Operating Temperature Range
-70°Cto 105°C
[-94°F to 221°F]
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nn
Series Raychem
CGPE-105 CGPE-105 SCD
Single Wall Tubing
CGPE-105 (Continued)
3-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.40 ± 0.08 [0.016 ± 0.003]
1/16 1.6 [0.063] 0.8 [0.031] 0.43 ± 0.08 [0.017 ± 0.003]
3/32 2.4 [0.093] 1.2 [0.046] 0.51 ± 0.08 [0.020 ± 0.003]
1/8 3.2 [0.125] 1.6 [0.062] 0.51 ± 0.08 [0.020 ± 0.003]
3/16 4.8 [0.187] 2.4 [0.093] 0.51 ± 0.08 [0.020 ± 0.003]
1/4 6.4 [0.250] 3.2 [0.125] 0.64 ± 0.08 [0.025 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.64 ± 0.08 [0.025 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.64 ± 0.08 [0.025 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.76 ± 0.08 [0.030 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.89 ± 0.12 [0.035 ± 0.005]
11/2 38.1 [1.500] 19.1 [0.750] 1.02 ± 0.15 [0.040 ± 0.006]
2 50.8 [2.000] 25.4 [1.000] 1.14 ± 0.18 [0.045 ± 0.007]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0), white (-9), clear (-X), red (-2), blue (-6), yellow (-4)
Nonstandard Green (-5), violet (-7)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, CGPE-105-1/4-0).
Single Wall Tubing
CGPT
3-9
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
General Purpose, Flame-
Retardant* Polyolefin
Tubing
Product Facts
n2:1 and 3:1 shrink ratio
nVery good chemical and
solvent resistance
nFlexible
nExcellent physical and
electrical performance
Applications
CGPT is a tough, flexible,
general purpose polyolefin
tubing with good resistance
to common fluids and
solvents and a high
dielectric strength. Its
unique blend of chemical,
electrical, and physical
properties makes it
suitable for a wide range
of applications, including
electrical insulation, strain
relief, cable bundling, color-
coding and identification
of wires, cables, pipes,
and electrical and
electronic components,
and mechanical protection.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 120°C [248°F]
Operating Temperature Range
-40°Cto 135°C
[-40°F to 275°F]
Series UL CSA Raychem
CGPT E35586 LR31929 RW-2059
600 V, 125°C 600 V, 125°C
*Clear product (-X) is not flame-retardant.
Specifications/Approvals
Available in: Americas Europe Asia Pacific
n
Single Wall Tubing
CGPT (Continued)
3-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
2:1 1.2/06 1.2 [0.046] 0.6 [0.023] 0.45 ± 0.12 [0.018 ± 0.005]
1.6/0.8 1.6 [0.062] 0.8 [0.031] 0.45 ± 0.12 [0.018 ± 0.005]
2.4/1.2 2.4 [0.093] 1.2 [0.046] 0.50 ± 0.12 [0.019 ± 0.005]
3.2/1.6 3.2 [0.125] 1.6 [0.062] 0.50 ± 0.12 [0.019 ± 0.005]***
4.8/2.4 4.8 [0.187] 2.4 [0.093] 0.50 ± 0.12 [0.019 ± 0.005]***
6.4/3.2 6.4 [0.250] 3.2 [0.125] 0.65 ± 0.15 [0.026 ± 0.006]***
9.5/4.8 9.5 [0.375] 4.8 [0.187] 0.65 ± 0.15 [0.026 ± 0.006]***
12.7/6.4 12.7 [0.500] 6.4 [0.250] 0.65 ± 0.15 [0.026 ± 0.006]***
19/9.5 19.0 [0.748] 9.5 [0.375] 0.75 ± 0.15 [0.029 ± 0.006]***
25.4/12.7 25.4 [1.000] 12.7 [0.500] 0.90 ± 0.20 [0.035 ± 0.008]***
32/16 32.0 [1.250] 16.0 [0.630] 0.95 ± 0.20 [0.037 ± 0.008]***
38/19 38.0 [1.496] 19.0 [0.748] 1.00 ± 0.20 [0.039 ± 0.008]***
51/26 51.0 [2.000] 26.0 [1.000] 1.15 ± 0.25 [0.045 ± 0.010]
76/38 76.0 [2.992] 38.0 [1.496] 1.25 ± 0.25 [0.049 ± 0.010]
102/51 102.0 [4.016] 51.0 [2.008] 1.40 ± 0.30 [0.055 ± 0.012]
3:1 1.5/0.5 1.5 [0.059] 0.5 [0.020] 0.45 ± 0.12 [0.018 ± 0.005)***
3/1 3.0 [0.118] 1.0 [0.040] 0.55 ± 0.12 [0.022 ± 0.005)***
6/2 6.0 [0.236] 2.0 [0.079] 0.65 ± 0.12 [0.026 ± 0.005)***
9/3 9.0 [0.354] 3.0 [0.118] 0.75 ± 0.15 [0.030 ±0.006)***
12/4 12.0 [0.472] 4.0 [0.157] 0.75 ± 0.15 [0.030 ± 0.006)***
18/6 18.0 [0.709] 6.0 [0.236] 0.85 ± 0.15 [0.033 ± 0.006)***
24/8 24.0 [0.945] 8.0 [0.315] 1.00 ± 0.20 [0.039 ± 0.008]***
39/13 39.0 [1.540] 13.0 [0.512] 1.15 ± 0.25 [0.045 ± 0.010]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0), White (-9), red (-2), blue (-6), yellow (-4), green (-5),
clear (-X), yellow/green (-45) as indicated by an ***
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging**** On spools.
Ordering description Specify product name, size and color (for example, CGPT 4.8/2.4-0).
****Available in the convenient RaySpool packaging/dispensing system for sizes:
2:1 - 2.4/1.2 up to 25.4/12.7
3:1 - 3/1 up to 24/8
Single Wall Tubing
3-11
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRN
Applications
Ideally suited for wire
strain-relief applications
such as soldered or
crimped connections, wire
splices, and terminations.
Provides mechanical
protection for delicate
components. Can be used
for component packaging
and for rugged marking of
cables.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL CSA Military Raychem
CRN Type 1 E35586 LR31929 AMS-DTL-23053/6*, Class l RT-360, Type 1
(colors) 600 V,125°C(black only) Def. Stan. 59-97 Type 2C RK-6003
600 V, 125°C (not red)
CRN Type 2 (clear) — — AMS-DTL-23053/6*, Class 2 RT-360, Type 2
*Formerly MIL-I-23053/6 and MIL-DTL-23053/6.
Specifications/Approvals
Semirigid,
Flame-Retardant,
Polyolefin Tubing
Product Facts
n2:1 shrink ratio
nHigh abrasion resistance
nTransfer of flex stress away
from typically weak points
such as solder and crimp
joints, helping ensure a
reliable connection
nFlame-retardance (colors
only)
nOutstanding physical and
electrical performance
nExcellent chemical and
solvent-resistance
properties
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
3-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRN (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.51 ± 0.08 [0.020 ± 0.003]
1/16 1.6 [0.063] 0.8 [0.031] 0.51 ± 0.08 [0.020 ± 0.003]
3/32 2.4 [0.093] 1.2 [0.046] 0.51 ± 0.08 [0.020 ± 0.003]
1/8 3.2 [0.125] 1.6 [0.062] 0.51 ± 0.08 [0.020 ± 0.003]
3/16 4.8 [0.187] 2.4 [0.093] 0.64 ± 0.08 [0.025 ± 0.003]
1/4 6.4 [0.250] 3.2 [0.125] 0.64 ± 0.08 [0.025 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.76 ± 0.08 [0.030 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.76 ± 0.08 [0.030 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.89 ± 0.12 [0.035 ± 0.005]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard Clear (-X, not flame-retardant)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, CRN 1/4-0).
***Europe only.For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Single Wall Tubing
3-13
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
DCPT
Applications
Used to identify “ground”
on wires and in cables,
and to jacket and insulate
light-duty harnesses.
Easily marked by conven-
tional techniques for
additional identification
of wires and cables.
Installation
Minimum shrink
temperature: 95°C [203°F]
Minimum full recovery
temperature: 120°C [248°F]
Flexible, Flame-Retardant,
Dual-Color, Polyolefin
Tubing
Product Facts
n2:1 and 3:1 shrink ratio
nDual colors (yellow/green)
for instant identification
nCo-extrusion of tubing
colors, giving color
permanence superior to that
of conventional ink marking
nFlame-retardance
nFlexibility: able to conform
to irregular shapes
nExcellent physical,
chemical, and electrical
properties that meet industry
standards for highly
reliable, general purpose
tubing
Series UL CSA Military Agency Raychem
DCPT E35586 LR31929 Def Stan 59-97 Issue 3 Type 2B AFS 2270 RW-2056
600 V,125°C600 V,125°CVG 95343 Pt 5 Type A DIN 29807
VDE 0341
Pt 9005 Type A
Specifications/Approvals
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
3-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
DCPT (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
2:1 3/1.5 3 [0.118] 1.5 [0.059] 0.51 ± 0.10 [0.020 ± 0.004]
6/3 6 [0.236] 3.0 [0.118] 0.58 ± 0.10 [0.023 ± 0.004]
8/4 8 [0.315] 4.0 [0.158] 0.64 ± 0.10 [0.025 ± 0.004]
10/5 10 [0.394] 5.0 [0.197] 0.64 ± 0.10 [0.025 ± 0.004]
12/6 12 [0.472] 6.0 [0.236] 0.64 ± 0.10 [0.025 ± 0.004]
19/9 19 [0.748] 9.0 [0.354] 0.76 ± 0.12 [0.030 ± 0.005]
26/13 26 [1.024] 13.0 [0.512] 0.89 ± 0.12 [0.035 ± 0.005]
38/19 38 [1.500] 19.0 [0.748] 1.00 ± 0.12 [0.039 ± 0.005]
51/19 51 [2.000] 19.0 [0.748] 1.02 ± 0.15 [0.040 ± 0.006]
3:1 (Europe only)
3/1 3.0 [0.118] 1.0 [0.039] 0.55 ± 0.10 [0.022 ± 0.004]
6/2 6.0 [0.236] 2.0 [0.079] 0.65 ± 0.10 [0.026 ± 0.004]
9/3 9.0 [0.354] 3.0 [0.118] 0.75 ± 0.15 [0.030 ± 0.006]
12/4 12.0 [0.472] 4.0 [0.157] 0.75 ± 0.15 [0.030 ± 0.006]
18/6 18.0 [0.709] 6.0 [0.236] 0.85 ± 0.15 [0.033 ± 0.006]
24/8 24.0 [0.945] 8.0 [0.315] 1.00 ± 0.20 [0.039 ± 0.008]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Yellow/green stripe (-45)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description** Specify product name, size and color (for example, DCPT 8/4-45).
**Europe only. For supply to Def Stan and BS add -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Single Wall Tubing
3-15
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
LSTT
Applications
LSTT is a highly flexible,
low-shrink-temperature,
heat-shrinkable tubing. Its
low shrink temperature
offers exceptionally fast
recovery for maximum
efficiency in high-volume
commercial applications
and makes it suitable for
use on or near delicate,
temperature-sensitive
materials, such as PVC
jacketed wire and cable.
Although not flame-
retardant, LSTT meets
the automotive flame
propagation standard
MVSS 302.
Typical applications
include electrical
termination insulation,
color-coding, covering of
heat-sensitive devices,
cosmetic coverings, and
mechanical protection.
Installation
Minimum shrink
temperature: 65°C [149°F]
Minimum full recovery
temperature: 110°C [230°F]
Series Industry Raychem
LSTT MVSS302 RW-2051
Low-Shrink-Temperature,
Non-Flame-Retardant,
Heat-Shrinkable, Polyolefin
tubing
Product Facts
n2:1 shrink ratio
nRapid recovery at low
temperatures
nCan be used with
temperature-sensitive
materials
nFlexible
nNot flame-retardant
nExcellent physical and
electrical performance
Specifications/Approvals
Operating Temperature Range
-40°Cto 125°C
[-40°F to 257°F]
Available in: Americas Europe Asia Pacific
n
Single Wall Tubing
3-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
LSTT (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
1.6 1.6 [0.063] 0.8 [0.031] 0.50 ± 0.12 [0.018 ± 0.005]
2.4 2.4 [0.093] 1.2 [0.046] 0.55 ± 0.12 [0.022 ± 0.005]
3.2 3.2 [0.125] 1.6 [0.062] 0.55 ± 0.12 [0.022 ± 0.005]
4.8 4.8 [0.187] 2.4 [0.093] 0.55 ± 0.12 [0.022 ± 0.005]
6.4 6.4 [0.250] 3.2 [0.125] 0.65 ± 0.15 [0.026 ± 0.006]
9.5 9.5 [0.375] 4.8 [0.187] 0.65 ± 0.15 [0.026 ± 0.006]
12.7 12.7 [0.500] 6.4 [0.250] 0.65 ± 0.15 [0.026 ± 0.006]
19.0 19.0 [0.748] 9.5 [0.375] 0.80 ± 0.15 [0.032 ± 0.006]
25.4 25.4 [1.000] 12.7 [0.500] 0.95 ± 0.18 [0.037 ± 0.007]
32.0 32.0 [1.260] 16.0 [0.630] 1.05 ± 0.20 [0.041 ± 0.008]
38.0 38.0 [1.496] 19.0 [0.748] 1.05 ± 0.20 [0.041 ± 0.008]
52.0** 52.0 [2.047] 26.0 [1.024] 1.14 ± 0.18 [0.045 ± 0.007]
*Wall thickness will be les if tubing recovery is restricted during shrinkage.
**Available in black only.
Product Dimensions
Ordering Information Color Standard Black (-0), white (-9), red (-2), blue (-6), yellow (-4)
Nonstandard Green (-5), grey (-8), clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On plastic spools***
Ordering description Specify product name, size and color (for example, LSTT 6.4-0).
***Available in the convenient RaySpool packaging/dispensing system, for sizes 2.4 up to 25.4
Single Wall Tubing
3-17
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RNF-100
Applications
Designed to provide
superior mechanical
(abrasion, cut-through,
and strain relief), thermal,
and fluid-resistance
performance in demanding
environments. Widely used
to provide insulation and
strain relief of wire termina-
tions and connections.
Used for jacketing wire
bundles and light-duty
harnesses where superior
abrasion resistance is a
plus. Also used to identify
and color-code electrical
connections and wire
bundles.
Installation
Minimum shrink
temperature: 95°C [203°F]
Minimum full recovery
temperature: 121°C [250°F]
Series UL CSA MilitaryIndustryRaychem
RNF-100 Type 1 E35586 LR31929 AMS-DTL-23053/5*, VDE 0341 Pt 9005 RT-350, Type 1
(colors) 600 V, 125°C 600 V, 125°C Class 1 Type Aand B RK-6001
Def. Stan. 59-97 Type 2B
RNF-100 Type 2 AMS-DTL-23053/5*, RT-350, Type 2
(clear) ——Class 2 —RK-6001
VG 95343 Pt 5 Type B
*Formerly MIL-I-23053/5 and MIL-DTL-23053/5.
Flexible, Flame-Retardant,
General Purpose,
Polyolefin Tubing
Product Facts
n2:1 shrink ratio
nSuperior abrasion and
solvent resistance when
compared with that of many
flexible, general purpose
polyolefin tubings
nExcellent physical,
chemical, and electrical
properties that meet or
exceed industrial and
military standards for highly
reliable, general purpose
tubing
nFlexible; conforms to
irregular shapes
nFlame-retardant (colors
only)
nWide range of sizes and
colors
Specifications/Approvals
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
3-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RNF-100 (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.40 ± 0.08 [0.016 ± 0.003]
1/16 1.6 [0.063] 0.8 [0.031] 0.43 ± 0.08 [0.017 ± 0.003]
3/32 2.4 [0.093] 1.2 [0.046] 0.51 ± 0.08 [0.020 ± 0.003]
1/8 3.2 [0.125] 1.6 [0.062] 0.51 ± 0.08 [0.020 ± 0.003]
3/16 4.8 [0.187] 2.4 [0.093] 0.51 ± 0.08 [0.020 ± 0.003]
1/4 6.4 [0.250] 3.2 [0.125] 0.64 ± 0.08 [0.025 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.64 ± 0.08 [0.025 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.64 ± 0.08 [0.025 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.76 ± 0.08 [0.030 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.89 ± 0.12 [0.035 ± 0.005]
11/4 31.8 [1.250] 15.9 [0.625] 1.02 ± 0.15 [0.040 ± 0.006]
11/2 38.1 [1.500] 19.1 [0.750] 1.02 ± 0.15 [0.040 ± 0.006]
2 50.8 [2.000] 25.4 [1.000] 1.14 ± 0.16 [0.045 ± 0.007]
3 76.2 [3.000] 38.1 [1.500] 1.27 ± 0.20 [0.050 ± 0.008]
4101.6 [4.000] 50.8 [2.000] 1.40 ± 0.23 [0.055 ± 0.009]
5127.0 [5.000] 63.5 [2.500] 1.52 ± 0.23 [0.060 ± 0.009]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information Color Standard Black (-0, BK), white (-9, WH), red (-2, RD), blue (-6, BU), yellow (-4, YO),
green (-5, GN), clear (-X, CL)
Nonstandard Brown (-1, BN), orange (-3, OR), violet (-7, VT), gray (-8, GY)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request
Standard packaging On spools or in 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, RNF-100 1/4-0 [Europe]
or RNF-100 1/4-BK [Americas).
***Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Single Wall Tubing
RNF-3000
3-19
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Used for insulation
and strain relief of wire
terminations and electrical
connections. Also ideal for
light-duty harnessing,
jacketing, and identification
of wires, cables, and
electrical and electronic
components.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 120°C [248°F]
Series UL CSA MilitaryIndustryRaychem
RNF-3000 E35586 LR31929 Def. Stan. 59-97 Type 2B VDE 0341 Pt 9005 RW-2053
600 V, 125°C 600 V, 125°C VG 95343 Pt 5 Type A(color) Type A and B
VG 95343 Pt 5 Type B (clear)
Flexible, High-Shrink-Ratio,
Flame-Retardant, General
Purpose, Polyolefin Tubing
Product Facts
n3:1 shrink ratio easily
accommodates awkward,
irregular shapes
nFew sizes cover a wide
range of diameters, allowing
reduced inventory
nExcellent physical,
chemical, and electrical
properties meet industry
standards for highly
reliable, general purpose
tubing
nFlame-retardant (colors
only)
Specifications/Approvals
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
3-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RNF-3000 (Continued)
Color Standard** Black (-0), white (-9), red (-2), blue (-6), yellow (-4), green (-5), clear (-X)
Nonstandard Brown (-1), orange (-3), violet (-7), gray (-8)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging*** On spools or in 1.2-meter [4-foot] lengths.
Ordering description**** Specify product name, size and color (for example, RNF-3000 6/2-0).
**Black is the only standard color in the Americas. All other colors are nonstandard.
***Only spools are standard in the Americas. 1.2 meter [4-foot] lengths are nonstandard.
****Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
1.5/0.5 1.5 [0.060] 0.5 [0.019] 0.45 ± 0.10 [0.018 ± 0.003]
3/1 3 [0.118] 1 [0.039] 0.55 ± 0.10 [0.022 ± 0.003]
4.5/1.5 4.5 [0.177] 1.5 [0.059] 0.55 ± 0.10 [0.022 ± 0.003]
6/2 6 [0.236] 2 [0.079] 0.65 ± 0.10 [0.026 ± 0.003]
9/3 9 [0.354] 3 [0.118] 0.75 ± 0.12 [0.030 ± 0.004]
12/4 12 [0.472] 4 [0.157] 0.75 ± 0.12 [0.030 ± 0.004]
18/6 18 [0.709] 6 [0.236] 0.85 ± 0.12 [0.033 ± 0.004]
24/8 24 [0.944] 8 [0.315] 1.00 ± 0.18 [0.039 ± 0.007]
39/13 39 [1.534] 13 [0.512] 1.15 ± 0.20 [0.045 ± 0.008]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
Single Wall Tubing
RP-4800
3-21
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Ideal for repairing
harnesses or cables; will
pass over a large-diameter
connector or transition, and
then shrink down onto a
smaller-diameter jacket.
Can insulate or protect a
substrate of varying
dimensions. Also provides
the abrasion and fluid
resistance required in
harnessing applications.
Installation
Minimum shrink
temperature: 95°C [203°F]
Minimum full recovery
temperature: 121°C [250°F]
Series UL MilitaryIndustryRaychem
RP-4800 E35586 AMS-DTL-23053/5*, VDE 0341 Pt 9005 Type A RT-1122
600V, 125°C Class 1 Overexpanded
(black only) VG 95343 Pt 5 Type A
*Formerly MIL-I-23053/5 and MIL-DTL-23053/5.
High-Shrink-Ratio,
Flame-Retardant,
Polyolefin Tubing
Product Facts
n4:1 shrink ratio
nConforms well to highly
variable substrate
dimensions
nHas excellent physical,
chemical, and electrical
properties that meet or
exceed industrial and
military standards
nShows no significant
degradation when exposed
to common solvents and
chemicals, including
aviation fuel and hydraulic
fluid
Specifications/Approvals
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
RP-4800 (Continued)
3-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
No. 1 25.4 [1.000] 7.0 [0.275] 1.14 ± 0.18 [0.045 ± 0.007]
No. 2 50.8 [2.000] 14.0 [0.550] 1.14 ± 0.18 [0.045 ± 0.007]
No. 3 76.2 [3.000] 20.6 [0.810] 1.14 ± 0.18 [0.045 ± 0.007]
No. 4 101.6 [4.000] 26.7 [1.050] 1.14 ± 0.18 [0.045 ± 0.007]
No. 5 25.4 [1.000] 11.7 [0.462] 1.14 ± 0.18 [0.045 ± 0.007]
No. 6 60.3 [2.375] 17.3 [0.680] 1.14 ± 0.18 [0.045 ± 0.007]
No. 7 76.2 [3.000] 21.3 [0.840] 1.14 ± 0.18 [0.045 ± 0.007]
No. 8 95.3 [3.750] 23.6 [0.930] 1.14 ± 0.18 [0.045 ± 0.007]
No. 9 114.3 [4.500] 36.8 [1.450] 1.14 ± 0.18 [0.045 ± 0.007]
No. 10 38.1 [1.500] 9.5 [0.375] 1.14 ± 0.18 [0.045 ± 0.007]
No. 11 19.1 [0.750] 4.6 [0.180] 1.14 ±0.18 [0.045 ± 0.007]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5), brown (-1),
orange (-3), violet (-7), gray (-8)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools or in 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, RP-4800 NO.1-0).
***Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Single Wall Tubing
RT-3
3-23
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Suitable for wirestrain-relief
applications — soldered or
crimped connections, wire
splices, terminations.
Well suited for use with
semiautomated production
equipment requiring tubing
with a tightly controlled
expanded diameter.Acts
as a tough covering for
delicate components;
provides mechanical
protection.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL CSA Raychem
RT-3 E35586 LR31929 (black only) RT-360*
600 V,125°C600 V, 125°C
*Except dimensions and longitudinal change.
Semirigid, Flame-
Retardant, Polyolefin
Tubing
Product Facts
n2.5:1 shrink ratio
nTightly controlled expanded
diameters
nHigh abrasion resistance
nSemirigidity that transfers
flex stress away from
typically weak points such
as solder and crimp joints,
helping to ensure a reliable
connection
nExcellent chemical and
solvent resistance
nOutstanding physical and
electrical performance
Specifications/Approvals
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nn
Single Wall Tubing
RT-3 (Continued)
3-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
No. 1 6.1 ± 0.4 [0.240 ± 0.015] 2.4 [0.095] 0.79 ± 0.08 [0.031 ± 0.003]
No. 2 8.1 ± 0.4 [0.320 ± 0.015] 3.2 [0.125] 0.79 ± 0.08 [0.031 ± 0.003]
No. 3 9.5 ± 0.5 [0.375 ± 0.020] 3.8 [0.150] 0.79 ± 0.08 [0.031 ± 0.003]
No. 4 12.3 ± 0.5 [0.485 ± 0.020] 5.1 [0.200] 0.79 ± 0.08 [0.031 ± 0.003]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Black only
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1-inch cut pieces or in 1.2-meter [4-foot] lengths.
Ordering description Specify product name, size and color (for example, RT-3 No. 1-0).
Product Dimensions
Ordering Information
Single Wall Tubing
TUGA-GP
3-25
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
TUGA-GP is a commercial
grade tubing for general
applications where a
flame-retardant product is
not needed but where
electrical insulation and
mechanical performance
areimportant. TUGA-GP
makes an attractive cover-
ing for many automotive,
appliance, and consumer-
goods applications.
Exceptional transparency
of clear vision makes it an
ideal choice for protecting
marked surfaces.
Installation
Minimum shrink
temperature: 85°C [85°F]
Minimum full recovery
temperature: 110°C
[230°F] for black; 100°C
[212°F] for all other colors
and clear.
Series Raychem
TUGA-GP RW-2201
Brightly Colored, Shiny,
Non-Flame-Retardant,
Polyolefin Tubing
Product Facts
n2:1 Shrink ratio
nCan be easily hot-stamped
nBright, shiny surface; clear
version offers exceptional
clarity
nSemiflexible, non-flame-
retardant, halogen free
nConforms to substrates more
uniformly and with less
longitudinal change than
most PVC-based materials
Specifications/Approvals
Operating Temperature Range
-55°Cto 125°C
[-67°F to 257°F]
Available in: Americas Europe Asia Pacific
n
Single Wall Tubing
TUGA-GP (Continued)
3-26 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating Nominal After Heating
1.2/0.6 1.2 [0.046] 0.6 [0.023] 0.4 [0.016]
1.6/0.8 1.6 [0.062] 0.8 [0.031] 0.4 [0.016]
2.4/1.2 2.4 [0.093] 1.2 [0.046] 0.5 [0.019]
3/1.5 3.0 [0.118] 1.5 [0.059] 0.5 [0.019]
5/2.5 5.0 [0.197] 2.5 [0.098] 0.5 [0.019]
6.4/32 6.4 [0.250] 3.2 [0.125] 0.6 [0.024]
8/4 8.0 [0.315] 4.0 [0.157] 0.6 [0.024]
9.5/4.8 9.5 [0.375] 4.8 [0.187] 0.6 [0.024]
11/5.5 11.0 [0.433] 5.5 [0.217] 0.6 [0.024]
12.7/6.4 12.7 [0.500] 6.4 [0.250] 0.6 [0.024]
15/7.5 15.0 [0.591] 7.5 [0.295] 0.8 [0.031]
20/10 20.0 [0.787] 10.0 [0.394] 0.8 [0.031]
25.4/12.7 25.4 [1.000] 12.7 [0.500] 0.9 [0.035]
38/19 38.0 [1.496] 19.0 [0.748] 1.0 [0.039]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0), white (-9), red (-2)
Nonstandard Yellow (-4), clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, TUGA 3/1.5-0).
Product Dimensions
Ordering Information
Single Wall Tubing
Versafit
3-27
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Highly Flame-Retardant,
Very Flexible, Low-Shrink-
Temperature, Polyolefin
Tubing
Product Facts
n2:1 shrink ratio
nLow shrink temperature
reduces installation time
and the risk of damage to
temperature-sensitive
components
nVery flexible; doesn’t easily
wrinkle when bent
nHighly flame-retardant
nHot stamps extremely well
nHigher temperature rating,
better thermal stability, and
higher resistance to physical
abuse than noncrosslinked
materials
nFree of polybrominated
biphenyls (PBBs) and
polybrominated biphenyl
oxides and ethers (PBBOs
and PBBEs), which are
classified as
environmentally
hazardous substances
Specifications/Approvals Series UL CSA Military Raychem
Versafit E35586 VW-1 LR31929 VW-1 AMS-DTL-23053/5* RW-3009
600 V,125°C 600 V, 125°C Classes 1 & 3
*Formerly MIL-I-23053/5 and MIL-DTL-23053/5.
Applications
Cost-effective choice for
many commercial and
militaryapplications;
electrically insulates
and protects in-line
components, disconnect
terminals, and splices.
Bundles wires for very
flexible light-duty
harnesses. Strain-relieves
electrical wireconnections
for commercial applications.
Identifies or color-codes
wires, cables, terminals,
and components.
Installation
Minimum shrink
temperature: 70°C [158°F]
Minimum full recovery
temperature: 90°C [194°F]
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
Versafit (Continued)
3-28 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.63 ± 0.2 [0.064 ± 0.008] 0.6 [0.023] 0.40 ± 0.08 [0.016 ± 0.003]
1/16 1.85 ± 0.2 [0.073 ± 0.008] 0.8 [0.031] 0.43 ± 0.08 [0.017 ± 0.003]
3/32 2.79 ± 0.2 [0.110 ± 0.008] 1.2 [0.046] 0.51 ± 0.08 [0.020 ± 0.003]
1/8 3.43 ± 0.2 [0.135 ± 0.008] 1.6 [0.062] 0.51 ± 0.08 [0.020 ± 0.003]
3/16 5.21 ± 0.3 [0.205 ± 0.010] 2.4 [0.093] 0.51 ± 0.08 [0.020 ± 0.003]
1/4 7.11 ± 0.3 [0.280 ± 0.010] 3.2 [0.125] 0.64 ± 0.08 [0.025 ± 0.003]
3/8 10.16 ± 0.4 [0.400 ± 0.015] 4.8 [0.187] 0.64 ± 0.08 [0.025 ± 0.003]
1/2 13.72 ± 0.4 [0.540 ± 0.015] 6.4 [0.250] 0.64 ± 0.08 [0.025 ± 0.003]
5/8*** 16.90 ± 0.4 [0.665 ± 0.015] 8.0 [0.315] 0.76 ± 0.08 [0.030 ± 0.003]
3/4 20.45 ± 0.4 [0.805 ± 0.015] 9.5 [0.375] 0.76 ± 0.08 [0.030 ± 0.003]
1 25.53 ± 0.4 [1.055 ± 0.015] 12.7 [0.500] 0.89 ± 0.12 [0.035 ± 0.005]
11/4*** 33.40 ± 0.7 [1.315 ± 0.025] 15.9 [0.625] 1.02 ± 0.15 [0.040 ± 0.006]
11/2 39.88 ± 0.8 [1.570 ± 0.030] 19.1 [0.750] 1.02 ± 0.15 [0.040 ± 0.006]
2 52.83 ± 1.0 [2.080 ± 0.040] 25.4 [1.000] 1.14 ± 0.16 [0.045 ± 0.007]
378.49 ± 1.0 [3.090 ± 0.040] 38.1 [1.500] 1.27 ± 0.20 [0.050 ± 0.008]
4104.14 ± 1.3 [4.100 ± 0.050] 50.8 [2.000] 1.40 ± 0.23 [0.055 ± 0.009]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
***Nonstandard size; available by special order only.
Color Standard Black (-0), white (-9), red (-2), blue (-6), yellow (-4), green (-5)
Nonstandard Brown (-1), orange (-3), violet (-7), gray (-8)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging**** On spools.
Ordering description***** Specify product name, size and color (for example, Versafit 1/4-0).
****Available in the convenient RaySpool packaging/dispensing system, for sizes 1/16” up to 1”.
*****Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Single Wall Tubing
Versafit V2
3-29
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Highly Flame-Retardant,
Very Flexible, Low-Shrink-
Temperature, Polyolefin
Tubing
Product Facts
n2:1 shrink ratio
nLow shrink temperature
reduces installation time
and the risk of damage to
temperature-sensitive
components
nVery flexible; doesn’t easily
wrinkle when bent
nHighly flame-retardant
nHot stamps extremely well
nHigher temperature rating,
better thermal stability, and
higher resistance to physical
abuse than noncrosslinked
materials
nFree of polybrominated
biphenyls (PBBs) and
polybrominated biphenyl
oxides and ethers (PBBOs
and PBBEs), which are
classified as
environmentally
hazardous substances
Specifications/Approvals Series UL CSA Raychem
Versafit V2 E35586 VW-1 LR31929 VW-1 RW-3023
600 V,125°C600 V, 125°C
Applications
Cost-effective choice
for many commercial
applications; electrically
insulates and protects
in-line components,
disconnect terminals, and
splices. Bundles wires for
veryflexible light-duty
harnesses. Strain-relieves
electrical wire connections.
Identifies or color-codes
wires, cables, terminals,
and components.
Installation
Minimum shrink
temperature: 70°C [158°F]
Minimum full recovery
temperature: 90°C [194°F]
Operating Temperature Range
-30°Cto 125°C
[-22°F to 257°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
Versafit V2 (Continued)
3-30 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information Color Standard Black (-0)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5), orange (-3),
violet (-7), brown (-1), gray (-8)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, Versafit V2-3.0-0).
Inside Diameter Wall Thickness
Size Expanded Maximum Recovered Expanded as Recovered*
asSupplied After Heating Supplied (Nominal) After Heating (Minimum)
1.0 1.5 ± 0.2 [0.059 ± 0.008] 0.50 [0.020] 0.20 [0.008] 0.33 [0.013]
1.5 2.1 ± 0.2 [0.075 ± 0.008] 0.75 [0.030] 0.20 [0.008] 0.35 [0.014]
2.0 2.6 ± 0.2 [0.102 ± 0.008] 1.00 [0.039] 0.25 [0.010] 0.43 [0.017]
2.5 3.1 ± 0.2 [0.122 ± 0.008] 1.25 [0.049] 0.25 [0.010] 0.43 [0.017]
3.0 3.6 ± 0.2 [0.142 ± 0.008] 1.50 [0.059] 0.25 [0.010] 0.43 [0.017]
3.5 4.1 ± 0.3 [0.161 ± 0.012] 1.75 [0.069] 0.25 [0.010] 0.43 [0.017]
4.0 4.6 ± 0.3 [0.181 ± 0.012] 2.00 [0.079] 0.25 [0.010] 0.43 [0.017]
5.0 5.6 ± 0.3 [0.221 ± 0.012] 2.50 [0.098] 0.30 [0.012] 0.56 [0.022]
6.0 6.6 ± 0.3 [0.260 ± 0.012] 3.00 [0.118] 0.30 [0.012] 0.56 [0.022]
7.0 7.6 ± 0.3 [0.299 ± 0.012] 3.50 [0.138] 0.30 [0.012] 0.56 [0.022]
8.0 8.6 ± 0.3 [0.339 ± 0.012] 4.00 [0158] 0.30 [0.012] 0.56 [0.022]
9.0 9.6 ± 0.3 [0.378 ± 0.012] 4.50 [0.177] 0.30 [0.012] 0.56 [0.022]
10.0 10.4 ± 0.3 [0.409 ± 0.012] 5.00 [0.197] 0.30 [0.012] 0.56 [0.022]
11.0 11.4 ± 0.3 [0.449 ± 0.012] 5.50 [0.217] 0.30 [0.012] 0.56 [0.022]
12.0 12.7 ± 0.3 [0.500 ± 0.012] 6.00 [0.236] 0.30 [0.012] 0.56 [0.022]
13.0 13.5 ± 0.3 [0.532 ± 0.012] 6.50 [0.256] 0.35 [0.014] 0.66 [0.026]
14.0 14.4 ± 0.4 [0.567 ± 0.016] 7.00 [0.276] 0.35 [0.014] 0.68 [0.027]
15.0 15.7 ± 0.4 [0.618 ± 0.016] 7.50 [0.295] 0.35 [0.014] 0.68 [0.027]
16.0 16.9 ± 0.4 [0.665 ± 0.016] 8.00 [0.315] 0.35 [0.014] 0.68 [0.027]
18.0 19.0 ± 0.4 [0.748 ± 0.016] 9.00 [0.354] 0.40 [0.016] 0.76 [0.030]
20.0 21.4 ± 0.4 [0.843 ± 0.016] 10.00 [0.394] 0.40 [0.016] 0.76 [0.030]
22.0 23.2 ± 0.4 [0.913 ± 0.016] 11.00 [0.433] 0.45 [0.018] 0.89 [0.035]
25.0 26.8 ± 0.4 [1.055 ± 0.016] 12.50 [0.492] 0.45 [0.018] 0.89 [0.035]
27.0 28.2 ± 0.5 [1.110 ± 0.020] 12.50 [0.492] 0.45 [0.018] 0.89 [0.035]
28.0 30.0 ± 0.5 [1.181 ± 0.020] 14.00 [0.551] 0.45 [0.018] 0.89 [0.035]
30.0 32.1 ± 0.5 [1.264 ± 0.020] 15.00 [0.591] 0.45 [0.018] 0.89 [0.035]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Single Wall Tubing
Versafit V4
3-31
Heat-Shrinkable Tubing
3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Typically used where
space saving is important.
Offers the ability to pack
components moreclosely
than is possible with
standard tubings. Cost-
effective choice for many
commercial applications;
electrically insulates and
protects in-line compo-
nents, disconnect terminals,
and splices. Used for strain
relief on high-density
connectors.
Installation
Minimum shrink
temperature: 70°C [158°F]
Minimum full recovery
temperature: 90°C [194°F]
Series UL CSA Raychem
Versafit V4 E85381 VW-1 LR31929 VW-1 RW-3023
300 V,125°C150 V, 125°C
Very-Thin-Wall, Very
Flexible, Highly
Flame-Retardant,
Polyolefin Tubing
Product Facts
n2:1 shrink ratio
nVery thin wall provides
space savings and rapid
shrinking
nLow shrink temperature
further reduces installation
time and risk of damage to
temperature-sensitive
components
nVery flexible; doesn’t easily
wrinkle when bent
nFree of polybrominated
biphenyls (PBBs) and
polybrominated biphenyl
oxides and ethers (PBBOs
and PBBEs), which are
classified as
environmentally
hazardous substances
Specifications/Approvals
Operating Temperature Range
-30°Cto 125°C
[-22°F to 257°F]
Available in: Americas Europe Asia Pacific
nnn
Single Wall Tubing
Versafit V4 (Continued)
3-32 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0)
Nonstandard Other colors available upon request.
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Marking Marked with UL/CSA/-F- legends (metric sizes) or unmarked (inch sizes).
Ordering description Specify product name, size (mm or in.) and color (for example, Versafit V4-1.0-0).
Inside Diameter Wall Thickness
Metric Expanded Maximum Recovered Expanded as Recovered*
Size asSupplied After Heating Supplied (Nominal) After Heating (Minimum)
0.6/0.3 0.95 ± 0.25 [0.037 ± 0.010] 0.30 [0.012] 0.10 [0.004] 0.25 [0.010]
0.8/0.4 1.20 ± 0.25 [0.047 ± 0.010] 0.40 [0.016] 0.10 [0.004] 0.25 [0.010]
1.0/0.5 1.40 ± 0.25 [0.055 ± 0.010] 0.50 [0.020] 0.10 [0.004] 0.25 [0.010]
1.5/0.75 1.90 ± 0.25 [0.075 ± 0.010] 0.75 [0.030] 0.10 [0.004] 0.25 [0.010]
2.0/1.0 2.30 ± 0.25 [0.091 ± 0.010] 1.00 [0.039] 0.10 [0.004] 0.25 [0.010]
2.5/1.25 2.80 ± 0.25 [0.110 ± 0.010] 1.25 [0.049] 0.15 [0.006] 0.25 [0.010]
3.0/1.5 3.30 ± 0.25 [0.130 ± 0.010] 1.50 [0.059] 0.15 [0.006] 0.25 [0.010]
3.5/1.75 3.80 ± 0.25 [0.150 ± 0.010] 1.75 [0.069] 0.15 [0.006] 0.25 [0.010]
4.0/2.0 4.40 ± 0.25 [0.173 ± 0.010] 2.00 [0.079] 0.15 [0.006] 0.25 [0.010]
5.0/2.5 5.50 ± 0.25 [0.217 ± 0.010] 2.50 [0.098] 0.15 [0.006] 0.25 [0.010]
6.0/3.0 6.50 ± 0.40 [0.256 ± 0.016] 3.00 [0.118] 0.15 [0.006] 0.28 [0.011]
7.0/3.5 7.50 ± 0.40 [0.295 ± 0.016] 3.50 [0.138] 0.15 [0.006] 0.28 [0.011]
8.0/4.0 8.50 ± 0.40 [0.335 ± 0.016] 4.00 [0.158] 0.15 [0.006] 0.28 [0.011]
9.0/4.5 9.50 ± 0.40 [0.374 ± 0.016] 4.50 [0.177] 0.15 [0.006] 0.28 [0.011]
10.0/5.0 10.50 ± 0.50 [0.413 ± 0.020] 5.00 [0.197] 0.15 [0.006] 0.28 [0.011]
Inch Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
as Supplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.30 ± 0.05 [0.012 ± 0.002]
1/16 1.6 [0.062] 0.8 [0.031] 0.30 ± 0.05 [0.012 ± 0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.30 ± 0.05 [0.012 ± 0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.33 ± 0.05 [0.013 ± 0.002]
3/16 4.8 [0.187] 2.4 [0.093] 0.33 ± 0.05 [0.013 ± 0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.36 ± 0.08 [0.014 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.36 ± 0.08 [0.014 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.36 ± 0.08 [0.014 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.51 ± 0.08 [0.020 ± 0.003]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-33
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
ATUM
Applications
Environmentally seals
and protects a wide variety
of electrical applications,
including back end
connector sealing,
breakouts, and connector-
to-cable transitions. High
expansion ratio makes it
possible to repair most
damaged cable jackets
without removing
connectors.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 110°C [230°F]
Series UL** MilitaryRaychem
ATUM E85381 AMS-DTL-23053/4*, Class 3 RW-2063 - Black
600V, 110°C RK-6024 - Colors and clear
*Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Sizes 3/1, 6/2, 12/4, 24/8, and 40/13 only.
**Black only, except sizes 3/1 and 4/1.
High-Shrink-Ratio,
Adhesive-Lined
Polyolefin Tubing
Product Facts
n3:1 and 4:1 shrink ratios
allow for connector-to-cable
sealing
nTubing environmentally
seals and protects
components and
interconnections
nMedium wall provides
increased mechanical
protection
nATUM adhesive bonds to a
wide variety of plastics,
rubbers, and metals,
including polyethylene,
aluminum, steel, and copper
Specifications/Approvals
Operating Temperature Range
-55°Cto 110°C
[-67°F to 230°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-34 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ATUM (Continued)
Inside Diameter Recovered Wall Thickness**
Size Minimum Expanded Maximum Recovered Total Wall Adhesive Wall
asSupplied After Heating After Heating After Heating (Nominal)
3:1 3/1 3.0 [0.118] 1.0 [0.039] 1.00 ± 0.28 [0.039 ± 0.010] 0.50 [0.020]
4.5/1.5 4.5 [0.177] 1.5 [0.059] 1.10 ± 0.25 [0.043 ± 0.011] 0.50 [0.020]
6/2 6.0 [0.236] 2.0 [0.079] 1.00 ± 0.28 [0.039 ± 0.010] 0.50 [0.020]
9/3 9.0 [0.354] 3.0 [0.118] 1.40 ± 0.28 [0.055 ± 0.010] 0.61 [0.024]
12/4 12.0 [0.472] 4.0 [0.157] 1.78 ± 0.38 [0.070 ± 0.015] 0.76 [0.030]
19/6 19.0 [0.748] 6.0 [0.236] 2.25 ± 0.55 [0.088 ± 0.022] 0.76 [0.030]
24/8 24.0 [0.940] 8.0 [0.315] 2.54 ± 0.55 [0.100 ± 0.022] 1.02 [0.040]
40/13 40.0 [1.570] 13.0 [0.512] 2.54 ± 0.55 [0.100 ± 0.022] 1.02 [0.040]
4:1 4/1 4.0 [0.158] 1.0 [0.039] 1.00 ± 0.28 [0.039 ± 0.010] 0.50 [0.020]
8/2 8.0 [0.315] 2.0 [0.079] 1.00 ± 0.28 [0.039 ± 0.010] 0.50 [0.020]
12/3 12.0 [0.472] 3.0 [0.118] 1.40 ± 0.28 [0.055 ±0.010] 0.61 [0.024]
16/4 16.0 [0.630] 4.0 [0.158] 1.78 ± 0.38 [0.070 ± 0.015] 0.76 [0.030]
24/6 24.0 [0.945] 6.0 [0.236] 2.25 ± 0.55 [0.088 ± 0.022] 0.76 [0.030]
32/8 32.0 [1.260] 8.0 [0.315] 2.54 ± 0.55 [0.100 ± 0.022] 1.02 [0.040]
52/13 52.0 [2.050] 13.0 [0.512] 2.54 ± 0.55 [0.100 ± 0.022] 1.02 [0.040]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard Clear in 3:1 sizes only (non-flame-retardant jacket);
other colors available on request.
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, ATUM 8/2-0).
***Europe Only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-35
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
DWP-125
Applications
Environmentally seals and
protects a wide variety of
electrical applications,
including wiresplices,
breakouts, and connector-
to-cable transitions. Ideal
for applications whereUL
recognized/CSA certified
adhesive-lined tubing is
required.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 125°C [257°F]
Series UL CSA Military Raychem
DWP-125 E35586 LR31929 AMS-DTL-23053/4*, DWP-125 SCD
600 V,125°C600 V,125°CClass 3 (colors only)
*Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Meets the material properties except for Sealing Efficiency.
Flexible, High-Shrink-
Ratio, Adhesive-Lined,
Polyolefin Tubing
Product Facts
n3:1 shrink ratio allows for
insulation and sealing of
irregular shapes
nMedium wall provides
increased mechanical
protection while maintaining
flexibility when installed
nAdhesive bonds to a wide
variety of plastics, rubber,
and metals, including
polyethylene, neoprene,
and steel
Specifications/Approvals
Operating Temperature Range
-40°Cto 110°C
[-40°F to 230°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-36 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
DWP-125 (Continued)
Inside Diameter Recovered Wall Thickness*
Minimum Maximum Nominal Nominal
Size Expanded Recovered Total Wall Adhesive Wall
asSupplied After Heating After Heating After Heating
1/8 3.2 [0.125] 1.0 [0.040] 1.02 [0.040] 0.25 [0.010]
3/16 4.8 [0.187] 1.5 [0.060] 1.40 [0.055] 0.51 [0.020]
1/4 6.4 [0.250] 2.0 [0.080] 1.45 [0.057] 0.56 [0.022]
3/8 9.5 [0.375] 3.0 [0.120] 1.65 [0.065] 0.68 [0.027]
1/2 12.7 [0.500] 4.0 [0.157] 1.78 [0.070] 0.76 [0.030]
3/4 19.1 [0.750] 6.0 [0.230] 2.03 [0.080] 0.76 [0.030]
1 25.4 [1.000] 8.0 [0.320] 2.50 [0.100] 0.76 [0.030]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5), clear
(-X, non-flame-retardant jacket).
Other colors available upon request.
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description Specify product name, size and color (for example, DWP-125 1/4-0).
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-37
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
ES1000
Applications
Specially designed for
environmental sealing and
electrical insulation of wire
splices, terminations, and
components where see-
through inspection is
required.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL Raychem
ES1000 E85381 RT-1113
600 V,125°C
Clear, High-Shrink-Ratio,
Adhesive-Lined, Semirigid
Polyolefin Tubing
Product Facts
n4:1 shrink ratio allows a few
sizes to cover a wide range
of splice and component
diameters
nMechanically tough tubing
provides strain relief and
abrasion protection of wire
splices, terminals and other
components
nThick adhesive liner forms
an effective barrier against
fluids and moisture and
performs well at an
extended temperature range
Specifications/Approvals
Operating Temperature Range
-40°Cto 130°C
[-40°F to 266°F]
Available in: Americas Europe Asia Pacific
nn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-38 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ES1000 (Continued)
Inside Diameter (Including Core) Recovered Wall Thickness*
Part Minimum Maximum Minimum Minimum Minimum
Number Expanded Recovered Total Wall Jacket Wall Adhesive Wall
asSupplied After Heating After Heating After Heating After Heating
ES1000-No.1 5.72 [0.225] 1.27 [0.050] 1.20 [0.047] 0.64 [0.025] 0.56 [0.022]
ES1000-No.2 7.44 [0.293] 1.65 [0.065] 1.52 [0.060] 0.76 [0.030] 0.76 [0.030]
ES1000-No.3 10.85 [0.427] 2.41 [0.095] 1.91 [0.075] 0.89 [0.035] 1.02 [0.040]
ES1000-No.4 17.78 [0.700] 4.45 [0.175] 2.41 [0.095] 1.04 [0.041] 1.37 [0.054]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging Cut pieces.
Marking Tubing will be printed with its numbered size (such as ES-1, ES-2, ES-3, or ES-4).
Ordering description Specify product name, numbered size, color,and cut length
(for example, ES1000-NO.2-X-50MM).
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
ES2000
Applications
Specially designed for
environmental sealing and
electrical insulation of wire
splices, terminations, and
components.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL Raychem
ES2000 E85381 RT-1112
600 V, 125°C
Flame-Retardant, High-
Shrink-Ratio, Adhesive-
Lined Semirigid Polyolefin
Tubing
Product Facts
n4:1 shrink ratio allows a few
sizes to cover a wide range
of splice and component
diameters
nFlame-retardant and
mechanically tough, the
tubing provides strain relief
and abrasion protection of
wire splices, terminals, and
other components
nThick adhesive liner forms
an effective barrier against
fluids and moisture and
performs well at an
extended temperature range
nUL recognized
Specifications/Approvals
Operating Temperature Range
-40°Cto 130°C
[-40°F to 266°F]
Available in: Americas Europe Asia Pacific
nn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-40 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ES2000 (Continued)
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging Cut pieces.
Marking Tubing will be printed with its numbered size (such as ES-1, ES-2, ES-3, or ES-4).
Ordering description Specify product name, numbered size, color,and cut length
(for example, ES2000-NO.2-0-50MM).
Inside Diameter (Including Core) Recovered Wall Thickness*
Part Minimum Maximum Minimum Minimum Minimum
Number Expanded Recovered Total Wall Jacket Wall Adhesive Wall
asSupplied After Heating After Heating After Heating After Heating
ES2000-No.1 5.72 [0.225] 1.27 [0.050] 1.20 [0.047] 0.64 [0.025] 0.56 [0.022]
ES2000-No.2 7.44 [0.293] 1.65 [0.065] 1.52 [0.060] 0.76 [0.030] 0.76 [0.030]
ES2000-No.3 10.85 [0.427] 2.41 [0.095] 1.91 [0.075] 0.89 [0.035] 1.02 [0.040]
ES2000-No.4 17.78 [0.700] 4.45 [0.175] 2.41 [0.095] 1.04 [0.041] 1.37 [0.054]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
FL2500
3-41
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Tough flame-retardant
polyolefin tubing lined with
aflame-retardant adhesive
provides the optimum
solution for applications
where full flame-retardancy
is preferred or specified.
Rated to 135°C [275°F] for
3000 hours, it is suitable
for use on harnesses which
will be exposed to harsh
environments. As the tubing
shrinks, the adhesive lining
melts and flows to
fill all voids and create a
complete seal against
moisture, oils, chemicals
and other fluids.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [275°F]
Series Raychem
FL2500 FL2500 SCD
Fully Flame-Retardant,
Adhesive-Lined, Polyolefin
Heat-Shrinkable Tubing
Product Facts
n4:1 shrink ratio allows a few
sizes to cover a wide range
of wire terminations and
components
nFlame-retardant tubing
jacket and adhesive provide
full flame-retardancy
nFully flame-retardant and
mechanically tough, the
tubing provides strain relief
and abrasion protection of
wire splices, terminals and
other components
nThick high-performance
adhesive lining offers
permanent sealing of
splices, fusible links,
terminals and in-line
components
Specifications/Approvals
Operating Temperature Range
-40°Cto 135°C
[-40°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
FL2500 (Continued)
3-42 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Black (-0) with a white adhesive liner
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging Cut pieces.
Marking Tubing will be marked with its numbered size (such as FL-1, FL-2, FL-3, FL-4).
Ordering description Specify product name, size, color, and cut length
(for example, FL2500-NO.2-0-50MM).
Ordering Information
Inside Diameter (Including Core) Recovered Wall Thickness*
Part Minimum Maximum Total Minimum
Number Expanded Recovered Wall Adhesive Wall
asSupplied After Heating After Heating After Heating
FL2500-No. 1 7.62 [0.300] 1.65 [0.065] 1.52 ± 0.3 [0.060 ± 0.012] 0.762 [0.030]
FL2500-No. 2 9.02 [0.355] 2.29 [0.090] 1.52 ± 0.3 [0.060 ± 0.012] 0.762 [0.030]
FL2500-No. 3 11.56 [0.455] 2.54 [0.100] 2.29 ± 0.3 [0.090 ± 0.012] 1.397 [0.055]
FL2500-No. 4 17.79 [0.700] 4.45 [0.175] 2.54 ± 0.3 [0.100 ± 0.012] 1.524 [0.060]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-43
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
HTAT
Applications
Designed to provide
environmental sealing for
arange of substrates, at
elevated temperatures.
Manufactured by Tyco
Electronics from radiation-
crosslinked polyolefins,
the inner wall melts when
heated and is forced into
interstices by the shrinking
of the outer wall so that,
when cooled, the substrate
is encapsulated by a tough,
protective moisture barrier.
An operating range of
-55˚C to 125˚C [-67˚F
to 257˚F] and a high shrink
ratio as standard, mean
that the tubing offers
superior environmental
protection to a wide range
of irregular shapes with
varying dimensions. The
jacket is flame-retardant to
reduce flame propagation.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 110°C [230°F]
Series Raychem
HTAT RW-2052
Semiflexible, Dual Wall,
Moisture-Resistant,
Heat-Shrinkable Tubing
Product Facts
n4:1 shrink ratio
nEnvironmental sealing
nHigh-strength bonding
nIdeal connector sealing
covering large diameter
differences
Specifications/Approvals
Operating Temperature Range
-55°Cto 125°C
[-67°F to 257°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
HTAT (Continued)
3-44 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Inside Diameter Recovered Wall Thickness*
Minimum Maximum Nominal Nominal
Size Expanded Recovered Total Wall Adhesive Wall
asSupplied After Heating After Heating After Heating
4/1 4.0 [0.158] 1.0 [0.039] 1.00 [0.039] 0.40 [0.016]
8/2 8.0 [0.315] 2.0 [0.079] 1.00 [0.039] 0.50 [0.020]
12/3 12.0 [0.472] 3.0 [0.118] 1.40 [0.055] 0.60 [0.024]
16/4 16.0 [0.630] 4.0 [0.158] 1.75 [0.069] 0.75 [0.030]
24/6 24.0 [0.945] 6.0 [0.236] 2.25 [0.088] 0.80 [0.032]
32/8 32.0 [1.260] 8.0 [0.315] 2.50 [0.098] 1.00 [0.039]
48/13 48.0 [1.890] 13.0 [0.512] 2.55 [0.100] 1.00 [0.039]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2 meter [4-ft] lengths.
Ordering description Specify product name, size and color (for example, HTAT 8/2-0).
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
RPPM
3-45
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
RPPM is a flexible, heat-
shrinkable, dual wall tubing
with an integrally bonded
meltable adhesive liner.
Available in clear and
black, the tough outer
jacket offers excellent
mechanical strength.
RPPM is used for moisture
proof encapsulation of a
wide variety of components.
In particular, it adheres well
to PVC. The high shrink
ratio allows RPPM to be
used with a range of
dimensions. Clear RPPM
offers excellent clarity for
protection of substrates that
may need to be inspected
during service. Black RPPM
has a high gloss finish
suitable for cosmetic
applications.
Installation
Minimum shrink
temperature: 60°C [140°F]
Minimum full recovery
temperature: 80°C [176°F]
Series Raychem
RPPM RK-6214
Flexible, Dual Wall,
Moisture Proof,
Heat-Shrinkable Tubing
Product Facts
nEnvironmental sealing
nExcellent mechanical
strength
nAbrasion resistance
n4:1 shrink ratio
Specifications/Approvals
Operating Temperature Range
-40°Cto 85°C
[-40°F to 185°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
RPPM (Continued)
3-46 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Inside Diameter Recovered Wall Thickness*
Minimum Maximum Nominal Nominal
Size Expanded Recovered Total Wall Adhesive Wall
asSupplied After Heating After Heating After Heating
4/1 4.0 [0.158] 1.0 [0.039] 0.8 [0.032] 0.3 [0.012]
8/2 8.0 [0.315] 2.0 [0.079] 0.9 [0.035] 0.3 [0.012]
12/3 12.0 [0.472] 3.0 [0.118] 1.2 [0.047] 0.4 [0.016]
16/4 16.0 [0.630] 4.0 [0.158] 1.5 [0.059] 0.5 [0.020]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Clear (-X)
Nonstandard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools, In 1.2 meter [4-foot] lengths or cut pieces.
Ordering description Specify product name, size and color (for example, RPPM 4/1-X).
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-47
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
SCL
Applications
Encapsulates components,
splices, and terminations
wheremoisture resistance
and mechanical protection
are required. Encapsulant
melts and flows to fill
surface irregularities of the
substrate. While still hot,
the tubing can be blocked
to form a wire breakout.
Installation
Minimum shrink
temperature: 125°C [257°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL Military Raychem
SCL E85381 AMS-DTL-23053/4*, Class 1 RT-1301
600 V, 125°C
*Formerly MIL-I-23053/4 and MIL-DTL-23053/4.
Semirigid,
Encapsulant-Lined,
Polyolefin Tubing
Product Facts
n3:1 shrink ratio
nSplash-resistant, moisture-
resistant covering; not
intended for use where
immersion in fluids is
required
nRugged protection against
abrasion, vibration, and
flexing
nExcellent strain relief and
insulation of weak points
Specifications/Approvals
Operating Temperature Range
-55°Cto 110°C
[-67°F to 230°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-48 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SCL (Continued)
Inside Diameter Recovered Wall Thickness**
Size Additional Minimum Maximum Meltable Wall
Standard Color Expanded Recovered Total Wall After Heating
as Supplied After Heating After Heating (Nominal)
1/8 Brown 3.2 [0.125] 0.6 [0.023] 0.96 ± 0.15 [0.038 ± 0.006] 0.51 [0.020]
3/16 Gray 4.8 [0.187] 1.5 [0.060] 1.09 ± 0.15 [0.043 ± 0.006] 0.64 [0.025]
1/4 White 6.4 [0.250] 2.0 [0.080] 1.19 ± 0.15 [0.047 ± 0.006] 0.69 [0.027]
3/8 Red 9.5 [0.375] 3.4 [0.135] 1.27 ± 0.18 [0.050 ± 0.007] 0.76 [0.030]
1/2 Blue 12.7 [0.500] 5.0 [0.195] 1.39 ± 0.18 [0.055 ± 0.007] 0.89 [0.035]
3/4 Yellow 19.1 [0.750] 8.0 [0.313] 1.65 ± 0.18 [0.065 ± 0.007] 1.02 [0.040]
1N/A 25.4 [1.000] 10.2 [0.400] 1.90 ± 0.18 [0.075 ± 0.007] 1.02 [0.040]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0) for all sizes, plus one additional color per size per
Product Dimensions table.
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, SCL 1/4-0).
***Europe only.For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
SCT
Applications
Specially designed to
insulate and seal
automotive wiresplices
and components in an
under-the-hood automotive
environment. Specially
formulated to function at
an extended temperature
range.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 135°C [266°F]
Series Raychem
SCT SCT SCD
Flame-Retardant,
Adhesive-Lined, Semirigid
Polyolefin Tubing (Extended
Temperature Range)
Product Facts
n4:1 shrink ratio allows a few
sizes to cover a wide range
of splice and component
diameters
nFlame-retardant and
mechanically tough, the
tubing provides strain relief
and abrasion protection of
wire splices, terminals, and
other components
nThick adhesive liner forms
an effective barrier against
fluids and moisture and
performs well at an
extended temperature range
Specifications/Approvals
Operating Temperature Range
-40°Cto 150°C
[-40°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-50 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SCT (Continued)
Inside Diameter Recovered Wall Thickness*
Part Minimum Maximum Total Wall Meltable Wall
Number Expanded Recovered After Heating After Heating
asSupplied After Heating (Nominal)
SCT No. 1 7.6 [0.300] 1.7 [0.065] 1.52 ± 0.30 [0.060 ± 0 .012] 0.76 [0.030]
SCT No. 2 9.0 [0.355] 2.3 [0.090] 1.52 ± 0.30 [0.060 ± 0 .012] 0.76 [0.030]
SCT No. 3 11.6 [0.455] 2.5 [0.100] 2.29 ± 0.30 [0.090 ± 0.012] 1.40 [0.055]
SCT No. 4 17.8 [0.700] 4.4 [0.175] 2.54 ± 0.30 [0.100 ± 0.012] 1.52 [0.060]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Black
Size selection Always order the largest size that will shrink snugly over the component being covered.
Special order sizes are available upon request.
Standard packaging Cut pieces.
Marking Tubing will be printed with its numbered size (such as SCT-1, SCT-2, SCT-3, SCT-4).
Ordering description Specify product name, numbered size, color and cut length
(for example, SCT-NO.3-0-75MM).
Product Dimensions
Ordering Information
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
TAT-125
Applications
Seals and protects simple
in-line splices, bimetallic
joints, and components
from fluids, moisture, and
corrosion. Repairs
damaged wire insulation,
especially whereflexibility
is required. Provides one-
step electrical insulation
and moisture sealing.
Installation
Minimum shrink
temperature: 95°C [203°F]
Minimum full recovery
temperature: 121°C [250°F]
Series UL MilitaryRaychem
TAT-125 Type 1 (colors) E85381 AMS-DTL-23053/4*, Class 2 TAT-125 SCD
600 V, 125°C
TAT-125 Type 2 (clear) — — TAT-125 SCD
*Formerly MIL-I-23053/4 and MIL-DTL-23053/4. Sizes 1/4" through 1 1/2" only.
Adhesive-Lined,
Flexible,
Polyolefin Tubing
Product Facts
n2:1 shrink ratio
nThin adhesive lining that
bonds to outer tubing and
surface below, forming a
positive environmental seal
nFlexibility of both tubing and
adhesive
nMoisture seal that is
resistant to bending of the
substrate
nGood mechanical strength
and cut-through resistance
nAdhesive that bonds to a
wide variety of plastics,
rubbers, and metals,
including polyethylene,
neoprene, lead, and steel
Specifications/Approvals
Operating Temperature Range
-55°Cto 110°C
[-67°F to 230°F]
Available in: Americas Europe Asia Pacific
nn
Dual Wall Tubing (Adhesive & Encapsulant-Lined)
3-52 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
TAT-125 (Continued)
Inside Diameter Recovered Wall Thickness**
Minimum Maximum Total Wall Adhesive Wall
Size Expanded Recovered After Heating After Heating
asSupplied After Heating (Nominal) (Nominal)
1/8 3.2 [0.125] 1.6 [0.062] 0.69 [0.027] 0.23 [0.009]
3/16 4.8 [0.187] 2.4 [0.093] 0.71 [0.028] 0.25 [0.010]
1/4 6.4 [0.250] 3.2 [0.125] 0.74 [0.029] 0.13 [0.005]
3/8 9.5 [0.375] 4.8 [0.187] 0.74 [0.029] 0.13 [0.005]
1/2 12.7 [0.500] 6.4 [0.250] 0.76 [0.030] 0.15 [0.006]
3/4 19.1 [0.750] 9.5 [0.375] 0.89 [0.035] 0.15 [0.006]
1 25.4 [1.000] 12.7 [0.500] 1.07 [0.042] 0.20 [0.008]
11/2 38.1 [1.500] 19.1 [0.750] 1.19 [0.047] 0.28 [0.011]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5), brown (-1),
orange (-3), violet (-7), gray (-8), clear (-X , not flame-retardant)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description Specify product name, size and color (for example, TAT-125 1/4-0).
Product Dimensions
Ordering Information
Heat-Shrinkable Tubing
3
Heavy-Duty Tubing
3-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
BSTS/BSTS-FR
Applications
BSTS heat-shrinkable
tubing is made of a
rugged polymer that
resists moisture, fungus,
and weathering. It also has
excellent electrical
properties. This tubing is
useful in applications
whereinsulation, abrasion
resistance, and strain relief
areimportant. When used
with SFTS tape sealant, it
can provide a watertight
system in nonpressurized
applications.
Installation
Minimum shrink
temperature: 90°C [194°F]
Minimum full recovery
temperature: 121°C [250°F]
Series Military Industry Raychem
BSTS — — RW-2017
BSTS-FR AMS-DTL-23053/15*, ASTM D 685, nonburning RW-2017
Class 1 and Class 2** ASTM D 2863, oxygen index
IPCEA S-19-81, cable insulation and jackets
*Formerly MIL-I-23053/15 and MIL-DTL-23053/15.
**Except for coatings requirement. Refer to SST-FR when coating is required.
General Purpose,
Heat-Shrinkable Tubing
Product Facts
nExcellent thick-wall
insulation and abrasion
protection
nNo adhesive – can be
removed easily
nExpansion ratios as high as
3:1
nAvailability in flame-
retardant material with FR
callout (see “Ordering
information and Part
numbering system” on the
next page)
nBSTS has the following
agency approvals:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s (Lloyd’s Register of
Shipping)
Specifications/Approvals
Operating Temperature Range
-55°Cto 90°C
[-67°F to 194°F]
Available in: Americas Europe Asia Pacific
nnn
Heavy-Duty Tubing
3-54 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
BSTS/BSTS-FR (Continued)
Inside Diameter Wall Thickness (Nominal)
Minimum Maximum
Size Expanded recovered Expanded Recovered
asSupplied After Heating as Supplied After Heating****
BSTS-03 7.62 [0.300] 2.54 [0.100] 0.63 [0.025] 1.52 [0.060]
BSTS-04 10.16 [0.400] 3.81 [0.150] 0.63 [0.025] 1.52 [0.060]
BSTS-07M*** 19.05 [0.750] 5.59 [0.220] 0.51 [0.020] 1.52 [0.060]
BSTS-07 19.05 [0.750] 5.59 [0.220] 0.76 [0.030] 2.41 [0.095]
BSTS-11M 27.94 [1.100] 9.52 [0.375] 0.76 [0.030] 2.67 [0.110]
BSTS-11 27.94 [1.100] 9.52 [0.375] 1.02 [0.040] 3.05 [0.120]
BSTS-13M 33.02 [1.300] 9.52 [0.375] 0.63 [0.025] 2.67 [0.110]
BSTS-13 33.02 [1.300] 9.52 [0.375] 0.89 [0.035] 3.05 [0.120]
BSTS-15M 38.10 [1.500] 12.70 [0.500] 0.89 [0.035] 3.05 [0.120]
BSTS-15 38.10 [1.500] 12.70 [0.500] 1.27 [0.050] 3.56 [0.140]
BSTS-17M 43.18 [1.700] 12.70 [0.500] 1.02 [0.040] 3.05 [0.120]
BSTS-17 43.18 [1.700] 12.70 [0.500] 1.14 [0.045] 3.56 [0.140]
BSTS-20M 50.80 [2.000] 19.05 [0.750] 1.27 [0.050] 3.05 [0.120]
BSTS-20 50.80 [2.000] 19.05 [0.750] 1.27 [0.050] 3.94 [0.160]
BSTS-27 65.58 [2.700] 22.86 [0.900] 1.27 [0.050] 3.94 [0.160]
BSTS-30 76.20 [3.000] 31.75 [1.250] 1.27 [0.050] 3.94 [0.160]
BSTS-35 88.90 [3.500] 31.75 [1.250] 1.27 [0.050] 3.94 [0.160]
BSTS-40 101.60 [4.000] 44.45 [1.750] 1.27 [0.050] 3.94 [0.160]
BSTS-45 114.30 [4.500] 44.45 [1.750] 1.27 [0.050] 3.94 [0.160]
***M = Medium wall tubing. ****Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard Red (-2), white (-9), clear (-X not flame-retardant)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths.
Ordering description See below.
Product Dimensions
Ordering Information
Part Numbering System
“NM” - no mark
Color
Black / leave blank (standard)
White / WHT
Red / RED
Clear / CL
“FR” - flame-retardant
Length in feet (4 and 25 feet standard)
“M” medium wall
Size
Family
BSTS - _ _ x _ _ / _ / _
Example: BSTS-11MX4/NM
Heat-Shrinkable Tubing
3
Heavy-Duty Tubing
3-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HF
Applications
Developed for cable
jacketing applications
wherecable flexibility is
important, high-flex (HF)
tubing is ideal for jacketing
cables where sharp bends
or turns are required. Also
ideal for situations where
the cable is subject to
motion. Such situations are
common for industrial
machinery, transportation
equipment, robotics,
welding, and many other
cabling applications. To
complete the cable jacket
seal, the ends may be
sealed for further water and
corrosion protection by
using available tape
sealant or adhesive.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 121°C [250°F]
Series Military Raychem
HF AMS-DTL-23053/15* Class 1** RW-2023
*Formerly MIL-I-23053/15 and MIL-DTL-23053/15.
**Except for coatings requirement.
High-Flex, Heavy-Wall,
Heat-Shrinkable Tubing
Product Facts
nOffers high flexibility
nProvides excellent insulation
and abrasion-protection, per
U.S. Mine Safety and Health
Administration (MSHA)
regulations
nFlame-retardant
nHF has the following agency
approvals:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s (Lloyd’s Register of
Shipping)
Specifications/Approvals
Operating Temperature Range
-55°Cto 90°C
[-67°F to 194°F]
Available in: Americas Europe Asia Pacific
nnn
Heavy-Duty Tubing
3-56 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HF (Continued)
Inside Diameter Wall Thickness**
Size Standard Minimum Maximum Nominal
Nominal Length Expanded Recovered Recovered
(m/ft) as Supplied After Heating After Heating
HF04 1.2, 7.5 [4, 25] 10.16 [0.40] 3.81 [0.150] 1.52 [0.060]
HF07 1.2, 7.5 [4, 25] 19.05 [0.75] 5.59 [0.220] 1.52 [0.060]
HF11 1.2, 7.5 [4, 25] 27.94 [1.10] 9.52 [0.375] 2.67 [0.105]
HF13 1.2, 7.5 [4, 25] 33.02 [1.30] 9.52 [0.375] 2.67 [0.105]
HF15 1.2, 7.5 [4, 25] 38.10 [1.50] 12.70 [0.500] 3.05 [0.120]
HF17 1.2, 7.5 [4, 25] 43.14 [1.70] 12.70 [0.500] 3.05 [0.120]
HF20 1.2, 7.5 [4, 25] 50.80 [2.00] 19.05 [0.750] 3.56 [0.140]
HF27 1.2, 7.5 [4, 25] 68.58 [2.70] 22.86 [0.900] 3.94 [0.155]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Part Numbering System
“NM” - no mark
Length in feet (4 and 25 feet standard)
“FR” - flame-retardant
Size
Product Name
HF - _ _ X _ / _
Product Dimensions
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths. Nonstandard lengths are available upon
request.
Ordering description See below.
Ordering Information
Example: HF-17FRX25/NM
Heat-Shrinkable Tubing
3
Heavy-Duty Tubing
3-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HRHF/HRNF/HRSR
Applications
High-ratio (HR) heat-
shrinkable tubing, with
expansion ratios as high
as 5.6 to 1, is designed to
accommodate large size
differences between cables
and cable connectors and
backshells, thus simplifying
repair of damaged cable.
High-ratio tubing is
available in semirigid
flame-retardant (SR),
standard (NF), or high-flex
flame-retardant (HF)
material and with or without
factory-applied sealants
and adhesives. The water-
proofing sealant provides
environmental sealing and
is watertight in wet and
corrosive locations per
USCG CGHQ-3774.
The thermoplastic
adhesive coating offers
excellent strain relief and
environmental sealing.
Series Military Agency Raychem
HRSR AMS-DTL-23053/15* ABS, DNV,Lloyd’s RW-2013
HRHF AMS-DTL-23053/15* ABS, DNV, Lloyd’s RW-2013
HRNF — — —
*Formerly MIL-I-23053/15 and MIL-DTL-23053/15.
High-Ratio,
Heat-Shrinkable Tubing
Product Facts
nOffers toughness and
durability
nProvides excellent insulation
and abrasion protection
nIsavailable in flame-
retardant material.
nShrinks to fit (5.6:1)
nFR callouts meet the
flame-retardant material
requirements of
AMS-DTL-23053/15*
nHRHF and HRSR have the
following agency approvals:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s(Lloyd’s Register of
Shipping)
Specifications/Approvals
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 121°C [250°F]
Operating Temperature Range
-55°C to 90°C
[-67°F to 194°F]
Available in: Americas Europe Asia Pacific
nnn
Heavy-Duty Tubing
3-58 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HRHF/HRNF/HRSR(Continued)
Color Standard Black (-0)
Nonstandard Clear (-X) available on request (not flame-retardant)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Other sizes are available upon request.
Standard packaging 10-inch-maximum* lengths.
Ordering description See below.
*Cutting tolerance is ± .125".
Ordering Information
Part Numbering System –
MilitaryApproved Part
Numbers
“NM” - no mark
Coating
Adhesive (/97)
Sealant (/226)
Length in inches (10 inches standard)
“FR” - flame-retardant for SR and HF
Size
Product Name
HRHF - high flex
HRNF - non-flame-retardant
HRSR - semirigid
HRHF - _ _ - _ / _ _
Inside Diameter Recovered Wall Thickness††
Size† Minimum Maximum Nominal
Expanded Recovered After
asSupplied After Heating Heating
HR**060 15.24 [0.60] 3.81 [0.150] 1.52 [0.060]
HR**125 31.75 [1.25] 5.59 [0.220] 1.52 [0.060]
HR**175 44.45 [1.75] 8.00 [0.315] 2.41 [0.095]
HR**200 50.80 [2.00] 9.52 [0.375] 2.67 [0.105]
HR**250 63.50 [2.50] 12.70 [0.500] 3.05 [0.120]
HR**300 76.20 [3.00] 19.05 [0.750] 3.05 [0.120]
HR**400 101.60 [4.00] 22.86 [0.900] 3.56 [0.140]
†For ** substitute HF, NF or SR for material required. Add FR to end of number for flame-retardant material.
††Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Example: HRHF-125FR-10/226-NM
Heavy-Duty Tubing
RHW
3-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Rugged, heavy wall RHW
tubing is specifically
designed for insulating,
protecting and sealing
electrical connections and
joints in low-voltage cables.
It provides splice insulation
thickness equal to or
greater than standard wire
insulation manufactured to
common industrystandards.
RHW is the ideal choice
for applications where
maximum reliability and
product performance, and
simplified installation are
required. Because RHW is
heat-shrinkable, a minimum
number of sizes are
needed to cover a wide
range of cables and splice
diameters.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 125°C [257°F]
Rugged, Heavy Wall,
Adhesive-Lined, Polyolefin
Heat-Shrinkable Tubing
Product Facts
nWithstands mechanical
abuse for increased product
reliability
nHighly resistant to impact
and abrasion
nProvides high level of strain
relief when installed on
splices and joints
nResistant to chemicals,
moisture and oils
nProvides a complete
moisture-proof seal
preventing corrosion of
underlying components
Operating Temperature Range
-55°Cto 110°C
[-67°F to 230°F]
Series UL** Raychem
RHW File E115664 RHW SCD
**Sizes 9/3 through 70/21 only.
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nnn
Heavy-Duty Tubing
RHW (Continued)
3-60 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0) is available in all sizes
Red (-2) is available in sizes 9/3, 13/4, 20/6 and 33/8
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging 1200mm lengths
Marking Tubing will be marked with the product name, size and batch number.
Sizes 9/3 through 70/21 will also be marked with the UL Logo
Ordering description Specify product name, size, cut length, coating option and color (for example,
RHW 20/6-1200/ADH-0 (ADH = Adhesive-lined, 0= Black, 2 = Red)
Ordering Information
Product Dimensions Inside Diameter Recovered Wall Thickness**
Size Minimum Recovered Nominal Nominal
Expanded After Jacket Adhesive
asSupplied Heating Wall Wall
9/3 9 [0.354] 3 [0.118] 2.0 [0.079] 0.25 [0.010]
13/4 13 [0.512] 4 [0.158] 2.4 [0.094] 0.30 [0.012]
20/6 20 [0.787] 6 [0.236] 2.5 [0.098] 0.35 [0.014]
33/8 33 [1.299] 8 [0.315] 3.2 [0.126] 0.35 [0.014]
43/12 43 [1.693] 12 [0.472] 4.3 [0.169] 0.40 [0.016]
51/16 51 [2.008] 16 [0.630] 4.5 [0.177] 0.40 [0.016]
70/21 70 [2.756] 21 [0.827] 4.4 [0.173] 0.40 [0.016]
85/25 85 [3.346] 25 [0.984] 4.3 [0.169] 0.40 [0.016]
105/30 105 [4.134] 30 [1.181] 4.3 [0.169] 0.45 [0.018]
130/36 130 [5.118] 36 [1.417] 4.3 [0.169] 0.45 [0.018]
160/50 160 [6.299] 50 [1.968] 4.3 [0.169] 0.45 [0.018]
180/50 180 [7.087] 50 [1.968] 4.3 [0.169] 0.50 [0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Heavy-Duty Tubing
RMW
3-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Medium wall, general
purpose RMW tubing is
specifically designed for
use in a broad range of
low-voltage applications.
RMW is tough and flexible,
making it particularly suited
for the insulation and
protection of cable joints
as well as for cable repair.
Uncoated RMW provides
insulation and strain relief.
Adhesive-lined RMW also
provides an environmental
seal.
RMW is the ideal choice
for applications where
maximum reliability and
product performance, and
simplified installation are
required. Because RMW is
heat-shrinkable, a minimum
number of sizes are needed
to cover a wide range
of cables and splice
diameters.
Medium Wall, Polyolefin
Heat-Shrinkable Tubing
Product Facts
nWithstands mechanical
abuse for increased product
reliability
nHighly resistant to impact
and abrasion
nInstallation is fast and easy
nResistant to chemicals and
moisture
nAdhesive-lined version
provides a complete
moisture-proof seal
preventing corrosion of
underlying components
Operating Temperature Range
-55°C to 110°C
[-67°F to 230°F]
Series Raychem
RMW RMW SCD
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nnn
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 125°C [257°F]
Heavy-Duty Tubing
RMW (Continued)
3-62 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging 1200mm lengths
Marking Tubing will be marked with the product name, size and batch number.
Ordering description Specify product name, size, cut length, coating option and color (for example, RMW 25/8-
1200/ADH-0 or RMW 75/22-1200/U-0 (ADH = Adhesive-lined, U = Uncoated, 0= Black)
Ordering Information
Product Dimensions Inside Diameter Recovered Wall Thickness**
Size Minimum Recovered Nominal Nominal
Expanded After Jacket Adhesive
asSupplied Heating Wall Wall
10/3 10 [0.394] 3 [0.118] 1.0 [0.039] 0.25 [0.010]
16/5 16 [0.630] 5 [0.197] 1.4 [0.055] 0.30 [0.012]
25/8 25 [0.984] 8 [0.315] 2.0 [0.079] 0.35 [0.014]
35/12 35 [1.378] 12 [0.472] 2.0 [0.079] 0.35 [0.014]
50/16 50 [1.968] 16 [0.630] 2.0 [0.079] 0.35 [0.014]
63/19 63 [2.480] 19 [0.748] 2.4 [0.095] 0.40 [0.016]
75/22 75 [2.953] 22 [0.866] 2.7 [0.106] 0.40 [0.016]
85/25 85 [3.346] 25 [0.984] 2.8 [0.110] 0.40 [0.016]
95/29 95 [3.740] 29 [1.142] 3.1 [0.122] 0.45 [0.018]
115/34 115 [4.527] 34 [1.339] 3.1 [0.122] 0.45 [0.018]
140/42 140 [5.512] 42 [1.654] 3.1 [0.122] 0.45 [0.018]
160/50 160 [6.299] 50 [1.968] 3.2 [0.126] 0.50 [0.020]
180/60 180 [7.087] 60 [2.362] 3.2 [0.126] 0.50 [0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Heat-Shrinkable Tubing
3
Heavy-Duty Tubing
3-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SST/SST-FR
Applications
SST provides a simple,
positive splice-sealing
method that offers
protection under adverse
environmental conditions.
Tubing supplied with
standardsealant provides
water sealing and environ-
mental protection in wet or
underground applications.
The thermoplastic adhesive
not only seals, but also
provides mechanical strain
relief. The polymer tubing
has excellent insulating,
abrasion-resistance, and
strain-relief properties.
Installation
Minimum shrink
temperature: 90°C [195°F]
Minimum full recovery
temperature: 121°C [250°F]
Series Military Industry Raychem
SST ——RW- 2011
SST-FR AMS-DTL-23053/15*, ASTM D 685, nonburning RW -2011
Classes 1 and 2 ASTM D 2863, oxygen index
IPCEA S-19-81, cable insulation and jackets
IEEE-383 Section 2.5 massive flame vertical tray
ABS, DNV, Lloyd’s Register
*Formerly MIL-I-23053/I5 and MIL-DTL-23053/15.
Self-Sealing,
Heat-Shrinkable Tubing
Product Facts
nThick adhesive liner forms
aneffective barrier against
fluids and moisture
nThick-wall insulation,
strain relief and abrasion
protection
nNo need for greases, tape,
or epoxy
nExpansion ratios as high as
3:1
nAvailable in flame-retardant
material
nSST has the following
agency approvals:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s (Lloyd’s Register of
Shipping)
Specifications/Approvals
Operating Temperature Range
-55°Cto 90°C
[-67°F to 194°F]
Available in: Americas Europe Asia Pacific
nnn
Heavy-Duty Tubing
3-64 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SST/SST-FR (Continued)
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging See Product Dimensions table.
Ordering description Specify product name, cut length, size and color (for example, SST 48-07/FR/RS).
Inside Diameter Wall Thickness Recommended
Size† Standard Minimum Maximum Nominal Wall Cable
Nominal Expanded Recovered Expanded After Range for
Length asSupplied After Heating Heating†† 600-Volt Cable
SST*-03 6, 30 0.300 0.100 0.025 0.060 18 through 14 AWG
SST*-04 6, 30 0.400 0.150 0.025 0.060 14 through 10 AWG
SST*-07M 6, 9, 12, 48 0.750 0.220 0.020 0.060 8 through 1 AWG
SST*-07 6, 9, 12, 48 0.750 0.220 0.030 0.095 8 through 1 AWG
SST*-11M 6, 9, 12, 48 1.100 0.375 0.030 0.105 2 through 4/0 AWG
SST*-11 6, 9, 12, 48 1.100 0.375 0.040 0.120 2 through 4/0 AWG
SST*-13M 6, 9, 12, 48 1.300 0.375 0.025 0.105 2 through 4/0 AWG
SST*-13 6, 9, 12, 48 1.300 0.375 0.035 0.120 2 through 4/0 AWG
SST*-15M 6, 9, 12, 48 1.500 0.500 0.035 0.120 2/0 AWG through 500 MCM
SST*-15 6, 9, 12, 48 1.500 0.500 0.050 0.140 2/0 AWG through 500 MCM
SST*-17M 6, 9, 12, 48 1.700 0.500 0.030 0.120 2/0 AWG through 500 MCM
SST*-17 6, 9, 12, 48 1.700 0.500 0.045 0.140 2/0 AWG through 500 MCM
SST*-20M 6, 9, 12, 48 2.000 0.750 0.040 0.120 350 MCM through 1000 MCM
SST*-20 6, 9, 12, 48 2.000 0.750 0.050 0.155 350 MCM through 1000 MCM
SST*-27 12, 18, 24, 48 2.700 0.900 0.050 0.155 500 MCM through 1250 MCM
SST*-30 12, 18, 24, 48 3.000 1.250 0.050 0.155 900 MCM through 1500 MCM
SST*-40 12, 18, 24, 48 4.000 1.750 0.050 0.155 1500 MCM through 2500 MCM
SST*-45 12, 18, 24, 48 4.500 1.750 0.050 0.155 1500 MCM through 2500 MCM
†In place of asterisk* substitute length of tubing to be ordered. For example, SST*-11, as the third column indicates, comes in
6-, 9-,12- and 48-inch lengths, so a 9-inch cut piece of SST tubing would be SST 9-11.
The suffix M = medium-wall tubing. ††Wall thickness will be less if tubing recovery is restricted during shrinkage.
Part Numbering System
“NM” - no mark
Color
Black/leave blank (standard)
White/WHT
Red/RED
Clear/CL
Adhesive/sealant
/97 standard with FR /226 standard with NF
“FR” - flame-retardant
“M” - medium wall
Size in inches (48 inch max.)
Length in inches
Family
SST - _ - _ _ / _ / _ / _ / _
Product Dimensions
(inches)
Ordering Information
Example: SST-48-07M/FR/97/NM
3-65
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
DR-25
Applications
Specially formulated for
optimum high temperature
fluid resistance, and long
termheat resistance.
Resistant to aviation and
diesel fuels, hydraulic fluids
and lubricating oils.
Particularly suitable as a
jacketing material for
military ground vehicle
cables and harnesses. It is
also ideally suited for the
demands of motorsport
cable harnesses. When
used in conjunction with
System 25 heat-shrinkable
molded shapes and S1125
high performance adhesive,
these products provide a
complete cable harness
system.
Installation
Minimum shrink
temperature: 150°C [302°F]
Minimum full recovery
temperature: 175°C [347°F]
Series MilitaryRaychem
DR-25 AMS-DTL-23053/16* RT-1116
VG95343 Part 5 Type D RK-6008/1
VDE 0341/Pt 9005
Def Stan 59-97 Issue 3 Type 6B
BS 4G-198 Part 3 10A
*Formerly MIL-I-23053/16 and MIL-DTL-23053/16.
Heat-Shrinkable, Flexible,
Chemical and Abrasion
Resistant Tubing
Product Facts
nFlame-retardant
nSystem 25 tubing
nShrink ratio 2:1
Specifications/Approvals
Operating Temperature Range
-75°Cto 150°C
[-103°F to 302°F]
(per VG 95343 Part 5
Type D)
Available in: Americas Europe Asia Pacific
nnn
3-66
Special Purpose Tubing
DR-25 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered
Size Minimum Expanded Maximum Recovered Wall Thickness**
asSupplied After Heating After Heating
1/8 3.2 [0.125] 1.6 [0.062] 0.76 ± 0.15 [0.030 ± 0.006]
3/16 4.8 [0.187] 2.4 [0.093] 0.84 ± 0.15 [0.033 ± 0.006]
1/4 6.4 [0.250] 3.2 [0.125] 0.89 ± 0.15 [0.035 ± 0.006]
3/8 9.5 [0.375] 4.8 [0.187] 1.02 ± 0.20 [0.040 ± 0.008]
1/2 12.7 [0.500] 6.4 [0.250] 1.22 ± 0.20 [0.048 ± 0.008]
3/4 19.0 [0.748] 9.5 [0.375] 1.45 ± 0.28 [0.057 ± 0.011]
1 25.4 [1.000] 12.7 [0.500] 1.78 ± 0.28 [0.070 ± 0.011]
11/2 38.0 [1.500] 19.0 [0.748] 2.41 ± 0.41 [0.095 ± 0.016]
2 51.0 [2.000] 25.4 [1.000] 2.79 ± 0.41 [0.110 ± 0.016]
3 76.0 [3.000] 38.0 [1.500] 3.18 ± 0.50 [0.125 ± 0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description*** Specify product name, size and color (for example, DR-25 1/8-0)
***Europe only. For supply to Def Stan and BS add -DS or -BS to ordering description.
Product Dimensions
Ordering Information
3-67
Special Purpose Tubing
ES Caps
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Specially designed to
provide mechanical and
environmental protection of
stub splices in electrical
harnesses. Clear caps allow
see-through inspection;
black caps areflame-
retardant.
Installation
Minimum shrink
temperature: 100°C [212°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL Raychem
ES Caps E85381 RW-3006
600 V,125°C
High-Shrink-Ratio,
Adhesive-Lined, Semirigid
Polyolefin Caps
Product Facts
n4:1 shrink ratio allows a few
sizes to cover a wide range
of splice and component
diameters
nMechanically tough jacket
provides strain relief and
abrasion protection
nThick adhesive liner forms
an effective barrier against
fluids and moisture and
performs well at an
extended temperature range
Specifications/Approvals
Operating Temperature Range
-40°Cto 105°C
[-40°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-68
Special Purpose Tubing
ES Caps (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter (Including Core) Recovered Wall Thickness**
Part Standard Minimum Maximum Minimum Minimum Minimum
Number Length* as Supplied Expanded Recovered Total Wall Jacket Wall Adhesive Wall
(Millimeters) as supplied After Heating After Heating After Heating After Heating
ESCap-No.1 30, 35 5.72 [0.225] 1.27 [0.050] 1.20 [0.047] 0.64 [0.025] 0.56 [0.022]
ES Cap-No.2 30, 35 7.44 [0.293] 1.65 [0.065] 1.52 [0.060] 0.76 [0.030] 0.76 [0.030]
ES Cap-No.3 40, 50 10.85 [0.427] 2.41 [0.095] 1.91 [0.075] 0.89 [0.035] 1.02 [0.040]
*Other cap lengths available upon request.
**Wall thickness will be less if cap recovery is restricted during shrinkage.
Color Standard Black (-0), clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Other cap lengths available on request.
Standard packaging In pieces.
Marking Caps will be marked with their numbered size (such as ES-1, ES-2, or ES-3).
Ordering description Specify product name, size, color, and length (for example, ES CAP-NO.2-X-35MM).
Product Dimensions
Ordering Information
3-69
Special Purpose Tubing
HCTE
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Used as a conduit to
provide mechanical
protection for electrical
wiring systems in
applications requiring
flexibility, high-temperature
performance and good
resistance to a variety of
fluids. Widely used in the
military and commercial
aerospace industries.
Can be used in conjunction
with other Raychem
components to form an
integrated harnessing
system.
Installation
It is recommended that
no more than 70% of the
internal area (“fill factor”)
of the HCTE conduit be
occupied by wires in any
application.
Series Military Raychem
HCTE VG 96936 Part 6 RT-1162
Helical Convolex Tubing
with a High Crush
Resistance
Product Facts
nHighly flame-retardant
nHighly flexible and fluid
resistant
nNot heat-shrinkable
nHigh crush resistance
nSystem 300 conduit tubing
Specifications/Approvals
Operating Temperature Range
-55°Cto 200°C
[-67°F to 392°F]
Available in: Americas Europe Asia Pacific
nnn
3-70
Special Purpose Tubing
HCTE (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Outside Diameter Maximum
Size Minimum Maximum Wall Thickness
0187 4.60 [0.181] 8.10 [0.320] 0.46 [0.018]
0281 6.90 [0.273] 10.50 [0.414] 0.46 [0.018]
0312 7.70 [0.306] 11.80 [0.450] 0.46 [0.018]
0375 9.20 [0.364] 12.90 [0.510] 0.46 [0.018]
0437 10.80 [0.427] 14.50 [0.571] 0.46 [0.018]
0500 12.30 [0.485] 16.50 [0.650] 0.58 [0.023]
0625 15.40 [0.608] 19.50 [0.770] 0.58 [0.023]
0750 17.90 [0.730] 23.60 [0.930] 0.58 [0.023]
0875 21.80 [0.860] 27.20 [1.073] 0.58 [0.023]
1000 24.70 [0.975] 31.10 [1.226] 0.58 [0.023]
1250 30.70 [1.210] 35.30 [1.539] 0.58 [0.023]
1500 36.50 [1.437] 46.50 [1.832] 0.58 [0.023]
1625 39.60 [1.562] 50.17 [1.975] 0.58 [0.023]
1750 42.67 [1.688] 52.88 [2.082] 0.58 [0.023]
2000 49.20 [1.937] 59.23 [2.332] 0.58 [0.023]
Color Standard Black (-0)
Size selection Always order a conduit size that will ensure that a “fill factor” of 70% is not exceeded.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, HCTE-0187-0).
Product Dimensions
Ordering Information
3-71
Special Purpose Tubing
HFT5000
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Designed primarily to
provide mechanical
abrasion protection for
components such as rubber
hoses, plastic pipes, and
harness wiring bundles.
Also suitable for other
applications, such as noise
and rattle suppression.
The woven construction
makes HFT5000 extremely
flexible and resistant to
trapping water,heat and
humidity. Provides
outstanding abrasion,
chafing and cutting
protection, even at high
temperatures.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 110°C [230°F]
Maximum storage
temperature: 60°C [140°F]
Series UL Raychem
HFT5000 E199379 RW-2060
Rated 135˚C
Heat-Shrinkable
Fabric Tubing
Product Facts
nHighly flexible woven fabric
tubing
nPolyethylene/polyester
construction for excellent
abrasion resistance
nHalogen free
nHeat-shrinkable to grip
substrates tightly without
additional fixing
n2:1 shrink ratio for easy
installation onto different
substrate diameters and
sizes
nHighly flexible woven fabric
construction for easy,
compliant installation onto
awkward substrates such as
bent hoses
nOutstanding abrasion
resistance over a wide
temperature range
nEasily cut with standard
industrial cutting equipment
nResistant to harsh
environments
nMultifilament construction
that ensures soft, safe
handling
nLow shrink temperature for
safe installation onto heat
sensitive substrates
Specifications/Approvals
Operating Temperature Range
3000 hours:
-40°C to 125°C
[-40°Fto 257°F]
1000 hours:
-40°Cto 150°C
[-40°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
3-72
Special Purpose Tubing
HFT5000 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter
Size Minimum Expanded Maximum Recovered
asSupplied After Heating
Standard
12/6 12[0.47] 6 [0.24]
20/10 20 [0.79] 10 [0.39]
30/15 30 [1.18] 15 [0.59]
40/20 40 [1.57] 20 [0.79]
50/25 50 [1.97] 25 [0.98]
60/30 60 [2.36] 30 [1.18]
70/35 70 [2.76] 35[1.38]
Nonstandard High Volume
25/12 25 [0.98] 12 [0.47]
34/17 34 [1.34] 17 [0.67]
80/40 80 [3.15] 40 [1.57]
Color Standard Black (-0)
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, HFT5000-12/6-0)
Product Dimensions
Ordering Information
3-73
Special Purpose Tubing
MicroFit
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Installation
Minimum full recovery
temperature:
175°C[347°F] (MT1000)
140°C[284°F] (MT2000)
175°C [347°F] (RW-175)
Applications
The MicroFit family of small-
diameter, high-shrink-ratio
tubing is ideal for electrical
insulation, mechanical
protection, and strain relief
in smaller, more compact
medical devices and
commercial electronics
products. Offered in a
variety of materials. The
RW-175 version of MicroFit
tubing is suitable for use in
space applications.
Series Material Master File Number Raychem
Altera MicroFit USP Class VI (MT1000) MAF-444 (MT1000) Altera MicroFit SCD
USP Class VI (MT2000) MAF-727 (MT2000)
RW-175 MicroFit ——RW-175 MicroFit SCD
Small-Diameter,
High-Shrink-Ratio Tubing
Product Facts
nSmall diameter
nHigh shrink ratio
nThin wall
nPolyolefin and
fluoropolymer materials
Specifications/Approvals
Operating Temperature Range
MT1000:-55°C to 175°C
[-67°F to 347°F]
MT2000:-40°Cto 105°C
[-40°F to 221°F]
RW-175:-55°Cto 175°C
[-67°F to 347°F]
Available in: Americas Europe Asia Pacific
nnn
3-74
Special Purpose Tubing
MicroFit (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Wall Thickness
Size Minimum Maximum
Expanded Recovered AsSupplied Recovered***
asSupplied After Heating (Nominal) (Maximum)
MFT-*-No. 1-** 0.356 [0.014] 0.178 [0.007] 0.076 [0.003] 0.127 [0.005]
MFT-*-No. 2-** 0.610 [0.024] 0.305 [0.012] 0.064 [0.0025] 0.152 [0.006]
MFT-*-No. 33-** 1.143 [0.045] 0.432 [0.017] 0.064 [0.0025] 0.178 [0.007]
MFT-*-No. 65-** 0.635 [0.025] 0.254 [0.010] 0.127 [0.005] 0.330 [0.013]
*Replace single asterisk with material type: MT1000, MT2000, or RW-175.
**Replace double asterisk with color-code number.
***Wall thickness will be less if tubing recovery is restricted during shrinkage.
MT1000 MT2000 RW-175
Color Standard Translucent (-X) Black (-0), clear (-X) Translucent (-X)
Nonstandard Black (-0) White (-9), red (-2), yellow (-4), Black (-0)
blue (-6), orange (-3)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging On plastic spools****
Ordering description Specify product name, material, size and color (for example, MFT-MT2000-NO.1-0).
****MFT-MT1000 and MFT-MT2000 are double bagged.
Product Dimensions
Ordering Information
3-75
Special Purpose Tubing
MT1000
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Ideal for electrical insulation
and strain relief of
components that are
exposed to high
temperatures - either
during operation or during
sterilization.
Thin-wall construction is
well suited for applications
with clearance constraints.
Installation
Minimum shrink
temperature: 155°C [311°F}
Minimum full recovery
temperature: 175°C [347°F]
Series Material Master File Number Raychem
MT1000 USP Class VI MAF-444 MT1000 SCD
MT1000A USP Class VI MAF-798 MT1000A SCD
Altera Medical-Grade,
USP Class VI,
High-Temperature,
Semirigid,
Fluoropolymer Tubing
Product Facts
n2:1 shrink ratio
nTough, semirigid,
very-thin-wall insulation
nExcellent resistance to a
variety of fluids
nOptional inner adhesive
lining in sizes 1/8" and
larger (MT1000A)
nUSP Class VI material,
no heavy metals
nDouble-bagged packaging
nCompatibility with gamma,
ETO, steam, and dry-heat
sterilization
Specifications/Approvals
Operating Temperature Range
-55°Cto 175°C
[-67°F to 347°F]
Available in: Americas Europe Asia Pacific
nnn
3-76
Special Purpose Tubing
MT1000 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Translucent (-X)
Nonstandard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter (4-foot) lengths, double bagged.
Ordering description Specify product name, size and color (for example, MT1000-1/8-X).
Specify MT1000A for adhesive-lined constructions (special order).
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64** 1.17 [0.046] 0.58 [0.023] 0.25 ± 0.05 [0.010 ± 0.002]
1/16 1.6 [0.063] 0.8 [0.031] 0.25 ± 0.05 [0.010 ± 0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.25 ± 0.05 [0.010 ± 0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.25 ± 0.05 [0.010 ± 0.002]
3/16 4.7 [0.187] 2.4 [0.093] 0.25 ± 0.05 [0.010 ± 0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.33 ± 0.05 [0.013 ± 0.002]
3/8 9.5 [0.375] 4.7 [0.187] 0.33 ± 0.05 [0.013 ± 0.002]
1/2 12.7 [0.500] 6.4 [0.250] 0.33 ± 0.05 [0.013 ± 0.002]
3/4** 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ± 0.003]
1** 25.4 [1.000] 12.7 [0.500] 0.48 ± 0.08 [0.019 ± 0.003]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
**Nonstandard size; available by special order only.
Product Dimensions
Ordering Information
3-77
Special Purpose Tubing
MT2000
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Especially suitable for
medical applications
requiring lubricity,flexibility,
and excellent electrical
insulation performance.
Acost-effective alternative
to FEP (fluorinated
ethylene-propylene) while
maintaining performance
after gamma sterilization.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 140°C [284°F]
Series Material Master File Number Raychem
MT2000 USP Class VI MAF-727 MT2000 SCD
MT2000A USP Class VI MAF-799 MT2000A SCD
Altera Medical-Grade,
USP Class VI, Lubricious,
Thin-Wall, Polyolefin
Tubing
Product Facts
n2.5:1 shrink ratio
nLubricity comparable to FEP
nExcellent electrical
insulation properties
nCan be manufactured with
avery thin wall
nOptional inner adhesive
lining in sizes 3.0 and
larger (MT2000A)
nUSP Class VI material,
no heavy metals
nPlastic spools and
double-bagged packaging
nCompatibility with gamma
and ETO sterilization
Specifications/Approvals
Operating Temperature Range
-40°Cto 105°C
[-40°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-78
Special Purpose Tubing
MT2000 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0), clear (-X)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), orange (-3)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On plastic spools, double-bagged.
Ordering description Specify product name, size and color (for example, MT2000-3.0-0).
Specify MT2000A for adhesive-lined constructions (special order).
Inside Diameter Wall Thickness
Size Minimum Maximum
Expanded Recovered AsSupplied Recovered*
asSupplied After Heating (Nominal) After Heating
1.0 1.0 [0.040] 0.45 [0.018] 0.12 [0.005] 0.25 ± 0.05 [0.010 ± 0.002]
2.0 2.0 [0.080] 0.80 [0.032] 0.12 [0.005] 0.25 ± 0.05 [0.010 ± 0.002]
3.0 3.0 [0.120] 1.20 [0.048] 0.12 [0.005] 0.25 ± 0.05 [0.010 ± 0.002]
6.0 6.0 [0.240] 2.40 [0.096] 0.12 [0.005] 0.25 ± 0.05 [0.010 ± 0.002]
10.0 10.0 [0.400] 4.00 [0.160] 0.15 [0.006] 0.36 ± 0.05 [0.014 ± 0.002]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
3-79
Special Purpose Tubing
MT3000
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Used for electrical
insulation and strain
relief of components that
areexposed to high
temperatures - either
during operation or during
sterilization. Exceptional
flexibility and thin-wall
construction are well-suited
for applications where
pliancy coupled with
small overall bundle size
is desired.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 150°C [302°F]
Series Material Master File Number Raychem
MT3000 USP Class VI MAF-472 MT3000 SCD
Altera Medical-Grade,
USP Class VI,
High-Temperature,
Flexible, Fluoropolymer
Tubing
Product Facts
n2:1 shrink ratio
nTough, flexible,
very-thin-wall insulation
nExcellent resistance to a
variety of fluids
nUSP Class VI material,
no heavy metals
nPlastic spools and
double-bagged packaging
nCompatibility with steam
(limited cycles), gamma,
ETO, and dry-heat
sterilization
Specifications/Approvals
Operating Temperature Range
-55°Cto 150°C
[-67°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
3-80
Special Purpose Tubing
MT3000 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
3/64** 1.17 [0.046] 0.58 [0.023] 0.25 ± 0.05 [0.010 ± 0.002]
1/16 1.6 [0.063] 0.8 [0.031] 0.25 ± 0.05 [0.010 ± 0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.25 ± 0.05 [0.010 ± 0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.25 ± 0.05 [0.010 ±0.002]
3/16 4.7 [0.187] 2.4 [0.093] 0.25 ± 0.05 [0.010 ± 0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.30 ± 0.05 [0.012 ± 0.002]
3/8 9.5 [0.375] 4.7 [0.187] 0.30 ± 0.05 [0.012 ±0.002]
1/2 12.7 [0.500] 6.4 [0.250] 0.30 ± 0.05 [0.012 ± 0.002]
3/4** 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ±0.003]
1** 25.4 [1.000] 12.7 [0.500] 0.48 ± 0.08 [0.019 ± 0.003]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
**Nonstandard size; available by special order only.
Color Standard Black (-0)
Nonstandard White (-9)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On plastic spools, double-bagged.
Ordering description Specify product name, size and color (for example, MT3000 1/4-0).
Product Dimensions
Ordering Information
3-81
Special Purpose Tubing
MT5000
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Especially suitable for
applications requiring
excellent electrical
insulation performance
and resistance to abrasion
and harmful solvents such
as electrosurgical
instruments. Also used for
strain relief, color coding,
and identification of many
medical components and
devices.
Installation
Minimum shrink
temperature: 90°C [194°F]
Minimum full recovery
temperature: 110°C [230°F]
Series Material Master file number Raychem
MT5000 USP Class VI MAF-469 MT5000 SCD
MT5000A USP Class VI MAF-800 MT5000ASCD
Altera Medical-Grade,
USP Class VI, Flexible,
Polyolefin Tubing
Product Facts
n2:1 shrink ratio
nFlexibility; variety of colors
nExcellent electrical
insulation properties
nInner adhesive lining
optional in sizes 1/8" and
larger (MT5000A)
nUSP Class VI material,
no heavy metals
nPlastic spools and
double-bagged packaging
nCompatibility with gamma
and ETO sterilization
Specifications/Approvals
Operating Temperature Range
-70°C to 105°C
[-94°Fto 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-82
Special Purpose Tubing
MT5000 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
3/64** 1.17 [0.046] 0.58 [0.023] 0.40 ± 0.08 [0.016 ± 0.003]
1/16 1.6 [0.063] 0.8 [0.031] 0.43 ± 0.08 [0.017 ± 0.003]
3/32 2.4 [0.093] 1.2 [0.046] 0.51 ± 0.08 [0.020 ± 0.003]
1/8 3.2 [0.125] 1.6 [0.062] 0.51 ± 0.08 [0.020 ± 0.003]
3/16 4.8 [0.187] 2.4 [0.093] 0.51 ± 0.08 [0.020 ± 0.003]
1/4 6.4 [0.250] 3.2 [0.125] 0.64 ± 0.08 [0.025 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.64 ± 0.08 [0.025 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.64 ± 0.08 [0.025 ± 0.003]
3/4** 19.1 [0.750] 9.5 [0.375] 0.76 ± 0.08 [0.030 ± 0.003]
1** 25.4 [1.000] 12.7 [0.500] 0.89 ± 0.12 [0.035 ± 0.005]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
**Nonstandard size; available by special order only.
Color Standard Black (-0), clear (-X), and blue (-6)
Nonstandard White (-9), red (-2), yellow (-4)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On plastic spools, double-bagged.
Ordering description Specify product name, size and color (for example, MT5000-1/4-0).
Specify MT5000A for adhesive-lined constructions (special order).
Product Dimensions
Ordering Information
3-83
Special Purpose Tubing
NT
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Widely used for insulation,
strain relief, and abrasion
protection on cable
harnesses and wire
bundles in the commercial
electronics industries where
a reliable general-purpose
tubing is needed. Suitable
for applications requiring
some exposure to common
fluids and solvents.
Installation
Minimum shrink
temperature: 90°C [194°F]
Minimum full recovery
temperature: 135°C [275°F]
Flexible, General Purpose
Modified Elastomeric
Tubing
Product Facts
nRemains flexible at
temperatures as low as
-55˚C [-67˚F]
nOffers good resistance to
abrasion and physical abuse
while providing the
flexibility and strain relief
needed in general-purpose
harnessing applications
nResistant to most common
fluids and solvents
Series UL CSA Raychem
NT UL E35586 CSA LR31929 RT-510
600V, 90°C 600V, 90°C
Specifications/Approvals
Operating Temperature Range
-55°Cto 90°C
[-67°F to 194°F]
Available in: Americas Europe Asia Pacific
nnn
3-84
Special Purpose Tubing
NT (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
1/8 3.2 [0.125] 1.6 [0.061] 0.69 ± 0.20 [0.027 ± 0.008]
3/16 4.8 [0.187] 2.5 [0.100] 0.84 ± 0.25 [0.033 ± 0.010]
1/4 6.4 [0.250] 3.6 [0.143] 0.89 ± 0.25 [0.035 ± 0.010]
3/8 9.5 [0.375] 5.4 [0.211] 1.01 ± 0.25 [0.040 ± 0.010]
1/2 12.7 [0.500] 7.3 [0.286] 1.21 ± 0.38 [0.048 ± 0.015]
5/8 15.9 [0.625] 9.1 [0.357] 1.32 ± 0.38 [0.052 ± 0.015]
3/4 19.1 [0.750] 10.9 [0.428] 1.44 ± 0.38 [0.057 ± 0.015]
7/8 22.2 [0.875] 12.7 [0.500] 1.65 ± 0.38 [0.065 ± 0.015]
1 25.4 [1.000] 14.5 [0.570] 1.77 ± 0.51 [0.070 ± 0.020]
11/4 31.8 [1.250] 18.1 [0.714] 2.20 ± 0.51 [0.087 ± 0.020]
11/2 38.1 [1.500] 21.8 [0.857] 2.41 ± 0.51 [0.095 ± 0.020]
13/4 44.5 [1.750] 25.4 [1.000] 2.71 ± 0.51 [0.107 ± 0.020]
2 50.8 [2.000] 29.0 [1.140] 2.79 ± 0.51 [0.110 ± 0.020]
3 76.2 [3.000] 43.4 [1.710] 3.17 ± 0.51 [0.125 ± 0.020]
4101.6 [4.000] 57.9 [2.280] 3.55 ± 0.51 [0.140 ± 0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, NT 1/4-0).
Product Dimensions
Ordering Information
Applications
Widely used for insulation,
strain relief and abrasion
protection on cable
harnesses and wire
bundles in the military and
aerospace industries where
a reliable rugged tubing is
needed. Especially suitable
for applications requiring
exposure to common fluids
and solvents.
Installation
Minimum shrink
temperature: 90°C [194°F]
Minimum full recovery
temperature: 135°C [275°F]
Series Military Raychem
NT-MIL AMS-DTL-23053/1*, Classes 1 & 2 RW-3030
*Formerly MIL-I-23053/1 and MIL-DTL-23053/1
Flexible, Rugged,
Modified Elastomeric
Tubing
Product Facts
nRemains flexible at
temperatures as low as
-70°C [-94°F] without
cracking
nWithstands heat shock at
200°C [392°F] without
dripping, flowing or
cracking
nOffers outstanding
resistance to abrasion
and physical abuse while
providing flexibility and
strain relief needed in
rugged harnessing
applications
nResistant to most fluids and
solvents, including aviation
and ground vehicle fuels,
lubricating oil, and
hydraulic fluids
nMeets the stringent
requirements of
SAE-AMS-DTL-23053/1,
Classes 1 and 2
Specifications/Approvals
Operating Temperature Range
-70°Cto 121°C
[-94°F to 250°F]
3-85
Special Purpose Tubing
NT-MIL
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Available in: Americas Europe Asia Pacific
nnn
3-86
Special Purpose Tubing
NT-MIL (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, NT-MIL 1/4-0).
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
1/8 3.2 [0.125] 1.6 [0.061] 0.69 ± 0.20 [0.027 ± 0.008]
3/16 4.8 [0.187] 2.5 [0.100] 0.84 ± 0.25 [0.033 ± 0.010]
1/4 6.4 [0.250] 3.6 [0.143] 0.89 ± 0.25 [0.035 ± 0.010]
3/8 9.5 [0.375] 5.4 [0.211] 1.01 ± 0.25 [0.040 ± 0.010]
1/2 12.7 [0.500] 7.3 [0.286] 1.21 ± 0.38 [0.048 ± 0.015]
5/8 15.9 [0.625] 9.1 [0.357] 1.32 ± 0.38 [0.052 ± 0.015]
3/4 19.1 [0.750] 10.9 [0.428] 1.44 ± 0.38 [0.057 ± 0.015]
7/8 22.2 [0.875] 12.7 [0.500] 1.65 ± 0.38 [0.065 ± 0.015]
1 25.4 [1.000] 14.5 [0.570] 1.77 ± 0.51 [0.070 ± 0.020]
11/4 31.8 [1.250] 18.1 [0.714] 2.20 ± 0.51 [0.087 ± 0.020]
11/2 38.1 [1.500] 21.8 [0.857] 2.41 ± 0.51 [0.095 ± 0.020]
13/4 44.5 [1.750] 25.4 [1.000] 2.71 ± 0.51 [0.107 ± 0.020]
2 50.8 [2.000] 29.0 [1.140] 2.79 ± 0.51 [0.110 ± 0.020]
3 76.2 [3.000] 43.4 [1.710] 3.17 ± 0.51 [0.125 ± 0.020]
4101.6 [4.000] 57.9 [2.280] 3.55 ± 0.51 [0.140 ± 0.020]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
3-87
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
NTFR
Applications
Widely used for insulation,
strain relief, and abrasion
protection on cable
harnesses and wire
bundles in the military
and aerospace industries.
Especially suitable for
applications requiring
exposureto fluids and
solvents at elevated
temperatures.
Installation
Minimum shrink
temperature: 90°C[194°F]
Minimum full recovery
temperature: 135°C [275°F]
Very Flexible, Rugged
Neoprene Elastomer
Tubing
Product Facts
nRemains flexible at low
temperatures without
cracking
nOffers outstanding
resistance to abrasion and
physical abuse while
providing the flexibility and
strain relief needed for
rugged applications
nResistant to most fluids and
solvents, including aviation
and ground-vehicle fuels,
lubricating oil, and hydraulic
fluids (see Raychem
Specification RT-511)
nPerformance exceeds the
stringent requirements of
SAE-AMS-DTL-23053/1,
Class 2
nSystem 20
Series Military Agency Raychem
NTFR SC-X-15112 AMS 3623 RT-511
Specifications/Approvals
Operating Temperature Range
-70°Cto 121°C
[-94°Fto 250°F]
Available in: Americas Europe Asia Pacific
nnn
3-88
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
NTFR (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
1/8 3.2 [0.125] 1.6 [0.061] 0.69 ± 0.20 [0.027 ± 0.008]
3/16 4.8 [0.187] 2.5 [0.100] 0.84 ± 0.25 [0.033 ± 0.010]
1/4 6.4 [0.250] 3.6 [0.143] 0.89 ± 0.25 [0.035 ± 0.010]
3/8 9.5 [0.375] 5.4 [0.211] 1.01 ± 0.25 [0.040 ± 0.010]
1/2 12.7 [0.500] 7.3 [0.286] 1.21 ± 0.38 [0.048 ± 0.015]
5/8 15.9 [0.625] 9.1 [0.357] 1.32 ± 0.38 [0.052 ± 0.015]
3/4 19.1 [0.750] 10.9 [0.428] 1.44 ± 0.38 [0.057 ± 0.015]
7/8 22.2 [0.875] 12.7 [0.500] 1.65 ± 0.38 [0.065 ± 0.015]
1 25.4 [1.000] 14.5 [0.570] 1.77 ± 0.51 [0.070 ± 0.020]
11/4 31.8 [1.250] 18.1 [0.714] 2.20 ± 0.51 [0.087 ± 0.020]
11/2 38.1 [1.500] 21.8 [0.857] 2.41 ± 0.51 [0.095 ± 0.020]
13/4 44.5 [1.750] 25.4 [1.000] 2.71 ± 0.51 [0.107 ± 0.020]
2 50.8 [2.000] 29.0 [1.140] 2.79 ± 0.51 [0.110 ± 0.020]
3 76.2 [3.000] 43.4 [1.710] 3.17 ± 0.51 [0.125 ± 0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, NTFR 1/4-0).
Product Dimensions
Ordering Information
3-89
Special Purpose Tubing
PD Caps
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
PD Caps offer an improved,
inexpensive way to
encapsulate crimped
electrical connections,
including those on motor
coils. Their encapsulant
lining melts and flows to fill
surface irregularities of the
substrate. These vibration-
proof caps are used to
insulate and terminate
dead-end electrical
cables, fixtures,
connectors, and other
electrical components.
Installation
Minimum shrink
temperature: 125°C [257°F]
Minimum full recovery
temperature: 135°C [275°F]
Series UL Raychem
PD Caps E85381 PD Caps SCD
600 V,125°C
Semirigid,
Encapsulant-Lined,
Polyolefin Caps
Product Facts
n3:1 shrink ratio
nPermanent or temporary way
to terminate wires
nRapid, simple installation
nRugged protection against
abrasion, vibration, and
flexing
nPD caps provide a splash-
resistant, moisture-resistant
covering (but not intended
for use where immersion in
fluids is required)
Specifications/Approvals
Operating Temperature Range
-55°Cto 110°C
[-67°F to 230°F]
Available in: Americas Europe Asia Pacific
nnn
3-90
Special Purpose Tubing
PD Caps (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Length Inside Diameter Recovered
Size Nominal Minimum Open Minimum Maximum Wall Thickness**
Overall as Barrel as Expanded Recovered Total Wall
Supplied Supplied* as Supplied After Heating After Heating
1/8 22.0 [0.87] 12.7 [0.50] 3.2 [0.125] 0.58 [0.023] 1.22 ± 0.15 [0.048 ± 0.006]
3/16 25.4 [1.00] 15.2 [0.60] 4.8 [0.187] 1.52 [0.060] 1.57 ± 0.20 [0.062 ± 0.008]
1/4 28.4 [1.12] 15.2 [0.60] 6.4 [0.250] 2.03 [0.080] 1.98 ± 0.25 [0.078 ± 0.010]
3/8 31.8 [1.25] 18.3 [0.72] 9.5 [0.375] 2.29 [0.090] 2.08 ± 0.25 [0.082 ± 0.010]
1/2 38.1 [1.50] 21.6 [0.85] 12.7 [0.500] 2.29 [0.090] 2.54 ± 0.25 [0.100 ± 0.010]
*See glossary for definition of “barrel.”
**Wall thickness will be less if recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In pieces.
Ordering description Specify product name, size and color (for example, PD Caps 1/4-0).
Product Dimensions
Ordering Information
3-91
Special Purpose Tubing
RayBlock 85
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Designed to provide
consistent sealing for cable
bundles and the back of
connectors. The wires are
placed within the channels
of a specially formulated
hot-melt adhesive profile,
then covered by dual-wall,
heat-shrinkable tubing with
aflame-retardant, radiation-
crosslinked outer wall and
hot-melt-adhesive inner
wall. When the tubing is
heated, the hot-melt
adhesive melts and the
tubing shrinks, forcing the
molten adhesive to fill all
the voids within the wire
bundle and tubing. The
result is a solid plug of
adhesive molded around
each wire in the bundle,
creating a moisture-
resistant seal.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 110°C [230°F]
Series Raychem
RayBlock 85 RayBlock 85 SCD
RW-2101
Heat-Shrinkable
Water-Blocking System
Product Facts
nEnvironmentally seals wire
bundles of up to 20 wires
nWithstands temperature
excursions to 105°C [221°F]
nProvides excellent strain
relief and reduces noise
nOffers a low-profile installed
product only marginally
larger than the cable bundle
itself
Specifications/Approvals
Operating Temperature Range
-40°Cto 85°C
[-40°F to 185°F]
Available in: Americas Europe Asia Pacific
nnn
Tubing
Part No. of Profile Inside Diameter
No. Channels Minimum Maximum
Outside Length Width Expanded Recovered Nominal
Height as Supplied After Heating Length
RayBlock 85 Kit 0102-A0 2 8.5 [0.335] 2.75 [0.108] 8.50 [0.335] 12.0 [0.472] 3.0 [0.118] 40 [1.57]
RayBlock 85 Kit 0203-A0 3 8.5 [0.335] 2.75 [0.108] 12.25 [0.482] 24.0 [0.945] 6.0 [0.236] 47 [1.85]
RayBlock 85 Kit 0504-A0 4 8.5 [0.335] 2.75 [0.108] 16.00 [0.630] 16.0 [0.630] 4.0 [0.158] 40 [1.57]
RayBlock 85 Kit 0405-A0 5 8.5 [0.335] 2.75 [0.108] 19.75 [0.778] 24.0 [0.945] 6.0 [0.236] 45 [1.77]
RayBlock 85 Kit 0107-A0 7 8.5 [0.335] 2.75 [0.108] 27.25 [1.070] 24.0 [0.945] 6.0 [0.236] 65 [2.56]
RayBlock 85 Kit 0510-A0 10 8.5 [0.335] 2.75 [0.108] 38.50 [1.520] 32.0 [1.260] 8.0 [0.315] 55 [2.17]
3-92
Special Purpose Tubing
RayBlock 85 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0)
Size selection For wire with an outside diameter smaller than 2.8 [0.110] ,
use a maximum of two wires per channel.
For wire with an outside diameter of 2.8–3.5 [0.110 to 0.138],
use a maximum of one wire per channel.
Special order sizes are available upon request.
Standard packaging One kit (contains 1000 pcs. of profile and 1000 pcs. of tubing).
Product Dimensions
Ordering Information
3-93
Special Purpose Tubing
RayBlock 105
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Specifications/Approvals
Applications
Designed to provide
consistent sealing for cable
bundles and the back of
connectors. The wires in the
bundle are placed within
the channels of a specially
formulated hot-melt
adhesive profile, and then
covered by dual wall, heat-
shrinkable tubing with a
flame-retardant radiation-
crosslinked outer wall and
hot-melt-adhesive inner
wall. When the tubing is
heated, the hot-melt
adhesive melts and the
tubing shrinks, forcing the
molten adhesive to fill all the
voids within the wire bundle
and tubing. The result is a
solid plug of adhesive
molded around each wire
in the bundle, creating a
moisture-resistant seal.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 110°C [230°F]
Series Raychem
RayBlock 105 RayBlock 105 SCD
RW-2102
Heat-Shrinkable
Water-Blocking System
Product Facts
nEnvironmentally seals wire
bundles of up to 20 wires
nWithstands temperature
excursions to 120°C [248°F]
nProvides excellent strain
relief and reduces noise
nOffers a low-profile installed
product only marginally
larger than the cable bundle
itself
Operating Temperature Range
-40°Cto 105°C
[-40°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-94
Special Purpose Tubing
RayBlock 105 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions
Ordering Information
Tubing
Part No. of Profile Inside Diameter
No. Channels Minimum Maximum
Outside Length Width Expanded Recovered Nominal
Height as Supplied After Heating Length
RayBlock 105 Kit 0102-A0 2 8.5 [0.335] 2.75 [0.108] 8.50 [0.335] 12.0 [0.472] 3.0 [0.118] 40 [1.57]
RayBlock 105 Kit 0103-A0 3 8.5 [0.335] 2.75 [0.108] 12.25 [0.482] 16.0 [0.630] 4.0 [0.158] 40 [1.57]
RayBlock 105 Kit 0504-A0 4 8.5 [0.335] 2.75 [0.108] 16.00 [0.630] 16.0 [0.630] 4.0 [0.158] 45 [1.77]
RayBlock 105 Kit 0105-A0 5 8.5 [0.335] 2.75 [0.108] 19.75 [0.778] 24.0 [0.945] 6.0 [0.236] 45 [1.77]
RayBlock 105 Kit 0107-A0 7 8.5 [0.335] 2.75 [0.108] 27.20 [1.070] 24.0 [0.945] 6.0 [0.236] 65 [2.56]
RayBlock 105 Kit 0110-A0 10 8.5 [0.335] 2.75 [0.108] 38.50 [1.520] 32.0 [1.260] 8.0 [0.315] 65 [2.56]
Color Standard Black (-0)
Size selection For wire with an outside diameter smaller than 2.8 [0.110], use a maximum of two wires per
channel.
For wire with an outside diameter of 2.8–3.5 [0.110–0.138], use a maximum of one wire per
channel.
Special order sizes are available upon request.
Standard packaging One kit (contains 1000 pcs. of profile and 1000 pcs. of tubing).
3-95
Special Purpose Tubing
Rayflex Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Rayflex tubing is suited for
the mechanical protection
of wireharnesses, hoses,
and all other applications
where exceptional flexibility
combined with superior
abrasion/cut resistance is
required. It also serves as
an economical means for
wire bundling that will not
trap heat or moisture;
expanding easily to fit over
irregular shapes, then
contracting to conform and
grip. To prevent fraying,
these products should be
cut to length using a hot
knife.
Installation
This product is cold
applied.
PET and PFR Expandable,
Braided, Polyester Sleeving
Product Facts
nExcellent abrasion and
cut-through resistance
nLightweight
nFlexible (even at low
temperatures)
nFungus-proof
nNot affected by most
chemicals and solvents,
non-hygroscopic
nPFR meets UL VW-1,
FAR25, and is
Self-Extinguishing
nFiber diameter is 0.254
[0.010]
Operating Temperature Range
-50°Cto 150°C
[-58°F to 302°F]
(220°C[428°F] for short
periods)
Specifications/Approvals Series UL CSA Raychem
Rayflex PET RW-2069
Rayflex PFR E197586 LR31929
Rated 125˚C Rated 125˚C
Available in: Americas Europe Asia Pacific
nn
3-96
Special Purpose Tubing
Rayflex Tubing (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard RF-PET: Black (-0)
RF-PFR: Black with white X-Cross tracers (-09)
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, RF-PET 1/8-0).
Size Nominal Size
Size Range
RAYFLEX PET expandable polyester braid
1/8 3 [0.125] 2.4-6.4 [0.094-0.250]
1/4 6 [0.250] 3.2-9.5 [0.125-0.375]
3/8 10 [0.375] 4.7-16 [0.188-0.630]
1/2 13 [0.500] 6.4-19 [0.250-0.750]
3/4 19 [0.750] 13-32 [0.500-1.250]
1-1/4 32 [1.250] 19-45 [0.750-1.750]
1-3/4 45 [1.750] 32-70 [1.250-2.750]
251 [2.000] 38-76 [1.500-3.000]
RAYFLEX PFR flame-retardant, expandable polyester braid
1/8 3 [0.125] 2.4-6.4 [0.094-0.250]
1/4 6 [0.250] 3.2-9.5 [0.125-0.375]
3/8 10 [0.375] 4.7-16 [0.188-0.630]
1/2 13 [0.500] 6.4-19 [0.250-0.750]
3/4 19 [0.750] 13-32 [0.500-1.250]
1-1/4 32 [1.250] 19-45 [0.750-1.750]
1-3/4 45 [1.750] 32-70 [1.250-2.750]
2 51 [2.000] 38-76 [1.500-3.000]
Product Dimensions
Ordering Information
3-97
Special Purpose Tubing
Rayflex PETM Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Rayflex tubing is suited for
the mechanical protection
of wireharnesses, hoses,
and all other applications
where exceptional flexibility
combined with superior
abrasion/cut resistance is
required. It also serves as
an economical means for
wire bundling that will not
trap heat or moisture;
expanding easily to fit over
irregular shapes, then
contracting to conform and
grip. To prevent fraying,
these products should be
cut to length using a hot
knife.
Installation
This product is cold
applied.
Expandable, Braided,
Polyester Sleeving
Product Facts
nExcellent abrasion and
cut-through resistance
nLightweight construction
with 0.22 [.009] fiber
nFlexible (even at low
temperatures)
nFungus-resistant
nResistant to most
chemicals and solvents,
non-hygroscopic
nWide range of metric sizes
Operating Temperature Range
-50°Cto 150°C
[-58°F to 302°F]
(220°C[428°F] for short
periods)
Available in: Americas Europe Asia Pacific
nn
3-98
Special Purpose Tubing
Rayflex PETM Tubing (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Color Standard Black (-0), Grey (-8)
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, RF-PETM-03-0).
Nominal Size Range
Size Minimum Maximum
3[0.119] 1 [0.039] 5 [0.197]
4[0.158] 2 [0.079] 7 [0.276]
5[0.197] 3 [0.118] 9 [0.354]
6[0.236] 4 [0.158] 12 [0.472]
8[0.315] 5 [0.197] 12 [0.472]
10[0.394] 7 [0.276] 15 [0.591]
12[0.472] 8 [0.315] 17 [0.669]
15[0.591] 10 [0.394] 20 [0.787]
20[0.787] 14 [0.551] 26 [1.024]
25 [0.984] 18 [0.709] 34 [1.339]
30 [1.181] 20 [0.787] 40 [1.575]
40 [1.575] 30 [1.181] 50 [1.969]
50[1.969] 40 [1.575] 60 [2.362]
Product Dimensions
Ordering Information
3-99
Special Purpose Tubing
Rayrim Edging Material
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Raychem Rayrim edging
material is an extruded strip
internally coated with a heat
activated adhesive, so that
on heating the profile
changes from a "V" to a "U"
section and the adhesive
bonds to the substrate
profile.
Manufactured from a
Raychem radiation cross-
linked polyolefin material,
the profile offers a clean
and rapid means of
covering metal, wood and
glass edges for all-round
protection.
The flexible nature of the
product allows application
to both internal and external
radii, as well as straight
edges, and the continuous
operating temperature
of -55°C to +80°C [-67°F
to 176°F] means that the
product can give protection
under the most testing
circumstances.
Commercial Protective,
Self-Adhering, Edging
Material
Product Facts
nFlexible to allow for
protection of curved edges
Installation
Minimum shrink
temperature: 120°C [248°F]
Minimum full recovery
temperature: 150°C [302°F]
Operating Temperature Range
-55°C to 80°C
[-67°F to 176°F]
Series Raychem
Rayrim RK-6182
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nnn
3-100
Special Purpose Tubing
Rayrim Edging Material (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
BA
C
E
D
Adhesive
Product Dimensions
Application range
Size A (maximum) B (minimum) C (minimum) D (minimum) E (typical)
Nr. 6 0.6 [0.024] 0.5 [0.020] 3.5 [0.138] 0.8 [0.032] 1.25 [0.049]
Nr. 7 1.0 [0.039] 0.9 [0.035] 4.8 [0.189] 1.6 [0.063] 1.25 [0.049]
Nr. 8 2.0 [0.079] 0.9 [0.035] 6.6 [0.260] 2.5 [0.098] 2.25 [0.089]
Nr. 9 4.2 [0.165] 0.9 [0.035] 13.5 [0.532] 4.5 [0.177] 2.20 [0.087]
Plate SWG Thickness Recommended minimum bend radius
30-24 0.31-0.56 [0.012-0.022] 10 [0.394]
23-16 0.61-1.63 [0.026-0.064] 15 [0.591]
15-10 1.83-3.25 [0.072-0.128] 20 [0.787]
9-5 3.66-5.38 [0.144-0.212] 25 [0.984]
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly on edge of the panel.
Standard packaging 1.2-meter [4-foot] lengths.
Ordering description Specify product name, size number and color (for example, Rayrim Nr.6-0).
Ordering Information
3-101
Special Purpose Tubing
RNF-150
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Can be used for jacketing
and bundling of wires to
formlight-duty harnesses,
especially wherealow
profile, abrasion resistance,
and flexibility are needed.
Can also be used to
provide insulation and
strain relief of electrical
connections and wire
terminations, identification
of wires, and packaging of
components.
Installation
Minimum shrink
temperature: 110°C [230°F]
Minimum full recovery
temperature: 150°C [302°F]
Series UL Military Raychem
RNF-150 E35586 VW-1 AMS-DTL-23053/18*, Class 2 RT-370
600 V, 150°C
*Formerly MIL-I-23053/18 and MIL-DTL-23053/18.
High-Performance,
Flame-Resistant, Flexible,
Fluoropolymer Tubing
Product Facts
n2:1 shrink ratio
nApproximately 40 percent
thinner walls than most
general purpose polyolefin
tubings
nHigh flame-resistance
nExcellent physical and
electrical properties after
exposure to many chemicals
and solvents at 50°C [122°F]
(but not recommended for
use in direct contact with
ketones)
nRecommended maximum
temperature for use as a
primaryinsulator: 135°C
[275°F]
Specifications/Approvals
Operating Temperature Range
-55°Cto 150°C
[-67°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
3-102
Special Purpose Tubing
RNF-150 (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.25 ± 0.05 [0.010 ±0.002]
1/16 1.6 [0.063] 0.8 [0.031] 0.25 ± 0.05 [0.010 ±0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.25 ± 0.05 [0.010 ±0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.25 ± 0.05 [0.010 ± 0.002]
3/16 4.8 [0.187] 2.4 [0.093] 0.25 ± 0.05 [0.010 ±0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.30 ± 0.08 [0.012 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.30 ± 0.08 [0.012 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.30 ± 0.08 [0.012 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.48 ± 0.08 [0.019 ± 0.003]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Nonstandard White (-9)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description*** Specify product name, size and color (for example, RNF-150 1/4-0).
***Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
3-103
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
RT-375
Applications
Protects wireand cable
markers subject to extreme
abuse, while permitting full
inspectability of each item
covered. Provides bundling
and jacketing of wires and
cables, protecting them
from mechanical and
chemical abuse. Protects
electronic components
while permitting their
identification and
inspection.
Installation
Minimum shrink
temperature: 125°C [257°F]
Minimum full recovery
temperature: 150°C [302°F]
Series UL CSA Military Raychem
RT-375 E35586 VW-1 LR31929 VW-1 AMS-DTL-23053/18*, Class 2 RT-375
600 V, 150°C 600 V, 150°C
*Formerly MIL-I-23053/18 and MIL-DTL-23053/18.
Clear, Flame-Resistant,
Flexible, Fluoropolymer
Tubing
Product Facts
n2:1 shrink ratio
nExceptional clarity and
clarity stability
nToughness, chemical
resistance, and
high-temperature
performance
nHigh flame-resistance
nApproximately 40 percent
thinner walls than most
general purpose polyolefin
tubings
nRecommended maximum
temperature for use as a
primaryinsulator: 135°C
[275°F]
Specifications/Approvals
Operating Temperature Range
-55°Cto 150°C
[-67°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
3-104
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RT-375 (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046) 0.6 [0.023] 0.25 ± 0.05 [0.010 ± 0.002]
1/16 1.6 [0.063] 0.8 [0.031] 0.25 ± 0.05 [0.010 ± 0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.25 ± 0.05 [0.010 ± 0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.25 ± 0.05 [0.010 ± 0.002]
3/16 4.8 [0.187] 2.4 [0.093] 0.25 ± 0.05 [0.010 ± 0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.30 ± 0.08 [0.012 ± 0.003]
3/8 9.5 [0.375] 4.8 [0.187] 0.30 ± 0.08 [0.012 ± 0.003]
1/2 12.7 [0.500] 6.4 [0.250] 0.30 ± 0.08 [0.012 ± 0.003]
3/4 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.48 ± 0.08 [0.019 ± 0.003]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description*** Specify product name, size and color (for example, RT-375 1/4-X).
***Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
3-105
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
RT555
Applications
Suitable for commercial
applications requiring heat
resistance (electrical and
hydraulic systems near
aircraft or automotive
engines or in fuel tanks),
applications in chemically
exposed environments
(industrial process
equipment in the pulp and
paper,steel, and chemical
industries), and equipment
for handling caustic or
dangerous chemicals or
inks. Use for insulation and
strain relief on appliances
(electric ranges, microwave
ovens, gas grills, and
industrial paint-drying
equipment) and for
protection of delicate
electronic instruments in
down-hole applications.
Installation
Minimum shrink
temperature: 150°C [302°F]
Minimum full recovery
temperature: 220°C [428°F]
Series UL Raychem
RT555 Listed for 185°C for 100,000-hr continuous use (File E85381) RT-555
Listed for 200°C for 40,000-hr cumulative intermittent exposure
Fluid-Resistant, Chemical-
Resistant, Crosslinked
Fluoropolymer Tubing with
Extended Temperature
Range
Product Facts
nResistance to high
temperatures, solvents,
corrosive chemicals, and
radiation
nExtreme resistance to
hydrocarbons
nLow outgassing
(successfully tested for
NASA outgassing
requirements)
nHighly flame-retardant
n40 percent lighter weight
than tubing made with
Viton®fluoroelastomer
nSystem 300 tubing
Specifications/Approvals
Operating Temperature Range
-65°Cto 200°C
[-85°F to 392°F]
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
3-106
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RT555 (Continued)
Inside diameter Recovered wall thickness*
Size Minimum expanded Maximum recovered After heating
assupplied after heating Minimum Maximum Nominal
1/8 3.18 [0.125] 1.57 [0.062] 0.25 [0.010] 0.41 [0.016] 0.30 [0.012]
3/16 4.75 [0.187] 2.36 [0.093] 0.28 [0.011] 0.46 [0.018] 0.36 [0.014]
1/4 6.35 [0.250] 3.18 [0.125] 0.33 [0.013] 0.51 [0.020] 0.41 [0.016]
3/8 9.53 [0.375] 4.75 [0.187] 0.41 [0.016] 0.58 [0.023] 0.48 [0.019]
1/2 12.70 [0.500] 6.35 [0.250] 0.41 [0.016] 0.58 [0.023] 0.48 [0.019]
5/8 15.88 [0.625] 7.95 [0.313] 0.48 [0.019] 0.66 [0.026] 0.56 [0.022]
3/4 19.05 [0.750] 9.53 [0.375] 0.61 [0.024] 0.79 [0.031] 0.69 [0.027]
125.40 [1.000] 12.70 [0.500] 0.71 [0.028] 0.89 [0.035] 0.79 [0.031]
11/4 31.75 [1.250] 15.88 [0.625] 0.76 [0.030] 0.94 [0.037] 0.84 [0.033]
11/2 38.10 [1.500] 19.05 [0.750] 0.86 [0.034] 1.04 [0.041] 0.94 [0.037]
2 50.80 [2.000] 25.40 [1.000] 0.94 [0.037] 1.12 [0.044] 1.02 [0.040]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, RT555 1/8-0).
Product Dimensions
Ordering Information
3-107
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
RW-175
Applications
Especially suitable for
applications requiring high-
temperatureperformance,
outstanding abrasion
resistance and cut-through
resistance, or superior
chemical and solvent
properties. Provides
electrical insulation and
strain relief of multipin
connectors and solder
joints. Ideal for applications
that require dense packing
of components or visual
inspection of covered
components.
Installation
Minimum shrink
temperature: 155°C [311°F]
Minimum full recovery
temperature: 175°C [347°F]
Series UL CSA Military Industry Raychem
RW-175 E35586 VW-1 LR31929 VW-1 AMS-DTL-23053/8* VDE 0341 Pt 9005 RW-3029/1
600 V, 150°C 600 V, 150°C Def. Stan. 59-97 Type 3 RW-3029/2
VG 95343 Pt 5 Type F
BS 3G 198 Pt4
*Formerly MIL-I-23053 and MIL-DTL-23053/8.
High temperature,
Chemical-Resistant,
Polyvinylidene Fluoride
Tubing
Product Facts
n2:1 shrink ratio
nTough, semirigid, very-thin-
wall insulation
nHigh flame-resistance,
meeting the requirements of
AMS-DTL-23053*, Test C,
with UL and CSA VW-1
rating
nHigh-temperature
performance that meets or
exceeds military and
industrial standards
nProtection from most
industrial solvents, fuels,
and chemicals
nRecommended maximum
temperature for use as a
primaryinsulator: 135°C
[275°F]
Specifications/Approvals
Operating Temperature Range
-55°Cto 175°C
[-67°F to 347°F]
Available in: Americas Europe Asia Pacific
nnn
3-108
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RW-175 (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
3/64 1.2 [0.046] 0.6 [0.023] 0.25 ± 0.05 [0.010 ± 0.002]
1/16 1.6 [0.063] 0.8 [0.031] 0.25 ± 0.05 [0.010 ± 0.002]
3/32 2.4 [0.093] 1.2 [0.046] 0.25 ± 0.05 [0.010 ± 0.002]
1/8 3.2 [0.125] 1.6 [0.062] 0.25 ± 0.05 [0.010 ± 0.002]
3/16 4.8 [0.187] 2.4 [0.093] 0.25 ± 0.05 [0.010 ± 0.002]
1/4 6.4 [0.250] 3.2 [0.125] 0.33 ± 0.05 [0.013 ± 0.002]
3/8 9.5 [0.375] 4.8 [0.187] 0.33 ± 0.05 [0.013 ± 0.002]
1/2 12.7 [0.500] 6.4 [0.250] 0.33 ± 0.05 [0.013 ± 0.002]
3/4 19.1 [0.750] 9.5 [0.375] 0.43 ± 0.08 [0.017 ± 0.003]
1 25.4 [1.000] 12.7 [0.500] 0.48 ± 0.08 [0.019 ± 0.003]
11/2 38.1 [1.500] 19.1 [0.750] 0.51 ± 0.08 [0.020 ± 0.003]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Clear (-X)
Nonstandard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example, RW-175 3/64-X).
***Europe only.For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
3-109
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
SFR
Applications
Provides cable jacketing,
harness protection, and
strain relief for electronic
components, semi-
conductor leads, and
wire splices. Ideal for
applications that require
flexibility over a wide range
of operating temperatures.
Installation
Minimum shrink
temperature: 135°C [285°F]
Minimum full recovery
temperature: 175°C [347°F]
Series Military Raychem
SFR AMS-DTL-23053/10* RT-1140
MIL-PRF-46846, Type II, Class 1
*Formerly MIL-I-23053/10 and MIL-DTL-23053/10.
Very Flexible,
Flame-Retardant,
Silicone Elastomer
Tubing
Product Facts
nOutstanding low-temperature
flexibility
nResistance to hydraulic
fluids, fuel, and lubricating
oil
nVery good ablative
characteristics: when
exposed to flame, surface
turns to insulative char or
“ablates”
Specifications/Approvals
Operating Temperature Range
-75°Cto 180°C
[-103°F to 356°F]
Available in: Americas Europe Asia Pacific
nnn
3-110
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SFR (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating
1/4 6.4 [0.250] 3.6 [0.143] 0.88 ± 0.25 [0.035 ± 0.010]
3/8 9.5 [0.375] 5.4 [0.214] 1.02 ± 0.25 [0.040 ± 0.010]
1/2 12.7 [0.500] 7.3 [0.286] 1.21 ± 0.38 [0.048 ± 0.015]
5/8 15.9 [0.625] 9.1 [0.357] 1.32 ± 0.38 [0.052 ± 0.015]
3/4 19.1 [0.750] 10.9 [0.428] 1.44 ± 0.38 [0.057 ± 0.015]
7/8 22.2 [0.875] 12.7 [0.500] 1.65 ± 0.38 [0.065 ± 0.015]
1 25.4 [1.000] 14.5 [0.570] 1.77 ± 0.51 [0.070 ± 0.020]
11/4 31.8 [1.250] 18.1 [0.714] 2.21 ± 0.51 [0.087 ± 0.020]
11/2 38.1 [1.500] 21.8 [0.857] 2.41 ± 0.51 [0.095 ± 0.020]
13/4 44.5 [1.750] 25.4 [1.000] 2.71 ± 0.51 [0.107 ± 0.020]
2 50.8 [2.000] 29.0 [1.140] 2.79 ± 0.51 [0.110 ±0.020]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description*** Specify product name, size and color (for example, SFR 1/4-0).
***Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
3-111
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
SRFR
Applications
Highly flexible and
resistant to high and low
temperatures. Unlike other
silicone materials, SRFR
displays outstanding
physical strength. It resists
extreme heat shocks, and
exhibits good thermal
insulation. SRFR is non-
burning and has
outstanding ablative
properties as well as
excellent physical and
electrical properties. SRFR
is used in medical
equipment where its key
properties are outstanding
flexibility and ability to
withstand exposure to
sterilization conditions.
Other applications include
thyristor power cable
insulation, heating element
and bus bar insulation, fiber
optic bundle sheathing,
and rocketry support cable
protection.
Series UL Raychem
SRFR E85381 VW-1 RT-1142
600V,200˚C RW-2057
Highly Flexible, Silicone
Rubber Tubing
Product Facts
nHighly flame-retardant
nExtremely flexible at high
and low temperatures
nShrink ratio 1.5:1 minimum
except sizes 4/2.9 and 29/20
Specifications/Approvals
Installation
Minimum shrink
temperature: 135°C [275°F]
Minimum full recovery
temperature: 175°C [347°F]
Operating Temperature Range
-75°C to 200°C
[-103°F to 392°F]
Available in: Americas Europe Asia Pacific
nnn
3-112
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SRFR (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating (Nominal)
2.9/1.7 2.9 [0.114] 1.7 [0.067] 1.0 ± 0.50 [0.039 ± 0.020]
4/2.9 4.0 [0.158] 2.9 [0.114] 1.0 ± 0.50 [0.039 ± 0.020]
7.8/4.6 7.8 [0.307] 4.6 [0.181] 1.0 ± 0.50 [0.039 ± 0.020]
10/6.5 10.0 [0.394] 6.5 [0.256] 1.5 ± 0.50 [0.059 ± 0.020]
15/9.6 15.0 [0.591] 9.6 [0.378] 1.5 ± 0.50 [0.059 ± 0.020]
21/13 21.0 [0.827] 13.0 [0.512] 2.0 ± 0.75 [0.079 ± 0.030]
29/20 29.0 [1.142] 20.0 [0.787] 2.0 ± 0.75 [0.079 ± 0.030]
41/27 41.0 [1.614] 27.0 [1.063] 3.0 ± 1.00 [0.118 ± 0.039]
51/33 51.0 [2.008] 33.0 [1.299] 3.0 ± 1.00 [0.118 ± 0.039]
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Gray (-8)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging On spools.
Ordering description Specify product name, size and color (for example, SRFR 2.9/1.7-8).
Product Dimensions
Ordering Information
3-113
Special Purpose Tubing
TFE and TFE-R
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
Designed to provide
insulation and mechanical
protection in severe
chemical and thermal
environments. Used to
cover hydraulic hose and
couplings to prevent
contamination and
corrosion. The high
mechanical strength and
extremely low coefficient
of friction make it ideal for
reducing damage to
bearing shafts and similar
applications.
Installation
Minimum shrink
temperature: 330°C [625°F]
Minimum full recovery
temperature: 340°C [644°F]
Series Military Raychem
TFE, TFE-R AMS-DTL-23053/12*, Classes 1 and 3 RW-2055 (TFE)
Def. Stan. 59-97 Type 5A (TFE) RW-2054 (TFE-R)
Def. Stan. 59-97 Type 5B (TFE-R)
*Formerly MIL-I-23053/12 and MIL-DTL-23053/12.
High-Temperature,
Chemically Inert, Modified
Tubing made with Teflon®
Fluoropolymer
Product Facts
nShrink ratio: 1.8:1 (TFE)
3.2:1 (TFE-R)
nHigh flame-resistance
nExcellent chemical
resistance
Specifications/Approvals
Operating Temperature Range
-67°Cto 250°C
[-88.6°F to 482°F]
Available in: Americas Europe Asia Pacific
nn
TEFLON is a trademark of E.I. du Pont
de Nemours and Company
3-114
Special Purpose Tubing
TFE and TFE-R (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness**
asSupplied After Heating After Heating (Nominal)
TFE TFE-R TFE TFE-R TFE TFE-R TFE TFE-R
30 5/64 0.8 2.0 0.38 0.6 0.23 0.23
28 1/8 0.9 3.2 0.46 1.0 0.23 0.25
26 1/4 1.1 6.4 0.56 1.6 0.25 0.30
24 3/8 1.2 9.5 0.68 2.4 0.25 0.30
22 1/2 1.4 12.7 0.81 3.7 0.30 0.38
20 5/8 1.5 15.9 0.99 4.5 0.30 0.38
18 3/4 1.9 19.0 1.24 5.7 0.30 0.38
16 1 2.3 25.4 1.55 7.1 0.30 0.38
14 1 1/4 3.0 32.0 1.83 8.8 0.30 0.38
12 3.8 2.26 0.30
10 4.8 2.84 0.30
8 6.1 3.58 — 0.38 —
6 — 7.6 — 4.52 — 0.38 —
4— 9.4 — 5.69 — 0.38 —
2— 10.9 — 7.06 — 0.38 —
0— 11.9 — 8.81 — 0.38 —
**Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Clear (-X)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging In 1.2-meter [4-foot] lengths.
Ordering description*** Specify product name, size and color (for example,TFE 22-X).
***Europe only.For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
(millimeters)
Ordering Information
3-115
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Viton®/Viton®-HW/Viton®-E/Viton®-TW
Applications
Raychem premium heat-
shrinkable tubing is fabri-
cated from Viton®fluoro-
elastomers – a crosslinked
material designed for a
wide range of applications.
It is available in three
configurations. Viton®-E is
the thickest wall version,
Viton®-HW has a thinner
wall. Viton®and Viton®-TW
have the thinnest wall for
lighter weight applications.
Offering fluid resistance,
Viton®tubing can be used
in applications up to 200°C
[392°F].
Installation
Minimum shrink
temperature: 100°C [212°F]
Minimum full recovery
temperature: 175°C [347°F]
Series Military Raychem
Viton®AMS-DTL 23053/13** RT-1146
Viton®-TW RK-6014/2
Viton®-E Def. Stan. 59-97 Issue 3 Type 4A RK-6014
VG 95343 Part 5 Type E
VDE 0341/Pt9005
BS 4G-198 Part 3 12A
Viton®-HW MIL-PRF-46846 Type III, Class I RT-1145
*Viton®-TW is rated for -5°C when tested in accordance with RK-6014/2.
**Formerly MIL-I-23053/13 and MIL-DTL-23053/13.
Heat-Shrinkable,
Chemical-Resistant,
High-Temperature Tubing
Product Facts
nHigh resistance to impact
and abrasion
nResistance to a wide variety
of fuels, lubricants, acids,
and solvents at elevated
temperatures
nFlexibility at low
temperatures without
cracking
Specifications/Approvals
Operating Temperature Range
Viton®, Viton®-HW,and
Viton®-TW: -40°C* to 200°C
[-40°Fto 392°F]
Viton®-E: -55°C to 200°C
[-67°Fto 392°F]
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
3-116
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Viton®/Viton®-HW/Viton®-E/Viton®-TW (Continued)
Inside Diameter Recovered Wall Thickness***
Minimum Expanded Maximum Recovered After Heating (Nominal)
Size as Supplied After Heating Viton
®
-E Viton
®
-HW Viton
®
/Viton
®
-TW
1/8 3.2 [0.125] 1.6 [0.062] 0.76 [0.030] — 0.76 [0.030]
3/16 4.8 [0.187] 2.4 [0.093] 0.84 [0.033] — 0.89 [0.035]
1/4 6.4 [0.250] 3.2 [0.125] 0.89 [0.035] 0.76 [0.030] 0.89 [0.035]
3/8 9.5 [0.375] 4.8 [0.187] 1.02 [0.040] 0.89 [0.035] 0.89 [0.035]
1/2 12.7 [0.500] 6.4 [0.250] 1.22 [0.048] 1.09 [0.043] 0.89 [0.035]
5/8 15.9 [0.625] 7.9 [0.312] — 1.19 [0.047] 1.07 [0.042]
3/4 19.1 [0.750] 9.5 [0.375] 1.45 [0.057] 1.32 [0.057] 1.07 [0.042]
7/8 22.2 [0.875] 11.1 [0.437] — 1.53 [0.060] 1.25 [0.049]
1 25.4 [1.000] 12.7 [0.500] 1.78 [0.070] 1.65 [0.065] 1.25 [0.049]
11/4 31.8 [1.250] 15.9 [0.625] — 1.78 [0.070] 1.40 [0.055]
11/2 38.1 [1.500] 19.1 [0.750] 2.41 [0.095] 1.91 [0.075] 1.40 [0.055]
2 50.8 [2.000] 25.4 [1.000] 2.79 [0.110] 2.79 [0.110] 1.65 [0.065]
***W all thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description**** Specify product name, size and color (for example, Viton®1/4-0).
****Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Product Dimensions
Ordering Information
VITON is a trademark of Dupont Dow
Elastomers LLC.
3-117
Special Purpose Tubing
XFFR
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
Applications
XFFR halogen-free tubing
can be used for rejacketing
and repairing halogen-free
cables in any enclosed area
where a flame-retardant,
halogen-free environment
is required. These
environments include
tunnels, buildings, mass
transit vehicles, and ships.
When installed with SFTS-
FR1 tape, the tubing can
also be used in applications
requiring water sealing and
protection from abrasion
and corrosion.
Installation
Minimum shrink
temperature: 70°C [158°F]
Minimum full recovery
temperature: 121°C [250°F]
Series Military Industry Raychem
XFFR MIL-C-24643 NES 713 RW-2016
NES 711
Halogen-Free,
Flame-Retardant,
Heat-Shrinkable Tubing
Product Facts
nEmits minimal amounts of
toxic or acid gases during
combustion
nMeets performance
requirements of
MIL-C-24640 and
MIL-C-24643 cable jackets
nResists moisture, fungus,
and weathering
nAvailable in expansion
ratios as high as 3:1
nXFFR has the following
approvals:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s(Lloyd’s Register of
Shipping)
Specifications/Approvals
Operating Temperature Range
-55°Cto 105°C
[-67°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-118
Special Purpose Tubing
XFFR (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Inside Diameter Recovered Wall Thickness*
Size Minimum Expanded Maximum Recovered After Heating
asSupplied After Heating (Nominal)
XFFR-03 7.62 [0.300] 2.54 [0.100] 1.52 [0.060]
XFFR-04 10.16 [0.400] 3.81 [0.150] 1.52 [0.060]
XFFR-07 19.05 [0.750] 5.59 [0.220] 2.03 [0.080]
XFFR-11 27.94 [1.100] 9.52 [0.375] 2.67 [0.105]
XFFR-15 38.10 [1.500] 12.70 [0.500] 3.05 [0.120]
XFFR-20 50.80 [2.000] 19.05 [0.750] 3.05 [0.120]
XFFR-30 76.20 [3.000] 31.75 [1.250] 3.94 [0.155]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Standard packaging 1.2-meter [4-foot] or 7.5-meter [25-foot] lengths.
Part Numbering System
Product Dimensions
Ordering Information
“NM” - no mark
Length in feet (4 feet standard)
Size
Family
XFFR - 03 X 4 / NM
No adhesive.
3-119
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
ZH-100
Applications
ZH-100 is a flexible,
thin-wall, heat-shrinkable
tubing designed for low-fire-
hazardapplications.
ZH-100 contains no added
halogens, and exhibits
excellent firesafety
characteristics combined
with low evolution of acid
gases, while retaining good
mechanical and fluid
resistance properties.
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 120°C [248°F]
Series Military Agency Raychem
ZH-100 Def. Stan. 59-97 Issue 3 Type 8 BR 1326A RW-2031
BS 3G-198 Part 3 Type 15
Flexible, Thin-Wall, Low-
Fire-Hazard Tubing
Product Facts
n2:1 shrink ratio
nLow smoke emissions
nFlexible, flame-retardant
nNo added halogens
nLow evolution of acid gases
Specifications/Approvals
Operating Temperature Range
-30°Cto 105°C
[-22°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-120
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ZH-100 (Continued)
Color Standard Black (-0)
Nonstandard White (-9), red (-2), blue (-6), yellow (-4), green (-5)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description** Specify product name, size and color (for example, ZH-100 1/8-0).
**Europe only. For supply to MIL, Def Stan and BS add -MS, -DS or -BS to ordering description.
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
1/8 3.2 [0.125] 1.6 [0.062] 0.50 ± 0.10 [0.019 ± 0.004]
3/16 4.8 [0.187] 2.4 [0.093] 0.50 ± .0.10 [0.019 ± 0.004]
1/4 6.4 [0.250] 3.2 [0.125] 0.65 ± 0.15 [0.026 ± 0.006]
3/8 9.5 [0.375] 4.8 [0.187] 0.65 ± 0.15 [0.026 ± 0.006]
1/2 12.7 [0.500] 6.4 [0.250] 0.65 ± 0.15 [0.026 ± 0.006]
3/4 19.0 [0.750] 9.5 [0.375] 0.75 ± 0.15 [0.030 ± 0.006]
1 25.4 [1.000] 12.7 [0.500] 0.90 ± 0.15 [0.035 ± 0.006]
11/2 38.0 [1.500] 19.0 [0.750] 1.00 ± 0.20 [0.039 ± 0.008]
2 51.0 [2.000] 25.4 [1.000] 1.15 ± 0.25 [0.045 ± 0.010]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Product Dimensions
Ordering Information
3-121
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Heat-Shrinkable Tubing
3
ZHTM
Applications
Aflexible, thick-wall, heat-
shrinkable tubing to be
used in conjunction with
-100 molded parts and
Zerohal cable to form
Raychem System 100. This
material exhibits excellent
firesafety characteristics
combined with low smoke
emission and low evolution
of acid gases while
retaining good mechanical
and fluid-resistance
properties. Used for
insulation and protection
of cables, harnesses, and
electrical and electronic
components in enclosed
spaces, such as in marine
applications, mass transit
systems, and offshore
installations, to reduce
toxicity risks, or where
equipment would be
irreparably damaged
by corrosive products
of combustion.
Series Military Agency Industry Raychem
ZHTM Def. Stan. 59-97 BS 4G-198 Part 3 Type 15 BR 1326A RW-2058
Issue 3 Type 8 VG 95343 Part 5 Type L
VDE 0341/Pt 9005
Heat-Shrinkable, Flexible
Tubing with Low Toxicity for
Fire Safety Applications
Product Facts
n2:1 shrink ratio
nLow smoke emission
nSystem 100 tubing
Specifications/Approvals
Installation
Minimum shrink
temperature: 80°C [176°F]
Minimum full recovery
temperature: 121°C [250°F]
Operating Temperature Range
-30°C to 105°C
[-22°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
3-122
Special Purpose Tubing
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ZHTM (Continued)
Inside Diameter Recovered Wall
Size Minimum Expanded Maximum Recovered Thickness*
asSupplied After Heating After Heating
3/1.5 3.0 [0.118] 1.5 [0.059] 0.70 ± 0.10 [0.028 ± 0.004]
5/2.5 5.0 [0.197] 2.5 [0.098] 0.75 ± 0.12 [0.030 ± 0.005]
8/4 8.0 [0.315] 4.0 [0.157] 0.80 ± 0.15 [0.031 ± 0.006]
12/6 12.0 [0.472] 6.0 [0.236] 0.90 ± 0.15 [0.035 ± 0.006]
18/9 18.0 [0.709] 9.0 [0.354] 1.00 ± 0.18 [0.039 ± 0.007]
24/12 24.0 [0.945] 12.0 [0.472] 1.10 ± 0.20 [0.043 ± 0.008]
40/20 40.0 [1.575] 20.0 [0.789] 1.30 ± 0.23 [0.051 ± 0.009]
50/30 50.0 [1.969] 30.0 [1.181] 1.50 ± 0.28 [0.059 ± 0.011]
*Wall thickness will be less if tubing recovery is restricted during shrinkage.
Color Standard Black (-0)
Size selection Always order the largest size that will shrink snugly over the component to be covered.
Special order sizes are available upon request.
Standard packaging On spools.
Ordering description** Specify product name, size and color (for example, ZHTM 8/4-0).
**Europe only. For supply to Def Stan and BS add -DS or -BS to ordering description.
Product Dimensions
Ordering Information
Molded Parts
Table of Contents
4-1
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Overview ………………………………………………………………………………………………4-2
General Information ………………………………………………………………………………4-3, 4-4
Selection Tables …………………………………………………………………………………4-5, 4-6
Part Numbering System ………………………………………………………………………………4-7
Visual Selection Guide …………………………………………………………………………4-8 to 4-20
Boot Adapter Selection Tables ………………………………………………………………4-21 to 4-23
Material Selection Table ……………………………………………………………………………4-24
Materials
-3 Semirigid modified polyolefin …………………………………4-25, 4-26
-4 Flexible polyolefin ………………………………………………4-27, 4-28
-12 Modified fluoroelastomer ………………………………………4-29, 4-30
-25 Fluid-resistant modified elastomer ……………………………4-31, 4-32
-25S Fluid-resistant screened elastomer ……………………………4-33, 4-34
-50 Fluid-resistant modified elastomer ……………………………4-35, 4-36
-51 Chemical-resistant fluoroelastomer ……………………………4-37, 4-38
-55 Flexible fluoropolymer……………………………………………4-39, 4-40
-71 Semirigid modified polyolefin …………………………………4-41, 4-42
-100 Low-fire-hazard material…………………………………………4-43, 4-44
-100S Low-fire-hazard screened material ……………………………4-45, 4-46
-125 Flexible fluoropolymer……………………………………………4-47, 4-48
Caps101A011 to 094 End caps …………………………………………………………4-49, 4-50
SSC Heat-shrinkable end caps ………………………………………4-51, 4-52
Boots
202A111 to 196 Straight boot ……………………………………………………………4-53
202C611 to 663 Uniboot …………………………………………………………………4-54
202D121 to 196 Straight, lipped boot ……………………………………………………4-55
202D211 to 299 Straight, lipped boot ……………………………………………………4-56
202D921 to 963 Straight, lipped boot ……………………………………………………4-57
202F211 to 274 Straight, lipped boot ……………………………………………………4-58
202G211 to 253 Straight, lipped boot ……………………………………………………4-59
202G611 to 653 Uniboot …………………………………………………………………4-60
202K121 to 185 Straight, lipped boot ……………………………………………………4-61
214A011 to 052 D-subminiature, straight boot …………………………………………4-62
214A311 to 352 D-subminiature, straight boot …………………………………………4-63
214P009 to 037 D-subminiature, straight boot with jack screws ……………………4-64
222A111 to 196 Right-angled boot ………………………………………………………4-65
222D121 to 196 Right-angled, lipped boot ……………………………………………4-66
222D211 to 299 Right-angled, lipped boot ……………………………………………4-67
222D921 to 963 Right-angled, lipped boot ……………………………………………4-68
222F211 to 285 Right-angled, lipped boot ……………………………………………4-69
222K121 to 185 Right-angled, lipped boot ……………………………………………4-70
234A011 to 071 D-subminiature, right-angled boot ……………………………………4-71
234A111 to 152 D-subminiature, side-entryboot ………………………………………4-72
234A611 to 671 D-subminiature, 90˚ end-entry boot …………………………………4-73
242W042 to 63 45˚ angled boot…………………………………………………………4-74
Feedthroughs
207W213 to 256 Two-part feedthrough …………………………………………………4-75
Transitions
301A011 to 048 T transition ………………………………………………………………4-76
301A511 to 514 Slimline T transition ……………………………………………………4-77
322A112 to 158 Ttransition ………………………………………………………………4-78
342A012 to 058 45˚ side-breakout transition……………………………………………4-79
362A014 to 114 30˚ side-breakout transition……………………………………………4-80
381A301 to 304 Slimline Y transition ……………………………………………………4-81
382A012 to 046 Y transition ………………………………………………………………4-82
382C312, 322 & 332 Slimline Y transition ……………………………………………………4-83
462A011 to 060 Transition, one to three cables…………………………………………4-84
462A421 to 424 Slimline transition, one to three cables ………………………………4-85
562A011 to 067 Transition, one to four cables …………………………………………4-86
QFT Configurable heat-shrink transition ……………………………4-87, 4-88
SSB, T,Fto 8S Chem-X Heavy Duty Breakout Boots …………………………4-89, 4-90
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Molded Parts
Table of Contents (Continued)
Overview
4-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Raychem heat-shrinkable
molded parts, with adhesive
coating, form a watertight
seal, protecting cables and
equipment from corrosion
and mechanical abuse while
providing excellent electrical
insulating properties. Meeting
requirements for most mass-
transit, military, and
commercial marine
applications, Raychem
molded parts include:
nRaychem SSC end caps,
which provide optimum
waterproofing and environ-
mental protection for
underwater, underground,
or outdoor applications.
The end caps are highly
resistant to moistur e,
fungus, and weathering.
nRaychem heat-shrinkable
boots and transitions,which
replace tapes, mold-in-
place epoxies, and grease.
These molded parts can
be used for cable
breakouts, transitions, and
terminations. For example,
they provide r eliable sealing
to specific altitudes on
standardNavy cable
jackets and on lead, steel,
aluminum, copper, and
most elastomeric insulation
materials.
All of these molded parts fit a
wide variety of applications.
To select the right part for
your application, follow these
steps:
nSelect the necessaryshape.
nMatch the shape with the
appropriate material.
nSelect a compatible adhe-
sive, if needed, to provide
additional environmental
protection. Adhesives come
either preinstalled or as
separate components
(see Section 5).
Also available is an extensive
line of adapters (see Section
6) and heat-shrinkable
tubings (see Section 3) to
further integrate and
strengthen harness
assemblies.
Whatever your application,
Raychem molded parts
almost always meet the
performance characteristics
you requir e, including
operation in low- and high-
temperatureenvironments;
mechanical strength;
resistance to fluids, flame,
and mechanical abuse;
environmental sealing;
and strain relief.
Accessories
202W302 to 342 Heat-shrink bobbins ……………………………………………4-91, 4-92
400W242 Heat-shrink
positioning ring …………………………………………………4-93, 4-94
CES Heat-shrinkable
cable entry seals ………………………………………………4-95 to 4-98
RayOLOn Kits Roll-on sealing sleeve …………………………………………4-99, 4-100
shrinkHOoP Cable clamp
heat-shrink grommet ………………………………………4-101 to 4-103
XL Products Conversion Table ……………………………………………4-104, 4-105
Molded Parts
General Information
4-3
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Bulbous Molded Parts
Raychem bulbous-shaped
molded parts provide
rugged mechanical and
environmental protection,
meet numerous specifica-
tions, and have been used
successfully in militarywire
and cable harnesses for
more than 30 years.
Most connector strain relief
boots come in two versions:
nWith an adapter lip mold-
ed into the “H” end, which
locks into the groove on
the backshell adapter
(partnumber is identified
with a “D” or “K”).
nWithout the adapter lip
(the boot may be installed
directly on the rear of con-
nector threads 12 mm
[.472] long or longer).
This part number is
identified with an “A.”
Many other optional fea-
tures are available, such
as molding ports and drain
holes. For other modifica-
tions and custom
shapes, please contact
Tyco Electronics.
Modifications
Certain variations of the
standard shapes, such as
shorter leg lengths or spe-
cific over expansions, are
possible. Modifications
must be requested prior to
your order,for feasibility.
Molding Port
Modifications (-00)
Some specifications call for
potting the molded shape
with sealant to provide addi-
tional protection from mois-
ture. Most of the bulbous
boots and transitions can
be ordered with molding
ports for this purpose.
Drain Hole Modification (-88)
Some specifications require
drain holes in the molded
part to provide an exit for
condensation. Drain holes
must be requested when
you place your order.
Specials
Complete design, tooling,
and production of custom
molded shapes and special
adaptations arealso possi-
ble. Estimates aremade
upon request.
Molded Parts
General Information (Continued)
4-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Breakout Boots
Heavy-duty breakouts
provide mechanical strain
relief and environmental
sealing for power cables
where the cable jacket is
cut back and conductors
broken out.
These boots are used
widely in ship building and
meet the requirements of
the following:
nLloyd’s Register of
Shipping
nDet Norske Veritas (DNV)
nAmerican Bureau of
Shipping (ABS)
nDOD-STD-2003
nMIL-I-81765/1A
Slim-Line Molded Parts
With their low profile, these
flexible molded parts
conform to cables better
and create less bulk at tran-
sition points and connectors
than bulbous molded parts.
Raychem molded parts are
available in a variety of slim-
line shapes, including
straight and right-angle
boots as well as transitions.
Asmall family of parts can
provide a wide variety of
expansions (under expan-
sion, over expansion, cut-
off). Modifications are easily
provided.
Cable End Caps
Heat-shrinkable end caps
provide a reliable method of
sealing power cables,
pipes, conduit, and other
cylindrical objects against
corrosion and moisture
penetration.
Application Family Description Typical Shapes
202D121 to 196
222D121 to 196
Lipped boots for use with a circular adapter 202K121 to 185
222K121 to 185
242W042 to 063
Nonlipped boots for use directly on a 202A111 to 196
circular connector 222A111 to 196
202D211 to 299
Low-profile lipped boots for use with a 222D211to 299
circular adapter 202F211 to 274
222F211 to 285
202G211to 253
Lipped boots for use with a 202D921 to 963
circular adapter 222D921 to 963
Lipped boots with compressible design 202C611 to 663
for use with a circular adapter 202G611 to 653
214A011 to 052
Adapter boots for use with 234A011 to 071
D-subminiature connectors 214A311 to 352
234A111 to 152
234A611 to 671
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Molded Parts
4-5
Selection Tables
Boots
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Molded Parts
4-6
Selection Tables (Continued)
Application Family Description Typical Shapes
Breakout Boots SSB, T, F, 6S, 85
301A011 to 048
"T" Transitions 301A511 to 514
322A112 to 158
45° Transitions 342A012 to 058
30° Transitions 362A014 to 114
“Y” T ransitions 381A301 to 304
382A012 to 046
3:1 Transitions 462A011to 060
462A421 to 424
4:1 Transitions 562A011 to 067
Transitions
Shape Selection:
Other Products
Application Family Description Typical Shapes
Feedthroughs 207W213 to 256
and
CES
D-Subminiatures 214P009 to 037
End Caps 101A011 to 094
and
SSC
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Molded Parts
4-7
Part Numbering System
Color (TD-0 = Black). Other colors factory quote
Optional Adhesive* Coating (precoated in factory)
Modification (available on request)
• Over expansion
• Cutoff
• Molding ports (injection and vent)
Material**
Size of Part in Family: From 11 (= smallest) to 99 (= largest)
Family Number
Type of Part:
A = Nonlipped boots/transitions
C = Lipped boot
D = Lipped boot
F = Lipped boot
K = Lipped boot
S = Rayaten
G = Lipped boot
W, P = Other shapes
Angle of Part:
All openings One opening
Circular Noncircular
0 = Straight 0 = Straight
2 = 90°3 = 90°
4 = 45°5 = 45°
6 = 30°7 = 30°
Number of openings in the part
2 0 2D 1 21 - 3 - 01 / 42 - 0
*See section 5 for details on adhesives.
**See page 4-24 for details on materials.
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Molded Parts
4-8
Visual Selection Guide
Lipped Boots for Use
With an Adapter
Assupplied
After recovery
202D121 through 196 202D21 1 through 299 202D921 through 963 202K121 through 185
As supplied
After recovery
222B012 through 063 222B112 and 123 222D121 through 196 222D211 through 299
As supplied
After recovery
222D921 through 963 202K121 through 185 242 A312 and 322
222K121
Boots:
Circular Connectors —
Lipped
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Molded Parts
4-9
Visual Selection Guide (Continued)
Boots:
Circular Connectors —
Nonlipped
Nonlipped Boots for Direct
Attachment on Connectors
As supplied
After recovery
202A011 through 096 202A111 through 196 202A212 through 264 202A312 through 364 202A512
As supplied
After recovery
202A915 202A921 202B422 and 433 203A021
As supplied
After recovery
203A211 203A312 204A011 204A311
As supplied
After recovery
204A411 204A511 204A612 208A01 1 through 098 222A011 through 096
Molded Parts
Visual Selection Guide (Continued)
4-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Nonlipped Boots for Direct
Attachment on Connectors
As supplied
After recovery
222A11 1 through 196 222A213 through 255 222A313 through 355 223A213 through 233 224A012
As supplied
After recovery
226A045 & 075 228A011 through 097 242A142 243A012 & 022 246A166
As supplied
After recovery
202B521 through 598
As supplied
After recovery
202C611through 633 202F211 through 274
202G621 through 653 202E334 through 346 202G211 through 253 222F211 through 285
Boots:
Circular Connectors —
Nonlipped (Continued)
Boots: Circular
Connectors–Slim-Line
Molded Parts
Visual Selection Guide (Continued)
4-11
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Assupplied
After recovery
Assupplied
After recovery
214A511thru 552 214A613 214A814 214A923 214B623
As supplied
After recovery
As supplied
After recovery
Boots: Rectangular
Connectors
211A012 214A011 214A124 214A311 214A452
through 052 and 133 through 352
214B713 234A011 234A111 234A313 234A413
through 071 through 152 through 333 through 434
234A611 234A711 234A911 234B011
through 671 through 752 through 971 through 052
Molded Parts
Visual Selection Guide (Continued)
4-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Transitions: Bulbous
As supplied
After recovery
301A011 through 048 302A012 through 037 302A214 322A012 through 037 322A112 through 158
Assupplied
After recovery
322A315 322A412 through 434 322A514 322B813
As supplied
After recovery
323A211 323A222 341A015 342A012 through 058
As supplied
After recovery
342A112 through 138 342A215 342A313 and 323 343A014 through 027 362A014 through 114
Molded Parts
Visual Selection Guide (Continued)
4-13
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Transitions: Bulbous
(Continued)
As supplied
After recovery
363A018 and 020 381A015 381A115 382A012 through 046 402A013
Assupplied
After recovery
403A123 through 155 413A013 and 024 422A011 422A114 422A414
As supplied
After recovery
422A616 422A716 422A813 423A014 423A117
As supplied
After recovery
453A017 453A215 and 225 462A01 1 through 060 462A214
Molded Parts
Visual Selection Guide (Continued)
4-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Transitions: Bulbous
(Continued)
Transitions: Slim-Line
Assupplied
After recovery
502A516 502A812 through 845 522A013 561A017
As supplied
After recovery
562A011 through 067 602A012 602A022 602A114 602A212
As supplied
After recovery
622A014 703A155 704A011 and 012 902A014
As supplied
After recovery
301A511through 514 381A301 through 304 462A421 through 424
Molded Parts
Visual Selection Guide (Continued)
4-15
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
As supplied
After recovery
102A911 102A951 102A961 102A962 102A981
As supplied
After recovery
102A992 102A993 102A994 202A817
As supplied
After recovery
301A212
220A012 through 023 234A211 234B1 11 and 122 254A015 301A222, 302A312
As supplied
After recovery
302A734 401A112 and 402A212
Covers
Molded Parts
Visual Selection Guide (Continued)
4-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Covers (Continued)
Assupplied
After recovery
401A212 and 403A312 401A414 402A222 403A016 501A012 and 502A212
Assupplied
After recovery
501A112 601A012
Sleeves
As supplied
After recovery
207W213 through 264 207W213-x-01 through
with A-type nut 264-x-01 with B-type nut
As supplied
After recovery
200A413 and 200A426 200D944 thru 988
As supplied
After recovery 202B211 through 302
(Not heat-shrinkable)
201A711 through 792 202B811 through 832
Assupplied
After recovery
101A011 thru 094 102A811 through 865
Miscellaneous
204A711and 002A01 1
Riser and Plug
(Not heat-shrinkable)
Caps
Molded Parts
Visual Selection Guide (Continued)
4-17
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Molded Parts
Visual Selection Guide (Continued)
4-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Selected Molded Shapes
Families
As supplied
After recovery
202A111through 196 Nonlipped boot
As supplied
After recovery
202D121 through 196 Lipped boot
Molded Parts
Visual Selection Guide (Continued)
4-19
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Selected Molded Shapes
Families (Continued)
Assupplied
After recovery
202A212 through 264 Nonlipped boot 202D211 through 299 Lipped boot
Assupplied
After recovery
202D921 through 963 Lipped boot 202K121 through 185 Lipped boot
As supplied
After recovery
207W213 through 264 Feedthrough 214A011 through 052 Rectangular boot
As supplied
After recovery
222A111through 196 90°boot nonlipped 222A213 through 255 90° boot nonlipped
Molded Parts
Visual Selection Guide (Continued)
4-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Selected Molded Shapes
Families (Continued)
Assupplied
After recovery
222A313 through 355 90° boot nonlipped 222D121 through 196 90° boot lipped
As supplied
After recovery
222D211 through 299 90° boot lipped 222D921 though 963 90° boot lipped
As supplied
After recovery
222K121 through 185 90° boot lipped 301A011 through 048 T transition
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Molded Parts
4-21
Boot Adapter Selection Tables
Dimensions Fits Adapter
Boot Material Part Cable Order Number
Type Dash No. Diameter Length Spin Entry Size
Number Range Solid Coupling Shielded Tinel-Lock
202C611 4.83-9.65 [.19-.38] 120.65 [4.75] — — 04 04
202C621 8.13-16.26 [.32-.64] 133.35 [5.25] 12 12—14 06-08 04-07
50, 51 202C632 12.70-25.40 [.50-1.00] 146.05 [5.75] 14-16 16-18 10-14 10-16
71 202C642 17.53-35.05 [.69-1.38] 158.75 [6.25] 18-20 20 12-18 12-18
202C653 22.35-44.20 [.88-1.74] 171.45 [6.75] 22-32 22-32 18-20 16-20
Uni-boot 202C663 22.86-55.63 [.90-2.19] 236.22 [9.30] 24, 28, 31 32, 36 — —
202G621 8.13-16.26 [.32-.64] 133.86 [5.27] 12-14 12-14 06-08 04-07
202G632 12.70-25.40 [.50-1.00] 151.13 [5.95] 16 16-18 10-14 08-12
55 202G642 17.53-35.05 [.69-1.38] 157.23 [6.19] 18-20 20 12-18 12-18
202G653 22.35-44.20 [.88-1.74] 170.18 [6.70] 22-32 22-32 18-20 16-22
— — — 16-24, 61 22-28, 61 — —
202F211 6.60-15.75 [.26-.62] 105.16 [4.14] 10 08-10 04-07 04-07
202F221 7.62-19.30 [.30-.76] 123.95 [4.88] 12-14 12-14 07-10 05-08
202F232 8.89-22.86 [.35-.90] 146.30 [5.76] 16 16-18 10-14 08-12
50, 51 202F242 10.16-27.18 [.40-1.07] 172.21 [6.78] 18-20 20 12-18 12-16
Low-profile, 71202F253 10.92-29.97 [.43-1.18] 185.16 [7.29] 22 22 18-20 16-18
Straight 202F263 12.70-36.83 [.50-1.45] 213.61 [8.41] 24-28 24-28 20 18-20
202F274 14.99-42.93 [.59-1.69] 203.20 [8.00] 24 32 — —
202G221 7.62-19.30 [.30-.76] 121.16 [4.77] 12-14 12-14 07-10 05-08
202G232 8.89-22.86 [.35-.90] 138.68 [5.46] 16 16-18 10-14 10-12
55 202G242 10.16-27.18 [.40-1.07] 159.51 [6.28] 18-20 20 14-18 12-16
202G253 10.92-29.97 [.43-1.18] 177.80 [7.00] 22-28 22-24 16-20 16-18
— — — 16-20 20-24 — —
222F211 6.60-15.75 [.26-.62] 105.16 [4.14] 10 08-10 04-07 04-07
222F221 7.62-20.83 [.30-.82] 123.95 [4.88] 12-14 12-14 07-10 05-10
222F232 8.89-22.86 [.35-.90] 146.30 [5.76] 16 16-18 10-14 08-12
Low-profile, 50, 51 222F242 10.16-27.18 [.40-1.07] 172.21 [6.78] 18-20 20 12-18 12-16
90° 71 222F253 10.92-29.97 [.43-1.18] 185.16 [7.29] 22 22 18, 20 16-18
222F263 12.70-36.83 [.50-1.45] 213.61 [8.41] 24-28 24-28 20 18, 20
222F274 14.99-42.43 [.59-1.69] 224.54 [8.84] 24 32 — —
222F285 17.53-61.21 [.69-2.41] 227.33 [8.95] 24-32 32-40 — —
Table 1. Boots
(continued on next page)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Molded Parts
4-22
Boot Adapter Selection Tables (Continued)
Dimensions Fits Adapter
Boot Material Part Cable Order Number
Type Dash No. Diameter Length Spin Entry Size
Number Range Solid Coupling Shielded Tinel-Lock
202D211 6.60-15.75 [.26-.62] 105.92 [4.17] 08 08-10 06-07 04-07
202D221 7.62-19.30 [.30-.76] 121.16 [4.77] 08-10 08-10 08 06-07
202D232 8.89-22.86 [.35-.90] 138.68 [5.46] 10-12 10-12 10-12 08-10
202D242 10.16-27.18 [.40-1.07] 159.51 [6.28] 12-14 12-14 12-14 10-12
Low-profile, 3,4,25 202D253 10.92-29.97 [.43-1.18] 177.80 [7.00] 16-18 16-18 16-18 14-16
Straight 202D263 12.70-36.83 [.50-1.45] 203.20 [8.00] 20-22 20-22 18-20 18-20
202D274 14.99-42.93 [.59-1.69] 203.20 [8.00] 24 28 22-24 22-24
202D285 18.29-55.88 [.72-2.20] 203.20 [8.00] 28 32-34 28 —
202D296 20.07-59.69 [.79-2.35] 203.20 [8.00] — 40 — —
202D299 23.37-72.39 [.92-2.85] 203.20 [8.00] — 44 — —
222D211 6.60-15.75 [.26-.62] 105.16 [4.14] 08 08-10 06-07 04-07
222D221 7.62-19.30 [.30-.76] 123.95 [4.88] 08-10 08-10 08 06-08
222D232 8.89-22.86 [.35-.90] 146.30 [5.76] 10-12 10-12 10-12 08-10
222D242 10.16-27.18 [.40-1.07] 172.21 [6.78] 12-14 12-14 12-14 10-12
Low-profile, 3,4,25 222D253 10.92-29.97 [.43-1.18] 185.16 [7.29] 16-18 16-18 16-18 14-16
90° 222D263 12.70-36.83 [.50-1.45] 213.61 [8.41] 20-22 20-22 18-20 18-20
222D274 14.99-42.93 [.59-1.69] 224.54 [8.84] 24 2822-24 22-24
222D285 18.29-55.88 [.72-2.20] 227.33 [8.95] 28 32-34 28
222D296 20.07-59.69 [.79-2.35] 233.43 [9.19] — 40 — —
222D299 23.37-72.39 [.92-2.85] 203.20 [8.00] —44 — —
202D121 6.10-19.05 [.24-.75] 38.10 [1.50] — 08 04-05 04-07
202D132 7.11-23.37 [.28-.92] 54.86 [2.16] 08 10 06-07 06-08
202D142 7.62-25.15 [.30-.99] 66.80 [2.63] 10 12-14 09-10 07-10
202D153 8.89-30.48 [.35-1.20] 80.10 [3.15] 12-14 16-18 11-14 10-12
202D163 10.41-34.29 [.41-1.35] 103.63 [4.08] 16-18 20-22 15-16 14-16
202D174 10.41-34.29 [.41-1.35] 103.63 [4.08] 16-18 20-22 15-16 14-16
Bulbous, 3,4,25 202D185 20.83-53.34 [.82-2.10] 165.10 [6.50] — — 24 24
Straight 202D196 25.91-69.85 [1.02-2.75] 177.80 [7.00] — — — —
202K121 6.10-19.05 [.24-.75] 38.10 [1.50] — 08 04-05 04-07
202K132 7.11-23.37 [.28-.92] 54.86 [2.16] 08 10 06-07 06-08
202K142 7.62-25.15 [.30-.99] 66.80 [2.63] 10 12-14 09-10 07-10
202K153 8.89-30.48 [.35-1.20] 80.10 [3.15] 12-14 16-18 11-14 10-12
202K163 10.41-34.29 [.41-1.35] 103.63 [4.08] 16-18 20-22 15-16 14-16
202K174 10.41-34.29 [.41-1.35] 103.63 [4.08] 16-18 20-22 15-16 14-16
202K185 20.83-53.34 [.82-2.10] 165.10 [6.50] — — 24 24
222D121 6.10-19.05 [.24-.75] 21.34 [0.84] 08 04-05 04-07
222D132 7.11-23.37 [.28-.92] 33.78 [1.33] 08 10 06-07 05-08
222D142 7.62-25.15 [.30-.99] 36.58 [1.44] 10 12-14 09-10 08-10
Bulbous, 3,4,25 222D153 8.89-30.48 [.35-1.20] 43.69 [1.72] 12-14 16-18 11-14 10-14
90° 222D163 10.41-34.29 [.41-1.35] 53.59 [2.11] 16-18 20-22 15-16 14-18
222D174 16.26-44.96 [.64-1.77] 77.98 [3.07] 20-24 24 18-22 18-22
222D185 20.83-53.34 [.82-2.10] 97.54 [3.84] — — 24 24
222D196 25.91-69.85 [1.02-2.75] 117.86 [4.64] — — — —
222K121 6.10-19.05 [.24-.75] 21.34 [0.84] 08 04-05 04-07
222K132 7.11-23.37 [.28-.92] 33.78 [1.33] 08 10 06-07 05-08
222K142 7.62-25.15 [.30-.99] 36.58 [1.44] 10 12-14 09-10 08-10
222K153 8.89-30.48 [.35-1.20] 43.69 [1.72] 12-14 16-18 11-14 10-14
222K163 10.41-34.29 [.41-1.35] 53.59 [2.11] 16-18 20-22 15-16 14-18
222K174 16.26-44.96 [.64-1.77] 77.98 [3.07] 20-24 24 18-22 18-22
222K185 20.83-53.34 [.82-2.10] 97.54 [3.84] — — 24 24
Note: 202KXXX and 222KXXX parts Europe only.
Table 1. Boots (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Molded Parts
4-23
Boot Adapter Selection Tables (Continued)
Part No. Cable Diameter Range Shim Boot or Tubing
202C611 3.81-4.83 [.15-.19] Tubing
202C621 6.35-8.13 [.25-.32] Tubing
202C632 9.65-12.70 [.38-.50] Tubing
202C632 3.30-9.65 [.13-.38] 202E334
202C632 14.48-17.53 [.57-.69] Tubing
202C642 9.91-14.48 [.39-.57] 202E346
202C642 3.30-9.65 [.13-.38] 202E344
202C642 19.30-22.35 [.76-.88] Tubing
202C653 9.91-19.30 [.39-.76] 202E346
202C653 3.30-9.65 [.13-.38] 202E344
202C658 17.53-22.86 [.69-.90] Tubing
202C663 17.53-22.86 [.69-.90] Tubing
202D211/202F211 5.08-6.60 [.20-.26] Tubing
222D211/222F211 5.08-6.60 [.20-.26] Tubing
202D221/202F221 5.84-7.62 [.23-.30] Tubing
222D221/222F221 5.84-7.62 [.23-.30] Tubing
202D221/202F221 5.92 [.233] Tubing
222D221/222F221 5.92 [.233] Tubing
202D232/202F232 6.86-8.89 [.27-.35] Tubing
222D232/222F232 6.86-8.89 [.27-.35] Tubing
202D2421202F242 7.87-10.16 [.31-.40] Tubing
222D242/222F242 3.30-7.87 [.13-.31] 202E334
202D253/202F253 8.38-10.92 [.33-.43] Tubing
222D253/222F253 3.30-8.38 [.13-.33] 202E334
202D263/202F263 9.65-12.70 [.38-.50] Tubing
222D263/222F263 3.30-9.65 [.13-.38] 202E334
202D274/202F274 11.43-14.99 [.45-.59] Tubing
222D274/222F274 9.91-11.43 [.39-.45] 202E346
222D274/222F274 3.30-9.65 [.13-.38] 202E344
222D274/222F274 13.46-17.53 [.53-.69] Tubing
222D285/222F285 9.91-13.46 [.39-.53] 202E346
222D285/222F285 3.30-9.65 [.13-.38] 202E344
222D1XDU222D1XX — Use tubing as a shim if necessary
Table 2. Shims
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4-24
Materials
Material Selection Table
Tyco Electronics offers Raychem products in a variety of materials to enable designers
and material specifiers to obtain optimum performance.
Material* Characteristics
-3 Molded Part Material
A general purpose, heat-shrinkable semi rigid and flame retarded polyolefin molding compound with
good resistance to fluids and heat. -3 molded parts are ideal for use in applications where toughness
combined with resistance to occasional exposure to fluids or heat is required. -3 molded parts are
recommended for use in System 10.
-3S Molded Part Material
A general purpose, heat-shrinkable flame retarded, polyolefin compound used to make shielded
molded parts.-3S molded parts form part of the Rayaten shielding system and are ideal for use in
applications where toughness combined with resistance to occasional exposure to fluids or heat is
required. -3S molded parts are recommended for use in System 10.
-4 Molded Part Material
A general purpose, heat-shrinkable flexible and flame retarded polyolefin molding compound with good
resistance to fluids and heat. -4 molded parts are ideal for use in applications where toughness
combined with resistance to occasional exposure to fluids or heat is required. -4 molded parts are
recommended for use in System 10.
-6 Molded Part Material Designed for use in applications where extreme flexibility is required. The parts provide excellent strain
relief and sealing over a broad temperature range and remain flexible at very low temperatures. The
standard color is black.
-8 Molded Part Material For use in outer space, where use of low outgassing components is required. The parts provide
excellent strain relief at connector cable terminations. Please contact Raychem for available shapes.
The standard color is black.
-12 Molded Part Material A high temperature, heat-shrinkable, flexible, flame retarded, fluoroelastomeric molding compound with
excellent resistance to long term fluid immersion and heat exposure. Awide range of shapes are
available in this material. -12 molded parts are recommended for use in System 200.
-25 Molded Part Material
A heat-shrinkable, semi rigid, fluid and temperature resistant, elastomeric molding compound,
designed to offer excellent performance in harsh environments. Ideal for use in military vehicles where
high temperatures and long term exposure to hot fluids is expected. A wide range of shapes are
available in this material. -25 molded parts are recommended for use in System 25.
-25S Molded Part Material
A heat-shrinkable, semi rigid, fluid and temperature resistant, elastomeric compound, used to make
shielded molded parts. -25S molded parts form part of the Rayaten shielding system and are ideal for
use in military vehicles where high temperatures and long term exposure to hot fluids is expected.
-25S molded parts are recommended for use in System 25.
-50 Molded Part Material
A heat-shrinkable, highly flexible, fluid and temperature resistant, VPB molding compound, ideal for
use in general purpose and high temperature military applications where exposure to petroleum based
solvents is expected. Uniboots and a wide range of low profile shapes are available in this material.
-50 molded parts are recommended for use in System 30.
-51 Molded Part Material A heat-shrinkable, rugged, flexible, fluid and temperature resistant, EPB molding compound, ideal for
use in general purpose applications where exposure to petroleum based solvents is expected.
Uniboots and a wide range of low profile shapes are available in this material. -51 molded parts are
recommended for use in System 20.
-55 Molded Part Material A heat-shrinkable, flexible, flame retarded, fluid and high temperature resistant, modified fluoropolymer
molding compound. Awide range of shapes is available. -55 molded parts are recommended for use
in System 300.
-71 Molded Part Material Aheat-shrinkable, flexible, fluid and temperature resistant, polyolefin molding compound, ideal for use
in general purpose applications where a good balance of fluid and heat resistance properties is
required. Uniboots and a wide range of low profile shapes are available. -71 molded parts are suitable
for use in System 10.
-100 Molded Part Material A heat-shrinkable, semi flexible, low fire hazard molding compound designed to offer excellent fire
safety characteristics combined with low smoke and low acid gas emission -100 also exhibits good
mechanical and fluid resistance properties. Awide range of shapes are available in this material. -100
molded parts are recommended for use in System 100.
-100S Molded Part Material A heat-shrinkable, semi flexible, low fire hazard compound used to make shielded molded parts. 100S
molded parts form part of the Rayaten shielding system and are designed to offer excellent fire safety
characteristics combined with low smoke and low acid gas emission. -100S also exhibits good mech-
anical and fluid resistance properties. -100S molded parts are recommended for use in System 100.
-125 Molded Part Material Aheat-shrinkable, flame retarded, fluid and high temperature resistant, modified fluoropolymer molding
compound. Arange of shapes are available. -125 molded parts are recommended for use in System
300.
-130 Molded Part Material Non flame-retarded molded material. Low shrink temperature.
-146 Molded Part Material Flame retarded, ultra-high ratio heat-shrinkable material.
-152 Molded Part Material Flame retarded, high ratio heat-shrinkable material.
*Check with specific part page for applicable materials.
Applications
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Materials
4-25
-3
Semi-Rigid Modified
Polyolefin
Applications
Raychem molded parts in
-3 material are designed for
use in general harnessing
applications where
toughness is required and
systems are occasionally
exposed to fluids or heat.
The adhesive-lined parts
provide excellent sealing
and strain relief at
connector-cable
terminations and transitions.
Awide range of shapes are
available in this material.
The standard color is black.
Installation
Raychem -3 molded parts
will shrink on the application
of heat above 125°C
[257°F].
Recommended installation
temperature: 150°C [302°F]
Product Facts
nHeat-shrinkable
nSemi-Rigid
nFlame Retardant
nGood resistance to fluids
and heat
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-26
-3 (Continued)
Military Raychem
ULSAE-AS81765/1, Type I
224, File E85381 Def. Stan. 59-97 Issue 3 Type DA(Europe) RT-301
BS-G-198-5-DA (Europe)
Product Characteristics
Specification Requirements Test Method
Tensile strength 10.5 MPa (min.) ISO 37; ASTM D 412
Physical Ultimate elongation 250% (min.) ISO 37; ASTM D 412
2%secant modulus 80–160 MPa ASTM D 882
Specific gravity 1.4 (max.) ISO 1183; ASTM D 792
Heat aging for 168 h at 175°C [347°F] Ultimate elongation 150% (min.) ISO 188, ISO 37
Thermal Heat shock for 4 h at 225°C [437°F] No dripping, cracking, or flowing ASTM D 2671
Low-temperature flex at -55°C [-67°F] No cracking during mandrel bend RK-6703, CL 2.7: RT-301 Sec. 4.3.4
Flammability Self-extinguishing RK-6703, CL 2.8: ASTM D 635
Electrical Electric strength 8 MV/m (min.) IEC 243
Water absorption — 0.5% (max.) ISO 62
Aviation fuel F40 Tensile strength 8.5 MPa (min.) ISO 1817 and ISO 37
Ultimate elongation 200% (min.) after immersion for 24 h at 23°C[73°F]
Fluid resistance Lubricating oil O-149 Tensile strength 8.5 MPa (min.) ISO 1817 and ISO 37
Ultimate elongation 200% (min.) after immersion for 24 h at 23°C[73°F]
Phosphate ester hydraulic fluid Tensile strength 8.5 MPa (min.) ISO 1817 and ISO 37
(DTD 900/4881A) Ultimate elongation 200% (min.) after immersion for 24 h at 23°C [73°F]
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-27
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-4
Applications
Raychem molded parts in
-4 material are designed for
use in general harnessing
applications where
toughness is required and
systems are occasionally
exposed to fluids or heat.
The adhesive-lined parts
provide excellent sealing
and strain relief at
connector-cable
terminations and transitions.
Awide range of shapes are
available in this material.
The standard color is black.
Installation
Raychem -4 molded parts
will shrink on the application
of heat above 100°C
[212°F].
Recommended installation
temperature: 150°C [302°F]
Product Facts
nHeat-shrinkable
nFlexible
nFlame Retardant
nGood resistance to fluids
and heat
Flexible Polyolefin
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-28
-4 (Continued)
Military Raychem
UL
224, File E85381 SAE-AS81765/1, Type II RT-1304
Product Characteristics
Specification Requirements Test Method
Tensile strength 1800 psi (min.) ASTM D 412
Physical Ultimate elongation 400% (min.) ASTM D 412
Specific gravity 1.3 (max.) ASTM D 792
Heat aging for 168 h at 175°C[347°F] Ultimate elongation 300% (min.) RT 1304 Sec. 4.3.3
Thermal Heat shock for 4 h at 225°C [437°F] No dripping, flowing, or cracking RT 1304 Sec. 4.3.5
Low-temperature flex at -55°C [-67°F] No cracking RT 1304 Sec. 4.3.4
Flammability (burn time) Average flame time: 120 s (max.) ASTM D 635
Electrical Dielectric strength 350 V/mil (min.) ASTM D 149
Water absorption — 0.3% (max.) ASTM D 570
Fluid resistance JP-4 fuel, aviation gasoline, water, Tensile strength 8.5 MPa psi (min.) RT-1304 Sec. 4.3.3
hydraulic fluid Ultimate elongation 200% (min.)
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-29
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-12
Applications
Raychem -12 molded parts
with Viton®fluoroelastomers
are designed to be used in
conjunction with tubing
made from Viton®fluoro-
elastomers or multi-
conductor cable jackets
and a suitable adhesive
in Raychem System 200.
This system provides
excellent resistance to
elevated temperatures and
continuous fuel immersion.
Available in a wide range of
configurations, -12 molded
parts will operate from -
55°C [-67°F] to 200°C
[392°F]. The standardcolor
is black.
Product Facts
nHeat-shrinkable, flexible,
fluid-resistant modified
fluoro-elastomer
nExcellent resistance to long-
term fuel immersion
Installation
Raychem -12 molded parts
will shrink on the application
of heat above 175°C
[347°F].
Recommended installation
temperature: 220°C [428°F]
Modified Fluoroelastomer
Operating Temperature Range
-55°Cto 200°C
[-67°F to 392°F]
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Materials
4-30
-12 (Continued)
Military Raychem
SAE-AS81765/4 RT-1312
Def. Stan. 59-97 Issue 3 Type DD (Europe) —
BS-G-198-5-DD-P (Europe) —
Product Characteristics
Specification Requirements Test Method
Tensile strength 12.4 MPa (min.) ISO 37
Physical Ultimate elongation 300% (min.) ISO 37
2%secant modulus 70 MPa (max.) ASTM D 882
Specific gravity 1.95 (max.) ISO 1183
Heat aging for 168 h at 250°C [482°F] Ultimate elongation 250% (min.) ISO 188, ISO 37
Thermal Heat shock for 4 h at 300°C [572°F] No dripping, cracking, or flowing ASTM D 2671
Low temperature flex at -55°C [-67°F] No cracking ASTM D 2671
Flammability (burn time) 30 s (max.) ASTM D 635
Electrical Electric strength 8 MV/m (min). IEC 243
Water absorption — 0.5% (max.) ISO 62
Aviation fuel F40 Tensile strength 11 MPa (min.) ISO 1817
Ultimate elongation 200% (min.) after immersion for 24 h at 23°C[73°F]
Fluid resistance Lubricating oil O-149 Tensile strength 11 MPa (min.) ISO 1817
Ultimate elongation 200% (min.) after immersion for 24 h at 93°C[200°F]
Hydraulic fluid H515 Tensile strength 11MPa (min.) ISO 1817
Ultimate elongation 200% (min.) after immersion for 24 h at 93°C [200°F]
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-31
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-25
Applications
Raychem heat-shrinkable
molded parts in -25 material
are designed to be used in
conjunction with other
System 25 components
such as DR-25 tubing and
S1125 adhesive, providing
acomplete cable harness
system capability.
-25 parts have been
specifically formulated
and designed to provide
optimum high-temperature
fluid resistance and long-
term heat resistance.
This unique balance of
properties makes -25 parts
particularly suitable for
sealing and strain relief
at connector-cable
terminations and cable-to-
cable transitions on military
vehicle cables and
harnesses. Available in a
wide range of configura-
tions, -25 parts will operate
from -75°C to 150°C [-103°F
to 302°F] for long periods.
The standard color is black.
Operating Temperature Range
-75°Cto 150°C
[-103°F to 302°F]
Installation
Raychem -25 molded parts
will shrink on the applica-
tion of heat above 135°C
[275°F].
Recommended installation
temperature: 175°C [347°F]
Product Facts
nHeat-shrinkable, semi-rigid,
chemical- and abrasion-
resistant molded shapes
nExcellent resistance to high-
temperature fluids
nResistance to long-term
exposure at elevated
temperatures
Fluid-Resistant Modified
Elastomer
Available in: Americas Europe Asia Pacific
nnn
Materials
4-32
-25 (Continued)
Military Raychem
VG95343 Parts 6, 7, 8 and 9 (Europe) RT-1325
Def Stan 59-97, Issue 3, Type DE (Europe) —
BSG-198-5-DE-P —
Product Characteristics
Specification Requirements Test Method
Tensile strength 15 MPa (min.) ASTM D 412
Physical Ultimate elongation 350% (min.) ASTM D 412
Specific gravity 1.5 (max.) ASTM D 792
Heat aging for 168 h at 150°C[302°F Ultimate elongation 300% (min.) ASTM D 412
Thermal Heat shock for 4 h at 225°C [437°F] No dripping, cracking, or flowing ASTM D 2671
Low-temperature flex for 4 h at -70°C [-94°F] No cracking during mandrel bend ASTM D 2671
Flammability (burn time) 120 s (max.) ASTM D 635
Electrical Electric strength 8MV/m ASTM D 149
Aviation fuel JP-4 Tensile strength 12 MPa (min.) ASTM D 412
(MIL-T-5624) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Hydraulic fluid Tensile strength 12 MPa (min.) ASTM D 412
Fluid resistance (MIL-H-6083) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Diesel fuel Tensile strength 12 MPa (min.) ASTM D 412
(VV-F-800 No 2) Ultimate elongation 300% (min.) after immersion for 24 h at 50°C [122°F]
Automotive gasoline Tensile strength 12 MPa (min.) ASTM D 412
(MIL-G-3056) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-33
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-25S
Applications
Rayaten screened molded
parts in -25S material are
designed for use with
FDR-25 or DR-25 jacketed
screened multiconductor
cable and S1125 adhesive
to provide a complete high-
performance harness
system offering high levels
of RFI and EMI protection.
This -25 material provides
optimum high-temperature
fluid-resistance and long-
term heat-aging properties.
The material is particularly
suitable for providing
encapsulation, mechanical
protection, and strain
relief on terminations and
cable transitions in harsh
environments.The standard
color is black. Products
made from this material are
normally used in an assembly
(see section 7).
Operating Temperature Range
-55°Cto 150°C
[-67°F to 302°F]
Product Facts
nFuel and heat resistance
nRFI, EMI protection
Fluid-Resistant Screened
Elastomer
Available in: Americas Europe Asia Pacific
nnn
Materials
4-34
-25S (Continued)
Military Raychem
VG95343 Pt. 20, Pt. 22 RK-6719
Product Characteristics
Screening effectiveness in dB at
Specification 3KHz to >30 MHz to
Requirements* 30 MHz (min.) 100 MHz (min.)
Tensile strength: 12 MPa (min.) — —
Initial values Ultimate elongation: 400% (min.) — —
Metal adhesion: 15 N/cm (min.) — —
Shielding effectiveness 75 70
Tensile strength: 12 MPa (min.) — —
Heat shock (1/2 h at 200°C [392°F]) Ultimate elongation: 400% (min.) — —
Thermal Shielding effectiveness 75 70
Tensile strength: 12 MPa (min.) — —
Heat aging (168 h at 160°C [320°F]) Ultimate elongation: 400% (min.) — —
Shielding effectiveness 75 70
3thermal cycles of -75°C to 150°C
[-103°F to 302°F] Shielding effectiveness 75 70
Immersion in the following fluids for 24 h: Tensile strength: 10 MPa (min.) — —
Lubricating oil (O-156, at 100°C [212°F]) Ultimate elongation: 300% (min.) — —
Shielding effectiveness 75 70
Tensile strength: 10 MPa (min.) — —
Hydraulic fluid H515, at 50°C[122°F] Ultimate elongation: 300% (min.) — —
Shielding effectiveness 75 70
Chemical Tensile strength: 10 MPa (min.) — —
Aviation fuel JP4 F40, at 23°C [73°F] Ultimate elongation: 300% (min.) — —
Shielding effectiveness 75 70
Tensile strength: 10 MPa (min.) — —
Diesel fuel F54, at 23°C [73°F] Ultimate elongation: 300% (min.) — —
Shielding effectiveness 75 70
Tensile strength: 10 MPa (min.) — —
1, 1, 1, trichloroethane (1 h, at 23°C [73°F]) Ultimate elongation: 300% (min.) — —
Shielding effectiveness 75 70
*Values quoted are for the polymer/metal composite in all cases when terminated using epoxy adhesives.
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-35
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-50
Applications
Ahigh-performance blend
of Viton®and other poly-
mers, Raychem -50 offers
excellent fluid and tempera-
ture resistance. It is suitable
for use in most areas of
militaryvehicle harnessing.
This material is available
in the Uniboot range and
should be chosen in
applications that use
System 30 components.
The standard color is black.
Installation
Raychem -50 molded parts
will shrink on the application
of heat above 125°C
[257°F].
Recommended installation
temperatureis 175°C
[347°F]
Fluid-Resistant Modified
Elastomer
Product Facts
nExcellent heat and fluid
resistance
nLow profile
nRugged
nLightweight
Operating Temperature Range
-55°Cto 150°C
[-67°F to 302°F]
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Materials
4-36
-50 (Continued)
Military Raychem
SC-X-15111 (U.S.) RT-1313
Product Characteristics
Specification Requirements Test Method
Tensile strength 15 MPa (min.) ASTM D 412
Physical Ultimate elongation 350% (min.) ASTM D 412
Specific gravity 1.5 (max.) ASTM D 792
Heat aging for 168 h at 150°C[302°F] Ultimate elongation 300% (min.) ASTM D 412
Thermal Heat shock for 4 h at 225°C [437°F] No dripping, cracking, or flowing ASTM D 2671
Low-temperature flex for 4 h at -70°C [-94°F] No cracking during mandrel bend ASTM D 2671
Flammability (burn time) 120 s (max.) ASTM D 635
Electrical Electric strength 8MV/m ASTM D 149
Aviation fuel JP-4 Tensile strength 12 MPa (min.) ASTM D 412
(MIL-T-5624) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Hydraulic fluid Tensile strength 12 MPa (min.) ASTM D 412
Fluid resistance (MIL-H-6083) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Diesel fuel Tensile strength 12 MPa (min.) ASTM D 412
(VV-F-800 No 2) Ultimate elongation 300% (min.) after immersion for 24 h at 50°C [122°F]
Automotive gasoline Tensile strength 12 MPa (min.) ASTM D 412
(MIL-G-3056) Ultimate elongation 300% (min.) after immersion for 24 h at 25°C [77°F]
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-37
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-51
Applications
Ahigh-performance
elastomeric blend of
polymers, Raychem -51
offers excellent fluid
resistance.
It is suitable for use in most
areas of military vehicle
harnessing. This material
is available in the Uniboot
range and other slimline
boots and transitions. The
standard color is black.
Installation
Raychem -51 molded parts
will shrink on the application
of heat above 125°C
[257°F].
Recommended installation
temperatureis 150°C
[302°F]
Product Facts
nExcellent fuel resistance
nLow profile
nRugged
nLightweight
Chemical-Resistant
Fluoroelastomer
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-38
-51 (Continued)
Military Raychem
SC-X-15112 (U.S.) RT-1321
Product Characteristics
Specification Requirements Test Method
Tensile strength 1500 psi (min.) ASTM D 412
Physical Ultimate elongation 300% (min.) ASTM D 412
Specific gravity 1.6 (max.) ASTM D 792
Heat aging for 168 h at 121°C [250°F] Tensile strength 1200 psi. (min.) RT-1321 Sec. 4.3.3
Elongation 250% (min.) RT-1321 Sec. 4.3.3
Thermal Heat shock for 4 h at 200°C [392°F] No dripping, flowing, or cracking RT-1321 Sec. 4.3.5
Low-temperature flex for 4 h at -55°C[-67°F] No cracking RT-1321 Sec. 4.3.4
Flammability (burn time) 120 seconds, 1 inch (max.) ASTM D 635
Electrical Dielectric strength 200 V/mil (min.) ASTM D 149
Lubricating oil, diesel oil, water for 24 h Tensile strength 1000 psi (min.)
at 25°C[77°F] Elongation 225% (min.) RT-1321 Sec. 4.3.3 and 4.3.7
Weight increase 10% (max.)
Tensile strength 800 psi (min.)
Gasoline for 24 h at 25°C [77°F] Elongation 225% (min.) RT-1321 Sec. 4.3.3 and 4.3.7
Fluid resistance Weight increase 25% (max.)
Isopropyl alcohol, cleaning fluid for 24 h Tensile strength 1400 psi (min.)
at 25°C 77°F] Elongation 225% (min.) RT-1321 Sec. 4.3.3 and 4.3.7
Weight increase 10% (max.)
Tensile strength 1000 psi (min.)
Hydraulic fluid for 24 h at 71°C[160°F] Elongation 225% (min.) RT-1321 Sec. 4.3.3 and 4.3.7
Weight increase 25% (max.)
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
-55
Flexible Fluoropolymer Applications
Aheat-shrinkable, flexible,
flame retardant, fluid and
high temperature resistant,
modified fluoropolymer
molding compound. -55
molded parts are ideal for
use in applications where
chemical resistance and
abrasion resistance is
required. A wide range of
shapes are available. -55
molded parts are recom-
mended for use in System
300.
Use the System 300 family
of parts in military and
industrial applications
where excellent high
temperature performance
and good physical and
chemical properties are a
requirement.
System 300 jacketing is
based on a modified fluo-
ropolymer and features a
one part epoxy adhesive in
tape form.
Installation
This specification covers
the requirements for one
type of flexible, electrical
insulating molded compo-
nent whose expanded
dimensions will reduce to a
predetermined size upon
the application of heat in
excess of 220°C [428°F].
RT-1330
Tensile Strength psi (MPa) 3500 minimum (24.1) Section 4.3.3
Ultimate Elongation percent 200 minimum ASTM D 2671
Specific Gravity — 2.0 maximum ASTM D 792
Low Temperature Flexibility — No cracking Section 4.3.4
Physical 4hours at -65 ±2°C [-85 ± 4°F]
Heat Shock — No dripping, flowing or cracking Section 4.3.5
4hours at 300°C [572°F]
Heat Resistance
336 hours at 250°C[482°F] — — Section 4.3.6
Followed by tests for:
Tensile Strength psi (MPa) 2000 minimum (13.8) Section 4.3.3
Elongation percent 150 minimum ASTM D 2671
Product Facts
nFlame retardant
nAbrasion and cut through
resistance
nFlexible
nHigh temperature resistance
nHigh fluid resistance
nEnvironmentally sealed
Operating Temperature Range
-65°C to 200°C
[-85°f to 392°F]
Specifications/Approvals
Product Characteristics
Available in: Americas Europe Asia Pacific
nnn
Materials
4-40
-55 (Continued)
Electrical
Dielectric Strength volts/mil 200 minimum ASTM D 149
Volume Resistivity ohm-cm 1011 minimum ASTM D 257
Chemical
Corrosive Effect Section 4.3.7
16hours at 200 ± 3°C [392 ± 5°F] —Noncorrosive ASTM D 2671
Procedure A
Flammability
Average Time of Burning seconds 15 maximum ASTM D 635
Average Extent of Burning inches (mm) 0.5 maximum (12.5)
Fungus Resistance — Rating of 1 or less ASTM G 21
W ater Absorption percent 0.5 maximum ASTM D 570
24 hours at 23 ± 3°C [73 ± 5°F)]
Fluid Resistance — — Section 4.3.8
24hours at 23 ± 3°C [73 ± 5°F] in:
Gasoline, Aviation Grade 100
(ASTM D 910)
1,1,1 T richloroethane
(MIL-T-81533)
Coolanol 25
Followed by tests for:
Tensile Strength psi (MPa) 3000 minimum (20.7) Section 4.3.3
Ultimate Elongation percent 150 minimum ASTM D 2671
24hours at 50 ± 3°C [122 ± 5°F] in:
JP-5 (MIL-T-5624)
Deicing Fluid (MIL-A-8243)
Cleaning Compound
(MIL-C-43616)
5% Salt Solution (O-S-1926)
Fuel Oil, Diesel (VV-F-800, DF-2)
Followed by tests for:
Tensile Strength psi (MPa) 3000 minimum (20.7) Section 4.3.3
Ultimate Elongation percent 150 minimum ASTM D 2671
24 hours at 75 ± 3°C[167 ± 5°F] in: — — Section 4.3.8
Hydraulic Fluid (MIL-H-5606)
Skydrol® 500
Lubricating Oil (MIL-L-2104)
Lubricating Oil (MIL-L-7808)
Followed by tests for:
Tensile Strength psi (MPa) 3000 minimum (20.7) Section 4,3.3
Ultimate Elongation percent 150 minimum ASTM D 2671
Fluid Resistance — — Section 4.3.8
5hours at 23 ± 3°C [73± 5°F]
Tensile Strength psi (MPa) 3500 minimum (24.1) Section 4.3.3
Ultimate Elongation Percent 150 minimum ASTM D 2671
Nuclear Section 4.3.9
Radiation Resistance
Followed by tests for:
Tensile Strength psi (MPa) 3500 minimum (24.1) —
Ultimate Elongation percent 150 minimum
Product Characteristics
(Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-41
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-71
Applications
Raychem -71 is a flexible,
flame-retardant polyolefin
suitable for use in general
harnessing applications.
The material is very flexible
and offers a good balance
of fluid and heat resistance.
If Uniboot molded parts are
required, -71 should be
chosen as a replacement
for -3. The standardcolor is
black.
Installation
Raychem -71 molded parts
will shrink on the application
of heat above 100°C
[212°F].
Recommended installation
temperatureis 150°C
[302°F]
Product Facts
nFlexible
nFlame-retardant
Semirigid Modified
Polyolefin
Operating Temperature Range
-55°Cto 135°C
-67°F to 275°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-42
-71 (Continued)
Military Raychem
SAE-AS81765/1, Type I RT-1316
Specification Requirements Test Method
Tensile strength 10 MPa (min.) ASTM D 412
Physical Ultimate elongation 250% (min.) ASTM D 412
Specific gravity 1.40 (max.) ASTM D 792
Heat aging for 168 hr at 175°C [347°F] Ultimate elongation 200% (min.) ASTM D 412
Thermal Heat shock for 4 h at 250°C [482°F] No dripping, cracking, or flowing ASTM D 2671
Low-temperature flex for 4 h at -55°C[-67°F] No cracking during mandrel bend ASTM D 2671
Flammability (burn time) 90s(max.) ASTM D 635
Electrical Electric strength 8 MV/m ASTM D 149
Water absorption — 0.5% (max.) ASTM D 570
Aviation fuel JP-4 Tensile strength 5 MPa (min.) ASTM D 412 after
(MIL-T-5624) Ultimate elongation 200% (min.) immersion for 24 h at 25°C [77°F]
Lubricating oil O-149 Tensile strength 5 MPa (min.) ASTM D 412 after
Fluid resistance (MIL-L-7808) Ultimate elongation 200% (min.) immersion for 24 h at 25°C[77°F]
Hydraulic fluid Tensile strength 5 MPa (min.) ASTM D 412 after
(MIL-H-5606) Ultimate elongation 200% (min.) immersion for 24 h at 25°C [77°F]
Skydrol® 500 Tensile strength 5 MPa (min.) ASTM D 412 after
Ultimate elongation 200% (min.) immersion for 24 h at 25°C [77°F]
Product Characteristics
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-43
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-100
Applications
Raychem heat-shrinkable
molded parts in -100
material formpartof
Raychem’sSystem 100.
The molded parts are
designed for use in
conjunction with Raychem
Zerohal cable and tubing
for applications where
hazard reduction in the
event of fireis crucial. The
material exhibits excellent
fire safety characteristics
combined with low-smoke
and low-acid-gas emission
while retaining good
mechanical and fluid-
resistant properties. -100
parts with adhesive lining
provide location, sealing,
and strain relief of cable-
connector terminations and
cable–cable transitions on
harnesses used where
there is a need to lower
the risk (such as in marine
applications, mass transit
systems, and offshore
installations), or where
equipment would be
irreparably damaged by
the corrosive products of
combustion. Available in
awide range of
configurations, -100 parts
will operate continuously
from -30°C to 105°C
[-22°Fto 221°F].
The standard color is black.
Installation
Raychem -100 molded
parts will shrink on the
application of heat above
120°C [248°F].
Recommended installation
temperature: 150°C [302°F]
Product Facts
nHeat-shrinkable,
semiflexible molded shapes
for low fire hazard
applications
nLow-smoke index as defined
by BS G 198 Part 5
nLow-toxicity index as
defined by NES 713
nHigh-temperature index as
defined by ISO 4589-3
Low-Fire-Hazard Material
Operating Temperature Range
-30°Cto 105°C
[-22°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-44
-100 (Continued)
Military/NAVSEA Raychem
5617649 (U.S.) RT-1323
RK-6717
Def. Stan 59-97, Issue 3, Type DF (Europe) —
BSG 198 Part 5 Type DF (Europe) —
BR1326 listed Class C —
Specification Requirements Test Method
Tensile strength 8 MPa (min.) ISO 37
Physical Ultimate elongation 200% (min.) ISO 37
2% secant modulus 130 MPa (max.) ASTM D 882
Specific gravity 1.5 (max.) ISO 1183
Heat aging for 168 h at 150°C [302°F] Ultimate elongation 100% (min.) ISO 188, ISO 37
Thermal Heat shock for 4 h at 225°C [437°F] No dripping, cracking, or flowing ASTM D 2671
Low-temperature flex at -30°C [-22°F] No cracking during mandrel bend ASTM D 2671
Limiting oxygen index 29 min. ISO 4589-2
Temperature index 250
°C[482°F]
(min.) ISO 4589-3
Fire safety properties Flammability (burn time) 100 s (max.) ASTM D 635
Smoke index 20 (max.) BSG 198 Part 5
Toxicity index 5 (max.) per 100 g NES 713
Electrical Electric strength 15 MV/m (min.) IEC 243
Water absorption — 0.75% (max.) at 23°C [73°F] ISO 62
3.5% (max.) at 70°C [158°F]
ISO 1817 Gasoline fuel Tensile strength 5 MPa (min.) ISO 1817 and ISO 37
Ultimate elongation 150% (min.) after immersion for 24 h at 23°C [73°F]
Fluid resistance Lubricating oil O-149 Tensile strength 5 MPa (min.) ISO 1817 and ISO 37
Ultimate elongation 150% (min.) after immersion for 24 h at 50°C [122°F]
Hydraulic fluid H515 Tensile strength 5 MPa (min.) ISO 1817 and ISO 37
Ultimate elongation 150% (min.) after immersion for 24 h at 23°C [73°F]
Product Characteristics
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-45
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-100S
Applications
-100S is the Zerohal
material option in Raychem
Rayaten shield (screen)
termination system. This
material combines the fire
safety properties of -100
with the excellent EMI and
RFI screening of Rayaten
screened molded parts
where there is a need to
lower the risk.
-100S is suitable for high-
performance screen
terminations in areas where
Raychem Zerohal materials
arerequired.
The standard color is black.
Products made from these
materials are normally
used in an assembly
(see section 7).
Low-Fire-Hazard Screened
Material
Product Facts
nScreened Zerohal material
nLow smoke index as defined
by NES 711
nLow toxicity index as defined
by NES 713
nHigh temperature index as
defined by NES 715
Operating Temperature Range
-30°Cto 105°C
[-22°F to 221°F]
Available in: Americas Europe Asia Pacific
nnn
Materials
4-46
-100S (Continued)
Military Raychem
VG95343 Pt. 20, Pt. 22 RK-6724
Screening Effectiveness
indB at
Specification Requirements* 3 KHz to >30 MHz to
30MHz 100 MHz
(min.) (min.)
Tensile strength: 7 MPa (min.)
Initial values Metal adhesion: 15 N/cm (min.) 75 70
Shielding effectiveness
Thermal Heat shock (1/2 h at 200°C [392°F]) Metal adhesion: 15 N/cm (min.)
Shielding effectiveness 7570
Heat aging (168 h at 150°C[302°F]) Metal adhesion: 15 N/cm (min.)
Shielding effectiveness 75 70
Immersion in the following fluids for 24 h:
Phosphate ester hydraulic fluid Tensile strength: 5 MPa (min.)
DTD900/4881 at 23°C [73°F] Shielding effectiveness 75 70
Fluids W ater at 23°C [73°F] Tensile strength: 5 MPa (min.)
Shielding effectiveness 75 70
Lubricating oil O-149 at 50°C[122°F] Tensile strength: 5 MPa (min.)
Shielding effectiveness 75 70
T ransformer oil S-756 at 50°C [122°F] Tensile strength: 5 MPa (min.)
Shielding effectiveness 75 70
*Values quoted are for the polymer/metal composite in all cases when terminated using epoxy adhesives. (Refer to section 5.)
Product Characteristics
Specifications/Approvals
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Materials
4-47
4
Molded Parts
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
-125
Applications
Aheat-shrinkable, flame
retardant, fluid and high
temperature resistant, modi-
fied fluoropolymer molding
compound. A range
of shapes is available.
-125 molded parts are
recommended for use in
System 300.
Use the System 300 family
of parts in military and
industrial applications
where excellent high
temperature performance
and good physical and
chemical properties are a
requirement.
System 300 jacketing is
based on a modified fluo-
ropolymer and features a
one part epoxy adhesive in
tape form.
Installation
This specification covers
the requirements for one
type of electrically insulat-
ing molded component
whose dimensions will
reduce to a predetermined
size upon the application of
heat in excess of 160°C ±
3°C [320°F ± 5°F].
RT-1334
Elastic Memory Percent 275 minimum expansion Section 4.3.2
90 minimum retraction
Tensile Strength psi (MPa) 4000 minimum (27.5) Section 4.3.3
Ultimate Elongation Percent 300 minimum ASTM D 412
Secant Modulus psi (MPa) 100,000 maximum (689) Section 4.3.4
ASTM D 882
Specific Gravity —1.85 maximum ASTM D 792
Low Temperature Flexibility — No cracking Section 4.3.5
4hours at -57 ± 3°C [-70 ± 5°F]
Heat Shock —No dripping, flowing or cracking Section 4.3.6
Physical 4hours at 300 ± 5°C [572 ± 9°F]
Heat Resistance — — Section 4.3.7.1
168 hours at 250 ± 5°C [482 ± 9°F]
Followed by tests for:
Tensile Strength psi (MPa) 3500 minimum (24.1) Section 4.3.3
Ultimate Elongation Percent 250 minimum Section 4.3.3
2000 hours at 150 ± 3°C [302 ± 5°F] — — Section 4.3.7.2
Followed by tests for:
Tensile Strength psi (MPa) 3500 minimum (24.1) Section 4.3.3
Ultimate Elongation Percent 250 minimum Section 4.3.3
Product Facts
nFlame retardant
nAbrasion and cut through
resistance
nHigh temperature resistance
nHigh fluid resistance
nEnvironmentally sealed
Operating Temperature Range
-55°C to 175°C
[-67°F to 347°F]
Flexible Fluoropolymer
Product Characteristics
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nnn
Materials
4-48
-125 (Continued)
Electrical
Dielectric Strength Volts/mil (kV/mm) 300 minimum (11.9) ASTM D 149
Volume Resistivity ohm-cm 1013 minimum ASTM D 257
Chemical
Corrosive Effect Section 4.3.8
16hours at 175 ± 3°C [347 ± 5°F] —Noncorrosive ASTM D 2671
Procedure A
Flammability
Initial
Average Time of Burning Seconds 15 maximum ASTM D 635
Average Extent of Burning Inches (mm) 1 maximum (25)
After Fluid Immersion
24hours at 23 ± 3°C [73 ± 5°F]
Gasoline, Automotive, Section 4.3.10
Combat MIL-G-3056
Fuel Oil, Diesel VV-F-800 DF-2
Turbine Fuel, Aviation, JP-4 Seconds 30 maximum ASTM D 635
MIL-T-5624 Inches (mm) 1 maximum (25)
Average Time of Burning
Average Extent of Burning
Fungus Resistance — Rating of 1 or less ASTM G 21
W ater Absorption Percent 0.5 maximum ASTM D 570
24hours at 23 ± 3°C [73 ± 5°F]
Fluid Resistance — — Section 4.3.9
24 hours at 23 ± 3°C [73 ± 5°F]
Gasoline, Automotive, Combat MIL-G-3056
24hours at 50 ± 3°C [122 ± 5°F]
Fuel Oil Diesel VV-F-800 DF-2
Turbine Fuel, Aviation, JP-4
MIL-T-5624
Electrolyte 10873919
5% Salt Solution O-S-1926
Anti-Icing & Defrosting Fluid MIL-A-8243
Lube Oil, Aircraft, Synthetic MIL-L-23699
Lube Oil MIL-L-2104
Lube Oil, Aircraft, Synthetic MIL-L-7808
24 hours at 100 ± 3°C [212 ± 5°F]
Hydraulic Fluid, Synthetic MIL-H-46170
4hours at 50 ± 3°C [122 ± 5°F]
Cleaning Compound PC-437
5hours at 23 ± 3°C [73 ± 5°F]
Decontaminating Agent, DS-2 MIL-D-50030
Decontaminating Agent STB MIL-D-12468
Followed by tests for:
Tensile Strength psi (MPa) 3000 minimum (20.7) Section 4.3.3
Ultimate Elongation Percent 250 minimum Section 4.3.3
Weight Increase Percent 3maximum Section 4.3.9
Adhesive Compatibility
Lap Shear Strength psi (kPa) 100 minimum (689) Section 4.3.11
NSM to S-1264 to DCNS
Nuclear
Radiation Resistance Section 4.3.12
Followed by tests for:
Tensile Strength psi (MPa) 4000 (27.6) Section 4.3.3
Ultimate Elongation Percent 250
Product Characteristics
(Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Caps
End Caps, 101A011 to 094
Use for protecting cables
and pipes or capping
unused outlets in transi-
tions. Provides an environ-
mental seal when used with
adhesive.
Raychem end caps provide
optimum waterproofing and
environmental protection for
underwater, underground,
or outdoor applications.
The end caps are highly
resistant to moisture,
fungus, and weathering.
H Dia
.
HW P
H Dia.
H Dia
.
HW P
H Dia.
After Unrestricted Recovery (b)
AsSupplied (a)
Applications
Product Dimensions HPHW
Part Min. Max. Min. ±20%
No. abbb
101A011 5.10 [.20] 2.00 [.08] 22.90 [.90] 1.02 [.04]
101A021 7.40 [.29] 3.30 [.13] 25.40 [1.00] 1.27 [.05]
101A031 10.20 [.40] 4.80 [.18] 30.50 [1.20] 1.52 [.06]
101A041 15.20 [.60] 6.40 [.25] 40.60 [1.60] 1.78 [.07]
101A052 20.60 [.81] 9.40 [.37] 61.00 [2.40] 2.03 [.08]
101A062 25.40 [1.00] 11.40 [.45] 68.80 [2.70] 2.29 [.09]
101A073 39.40 [1.56] 18.00 [.71] 91.40 [3.60] 2.54 [.10]
101A083 50.80 [2.00] 22.90 [.90] 101.60 [4.00] 2.79 [.11]
101A094 83.80 [3.30] 38.10 [1.50] 114.30 [4.50] 3.05 [.12]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
Available in: Americas Europe Asia Pacific
nnn
Caps
4-50 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
End Caps, 101A011 to 094 (Continued)
Materials Available Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /180 S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
VITON is a trademark of Dupont Dow
Elastomers LLC.
Caps
4-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
SSC
Applications
These SSC heat-shrinkable
end caps are made from
athermally stabilized,
modified polyolefin, which
makes them highly resistant
to moisture, fungus, and
weathering. The end caps
also have excellent
electrical properties. End
caps coated with sealant
areavailable for underwater
Product Facts
nSelf-sealing for
waterproofing (sealant-
coated parts only)
nElectrical insulation to
1000 V
nAbrasion-resistance
nMechanical protection
nEasy installation, requiring
no special skills
nOperating temperature range
of -40°C to 85°C [-40°F to
185°F]
nMinimum shrink
temperature of 121°C
[250°F]
Heat-Shrinkable End Caps
or underground applica-
tions with a pressurediffer-
ential up to 20 psi between
the inside of the cable and
the outside environment.
End caps may be used over
lead, steel, aluminum,
copper, polyethylene,
polyolefin, EPR, and PVC
jacketing materials.
Available in: Americas Europe Asia Pacific
nnn
Caps
4-52 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SSC (Continued)
Type Raychem Military/Commercial
SSC-X and SSC-XTV SSC specification control drawing PPS-3011/6
— RT-1050-1 —
— RW-2019 —
—RW-2024 —
Caps have 1239 adhesive, Raychem Specification PPS 3012/70
Military
SSC-XTV Sealing end cap with adhesive
SSC-X Sealing end cap with adhesive
SSC-XU End cap, uncoated
Part Inner Diameter* Part Length Wall Thickness (nom.)
No. As Supplied Recovered Recovered Recovered
(min.) (max.) ± 10 % ±20 %
SSC-1 10.00 [.390] 4.00 [.160] 33.50 [1.320] 2.00 [.080]
SSC-2 20.00 [.790] 7.50 [.300] 55.30 [2.180] 2.30 [.090]
SSC-3 35.00 [1.380] 15.00 [.590] 89.90 [3.540] 3.00 [.120]
SSC-4 55.00 [2.170] 25.00 [.980] 143.20 [5.640] 3.30 [.130]
SSC-5 75.00 [2.950] 32.00 [1.250] 150.10 [5.910] 3.30 [.130]
SSC-5M1 75.00 [2.950] 32.00 [1.250] 79.25 [3.120] 3.30 [.130]
SSC-6 100.00 [3.940] 45.00 [1.770] 162.50 [6.400] 4.00 [.160]
SSC-7 120.00 [4.720] 70.00 [2.760] 145.00 [5.710] 3.80 [.150]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
*Adhesive is optional. As-supplied dimensions appearing in table are for uncoated parts. When adhesive is added,
entry diameters will be reduced by 1.5 [.06] maximum.
Specifications/Approvals
Product Dimensions
Ordering Information
Boots
4-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202A111 to 196
Applications
Use for mechanical protec-
tion and connector/cable
strain relief. This family of
boots has no lip, so that
aboot can be installed
directly onto the connector
accessory thread.
Tan
202A111 to 196
HDia. JDia.
P
W
RJO
Tan
H Dia. J
Tan
202A111 to 196
HDia. JDia.
P
W
RJO
Tan
H Dia. J Dia.
AsSupplied (a)
After Unrestricted Recovery (b)
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
HJ
Part Min. Min. PRJOW
No. -3, -4, -25 -12, -100 Max. -3, -4, -25 -12, -100 Max. ±10% ±10% Ref. ±20%
aa
baabbbbb
202A11116.5 [.65] 16.5 [.65] 7.9 [.31] 16.5 [.65] 1 1.9 [.47] 3.8 [.15] 25.4 [1.00] 14.2 [.56] 5.8 [.23] 1.27 [.05]
202A121 24.6 [.97] 22.6 [.89] 9.9 [.39] 24.6 [.97] 17.8 [.70] 5.3 [.21] 38.1 [1.50] 21.8 [.86] 9.1 [.36] 1.52 [.06]
202A132 28.4 [1.12] 26.2 [1.03] 14.2 [.56] 28.4 [1.12] 20.3 [.80] 6.6 [.26] 51.3 [2.02] 27.9 [1.10] 13.0 [.51] 1.78 [.07]
202A142 31.0 [1.22] 31.0 [1.22] 17.8 [.70] 31.0 [1.22] 25.4 [1.00] 7.4 [.29] 66.8 [2.63] 35.6 [1.40] 17.8 [.70] 1.78 [.07]
202A153 36.1 [1.42] 36.1 [1.42] 21.9 [.86] 36.1 [1.42] 26.2 [1.03] 8.6 [.34] 73.7 [2.90] 41.4 [1.63] 16.0 [.63] 1.78 [.07]
202A163 42.7 [1.68] 42.7 [1.68] 27.4 [1.08] 42.7 [1.68] 27.2 [1.07] 9.4 [.37] 99.1 [3.90] 62.7 [2.47] 18.0 [.71] 2.03 [.08]
202A174 51.8 [2.04] 48.3 [1.90] 35.3 [1.39] 51.8 [2.04] 48.3 [1.90] 16.0 [.63] 130.0 [5.13] 64.8 [2.55] 41.9 [1.65] 3.30 [.13]
202A185 66.0 [2.60] 66.0 [2.60] 43.7 [1.72] 66.0 [2.60] 54.1 [2.13] 19.6 [.77] 161.3 [6.35] 90.2 [3.55] 47.8 [1.88] 3.81 [.15]
202A196 86.4 [3.40] 86.4 [3.40] 57.2 [2.25] 86.4 [3.40] 71.4 [2.81] 26.9 [1.06] 212.6 [8.37] 113.0 [4.45] 62.2 [2.45] 4.06 [.16]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Materials Available
Product Dimensions
Straight Boot
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-54 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
202C611 to 663
Applications
Use to provide abrasion
protection for connectors.
The flexibility of design
allows a variety of cable
outlet angles. When
installed on a spin-coupling
adapter,cold reentryto the
202C611 to 663
H Dia. J Dia.
P
B (with 90°bend)
S
T
JO
W Typ.
Tan
JDia.
K Dia.
H Dia.
202C611 to 663
H Dia. JDia.
P
B (with 90°bend)
S
T
K Dia.
H Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-50 Viton®polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
KPJO STWB
Part Min. Max. Min. Max. Max. ±10% ±10% ±.03[0.76] ±.03[0.76] Min. Nom.
No. a-50, -51 a -71 b a -50, -51 a -71 b bbbbbb b
202C61114.2 [.56] 17.5 [.69] 6.9 [.27] 11.2 [.44] 14.2 [.56] 4.8 [.19] 21.1 [.83] 120.7 [4.75] 17.5 [.69] 1.52 [.06] 1.27 [.05] 0.33 [.013] 62.5 [2.46]
202C621 22.4 [.88] 26.4 [1.04] 11.7 [.46] 17.8 [.70] 26.4 [1.04] 8.1 [.32] 26.7 [1.05] 133.4 [5.25] 19.0 [.78] 1.52 [.06] 1.27 [.05] 0.46 [.018] 67.8 [2.67]
202C632 34.0 [1.34] 38.1 [1.50] 17.5 [.69] 26.9 [1.06] 38.1 [1.50] 12.7 [.50] 32.8 [1.29] 146.1 [5.75] 22.4 [.88] 1.78 [.07] 1.27 [.05] 0.51 [.020] 73.4 [2.89]
202C642 44.2 [1.74] 47.8 [1.88] 22.4 [.88] 36.6 [1.44] 47.8 [1.88] 17.5 [.69] 37.8 [1.49] 158.8 [6.25] 25.4 [1.00] 1.78 [.07] 1.27 [.05] 0.61 [.024] 78.2 [3.08]
202C653 21.2 [53.8] 54.9 [2.16] 27.9 [1.10] 45.7 [1.80] 54.9 [2.16] 22.4 [.88] 42.9 [1.69] 171.5 [6.75] 28.4 [1.12] 1.78 [.07] 2.03 [.08] 0.61 [.024] 82.8 [3.26]
202C663 22.5 [57.2] 77.2 [3.04] 40.6 [1.60] 57.2 [2.25] 54.6 [2.15] 22.9 [.90] 62.2 [2.45] 236.2 [9.30] 35.1 [1.38] 2.03 [.08] 2.03 [.08] 0.66 [.026] 138.4 [5.45]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Uniboot
Materials Available
Product Dimensions
connector is possible by
compressing the molded
part. When used with
adhesive it provides
environmental sealing.
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202D121 to 196
Applications
Use in conjunction with
Raychem adapters to pro-
vide strain relief for harness
systems using circular con-
nectors. Boot is compatible
with all Raychem grooved
adapters of appropriate
shell size.
202D121 to 196
H Dia. J Dia. J Dia.
H Dia.
W
P
Tan JO
R
202D121 to 196
H Dia. J Dia. H Dia.
P
Tan JO
R
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /180 S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
P JO W RR
Part Min.
No. Min. Max. -3, -4, -25 -12, -100 Max. ±10% ±10% ±20% ±10%
abaabbbbb
202D121 23.3 [.92] 10.5 [.41] 23.3 [.92] 12.4 [.49] 5.6 [.22] 38.1 [1.50] 10.2 [.40] 1.78 [.07] —
202D132 28.4 [1.12] 14.3 [.56] 28.4 [1.12] 14.7 [.58] 6.6 [.26] 54.9 [2.16] 16.5 [.65] 1.78 [.07] 21.6 [.85]
202D142 31.0 [1.22] 17.8 [.70] 31.0 [1.22] 16.0 [.63] 7.2 [.28] 66.8 [2.63] 17.8 [.70] 2.03 [.08] 24.5 [.96]
202D153 36.0 [1.42] 22.4 [.88] 36.0 [1.42] 18.5 [.73] 8.4 [.33] 80.0 [3.15] 20.8 [.82] 2.03 [.08] 29.7 [1.17]
202D163 42.7 [1.68] 28.2 [1.11] 42.7 [1.68] 22.0 [.87] 9.9 [.39] 103.6 [4.08] 24.6 [.97] 2.29 [.09] 36.7 [1.44]
202D174 51.8 [2.04] 35.1 [1.38] 51.8 [2.04] 35.3 [1.39] 15.8 [.62] 130.3 [5.13] 39.6 [1.56] 3.30 [.13] 53.8 [2.12]
202D185 66.0 [2.60] 44.5 [1.75] 66.0 [2.60] 45.7 [1.80] 20.4 [.80] 165.1 [6.50] 48.3 [1.90] 4.06 [.16] 65.6 [2.59]
202D196 81.7 [3.22] 57.6 [2.27] 81.7 [3.22] 57.1 [2.25] 25.4 [1.00] 177.8 [7.00] 47.8 [1.88] 4.06 [.16] 67.1 [2.64]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5
[.06] max.
Straight, Lipped Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-56 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
202D211 to 299
Applications
Use with circular connec-
tors and the appropriate
Raychem backshell adapter
to provide connector/cable
strain relief. Boot is used on
202D211 to 299
J Dia.
H Dia.
HW
JW
P
U
Tan
JO
J Dia.
H Dia.
202D211 to 299
H Dia.
HW
J
P
U
Tan
JO
J Dia.
H Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
Part Min. P JO U HW JW
No. Min. Max. -3, -4, -12, -100 Max. ±10% ±10% ±10% ±20% ±20%
a b -25abb b bbb
a
202D211 22.4 [.88] 11.4 [.45] 22.4 [.88] 14.0 [.55] 6.4 [.25] 105.9 [4.17] 86.4 [3.40] 14.2 [.56] 1.52 [.06] 1.14 [.045]
202D221 25.7 [1.01] 15.0 [.59] 25.7 [1.01] 16.0 [.63] 7.4 [.29] 121.2 [4.77] 98.6 [3.88] 15.0 [.59] 1.52 [.06] 1.14 [.045]
202D232 29.5 [1.16] 18.8 [.74] 29.5 [1.16] 18.3 [.72] 8.4 [.33] 138.7 [5.46] 112.8 [4.44] 15.5 [.61] 1.78 [.07] 1.14 [.045]
202D242 34.0 [1.34] 22.9 [.90] 34.0 [1.34] 21.3 [.84] 9.7 [.38] 159.5 [6.28] 130.8 [5.15] 15.7 [.62] 1.78 [.07] 1.14 [.045]
202D253 37.3 [1.47] 29.5 [1.16] 37.3 [1.47] 23.1 [.91] 10.4 [.41] 177.8 [7.00] 142.2 [5.60] 18.0 [.71] 2.0 [.08] 1.14 [.045]
202D263 43.7 [1.72] 34.0 [1.34] 43.7 [1.72] 27.2 [1.07] 12.2 [.48] 203.2 [8.00] 163.1 [6.42] 19.8 [.78] 2.0 [.08] 1.14 [.045]
202D274 50.0 [1.97] 41.2 [1.62] 50.0 [1.97] 31.5 [1.24] 14.2 [.56] 203.2 [8.00] 157.7 [6.21] 20.8 [.82] 2.3 [.09] 1.40 [.055]
202D285 62.7 [2.47] 47.0 [1.85] 62.7 [2.47] 39.1 [1.54] 17.5 [.69] 203.2 [8.00] 153.2 [6.03] 23.4 [.92] 2.5 [.10] 1.40 [.055]
202D296 69.3 [2.73] 59.7 [2.35] 69.3 [2.73] 43.2 [1.70] 19.6 [.77] 203.2 [8.00] 143.3 [5.64] 23.6 [.93] 2.5 [.10] 1.40 [.055]
202D299 81.8 [3.22] 67.1 [2.64] 81.8 [3.22] 51.1 [2.01] 22.9 [.90] 203.2 [8.00] 138.4 [5.45] 31.2 [1.23] 2.5 [.10] 1.40 [.055]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5
[.06] max.
Straight, Lipped Boot
Materials Available
Product Dimensions
open-wire-bundle airborne
harnesses, or applications
where the long tail replaces
cable jacketing removed
during termination.
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202D921 to 963
Applications
Use with circular connec-
tors and the appropriate
Raychem backshell adapter
to provide connector/cable
strain relief. Boot is used in
applications where only a
small number of the avail-
able contacts areutilized,
thus resulting in a high ratio
between the adapter and
cable diameters.
202D921 to 963
H Dia. H Dia.
J
Tan J
HW
J Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
HJ
Part Min. P JO HW JW
No. Min. Max. -3, -4, -12, -100 Max. ±10% ±10% ±20% ±20%
ab-25 abbbbb
a
202D921 19.3 [.76] 13.0 [.51] 6.3 [.25] 4.5 [.18] 2.1 [.08] 60.2 [2.37] 37.6 [1.48] 1.52 [.06] 1.14 [.045]
202D932 26.1 [1.03] 19.1 [.75] 7.6 [.30] 5.5 [.22] 2.6 [.10] 74.2 [2.92] 45.0 [1.77] 1.78 [.07] 1.14 [.045]
202D953 34.2 [1.35] 26.0 [1.02] 9.6 [.38] 6.6 [.26] 3.1 [.12] 84.3 [3.32] 51.1 [2.01] 1.78 [.07] 1.14 [.045]
202D963 43.6 [1.72] 34.1 [1.34] 11.4 [.45] 7.8 [.31] 3.6 [.14] 99.6 [3.92] 57.7 [2.27] 1.78 [.07] 1.14 [.045]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5
[.06] max.
202D921 to 963
H Dia.
P
H Dia.
J Dia.
JW
Tan JO
HW
J Dia.
Straight, Lipped Boot
Materials Available
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-58 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
202F211 to 274
Applications
Use in conjunction with
Raychem adapters to
provide strain relief for
harness systems using
circular connectors. Boot is
compatible with all
Raychem grooved adapters
of the appropriate shell size.
HDia.
HW R
Tan
Tan
JO
P
J Dia.
JW
H Dia. J Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-50 Flexible Viton®polymer blend N/A S-1125
-51 Flexible elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
H J P JO HW JW
Part Min. Max. Min. Max. ±10% ±10% ±20% ±20%
No.ababbbbb
202F211 23.9 [.94] 9.9 [.39] 17.3 [.68] 6.6 [.26] 105.9 [4.17] 86.4 [3.40] 1.5 [.06] 1.5 [.06]
202F221 27.2 [1.07] 13.2 [.52] 20.8 [.82] 7.6 [.30] 121.2 [4.77] 98.6 [3.88] 1.5 [.06] 1.5 [.06]
202F232 31.0 [1.22] 18.5 [.73] 24.4 [.96] 8.9 [.35] 138.7 [5.46] 112.8 [4.44] 1.8 [.07] 1.5 [.06]
202F242 35.6 [1.40] 22.1 [.87] 28.7 [1.13] 10.2 [.40] 159.5 [6.28] 130.8 [5.15] 1.8 [.07] 1.5 [.06]
202F253 38.9 [1.53] 28.2 [1.11] 31.5 [1.24] 10.9 [.43] 177.8 [7.00] 142.2 [5.60] 1.8 [.07] 1.5 [.06]
202F263 45.2 [1.78] 32.3 [1.27] 38.4 [1.51] 12.7 [.50] 203.2 [8.00] 163.1 [6.42] 1.8 [.07] 1.5 [.06]
202F274 51.6 [2.03] 41.1 [1.62] 45.5 [1.79] 15.0 [.59] 203.2 [8.00] 157.7 [6.21] 1.8 [.07] 1.8 [.07]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be
reduced by 1.5 [.06] max.
Straight, Lipped Boot
Materials Available
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202G211 to 253
Coating (see note 3)
J Dia.
H Dia. H Dia.
T
HW
S
RTan
Tan JO
P
Coating (see note 3)
J Dia.
H Dia. H Dia.
T
HW
S
RTan
Tan JO
J Dia.
P
JW
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
Part HJPRSTJO HW JW
Min. Max. Min. Max. ±10% ±10% Ref. Ref. ±10% Ref. Ref.
No. a b a b b bbbbbb
202G211 23.9 [.94] 9.9 [.39] 23.9 [.94] 7.4 [.29] 105.9 [4.17] 11.7 [.46] 1.0 [.04] 1.3 [.05] 86.4 [3.40] 1.0 [.04] 0.7 [.03]
202G221 27.2 [1.07] 13.2 [.52] 27.2 [1.07] 8.4 [.33] 121.2 [4.77] 12.2 [.48] 1.0 [.04] 1.3 [.05] 87.4 [3.44] 1.0 [.04] 0.7 [.03]
202G232 31.0 [1.22] 18.5 [.73] 31.0 [1.22] 9.4 [.37] 138.7 [5.46] 12.2 [.48] 1.0 [.04] 1.3 [.05] 104.4 [4.11] 1.0 [.04] 0.7 [.03]
202G242 31.7 [1.25] 22.1 [.87] 31.7 [1.25] 10.7 [.42] 159.5 [6.28] 12.2 [.48] 1.0 [.04] 1.5 [.06] 124.5 [4.90] 1.0 [.04] 0.7 [.03]
202G253 38.9 [1.53] 28.2 [1.11] 38.9 [1.53] 11.9 [.47] 177.8 [7.00] 10.6 [.42] 1.3 [.05] 1.8 [.07] 143.5 [5.65] 1.3 [.05] 1.0 [.04]
Material Dash No. Material Description Adhesive
-55 Fluoroploymer S-1255-04
Applications
Use in conjunction with
Raychem adapters to
provide strain relief for
harness systems using
circular connectors. This
range of parts is compatible
with all Raychem grooved
adapters of appropriate
shell or entrysize. When
used with adhesive it
provides environmental
sealing.
Straight, Low Profile
Lipped Boot
Materials Available
Available in: Americas Europe Asia Pacific
nnn
Boots
4-60 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
202G611 to 653
H Dia. J Dia.
K Dia.H Dia.
HW
TS
P
.50±10%
T
(with 90˚ bend)
B
H Dia. JDia.
KDia.H Dia.
HW
TS
P
.50±10%
Tan JO
J Dia.
JW
(with 90˚ bend)
B
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
Part HJ
K P JO HW JW S T B
No. Min. Max. Min. Max. Max. ±10% ±10% Ref. Ref. Ref. Ref. Nom.
abab
b b bbbbbb
202G611 14.2 [.56] 6.9 [.27] 11.2 [.44] 4.8 [.19] 21.1 [.83] 120.7 [4.75] 17.5 [.69] 1.0 [.04] 0.7 [.03] 1.0 [.04] 1.3 [.05] 62.5 [2.46]
202G621 26.6 [1.05] 11.7 [.46] 26.6 [1.05] 8.1 [.32] 26.6 [1.05] 133.8 [5.27] 19.9 [.78] 1.0 [.04] 0.7 [.03] 1.0 [.04] 1.3 [.05] 67.8 [2.67]
202G632 33.0 [1.30] 17.5 [.69] 33.0 [1.30] 12.7 [.50] 32.7 [1.29] 151.1 [5.95] 22.4 [.88] 1.0 [.04] 0.7 [.03] 1.0 [.04] 1.3 [.05] 73.4 [2.89]
202G642 35.5 [1.40] 22.3 [.88] 35.5 [1.40] 17.5 [.69] 37.8 [1.49] 157.2 [6.19] 25.4 [1.00] 1.3 [.05] 1.0 [.04] 1.3 [.05] 1.3 [.05] 78.2 [3.08]
202G653 42.6 [1.68] 27.9 [1.10] 42.6 [1.68] 22.4 [.88] 42.9 [1.69] 170.2 [6.70] 28.4 [1.12] 1.3 [.05] 1.0 [.04] 1.3 [.05] 1.5 [.06] 82.8 [3.26]
Material Dash No. Material Description Adhesive
-55 Fluoroploymer S-1255-04
Applications
Use to provide abrasion
protection for connectors.
The flexibility of design
allows a variety of cable
outlet angles. When
installed on a spin-coupling
adapter,cold re-entryto the
connector is possible by
Uniboot
Materials Available
unscrewing the adapter
and compressing the
molded part. When used
with adhesive it provides
environmental sealing.
Available in: Americas Europe Asia Pacific
nnn
Boots
4-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202K121 to 185
Applications
Use in conjunction with
Raychem adapters to pro-
vide strain relief for harness
systems using circular
connectors.
202K121 - 153 = 2 lips
202K163 - 185 = 3 lips
Mod 01 = 1 lip removed
Mod 02 = 2 lips removed
(only available in sizes 163, 174, 185).
For eyelet clip, order CS-1858 option.
202K121 to 185
JW
PY
J
Tan
HDia. JDia.
HW
UXR
Slight
taper
H Dia. J Dia.
202K121 to 185
P
Tan
HDia. JDia.
HW
UXR
H Dia. J
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
HJ
Part Min. Max. Min. Max. PRUJO HW JW XY
No. -3,-4,-12,-25 b-3, -4, -25 -12 -100 b±10% ±10% ±10% ±10% ±20% Min. ±20% ±20%
aaaa
bbbbbbb b
202K121 24.0 [.95] 10.4 [.41] 24.0 [.95] 13.0 [.51] 14.0 [.55] 5.6 [.22] 38.0 [1.50] 21.0 [.83] 12.0 [.47] 8.5 [.33] 1.6 [.06] .41 [.016] 24.0 [.94] 13.0 [.51]
202K132 30.0 [1.18] 14.2 [.56] 30.0 [1.18] 14.0 [.55] 15.0 [.59] 5.9 [.23] 55.0 [2.17] 32.0 [1.26] 12.0 [.47] 11.5 [.45] 1.8 [.07] .81 [.032] 24.0 [.94] 18.0 [.71]
202K142 31.0 [1.22] 18.0 [.71] 31.0 [1.22] 16.0 [.63] 18.0 [.71] 7.1 [.28] 67.0 [2.64] 35.0 [1.38] 20.0 [.79] 17.0 [.67] 1.8 [.07] .81 [.032] 32.0 [1.26] 25.0 [.98]
202K153 36.0 [1.42] 22.4 [.88] 36.0 [1.42] 19.0 [.75] 21.0 [.83] 8.4 [.33] 80.0 [3.15] 42.0 [1.65] 20.0 [.79] 19.5 [.76] 2.0 [.08] .81 [.032] 32.0 [1.26] 30.0 [1.18]
202K163 43.0[1.69] 28.2 [1.1 1] 43.0 [1.69] 22.0 [.87] 25.0 [.98] 9.9 [.39] 99.0 [3.90] 61.0 [2.40] 20.0 [.79] 21.0 [.82] 2.2 [.08] .81 [.032] 52.0 [2.05] 30.0 [1.18]
202K174 60.0 [2.36] 35.1 [1.38] 60.0 [2.36] 35.0 [1.38] 39.0 [1.54] 15.7 [.62] 130.0 [5.12] 72.0 [2.83] 20.0 [.79] 39.0 [1.53] 3.3 [.13] 1.02 [.040] 52.0 [2.05] 50.0 [1.97]
202K185 66.0 [2.60] 44.5 [1.75] 66.0 [2.60] 38.0 [1.50] 42.0 [1.65] 16.8 [.66] 170.0 [6.69] 90.0 [3.54] 20.0 [.79] 51.5 [2.02] 3.8 [.15] 1.63 [.064] 52.0 [2.05] 70.0 [2.76]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by
1.5 [.06] max.
Straight, Lipped Boot
Materials Available
Boot is compatible with all
Raychem grooved adapters
of the appropriate shell size.
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-62 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
214A011 to 052
Applications
Provides strain relief and
mechanical protection on
D-subminiatureconnector
terminations.
214A011 to 052
HK Dia.
JP
J
W
X Typ.
K Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJK
PWXThis Boot Fits
Part ±5% ±5% ±5% ±5% Min. Max. ±10% ±20% ±20% Cannon/ Amphenol
No. abababbbb
Cinch Series 17
214A01120.3 [.80] 20.3 [.80] 10.7 [.42] 10.7 [.42] 7.9 [.31] 4.1 [.16] 33.3 [1.31] 1.0 [.04] 3.0 [.12] DE-9 XX09X
214A021 28.2 [1.11] 28.2 [1.11] 10.7 [.42] 10.7 [.42] 10.2 [.40] 5.3 [.21] 38.9 [1.53] 1.0 [.04] 3.0 [.12] DA-15 XX15X
214A032 42.2 [1.66] 42.2 [1.66] 10.7 [.42] 10.7 [.42] 14.0 [.55] 8.1 [.32] 45.0 [1.77] 1.0 [.04] 3.0 [.12] DB-25 XX25X
214A042 58.7 [2.31] 58.7 [2.31] 10.7 [.42] 10.7 [.42] 17.3 [.68] 8.6 [.34] 53.3 [2.10] 1.0 [.04] 3.0 [.12] DC-37 XX37X
214A052 57.9 [2.28] 57.9 [2.28] 13.7 [.54] 13.7 [.54] 19.1 [.75] 10.7 [.42] 61.0 [2.40] 1.0 [.04] 3.0 [.12] DD-50 XX50X
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by
1.5 [.06] max.
214A011 to 052
HK Dia.
JP
J
X Typ.
D-Subminiature, Straight
Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
214A311 to 352
Applications
Provides strain relief and
mechanical protection on
D-subminiature connector
terminations.
214A311 to 352
H&J K Dia.
JR
W
P
H
X Typ.
K Dia.
214A311 to 352
H& J K Dia.
J
H
X Typ.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-25 Fluid-resistant elastomer /42 or /86 S-1017 or S-1048 or S-1125
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJKPRWX This Boot Fits
Part ±5% ±5% ±5% ±5% Min. Max. ±10% ±10% ±20% ±20% Cannon/ Amphenol
No. abababbbbbCinch Series 17
214A311 16.0 [.63] 20.3 [.80] 16.0 [.63] 10.7 [.42] 16.0 [.63] 4.1 [.16] 33.3 [1.31] 19.1 [.75] 1.02 [.04] 3.05 [.12] DE-9 XX09X
214A321 19.1 [.75] 28.2 [1.11] 19.1 [.75] 10.7 [.42] 19.1 [.75] 5.3 [.21] 38.9 [1.53] 22.1 [.87] 1.02 [.04] 3.05 [.12] DA-15 XX15X
214A332 29.2 [1.15] 42.2 [1.66] 29.2 [1.15] 10.7 [.42] 29.2 [1.15] 8.1 [.32] 45.0 [1.77] 25.4 [1.00] 1.02 [.04] 3.05 [.12] DB-25 XX25X
214A342 34.3 [1.35] 58.7 [2.31] 34.3 [1.35] 10.7 [.42] 34.3 [1.35] 8.6 [.34] 53.3 [2.10] 28.4 [1.12] 1.02 [.04] 3.05 [.12] DC-37 XX37X
214A352 37.6 [1.48] 57.9 [2.28] 37.6 [1.48] 13.7 [.54] 37.6 [1.48] 10.7 [.42] 61.0 [2.40] 31.8 [1.25] 1.02 [.04] 3.05 [.12] DD-50 XX50X
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by
1.5 [.06] max.
Materials Available
Product Dimensions
D-Subminiature, Straight
Boot
Available in: Americas Europe Asia Pacific
nnn
Boots
4-64 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
214P009 to 037
Applications
Provides strain relief and
mechanical protection on
D-subminiature connector
terminations.
K Dia.
0.12 max.
(end gap)
T
JH
P
S
K Dia.
W
#4-40 UNC
X
R
214P009 to 037
K Dia.
0.12 max.
(end gap)
JH
P
W
#
X
R
214P009 to 037
Material* Material Description
-111-0 Semirigid polyolefin (black)
-111-8 Semirigid polyolefin (gray)
*Contact Tyco Electronics for information on material properties.
AsSupplied (a)
After Unrestricted Recovery (b)
HJKPRSTXW
Part ±5% ±10% Min. Max. ±10% Ref. Nom. Nom. ±20% ±20% Fits Connector
No. bbab bb bbbb Size
214P009-XXX 17.3 [.68] 12.0 [.47] 9.0 [.35] 3.8 [.15] 43.0 [1.69] 22.0 [.87] 29.0 [1.14] 6.4 [.25] 1.80 [.07] 1.5 [.06] 9 pin
214P015-XXX 25.2 [.99] 12.0 [.47] 10.5 [.41] 3.8 [.15] 44.0 [1.73] 23.0 [.90] 29.0 [1.14] 6.4 [.25] 2.03 [.08] 1.5 [.06] 15 pin
214P025-XXX 38.4 [1.51] 12.0 [.47] 12.0 [.47] 5.1 [.20] 49.0 [1.87] 25.0 [.98] 29.0 [1.14] 6.4 [.25] 2.16 [.085] 1.5 [.06] 25 pin
214P037-XXX 54.2 [2.13] 12.0 [.47] 12.0 [.47] 5.8 [.22] 55.0 [2.16] 25.0 [.98] 29.0 [1.14] 6.4 [.25] 2.26 [.089] 1.5 [.06] 37 pin
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
D-Subminiature, Straight
Boot with Jack Screws
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
Boots
4-65
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
222A111 to 196
222A111 to 196
J Dia.
H Dia.
P
J Dia.
U
JO
W
T
R
H Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or/180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
Part Min. Max. Min. Max. PRTUJOW
No. ab
-3, -4, -25 -100 -12 b±10% ±10% ±10% ±10% ±10% ±20%
aaa bbbbb b
222A11117.8 [.70] 7.9 [.31] 17.8 [.70] 10.9 [.43] 9.9 [.39] 3.8 [.15] 17.3 [.68] 20.1 [.79] — 11.4 [.45] 4.3 [.17] 1.02 [.04]
222A121 24.9 [.98] 10.2 [.40] 24.9 [.98] 16.0 [.63] 18.0 [.71] 5.3 [.21] 21.3 [.84] 22.6 [.89] — 14.7 [.58] 5.8 [.23] 1.27 [.05]
222A132 30.0 [1.18] 14.2 [.56] 30.0 [1.18] 21.1 [.83] 20.6 [.81] 6.4 [.25] 26.9 [1.06] 26.7 [1.05] 19.1 [.75] 17.8 [.70] 7.1 [.28] 1.52 [.06]
222A142 32.5 [1.28] 17.3 [.68] 32.5 [1.28] 22.9 [.90] 22.9 [.90] 6.9 [.27] 36.6 [1.44] 30.5 [1.20] 19.1 [.75] 24.9 [.98] 10.2 [.40] 1.78 [.07]
222A152 36.1 [1.42] 21.8 [.86] 36.1 [1.42] 27.4 [1.08] 26.4 [1.04] 8.4 [.33] 43.7 [1.72] 35.1 [1.38] 19.1 [.75] 30.0 [1.18] 12.7 [.50] 1.78 [.07]
222A163 43.9 [1.73] 27.4 [1.08] 43.9 [1.73] 28.4 [1.12] 27.4 [1.08] 9.4 [.37] 53.6 [2.11] 43.9 [1.73] 19.1 [.75] 34.0 [1.34] 17.3 [.68] 2.03 [.08]
222A174 53.1 [2.09] 33.8 [1.33] 53.1 [2.09] 48.3 [1.90] 46.7 [1.84] 15.0 [.59] 75.7 [2.98] 52.8 [2.08] 25.4 [1.00] 53.3 [2.10] 32.0 [1.26] 3.30 [.13]
222A185 67.6 [2.66] 44.2 [1.74] 67.6 [2.66] 58.4 [2.30] 54.4 [2.14] 20.3 [.80] 97.5 [3.84] 66.0 [2.60] 25.4 [1.00] 71.1 [2.80] 40.6 [1.60] 3.81 [.15]
222A196 87.6 [3.45] 55.4 [2.18] 87.6 [3.45] 68.8 [2.71] 63.0 [2.48] 23.4 [.92] 128.0 [5.04] 79.2 [3.12] 25.4 [1.00] 87.6 [3.45] 56.4 [2.22] 4.57 [.18]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
222A111 to 196
J Dia.
H Dia.
PU
JO
T
R
H Dia.
Applications
Use for mechanical protec-
tion and connector-cable
strain relief. This family of
boots has no lip, so a boot
can be installed directly
onto the connector acces-
sory thread.
Materials Available
Product Dimensions
Right-Angled Boot
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-66 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
222D121 to 196
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
Applications
Use in conjunction with
Raychem adapters to
provide strain relief for
harness systems using
circular connectors. Boot
is compatible with all
Raychem grooved adapters
of the appropriate shell size.
222D121 to 196
H Dia.
P
J Dia.
H
L
JO
K
R
Tan
W
J Dia.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
Part Min. Max. Min. Max. PRJO W KL
No. aa-3, -4, -25 -100 -12 b±10% Ref. ±10% ±20% ±10% ±10%
bbb bbbb
222D121 23.4 [.92] 10.4 [.41] 23.4 [.92] 14.0 [.55] 12.4 [.49] 5.6 [.22] 21.3 [.84] 22.6 [.89] 5.8 [.23] 1.27 [.05] 15.2 [.60] 14.7 [.58]
222D132 28.4 [1.12] 14.2 [.56] 28.4 [1.12] 15.0 [.59] 14.7 [.58] 6.6 [.26] 33.8 [1.33] 27.2 [1.07] 15.5 [.65] 1.52 [.06] 19.1 [.75] 24.9 [.98]
222D142 31.0 [1.22] 17.8 [.70] 31.0 [1.22] 18.0 [.71] 16.0 [.63] 7.1 [.28] 36.6 [1.44] 31.0 [1.22] 12.7 [.50] 1.78 [.07] 19.1 [.75] 24.9 [.98]
222D152 36.0 [1.42] 22.4 [.88] 36.0 [1.42] 21.0 [.83] 18.5 [.73] 8.4 [.33] 43.7 [1.72] 35.1 [1.38] 14.5 [.57] 1.78 [.07] 19.1 [.75] 30.0 [1.18]
222D163 42.7 [1.68] 28.2 [1.1 1] 42.7 [1.68] 25.0 [.98] 22.1 [.87] 9.9 [.39] 53.6 [2.11] 43.9 [1.73] 17.5 [.69] 2.03 [.08] 19.3 [.76] 33.0 [1.30]
222D174 51.8 [2.04] 35.1 [1.38] 51.8 [2.04] 39.0 [1.54] 35.3 [1.39] 15.7 [.62] 78.0 [3.07] 52.8 [2.08] 33.5 [1.32] 3.30 [.13] 25.4 [1.00] 53.8 [2.12]
222D185 66.0 [2.60] 44.5 [1.75] 66.0 [2.60] 42.0 [1.65] 45.7 [1.80] 20.3 [.80] 97.5 [3.84] 66.0 [2.60] 40.1 [1.58] 3.81 [.15] 25.4 [1.00] 71.1 [2.80]
222D196 81.8 [3.22] 60.5 [2.38] 81.8 [3.22] 57.2 [2.25] 57.2 [2.25] 25.4 [1.00] 117.9 [4.64] 83.8 [3.30] 38.1 [1.50] 4.06 [.16] 25.4 [1.00] 80.0 [3.15]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 (.06) max.
222D121 to 196
H Dia.
P
H
K
R
T
W
J Dia.
Right-Angled, Lipped Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-67
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
222D211 to 299
Applications
Provides strain relief and
mechanical protection
between cable and connec-
tor. Boot is usually used on
open-wire-bundle airborne
harnesses, or applications
where the long tail replaces
cable jacketing removed
during termination.
222D211 to 299
H Dia. J Dia.
JW
R
HW
H Dia.
P
J Dia.
Tan JO
RR
P
222D211 to 299
H Dia. J Dia. R
HW
H Dia.
P
Tan JO
RR
P
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
P
Part Min. Max. Min. Max. R JO PP RR HW JW
No. -3, -4, -25 -12, -100 ±10% Ref ±10% ±10% 10%
abab
bbbbbb
±20% ±20%
222D211 22.4 [.88] 11.4 [.45] 22.4 [.88] 14.0 [.55] 6.4 [.25] 105.2 [4.14] 18.5 [.73] 87.6 [3.45] 6.9 [.27] 12.4 [.49] 1.52 [.06] 1.14 [.045]
222D221 25.7 [1.01] 15.0 [.59] 25.7 [1.01] 16.0 [.63] 7.4 [.29] 124.0 [4.88] 19.8 [.78] 99.1 [3.90] 8.4 [.33] 15.0 [.59] 1.52 [.06] 1.14 [.045]
222D232 29.5 [1.16] 18.8 [.74] 29.5 [1.16] 18.3 [.72] 8.4 [.33] 146.3 [5.76] 20.8 [.82] 114.3 [4.50] 10.4 [.41] 15.5 [.61] 1.78 [.07] 1.14 [.045]
222D242 34.0 [1.34] 22.9 [.90] 34.0 [1.34] 21.3 [.84] 9.7 [.38] 172.2 [6.78] 21.8 [.86] 132.6 [5.22] 12.2 [.48] 15.7 [.62] 1.78 [.07] 1.14 [.045]
222D253 37.3 [1.47] 29.5 [1.16] 37.3 [1.47] 23.1 [.91] 10.4 [.41] 185.2 [7.29] 24.4 [.96] 143.8 [5.66] 15.5 [.61] 17.8 [.70] 2.03 [.08] 1.14 [.045]
222D263 43.7 [1.72] 34.0 [1.34] 43.7 [1.72] 27.2 [1.07] 12.2 [.48] 231.6 [8.41] 27.4 [1.08] 169.2 [6.66] 18.3 [.72] 19.8 [.78] 2.03 [.08] 1.14 [.045]
222D274 50.0 [1.97] 41.1 [1.62] 50.0 [1.97] 31.5 [1.24] 14.2 [.56] 224.5 [8.84] 29.5 [1.16] 173.2 [6.82] 21.1 [.83] 20.8 [.82] 2.29 [.09] 1.40 [.055]
222D285 62.7 [2.47] 47.0 [1.85] 62.7 [2.47] 39.1 [1.54] 17.5 [.69] 227.3 [8.95] 33.3 [1.31] 168.1 [6.62] 24.1 [.95] 23.4 [.92] 2.54 [.10] 1.40 [.055]
222D296 69.3 [2.73] 59.7 [2.35] 69.3 [2.73] 43.2 [1.70] 19.6 [.77] 233.4 [9.19] 35.1 [1.38] 157.2 [6.19] 30.0 [1.18] 23.6 [.93] 2.54 [.10] 1.40 [.055]
222D299 81.8 [3.22] 67.1 [2.64] 81.8 [3.22] 51.1 [2.01] 22.9 [.90] 237.0 [9.33] 44.5 [1.75] 151.1 [5.95] 33.3 [1.31] 31.2 [1.23] 2.54 [.10] 1.40 [.055]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Right-Angled, Lipped Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-68 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
222D921 to 963
Applications
Provides strain relief and
mechanical protection
between cable and connec-
tor. It is used in applications
whereonly a small number
of the available contacts are
utilized, resulting in a high
ratio between the adapter
and cable diameters.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
HJ
Min. P R U JO HW JW
Part Min. Max. -3, -4, -12, Max. ±10% Ref. ±10% ±10% ±20% ±20%
No. a b -25 -100 b b b b b b b
aa
222D921 19.3 [.76] 13.0 [.51] 6.3 [.25] 4.5 [.18] 2.1 [.08] 44.5 [1.75] 16.3 [.64] 5.6 [.22] 21.8 [.86] 1.52 [.06] 1.14 [.045]
222D932 26.1 [1.03] 19.1 [.75] 7.6 [.30] 5.6 [.22] 2.6 [.10] 67.3 [2.65] 18.0 [.71] 8.4 [.33] 29.2 [1.15] 1.78 [.07] 1.14 [.045]
222D953 34.2 [1.35] 26.0 [1.02] 9.6 [.38] 6.6 [.26] 3.0 [.12] 81.3 [3.20] 18.8 [.74] 1 1.4 [.45] 36.3 [1.39] 1.78 [.07] 1.14 [.045]
222D963 43.6 [1.72] 34.1 [1.34] 11.4 [.45] 7.8 [.31] 3.6 [.14] 115.6 [4.55] 21.3 [.84] 15.5 [.61] 47.0 [1.85] 1.78 [.07] 1.14 [.045]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 mm [.06"] max.
222D921 to 963
R
JW
P
J Dia.
HW
H Dia.
U
JO
H
J Dia.
222D921 to 963
R
P
HW
H Dia.
U
H
J Dia.
Right-Angled, Lipped Boot
Materials Available
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-69
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
222F211 to 285
Material* Material Description Precoating No. Adhesive Part No.**
-50 Viton®polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
HJ
P R JO HW JW
Part Min. Max. Min. Max. ±10% ±10% ±10% +.06 to -.03 ±.03
No. ababbbbbb
222F21123.9 [.94] 9.9 [.39] 17.3 [.68] 6.6 [.26] 105.2 [4.14] 18.5 [.73] 87.6 [3.45] 1.52 [.06] 1.52 [.06]
222F221 27.2 [1.07] 13.2 [.52] 20.8 [.82] 7.6 [.30] 124.0 [4.88] 19.8 [.78] 99.1 [3.90] 1.52 [.06] 1.52 [.06]
222F232 31.0 [1.22] 18.5 [.73] 24.4 [.96] 8.9 [.35] 146.3 [5.76] 20.8 [.82] 114.3 [4.50] 1.78 [.07] 1.52 [.06]
222F242 35.6 [1.40] 22.1 [.87] 28.7 [1.13] 10.2 [.40] 172.2 [6.78] 21.8 [.86] 132.6 [5.22] 1.78 [.07] 1.52 [.06]
222F253 38.9 [1.53] 28.2 [1.1 1] 31.5 [1.24] 10.9 [.43] 185.2 [7.29] 24.4 [.96] 143.8 [5.66] 1.78 [.07] 1.52 [.06]
222F263 45.2 [1.78] 32.3 [1.27] 38.4 [1.51] 12.7 [.50] 213.6 [8.41] 27.4 [1.08] 169.2 [6.66] 1.78 [.07] 1.52 [.06]
222F274 51.6 [2.03] 41.1 [1.62] 44.5 [1.75] 15.0 [.59] 224.5 [8.84] 29.5 [1.16] 173.2 [6.82] 1.78 [.07] 1.78 [.07]
222F285 62.7 [2.47] 42.9 [1.69] 47.2 [1.86] 17.5 [.69] 227.3 [8.95] 33.3 [1.31] 168.1 [6.62] 2.03 [.08] 1.78 [.07]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Applications
Use in conjunction with
Raychem adapters to pro-
vide strain relief for harness
systems using circular con-
nectors. Boot is compatible
with all Raychem grooved
adapters of the appropriate
shell size.
H Dia.
JW
R
P
HW
Tan JO
222F211 to 285
J Dia. J Dia.
H Dia.
H Dia.
R
P
HW
Tan JO
222F211 to 285
J Dia. J
H Dia.
AsSupplied (a)
After Unrestricted Recovery (b)
Right-Angled, Lipped Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-70 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
222K121 to 185
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
HJPRJO HW JW X Y
Part Min. Max. Min. Max. ±10% ±10% ±10% ±20% ±20% ±20% ±20%
No. -3, -4, -25 -100 -3, -4, -25 -100 bbbbbbb
aabaa
b
222K121 24.0 [.95] 24.0 [.95] 10.4 [.41] 24.0 [.95] 14.0 [.55] 5.6 [.22] 25.0 [.98] 25.0 [.98] 8.5 [.33] 1.3 [.05] .41 [.016] 18.0 [.71] 16.0 [.63]
222K132 30.0 [1.18] 30.0 [1.18] 14.2 [.56] 30.0 [1.18] 15.0 [.59] 5.9 [.23] 32.0 [1.26] 27.0 [1.06] 8.5 [.33] 1.5 [.06] .61 [.024] 18.0 [.71] 20.0 [.79]
222K142 31.0 [1.22] 31.0 [1.22] 18.0 [.71] 31.0 [1.22] 18.0 [.71] 7.1 [.28] 39.0 [1.54] 31.0 [1.22] 15.0 [.59] 1.8 [.07] .81 [.032] 18.0 [.71] 20.0 [.79]
222K152 36.0 [1.42] 36.0 [1.42] 22.4 [.88] 36.0 [1.42] 21.0 [.83] 8.4 [.33] 46.0 [1.81] 38.0 [1.50] 18.0 [.63] 1.8 [.07] .81 [.032] 25.0 [.98] 25.0 [.98]
222K163 43.0 [1.69] 43.0 [1.69] 28.2 [1.11] 43.0 [1.69] 25.0 [.98] 9.9 [.39] 55.0 [2.17] 45.0 [1.77] 17.5 [.69] 2.0 [.08] .81 [.032] 25.0 [.98] 30.0 [1.18]
222K174 60.0 [2.36] 52.0 [2.05] 35.1 [1.38] 60.0 [2.36] 39.0 [1.54] 15.7 [.62] 80.0 [3.15] 54.0 [2.13] 32.0 [1.26] 3.3 [.13] 1.02 [.040] 25.0 [.98] 45.0 [1.77]
222K185 66.0 [2.60] 66.0 [2.60] 44.5 [1.75] 66.0 [2.60] 42.0 [1.65] 16.8 [.66] 108.0 [4.25] 68.0 [2.68] 48.0 [1.89] 3.8 [.15] 1.63 [.064] 35.0 [1.38] 70.0 [2.76]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
222K121 to 185
P
Y
JO
J Dia.
JW
RX
J Dia.H Dia.
H
HW
Slight
taper
222K121 to 185
P
RX
J Dia.H Dia.
H
HW
AsSupplied (a)
After Unrestricted Recovery (b)
Applications
Use in conjunction with
Raychem adapters to pro-
vide strain relief for harness
systems using circular
connectors. Boot is compat-
ible with all Raychem
grooved adapters of the
appropriate shell size.
Right-Angled, Lipped Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
For eyelet clip, order CS-1858 option.
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-71
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
234A011 to 071
Applications
Provides strain relief and
mechanical protection on
D-subminiature connector
terminations.
J
234A011 to 071
H
R
X
K Dia.
J
H
P
W
K Dia.
J
234A011 to 071
H
K Dia.
J
H
P
W
K Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
Product Dimensions
HJK
PRWX
This
Part ±5% ±5% ±5% ±5% Min. Max. ±10% ±10% ±20% ±20% Boot Fits
No. Cannon/
ababab b bbb
Cinch
234A011 20.3 [.80] 20.3 [.80] 10.7 [.42] 10.7 [.42] 7.9 [.31] 4.1 [.16] 25.9 [1.02] 21.6 [.85] 1.02 [.04] 3.05 [.12] DE-9
234A021 28.2 [1.11] 28.2 [1.11] 10.7 [.42] 10.7 [.42] 10.2 [.40] 5.3 [.21] 30.7 [1.21] 24.6 [.97] 1.02 [.04] 3.05 [.12] DA-15
234A032 42.2 [1.66] 42.2 [1.66] 10.7 [.42] 10.7 [.42] 14.0 [.55] 7.4 [.29] 42.9 [1.69] 27.9 [1.10] 1.02 [.04] 3.05 [.12] DB-25
234A042 58.7 [2.31] 58.7 [2.31] 10.7 [.42] 10.7 [.42] 17.3 [.68] 8.6 [.34] 53.3 [2.10] 30.5 [1.20] 1.02 [.04] 3.05 [.12] DC-37
234A052 57.9 [2.28] 57.9 [2.28] 13.7 [.54] 13.7 [.54] 19.1 [.75] 10.7 [.42] 55.9 [2.20] 32.3 [1.27] 1.02 [.04] 3.05 [.12] DD-50
234A061 20.3 [.80] 20.3 [.80] 10.7 [.42] 10.7 [.42] 7.9 [.31] 3.8 [.15] 25.9 [1.02] 18.5 [.73] 1.02 [.04] 3.05 [.12] DE-9
234A071 28.2 [1.11] 28.2 [1.11] 10.7 [.42] 10.7 [.42] 10.2 [.40] 5.1 [.20] 30.7 [1.21] 19.8 [.78] 1.02 [.04] 3.05 [.12] DA-15
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 (.06) max.
D-Subminiature,
Right-Angled Boot
Materials Available
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Boots
4-72 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
234A111 to 152
Applications
Provides strain relief and
mechanical protection on
D-subminiature connector
terminations.
234A111 to 152
H
K Dia.
J
H
J
W K Dia.
X
P
R
234A111 to 152
H
K Dia.
J
H
J
W K Dia.
X
P
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJK
P R W X This
Part ±5% ±5% ±5% ±5% Min. Max. ±10% ±10% ±20% ±20% Boot Fits
No. ababab
bbbbCannon/Cinch
234A11 1 20.3 [.80] 20.3 [.80] 10.7 [.42] 10.7 [.42] 7.9 [.31] 4.1 [.16] 27.9 [1.10] 18.5 [.73] 1.02 [.04] 3.05 [.12] DE-9
234A121 28.2 [1.11] 28.2 [1.11] 10.7 [.42] 10.7 [.42] 10.2 [.40] 5.3 [.21] 35.1 [1.38] 18.8 [.74] 1.02 [.04] 3.05 [.12] DA-15
234A132 42.2 [1.66] 42.2 [1.66] 10.7 [.42] 10.7 [.42] 14.0 [.55] 6.4 [.25] 47.5 [1.87] 20.1 [.79] 1.02 [.04] 3.05 [.12] DB-25
234A142 58.7 [2.31] 58.7 [2.31] 10.7 [.42] 10.7 [.42] 17.3 [.68] 7.9 [.31] 59.7 [2.35] 20.1 [.79] 1.02 [.04] 3.05 [.12] DC-37
234A152 57.9 [2.28] 57.9 [2.28] 13.7 [.54] 13.7 [.54] 19.1 [.75] 9.1 [.36] 63.2 [2.49] 26.4 [1.04] 1.02 [.04] 3.05 [.12] DD-50
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
D-Subminiature, Side-Entry
Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
Boots
4-73
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
234A611 to 671
Applications
Provides strain relief and
mechanical protection on
D-subminiature connector
terminations.
234A611 to 671
K Dia.
H
P
W
R
X
J
K Dia.
H&J
234A611 to 671
KDia.
H
P
K Dia.
H&J
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-25 Fluid-resistant elastomer /42 or /86 S-1017 or S-1048 or S-1125
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
HJK
P R W X This
Part ±5% ±5% ±5% ±5% Min. Max. ±10% ±10% ±20% ±20% Boot Fits
No. ababab
b b b b Cannon/Cinch
234A611 16.0 [.63] 20.3 [.80] 16.0 [.63] 10.7[.42] 16.0 [.63] 4.1 [.16] 25.9 [1.02] 21.6 [.85] 1.02 [.04] 3.05 [.12] DE-9
234A621 19.1 [.75] 28.2 [1.11] 19.1 [.75] 10.7 [.42] 19.1 [.75] 5.3 [.21] 30.7 [1.21] 24.6 [.97] 1.02 [.04] 3.05 [.12] DA-15
234A632 29.2 [1.15] 42.2 [1.66] 29.2 [1.15] 10.7 [.42] 29.2 [1.15] 7.4 [.29] 42.9 [1.69] 27.9 [1.10] 1.02 [.04] 3.05 [.12] DB-25
234A642 34.3 [1.35] 58.7 [2.31] 34.3 [1.35] 10.7 [.42] 34.3 [1.35] 8.6 [.34] 53.3 [2.10] 30.5 [1.20] 1.02 [.04] 3.05 [.12] DC-37
234A652 37.6 [1.48] 57.9 [2.28] 37.6 [1.48] 13.7 [.54] 37.6 [1.48] 10.7 [.42] 55.9 [2.20] 32.3 [1.27] 1.02 [.04] 3.05 [.12] DD-50
234A661 16.0 [.63] 20.3 [.80] 16.0 [.63] 10.7 [.42] 16.0 [.63] 3.8 [.15] 25.9 [1.02] 18.5 [.73] 1.02 [.04] 3.05 [.12] DE-9
234A671 19.1 [.75] 28.2 [1.11] 19.1 [.75] 10.7 [.42] 19.1 [.75] 5.1 [.20] 30.7 [1.21] 19.8 [.78] 1.02 [.04] 3.05 [.12] DA-15
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
D-Subminiature,
90° End-Entry Boot
Materials Available
Product Dimensions
Available in: Americas Europe Asia Pacific
nnn
Boots
4-74 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
242W042 to 63
Applications
Designed for use in the
aggressive environments
found adjacent to engines
inautomotive, aerospace
and military applications,
heat-shrinkable molded
parts provide rugged pro-
tection, strain relief and a
full 360°environmental seal.
The introduction of the 45°
option means there is now
achoice of three routes to
the connector for closer
positioning and greater
design freedom.
H Dia. J Dia.
JDia.
W Typ.
U
135˚
T
HDia.
PJO
S
H Dia. J Dia.
JDia.
W Typ.
U
135˚
T
HDia.
PJO
S
AsSupplied (a)
After Unrestricted Recovery (b)
HJ
Part Min. Max. Min. Max. PSTU JO W
No. ab
aa
b± 10% ± 10% ± 10% ± 10% ± 10% ± 20%
-12, -100, b b b b b b
-12, -100 -3, -25 -3, -25
242W042 31.0 [1.22] 17.9 [.70] 18.0 [.71] 31.0 [1.22] 7.0 [.28] 55.0 [2.17] 35.0 [1.38] 3.5 [.14] 2.0 [.08] 25.0 [.98] 1.8 [.07]
242W053 36.0 [1.42] 22.1 [.87] 21.0 [.83] 36.0 [1.42] 8.4 [.33] 60.0 [2.36] 40.0 [1.58] 3.5 [.14] 2.0 [.08] 30.0 [1.18] 2.0 [.08]
242W063 43.0 [1.69] 27.9 [1.10] 25.0 [.99] 43.0 [1.69] 9.9 [.39] 65.0 [2.56] 45.0 [1.77] 3.5 [.14] 2.0 [.08] 35.0 [1.38] 2.2 [.09]
As supplied dimensions are for uncoated parts, when coating is added, entry diameters will reduce by 1.5 [.06] max.
Material Dash Number Material Description Precoating No. Adhesive Part No.
-3 Polyolefin, semirigid /42, /86 S-1017 or S-1048
-4 Polyolefin, flexible /42, /86 S-1017 or S-1048
-25 Elastomer,fluid-resistant /42, /86, /225 S-1017, S-1125 or S-1048
-130 Polyolefin, commercial flexible /42, /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-100 Polyolefin, Zerohal /180 S-1030
45° Angled Boot
Compatibility Chart
Product Dimensions
Ordering Information
Adhesive slash number (if required see Compatibility chart)
Material dash number (see Compatibility chart)
Base part number
242W0XX-X/XX-0
Available in: Americas Europe Asia Pacific
nnn
VITON is a trademark of Dupont Dow
Elastomers LLC.
Feedthroughs
4-75
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
207W213 to 256
Applications
Use for strain relief and
abrasion protection when
cables pass through equip-
ment boxes or panels.
J Dia.
SU
J Dia.
Slight taper
JW
H
M
JO
Tan
B nut (-01 modification)
A nut (standard)
207W213 to 256
SU
J Dia.
Slight taper
JW
H
M
JO
Tan
B nut (-01 modification)
A nut (standard)
207W213 to 256
J Dia.
SU
J Dia.
Slight taper
JW
H
M
JO
Tan
B nut (-01 modification)
A nut (standard)
207W213 to 256
Material Dash Number Material Description Precoating No. Adhesive Part No.
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
J
Part H Min. JO M P R S U JW Hole
No. Ref. -3, -4, -12, -100 Max. Max. Thread ±10% ±10% ±10% ±10% ±20% Dia.
b-25 abbb b b b b b ±.51 [.02]
a
207W213 11.9 [.47] 9.9 [.39] 8.5 [.33] 4.1 [.16] 15.2 [.60] 20.1 [.79] 62.0 [2.44] 49.0 [1.93] 13.0 [.51] 9.9 [.39] 1.3 [.05] 23.9 [.94]
207W223 20.1 [.79] 18.0 [.71] 16.5 [.65] 7.1 [.28] 19.3 [.76] 30.0 [1.18] 71.9 [2.83] 58.9 [2.32] 16.0 [.63] 9.9 [.39] 1.8 [.07] 34.0 [1.34]
207W234 30.1 [1.22] 27.9 [1.10] 26.5 [1.04] 11.9 [.47] 26.9 [1.06] 41.9 [1.65] 87.1 [3.43] 73.9 [2.91] 18.0 [.71] 9.9 [.39] 2.03 [.08] 47.0 [1.85]
207W245 45.0 [1.77] 41.9 [1.65] 40.5 [1.59] 18.0 [.71] 32.0 [1.26] 55.9 [2.20] 102.1 [4.02] 88.9 [3.50] 18.0 [.71] 9.9 [.39] 3.05 [.12] 60.5 [2.38]
207W256 68.1 [2.68] 64.0 [2.52] 64.5 [2.54] 30.0 [1.18] 39.1 [1.54] 80.0 [3.15] 121.9 [4.80] 109.0 [4.29] 18.0 [.71] 9.9 [.39] 3.05 [.12] 85.1 [3.35]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Two-Part Feedthrough
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-76 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
301A011 to 048
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
H Dia.
K Dia.
J Dia.
H
J Dia.
S
P
301A011 to 048
Material Dash Number Material Description Precoating No. Adhesive Part No.
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86, /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
H, J & K PSTW
Part Min. Max. ±10% ±10% ±10% ±30%
No. ab bbbb
301A0116.6 [.26] 3.6 [.14] 29.7 [1.17] 15.1 [.59] — 1.02 [.04]
301A022 13.2 [.52] 6.9 [.27] 58.7 [2.31] 29.5 [1.16] 17.5 [.69] 1.52 [.06]
301A028 20.0 [0.79] 10.2 [.40] 90 [3.54] 45 [1.77] 30 [1.18] 2.0 [.08]
301A034 26.9 [1.06] 13.5 [.53] 120.1 [4.73] 60.2 [2.37] 35.6 [1.40] 2.29 [.09]
301A048 55.6 [2.19] 30.2 [1.19] 246.4 [9.70] 123.2 [4.85] 70.9 [2.79] 3.05 [.12]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
H Dia.
K Dia.
J Dia.
H Dia.
J Dia. K Dia.
SW
T
P
301A011 to 048
T Transition
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-77
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
301A511 to 514
Materials Available
Product Dimensions
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
301A511 to 514
H Dia.
P
KO
JO
Tan
HO Tan
W
K
J Dia.
K Dia.
JDia.
H Dia.
301A511 to 514
H Dia.
P
HOTan
W
K
J Dia.
K Dia.
HDia.
Material Dash Number Material Description Precoating No. Adhesive Part No.
-50 Viton®polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
-125 Fluoropolymer N/A S-1255-04
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
H J & K HO, JO, & KO W P
Part Min. Max. Min. Max. ±10% Nom. Nom.
No. ab ab bbb
301A511 19.8 [.78] 6.6 [.26] 13.2 [.52] 6.6 [.26] 25.4 [1.00] 1.02 [.04] 80.8 [3.18]
301A512 34.3 [1.35] 11.4 [.45] 22.9 [.90] 11.4 [.45] 41.1 [1.62] 1.27 [.05] 120.4 [4.74]
301A513 60.2 [2.37] 20.1 [.79] 40.1 [1.58] 20.1 [.79] 63.5 [2.50] 1.52 [.06] 175.8 [6.92]
301A514* 83.3 [3.28] 33.3 [1.31] 54.9 [2.16] 33.3 [1.31] 88.9 [3.50] 1.78 [.07] 242.3 [9.54]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
*301A514 is not available in -125 Fluoropolymer material.
Slimline T Transition
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-78 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
322A112 to 158
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
J Dia.
K Dia.
H Dia.
K Dia.
HDia. J Dia.
W
T
P
KW
HW
322A112 to 158
AsSupplied (a)
After Unrestricted Recovery (b)
J Dia.
K Dia.
H Dia.
K
H Dia.
P
K
HW
322A112 to 158
T Transition
Material Dash Number Material Description Precoating No. Adhesive Part No.
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Modified elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
H & J K P T HW & W KW
Part Min. Max. Min. Max. ±10% ±10% ±20% ±20%
No. ababbbbb
322A112 13.2 [.52] 5.8 [.23] 6.6 [.26] 3.0 [.12] 52.3 [2.06] — 1.52 [.06] 1.02 [.04]
322A123 26.9 [1.06] 12.4 [.49] 6.6 [.26] 3.0 [.12] 83.3 [3.28] 10.7 [.42] 2.54 [.10] 1.02 [.04]
322A134 26.9 [1.06] 12.7 [.50] 13.2 [.52] 5.8 [.23] 107.7 [4.24] 20.3 [.80] 2.54 [.10] 1.52 [.06]
322A148 55.6 [2.19] 25.4 [1.00] 13.2 [.52] 5.8 [.23] 180.6 [7.11] 25.4 [1.00] 4.57 [.18] 1.52 [.06]
322A158 55.6 [2.19] 25.4 [1.00] 26.9 [1.06] 12.4 [.49] 222.3 [8.75] 38.1 [1.50] 4.57 [.18] 2.54 [.10]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
4
Molded Parts
Transitions
4-79
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
342A012 to 058
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
342A012 to 158
H Dia. J Dia.
K Dia.
JW
T
PU
HW
KW
H Dia. J Dia.
K
342A012 to 158
H Dia. J Dia.
K Dia.
T
HW
HDia. J Dia.
K
AsSupplied (a)
After Unrestricted Recovery (b)
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
H & JK
P T U HW & JW KW
Part Min. Max. Min. Max. ±10% ±10% ±10% ±20% ±20%
No. aba bbbbbb
342A012 13.2 [.52] 6.9 [.27] 6.6 [.26] 3.6 [.14] 49.3 [1.94] 19.6 [.77] 19.6 [.77] 1.52 [.06] 1.02 [.04]
342A024 26.9 [1.06] 12.7 [.50] 6.6 [.26] 3.6 [.14] 92.5 [3.64] 31.8 [1.25] 39.6 [1.56] 2.54 [.10] 1.02 [.04]
342A034 26.9 [1.06] 13.7 [.54] 13.2 [.52] 6.1 [.24] 144.8 [5.70] 50.8 [2.00] 50.8 [2.00] 2.54 [.10] 1.52 [.06]
342A048 55.6 [2.19] 26.9 [1.06] 13.2 [.52] 6.9 [.27] 184.9 [7.28] 63.5 [2.50] 63.5 [2.50] 4.57 [.18] 1.52 [.06]
342A058 55.6 [2.19] 26.9 [1.06] 26.9 [1.06] 13.7 [.54] 203.5 [8.01] 66.0 [2.60] 66.0 [2.60] 4.57 [.18] 2.54 [.10]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5 [.06] max.
45° Side-Breakout
Transition
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-80 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
362A014 to 114
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
362A014 to 114
H Dia.
JW
KW
P
ST
HW
J Dia.
K
H Dia. J Dia.
K Dia.
362A014 to 114
H Dia.
J
P
ST
HW
J Dia.
K
H Dia. J Dia.
K
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton®N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
H & J KPST HW & JW KW
Part Min. Max. Min. Max. ±10% ±10% ±10% ±20% ±20%
No. ababb b b bb
362A014 30.5 [1.20] 15.7 [.62] 20.3 [.80] 10.7 [.42] 82.6 [3.25] 31.8 [1.25] 21.1 [.63] 2.54 [.10] 1.78 [.07]
362A024 35.6 [1.40] 18.3 [.72] 15.2 [.60] 8.6 [.34] 63.5 [2.50] 19.1 [.75] 22.4 [.88] 2.54 [.10] 1.52 [.06]
362A114 35.6 [1.40] 18.8 [.74] 10.2 [.40] 5.3 [.21] 61.0 [2.40] 19.1 [.75] 21.3 [.84] 2.79 [.11] 1.52 [.06]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
30° Side-Breakout
Transition
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
4
Molded Parts
Transitions
4-81
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
381A301 to 304
Materials Available
Product Dimensions
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
381A301 to 304
W
P
R
S
HDia.
JDia.
KDia.
J
K
HDia.
381A301 to 304
W
P
H Dia.
JDia.
KDia.
J
HDia.
Material* Material Description Precoating No. Adhesive Part No.**
-50 Viton® polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
-125 Fluoropolymer — S-1255-04
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
H J & K W P R & S
Part Min. Max. Min. Max. Nom. Nom. Nom.
No. ababbbb
381A301 19.8 [.78] 6.6 [.26] 13.2 [.52] 6.6 [.26] 1.0 [.04] 40.6 [1.60] 40.6 [1.60]
381A302 34.3 [1.35] 11.4 [.45] 22.9 [.90] 11.4 [.45] 1.3 [.05] 63.0 [2.48] 63.0 [2.48]
381A303 60.2 [2.37] 20.1 [.79] 40.1 [1.58] 20.1[.79] 1.5 [.06] 94.7 [3.73] 94.7 [3.73]
381A304* 83.3 [3.28] 33.3 [1.31] 54.9 [2.16] 33.3 [1.31] 1.8 [.07] 133.9 [5.27] 133.9 [5.27]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
*381A304 is not available in -125 Fluoropolymer material.
Slimline Y Transition
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-82 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
382A012 to 046
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
382A012 to 046
HW T
S
H Dia.
J Dia.
K Dia.
J
H Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton® N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
AsSupplied (a)
After Unrestricted Recovery (b)
H J & K S T HW JW & KW
Part Min. Max. Min. Max. ±10% ±10% ±20% ±20%
No. a b a b bbbb
382A012 13.2 [.52] 6.1 [.24] 6.6 [.26] 3.3 [.13] 23.9 [.94] 15.5 [.61] 1.52 [.06] 1.02 [.04]
382A023 26.9 [1.06] 12.4 [.49] 13.2 [.52] 6.1 [.24] 53.3 [2.10] 33.0 [1.30] 2.54 [.10] 1.52 [.06]
382A034 38.6 [1.52] 18.0 [.71] 26.9 [1.06] 12.4 [.49] 78.7 [3.10] 55.9 [2.20] 3.05 [.12] 2.54 [.10]
382A046 55.6 [2.19] 25.9 [1.02] 26.9 [1.06] 12.7 [.50] 111.8 [4.40] 71.1 [2.80] 4.57 [.18] 2.54 [.10]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
382A012 to 046
HW T
KW
JW
S
H Dia.
J Dia.
K Dia.
JDia.
K Dia.
H Dia.
Y Transition
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
4
Molded Parts
Transitions
4-83
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
382C312, 322 and 332
H Dia.
J Dia.
KDia.
HDia.
WTyp.
P
HO Tan Tan
RJO J Dia.
Tan
SKO
K Dia.
H Dia.
JDia.
KDia.
H Dia.
WTyp.
P
HO Tan Tan
RJOJDia.
Tan
SKO
K Dia.
As Supplied (a)
After Unrestricted Recovery (b)
382C312
HDia.
W Typ.
Tan
Tan
J Dia.
K Dia.
Tan
HO
RJO
SKO
P
After Unrestricted Recovery (b)
Applications
Provides strain relief and
mechanical protection at
two into one Y junctions in
cable harness assemblies.
382C322, 382C332
Slimline Y Transition
HJ K
P, R & S KO HO & JO W
Part Min. Max. Min. Max. Min. Max. Nom. ±15% ±15% Nom
No. abab ab bbbb
382C312 1.20 .45 .90 .45 .60 .30 2.48 .85 1.62 .04
[30.5] [11.4] [22.9] [11.4] [15.2] [7.6] [63.0] [21.6] [41.1] [1.0]
H J & K P, R & S HO JO & KO W
Part Min. Max. Min. Max. Nom. ±15% ±15% Nom.
No. abab bb b b
382C322 .90 .45 .40 .20 2.48 1.62 .85 .04
[22.9] [11.4] [10.2] [5.1] [63.0] [41.1] [21.6] [1.0]
HJ&K P, R & S HO JO & KO W
Part Min. Max. Min. Max. Nom. ±15% ±15% Nom.
No. abab bb b b
382C332 1.00 .45 .60 .30 2.48 1.62 .85 .04
[25.4] [11.4] [15.2] [7.5] [63.0] [41.1] [21.6] [1.0]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
Material Material Description Precoating No. Adhesive Part No.
-50 Viton® polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
-125 Fluoropolymer N/A S-1255-04
Materials Available
Product Dimensions
When used with adhesive
it provides environmental
sealing. These parts are
based on the 382A3 range.
They have the branched
outlet(s) reduced in size to
accommodate smaller
cable diameters without the
need for packing or
shimming.
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-84 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
462A011 to 060
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
462A011 to 060
KW Typ.
P
UT
HW
H Dia.
J Dia.
K Dia.
L Dia.
H Dia.
J Dia.
K Dia.
LDia.
462A011 to 060
P
UT
HW
H Dia.
J Dia.
K Dia.
L Dia.
H Dia.
J
AsSupplied (a)
After Unrestricted Recovery (b)
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton® N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
H J, K&L P
Part Min. Max. Min. Max. ±10%
No. ab ab
b
462A011 13.2 [.52] 6.6 [.26] 6.6 [.26] 3.6 [.14] 46.2 [1.82]
462A023 26.9 [1.06] 13.2 [.52] 13.2 [.52] 6.9 [.27] 93.2 [3.67]
462A034 38.6 [1.52] 18.8 [.74] 19.3 [.76] 9.7 [.38] 135.1 [5.32]
462A046 55.6 [2.19] 25.4 [1.00] 26.9 [1.06] 12.4 [.49] 192.0 [7.56]
462A060 91.4 [3.60] 54.6 [2.15] 45.7 [1.80] 27.4 [1.08] 390.4 [15.37]
T U HW KW
Part ±10% ±10% ±20% ±10%
No. bbbb
462A01130.5 [1.20] 15.7 [.62] 1.52 [.06] 1.02 [.04]
462A023 57.2 [2.25] 33.0 [1.30] 2.54 [.10] 1.52 [.06]
462A034 88.9 [3.50] 45.7 [1.80] 3.05 [.12] 1.78 [.07]
462A046 121.9 [4.80] 71.1 [2.80] 4.57 [.18] 3.05 [.12]
462A060 254.0 [10.00] 127.0 [5.00] 7.11 [.28] 4.57 [.18]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
Transition, One to Three
Cables
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
4
Molded Parts
Transitions
4-85
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
462A421 to 424
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
462A421 to 424
R
P
H Dia.
K Dia.
J & L Dia. K
H Dia.
462A421 to 424
W
R
S
T
P
H Dia.
KDia.
J & L Dia. K Dia.
J Dia.
L Dia.
H Dia.
Material* Material Description Precoating No. Adhesive Part No.**
-50 Viton® polymer blend N/A S-1125
-51 Elastomer polymer blend /164 S-1124
-71 Flexible polyolefin /42 or /86 S-1017 or S-1048
AsSupplied (a)
After Unrestricted Recovery (b)
HJ, K & L WPR, S & T
Part Min. Max. Min. Max. Nom. Nom. Nom.
No. ababbbb
462A421*19.8 [.78] 6.6 [.26] 13.2 [.52] 6.6 [.26] 1.0 [.04] 85.9 [3.38] 42.9 [1.69]
462A422*34.3 [1.35] 11.4 [.45] 20.6 [.81] 11.4 [.45] 1.3 [.05] 135.6 [5.34] 67.8 [2.67]
462A423*60.2 [2.37] 20.1 [.79] 36.1 [1.42] 20.1 [.79] 1.5 [.06] 207.3 [8.16] 103.6 [4.08]
462A424* 99.8 [3.93] 33.3 [1.31] 54.9 [2.16] 33.3 [1.31] 1.8 [.07] 207.2 [8.16] 103.6 [4.08]
*-01 modification only
Slimline Transition, One to
Three Cables
Materials Available
Product Dimensions
Materials Available Material* Material Description Precoating No. Adhesive Part No.**
-125 Fluoropolymer —S-1255-04
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
Product Dimensions H J, K & L WPR, S & T
Part Min. Max. Min. Max. Nom. Nom. Nom.
No. abab
bbb
462A421 19.8 [.78] 6.6 [.26] 13.2 [.52] 6.6 [.26] 1.0 [.04] 85.9 [3.38] 42.9 [1.69]
462A422 34.3 [1.35] 11.4 [.45] 20.6 [.81] 11.4 [.45] 1.3 [.05] 135.6 [5.34] 67.8 [2.67]
462A423 60.2 [2.37] 20.1 [.79] 36.1 [1.42] 20.1 [.79] 1.5 [.06] 207.3 [8.16] 103.6 [4.08]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
VITON is a trademark of Dupont Dow
Elastomers LLC.
Transitions
4-86 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
562A011 to 067
Applications
Provides strain relief and
mechanical protection on
cable harness assemblies.
HW U
T
W
J Dia.
P
H Dia.
K Dia.
J Dia.
N Dia.
L Dia.
K Dia.
L Dia.
H Dia.
562A011 to 067
N Dia.
HWU
T
H Dia.
KDia.
JDia.
N Dia.
LDia.
K
H Dia.
562A011 to 067
N
AsSupplied (a)
After Unrestricted Recovery (b)
Transition, One to Four
Cables
Material* Material Description Precoating No. Adhesive Part No.**
-3 Semirigid polyolefin /42 or /86 S-1017 or S-1048
-4 Flexible polyolefin /42 or /86 S-1017 or S-1048
-12 Viton® N/A S-1255-04
-25 Fluid-resistant elastomer /42 or /86 or /225 S-1017 or S-1048 or S-1125
-100 Polyolefin, Zerohal /86 or /180 S-1048 or S-1030
*For more information, please see the appropriate material page in this section.
**For more information, please see section 5.
H J, K, L & N PTUHW W
Part Min. Max. Min. Max. ±10% ±10% ±10% ±20% ±20%
No. aba bbbbb b
562A011 13.2 [.52] 6.9 [.27] 6.6 [.26] 3.4 [.14] 24.1 [.95] 43.9 [1.73] 18.0 [.71] 1.52 [.06] 1.02 [.04]
562A022 19.3 [.76] 9.7 [.38] 9.4 [.37] 5.3 [.21] 35.6 [1.40] 43.2 [1.70] 23.1 [.91] 1.78 [.07] 1.02 [.04]
562A032 19.3 [.76] 9.7 [.38] 13.2 [.52] 6.9 [.27] 49.3 [1.94] 50.5 [1.99] 25.4 [1.00] 1.78 [.07] 1.52 [.06]
562A043 26.9 [1.06] 13.0 [.51] 13.2 [.52] 6.9 [.27] 49.3 [1.94] 65.8 [2.59] 33.5 [1.32] 2.54 [.10] 1.52 [.06]
562A054 38.6 [1.52] 18.5 [.73] 19.3 [.76] 9.7 [.38] 71.9 [2.83] 95.3 [3.75] 46.5 [1.83] 3.05 [.12] 1.78 [.07]
562A067 55.6 [2.19] 26.7 [1.05] 26.9 [1.06] 13.0 [.51] 101.6 [4.00] 135.1 [5.32] 65.5 [2.58] 4.57 [.18] 2.54 [.10]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by
1.5 [.06] max.
Materials Available
Product Dimensions
VITON is a trademark of Dupont Dow
Elastomers LLC.
4
Molded Parts
Transitions
4-87
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
QFT
Applications
QFT heat-shrinkable transi-
tions formawatertight seal
protecting cable splices
from corrosion and mechan-
ical abuse while providing
excellent electrical insulating
properties. QFT products
use special crimps that allow
them to be employed as
1:2, 1:3, and even 1:4 tran-
sitions. With their high shrink
ratio and crimps the config-
urable QFT product line can
accommodate almost all of
your transition needs with
only 3 product sizes.
Raychem RW 2008 Molded Part
RT1050/1 Adhesive
Specifications/Approvals
Temperature Ratings
Dimensions Table
Operating temperature range -20°C to 70°C [-4°F to 158°F] (125°C [257°F] without sealant)
Minimum recovery temperature 55°C [131°F]
Maximum storage temperature 40°C [104°F]
HJPJO HW JW
Min. Max. Min. Max. +/- 10% +/- 10% +/- 20% +/- 20%
QFT1 31.0 [1.22] 9.0 [.35] 31.0 [1.22] 4.4 [.17] 60.0 [2.36] 12.0 [.47] 1.5 [.06] 1.0 [.039]
QFT2 43.0 [1.69] 14.0 [.55] 43.0 [1.69] 7.0 [.28] 75.0 [2.95] 18.0 [.71] 1.8 [.07] 1.0 [.039]
QFT3 57.0 [2.24] 24.0 [.95] 57.0 [2.24] 12.0 [.47] 90.0 [3.53] 25.0 [.98] 1.8 [.07] 1.0 [.039]
H Dia. J Dia.
HW H Dia. J Dia.
JW
P
JO
H Dia. J Dia.
HW H Dia. J Dia.
JW
P
JO
Expanded Recovered
Product Facts
nConfigurable heat-shrink
transition
nLow cost commercial
polyolefin
n80°C [176°F] shrink
temperature
nHigh shrink ratio
nSpecially engineered
easy-to-use crimp tool
Operating Temperature Range
-20°Cto 70°C
[-4°F to 158°F]
Configurable Heat-Shrink
Transition
Transitions
4-88 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
QFT (Continued)
Property Performance Test method
Tensile strength 10 MPa (1500psi) minimum ISO 37
Ultimate elongation 250% minimum ISO 37
Longitudinal change 0 to 20% maximum ISO 1183
Physical Specific gravity 1.4 maximum ISO 1183
Heat aging Minimum 200% ultimate elongation ISO 188
168 hours at 120°C [248°F] Tensile Strength 10 MPa min. ISO 37
Heat shock No cracking, dripping or flowing ASTM D 2671
4hours at 105°C
Electrical Dielectric strength 8MV/m minimum IEC 243-1
Fluid resistance 1 (24 +/- 2h immersion at 23C+/- 2C) ISO 1817
Engine Oil (SAE 20W/50) —
Hydraulic Fluid
Tensile Strength 10 MPa minimum ISO 37
Ultimate Elongation 200% minimum —
Fluid resistance 2 (30 +/- 3m immersion at 23C+/- 2C) ISO 1817
Chemical Automotive gasoline (BS 4040) —
Diesel fuel (BS 2869) —
Cleaning fluid (TL 6850-07) —
Antifreeze (Ethylene Glycol/Water 50/50 v/v) —
Engine cleaning fluid (Gunk)
Tensile strength 10 MPa minimum ISO 37
Ultimate elongation 200% minimum —
Color Standard Black (-0)
Code 0
Standard 10 pieces per bag, 30 clips
Packaging Bulk pack 500 pieces per box and 500 clips per bag
(clips ordered separately)
-contact Tyco Electronics for details
Crimp tool QFT-Crimp-Tool-Manual (069172-000) —
*Available in bulk pack, part number QFT3-130/42-0-B500 (US and UK).
Typical QFT Performance
Ordering Information
Part Numbering System
Color
Adhesive
Material
Size
Product name
QFT3 - 130/42 - 0*
4
Molded Parts
Transitions
4-89
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SSB, D, T, F to 8S
Applications
These flame-retardant heat-
shrinkable transitions are
especially designed for
shipboard applications and
meet or exceed all of the
U.S. Navy specifications
described in MIL-I-81765/1A
(as of 5/02). The transitions
aremade of a rugged, ther-
mally stabilized, modified
polyolefin and factory-
coated with a thermoplastic
adhesive sealant. As a
result, they offer excellent
water sealing, mechanical
abrasion-protection,
corrosion-resistance, weath-
erproofing, and electrical
insulation. The transitions
replace tapes, epoxies,
and grease in applications
involving cable breakouts,
transitions, and terminations.
Product Facts
nWatertight
nEasy installation, requiring
nospecial skills
nCompatibility with
polyethylene, PVC, lead,
steel, aluminum, standard
Navy cable jackets, and
copper wire and cable
nFour configurations and
twelve sizes
nMinimum shrink
temperature of 121°C
[250°F]
nType approval by:
-ABS (American Bureau of
Shipping)
-DNV (Det Norske Veritas)
-Lloyd’s (Lloyd’s Register of
Shipping)
Heavy Duty Breakout Boots
Transitions
4-90 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SSB, D, T, F to 8S (Continued)
Commercial Military
RW-2024 MIL-STD-2003
MIL-I-81765/1A
Number ID Base ID legs Length
Description of Legs Min. Exp. Max. Rec. Min. Exp. Min. Rec. Leg Body
SSB-1202 FR 2 40.64[1.60] 11.43 [0.45] 13.97[0.55] 3.81[0.15] 36.83[1.45] 62.23[2.45]
SSB-2002 FR 2 50.8[2.00] 35.56[1.40] 19.05[0.75] 8.89[0.35] 69.85[2.75] 88.90[3.50]
D3-9 FR 2 20.32[0.80] 9.39[0.37] 8.38[0.33] 2.79[0.11] 17.78[0.7] 50.8[2]
D14-30 FR 2 30.48[1.2] 15.24[0.6] 12.7[0.5] 4.32[0.17] 25.4[1] 63.5[2.5]
D50-100 FR 2 48.26[1.9] 22.86[0.9] 19.05[0.75] 7.62[0.3] 30.48[1.2] 76.2[3]
D200-400 FR 2 76.2[3] 38.1[1.5] 36.83[1.45] 12.7[0.5] 38.1[1.5] 88.9[3.5]
T3-9 FR 3 22.86[0.9] 9.14[0.36] 8.38[0.33] 2.29[0.09] 19.05[0.75] 50.80[2.0]
T14-23 FR 3 30.48[1.2] 17.78[0.70] 12.70[0.5] 4.57[0.18] 25.4[1] 60.96[2.40]
T14-50 FR 3 38.1[1.5] 12.7[0.5] 16.51[0.65] 4.06[0.16] 30.48[1.2] 76.2[2.3]
T42-100 FR 3 43.18[1.7] 22.86[0.9] 20.32[0.8] 4.83[0.19] 30.48[1.25] 57.15[2.25]
T150-300 FR 3 60.96[2.4] 35.56[1.4] 30.48[1.25] 12.70[0.5] 40.6[1.6] 88.90[3.50]
T400 FR 3 81.28[3.2] 50.8[2] 35.56[1.4] 17.78[0.7] 40.6[1.6] 88.9[3.5]
T500-600 FR 3 124.46[4.90] 58.93[2.32] 50.8[2] 22.86[0.9] 50.8[2] 187.96[7.40]
F3-9 FR 4 22.86[0.9] 10.92[0.43] 7.11[0.28] 2.79[0.11] 19.05[0.75] 50.8[2]
F-23 FR 4 31.75[1.25] 20.32[0.8] 12.7[0.5] 5.08[0.2] 27.94[1.1] 63.50[2.50]
F42-60 FR 4 44.45[1.75] 25.4[1] 20.32[0.8] 8.13[0.32] 30.48[1.25] 63.50[2.50]
F75-100 FR 4 59.69[2.35] 25.4[1] 25.4[1] 8.89[0.35] 43.18[1.7] 165.1[6.5]
F133-200 FR 4 67.31[2.65] 35.56[1.4] 30.48[1.2] 10.92[0.43] 38.1[1.5] 91.44[3.6]
F150-400 FR 4 133.35[5.25] 76.2[3] 34.29[1.35] 13.97[0.55] 76.2[3] 152.4[6]
6S100-200 FR 6 60.96[2.4] 36.83[1.45] 20.32[0.8] 8.89[0.35] 69.85[2.75] 86.36[3.4]
8S23-75 FR 8 35.56[1.4] 21.59[0.85] 10.16[0.4] 3.3[0.13] 30.48[1.25] 50.8[2]
8S14-50 FR 8 57.15[2.25] 21.59[0.85] 14.22[0.56] 3.3[0.13] 30.48[1.25] 50.8[2]
8S42-100 FR 8 63.50[2.50] 21.59[0.85] 22.1[0.87] 3.3[0.13] 30.48[1.25] 50.8[2]
Specifications/Approvals
Product Dimensions
Accessories
4-91
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
202W302 to 342
Product Facts
nFast installation
nTemperature range of -40°C
to 105°C [-40°F to 221°F]
nFits range of diameters
nLow cost, high volume
installation
nShrinks onto hose/pipe/ wire
harnesses
nGood mechanical, thermal
and chemical properties
nGood abrasion resistance
nExcellent location,
cushioning and protection of
cable or hoses from P clips
and wire ties
nStays in place when heated.
nSuits most hoses/pipes/wire
harnesses
nNo expensive tooling
required
nEngine area solution
Square expanded = -130 material
Circular expanded =-12 and -25 material
-3, -4
H
P
R
T
H Dia.
W
S
H
J
P
R
T
H Dia.
W
S
H
J
P
R
T
H Dia.
W
S
As Supplied (a) After Unrestricted Recovery (b)
Heat-Shrink Bobbins
Accessories
4-92 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
202W302 to 342 (Continued)
HJ P R S T W Recommended
Part Min. Max. Min. ±10% ±10% ±10% ±10% ±20% Hose Sizes
No. ababbbbbMin. Max.
202W302 29.0 [1.142] 9.5 [.374] 29.0 [1.142] 35.0 [1.378] 25.0 [.984] 5.0 [.197] 3.0 [.118] 1.5 [.059] 11.0 [.433] 25.0 [.984]
202W312 39.0 [1.535] 12.7 [.500] 39.0 [1.535] 35.0 [1.378] 25.0 [.984] 5.0 [.197] 3.0 [.118] 2.0 [.079] 14.0 [.551] 34.0 [1.339]
202W321 10.0 [.394] 3.0 [.118] 10.0 [.394] 29.0 [1.142] 23.0 [.906] 3.0 [.118] 3.0 [.118] 1.5 [.059] 4.0 [.157] 8.0 [.315]
202W331 19.0 [.748] 6.4 [.252] 19.0 [.748] 29.0 [1.142] 24.0 [.945] 2.5 [.098] 2.0 [.079] 1.5 [.059] 8.0 [.315] 17.0 [.669]
202W342 54.0 [2.126] 18.0 [.709] 54.0 [2.126] 35.0 [1.378] 25.0 [.984] 5.0 [.197] 3.0 [.118] 2.0 [.079] 20.0 [.787] 48.0 [1.889]
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added, entry diameters will be reduced by 1.5
[.06] max.
Material Material Description Precoating No. Adhesive Part No.
-3 Polyolefin, semi-rigid /42, /86 S-1017, S-1048
-4 Polyolefin, flexible /42, /86 S-1017, S-1048
-12 Viton® N/A S-1255-04
-25 Fluid resistant elastomer /86 or /225 S-1017 or S-1048 or S-1125
-130 Flexible polyolefin /42, /86 S-1017
Product Dimensions
Materials Available
VITON is a trademark of Dupont Dow
Elastomers LLC.
Accessories
4-93
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
400W242
Product Facts
nEasy to install
nClose fit to hose/pipe
nFits range of diameters due
to high expansion
nLow cost, high volume
installation
nShrinks onto hose/pipe
nMinimum distance between
substrates
nGood mechanical, thermal
and chemical properties
nPush on fit to hose/pipe
nStays in place when
installed
nNo expensive tooling
required
nPositions where needed
nKeeps hoses/pipes together,
optimizing space
nUnder body solution
nEngine area solution
nTwinning two hoses/pipes
rationalizes part
descriptions
nHose/pipe can be orientated
correctly for ease of fitting to
vehicle
H Dia.
V
P
J Dia.
K
W
H Dia.
Y
Z
H Dia.
V
P
J Dia.
K
W
H Dia.
Y
Z
H Dia.
V
P
J Dia.
K
W
H Dia.
Y
Z
After Unrestricted Recovery (b)
-3, -4, -25, -100 -130
As Supplied (a)
Heat-Shrink Positioning
Ring
Accessories
4-94 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
400W242 (Continued)
HJ K P V W Y* Z*
Part Min. Max. Max. ± 1.2 ± 1.7 ± 0.45 ± 1 ± 2 ± 2
No. abb bbbbaa
400W242 28 [1.102] 10.2 [.402] 19.3 [.760] 12 [.472] 17 [.669] 7.0 [.276] 10 [.394] 29 [1.142] 25 [.984]
*Applicable for -130 only.
Material Material Description Precoating no. Adhesive part no.
-3 Polyolefin, semi-rigid /42, /86 S-1017 or S-1048
-4 Polyolefin, flexible /42, /86 S-1017 or S-1048
-25 Elastomer, fluid resistant /86, /225 S-1017 or S-1048
-100 Polyolefin, Zerohal -100-CS1972 S-1030
(S1030 tape supplied in bag)
-130 Flexible polyolefin /42, /86 S-1017
Assupplied dimensions are for uncoated parts, when coating is added, entry diameters will reduce by 1.5 [.06] max.
Product Dimensions
Materials Available
Part Numbering System
Adhesive Slash Number
(if required see compatibility chart)
Material Dash Number
(see compatibility chart)
Base Part Number
400W242 -**/**-0
Accessories
4-95
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
CES
Applications
Raychem Heat-Shrinkable
Cable-Entry Seals (CESs)
provide a watertight,
fume-tight seal where
cables enter connection
boxes, bulkheads, or other
enclosures.
CESs are available in two
basic types: standardand
threaded. The standard
CES for thin-wall enclosures
consists of a three-part
assembly — a rigid plastic
nylon nut, an O-ring, and a
heat-shrinkable molded
area. The CES for threaded-
hole applications is a one-
part assembly that combines
atapered national pipe
thread (NPT) in rigid plastic
nylon with a heat-shrinkable
molded area.
All CESs are available with
the molded area configured
with one opening for a sin-
gle wireor cable entryor
with two, three, or four legs
Product Facts
nComes in many sizes and
configurations
nSeals multicable openings
nSAE-AS81765/1 Type 1
nSeals per U.S. Coast Guard
HQ 3774 in wet, dry, and
corrosive locations
of equal size to seal multi-
ple wires or cables at the
entry to enclosures and/or
bulkheads. To meet sealing
requirements, all CESs have
factory-applied adhesive
that provides the seal to
wireand cable jackets.
When armored cable is
being sealed it may be
necessaryto use additional
sealants, such as G.E. RTV
112 or Dow Corning RTV
732, to form the water seal.
Heat-Shrinkable Cable
Entry Seals
Step 1
Place rigid, externally threaded nut
through hole so flanged end is on
the inside of the can or cabinet.
Step 2
Place O-ring over threaded end and
position against outside of can or
cabinet.
Step 3
Screw shrinkable, internally
threaded component onto the rigid
nut and tighten, using appropriate
spanner wrenches, until O-ring is
slightly flattened — or use the
torque values shown in the table to
the left.
Step 4
Insertcable through expanded
opening and make necessary con-
nections (see note following Step 4
in the next section).
Step 5
Shrink expanded nose by applying
121˚C-135˚C [250˚F-275˚F] of heat
from a heat gun with circular reflec-
tor, or a gas torch, or other heat
source.* When parthas shrunk to
the cable, and when the sealant is
seen to flow, discontinue heat.
Additional heating will not make the
component shrink tighter.
*Follow the safety precautions of the manufacturer
of the heater.
Step 1
Apply a thread sealant to the
threaded end and then screw
threaded cable entry seal into pre-
tapped hole or pipe fitting.
Step 2
Tighten by applying wrench to
hexagonal nut.
Step 3
Insert cable through expanded
opening and make necessarycon-
nection (see Note).
Step 4
Shrink expanded nose by applying
121˚C-135˚C [250˚F-275˚F] of heat
from a heat gun with circular reflec-
tor, gas torch, or other heat source.*
When part has shrunk to the cable,
and when the sealant is seen to
flow,discontinue heat. Additional
heating will not make the compo-
nent shrink tighter.
Note
If armored cable is used, the
factory-applied sealant will not fill
the interstices of the armor. The
armor must be cut back so that the
partis allowed to shrink and seal to
the cable sheath as well as come
down over the armor. To keep the
armor from unraveling, some armor
must be approximately 1/4 inch to
3/8 inch [.01 to .02 mm] inside the
cable entry seal leg.
*Follow the safety precautions of the manufacturer
of the heater.
Threaded cable entry seal
installation instructions
Standard cable entry seal
installation instructions
Cable entry Torque
seal number in-pounds Nm
115-20 1.7-2.3
2 15-20 1.7-2.3
320-25 2.3-2.8
4 40-45 4.5-5.1
5 45-50 5.1-5.7
Note: Surfaces to be sealed should
be clean and free of burrs, pits, or
deep scratches.
Accessories
4-96 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CES (Continued)
Temperature rating -55°C to 90°C [-67°F to 194°F]
Minimum shrink temperature 121°C [250°F]
Type Raychem
Molded heat-shrink nose RT-301 Flame retardant polyolefin
Adhesive RW-2019 Hot melt adhesive
Overall Nom. Min. Max. Max.
Part No. Recommended Expanded Recovered Max. I.D. Drill O.D.
No. of Legs Length I.D. Nose I.D. Nose ofPart Size of Nut
CES-1 1 69.85 [2.75] 12.70 [0.50] 4.32 [0.17] 19.05 [0.75] 25.40 [1.00] 35.81 [1.410]
CES-2 1 69.85 [2.75] 19.05 [0.75] 6.35 [0.25] 19.05 [0.75] 25.40 [1.00] 35.81 [1.410]
CES-3 1 95.25 [3.75] 28.45 [1.12] 12.70 [0.50] 27.94 [1.10] 35.05 [1.38] 48.31 [1.902]
CES-4 1 114.30 [4.50] 40.64 [1.60] 19.05 [0.75] 39.62 [1.56] 50.80 [2.00] 69.09 [2.720]
CES-4S* 1 114.30 [4.50] 50.80 [2.00] 19.05 [0.75] 53.34 [2.10] 59.94 [2.36] 85.09 [3.350]
CES-5 1 177.80 [7.00] 69.85 [2.75] 36.32 [1.43] 73.66 [2.90] 88.90 [3.50] 103.38 [4.070]
*Part configuration may be different than depicted in figure. Contact Tyco Electronics for specification.
Temperature
Specifications
Product Dimensions
Standard CES
Min. Max.
Part No. Overall Nom. Expanded Recovered Max. I.D. Drill Max.
No. of Legs Recommended I.D. I.D. of Part Size O.D.
Length (Each Leg) (Each Leg) of Nut
CES-2-D1A 2 69.85 [2.75] 15.24 [0.60] 2.79 [0.11] 19.05 [0.75] 25.40 [1.00] 35.81 [1.41]
CES-2-T1 3 69.85 [2.75] 10.16 [0.40] 2.79 [0.11] 19.05 [0.75] 25.40 [1.00] 35.81 [1.41]
CES-2-T1B 3 88.90 [3.50] 15.24 [0.60] 4.32 [0.17] 19.05 [0.75] 25.40 [1.00] 35.81 [1.41]
CES-2-F1A 4 69.85 [2.75] 10.16 [0.40] 2.79 [0.11] 19.05 [0.75] 25.40 [1.00] 35.81 [1.41]
CES-2-F1 488.90 [3.50] 15.24 [0.60] 4.32 [0.17] 19.05 [0.75] 25.40 [1.00] 35.81 [1.41]
CES-3-D1 2 88.90 [3.50] 15.24 [0.60] 4.32 [0.17] 27.94 [1.10] 35.05 [1.38] 48.26 [1.90]
CES-3-T1 3 88.90 [3.50] 15.24 [0.60] 4.32 [0.17] 27.94 [1.10] 35.05 [1.38] 48.26 [1.90]
CES-3-F1 488.90 [3.50] 15.24 [0.60] 4.32 [0.17] 27.94 [1.10] 35.05 [1.38] 48.26 [1.90]
CES-4-D3 2 101.60 [4.00] 22.86 [0.90] 7.62 [0.30] 40.64 [1.60] 50.80 [2.00] 69.09 [2.72]
CES-4-T1 3 101.60 [4.00] 22.86 [0.90] 7.62 [0.30] 40.64 [1.60] 50.80 [2.00] 69.09 [2.72]
CES-4-F1 4 101.60 [4.00] 22.86 [0.90] 7.62 [0.30] 40.64 [1.60] 50.80 [2.00] 69.09 [2.72]
CES-5-T4 3 127.00 [5.00] 31.75 [1.25] 12.70 [0.50] 73.66 [2.90] 63.50 [2.50] 103.38 [4.07]
CES-5-F4 4 127.00 [5.00] 31.75 [1.25] 12.70 [0.50] 73.66 [2.90] 63.50 [2.50] 103.38 [4.07]
Product Dimensions
Breakout CES
Accessories
4-97
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
CES (Continued)
Overall Nom. Min. Max. National Pipe
Part Recommended Expanded Recovered Adapter Thread
No. Length I.D. Nose I.D. Nose I.D. Size
CES-2-A50 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] 12.70 [0.50] 1/2–14
CES-2-A75 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] 19.05 [0.75] 3/4–14
CES-2-A100 83.82 [3.30] 19.05 [0.75] 6.35 [0.25] 19.05 [0.75] 1–11 1/2
CES-3-A100 111.00 [4.37] 28.45 [1.12] 12.70 [0.50] 25.40 [1.00] 1–11 1/2
CES-3-A150 117.35 [4.62] 28.45 [1.12] 12.70 [0.50] 27.94 [1.10] 1 1/2–11 1/2
CES-4A-A150* 127.00 [5.00] 50.80 [2.00] 19.05 [0.75] 35.56 [1.40] 1 1/2–11 1/2
CES-5-A250* 152.40 [6.00] 69.85 [2.75] 25.40 [1.00] 60.96 [2.40] 2 1/2–10
*Not illustrated - refer to Specification Control Drawing for details.
Min. Max.
Part No. Overall Nom. Expanded Recovered Max. I.D. Pipe Thread
No. of Legs Recommended I.D. I.D. of Part Size (NPT)
Length (Each Leg) (Each Leg)
CES-2A-T1 3 95.25 [3.75] 10.16 [0.4] 2.79 [0.11] 12.70 [0.50] 1/2–14
CES-2A-F1 495.25 [3.75] 10.16 [0.4] 2.79 [0.11] 12.70 [0.50] 1/2–14
CES-2A-D1 2 95.25 [3.75] 15.24 [0.6] 2.79 [0.11] 19.05 [0.75] 3/4–14
CES-2A-T2 3 95.25 [3.75] 10.16 [0.4] 2.79 [0.11] 19.05 [0.75] 3/4–14
CES-2A-F2 4 95.25 [3.75] 10.16 [0.4] 2.79 [0.11] 19.05 [0.75] 3/4–14
CES-3A-D1 2 95.25 [3.75] 15.24 [0.6] 4.32 [0.17] 25.40 [1.00] 1–11 1/2
CES-2A-T3 3 95.25 [3.75] 15.24 [0.6] 4.32 [0.17] 25.40 [1.00] 1–11 1/2
CES-3A-F1 4 95.25 [3.75] 15.24 [0.6] 4.32 [0.17] 25.40 [1.00] 1–11 1/2
CES-3A-D2 2 95.25 [3.75] 15.24 [0.6] 4.32 [0.17] 27.94 [1.10] 1 1/2–11 1/2
CES-3A-T2 3 95.25 [3.75] 15.24 [0.6] 4.32 [0.17] 27.94 [1.10] 1 1/2–11 1/2
CES-3A-F2 495.25 [3.75] 15.24 [0.6] 4.32 [0.17] 27.94 [1.10] 11/2–11 1/2
CES-4A-D3 295.25 [3.75] 22.86 [0.9] 7.62 [0.30] 37.34 [1.47] 1 1/2–11 1/2
CES-4A-T3 3 95.25 [3.75] 22.86 [0.9] 7.62 [0.30] 37.34 [1.47] 1 1/2–11 1/2
CES-4A-F3 4 95.25 [3.75] 22.86 [0.9] 7.62 [0.30] 37.34 [1.47] 1 1/2–11 1/2
Note: Coating is optional. As supplied dimensions appearing in table are for uncoated parts. When coating is added,
entry diameters will be reduced by 1.5 [.06] max.
Product Dimensions
Threaded CES
Threaded Breakout CES
Accessories
4-98 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CES (Continued)
Part C B Length NPT
No. Min. Exp. ID Max. Rec. ID ID Min A D Size
CES-2R-A50 12.70 [0.50] 7.11 [0.28] 12.70 [0.50] 35.56 [1.4] 25.40 [1.00] 1/2-14
CES-2R-A75 18.03 [0.71] 8.38 [0.33] 19.05 [0.75] 43.18 [1.7] 27.94 [1.10] 3/4-14
CES-3R-A100 27.94 [1.10] 9.65 [0.38] 25.40 [1.00] 53.34 [2.1] 33.78 [1.33] 1-11 1/2
CES-3R-A150 40.64 [1.60] 15.75 [0.62] 27.94 [1.10] 78.74 [3.1] 39.62 [1.56] 1 1/2-11 1/2
C
C
D
A
B
D
A
B
Part C B Length Drill
No. Min. Exp. ID Max. Rec. ID ID Min D A Size
CES-1R 12.70 [0.50] 7.11 [0.28] 12.70 [0.50] 35.56 [1.4] 42.67 [1.68] 25.40 [1.00]
CES-2R 18.03 [0.71] 8.38 [0.33] 19.05 [0.75] 43.18 [1.7] 44.96 [1.77] 25.40 [1.00]
CES-3R 27.94 [1.10] 9.65 [0.38] 27.94 [1.10] 53.34 [2.1] 58.42 [2.30] 34.80 [1.37]
CES-4R 40.64 [1.60] 15.75 [0.62] 40.64 [1.60] 78.74 [3.1] 71.12 [2.80] 50.80 [2.00]
C
C
D
A
B
D
A
B
Right-Angle Threaded CES
Right-Angle Breakout CES
Accessories
4-99
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
RayOLOn Kits
heat guns or torches. This is
useful in the areas where
the use of motorized heat
sources or open flames are
prohibited or undesirable.
RayOLOn sealing sleeves
provide the sealing of the
substrates by simply rolling
the sleeve over the area to
be protected. If the sub-
strate requires servicing,
the sleeve can be rolled off
to provide access to the
Raychem RW 3031
Continuous operating temperature range -40°C to 70°C [-40°F to 158°F]
Short term temperature exposure -63°C to 90°C [-81°F to 194°F]
Minimum installation -25°C [-13°F]
Base Available
Dimensions (Reference) Recommended Connection
Part No. Kits Diameter Lengths Use Range Length
LNCL-11-125 GK 0.51 [13.0] 4.92 [125] 0.22 - 0.68 [6 - 17] 3.00 [75]
LNCL-11-205 GK 0.51 [13.0] 8.07 [205] 0.22 - 0.68 [6 - 17] 6.00 [150]
LNCL-12-140 GK, CK-N 0.56 [14.2] 5.51 [140] 0.48 - 0.90 [12 - 23] 4.00 [100]
LNCL-12-240 GK, CK-N 0.56 [14.2] 9.45 [240] 0.48 - 0.90 [12 - 23] 7.00 [175]
LNCL-13-155 GK, TK-8 0.75 [19.0] 6.10 [155] 0.69 - 1.20 [18 - 30] 4.00 [100]
LNCL-13-305 GK 0.75 [19.0] 12.00 [305] 0.69 - 1.20 [18 - 30] 9.00 [225]
LNCL-14-185 GK, TK-7 1.02 [25.9] 7.28 [185] 0.96 -1.50 [25 - 38] 5.00 [125]
LNCL-14-355 GK 1.02 [25.9] 14.00 [355] 0.96 -1.50 [25 - 38] 10.0 [250]
LNCL-15-185 GK, TK-1, TK-5, TK-6 1.45 [36.8] 7.28 [185] 1.40 - 2.00 [36 - 46] 5.00 [125]
LNCL-15-260 GK, SS 1.45 [36.8] 10.2 [260] 1.40 - 2.00 [36 - 46] 7.50 [190]
LNCL-15-450 GK, SS 1.45 [36.8] 17.72 [450] 1.40 - 2.00 [36 - 46] 12.0 [300]
Refer to Raychem specification control drawing LNCL-XX-125 thru LNCL-XX-450 for more details.
*Tyco Electronics Gel and Sealant product information available at www.tycoelectronics.com
Applications
RayOLOn re-useable roll-on
sealing sleeves are a family
of products designed to
protect connectors, electri-
cal cable splices, and other
cylindrical substrates from
harsh environmental ele-
ments like salt spray and
water moisture. RayOLOn
sleeves are a part of
Raychem’s“heatless” seal-
ing products that require no
Product Facts
nARaychem heatless sealing
solution
nRe-useable sealing solution
nRoll-on to seal, roll-off to
re-enter
nEnhanced sealing with
gel strips
nProtection of connectors
and splices against
corrosion
nAvailable in many
conveniently packaged kits
Specifications and Approvals
Temperature Ratings
Sleeve Dimensions
Inches (millimeters)
component under the
sleeve. After the service is
completed, the sleeve can
be rolled on the partagain
to provide the protection.
This operation may be
done many times through-
out the life of the sleeve
providing time and material
cost savings.
Operating Temperature Range
-40°C to 70°C
[-40°F to 158°F]
Roll-On Sealing Sleeve
Accessories
4-100 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RayOLOn Kits (Continued)
Property Performance Test method
Tensile strength 8.3 MPa (1200 psi) minimum ASTM D 2671
Ultimate elongation 100 % minimum ASTM D 412
Physical/ Density 1.1 g/cm3 maximum ASTM D 792
Chemical Water absorption 0.5 % maximum ASTM D 570
24hours at 23°C [73°F]
Flammability 40 mm/min maximum ASTM D 635
Electrical Dielectric strength 90 kV/cm (225 V/mil) minimum ASTM D 149
Volume resistivity 1x1012 Ω-cm ASTM D 257
Refer to Raychem specification RW3031 for more requirements and performance information.
Notes:
1.The sleeve is not intended to be heated during the installation process.
2.DO NOT CUT LNCL roll-on sealing sleeve.
3. In case of a conflict between this data sheet and RW3031, RW3031 takes precedence.
4. Not recommended for extended exposure to hydrocarbon based fuel or fluids.
GK—General kit: Roll-on sleeve, gel strip, cable tie, core tube, installation instruction
CK—Connector sealing kit: Roll-on sleeve, cable tie, connector flange cover, gel strip, installation instruction
TK—Panel boot sealing kit: Roll-on sleeve, ferrule, gel strip, cable tie, installation Instruction
SS—Ship-or-shore kit: Roll-on sleeve, connection shield, installation instruction
Note: Not all sizes and lengths are available for all kit combinations. Please refer to the table on the previous page.
Typical RayOLOn Roll-On
Sealing Sleeve Properties
Kits
Part Numbering System
Configuration Designator
(blank if not required)
Kit Designator
Length of Sleeve
Diameter Size Designator
Product Family Name
LNCL - XX - XXX - XX - XX
4-101
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Accessories
shrinkHOoP
Applications
shrinkHOoP grommet
(URHR) is an ultra high ratio
heat-shrinkable-strain-relief
grommet that can be
placed over the cable
assembly after the connec-
tor pinning operation is
completed. The ultra-high
expansion ratio material
conveniently fills the space
between the clamp type
connector accessory and
the cable. (When clamped
into position, shrinkHOoP
grommet provides strain
relief that is more consistent
and convenient than many
conventional practices —
for example, taping, grom-
met, or tape/grommet com-
bination). The high ratio
conformity of shrinkHOoP
grommets will match most
Product Facts
nLess assembly time
nSuperior strain-relief
nFewer errors — less rework
nRework made easier
nNo build-up taping or
feeding wire through
grommet
nTypical installation in just
10-20 seconds
nRe-expandable I.D. allows
wire addition to a cable
bundle
typical cable configurations
from single conductor to the
high density multiple con-
ductor arrangements.
With shrinkHOoP grommet,
repairs and rework are a
snap – simply heat the
grommet until soft, slide a
NON-METALLIC probe
through the center of the
wire bundle (enlarging the
grommet I.D.). Once
cooled, the grommet will
remain open allowing wires
to be added, removed or
reworked. The system can
then be checked, the grom-
met reheated (shrinking it
down again), positioned,
and clamped in place.
Cable Clamp Heat-Shrink
Grommet
Operating Temperature Range
-55°Cto 135°C
[-67°F to 275°F]
Accessories
4-102 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
shrinkHOoP (Continued)
Property Performance Test Method
Tensile strength 1500 psi (10.3 Mpa) ASTM D-412
Ultimate elongation 250% minimum ASTM D-412
Specific gravity 1.4 maximum ASTM D-792
Water absorption 0.5 % maximum ASTM D-570 A
Flammability Pass ASTM D-635
Physical Corrosion resistance Pass ASTM D-2671 A
Low temperature flex Pass ASTM D-2671 C
4hours at - 55+/-1°C [67+/-2°F]
Heat resistance 200% ultimate elongation,
minimum ASTM D-2671
168 hrs at 175+/-1°C [347+/-2°F] 1200 psi (8.3 Mpa) tensile
strength, minimum
Heat shock No cracking,
4hrs at 225+/-2°C[437+/-5°F] dripping or flowing ASTM D 2671
275% minimum expansion
to 4 inch (10 cm) of a fully
recovered test specimen,
Elastic Memory — and 93% recovery of expanded —
specimen after oven
conditioning for 1 minute
at 150+/-2°C[302 +/- 4°F]
Dielectric strength 200 v/mil (7880 v/mm)
Electrical minimum ASTM D-876
Volume resistivity 10 14 ohm-cm minimum ASTM D-257
200% ultimate Elongation,
Chemical Fluid — minimum 1200 psi (8.3 Mpa) ASTM F-146
Resistance tensile strength, minimum
Flammability* Avg. flame time = 30 sec. max FAR part 25,
Avg. burn length = 3 in. max. Appendix F,
Avg. flame time from part 1 (a),
drippings = 3 sec. max section 3
*applies to sizes 2, 3, and 4 only
Typical shrinkHOoP Grommet
Performance
RW
I.D. I.D.
Part Expanded Recovered O.D. Length Wt. (gm) Notes
No. (X1) min. (X) max. (Y) Ref. (L) Ref. Ref.
URHR-1 1 .08 0.25 0.5 0.75
[25] [2.1] [6] [13]
URHR-2 1.23 .10 0.375 0.5 1
[31] [2.6] [10] [13]
URHR-3 1.44 .14 0.5 0.5 1.5
[37] [3.6] [13] [13]
URHR-4 1.85 0.18 0.562 0.75 3.5
[47] [4.7] [14] [19]
URHR-5 2 0.20 0.812 0.75 5
[51] [5.1] [21] [19]
L
X
Y
X
1
L
X
Y
X
1
Specifications/Approvals
Product Dimensions
Inches (millimeters)
a)Recovered length will allow for
1.91 [0.075] either side of the
collar,minimum in most cases.
Accessories
4-103
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
shrinkHOoP (Continued)
Connector Size
Connector 810, 12 14, 16 18, 20 22, 24, 28*
Series (9) (11, 13) (15, 17) (19, 21)
MIL-C-5015
MS3451, 52, 56, 59 1 2 3 4 5
MS3450 2 3 4 5 *
MIL-C-26500**
MS24266 1 2 3 4 5
MS24264, 265 2 3 4 5 *
MIL-C-26482
MS3120, 21, 22, 26 1 2 3 4 5
MS3470, 71, 74, 75, 76 1 2 3 4 5
MS3124, MS3472 2 3 4 5 *
MIL-C-83723 Series I
M83723/01 & 02, 05 & 06 1 2 3 4 5
07 & 08, 13 & 14, 23 & 24 1 2 3 4 5
M83723/03 & 04 2 3 4 5 *
MIL-C-83723 Series II
M83723/17 & 18, 23 & 24 12345
M83723/12 & 20, 21 & 22 2 3 4 5 *
MIL-C-83723 Series III
M83723/71 & 72 thru 97 & 98 12345
M83723/66, 67, 68 & 69 2 3 4 5 *
MIL-C-38999 Series I
MS27469 1 2 3 4 5
MS27466, 68, 96, 27505, 27656 2 3 4 5 *
MIL-C-38999 Series II
MS27472, 97, 98, 27508, 27513 1 2 3 4 5
MS27473, 84, 27474 2 3 4 5 *
MIL-C-38999 Series III
38999/26 1 2 3 4 5
38999/20, 24 3 4 5 5 *
Boeing
BACC45, F, M, N, P, R, S, T — 2 3 4 5
BACC 63X — 3 4 5 *
Boeing
DC39, 31, 34, 35, 50-57 1 2 3 4 5
DC32, 33, 36, 37, 60, 61, 62, 63 2 3 4 5 *
*Consult Tyco Electronics for availability of larger sizes.
** Note: cable support clamp I.D. may effect the size of shrinkHOoP grommet selected.
Selection chart
XL Products
4-104 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Ordering Information
Tyco Electronics
Corporation has acquired
XLTechnologies. Use the
information in the following
table to convert the XL
part number into the new
Tyco Electronics Raychem
product description.
Description Convert to
XLPart No. Description
080EK025 SSC-2/239
080EK025-woA SSC-2/U
137EK050 SSC-3/239
137EK050-woA SSC-3/U
1-8117-2A CES-2A-D1
1-8117-3A CES-2A-T1
1-8117-4A CES-2A-F1
200EK075 SSC-4/239
200EK075-woA SSC-4/U
20432242 CES-4/HR-3
2-8115-2A CES-2-D1A
2-8115-2AOE CES-2-D1A
2-8115-2B CES-2-D1
2-8115-3A CES-2-T1
2-8115-3B CES-2-T1B
2-8115-4A CES-2-F1A
2-8115-4B CES-2-F1
2-8117-2A CES-2A-D1
2-8117-2AOE CES-2A-D1
2-8117-3A CES-2A-T2
2-8117-4A CES-2A-F2
2-8118-3A CES-2-T1
2S-8115-2A CES-2-D1A
2S-8115-3A CES-2-T1
2S-8115-4A CES-2-F1A
380EK150 SSC-6/239
380EK150woA SSC-6/U
3-8115-2B CES-3-D1
3-8115-3B CES-3-T1
3-8115-4B CES-3-F1
3-8118-4B CES-3-F1
3A-8117-2B CES-3A-D1
3A-8117-3B CES-2A-T3
3A-8117-4B CES-3A-F1
4-8115-2C CES-4-D3
4-8115-3C CES-4-T1
4-8115-4C CES-4-F1
4-8117-2B CES-3A-D2
4-8117-3B CES-3A-T2
4-8117-4B CES-3A-F2
4A-8117-2C CES-4A-D3
4A-8117-3C CES-4A-T3
4A-8117-4C CES-4A-F3
52451-2X12A 91385-2/12
5-8115-3D CES-5-T4
8114-1 CES-1
1/2/14 CES-1-2
8114-1-49R CES-1R
8114-2 CES-2
8114-2-50R CES-2R
8114-2S CES-2
8114-2V CES-2V
8114-2VL CES-2V
8114-3 CES-3
8114-3-51R CES-3R
8114-3L CES-3L
8114-3S CES-3S
8114-4 CES-4
8114-4-54R CES-4R
8114-4N CES-4
8114-4S CES-4S
8114-4S/C CES-4S
8114-5 CES-5
8116-1 CES-2-A50
8116-1-49R CES-2R-A50
8116-1A CES-2-A50
8116-2 CES-2-A75
8116-2-50R CES-2R-A75
8116-3 CES2-A100
8116-3-51R CES-3R-A100
8116-3A CES-3-A100
8116-4 CES-3-A150
8116-4-52R CES-3R-A150
8116-4A CES-4A-A150
8116-5 CES-5-A250
8118-2 CES-2
91342-1 D3-9 FR
91342-12 D3-30 FR
91342-2 D14-30 FR
91342-23 D14-100 FR
91342-3X2.5 D50-200 FR
91342-3 D50-100 FR
91342-34 D50-400 FR
91342-4 D200-400 FR
91343-1 T3-9 FR
91343-2 T14-23 FR
91343-2A T14-50 FR
91343-3 T42-100 FR
91343-4 T150-300 FR
91343-5 T-400 FR
91343-5678 T3-100 FR
91343-6 T500-600 FR
91343-910 T150-400 FR
91344-1 F3-9 FR
91344-1213 F3-23 FR
91344-1415 F42-100 FR
91344-1617 F75-200 FR
91344-2 F-23 FR
91344-3 F42-60 FR
91344-4 F75-100 FR
91344-5 F133-200 FR
91344-6 F150-400 FR
91346-3 6S100-200 FR
91346-30 202A111-3-0
91346-31 202A111-3/42-0
91346-32 202A111-3/86-0
91347-30 202A121-3-0
91347-31 202A121-3/42-0
91347-32 202A121-3/86-0
91348-1 8S23-75 FR
91348-2 8S14-50 FR
91348-3 8S42-100 FR
91348-30 202A132-3-0
91348-31 202A132-3/42-0
91348-32 202A132-3/86-0
91349-30 202A142-3-0
91349-31 202A142-3/42-0
91349-32 202A142-3/86-0
91350-30 202A153-3-0
91350-31 202A153-3/42-0
91350-32 202A153-3/86-0
91351-30 202A163-3-0
Description Convert to
XLPart No. Description
XL Products
4-105
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
4
Molded Parts
Ordering Information (Continued)
91351-31 202A163-3/42-0
91351-32 202A163-3/86-0
91352-30 202A174-3-0
91352-31 202A174-3/42-0
91352-32 202A174-3/86-0
91353-30 202A185-3-0
91353-31 202A185-3/42-0
91353-32 202A185-3/86-0
91354-30 202A196-3-0
91354-31 202A196-3/42-0
91354-32 202A196-3/86-0
913L87-30 202D921-3/-0
913L87-31 202D921-3/42-0
913L87-32 202D921-3/86-0
91387-30 202A921-3/-0
91387-31 202A921-3/42-0
913L47-30 202D121-3/-0
913L47-31 202D121-3/42-0
913L47-32 202D121-3/86-0
913L48-30 202D132-3/-0
913L48-31 202D132-3/42-0
913L48-32 202132-3/-86-0
913L49-30 202D142-3/-0
913L49-31 202D142-3/42-0
913L49-32 202D142-3/86-0
913L50-30 202D153-3-0
913L50-31 202D153-3/42-0
913L50-32 202D153-3/86-0
913L51-30 202D163-3-0
913L51-31 202D163-3/42-0
913L51-32 202D163-3/86-0
913L52-30 202D174-3-0
913L52-31 202D174-3/42-0
913L52-32 202D174-3/86-0
913L53-30 202D185-3-0
913L53-31 202D185-3/42-0
913L53-32 202D185-3/86-0
913L54-30 202D196-3-0
913L54-31 202D196-3/42-0
913L54-32 202D196-3/86-0
913L66-30 202D211-3-0
913L66-31 202D211-3/42-0
913L66-32 202D211-3/86-0
913L67-30 202D221-3-0
913L67-31 202D221-3/42-0
913L67-32 202D221-3/86-0
913L68-30 202D232-3-0
913L68-31 202D232-3/42-0
913L68-32 202D232-3/86-0
913L69-30 202D242-3-0
913L69-31 202D242-3/42-0
913L69-32 202D242-3/86-0
913L70-30 202D253-3-0
913L70-31 202D253-3/42-0
Description Convert to
XLPart No. Description 913L70-32 202D253-3/86-0
913L87-30 202D921-3-0
913L87-31 202D921-3/42-0
913L87-32 202D921-3/86-0
913R48-30 222A132-3-0
913R48-31 222A132-3/42-0
913R48-32 222A132-3/86-0
913R49-30 222A142-3-0
913R49-31 222A142-3/42-0
913R49-32 222A142-3/86-0
913R50-30 222A152-3-0
913R50-31 222A152-3/42-0
913R50-32 222A152-3/86-0
913R51-30 222A163-3-0
913R51-31 222A163-3/42-0
913R51-32 222A163-3/86-0
913R52-30 222A174-3-0
913R52-31 222A174-3/42-0
913R52-32 222A174-3/86-0
913RL48-30 222D132-3-0
913RL48-31 222D132-3/42-0
913RL48-32 222D132-3/86-0
913RL49-30 222D142-3-0
913RL49-31 222D142-3/42-0
913RL49-32 222D142-3/86-0
913RL50-30 222D152-3-0
913RL50-31 222D152-3/42-0
913RL50-32 222D152-3/86-0
913RL51-30 222D163-3-0
913RL51-31 222D163-3/42-0
913RL51-32 222D163-3/86-0
913RL52-30 222D174-3-0
913RL52-31 222D174-3/42-0
913RL52-32 222D174-3/86-0
913Y95-30 381A301-71/-0
913Y95-31 381A301-71/42-0
913Y95-32 381A301-71/86-0
913Y96-30 381A302-71/-0
913Y96-31 381A302-71/42-0
913Y96-32 381A302-71/86-0
HHW-1.3/6A SST-6-13FR/97-0
HHW-13/6A SST-6-13FR/97-0
HHW-15/12 SST-12-15FR/97-0
HHW-15/6 SST-6-15FR/97-0
HHW-15/9 SST-9-15FR/97-0
HHW-20/9 SST-9-20FR/97-0
HRSR-1 URHR-1
HRSR-2 URHR-2
HRSR-3 URHR-3
HRSR-4 URHR-4
HRSR-5 URHR-5
XHTA RHW
XHTU RHW
XMTARPRD
Description Convert to
XLPart No. Description
4-106
Molded Parts
Engineering Notes
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adhesives
Table of Contents
5-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
5
Adhesives
Selection Guide .........................................................5-1
Adhesive/Sealant Product Characteristics Table . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2, 5-3
Adhesive/Sealant Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Installation Guide ...................................................5-5 to 5-7
Tyco Electronics manufac-
turers Raychem adhesives
and sealants to accommo-
date a wide range of appli-
cations, materials, and
environmental conditions.
Raychem adhesives include
both thermosets and ther-
moplastics.
Thermosets are curable
two-part epoxies or
crosslinked elastomers.
Thermoplastics are hot-melt
adhesives that flow when
heated and set when
cooled. They reflow when
reheated to simplify
component repair.
Tyco Electronics also
manufactures Raychem
products that include a
thermoplastic adhesive or
amastic-type sealant for
water holdout applications.
The sealants adhere to non-
oily substrates and can be
removed where reentry is
necessary.
Todetermine the adhesive
or sealant most compatible
with a Raychem part, you
must know the part’s
product type.
Use the Adhesive/Sealant
Selection Table on page 5-4
to determine a Raychem
part’s product type and the
adhesive/sealant compatible
with that type.
Use the Adhesive/Sealant
Product Characteristics
Table (pages 5-2 and 5-3)
to be sure the adhesive or
sealant has the product
characteristics your appli-
cation requires.
Touse the Selection Table,
follow these four steps:
1. Under “Substrate
Category,” find the prod-
uct material and product
name/partnumber for the
Raychem part.
2. Across the top of the
table, find the part’s
product type and dash
number.
3. At the intersection of the
substrate category (prod-
uct material/name/part
number) and the product
type (by designated
dash number) you will
find the partnumber for
the most compatible
adhesive for the
Raychem part.
4. See the Adhesive/
Sealant Product
Characteristics Table to
verify the characteristics
of the adhesive/sealant
you selected.
Selection Guide
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Adhesives
Adhesive/Sealant Product Characteristics Tables
5-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Operating
Product Precoat Temperature Product Available Form/
Type Designation Type Range Designation Packaging
Thermosets
S-1006 — Epoxy/ -55°C to 135°C S-1009 Kit 8 50-ml dual syringe
polyamide [-67°F to 275°F] S-1006 Kit A Ten 3-gram packs
two-part paste
S-1009 — Epoxy/ -55°C to 135°C S-1009 Kit A Ten 3-gram packs
polymercaptan [-67°F to 275°F] S-1009 Kit 8 50-ml dual syringe
two-part paste
S-1255-04 — One-part epoxy -55°C to 200°C S-1255-04 Tape [3/4 in. x .020 x 100 ft.]
tape adhesive [-67°F to 392°F]
S-1125 — Epoxy/polyamide -55°C to 150°C S-1125 Kit 1 Five 10-gram packs
two-part paste [-67°F to 302°F] S-1125 Kit 2 Two 10-gram packs
S-1125 Kit 3 One 100-gram pack
S-1125 Kit 4 Five 10-gram packs
S-1125 Kit 5 One 10-gram pack
S-1125 Kit 8 50-ml dual syringe
/225 Precoated -75°C to 150°C Precoat only on —
latent-curing [-103°F to 302°F] -25 molded
epoxy/polyamide parts
Thermoplastics
S-1017 /42 Hot-melt/ -20°C to 60°C*** S-1017 Tape [1 in. x .010 in. x 50 ft.]
polyamide [-4°Fto 140°F]
S-1030 /180 Hot-melt/ -80°C to 80°C S-1030 Tape [3/4 in. x .010 in. x 33 ft.]
polyolefin [-112°F to 176°F]
S-1048 /86 Hot-melt, -55°C to 120°C S-1048 Tape [1 in. x .026 in. x 100 ft.]
high performance [-67°F to 248°F]
S-1124 /164 Hot-melt/ -55°C to 105°C S-1124
elastomeric [-67°F to 221°F] Tape [3/4 in. x .018 in.x 10 ft.]
polymer
S-1297 /97 Hot-melt/ -20°Cto 90°C] S-1297 Tape [1 in. x .010 in. x 10 ft.]
polyamide [-4°F to 194°F]
adhesive
Sealants
S-1278 — Hot-melt grey -40°C to 90°C S-1278-01 Tape [1 in. x .062 in. x 25 ft.]
butyl sealant [-40°F to 194°F] S-1278-02 Tape [33/4 in. x .125 in. x 10 ft.]
S-1305 — Hot-melt grey -40°C to 90°C S-1305-01 Tape [1 in. x.062 in. x25 ft.]
butyl sealant [-40°F to 194°F]
*Shelf life from date of manufacture.
**For specific adhesion properties, see product specification sheets.
***Passes cold bend at -40°C [-40°F] per RT-4204.
****Only S-1006 Kit Aconforms to MIL-A-46864.
5
Adhesives
Adhesives
5-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adhesive/Sealant Product Characteristics Tables (Continued)
Shelf life* at
Pot Life Curing orbelow
at 23°C [73.4°F] Conditions 25°C [77°F] Specifications** Comments
1h 96 h at 20°C [68°F] min. or 2 years RT-1006 General purpose harnessing adhesive.
1hr at 120°C [248°F] 1 year Kit 8 RK-6612 Not used on Viton®fluoroelastomers,silicone
MIL-A-46864**** or Kynar®;20-minute pot life
20min. 24 h at 20°C [68°F] min. or 2 years RT-1009 General purpose harnessing adhesive
1hr at 95°C [203°F] 1 year Kit 8 Not used on Viton®fluoroelastomers or silicone;
20-minute pot life
45min at 120°C [248°F] One-part epoxy tape used with Viton®fluoroelastomer
2hat 155°C [311°F] min. or 1 year RT-1014 harness systems. Heat cure required
15min at 240°C [464°F] (2 hours at 155°C [311°F])
90 min. 24 h at 20°C min. or 18 months RT-1011
1hr at 85°C [185°F] RK-6619 Good fluid-resistant epoxy used with
1year Kit 8 VG-95343 System 25
Cure during installation 36months VG-95343 Precoated epoxy system for System 25
ofmolded parts RK-6630
—120°C [248°F] Unlimited RT-1050/1 General purpose harnessing adhesive
Standard precoated adhesive for -3
and -4 molded parts
—120°C [248°F] Unlimited RT-1050/6 Good low-temperature flexibility
RK-6017 Available as a preinstalled tape for
molded parts
— 160°C [320°F] Unlimited RT-1050/3 Requires high temperature to achieve
RK-6626 bonding. Highest service temperature
for hot melt
— 135°C [275°F] Unlimited RT-1050/13 Requires reflowing in an oven at 150°C [302°F]
for 90 minutes. Designed to bond to
-51 molded parts.
— 120°C[248°F] Unlimited RW-2019 General purpose harnessing adhesive
Standard precoated adhesive in
Sigmaform molded parts, CES and
CSGA cable entry seals, and SST-FR
heat-shrinkable tubing
— 110°C [230°F] Unlimited RW-2020 General purpose sealant and cable
breakout area filler
— 110°C [230°F] Unlimited RW-2021 Halogen-free, flame-retardant sealant
and cable breakout area filler
*Shelf life from date of manufacture.
**For specific adhesion properties, see product specification sheets.
***Passes cold bend at -40°C [-40°F] per RT-4204.
****Only S-1006 Kit Aconforms to MIL-A-46864.
VITON is a trademark of
Dupont Dow Elastomers LLC
Adhesives
5-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adhesive/Sealant Selection Table
Substrate Product
Category Name Molded Part Material Dash Number
Examples -3 -4 -6 -8 -12 -25 -50 -51 -55 -71 -100 -125 -130
RNF-100 S-1006 S-1006 — — — — — — — S-1006 — — S-1006
Versafit S-1009 S-1009 — — — — — — — S-1009 — — S-1009
Polyolefin CRN S-1017 S-1017 — — — — — — — S-1017 — — S-1017
BSTS S-1030 S-1030 — — — — — — — S-1030 — — —
SST S-1048 S-1048 — — — — — — — S-1048 — — —
HR S-1297 S-1297 — — — — — — — S-1297 — — —
S-1009 S-1009 — S-1009 — S-1125 — — — S-1009 — S-1009 —
Kynar®S-1048 S-1048 — — — — — — — S-1048 — S-1048 —
Fluoro- S-1125 S-1125 — — — — — — — S-1125 — S-1125 —
polymer RT555 — — — — S-1255 — — — S-1255 — — S-1255 —
HCTE — — — — S-1255 S-1125 — — S-1255 — — — —
CONVOLEX — — — — S-1125 — — — S-1125 — — — —
S-1006 S-1006 — — — — — — — S-1006 — — —
Vinyl PVC S-1009 S-1009 — — — — — — — S-1009 — — —
S-1017 S-1017 — — — — — — — S-1017 — — —
DR-25 — — — — — S-1125 S-1125 S-1125 — — — — —
S-1006 S-1006 — — — — — S-1124 — S-1006 — — —
NT S-1009 S-1009 — — — — — — — S-1009 — — —
S-1017 S-1017 — — — — — — — S-1017 — — —
Elastomer NT-FR — — — — — S-1125 — S-1124 — — — — —
SFR — —* ——————— ———
SRFR — — * — — — — ——— ———
Viton®— — — — S-1255 — — — S-1255 — — S-1255 —
VPB — — — — — — S-1125 — — — — — —
— — — — — — S-1255 — — — — — —
Zerohal XFFR — — — — — — — — — — S-1030 — —
ZHTM — — — — — — — — — — S-1030 — —
*GE RTV 108 used with SFR SRFR and -6 (silicone) molded parts.
VITON is a trademark of
Dupont Dow Elastomers LLC
5
Adhesives
Adhesives
5-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Installation Guide
Substrate Preparation
Procedures
Preparation of the substrate
depends on the part to be
bonded. Following are two
preparation procedures.
The first applies to plated
metals and adapters; the
second applies to polymer
molded parts, cable jack-
ets, and tubing materials.
Plated Metals and Adapters
Thoroughly degrease the
surface with a clean cloth
or paper wipe dampened
with a solvent. The cloth or
paper should not be
saturated with the solvent.
Allow the part to stand for
aminute or two to allow
complete evaporation of
the solvent.
Molded Parts, Cable Jackets,
and Tubing Materials
Carefully and evenly abrade
the surface with #320 emery
cloth. Wipe contaminants
and abraded particles away
with a clean cloth or paper
wipe dampened with a sol-
vent. The cloth or paper
should not be saturated
with the solvent. Allow the
partto stand for a minute
or two to allow complete
evaporation of the solvent.
Note:
nAvoid contamination of the pre-
pared surface. If using primer,
apply it according to the manufac-
turer’s instructions and allow it to
dry.
nEpoxy adhesives may cause skin
and eye irritation. Be sure to
observe the handling instructions.
nWhen using hot-melt adhesives on
substrates with high heat-sink
capacity (such as connector back-
shells), preheat the substrate until
it is hot to touch, then apply the
adhesive tape and shrink the
molded part in place.
Caution:
The use of cleaning solvent
isdescribed in the prepara-
tion of various components
for adhesive bonding.
Please observe the solvent
manufacturer’s safety rec-
ommendations. Several
Raychem epoxy adhesives
and solvent base primers
are also described in some
cases. For specific handling
precautions, please consult
the appropriate Raychem
material safety data sheet
for the adhesive being used.
Installation Procedures
The three sets of installation
instructions that follow are
based on the type and/or
form of adhesive or sealant
to be used.
Select the set of instructions
that applies to your
application.
Tape Adhesives and Sealants
Connector Boot
1. Degrease the area of
the adapter to which
the boot will be bonded,
using appropriate
solvent on a paper
tissue or clean cloth. Do
not abrade the adapter.
2. Lightly abrade the
bonding area of the
cable jacket with #320
emery cloth, then wipe
offloose particles with
atissue or clean cloth
dampened with a
solvent.
3. Lightly abrade and wipe
25.4 [1.0] back inside
each end of the boot.
4. When using primer,
apply a thin, uniform
coating to the bonding
surface and let it air dry
(15–20 minutes).
5. Double-wrap the
adhesive tape around
the cleaned area of the
adapter,placing slight
tension on the tape as
you wrap. Tack the ends
in place with a soldering
iron or hot tool.
6. Double-wrap adhesive
tape around the cable
jacket where the end of
the boot is to be located.
7. Position the boot on the
adapter and the cable.
Apply heat, starting at
the connector end.
8. Recover the connector
end of the boot onto the
adapter and continue
heating until the area is
fully recovered and the
adhesive tape is prop-
erly melted.
9. Complete the recovery
of the boot, continuing
toward the cable end.
Heat the cable end of
the boot where the
adhesive is placed,
until the part is fully
recovered and the tape
has properly melted or
flowed. The tape should
appear wet, form a bead
or fillet between the
cable and boot, and
show no definition
between the layers
of tape.
10.Where oven curing is
required to complete
adhesive bonding, heat
the assembled harness
in a preheated oven
according to the
following schedule:
S-1255-02:
2hours at 155°C [311°F]
S-1124:
90 minutes at 150°C [302°F]
Transition
1. Lightly abrade the
bonding area of the
cable jacket with #320
emerycloth, then wipe
off loose particles with
atissue or clean cloth
dampened with a
solvent.
2. Abrade and wipe the
inside of each transition
opening.
3. When using primer,
apply a thin, uniform
coating to the bonding
surface and let it air dry
(15–20 minutes).
Adhesives
5-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Installation Guide (Continued)
4. Double-wrap the tape
around the abraded
areas of the cable,
placing slight tension
on the tape as you wrap.
Tack the ends in place
with a soldering iron or
hot tool.
5. Center the molded part
over the transition area.
When properly posi-
tioned, the part should
not fit tightly in the
“branched” area of the
breakout. A tight fit may
cause the part to crease
or wrinkle as it recovers.
The tape should extend
slightly beyond the end
of the transition.
6. Apply heat to the center
of the transition. Recover
one leg of the transition,
moving heat from the
center of the transition
to the adhesive opening
of the leg. Repeat the
procedureon each leg
of the transition.
7. Continue heating each
end of the transition until
the part is fully recov-
ered and the adhesive
tape has properly
melted or flowed. The
tape should now appear
wet, form a bead or fillet
between the cable and
transition, and show no
definition between the
layers of tape.
8. Where oven curing is
required to complete
adhesive bonding, heat
the assembled harness
in a preheated oven
according to the
following schedule:
S-1255-02:
2hours at 155°C[311°F]
S-1124:
90 minutes at 150°C [302°F]
Thermosets
Connector Boot
1. Thoroughly mix the two
parts according to the
instructions provided
with the kit.
2.Degrease the area of
the adapter to which
the boot will be bonded,
using appropriate
solvent on a paper
tissue or clean cloth. Do
not abrade the adapter.
3. Lightly abrade the
bonding area of the
cable jacket with #320
emery cloth, then wipe
off loose particles with a
tissue or clean cloth.
4. Lightly abrade back 25.4
mm [1.0] inside each
end of the boot.
5. Using a spatula, apply
the mixed adhesive to
the adapter and shrink
the boot to the end
of the adapter.
6. Apply adhesive to the
cable jacket and
complete the shrinking
process.
7. With a clean cloth,
remove excess adhesive
from all areas
immediately.
8. Follow the curing
conditions outlined in
this guide.
Transition
1.Thoroughly mix the two
parts according to the
instructions provided
with the kit.
2.Lightly abrade the
bonding area of the
cable jacket with #320
emery cloth, then wipe
off loose particles with a
tissue or clean cloth.
3. Abrade and wipe inside
each opening of the
transition.
4. Using a spatula, apply
the mixed adhesive to
the cable jacket.
5. Apply heat to the center
of the transition. Recover
one leg of the transition,
moving heat from the
center of the transition
to the adhesive opening
of the leg. Repeat the
procedure on each leg.
6. Remove excess
adhesive from all areas
immediately with a
clean cloth.
7. Follow the curing
conditions specified
for “thermosets” in the
“Adhesive/Sealant
Product Characteristics
Table” on pages 5-2 and
5-3.
Adhesives
5-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
5
Adhesives
Installation Guide (Continued)
Molded Parts Pre-coated
with Thermoplastic
Adhesive
Connector Boot
1.Degrease the area of
the adapter to which
the boot will be bonded,
using appropriate
solvent on a paper
tissue or clean cloth. Do
not abrade the adapter
or inside surface of the
boot.
2. Lightly abrade the
bonding area of the
cable jacket with #320
emery cloth, then wipe
off loose particles with a
tissue or clean cloth
dampened with solvent.
3. Position the boot on the
adapter and cable.
Apply heat starting at
the connector end.
4. Recover the connector
end of the boot onto the
adapter and continue
heating until the area is
fully recovered and the
adhesive is properly
melted.
5. Complete the recovery
of the boot, continuing
toward the cable end of
the boot until the part is
fully recovered and the
adhesive is properly
melted. The adhesive
should form a bead or
fillet between the cable
and boot when fully
melted.
6. With a clean cloth,
remove excess
adhesive from all
areas immediately.
7. Follow the curing
conditions outlined in
this guide.
Transition
1.Lightly abrade the
bonding area of the
cable jacket with #320
emery cloth, then wipe
off loose particles with a
tissue or clean cloth
dampened with solvent.
2. Center the molded part
over the transition area.
3. Apply heat to the center
of the transition. Recover
one leg of the transition,
moving heat from the
center of the transition
to the adhesive opening
of the leg. Repeat the
procedure on each leg
of the transition.
4. Continue heating each
end until the part is
fully recovered and the
adhesive has properly
melted. The adhesive
should form a bead or
fillet between the cable
and transition when
fully melted.
5. Follow the curing
conditions specified
for “thermosets” in the
“Adhesive/Sealant
Product Characteristics
Table” on pages 5-2 and
5-3.
5-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adhesives
Engineering Notes
Adapters
Table of Contents
6-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Adapter Fundamentals
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Types of Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3, 6-4
Adapter Selection Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Adapter Selection
Raychem Adapter Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 to 6-15
Raychem Adapter Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Raychem Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17, 6-18
Material and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
Entry Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 to 6-25
Tinel-Lock Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
CRES-Lock Bands/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Adapter Products
Code 18 MIL-C-5015 (MS3100)
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28, 6-29
Solid Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30, 6-31
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32, 6-33
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34 to 6-36
Code 21 MIL-C-26482 Series 1
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
Solid Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40, 6-41
CRES-Lock Adapters/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42, 6-43
Code 32 MIL-C-22992
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44, 6-45
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47
CRES-Lock Adapters/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48, 6-49
Code 40 MIL-C-38999 Series III and IV
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50, 6-51
Solid Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-53
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-54, 6-55
CRES-Lock Adapters/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56, 6-57
Code 41 MIL-C-38999 Series I and II
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58, 6-59
Solid Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-60
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-61
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62, 6-63
CRES-Lock Adapters/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64, 6-65
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL C-81703 Series III
Braided Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-66, 6-67
Solid Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-68
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-70, 6-71
CRES-Lock Adapters/BND Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-72, 6-73
Code 76 BS 9522 F0017 (Pattern105)
Spin-Coupling Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-74
Tinel-Lock Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-75, 6-76
For high-performance
sealing and strain relief, the
perfect mate for a Raychem
molded part in a wiring
application is a Raychem
adapter.
Tyco Electronics offers
avariety of Raychem
adapters for applications in
many industries, including
aerospace, marine, and
mass transit.
These adapters are:
nAvailable in many
configurations to match
applications
nEasy to install
nIdeal for high-reliability
applications
nKitted for customer
convenience.
In this section we present
Raychem spin-coupling
adapters and Tinel-Lock
adapters.
The Tinel-Lock adapter
utilizes Raychem's Tinel
ring to terminate the overall
shield to the adapter. The
Tinel ring is a low-profile,
high-strength, shape-
memory-alloy shield-
termination device
available in many sizes to
accommodate various
entry sizes and shield
configurations.
Tinel-Lock adapters are
ideal for lightweight
aerospace applications
requiring repeated high-
to-low temperature cycles.
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Adapter Fundamentals
Definitions
6-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Type
Tyco Electronics offers four
Raychem adapter types:
solid (sometimes called
“fixed”), spin-coupling,
braided, and Tinel-Lock.
Each is designed to offer a
suitable interface between a
connector and a heat-
shrinkable molded part.
Raychem Adapter Code
Anumerical code is used to
identify connectors with
similar adapter interfaces.
This code is used to deter-
mine the adapter family and
partnumber.
Adapter Part Number
The part number is the
sequence of numbers and
letters that describes the
adapter family (or series),
size, material, finish, and
modifications. The part
numbering system is
explained on pages 6-17
and 6-18.
Adapter Family
Tyco Electronics offers
several families (or series)
of Raychem adapter
products. Each Raychem
adapter partnumber begins
with an alphanumeric prefix
denoting the Raychem
product family.
EntrySize
Entry size is the diameter
of the hole through which
the cable enters into the
adapter.For example, the
08 entryis 12.7 [0.5]. Entry
sizes are specified on
braided and Tinel-Lock
adapters only.
Ring Designator
This is a two-letter code that
is partof each Tinel-Lock
adapter part number. It
specifies the size of the
Tinel-Lock ring suited to
specific types of cable braid.
Shell Size
This is the size of a
connector as specified by
the connector manufacturer.
It is normally a two-digit
number between 08 and 24,
although certain connectors
are obtainable in either
larger or smaller sizes and
some use letter codes.
Order Number
This is a two-digit number
that specifies the size of the
adapter that will mate to the
corresponding shell size of
aconnector. The order
number is frequently the
same as the connector
shell size, but should be
checked by reference to
the appropriate product
page(s) in this catalog.
Connector Adapter Heat-shrinkable
Molded Boot
Shell Size Entry Size
Introduction
For high-performance seal-
ing and strain relief, the
perfect mate for a Raychem
molded part in a wiring
application is a Raychem
adapter.
Tyco Electronics offers a
variety of Raychem
adapters for applications in
many industries, including
aerospace, marine, and
mass transit.
These adapters are:
nAvailable in many
configurations to match
applications
nEasy to install
nIdeal for high-reliability
applications
nKitted for customer
convenience.
In this section we present
Raychem spin-coupling
adapters and Tinel-Lock
adapters.
The Tinel-Lock adapter
utilizes Raychem's Tinel
ring to terminate the overall
shield to the adapter.The
Tinel ring is a low-profile,
high-strength, shape-mem-
ory-alloy shield-termination
device available in many
sizes to accommodate
various entry sizes and
shield configurations.
Tinel-Lock adapters are
ideal for lightweight aero-
space applications requir-
ing repeated high-to-low
temperaturecycles.
Adapter Fundamentals
Types of Adapters
6-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Adapter Types
Tyco Electronics offers
several types of Raychem
adapters for unscreened
and screened termination
systems. The choice is
largely dependent upon
the screening level required
and the braid termination
method.
The four principal adapter
types are:
nSolid (fixed)
nSpin-Coupling
nBraided
nTinel-Lock
Solid Adapters (Fixed)
Solid adapters are
designed for use whereno
access is required; for
example, when potting is
necessary or a lower space
profile is needed.
These adapters have a boot
groove to accommodate a
lipped heat-shrinkable boot.
Repair cannot be made
without removing the boot.
Spin-Coupling Adapters
Spin-coupling adapters are
two-partcomponents that
have a rotatable coupling
nut and a grooved body
designed to accommodate
lipped-type heat-shrinkable
boots.
Spin-couplings with an
appropriate molded part
areused for environmental
protection and strain relief
of unscreened cable termi-
nations. Cable repairs can
be made without damaging
the boot.
Braided Adapters
These are spin-coupling
adapters that have a short
length of tubular braided
shield attached to the rear
of the adapter.The braid is
constructed from tinned
copper wireand has a
handling characteristic
that enables it to be pulled
down onto a wide range of
cable diameters. This allows
astandard entry size to be
used with most cable sizes.
The shield is terminated to
the cable braid using a
SolderSleeve device, which
provides screen continuity
through to the connector.
Straight, 45°, and 90° con-
figurations areavailable.
Adapter
Adhesive Molded Part
Cable Jacket
Adhesive
Molded Part
Adapter
Sealing
Adhesive
Sealing
Adhesive Cable
Jacket
Adapter
Sealing
Adhesive Cable
Braid SolderSleeve
Device Cable
Jacket
Electro-
Magnetic
Force Ring
Cable
Braid Molded
Part Sealing
Adhesive
Solid Adapters (Fixed)
Spin-Coupling Adapters
Braided Adapters
Adapter Fundamentals
Types of Adapters (Continued)
6-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tinel-Lock Adapters
This termination system
consists of a modified
spin-coupling adapter with
aTinel-Lock ring. The
Tinel-Lock ring is made
from a special shape
memorymetal that shrinks
uniformly when heated
(see Application Tooling,
section 10).
The Tinel-Lock ring is used
to terminate copper cable
braid directly onto the rear
of the adapter. The adapter
entry size and ring designa-
tor must be selected to suit
the cable diameter and
braid type.
The resulting 360° termina-
tion withstands severe
shock, vibration, tempera-
turecycling, and corrosion.
Straight, 45°, and 90° con-
figurations are available.
Roll-back Repair with Adapters
More than 85 percent of
cable repairs aremade
within 75 [3.0] of the
connectors—usually
because of a broken pin or
wire. By reheating the heat-
shrinkable boot and
unscrewing the adapter
coupling nut, the boot can
be “rolled back,” providing
access to the rear of the
connector for repair. This
technique is applicable to
spin-coupling, shielded,
and Tinel-Lock adapters.
Adapter Molded part Adhesive
Adhesive Tinel-Lock
Ring Cable
Braid Cable
Jacket
Tinel-Lock Adapters
Adapter Fundamentals
Adapter Selection Process
6-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Selecting an adapter for
your application involves a
five-step process:
1. From the connector
number, determine:
nOrder number (shell
size)
nMaterial
nPlating
2.Decide what adapter
type you need for the
connector.
3. Determine the Raychem
connector code for that
adapter type. (Use Table
A, B, or C on pages 6-6
to 6-15).
Adapter Selection
Flowchart Decide on Adapter Type
Select Raychem Adapter Code
Select Raychem Adapter Family
Tinel Shielded Solid or Spin-Coupling
nChoose configuration nChoose configuration nSelect options
nDetermine entry size nDetermine entry size nSelect molded part
(based on cable diameter)
nChoose Tinel-Lock ring nSelect options
depending on braid
(AI or BI?) nSelect molded part
nSelect options
nSelect molded part
Step-by-Step Selection
Process 4. Determine the Raychem
adapter family for that
connector code. (Use
Table D on page 6-16).
5. Build the adapter part
number. (See page 6-17).
The chart below will lead
you through these steps.
Adapter Selection
Raychem Adapter Code
6-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Selecting the Raychem
Adapter Code
Tables A, B, and C that
follow provide Raychem
adapter codes for typical
connectors.
If you know the military part
number for the connector,
you can obtain the
Raychem adapter code
from Table A that begins on
this page.
If you know the manufactur-
er’s prefix for the connector,
you can obtain the
Raychem adapter code
from Table B that begins on
page 6-10.
If you know the connector
specification, you can
obtain the Raychem
adapter code from Table C
on page 6-15
Table A. Raychem Adapter
Code by Military Part
Number
Military Connector Raychem
Part No. Specification Series/Class Adapter Code
D38999/20 MIL-C-38999 Series III: Class C, F, K, W 40
D38999/24 MIL-C-38999 Series III: Class C, F, K, W 40
D38999/26 MIL-C-38999 Series III: Class C, F, K, W 40
D38999/40 MIL-C-38999 Series IV: Class C, F, W 40
D38999/42 MIL-C-38999 Series IV: Class C, F, W 40
D38999/44 MIL-C-38999 Series IV: Class C, F, W Contact Tyco Electronics
D38999/46 MIL-C-38999 Series IV: Class F, W 40
D38999/47 MIL-C-38999 Series IV: Class C, W 40
M28840/10 MIL-C-28840 Class D, DS 30
M28840/11 MIL-C-28840 Class D, DS 30
M28840/14 MIL-C-28840 Class D, DS 30
M28840/16 MIL-C-28840 Class D, DS 30
M81511/01 MIL-C-81511 Series 2: Class A, E, F 61
M81511/03 MIL-C-81511 Series 2: Class A, E, F 61
M81511/05 MIL-C-81511 Series 2: Class A, E, F 61
M81511/06 MIL-C-81511 Series 2: Class A, E, F 61
M81511/21 MIL-C-81511 Series 1: Class A, E, F 61
M81511/23 MIL-C-81511 Series 1: Class A, E, F 61
M81511/25 MIL-C-81511 Series 1: Class A, E, F 61
M81511/26 MIL-C-81511 Series 1: Class A, E, F 61
M81511/31 MIL-C-81511 Series 2: Class C, P, T 61
M81511/32 MIL-C-81511 Series 2: Class C, P, T 61
M81511/33 MIL-C-81511 Series 2: Class C, P,T61
M81511/34 MIL-C-81511 Series 2: Class C, P, T 61
M81511/35 MIL-C-81511 Series 1: Class C, P, T 61
M81511/36 MIL-C-81511 Series 1: Class C, P, T 61
M81511/37 MIL-C-81511 Series 1: Class C, P, T 61
M81511/38 MIL-C-81511 Series 1: Class C, P, T 61
M81511/41 MIL-C-81511 Series 3: Class A, E, F 61
M81511/45 MIL-C-81511 Series 3: Class A, E, F 61
M81511/46 MIL-C-81511 Series 3: Class A, E, F 61
M81511/49 MIL-C-81511 Series 3: Class A, E, F 61
M81511/51 MIL-C-81511 Series 4: Class A, E, F 61
M81511/53 MIL-C-81511 Series 4: Class A, E, F 61
M81511/55 MIL-C-81511 Series 4: Class A, E, F 61
M81511/56 MIL-C-81511 Series 4: Class A, E, F 61
M83723/01 MIL-C-83723 Series I: Class A, G, R 54
M83723/02 MIL-C-83723 Series I: Class A, G, R 54
M83723/03 MIL-C-83723 Series I: Class A, G, R 54
M83723/04 MIL-C-83723 Series I: Class A, G, R 54
M83723/05 MIL-C-83723 Series I: Class A, G, R 54
M83723/06 MIL-C-83723 Series I: Class A, G, R 54
M83723/07 MIL-C-83723 Series I: Class A, G, R 54
M83723/08 MIL-C-83723 Series I: Class A, G, R 54
M83723/13 MIL-C-83723 Series I: Class A, G, R 54
M83723/14 MIL-C-83723 Series I: Class A, G, R 54
M83723/17 MIL-C-83723 Series II: Class A, G, R 19
M83723/18 MIL-C-83723 Series II: Class A, G, R 19
M83723/19 MIL-C-83723 Series II: Class A, G, R 19
M83723/20 MIL-C-83723 Series II: Class A, G, R 19
M83723/23 MIL-C-83723 Series II: Class A, G, R 19
M83723/24 MIL-C-83723 Series II: Class A, G, R 19
M83723/36 MIL-C-83723 Series I: Class A, G, R 54
M83723/37 MIL-C-83723 Series I: Class A, G, R 54
M83723/38 MIL-C-83723 Series I: Class A, G, R 54
M83723/39 MIL-C-83723 Series I: Class A, G, R 54
M83723/40 MIL-C-83723 Series I: Class A, G, R 54
M83723/41 MIL-C-83723 Series I: Class A, G, R 54
M83723/42 MIL-C-83723 Series I: Class G, R 54
M83723/43 MIL-C-83723 Series I: Class G, R 54
M83723/48 MIL-C-83723 Series I: Class G, R 54
Adapter Selection
Raychem Adapter Code (Continued)
6-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Table A. Raychem Adapter
Code by Military Part
Number (Continued)
Military Connector Raychem
Part No. Specification Series/Class Adapter Code
M83723/49 MIL-C-83723 Series I: Class G, R 54
M83723/52 MIL-C-83723 Series II: Class K 19
M83723/53 MIL-C-83723 Series II: Class K 19
M83723/65 MIL-C-83723 Series III: Class H 54
M83723/66 MIL-C-83723 Series III: Class A, G, R 54
M83723/67 MIL-C-83723 Series III: Class A, G, R 54
M83723/68 MIL-C-83723 Series III: Class A, G, R 54
M83723/69 MIL-C-83723 Series III: Class A, G, R 54
M83723/71 MIL-C-83723 Series III: Class A, G, R 54
M83723/72 MIL-C-83723 Series III: Class A, G, R 54
M83723/73 MIL-C-83723 Series III: Class A, G, R 54
M83723/74 MIL-C-83723 Series III: Class A, G, R 54
M83723/75 MIL-C-83723 Series III: Class A, G, R 54
M83723/76 MIL-C-83723 Series III: Class A, G, R 54
M83723/77 MIL-C-83723 Series III: Class G, R 54
M83723/78 MIL-C-83723 Series III: Class G, R 54
M83723/82 MIL-C-83723 Series III: Class A, G, K, R, S 54
M83723/83 MIL-C-83723 Series III: Class A, G, K, R, S 54
M83723/84 MIL-C-83723 Series III: Class A, G, K, R, S 54
M83723/85 MIL-C-83723 Series III: Class A, G, K, R, S 54
M83723/86 MIL-C-83723 Series III: Class A, G, K, R 54
M83723/87 MIL-C-83723 Series III: Class A, G, K, R 54
M83723/91 MIL-C-83723 Series III: Class G, R, W 54
M83723/92 MIL-C-83723 Series III: Class G, R, W 54
M83723/95 MIL-C-83723 Series III: Class A, G, K, R 54
M83723/96 MIL-C-83723 Series III: Class A, G, K, R 54
M83723/97 MIL-C-83723 Series III: Class S 54
M83723/98 MIL-C-83723 Series III: Class S 54
MS17343 MIL-C-22992 Class C, J, R 32
MS17344 MIL-C-22992 Class C, J, R 32
MS17345 MIL-C-22992 Class C, J, R 32
MS17346 MIL-C-22992 Class C, R 32
MS17347 MIL-C-22992 Class C, J, R 32
MS17348 MIL-C-22992 Class C, R 32
MS24264 MIL-C-26500 (AL) Class F,G, R 51
Type B&T aluminum shell
MS24264 MIL-C-26500 (SST) Class E 52
Type B&T stainless steel shell
MS24265 MIL-C-26500 (AL) Class F, G, R 51
Type B&T aluminum shell
MS24265 MIL-C-26500 (SST) Class E 52
Type B&T stainless steel shell
MS24266 MIL-C-26500 (SST) Class E 52
Type B&T stainless steel shell
MS24266 MIL-C-26500 (AL) Class F,G, R 51
Type B&T aluminum shell
MS27466 MIL-C-38999 Series I: Class E, P, T 41
MS27467 MIL-C-38999 Series I: Class E, P, T 41
MS27468 MIL-C-38999 Series I: Class E, P, T 41
MS27469 MIL-C-38999 Series I: Class YContact Tyco Electronics
MS27472 MIL-C-38999 Series II: Class T 41
MS27473 MIL-C-38999 Series II: Class E, P, T 41
MS27474 MIL-C-38999 Series II: Class T41
MS27475 MIL-C-38999 Series II: Class YContact Tyco Electronics
MS27479 MIL-C-38999 Series II: Class T 41
MS27480 MIL-C-38999 Series II: Class E, T 41
MS27481 MIL-C-38999 Series II: Class T 41
MS27482 MIL-C-38999 Series II: Class Y Contact Tyco Electronics
MS27484 MIL-C-38999 Series II: Class E, T41
MS27497 MIL-C-38999 Series II: Class T 41
MS27515 MIL-C-38999 Series I: Class E Contact Tyco Electronics
Adapter Selection
Raychem Adapter Code (Continued)
6-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Table A. Raychem Adapter
Code by Military Part
Number (Continued)
Military Connector Raychem
Part No. Specification Series/Class Adapter Code
MS27613 MIL-C-26500 (SST) Class K Type B&T stainless steel shell 52
MS27614 MIL-C-26500 (SST) Class K Type B&T stainless steel shell 52
MS27615 MIL-C-26500 (SST) Class K Type B&T stainless steel shell 52
MS27652 MIL-C-38999 Series I: Class E, T 41
MS27653 MIL-C-38999 Series I: Class E, T 41
MS27654 MIL-C-38999 Series I: Class E, T Contact Tyco Electronics
MS27656 MIL-C-38999 Series I: Class E, T 41
MS27661 MIL-C-38999 Series I 41
MS27665 MIL-C-38999 Series I 41
MS3100 MIL-C-5015 Class A, E, F, R less endbell; solder contact 18
MS3101 MIL-C-5015 Class A, E, F, R less endbell; solder contact 18
MS3106 MIL-C-5015 Class A, E, F, R less endbell; solder contact 18
MS3107 MIL-C-5015 Class A, E, F, R less endbell; solder contact 18
MS3108 MIL-C-5015 Solder contact with endbell 15
MS3110 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3111 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3114 MIL-C-26482 Series 1: Class E, F, P 241
MS3116 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3120 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3121 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3124 MIL-C-26482 Series 1: Class E, F, P 241
MS3126 MIL-C-26482 Series 1: Class E, F, J, P 21
MS3128 MIL-C-26482 Series 1: Class E, F,J, P 21
MS3130 MIL-C-81703 Series 1: Class E, P, J 71
MS3132 MIL-C-81703 Series 1: Class E 71
MS3134 MIL-C-81703 Series 1: Class E, P, J 71
MS3137 MIL-C-81703 Series 1: Class E, P, J 71
MS3138 MIL-C-81703 Series 1: Class E, P,J71
MS3140 MIL-C-81703 Series 1: Class E, J 71
MS3144 MIL-C-81703 Series 1: Class E, J 71
MS3147 MIL-C-81703 Series 1: Class E, J 71
MS3148 MIL-C-81703 Series 1: Class E, J 71
MS3400 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3401 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3404 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3406 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3408 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3409 MIL-C-5015 Crimp contact 54
MS3412 MIL-C-5015 Class D, L, U, W crimp contact less endbell 54
MS3424 MIL-C-81703 Series 3: Class E, L 54
MS3445 MIL-C-81703 Series 2: Class E 71
MS3446 MIL-C-81703 Series 3: Class E, L 54
MS3450 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3451 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3454 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3456 MIL-C-5015 Class D, L, U, W crimp contact 54
MS3459 MIL-C-5015 Class L, W crimp contact 54
MS3464 MIL-C-81703 Series 3: Class E, L 54
MS3467 MIL-C-81703 Series 3: Class E, L 54
MS3468 MIL-C-81703 Series 3: Class E, L 54
MS3470 MIL-C-26482 Series 2: Class A, L 54
MS3471 MIL-C-26482 Series 2: Class A, L 54
MS3472 MIL-C-26482 Series 2: Class A, L 54
MS3474 MIL-C-26482 Series 2: Class A, L 54
MS3475 MIL-C-26482 Series 2: Class A, L 54
MS3476 MIL-C-26482 Series 2: Class A, L 54
NAS1599 MIL-C-81703 Series 3: 54
NAS1641 MIL-C-81703 Series 3: 54
NAS1642 MIL-C-81703 Series 3: 54
NAS1643 MIL-C-81703 Series 3: 54
1Code 24 connectors have an internal accessory thread.
Adapter Selection
Raychem Adapter Code (Continued)
6-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Table A. Raychem Adapter
Code by Military Part
Number (Continued)
Military Connector Raychem
Part No. Specification Series/Class Adapter Code
NAS1650 MIL-C-81703 Series 3: 54
NAS1651 MIL-C-81703 Series 3: 54
NAS1652 MIL-C-81703 Series 3: 54
NAS1653 MIL-C-81703 Series 3: 54
NAS1692 MIL-C-81703 Series 3: 54
NAS1693 MIL-C-81703 Series 3: 54
NAS1694 MIL-C-81703 Series 3: 54
NAS1699 MIL-C-81703 Series 3: 54
NAS1700 MIL-C-81703 Series 3: 54
NAS1701 MIL-C-81703 Series 3: 54
NAS1702 MIL-C-81703 Series 3: 54
Adapter Selection
Raychem Adapter Code (Continued)
6-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Manufacturer’s Connector Raychem
Prefix Manufacturer6Specification Series/Class Adapter Code
10-214 Bendix MIL-C-5015 MS3100 Class A, E, R 18
10-475 Bendix 40M38277 — 41
10-720 Bendix MIL-C-5015 MS3100 Class A, E, R 18
118 Amphenol MIL-C-26482 Series 2 54
149 Deutsch MIL-C-81703 Series 1 71
162GB Amphenol MIL-C-26482 Series 1 76, 774
164GB Amphenol BS9522 F0023 — Contact Tyco Electronics
165 Amphenol None — Contact T yco Electronics
172 Amphenol MIL-C-5015 — Contact T yco Electronics
179 Amphenol MIL-C-5015 — Contact T yco Electronics
182 Amphenol None — Contact T yco Electronics
246 Amphenol MIL-C-5015 MS3100 Class E, F, R 18
251 Cannon MIL-C-26482 Series 1 21
2PPN Plessey MIL-C-26482 Series 1 21
2PPN-07 Plessey MIL-C-26482 Series 1 243
2PSN Plessey BS9522 F0017 Patt 105 76, 774
2PSN-07 Plessey MIL-C-26482 Series 1 243
348 Amphenol MIL-C-81511 Series 1 and 2 61
381 Deutsch 40M39569 — 54
418 Amphenol MIL-C-38999 Series I and II 41
45/PT Socapex MIL-C-26482 Series 1 21
450 Deutsch MIL-C-26482 Series 1 21
451 Socapex PRL 54125 — 21or 243
460 Deutsch MIL-C-26482 Series 1 21
48 Amphenol MIL-C-26500 Alum Class F, G, R 51
486 Amphenol MIL-C-26482 Series 2 54
518 Amphenol MIL-C-83723 Series III 54
5MS FKI2Def. Stan. 59-35 Patt 121A 75
602 Amphenol Def. Stan. 59-56 Patt 602 54
602GB Amphenol Def. Stan. 59-56 Patt 602 54
62AB-14 Amphenol MIL-C-26482 Series 1 Contact Tyco Electronics
62GB Amphenol Def. Stan. 59-35 Patt 105 76, 774
650 Schaltbau VG 95329 — 61
652 Amphenol LN 29504 — 54
652 UMD PRL 54125 — 21 or 243
674 Schaltbau VG 95328 — Contact Tyco Electronics
675 Schaltbau VG 95328 — Contact Tyco Electronics
679 Schaltbau VG 95329 — 61
69 Amphenol MIL-C-5015 MS3100 Class E, F, R 18
71 Bendix MIL-C-5015 MS3100 Class A, E, R 18
711 Amphenol BS9522 F0042 — 54
801 Amphenol None — 54
837 Deutsch MIL-C-83723 Series III 54
83723 Souriau MIL-C-83723 Series III 54
83730 Deutsch MIL-C-83723 Series III 54
845 Souriau NFL 54120 — Contact Tyco Electronics
847 Souriau NFL 54120 — Contact Tyco Electronics
850 Souriau MIL-C-26482 Series 1 21
851 Souriau MIL-C-26482 Series 1 21
8520 Souriau MIL-C-26482 Series 2 54
8525 Souriau NAS 1599 — 54
8526 Souriau PAN 6432-1 — 54
853 Souriau MIL-C-83723 Series III 54
857 Souriau LN 29728 —54
89 Souriau NFL 54140 — 54
2FKI was previously Thorn.
3Code 24 connectors have an internal accessory thread.
4Code 77 braided version.
Table B. Raychem Adapter
Code by Manufacturer’s
Prefix
Adapter Selection
Raychem Adapter Code (Continued)
6-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Table B. Raychem Adapter
Code by Manufacturer’s
Prefix (Continued)
Manufacturer’s Connector Raychem
Prefix Manufacturer6Specification Series/Class Adapter Code
891 Souriau MIL-C-5015 Class K Contact Tyco Electronics
892 Souriau MIL-C-5015 Class K Contact Tyco Electronics
8LT Souriau MIL-C-38999 Series I 41
8ST Souriau VG 96912 Series 1 47
8T Souriau MIL-C-38999 Series II 41
9-815 Deutsch MIL-C-81511 Series 3 and 4 61
91-483 Bendix MIL-C-26482 Series 2 54
944 Matrix MIL-C-5015 MS3400 Class L, U, W 54
951 Deutsch LN 29500 — Contact Tyco Electronics
97 Amphenol MIL-C-5015 MS3100 Class A 18
981 Matrix MIL-C-5015 MS3400 54
A815 Deutsch MIL-C-81511 Series 3 61
AA70 Deutsch Not known — 71
AB05 AB Elec Def. Stan. 59-35 Patt 105 76, 774
AB06 AB Elec Def. Stan. 59-35 Patt 105 76, 774
ABB AB Elec BS9522 F0032 — 78
ABJ AB Elec MIL-C-38999 Series I and II 41
ADS Deutsch MIL-C-81703 — 71
AFD Deutsch MIL-C-83723 Series I 54
AFD5 Deutsch MIL-C-26482 Series 2 54
B815 Deutsch MIL-C-81511 Series 4 61
BE Pyle MIL-C-83723 Series III 54
BG Bendix MIL-C-26482 Series I 21
BL G&H Tech MIL-C-38999 Series IV 40
BL TRW MIL-C-38999 Series IV 40
BT Burndy MIL-C-26482 Series 1 21
BT Pyle MIL-C-83723 Series III 54
BTK Deutsch MIL-C-26482 Series 1 21
BY1 Pyle MIL-C-83723 Series III 54
C48 TRW MIL-C-26500 Aluminum 51
CA (Bayonet) Cannon VG 95234 — 58
CA3101 Cannon MIL-C-5015 MS3100 class E, F, R 18
CA3101 Cannon MIL-C-5015 MS3100 Class A 18
CA3101KE Cannon MIL-C-5015 Class K Contact Tyco Electronics
CIR VEAM VG 95234 — 64***, 66**, 78*
CN0930 TRW MIL-C-83723 Series III 54
CT Burndy MIL-C-38999 Series II 41
CT Plessey MIL-C-38999 Series II 41
CV-R Cannon MIL-C-83723 Series II 19
CV34 Cannon MIL-C-5015 MS3400 Class L, U, W 54
CVA Cannon MIL-C-83723 Series II 19
CWL Cannon None — 31
CWLD Cannon MIL-C-22992 Class C, J, R 32
D817 Deutsch MIL-C-81703 Series 3 54
DA Deutsch None — 71
DBAD Deutsch MIL-C-81703 — Contact Tyco Electronics
DBAS Deutsch MIL-C-81703 Series 3 54
DD Deutsch MIL-C-81703 Series 2 71
DFE Deutsch MIL-C-26482 Series 2 54
DKM Deutsch VG 95328 —Contact T yco Electronics
DL Deutsch MIL-C-83723 Series III 54
DM Deutsch MIL-C-81703 Series 1 71
DPX Cannon —Contact Tyco Electronics
DS Deutsch None —71
DTS Deutsch MIL-C-38999 Series III 40
*AB connectors only
** VEAM standard
***VEAM panel mount
4Code 77 braided version.
Adapter Selection
Raychem Adapter Code (Continued)
6-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Manufacturer’s Connector Raychem
Prefix Manufacturer6Specification Series/Class Adapter Code
EA Pyle None — 54
EB Pyle NAS 1599 — 54
EEG Pyle MIL-C-83723 Series I 54
ES Pyle None — 54
ESC004 Various MIL-C-5015 Class K Contact Tyco Electronics
ET Pyle NAS 1599 — 54
FC Flight MIL-C-5015 Rev E only Contact Tyco Electronics
FDBA Deutsch LN 29504 — 54
FF Flight MIL-C-5015 MS3400 Class D, L, U, W 54
FH Flight MIL-C-83723 Series III 54
FPK Pyle MIL-C-26500 Class K 52
FP5K Pyle MIL-C-26500 Class K Contact Tyco Electronics
FYL Pyle MIL-C-26500 Class K 52
G Burndy None — 21
GC-E General MIL-C-26482 Series 1 21
GTA Hughes MIL-C-28840 — 30
HAN Deutsch MIL-C-5015 MS3100 Class E, KE Contact Tyco Electronics
HD SAE MIL-C-28840 — 30
HTMAS Cannon MIL-C-5015 Class K Contact Tyco Electronics
HTMF Cannon MIL-C-83723 Series III: Class K 54
HTMS AB Elec MVEE 695 — 75
JTAmphenol MIL-C-38999 Series II 41
JT Bendix/FKI MIL-C-38999 Series II 41
JT Socapex MIL-C-38999 Series II 41
JT-R FKI2PAN 6433-1 — 41
JT-R Teldix PAN 6433-1 — 41
KFS Cannon MIL-C-28840 — 30
KJ Cannon MIL-C-38999 Series II 41
KJA Cannon MIL-C-38999 Series III 40
KJJ Cannon MIL-C-38999 Series II Contact Tyco Electronics
KJJL Cannon MIL-C-38999 Series I Contact Tyco Electronics
KJL Cannon MIL-C-38999 Series I 41
KPSE Cannon MIL-C-26482 Series 1 21
KPT Cannon MIL-C-26482 Series 1 21
KV-R Cannon NAS 1599 — 54
L Burndy MIL-C-26482 Series 1 21
LJT Bendix MIL-C-38999 Series I 41
LJT Socapex MIL-C-38999 Series I 41
LL3 Deutsch MIL-C-81511 — 61
LL5/6 Deutsch BS9540 F0001 Patt 602 Contact Tyco Electronics
LMB Litton-Veam Def. Stan. 59-35 Patt 121A 75
LPT Deutsch MIL-C-26482 Series 1 21
LS Pyle None — 54
LTT FKI2BS9522 F0029 Patt 616 41
M-T Burndy MIL-C-26482 Series 1 21
M723 Matrix MIL-C-83723 Series II 19
MB1 Matrix MIL-C-26482 Series 2 54
MB3 Matrix MIL-C-83723 Series III 54
MB9 Matrix MIL-C-38999 Series I and II 41
MD Matrix MIL-C-26482 Series 2 54
MDR Deutsch None — 71
MF Cannon MIL-C-83723 Series III 54
MK12 Plessey Def. Stan. 59-35 Patt 603 76, 774
MK18 Plessey Def. Stan. 59-35 Patt 608 795
MK38 Plessey MIL-C-38999 Series I 41
Table B. Raychem Adapter
Code by Manufacturer’s
Prefix (Continued)
2FKI was previously Thorn.
4Code 77 braided version.
5Free connectors only.
Adapter Selection
Raychem Adapter Code (Continued)
6-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Manufacturer’s Connector Raychem
Prefix Manufacturer6Specification Series/Class Adapter Code
MK25 Plessey MIL-C-38999 Series II 41
MK7 Plessey DEF 5325-2 Patt 104 Contact Tyco Electronics
MK8 Plessey Def. Stan. 59-35 Patt 105 76, 774
ML94 Matrix MIL-C-38999 Series IV 40
MQ3 Matrix MIL-C-83723 Series III 54
MT3 Matrix MIL-C-83723 Series III 54
MT93 Matrix MIL-C-38999 Series III 40
P5 Plessey NFL 54 125 — 76 or 243,774
PAT104D AB Elec Def. Stan. 59-35 Patt 104 Contact Tyco Electronics
PT Socapex MIL-C-26482 Series 1 76, 774
PT Teldix MIL-C-26482 Series 1 76, 774
PT-CE Bendix None — 22
PT-G Teldix VG 95328 — Contact Tyco Electronics
PT-SE Socapex MIL-C-26482 Series 1 76, 774
PT-SE Teldix MIL-C-26482 Series 1 76, 774
PT07 Bendix MIL-C-26482 Series 1 243
PT07SE FKI2MIL-C-26482 Series 1 243
PT33 FKI2BS9522 F0017 Patt 105 76, 774
PT33SE FKI2BS9522 N0001 Patt 603 76, 774
PT44 FKI2BS9522 F0017 Patt 105 76, 774
PT44SE FKI2BS9522 N0001 Patt 603 76, 774
PT55 FKI2BS9522 F0017 Patt 105 76, 774
PT55SE FKI2BS9522 N0001 Patt 603 76, 774
PT77 FKI2BS9522 F0017 Patt 105 76, 774
PT77SE FKI2BS9522 N0001 Patt 603 76, 774
PTG55 FKI2BS9522 F0017 Patt 105 76, 774
PTG55SE FKI2BS9522 N0001 Patt 603 76, 774
PTS-DR Bendix MIL-C-26482 Series 2 54
PV7 Cannon MIL-C-26482 Series 2 54
PVJ Cannon MIL-C-26482 Series 2 54
PVW Cannon — — 54
PVX Cannon Def. Stan. 59-56 Patt 602 54
QDP Bendix None — 32
QRP AB Elec — — 78
QWL Bendix None — 31
QWLD Bendix MIL-C-22992 Class C, J, R 32
RD1 Raychem MIS-20065 — 54
RR Deutsch Def. Stan. 59-56 Patt 602 54
RR20 Deutsch PAN 6432-2 — 54
RR50 Deutsch PAN 6432-1 — 54
RR70 Deutsch PAN 6432-2 — 54
RSM Deutsch None — 71
RTK Deutsch None — 71
SA SAE MIL-C-5015 MS3400 54
SB Bendix MIL-C-5015 Class E 18
SB-104 AB Elec Def. Stan. 59-35 Patt 104 Contact Tyco Electronics
SB-M4 AB Elec Def. Stan. 59-35 Patt 104 Contact Tyco Electronics
SB-MS AB BS9522 F0030 — 75
SC Bendix MIL-C-5015 MS3100 Class A18
SCB SICEM VG 95234 —Contact Tyco Electronics
SF Bendix MIL-C-5015 MS3100 Class E 18
SG Bendix MIL-C-5015 MS3100 Class E 18
SJT Various PAN 6433-2 — 47
SJT07 Various PAN 6433-2 — Contact Tyco Electronics
SLPT Deutsch MIL-C-26482 Series 1 76, 774
Table B. Raychem Adapter
Code by Manufacturer’s
Prefix (Continued)
2FKI was previously Thorn.
3Code 24 connectors have an internal accessory thread.
4Code 77 braided version.
Adapter Selection
Raychem Adapter Code (Continued)
6-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Manufacturer’s Connector Raychem
Prefix Manufacturer6Specification Series/Class Adapter Code
SM Bendix MIL-C-5015 MS3100 Class A, E, R 18
SPT Bendix MIL-C-26482 Series 1 76, 774
SPT Socapex MIL-C-26482 Series 1 76, 774
SPT07 Various MIL-C-26482 Series 1 243
STK Deutsch None — 71
STT FKI2BS9522 F0012 Patt 615 47
STT07 FKI2BS9522 F0012 Patt 615 Contact Tyco Electronics
T31Pyle MIL-C-38999 Series III 40
TRIM TRIO Burndy None — Contact Tyco Electronics
TT FKI2BS9522 N0003 Patt 614 41
TV FKI2/Bendix MIL-C-38999 Series III 40
TV-O-R Bendix MIL-C-38999 Series III and IV 40
TVP FKI2/Bendix MIL-C-38999 Series III 40
TVPS FKI2/Bendix MIL-C-38999 Series III Contact Tyco Electronics
TVS FKI2/Bendix MIL-C-38999 Series III Contact Tyco Electronics
Tri-Start Bendix MIL-C-38999 Series III and IV 40
VPT VEAM MIL-C-26482 Series 1 21
VTT FKI2MIL-C-38999 Series III 40
ZZY/ZZW Pyle MIL-C-26500 Class R, G (AL) 51
ZZY/ZZW Pyle MIL-C-26500 Class E (SST) 52
1May be a number or letter depending upon connector style.
2FKI was previously Thorn.
3Code 24 connectors have an internal accessory thread.
4Code 77 braided version.
5Free connectors only.
6Some of the connector manufacturers names may have changed and may not exist.
They are listed here to assist users who know them as listed names.
Table B. Raychem Adapter
Code by Manufacturer’s
Prefix (Continued)
Adapter Selection
Raychem Adapter Code (Continued)
6-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Table C. Raychem Adapter
Code by Connector
Specification
Connector Specification Series/Class Raychem Adapter Code
40M38277 — 41
40M39569 — 54
BS9520 G0001 41
BS9520 G0002 41
BS9520 G0003 40
BS9522 F0012 Patt 615 47
BS9522 F0014 Patt 104 Contact Tyco Electronics
BS9522 F0017 Patt 105 76
BS9522 F0020 Patt 608 792
BS9522 F0023 — Contact Tyco Electronics
BS9522 F0029 Patt 616 41
BS9522 F0030 Patt 121A 75
BS9522 F0032 Patt 121B 78
BS9522 F0042 — 54
BS9522 N0001 Patt 603 76
BS9522 N0003 Patt 614 41
BS9540 F0001 Patt 602 54
LN 29500 — 21
LN 29504 — 54
LN 29728 — 54
LN29729 —47
MIL-C-22992 Class C, J, R 32
MIL-C-26482 Series 1 21, 241
MIL-C-26482 Series 2 54
MIL-C-26500 Aluminum, Class F,G, R 51
MIL-C-26500 Stainless steel, Class E, K 52
MIL-C-28840 Class D 30
MIL-C-38999 Series I and II 41
MIL-C-38999 Series III and IV 40
MIL-C-5015 MS3400 54
MIL-C-5015 MS3100 18, 15 (with endbell)
MIL-C-5015 5MS 75
MIL-C-81511 Series 1, 2, 3, and 4 61
MIL-C-81703 Series 1, 2 71
MIL-C-81703 Series 3 54
MIL-C-83723 Series II 19
MIL-C-83723 Series I and III 54
MIL-C-85049/59 — 32
MIL-C-85049/60 — 54
MIL-C-85049/62 — 41
MIL-C-85049/69 —40
MIS-20065 — 54
MVEE 5MS 75
NAS 1599 — 54
NFL 54120 — Contact Tyco Electronics
NFL 54140 — 54
PAN 6432-1 — 54
PAN 6432-2 — 54
PAN 6433-1 —41
PAN 6433-2 — 47
PRL 54125 — 21, 241
VG 95234 —64***, 66**, 78*
VG 95328 —Contact Tyco Electronics
VG 95329 — 61
VG 96912 Series 2 41
VG 96912 Series 1 47
1Code 24 connectors have an internal accessory thread.
2Free connectors only.
*AB connectors only
** VEAM standard
***VEAM panel mount
Adapter Selection
Raychem Adapter Family
6-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Using Table D below and
the Raychem adapter code
you selected in Table A, B,
or C, select the Raychem
adapter family for the
adapter type you chose
(spin-coupling or
Tinel-Lock).
With the alphanumeric pre-
fix for that family you can
then build the part number
for your Raychem adapter.
Selecting the Raychem
Adapter Family
Raychem Boot Adapter Shielded Adapter Tinel-Lock Adapter Band-Strap
Connector Code Solid (Fixed) Spin-Coupling Straight 45° 90° Straight, 45°, and 90° Adapter*
15 210M5 202M5 219M0 219M1 219M2 TXR 15 —
18 218M5 218M6 218M7 218M8 218M9 TXR 18 BND 18
19 201M7 201M4 — — — — —
21 203M6 203M9 206M0 206M1 206M2zx TXR 21 BND 21
24 208M5 208M6 216M0 216M1 206M5 — —
30 211M8 211M9 211M5 211M6 211M7 TXR 30 —
32 — 204M3 207M3 212M4 212M5 TXR 32 BND 32
40 209M3 209M4 208M7 208M8 208M9 TXR 40 BND 40
41 202M1 202M2 204M0 204M1 204M2 TXR 41 BND 41
47 202M8 202M7 210M0 210M1 210M2 TXR 47 BND 47
51 207M4 205M5 207M0 207M1 207M2 TXR 51 —
52 208M3 209M6 208M0 208M1 208M2 TXR 52 —
54 201M9 201M1 203M0 203M1 203M2 TXR 54 BND 54
61 202M3 202M4 205M0 205M1 205M2 TXR 61 —
71 203M5 202M9 217M0 217M1 217M2 TXR 71 —
75 228M5 228M7 227M0 227M1 227M2 TXR 75 —
76 225M6 225M5 ———TXR 76 —
77 228M6 228M8 228M0 228M1 228M2 — —
78 225M4 225M3 225M0 225M1 225M2 TXR 78 —
79 — 229M3 229M1 229M2 229M0 TXR 79 —
80 215M4 213M5 213M6 213M7 213M8 TXR 80 —
81 214M3 214M4 214M5 214M6 214M7 TXR 81 —
Table D. Identification of
Adapter Family Prefix by
Raychem Adapter Code
Adapter Selection
Raychem Part Number
6-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Part Numbering System
201M1 16 - 19 B
Spin-Coupling or Solid Adapter
Adapter family
Order number
Manufacturer’s prefix (connector code 18 only)
Material
Finish
Options*
203M0 16 - 19 B 10
Shielded Adapter
Adapter family
Order number
Manufacturer’s prefix (connector code 18 only)
Material
Finish
Entry size
Options*
n
Standard braid length (6") requires no
modification code.
n
Nonstandard braid length is stated in inches
(12 = 12" length)
TXR54 A B 00 - 16 10 AI
Tinel-Lock Adapter
Adapter family
Material (A - aluminium alloy; S = stainless steel)
Finish
Angle (00 = straight; 45 = 45˚; 90 = 90˚)
Manufacturer’s prefix (connector code 18 only)
Order number
Entry size
Ring designator
Options*
*For full range of options, consult Tyco Electronics.
*For full range of options, consult Tyco Electronics.
*For full range of options, consult Tyco Electronics.
1. Start with the alphanu-
meric prefix you selected
inTable D. This will be
the basis of your part
number.
2. Add to the prefix the
codes and designators
required for your adapter
type and application.
These may include sever-
al or all of the following:
Having Selected the Right
Adapter Type and Raychem
Adapter Family, You Can
Now Construct a Part
Number for the Adapter.
nOrder number
nManufacturer’s prefix
nMaterial
nFinish
nEntry size
nRing designator
nOption codes
Using the right codes and
designators helps ensure
that the adapter you select
will meet the application
requirements.
To determine which codes
and designators you will
need, use the Part number-
ing system shown below. To
select the right codes and
designators, turn to the
pages that follow.
Adapter Selection
Raychem Part Number (Continued)
6-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Band Strap Adapters
Part Numbering System
Band Strap Adapter
Modification Option Field
(Omit if not required)
BND 54 A B 00 - 12 06 A
Product Designator
BND — Adapter and Band
BNX — Adapter only
Adapter Code
Material
2
A— Aluminum alloy per QQ-A-225
B — Nickel aluminum bronze per ASTM B150
S — Stainless steel per QQ-S-763
Finish (See S-CH00-0157-002)
Configuration
00 = Straight 45= 45°90 = 90°
4W = 45°9W = 90°
For BND 18, dash may be replaced by a letter
Order Number
Entry Size
3
Band Termination Device Code
1
A— BND-1225S (Standard Supply for Americas and Asia)
CRES-Lock Banding Strap
B — (Standard Supply European Countries)
Notes:
1.See Drawings BND-1225S or BND-XX25S for information on bands.Adapter dimensions for “A”
designation may be different than those listed in this catalog.Contact Tyco Electronics for
Specification Control Drawing (SCD) for these adapters.
2.Alternative equivalent material specifications to those shown may be supplied at Tyco Electronicsʼdiscretion.
3. For standard entry sizes see relevant specification control drawing. For entry sizes larger than standard
(Type II Adapters),see sheets 3 and 4.
BND54AB00-1206A D FHJL N PS
D — Drain holes modification
F — Internal abrasion resistant coating
H — Helical conduit thread
J — Chain attachment assembly
L — Lock wire holes manufacturerʼs option
Include mod if required
Standard on codes 40 and 54
Optional O-Ring material
Omit for standard silicone (ZZ-R-765,grade 70: S59)
C — Neoprene per AMS3209
U — Fluorosilicone per MIL-R-25988,class 1
N—Nitrile (Buna N) per AMS3215
V — Fluorocarbon per MIL-R-83248,class 1
P—Pre-coiled bandstrap option
(See drawings BND-1225Por BND-XX25P)
S — Self-locking spin nut
To ensure optimum compat-
ibility, select the adapter
material and finish to match
those of the connector.
Most circular connectors
are manufactured from
aluminum with a cadmium
finish.
Selecting the Material and
Finish
Material Code
Material* Solid, Spin-Coupling, Tinel-Lock Typical
Description and Shielded Adapters Adapters Applications
Aluminum alloy 19 A Standard material for normal applications
Stainless steel 62 S Corrosion-resistant and high-temperature
(firewall) applications
Nickel aluminum bronze 01BExposed marine environments
*Other materials available upon request.
Finish* Description Color Finish Code Typical Applications
Cadmium, Olive drab A Corrosion-resistant conductive finishper QQ-P-416,
Type II, Class 3
Cadmium,
Olive drab B Corrosion resistance for exposed
per QQ-P-416, environments
Type II, Class 3
over electroless nickel
(500-hour salt-spray–resistant finish)
Electroless nickel, —C
High conductivity for optimum
per MIL-C-26074, screening performance
Class 4, Grade B
Anodized, hard, Black G Nonconductive finish for
per MIL-A-8625, aluminum adapters
Type III, Class 2
Passivated, —J
Nonconductive,
per QQ-P-35 or MIL-S-5002 corrosion-resistant finish
for stainless steel adapters
Unplated, shotblast —W
Nonreflective finish for
nickel aluminum bronze adapters
*Other finishes available upon request.
Raychem Material Codes
Raychem Finish Codes
Adapter Selection
Material and Finish
6-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-20
Entry Size
Determining the Wire
Bundle Size
The entry size of an adapter
is based on the size of the
wire bundle. If you don’t
know the size of the wire
bundle, measure a proto-
type or calculate the size.
Calculation of the wire bun-
dle size is based on three
values:
nCable outside diameter
(COD)
nCable jacket thickness
nJacketed cable diameter
Instructions for calculating
these values follow.
COD Calculation
To calculate the cable out-
side diameter, first deter-
mine whether the wires in
the bundle are of the same
size or of different sizes.
COD Calculation for Wires of
the Same Size
For bundles with wires that
are all of the same size, fol-
low these steps:
1. Determine the number of
wires in the wirebundle.
2. Find the multiplication
factor for that number in
Table E shown on the
next page.
3. Find the wire diameter in
the Wire and Cable sec-
tion (Section 9) of this
catalog.
4. Multiply the wire diameter
(from Step 3) by the mul-
tiplication factor (from
Step 2) as shown below.
Formula: D = Fd
Where:
D = Bundle diameter
F = Multiplication factor
d=Wire diameter
D = 1.2 3 x 1.192 + 5 x 1.42 + 1 x 1.65
222
D = 1.2 3 x 1.4 + 5 x 2.02 + 1 x 2.7
D = 1.2 4.2 + 10.1 + 2.7
D = 1.2 17
D = 1.2 x 4.12
D = 4.95 mm
Example: A bundle of wires
containing 27 x 44A0111-22
F = 6.00 (the multiplication
factor for 27 wires from
Table E)
d=1.19 mm (.049 in)*
D = 6x1.19 mm (6 x .049
in)
D=7.14 mm (.294 in)
*Diameter of 44A0111-22 wire
obtained from the Wire and Cable
Section 9 of this catalog.
COD Calculation for Wires of
Different Sizes
Todetermine the wire bun-
dle diameter when using
wires of different sizes, fol-
low these steps:
1. Determine the number of
wires in the wirebundle.
2. Find the diameter of the
wires in the Wire and
Cable section of this cat-
alog.
3. Calculate the cable out-
side diameter by using
this formula:
D = 1.2 N1d12 + N2d 22 + N3d32
Where:
D=Bundle diameter
N=Number of wires
d=Diameter of wires
Example: A bundle of wires
containing
3x44A0111-221* (1.192-
mm dia.)
5x44A0111-201* (1.42-mm
dia.)
1x44A0111-181* (1.65-mm
dia.)
*For wire information see the Wire
and Cable Section 9 of this catalog.
6
Adapters
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-21
Entry Size (Continued)
Number of Wires Multiplication Factor Number of Wires Multiplication Factor
11.00 32 6.70
21.60 33 6.70
32.00 34 7.00
42.41 35 7.00
5 2.70 36 7.00
6 3.00 37 7.00
7 3.00 38 7.31
8 3.60 39 7.31
9 4.00 40 7.31
10 4.00 41 7.61
11 4.00 42 7.61
12 4.00 43 7.61
13 4.41 44 7.61
14 4.41 45 8.00
15 4.70 46 8.00
16 4.70 47 8.00
17 5.00 48 8.00
18 5.00 49 8.41
19 5.00 50 8.41
20 5.31 51 8.41
21 5.31 52 8.41
22 5.61 53 8.70
23 5.61 54 8.70
245.61 55 8.70
25 6.00 56 8.70
26 6.00 57 9.00
27 6.00 58 9.00
28 6.41 59 9.00
29 6.41 60 9.00
30 6.41 61 9.00
31 6.70 — —
Table E. Multiplication
Factors for Wire Bundles
with Equal Size Wires
This table provides multipli-
cation factors for wire bun-
dles of 1 to 61 wires.
To determine the approxi-
mate diameter of a wire
bundle when the wires are
all the same size, find the
factor for the number of
wires in the bundle and mul-
tiply the wire diameter by
that factor.
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-22
Entry Size (Continued)
14
Cable Jacket Thickness
Calculation
Todetermine the wall thick-
ness of a jacket over a wire
bundle:
1. Use the chartin Figure 1
to determine the unre-
solved recoveryof the
tubing jacket
2. Use the chart in Figure 3
to determine the wall
thickness reduction fac-
tor.
3. Calculate the jacket wall
thickness by multiplying
the fully shrunk wall thick-
ness (as detailed in the
Tubing section — Section
3 — of this catalog)
by the wall thickness
reduction factor.
Step 1. Determine the
Unresolved Recoveryof the
Tubing Jacket.
1. Locate the recovered and
expanded diameters of
the chosen tubing size on
the chartin Figure1.
2. Lay a straight edge
between the two values
and pencil in a straight
line connecting them.
3. Find the wire bundle
diameter on the
Expanded Diameter
scale of the chart in
Figure 1.
4. From the wire bundle
diameter value, draw a
straight horizontal line
across the chart.
5. From the intersection of
the line from step 3 and
the line from step 2, read
down vertically to the
“Unresolved Recovery”
for this combination.
Example (see Figure 2):
Recovered tubing diameter
=10 mm
Expanded tubing diameter
=20 mm
Wire bundle diameter
=13 mm
Unresolved recovery
=50%
0
100
10
1
100
10
1
20 40 60 80 100
Unresolved Recovery (%)
Recovered diameter (mm)
Expanded diameter (mm)
0
100
10
1
100
10
1
20 40 60 80 100
Unresolved Recovery (%)
Recovered diameter (mm)
Expanded diameter (mm)
Figure 1. Figure 2.
6
Adapters
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-23
Entry Size (Continued)
Step 2. Find the Wall
Thickness Reduction Factor.
1. On the Unresolved
Recovery scale of the
chart in Figure 3 above,
find the unresolved
recovery value deter-
mined in Step 1.
2. From the unresolved
recovery value, draw a
straight line across the
chart to the curved line.
3. At the point wherethat
line intersects the chart’s
curved line, read vertical-
ly down to the wall thick-
ness reduction factor.
Example shown:
Unresolved recovery = 50%
Reduction factor = 0.68
Step 3. Calculate the Jacket
Wall Thickness.
Multiply the fully shrunk wall
thickness of the tubing by
the reduction factor.
Example:
=1.45 mm
=0.68
=1.4 x 0.68
=0.99 mm
Note:
If the cable is to be shielded
(screened), an addition must be
made to the wire bundle diameter
for the braid. In the example, 0.8
mm would be added to the wire
bundle diameter for a single layer of
RAY101 (36 AWG) braid to make a
total wire bundle diameter of 13.8
mm.
100
90
80
70
60
50
40
30
20
10
0.4.3 .5 .6 .7 .8 .9 1.0
Wall thickness reduction factor
Unresolved recovery (%)
Figure 3.
Fully shrunk
wall thickness
of tubing
Wall thickness
reduction factor
(from Figure 3)
Jacket wall
thickness
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-24
Entry Size (Continued)
Determining the Entry Size
Once you have the wire
bundle size, you can use
the chart in Figure 4 to
select the entrysize. This
chart shows the minimum
entrysizes for cables from
3to 38 mm [.118 to
1.496 in] in diameter. In
other words, the white
spaces on the chart repre-
sent all of the cable outside
diameters each entry size
will fit.
Follow these steps:
1. Find the cable diameter
on the chart.
2. Note the lowest entrysize
that will fit the cable
diameter
Braided Adapters
The extreme flexibility of the
braid on these adapters
accommodates a large
range of cable diameters. It
is therefore recommended
that the standardentry size
for any given adapter part
number be specified as
indicated on the relevant
data sheet. Nonstandard
entry sizes are available on
special order.
Use the selection chart in
Figure 4 to ensure that the
standard entry size will pass
over the jacketed cable
diameter.
Tinel-Lock Adapters
With Tinel-Lock adapters,
the cable braid must be
opened up to fit onto the
outside diameter of the
adapter entry. For optimum
performance, select the
smallest entrysize that will
pass over the jacketed
cable diameter. Repair of
the connector will be easier
using the boot and shield
rollback if a slightly larger
than minimum entry size is
used.
The selection chart in
Figure4shows the mini-
mum entry sizes for cable
diameters in the range of
3mm to 38 mm. This will
ensure that the jacketed
cable passes through the
adapter for easy assembly.
It should be checked to be
sure the braid will open suf-
ficiently to fit the entrysize
selected and to ensurethat
the braid and boot can be
rolled back.
Figure 4. Entry Size by Cable Outside Diameter (in millimeters)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
04
05
06
07
08
10
12
14
16
18
20
22
24
Cable outside diameter (mm)
Figure 5. Cable outside diameter (in mm)
Entry size
6
Adapters
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-25
Entry Size (Continued)
Tyco Electronics manufac-
tures a range of Raychem
tubular braided shields
(sometimes called “screens”)
that are used for shielding
hand-built harnesses.
These braids are specially
designed to have:
nGood surface transfer
impedance
nLarge opening ratio
nGood handling character-
istics
nCompatibility with
Tinel-Lock adapters
Sizes are available to cover
wire bundle diameters from
2.5 to 38 [.10 to 1.50]. The
table below shows the wire
bundle diameter range for
each braid size and also
shows which adapter entry
sizes are compatible with
each of these braids and
bundle diameters.
The entry sizes do not allow
for the additional thickness
of the braid and the heat-
shrunk cable jacket.
Ray 101 Tinned-Copper
Braid
Ray 101 Data Number Number Individual Wire Bundle Diameter Range Tinel Adapter
Part of of Ends/ Strand Size Wall Thickness Entry Size
No. Carriers Carrier (mm/AWG) Min. Max. (Nom.) (Single-Layer Braid)
RAY 101-3.0 16 10 0.1 [38] 2.5 [.10] 5.0 [.20] N/A N/A
RAY 101-4.0 24 7 0.13 [36] 3.5 [.14] 7.5 [.30] 0.4 [.02] 04*
RAY 101-6.0 24 9 0.13 [36] 4.0 [.16] 9.5 [.37] 0.4 [.02] 04, 05, 06*, 07
RAY 101-7.5 24 14 0.13 [36] 6.0 [.24] 14.0 [.55] 0.4 [.02] 05, 06, 07, 10*
RAY 101-10.0 36 12 0.13 [36] 8.0 [.31] 22.0 [.87] 0.4 [.02] 07, 08, 10 12*
RAY 101-12.5 36 15 0.13 [36] 10.0 [.39] 24.0 [.94] 0.4 [.02] 08, 10, 12,14, 16*
RAY 101-20.0 48 16 0.13 (36] 16.0 [.63] 38.0 [1.50] 0.4 [.02] 12, 14, 16, 18, 20, 22
*Combination is not preferred; use only if absolutely necessary.
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Adapter Selection
6-26
Tinel-Lock Ring
Tinel-Lock Ring and Braid
The Tinel-Lock ring desig-
nator must be specified
according to the type of
cable braid used, and is
added to the part number
after the adapter entry size.
There are two types of
ring, AI and BI, for each
entry size.
Tinel rings are marked with
thermochromic paint, which
changes color when the
correct installation tempera-
ture is reached. BI-type
rings are identified with a
red spot.
Braid type, material, and
construction are variable.
If in doubt, contact
Tyco Electronics for advice.
Ring Area
Tinel Ring
1.8 [.071]
Nom.
Thermochromic
Paint
Boot Groove
Spin Nut
Braid Type Ring Designator
Single layer 36 AWG AI
Single layer 34 AWG AI
Single layer 32 AWG BI
Single layer 30 AWG BI
Double layer 36 AWG BI
Double layer 34 AWG BI
A or B = Size of Braid I = Insulating Layer
Table F.
Wire Gauge (AWG) to
Diameter Cross-Reference
Use this table to establish wire
gauge if not known.
Wire Gauge Diameter
(AWG)
40 0.079 [0.0031]
39 0.089 [0.0035]
38 0.102 [0.0040]
37 0.114 [0.0045]
36 0.127 [0.0050]
35 0.142 [0.0056]
34 0.160 [0.0063]
33 0.180 [0.0071]
32 0.203 [0.0080]
31 0.226 [0.0089]
30 0.254 [0.0100]
29 0.287 [0.0113]
28 0.320 [0.0126]
*Note: It may be necessary to use an ‘A’ rather than a ‘B” ring on entry sizes
04-07 when terminating a multicore cable with double layer machined braid.
Braid applied by machine provides less size flexibility than pull-on braid at the
smaller entry sizes. If disturbance during assembly causes loss of braid lay,
grip of the tinel ring may be affected. Evaluation is recommended. Contact
Tyco Electronics for more information.
Available in: Americas Europe Asia Pacific
nnn
Adapter Selection
CRES-Lock Bands
6-27
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
The CRES-Lock (Americas
and Asia)/BND (Europe)
band strap designator must
be specified when using a
band adapter. There are
two forms of band that are
available — precoiled
and straight. Straight is
astandardconfiguration
and does not require any
notation. If precoiled bands
are required, an option P
must be used. Refer to
CH00-0250-016 drawing for
more detailed information.
CRES-Lock band strap
comes in 12 inch length
and BND band strap comes
in 14 inch length. These fit
all entrysizes for both the
CRES-Lock and BND
adapter.
Use the band strap desig-
nation A in Americas and
Asia and B for Europe.
Clamping Band — Straight
Notes:
1. The band is constructed from 300 Series passivated stainless steel and is designed to be installed with
either a hand or electric banding tool. Contact Tyco Electronics for further information.
2. The band will be permanently marked with code identification number and full part number
(e.g. 06090-BND-1225S).
Part Number Entry SIzes A Ref. ±1.5 [±0.06]
BND-1225S 03 to 24 305.0
12.00
BND-1425S 03 to 34 362.0
14.25
8.4
[0.33] Ref.
2.5
[0.10] Ref. 6.6
[0.26] Ref.
ARef.
.5
[0.02] Ref.
6.4
[0.25] Max.
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 18 MIL-C-5015 (MS3100)
6-28 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Braided Adapters
29.7 Max. [6.00] Min.
Z Dia.
Tinned
Copper
Shield
Y Dia.
[1.17] 152.4
Manufacturer Connector Manufacturer
Code MS3100/3101/3106
AAmphenol-Class A
B Bendix-Class A/E/R
C Cannon-Class A/E/R
D* Unknown-Class A/E/R
R Amphenol-Class R
— Manufacturer code not required
*Additional pieces supplied when manufacturer is unknown.
All thread sizes for order number apply.
218M7XX-XXXXX
[6.00] Min.
Z Dia.
Tinned
Copper
Shield
Y Dia.
C
D
152.4
218M8XX-XXXXX
152.4 Min.
Tinned
Copper
Shield
Y Dia.
W
ZDia.
E
[6.00]
218M9XX-XXXXX
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-29
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Braided Adapters
(continued)
Entry Dimensions
Size ZDia. +0.25–0.5 Y Dia. ±0.38 W Max.
04 6.35 [0.250] 11.58 [0.456] 31.2 [1.23]
05 7.92 [0.312] 13.08 [0.515] 32.8 [1.29]
06 9.53 [0.375] 14.76 [0.581] 34.3 [1.35]
07 11.13 [0.438] 16.33 [0.643] 36.1 [1.42]
08 12.70 [0.500] 17.91 [0.705] 37.6 [1.48]
10 15.88 [0.625] 21.11 [0.831] 40.6 [1.60]
12 19.05 [0.750] 24.21 [0.953] 43.9 [1.73]
14 22.23 [0.875] 27.46 [1.081] 47.0 [1.85]
16 25.40 [1.000] 30.61 [1.205] 50.8 [2.00]
18 28.58 [1.125] 35.08 [1.381] 54.1 [2.13]
20 31.75 [1.250] 38.25 [1.506] 57.2 [2.25]
22 34.93 [1.375] 41.43 [1.631] —
24 38.10 [1.500] 44.60 [1.756] —
Order Shell Manufacturer Max. Entry Dimensions
No. Size Code Size, Type 1** Thread CMax. D Max. E Max.
08 8S B 04 .375-32 UNEF 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S C 04 .438-28 UNEF 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S A, R 04 .438-27 UNS 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S D 04 See * above. 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
10 10S — 06 .500-28 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
11 10SL C 07 .562-24 UNEF 21.1 [0.83] 24.1 [0.83] 31.2 [1.23]
11 10SL A, B, R 07 .625-24 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
11 10SL D 07 See * above. 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
12 12 & 12S B, C 08 .625-24 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
12 12 & 12S A, R 08 .688-24 UNEF 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
12 12 & 12S D 08 See * above. 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
14 14 & 14S — 10 .750-20 UNEF 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
16 16 & 16S — 12 .875-20 UNEF 22.6 [0.89] 25.9 [1.02] 36.1 [1.42]
18 18 — 12 1.000-20 UNEF 23.4 [0.92] 26.7 [1.05] 37.6 [1.48]
20 20 A, B, C 16 1.125-18 UNEF 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
20 20 R 16 1.125-24 UNS 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
20 20 D 16 See * above. 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
2222 — 18 1.250-18 UNEF 24.9 [0.98] 28.2 [1.11] 40.9 [1.61]
24 24 — 20 1.375-18 UNEF 24.9 [0.98] 28.2 [1.11] 42.4 [1.67]
28 28 — 24 1.625-18 UNEF 27.4 [1.08] 29.7 [1.17] 47.2 [1.86]
32 32 B, C 24 1.875-16 UN 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
32 32 A, R 24 1.906-18 UN 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
32 32 D 24 See * above. 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
36 36 B 24 2.062-16 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 R 24 2.062-20 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 C 24 2.125-16 UN 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 A 24 2.125-18 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 D 24 See * above. 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
40 40 B 24 2.312-16 UNS 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
40 40 A, C, R 24 2.375-16 UN 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
40 40 D 24 See * above. 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
44 44 – 24 2.625-16 UN 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 C 24 2.812-18 UNS 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 A, R 24 2.875-16 UN 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 D24 See * above. 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
**For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Table of Dimensions
Entry Size Dimensions
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-30 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
ZDia. Y Dia.
Min.
Max.
27.9
[1.10]
[.130]
3.30
Manufacturer Connector Manufacturer
Code MS3100/3101/3106
AAmphenol-Class A
BBendix-Class A/E/R
CCannon-Class A/E/R
D* Unknown-Class A/E/R
RAmphenol-Class R
—Manufacturer code not required
*Additional pieces supplied when manufacturer is unknown.
All thread sizes for order number apply.
218M6XX-XXX
Order Shell Manufacturer Dimensions
No. Size Code Thread Y±0.5 Z Min.
08 8S B .375–32 UNEF 13.2 [0.52] 6.22 [0.24]
088S C .438–28 UNEF 13.2 [0.52] 7.80 [0.31]
08 8SA, R .438–27 UNS 13.2 [0.52] 7.80 [0.31]
08 8SDSee * above. 13.2 [0.52] 7.80 [0.31]
10 10S — .500–28 UNEF 15.0 [0.59] 9.40 [0.37]
11 10SL C .562–24 UNEF 15.0 [0.59] 11.00 [0.43]
11 10SL A, B, R .625–24 UNEF 19.3 [0.76] 12.57 [0.49]
11 10SL D See * above. 19.3 [0.76] 11.00 [0.43]
12 12 & 12S B, C .625–24 UNEF 19.3 [0.76] 12.57 [0.49]
12 12 & 12S A, R .688–24 UNEF 19.3 [0.76] 14.15 [0.56]
12 12 & 12S D See * above. 19.3 [0.76] 12.57 [0.49]
14 14 & 14S — .750–20 UNEF 20.9 [0.82] 15.75 [0.62]
16 16 & 16S — .875–20 UNEF 24.1 [0.95] 18.92 [0.74]
18 18 — 1.000 - 20 UNEF 26.1 [1.03] 20.50 [0.81]
20 20 A, B, C 1.125–18 UNEF 34.0 [1.34] 25.27 [0.99]
20 20 R 1.125–24 UNS 34.0 [1.34] 25.27 [0.99]
20 20 D See * above. 34.0 [1.34] 25.27 [0.99]
22 22 — 1.250–18 UNEF 36.3 [1.43] 28.45 [1.12]
24 24 — 1.375–18 UNEF 40.5 [1.59] 31.62 [1.24]
28 28 — 1.625–18 UNEF 43.0 [1.69] 34.80 [1.37]
32 32 B, C 1.875–16 UN 48.4 [1.91] 41.15 [1.62]
32 32 A, R 1.906–18 UN 48.4 [1.91] 41.15 [1.62]
32 32 D See * above. 48.4 [1.91] 41.15 [1.62]
36 36 B 2.062–16 UNS 54.7 [2.15] 47.50 [1.87]
36 36 R 2.062–20 UNS 54.7 [2.15] 47.50 [1.87]
36 36 C 2.125–16 UN 54.7 [2.15] 47.50 [1.87]
36 36 A 2.125–18 UNS 54.7 [2.15] 47.50 [1.87]
36 36 D See * above. 54.7 [2.15] 47.50 [1.87]
40 40 B 2.312–16 UNS 60.6 [2.39] 53.85 [2.12]
40 40 A, C, R 2.375–16 UN 60.6 [2.39] 53.85 [2.12]
40 40 D See * above. 60.6 [2.39] 53.85 [2.12]
44 44 – 2.625–16 UN 67.1 [2.64] 60.20 [2.37]
48 48 C 2.812–18 UNS 73.5 [2.89] 66.55 [2.62]
48 48 A, R 2.875–16 UN 73.5 [2.89] 66.55 [2.62]
48 48 D See * above. 73.5 [2.89] 66.55 [2.62]
Solid Adapters
Table of Dimensions
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-31
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Solid Adapters
(continued)
Molded Part Selection Guide
(Solid) Standard K Parts Low-Profile D Parts
YDiameter Straight 90° Cable OD Straight 90° Cable OD
Part No. Part No. (min.) Part No. Part No. (Min.)
13.2 [0.52] 202W232 — 4.3 [0.19] — — —
13.2 [0.52] 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
15.0 [0.59] 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
19.2 [0.76] 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
20.9 [0.82] 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
24.1 [0.95] 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
26.1 [1.03] 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
34.0 [1.34] 202K163 222K163 9.9 [0.33] 202D253 222D253 10.4 [0.41]
36.2 [1.43] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
40.5 [1.59] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
43.0 [1.69] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
48.4 [1.91] 202K185 222K185 16.8 [0.66] 202D274 222D274 14.3 [0.56]
54.7 [2.15] 202K185 222K185 16.8 [0.66] 202D274 222D274 14.3 [0.56]
60.6 [2.39] — — — 202D285 222D285 17.5 [0.68]
67.1 [2.64] — — — 202D296 222D296 19.6 [0.76]
73.5 [2.89] — — — 202D299 222D299 22.9 [0.89]
YPart Cable OD
Diameter No. (Min.)
13.2 [0.52] 202C611 4.8 [0.19]
15.0 [0.59] 202C621 8.1 [0.32]
19.3 [0.76] 202C621 8.1 [0.32]
20.9 [0.82] 202C632 12.7 [0.50]
24.1 [0.95] 202C632 12.7 [0.50]
26.1 [1.03] 202C642 17.5 [0.69]
34.0 [1.34] 202C653 22.4 [0.88]
36.3 [1.43] 202C653 22.4 [0.88]
40.5 [1.59] 202C653 22.4 [0.88]
43.0 [1.69] 202C663 22.9 [0.90]
48.4 [1.91] 202C663 22.9 [0.90]
54.7 [2.15] 202C663 22.9 [0.90]
60.6 [2.39] 202C663 22.9 [0.90]
67.1 [2.64] 202C663 22.9 [0.90]
73.5 [2.89] 202C663 22.9 [0.90]
Uniboot Parts
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-32 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Z
Min.
Max.
Y
Thread [1.098]
27.9
10.4
[.409]
Manufacturer Connector Manufacturer
Code MS3100/3101/3106
A Amphenol-Class A
B Bendix-Class A/E/R
C Cannon-Class A/E/R
D* Unknown-Class A/E/R
R Amphenol-Class R
— Manufacturer code not required
*Additional pieces supplied when manufacturer is unknown.
All thread sizes for order number apply.
218M6XX-XXX
Order Shell Manufacturer Dimensions
No. Size Code Thread Y±0.5 Z Min.
08 8S B .375–32 UNEF 13.2 [0.52] 6.22 [0.24]
088S C .438–28 UNEF 13.2 [0.52] 7.80 [0.31]
08 8SA, R .438–27 UNS 13.2 [0.52] 7.80 [0.31]
08 8SDSee * above. 13.2 [0.52] 7.80 [0.31]
10 10S — .500–28 UNEF 15.0 [0.59] 9.40 [0.37]
11 10SL C .562–24 UNEF 15.0 [0.59] 11.00 [0.43]
11 10SL A, B, R .625–24 UNEF 19.3 [0.76] 12.57 [0.49]
11 10SL D See * above. 19.3 [0.76] 11.00 [0.43]
12 12 & 12S B, C .625–24 UNEF 19.3 [0.76] 12.57 [0.49]
12 12 & 12S A, R .688–24 UNEF 19.3 [0.76] 14.15 [0.56]
12 12 & 12S D See * above. 19.3 [0.76] 12.57 [0.49]
14 14 & 14S — .750–20 UNEF 20.9 [0.82] 15.75 [0.62]
16 16 & 16S — .875–20 UNEF 24.1 [0.95] 18.92 [0.74]
18 18 — 1.000 - 20 UNEF 26.1 [1.03] 20.50 [0.81]
20 20 A, B, C 1.125–18 UNEF 34.0 [1.34] 25.27 [0.99]
20 20 R 1.125–24 UNS 34.0 [1.34] 25.27 [0.99]
20 20 D See * above. 34.0 [1.34] 25.27 [0.99]
22 22 — 1.250–18 UNEF 36.3 [1.43] 28.45 [1.12]
24 24 — 1.375–18 UNEF 40.5 [1.59] 31.62 [1.24]
28 28 — 1.625–18 UNEF 43.0 [1.69] 34.80 [1.37]
32 32 B, C 1.875–16 UN 48.4 [1.91] 41.15 [1.62]
32 32 A, R 1.906–18 UN 48.4 [1.91] 41.15 [1.62]
32 32 D See * above. 48.4 [1.91] 41.15 [1.62]
36 36 B 2.062–16 UNS 54.7 [2.15] 47.50 [1.87]
36 36 R 2.062–20 UNS 54.7 [2.15] 47.50 [1.87]
36 36 C 2.125–16 UN 54.7 [2.15] 47.50 [1.87]
36 36 A 2.125–18 UNS 54.7 [2.15] 47.50 [1.87]
36 36 D See * above. 54.7 [2.15] 47.50 [1.87]
40 40 B 2.312–16 UNS 60.6 [2.39] 53.85 [2.12]
40 40 A, C, R 2.375–16 UN 60.6 [2.39] 53.85 [2.12]
40 40 D See * above 60.6 [2.39] 53.85 [2.12]
44 44 – 2.625–16 UN 67.1 [2.64] 60.20 [2.37]
48 48 C 2.812–18 UNS 73.5 [2.89] 66.55 [2.62]
48 48 A, R 2.875–16 UN 73.5 [2.89] 66.55 [2.62]
48 48 D See * above 73.5 [2.89] 66.55 [2.62]
Table of Dimensions
Spin-Coupling Adapters
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-33
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Molded Part Selection Guide
(Spin-Coupling) Standard K Parts Low-Profile D Parts
YDiameter Straight 90° Cable OD Straight 90° Cable OD
Part No. Part No. (Min.) Part No. Part No. (Min.)
13.2 [0.52] 202W232 4.3 [0.19]
13.2 [0.52] 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
15.0 [0.59] 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
19.2 [0.76] 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
20.9 [0.82] 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
24.1 [0.95] 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
26.1 [1.03] 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
34.0 [1.34] 202K163 222K163 9.9 [0.33] 202D253 222D253 10.4 [0.41]
36.2 [1.43] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
40.5 [1.59] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
43.0 [1.69] 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
48.4 [1.91] 202K185 222K185 16.8 [0.66] 202D274 222D274 14.3 [0.56]
54.7 [2.15] 202K185 222K185 16.8 [0.66] 202D274 222D274 14.3 [0.56]
YPart Cable OD
Diameter No. (Min.)
13.2 [0.52] 202C611 4.8 [0.19]
15.0 [0.59] 202C621 8.1 [0.32]
19.3 [0.76] 202C621 8.1 [0.32]
20.9 [0.82] 202C632 12.7 [0.50]
24.1 [0.95] 202C632 12.7 [0.50]
26.1 [1.03] 202C642 17.5 [0.69]
34.0 [1.34] 202C653 22.4 [0.88]
36.3 [1.43] 202C653 22.4 [0.88]
40.5 [1.59] 202C653 22.4 [0.88]
43.0 [1.69] 202C663 22.9 [0.90]
48.4 [1.91] 202C663 22.9 [0.90]
54.7 [2.15] 202C663 22.9 [0.90]
Uniboot Parts
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-34 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tinel-Lock Adapters
Max.
Thread
13.0 Min.
ZSY
29.7
[1.169]
[.512]
Manufacturer Connector Manufacturer
Code MS3100/3101/3106
AAmphenol-Class A
B Bendix-Class A/E/R
CCannon-Class A/E/R
D* Unknown-Class A/E/R
R Amphenol-Class R
—Manufacturer code not required
*Additional pieces supplied when manufacturer is unknown.
All thread sizes for order number apply.
TXR18XX00-XXXXXX
Thread C Max.
D Max.
Min.
ZSY
13.0
[.512]
TXR18XX45-XXXXXX
Thread WMax.
Min.
E Max.
Z
S
Y
13.0
[.512]
TXR18XX90-XXXXXX
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-35
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Order Shell Manufacturer Max. Entry Dimensions
No. Size Code Size, Type 1** Thread CMax. D Max. E Max.
08 8S B 04 .375-32 UNEF 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S C 04 .438-28 UNEF 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S A, R 04 .438-27 UNS 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
08 8S D 04 * 20.3 [0.80] 23.4 [0.92] 31.2 [1.23]
10 10S — 06 .500-28 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
11 10SL C 07 .562-24 UNEF 21.1 [0.83] 24.1 [0.83] 31.2 [1.23]
11 10SL A, B, R 07 .625-24 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
11 10SL D 07 * 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
12 12 & 12S B, C 08 .625-24 UNEF 21.1 [0.83] 24.1 [0.95] 31.2 [1.23]
12 12 & 12S A, R 08 .688-24 UNEF 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
12 12 & 12S D 08 * 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
14 14 & 14S — 10 .750-20 UNEF 21.8 [0.86] 24.9 [0.98] 33.0 [1.30]
16 16 & 16S — 12 .875-20 UNEF 22.6 [0.89] 25.9 [1.02] 36.1 [1.42]
18 18 — 12 1.000-20 UNEF 23.4 [0.92] 26.7 [1.05] 37.6 [1.48]
2020 A,B, C 16 1.125-18 UNEF 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
20 20 R 16 1.125-24 UNS 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
20 20 D 16 * 24.1 [0.95] 27.4 [1.08] 39.4 [1.55]
22 22 — 18 1.250-18 UNEF 24.9 [0.98] 28.2 [1.11] 40.9 [1.61]
24 24 — 20 1.375-18 UNEF 24.9 [0.98] 28.2 [1.11] 42.4 [1.67]
28 28 — 24 1.625-18 UNEF 27.4 [1.08] 29.7 [1.17] 47.2 [1.86]
32 32 B, C 24 1.875-16 UN 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
32 32 A, R 24 1.906-18 UN 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
32 32 D 24 * 28.2 [1.11] 31.2 [1.23] 48.8 [1.92]
36 36 B 24 2.062-16 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 R 24 2.062-20 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 C 24 2.125-16 UN 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 A 24 2.125-18 UNS 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
36 36 D 24 * 31.2 [1.23] 32.3 [1.27] 52.1 [2.05]
40 40 B 24 2.312-16 UNS 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
40 40 A, C, R 24 2.375-16 UN 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
40 40 D 24 * 32.3 [1.27] 33.0 [1.30] 55.1 [2.17]
44 44 — 24 2.625-16 UN 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 C 24 2.812-18 UNS 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 A, R 24 2.875-16 UN 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
48 48 D 24 * 34.0 [1.34] 34.5 [1.36] 61.5 [2.42]
*Additional pieces, etc. (from page 6-36)
**For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied.
Contact Tyco Electronics for information.
Table of Dimensions
Tinel-Lock Adapters
(continued)
Adapter Products
Code 18 MIL-C-5015 (MS3100) (Continued)
6-36 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
Entry Size Part No. Part No. (min.) Part No. Part No. (Min.)
04 202K232 — 3.30 [0.13] — — —
04 202W232 — 4.30 [0.19] — — —
04 202K121 222K121 5.60 [0.22] 202D211 222D211 6.40 [0.25]
05, 06 202K132 222K132 5.90 [0.23] 202D221 222D221 7.40 [0.29]
07, 08 202K142 222K142 7.10 [0.28] 202D232 222D232 8.40 [0.33]
10, 12 202K153 222K152 8.40 [0.33] 202D242 222D242 9.70 [0.38]
14, 16 202K163 222K163 9.90 [0.39] 202D253 222D253 10.50 [0.41]
18, 20, 22 202K174 222K174 15.70 [0.62] 202D263 222D263 12.20 [0.48]
24 202K185 222K185 16.80 [0.66] — — —
Molded Part Selection Guide
(Tinel)
Tinel-Lock Part Cable OD
EntrySize No. (min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
Uniboot Parts
Tinel-Lock Adapters
(continued)
Entry Dimensions
Size ZDia. +0.25–0.5 S Diameter (min.–max.) Y Dia. ±0.38 W Max.
04 6.35 [0.25] 9.39–9.56 [0.37–0.38] 13.97 [0.55] 31.50 [1.24]
05 7.92 [0.31] 10.97–11.13 [0.43–0.44] 15.54 [0.61] 34.30 [1.35]
06 9.52 [0.37] 12.57–12.73 [0.49–0.50] 17.14 [0.67] 35.80 [1.41]
07 11.09 [0.44] 14.12–14.31 [0.55–0.56] 18.71 [0.74] 37.30 [1.47]
08 12.70 [0.50] 15.72–15.91 [0.62–0.63] 20.32 [0.80] 39.10 [1.54]
10 15.87 [0.62] 18.84–19.11 [0.74–0.75] 23.49 [0.92] 41.40 [1.63]
12 19.05 [0.75] 22.02–22.28 [0.87–0.88] 26.67 [1.05] 45.50 [1.79]
14 22.23 [0.88] 25.17–25.46 [0.99–1.00] 29.84 [1.17] 48.80 [1.92]
16 25.40 [1.00] 28.34–28.63 [1.12–1.13] 33.02 [1.30] 51.80 [2.04]
18 28.57 [1.12] 31.52–31.81 [1.24–1.25] 36.19 [1.42] 54.90 [2.16]
20 31.75 [1.25] 34.69–34.98 [1.37–1.38] 39.37 [1.55] 58.20 [2.29]
22 34.93 [1.38] 37.79–38.15 [1.49–1.50] 42.55 [1.68] 66.80 [2.63]
24 38.10 [1.50] 40.97–41.33 [1.61–1.63] 45.72 [1.80] 70.10 [2.76]
Entry Size Dimensions
Order Shell Max. Entry Dimensions
No. Size Size, Type 1* Thread CMax. DMax. E Max.
08 8 04 .438-28 UNEF 21.6 [0.85] 23.1 [0.91] 29.0 [1.14]
10 10 06 .562-24 UNEF 22.4 [0.88] 23.9 [0.94] 30.5 [1.20]
12 12 08 .688-24 UNEF 23.1 [0.91] 24.6 [0.97] 32.3 [1.27]
14 14 10 .812-20 UNEF 23.4 [0.92] 24.9 [0.98] 33.5 [1.32]
16 16 12 .938-20 UNEF 24.1 [0.95] 25.7 [1.01] 34.8 [1.37]
18 18 12 1.062-18 UNEF 24.4 [0.96] 25.9 [1.02] 36.3 [1.43]
20 20 14 1.188-18 UNEF 25.1 [0.99] 26.7 [1.05] 38.1 [1.50]
22 22 16 1.312-18 UNEF 25.7 [1.01] 27.4 [1.08] 39.6 [1.56]
24 24 18 1.438-18 UNEF 26.2 [1.03] 27.7 [1.09] 40.9 [1.61]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Entry Dimensions
Size Z +0.25–0.5 Y Dia. W Max.
04 6.35 [0.25] 13.97 [0.55] 31.0 [1.22]
05 7.92 [0.31] 15.54 [0.61] 32.8 [1.29]
06 9.52 [0.37] 17.14 [0.67] 34.3 [1.35]
07 11.09 [0.44] 18.71 [0.74] 35.8 [1.41]
08 12.70 [0.50] 20.32 [0.80] 37.3 [1.47]
10 15.87 [0.62] 23.49 [0.92] 40.6 [1.60]
12 19.05 [0.75] 26.67 [1.05] 43.7 [1.72]
14 22.23 [0.88] 29.84 [1.17] 47.0 [1.85]
16 25.40 [1.00] 33.02 [1.30] 50.0 [1.97]
18 28.57 [1.12] 36.19 [1.42] 53.3 [2.10]
Table of Dimensions
Entry Size Dimensions
Z Dia. Tinned
Copper
Shield
Y Dia.
Max.
30.5 Max.
152.4
[6.00]
[1.20]
206M0XX-XXXXX
D
Z Dia.
Tinned
Copper
Shield
Y Dia.
C
152.4
[6.00]
Min.
W
E
Z Dia.
Tinned
Copper
Shield
Y Dia.
Min.
[6.00]
152.4
206M1XX-XXXXX
206M2XX-XXXXX
Braided Adapters
Adapter Products
Code 21 MIL-C-26482 Series 1
6-37
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-38 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
08 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
10 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
12, 14 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
16, 18 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
20, 22, 24 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
Molded Part Selection Guide
(Solid)
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C621 8.1 [0.32]
10 202C632 12.7 [0.50]
12, 14 202C642 17.5 [0.69]
16, 18, 20, 22, 24 202C653 22.4 [0.88]
Solid Adapters
Table of Dimensions
Z Dia. Y Dia.
15.8
[0.62]
Max.
203M6XX-XXX
Dimensions
Order Shell Thread Y +0.000-0.030
Number Size (+0.00) (-0.76) Dia. ZMin.
08 8 .438-28 UNEF 17.88 [0.704] 6.63 [0.26]
10 10 .562-24 UNEF 21.06 [0.829] 9.27 [0.36]
12 12 .688-24 UNEF 24.23 [0.954] 12.98 [0.51]
14 14.812-20 UNEF 27.41 [1.079] 15.37 [0.61]
16 16 .938-20 UNEF 31.85 [1.254] 18.54 [0.73]
18 18 1.062-18 UNEF 33.03 [1.316] 20.90 [0.82]
20 20 1.188-18 UNEF 36.63 [1.442] 24.10 [0.95]
22 22 1.312-18 UNEF 39.78 [1.566] 27.28 [1.07]
24 24 1.438-18 UNEF 42.98 [1.692] 29.67 [1.17]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Spin-Coupling Adapters
ZY
Thread
10.4
[.409] Min.
30.15
[1.187]Max.
203M9XX-XXX
Order Shell Dimensions
No. Size Thread Y+0.00–0.76 Dia. ZMin.
08 8 .438-28 UNEF 13.54 [0.53] 6.63 [0.26]
10 10 .562-24 UNEF 15.37 [0.61] 9.27 [0.36]
12 12 .688-24 UNEF 19.66 [0.77] 12.98 [0.51]
14 14 .812-20 UNEF 21.29 [0.84] 15.37 [0.61]
16 16 .938-20 UNEF 24.46 [0.96] 18.54 [0.73]
18 18 1.062-18 UNEF 26.47 [1.04] 20.90 [0.82]
20 20 1.188-18 UNEF 30.91 [1.22] 24.10 [0.95]
22 22 1.312-18 UNEF 34.42 [1.36] 27.28 [1.07]
24 24 1.438-18 UNEF 36.65 [1.44] 29.67 [1.17]
Table of Dimensions
Standard K Parts Low-profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
08 202W232 — 4.3 [0.19] — — —
08 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
10 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
12, 14 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
16, 18 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
20, 22 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
24 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
Molded Part Selection Guide
(Spin-Coupling)
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C611 4.8 [0.19]
10, 12 202C621 8.1 [0.32]
14, 16 202C632 12.7 [0.50]
18, 20 202C642 17.5 [0.69]
22, 24 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-40 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Max.
Thread
Z
Min.
SY
[1.201]
30.5
13.0
[.512]
Thread C Max.
D Max.
Min.
ZSY
13.0
[.512]
W Max.
E Max.
Thread
Min.
Z
S
Y
13.0
[.512]
TXR21XX00-XXXX XX
TXR21XX45-XXXXXX
TXR21XX90-XXXXXX
Tinel-Lock Adapters
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-41
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Order Shell Max. Entry Dimensions
No. Size Size, Type 1* Thread CMax. D Max. E Max.
08 8 04 .438-28 UNEF 21.6 [0.85] 23.1 [0.91] 29.0 [1.14]
10 10 06 .562-24 UNEF 22.4 [0.88] 23.9 [0.94] 30.5 [1.20]
12 12 08 .688-24 UNEF 23.1 [0.91] 24.6 [0.97] 32.3 [1.27]
14 14 10 .812-20 UNEF 23.4 [0.92] 24.9 [0.98] 33.5 [1.32]
16 16 12 .938-20 UNEF 24.1 [0.95] 25.7 [1.01] 34.8 [1.37]
18 18 12 1.062-18 UNEF 24.4 [0.96] 25.9 [1.02] 36.3 [1.43]
20 20 14 1.188-18 UNEF 25.1 [0.99] 26.7 [1.05] 38.1 [1.50]
22 22 16 1.312-18 UNEF 25.7 [1.01] 27.4 [1.08] 39.6 [1.56]
24 24 18 1.438-18 UNEF 26.2 [1.03] 27.7 [1.09] 40.9 [1.61]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Table of Dimensions
Entry Dimensions
Size Z +0.25–0.5 SDiameter(Min.–Max.) YDia. W Max.
04 6.35 [0.25] 9.39–9.56 [0.37–0.38] 13.97 [0.55] 31.0 [1.22]
05 7.92 [0.31] 10.97–11.13 [0.43–0.44] 15.54 [0.61] 32.8 [1.29]
06 9.52 [0.37] 12.57–12.73 [0.49–0.50] 17.14 [0.67] 34.3 [1.35]
07 11.09 [0.44] 14.12–14.31 [0.55–0.56] 18.71 [0.74] 35.8 [1.41]
08 12.7 [0.50] 15.72–15.91 [0.62–0.63] 20.32 [0.80] 37.3 [1.47]
10 15.87 [0.62] 18.84–19.11[0.74–0.75] 23.49 [0.92] 40.6 [1.60]
12 19.05 [0.75] 22.02–22.28 [0.87–0.88] 26.67 [1.05] 43.7 [1.72]
14 22.23 [0.88] 25.17–25.46 [0.99–1.00] 29.84 [1.17] 47.0 [1.85]
16 25.4 [1.00] 28.34–28.63 [1.12–1.13] 33.02 [1.30] 50.0 [1.97]
18 28.57 [1.12] 31.52–31.81 [1.24–1.25] 36.19 [1.42] 53.3 [2.10]
Entry Size Dimensions
Standard K Parts Low-profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
Entry Size Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] ———
Molded Part Selection Guide
(Tinel)
Uniboot Parts Tinel-Lock Part Cable OD
Entry Size No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Tinel-Lock Adapters
(continued)
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-42 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRES-Lock Adapters (USA)
BND Adapters (Europe)
Code 21 Band Strap
Adapter
Notes:
1. This product is designed to
terminate a braided cable shield
bymeans of a band strap and a
heat shrinkable lipped boot to
aconnector.
2. See CH00-0250-016 for ordering
information, modifications and
additional dimensions.
3. See drawing BND-XX25S for band
strap dimensions and information.
4.Adapter to be permanently
marked with code identification
number and full part number (e.g.
06090-BND21AB00-1812). Band
strap shall bear no part marking.
5.All entry sizes are shown in Table
II. Maximum entry sizes are as
shown in Table I. For larger entry
sizes than the maximum, a Type II
adapter may be supplied. See
CH00-0250-016 for further details.
6. Adapter mates to: MIL-C-26482
Series I, MS3110, MS3116,
MS3120 and MS3126 Class E
and F Connectors.
7. Anti-rotational set screw, 3
threaded holes 120° ± 5° apart,
single mating set screw supplied:
AN565DC4H2. Not required for
Type II adapters.
For additional codes available, contact
Tyco Electronics.
Ø B Max.
Typ. ØAThd.
Typ.
34.5
[1.36] Max.
ØZ
Typ. ØS
Typ. ØY
Typ.
16.5
[0.65]
Max.
Typ.
C
Max.
D
Max.
Straight Adapter
Code 00
45° Adapter
Code 45
16.0
[0.63]
Max.
Ø A Thd.
Typ.
ØBMax.
Typ.
Type II Modification
(See Note 5)
E
Max.
C
F
Max.
90° Adapter
Code 90
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 21 MIL-C-26482 Series 1(Continued)
6-43
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
CRES-Lock Adapters (USA)
BND Adapters (Europe)
(continued)
Code 21 Band Strap
Adapter (Continued)
Table I
Order Shell Entry Size Ø A Unified ØBC D F
Number Size2Max. Thread UNEF Max. Max. Max. Max.
Type I1Class 2B
08 08 04 0.4375–28 18.3 21.6 27.2 33.0
0.72 0.85 1.07 1.30
10 10 06 0.5625–24 21.6 22.4 27.9 34.5
0.85 0.88 1.10 1.36
12 12 08 0.6875–24 24.9 23.1 28.7 36.3
0.98 0.91 1.13 1.43
14 14 10 0.8125–20 28.2 23.4 29.0 37.6
1.11 0.92 1.14 1.48
16 16 12 0.9375–20 31.2 24.1 29.7 38.9
1.23 0.95 1.17 1.53
18 18 13 1.0625–18 34.5 24.4 30.0 40.4
1.36 0.96 1.18 1.59
20 20 15 1.1875–18 37.6 25.1 30.7 42.2
1.48 0.99 1.21 1.66
22 22 16 1.3125–18 40.6 25.7 31.5 43.7
1.60 1.01 1.24 1.72
24 24 18 1.4375–18 43.2 26.2 31.8 45.0
1.70 1.03 1.25 1.77
1.All entry sizes are shown in Table II. Maximum entry sizes are as shown in Table I. For larger entry sizes than the
maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details.
2. Adapter mates to: MIL-C-26482 Series I, MS3110, MS3116, MS3120 and MS3126 Class E and F Connectors.
Table II
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
03 4.75 7.92 11.10 19.0
0.188 0.312 0.438 0.75
04 6.35 9.52 12.70 19.8
0.250 0.375 0.500 0.78
05 7.92 11.12 14.30 20.1
0.312 0.438 0.563 0.79
06 9.52 12.70 15.88 21.1
0.375 0.500 0.625 0.83
07 11.12 14.30 17.50 21.6
0.438 0.562 0.689 0.85
08 12.70 15.88 19.05 22.6
0.500 0.625 0.750 0.89
09 14.30 17.50 20.65 23.6
0.562 0.688 0.813 0.93
10 15.88 19.05 22.23 24.4
0.625 0.750 0.875 0.96
11 17.50 20.65 23.80 24.9
0.688 0.812 0.938 0.98
12 19.05 22.23 25.40 25.9
0.750 0.875 1.000 1.02
13 20.65 23.83 27.00 26.7
0.812 0.938 1.063 1.05
14 22.23 25.40 30.16 27.4
0.875 1.000 1.189 1.08
Table II (Continued)
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
15 23.83 27.00 31.75 28.2
.0938 1.062 1.250 1.11
16 25.40 28.58 33.34 29.0
1.000 1.125 1.313 1.14
18 28.58 31.75 36.51 30.5
1.125 1.250 1.438 1.20
20 31.75 34.90 39.69 N/A
1.250 1.375 1.563
22 34.90 38.10 42.86 N/A
1.375 1.500 1.688
24 38.10 41.28 46.83 N/A
1.500 1.625 1.844
26 41.28 44.45 49.61 N/A
1.625 1.750 1.953
28 44.45 47.63 52.78 N/A
1.750 1.875 2.078
30 47.65 50.80 56.36 N/A
1.875 2.000 2.219
32 50.80 54.00 59.53 N/A
2.000 2.125 2.344
34 54.00 57.15 62.71 N/A
2.125 2.250 2.469
Adapter Products
Code 32 MIL-C-22992
6-44 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
207M3XX-XXXXX
212M4XX-XXXXX
212M5XX-XXXXX
A Thd. Typ.
O-ring
Silicone Typ.
Z Dia.
Y Dia.
Tinned
Copper
Shield
Min.
152.4
Max.
43.2
[1.70] [6.00]
ZDia.
D
Tinned
Copper
Shield
Y Dia.
C
152.4 Min.
[6.00]
W
E
Z Dia.
Y Dia.
A Thd. Typ.
152.4 Min.
[6.00]
Braided Adapters
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 32 MIL-C-22992 (Continued)
6-45
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Order Shell Max. Entry A Left Hand Thd. Dimensions
No. Size Size, Type 1* Class 2B CMax. D Max. E Max
12 12 08 .750-20 UNEF 29.0 [1.14] 25.4 [1.00] 33.5 [1.32]
14 14 10 .875-20 UNEF 29.7 [1.17] 25.9 [1.02] 35.3 [1.39]
16 16 12 1.000-20 UNEF 30.0 [1.18] 26.2 [1.03] 37.1 [1.46]
18 18 14 1.125-18 UNEF 30.7 [1.21] 26.9 [1.06] 38.6 [1.52]
20 20 16 1.250-18 UNEF 31.2 [1.23] 27.7 [1.09] 40.1 [1.58]
22 22 18 1.375-18 UNEF 32.0 [1.26] 28.2 [1.11] 41.7 [1.64]
24 24 22 1.625-18 UNEF 33.5 [1.32] 30.0 [1.18] 46.5 [1.83]
28 28 24 1.875-16 UN 34.8 [1.37] 31.2 [1.23] 49.8 [1.96]
32 32 28 2.062-16 UNS 36.3 [1.43] 32.5 [1.28] 52.8 [2.08]
36 36 28 2.312-16 UNS 37.6 [1.48] 33.8 [1.33] 56.1 [2.21]
40 40 28 2.625-16 UN 38.9 [1.53] 35.3 [1.39] 58.9 [2.32]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied.
Contact Tyco Electronics for information.
Table of Dimensions
Entry Dimensions
Size Z ± 0.20 (± 0.51) Y Dia. Min. W Max.
03 4.75 [.187] 9.98 [.393] 39.6 [1.56]
04 6.35 [.250] 11.58 [.456] 39.6 [1.56]
05 7.92 [.312] 13.08 [.515] 42.9 [1.69]
06 9.53 [.375] 14.76 [.581] 42.9 [1.69]
07 11.13 [.438] 16.33 [.643] 46.0 [1.81]
08 12.70 [.500] 17.91 [.705] —
09 14.27 [.562] 17.91 [.705] 49.3 [1.94]
10 15.88 [.625] 21.11 [.831] 49.3 [1.94]
11 17.48 [.688] 22.68 [.893] 52.3 [2.06]
12 19.05 [.750] 24.21 [.953] 52.3 [2.06]
13 20.62 [.812] 24.21 [.953] 55.6 [2.19]
14 22.23 [.875] 27.46 [1.081] 55.6 [2.19]
15 23.83 [.938] 29.03 [1.143] 59.9 [2.36]
16 25.40 [1.000] 30.61 [1.205] 59.9 [2.36]
18 28.58 [1.125] 35.08 [1.381] 69.6 [2.74]
20 31.75 [1.250] 38.25 [1.506] 72.6 [2.86]
22 34.93 [1.375] 41.43 [1.631] 75.9 [2.99]
24 38.10 [1.500] 44.60 [1.756] 79.0 [3.11]
28 44.45 [1.750] 50.90 [2.004] 85.3 [3.36]
Entry Size Dimensions
Braided Adapters
(continued)
Adapter Products
Code 32 MIL-C-22992 (Continued)
6-46 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Spin-Coupling Adapters
[1.450]
Z Dia. Y Dia.
+.000
.145 - .015
+0.00
3.70 - 0.40
A
Thread
36.83 Max.
Base Dimensions
Part Shell AYZ
Number Size L.H. Thread Class 2B ± .020 (±0.51) Min.
12 12 .750-20 UNEF 20.24 [.797] 12.47 [.491]
14 14 .875-20 UNEF 23.44 [.923] 14.35 [.565]
16 16 1.000-20 UNEF 26.42 [1.040] 17.53 [.690]
18 18 1.125-18 UNEF 31.17 [1.227] 18.19 [.716]
20 20 1.250-18 UNEF 34.49 [1.358] 21.72 [.855]
22 22 1.375-18 UNEF 37.21 [1.465] 25.02 [.985]
24 24 1.625-18 UNEF 42.82 [1.686] 30.48 [1.200]
28 28 1.875-16 UN 50.06 [1.971] 36.58 [1.440]
32 32 2.062-16 UNS 55.35 [2.179] 40.77 [1.605]
36 36 2.312-16 UNEF 61.01 [2.402] 52.96 [2.085]
40 40 2.625-16 UNS 67.46 [2.656] 57.15 [2.250]
44 44 2.875-16 UNS 70.66 [2.782] 62.46 [2.549]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied.
Contact Tyco Electronics for information.
Table of Dimensions
204M3XX-XXX
Molded Part Size Selection
Guide (Spin-Coupling) Standard K Parts Low-profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
12 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
14, 16 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
18, 20 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
22, 24 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
26, 32, 36 202K185 222K185 16.8 [0.66] — — —
Uniboot Parts Order Part Cable OD
No. No. (Min.)
12 202C632 12.7 [0.50]
14, 16 202C642 17.5 [0.69]
18, 20, 22, 24 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 32 MIL-C-22992 (Continued)
6-47
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Tinel-Lock Adapters
TXR32XX00-XXXXXX
TXR32XX90-XXXXXX
TXR32XX45-XXXXXX
O-Ring Silicone Typ.
A Thd. Typ.
B Dia.
Typ.. Z Dia.
Typ.. S Dia.
Typ.. Y Dia.
Typ..
Tinel-Lock Ring
38.1 Max.
[1.50]
C
D
W
E
Dimensions
Order Shell Max. Entry A C D E ZSYW
No. Size Size Type I Left Hand Thd Max. Max. Max. + .010 Dia. ± .015 Max.
Class 2B -.020 (± 0.38)
12 12 08 .750-20 UNEF 29.0 [1.14] 25.4 [1.00] 33.5 [1.32] 19.05 [.750] 22.28 [.877] 26.67 [1.050] 52.3 [2.06]
22.02 [.867]
14 14 10 .875-20 UNEF 29.7 [1.17] 25.9 [1.02] 35.3 [1.39] 22.23 [.875] 25.46 [1.002] 29.84 [1.175] 55.6 [2.19]
25.17 [.991]
16 16 12 1.000-20 UNEF 30.0 [1.18] 26.2 [1.03] 37.1 [1.46] 25.40 [1.000] 28.63 [1.127] 33.02 [1.300] 59.01 [2.36]
28.34 [1.116]
18 18 14 1.125-18 UNEF 30.7 [1.21] 26.9 [1.06] 38.6 [1.52] 28.57 [1.125] 31.81 [1.252] 36.19 [1.425] 69.6 [2.74]
31.52 [1.241]
20 20 16 1.250-18 UNEF 31.2 [1.23] 27.7 [1.09] 40.1 [1.58] 31.75 [1.250] 34.98 [1.377] 39..37 [1.550] 72.6 [2.86]
34.69 [1.366]
22 22 18 1.375-18 UNEF 32.0 [1.26] 28.2 [1.11] 41.7 [1.64] 34.93 [1.375] 38.15 [1.502] 42.55 [1.675] 75.9 [2.99]
37.79 [1.488]
24 24 22 1.625-18 UNEF 33.5 [1.32] 30.0 [1.18] 46.5 [1.83] 38.10 [1.500] 41.33 [1.627] 45.72 [1.800] 79.0 [3.11]
40.97 [1.613]
28 28 24 1.875-16 UN 34.8 [1.37] 31.2 [1.23] 49.8 [1.96] — — — —
32 32 24 2.062-16 UNS 36.3 [1.43] 32.5 [1.28] 52.8 [2.08] — — — —
36 36 24 2.312-16 UNS 37.6 [1.48] 33.8 [1.33] 56.1 [2.21] — — — —
40 40 24 2.625-16 UN 38.9 [1.53] 35.3 [1.39] 58.9 [2.32] — — — —
**For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for information.
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 32 MIL-C-22992 (Continued)
6-48 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRES-Lock Adapters (USA)
BND Adapters (Europe)
Code 32 Band Strap
Adapter
Notes:
1. This product is designed to
terminate a braided cable shield
bymeans of a band strap and a
heat shrinkable lipped boot to
aconnector.
2. See CH00-0250-016 for ordering
information, modifications and
additional dimensions.
3. See drawing BND-XX25S for band
strap dimensions and information.
4.Adapter to be permanently
marked with code identification
number and full part number (e.g.
06090-BND32AB00-1812). Band
strap shall bear no part marking.
5.All entry sizes are shown in Table
II. Maximum entry sizes are as
shown in Table I. For larger entry
sizes than the maximum, a Type II
adapter may be supplied. See
CH00-0250-016 for further details.
6. Adapter mates to: MIL-C-22992,
Class C and R, MS17343, 44, 45
and 47 Connectors.
7. Anti-rotational set screw, 3
threaded holes 120° ± 5° apart,
single mating set screw supplied:
AN565DC4H2. Not required for
Type II adapters.
For additional codes available, contact
Tyco Electronics.
Ø B Max.
Typ. ØAThd.
Typ.
41.2
[1.62] Max.
ØZ
Typ. ØS
Typ. ØY
Typ.
16.5
[0.65]
Max.
Typ.
C
Max.
D
Max.
Straight Adapter
Code 00
45° Adapter
Code 45
24.1
[0.95]
Max.
Ø A Thd.
Typ.
ØBMax.
Typ.
Type II Modification
(See Note 5)
E
Max.
F
Max.
90° Adapter
Code 90
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 32 MIL-C-22992 (Continued)
6-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
CRES-Lock Adapters (USA)
BND Adapters (Europe)
(continued)
Code 32 Band Strap
Adapter (Continued)
Table I
Order Shell Entry Size Ø A ØBC D F
Number Size2Max. Unified Thread Max. Max. Max. Max.
Type I1Class 2B
12 12 08 0.7500–20 UNEF 27.2 29.0 28.4 36.6
1.07 1.14 1.12 1.44
14 14 10 0.8750–20 UNEF 30.2 29.7 28.9 38.4
1.19 1.17 1.14 1.51
16 16 12 1.0000–20 UNEF 33.5 30.0 29.2 40.1
1.32 1.18 1.15 1.58
18 18 14 1.1250–18 UNEF 36.6 30.7 30.0 41.7
1.44 1.21 1.18 1.64
20 20 16 1.2500–18 UNEF 39.9 31.2 30.7 43.2
1.57 1.23 1.21 1.70
22 22 18 1.3750–18 UNEF 42.9 32.0 31.2 44.7
1.69 1.26 1.23 1.76
24 24 22 1.6250–18 UNEF 52.6 33.5 33.0 49.5
2.07 1.32 1.30 1.95
28 28 26 1.8750–16 UN 58.9 34.8 34.3 52.8
2.32 1.37 1.35 2.08
32 32 30 2.0625–16 UNS 65.3 36.3 35.6 55.9
2.57 1.43 1.40 2.20
36 36 34 2.3125–16 UNS 71.6 37.6 36.8 59.2
2.82 1.48 1.45 2.33
40 40 34 2.6250–16 UN 78.0 38.9 38.4 62.0
3.07 1.53 1.51 2.44
1. All entry sizes are shown in Table II. Maximum entry sizes are as shown in Table I. For larger entry sizes than the
maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details.
2. Adapter mates to: MIL-C-22992, Class C and R, MS17343, 44, 45 and 47 Connectors.
Table II
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
03 4.75 7.92 11.10 28.3
0.188 0.312 0.438 1.12
04 6.35 9.52 12.70 29.3
0.250 0.375 0.500 1.15
05 7.92 11.12 14.30 30.0
0.312 0.438 0.563 1.18
06 9.52 12.70 15.88 30.8
0.375 0.500 0.625 1.21
07 11.12 14.30 17.50 31.5
0.438 0.562 0.689 1.24
08 12.70 15.88 19.05 32.3
0.500 0.625 0.750 1.27
09 14.30 17.50 20.65 33.3
0.562 0.688 0.813 1.31
10 15.88 19.05 22.23 34.0
0.625 0.750 0.875 1.34
1117.50 20.65 23.80 35.0
0.688 0.812 0.938 1.38
12 19.05 22.23 25.40 35.8
0.750 0.875 1.000 1.41
13 20.65 23.83 27.00 36.0
0.812 0.938 1.063 1.42
14 22.23 25.40 30.16 37.5
0.875 1.000 1.189 1.48
Table II (Continued)
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
15 23.83 27.00 31.75 37.8
.0938 1.062 1.250 1.49
16 25.40 28.58 33.34 38.3
1.000 1.125 1.313 1.51
18 28.58 31.75 36.51 39.8
1.125 1.250 1.438 1.57
20 31.75 34.90 39.69 41.3
1.250 1.375 1.563 1.63
22 34.90 38.10 42.86 43.0
1.375 1.500 1.688 1.69
24 38.10 41.28 46.83 44.5
1.500 1.625 1.844 1.75
26 41.28 44.45 49.61 46.3
1.625 1.750 1.953 1.82
28 44.45 47.63 52.78 48.3
1.750 1.875 2.078 1.90
30 47.65 50.80 56.36 50.0
1.875 2.000 2.219 1.97
32 50.80 54.00 59.53 51.5
2.000 2.125 2.344 2.03
34 54.00 57.15 62.71 53.3
2.125 2.250 2.469 2.10
Adapter Products
Code 40 MIL-C-38999 Series III and IV
6-50 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
208M7XX-XXXXX
208M8XX-XXXXX
208M9XX-XXXXX
Z Dia.
YDia.
C
D
Y Dia.
Z Dia.
W
Z Dia.
152.4
[6.00] Min.
E
Y Dia.
Table of Dimensions
Braided Adapters
Order Shell Size Max. Entry* Dimensions
No. Commercial Military Size Type 1 Thread CMax. D Max. E Max.
08 9 A 04 M12 x 1.0 20.8 [0.82] 22.6 [0.89] 29.2 [1.15]
10 11 B 07 M15 x 1.0 21.3 [0.84] 23.4 [0.92] 30.7 [1.21]
12 13 C 09 M18 x 1.0 22.1 [0.87] 24.1 [0.95] 32.5 [1.28]
14 15 D 10 M2 x 1.0 22.6 [0.89] 24.1 [0.95] 34.0 [1.34]
16 17 E 12 M25 x 1.0 23.4 [0.92] 24.9 [0.98] 35.6 [1.40]
18 19F14 M28 x 1.0 24.1 [0.95] 25.7 [1.01] 37.1 [1.46]
20 21 G 16 M31 x 1.0 24.6 [0.97] 26.4 [1.04] 38.9 [1.53]
22 23 H 18 M34 x 1.0 25.4 [1.00] 27.2 [1.07] 40.4 [1.59]
24 25 J 20 M37 x 1.0 25.9 [1.02] 27.2 [1.07] 42.4 [1.67]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Entry Dimensions
Size Z +0.25–0.5 Y Dia. W Max.
04 6.35 [0.25] 13.97 [0.55] 31.2 [1.23]
05 7.92 [0.31] 15.54 [0.61] 32.8 [1.29]
06 9.52 [0.37] 17.14 [0.67] 34.3 [1.35]
07 11.09 [0.44] 18.71 [0.74] 36.1 [1.42]
08 12.7 [0.50] 20.32 [0.80] 37.6 [1.48]
10 15.87 [0.62] 23.49 [0.92] 40.6 [1.60]
12 19.05 [0.75] 26.67 [1.05] 43.9 [1.73]
14 22.23 [0.88] 29.84 [1.17] 47.0 [1.85]
16 25.4 [1.00] 33.02 [1.30] 50.8 [2.00]
18 28.57 [1.12] 36.19 [1.42] 54.1 [2.13]
20 31.75 [1.25] 39.37 [1.55] 57.21 [2.25]
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
Entry Size Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Entry Size Dimensions
Molded Part Selection Guide
(Braided)
Uniboot Parts Tinel- Lock Part Cable OD
Entry Size No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Braided Adapters
(continued)
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-52 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Solid Adapters
Z Dia. Y Dia.
A
Thread
209M3XX-XXX
Table of Dimensions
Molded Part Selection Guide
(Solid)
Dimensions
Order Shell Size Military AY+.000- .030 Z Dia.
No. Commercial Thread (+0.00) (–0.76) Min.
08 9 A M12 x 1.0 18.26 [.719] 6.35 [.250]
10 11 B M15 x 1.0 21.44 [.844] 9.52 [.375]
12 13 C M18 x 1.0 24.61 [.969] 12.70 [.500]
14 15 D M22 x 1.0 30.91 [1.217] 15.88 [.625]
16 17 E M25 x 1.0 34.40 [1.354] 19.05 [.750]
18 19 F M28 x 1.0 37.50 [1.476] 20.62 [.812]
20 21 G M31 x 1.0 38.89 [1.531] 23.80 [.937]
22 23 H M34 x 1.0 42.06 [1.656] 26.97 [1.062]
24 25 J M37 x 1.0 45.24 [1.781] 30.18 [1.188]
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
08 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
10 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
12, 14 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
16, 18 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
20, 22, 24 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C621 8.1 [0.32]
10 202C632 12.7 [0.50]
12, 14 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Spin-Coupling Adapters
209M4XX-XXX
Z
10.4
[0.40]
Max.
Y
Thread [.710]
18.03
Min.
Table of Dimensions
Molded Part Selection Guide
(Spin-Coupling)
Order Shell Size Dimensions
No. Commercial Military Thread YDia. Max. Z Dia. Max.
08 9 A M12 x 1.0 13.54 [0.53] 6.35 [0.25]
10 11 B M15 x 1.0 15.37 [0.61] 9.52 [0.37]
1213 C M18 x 1.0 19.66 [0.77] 12.7 [0.50]
14 15 D M22 x 1.0 21.29 [0.84] 15.75 [0.62]
16 17 E M25 x 1.0 24.46 [0.96] 18.92 [0.74]
18 19 F M28 x 1.0 26.47 [1.04] 20.62 [0.81]
20 21 G M31 x 1.0 30.91 [1.22] 23.8 [0.94]
22 23 H M34 x 1.0 34.42 [1.36] 26.97 [1.06]
24 25 J M37 x 1.0 36.65 [1.44] 29.85 [1.18]
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
03, 08 202W232 — 4.3 [0.19] — — —
03, 08 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
10, 11 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
12, 14 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
16, 18 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
20, 22 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
24, 28 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
32, 36 202K185 222K185 16.8 [0.66] — — —
Uniboot Parts Order Part Cable OD
No. No. (Min.)
03, 08 202C611 4.8 [0.19]
10, 11, 12 202C621 8.1 [0.32]
14, 16 202C632 12.7 [0.50]
18, 20 202C642 17.5 [0.69]
22, 24 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-54 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tinel-Lock Adapters
Max.
Thread
Z
Min.
SY
[1.059]
26.9
13.0
[.512]
Thread C Max.
D Max.
Min.
ZSY
13.0
[.512]
W Max.
E Max.
Thread
Min.
Z
S
Y
[.512]
13.0
TXR40XX00-XXXXXX
TXR40XX45-XXXXXX
TXR40XX90-XXXXXX
Order Shell Size Max. Entry* Dimensions
No. Commercial Military Size Type 1 Thread CMax. D Max. E Max.
08 9A04 M12 x 1.0 20.8 [0.82] 22.6 [0.89] 27.9 [1.10]
10 11 B 07 M15 x 1.0 21.3 [0.84] 23.4 [0.92] 30.5 [1.20]
12 13 C 08 M18 x 1.0 22.1 [0.87] 24.1 [0.95] 32.0 [1.26]
14 15 D 10 M2 x 1.0 22.6 [0.89] 24.1 [0.95] 34.0 [1.34]
16 17 E 12 M25 x 1.0 23.4 [0.92] 24.9 [0.98] 35.6 [1.40]
18 19 F 14 M28 x 1.0 24.1 [0.95] 25.7 [1.01] 36.8 [1.45]
20 21 G 16 M31 x 1.0 24.6 [0.97] 26.4 [1.04] 38.4 [1.51]
22 23 H 18 M34 x 1.0 25.4 [1.00] 27.2 [1.07] 39.9 [1.57]
24 25 J 20 M37 x 1.0 25.9 [1.02] 27.2 [1.07] 42.4 [1.67]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Table of Dimensions
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Entry Size Dimensions
Molded Part Selection Guide
(Tinel)
Uniboot Parts Tinel-Lock Part Cable OD
Entry Size No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Entry Dimensions
Size Z +0.25–0.5 S Diameter (Min.–Max.) Y Dia. W Max.
04 6.35 [0.25] 9.39–9.56 [0.37–0.38] 13.97 [0.55] 31.2 [1.23]
05 7.92 [0.31] 10.97–11.13 [0.43–0.44] 15.54 [0.61] 32.8 [1.29]
06 9.52 [0.37] 12.57–12.73 [0.49–0.50] 17.14 [0.67] 34.3 [1.35]
07 11.09 [0.44] 14.12–14.31 [0.55–0.56] 18.71 [0.74] 36.1 [1.42]
08 12.7 [0.50] 15.72–15.91 [0.62–0.63] 20.32 [0.80] 37.6 [1.48]
10 15.87 [0.62] 18.84–19.11 [0.74–0.75] 23.49 [0.92] 40.6 [1.60]
12 19.05 [0.75] 22.02–22.28 [0.87–0.88] 26.67 [1.05] 43.9 [1.73]
14 22.23 [0.88] 25.17–25.46 [0.99–1.00] 29.84 [1.17] 47.0 [1.85]
1625.4 [1.00] 28.34–28.63 [1.12–1.13] 33.02 [1.30] 50.8 [2.00]
18 28.57 [1.12] 31.52–31.81 [1.24–1.25] 36.19 [1.42] 54.1 [2.13]
20 31.75 [1.25] 34.69–34.98 [1.37–1.38] 39.37 [1.55] 57.21 [2.25]
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
EntrySize Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Tinel-Lock Adapters
(continued)
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-56 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRES-Lock Adapters (USA)
BND Adapters (Europe)
Code 40 Band Strap
Adapter
Notes:
1. This product is designed to
terminate a braided cable shield
bymeans of a band strap and a
heat shrinkable lipped boot to
aconnector.
2. See CH00-0250-016 for ordering
information, modifications and
additional dimensions.
3. See drawing BND-XX25S for band
strap dimensions and information.
4.Adapter to be permanently
marked with code identification
number and full part number (e.g.
06090-BND40AB00-1814). Band
strap shall bear no part marking.
5.All entry sizes are shown in Table
II. Maximum entry sizes are as
shown in Table I. For larger entry
sizes than the maximum, a Type II
adapter may be supplied. See
CH00-0250-016 for further details.
6. Adapter mates to: MIL-C-38999
Series III and IV,Class C, F, K
and W,D38999/20, /24, /26, /40,
/46 and /47 Connectors. When so
mated it shall provide a water-
tight seal meeting the require-
ments of MIL-C-85049, paragraph
3.5.7.
7. Coupling nut shall have 3 lock
wire holes 120° apart.
For additional codes available, contact
Tyco Electronics.
Ø B Max.
Typ. ØAThd.
Typ.
31.0
[1.22] Max.
ØZ
Typ. ØS
Typ. ØY
Typ.
16.5
[0.65]
Max.
Typ.
C
Max.
D
Max.
Straight Adapter
Code 00
45° Adapter
Code 45
16.5
[0.65]
Ø A Thd.
Typ.
ØBMax.
Typ.
Max.
Type II Modification
(See Note 5)
E
Max.
F
Max.
90° Adapter
Code 90
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 40 MIL-C-38999 Series III and IV (Continued)
6-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
CRES-Lock Adapters (USA)
BND Adapters (Europe)
(continued)
Code 40 Band Strap
Adapter (Continued)
Table I
Order Shell Entry Size Ø A ØBØ B C D F
Number Size2Max. Metric Thread Max. Max.3Max. Max. Max.
Com. MIL Type I1Class 2B
89 A 04 M12 x 1.0 19.1 24.6 20.8 26.7 32.0
0.75 0.97 0.82 1.05 1.26
10 11 B 07 M15 x 1.0 21.6 27.0 21.3 27.4 34.5
0.85 1.06 0.84 1.08 1.36
12 13 C 09 M18 x 1.0 25.4 31.0 22.1 28.2 36.1
1.00 1.22 0.87 1.11 1.42
14 15 D 10 M22 x 1.0 29.2 35.8 22.6 28.2 38.1
1.15 1.41 0.89 1.11 1.50
16 17 E 12 M25 x 1.0 31.8 37.3 23.4 29.0 39.6
1.25 1.47 0.92 1.14 1.56
18 19 F 14 M28 x 1.0 35.6 40.6 24.1 29.7 40.9
1.40 1.60 0.95 1.17 1.61
20 21 G 16 M31 x 1.0 38.1 44.5 24.6 30.5 42.4
1.50 1.75 0.97 1.20 1.67
22 23 H 18 M34 x 1.0 41.9 47.0 25.4 31.3 43.9
1.65 1.85 1.00 1.23 1.73
24 25 J 20 M37 x 1.0 44.5 51.6 25.9 31.3 46.5
1.75 2.03 1.02 1.23 1.83
1. All entry sizes are shown in Table II. Maximum entry sizes are as shown in Table I. For larger entry sizes than the
maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details.
2.Adapter mates to: MIL-C-38999 Series III and IV, Class C, F, K and W , D38999/20, /24, /26, /40, /46 and /47
Connectors. When so mated it shall provide a water-tight seal meeting the requirements of MIL-C-85049, paragraph
3.5.7.
3. These dimensions apply if a self-locking coupling nut is used, modification code “S”.
Table II
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
03 4.75 7.92 11.10 15.8
0.188 0.312 0.438 0.62
04 6.35 9.52 12.70 16.3
0.250 0.375 0.500 0.64
05 7.92 11.12 14.30 16.8
0.312 0.438 0.563 0.66
06 9.52 12.70 15.88 17.8
0.375 0.500 0.625 0.70
07 11.12 14.30 17.50 18.3
0.438 0.562 0.689 0.72
08 12.70 15.88 19.05 19.8
0.500 0.625 0.750 0.78
09 14.30 17.50 20.65 21.3
0.562 0.688 0.813 0.84
10 15.88 19.05 22.23 22.4
0.625 0.750 0.875 0.88
1117.50 20.65 23.80 22.9
0.688 0.812 0.938 0.90
12 19.05 22.23 25.40 23.4
0.750 0.875 1.000 0.92
13 20.65 23.83 27.00 24.4
0.812 0.938 1.063 0.96
14 22.23 25.40 30.16 25.4
0.875 1.000 1.189 1.00
Table II (Continued)
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
15 23.83 27.00 31.75 25.4
.0938 1.062 1.250 1.00
16 25.40 28.58 33.34 26.4
1.000 1.125 1.313 1.04
18 28.58 31.75 36.51 27.7
1.125 1.250 1.438 1.09
20 31.75 34.90 39.69 29.2
1.250 1.375 1.563 1.15
22 34.90 38.10 42.86 N/A
1.375 1.500 1.688
24 38.10 41.28 46.83 N/A
1.500 1.625 1.844
26 41.28 44.45 49.61 N/A
1.625 1.750 1.953
28 44.45 47.63 52.78 N/A
1.750 1.875 2.078
30 47.65 50.80 56.36 N/A
1.875 2.000 2.219
32 50.80 54.00 59.53 N/A
2.000 2.125 2.344
34 54.00 57.15 62.71 N/A
2.125 2.250 2.469
Adapter Products
Code 41 MIL-C-38999 Series I and II
6-58 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Braided Adapters
Y Dia.
27.2 Max.
[1.07] 152.4 Min.
[6.00]
ZDia.
C
D
Z Dia. [6.00]
152.4 Min.
Y Dia.
[6.00]
152.4 Min.
Y Dia.
Z Dia.
W
E
204M1XX-XXXXX
204M2XX-XXXXX
204M0XX-XXXXX
Table of Dimensions Order Shell Size Max. Entry* A Unified Thread Dimensions
No. Series I Series II Size Type 1 Class 2B CMax. D Max. E Max.
08 9 8 04 .438-28 UNEF 19.8 [0.78] 23.1 [0.91] 29.2 [1.15]
10 11 10 06 .562-24 UNEF 20.3 [0.80] 23.6 [0.93] 30.7 [1.21]
12 13 12 08 .688-24 UNEF 21.1 [0.83] 24.4 [0.96] 32.5 [1.28]
14 15 14 10 .812-20 UNEF 21.6 [0.85] 24.9 [0.98] 34.0 [1.34]
16 17 16 12 .938-20 UNEF 22.4 [0.88] 25.4 [1.00] 35.6 [1.40]
18 19 18 13 1.062-18 UNEF 22.9 [0.90] 26.2 [1.03] 37.1 [1.46]
20 21 20 15 1.188-18 UNEF 23.6 [0.93] 26.9 [1.06] 38.9 [1.53]
22 23 22 16 1.312-18 UNEF 24.4 [0.96] 27.4 [1.08] 40.4 [1.59]
24 25 24 18 1.438-18 UNEF 24.9 [0.98] 28.2 [1.11] 41.9 [1.65]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied.
Contact Tyco Electronics for information.
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 41 MIL-C-38999 Series I and II(Continued)
6-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Entry Size Dimensions Entry Dimensions
Size Z±0.020 (±0.51) Y Dia. Min. W Max.
03 4.75 [.187] 9.98 [.393] 27.2 [1.07]
04 6.35 [.250] 11.58 [.456] 27.2 [1.07]
05 7.92 [.312] 13.08 [.515] 28.7 [1.13]
06 9.53 [.375] 14.76 [.581] 30.2 [1.19]
07 11.13 [.438] 16.33 [.643] 31.8 [1.25]
08 12.70 [.500] 17.91 [.705] 33.5 [1.32]
09 14.27 [.562] 17.91 [.705] 36.6 [1.44]
10 15.88 [.625] 21.11 [.831] 36.6 [1.44]
11 17.48 [.688] 22.68 [.893] 39.9 [1.57]
12 19.05 [.750] 24.21 [.953] 39.9 [1.57]
13 20.62 [.812] 24.21 [.953] 42.9 [1.69]
14 22.23 [.875] 27.46 [1.081] 42.9 [1.69]
15 23.83 [.938] 29.03 [1.143] 46.2 [1.82]
16 25.40 [1.000] 30.61 [1.205] 46.2 [1.82]
18 28.58 [1.125] 35.08 [1.381] 49.3 [1.94]
20 31.75 [1.250] 38.25 [1.506] —
22 34.93 [1.375] 41.43 [1.631] —
24 38.10 [1.500] 44.60 [1.756] —
28 44.45 [1.750] 50.90 [2.004] —
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
Entry Size Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] —— —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Molded Part Selection Guide
(Braided)
Uniboot Parts Order Part Cable OD
No. No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Braided Adapters
(continued)
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-60 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Solid Adapters
202M1XX-XXX
ZY
Table of Dimensions
Molded Part Selection Guide
(Solid)
Dimensions
Order Shell Size Series II Thread Y +0.00-0.30
No. Series I (+0.00) (-0.76) dia. Z min.
08 9 8 .438-28 UNEF 18.26 [.719] 6.71 [.264]
10 11 10 .562-24 UNEF 21.44 [.844] 9.96 [.392]
12 13 12 .688-24 UNEF 24.61 [.969] 12.85 [.506]
14 15 14 .812-20 UNEF 27.79 [1.094] 16.03 [.631]
16 17 16 .938-20 UNEF 32.54 [1.281] 19.20 [.756]
18 19 18 1.062-18 UNEF 35.71 [1.406] 21.44 [.844]
20 21 20 1.188-18 UNEF 38.89 [1.531] 24.64 [.970]
22 23 22 1.312-18 UNEF 42.06 [1.656] 27.79 [1.094]
24 25 24 1.438-18 UNEF 45.24 [1.781] 30.71 [1.209]
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
08 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
10 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
12, 14 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
16, 18 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
20, 22, 24 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C621 8.1 [0.32]
10 202C632 12.7 [0.50]
12, 14 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Spin-Coupling Adapters
202M2XX-XXX
Z
10.4
23.78
Thread
Y
[.936] Max.
Min.
[.409]
Table of Dimensions
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
08 202W232 — 4.3 [0.19] — — —
08 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
10 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
12, 14 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
16, 18 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
20, 22 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
24, 28 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
Molded Part Selection Guide
(Spin-Coupling)
Order Shell Size Dimensions
No. Series I Series II Thread Y+0.00-0.76 Dia. ZMin.
08 9 8 .438-28 UNEF 13.54 [0.53] 6.35 [0.25]
10 11 10 .562-24 UNEF 15.37 [0.61] 9.53 [0.38]
12 1312 .688-24 UNEF 19.66 [0.77] 12.70 [0.50]
14 15 14 .812-20 UNEF 21.29 [0.84] 15.88 [0.63]
16 17 16 .938-20 UNEF 24.46 [0.96] 19.05 [0.75]
18 19 18 1.062-18 UNEF 26.47 [1.04] 20.62 [0.81]
20 21 20 1.188-18 UNEF 30.91 [1.22] 23.80 [0.94]
22 23 22 1.312-18 UNEF 34.42 [1.36] 26.97 [1.06]
24 25 24 1.438-18 UNEF 36.65 [1.44] 30.18 [1.19]
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C611 4.8 [0.19]
10, 12 202C621 8.1 [0.32]
14, 16 202C632 12.7 [0.50]
18, 20 202C642 17.5 [0.69]
22, 24 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-62 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tinel-Lock Adapters
Max.
Thread
13.0
ZSY
[1.059]
26.9
[.512] Min.
Thread C Max.
Min.
ZSY
D Max.
[.512]
13.0
WMax.
EMax.
Thread
13.0
Z
S
Y
[.512] Min.
TXR41XX45-XXXXXX TXR41XX90-XXXXXX
TXR41XX00-XXXXXX
Table of Dimensions Order Shell Size Max. Entry* A Unified Thread Dimensions
No. Series I Series II Size Type 1 Class 2B CMax. DMax. EMax.
08 9 8 — .438-28 UNEF 17.5 [0.69] 23.1 [0.91] 29.2 [1.15]
10 11 10 — .562-24 UNEF 18.3 [0.72] 23.6 [0.93] 30.7 [1.21]
12 13 12 08 .688-24 UNEF 18.8 [0.74] 24.4 [0.96] 32.5 [1.28]
14 15 14 10 .812-20 UNEF 19.3 [0.76] 24.9 [0.98] 34.0 [1.34]
16 17 16 12 .938-20 UNEF 20.1 [0.79] 25.4 [1.00] 35.6 [1.40]
18 19 18 13 1.062-18 UNEF 20.6 [0.81] 26.2 [1.03] 37.1 [1.46]
20 21 20 15 1.188-18 UNEF 21.3 [0.84] 26.9 [1.06] 38.9 [1.53]
22 23 22 16 1.312-18 UNEF 22.1 [0.87] 27.4 [1.08] 40.4 [1.59]
24 25 24 18 1.438-18 UNEF 22.6 [0.89] 28.2 [1.11] 41.9 [1.65]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Entry Size Dimensions
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Molded Part Selection Guide
(Tinel)
Uniboot Parts Order Part Cable OD
No. No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Entry Dimensions
Size Z+0.25–0.5 S Diameter (Min.–Max.) Y ±0.38 W Max.
04 6.35 [0.25] 9.39–9.56 [0.37–0.38] 13.97 [0.55] 27.2 [1.07]
05 7.92 [0.31] 10.97–11.13 [0.43–0.44] 15.54 [0.61] 28.7 [1.13]
06 9.52 [0.37] 12.57–12.73 [0.49–0.50] 17.14 [0.67] 30.2 [1.19]
07 11.09 [0.44] 14.12–14.31 [0.55–0.56] 18.71 [0.74] 31.8 [1.25]
08 12.70 [0.50] 15.72–15.91 [0.62–0.63] 20.32 [0.80] 33.5 [1.32]
10 15.87 [0.62] 18.84–19.11 [0.74–0.75] 23.49 [0.92] 36.6 [1.44]
12 19.05 [0.75] 22.02–22.28 [0.87–0.88] 26.67 [1.05] 39.9 [1.57]
14 22.23 [0.88] 25.17–25.46 [0.99–1.00] 29.84 [1.17] 42.9 [1.69]
16 25.4 [1.00] 28.34–28.63 [1.12–1.13] 33.02 [1.30] 46.2 [1.82]
18 28.57 [1.12] 31.52–31.81 [1.24–1.25] 36.19 [1.42] 49.3 [1.94]
Tinel-Lock Adapters
(continued)
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-64 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRES-Lock Adapters (USA)
BND Adapters (Europe)
Code 41 Band Strap
Adapter
Notes:
1. This product is designed to
terminate a braided cable shield
bymeans of a band strap and a
heat shrinkable lipped boot to
aconnector.
2. See CH00-0250-016 for ordering
information, modifications and
additional dimensions.
3. See drawing BND-XX25S for band
strap dimensions and information.
4.Adapter to be permanently
marked with code identification
number and full part number (e.g.
06090-BND41AB00-1812). Band
strap shall bear no part marking.
5.All entry sizes are shown in Table
II. Maximum entry sizes are as
shown in Table I. For larger entry
sizes than the maximum, a Type II
adapter may be supplied. See
CH00-0250-016 for further details.
6. Adapter mates to: MIL-C-38999
Series I and II, Class E and T,
MS27466, MS27467, MS27468,
MS27472, MS27473, MS27474,
MS27479, MS27480, MS27481,
MS27484, MS27497, MS27652,
MS27653 and MS27656
Connectors.
For additional codes available, contact
Tyco Electronics.
Ø B Max.
Typ. ØAThd.
Typ.
31.0
[1.22] Max.
ØZ
Typ. ØS
Typ. ØY
Typ.
16.5
[0.65]
Max.
Typ.
C
Max.
D
Max.
Straight Adapter
Code 00
45° Adapter
Code 45
17.0
[0.67]
Ø A Thd.
Typ.
ØBMax.
Typ.
Max.
Type II Modification
(See Note 5)
E
Max.
F
Max.
90° Adapter
Code 90
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 41 MIL-C-38999 Series I and II (Continued)
6-65
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
CRES-Lock Adapters (USA)
BND Adapters (Europe)
(continued)
Code 41 Band Strap
Adapter (Continued)
Table I
Shell Size2Entry Size Ø A
Order Series Series Max. Unified Thread ØBØ B C D F
Number III Type I1UNEF Class 2B Max. Max.3Max. Max. Max.
08 9 08 04 0.4375–28 19.1 24.6 17.5 27.2 33.3
0.75 0.97 0.69 1.07 1.31
10 11 10 06 0.5625–24 20.8 27.0 18.3 27.7 34.8
0.85 1.06 0.72 1.09 1.37
12 13 12 08 0.6875–24 25.4 31.0 18.8 28.4 36.6
1.00 1.22 0.74 1.12 1.44
14 15 14 10 0.8125–20 27.2 35.8 19.3 29.0 38.1
1.10 1.41 0.76 1.14 1.50
16 17 16 12 0.9375–20 31.8 37.3 20.1 29.5 39.6
1.25 1.47 0.79 1.16 1.56
18 19 18 13 1.0625–18 35.6 40.6 20.6 30.2 41.1
1.40 1.60 0.81 1.19 1.62
20 21 20 15 1.1875–18 38.1 44.5 21.3 31.0 42.9
1.50 1.75 0.84 1.22 1.69
22 23 22 16 1.3125–18 41.9 46.8 22.1 31.5 44.5
1.65 1.84 0.87 1.24 1.75
24 25 24 18 1.4375–18 44.5 51.6 22.6 32.3 46.0
1.75 2.03 0.89 1.27 1.81
1. All entry sizes are shown in Table II. Maximum entry sizes are as shown in Table I. For larger entry sizes than the
maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details.
2.Adapter mates to: MIL-C-38999 Series I and II, Class E and T, MS27466, MS27467, MS27468, MS27472,
MS27473, MS27474, MS27479, MS27480, MS27481, MS27484, MS27497, MS27652, MS27653 and MS27656
Connectors.
3. These dimensions apply if a self-locking coupling nut is used, modification code “S”.
Table II
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
03 4.75 7.92 11.10 15.3
0.188 0.312 0.438 0.60
04 6.35 9.52 12.70 16.3
0.250 0.375 0.500 0.64
05 7.92 11.12 14.30 16.8
0.312 0.438 0.563 0.66
06 9.52 12.70 15.88 17.8
0.375 0.500 0.625 0.70
07 11.12 14.30 17.50 18.8
0.438 0.562 0.689 0.74
08 12.70 15.88 19.05 19.3
0.500 0.625 0.750 0.76
09 14.30 17.50 20.65 20.3
0.562 0.688 0.813 0.80
10 15.88 19.05 22.23 21.3
0.625 0.750 0.875 0.84
1117.50 20.65 23.80 21.8
0.688 0.812 0.938 0.86
12 19.05 22.23 25.40 22.9
0.750 0.875 1.000 0.90
13 20.65 23.83 27.00 23.8
0.812 0.938 1.063 0.94
14 22.23 25.40 30.16 24.4
0.875 1.000 1.189 0.96
Table II (Continued)
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
15 23.83 27.00 31.75 25.4
.0938 1.062 1.250 1.00
16 25.40 28.58 33.34 25.9
1.000 1.125 1.313 1.02
18 28.58 31.75 36.51 27.4
1.125 1.250 1.438 1.08
20 31.75 34.90 39.69 N/A
1.250 1.375 1.563
22 34.90 38.10 42.86 N/A
1.375 1.500 1.688
24 38.10 41.28 46.83 N/A
1.500 1.625 1.844
26 41.28 44.45 49.61 N/A
1.625 1.750 1.953
28 44.45 47.63 52.78 N/A
1.750 1.875 2.078
30 47.65 50.80 56.36 N/A
1.875 2.000 2.219
32 50.80 54.00 59.53 N/A
2.000 2.125 2.344
34 54.00 57.15 62.71 N/A
2.125 2.250 2.469
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III
6-66 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Braided Adapters
Z Dia.
YDia.
[6.00]
152.4 Min.
C
D
Z Dia.
Y Dia.
[6.00]
152.4 Min.
W
E
Y Dia.
Z Dia.
203M0XX-XXXXX
203M2XX-XXXXX
203M1XX-XXXXX
Order Shell Size Max. EntryDimensions
No. MIL-C-81703 MIL-C-5015 Size Type 1* Thread CMax. D Max. E Max.
03 3 — 04 .562-24 UNEF 19.10 [0.75] 23.10 [0.91] 28.70 [1.13]
08 — 8 & 8S 04 .500-20 UNF 19.10 [0.75] 23.10 [0.91] 27.90 [1.10]
10 — 10, 10S & 10 SL 06 .625-24 UNEF 19.60 [0.77] 23.60 [0.93] 29.50 [1.16]
12 712 & 12S 08 .750-20 UNEF 20.30 [0.80] 24.10 [0.95] 31.00 [1.22]
14 12 14 & 14S 08 .875-20 UNEF 20.80 [0.82] 24.60 [0.97] 32.50 [1.28]
16 19 16 & 16S 10 1.000-20 UNEF 21.30 [0.84] 25.40 [1.00] 34.30 [1.35]
18 27 18 12 1.062-18 UNEF 21.80 [0.86] 25.70 [1.01] 35.60 [1.40]
20 37 20 14 1.188-18 UNEF 22.40 [0.88] 26.40 [1.04] 37.10 [1.46]
22 — 22 16 1.312-18 UNEF 23.10 [0.91] 26.90 [1.06] 38.90 [1.53]
24 — 24 18 1.438-18 UNEF 23.60 [0.93] 27.70 [1.09] 40.40 [1.59]
28 — 28 22 1.750-18 UNS 24.90 [0.98] 29.20 [1.15] 45.20 [1.78]
32 — 32 24 2.000-18 UNS 26.20 [1.03] 30.50 [1.20] 48.30 [1.90]
36 —36 24 2.250-16 UN 27.40 [1.08] 31.80 [1.25] 51.60 [2.03]
40 — 40 24 2.500-16 UN 29.00 [1.14] 33.30 [1.31] 54.60 [2.15]
44 — 44 24 2.750-16 UN 30.20 [1.19] 34.50 [1.36] 57.90 [2.28]
48 —48 24 3.000-16 UN 31.50 [1.24] 35.10 [1.38] 61.00 [2.40]
61 61 — 18 1.500-18 UNEF 23.90 [0.94] 27.90 [1.10] 41.10 [1.62]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Table of Dimensions
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III (Continued)
6-67
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Braided Adapters
(continued)
Entry Size Dimensions
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
EntrySize Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Molded Part Selection Guide
(Braided)
Entry Dimensions
Size Z+0.25–0.5 S Diameter (Min.–Max.) Y ±0.38 W Max.
04 6.35 [0.25] 9.39–9.56 [0.37–0.38] 13.97 [0.55] 28.4 [1.12]
05 7.92 [0.31] 10.97–11.13 [0.43–0.44] 15.54 [0.61] 30.2 [1.19]
06 9.52 [0.37] 12.57–12.73 [0.49–0.50] 17.14 [0.67] 31.8 [1.25]
07 11.09 [0.44] 14.12–14.31 [0.55–0.56] 18.71 [0.74] 33.3 [1.31]
08 12.7 [0.50] 15.72–15.91 [0.62–0.63] 20.32 [0.80] 35.1 [1.38]
10 15.87 [0.62] 18.84–19.11 [0.74–0.75] 23.49 [0.92] 38.1 [1.50]
12 19.05 [0.75] 22.02–22.28 [0.87–0.88] 26.67 [1.05] 41.1 [1.62]
14 22.23 [0.88] 25.17–25.46 [0.99–1.00] 29.84 [1.17] 44.5 [1.75]
16 25.4 [1.00] 28.34–28.63 [1.12–1.13] 33.02 [1.30] 47.8 [1.88]
18 28.57 [1.12] 31.52–31.81 [1.24–1.25] 36.19 [1.42] 50.8 [2.00]
20 31.75 [1.25] 34.69-34.98 [1.37-1.38] 39.37 [1.55] 53.8 [2.12]
22 34.93 [1.38] 37.79-38.15 [1.49-1.50] 42.55 [1.68] 57.2 [2.25]
24 38.1 [1.50] 40.97-41.33 [1.61-1.63] 45.72 [1.80] 60.5 [2.38]
Uniboot Parts Tinel-Lock Part Cable OD
Entry Size No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-68 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Solid Adapters
3.43 ±0.13
[.135 ±.005]
ZY
Table of Dimensions
Molded Part Selection Guide
(Solid)
201M9XX-XXX
Order Shell Size Dimensions
No. MIL-C-81703 MIL-C-5015 Thread Y+0.00-0.51 Dia. Z Dia. Min.
03 3 — .562-24 UNEF 13.54 [0.53] 6.35 [0.25]
08—8&8S .500-20 UNF 13.54 [0.53] 6.35 [0.25]
10 — 10, 10S & 10SL .625-24 UNEF 15.37 [0.61] 9.02 [0.36]
12 7 12 & 12S .750-20 UNEF 19.66 [0.77] 12.47 [0.49]
14 12 14 & 14S .875-20 UNEF 21.29 [0.84] 14.35 [0.56]
16 19 16 & 16S 1.000-20 UNEF 24.46 [0.96] 17.53 [0.69]
18 27 18 1.062-18 UNEF 26.47 [1.04] 19.53 [0.77]
20 37 20 1.188-18 UNEF 30.91 [1.22] 22.71 [0.89]
22 — 22 1.312-18 UNEF 34.42 [1.36] 25.88 [1.02]
24 — 24 1.438-18 UNEF 36.65 [1.44] 28.80 [1.13]
28 — 28 1.750-18 UNS 43.41 [1.71] 34.77 [1.37]
32 — 32 2.000-18 UNS 48.74 [1.92] 41.02 [1.61]
36 — 36 2.250-16 UN 55.09 [2.17] 46.48 [1.83]
40 — 40 2.500-16 UN 61.01 [2.40] 51.94 [2.04]
44 — 44 2.750-16 UN 67.49 [2.66] 58.42 [2.30]
48 — 48 3.000-16 UN 73.84 [2.91] 64.77 [2.55]
61 61 — 1.500-18 UNEF 36.65 [1.44] 29.82 [1.17]
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C621 8.1 [0.32]
7, 10, 12 202C632 12.7 [0.50]
12, 14 202C642 17.5 [0.69]
24, 27, 37, 61 202C653 22.4 [0.88]
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
03 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
10 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
12, 14 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
16, 18, 19, 27 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
20, 22, 24, 28, 37 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
28, 32 202K185 222K185 16.8 [0.66] — — —
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-69
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Z
Min.
26.90
Y
Thread [1.059] Max.
10.40
[.409]
Spin-Coupling Adapters
Table of Dimensions
201M1XX-XXX
Molded Part Selection Guide
(Spin-coupling)
Order Shell Size Dimensions
No. MIL-C-81703 MIL-C-5015 Thread Y+0.00-0.51 Dia. Z Dia. Min.
03 3 — .562-24 UNEF 13.54 [0.53] 6.35 [0.25]
08 — 8 & 8S .500-20 UNF 13.54 [0.53] 6.35 [0.25]
10 — 10, 10S & 10SL .625-24 UNEF 15.37 [0.61] 9.02 [0.36]
12 7 12 & 12S .750-20 UNEF 19.66 [0.77] 12.47 [0.49]
14 12 14 & 14S .875-20 UNEF 21.29 [0.84] 14.35 [0.56]
16 19 16 & 16S 1.000-20 UNEF 24.46 [0.96] 17.53 [0.69]
18 27 18 1.062-18 UNEF 26.47 [1.04] 19.53 [0.77]
20 37 20 1.188-18 UNEF 30.91 [1.22] 22.71 [0.89]
22 — 22 1.312-18 UNEF 34.42 [1.36] 25.88 [1.02]
24 — 24 1.438-18 UNEF 36.65 [1.44] 28.80 [1.13]
28 — 28 1.750-18 UNS 43.41 [1.71] 34.77 [1.37]
32 — 32 2.000-18 UNS 48.74 [1.92] 41.02 [1.61]
36 — 36 2.250-16 UN 55.09 [2.17] 46.48 [1.83]
40 — 40 2.500-16 UN 61.01 [2.40] 51.94 [2.04]
44 — 44 2.750-16 UN 67.49 [2.66] 58.42 [2.30]
48 — 48 3.000-16 UN 73.84 [2.91] 64.77 [2.55]
61 61 — 1.500-18 UNEF 36.65 [1.44] 29.82 [1.17]
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
03, 08 202W232 — 4.3 [0.19] — — —
03, 08 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
10, 11 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
12, 14 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
16, 18 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
20, 22 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
24, 28, 61 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
32, 36 202K185 222K185 16.8 [0.66] — — —
Uniboot Parts Order Part Cable OD
No. No. (Min.)
08 202C621 8.1 [0.32]
7, 10, 12 202C632 12.7 [0.50]
12, 14 202C642 17.5 [0.69]
24, 27, 37, 61 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-70 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Max.
Thread
Min.
ZSY
27.9
[1.098]
13.0
[.512]
Thread C Max.
D Max.
Min.
ZSY
13.0
[.512]
WMax.
E Max.
Thread
Min.
Z
S
Y
13.0
[.512]
TXR54XX00-XXXXXX
TXR54XX45-XXXXXX
TXR54XX90-XXXXXX
Tinel-Lock Adapters
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-71
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Table of Dimensions
Entry Dimensions
Size Z +0.25–0.5 S Diameter (Min.–Max.) Y ±0.38 W Max.
04 6.35 [0.25] 9.39—9.56 [0.37—0.38] 13.97 [0.55] 28.4 [1.12]
05 7.92 [0.31] 10.97—11.13 [0.43—0.44] 15.54 [0.61] 30.2 [1.19]
06 9.52 [0.37] 12.57—12.73 [0.49—0.50] 17.14 [0.67] 31.8 [1.25]
07 11.09 [0.44] 14.12—14.31 [0.55—0.56] 18.71 [0.74] 33.3 [1.31]
08 12.70 [0.50] 15.72—15.91 [0.62—0.63] 20.32 [0.80] 35.1 [1.38]
10 15.87 [0.62] 18.84—19.11 [0.74—0.75] 23.49 [0.92] 38.1 [1.50]
12 19.05 [0.75] 22.02—22.28 [0.87—0.88] 26.67 [1.05] 41.1 [1.62]
14 22.23 [0.88] 25.17—25.46 [0.99—1.00] 29.84 [1.17] 44.5 [1.75]
16 25.40 [1.00] 28.34—28.63 [1.12—1.13] 33.02 [1.30] 47.8 [1.88]
18 28.57 [1.12] 31.52—31.81 [1.24—1.25] 36.19 [1.42] 50.8 [2.00]
20 31.75 [1.25] 34.69-34.98 [1.37-1.38] 39.37 [1.55] 53.8 [2.12]
22 34.93 [1.38] 37.79-38.15 [1.49-1.50] 42.55 [1.68] 57.2 [2.25]
24 38.10 [1.50] 40.97-41.33 [1.61-1.63] 45.72 [1.80] 60.5 [2.38]
EntrySize Dimensions
Order Shell Size Max. Entry Dimensions
No. MIL-C-81703 MIL-C-5015 Size Type 1* Thread C Max. D Max. E Max.
03 3 — 04 .562-24 UNEF 19.10 [0.75] 23.10 [0.91] 28.70 [1.13]
08 — 8 & 8S 04 .500-20 UNF 19.10 [0.75] 23.10 [0.91] 27.90 [1.10]
10 — 10, 10S & 10 SL 06 .625-24 UNEF 19.60 [0.77] 23.60 [0.93] 29.50 [1.16]
12 7 12 & 12S 08 .750-20 UNEF 20.30 [0.80] 24.10 [0.95] 31.00 [1.22]
14 12 14 & 14S 08 .875-20 UNEF 20.80 [0.82] 24.60 [0.97] 32.50 [1.28]
16 19 16 & 16S 10 1.000-20 UNEF 21.30 [0.84] 25.40 [1.00] 34.30 [1.35]
18 27 18 12 1.062-18 UNEF 21.80 [0.86] 25.70 [1.01] 35.60 [1.40]
20 37 20 14 1.188-18 UNEF 22.40 [0.88] 26.40 [1.04] 37.10 [1.46]
22 — 22 16 1.312-18 UNEF 23.10 [0.91] 26.90 [1.06] 38.90 [1.53]
24 — 24 18 1.438-18 UNEF 23.60 [0.93] 27.70 [1.09] 40.40 [1.59]
28 — 28 22 1.750-18 UNS 24.90 [0.98] 29.20 [1.15] 45.20 [1.78]
32 — 32 24 2.000-18 UNS 26.20 [1.03] 30.50 [1.20] 48.30 [1.90]
36 — 36 24 2.250-16 UN 27.40 [1.08] 31.80 [1.25] 51.60 [2.03]
40 — 40 24 2.500-16 UN 29.00 [1.14] 33.30 [1.31] 54.60 [2.15]
44 — 44 24 2.750-16 UN 30.20 [1.19] 34.50 [1.36] 57.90 [2.28]
48 — 48 24 3.000-16 UN 31.50 [1.24] 35.10 [1.38] 61.00 [2.40]
6161 — 18 1.500-18 UNEF 23.90 [0.94] 27.90 [1.10] 41.10 [1.62]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
EntrySize Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Molded Part Selection Guide
(Tinel)
Uniboot Parts Tinel-Lock Part Cable OD
EntrySize No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Tinel-Lock Adapters
(continued)
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-72 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
CRES-Lock Adapters (USA)
BND Adapters (Europe)
Code 54 Band Strap
Adapter
Notes:
1. This product is designed to
terminate a braided cable shield
by means of a band strap and a
heat shrinkable lipped boot to
aconnector.
2. See CH00-0250-016 for ordering
information, modifications and
additional dimensions.
3.See drawing BND-XX25S for band
strap dimensions and information.
4. Adapter to be permanently
marked with code identification
number and full part number (e.g.
06090-BND54AB00-1812). Band
strap shall bear no part marking.
5. All entry sizes are shown in Table
II. Maximum entry sizes are as
shown inTable I. For larger entry
sizes than the maximum, a Type II
adapter may be supplied. See
CH00-0250-016 for further details.
For additional codes available, contact
Tyco Electronics.
Ø B Max.
Typ. ØAThd.
Typ.
31.2
[1.23] Max.
ØZ
Typ. ØS
Typ. ØY
Typ.
16.5
[0.65]
Max.
Typ.
C
Max.
D
Max.
Straight Adapter
Code 00
45° Adapter
Code 45
22.4
[0.88]
Ø A Thd.
Typ.
ØBMax.
Typ.
Max.
Type II Modification
(See Note 5)
E
Max.
F
Max.
90° Adapter
Code 90
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 54 MIL-C-5015 (MS3400), MIL-C-26482 Series 2,
MIL-C-83723 Series I and III, MIL-C-81703 Series III(Continued)
6-73
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
CRES-Lock Adapters (USA)
BND Adapters (Europe)
(continued)
Code 54 Band Strap
Adapter (Continued)
Table I
Shell Size Entry Size Ø A
Order Series2Series3Max. Unified Thread ØBØ B C D F
Number Type I1Class 2B Max. Max.4Max. Max. Max.
08 — 08 04 0.5000–20 UNF 15.7 22.6 19.0 26.2 31.0
0.67 0.89 0.75 1.03 1.22
10 — 10 06 0.6250–24 UNEF 18.5 25.7 19.6 26.7 32.5
0.73 1.01 0.77 1.05 1.28
12 7 12 08 0.7500–20 UNEF 21.8 29.0 20.3 27.2 34.3
0.86 1.14 0.80 1.07 1.35
14 12 14 09 0.8750–20 UNEF 24.9 32.0 20.9 27.7 35.6
0.98 1.26 0.82 1.09 1.40
16 19 16 11 0.9375–20 UNEF 28.2 35.3 21.3 28.4 37.1
1.11 1.39 0.84 1.12 1.46
18 27 18 12 1.0000–20 UNEF 31.0 38.4 21.8 28.7 38.9
1.22 1.51 0.86 1.13 1.53
20 37 20 14 1.1875–18 UNEF 34.3 41.7 22.4 29.5 40.4
1.35 1.64 0.88 1.16 1.59
22 — 22 16 1.3125–18 UNEF 37.3 44.7 23.1 30.0 41.9
1.47 1.76 0.91 1.18 1.65
24 — 24 18 1.4375–18 UNEF 40.5 48.0 23.6 30.7 43.4
1.59 1.89 0.93 1.21 1.71
28 — 28 22 1.7500–18 UNS 50.0 54.4 24.9 31.8 48.3
1.97 2.14 0.98 1.25 1.90
32 — 32 26 2.0000–18 UNS 56.4 61.0 26.2 33.3 51.6
2.22 2.40 1.03 1.31 2.03
36 — 36 28 2.2500–16 UN 62.7 67.1 27.4 34.3 54.6
2.47 2.64 1.08 1.35 2.15
40 — 40 32 2.5000–16 UN 69.1 73.4 28.4 35.6 57.7
2.72 2.89 1.12 1.40 2.27
44 — 44 34 2.75000–16 UN 75.4 79.8 29.7 36.8 61.0
2.97 3.14 1.17 1.45 2.40
48 — 48 34 3.0000–16 UN 81.8 86.1 31.0 38.1 64.0
3.22 3.39 1.22 1.50 2.52
61 61 — 18 1.5000–18 UNEF 41.9 47.8 23.9 30.7 44.2
1.65 1.88 0.94 1.21 1.74
1. All entry sizes are shown in Table II. Maximum entry sizes are as shown in Table I. For larger entry sizes than the
maximum, a Type II adapter may be supplied. See CH00-0250-016 for further details.
2. Adapter mates to: MIL-C-81703 Series III, MS3424, MS3446, MS3464, MS3467, MS3468, Class E and LConnectors.
3. Adapter mates to MIL-C-5015G, MS3400 Series, Class D, E, K, L, U and W: MS3400, MS3401, MS3404, MS3406,
MS3450, MS3451, MS3454, MS3456, MS3470, MS3471, MS3472, MS3474, MS3475, MS3476, MIL-C-83723
Series II, Class Aand L. MIL-C-83723, /14, /36, /37, /38, /39, /40, /41, /42, /43, /48, /49, /65, /66, /67, /68, /69, /70, /71,
/72, /73, /74, /75, /76, /77, /78, /82, /83, /84, /85, /86, /87, /91, /92, /95, /97, and /98 Connectors, MS3155 controlled
interfaces.
4. These dimensions apply if a self-locking coupling nut is used, modification code ”S”.
Table II
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
03 4.75 7.92 11.10 16.3
0.188 0.312 0.438 0.64
04 6.35 9.52 12.70 16.3
0.250 0.375 0.500 0.64
05 7.92 11.12 14.30 17.3
0.312 0.438 0.563 0.68
06 9.52 12.70 15.88 17.8
0.375 0.500 0.625 0.70
07 11.12 14.30 17.50 18.8
0.438 0.562 0.689 0.74
08 12.70 15.88 19.05 19.8
0.500 0.625 0.750 0.78
09 14.30 17.50 20.65 20.3
0.562 0.688 0.813 0.80
10 15.88 19.05 22.23 20.8
0.625 0.750 0.875 0.82
11 17.50 20.65 23.80 21.8
0.688 0.812 0.938 0.86
12 19.05 22.23 25.40 22.9
0.750 0.875 1.000 0.90
13 20.65 23.83 27.00 23.9
0.812 0.938 1.063 0.94
14 22.23 25.40 30.16 24.4
0.875 1.000 1.189 0.96
Table II (Continued)
Entry ØZ Ø S Ø Y E
Size +0.25/-0.50 ±0.51 ±0.38 Max.
[+0.010/-0.020] [±0.020] [±0.015]
15 23.83 27.00 31.75 24.9
0.938 1.062 1.250 0.98
16 25.40 28.58 33.34 25.9
1.000 1.125 1.313 1.02
18 28.58 31.75 36.51 28.3
1.125 1.250 1.438 1.11
20 31.75 34.90 39.69 29.8
1.250 1.375 1.563 1.17
22 34.90 38.10 42.86 31.3
1.375 1.500 1.688 1.23
24 38.10 41.28 46.83 33.8
1.500 1.625 1.844 1.33
26 41.28 44.45 49.61 35.1
1.625 1.750 1.953 1.38
28 44.45 47.63 52.78 36.3
1.750 1.875 2.078 1.43
30 47.65 50.80 56.36 37.8
1.875 2.000 2.219 1.49
32 50.80 54.00 59.53 39.6
2.000 2.125 2.344 1.56
34 54.00 57.15 62.71 41.1
2.125 2.250 2.469 1.62
Adapter Products
Code 76 BS 9522 F0017 (Pattern 105)
6-74 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Spin-Coupling Adapters
Order Dimensions
No. Shell Size Thread YMax. Z Min.
08 8 .438-28 UNEF 13.54 [0.53] 6.9 [0.27]
10 10 .562-24 UNEF 15.37 [0.61] 9.9 [0.39]
12 12 .688-24 UNEF 19.66 [0.77] 13.4 [0.53]
14 14 .812-20 UNEF 21.29 [0.84] 15.9 [0.63]
16 16 .938-20 UNEF 24.47 [0.96] 18.9 [0.74]
18 18 1.062-18 UNEF 26.47 [1.04] 21.4 [0.84]
20 20 1.188-18 UNEF 30.92 [1.22] 23.9 [0.94]
22 22 1.312-18 UNEF 34.42 [1.36] 27.4 [1.08]
24 24 1.438-18 UNEF 36.40 [1.44] 29.9 [1.18]
Z
10.4
[.409]Min.
29.4
[1.157] Max.
Thread
Y
Table of Dimensions
Standard K Parts Low-Profile D Parts
Order Straight 90° Cable OD Straight 90° Cable OD
No. Part No. Part No. (Min.) Part No. Part No. (Min.)
03, 08 202W232 — 4.3 [0.19] — — —
03, 08 202K121 222K121 5.6 [0.22] 202D211 222D211 6.4 [0.25]
10, 11 202K132 222K132 5.9 [0.23] 202D221 222D221 7.4 [0.29]
12, 14 202K142 222K142 7.1 [0.28] 202D232 222D232 8.4 [0.33]
16, 18 202K153 222K152 8.4 [0.33] 202D242 222D242 9.7 [0.38]
20, 22 202K163 222K163 9.9 [0.39] 202D253 222D253 10.5 [0.41]
24, 28, 202K174 222K174 15.7 [0.62] 202D263 222D263 12.2 [0.48]
32, 36 202K185 222K185 16.8 [0.66] 202D274 222D274 14.3 [0.56]
Molded Part Selection Guide
(Spin-Coupling)
Uniboot Parts Order Part Cable OD
No. No. (Min.)
03, 08 202C611 4.8 [0.19]
10, 11, 12 202C621 8.1 [0.32]
14, 16 202C632 12.7 [0.50]
18, 20 202C642 17.5 [0.69]
22, 24 202C653 22.4 [0.88]
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 76 BS 9522 F0017 (Pattern 105) (Continued)
6-75
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
6
Adapters
Tinel-Lock Adapters
Order Shell Max. Entry Size Dimensions
No. Size Type 1* Thread CMax. D Max. E Max.
08 8 04 .438-28 UNEF 18.0 [.74] 21.3 [.87] 26.7 [1.05]
10 10 07 .562-24 UNEF 18.8 [.76] 22.1 [.90] 28.2 [1.11]
12 12 08 .688-24 UNEF 19.3 [.79] 22.9 [.92] 30.2 [1.19]
14 14 10 .812-20 UNEF 20.1 [.82] 23.4 [.95] 31.8 [1.25]
16 16 12 .938-20 UNEF 20.8 [.84] 24.1 [.97] 33.5 [1.32]
18 18 12 1.062-18 UNEF 21.3 [.87] 24.6 [1.00] 35.1 [1.38]
20 20 16 1.188-18 UNEF 22.1 [.89] 25.4 [1.02] 36.6 [1.44]
22 22 18 1.312-18 UNEF 22.6 [.92] 25.9 [1.05] 38.1 [1.50]
24 24 20 1.438-18 UNEF 23.4 [.97] 26.7 [1.07] 39.4 [1.55]
*For larger than maximum type 1 entry sizes, a two-piece adapter will be supplied. Contact Tyco Electronics for
information.
Max.
Thread
Z
Min.
SY
36.8
[1.449]
13.0
[.512]
Thread C Max.
D Max.
Min.
ZSY
13.0
[.512]
Z
S
Y
Min
E Max
W Max
Thread
13.0
[.512]
TXR76XX00-XXXXXX
TXR76XX45-XXXXXX
TXR76XX90-XXXXXX
Table of Dimensions
Available in: Americas Europe Asia Pacific
nnn
Adapter Products
Code 76 BS 9522 F0017 (Pattern 105) (Continued)
6-76 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Entry Dimensions
Size Z+0.25–0.5 S Diameter (Min.–Max.) Y ±0.38 W Max.
04 6.35 [0.25] 9.39—9.56 [0.37—0.38] 13.97 [1.22] 31.0 [0.55]
05 7.92 [0.31] 10.97—11.13 [0.43—0.44] 15.54 [1.29] 32.8 [0.61]
06 9.52 [0.37] 12.57—12.73 [0.49—0.50] 17.14 [1.35] 34.3 [0.67]
07 11.09 [0.44] 14.12—14.31 [0.55—0.56] 18.71 [1.41] 35.8 [0.74]
08 12.7 [0.50] 15.72—15.91 [0.62—0.63] 20.32 [1.47] 37.3 [0.80]
1015.87 [0.62] 18.84—19.11 [0.74—0.75] 23.49 [1.60] 40.6 [0.92]
12 19.05 [0.75] 22.02—22.28 [0.87—0.88] 26.67 [1.72] 43.7 [1.05]
14 22.23 [0.88] 25.17—25.46 [0.99—1.00] 29.84 [1.85] 47.0 [1.17]
16 25.4 [1.00] 28.34—28.63 [1.12—1.13] 33.02 [1.97] 50.0 [1.30]
18 28.57 [1.12] 31.52—31.81 [1.24—1.25] 36.19 [2.10] 53.3 [1.42]
20 31.75 [1.25] 34.69—34.98 [1.37—1.38] 39.37 [1.55] 53.8 [2.19]
Entry Size Dimensions
Standard K Parts Low-Profile D Parts
Tinel-Lock Straight 90° Cable OD Straight 90° Cable OD
EntrySize Part No. Part No. (Min.) Part No. Part No. (Min.)
04 202K232 — 3.3 [0.1] — — —
04 202W232 — 4.3 [0.2] — — —
04 202K121 222K121 5.6 [0.2] 202D211 222D211 6.4 [0.3]
05, 06 202K132 222K132 5.9 [0.2] 202D221 222D221 7.4 [0.3]
07, 08 202K142 222K142 7.1 [0.3] 202D232 222D232 8.4 [0.3]
10, 12 202K153 222K152 8.4 [0.3] 202D242 222D242 9.7 [0.4]
14, 16 202K163 222K163 9.9 [0.4] 202D253 222D253 10.5 [0.4]
18, 20, 22 202K174 222K174 15.7 [0.6] 202D263 222D263 12.2 [0.5]
24 202K185 222K185 16.8 [0.7] — — —
Molded Part Selection Guide
(Tinel)
Uniboot Parts Tinel-Lock Part Cable OD
EntrySize No. (Min.)
04 202C611 4.8 [0.19]
05, 06, 07 202C621 8.1 [0.32]
08, 10, 12 202C632 12.7 [0.50]
12, 14, 16 202C642 17.5 [0.69]
16, 18, 20, 22 202C653 22.4 [0.88]
24 202C663 22.9 [0.90]
Tinel-Lock Adapters
(continued)
7
Assemblies
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Assemblies
Table of Contents
7-1
Assemblies
KTKK Product Family Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
KTKK Assemblies Screened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 to 7-5
Feedthroughs
TCFS/R Cable Feedthroughs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 to 7-8
Preinstalled Adhesives
S-1030, S-1048, S-1275 (Rayaten) Preinstalled Adhesives . . . . . . . . . . . . . . . . . . . . . .7-9
Kits
SESK Shipboard Electrical Splice Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 to 7-12
Ship or Shore Breakout Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Raychem assemblies and
kits fit a wide variety of
applications.
KTKK assemblies are avail-
able with Rayaten screened
molded parts, to suit a wide
range of connectors. For
correct part number
referencing, please contact
Tyco Electronics.
Unscreened versions are
available as well.
TCFS/R feedthroughs are
also available, both with
Rayaten screened molded
parts or in unscreened
versions.
Raychem's KTKK and
TCFS/R product families
come with the added
advantage of preinstalled
adhesives, which can
drastically reduce the
installation time and cost
of harness building.
SESK shipboard electrical
splice kits can be used to
splice multiconductor
cables in new ship con-
struction, allowing modular
wiring techniques and use
of existing wiring when
jumbo-sizing commercial
ships.
Ship-to-shorekits areused
to bring shore power to a
ship in dock.
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Assemblies
KTKK Product Family Overview
7-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
KTKK cable assemblies are
one-part assemblies for
screened and unscreened
cables. Constructed from
Raychem heat-shrinkable
screened molded parts and
connector adapters, the
assembly consists of parts
already well proven in harsh
military environments.
Installation is simply effect-
ed by coupling the adapter
to the connector and shrink-
ing the rear of the molded
part onto the cable with a
hot air gun.
The molded part has a
hot-melt adhesive prein-
stalled to provide a bond
between the cable jacket
and the molded part.
When used in conjunction
with shielded (screened)
cables, the assembly
provides electrical
continuity between the
cable shield and the
connector with Rayaten
molded parts.
Rayaten molded parts are
shielded, heat-shrinkable
parts providing shielding
levels better than 80 dB
at 100 MHz.
Assembly Types
ab
a
b
ab
a= Preinstalled conductive adhesive for use
with Rayaten screened molded parts only.
b= Preinstalled environment adhesive for use
with screened and unscreened KTKK assemblies
(see “Preinstalled adhesives,” page 7-9).
Straight Assemblies 45° Assemblies
90°Assemblies
Material Specification
-25 fluid-resistant modified elastomer -25S fluid-resistant modified elastomer;
shielded RK-6719
-100 low-fire-hazard material -100S low-fire-hazard; shielded RK-6724
Material Available Coatings (Unshielded) Available Coatings (Shielded)
-25 S-1048 (/86) high-temperature hot-melt adhesive —
-25S — S-1030 (/180) low-fire-hazard hot-melt adhesive
-100 S-1030 (/180) low-fire-hazard hot-melt adhesive —
-100S —S-1275 conductive adhesive for use with Rayaten
molded parts.
Applications
Materials Available
Precoated Adhesives
Available in: Americas Europe Asia Pacific
nnn
Assemblies
KTKK Assemblies Screened
7-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
Straight Assemblies 45° Assemblies 90° Assemblies
Connector Raychem Cable O.D. Raychem Cable O.D. Raychem Cable O.D.
Shell Size Part No. Range Part No. Range Part No. Range
08 KTKK 0840 5.0-8.0 [.197-.315] KTKK 0970 5.0-7.0 [.197-.276] — —
10 KTKK 0841 6.0-13.0 [.236-.512] KTKK 0971 6.0-9.0 [.236-.354] KTKK 0851 6.0-13.0 [.236-.512]
12 KTKK 0842 7.2-15.0 [.283-.591] KTKK 0972 7.2-1 1.0 [.283-.433] KTKK 0852 7.2-15.0 [.283-.591]
14 KTKK 0843 7.2-15.0 [.283-.591] KTKK 0973 7.2-1 1.0 [.283-.433] KTKK 0853 7.2-15.0 [.283-.591]
16 KTKK 0844 8.5-19.0 [.335-.748] KTKK 0974 8.5-17.0 [.335-.669] KTKK 0854 8.5-19.0 [.335-.748]
18 KTKK 0845 8.5-19.0 [.335-.748] KTKK 0975 8.5-17.0 [.335-.669] KTKK 0855 8.5-19.0 [.335-.748]
20 KTKK 0846 10.0-24.0 [.394-.945] KTKK 0976 10.0-21.0 [.394-.827] KTKK 0856 10.0-24.0 [.394-.945]
22 KTKK 0847 10.0-24.0 [.394-.945] KTKK 0977 10.0-21.0 [.394-.827] KTKK 0857 10.0-24.0 [.394-.945]
24 KTKK 0848 15.8-33.0 [.622-1.299] KTKK 0978 15.8-29.0 [.622-1.142] KTKK 0858 15.8-33.0 [.622-1.299]
08 KTKK 0612 5.0-7.0 [.197-.276] KTKK 0780 5.0-7.0 [.197-.276] — —
10 KTKK 0613 6.0-9.0 [.236-.354] KTKK 0781 6.0-9.0 [.236-.354] KTKK 1241 6.0-9.0 [.236-.354]
12 KTKK 0614 7.2-11.0 [.283-.433] KTKK 0782 7.2-11.0 [.283-.433] KTKK 1242 7.2-11.0 [.283-.433]
14 KTKK 0615 7.2-11.0 [.283-.433] KTKK 0783 7.2-11.0 [.283-.433] KTKK 1243 7.2-11.0 [.283-.433]
16 KTKK 0616 8.5-17.0 [.335-.669] KTKK 0784 8.5-17.0 [.335-.669] KTKK 1244 8.5-17.0 [.335-.669]
18 KTKK 0617 8.5-17.0 [.335-.669] KTKK 0785 8.5-17.0 [.335-.669] KTKK 1245 8.5-17.0 [.335-.669]
20 KTKK 0618 10.0-21.0 [.394-.827] KTKK 0786 10.0-21.0 [.394-.827] KTKK 1246 10.0-21.0 [.394-.827]
22 KTKK 0619 10.0-21.0 [.394-.827] KTKK 0787 10.0-21.0 [.394-.827] KTKK 1247 10.0-21.0 [.394-.827]
24 KTKK 0620 15.8-29.0 [.622-1.142] KTKK 0788 15.8-29.0 [.622-1.142] KTKK 1248 15.8-29.0 [.622-1.142]
Pattern 602 Connectors or
Connector Code 54
25S Fluid Resistant Elastomer
100S Low Fire Hazard Material
Straight Assemblies 45° Assemblies 90° Assemblies
Connector Raychem Cable O.D. Raychem Cable O.D. Raychem Cable O.D.
Shell Size Part No. Range Part No. Range Part No. Range
08 KTKK 0520 5.0-8.0 [.197-.315] KTKK 0560 5.0-7.0 [.197-.276] — —
10 KTKK 0521 6.0-13.0 [.236-.512] KTKK 0561 6.0-9.0 [.236-.354] KTKK 1051 6.0-13.0 [.236-.512]
12 KTKK 0522 7.2-15.0 [.283-.591] KTKK 0562 7.2-1 1.0 [.283-.433] KTKK 1052 7.2-15.0 [.283-.591]
14 KTKK 0523 7.2-15.0 [.283-.591] KTKK 0563 7.2-1 1.0 [.283-.433] KTKK 1053 7.2-15.0 [.283-.591]
16 KTKK 0524 8.5-19.0 [.335-.748] KTKK 0564 8.5-17.0 [.335-.669] KTKK 1054 8.5-19.0 [.335-.748]
18 KTKK 0525 8.5-20.0 [.335-.748] KTKK 0565 8.5-17.0 [.335-.669] KTKK 1055 8.5-19.0 [.335-.748]
20 KTKK 0526 10.0-24.0 [.394-.945] KTKK 0566 10.0-21.0 [.394-.827] KTKK 1056 10.0-24.0 [.394-.945]
22 KTKK 0527 10.0-24.0 [.394-.945] KTKK 0567 10.0-21.0 [.394-.827] KTKK 1057 10.0-24.0 [.394-.945]
24 KTKK 0528 15.8-33.0 [.622-1.299] KTKK 0568 15.8-29.0 [.622-1.142] KTKK 1058 15.8-33.0 [.622-1.299]
08 KTKK 0465 5.0-7.0 [.197-.276] KTKK 0603 5.0-7.0 [.197-.276] — —
10KTKK 0466 6.0-9.0 [.236-.354] KTKK 0604 6.0-9.0 [.236-.354] KTKK 1251 6.0-9.0 [.236-.354]
12 KTKK 0467 7.2-11.0 [.283-.433] KTKK 0605 7.2-11.0 [.283-.433] KTKK 1252 7.2-11.0 [.283-.433]
14 KTKK 0468 7.2-11.0 [.283-.433] KTKK 0606 7.2-11.0 [.283-.433] KTKK 1253 7.2-11.0 [.283-.433]
16 KTKK 0469 8.5-17.0 [.335-.669] KTKK 0607 8.5-17.0 [.335-.669] KTKK 1254 8.5-17.0 [.335-.669]
18 KTKK 0470 8.5-17.0 [.335-.669] KTKK 0608 8.5-17.0 [.335-.669] KTKK 1255 8.5-17.0 [.335-.669]
20KTKK 0471 10.0-21.0 [.394-.827] KTKK 0609 10.0-21.0 [.394-.827] KTKK 1256 10.0-21.0 [.394-.827]
22 KTKK 0472 10.0-21.0 [.394-.827] KTKK 0610 10.0-21.0 [.394-.827] KTKK 1257 10.0-21.0 [.394-.827]
24 KTKK 0473 15.8-29.0 [.622-1.142] KTKK 0611 15.8-29.0 [.622-1.142] KTKK 1258 15.8-29.0 [.622-1.142]
Pattern 105 Connectors or
Connector Code 76
100S Low Fire Hazard Material
25S Fluid Resistant Elastomer
Assemblies
KTKK Assemblies Screened (Continued)
7-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Straight Assemblies 45° Assemblies 90° Assemblies
Connector Raychem Cable O.D. Raychem Cable O.D. Raychem Cable O.D.
Shell Size Part No. Range (mm) Part No. Range (mm) Part No. Range (mm)
08 KTKK 1 110 5.0-8.0 [.197-.315] KTKK 1120 5.0-7.0 [.197-.276] — —
10 KTKK 1 111 6.0-13.0 [.236-.512] KTKK 1121 6.0-9.0 [.236-.354] KTKK 1131 6.0-13.0 [.236-.512]
12 KTKK 1 112 7.2-15.0 [.283-.591] KTKK 1122 7.2-11.0 [.283-.433] KTKK 1 132 7.2-15.0 [.283-.591]
14 KTKK 1 113 7.2-15.0 [.283-.591] KTKK 1123 7.2-11.0 [.283-.433] KTKK 1 133 7.2-15.0 [.283-.591]
16 KTKK 1 114 8.5-19.0 [.335-.748] KTKK 1124 8.5-17.0 [.335-.669] KTKK 1 134 8.5-19.0 [.335-.748]
18 KTKK 1 115 8.5-19.0 [.335-.748] KTKK 1125 8.5-17.0 [.335-.669] KTKK 1 135 8.5-19.0 [.335-.748]
20 KTKK 1 116 10.0-24.0 [.394-.945] KTKK 1126 10.0-21.0 [.394-.827] KTKK 1136 10.0-24.0 [.394-.945]
22 KTKK 1 117 10.0-24.0 [.394-.945] KTKK 1127 10.0-21.0 [.394-.827] KTKK 1137 10.0-24.0 [.394-.945]
24 KTKK 1 118 15.8-33.0 [.622-1.299] KTKK 1128 15.8-29.0 [.622-1.142] KTKK 1138 15.8-33.0 [.622-1.299]
08 KTKK 0670 5.0-7.0 [.197-.276] KTKK 0660 5.0-7.0 [.197-.276] — —
10 KTKK 0671 6.0-9.0 [.236-.354] KTKK 0661 6.0-9.0 [.236-.354] KTKK 1 181 6.0-9.0 [.236-.354]
12 KTKK 0672 7.2-11.0 [.283-.433] KTKK 0662 7.2-11.0 [.283-.433] KTKK 1182 7.2-11.0 [.283-.433]
14 KTKK 0673 7.2-11.0 [.283-.433] KTKK 0663 7.2-11.0 [.283-.433] KTKK 1 183 7.2-11.0 [.283-.433]
16 KTKK 0674 8.5-17.0 [.335-.669] KTKK 0664 8.5-17.0 [.335-.669] KTKK 1184 8.5-17.0 [.335-.669]
18 KTKK 0675 8.5-17.0 [.335-.669] KTKK 0665 8.5-17.0 [.335-.669] KTKK 1185 8.5-17.0 [.335-.669]
20 KTKK 0676 10.0-21.0 [.394-.827] KTKK 0666 10.0-21.0 [.394-.827] KTKK 1186 10.0-21.0 [.394-.827]
22 KTKK 0677 10.0-21.0 [.394-.827] KTKK 0667 10.0-21.0 [.394-.827] KTKK 1187 10.0-21.0 [.394-.827]
24 KTKK 0678 15.8-29.0 [.622-1.142] KTKK 0668 15.8-29.0 [.622-1.142] KTKK 1188 15.8-29.0 [.622-1.142]
38999 Series III and IV
Connectors or Connector
Code 40
25S Fluid Resistant Elastomer
100S Low Fire Hazard Material
Straight Assemblies 45° Assemblies 90° Assemblies
Connector Raychem Cable O.D. Raychem Cable O.D. Raychem Cable O.D.
Shell Size Part No. Range Part No. Range Part No. Range
08 KTKK 0530 5.0-8.0 [.197-.315] KTKK 0540 5.0-7.0 [.197-.276] — —
10 KTKK 0531 6.0-13.0 [.236-.512] KTKK 0541 6.0-9.0 [.236-.354] KTKK 1261 6.0-13.0 [.236-.512]
12 KTKK 0532 7.2-15.0 [.283-.591] KTKK 0542 7.2-1 1.0 [.283-.433] KTKK 1262 7.2-15.0 [.283-.591]
14 KTKK 0533 7.2-15.0 [.283-.591] KTKK 0543 7.2-1 1.0 [.283-.433] KTKK 1263 7.2-15.0 [.283-.591]
16 KTKK 0534 8.5-19.0 [.335-.748] KTKK 0544 8.5-17.0 [.335-.669] KTKK 1264 8.5-19.0 [.335-.748]
18 KTKK 0535 8.5-19.0 [.335-.748] KTKK 0545 8.5-17.0 [.335-.669] KTKK 1265 8.5-19.0 [.335-.748]
20 KTKK 0536 10.0-24.0 [.394-.945] KTKK 0546 10.0-21.0 [.394-.827] KTKK 1266 10.0-24.0 [.394-.945]
22 KTKK 0537 10.0-24.0 [.394-.945] KTKK 0547 10.0-21.0 [.394-.827] KTKK 1267 10.0-24.0 [.394-.945]
24 KTKK 0538 15.8-33.0 [.622-1.299] KTKK 0548 15.8-29.0 [.622-1.142] KTKK 1268 15.8-33.0 [.622-1.299]
08 KTKK 0444 5.0-7.0 [.197-.276] KTKK 0580 5.0-7.0 [.197-.276] — —
10 KTKK 0445 6.0-9.0 [.236-.354] KTKK 0581 6.0-9.0 [.236-.354] KTKK 1021 6.0-9.0 [.236-.512]
12 KTKK 0446 7.2-11.0 [.283-.433] KTKK 0582 7.2-11.0 [.283-.433] KTKK 1022 7.2-11.0 [.283-.591]
14 KTKK 0447 7.2-11.0 [.283-.433] KTKK 0583 7.2-11.0 [.283-.433] KTKK 1023 7.2-11.0 [.283-.591]
16KTKK 0448 8.5-17.0 [.335-.669] KTKK 0584 8.5-17.0 [.335-.669] KTKK 1024 8.5-17.0 [.335-.748]
18 KTKK 0449 8.5-17.0 [.335-.669] KTKK 0585 8.5-17.0 [.335-.669] KTKK 1025 8.5-17.0 [.335-.748]
20 KTKK 0450 10.0-21.0 [.394-.827] KTKK 0586 10.0-21.0 [.394-.827] KTKK 1026 10.0-21.0 [.394-.827]
22 KTKK 0451 10.0-21.0 [.394-.827] KTKK 0587 10.0-21.0 [.394-.827] KTKK 1027 10.0-21.0 [.394-.827]
24 KTKK 0452 15.8-29.0 [.622-1.142] KTKK 0588 15.8-29.0 [.622-1.142] KTKK 1028 15.8-29.0 [.622-1.142]
Pattern 608 Connectors or
Connector Code 79
25S Fluid Resistant Elastomer
100S Low Fire Hazard Material
Assemblies
KTKK Assemblies Screened(Continued)
7-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
Straight Assemblies 45° Assemblies 90° Assemblies
Connector Raychem Cable O.D. Raychem Cable O.D. Raychem Cable O.D.
Shell Size Part No. Range Part No. Range Part No. Range
08 KTKK 0500 5.0-8.0 [.197-.315] KTKK 0510 5.0-7.0 [.197-.276] — —
10 KTKK 0501 6.0-13.0 [.236-.512] KTKK 0511 6.0-9.0 [.236-.354] KTKK 0831 6.0-13.0 [.236-.512]
12 KTKK 0502 7.2-15.0 [.283-.591] KTKK 0512 7.2-1 1.0 [.283-.433] KTKK 0832 7.2-15.0 [.283-.591]
14 KTKK 0503 7.2-15.0 [.283-.591] KTKK 0513 7.2-1 1.0 [.283-.433] KTKK 0833 7.2-15.0 [.283-.591]
16 KTKK 0504 8.5-19.0 [.335-.748] KTKK 0514 8.5-17.0 [.335-.669] KTKK 0834 8.5-19.0 [.335-.748]
18 KTKK 0505 8.5-19.0 [.335-.748] KTKK 0515 8.5-17.0 [.335-.669] KTKK 0835 8.5-19.0 [.335-.748]
20 KTKK 0506 10.0-24.0 [.394-.945] KTKK 0516 10.0-21.0 [.394-.827] KTKK 0836 10.0-24.0 [.394-.945]
22 KTKK 0507 10.0-24.0 [.394-.945] KTKK 0517 10.0-21.0 [.394-.827] KTKK 0837 10.0-24.0 [.394-.945]
24 KTKK 0508 15.8-33.0 [.622-1.299] KTKK 0518 15.8-29.0 [.622-1.142] KTKK 0838 15.8-33.0 [.622-1.299]
08 KTKK 0640 5.0-7.0 [.197-.276] KTKK 0630 5.0-7.0 [.197-.276] — —
10 KTKK 0641 6.0-9.0 [.236-.354] KTKK 0631 6.0-9.0 [.236-.354] KTKK 0721 6.0-9.0 [.236-.354]
12 KTKK 0642 7.2-11.0 [.283-.433] KTKK 0632 7.2-11.0 [.283-.433] KTKK 0722 7.2-11.0 [.283-.433]
14KTKK 0643 7.2-11.0 [.283-.433] KTKK 0633 7.2-11.0 [.283-.433] KTKK 0723 7.2-11.0 [.283-.433]
16 KTKK 0644 8.5-17.0 [.335-.669] KTKK 0634 8.5-17.0 [.335-.669] KTKK 0724 8.5-17.0 [.335-.669]
18 KTKK 0645 8.5-17.0 [.335-.669] KTKK 0635 8.5-17.0 [.335-.669] KTKK 0725 8.5-17.0 [.335-.669]
20 KTKK 0646 10.0-21.0 [.394-.827] KTKK 0636 10.0-21.0 [.394-.827] KTKK 0726 10.0-21.0 [.394-.827]
22 KTKK 0647 10.0-21.0 [.394-.827] KTKK 0637 10.0-21.0 [.394-.827] KTKK 0727 10.0-21.0 [.394-.827]
24 KTKK 0648 15.8-29.0 [.622-1.142] KTKK 0638 15.8-29.0 [.622-1.142] KTKK 0728 15.8-29.0 [.622-1.142]
38999 Series I and II
Connectors or Connector
Code 41
25S Fluid Resistant Elastomer
100S Low Fire Hazard Material
Cable Feedthroughs
TCFS/R
7-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Single-Sided Standard Assembly
Double-Sided Assembly
Applications
Provides environmental
sealing and screen continu-
ity to a bulkhead as a cable
passes through. The
assembly consists of a
specifically designed lock-
nut and O-ring seal, onto
the rear of which is prein-
stalled a Raychem heat-
shrinkable molded part.
Feedthrough installation is
simply effected by tighten-
ing the locknut on the rear
of the bulkhead, which
compresses the O-ring and
ensures that a small knife-
edge provides electrical
contact between the
assembly and the bulk-
head.
When heat is applied to the
molded part in the form of
hot air,aseal to the cable is
formed with hot-melt adhe-
sive. When specified for
screened cables, the
assembly contains a con-
ductive adhesive, which
provides electrical continu-
ity between the screen and
the bulkhead via Rayaten
molded parts.
These molded parts are
shielded (screened), heat-
shrinkable parts providing
shielding levels better than
80 dB at 100 MHz.
Product Facts
nScreened or unscreened
cables
nOne-piece part
nEach size covers a wide
cable range
nLight weight
nSingle- or double-sided
assembly
Available in: Americas Europe Asia Pacific
nnn
Cable Feedthroughs
TCFS/R (Continued)
7-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
Adhesive System
E = Epoxy (consult factory)
H = S-1030 hot melt
W = S-1048 hot melt
Molded Part Type
A = Straight unscreened
B = 90°unscreened
C = Straight screened
D = 45°screened
E = 90°screened (16–36 only)
Molded Part Material
-25 = Semirigid elastomer
-100 = Low fire hazard
Thread Length
(may be three digits if more than 95 mm required)
20 mm standard
5 mm increments, minimum 15 mm
Assembly Modification Code
0 = Standard assembly
1 = Double-sided assembly (only straight unshielded boot
available on double nut)
2 = Same as 1 but with potting ports
3 = Locknut
4 = 60°metalwork
5 = Same as 0 but with potting ports
Feedthrough Material/Finish
01W = Nickel aluminium bronze, shotblast
19B = Aluminium-alloy–plated cadmium, olive drab,
over electroless nickel
19C = Aluminium-alloy–plated electroless nickel
19Q = Aluminium-alloy–plated zinc cobalt
62C = Stainless-steel–plated electroless nickel
Feedthrough Size
Part Description
TCFS uses a full-length molded part
TCFR uses a shortened molded part
(only available on straight assemblies)
TCFX* - 12 62C - 0 - 20 - 100 A H
*See Molded Parts Materials Section 4 for -25 and -100 information.
Part Numbering System
Cable Feedthroughs
TCFS/R (Continued)
7-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Double knife-edge to ensure
good electrical contact.
Single-sided dovetail to ensure
O-ring remains in place.
Adhesive Double-nut
Assembly Hexagonal
Nut
A/F size
A/F size
Feedthrough
Body Preinstalled
Molded Part Hot-melt
Adhesive
Washer
5.0
[.20] 5.0
[.20]
PS
A dia. J dia.
M thread
PS = screened PR = unscreened
PR
P
Product Dimensions
JDiameter*
Feed- Unshielded Shielded ADia. A/F A/F P±10% Hole
through aMin. MThread Max. Body Nut Unscreened Size
Size aMin. b Max. -25S -100S b Max. PPS PR
TCFS/R-12 1 1 [.43] 5.6 [.22] 7.5 [.30] 6.5 [.26] 5.0 [.20] M12 x 1.5 7.5 [.30] 24 [.95] 17 [.67] 52 50 43 13.0 [.51]
TCFS/R-16 15 [.59] 5.9 [.23] 12.5 [.49] 8.5 [.33] 6.0 [.24] M16 x 1.5 10.2 [.40] 29 [1.14] 22 [.87] 57 65 48 17.0 [.67]
TCFS/R-20 19 [.75] 7.1 [.28] 14.5 [.57] 10.5 [.41] 7.2 [.28] M20 x 1.5 14.0 [.55] 34 [1.34] 27 [1.06] 61 77 52 21.0 [.83]
TCFS/R-24 23 [.90] 8.4 [.33] 18.5 [.73] 16.5 [.65] 8.5 [.33] M24 x 1.5 19.2 [.76] 38 [1.50] 30 [1.18] 74 90 65 25.0 [.98]
TCFS/R-30 29 [1.14] 9.9 [.39] 23.5 [.93] 20.5 [.81] 10.0 [.39] M30 x 1.5 24.2 [.95] 48 [1.89] 36 [1.48] 73 115 64 31.0 [1.22]
TCFS/R-36 35 [1.38] 15.7 [.62] 32.5 [1.28] 28.5 [1.12] 15.8 [.62] M36 x 1.5 30.2 [1.49] 52 [2.05] 41 [1.61] 104 140 95 37.0 [1.46]
TCFR-48 45 [1.77] 16.8 [.66] 38.5 [1.52] 35.5 [1.40] N/A M48 x 1.5 40.2 [1.58] 67 [2.64] 55 [2.17] 144 110 135 50.0 [1.97]
*a = Supplied dimension
b=Dimension after free recovery
Preinstalled Adhesives
S-1030, S-1048, S-1275 (Rayaten)
7-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
S-1030 Polyolefin Hot-Melt Adhesive
Precoat designation /180
Type Polyolefin hot-melt adhesive
Operating temperature range -80°C to 80°C [-112°F to 176°F]
Bonding temperature 120°C [248°F]
Minimum shelf life at or below 25°C 4 years
Specification RK-6017, RT-1050/6
Comments Excellent water blocking and low temperature
S-1048 HIgh-Performance Hot-Melt Adhesive
Precoat designation /86
Type High-performance hot-melt adhesive
Operating temperature range -55°C to 120°C [-67°F to 248°F]
Bonding temperature 160°C [320°F]
Minimum shelf life at or below 25°C 4 years
Specification RK-6626, RT-1050/3
Comments Good solvent resistance but requires higher temperature
toachieve bonding
S-1275 Rayaten Conductive Adhesive* (for KTKK assemblies only)
Type Electrically conductive polyamide hot-melt adhesives
Operating temperature range -40°Cto 70°C [-40°F to 158°F]
Bonding temperature 160°C [320°F]
Minimum shelf life at or below 25°C 2 years
Specification RK-6637
Comments Conductive adhesive for use with Rayaten parts
*Not sold separately.
Product Characteristics
Available in: Americas Europe Asia Pacific
nnn
Kits
SESK — Shipboard Electrical Splice Kits
7-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Series Military Industry Agency Raychem
MIL-DTL-23053* IEEE-383 Massive Flame Lloyd’s—
SESK Vertical Tray Test Register
USCG CGHQ-3774 SST-FR DNV —
U.S. Navy drawing 5001027-19 RW-2011ABS —
T ubing used to SST-FR SST -FR — Sigmaform FR
replace cable jacket — — SST-FR RW-2011
*Formerly MIL+23053/15A
Product Facts
nWaterproofing and corrosion
proofing
nStandard sizes that cover
most single-, two-, three-,
four-, and multi-conductor
cables
nExcellent electrical-
insulation properties and
abrasion protection
nEasy installation
nOperating temperature range
of -55°C to +90°C
[-67°F to +194°F]
nApproved for new ship
construction
Applications
SESK kits provide fast,
waterproof repair of single-,
two-, three-, four-, and multi-
conductor cables. Kits are
suitable for both permanent
and temporary repairs. The
self-sealing heat-shrinkable
tubing used in each kit pro-
vides a watertight seal for
the inner insulation and
outer jacket. The flame-
retardant tubing material
provides electrical and
thermal properties similar to
those of most Navy
standardcables.
Installation
Minimum shrink
temperature: 121°C[250°F]
Specifications/Approvals
Available in: Americas Europe Asia Pacific
nnn
Kits
SESK — Shipboard Electrical Splice Kits(Continued)
7-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
Part Cable Range Approx.
No. (Navy Standard) AWG Equivalent
Single-Conductor Cable
SESK S-4 S-4–S-10 #14–#10
SESK S-16 S-16–S-41 #8–#4
SESK S-52 S-52–S-106 #3–#1/0
SESK S-133 S-133–S-250 #2/0–250 mcm
SESK S-300 S-300–S-600 300 mcm–600 mcm
SESK S-650 S-650–S-1000 650 mcm–1000 mcm
Two-Conductor Cable
SESK D-3 D-3 #22–#16
SESK D-4 D-4–D-10 #14–#10
SESK D-14 D-14 #9
SESK D-23 D-23–D-41 #7–#4
SESK D-50 D-50–D-168 #3–#3/0
SESK D-200 D-200–D-250 #4/0–250 mcm
SESK D-300 D-300–D-350 300 mcm–350 mcm
SESK D-400 D-400–D-450 400 mcm–450 mcm
Three-Conductor Cable
SESK T-3T-3#22–#16
SESK T-4 T-4–T-10 #14–#10
SESK T-14 T-14–T-20 #9–#7
SESK T-23 T-23–T-41 #6–#4
SESK T-50 T-50–T-168 #3/0
SESK T-200 T-200–T-250 #4/0–250 mcm
SESK T-300 T-300–T-350 300 mcm–350 mcm
SESK T-400 T-400–T-450 400 mcm–450 mcm
SESK T-500 T-500–T-600 500 mcm–600 mcm
Four-Conductor Cable
SESK F-3 F-3 #22–#16
SESK F-4 F-4–F-9 #14–#10
SESK F-23 F-23 #6
SESK F-50 F-50 #3
SESK F-75 F-75–F-100 #1–#1/0
SESK F-150 F-150–F-200 #3/0–#4/0
Multiconductor Cable
SESK M-2 2 #18–#22
SESK M-4 4 #18–#22
SESK M-6 6 #18–#22
SESK M-8 8 #18–#22
SESK M-10 10 #18–#22
SESK M-12 12 #18–#22
SESK M-14 14 #18–#22
SESK M-16 16 #18–#22
SESK M-18 18 #18–#22
SESK M-20 20 #18–#22
SESK M-22 22 #18–#22
SESK M-24 24 #18–#22
SESK M-26 26 #18–#22
SESK M-28 28 #18–#22
SESK M-30 30 #18–#22
SESK M-32 32 #18–#22
Note: SESK kits are also available for UJIS cables. Contact Tyco Electronics for details.
Kits
SESK — Shipboard Electrical Splice Kits (Continued)
7-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Example Cable Number
Connector Option = C
Armor Option = E (if electrical continuity is desired)
Both Connector and Armor = CE
Kit Part Number
SESK-300 C TSGU-300
Part Numbering System
Kits
Ship or Shore Breakout Kits
7-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
7
Assemblies
Product Facts
nHeat-shrinkable boot
replaces potting or molding
nFlame-retardant tubing has
a3:1 shrink ratio
nKit offers resistance to
moisture, fungus, and
weathering
nOperating temperature range
of-55°C to +90°C
[-67°F to +194°F]
Applications
Waterproof splices for
power cables areavailable
in red, white, and black for
positive identification of
each conductor.
Bolting power cables
together and wrapping the
splice with tape used to be
the accepted method. Now
the in-line splice—with
thick-wall, self-sealing, heat-
shrinkable products—is the
accepted system for strain
relief, environmental seal-
ing, and phase identifica-
tion for power cables.
Tubing accommodates a
large difference between
cable diameters. Sigmaform
boots can replace tapes,
epoxies, and dips.
Series Military Industry
NAVSEA 803-5001027-17 DNV
2E171-4 MIL-C-24368 Lloyd’s
MIL-DTL-23053/15* and MIL-I-81765/1 ABS
Specifications/Approvals
Part No. Model
2E171-4 In-line splice cable sealing kit**
**Each kit contains:
•Cable breakout boot
•Three-phase identification tubings (red, white, and black)
•Three connector tubings
•A #100 grit emery cloth
•Installation instructions
Ordering Information
Installation
Minimum shrink
temperature:
121°C[250°F]
Available in: Americas Europe Asia Pacific
nnn
7-14
Engineering Notes
Assemblies
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Electrical Interconnect Products
Table of Contents
8-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
Typical SolderSleeve Device/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3, 8-4
Wire-to-Wire Splicing
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
SolderSleeve Wire Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 to 8-11
SolderGrip Closed End Connector Splices . . . . . . . . . . . . . . . . . . . . . . . . .8-12 to 8-17
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18, 8-19
PolyCrimp Heat-Shrinkable Polyethylene Crimp Splices . . . . . . . . . . . . . . . .8-20, 8-21
MiniSeal High-Performance, Immersion-Resistant Crimp Splices . . . . . . . .8-22 to 8-25
Insulated Terminals and Disconnects
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
DuraSeal Heat-Shrinkable, Environmentally-Sealed,
Nylon-Insulated Crimp Terminals and Disconnects . . . . . . . . . . . . . . . . .8-27 to 8-32
SolderGrip Self-Fixturing Insulated Terminals . . . . . . . . . . . . . . . . . . . . . . .8-33 to 8-37
Wire Termination to Pin/Post/Tab
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-38
SolderSleeve Discrete Wire Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39 to 8-42
Shield Termination
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43
SolderSleeve Shield Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44 to 8-49
Coaxial Cable Termination
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-50
SolderSleeve Coaxial Cable Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-51, 8-52
SolderSleeve PCB/Coaxial Cable Terminators . . . . . . . . . . . . . . . . . . . . . . . .8-53, 8-54
RF One-Step BNC/TNC Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-55 to 8-60
Cable-to-Cable Splicing
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-61
SolderShield Shielded and Coaxial Cable Splices . . . . . . . . . . . . . . . . . . .8-62 to 8-65
Shielded Contacts
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-66
SolderTacts shielded one-piece solder contacts . . . . . . . . . . . . . . . . . . . .8-67 to 8-75
Data Bus (MIL-STD-1553B) Components
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-76
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-77, 8-78
In-Line Microcouplers: One- and Two- Stub . . . . . . . . . . . . . . . . . . . . . . . .8-79 to 8-81
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub . . . . . . . . . . . .8-82 to 8-84
Box Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-85, 8-86
Discrete Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-87, 8-88
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89 to 8-93
Triaxial Size 8 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-94
Space-Grade Data Bus Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-95 to 8-97
Customer-Specified Harness Assemblies and HarnWare . . . . . . . . . . . . . . . . . . . .8-98
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-98
Other
HexaShield, High Performance EMC Adapters . . . . . . . . . . . . . . . . . . . . .8-99 to 8-104
MTC Crimp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-105 to 8-111
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Electrical Interconnect Products
8-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
Typical SolderSleeve
Device (illustration of
shield terminator concept)
Transparent, heat-shrinkable
thermoplastic sleeve Thermoplastic sealing ring
Optional preinstalled wire lead
Fluxed solder preform
Sleeve shrinks, conforms to
cable contours, and provides
strain relief
Solder preform melts and flows,
Installation quality is fully visible
through transparent sleeve
Sealing rings melt to provide
environmental protection
Typical Installation
1. Insert prepared cable
2. Apply heat
Tyco Electronics' depend-
able, economical wire and
cable termination products
provide solutions for
hundreds of wire and cable
interconnect requirements.
All Raychem wire termina-
tion products are housed
inside transparent heat-
shrinkable insulation
sleeves, which provide
inspectability and can
provide various levels of
environmental protection.
Most Raychem termination
products incorporate a
fluxed solder preform,
which is essential for a
highly controlled soldering
process. Other products
incorporate controlled
crimping or a unique
process of combining a
twist-on coil with controlled
soldering to provide high-
reliability joints on the
widest variety of conductor
types and platings.
SolderSleeve technology
ensures high-quality
electrical and mechanical
performance time after time.
Premeasured solder and
flux create repeatable, reli-
able terminations, reducing
rejects and field failures.
When the SolderSleeve
device is heated, the tubing
shrinks and the solder
preform melts to make a
fully insulated, strain-
relieved, protected solder
connection. Heat-shrinkable
tubing provides the benefits
of insulation, strain relief,
and protection for our
controlled crimp products.
Many Raychem intercon-
nect products have earned
UL recognition or MIL-Spec
approval.
Many SolderSleeve and
related devices are made
from polyvinylidene fluoride
tubings that meet the
requirements of AMS-DTL-
23053/8 (formerly MIL-DTL-
23053/8).
Raychem interconnect
devices combine high-
strength materials with
innovative design for
consistent, long-life
performance. And
because the insulation
sleeve is transparent,
operators can easily
inspect the connection.
Raychem shrink-to-fit
technology even helps
reduce inventory, because
one device size will fit a
wide range of wire gauges,
cable diameters, and
component shapes.
Raychem interconnect
products are designed
for many applications,
from simple splices to
terminators for sophisti-
cated electronic systems,
either sealed or unsealed,
and for high- or low-
temperatureenvironments.
8
Electrical Interconnect Products
Electrical Interconnect Products
8-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Selection
Application Type Max. Operating Connection Page
Temp. Type Product Description Series Number
Wire-to-wire splicing
125°C [257°F] Solder SolderSleeve wire splices CWT-900X 8-6
150°C [302°F] Solder SolderSleeve wire splices D-110, D-1744 8-6
125°C [257°F] Coil and solder SolderGrip closed end
connector splices (stub) SGRP, SGRS 8-12
125°C [257°F] Crimp DuraSeal crimp splices D-406 8-18
125°C [257°F] Crimp PolyCrimp wire splices C-203 8-20
150°C [302°F] Crimp MiniSeal crimp splices D-436 (M81824) 8-22
Terminals and 125°C [257°F] Crimp DuraSeal crimp terminals
disconnects and disconnects B-106 8-27
150°C [302°F] Coil and solder SolderGrip terminals SGRT 8-33
Wire termination 125°C [257°F] Solder SolderSleeve wire terminators CWT-15XX 8-39
to pin/post/tab 150°C [302°F] Solder SolderSleeve wire terminators D-129, D-141,
D-71X 8-39
Shield termination
125°C[257°F]Solder SolderSleeve shield terminators CWT-X 8-44
150°C [302°F] Solder SolderSleeve shield terminators S01, S02,
M83519, SO63 8-44
175°C[347°F] Solder SolderSleeve shield terminators SO96 8-44
Coaxial cable 125°C [257°F] Solder SolderSleeve coaxial cable terminators CWT-4XXX 8-51
termination 150°C [302°F] Solder SolderSleeve coaxial cable terminators B-02X, B-04X 8-51
150°C [302°F] Solder SolderSleeve PCB/coaxial cable terminators D-607, B-046 8-53
135°C [275°F] Solder RF one-step BNC/TNC connectors RBD, RTD 8-55
Cable-to-cable splicing 150°C [302°F] Solder/Crimp SolderShield cable splices D-150 8-62
Shielded contacts 150°C [302°F] Solder SolderTacts shielded contacts D-602 8-67
Triax connectors 150°C [302°F] Solder Triax discrete connectors D-621, DK-621 8-87
MIL-STD-1553 150°C [302°F] Solder Triax discrete connectors D-621, DK-621 8-87
Data bus connectors 150°C[302°F] Solder Triax discrete connectors D-621, DK-621 8-87
MIL-STD-1553 150°C[302°F] Solder or In-line data bus
In-line couplers connectorized microcoupler D-500-04 8-79
MIL-STD-1533 150°C [302°F] Connectorized Data bus box couplers D-500-025 8-85
Triaxial size 8
contacts 150°C [302°F] Solder Size 8, triaxial MIL-C-38999 contacts D-602, DK-602 8-94
Data bus cables 150°C [302°F] Crimp or solder MIL-STD-1553 B shielded cable 1061X 8-77
Data bus terminators 150°C [302°F] Solder or MIL-STD-1553
connectorized 78 Ohms and 3000 Ohms terminators D-621, D-500 8-89
Data bus accessories 150°C [302°F] Solder or Dust caps, braid terminators, splices D-600,D-150 8-89
mechanical
Electrical Interconnect Products
8-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Selection (Continued)
SolderSleeve wire splices
Application Type Connection Max. Product Description Series Page
Type Operating Number
Temp.
Wire-to-Wire
Splicing
Terminals
and Disconnects
Wire Termination
to pin/post/tab
Shield Termination
Coax Cable
Termination
Cable-to-Cable
Splicing
Shielded Contacts
125°C CWT-900X
Solder
Crimp
Coil and
Solder
Coil and
Solder
Crimp
Solder
Solder
Solder
Solder/Crimp
Solder
8-6
8-6
8-18
8-20
8-12
8-27
8-39
8-39
8-44
8-44
8-44
8-51
8-55
8-51
8-53
8-62
8-67
8-76
SolderSleeve wire splices
150°C D-110,
D-1744
DuraSeal crimp splices
125°C D-406
PolyCrimp crimp splices
125°C C-203
8-22
MiniSeal crimp splices
150°C D-436
(M81824)
SolderGrip closed end
connector splices (stub)
125°C SGRP,
SGRS
DuraSeal crimp terminals
and disconnects
125°C B-106
8-33
SolderGrip terminals
150°C SGRT
SolderSleeve wire terminators
125°C CWT-15XX
SolderSleeve wire terminators
150°C D-129,
D-141,
D-71X
SolderSleeve shield terminators
125°C CWT-X
SolderSleeve shield terminators
150°C S01, S02,
M83519,
SO63
SolderSleeve shield terminators
175°C SO96
SolderSleeve
coaxial cable terminators
125°C CWT-4XXX
SolderTacts shielded contacts
150°C D-602
SolderShield cable splices
150°CD-150,
B-202
SolderSleeve
coaxial cable terminators
150°C B-02X/04X
SolderSleeve
PCB/coaxial cable terminators D-607,
B-046
RF one-step BNC/TNC
connector
135°C RBD,
RTD
MIL-STD-1553B
Data Bus
Components
Solder Data bus couplers, connectors,
terminators, accessories
150°C D-500,
D-600,
D(K)-621
8
Electrical Interconnect Products
8-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
Introduction
Tyco Electronics offers
many products for
wire-to-wire splicing:
Raychem SolderSleeve
splicing devices; SolderGrip
splices; and DuraSeal and
MiniSeal crimp splices.
Like all Raychem intercon-
nect products, the wire-to-
wire splicing devices are
rugged and reliable, yet
easy to install.
Designed for applications
with temperatures up to
150°C [302°F], products
in this section include:
nSolderSleeve splicing
devices, which can be
used to make sealed or
unsealed splices. In a
single step, they solder,
insulate, encapsulate, and
strain-relieve a wide
range of wiresizes.
nDuraSeal heat-shrinkable
nylon crimp splices are
easy to use in factory or
repair applications.
DuraSeal crimp splices
provide watertight sealing
and superior protection
against corrosion,
abrasion, and vibration.
nSmall, lightweight, and
low-profile MiniSeal high-
performance crimp
splices, which substantially
reduce wir e bundle size
and weight, are QPL-listed
to the MIL-S-81824
specification, and are
requir ed by the MIL-W-
5088 specification.
nSolderGrip splices, which
are closed-end connec-
tors utilizing a spiral
copper coil that grips
and compresses the
conductors and allows a
prefluxed solder ring to
flow to the center of the
splicing area, resulting
in a high-reliability,
repeatable solder joint.
nPolyCrimp heat-shrinkable
polyethylene crimp
splices offer a one-piece
design and translucent
tubing which allows for
visual inspection of the
splice. The dual wall
polyethylene tubing pro-
vides strain relief and
protection against the
environment.
8-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices
Product Options
Product Series Minimum Wire Maximum Operating Intended Application
Temperature Rating Temperature Environment
CWT 85°C [185°F] 125°C [257°F] Splashproof
D-110 125°C [257°F] 150°C [302°F] Splashproof
D-1744 (NAS 1744) 125°C[257°F] 150°C [302°F] Immersion sealed
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult Tyco Electronics for details.
Product Facts
nTransparent polyvinylidene
fluoride or polyolefin sleeve
provides encapsulation,
inspectability, strain relief,
and insulation
nPrefluxed solder preform
provides a controlled
soldering process
nOne-piece design makes
installation easy and lowers
the installed cost
nWith one or two wires per
end, the NAS 1744 splices
meet 75,000 ft [22,000 m]
altitude immersion
requirement
nThermochromic temperature
indicator in the NAS splices
facilitates termination and
inspection
nUL and CUL
recognized
R
Product Selection Process
From the Product Options
table above, select the
product series appropriate
for your application based
on the temperature rating
and sealing performance
required.
I
If
f t
th
he
e a
ap
pp
pl
li
ic
ca
at
ti
io
on
n h
ha
as
s o
on
nl
ly
y
o
on
ne
e s
si
iz
ze
e o
of
f w
wi
ir
re
e p
pe
er
r s
si
id
de
e
and no more than two wires
on either side:
1. Determine wire gauge
sizes for both sides of
splice.
2. Determine number of
wires (one or two wires)
for each side of splice.
3. Select part numbers from
the appropriate table:
nFor CWT series (low
temperature): Use
Table A on page 8-7.
nFor D-110 series
(splashproof): Use
Table B on page 8-8.
nFor D-1744 series
(immersion sealed):
Use Table C on
page 8-9.
I
If
f t
th
he
e a
ap
pp
pl
li
ic
ca
at
ti
io
on
n h
ha
as
s m
mo
or
re
e
t
th
ha
an
n o
on
ne
e s
si
iz
ze
e o
of
f w
wi
ir
re
e p
pe
er
r
s
si
id
de
e
or more than two wires
on either side (or if you pre-
fer to work with CMA or mm2
sizes):
1. Turn to “CMA/mm2
Calculation” on page
8-10 and use the work-
space there to calculate
the total cross section to
be spliced.
2. Use Table E on page
8-11 to select the sleeve
recommended for that
cross section.
Notes:
While all combinations listed
will provide satisfactory
solder joints, the degree
of strain relief obtained
depends on the outer diam-
eter of the wires being
joined. Refer to Table E for
the recommended size
ranges for the sleeves.
Wires 16 AWG (1.21 mm2)
and larger, and wires hav-
ing more than 19 strands,
should be pretinned prior
to splicing, to obtain the
optimum solder joint quality.
Part selection for wires
26 AWG (0.15 mm2) and
smaller is covered on page
8-8.
Applications
In-line wire splices.
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 A WG 1CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002
24 A WG 1CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002
2CWT-9001 CWT-9002 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
22 AWG 1CWT-9001 CWT-9001 CWT-9001 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002
2CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
20 A WG 1CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
18 A WG 1 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
16 A WG 1CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9002 CWT-9003 CWT-9003 CWT-9003
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
14 A WG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003
2CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004
12 A WG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004
2CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
10 A WG 1 CWT -9005 CWT -9005 CWT -9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of 121212121
Conductors
26 AWG 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
24 A WG 1 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
22 A WG 1CWT-9002 CWT-9003 CWT-9002 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
20 AWG 1 CWT-9002 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
18 A WG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
16 A WG 1 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
14 A WG 1CWT-9003 CWT-9003 CWT-9003 CWT-9004 CWT-9003 CWT-9004 CWT-9004 CWT-9005 CWT-9005
2 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005 CWT-9005 CWT-9005
12 A WG 1 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9004 CWT-9005 CWT-9004 CWT-9005 CWT-9005
2 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
10 A WG 1 CWT -9005 CWT -9005 CWT -9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005 CWT-9005
Table A:
CWT Series Selection
8-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 A WG 1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
2 D-110-35 D-110-35 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41
24 A WG 1 D-110-35 D-110-35 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41
2 D-110-35 D-110-41 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
22 A WG 1 D-110-35 D-110-35 D-110-35 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
20 A WG 1 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
2 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
18 A WG 1D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181
2D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
16 A WG 1D-110-41 D-110-41 D-110-41 D-110-41 D-110-41 D-110-0181 D-110-0181 D-110-0181
2D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101
14 A WG 1D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0101
2D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090
12 A WG 1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090
10 A WG 1 D-1 10-0090 D-1 10-0090 D-1 10-0090 D-1 10-0090 D-1 10-0090 D-1 10-0083 D-1 10-0083 D-1 10-0083
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG 10 AWG
Number of 121212121
Conductors
26 A WG 1 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
24 A WG 1D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0181 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
22 A WG 1 D-110-41 D-110-0181 D-110-41 D-110-0181 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
20 A WG 1 D-110-41 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090
2 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
18 A WG 1D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
2 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
16 A WG 1 D-110-0181 D-110-0101 D-110-0181 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090
2 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0083 D-110-0083
14 A WG 1 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0083
2 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
12 AWG 1 D-110-0101 D-110-0090 D-110-0101 D-110-0090 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0083
2 D-110-0090 D-110-0090 D-110-0090 D-110-0083 D-110-0090 D-110-0083 D-110-0083 D-110-0083 D-110-0083
10 A WG 1 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083 D-1 10-0083
Table B:
D-110 Series Selection
Part Inside Diameter
No. As Supplied* Fully Recovered** Length***
D-110-0071 0.9 [0.035] 0.6 [0.025] 4.7 [0.185]
D-110-0213 0.9 [0.035] 0.6 [0.025] 4.2 [0.165]
D-110-0214 0.6 [0.025] 0.3 [0.013] 6.3 [0.250]
D-110-0217 1.0 [0.040] 0.6 [0.025) 9.1 [0.360]
D-110-40 0.6 [0.025] 0.5 [0.021] 5.1 [0.200]
Note: Micro SolderSleeve terminations are used for splicing wires smaller than 26 AWG [0.15 mm2].
*Minimum. Wire insulation must be smaller than this.
**Maximum. Wire insulation and combined conductor diameters must be greater than this.
***Nominal. Wire strip length must be approximately one-half of this.
Fine Wire Splices 26 AWG
(0.15 mm2) and Smaller
8
Electrical Interconnect Products
8-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
Side A: Side B: Size and Number of Conductors
Size and 26 AWG 24 AWG 22 AWG 20 AWG
Number of 12121212
Conductors
26 A WG 1D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
2D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
24 A WG 1D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02
2D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-02 D-1744-02
22 A WG 1D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02
2D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02
20 A WG 1D-1744-01 D-1744-01 D-1744-01 D-1744-02 D-1744-01 D-1744-02 D-1744-02 D-1744-02
2 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
18 A WG 1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
16 A WG 1 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-02 D-1744-03
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
14 A WG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03
2D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
12 AWG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04
2D-1744-04 D-1744-04 D-1744-04 — D-1744-04 — — —
Side A: Side B: Size and Number of Conductors
Size and 18 AWG 16 AWG 14 AWG 12 AWG
Number of 12121212
Conductors
26 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
24 A WG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
22 AWG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04
2 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
20 A WG 1 D-1744-02 D-1744-03 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-04 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
18 A WG 1 D-1744-02 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
16 A WG 1D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
2 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-04 —
14 A WG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 —
2 D-1744-03 D-1744-04 D-1744-04 D-1744-04 D-1744-04 — — —
12 A WG 1 D-1744-03 D-1744-03 D-1744-03 D-1744-04 D-1744-03 — D-1744-04 —
Table C:
D-1744 Series Selection
8-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices (Continued)
To calculate the total circu-
lar mil or mm2area of the
conductors to be termi-
nated in a single splice, fol-
low these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue
to use it for all your
selection criteria.
2. In the workspace below,
list the CMA or mm2for
each conductor that will
go into the same splice.
(To assist you, Table D on
this page provides
the CMA of typical
conductors.)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. From Table E on the next
page, select the part
number recommended
for the total CMA or mm2
you have calculated.
5. Refer to the examples on
this page for further
clarification.
Total CMA = 3180 Total CMA = 3408
Total mm2= 1.59 Total mm2= 1.71
Correct part number selection from Table E Correct part number selection from Table E
(based on CMA/mm2and nominal jacket wire OD) (based on CMA/mm2and nominal jacket wire OD)
= CWT-9002 or D-110-41 or D-1744-02. = CWT-9003 or D-110-0181 or D-1744-03.
CMA/mm2Examples
One-to-One Wire Splice Multiwire Splice
Wire Number CMA mm2
1
2
3
4
5 Part Number:
Total
16 AWG (CMA 2426)
[1.21 mm
2
]
2.50 [.100] 1.50 [.060]
22 AWG (CMA 754)
[0.38 mm
2
]
2 at 22 AWG (CMA 1508)
[0.38 mm
2
]
1.50 [.060]
1.50 [.060]
3.00 [.120] 2.25 [.090]
18 AWG (CMA 1900)
[0.24 mm
2
]
CMA of Typical AWG Conductors
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
CMA/mm2Calculation
Table D.
8
Electrical Interconnect Products
8-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderSleeve Wire Splices(Continued)
CMA mm2
Product Wire Jacket OD Combined Total Combined Total
Series Min. Max. Min. Max. Min. Max.
CWT-9001 0.4 [0.015] 1.7 [0.066] 450 1500 0.3 1.8
CWT-9002 1.3 [0.05] 2.7 [0.106] 1250 3500 0.8 2.0
CWT-9003 1.8 [0.07] 4.5 [0.18] 2500 7200 2.0 4.0
CWT-9004 2.8 [0.11] 6.0 [0.236] 6100 19000 4.0 6.0
CWT-9005 3.2 [0.125] 7.0 [0.275] 12000 25000 6.0 10.0
D-1744-01 0.50 [0.020] 1.90 [0.075] 350 2000 – –
D-1744-02 0.80 [0.031] 2.80 [0.110] 2000 4000 – –
D-1744-03 1.30 [0.050] 4.57 [0.180] 4000 10000 – –
D-1744-04 2.00 [0.080] 7.11 [0.280] 10000 13000 – –
D-110-35 0.51 [0.020] 1.78 [0.070] 500 1500 ––
D-110-41 1.27 [0.050] 2.54 [1.00] 1200 3500 – –
D-110-0181 1.9 [0.075] 4.5 [0.177] 3600 6000 – –
D-110-0101 2.41 [0.095] 4.32 [0.17] 4800 9000 – –
D-110-0090 3.56 [0.140] 7.11 [0.28] 8500 16200 – –
D-110-0083 4.0 [0.160] 8.76 [0.345] 16200 25000 – –
Series Agency Raychem
CWT UL E87681 D-5023
D-110 UL E87681 RT-1404
D-1744 NAS-1744 RT-1404
Material
Insulation (D-110, D-1744) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation (CWT) Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux (D-110, D-1744) Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAflux)
Solder and flux (CWT) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ASNS-J-004 (RAflux)
Meltable inserts (CWT, D-1744) Meltable thermoplastic
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating (CWT) -55°C to +125°C [-67°F to +257°F]
Temperature rating (D-110, D-1744) -55°C to +150°C [-67°F to +302°F]
Insulation resistance 1000 megohms
Installation Requirements
Table E:
Multiwire Splice Selection
Product Characteristics
Specifications/Approvals
For proper installation of
these devices the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
nHL1802E
nIR-1759 MiniRay
nAA-400 Super Heater
nCV-1981
Refer to Raychem installa-
tion procedure RPIP 850-00
for D-1744 Series and RPIP
824-00 for CWT Series.
You will find ordering
information for these tools
in Section 10.
8-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices
Applications
SolderGrip heat-shrinkable
solder-type closed-end
connectors are designed
for electrical termination of
multiple-wire combinations.
They provide a reliable
alternative to crimping,
welding, or conventional
twist-on-style closed-end
connectors.
Their unique combination of
wire fixturing and controlled-
soldering technology pro-
vides dependable electrical
termination of multiple wire
combinations.
SolderGrip terminators
consist of a heat-shrinkable
thermoplastic sleeve con-
taining a spiral-wound cop-
per insert. The insert is
fitted with a prefluxed
solder band.
This innovation design
allows SolderGrip products
to reliably terminate as
many as 10 wires of
different sizes and types in
a single device.
The capability of SolderGrip
terminators encompasses
single or multistranded,
bare or tinned copper
wires with low- or high-
temperature insulation.
The termination is
environmentally protected
and strain relieved.
SolderGrip splice termina-
tors are color-coded for
easy identification.
Product Options
Product Series Environmental Protection Max. Operating Temp.
SGRP Splashproof 125°C [257°F]
SGRS Sealed 125°C [257°F]
Product Facts
nSoldered connection
nElectrical insulation
nSealed for immersion
(SGRS)
nExcellent strain relief
nSimple installation
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Product Dimensions (Min.) Product Dimensions (Min.)
Part Color L ØA Wire Range (Min.-Max.) L ØA Wire Range (Min.-Max.)
No. Code CMA/mm2CMA/mm2
SGRP-1 Green 1.370 .120 1400 - 4800 SGRS-1 Green 1.370 0.130 1400 - 4800
[34.8] [2.9] [0.7 - 2.4] [34.8] [3.4] [0.7 - 2.4]
SGRP-2 Red 1.350 .150 4000 - 8000 SGRS-2 Red 1.350 0.190 4000 - 8000
[34.2] [3.7] [2.0 - 4.0] [34.2] [4.8] [2.0 - 4.0]
SGRP-3 Blue 1.610 .200 7000 - 18000 SGRS-3 Blue 1.650 0.290 7000 - 16000
[41.0] [5.1] [3.5 - 8.0] [42.0] [7.3] [3.5 - 8.0]
SGRP-4 Yellow 1.650 .270 15000 - 30000 SGRS-4 Yellow 1.630 0.360 15000 - 24000
[42.0] [6.8] [7.5 - 12.0] [41.5] [9.1] [7.5 - 12.0]
L
Sealing insert
ØA
L
ØA
1. From the Product Options
table on the previous
page, select the product
series appropriate for
your application.
2. Determine the wire com-
bination (number of wires
and size) of the wire bun-
dle you wish to splice.
3. Use Table C (page 8-15)
to select the correct con-
nector for AWG wire com-
binations.*
For mm2wire combina-
tions use Table A to
select a SolderGrip part
number.
Example: For connecting
a bundle with one 12
AWG wire (1 #12) and
two 14 AWG wires (+2
#14), you need an SGRP-
3 connector. For sealed
parts, select the SGRS
series.
*If the wire combination is not
listed in Table C, use the CMA
(mm2) method of determining
wire bundle size (see “CMA/
mm2Calculation” on page 8-14).
Using Table B (page 8-14, select
the smallest size connector that
will fit your total wire CMA (mm2)
value.
4. Verify that the wire bundle
(with wire insulation) does
not exceed the maximum
diameter allowed for the
connector you selected.
Simply check the bundle’s
diameter against the
maximum diameter that
Table A (below) lists for
that part.
5. Verify that the total
amperage to be applied
does not exceed the
maximum amp rating for
the part.
Product Selection Process
Insulated Closed-End Connectors (SGRP series) Insulated and Sealed Closed-End Connectors (SGRS series)
Part Color
No. Code
Table A - Product Dimensions
and Part Number Descriptions
8-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
CMA/mm2Example
22 AWG/.38
CMA 754 OD Bundle Insulation
Conductor
Bundle diameter must not
exceed 6.0 mm (0.24 in) for
SGRP-2 or 0.18 mm (4.5 in)
for SGRS-2.
Total CMA = 5834
Total mm2 = 2.92
Correct part number (based on CMA of 5834
or mm2of 2.92): SGRP-2or SGRS-2
22 AWG/.38
CMA 754
18 AWG/.95
CMA 1900
16 AWG/1.21
CMA 2426
AWG 30 28 26 24 22 20 18 16 14 12 10 8
CMA 112 177 304 475 754 1216 1900 2426 3831 5874 9354 16983
mm20.05 0.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94 4.74 8.61
To calculate the total circu-
lar mil or mm2area of the
wire bundle to be termi-
nated, follow these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue to
use it for all your selec-
tion criteria. (Both meas-
ures provide the same
results.)
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Solder Grip Part No.
Total
CMA/mm2Calculation 2. In the workspace below,
list the CMA or mm2for
each conductor in the
bundle. (Table B provides
the CMA of typical con-
ductors.)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. Use Table A to select the
smallest terminator that
will fit the total CMA (mm2).
Table B. CMA of Typical
Copper Conductors
8
Electrical Interconnect Products
8-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Wire Splash- Wire Splash- Wire Splash-
Combinations proof Sealed Combinations proof Sealed Combinations proof Sealed
1 # 8 + 1 # 12 SGRP-4 SGRS-4 1 # 14 + 3 # 20 SGRP-2 SGRS-2 2 # 16 + 1 # 18 + 3 # 20 SGRP-3 SGRS-3
1 # 8 + 1 # 16 SGRP-4 SGRS-4 1 # 14 + 4 # 20 SGRP-3 SGRS-3 2 # 16 + 1 # 18 + 2 # 20 SGRP-3 SGRS-3
2 # 8 + 2 # 16 SGRP-4 SGRS-4 1 # 14 + 1 # 18 SGRP-2 SGRS-2 2 # 16 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2
1 # 8 + 1 # 14 SGRP-4 SGRS-4 1 # 14 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2 2 # 16 + 1 # 18 SGRP-2 SGRS-2
1 # 8 + 1 # 14 + 1 # 16 SGRP-4 SGRS-4 1 # 14 + 2 # 18 SGRP-2 SGRS-2 2 # 16 + 4 # 20 SGRP-3 SGRS-3
1 # 10 + 1 # 18 SGRP-3 SGRS-3 1 # 14 + 3 # 18 SGRP-3 SGRS-3 2 # 16 + 3 # 20 SGRP-3 SGRS-3
1 # 10 + 2 # 18 SGRP-3 SGRS-3 1 # 14 + 4 # 18 SGRP-3 SGRS-3 2 # 16 + 2 # 20 SGRP-2 SGRS-2
1 # 10 + 3 # 18 SGRP-3 SGRS-3 1 # 14 + 5 # 18 SGRP-3 SGRS-3 2 # 16 + 1 # 20 SGRP-2 SGRS-2
1 # 10 + 1 # 16 SGRP-3 SGRS-3 1 # 14 + 1 # 16 SGRP-2 SGRS-3 2 # 16 SGRP-2 SGRS-2
1 # 10 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3 1 # 14 + 1 # 16 + 1 # 20 SGRP-2 SGRS-2 1 # 16 + 5 # 18 SGRP-3 SGRS-3
1 # 10 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3 1 # 14 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3 1 # 16 + 4 # 18 + 1 # 20 SGRP-3 SGRS-3
1 # 10 + 2 # 16 SGRP-3 SGRS-3 1 # 14 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3 1 # 16 + 4 # 18 SGRP-3 SGRS-3
1 # 10 + 3 # 16 SGRP-4 SGRS-4 1 # 14 + 1 # 16 + 3 # 18 SGRP-3 SGRS-3 1 # 16 + 3 # 18 + 2 # 20 SGRP-3 SGRS-3
1 # 10 + 4 # 16 SGRP-4 SGRS-4 1 # 14 + 1 # 16 + 4 # 18 SGRP-3 SGRS-3 1 # 16 + 3 # 18 + 1 # 20 SGRP-3 SGRS-3
1 # 10 + 5 # 16 SGRP-4 SGRS-4 1 # 14 + 2 # 16 SGRP-3 SGRS-3 1 # 16 + 2 # 18 + 3 # 20 SGRP-3 SGRS-3
1 # 10 + 1 # 14 SGRP-3 SGRS-3 1 # 14 + 2 # 16 + 1 # 18 SGRP-3 SGRS-3 1 # 16 + 2 # 18 + 1 # 20 SGRP-2 SGRS-2
1 # 10 + 1 # 14 + 1 # 18 SGRP-3 SGRS-3 1 # 14 + 2 # 16 + 2 # 18 SGRP-3 SGRS-3 1 # 16 + 2 # 18 SGRP-2 SGRS-2
1 # 10 + 1 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 14 + 2 # 16 + 3 # 18 SGRP-3 SGRS-3 1 # 16 + 1 # 18 + 4 # 20 SGRP-3 SGRS-3
1 # 10 + 1 # 14 + 2 # 16 SGRP-3 SGRS-3 1 # 14 + 3 # 16 SGRP-3 SGRS-3 1 # 16 + 1 # 18 + 3 # 20 SGRP-2 SGRS-2
1 # 10 + 1 # 14 + 3 # 16 SGRP-4 SGRS-4 1 # 14 + 3 # 16 + 1 # 18 SGRP-3 SGRS-3 1 # 16 + 1 # 18 + 2 # 20 SGRP-2 SGRS-2
1 # 10 + 2 # 14 SGRP-4 SGRS-4 1 # 14 + 3 # 16 + 2 # 18 SGRP-3 SGRS-3 1 # 16 + 1 # 18 + 1 # 20 SGRP-2 SGRS-2
1 # 10 + 3 # 14 SGRP-4 SGRS-4 1 # 14 + 4 # 16 SGRP-3 SGRS-3 1 # 16 + 1 # 18 SGRP-1 SGRS-1
1 # 10 + 1 # 12 SGRP-3 SGRS-3 1 # 14 + 4 # 16 + 1 # 18 SGRP-3 SGRS-3 1 # 16 + 4 # 20 SGRP-2 SGRS-2
1 # 10 + 1 # 12 + 1 # 14 SGRP-4 SGRS-4 1 # 14 + 5 # 16 SGRP-3 SGRS-3 1 # 16 + 3 # 20 SGRP-2 SGRS-2
1 # 10 + 2 # 12 SGRP-4 SGRS-4 2 # 14 SGRP-2 SGRS-2 1 # 16 + 1 # 20 + 1 # 22 SGRP-1 SGRS-1
2 # 10 SGRP-4 SGRS-4 2 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 16 + 1 # 20 SGRP-1 SGRS-1
2 # 10 + 1 # 16 SGRP-4 SGRS-4 2 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 16 + 3 # 22 SGRP-1 SGRS-1
1 # 12 + 1 # 18 SGRP-2 SGRS-2 2 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 16 + 2 # 22 SGRP-1 SGRS-1
1 # 12 + 2 # 18 SGRP-3 SGRS-3 2 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 16 + 1 # 22 SGRP-1 SGRS-1
1 # 12 + 3 # 18 SGRP-3 SGRS-3 2 # 14 + 2 # 16 SGRP-3 SGRS-3 1 # 18 + 1 # 22 SGRP-1 SGRS-1
1 # 12 + 4 # 18 SGRP-3 SGRS-3 2 # 14 + 2 # 16 SGRP-3 SGRS-3 1 # 18 + 2 # 22 SGRP-1 SGRS-1
1 # 12 + 5 # 18 SGRP-3 SGRS-3 2 # 14 + 3 # 16 SGRP-3 SGRS-3 1 # 18 + 3 # 22 SGRP-1 SGRS-1
1 # 12 + 1 # 16 SGRP-3 SGRS-3 2 # 14 + 4 # 16 SGRP-4 SGRS-4 1 # 18 + 1 # 20 SGRP-1 SGRS-1
1 # 12 + 1 # 16 + 1 # 18 SGRP-3 SGRS-3 3 # 14 SGRP-3 SGRS-3 1 # 18 + 1 # 20 + 1 # 22 SGRP-1 SGRS-1
1 # 12 + 1 # 16 + 2 # 18 SGRP-3 SGRS-3 3 # 14 + 1 # 16 SGRP-3 SGRS-3 1 # 18 + 1 # 20 + 2 # 22 SGRP-1 SGRS-1
1 # 12 + 1 # 16 + 3 # 18 SGRP-3 SGRS-3 3 # 14 + 2 # 16 SGRP-4 SGRS-4 1 # 18 + 2 # 20 SGRP-1 SGRS-1
1 # 12 + 1 # 16 + 4 # 18 SGRP-4 SGRS-4 3 # 14 + 3 # 16 SGRP-4 SGRS-4 1 # 18 + 3 # 20 SGRP-2 SGRS-2
1 # 12 + 2 # 16 SGRP-3 SGRS-3 4 # 14 SGRP-3 SGRS-3 1 # 18 + 4 # 20 SGRP-2 SGRS-2
Table C. SolderGrip Wire
Combinations
8-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Wire Splash- Wire Splash- Wire Splash-
Combinations proof Sealed Combinations proof Sealed Combinations proof Sealed
1 # 12 + 2 # 16 + 1 # 18 SGRP-3 SGRS-3 4 # 14 + 1 # 16 SGRP-4 SGRS-4 1 # 18 + 5 # 20 SGRP-2 SGRS-2
1 # 12 + 2 # 16 + 2 # 18 SGRP-3 SGRS-3 4 # 14 + 2 # 16 SGRP-4 SGRS-4 2 # 18 SGRP-1 SGRS-1
1 # 12 + 3 # 16 SGRP-3 SGRS-3 5 # 14 SGRP-4 SGRS-4 2 # 18 + 1 # 22 SGRP-1 SGRS-1
1 # 12 + 4 # 16 SGRP-3 SGRS-3 5 # 14 + 1 # 16 SGRP-4 SGRS-4 2 # 18 + 1 # 20 SGRP-2 SGRS-2
1 # 12 + 5 # 16 SGRP-4 SGRS-4 1 # 16 + 3 # 18 SGRP-3 SGRS-3 2 # 18 + 2 # 20 SGRP-2 SGRS-2
1 # 12 + 1 # 14 + 1 # 18 SGRP-3 SGRS-3 1 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3 2 # 18 + 3 # 20 SGRP-2 SGRS-2
1 # 12 + 1 # 14 + 2 # 18 SGRP-3 SGRS-3 1 # 16 + 5 # 20 SGRP-3 SGRS-3 2 # 18 + 4 # 20 SGRP-3 SGRS-3
1 # 12 + 1 # 14 + 3 # 18 SGRP-3 SGRS-3 1 # 16 + 2 # 20 SGRP-2 SGRS-2 3 # 18 SGRP-2 SGRS-2
1 # 12 + 1 # 14 + 1 # 16 SGRP-3 SGRS-3 6 # 16 SGRP-3 SGRS-3 3 # 18 + 1 # 20 SGRP-2 SGRS-2
1 # 12 + 1 # 14 + 2 # 16 SGRP-3 SGRS-3 5 # 16 + 1 # 18 SGRP-3 SGRS-3 3 # 18 + 2 # 20 SGRP-3 SGRS-3
1 # 12 + 1 # 14 + 3 # 16 SGRP-4 SGRS-4 5 # 16 + 1 # 20 SGRP-3 SGRS-3 3 # 18 + 3 # 20 SGRP-3 SGRS-3
1 # 12 + 1 # 14 + 4 # 16 SGRP-4 SGRS-4 5 # 16 SGRP-3 SGRS-3 4 # 18 SGRP-2 SGRS-2
1 # 12 + 2 # 14 SGRP-3 SGRS-3 4 # 16 + 2 # 18 SGRP-3 SGRS-3 4 # 18 + 1 # 20 SGRP-3 SGRS-3
1 # 12 + 2 # 14 + 1 # 18 SGRP-3 SGRS-3 4 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3 4 # 18 + 2 # 20 SGRP-3 SGRS-3
1 # 12 + 2 # 14 + 1 # 16 SGRP-4 SGRS-4 4 # 16 + 1 # 18 SGRP-3 SGRS-3 5 # 18 SGRP-3 SGRS-3
1 # 12 + 2 # 14 + 2 # 16 SGRP-4 SGRS-4 4 # 16 + 2 # 20 SGRP-3 SGRS-3 5 # 18 + 1 # 20 SGRP-3 SGRS-3
1 # 12 + 2 # 14 + 3 # 16 SGRP-4 SGRS-4 4 # 16 + 1 # 20 SGRP-3 SGRS-3 6 # 18 SGRP-3 SGRS-3
1 # 12 + 3 # 14 SGRP-4 SGRS-4 4 # 16 SGRP-3 SGRS-3 1 # 20 + 1 # 22 SGRP-1 SGRS-1
1 # 12 + 3 # 14 + 1 # 16 SGRP-4 SGRS-4 3 # 16 + 3 # 18 SGRP-3 SGRS-3 1 # 20 + 2 # 22 SGRP-1 SGRS-1
1 # 12 + 4 # 14 SGRP-4 SGRS-4 3 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3 1 # 20 + 3 # 22 SGRP-1 SGRS-1
2 # 12 SGRP-4 SGRS-4 3 # 16 + 2 # 18 SGRP-3 SGRS-3 1 # 20 + 4 # 22 SGRP-1 SGRS-1
2 # 12 + 1 # 18 SGRP-3 SGRS-3 3 # 16 + 1 # 18 + 2 # 20 SGRP-3 SGRS-3 2 # 20 SGRP-1 SGRS-1
2 # 12 + 1 # 18 SGRP-3 SGRS-3 3 # 16 + 1 # 18 + 1 # 20 SGRP-3 SGRS-3 2 # 20 + 1 # 22 SGRP-1 SGRS-1
2 # 12 + 1 # 16 SGRP-3 SGRS-3 3 # 16 + 1 # 18 SGRP-3 SGRS-3 2 # 20 + 2 # 22 SGRP-1 SGRS-1
2 # 12 + 2 # 16 + 1 # 18 SGRP-4 SGRS-4 3 # 16 + 3 # 20 SGRP-3 SGRS-3 2 # 20 + 3 # 22 SGRP-1 SGRS-1
2 # 12 + 3 # 16 SGRP-4 SGRS-4 3 # 16 + 2 # 20 SGRP-3 SGRS-3 3 # 20 SGRP-1 SGRS-1
2 # 12 + 1 # 14 + 1 # 18 SGRP-4 SGRS-4 3 # 16 + 1 # 20 SGRP-3 SGRS-3 3 # 20 + 1 # 22 SGRP-1 SGRS-1
2 # 12 + 1 # 14 + 1 # 16 SGRP-4 SGRS-4 3 # 16 SGRP-2 SGRS-2 4 # 20 SGRP-2 SGRS-2
3 # 12 + 1 # 14 SGRP-4 SGRS-4 2 # 16 + 4 # 18 SGRP-3 SGRS-3 5 # 20 SGRP-2 SGRS-2
2 # 12 + 2 # 14 SGRP-4 SGRS-4 2 # 16 + 3 # 18 + 1 # 20 SGRP-3 SGRS-3 6 # 20 SGRP-2 SGRS-2
3 # 12 + 1 # 18 SGRP-4 SGRS-4 2 # 16 + 3 # 18 SGRP-3 SGRS-3 3 # 22 SGRP-1 SGRS-1
3 # 12 + 1 # 16 SGRP-4 SGRS-4 2 # 16 + 2 # 18 + 2 # 20 SGRP-3 SGRS-3 4 # 22 SGRP-1 SGRS-1
1 # 14 + 1 # 22 SGRP-1 SGRS-1 2 # 16 + 2 # 18 + 1 # 20 SGRP-3 SGRS-3 5 # 22 SGRP-1 SGRS-1
1 # 14 + 1 # 20 SGRP-2 SGRS-2 2 # 16 + 2 # 18 SGRP-3 SGRS-3 6 # 22 SGRP-1 SGRS-1
1 # 14 + 2 # 20 SGRP-2 SGRS-2 ——— — ——
Table C. SolderGrip Wire
Combinations (Continued)
8
Electrical Interconnect Products
8-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
SolderGrip Closed End Connector Splices (Continued)
Approvals and Reference
Documents
Installation
Agency Approvals UL, CUL E87681
Reference documents Raychem Specification RB-109 for splices
Specification Control Drawings
Splices—Non Sealed (SGRP-X), Splices—Sealed (SGRS-X)
The SolderGrip product is
pushed onto the conductors
with a twisting motion. With
the product in place, instal-
lation can be completed
with the proper selection
and use of heating tools
and reflectors. Either of the
following Raychem heating
tools is recommended:
nHL1802E
nCV-1981
Material
Insulation Radiation-crosslinked, transparent heat-shrinkable polyvinylidene fluoride
Solder preform with flux Sn 60, Pb 40, ROM1 flux per ANSI-J-STD-004 (RAflux).
Sealing insert (SGRS) Hot melt adhesive
Spiral wound insert Copper alloy
Physical Unit Method of test Requirement
Dimensions inches RB-109 See product dimensions.
Electromechanical Unit Method of test Typical values
Dielectric withstand voltage kilovolts RB-109 2.0
Static heating degrees RB-109 Less than 50°C rise
Environmental* Unit Method of test Requirement
Insulation resistance after water immersion (SGRS only) megohms RB-109 100
Contact resistance after testing milliohms RB-109 Less than 6 milliohms
Operating condition Unit Method of test Value
Temperature rating — — -55°C to 125°C [-67°F to 257°F]
Voltage rating volts — 600
*Immersion resistance sealing is dependent on the wire combinations used. The user should test specific wire combinations. Refer to RB-109 Raychem
specification for procedures.
Product Characteristics
Refer to Raychem installa-
tion procedure RPIP 820-00
for detailed instructions and
recommended reflector
attachments.
You will find ordering
information for these tools in
Section 10.
8-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
DuraSeal Heat-Shrinkable, Environmentally Sealed,
Nylon-Insulated Crimp Splices
Applications
nAutomotive/truck wiring
repair and maintenance.
nAutomotive accessory
installations.
nOEM automotive/truck/RV
wire harness fabrication.
Specifications/Approvals
Series Agency Raychem
D-406 UL and CUL listed 91J4, File E87681 RB-107
—Lloyd’s listed, File 65 247 HH 02-93 —
Butt Splice Dimensions Wire Dimensions
Part A L Insulation Insulation
No. Min. Nom. Color Conductor O.D. (Max.) O.D. (Min.)
D-406-0001 3.68 [.145] 31.75 [1.25] Red 22–18 3.56 [.140] 1.40 [.055]
D-406-0002 4.57 [.180] 31.75 [1.25] Blue 16–14 4.45 [.175] 2.03 [.080]
D-406-0003 6.35 [.250] 38.10 [1.50] Yellow 12–10 6.22 [.245] 2.79 [.110]
ØA min.
L
Product Facts
nProtects splices from water,
condensation, salt, and
corrosion
nProvides strain relief
nProtects against vibration in
rugged environments
nCompletely insulates and
protects electrical
connections
nHas adhesive lining for
protection that is more
reliable than conventional
splices
nUL, CUL, and
Lloyd’s listed
R
Product Dimensions
Butt Splices
nMarine electronics.
nFleet maintenance.
nCommercial wiring
(pumps/pools/spas).
nAppliances.
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
DuraSeal Heat-Shrinkable, Environmentally Sealed,
Nylon-Insulated Crimp Splices (Continued)
Wire Size mm2Part No. Color
AWG
22–18 0.38–0.95 D-406-0001 Red
16–14 1.2–2.5 D-406-0002 Blue
12–10 3–6 D-406-0003 Yellow
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Cut-through resistance: 31 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb];
yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 h at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid,
diesel fuel, motor oil, antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 2500 Vac
Insulation resistance: 1000 megohms at 100 Vdc
Installation
1. Select splice of appropri-
ate size. Strip wire 7.5
mm (5/16 in). Insert into
crimp barrel.
2. Crimp using Raychem
AD-1522 crimp tool for
preinsulated crimps.
3. Heat crimped splice with
heat gun until tubing
recovers and adhesive
flows.
Installation Requirements
For proper installation of
these devices, the correct
crimp tool and a heating
tool with a reflector attach-
ment must be used. The
Raychem AD-1522 crimp
tool and HL1802E heating
tool are recommended.
You will find ordering infor-
mation for these tools in
Section 10.
Refer to Raychem installa-
tion procedure RPIP 821-00
for detailed instructions.
Product Selection Process
1. Determine wire size.
2. Select part number.
Product Characteristics
(Typical)
Physical properties
Wire-to-Wire Splicing
PolyCrimp Heat-Shrinkable Polyethylene Crimp Splices
8-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Facts
nOne-piece product reduces
inventory management
nTranslucent tubing allows
visual inspection
nColor coded for easy
selection of correct AWG
nDual wall polyethylene
tubing provides strain relief
and protection against
environment
Applications
nAlarms.
nMarine electronics.
nMass transit signal wire.
nTelecom aerial splices.
Specifications/Approvals
Series Raychem
C203 D5203
Butt Splice Dimensions Wire Dimensions
Part A L Insulation Insulation
No. Min. Nom. Color Conductor O.D. (Max.) O.D. (Min.)
C-203-01 3.68 [.145] 31.75 [1.25] Red 22–18 3.56 [.140] 1.40 [.055]
C-203-02 4.57 [.180] 31.75 [1.25] Blue 16–14 4.45 [.175] 2.03 [.080]
C-203-03 6.35 [.250] 38.10 [1.50] Yellow 12–10 6.22 [.245] —
Product Dimensions
Butt Splices
nTraffic light junction
boxes.
nCommercial wiring
(pumps).
nHeavy industrial
environments.
Available in:
Americas n
Europe n
Asia Pacific n
ØA min.
L
L
dia. A min.
Wire-to-Wire Splicing
PolyCrimp Heat-Shrinkable Polyethylene Crimp Splices (Continued)
8-21
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Wire Size mm2Part No. Color
AWG
22–18 0.38–0.95 C-203-01 Red
16–14 1.2–2.5 C-203-02 Blue
12–10 3–6 C-203-03 Yellow
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Wire pullout after crimping and recovery: red: 6.8 kg [15 lb]; blue: 18.14 kg [40 lb];
yellow: 22.7 kg [50 lb]
Chemical properties Meets electrical test after conditioning in diesel fuel, brake fluid, ASTM fuel C
and engine degreaser.
Electrical properties Dielectric strength: 2500 Vac
Insulation resistance: 1000 megohms at 100 Vdc
Voltage rating: 600 Volts max.
Product Selection Process
1. Determine wire size.
2. Select part number.
Product Characteristics
(Typical)
Physical properties
8-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices
Applications
MiniSeal wire-to-wire splic-
ing products offer solutions
for hundreds of aerospace
and defense applications.
These environment-resistant
splices provide excellent
reliability, long term per-
formance, MIL-S-81824/1
qualification, and a low
installed cost.
MiniSeal crimp splices con-
sist of a plated copper
crimp barrel and a sepa-
rate, heat-shrinkable, trans-
parent sealing sleeve. They
can be used on a combina-
tion of wires, from 1:1 to
10:10. MiniSeal splices are
one of the smallest, lightest,
and most environment-
resistant splices available.
They preserve the electrical
integrity of the splice by
preventing the penetration
of liquids and the resulting
chemical and galvanic
corrosion.
Product Selection Process
1. Determine the type of
splice required.
nStub (parallel) splice:
nButt (in-line) splice:
2. Determine which crimp
barrel plating is required:
nTin plating,
recommended for tin
or silverplated wire
nNickel plating,
recommended for
nickel-plated wire, or
silver-plated wire in
applications above
150°C [302°F].
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
(mm2) of each wire.
Stub splice: Add the
CMA or mm2of all wires
together.
Butt splice: Calculate
each side separately
(see example on the
worksheet).
Table A provides the
CMA of typical conduc-
tors. (Both CMA and mm2
give the same results, so
choose either CMA or
mm2as your unit of
measure for selection
purposes and continue
to use it for all your
selection criteria.)
4. Select the color code for
the size crimp barrel
required. Using Table B
(page 8-23), select the
crimp barrel—color-
coded red, blue, or
yellow—for the CMA or
mm2you calculated.
Stub splice: Select the
barrel that will accommo-
date the total cross
section.
Butt splice: Select the
smallest barrel that will
accommodate the
largest CMA/mm2
required. (Refer to the
example in the work-
sheet for a more specific
description.) If the
CMA/mm2of 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 applica-
tion. Then select the
part number for the type
of plating required. The
color code accompany-
ing that part number
should match the color
code you arrived at in
Table B, confirming that
the part number you
have selected is correct.
Product Facts
nImmersion-resistant crimp
splices are on QPL for
MIL-S-81824
nMIL-Spec approval
nSmall size
nLight weight
nInsulation and strain relief
nEasy installation
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-23
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Strands 7 19 19 19 19 19 19 19 37
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
CMA Range mm2Range 1:1 Splice (AWG Size) Color Code
304–1510 0.15–0.75 26–20 Red
779–2680 0.39–1.34 20–16 Blue
1900–6755 0.95–3.37 18–12 Yellow
Example:
Application: A butt splice
with three AWG 22 wires in
one side and one AWG 18
wire in the other side:
The CMA for AWG 22 wire
in Table A is 754 (0.38 mm2).
Side one is therefore calcu-
lated as follows:
CMA = 3 x 754 = 2262
(mm2= 3 x 0.38 = 1.14)
The other side, where the
CMA for AWG 18 is 1900, is
calculated as:
CMA = 1 x 1900 = 1900
(mm2= 1 x 0.95 = 0.95)
Using Table B to select the
smallest crimp barrel that
will easily fit 2262 CMA
(0.95 mm2), the blue barrel
is the correct choice.
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Part Number:
Total
Table A. CMA of Typical
Conductors
Table B. Crimp Barrel Color
Code Selection
CMA/mm2Worksheet
Table C. Stub (Parallel) Splices
Crimp Barrel I.D.dimensions
Illustration Part No. Size Range Side 1 Side 2
CMA [mm2]Sealing Max. No. Sealing Max. No.
Tin Plated Nickel Plated Min.–Max. Insert of Wires Insert of Wires
D-436-0128 D-436-0119 304–1510 22
Red Red [0.15–0.75]
D-436-58 D-436-75 779–2680 22
Blue Blue [0.39–1.34]
D-436-59 D-436-76 1900—6755 22
Yellow Yellow [0.95–3.37]
D-436-60 D-436-77 779–2680 10 2
Blue Blue [0.39–1.34] (2 per hole)
D-436-61 D-436-78 1900–6755 10 2
Yellow Yellow [0.95–3.37] (2 per hole)
2.16 [.085]
4.56 [.180]
4.56 [.180]
2.03
[.080]
1.01 [.040]
2.28 [.090]
2.28 [.090]
6.35 [.250]
2.03
[.080]
6.35 [.250]
8-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices(Continued)
Table D. Butt (in-line) splices
Crimp Barrel I.D.dimensions
Illustration Part No. Size Range Side 1 Side 2
CMA [mm2]Sealing Max. No. Sealing Max. No.
Tin Plated Nickel Plated Min.–Max. Insert of Wires Insert of Wires
D-436-36* D-436-82 304–1510 22
Red Red [0.15–0.75]
D-436-37* D-436-83 779–2680 22
Blue Blue [0.39–1.34]
D-436-38* D-436-84 1900–6755 22
Yellow Yellow [0.95–3.37]
D-436-0110 D-436-85 304–1510 62
Red Red [0.15–0.75]
D-436-52 D-436-86 779–2680 62
Blue Blue [0.39–1.34] (2 per hole)
D-436-53 D-436-87 1900–6755 62
Yellow Yellow [0.95–3.37] (2 per hole)
D-436-0115D-436-88 304–1510 6 6
Red Red [0.15–0.75] (2 per hole) (2 per hole)
D-436-42 D-436-89 779–2680 66
Blue Blue [0.39–1.34] (2 per hole) (2 per hole)
D-436-43 D-436-90 1900–6755 66
Yellow Yellow [0.95–3.37] (2 per hole) (2 per hole)
*Qualified to MIL-S-81824/1.
2.16 [.085]
2.79 [.110]
4.32 [.170]
2.16 [.085]
2.79 [.110]
4.32 [.170]
2.36
[.093]
2.36
[.093]
4.06 [.160]
4.06 [.160]
2.36
[.093]
4.06 [.160]
2.36
[.093]
2.36
[.093]
2.36
[.093]
2.36
[.093]
2.36
[.093]
2.36
[.093]
Table E. Crimp Barrel Only
Crimp Barrel Size Range
Type Color Code Tin-Plated Nickel Plated CMA [mm2] Min. - Max.
Butt (in-line) Red D-609-06 D-609-09 304-1510 [0.15-0.75]
Butt (in-line) Blue D-609-07 D-609-10 779-2680 [0.39-1.34]
Butt (in-line) Yellow D-609-08 D-609-11 1900-6755 [0.95-3.37]
Stub (Parrel) Red D-609-03 D-609-12 304-1510 [0.15-0.75]
Stub (Parrel) Blue D-609-04 D-609-13 779-2680 [0.39-1.34]
Stub (Parrel) Yellow D-609-05 D-609-14 1900-6755 [0.95-3.37]
Table F. Sealing Sleeve Only
Part No. Color Code L Max. A Min.
D-436-0096 Red 29.2 [1.15] 2.16 [0.085]
D-436-0097 Blue 29.2 [1.15] 2.8 [0.110]
D-436-0098 Yellow 29.2 [1.15] 4.32 [0.170]
L max.
∅
A min.
8
Electrical Interconnect Products
8-25
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire-to-Wire Splicing
MiniSeal High-Performance, Immersion-Resistant Crimp Splices (Continued)
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Crimp barrel Tin- or nickel-plated copper
Meltable inserts Meltable thermoplastic
Typical Performance
Voltage drop 6.9 mV at 4.5 A vs 8.1 mV for an equal length of wire
Tensile strength Exceeds strength of conductor
Dielectric strength 2.5 kV
Temperature rating -55°C to 150°C [-67°F to 302°F]
Insulation resistance 5000 megohms
Series Military
D-436 MIL-S-81824/1 for D-436-36/37/38
For proper installation of
these devices, the correct
crimp tool (Raychem part
number AD-1377) and a
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
nHL1802E
nAA-400 Super Heater
Refer to Raychem installa-
tion procedure RCPS 200-
20 for detailed instructions
and recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
Product Characteristics
Specifications/Approvals
Installation
8-26 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
Introduction
Raychem insulated electrical
terminal products provide
reliable, repeatable, and
rugged examples of termi-
nals available. We start on
the front end with terminal
sizes and configurations
that meet or exceed indus-
try standards in terms of
material selection, surface
treatment, and electrical
performance.
Here the comparison stops.
What separates Raychem
products from the rest of the
industry are the materials
and termination techniques
used on the back end of the
products, which provide
unparalleled value.
Products include:
nDuraSeal heat-shrinkable
nylon crimp products,
which protect against
water, condensation, salt,
and corrosion. Their
tough, heat-shrinkable
nylon tubing resists abra-
sion and cut-through
SolderGrip technology is
a reliable means of termi-
nating more than two
conductors time after
time. SolderGrip terminals
can terminate a variety of
conductor types (solid
and stranded) and
platings. Terminations on
more than eight individual
conductors in a single
joint have been success-
fully demonstrated using
this product.
DuraSeal product delivers
protected electrical joints on
industry standard terminals
and is suitable for harsh
environments.
damage, provides strain
relief, and protects
against vibration damage.
DuraSeal products are
simple and quick to install
using a crimp tool and a
heat source. They accom-
modate a wide range of
wire sizes and are color-
coded for easy identifica-
tion, yet are transparent
for visual inspection of the
finished splice.
nSolderGrip heat-shrinkable
twist-on products, which
utilize a spiral copper
coil that grips and com-
presses the conductors
and allows a prefluxed
solder ring to flow to the
center of the splicing
area, resulting in a highly
reliable, repeatable joint.
SolderGrip terminals use
a durable polyvinylidene
fluoride heat-shrinkable
tubing that protects the
electrical joint and
provides insulation and
strain relief. The
8
Electrical Interconnect Products
8-27
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects
Applications
DuraSeal products insulate
and protect electrical con-
nections from mechanical
abuse, wire pull-out, and
abrasion while resisting
water, salt, and other
contaminants.
DuraSeal devices provide a
tough, environmentally
sealed wire connection.
Their crimp barrel or termi-
nal, encased in rugged,
heat-shrinkable nylon
tubing lined with a special
hot-melt adhesive, resists
damage from abrasions
and cuts.
DuraSeal devices retain
flexibility and impact-
resistance long after similar
products have become
brittle.
DuraSeal devices
accommodate wire gauge
sizes 22 to 10. They are
color-coded for easy
identification of gauge
sizes, yet transparent for
inspection of the finished
splice.
Agency approvals UL listed component, file E87681, terminals except quick connect terminals;
file E157833, quick connect terminals
Reference documents Raychem specifications RB-108, Specification DuraSeal crimp terminals
DuraSeal selection guide (H54153)
DuraSeal installation guidelines (H54154)
Product Facts
nResistance to moisture and
abrasion
nStrain relief
nProtection from wire pull-out
nEasy installation
nUL and CUL
listed
R
Approvals and Reference
Documents
Available in:
Americas n
Europe n
Asia Pacific n
Fork Terminals
Fork Terminal Dimensions Wire Dimensions
Part Insulation Insulation
No. A Stud C L Color Conductor O.D. O.D.
Min. Size Nom. Max. (AWG) (Max.) (Min.)
Metric Imperial
B-106-2401 3.81 [.15] M4 8 7.87 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-2402 4.57 [.18] M4 8 7.87 [.31] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2403 6.35 [.25] M4 8 7.87 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-2502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-2503 6.35 [.25] M5 10 9.91 [.39] 40.15 [1.58
]
Yellow 12–10 6.35 [.250] 2.79 [.110]
ØA min.
L max.
ØB nom. C nom.
8-28 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Product Characteristics
Property Unit Requirement Method of Test
Physical Dimensions Inches None See product dimensions
Tensile strength Pounds 8 to 40 lbs depending on AWG UL486C, IEC512-8
Property Unit Typical value Method of Test
Electrical Voltage drop Millivolts Less than equal length of wire MIL-S-81824, IEC512-2
Insulation resistance Megohms 103 min. MIL-STD-202 method 302
Dielectric withstand Kilovolts 2.5 MIL-STD-202F method 301,
voltage IEC512-2
Property Unit Requirement Method of Test
Chemical
Diesel fuel ASTM D 3032, ESA-603D
Brake fluid
Antifreeze — Meet electrical test listed above
5% salt water after conditioning.
Motor oil
Environmental
Humidity MIL-STD-202F method 106, IEC68-2-30
(Fluid)
Immersion MIL-STD-202F condition C, IEC68-2-14 test NC
Vibration Meet electrical test MIL-STD-202F method 201, IEC68-2-6
Bending — listed above after UL486C, IEC512-8
Thermal shock conditioning. MIL-STD-202F method 107, IEC68-2-14 test N
Heat aging (168h @ 85°C [185°F) MIL-STD-202F, IEC68-2-2
Salt spray MIL-STD-202F method 101, IEC68-2-11
Operating Temperature rating -55°C to +125°C [-67°F to -257°F] None
conditions Minimum shrink temperature — 180°C [356°F] None
Voltage rating 600 Volt max None
8
Electrical Interconnect Products
8-29
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Fork Terminal Dimensions Wire Dimensions
Part Insulation Insulation
No. A Stud C L Color Conductor O.D. O.D.
Min. Size Nom. Max. (AWG) (Max.) (Min.)
Metric Imperial
B-106-1401 3.81 [.15] M4 8 7.88 [.31] 32.00 [1.26] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1501 3.81 [.15] M5 10 9.91 [.39] 34.04 [1.34] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1601 3.81 [.15] M6 1/4 11.94 [.47] 36.07 [1.42] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1801 3.81 [.15] M8 5/16 13.97 [.55] 39.12 [1.54] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1991 3.81 [.15] M10 3/8 17.78 [.70] 43.18 [1.70] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-1402 4.57 [.18] M4 8 7.88 [.31] 33.02 [1.30] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1502 4.57 [.18] M5 10 9.91 [.39] 35.05 [1.38] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1602 4.57 [.18] M6 1/4 11.94 [.47] 36.58 [1.44] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1802 4.57 [.18] M8 5/16 13.97 [.55] 40.13 [1.58] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1992 4.57 [.18] M10 3/8 17.78 [.70] 43.94 [1.73] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-1403 6.35 [.25] M4 8 7.88 [.31] 38.10 [1.50] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1503 6.35 [.25] M5 10 9.91 [.39] 40.13 [1.58] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1603 6.35 [.25] M6 1/4 11.94 [.47] 41.66 [1.64] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1803 6.35 [.25] M8 5/16 13.97 [.55] 45.21 [1.78] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-1993 6.35 [.25] M10 3/8 17.78 [.70] 46.99 [1.85] Yellow 12–10 6.35 [.250] 2.79 [.110]
ØA min.
L max.
B nom. ØC nom.
Ring Terminals
8-30 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
B nom.
C nom.
L max.
A min.
L max.
ØA min.
C nom.
B nom.
Push-on Terminal Dimensions Wire Dimensions
Part Tab Color Insulation Insulation
No. Size ABC L Conductor O.D. O.D.
(inches) Min. Nom. Nom. Max. (AWG) (Max.) (Min.)
B-106-3631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.200] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-3632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.260] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-3633 .250 x .032 6.35 [.250] 6.35 [.250] .81 [.032] 33.02 [1.300] Yellow 12–10 6.35 [.250] 2.79 [.110]
B-106-3281 .110 x .020 3.81 [.150] 2.79 [.110] .51 [.020] 22.86 [.900] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-3481 .187 x .020 3.81 [.150] 4.75 [.187] .51 [.020] 30.48 [1.200] Red 22–18 3.81 [.150] 1.40 [.055]
Tab Terminal Dimensions Wire Dimensions
Part Tab Color Insulation Insulation
No. Size ABCL Conductor O.D. O.D.
(inches) Min. Nom. Nom. Max. (AWG) (Max.) (Min.)
B-106-4631 .250 x .032 3.81 [.150] 6.35 [.250] .81 [.032] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-4632 .250 x .032 4.57 [.180] 6.35 [.250] .81 [.032] 32.00 [1.26] Blue 16–14 4.45 [.175] 2.00 [.080]
Push-on Terminals
Tab Terminals
8
Electrical Interconnect Products
8-31
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Pin Terminal Dimensions Wire Dimensions
Part Color Insulation Insulation
No. ABL Conductor O.D. O.D.
Min. Nom. Max. (AWG) (Max.) (Min.)
B-106-6201 3.81 [.150] 2.00 [.080] 30.99 [1.220] Red 22–18 3.81 [.150] 1.40 [.055]
Fig. 1
Fig. 2
Bullet Terminal Dimensions Wire Dimensions
Part Color Conductor Insulation Insulation
No. Fig. Type AB C L (AWG) O.D. O.D.
Min. Nom. Min. Max. (Max.) (Min.)
B-106-7401 1 M 3.81 [.150] 3.81 [.150] — 33.53 [1.32] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-7502 1 M 4.57 [.180] 5.08 [.200] — 34.54 [1.36] Blue 16–14 4.45 [.175] 2.00 [.080]
B-106-8401 2 F 3.81 [.150] 3.81 [.150] 5.59 [.220] 30.48 [1.20] Red 22–18 3.81 [.150] 1.40 [.055]
B-106-8502 2 F 4.57 [.180] 5.08 [.200] 6.10 [.240] 32.51 [1.28] Blue 16–14 4.45 [.175] 2.00 [.080]
ØA min.
ØB
L max.
ØA min. B nom.
ØA min. ØB ØC min.
L max.
L max.
Pin Terminals
Bullet Terminals
8-32 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
DuraSeal Heat-Shrinkable Environmentally
Sealed, Nylon Insulated Crimp Terminals and Disconnects (Continued)
Operating temperature -55°C to 125°C [-67°F to 257°F]
Shrink ratio Approximately 2:1
Physical properties Cut-through resistance: 31.7 kg [70 lb]
Wire pullout after crimping and recovery: red: 11.3 kg [25 lb]; blue: 22.7 kg [50 lb]; yellow: 27.2 kg [60 lb]
Not flame-retardant
No cracking after heat aging for 168 hr at 160°C [320°F]
Chemical properties Solvent resistance: isopropyl alcohol, trichloroethylene, gasoline, battery acid, diesel fuel, motor oil,
antifreeze, brake fluid, 5% salt water
Electrical properties Dielectric strength: 1000 V
Insulation resistance: 10 megohms
Series Agency Raychem
B-106 UL and CUL 91J4, File E87681 RB-108
Lloyd’s listed, File 65 247 HH 02-93
UL and CUL E157833
(B-106-3XXX/B-106-4XXX)
1. Select appropriate size.
For terminal and discon-
nect terminations, strip
wire 6.5 mm (1/4 inch).
2. Crimp using Raychem
AD-1522 crimp tool for
preinsulated crimps.
3. Heat terminal or discon-
nect with heat gun until
tubing recovers and
adhesive flows. Avoid
heating ring or fork
metallic parts.
For proper installation of
these devices, the correct
crimp tool and heating tool
with reflector attachment
must be used. The
Raychem AD-1522 crimp
tool and HL1802E heating
tool are recommended. You
will find ordering information
for these tools in Section 10.
Refer to Raychem installa-
tion procedure RPIP 684-00
for detailed instructions.
Product Characteristics
(Typical)
Specifications/Approvals
Installation
8
Electrical Interconnect Products
8-33
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals
Product Facts
nTransparent insulation
sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
nSpiral copper coil grips and
compresses the conductors
for optimum solder
connection
nPrefluxed solder preform
provides a controlled
soldering process.
nOne-piece design for easy
installation
nAccommodates a wide
variety of conductor types,
quantities, sizes, and
plating types unmatched by
any other termination
technique
nParts meet the performance
requirements of
MIL-T-7928G
Product option
Product Series Environmental Protection
SGRT Splashproof
Applications
Used for terminating multi-
ple wires to terminals.
Maximum Maximum Wire Range Typical
SolderGrip Stud Bundle Amp (Min.–Max.) Length
Part No. Size Diameter† Rating CMA [mm2]
SGRT-1-02 2 [2] 4.1 [.161] 12.5 A 1400–5000 38 [1 1/2]
[0.7–2.5]
SGRT-2-03 3 [6] 5.0 [.195] 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-04 4 [8] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-05 5 [10] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-2-06 6 [1/4] — 15 A 2400–6000 38 [1 1/2]
[1.2–3.0]
SGRT-3-06 6 [1/4] 6.5 [.255] 33 A 5000–13,200 44.5 [1 3/4]
[2.5–6.6]
SGRT-3-08 8[5/16] —33 A5000–13,200 51.0 [2]
[2.5–6.6]
SGRT-4-06 6 [1/4] 9.0 [.355] 56 A 12,000–22,400 44.5 [1 3/4]
[6.0–11.2]
SGRT-4-08 8[5/16] — 56 A 12,000–22,400 51 [2]
[6.0–11.2]
†Maximum bundle diameter is measured over wire insulation.
Table A. Part Number
Selection
Product Selection Process
1. Determine the wire com-
bination (number of wires
and size) of the wirebun-
dle you wish to terminate.
2. Use Table C to select the
correct terminal for AWG
wirecombination.*
Example: For connecting
abundle with one 12
AWG wire (1 #12) and
two 18 AWG wires (+ 2
#18) to a terminal, you
need an SGRT-4-XX
terminal.
3. Determine the correct
stud size.
4. Select the correct part
number from Table A for
that stud size in the termi-
nal series and size you
selected in Step 2.
Example: If the stud size
is 1/4, select part number
SGRT-4-06.
5. Verify that the wire bundle
(with wireinsulation) does
not exceed the maximum
diameter allowed for the
partyou selected. Simply
check the bundle’s
diameter against the
maximum diameter that
Table A lists for that part.
6. Verify that the total
amperage to be applied
does not exceed the
maximum amp rating for
the partas specified in
Table A.
*If the wire combination is
not listed in Table B, use
the CMA (mm2)method of
determining wirebundle
size (see “CMA/mm2
Calculation” on page 8-34).
Using Table B, select the
smallest size part that will fit
your total wire CMA (mm2)
value.
Available in:
Americas n
Europe n
Asia Pacific n
8-34 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals(Continued)
3. Add together the values
listed in the workspace
below to obtain the total
area.
4. Use Table A to select the
smallest terminator that
will fit the total CMA
(mm2).
To calculate the total circular
mil or mm2area of the wire
bundle to be terminated,
follow these steps:
1. Choose either CMA or
mm2as your unit of
measure for selection
purposes and continue to
use it for all your selec-
tion criteria. (Both meas-
ures provide the same
results.)
2. In the workspace below,
list the CMA or mm2for
each conductor in the
bundle. (Table B provides
the CMA of typical con-
ductors.)
Wire Number CMA mm2
1
2
3
4
5
6
7
8
9
10 Solder Grip Part No.
Total
CMA/mm2Example 22 AWG/.38
CMA 754
Total CMA = 5834
Total mm2=2.92
Correct part number (based on CMA
of 5834 or mm2of 2.92):
SGRT-2-XX if bundle OD is less
than 5.0 mm (0.195 in).
OD Bundle Insulation
Conductor
Bundle diameter must not
exceed 5.0 mm [0.195 in] for
this example
22 AWG/.38
CMA 754
18 AWG/.95
CMA 1900
16 AWG/1.21
CMA 2426
CMA/mm2Calculation
8
Electrical Interconnect Products
8-35
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals (Continued)
Strands 7 19 19 19 19 19 19 19 37
AWG 28 26 24 22 20 18 16 14 12
CMA 177 304 475 754 1216 1900 2426 3831 5874
mm20.09 0.15 0.24 0.38 0.61 0.95 1.21 1.92 2.94
Wire Part Wire Part Wire Part
Combinations No. Combinations No. Combinations No.
1#8 SGRT-4-XX 1#12 + 1 # 16 + 4 # 18 SGRT-4-XX 1 # 14 + 4 # 20 SGRT-3-XX
1#8+1#16 SGRT-4-XX 1 # 12 + 2 # 16 SGRT-3-XX 1 # 14 + 1 # 18 SGRT-2-XX
2#8+2#16 SGRT-4-XX 1#12 + 2 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 18 + 1 # 20 SGRT-3-XX
1#8+1#14 SGRT-4-XX 1 # 12 + 2 # 16 + 2 # 18 SGRT-4-XX 1 # 14 + 2 # 18 SGRT-3-XX
1#10 SGRT-3-XX 1 # 12 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 18 SGRT-3-XX
1#10 + 1 to 3 # 18 SGRT-3-XX 1 # 12 + 4 # 16 SGRT-4-XX 1 # 14 + 4 # 18 SGRT-3-XX
1#10 + 2 # 18 SGRT-3-XX 1 # 12 + 5 # 16 SGRT-4-XX 1 # 14 + 5 # 18 SGRT-4-XX
1#10 + 3 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 16 SGRT-3-XX
1#10 + 1 # 16 SGRT-3-XX 1 # 12 + 1 # 14 + 2 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 20 SGRT-3-XX
1#10 + 1 # 16 + 1 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 18 SGRT-4-XX 1 # 14 + 1 # 16 + 1 # 18 SGRT-3-XX
1#10 + 1 # 16 + 2 # 18 SGRT-4-XX 1 # 12 + 1 # 14 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 16 + 2 # 18 SGRT-3-XX
1#10 + 2 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 3 # 18 SGRT-3-XX
1#10 + 3 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 1 # 16 + 4 # 18 SGRT-4-XX
1#10 + 4 # 16 SGRT-4-XX 1 # 12 + 1 # 14 + 4 # 16 SGRT-4-XX 1 # 14 + 2 # 16 SGRT-3-XX
1#10 + 5 # 16 SGRT-4-XX 1 # 12 + 2 # 14 SGRT-4-XX 1 # 14 + 2 # 16 + 1 # 18 SGRT-3-XX
1#10 + 1 # 14 SGRT-3-XX 1#12 + 2 # 14 + 1 # 18 SGRT-4-XX 1 # 14 + 2 # 16 + 2 # 18 SGRT-3-XX
1#10 + 1 # 14 + 1 # 18 SGRT-4-XX 1 # 12 + 2 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 2 # 16 + 3 # 18 SGRT-4-XX
1#10 + 1 # 14 + 1 # 16 SGRT-4-XX 1 # 12 + 2 # 14 + 2 # 16 SGRT-4-XX 1 # 14 + 3 # 16 SGRT-3-XX
1#10 + 1 # 14 + 2 # 16 SGRT-3-XX 1 # 12 + 2 # 14 + 3 # 16 SGRT-4-XX 1 # 14 + 3 # 16 + 1 # 18 SGRT-3-XX
1#10 + 1 # 14 + 3 # 16 SGRT-4-XX 1 # 12 + 3 # 14 SGRT-4-XX 1 # 14 + 3 # 16 + 2 # 18 SGRT-4-XX
1#10 + 2 # 14 SGRT-4-XX 1#12 + 3 # 14 + 1 # 16 SGRT-4-XX 1 # 14 + 4 # 16 SGRT-4-XX
1#10 + 3 # 14 SGRT-4-XX 1 # 12 + 4 # 14 SGRT-4-XX 1 # 14 + 4 # 16 + 1 # 18 SGRT-4-XX
1#10 + 1 # 12 SGRT-4-XX 2 # 12 + 1 # 18 SGRT-4-XX 1 # 14 + 5 # 16 SGRT-4-XX
1#10 + 1 # 12 + 1 # 14 SGRT-4-XX 2 # 12 + 1 # 16 SGRT-4-XX 2#14 SGRT-3-XX
1#10 + 2 # 12 SGRT-4-XX 2 # 12 + 2 # 16 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
2#10 SGRT-4-XX 2 # 12 + 3 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
2#10 + 1 # 16 SGRT-4-XX 2 # 12 + 1 # 14 + 1 # 18 SGRT-4-XX 2 # 14 SGRT-3-XX
1#12 SGRT-3-XX 2 # 12 + 1 # 14 + 1 # 16 SGRT-4-XX 2 # 14 SGRT-3-XX
1#12 + 1 # 18 SGRT-3-XX 2 # 12 + 2 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1#12 + 2 # 18 SGRT-3-XX 3 # 12 + 1 # 18 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1#12 + 3 # 18 SGRT-3-XX 3 # 12 + 1 # 16 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1#12 + 4 # 18 SGRT-4-XX 3 # 12 + 1 # 14 SGRT-4-XX 2 # 14 + 1 # 16 SGRT-3-XX
1#12 + 5 # 18 SGRT-4-XX 1#14 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1#12 + 1 # 16 SGRT-3-XX 1 # 14 + 1 # 22 SGRT-2-XX 2 # 14 + 2 # 16 SGRT-3-XX
1#12 + 1 # 16 + 1 # 18 SGRT-3-XX 1 # 14 + 1 # 20 SGRT-2-XX 2 # 14 + 3 # 16 SGRT-4-XX
1#12 + 1 # 16 + 2 # 18 SGRT-3-XX 1 # 14 + 2 # 20 SGRT-3-XX 2 # 14 + 4 # 16 SGRT-4-XX
1#12 + 1 # 16 + 3 # 18 SGRT-4-XX 1 # 14 + 3 # 20 SGRT-3-XX 3 # 14 SGRT-3-XX
Table B. CMA of Typical
Copper Conductors
Table C. SolderGrip Wire
Combinations (see Table A
for Terminal Size [-XX])
8-36 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Insulated Terminals and Disconnects
SolderGrip Self-Fixturing Insulated Terminals (Continued)
Wire Part Wire Part Wire Part
Combinations No. Combinations No. Combinations No.
3#14 + 1 # 16 SGRT-4-XX 2 # 16 + 4 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 2 # 22 SGRT-2-XX
3#14 + 2 # 16 SGRT-4-XX 2 # 16 + 1 # 18 SGRT-3-XX 1 # 18 + 2 # 20 SGRT-2-XX
3#14 + 3 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 3 # 20 SGRT-2-XX
4#14 SGRT-4-XX 2 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 1 # 18 + 4 # 20 SGRT-3-XX
4#14 + 1 # 16 SGRT-4-XX 2 # 16 + 1 # 18 + 3 # 20 SGRT-3-XX 1 # 18 + 5 # 20 SGRT-3-XX
4#14 + 2 # 16 SGRT-4-XX 2 # 16 + 2 # 18 SGRT-3-XX 2 # 18 SGRT-2-XX
5#14 SGRT-4-XX 2 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 1 # 22 SGRT-2-XX
5#14 + 1 # 16 SGRT-4-XX 2 # 16 + 2 # 18 + 2 # 20 SGRT-3-XX 2 # 18 + 1 # 20 SGRT-2-XX
1#16 SGRT-2-XX 2 # 16 + 3 # 18 SGRT-3-XX 2 # 18 + 2 # 20 SGRT-3-XX
1#16 + 1 # 22 SGRT-2-XX 2 # 16 + 3 # 18 + 1 # 20 SGRT-3-XX 2 # 18 + 3 # 20 SGRT-3-XX
1#16 + 2 # 22 SGRT-2-XX 2 # 16 + 4 # 18 SGRT-3-XX 2 # 18 + 4 # 20 SGRT-3-XX
1#16 + 3 # 22 SGRT-2-XX 3 # 16 SGRT-3-XX 3 # 18 SGRT-2-XX
1#16 + 1 # 20 SGRT-2-XX 3 # 16 + 1 # 20 SGRT-3-XX 3 # 18 + 1 # 20 SGRT-3-XX
1#16 + 1 # 20 + 1 # 22 SGRT-2-XX 3#16 + 2 # 20 SGRT-3-XX 3 # 18 + 2 # 20 SGRT-3-XX
1#16 + 2 # 20 SGRT-2-XX 3 # 16 + 3 # 20 SGRT-3-XX 3 # 18 + 3 # 20 SGRT-3-XX
1#16 + 3 # 20 SGRT-3-XX 3 # 16 + 1 # 18 SGRT-3-XX 4 # 18 SGRT-3-XX
1#16 + 4 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 4 # 18 + 1 # 20 SGRT-3-XX
1#16 + 5 # 20 SGRT-3-XX 3 # 16 + 1 # 18 + 2 # 20 SGRT-3-XX 4 # 18 + 2 # 20 SGRT-3-XX
1#16 + 1 # 18 SGRT-2-XX 3 # 16 + 2 # 18 SGRT-3-XX 5 # 18 SGRT-3-XX
1#16 + 1 # 18 + 1 # 20 SGRT-2-XX 3 # 16 + 2 # 18 + 1 # 20 SGRT-3-XX 5#18 + 1 # 20 SGRT-3-XX
1#16 + 1 # 18 + 2 # 20 SGRT-3-XX 3 # 16 + 3 # 18 SGRT-3-XX 6 # 18 SGRT-3-XX
1#16 + 1 # 18 + 3 # 20 SGRT-3-XX 4 # 16 SGRT-3-XX 1 # 20 + 2 # 22 SGRT-2-XX
1#16 + 1 # 18 + 4 # 20 SGRT-3-XX 4#16 + 1 # 20 SGRT-3-XX 1 # 20 + 3 # 22 SGRT-2-XX
1#16 + 2 # 18 SGRT-3-XX 4 # 16 + 2 # 20 SGRT-3-XX 1 # 20 + 4 # 22 SGRT-2-XX
1#16 + 2 # 18 + 1 # 20 SGRT-3-XX 4 # 16 + 1 # 18 SGRT-3-XX 2 # 20 SGRT-2-XX
1#16 + 2 # 18 + 2 # 20 SGRT-3-XX 4 # 16 + 1 # 18 + 1 # 20 SGRT-3-XX 2 # 20 + 1 # 22 SGRT-2-XX
1#16 + 2 # 18 + 3 # 20 SGRT-3-XX 4 # 16 + 2 # 18 SGRT-4-XX 2 # 20 + 2 # 22 SGRT-2-XX
1#16 + 3 # 18 SGRT-3-XX 5 # 16 SGRT-3-XX 2 # 20 + 3 # 22 SGRT-2-XX
1#16 + 3 # 18 + 1 # 20 SGRT-3-XX 5#16 + 1 # 20 SGRT-4-XX 3 # 20 SGRT-2-XX
1#16 + 3 # 18 + 2 # 20 SGRT-3-XX 5 # 16 + 1 # 18 SGRT-4-XX 3 # 20 + 1 # 22 SGRT-2-XX
1#16 + 4 # 18 SGRT-3-XX 6 # 16 SGRT-4-XX 4 # 20 SGRT-2-XX
1#16 + 4 # 18 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 22 SGRT-2-XX 5 # 20 SGRT-3-XX
1#16 + 5 # 18 SGRT-3-XX 1 # 18 + 2 # 22 SGRT-2-XX 6 # 20 SGRT-3-XX
2#16 SGRT-2-XX 1#18 + 3 # 22 SGRT-2-XX 4 # 22 SGRT-2-XX
2#16 + 1 # 20 SGRT-3-XX 1 # 18 + 1 # 20 SGRT-2-XX 5 # 22 SGRT-2-XX
2#16 + 2 # 20 SGRT-3-XX 1 # 18 + 1 # 20 + 1 # 22 SGRT-2-XX 6 # 22 SGRT-2-XX
2#16 + 3 # 20 SGRT-3-XX ————
Table C. SolderGrip Wire
Combinations (see Table A
for Terminal Size [-XX])
(Continued)
8
Electrical Interconnect Products
Solder Style
8-37
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderGrip Self-Fixturing Insulated Terminals(Continued)
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride (Kynar®)
Solder and flux Sn60 Pb40 with RA flux
Typical Performance
Tensile strength Exceeds strength of individual wires
Temperature rating -55°C to +150°C [-67°F to +302°F]
Voltage Drop Not to exceed that of equivalent length of wire by more than 1 mV
Dielectric Withstanding Voltage Current leakage less than 2 mA (1.5 kV)
The SolderGrip product is
pushed onto the conductors
with a twisting motion. With
the product in place, instal-
lation can be completed
with the proper selection
and use of heating tools
and reflectors.
Either of the following
Raychem heating tools is
recommended:
nHL1802E
nCV-1981
Product Characteristics
Installation Refer to Raychem installa-
tion procedure RPIP 820-01
for detailed instructions and
recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
8-38 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
Introduction
Raychem SolderSleeve
terminators offer easy,
one-step solutions for wire
connections to pins, posts,
and tabs and for mass wire
terminations.
Designed for applications
with temperatures up to
150°C [302°F], the products
in this section include
SolderSleeve discrete wire
terminators, which are
heat-shrinkable thermoplas-
tic sleeves containing a
precisely engineered fluxed
solder preform.
SolderSleeve terminators
are also available on carrier
tape, spaced precisely to
match connector terminal
spacing, enabling termina-
tion of an entire row of wires
at one time.
SolderSleeve wire-to-pin,
wire-to-post, and wire-to-tab
terminators, like all Raychem
termination products, pro-
vide reliability and economi-
cal installation for greater
productivity. They can be
supplied either in bulk or
on carrier tape.
8
Electrical Interconnect Products
8-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators
Applications
Used for terminating wires
to component terminals,
such as motor tabs, con-
nector pins, and switch
terminals.
Product selection process
1. Determine the application
operating temperature.
2. From the Product Options
table on the next page,
select the product series
appropriate for the appli-
cation, based on the tem-
perature required.
3. Determine your compo-
nent connection point
type (pin, post, or tab)
and dimensions.
4. Determine your wire
gauge.
5. Optional: Select tape
carrier center-to-center
spacing (D-71X series
only). This should match
center spacing of com-
ponent terminals.
6. Select part number from
the appropriate table:
nFor CWT series
(applications with low-
temperature wires—
below 125°C [257°F]),
use Table A.
nFor D-129/141/71X
series (applications with
wires rated higher than
125°C[257°F]), use
Table B.
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Either of the following
Raychem heating tools are
recommended:
nHL1802E
nAA-400 Super Heater
Refer to Raychem installa-
tion procedureRCPS 200-
12 (for D-129, D-141, D-71X)
or RPIP 824-00 (for CWT)
for detailed instructions and
recommended reflector
attachment.
You will find ordering infor-
mation for these tools see
section 10.
Product Facts
nTransparent polyvinylidene
fluoride or polyolefin
insulation sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
nPrefluxed solder preform
offers a controlled soldering
process
nOne-piece design means
easy installation and low
installed cost
nOptional tape carrier
provides convenience and
ease of installation
nUL and CUL
Recognized
R
Available in:
Americas n
Europe n
Asia Pacific n
8-40 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Connection-point
Type and Size Terminal Dimensions Wire AWG/mm2Part No.
W=up to 0.63 [.025] 24 [0.24] CWT-1501
20[0.61] CWT-1502
W=0.63 [.025] to 24 [0.24] CWT-1501
0.89 [0.035] 22[0.38] CWT-1502
20 [0.61] CWT-1503
W=0.89 [0.035] to 24–22 [0.24–0.38] CWT-1502
1.14 [.045] 20–18 [0.61–0.95] CWT-1503
W = 1.14 [.045] to 24–22 [0.24–0.38] CWT-1503
1.52 [.060] 20–18 [0.61–0.95] CWT-1504
W = up to1.52 [.060] 24–20 [0.24–0.61] CWT-1501
W=1.27 [.050] to 24-18 [0.24–0.95] CWT-1502
2.28 [.090]
W = 1.77 [.070] to 24-18 [0.24–0.95] CWT-1503
2.79 [.110]
W = 2.54 [.100] to 24-18 [0.24–0.95] CWT-1504
3.80 [.150]
W = 2.28 [.090] to 22-16 [0.38–1.21] CWT-1505
4.70 [.187]
Product Series Max. Operating Temperature Min. Wire Temperature Rating
CWT 125°C [257°F] 85°C [185°F]
D-129, D-141, D-71X 150°C [302°F] 125°C [257°F]
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F].
Consult Tyco Electronics for details.
Product Options
Table A. CWT Series
(125°C [257°F] rated)
pin
W
post
W
tab
W
8
Electrical Interconnect Products
8-41
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Wire Tape Carrier Spacing of Sleeves (Center-to-Center)
Terminal 1.27 2.54 3.17 4.0
Dimensions AWG mm2None [0.050] [0.100] [0.125] [0.156]
W=up to 0.61 [.024] 30–26 [0.05–0.15] D-141-30 D-713-03 — — —
24–22 [0.24–0.38] D-141-07 — D-711-00 — —
W=0.63 [.025] to 20[0.61] D-141-31 — D-711-04 D-711-07 D-711-08
0.81 [.032]
W = 0.76 [.030] to 24–20 [0.24–0.61] D-141-56 — — — —
1.27 [.050]
W=up to 1.52 [.060] 24–20 [0.24–0.61] D-129-05 — D-714-01 ——
W = 1.27 [.050] to 24–20 [0.24–0.61] D-129-03 — — — D-714-00
2.28 [.090]
W=2.28 [.090] to 24–20 [0.24–0.61] D-129-0043 — — — —
3.55 [.140]
Part Inside Diameter Fully
No.* As Supplied** Recovered† Length††
D-110-0062 1.0 [0.040] 0.6 [0.025] 16.0 [0.630]
D-110-0217 1.0 [0.040] 0.6 [0.025] 9.0 [0.360]
D-141-13 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 4.7 [0.185]
D-141-22 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 6.0 [0.240]
D-141-30 0.75 x 1.65 [0.030 X 0.065] 0.75 [0.030] 9.5 [0.375]
Note: Micro SolderSleeve terminators are used for attaching leads smaller than 26 AWG (0.15 mm2)to terminals less
than 0.6 [.025] wide.
*The D-110 series sleeves are primarily for single wire terminations and do not have a wire stop. The D-141 series will
accept either one or two wires; the parts have a built-in wire stop that will locate the wire approximately 0.76 [0.03]
from bottom of terminal.
**Minimum. Wire insulation must be smaller than this. When using the D-141 parts for two-wire terminations, the com-
bined wire insulation diameters must be less than 1.5 [.060].
†Maximum. The combination of conductor diameter and terminal width and the wire insulation must be greater than
this.
††The terminal length should be at least 1.2 [0.05] shorter than this. The wire strip length must be adjusted so that,
when terminated, the exposed conductor is covered by the sleeve.
pin
W
post
W
tab
W
For Fine Wire Terminations
0.15 mm2(26 AWG) and
Smaller*
Table B. D-129/141/71X Series
(up to 150°C [302°F] rated)
Connection-point
Type and Size
8-42 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Wire Termination to Pin/Post/Tab
SolderSleeve Discrete Wire Terminators (Continued)
Material
Insulation [D-129, D-141, D-71X] Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation [CWT] Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux [D-129, D-141, D-71X] Solder: Sn63 Pb37 Flux: ROL1 per ANSI -J - 004 [RMA flux]
Solder and flux [CWT] Solder: Sn50 Pb32 Cd 18 Flux: ROM1 per ANSI -J - 004 [RA flux]
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating [CWT] -55°C to 125°C [-67°F to 257°F]
Temperature rating [D-129, D-141, D-71X] -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Series Agency Raychem
CWT UL and CUL E87681 D-5023
D-129, D-141 UL and CUL E87681 RT-1404
Product Characteristics
Specifications/Approvals
8
Electrical Interconnect Products
8-43
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
Introduction
Raychem SolderSleeve
shield grounding termina-
tors provide an environmen-
tally sealed, insulated,
and encapsulated solder
connection for a variety of
applications. SolderSleeve
terminators are available in
many styles.
Designed for a wide variety
of temperature applications
ranging from -65°C to
200°C [-85°F to 392°F], the
products in this section
include:
nCWT-X SolderSleeve
terminators, designed for
low-temperature cables
with operating
temperatures up to 125°C
[257°F] and suitable for
most commercial
environments.
nMIL-S-83519
SolderSleeve terminators,
which are immersion
resistant and available
with or without a
preinstalled ground lead.
nSO Series SolderSleeve
terminators, which also
are immersion resistant
and feature the Raychem
BiAlloy temperature
indication system.
All SolderSleeve products
are reliable, versatile, and
easy to install, resulting in
lower installed costs.
8-44 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators
Product Selection Process
1. Select product series
from the Product Options
table below.
2. Determine cable
dimensions.
3. Optional: Select prein-
stalled wirelead type
(see Table G on page
8-47 for type
descriptions).
4. Select part number (use
the selection table indi-
cated for your product
series in the Product
Options table below).
5. Refer to Table H on page
8-49 for cross-reference
information.
Product Options (Refer to Table G on Page 8-47 for Additional Information)
System Oper.Used on Part No.
Product Temperature Cables Rated Environmental Solder Flux Insulation Selection
Series (Max.) (Min.) Protection Alloy Type Material Table
CWT 125°C [257°F] 85°C [185°F] Splash resistant Cd18 RA Polyolefin A
SO63* 150°C[302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride B
S01/S02**, S03 150°C [302°F] 125°C [257°F] Immersion resistant Sn63 RMA Polyvinylidene fluoride C, D
SO96*** 175°C [347°F] 150°C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride E
SO175**** 175˚C [347°F] 150˚C [302°F] Immersion resistant Sn96 RA Polyvinylidene fluoride F
*Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with BiAlloy temperature indicator.
**Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with thermochromic temperature indicator.
****Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519), supplied with BiAlloy temperature indicator.
Note: Cadmium-free option (B-152 series) is available for operating temperature of 125˚C [257˚F]. Consult Tyco Electronics for details.
Jacket OD (max.) Shield OD (min.)
Product Facts
nTransparent insulation
sleeve provides
encapsulation,
inspectability, strain relief,
and insulation
nPrefluxed solder preform
provides a controlled
soldering process
nOne-piece design offers
easy installation and lower
installed cost
nOptional preinstalled ground
leads provide convenience
and ease of installation
Applications
Used for shield-to-ground
termination.
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-45
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Table A. CWT Series
(125°C [257°F] rated)
Cable OD Part Nos.
Jacket Shield No Preinstalled With Preinstalled Lead
ODMax. OD Min. Lead (22AWG/0.38 mm2green)
1.7 [.065] 0.9 [.035] CWT-3801 —
1.95 [.075] 1.1 [.043] CWT-3802 —
2.7 [.105] 1.5 [.059] CWT-3 CWT-3-W122-5
4.5 [.180] 2.0 [.079] CWT-5 CWT-5-W122-5
6.0 [.235] 3.3 [.130] CWT-6 CWT-6-W122-5
7.0 [.275] 3.3 [.130] CWT-7 CWT-7-W122-5
8.7 [.340] 4.5 [.177] CWT-9 CWT-9-W122-5
10.7 [.420] 4.5 [.177] CWT-11 CWT-11-W122-5
13.0 [.510] 7.0 [.276] CWT-13 CWT-13-W122-5
*See Table G on page 8-47 for lead description.
Note: The CWT series is suitable for applications using low-temperature wires (typically rated at 85°C [185°F] to 125°C [257°F]) with bare copper or tin plating.
Cable OD Part Nos.
No Preinstalled Lead Option* Braid Strap
Jacket OD Shield OD Preinstalled
Max. Min. Lead 20 AWG 22 AWG 24 AWG 26 AWG Nickel Plated Tin Plated
1.95 [0.075] 0.90 [.035] SO63-1-00 SO63-1-55-20-90 SO63-1-55-22-90 SO63-1-55-24-90 SO63-1-55-26-90 SO63-1-01 SO63-1-9030
2.7 [0.105] 1.40 [.055] SO63-2-00 SO63-2-55-20-90 SO63-2-55-22-90 SO63-2-55-24-90 SO63-2-55-26-90 SO63-2-01 SO63-2-9030
4.3 [0.170] 2.15 [.085] SO63-3-00 SO63-3-55-20-90 SO63-3-55-22-90 SO63-3-55-24-90 SO63-3-55-26-90 SO63-3-01 SO63-3-9030
6.0 [0.235] 3.30 [.130] SO63-4-00 SO63-4-55-20-90 SO63-4-55-22-90 SO63-4-55-24-90 SO63-4-55-26-90 SO63-4-01 SO63-4-9030
7.0 [0.275] 4.30 [.170] SO63-5-00 SO63-5-55-20-90 SO63-5-55-22-90 SO63-5-55-24-90 SO63-5-55-26-90 SO63-5-01 SO63-5-9030
*See Table G on page 8-47 for lead description. Color of wire lead is denoted by the last two digits of the part number as follows:
90 = White with a black stripe 9 = White 0 = Black 6 = Blue (24 AWG only) 5 = Green (20, 22, 24 AWG)
The SO63 series is immersion resistant, features the Raychem BiAlloy temperature indication system, and meets the performance requirements of
SAE-AS83519 (formerly MIL-S-83519) .
BiAlloy Temperature
Indication System
This system greatly enhances the reliability and repeatabil-
ity of SO63 series terminators while reducing installed cost.
The heat-shrinkable thermoplastic sleeve contains a pre-
cisely engineered, fluxed solder band that is visible through
the sleeve. The band provides exactly the amount of solder
and flux required to terminate the ground lead to the cable
shield. Encircling the band is a small temperature indicator
ring. This ring melts only when the surfaces to be joined
have reached the correct soldering temperature, thus
ensuring a properly soldered connection. Process control is
built into each sleeve.
Table B. SO63 Series
8-46 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Cable OD Part No. (MIL Part Number and Raychem Part No.) by Lead Option
Preinstalled Lead Option*
Jacket OD Shield OD No Preinstalled Lead 20 AWG 22 AWG
Max Min MIL Raychem MIL Raychem MIL Raychem
1.95 [0.075] 0.9 [.035] M83519/1-1 S01-01-R M83519/2-1 S02-01-R M83519/2-6 S02-06-R
2.7[0.105] 1.40 [.055] M83519/1-2 S01-02-R M83519/2-2 S02-02-R M83519/2-7 S02-07-R
4.3 [0.170] 2.15 [.085] M83519/1-3 S01-03-R M83519/2-3 S02-03-R M83519/2-8 S02-08-R
6.0 [0.235] 3.30 [.130] M83519/1-4 S01-04-R M83519/2-4 S02-04-R M83519/2-9 S02-09-R
7.0 [0.275] 4.30 [.170] M83519/1-5 S01-05-R M83519/2-5 S02-05-R M83519/2-10 S02-10-R
Jacket OD Shield OD Preinstalled Lead Option*
Max. Min. 24 AWG 26 AWG
1.95 [0.075] 0.9 [.035] M83519/2-11 S02-11-R M83519/2-16 S02-16-R
2.7 [0.105] 1.40 [.055] M83519/2-12 S02-12-R M83519/2-17 S02-17-R
4.3[0.170] 2.15 [.085] M83519/2-13 S02-13-R M83519/2-18 S02-18-R
6.0 [0.235] 3.30 [.130] M83519/2-14 S02-14-R M83519/2-19 S02-19-R
7.0 [0.275] 4.30 [.170] M83519/2-15 S02-15-R M83519/2-20 S02-20-R
*See Table G for lead description.
M83519 is the qualified product listed in SAE-AS83519 (formerly MIL-S-83519) . The series features a thermochromic temperature indicator to assist in termi-
nation and inspection. The Raychem part number is permanently marked on the sleeve.
Thermochromic Temperature Indicator
The M83519 (S01 and S02) series terminators contain
acolored thermochromic temperature indicator that
exhibits a distinct color change when surfaces have
reached wetting temperature. This color change gives both
manufacturing and Quality Control an aid in the inspection
of the completed termination.
Table C. S01/S02 M83519
Series
Thermochromic Temperature Indicator
The S03 series terminators contain a colored ther-
mochromic temperature indicator that exhibits a
distinct color change when surfaces have reached wetting
temperature. This color change gives both Manufacturing
and Quality Control an aid in the inspection of the
completed termination.
Table D. S03 Series
Cable OD Part No.
Preinstalled Lead Option*
Jacket OD Shield OD
Max. Min. Tin plated Braid Strap Nickel plated Braid Strap
1.95 [0.075] 0.9 [.035] S03-01-R S03-06-R
2.7 [0.105] 1.40 [.055] S03-02-R S03-07-R
4.3 [0.170] 2.15 [.085] S03-03-R S03-08-R
6.0 [0.235] 3.30 [.130] S03-04-R S03-09-R
7.0 [0.275] 4.30 [.170] S03-05-R S03-10-R
*See Table G for lead description.
8
Electrical Interconnect Products
8-47
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Cable OD Part No.
Preinstalled Lead Option*Jacket OD Shield OD No
Max. Min. Preinstalled Lead 22 AWG Braid Strap
1.95 [0.075] 0.9 [.035] SO96-1-00 SO96-1-55-22-90 SO96-1-01
2.7 [0.105] 1.40 [.055] SO96-2-00 SO96-2-55-22-90 SO96-2-01
4.3 [0.170] 2.15 [.085] SO96-3-00 SO96-3-55-22-90 SO96-3-01
6.0 [0.235] 3.30 [.130] SO96-4-00 SO96-4-55-22-90 SO96-4-01
7.0 [0.275] 4.30 [.170] SO96-5-00 SO96-5-55-22-90 SO96-5-01
*See Table G for lead description.
The SO96 series is designed for high-temperature applications with operating temperature requirements up to 200°C [392°F]. This series features a ther-
mochromic temperature indicator and meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) . The solder is Sn96 with RAflux compatible
with nickel-plated shields.
Table G. Preinstalled Lead
Description
Series Lead Type Remarks Plating Stranding Min. Length
M83519, SO63 55A0111MIL-W-22759/32 Tin Stranded 150 [6.00]
SO96, SO175 55A0813 MIL-W-22759/41 Nickel Stranded 150 [6.00]
SO63, SO96, S03 Braid strap Uninsulated Nickel 40 x 38 AWG 150 [6.00]
CWT XL polyethylene UL Listed Tin Stranded (W1) 150 [6.00]
SO63, S03 Braid Strap Uninsulated Tin Stranded 150 [6.00]
Cable OD Part No.
Preinstalled Lead Option*
Jacket OD Shield OD No
Max. Min. Preinstalled Lead 22 AWG Braid Strap
1.95 [0.075] 0.90 [0.035] SO175-1-00 SO175-1-1-55-22-90 SO175-1-01
2.7 [0.105] 1.40 [0.055] SO175-2-00 SO175-2-1-55-22-90 SO175-2-01
4.3 [0.170] 2.15 [0.085] SO175-3-00 SO175-3-1-55-22-90 SO175-3-01
6.0 [0.235] 3.30 [0.130] SO175-4-00 SO175-4-1-55-22-90 SO175-4-01
7.0 [0.275] 4.30 [0.170] SO175-5-00 SO175-5-1-55-22-90 SO175-5-01
*See Table G for lead description.
Thermochromic
Temperature Indicator
The SO96 series terminators contain a colored ther-
mochromic temperature indicator that exhibits a
distinct color change when surfaces have reached
wetting temperature. This color change gives both manu-
facturing and Quality Control an aid in the
inspection of the completed termination.
Table E. SO96 Series
(175°C [347°F] rated)
BiAlloy Temperature Indication System
This system greatly enhances the reliability and
repeatability of SO175 series terminators while reducing
installed cost. The temperature indicator ring, encircling the
solder preform, melts to indicate the veryminimum amount
of heat.
Table F. SO175 Series
(175°C [347°F] rated)
8-48 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Material
Insulation
SO, M83519 Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
CWT Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux
SO63, M83519, S03 Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMA Flux)
SO96, SO175 series Solder: Sn96 Ag4 Flux: ROM1 per ANSI - J - 004 (RAFlux)
CWT Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI - J - 004 (RAFlux)
Ground lead
CWT series XL polyethylene
SO, M83519, SO175 MIL-W-22759/32 or /41
Typical Performance
Voltage drop 2.5 mV
Tensile strength Exceeds strength of ground lead
Dielectric strength 1.0 kV immersed
Temperature rating
CWT -55°C to 125°C [-67°F to 257°F]
SO63/M83519/S03 -55°C to 150°C [-67°F to 302°F]
SO96/SO175 series -55°C to 175°C [-67°F to 347°F]
Insulation resistance 1000 megohms
Series Agency Raychem
CWT — D-5023
SO63* NAS 1747 RT-1404
M83519** MIL-S-83519/1&/2 RT-1404
SO96*** NAS 1747 RT-1404
SO175 RT-1404
* Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747,
supplied with BiAlloy temperature indicator.
** Qualified to SAE-AS83519 (formerly MIL-S-83519), supplied with thermochromic temperature indicator.
***Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519) and NAS 1747, supplied with
thermochromic temperature indicator.
Shield Termination
SolderSleeve Shield Terminators (Continued)
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
nHL1802E
nAA-400 Super Heater
nCV-1981
nMiniRay
nIR-1759
Product Characteristics
Specifications/Approvals
Installation For detailed instructions and recommended reflector
attachments, refer to the appropriate Raychem
installation procedure:
Series Procedure
CWT RPIP 655-00-D
SO63 RCPS 100-70
M83519 (S01/S02) RCPS 100-70
SO96 RCPS 100-70
S03 RCPS 100-70
SO175 RCPS-100-70
You will find ordering information for these tools
in section 10.
8
Electrical Interconnect Products
8-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Shield Termination
SolderSleeve Shield Terminators (Continued)
Table H. NAS, M83519, and
Raychem Cross-Reference NAS Raychem D Series NAS
Part No. Part No. Comment
1744-1 D-1744-01
1744-2 D-1744-02
1744-3 D-1744-03
1744-4 D-1744-04
1744-5 D-1744-05
1744-6 D-1744-06
1744-7 D-1744-07
1744-8 D-1744-08
1745-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-2 D-100-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1745-3 D-101-00 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-4 D-103-00 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-5 D-144-26
1745-6 D-100-31
1745-7 D-101-31
1745-8 D-103-31
1745-9 Obsolete - Use NAS1745-13
1745-10 Obsolete - Use NAS1745-14
1745-11 Obsolete - Use NAS1745-15
1745-12 Obsolete - Use NAS1745-16
1745-13 D-142-83 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1745-14 D-142-50 Inactive, Use SAE-AS83519/1-2(formerly MIL-S-83519)
1745-15 D-142-51 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1745-16 D-142-52 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1745-17 D-107-00 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-18 D-104-00
1745-19 D-105-00
1745-20 D-107-31
1745-21 D-104-31
1745-22 D-105-31
1745-23 D-142-56 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1745-24 D-142-65
1745-25 D-142-66
1746-1 D-144-25 Inactive, Use SAE-AS83519/1-1 (formerly MIL-S-83519)
1746-2 D-144-00 Inactive, Use SAE-AS83519/1-2 (formerly MIL-S-83519)
1746-3 D-144-01 Inactive, Use SAE-AS83519/1-3 (formerly MIL-S-83519)
1746-4 D-144-02 Inactive, Use SAE-AS83519/1-5 (formerly MIL-S-83519)
1746-5 D-144-26
1746-6 D-144-03
1746-7 D-144-04
1746-8 D-144-05
1746-9 D-144-46 Inactive, Use SAE-AS83519/1-4 (formerly MIL-S-83519)
1746-10 D-144-37
Military Raychem S01/S02 Series* Raychem SO63 Series**
Part No. Part No. Part No.
M83519/1-1 S01-01-R SO63-1-00
M83519/1-2 S01-02-R SO63-2-00
M83519/1-3 S01-03-R SO63-3-00
M83519/1-4 S01-04-R SO63-4-00
M83519/1-5 S01-05-R SO63-5-00
M83519/2-1 S02-01-R SO63-1-55-20-90
M83519/2-2 S02-02-R SO63-2-55-20-90
M83519/2-3 S02-03-R SO63-3-55-20-90
M83519/2-4 S02-04-R SO63-4-55-20-90
M83519/2-5 S02-05-R SO63-5-55-20-90
M83519/2-6 S02-06-R SO63-1-55-22-90
M83519/2-7 S02-07-R SO63-2-55-22-90
M83519/2-8 S02-08-R SO63-3-55-22-90
M83519/2-9 S02-09-R SO63-4-55-22-90
M83519/2-10 S02-10-R SO63-5-55-22-90
M83519/2-11 S02-11-R SO63-1-55-24-90
M83519/2-12 S02-12-R SO63-2-55-24-90
M83519/2-13 S02-13-R SO63-3-55-24-90
M83519/2-14 S02-14-R SO63-4-55-24-90
M83519/2-15 S02-15-R SO63-5-55-24-90
M83519/2-16 S02-16-R SO63-1-55-26-90
M83519/2-17 S02-17-R SO63-2-55-26-90
M83519/2-18 S02-18-R SO63-3-55-26-90
M83519/2-19 S02-19-R SO63-4-55-26-90
M83519/2-20 S02-20-R SO63-5-55-26-90
*QPL listed to SAE-AS83519 (formerly MIL-S-83519)
** Meets performance requirements of SAE-AS83519 (formerly MIL-S-83519)
8-50 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
Introduction
Raychem SolderSleeve
coaxial cable terminators
allow reliable, easy termina-
tions in a variety of coaxial
cable applications, includ-
ing printed circuit boards
(PCBs). The insulating and
strain-relieving capabilities
of SolderSleeve terminators
provide the ideal solution to
center-conductor breakage
problems.
Designed for applications
with temperatures up to
150°C [302°F], the products
in this section include:
nSolderSleeve coaxial
cable terminators, which
allow reliable, economical
attachment of coaxial
cable to connector
terminals, printed wiring
assemblies, or solderless
wrap terminals.
nOne-piece SolderSleeve
PCB coaxial cable termi-
nators, which permit
quick, easy, and cost-
effective terminations of
coaxial cable to printed
circuit boards.
nRFone-step BNC/TNC
connectors, which are
single-piece assemblies
for terminating the center
conductor and the braid
of a broad range of coax-
ial cables. They are fully
intermateable with MIL-C-
39012C connectors and
are available in 50-ohm
and 75-ohm versions
(refer to pages 8-55
to 8-60 for product
information).
With precisely measured
solder and flux, SolderSleeve
products provide exact
process control of termina-
tions. The SolderSleeve
method means strong
connections with the lowest
possible voltage drop. Small,
lightweight SolderSleeve
terminators are also the ideal
solution for high-density
packaging problems.
8
Electrical Interconnect Products
8-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve Coaxial Cable Terminators
Product Facts
nTransparent polyvinylidene
fluoride or polyolefin
insulation sleeve provides
encapsulation,
inspectability, strain relief
(eliminates center conductor
breakage), and insulation.
nPrefluxed solder preform
provides a controlled
soldering process
nOne-piece design provides
easy installation and lower
installed cost
nPreinstalled termination
leads provide convenience
and ease of installation
Product Options
Product Series Max. Operating Temp. Use on Cables Rated (Min) Cable Shield Plating Part No. Selection Table Design
CWT 125°C[257°F] 85°C [185°F] Tin, copper A 2-pc.
B-02X/B-04X 150°C[302°F] 125°C[257°F] Tin, silver B 1-pc.
D-181 150°C [302°F] 125°C [257°F] Tin, silver C 2-pc.
D-184 125°C [257°F] 85°C [185°F] Tin D 2-pc.
Preinstalled Lead Descriptions
Series Lead Type Plating Stranding AWG Length Color
CWT XL polyethelene Tin Stranded (W1) 22 150 [6.000] White (cntr), green (grnd)
B-021 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-041 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-043 M81822/13 (solderless wrap) Silver Solid-OFHC 24—30 150 [6.000] White (cntr), blue (grnd)
B-020 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-040 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
B-044 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), blue (grnd)
D-181-12XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-22XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-32XX 55A0111 (MIL-W-22759/32) Tin Stranded 20—30 150 [6.000] White (cntr), white w/black stripe (grnd)
D-181-18XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-181-28XX M81822/13 Silver Solid 26 – 30 150 [6.000] White (cntr), blue (grnd)
D-184 55A0111(MIL-W-22759/32) Tin Stranded 20 – 26 150 [6.000] White (cntr), white w/black stripe (grnd)
Applications
Used for terminating coaxial
cable to component termi-
nals, contacts, printed cir-
cuit boards, and solderless
wrap terminals.
Product Selection Process
1. Select product series
from the product options
table below.
2. Select preinstalled lead
type from the table below.
3. Determine cable RG
number or dimensions.
4. Select partnumber from
Table A (CWT series) or
Table B (B-02X/B-04X
series) on the next page.
Product Characteristics
Material
Insulation (B-02X/B-04X, D-181, D-184) Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Insulation (CWT series) Radiation-crosslinked, heat-shrinkable polyolefin
Solder and flux (B-02X/B-04X, D-181) Solder: Sn63 Pb37 Flux: ROL1 per ANSI-J-004 (RMAFlux)
Solder and flux (CWT series, D-184) Solder: Sn50 Pb32 Cd18 Flux: ROM1 per ANSI-J-004 (RA Flux)
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating (CWT, D-184) -55°C to 125°C [-67°F to 257°F]
Temperature rating (B-02X/B-04X, D-181) -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Available in:
Americas n
Europe n
Asia Pacific n
8-52 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve Coaxial Cable Terminators (Continued)
Part 1: Coaxial Product Group Selection
Typical Compatible
Part No. Dimension Range
Raychem One-Piece
RG Cable Cable Jacket OD (Max.) Shield OD Dielectric Conductor Coaxial Product
Number Description ODOD Group
RG178, RG404 5030A13XX 3.40 1.30–2.30 0.50–1.70 0.30–0.80
Group 1
5028A13XX [.134] [.051–.091] [.019–.067] [.011–.032]
5024A13XX
RG179, RG316 7530A13XX 4.40 1.50–2.80 1.20–2.50 0.30–1.60 Group 2
7526A13XX [.173] [.060–.110] [.047–.100] [.011–.063]
9530A13XX
RG180, RG302, 9527A13XX 6.30 2.40–4.60 1.40–4.30 0.30–2.80 Group 3
RG303 9528A13XX [.248] [.094–.181] [.055–.169] [.011–.110]
Part 2: Product Part Number Selection
One-Piece Preinstalled Wire Size
Coaxial Preinstalled 20 22 24 26 28 30
Product Group Wire Type AWG AWG AWG AWG AWG AWG
Stranded — B-044-22-N B-044-24-N B-044-26-N — —
Group 1 (M22759)
Solid — — B-043-24-N B-043-26-N B-043-28-N B-043-30-N
(M81822)
Stranded B-040-20-N B-040-22-N B-040-24-N B-040-26-N B-040-28-N B-040-30-N
Group 2 (M22759)
Solid — — B-041-24-N B-041-26-N B-041-28-N B-041-30-N
(M81822)
Stranded B-020-20-N B-020-22-N B-020-24-N B-020-26-N — —
Group 3 (M22759)
Solid — — — B-021-26-N — —
(M81822)
1. The B-02X/B-04X series uses a one-piece design to terminate coaxial cables rated at 125°Cminimum.
2. Using Part 1 of this table, select the appropriate coaxial product group (1, 2, or 3) based on your RG cable number, Raychem cable
description, or cable dimensions.
3. Using Part 2 of this table, select the product part number based on the coaxial product group you selected in Part 1 and the appropriate
preinstalled lead type you selected on the previous page.
Table B. B-02X/B-04X
Series Part Numbers
Table A. CWT Series
Part Numbers
Table C. D-181 Series
Part Numbers Product Dimensions
Product A B C D E F L1 L2 Wire
Name min. min. min. min. min. min. max. max. AWG
D-181-1220-90/9 20
D-181-1222-90/9 22
D-181-1224-90/9 3.7 3.2 2.7 2.4 2.3 0.71 17 21.5 24
D-181-1226-90/9 [0.145] [0.125] [0.105] [0.095] [0.09] [0.028] [0.67] [0.85] 26
D-181-1826-6/9 26
D-181-1830-6/9 30
D-181-2220-90/9 20
D-181-2222-90/9 22
D-181-2224-90/9 4.5 4 3.45 2.9 3 1.1 17 22.7 24
D-181-2226-90/9 [0.18] [0.16] [0.135] [0.115] [0.12] [0.045] [0.67] [0.895] 26
D-181-2826-6/9 26
D-181-2830-6/9 30
D-181-3220-90/9 20
D-181-3222-90/9 ]22
D-181-3224-90/9 5.2 4.7 4.45 3.95 4 1.3 17 21.5 24
D-181-3226-90/9 [0.205] [0.185] [0.175] [0.155] [0.16] [0.055] [0.67] [0.85] 26
D-181-3826-6/9 26
D-181-3830-6/9 30
∅
Emin.
∅
F min.
∅
Amin.
∅
B min.
∅
C min.
∅
Dmin.
L1 max.
L2 max.
Table D. D-184 Series
Part Numbers Product Dimensions
Product ∅A∅B∅C∅D∅E∅F L1 L2 Wire
Name min. min. min. min. min. min. max. max. AWG
D-184-1220-90/9 20
D-184-1222-90/9 3.7 3.2 2.7 2.4 2.3 0.71 17 21.5 22
D-184-1224-90/9 [0.145] [0.125] [0.105] [0.095] [0.09] [0.028] [0.67] [0.85] 24
D-184-1226-90/9 26
D-184-2220-90/9 20
D-184-2222-90/9 4.5 4 3.45 2.9 3 1.1 17 22.7 22
D-184-2224-90/9 [0.18] [0.16] [0.135] [0.115] [0.12] [0.045] [0.67] [0.895] 24
D-184-2226-90/9 26
∅
E min.
∅
F min.
∅
A min.
∅
B min.
∅
C min.
∅
D min.
L1 max.
L2 max.
Dimensions Part No.
Cable RG Number Dielectric OD Jacket OD With Preinstalled Lead
AWG/0.38 mm2Green/White)
174 0.80–2.30 [.032–.091] 1.30–2.80 [.051–.110] CWT-4174-W122-5/9
58, 122 2.00–2.80 [.079–.110] 2.50–4.40 [.100–.173] CWT-4058-W122-5/9
59 2.80–3.30 [.110–.130] 3.20–6.00 [.125–.235] CWT-4059-W122-5/9
8
Electrical Interconnect Products
8-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve PCB/Coaxial Cable Terminators
Product Options
Product Series Typical Application Performance Shield Method Part No. Selection Table
D-607 Matched impedance up to 2.3 GHz Metal body A
B-046 Effective transmission up to 100 MHz Pin to ground B
Product Selection Process
1. Select product series
from the Product Options
table below.
2. Determine cable RG
number or outside diame-
ter dimensions.
3. Select the appropriate
partnumber from Table A
(D-607 series) or Table B
(B-046 series).
nFor D-607 (matched
impedance) series, deter-
mine straight or right-
angle entry to PCB and
grid pattern, then select
the appropriate part num-
ber from Table A on the
next page.
nFor B-046 (PinPak, or pin
to ground) series, deter-
mine hole spacing and
diameter. Refer to Table B
for product selection (see
illustration below for cable
dimensions).
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
nHL1802E
nAA-400 Super Heater
nIR-1759 MiniRay
nCV-1981
Refer to Raychem installa-
tion procedureES61139 for
detailed instructions and
recommended reflector
attachments.
You will find ordering infor-
mation for these tools in
Section 10.
AB CD
Product Facts
nProvides a completely
shielded, low-resistance,
matched-impedance
termination with very low
VSWR (D-607 series only)
nTransparent polyvinylidene
fluoride insulation sleeve
provides encapsulation,
inspectability, strain relief,
and insulation
nPrefluxed solder preform
provides a controlled
soldering process
nOne-piece design offers
easy installation and lower
installed cost
nPreinstalled PCB
termination body provides
convenience and ease of
installation
Applications
Used for terminating coaxial
cable to printed circuit
boards.
Available in:
Americas n
Europe n
Asia Pacific n
8-54 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Coaxial Cable Termination
SolderSleeve PCB/Coaxial Cable Terminators (Continued)
Table A. D-607 Series
Part Numbers
Cable Dimensions (mm/in) Part No.
RGCable No. Max. Outside Diameter Entry to PCB
Straight Right-Angle Straight
Jacket Shield Dielectric grid 5.08 [.200] Grid 5.08 [.200] Grid 2.54 [.100]
174, 178, 179, 1.5–3.55 1.1–3.15 0.60–2.25 D-607-09 D-607-10 D-607-40*
316, 404 [.060–.140] [.045–.125] [.025–.090]
Table B. B-046 Series
Part Numbers
Cable Dimensions Part No.
RG Cable No. AB CD Pin Diameter Spacing Between Pins
Max. 2.54 [.100] 5.08 [.200] 6.35 [.250]
178, 404 0.30–0.80 0.5–1.7 1.3–2.3 3.4 0.6 [.023] B-046-14-N B-046-10-N B-046-12-N
[.011–.032] [.019–.067] [.050–.091] [.134] 0.8 [.031] B-046-11-N B-046-13-N
179, 316 0.3–1.6 1.2–2.5 .1.5–2.8 4.4 0.6 [.023] B-046-15-N B-046-66-N B-046-16-N
[.011–.063] [.047–.100] [.060–.110] [.173] 0.8 [.031] B-046-68-N B-046-18-N
Product Characteristics
Material
Insulation Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride
Solder and flux Solder: Sn63 Pb37 Flux: ROL1 per ANSI - J - 004 (RMA flux)
Termination body/pin Copper alloy,solder-plated
Typical Performance
Voltage drop 2.0 mV
Tensile strength Exceeds strength of conductor
Dielectric strength 2.0 kV
Temperature rating -55°C to 150°C [-67°F to 302°F]
Insulation resistance 1000 megohms
Electrical Performance (typical) D-607 Series Only
Frequency VSWR (D-607-09, -40) VSWR (D-607-10)
350 MHz 1.04 max. 1.04 max.
700 MHz 1.05 max. 1.09 max.
2.3 GHz 1.09 max. 1.12 max.
Specifications/Approvals
Series Raychem
D-607 RT-1404
B-046 RT-1404
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors
8-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Applications
One-Step BNC/TNC con-
nectors are single-piece
assemblies for terminating
the center conductor and
the braid of a broad range
of coaxial cables.
The connectors are fully
intermateable with
MIL-C-39012 connectors
and are available in 50-ohm
and 75-ohm versions.
Specifications Installation
For proper installation of these devices,
the correct heating tool and reflector
Raychem attachment must be used. Refer to Raychem installation procedure
RB-115 Any one of the following Raychem RPIP 683-00 for detailed instructions.
heating tools is recommended:
•Steinel®Model HL1802E
•CV-1981
Product Facts
nEasy, quick installation
nOutstanding cable-retention
force
nSolder-solder connection
type (center conductor and
braid)
nOne-step termination for
easy, quick installation and
lower installed cost
nExceptional cable retention
force to withstand high
vibration and frequent mates
and unmates
nFully soldered center
conductor and braid
nExcellent built-in strain
relief against vibration and
excessive handling
nLong-term reliability
nControlled soldering
termination
nUse with standard RG/U
cables and Raychem
Cheminax cables
nThree product sizes to
accommodate a wide range
of cables
nMeets performance
requirements of
MIL-C-39012 up to 2.8 GHz
Available in:
Americas n
Europe n
Asia Pacific n
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-56 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Connector Style
Dash No. Style Connector Type
RXX-XX-X-XX
-XX TNC BNC
-00 Straight plug
-01 Right-angle plug
-02 Straight bulkhead jack
-03 Straight jack
-04 Straight panel jack
Connector size
L=Large
M = Medium
S=Small
50 = 50 ohms
75 = 75 ohms
D = Nickel-plated brass body, gold-plated brass pin
B=BNC
T = TNC
Example: RBD-50-L-00 is a BNC connector, 50 ohms, large size, with straight plug body.
24.5 max.
[.965]
Male
Female
24.5 Max.
[.965]
25.4 Max.
[1.0]
25.4 max.
[1.0]
25.4 Max.
[1.0]
25.4 max.
[1.0]
4 x M2.5 x 0.45
25.4 Max.
[1.0]
4 x M2.5 x 0.45
25.4 Max.
[1.0]
31.5 max.
[1.23]
28 [1.09]
33.5 Max.
[1.32]
28 [1.09]
Female
Male
Product Options and Part
Numbering System
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Part Selection Process
1. From Product Options and Part Numbering System on page 8-56, select the connector style you need
(BNC or TNC, plug or jack, male or female contacts).
2. From the tables that follow, find the appropriate table for the connector style you selected.
3. From the appropriate table, select the connector part number based on the RG cable type or
Raychem cable part number. For cable types not shown use the cable dimensions.
Note: The cable dimensions in each table are keyed to the diagram below.
Product Characteristics
Material
Center contact Gold-plated beryllium copper (female)
Gold-plated brass (male)
Dielectric insulator PTFE
Transition Silver-plated brass
Connector body Nickel-plated brass
Solder and flux Sn63Pb37, RMA flux
Braided shield Tin-plated copper wire per ASTM B3
Insulation sleeve Radiation-crosslinked, heat-shrinkable polyvinylidene fluoride, transparent blue
Strain relief/sealing sleeve Radiation-crosslinked, heat-shrinkable modified polyolefin with adhesive, black
Typical Performance
Dielectric withstand voltage 1500 V
Insulation resistance 5000 megohms
Temperature rating -55˚C to 150˚C [-67˚F to 302˚F]
Contact resistance-straight Inner = 1.5 milliohms, outer = 1.0 milliohm
Contact resistance — right-angle Inner = 2.5 milliohms, outer = 1.5 milliohms
Cable retention force 295N (66 lb) to 822N (196 lb)
Voltage rating 500 V RMS
Connector durability 500 mating cycles minimum
Electrical Performance
Nominal impedance 50 and 75 ohms
Frequency range Up to 2.8 GHz
D E F G
Solder Transition Center
Contact Dielectric
Insulator Connector
Body
Insulation Sleeve
and Solder
Shield
Insulation
Sleeve
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-58 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable Type Cable Dimensions
Impedance RG Cables Raychem Cables DE F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
BNC Straight Plugs, Male Contacts
50RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RBD-50-S-00
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-00
50RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-00
75RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-00
75 —7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.126] [.050] RBD-75-M-00
75RG-6, RG-11, RG-12, RG-59 —5.00–.12.50 4.10–9.50 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-00
BNC Right-Angle Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RBD-50-S-01
50RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-01
50RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.1–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.9-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-01
75 — 524A1311, 7528A1317 3.50–7.00 2.1–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.1–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-01
BNC Straight Bulkhead Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RBD-50-S-02
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-02
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-02
75 RG-179, RG-187 7530A1317 1.50–5.00 5 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-02
75 75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
—[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 —5.00-12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-02
BNC Straight Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025] RBD-50-S-03
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A33115.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-03
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-03
75 —75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-03
BNC Straight Panel Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RBD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RBD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RBD-50-L-04
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RBD-75-S-04
75 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
—[.138–.276] [.083–.197] [.146] [.050] RBD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.5o 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RBD-75-L-04
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Cable Type Cable Dimensions
Impedance RGCables Raychem Cables D E F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
TNC Straight Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RTD-50-S-00
50RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-00
50RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-00
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90-3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-00
75— 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-00
75 RG-6, RG-11, RG-12, RG-59 —5.00–12.50 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-00
TNC Straight Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RTD-50-S-03
50RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-03
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-03
75RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-03
75— 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-03
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-03
TNC Straight Panel Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.5–5.5 0.9–3.0 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RTD-50-S-04
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.1–5.0 3.0 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050]
RTD-50-M-04
50 RG-165, RG-215, RG-213, 5012F3332, 5012A33115.0–12.5 4.1–9.5 7.3 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-04
75 RG-179, RG-187 7530A1317 1.5–5.5 0.9–3.0 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-04
75 — 7524A1311, 7528A1317 3.5–7.0 2.1–5.0 3.7 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-04
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.1–9.5 7.3 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-04
TNC Coaxial Connectors
Coaxial Cable Termination
RF One-Step BNC/TNC Connectors (Continued)
8-60 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
12.7 [.5]
RBD-XX-X-04
RTD-XX-X-04
Panel thickness: 3.2 [.125] max.
RBD-XX-X -02
RTD-XX-X -02
20.5 [.8] min.
∅12.9 [.51]
12 [.47]
18 [.7] min.
=
=
=
=
∅11.2 [.44]
∅3 [.12]
12.7
[.5]
Cable Type Cable Dimensions
Impedance RG Cables Raychem Cables D E F G Part
(ohms) (Min.–Max.) (Min.–Max.) (Max.) (Max.) No.
TNC Straight Bulkhead Jacks, Female Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RTD-50-S-02
50RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.5–7.0 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-02
50RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.0–12.5 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-02
75 RG-179, RG-187 7530A1317 1.5–5.5 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-02
75 — 7524A1311, 7528A1317 3.5–7.0 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-02
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-02
TNC Right-Angle Plugs, Male Contacts
50 RG-174, RG-178, RG-188, 5026A1311, 5028A1317, 1.50–5.50 0.90–3.00 1.55 0.65
RG-196,RG–316 5030A1317 [.060–.217] [.035–.118] [.060] [.025]
RTD-50-S-01
50 RG-58, RG-141, RG-142, 5019D3318, 5021D1331, 3.50–7.00 2.10–5.00 3.00 1.25
RG-303, RG-400 5020A1311 [.138–.276] [.083–.197] [.118] [.050] RTD-50-M-01
50 RG-165, RG-215, RG-213, 5012F3332, 5012A3311 5.00–12.50 4.10–9.50 7.30 2.45
RG-225, RG-214 [.197–.500] [.161–.375] [.287] [.100] RTD-50-L-01
75 RG-179, RG-187 7530A1317 1.50–5.50 0.90–3.00 1.55 0.65
[.060–.217] [.035–.118] [.060] [.025] RTD-75-S-01
75 — 7524A1311, 7528A1317 3.50–7.00 2.10–5.00 3.70 1.25
[.138–.276] [.083–.197] [.146] [.050] RTD-75-M-01
75 RG-6, RG-11, RG-12, RG-59 —5.0–12.5 4.10–9.50 7.30 2.45
RG-144, RG-216 [.197–.500] [.161–.375] [.287] [.100] RTD-75-L-01
TNC Coaxial Connectors
8
Electrical Interconnect Products
8-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
Introduction
The question is, how to
meet growing performance
requirements for shielded
cable system fabrication
and maintenance while
minimizing electromagnetic
interference (EMI). The
answer is Raychem
SolderShield cable splices.
SolderShield devices are
one-piece products consist-
ing of a flux-coated, solder-
impregnated copper shield
braid encased in a heat-
shrinkable insulation sleeve.
SolderShield cable-to-cable
splice kits, designed for
single-conductor or multi-
conductor shielded cables,
are ideal for fabrication/
repair/rework while restoring
the electrical integrity of
the cable.
SolderShield devices
perform even in demanding
environments. They are
reliable, versatile, and easy
to install.
8-62 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices
Applications
Used for splicing a wide
range of cables, including
coaxial and multiconductor
cables.
SolderShield devices can
be used to repair or splice
shielded or coaxial cables.
These products consist of
aMiniSeal crimp splice
plus a flux-coated, solder-
impregnated copper shield
encased in a heat-shrinkable
sealing sleeve, for splicing
the shields. SolderShield
kits terminate single- or
multiple-conductor cables,
eliminate EMI problems at
the splice, and provide
strain relief for the cable.
Product Selection Process
For splicing multiconductor
cables refer to Table A.
For splicing coaxial cables
refer to Table B.
Installation
For proper installation of
these devices, the correct
heating tool and reflector
attachment must be used.
Any one of the following
Raychem heating tools is
recommended:
nHL1802E
nIR-1759 MiniRay
nCV-1981
Specifications/Approvals
Series Military Raychem
D-150 US: M81824 (conductor splice only) RT-1404
UK: RAF AP 1130-2008-1
Product Facts
nFlux-coated, solder-
impregnated copper shield
braid encased in a
transparent heat-shrinkable
insulation sleeve provides a
controlled soldering
process, encapsulation,
inspectability, strain relief,
and insulation
nOne-piece design provides
easy installation and lower
installed cost
nCircumferential (360°)
shielding results in EMI
protection and shield
continuity equal to or better
than the original cable
nConductor splices are made
using Raychem MiniSeal
crimp products, which are
recognized by MIL-S-81824
and MIL-W-5088
Refer to Raychem installa-
tion procedure RCPS 150-
02 (D-150 series) and RPIP
699-00 (B-202 series) for
detailed instructions and
recommended reflector
attachment.
You will find ordering infor-
mation for most of these
tools in Section 10.
Available in:
Americas n
Europe n
Asia Pacific n
8
Electrical Interconnect Products
8-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices(Continued)
SolderShield Product Dimensions Conductor Splice
Part No. Dimensions Size Range Color Quantity
L1L2 L3 ID CMA [mm2] Code Per Kit
Tin Plated Nickel Plated Max. Nom. Min. Min. Min.–Max.
D-150-0168 D-150-0228 80.50 50.00 10.20 3.00 304–1510 Red 1
[3.17] [1.97] [.400] [.118] [0.15–0.75]
D-150-0169 D-150-0229 80.50 50.00 10.20 4.00 779–2680 Blue 1
[3.17] [1.97] [.400] [.157] [0.39–1.34]
D-150-0170 D-150-0230 80.50 50.00 10.20 5.00 1900–6755
Yellow 1
[3.17] [1.97] [.400] [.197] [0.95–3.37]
D-150-0174 D-150-0231 10.60 75.00 10.20 4.00 304–1510 Red 2
[4.17] [2.95] [.400] [.157] [0.15–0.75]
D-150-0175 D-150-0232 10.60 75.00 10.20 5.00 779–2680 Blue 2
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0176 D-150-0233 10.60 75.00 10.20 6.00 1900–6755 Yellow 2
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0177 D-150-0234 10.60 75.00 10.20 9.00 304–1510 Yellow 2
[4.17] [2.95] [.400] [.356] [0.15–0.75]
D-150-0178 D-150-0235 10.60 75.00 10.20 4.00 304–1510 Red 4
[4.17] [2.95] [.400] [.157 ] [0.15–0.75]
D-150-0179 D-150-0236 10.60 75.00 10.20 5.00 779–2680 Red 4
[4.17] [2.95] [.400] [.197] [0.39–1.34]
D-150-0180 D-150-0237 10.60 75.00 10.20 6.00 1900–6755 Blue 4
[4.17] [2.95] [.400] [.236] [0.95–3.37]
D-150-0181 D-150-0238 10.60 75.00 10.20 9.00 1900–6755 Yellow 4
[4.17] [2.95] [.400] [.353] [0.95–3.37]
Note: The SolderShield splice kits listed in this table are for 1:1 cable splices. The kits can be used on cables with tin-, silver-, and nickel-plated copper conduc-
tors. All the kits have environmental-sealing capability. The cable temperature rating must be 125°C minimum.
Tofind the splice kit part number for your application:
1. Determine the number of conductors in the cable to be spliced.
2. Determine the gauge of each conductor or the maximum jacket OD.
3. Determine the conductor plating.
4. Select the appropriate part number from the table above.
L1
I.D.
L2
L3
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers of
conductor splices.
SolderShield Splice Crimp Splice
L1
L2
L3
Table A. Multiconductor
Cable Splices
8-64 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
RG Cable No. Raychem Conductor Part SolderShield Dimensions
Cable Description Splice Qty/Kit No. L1Max L2 Min ID Min
8A, 9B, 11 5012A3311
13, 26, 31 5012E1339
115, 144, 149 7518A1311 1 D-150-0214 80.50 50.00 12.00
165, 213, 214 — [3.170] [1.970] [.472]
216, 235, 391 —
393, 397 —
178, 196, 5028A1317
179, 187, 188, 7528A1317 1D-150-0094 80.50 50.00 3.00
316, 404, M17/138-00001, 5030A1317 [3.170] [1.970] [.118]
M17/136-00001 7530A1317
180, 195 5024A1311
M17/137-00001 7526A1311 1 D-150-0095 80.50 50.00 4.00
M17/139-00001 9527A1318 [3.170] [1.970] [.157]
— 9530E1014
124, 140, 141 5020A1311
159, 302, 303 5022A1311 1 D-150-0096 80.50 50.00 5.00
— 7522A1311 [3.170 ] [1.970] [.236]
— 7523D1331
— 7524A1311
29, 30, 55B 5019D3318 1 B-202-81* 56.00 23.00 7.00
58, 223 5021D1331 [2.200] [.900] [.275]
— 5022A1311
59, 62, 71 7523D1331 1 B-202-82* 56.00 23.00 7.00
— 7524A1311 [2.200 ] [.900] [.275]
— 9524A1311
*These kits use solder to terminate the center conductors. All other kits use crimp.
All kits are for one-to-one coaxial cable splices, and all kits have environmental sealing capability. Each kit contains products to splice conductors, build up
dielectric, splice the shield, and provide insulation.
Each SolderShield part
consists of a SolderShield
splice and one or more
conductor splices. Refer to
information below for
description and numbers of
conductor splices.
L1
I.D.
L2
L3
SolderShield Splice Crimp Splice
L1
L2
L3
Table B. Coaxial Cable
Splices
8
Electrical Interconnect Products
8-65
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable-to-Cable Splicing
SolderShield Shielded and Coaxial Cable Splices (Continued)
Product Characteristics
Materials
Insulation sleeve Radiation-crosslinked polyvinylidene fluoride
Meltable inserts Fluorocarbon-based thermoplastic
MiniSeal crimp splice Base metal: Copper alloy C10200 per ASTM B75
Plating: Tin per MIL-T-10727 or nickel per QQ-N-290
SolderShield shield splice Base metal: Tin-plated copper wire braid per ASTM B3
Solder and flux coating: Type Sn63 Pb37. Flux: ROM1 per ANSI - J - STD - 004 (RAflux)
Parameter Test Method Requirement
Electromechanical Performance
Dielectric strength (shield connection) — No breakdown or arcing at 1000 Vac (RMS)
Dielectric strength (conductor connection) — 2.5 kV
Voltage drop MIL-S-81824 Less than 2.0-millivolt increase
Insulation resistance (shield connection) — 1000 megohms minimum at 500 Vdc
Insulation resistance (conductor connection) — 5000 megohms
Tensile strength for MiniSeal MIL-S-81824 Exceed yield strength (pounds) of wire.
Tensile strength for SolderShield MIL-S-81824 75% of strength (pounds) of unspliced cable
Temperature rating — -55°C to 150°C [-67°F to 302°F]
Environmental Resistance
Salt spray MIL-STD-202 M101 Meet voltage drop requirement.
Heat aging 750 hours at 150°C [302°F] Meet all electromechanical requirements.
Temperature cycling MIL-STD-202 M107C Meet all electromechanical requirements.
Altitude immersion Immersion at 22,860m [75,000 ft] Meet insulation-resistance requirement.
Corrosion resistance — No evidence of corrosion after testing in accordance
with MIL-STD-202, Method 101, Test Condition A
Shielded Contacts
8-66 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
Raychem SolderTacts
shielded contacts are
designed to provide
reliable, one-piece solder
terminations for use with
circular and rectangular
connectors. These con-
trolled soldering contacts
help speed installation
and reduce installed costs
while eliminating the
variables associated
with hard-to-handle
crimped terminations.
With Tyco Electronics’
controlled soldering
technology, the connections
typically exceed the
strength of the wire.
Transparent insulation
and inspection windows
permit fully inspectable
terminations.
SolderTacts products ar e
available to terminate coaxial
cable and twisted wire
pairs in both military and
commercial applications.
SolderTacts Shielded One-Piece Solder Contacts
Applications
One-piece controlled-sol-
dering SolderTacts contacts
connectors are designed to
terminate coaxial cables,
shielded wires, and twisted
pairs faster and more reli-
ably than any other method.
SolderTacts contacts elimi-
nate the variables associat-
ed with hard-to-handle
crimping. Their one-step
installation accelerates
production while reducing
handling and installed
costs.
Controlled Soldering
SolderTacts contacts pro-
vide the optimum amount
and type of solder and flux
in prefluxed solder preforms
to control soldering and
reduce operator sensitivity.
The geometry of the coaxial
cable is carried through the
connector to eliminate
separate pins, help reduce
cross talk, and improve
shielding effectiveness and
signal transmission.
SolderTacts contacts pro-
vide simultaneous electrical
connection and strain relief.
Heat-shrinkable tubing
insulations eliminate stress
concentration on the wire
within the contact. Because
the insulation is transparent
and inspection windows are
provided, terminations are
fully inspectable.
Compatibility
The design versatility of
SolderTacts contacts makes
them exceptionally well suit-
ed to military applications,
along with commercial
aerospace, instrumentation
and computers. SolderTacts
products are compatible
with most standard connec-
tor cavities. SolderTacts
contacts areintermateable
and intermountable with
contacts qualified to the
indicated specification.
SolderTacts shielded
contacts can be terminated
with standardRaychem
heating tools. Once termi-
nated, they can be installed
into connector cavities with
standard insertion and
extraction tools. They are
replaceable without cutting
and restripping or shorten-
ing the cable.
Specifications/Approvals
Series Raychem
D-602 D-6002
Product Facts
nReliable one-piece solder
contacts: through-connector
shielding reduces cross-
talk, and improves signal
transmission
nOne-step installation
nSolder joints are strong and
reliable
nTerminations are fully
inspectable
nTermination for coax cables,
shielded wires, twisted
pairs, triaxial cables, for a
variety of commercial and
military connectors
Shielded Contacts
8-67
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Available in:
Americas n
Europe n
Asia Pacific n
Shielded Contacts
8-68 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter Raychem
Military Wire SolderTacts Size Polarity Cable Type
Specification JOD SOD DOD COD (AWG) Part No.
MIS-20067/5-001† 1.78–4.70 1.65–2.79 .76–2.03 .23–.51 24–32 D-602-16 12 S Coaxial
[.070–.185] [.065–.110] [.030–.080] [.009–.020]
MIS-20067/6-001† 1.78–4.70 1.65–2.79 .76–2.03 .23–.51 24–32 D-602-17 12 P Coaxial
[.070–.185] [.065–.110] [.030–.080] [.009–.020]
— 1.52–3.30 1.68–2.13 .91–1.75 .30–.66 24–30 D-602-46 16 P Coaxial
[.060–.130] [.066–.089] [.036–.069] [.012–.026]
— 1.52–3.30 1.68–2.13 .91–1.75 .30–.66 26–32 D-602-47 16 S Coaxial
[.060–.130] [.066–.089] [.036–.069] [.012–.026]
— — — .76–1.24 .28–.79 24–30 D-602-56 16 P Twinax
[.030–.049] [.011–.031]
— — — .76–1.24 .28–.79 24–30 D-602-57 16 S Twinax
[.030–.049] [.011–.031]
†These SolderTacts contacts are on qualified parts list for indicated specification.
Engineering Convection
Standard (Hot Air) Heating Contact Contact
(Termination AT-1319 Repair Insertion Removal
Part Numbers
Instructions) Adapter Wand Tool Tool
D-602-46/47 ES61137 AT-1319-17 *AD-1525 AD-1526
D-602-56/57 ES61138 — — (M81969/17-04) (M81969/19-08)
D-602-16/17 ES61161 — — — —
*Could be developed.
Note:
AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel® General Purpose Hot-Air
Heating Tool shown on page 10-13.
SolderTacts Product Construction, MIL-C-26482 Series
Jacket
(JOD) Shield
(SOD) Dielectric
(DOD) Conductor
(COD)
SolderTacts Series:
MIL-C-26482
Tooling Selection Guide
Shielded Contacts
8-69
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter Raychem
MilitaryWire SolderTacts Size Polarity Cable Type
Specification JOD SOD DOD COD
(AWG) Part No.
MIS-20067/2-002a1.52–3.35 1.68–2.13 .91–1.78 .23–.89 26–32 D-602-44 16 P Coaxial
[.060-.132] [.066-.084] [.036-.070] [.009-.035]
MIS-20067/1-001a1.52–3.35 1.68–2.13 .91–1.78 .23–.89 26–32 D-602-45 16 S Coaxial
[.060-.132] [.066-.084] [.036-.070] [.009-.035]
MIS-20067/4-001a——.76–1.24 .28–.79 24–30 D-602-54 16 P Twisted pair
[.030-.049] [.011-.031]
MIS-20067/3-001a— — .76–1.24 .28–.79 24–30 D-602-55 16 STwisted pair
[.030-.049] [.011-.031]
M39029/79b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-72 16 P Coaxial
[.060-.132] [.066-.084] [.036-.066] [.012-.026]
M39029/80b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-73 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
M39029/40b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-76 16 P Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
M39029/41b1.52–3.35 1.68–2.13 .91–1.68 .30–.66 26–32 D-602-77 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.066] [.012-.026]
— — — .76–1.24 .28–.79 24–30 D-602-0126 16 P Twisted pairc
[.030-.049] [.011-.031]
———
.76–1.24 .28–.79 24–30 D-602-0127 16 S Twisted pairc
[.030-.049] [.011-.031]
—1.52–3.35 1.68–2.13 .91–1.78 .23–.46 28–32 D-602-0172 16 P Coaxial
[.060-.132] [.066-.084 ] [.036-.070] [.009-.018]
MIS-20067/2-001, 003a1.52–3.35 1.68–2.13 .91–1.78 .23–.46 28–32 D-602-0173 16 S Coaxial
[.060-.132] [.066-.084 ] [.036-.070] [.009-.018]
MIS-20067/8-001a——
1.40–3.15 .64–1.57 16–20 D-610-09 16 P Power
[.055-.124] [.025-.062]
MIS-20067/7-001a——
1.40–3.15 .64–1.57 16–20 D-610-10 16 S Power
[.055-.124] [.025-.062]
aThese SolderTacts contacts are on the qualified parts list for indicated specification.
bThese SolderTacts contacts are intermateable and intermountable with contacts qualified to the indicated specification; they replace crimp-style termination.
cThese SolderTacts contacts are designed for twisted-pair cable per MIL-STD-1553B.
SolderTacts product construction, MIL-C-28748 Series
Jacket
(JOD) Shield
(SOD) Dielectric
(DOD) Conductor
(COD)
SolderTacts Series:
MIL-C-28748 Series
Shielded Contacts
8-70 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Convection (Hot Air) Heating
SolderTacts Part Engineering Standard AT-1319 Repair
Series No. (Termination Instructions)
Adapter Wand
D-602-44/45 ES61133 AT-1319-14 AD-1480
D-602-0172/0173 ES61240 — —
D-602-54/55 ES61132 — —
D-602-0126/0127 ES61199 — —
748 D-610-09/10 ES61187 AT-1319-15 AD-1571
D-602-72/73 ES61135 AT-1319-18 AD-1486
D-602-76/77 ES61164 AT-1319-20 AD-1554
Contact Contact
SolderTacts Series Insertion Tool Removal Tool Special Tools
AD-1457A AD-1464
748 *AD-1447 (bushing tool) (flex tip
removal tool)
*Not applicable.
Note:
AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel®
General Purpose Hot-Air Heating Tool shown on page 10-13.
Tooling Selection Guide:
MIL-C-28748 Series
Shielded Contacts
8-71
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact United States Cable Diameter Raychem
Military Air Force Wire SolderTacts Size Polarity Cable Type
Specification Drawing No. JOD SOD DOD COD (AWG) Part Number
Series I, III, and IV
M39029/60
a
—3.81–5.94 3.10–4.32 1.52–3.84 .48–1.09 22–24 D-602-0122 8 P Coaxial
[.150-.234] [.150-.170] [.060-.151] [.019-.043]
M39029/59
a
—3.81–5.94 3.10–4.32 1.52–3.84 .48–1.09 22–24 D-602-0123 8 S Coaxial
[.150-.234] [.150-.170] [.060-.151] [.019-.043]
M39029/76
a
915304-1 1.27–2.62 1.68–2.13 .91–1.73 .23–.58 26–30 D-602-0140 16 PCoaxial
[.050-.103] [.066-.084] [.036-.068] [.009-.023]
M39029/77
a
915305-1 1.27–2.62 1.68–2.13 .91–1.73 .23–.58 26–30 D-602-0141 16 S Coaxial
[.050-.103] [.066-.084] [.036-.068] [.009-.023]
M39029/76
a
915304-2 — —
.64–1.09 .23–.58 26–30 D-602-0142 16 P Twisted pair
[.025-.043] [.009-.023]
M39029/77
a
915305-2 — — .64–1.09 .23–.58 26–30 D-602-0143 16 S Twisted pair
[.025-.043] [.009-.023]
M39029/28
a
915307-1 1.47–3.10 1.68–2.39 1.12–2.03 .48–.89 24–32 D-602-0144 12 PCoaxial
[.058-.122] [.066-.094] [.044-.080] [.019-.035]
M39029/75
a
915308-1 1.47–3.10 1.68–2.39 1.12–2.03 .48–.89 24–32 D-602-0145 12 S Coaxial
[.058-.122] [.066-.094] [.044-.080] [.019-.035]
M39029/28
a
915307-3 ——.74–1.45 .48–.89 22–26 D-602-0146 12 P Twisted pair
[.029-.057] [.019-.035]
M39029/75
a
915308-3 — — .74–1.45 .48–.89 22–26 D-602-0147 12 S Twisted pair
[.029-.057] [.019-.035]
M39029/28
a
915307-2 1.90–3.81 2.54–2.97 1.27–2.62 .48–.89 22, 28 D-602-0150 12 P Coaxial
[.075-.150] [.100-.117] [.050-.103] [.019-.035]
M39029/75
a
915308-2 1.90–3.81 2.54–2.97 1.27–2.62 .48–.89 22, 28 D-602-0151 12 S Coaxial
[.075-.150] [.100-.117] [.050-.103] [.019-.035]
—8340712-OS-01 2.49–3.42 1.68–3.05 .76–1.24 .27–.79 24–26 D-602-1108 8STwisted pair
b
[.098-.135] [.066-.120] [.030-.049] [.011-.031]
— 8340713-OS-01 2.49–3.42 1.68–3.05 .76–1.24 .27–.79 24–26 D-602-1109 8 P Twisted pair
b
[.098-.135] [.066-.120] [.030-.049] [.011-.031]
——
2.49–3.76 1.68–3.30 .91–1.78 .23–.89 22–26 D-602-1110 8 S Triaxial
[.098-.148] [.066-.130] [.036-.070] [.009-.035]
——
2.49–3.76 1.68–3.30 .91–1.78 .23–.89 22–26 D-602-1111 8 P Triaxial
[.098-.148] [.066-.130] [.036-.070] [.009-.035]
— 8340712-OL-01 2.49–3.42 1.68–3.05 .76–1.24 .27–.79 24–26 D-602-1112 8 S Twisted pair
b
[.098-.135] [.066-.120] [.030-.049] [.011-.031]
—8340713-OL-01 2.49–3.42 1.68–3.05 .76–1.24 .27–.79 24–26 D-602-1113 8 P Twisted pair
b
[.098-.135] [.066-.120] [.030-.049] [.011-.031]
M39029/90
a
8912020-OS-01 3.68 —.64–1.29 .27–.74 24–26 DK-602-0156-N-1 8PTwinaxial
c
[.145 ] Max. [.029-.051] [.011-.029]
M39029/90
a
8912020-DL-01 4.11 —.64–1.29 .27–.74 24–26 DK-602-0156-N-2 8 P Twinaxial
c
[.162] Max. [.029-.051] [.011-.029]
aThese SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination.
bThese SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B.
cThese SolderTacts contacts are designed for databus contacts per MIL-STD-1553B.
SolderTacts Product Construction, MIL-C-38999 Series
Jacket
(JOD) Shield
(SOD) Dielectric
(DOD) Conductor
(COD)
SolderTacts Series:
MIL-C-38999, Series I, II,
III, IV Circular Connectors
Shielded Contacts
8-72 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact United States Cable Diameter (in inches) Raychem
Military Air Force Wire SolderTacts Size Polarity Cable Type
Specification Drawing No. JOD SOD DOD COD (AWG) Part Number
Series I, III, and IV
M39029/90
a
8912020-EL-01 4.50 max. — .74-1.30 .24-.74 24–26 DK-602-0156-N-3 8 P Twinaxial
c
[.177] [.029–.051] [.011–.029]
M39029/91
a
8912019-OS-01 3.68 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-1 8 S Twinaxial
c
[.145] [.029–.051] [.011–.029]
M39029/91
a
8912019-DL-01 4.12 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-2 8 S Twinaxial
c
[.162] [.029–.051] [.011–.029]
M39029/91
a
8912019-EL-01 4.50 max. — .74-1.30 .24-.74 24–26 DK-602-0157-N-3 8 S Twinaxial
c
[.177] [.029–.051] [.011–.029]
M39029/90
a
8912020-OL-01 4.67 max. —— — 20 DK-602-0169-1 8 P Twinaxial
c
[.184]
M39029/91
a
8912019-OL-01 4.67 max. ——— 20 DK-602-0170-1 8 S Twinaxial
c
[.184]
Series II
M39029/76
a
915304-1 1.27-2.62 1.68-2.13 .91-1.73 .23-.58 26–30 D-602-0140 16 P Coaxial
[.050–.103] [.066–.084] [.036–.068] [.009–.023]
M39029/77
a
915306-1 1.27-2.62 1.68-2.13 .91-1.73 .23-.58 26–30 D-602-0171 16 S Coaxial
[.050–.103] [.066–.084] [.036–.068] [.009–.023]
M39029/76
a
915304-2 — — .64-1.09 .23-.58 26–30 D-602-0142 16 P Twisted pair
[.025–.043] [.009–.023]
M39029/77
a
915306-2 — — .64-1.07 .23-.58 26–30 D-602-0174 16 S Twisted pair
[.025–.042] [.009–.023]
aThese SolderTacts contacts are intermateable and intermountable with contacts qualified to indicated specification; they replace crimp-style termination.
bThese SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B.
cThese SolderTacts contacts are designed for databus contacts per MIL-STD-1553B.
Engineering Convection
SolderTacts Part Numbers Standard (Hot Air) Heating Repair Contact Contact
Series (D-602-) (Termination AT-1319 Wand Insertion Removal
Instructions) Adapter Tool Tool*
999 0140/0141 ES61226 AT-1319-78 AD-1565 M81969/8-07 M81869/8-08
Size 16 0142/0143 ES61224 — — or or
0171 ES61226 AT-1319-27 AD-1572 M81969/14-03 M81969/14-03
0174 ES61224 — —
999 0144/0145 ES61206 AT-1319-24 AD-1566 M81969/8-09 M81969/8-10
Size 12 0146/0147 ES61218 — — or or
0150/0151 ES61223 ——M81969/14-04 M81969/14-04
999
0122/0123 ES61179 AT-1319-22 AD-1568
Size 8
1108/1109 ES61172 — M81969/14-06
1110/1111 ES61172 AT-1319-22 AD-1568 or
1112/1113 ES61184 and and — Astro A TBX-2277
0156/0157-X ES61231 AT-1319-14 AD-1480
0169/0170-X ES61235
*Tyco Electronics does not provide this tool. See connector manufacturer.
Note:
AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel® General Purpose Hot-Air
Heating Tool shown on page 10-13.
SolderTacts Series:
MIL-C-38999, Series I, II,
III, IV Circular Connectors
(Continued)
Tooling Selection Guide
Shielded Contacts
8-73
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Cable Diameter
SolderTacts Size Polarity Cable Type JOD SOD DOD COD (AWG)
D-602-0278 16 P Coaxial 1.52–2.92 1.85–2.18 .64–1.91 .23–.74 24–32
[.060-.115] [.073-.086] [.025-.075] [.009-.029]
D-602-0279 16 S Coaxial
1.52–2.92 1.85–2.18 .64–1.91 .23–.74 24–32
[.060-.115] [.073-.086] [.025-.075] [.009-.029]
D-602-0288 16 P Twisted pair — — .74–1.40 .23–.74 24–32
[.029-.055] [.009-.029]
D-602-0289 16 S Twisted pair — — .74–1.40 .23–.74 24–32
[.029-.055] [.009-.029]
*These SolderTacts contacts belong to the Raychem “Subminiature” series of contacts, which are designed for use in commercial connectors.
Tooling Selection Guide
Engineering Convection Contact Contact
SolderTacts Part Numbers Standard (hot air) Heating Removal
Series (D-602-) (Termination AT-1319
Repair Insertion Tool
Instructions) Adapter Wand Tool
Submin 0278/0279 ES61170 AT-1319-12 AD-1481 * AD-1447
— 0288/0289 ES61414 — — — —
*Not applicable.
Note:
AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel® General Purpose Hot-Air
Heating Tool shown on page 10-13.
SolderTacts Product Construction, Submin Series
Jacket
(JOD) Shield
(SOD) Dielectric
(DOD) Conductor
(COD)
SolderTacts Series:
Subminiature*
Raychem Cable Diameter
Shielded Contacts
8-74 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Contact Cable Diameter
Military Wire Raychem Size Polarity Cable Type
Specification* JOD SOD DOD COD
(AWG) SolderTacts
M39029/74-400 2.39–3.56 1.96–2.49 1.32–2.06 .28–.74 24–32 D-602-0094 12 P Coaxial
[.094-.140] [.077-.098] [.052-.081] [.011-.029]
M39029/73-397 2.39–3.56 1.96–2.49 1.32–2.06 .28–.74 24–32 D-602-0095 12 S Coaxial
[.094-.140] [.077-.098] [.052-.081] [.011-.029]
M39029/74-401 — — .74–1.45 .28–.74 24–32 D-602-0104 12 P Twisted pair
[.029-.057] [.011-.029]
M39029/73-398 — — .74–1.45 .28–.74 24–32 D-602-0105 12 S Twisted pair
[.029-.057] [.011-.029]
M39029/74-399 3.05–3.68 3.10–3.15 2.36–2.67 .28–.74 24–32 D-602-0106 12 P Large coaxial
[.120-.145] [.122-.124] [.093-.105] [.011-.029]
M39029/73-396 3.05–3.68 3.10–3.15 2.36–2.67 .28–.74 24–32 D-602-0107 12 S Large coaxial
[.120-.145] [.122-.124] [.093-.105] [.011-.029]
*These SolderTacts contacts are on qualified parts list for indicated specification.
Tooling Selection Guide
Engineering Convection
Raychem Standard (Hot Air) Heating Repair Contact Contact Special
SolderTacts (Termination AT-1319 Wand Insertion Removal Tools
Part Number Instructions) Adapter Tool Tool
D-602-0094/0095 ES61128 AT-1319-19 AD-1494 AD-1527 AD-1527 AD-1496
D-602-0106/0107 ES61134 Rev. D Rev. C (M81969/14-04) (M81969/14-04) (twisted)
D-602-0104/0105 ES61129 — — — — —
Note:
AA-400 SuperHeater Compressed Air Heating Tool shown on page 10-2 can be used for installation. Another option is the Steinel® General Purpose Hot-Air
Heating Tool shown on page 10-13.
Raychem SolderTacts Size Polarity Cable Type Contact Military
Reference Specification
D-602-0185 16 socket Coaxial —
D-602-0094 12 pin Coaxial M39029/74
D-602-0093* 12 socket Coaxial M39029/73
D-602-0106 12 pin Coax (large) M39029/74
D-602-0189* 12 socket Coax (large) M39029/73
*These SolderTacts contacts are intermateable with M39029/73, but are not on QPL.
Raychem SolderTacts Size Polarity Cable Type Contact Military
Reference Specification
D-602-0186 8 pin Twisted pair M39029/96
D-602-0187 8 socket Twisted pair M39029/95
DK-602-0186-2 8 pin Sh. twisted pair M39029/96
DK-602-0187-2 8socket Sh. twisted pair M39029/95
** These SolderTacts contacts are designed for shielded twisted pair cable per MIL-STD-1553B.
SolderTacts Series:
MIL-C-83723
SolderTacts Series:
DOD-C-83527
SolderTacts Series:
DOD-C-83527
(data bus contacts)**
Shielded Contacts
8-75
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
SolderTacts Shielded One-Piece Solder Contacts (Continued)
Raychem SolderTacts Size Polarity
Reference
D-600-0071 — For shielded twisted pair
D-600-0116 For size 8 DOD-C-83527 series —
D-600-0125 For size 8 MIL-C-38999 series, for twisted pair —
Performance
The performance of
SolderTacts contacts is
defined by the applicable
Raychem specification con-
trol drawing (SCD) and
Raychem Specification
D-6002. Products on quali-
fied product lists meet the
requirements of the base
specification.
Termination
Termination of SolderTacts
contacts is defined in the
appropriate Raychem
Engineering Standard.
To obtain a copy, contact
Tyco Electronics.
SolderTacts Series:
Grommets
Data Bus (MIL-STD-1553B) Components
8-76 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
The full line of Raychem
data bus products offers a
complete system of inter-
connection hardware for
all MIL-STD-1553B multi-
plexing needs.
Available components
include:
nCouplers (micros, boxes,
flat packs)
nData bus cables
nTriax connectors and
contacts with strain relief
nOne-piece triaxial con-
tacts for MIL-C-38999
connectors (size 8 cavity)
nBus and stub terminators
nCable marker sleeves
(TMS)
nLightweight couplers
(see pages 8-82 to 8-84)
nSpace components
(see pages 8-95 to 8-97)
nHarness design
(HarnWare)
All Raychem data bus
components offer:
nHigh packaging density
and weight savings
nDesign flexibility
nHigh performance
(to 150°C [302°F] rating)
Raychem MIL-STD-1553B
data bus components are
also specified in the
Air Force drawings listed in
Air Force Drawing 8340707.
Tyco Electronics also sup-
plies complete Raychem
data bus networks in
accordance with customer
harness drawings. Using
factory-built harnesses
eliminates unnecessary
splices and connectors,
reducing the cost and
increasing the reliability of
the networks. Factory-built
harnesses are pre-tested
and ready for installation.
8
Electrical Interconnect Products
Data Bus (MIL-STD-1553B) Components
8-77
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cables
Product Facts
nLight weight
nHighly flexible
nFlame resistant
nChemical resistant to all
aircraft fluids
nSolder iron resistant
nDefined shielding levels
Applications
Tyco Electronics manufac-
tures a line of Raychem
SPEC 55 data bus cables
that meet or exceed the
performance requirements
of MIL-STD-1553B.
SPEC 55 insulation is a
high-temperature, radiation-
crosslinked, modified ETFE
material that can be used in
wireconstructions rated up
to 200°C [392°F].
Note: Tyco Electronics will build
harnesses with any customer
specified cables and/or connectors.
Data Bus (MIL-STD-1553B) Components
8-78 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cables (Continued)
Cable Type Part No.
24 AWG Single Optimized Shield 10612
24AWG Double Optimized Shield 10613
24 A WG EMP Hardened 10614
24 AWG Flat Shield, Unfilled 7724 H 0664
Series Military
SPEC 55 insulation MIL-W-22759/32–/35
MIL-W-22759/41–/46
Specifications/Approvals
Product Selection
8
Electrical Interconnect Products
Data Bus (MIL-STD-1553B) Components
8-79
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub
Product Facts
nEnvironmental sealing
nNo connectors
nVery small size
nLight weight (1 stub: 10 g
max.; 2 stubs: 15 g max.)
nIn-line profile that makes
wire bundle mounting
possible
n360° continuous low-
impedance cable-shield
terminations
nReliable solder termination
of all components
nPotted circuit elements for
maximum durability and in-
use reliability
nEase of installation
nAltitude immersion
resistance
nOptional eyelet
configurations for bulkhead
mounting
nMean time between failures
>1,000,000 hours
Series Military Raychem
D-500-04 MIL-STD-1553B D-6020
Applications
The low-profile configuration
of these couplers enables
avionics system designers
to plan for optimum coupler
locations. Microcouplers are
supplied with Raychem
SPEC 55 data bus cables,
Specifications/Approvals
Available in:
Americas n
Europe n
Asia Pacific n
including EMP-hardened
versions. They arealso
available assembled with
other components into a
complete data bus harness.
Data Bus (MIL-STD-1553B) Components
8-80 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub (Continued)
Single Stub Double Stub
D-500-0455-1-YYY-ZZZ D-500-0455-2-YYY-ZZZ
D-500-0465-1-YYY-ZZZ D-500-0465-2-YYY-ZZZ
D-500-0456-1-YYY-ZZZ D-500-0456-2-YYY-ZZZ
D-500-0466-1-YYY-ZZZ D-500-0466-2-YYY-ZZZ
D-500-0457-1-YYY-ZZZ D-500-0457-2-YYY-ZZZ
D-500-0467-1-YYY-ZZZ D-500-0467-2-YYY-ZZZ
D-500-0458-1-YYY-ZZZ D-500-0458-2-YYY-ZZZ
D-500-0468-1-YYY-ZZZ D-500-0468-2-YYY-ZZZ
Note:
1. Bus cable
2. Stub cable
Product Selection
8
Electrical Interconnect Products
Data Bus (MIL-STD-1553B) Components
8-81
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
In-Line Microcouplers: One- and Two-Stub (Continued)
Standard Cable Length
012 = 12 in (1 ft)
078 = 78 in (6.5 ft)
079 = 79 in (2 m)
120 = 120 in (10 ft)
236 = 236 in (6 m)
240 = 240 in (20 ft)
360 = 360 in (30 ft)
Cable Type
612 = 1061224 AWG single optimized shield
613 = 1061324 AWG double optimized shield
614 = 1061424 AWG EMP hardened
H06 = 7724H0664 (24 AWG Flat Wire Unfilled)
Number of Stubs
1 or 2
Design
5 = Without internal terminator
6 = Same as 5 but with reverse bus
7 = With internal terminator
8 = Same as 7 but with reverse bus
Boot
5 = Without mounting eyelet
6 = With mounting eyelet
D-500-04W W-X-YYY-ZZZ
Microcoupler Part
Numbering System
Data Bus (MIL-STD-1553B) Components
8-82 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub
Applications
Building on over 20 years of
experience and continuous
improvement in data bus,
including pioneering
in-line microcouplers,
Tyco Electronics introduces
anew family of ultra light-
weight In-line Raychem
Microcouplers, available in
1- through 6-stub
configurations.
These couplers offer the
same high performance
and reliability as Raychem
current microcouplers, but
their weight is further
reduced. They are available
in configurations up to 6-
stub, and minimize weight
thereis no option with a
mounting eyelet.
Combined with Raychem
24 AWG data bus cables,
these ultra light couplers
allow designers to signifi-
cantly reduce weight. An
unfilled flat braid cable is
available for additional
weight savings.
They are also available
assembled with other
customer specified compo-
nents into a complete
factory-built and tested
data bus harness.
Product Facts
nEnvironmental sealing
nNo connectors
nVery small size
nUltra Light weight
(1 stub: 6.5 g max.; 2 stubs:
9.5 g max.)
nIn-line profile that makes
wire bundle mounting
possible
n360° continuous low-
impedance cable-shield
terminations
nReliable solder termination
of all components
nPotted circuit elements for
maximum durability and
in-use reliability
nEase of installation
nAltitude immersion
resistance
nMean time between failures
>1,000,000 hours
Specifications/approvals
Series Military Raychem
D-500-L4xx MIL-STD-1553B D-6020 (same as current microcouplers)
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-83
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued)
Cable Length
012 = 12 in 079 = 79 in 236 = 236 in
078 = 78 in 120 = 120 in 240 = 240 in
360 = 360 in
Cable Type
612 = 10612 (24 AWG single optimized shield)
613 = 10613 (24 AWG double optimized shield)
614 = 10614 (24 AWG EMP hardened)
H06 = 7724H0664 (24 AWG flat shield, unfilled)
Lightest cable
Number of Stubs
1, 2, 3, 4, 5 or 6
Design
5 = Without internal terminator
7 = With internal terminator
Style
5 = Without eyelet
D-500-L4 5 W -X -YYY -ZZZ
Lightweight In-Line
Couplers Part Numbering
System
Data Bus (MIL-STD-1553B) Components
8-84 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Ultra Lightweight In-Line Microcouplers 1- Through 6-Stub (Continued)
D-500-L455-X-YYY-ZZZ D-500-L456-X-YYY-ZZZ
End View End View End View End View
Left Side Right Side Left Side Right Side
D-500-L457-X-YYY-ZZZ D-500-L458-X-YYY-ZZZ
End View End View End View End View
Left Side Right Side Left Side Right Side
1stub
2stub
3stub
4stub
5stub
6stub
1stub
2stub
3stub
4stub
5stub
6stub
1stub
2stub
3stub
4stub
5stub
6stub
1stub
2stub
3stub
4stub
5stub
6stub
Legend
Bus cable
Stub cable
Product Selection
Data Bus (MIL-STD-1553B) Components
8-85
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Box Couplers
Product Facts
nLight, robust coupler
modules with connector
versatility
nUpto eight stub connectors
can be arrayed on the “face”
ofthe box coupler. Bus
connectors can also be on
the “face” or on the “side”
of the box
nDesigned with Raychem
D-621 series corrosion-
resistant threaded-type or
bayonet-type connectors
Series Military Raychem
D-500-0255 MIL-STD-1553 D-6021
Applications
The multiport capability of
these couplers (up to eight
stubs) enables avionics
system designers to inter-
connect black boxes with
minimum wire runs. Box
couplers are supplied with
Raychem triaxial threaded
or bayonet connectors.
Note: Tyco Electronics also designs
and manufactures customized
Raychem data bus box couplers.
Specifications/Approvals
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-86 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Box Couplers (Continued)
Part No.
Coupler Type Threaded Bayonet A* Bayonet B* Bayonet C*
Face - 1 Stub D-500-0255-511-1 D-500-0255-513-1 D-500-0255-515-1 D-500-0255-517-1
Face - 2 Stub D-500-0255-521-1 D-500-0255-523-1 D-500-0255-525-1 D-500-0255-527-1
Face - 3 Stub D-500-0255-531-1 D-500-0255-533-1 D-500-0255-535-1 D-500-0255-537-1
Face - 4 Stub D-500-0255-541-1 D-500-0255-543-1 D-500-0255-545-1 D-500-0255-547-1
Face - 5 Stub D-500-0255-551-1 D-500-0255-553-1 D-500-0255-555-1 D-500-0255-557-1
Face - 6 Stub D-500-0255-561-1 D-500-0255-563-1 D-500-0255-565-1 D-500-0255-567-1
Face - 7 Stub D-500-0255-571-1 D-500-0255-573-1 D-500-0255-575-1 D-500-0255-577-1
Face - 8 Stub D-500-0255-581-1 D-500-0255-583-1 D-500-0255-585-1 D-500-0255-587-1
Side - 1 Stub D-500-0255-512-1 D-500-0255-513-2 D-500-0255-515-2 D-500-0255-517-2
Side - 2 Stub D-500-0255-522-1 D-500-0255-523-2 D-500-0255-525-2 D-500-0255-527-2
Side - 3 Stub D-500-0255-532-1 D-500-0255-533-2 D-500-0255-535-2 D-500-0255-537-2
Side - 4 Stub D-500-0255-542-1 D-500-0255-543-2 D-500-0255-545-2 D-500-0255-547-2
Side - 5 Stub D-500-0255-552-1 D-500-0255-553-2 D-500-0255-555-2 D-500-0255-557-2
Side - 6 Stub D-500-0255-562-1 D-500-0255-563-2 D-500-0255-565-2 D-500-0255-567-2
Side - 7 Stub D-500-0255-572-1 D-500-0255-573-2 D-500-0255-575-2 D-500-0255-577-2
Side - 8 Stub D-500-0255-582-1 D-500-0255-583-2 D-500-0255-585-2 D-500-0255-587-2
*The bayonet polarization listed is for the bus connector.All stub connectors are Bayonet D polarization. Polarizations
are depicted as follows (jack view):
1=A
2=B
3=C
4=D
Product Selection
Data Bus (MIL-STD-1553B) Components
8-87
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Discrete Connectors
Product Facts
nCompliance with
MIL-STD-1553B hardware
requirements
nLight weight
nRemovable pin or socket
contacts
nTermination with Raychem
MIL-STD-1553B data bus
cables, including EMP-
hardened versions
nContinuous 360° shield
coverage
nRugged constructions
nTermination time of 1 to 2
minutes
nInspectable solder
terminations
nLow-skill assembly
nReworkable and repairable
terminations
nStrain relief built into the
design
nLow-voltage drop and high
reliability because of
precisely controlled solder
terminations
nThreaded and bayonet
coupling styles
nLow total installed cost
n1000-hour salt spray
resistance
nLower-cost connectors, for
benchtop and mock-up
Series Military Raychem
DK-621 MIL-STD-1553B D-6025
Applications
Designed specifically for
MIL-STD-1553B data bus
applications, the D-621
connector is intended to be
aperfect match for the
Raychem airworthy data
bus cable. Together they
provide durable, reliable,
and reworkable intercon-
nection hardware for the
MIL-STD-1553B market.
Specifications/Approvals
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-88 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Discrete Connectors (Continued)
Contact (supplied in DK-621 kits only)
P = Pin
S = Socket
Polarization (bayonet styles only) (jack view)
Basic Connector Configurations
Threaded styles
11 = Plug
12 = Jack
Bayonet styles
33 = Plug, A polarization
34 = Jack, A polarization
35 = Plug, B polarization
36 = Jack, B polarization
37 = Plug, C polarization
38 = Jack, C polarization
39 = Plug, D polarization
40 = Jack, D polarization
D-621 connector, kitted with accessories
DK-621-04 XX-XX
4=D
3 = C
2=B
1 = A
Connector Kit Part
Numbering System
Example:
DK-621-0434-1P = D-621
connector, kitted with
accessories, jack bayonet
style with A polarization and
pin contact.
Data Bus (MIL-STD-1553B) Components
8-89
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Accessories
Applications
Tyco Electronics manufac-
tures all the products
needed to build a MIL-STD-
1553B data bus network. In
addition to the main compo-
nents (couplers, connec-
tors, contacts, and cables),
Tyco Electronics supplies
the accessory components
that may be necessary to
complete a data bus
system.
These include:
nBus and stub terminators
(spliced-in and connec-
torized D-621 series).
nCable splice kits.
nEMI/environment-resistant
connector caps.
nBraid terminators and
strain relief tubing (for
rework applications).
nCable marking materials.
Product Facts
nAsingle source for all
harness components
nProducts designed to work
together
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-90 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Accessories (Continued)
Spliced-in 12-inch Cable
77-ohm 10612 cable D-500-0463-612
77-ohm 10613 cable D-500-0463-613
77-ohm 10614 cable D-500-0463-614
77-ohm 7724H0664 cable D-500-0463-H06
D-621 Series—Plug Threaded Bayonet A Bayonet B Bayonet C Bayonet D
77-ohm pin contact D-621-0413 D-621-0453 D-621-0454 D-621-0455 D-621-0456
77-ohm socket contact D-621-0415 D-621-0469 D-621-0470 D-621-0471 D-621-0472
3000-ohm pin contact D-621-0417 D-621-0457 D-621-0458 D-621-0459 D-621-0476
3000-ohm socket contact D-621-0407 D-621-0473 D-621-0474 D-621-0475 D-621-0460
D-621 Series—Jack Threaded Bayonet A Bayonet B Bayonet C Bayonet D
77-ohm pin contact D-621-0418 D-621-0477 D-621-0478 D-621-0479 D-621-0480
77-ohm socket contact D-621-0406 D-621-0461 D-621-0462 D-621-0463 D-621-0464
3000-ohm pin contact D-621-0423 D-621-0481 D-621-0482 D-621-0483 D-621-0484
3000-ohm socket contact D-621-0424 D-621-0465 D-621-0466 D-621-0467 D-621-0468
D-621 Series—L Lanyard 7” — — — —
D-621 Series Threaded Bayonet A Bayonet B Bayonet C Bayonet D
Plug cap for jack connector D-600-0083 D-600-0068 D-600-0068 D-600-0068 D-600-0065
Supplied with 7” Lanyard
Cables Flexible Crimp
All data bus cables D-150-0708-5
1=A
2=B
3=C
4=D
Splice-in
D-621 plug
D-621 jack
D-621 Plug D-621 Jack
Splice-in
Bus and Stub Terminators
Product Selection
Connector Caps
Cable Splice Kits
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-91
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Panel Connector Contact Terminator Mate with
Thickness Reference Standard Connector Long Reach Connector
Bayonet Connectors
Polarity A Plug Pin D-621-0453(-L) DK-621-0434-1S DK-621-0550-1S
77 Ohm bus Plug Socket D-621-0469(-L) DK-621-0434-1P DK-621-0550-1P
terminator Jack Pin D-621-0477(-L) DK-621-0433-1S —
Jack Socket D-621-0461(-L) DK-621-0433-1P —
Plug Pin D-621-0457(-L) DK-621-0434-1S DK-621-0550-1S
3KOhm stub Plug Socket D-621-0473(-L) DK-621-0434-1P DK-621-0550-1P
terminator Jack Pin D-621-0481(-L) DK-621-0433-1S —
Jack Socket D-621-0465(-L) DK-621-0433-1P —
Polarity B Plug Pin D-621-0454-(-L) DK-621-0436-2S DK-621-0548-2S
77Ohm bus Plug Socket D-621-0470-(-L) DK-621-0436-2P DK-621-0548-2P
terminator Jack Pin D-621-0478-(-L) DK-621-0435-2S —
Jack Socket D-621-0462-(-L) DK-621-0435-2P —
Plug Pin D-621-0458-(-L) DK-621-0436-2S DK-621-0548-2S
3KOhm stub Plug Socket D-621-0474-(-L) DK-621-0436-2P DK-621-0548-2P
terminator Jack Pin D-621-0482-(-L) DK-621-0435-2S —
Jack Socket D-621-0466-(-L) DK-621-0435-2P —
Polarity C Plug Pin D-621-0455(-L) DK-621-0438-3S DK-621-0546-3S
77 Ohm bus Plug Socket D-621-0471(-L) DK-621-0438-3P DK-621-0546-3P
terminator Jack Pin D-621-0479(-L) DK-621-0437-3S —
Jack Socket D-621-0463(-L) DK-621-0437-3P —
Plug Pin D-621-0459(-L) DK-621-0438-3S DK-621-0546-3S
3K Ohm stub Plug Socket D-621-0475(-L) DK-621-0438-3P DK-621-0546-3P
terminator Jack Pin D-621-0483(-L) DK-621-0437-3S —
Jack Socket D-621-0467(-L) DK-621-0437-3P —
Polarity D Plug Pin D-621-0456(-L) DK-621-0440-4S DK-621-0551-4S
77 Ohm bus Plug Socket D-621-0472(-L) DK-621-0440-4P DK-621-0551-4P
terminator Jack Pin D-621-0480(-L) DK-621-0439-4S —
Jack Socket D-621-0464(-L) DK-621-0439-4P —
Plug Pin D-621-0460(-L) DK-621-0440-4S DK-621-0551-4S
3K Ohm stub Plug Socket D-621-0476(-L) DK-621-0440-4P DK-621-0551-4P
terminator Jack Pin D-621-0468(-L) DK-621-0439-4S —
Jack Socket D-621-0484(-L) DK-621-0439-4P —
Threaded Connectors Plug Pin D-621-0413(-L) DK-621-0412-S DK-621-0512-S
77 Ohm bus Plug Socket D-621-0415(-L) DK-621-0412-P DK-621-0512-P
terminator Jack Pin D-621-0418(-L) DK-621-0411-S —
Jack Socket D-621-0406(-L) DK-621-0411-P —
Plug Pin D-621-0417(-L) DK-621-0412-S DK-621-0512-S
3K Ohm stub Plug Socket D-621-0407(-L) DK-621-0412-P DK-621-0512-P
terminator Jack Pin D-621-0423(-L) DK-621-0411-S —
Jack Socket D-621-0424(-L) DK-621-0411-P —
Terminator and Connector
and Compatibility —
Bayonet and Threaded
Connectors
Panel Connector Contact Connector Mate with
Thickness Reference Connector 77 Ohm Bus Terminator 3K Ohm Stub Terminator
Bayonet Connectors
Polarity A Plug Pin DK-621-0433-1P DK-621-0434-1S D-621-0461(-L) D-621-0465 (-L)
Plug Socket DK-621-0433-1S DK-621-0434-1P D-621-0477(-L) D-621-0481(-L)
Standard Jack Pin DK-621-0434-1P DK-621-0433-1S D-621-0461(-L) D-621-0473(-L)
2.4mm max. Jack Socket DK-621-0434-1S DK-621-0433-1P D-621-0453(-L) D-621-0457(-L)
Long Reach Jack Pin DK-621-0550-1P DK-621-0433-1S D-621-0469(-L) D-621-0473(-L)
12.5mm max. Jack Socket DK-621-0550-1S DK-621-0433-1P D-621-0453(-L) D-621-0457(-L)
Polarity B Plug Pin DK-621-0435-2P DK-621-0436-2S D-621-0462(-L) D-621-0474 (-L)
Plug Socket DK-621-0435-2S DK-621-0436-2P D-621-0478(-L) D-621-0458(-L)
Standard Jack Pin DK-621-0436-2P DK-621-0435-2S D-621-0470(-L) D-621-0474(-L)
2.4mm max. Jack Socket DK-621-0436-2S DK-621-0435-2P D-621-0454(-L) D-621-0458(-L)
Long Reach Jack Pin DK-621-0448-2P DK-621-0435-2S D-621-0470(-L) D-621-0467(-L)
12.5mm max. Jack Socket DK-621-0448-2S DK-621-0435-2P D-621-0454(-L) D-621-0483(-L)
Polarity C Plug Pin DK-621-0437-3P DK-621-0438-3S D-621-0463(-L) D-621-0467(-L)
Plug Socket DK-621-0437-3S DK-621-0438-3P D-621-0479(-L) D-621-0483(-L)
Standard Jack Pin DK-621-0438-3P DK-621-0437-3S D-621-0471(-L) D-621-0475(-L)
2.4mm max. Jack Socket DK-621-0438-3S DK-621-0437-3P D-621-0455(-L) D-621-0459(-L)
Long Reach Jack Pin DK-621-0446-3P DK-621-0437-3S D-621-0471(-L) D-621-0475(-L)
12.5mm max. Jack Socket DK-621-0446-3S DK-621-0437-3P D-621-0455(-L) D-621-0459(-L)
Polarity D Plug Pin DK-621-0439-4P DK-621-0440-4S D-621-0464(-L) D-621-0468(-L)
Plug Socket DK-621-0439-4S DK-621-0440-4P D-621-0480(-L) D-621-0484(-L)
Standard Jack Pin DK-621-0440-4P DK-621-0439-4S D-621-0472(-L) D-621-0476(-L)
2.4mm max. Jack Socket DK-621-0440-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L)
Long Reach Jack Pin DK-621-0551-4P DK-621-0439-4S D-621-0472(-L) D-621-0476(-L)
12.5mm max. Jack Socket DK-621-0551-4S DK-621-0439-4P D-621-0456(-L) D-621-0460(-L)
Threaded Connectors Plug Pin DK-621-0411-P DK-621-0412-S D-621-0406(-L) D-621-0424(-L)
Plug Socket DK-621-0411-S DK-621-0412-P D-621-0418(-L) D-621-0423(-L)
Standard Jack Pin DK-621-0412-P DK-621-0411-S D-621-0415(-L) D-621-0407(-L)
2.4mm max. Jack Socket DK-621-0412-S DK-621-0411-P D-621-0413(-L) D-621-0417(-L)
Long Reach Jack Pin DK-621-0412-P DK-621-0411-S D-621-0415(-L) D-621-0407(-L)
12.5mm max. Jack Socket DK-621-0412-S DK-621-0411-P D-621-0413(-L) D-621-0417(-L)
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-92 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Triaxial Connectors and
Terminator Compatibility —
Bayonet and Threaded
Connectors
Data Bus (MIL-STD-1553B) Components
Accessories (Continued)
8-93
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Triaxial Connectors and
Terminator Compatibility —
to European norme 3716
Panel Connector Contact Connector Mate with
Thickness Reference Connector 77 Ohm Bus Terminator 3K Ohm Stub Terminator
Triaxial Connectors Plug Pin DK-3716-F101-TP DK-621-E102-TS D-621-E077-S D-621-E03K-S
Plug Socket DK-3716-F101-TS DK-621-E102-TP D-621-E077-P D-621-E03K-P
Plug Pin DK-3716-F201-TP DK-621-E202-TS D-621-E077-S D-621-E03K-S
Plug Socket DK-3716-F201-TS DK-621-E202-TP D-621-E077-P D-621-E03K-P
Jack Pin DK-3716-E102-TP DK-621-F101-TS D-621-F077-S D-621-F03K-S
Standard Jack Socket DK-3716-E102-TS DK-621-F101-TP D-621-F077-P D-621-F03K-P
2.4mm max. Jack Pin DK-3716-E202-TP DK-621-F201-TS D-621-F077-S D-621-F03K-S
Jack Socket DK-3716-E202-TS DK-621-F201-TP D-621-F077-P D-621-F03K-P
Jack Pin DK-3716-E112-TP DK-621-F101-TS D-621-F077-S D-621-F03K-S
Long Reach Jack Socket DK-3716-E112-TS DK-621-F101-TP D-621-F077-P D-621-F03K-P
12.5mm max. Jack Pin DK-3716-E212-TP DK-621-F201-TS D-621-F077-S D-621-F03K-S
Jack Socket DK-3716-E212-TS DK-621-F201-TP D-621-F077-P D-621-F03K-P
Panel Connector Contact Terminator Mate with
Thickness Reference Standard Connector Long Reach Connector
Terminators Plug Pin DK-3716-F077-P DK-3716-E#02-TS DK-3716-E#12K-TS
77 Ohm bus Plug Socket DK-3716-F077-S DK-3716-E#02-TP DK-3716-E#12K-TP
terminator Jack Pin DK-3716-F077-P DK-3716-E#01-TS —
Jack Socket DK-3716-F077-S DK-3716-E#01-TP —
Plug Pin DK-3716-E03K-P DK-3716-E#02-TS DK-3716-E#12K-TS
3K Ohm stub Plug Socket DK-3716-E03K-S DK-3716-E#02-TP DK-3716-E#12K-TP
terminator Jack Pin DK-3716-E03K-P DK-3716-E#01-TS —
Jack Socket DK-3716-E03K-S DK-3716-E#01-TP —
Data Bus (MIL-STD-1553B) Components
8-94 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Triaxial Size 8 Contacts
Applications
Contacts provide full shield
coverage with a simple,
quick, and reliable termina-
tion system. 24 AWG twist-
ed-pair data bus cables
are terminated with triaxial
SolderTacts contacts,
which fit size 8 cavities of
MIL-C-38999, Series 1, 3,
or 4 connectors.
Raychem size 8 triaxial
data bus contacts for
MIL-C-38999 connectors
have interfaces that comply
with MIL-C-39029/90 and
/91 to provide ease of termi-
nation, and intermateability
with more cumbersome
crimp contacts.
Product Facts
nOne-step termination
nTermination time of 1 to 2
minutes
nNorequirements for special
termination tools
nNo requirements for special
skills
nReworkable and repairable
terminations
nStrain relief
nContinuous 360° shield
coverage
nTriaxial mating face for least
susceptibility to damage
nRugged construction,
because only two parts are
being soldered together
nInspectable solder
terminations
nLow voltage drop and high
reliability due to precisely
controlled solder
termination
Series Raychem
Size 8 D-6002
Cable Type Pin Socket
10612 DK-602-0156-N-1 DK-602-0157-N-1
10613 DK-602-0156-N-2 DK-602-0157-N-2
10614 DK-602-0156-N-3 DK-602-0157-N-3
Specifications/Approvals
Product Selection
These contacts provide
afast and convenient
method of implementing
MIL-STD-1553B connec-
tions in MIL-STD-1760
applications.
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-95
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Space-Grade Data Bus Components
Applications
Tyco Electronics full line of
Raychem data bus prod-
ucts includes space-grade
couplers, terminators,
triaxial connectors, and
SolderShield splices. These
space-grade components
meet the low outgassing
requirements of NASA
specification SP-R-0022A
and can be used in outer-
space applications.
Raychem space-grade
components are designed
in a variety of configurations
and arecurrently available
either as discrete items or
as Raychem- assembled
harnesses. Using factory-
built harnesses eliminates
unnecessary splices and
connectors, reducing the
cost and increasing the
reliability of the networks.
Specification control draw-
ings describe the design
features and performance
characteristics of Raychem
space-grade couplers,
terminators, connectors,
and splices. The space-
grade data bus couplers,
terminators, and connectors
have tin/nickel-plated metal-
lic parts and baked silicone
rubber components. For
strain relief they include
low-outgassing tubing.
Unlike parts intended for
aircraft applications, these
components do not have
polym e r i c environmental
covers.
The table on the next page
lists Raychem standard
space-grade data bus
components with their part
numbers and descriptions.
New components will
become available per
customer request.
Figure 1. In-line couplers and
terminators
Figure 2. Threaded triaxial
connectors
Figure 3. Bayonet triaxial
connectors
Figure 4. Splice kit
Product Facts
nComplete line of space-
qualified MIL-STD-1553B
components
nLow outgassing levels that
meet NASA requirements
nLight weight
nRugged construction
Available in:
Americas n
Europe n
Asia Pacific n
Data Bus (MIL-STD-1553B) Components
8-96 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Space-Grade Data Bus Components (Continued)
Series Raychem
Space-grade data bus components D-6022
Cable Length
012 = 12 in
078 = 78 in
079 = 79 in
120 = 120 in
236 = 236 in
240 = 240 in
360 = 360 in
Cable Type
S16 = 7724S1664 (24 AWG single optimized shield)
S36 = 7724S3664 (24 AWG double optimized shield)
S86 = 7724S8664 (24 AWG EMP hardened)
H06 = 7742H0664 flat shield, unfilled (lightest cable)
Number of Stubs
1, 2, 3, or 4
Design
5 = Without internal terminator
6 = Same as 5 but with reverse bus
7 = With internal terminator
8 = Same as 7 but with reverse bus
Style
5 = Without mounting eyelet
6 = With mounting eyelet
D-500-94 W W -X -YYY -ZZZ
Space-Grade In-Line Coupler
Part Numbering System
Specifications/Approvals
Data Bus (MIL-STD-1553B) Components
8-97
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
8
Electrical Interconnect Products
Space-Grade Data Bus Components (Continued)
Contact (installed, DK-621 kits only)
P = Pin*
S = Socket*
*May be ordered separately as D-602-0126 (pin)
and D-602-0127 (socket)
Polarization (bayonet styles only) (jack view)
Basic Connector Configurations
Threaded styles:
11 = Plug
12 = Jack
Bayonet styles:
33 = Plug, A polarization
34 = Jack, A polarization
35 = Plug, B polarization
36 = Jack, B polarization
37 = Plug, C polarization
38 = Jack, C polarization
39 = Plug, D polarization
40 = Jack, D polarization
D-621 Connector, Kitted with Accessories
DK-621 -09 XX -X X
4= D
3 = C
2 = B
1= A
Space-Grade Connectors
Part Numbering System
Cable Type
612 = 10612 (24 AWG single optimized shield)
613 = 10613 (24 AWG double optimized shield)
614 = 10614 (24 AWG EMP hardened)
H06 = 7724H0664 flat shield, unfilled (lightest cable)
D-500-9463- ZZZ
Space-Grade Terminators
Part Numbering System
Space-Grade Splice Kit =
D-150-9708-5
Data Bus (MIL-STD-1553B) Components
8-98 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Customer-Specified Harness Assemblies and HarnWare Harness Design Software
Sample Drawing
Tyco Electronics supplies
complete Raychem data
bus networks in accordance
with customer harness
drawings, with any cus-
tomer-specified cables
and/or connectors. Using
factory-built harnesses
eliminates unnecessary
splices and connectors,
reducing the cost and
increasing the reliability of
the networks. Factory-built
harnesses are pre-tested
and ready for installation.
HarnWare Harness Design
Software allows designers
todraw a data bus harness
in a matter of minutes, while
selecting Raychem or oth-
ers’ components; a bill of
materials is automatically
generated.
Raychem
DATABUSCOUPLER
Raychem
DATA BUS COUPLER
Raychem
DATA BUS COUPLER
STBD
CMC1
CMC2
WHEELBAY
D-600-XXXX
ISSUE x
LOT N˚ XXXX
NOSE
NOSE
CMC 2
CMC 1
STBD
WHEELBAY
11
10
9
6
12
12
12
12
12
12
8
7
5
43
2
2
2
2
111
Parts List
Item Description Part No. Spec/Remarks Qty Unit
1 Data bus Cable 10613-9 Raychem 5.3 M
2 Data bus Cable 10613-96 Raychem 7 M
3 Data bus Coupler D-500-0455-1 Raychem 1 Pc
4 Data bus Coupler D-500-0455-2 Raychem 1 Pc
5 Data bus Coupler D-500-0457-1 Raychem 1 Pc
6 Data bus Terminator D-621-0469-L Raychem 1 Pc
7Data bus Contact DK-602-0156-N-2 Raychem 1Pc
8Data bus Contact DK-602-0157-N-2 Raychem 1 Pc
9Data bus Connector DK-621-0411-P Raychem 1 Pc
10 Data bus Connector DK-621-0412-P Raychem 1 Pc
11 Data bus Connector DK-621-0434-1P Raychem 1 Pc
12 Marker Sleeve TMS-SCE-3/16-2.0-9 Raychem 6 Pc
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC/EMI Adapters
8-99
8
Electrical Interconnect Products
Introduction
Applications
Tyco Electronics, a longtime
leader in harnessing tech-
nology,has written a new
chapter in EMC shielding
with the introduction of the
Raychem HexaShield EMC
adapter.
Designed to provide EMC
protection solutions for both
commercial and military
applications, HexaShield
adapters represent a signifi-
cant improvement over pig-
tail termination methods. By
providing 360-degree EMC
shielding on the termination
area of each individual
cable, HexaShield adapters
provide outstanding shield-
ing effectiveness.
HexaShield adapters are
simple to install, easy to
nWeight reduction, by pos-
sibly eliminating the need
for overall shielding.
nCompact size - not
exceeding outer diameter
of connector.
nAvailable in straight, 45°
and 90° angles, as well as
swept and long bodies.
Simple assembly and installa-
tion
1. Solder cable or wire
shield to a ferrule with a
Raychem heat-shrinkable
SolderShield terminator.
2. Clip ferrule into one of the
grounding star cavities.
3. Secure the back nut of
the HexaShield adapter
so that the conic ring
assembly automatically
compresses the ferrules.
maintain, and dependably
resistant to mechanical and
environmental stresses.
Principal points and features
nEasy reentry: Toinsertor
remove ferrules from the
HexaShield adapter, sim-
ply loosen the back nut.
nSuperior protection: No
degradation of shielding
performance.
nUp to four shielded
cables accommodated
by each ferrule.
nMechanical and environ-
mental protection equal to
backshells complying
with MIL-C-85049
Category 3B.
nStrain relief on each
individual cable.
Two Platings Available Raychem Product Specifications
Electroless nickel (MIL-DTL-26074) RB-110 and RB-114
Olive drab cadmium —
(QQ-P-416 Type II Class 3)
*Contact Tyco Electronics for additional platings.
Installation procedure for HET-A-02X Installation procedure for HET-03X General procedure for cylindrical
and HET-A-04X (RPIP-696-00) (RPIP-696-03) connectors, right-angle body
(RPIP-696-07)
General procedure for ARINC 600 Size II General procedure for cylindrical
connectors (RPIP-696-01) connectors, straight body (RPIP-696-04) —
General procedure for ARINC 600 Size III ——
connectors (RPIP-696-02)
Product Facts
nSuperior EMC/EMI Shielding
Performance
nSimple installation
nEasy reentry
nSimplified maintenance and
repair
nExcellent mechanical and
environmental resistance
nEfficient strain relief
nFlexibility
nVersatility
Designed to corresponding
connector specifications.
Installation Procedures
Available in:
Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC/EMI Adapters
8-100
Kit Descriptions
Item Description
1 Straight adapter assembly
2 Conic ring assembly
Star
3Plain (Standard)
Drilled (Option)
Split (Option) _
4Straight adapter assembly - “L” version
-nominally 0.5" [12.7] longer body
545° adapter assembly - welded
645° adapter assembly - swept
790° adapter assembly - welded
90° adapter assembly - swept
8 Standard products shown.
Variants available on request.
Split star assemblies are shown
on relevant S.C.D’s where applicable.
Item HexaShield Version
-1 Back Nut
-2 Tinel adapter assembly
Tinel-Lock ring for single braid
-3 Bandstrap adapter assembly
-C Conduit adapter
Item Description
1Left side support
2 Right side support
3 Retention bars
Body assemblies
Body
4Holding nut
Conic ring assembly
Star _
Back nut
Cavity plug assemblies
5Plug
Holding nut
6Pan head screws - 4-40 UNC
7Spring washers
ARINC 600 Size 2 shown
Stars are available as plain, drilled or split.
See relevant S.C.D’s for further information
Hexashield Adapters for
Circular Connectors:
Straight, 45°and 90°
Assemblies
HexaShield Adapters for
ARINC 404/600 Connectors:
Sizes 1, 2, 3 and 4
Assemblies
1
2
3
c
1
2
3
4
56
78
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-101
8
Electrical Interconnect Products
Ordering Information
Drilled Star:
See applicable SCD for star options
Type of Back Nut:
1 = Standard back nut
2 = Clamping nut for tinel ring (for overbraid protection)
3 = Clamping nut with bandstrap
C = Clamping nut for conduit applicator
Max. number of ferrules that can be accommodated
See applicable SCD for options
Hexashield Size Code:
See applicable SCD for order number (shell size)
S = Swept version
Configuration:
00 = Straight body
45 = 45 degree angle body
90 = 90 degree angle body
Type of Plating:
B = Cadmium plated
C = Electroless nickel
L = Long body
See applicable SCD for availability
Connector Code Number:
21 = MIL-C-26482 Series 1
40 = MIL-DTL-38999 Series 3 and 4
41 = MIL-DTL-38999 Series 1 and 2
54 = MIL-DTL-38723 Series 1 and 3
MIL-C-25482 Series 2
HEXYY L -AY -00 S -YY -AY -Y -DS
Part Numbering for
Standard Products
HexaShield Adapter for
Circular Connectors
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-102
Ordering Information (Continued)
00 = Straight body
90 = Right-angle body
HEXDB-AC-00-A9-1
HexaShield Adapter for
Collins Connectors
Clamping nut version:
1 = Clamping nut alone
2 = Clamping nut for tinel ring
Number of ferrules:
18 for ARINC 600 size II (A and B cavities)
25 for ARINC 600 size II (A, B and C cavities)
18 for ARINC 600 size III (A and B cavities)
See applicable SCD for options
ARINC Connector Size:
02 = ARINC 600 size II
03 = ARINC 600 size III
Configuration:
00 = Straight body
90 = Right-angle body
Plating:
B = Cadmium plated
C = Electroless nickel
Drilled Stars are standard on ARINC 600 adapters.
HEXA6-AY-00-YY-AY-Y
HexaShield Adapter for
ARINC 600 Connectors
Type of Plating:
B = Cadmium plated
C = Electroless nickel
HET-A-02X for small-size cable with SolderShield terminator
HET-A-03X for connection of unshielded cables
ferrules with heat-shr inkable tubing (no shield)
HET-A-04X for large-size cables with SolderShield terminator
Type of Plating:
B = Cadmium plated
C = Electroless nickel
HEX07-AX ferrule - solid blank for use when a HET-A is not needed
Part Numbering of Ferrule
Kits*
*Not all part numbers are standard; your local Tyco Electronics representative will assist you in selecting the
appropriate standard product
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-103
8
Electrical Interconnect Products
EMC Performance
1075
85
95
105
115
125
135
1.0
.1
.01
.01 .1 1.0
Frequency (MHz)
Zt (mΩ/m)
Shielding effectiveness (dB)
10 100 1000
Transfer Impedance
Protection Level
Generalized system per-
formance (Actual system
performance in any one
test method may differ.)
HexaShield size: 23
Cable: Raychem 5024H8424
(one cable installed)
Test method: CEI 96-1
100
80
60
40
20
00 10 100
MHz
Lightning
EMP
Cross talk
HIRF
Lightning
Stirred mode
Frequency
spectrum
of threats
Frequency
spectrum
of test
methods
Surface transfer impedance
Bulk cable injection
Radiated susceptibility
1000 10,000
dB
HexaShield
terminated, shielded,
twisted pairs without
overbraid
Pigtailed, shielded
twisted pairs Pigtailed, shielded
twisted pairs with
overbraid
Product Facts
nOutperforms traditional
pigtail termination,
especially in HIRF
performance
nWithstands 10-kA peak
current lightning transients
of SAE AE4L-87-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
HexaShield High-Performance EMC Adapters
8-104
EMC Performance (Continued)
Civilian and military aircraft
Avionics
Fighter aircraft
Missiles and launch support systems
Armored and military support vehicles
Navy ships (total shipboard hardening)
Military communications
Engines (FADEC harness hardening)
Accommodates the following connector types*:
MIL-C-26482 Series 1
MIL-DTL-38999 Series 1, 2, 3, and 4
MIL-C-26482 Series 2
MIL-DTL-83723 Series 1 and 3
DBAD
ARINC 600
ARINC 404
*Please contact Tyco Electronics for other connector types and special
requests.
Typical HexaShield
Applications
HexaShield Product Range
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-105
8
Electrical Interconnect Products
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Introduction
System
The Raychem MTC product
line is a complete modular
connector system consist-
ing of lightweight, environ-
mentally sealed miniature
rectangular connectors
(shell housings with remov-
able inserts) and individually
removable rear-release
contacts.
Components
MTC connectors are
now available with quick-
disconnect mating hard-
ware, EME shielding acces-
sories, and modular inserts
that can accommodate a
mix of signal and power
crimp contacts and coaxial
contacts. The need for spe-
cial termination tooling has
been minimized, while the
ease of manufacturing and
maintenance has been
improved.
Configurations
MTC rectangular connectors
using jack screws or quick-
disconnect hardwarecan be
stacked or panel-mounted
next to each other without
any provision for grip
space, a featurethat can
save significant panel area.
MTC connectors are avail-
able in 1-inch and 2-inch
configurations. Modular
removable inserts with size
22 and/or size 16 contact
cavities can be combined
into the 1-inch and 2-inch
MTC housings.
Inserts
MTC inserts are available
in 20-cavity and 5-cavity
versions. The 20-cavity
insertaccepts size 20-22
(24 AWG to 20 AWG wire)
crimp contacts. The
5-cavity insertaccepts size
16–14 crimp contacts.
Insertion/extraction of the
contacts is rear release.
Note:
Other configurations are available
in the MTC family (size 12 contacts;
50 mil spacing for double density;
accessories). Please contact
Tyco Electronics.
Product Facts
nLow-profile rectangular
design for high packaging
density
nEnvironmental sealing for
aerospace applications
nModular components for
design versatility and
logistics savings
nLightweight materials for
weight savings
nQuick-disconnect mating
hardware
Available in:
Americas n
Europe n
Asia Pacific n
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-106 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
20-Cavity Inserts
Pin Insert Socket Insert
MTCP-122-20P1 MTCP-122-20S1
MTCP-122-20P2 MTCP-122-20S2
10 5 1
27 max.
1051
27 max.
A1
Raychem
2015
A2Raychem
20
15
A2
Raychem
2-inch shell with inserts
MTCP-122-20 inserts areused with MTC100 1-inch and 2-inch shells.
The 1-inch shell takes:
nOne MTCP-122-20P (pin contact) or
nOne MTCP-122-20S (socket contact)
The 2-inch shell takes:
nOne MTCP-122-20P1 and one MTCP-122-20P2 (pin contact) or
nOne MTCP-122-20S1 and one MTCP-122-20S2 (socket contact)
2x20 Cavity Inserts
(Size 20–22)—2-Inch Shell
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-107
8
Electrical Interconnect Products
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
20-Cavity Inserts (Continued)
Pin Insert Socket Insert
MTCP-122-20P MTCP-122-20S
Contacts for 20-Cavity Inserts
The contacts for 20-cavity inserts must be ordered separately.They are:
nCTA-0166—pin contact
nCTA-0165—socket contact
Contacts accept 24 AWG to 20 AWG wires.
Tools Tools
Positioner for pin contact CE-1605900 Positioner for socket contact CE-1606000
Installation process ES-61413 Installation process ES-61413
Contact removal tool (plastic) CTA-1160 Contact removal tool (plastic) CTA-1160
Extraction tool for MTCP inserts CTA-0161 Extraction tool for MTCP inserts CTA-0161
10 3 1
27 max.
A
Raychem
A
Raychem
101 5
27 max.
1-inch shell with insert
1x20 Cavity Inserts (Size
20–22)—1-Inch Shell
Pin Contact
CTA-0166 Socket Contact
CTA-0165
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-108 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
5-Cavity Inserts
5-Cavity Inserts (Size 16)
Pin Insert Socket Insert
MTCP-116-05P1 MTCP-116-05S1
MTCP-116-05P2 MTCP-116-05S2
The contacts for 5-cavity inserts must be ordered separately.They include:
nCTA-0079 - pin contact (MS 27493-16) (MIL-C-39029/58 intermateable)
nCTA-0078 - socket contact (MS 27491-16) (MIL-C-39029/57 intermateable)
nD-602-0140 -coaxial pin contact (MIL-C-39029/76 intermateable)
nD-602-0171 -coaxial socket contact (MIL-C-39029/78 intermateable)
Other contacts designed for M38999 Series II connectors can be used.
Pin Contact Socket Contact
D-602-0140 (coaxial) D-602-0171 (coaxial)
CTA-0079 (power) CTA-0078 (power)
ABCDE
27 max.
27 max.
A1
AB C DE
A2
ABCDE
ABCDE
ABCDE
A2
FGH J K
KF GHJ
FGHJ K
MTCP-116-05 inserts are used with MTC100 1-inch and 2-inch shells.
The 1-inch shell takes:
nOne MTCP-116-05-P1 (pin contact) or
nOne MTCP-116-05-S1 (socket contact)
The 2-inch shell takes:
nOne MTCP-116-05P1 and one MTC-116-05P2 (pin contact) or
nOne MTCP-116-05-S1 and one MTCP-116-05-S2 (socket contact)
5-Cavity Inserts (Size 16)
Contacts for 5-Cavity
Inserts
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-109
8
Electrical Interconnect Products
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Hybrid Inserts
Hybrid insert combinations of size 22 and size 16 contact cavities are also possible.
2-Inch Shell—Hybrid Assembly
Power and signal
FGHJK
1 A1 10
10B11
ABCDE
11 A2 20
20B211
Shells
MTC connector housing
shells are available with
nickel plating (48-hr salt
spray performance) or
cadmium over nickel
plating (500-hr salt spray
performance).
MTC connector housings
are offered with quick-
disconnect or jack-screw
mating hardware. Each
connector shell is polarized
and has 64 user-defined
keying combinations.
Lightweight, low-profile
EME backshells arealso
available for increased
shielding effectiveness of
the connector.
Receptacle
1" = 1.75
2" = 2.75
1" = 2.00
2" = 3.00
MTC100-JH1-P32 XXXX
Raychem
A
.34
1.09
.39
max.
1" = 1.75
2" = 2.75
1" = 1.75
2" = 2.75 flanged
1" = 2.06
2" = 3.06 flangeless
MTC100-JH1-R32 XXXX
Raychem
A
.394 max.
flangeless
.60
max.
flanged
.34
1.09
Plug
Hybrids
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-110 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
MTC Shells Ordering Information
*Some combinations of shells, mating hardware and EME shielding accessories are not available.
Contact Tyco Electronics for product information.
2 = Nickel plating.
48-hr salt spray test performance
3 = Cadmium over nickel plating.*
500-hr salt spray test performance
P = Plug housing
R = Receptacle housing, flangeless
F = Receptacle housing, flanged
1 = 1"
2 = 2"
J = Standard housing
S = EMI housing
Q = Quick-disconnect mating hardware
(connector performance per Raychem
specification C-6114)
Blank = Jack-screw mating hardware
(connector performance per
Raychem specification C-6115)
MTC100X-XHX-XX2
MTC High-Performance Modular Rectangular
Connectors with Removable Contacts
8-111
8
Electrical Interconnect Products
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Accessories
Low-Profile EME Backshells
Lightweight rectangular
EME backshells connect
the overall bundle shield to
the MTC connector hous-
ing. Individual cable shields
can also be terminated to
the backshell braid by
using Raychem
SolderSleeve devices.
The backshell is mounted
on the MTC housing via the
cable clamp screws.
MTC backshell features
include a low profile, light
weight, and Level II EME
performance.
EME Backshell Adapters
CHA-0275 2-inch adapter
(plug or recep-
tacle)
CHA-0276 1-inch adapter
(plug or recep-
tacle)
MTC Shield-Grounding
BusBars
Raychem MTC shield-
grounding busbars allow for
simple, cost-effective termi-
nation of cable shielding to
MTC aluminum housings.
Two-inch shield-grounding
busbars terminate up to 20
shielded twisted pairs on a
2-inch MTC connector.The
individual shields are termi-
nated to “fingers” on the
busbar with Raychem
SolderSleeve devices.
The busbar is mounted on
the MTC housing via cable
clamp screws.
MTC busbar features
include a simple termina-
tion, cost effectiveness, light
weight, and Level I EME
performance.
EME Shielding Accessories for
MTC Connectors
Grounding Block
Allows for cable shield ter-
mination grounding on the
MTC shell housing via
crimp-removable contacts.
This grounding scheme
allows individual cables to
be removed from the con-
nector without cutting a
ganged ground connection.
Sufficient ground contacts
are available to handle
shielded twisted-pair
cables.
Grounding Block
CHA-0301 1-inch ground-
ing block recep-
tacle shell
CHA-0302 2-inch ground-
ing block recep-
tacle shell
CHA-0303 1-inch ground-
ing block plug
shell
CHA-0304 2-inch ground-
ing block plug
shell
Shield-Grounding Busbars
CTA-0022 1-inch busbar
(with 5
SolderSleeve
terminators)
CTA-0023 2-inch busbar
(with 10
SolderSleeve
terminators)
8-112 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Electrical Interconnect Products
Engineering Notes
Wire and Cable
Table of Contents
9-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Introduction .............................................................9-2
High-Performance Wire and Cable
SPEC 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3 to 9-9
SPEC 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10 to 9-18
RCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19 to 9-24
FlexLine (SPEC 80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-25, 9-26
Low-Fire-Hazard Wire and Cable
FR-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27 to 9-34
Type 99M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-35 to 9-38
Zerohal 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-39 to 9-41
Zerohal 100G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-42 to 9-44
Commercial Wire Family
FlexLite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-45, 9-46
FlexLite DW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-47, 9-48
FlexLite TW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-49, 9-50
FlexLite MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-51, 9-52
FlexLite HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-53, 9-54
FlexLite TX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-55, 9-56
FLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-57 to 9-59
Thermocouple Extension Cable
Thermocouple Extension Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-60 to 9-62
Controlled Electrical Cables
ElectrolossFilterLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-63 to 9-67
Cheminax Coaxial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-68 to 9-70
Cheminax High-Performance Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-71, 9-72
Cheminax Twin Axial Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-73, 9-74
Multiconductor (Multicore) Cables
Custom Designed and Standard Multiconductor Cables . . . . . . . . . . . . . . . . . . . . . . .9-75
MulticoreCables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-76
Cable Jacket Materials
Properties and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-77, 9-78
FDR 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-79, 9-80
Zerohal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-81 to 9-83
Thermorad HTF/Fluoroelastomer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-84
Thermorad/Thermorad F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-85
Raythane, Neoprene, Rayolin, and AFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-86
Miscellaneous
Electrical Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-87, 9-88
Computer-Aided Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-89
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-90 to 9-93
Conductor Sizes, Strandings, and Resistance Values . . . . . . . . . . . . . . . . . . . .9-94, 9-95
Fiber Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-96 to 9-99
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data.
Wire and Cable
Introduction
9-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Tyco Electronics provides
wire and cable solutions for
challenging environments
and demanding applica-
tions. The Raychem product
range includes high-
performance insulated
wires, coaxial and data
bus cables, power cables,
electronics wire, and
multicore cables.
nSPEC 44 wire is an
economical yet rugged
dual-wall insulation
system rated at 150°C
[221°F], with consistently
low cost and reliable
performance.
nSPEC 55 wireinsulation
provides high reliability
in harsh environments
from -65°C to +200°C
[-85°F to +392°F].
Resistant to electrical
arc tracking, it combines
the easy handling of a
flexible wire with excellent
resistance to scrapes,
abrasion, and cut-
through.
nRCW is a small size, ultra
light weight insulated wire
with a temperaturerating
of -65°Cto +260°C
[-85°F to +500°F]. It is
resistant to electrical arc
tracking in wet or drycon-
ditions and has excellent
cut-through resistance.
nType 99T dual-wall
insulation system is a
105°C [221°F] rated wire
that combines excellent
chemical and mechanical
resistance with limited fire
hazard performance.
nElectroLoss Filterline wire
reduces the vulnerability
of critical circuits to
high-frequency electro-
magnetic interference.
nCheminax coaxial and
data bus cables allow
system designers to
optimize minimum size
and weight with imped-
ance and attenuation
characteristics.
nMulticonductor (multicore)
cables organize a variety
of Raychem wire and
cable products in con-
trolled geometries for
specific applications.
Using a computer-aided
design system, Tyco
Electronics can quickly
design multicore cables
to meet your needs. A
variety of cable jackets
are available to suit most
applications.
Raychem wire and cable
products can meet your
specific application needs.
Here are just a few
examples:
nLimited-fire-hazard wire
and cable for mass transit
and marine applications.
nHigh-performance, high
temperature automotive
wiring.
nSmall, light hookup wires
for high-temperature
applications in commercial
appliances, tools, and
devices.
nVery flexible, rugged,
thin-wall insulated power
cables.
nLow-outgassing space-
vehicle wiring.
nLightweight, shielded wire
and cable constructions
for aerospace applications.
nThermocouple extension
cables with a range of
our high-performance
insulations materials.
Contact Tyco Electronics
to find out more about
wireand cable and our
associated interconnection
products.
High Performance Wire and Cable
SPEC 44
9-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
SPEC 44 wirehas a dual
wall construction which
combines the outstanding
physical and electrical
characteristics of radiation
crosslinked polyalkene with
the excellent mechanical
and chemical properties of
radiation cross-linked
polyvinylidene fluoride
(PVDF).
The result is a wire insula-
tion system that offers a
150°C [302°F] temperature
rating, small size, light
weight, solder iron resist-
ance, and resistance to
most solvents, fuels and
lubricants.
SPEC 44 wire and cable is
highly flame retardant, non-
melting, does not cold flow,
and though mechanically
very tough, is easy to han-
dle and install using con-
ventional tools.
Originally developed for
aerospace and military
requirements in applica-
tions of high density and
complex circuitry, SPEC 44
wireand cable now finds
wide use throughout indus-
try, in commercial and mili-
tary electronics, avionics,
on satellites, aircraft, heli-
copters, ships, trains, and
offshoreplatforms where
environmental conditions
demand consistently reli-
able performance. In air-
frame applications SPEC 44
constructions can offer a
modern dimensional
Primar y Insulation -
Radiation Crosslinked,
Extruded Polyalkene
Jacket -
Radiation Crosslinked,
Modified PVDF
Conductor
Primar y Insulation -
Radiation Crosslinked,
Extruded Polyalkene
Jacket -
Radiation Crosslinked,
Modified PVDF
Conductor
Product Facts
nDual wall construction
n600, 1000 and 2500 voltage
rating
nSmall size, light weight
nLow smoke and low
corrosive gas generation
nResistant to most chemicals
and electrical arc tracking
replacement for PVC/Nylon/
Glass braid type wire and
cables. SPEC 44 wireis
offered in a wide range of
sizes in stranded conduc-
tors, standard materials
available being tin or
silver-plated copper and
high strength copper alloy.
Voltage ratings of 600, 1000
and 2500 volts are available
as standard. Shielded and
jacketed versions include
single and multi-conductor
constructions and flat braid
shields wherefurther size
and weight savings are
achieved.
Available in: Americas Europe Asia Pacific
nnn
High Performance Wire and Cable
SPEC 44 (Continued)
9-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Physical Characteristics
Small Size
SPEC 44 equipment wire,
600 volt rated has a 0.19
[.008] nominal wall thick-
ness compared to 0.25
[.010] and 0.38 [.015] for
equivalent PTFE and PVC
wires in MIL-W-16878, MIL-
W-22759 or BS G210.
Light Weight
Because of the thin wall and
low density of the insulation
materials considerable
weight savings are made
over similarly rated PTFE
wires, eg:- 44A0111-22AWG
equipment wire 4.62
grams/meter max
22 AWG PTFE equipment
wire, MIL-W-81044
5.54 grams/meter max
General Handling
The flexibility of SPEC 44
and the ease with which it
takes a 'set' makes it one of
the easiest of the 'high
performance' wires to
install. Stripping is done
with conventional die blade
strippers.
For details of appropriate
tools see separate wire han-
dling guide. The tin-plated
conductor usually specified
is easily soldered or
crimped. The insulation may
be hot stamp marked or
printed and does not need
etching before potting.
Specifications/Approvals
MIL-W-81044, NEMA-WC-27500 (Cables)
Def Stan. 61-12 Part 18 Issue 4 - Type 1 pliable (Maintenance Range)
Def Stan. 61-12 Part 26 Issue 3 Type 2, 3, 8 & 9 & METS
VG 95218 Parts 20, 21, 22, 23 and 1000
NATOStock Numbers (NSN's) exist for most standard constructions
Civil Aviation Authority Accessory Approval E1 1623
Lloyds Register of Shipping
NASA Preferred Product List
Raychem Specification 44
Typical Properties
Temperature rating -65°Cto +150°C [-85°F to +302°F]
Voltage rating (thin wall) 600 V
Voltage rating (thick wall) 2500 V
Tensile strength and elongation of insulation 28 N/mm2 , 230%, 4000 PSI
Notch propagation, 0.05mm notch Pass
Solder iron resistance (370°C, 1 minute) Pass
Shrinkage, 200°C <1%
Low temperature bend -65°C [-85°F]
Voltage withstand (thin wall) 2500 V
Resistance: fuels, oils, solvents Pass
Lengths
SPEC 44 is available in long
continuous lengths and can
be supplied for use on auto-
matic cut and strip wire
preparation machines.
High Performance Wire and Cable
9-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
SPEC 44 (Continued)
Environmental Performance Temperature Rating
SPEC 44 wire and cable is
rated for continuous opera-
tion from -65°C to +150°C
[-85°F to +302°F] and for
short periods at tempera-
tures as high as 300°C
[572°F]. Heat ageing tests
are routinely performed at
temperatures of 200°C
[392°F] (168 h) and 300°C
[572°F] (6 h). In addition
SPEC 44 insulation will not
shrink back under repeated
cycling.
Mechanical Performance
SPEC 44 wire provides bet-
ter cut through resistance
than some wires with much
thicker walls. 600 volt equip-
ment wire 44A0111 (0.19
mm wall) has 40% greater
cut through resistance than
600 volt PTFE insulated wire
(0.25 mm wall).
Solder Iron/Overload
Resistance
The radiation crosslinking
of the materials used in
SPEC 44 makes them non-
melting at high temperature.
As a result SPEC 44 wire is
resistant to prolonged con-
tact with solder irons and is
resistant to current over-
loads which would melt most
thermoplastic insulations.
Chemical Resistance
The irradiated dual wall
construction of SPEC 44
wire is highly resistant to
many acids, alkalis, hydro-
carbon solvents, fuels, lubri-
cants, water, and many
missile fuels and oxidizers.
Cold Flow
Radiation cross-linking of
SPEC 44 prevents cold flow
of the insulation — a recog-
nized problem of some
uncrosslinked materials.
Voltage Ratings
Standard available voltage
ratings for SPEC 44 wire are
600 volts (0.19 mm wall
thickness), 1000 volts (0.28
mm wall) and 2500 volts
(0.48 mm wall).
Electrical Arc Track Resistance
SPEC 44 insulation demon-
strates a total resistance to
arc tracking under both wet
and dry conditions at air-
craft system voltages.
Low Outgassing
For use in space applica-
tions, special constructions
of SPEC 44 wire are avail-
able with low outgassing
characteristics, for use in an
environment of high vacuum
and high temperature.
Federal Aviation Reg FAR-25 Pass
BS4066 vertical flammability Pass
Flammability S424 14751 (Swedish chimney) Pass
NFC 32070 (2) (French chimney) Pass
IEC 332 part 3 (Cable ladder) Pass
Smoke Index, Def Stan 61-12 (18) 6 per meter of wire
Smoke/Toxicity Index Toxicity Index, Def Stan 61-12 (18) 0.8 per meter of wire
Oxygen Index, NES 714 30% Oxygen
Temperature Index, NES 715 >300°C [572°F]
Fire Hazard Performance
*Classes 4, 5 and 6 available only as “44/” constructions. 44/7xxx and 44A7xxx will be available as indicated on the applicable SCD.
**Shield coating same as conductor coating except: - for Conductor Type 4, 6, C and D, shield shall be tin-coated copper
Typical ordering example 3conductors, brown, yellow with green stripe, blue, white jacket. If 600 volt, round braid, 20 AWG tinned
conductor,44A1131-20-1/45/6-9.
Ordering information Other constructions and custom designed wire and cable are available on request.
High Performance Wire and Cable
SPEC 44 (Continued)
9-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
44 X X X X X- AWG- X/X- X
Basic Product Number
Temperature Rating:
/ - 135˚C (XL-PVF2 cable jacket)
A - 150˚C (XL-PVF2 cable jacket)
AC - 150˚C (same as 44AM with 90% min. shield coverage)
AM - 150˚C (M27500, shielded and/or XL-PVF2 jacketed cable)
B - 150˚C (XL-ETFE cable jacket)
Construction
0 - Primary wire; or unshielded & unjacketed cable
1 - Round braid shielded and jacketed cable**
2 - Tin-coated copper flat braid shielded & jacketed cable
3 - Round braid shielded cable, no jacket**
4 - Jacketed cable, no shield
5 - Spiral braid shielded & jacketed cable**
7-9 - Special constructions
Class of Wire
1 - 600 V, general purpose 6 - 2500 V, outerspace*
2 - 1000 V, general purpose 7- 600 V, airframe
3 - 2500 V, general purpose 8 - 600 V, medium weight
4 - 600 V, outerspace*
5 - 1000 V, outerspace*
Number of Conductors
1 through 10 (designator for 10 conductor = 0)
Conductor Size (AWG)
Conductor Type
1 - Tin-coated copper A - Silver-coated CS95
2 - Silver-coated copper C - Silver-coated high strength
3 - Nickel-coated copper copper alloy (cadmium-free)
4 - Silver-coated high strength D - Nickel-coated high strength
copper alloy copper alloy (cadmium-free)
5 - Aluminum
6-Nickel-coated high strength
copper alloy
Primary Wire Insulation Color
(code per MIL-STD-681)
0 - Black 5 - Green
1 - Brown 6 -Blue
2 - Red 7 - Violet
3 - Orange 8 -Gray
4 - Yellow 9 - White
Jacket Color
(codes same as for Primary Wire Insulation Color)
Part Numbering System
High Performance Wire and Cable
SPEC 44 (Continued)
9-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Basic Specification Number
Component Wire ID/Shield Coverage Code
Shield Coverage
85% 90% Component Wire Identification
-C Colored Stripes on White Wire
(9/96/93/95/92/90/94/97/98/91... etc.)
A D Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.)
B E Band Marks on Solid Colors (by AWG)
F H Alternate Colored Stripes
(92/96/94/95/9/90/91/93/97/98...etc)
G J Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.)
K M Number Marking on Solid Colors (by AWG)
L N Number Marking on White Wires
P R Band Marks on Colored Stripes (by AWG)
S T Band Marks on White Wires
Conductor Size (AWG)
Basic Wire Spec Code (MIL-W-81044) and Slash Sheet
MD - M81044/5 (44A0712)
ME - M81044/6 (44A0711)
MF - M81044/7 (44A0714)
MG - M81044/8 (44A0812)
MH - M81044/9 (44A0811)
MJ - M81044/10 (44A0814)
MK - M81044/11 (44A0112)
ML - M81044/12 (44A0111)
MM - M81044/13 (44A0114)
Number of Component Wires
Shield Material and Style Code
U - No shield
T - Tin-coated copper, round
J - Tin-coated copper, flat
S - Silver-coated copper, round
G - Silver-coated copper, flat
N - Nickel-coated copper, round
Jacket Material and Style Code
00 - No jacket
08 - Crosslinked, white PVDF
23 - Crosslinked, white Modified ETFE
M27500 X AWG XX X X XX
Raychem Part No.
Military Part No.
M27500-22ML3T08 = 44AM1131-22-9/96/93-9
NEMA WC-27500 Cable
Part Numbering System
Example:
High Performance Wire and Cable
SPEC 44 (Continued)
9-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
44A031X (2500 V) 44A081X (600 V) 44A012X (1000 V)
Nom. Max. Nom. Max Nom. Max.
OD Weight OD Weight OD Weight
(g/m) lb/kft (g/m) lb/kft (g/m) lb/kft
— — — — 1.37 [0.054] 2.38 [1.6]
— — — — 1.52 [0.060] 3.13 [2.1]
1.35 [0.053] 3.13 [2.1] 1.22 [0.048] 2.98 [2.0] 1.73 [0.068] 4.47 [3.0]
1.44 [0.057] 4.46 [3.0] 1.37 [0.054] 3.87 [2.6] 2.03 [0.080] 6.69 [4.5]
1.75 [0.069] 6.40 [4.3] 1.57 [0.062] 5.65 [3.8] 2.38 [0.094] 9.82 [6.6]
1.98 [0.078] 9.08 [6.1] 1.78 [0.070] 8.04 [5.4] 2.79 [0.110] 14.73 [9.9]
2.23 [0.088] 12.95 [8.7] 2.03 [0.080] 11.91 [8.0] 3.30 [0.130] 22.32 [15.0]
2.46 [0.097] 16.22 [10.9] 2.26 [0.089] 14.73 [9.9] 3.65 [0.144] 28.42 [19.1]
2.92 [0.115] 24.10 [16.2] 2.74 [0.108] 22.17 [14.9] 4.52 [0.178] 44.35 [29.8]
3.32 [0.131] 36.01 [24.2] 3.20 [0.126] 32.59 [21.9] 5.48 [0.216] 69.00 [46.5]
4.09 [0.161] 54.32 [36.5] 3.94 [0.155] 52.08 [35.0] — —
96.20 [0.219] 96.73 [65.0] 92.94 [0.214] 93.46 [62.8] — —
44A011X (600 V) 44A021X (1000 V)
Wire Stranding Nom. Max. Nom. Max.
Size CSA
ODWeight ODWeight
(AWG) (mm) #/AWG (mm2)(g/m) lb/kft (g/m) lb/kft
30 7/0.10 7/38 0.06 0.68 [0.027] 1.06 [0.71] — —
28 7/0.13 7/36 0.09 0.76 [0.030] 1.43 [0.96] — —
26* 19/0.10 19/38 0.15 0.86 [0.034] 2.08 [1.4] 1.02 [0.040] 2.38 [1.6]
2419/0.13 19/36 0.25 1.02 [0.040] 2.98 [2.0] 1.17 [0.046] 3.57 [2.4]
2219/0.16 19/34 0.40 1.19 [0.047] 4.46 [3.0] 1.37 [0.054] 5.20 [3.5]
2019/0.20 19/32 0.60 1.40 [0.055] 6.70 [4.5] 1.57 [0.062] 7.59 [5.1]
1819/0.25 19/30 1.00 1.65 [0.065] 10.12 [6.8] 1.85 [0.073] 11.46 [7.7]
1619/0.29 19/29 1.25 1.83 [0.072] 12.80 [8.6] 2.06 [0.081] 14.58 [9.8]
1419/0.36 19/27 2.00 2.26 [0.089] 19.64 [13.2] 2.49 [0.098] 21.88 [14.7]
1237/0.32 37/28 3.00 2.74 [0.108] 30.06 [20.0] 2.97 [0.117] 32.89 [22.1]
10 37/0.40 37/26 5.00 3.28 [0.129] 46.28 [31.1] 3.71 [0.146] 52.98 [35.6]
8133/0.29 133/29 — — — 5.23 [0.206] 91.97 [61.8]
*For 44A0211-26 the stranding is 7/0.16mm 7/34 AWG
Primary Wires/Twisted Pair
44A011X (600 V)
Primary Wire 44A021X (1000 V)
Primary Wire
44A031X (2500 V)
PrimaryWire 44A081X (600 V)
Airframe Wire 44A012X (600 V)
Twisted Pair
High Performance Wire and Cable
SPEC 44 (Continued)
9-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
44A181X (600 V) 44A112X (600 V)
Wire Nom. Max. Nom. Max.
Size OD Weight OD Weight
(AWG) (g/m) lb/kft (g/m) lb/kft
30 — — 2.23 [0.088] 8.63 [5.8]
28 — — 2.38 [0.094] 9.82 [6.6]
26 — — 2.59 [0.102] 12.05 [8.1]
24 2.26 [0.089] 11.76 [07.9] 2.99 [0.118] 16.82 [11.3]
22 2.57 [0.101] 15.48 [10.4] 3.35 [0.132] 21.57 [14.5]
20 2.77 [0.109] 19.19 [12.9] 3.76 [0.148] 27.97 [18.8]
18 3.02 [0.119] 24.11 [16.2] 4.32 [0.170] 38.24 [25.7]
16 3.25 [0.128] 28.13 [18.9] 4.67 [0.184] 44.94 [30.2]
14 3.73 [0.147] 38.69 [26.0] 5.53 [0.218] 64.28 [43.2]
12 4.19 [0.165] 52.38 [35.2] 6.50 [0.256] 91.51 [61.5]
Other sizes are also available in some constructions depending on conductor type and construction required.
44A181X (600 V)
1Conductor 44A112X (600 V)
2Conductor
44A111X (600 V) 44A121X (600 V)
Wire Stranding Nom. Max. Nom. Max.
Size ODWeight ODWeight
(AWG) (mm) #/AWG (g/m) lb/kft (g/m) lb/kft
30 7/0.10 7/38 1.47 [0.058] 5.20 [3.5] — —
287/0.13 7/36 1.55 [0.061] 5.80 [3.9] 1.60 [0.063] 5.65 [3.8]
2619/0.10 19/38 1.57 [0.065] 6.84 [4.6] 1.73 [0.068] 6.85 [4.6]
2419/0.13 19/36 1.83 [0.072] 8.63 [5.8] 1.98 [0.078] 9.67 [6.5]
2219/0.16 19/34 2.01 [0.079] 10.71 [7.2] 2.24 [0.088] 12.35 [8.3]
2019/0.20 19/32 2.26 [0.089] 14.73 [9.9] 2.54 [0.100] 17.41 [11.7]
1819/0.25 19/30 2.62 [0.103] 20.68[13.9] 2.82 [0.111] 22.62 [15.2]
1619/0.29 19/29 2.79 [0.110] 24.55 [16.5] 3.02 [0.119] 26.64 [17.9]
1419/0.36 19/27 3.22 [0.127] 34.08 [22.9] 3.45 [0.136] 36.16 [24.3]
1237/0.32 37/28 3.70 [0.146] 47.77 [32.1] 4.14 [0.155] 49.56 [33.3]
Other sizes are also available in some constructions depending on conductor type and construction required.
Shielded and Jacketed
Cable
44A111X (600 V)
1Conductor 44A121X (600 V)
1Conductor
High Performance Wire and Cable
SPEC 55
9-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
SPEC 55 wire is insulated
with modified radiation
cross-linked ETFE polymer.
It has a temperaturerating
of -65°C to 200°C [-85°F to
392°F] continuous using a
silver plated copper con-
ductor,and combines the
easy handling of a flexible
wire with excellent scrape
abrasion and cut-through
characteristics.
The dual wall airframe con-
struction of SPEC 55 wireis
currently used on numerous
aircraft programs. It has a
choice of two total wall
thicknesses, 0.25 [.010]
(55A08XX 10 mil) and 0.2
[.008] (55A02XX 8 mil).
Both have a contrasting
core color to act as a dam-
age indicator. Chosen for its
balance of properties,
SPEC 55 wire has outstand-
ing resistance to chemicals
and solvents, excellent
electrical arc track resist-
ance, and is not susceptible
to UV and moisturedegra-
dation. Single wall equip-
ment wire constructions
are available in 0.10 [.004]
(55/03XX 4 mil) and 0.15
[.006] (6 mil) wall thicknesses
for use inside black boxes
where flexibility and solder-
iron resistance make it a
wirewhich is veryeasy to
install reliably.
Both single and dual wall
insulated wires are available
in twisted pairs, triples, etc.,
and as shielded and jacket-
ed cables.
Physical Characteristics
Size and Weight
SPEC 55 wire provides one
of the most comprehensive
wiring product ranges for
aerospace users, with a
wide choice of conductor
sizes and insulation wall
thicknesses.The dual wall
airframe wire has an insula-
tion wall thickness of either
0.2 [.008] or 0.25 [.010] for
robustness in unprotected
harnesses and has excel-
lent wire to wire abrasion
properties.
The single wall equipment
wirehas a 0.15 [.006] wall
thickness for use inside
equipment and protected
harnesses. For high density,
interconnect wiring, the 450
volt 55M041X series of
equipment wirehas a nomi-
nal 0.1 [.004] wall and pro-
vides considerable weight
and size savings over other
comparable wires.
Handling
The excellent flexibility
and handleability makes
SPEC 55 the ideal wire to
install, both in new aircraft
and equipment and for
maintenance purposes. The
wire is easily stripped with
conventional tooling. The
insulation is readily marked
by hot stamp, ink jet or laser,
and can be potted without
pre-etching.
SPEC 55PC Wire and Cable
Insulation System
This product was originally
developed to meet Boeing’s
material standard BMS13-
48 for the 777 airliner.
SPEC 55PC provides light-
weight, compact insulation
that matches the proven
performance of our
SPEC 55 wire. Today, 55PC
is specified and utilized on
the majority of aerospace
platforms worldwide.
Tyco Electronics’ rigorous,
statistical-process-con-
trolled manufacturing has
produced Raychem wiring
that is rugged and versatile
enough for a wide range of
commercial and defense
aerospace applications,
including electronic hook-
ups in harsh, open airframe
environments.
SPEC 55PC wire and cable
systems featurean 8-mil air-
frame wire that is lighter and
smaller than typical 10-mil
wire, with little reduction in
key mechanical perform-
ance features. SPEC 55PC
wireoffers flame resistance
superior to FAA standards
and also resists scrape
abrasion, notch, propaga-
tion, cut-through, and
electrical arc tracking.
nMeets Boeing material
standard BMS 13-48.
nExceeds FAR 25 test
requirements for flame
resistance and smoke
density.
Product Facts
nResistant to electrical arc
tracking in wet or dry
conditions
nSingle or dual wall
constructions
nSmall size, ultra light weight
nExceptional chemical
resistance
n-65°C to 200°C [-85°F to
392°F]
Available in:
Americas n
Europe n
Asia Pacific n
High Performance Wire and Cable
SPEC 55 (Continued)
9-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Specifications
Conductor
Insulations -
Radiation Crosslinked, Modified ETFE
Inner layer colored blue
Conductor
Insulation -
Radiation Crosslinked, Modified ETFE
SPEC 55 insulation system - single wall SPEC 55 insulation system - dual wall
MIL-W-22759/32-35 and /41 to /46 and NEMA-WC-27500 (Cables)
Defense Standard 61-12 Part 33 Issue 4
Part 1001 and Part 1002
VDE 9426, 9427, 9428
British Standard 3G233
Civil Aviation Authority Accessory Approval E1 1749
Boeing BMS 13-48
Airbus ABS 0820 to 0826
NASA preferred product list
European Space Agency 3901/012, 3901/020 and 3901/022
Raychem Specification 55
Typical Properties Temperature rating (Tin plated conductor) -65°C to +150°C [-85°F to +302°F]
(Silver or nickel plated conductor) -65°C to +200°C [-85°F to +392°F]
Thermal endurance 200 °C [392°F], 10000 h
Scrape abrasion (BS 3G233) >100 cycles at 150°C [302°F]
Flexing endurance (Boeing BSS 7324) >1000 cycles
Voltage rating 600 V, 450V
Tensile strength + elongation (core only) (Dual wall wire) 35 N/mm2, 125% min.
Tensile strength + total elongation (core & primary jacket) (Dual wall wire) 35 N/mm2, 75% min.
Notch propagation BS 3G230 0.05 mm notch Pass
Solder iron resistance (370 °C, 1 minute) Pass
Solderability - Tin plated copper conductor <0.8 secs to wet
BS 3G233 conditions
Shrinkage <1%
Long term water resistance Will not hydrolyze
Permitivity 1 KHz (ASTM D150) 2.7
Dissipation factor (ASTM D150) 0.001
FAR 25 O
Afterburn (sec) 30 sec. max.
Burn length 75 mm [3 in.] max.
High Performance Wire and Cable
SPEC 55 (Continued)
9-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Environmental Performance Temperature Rating
SPEC 55 wire and cable is
rated for continuous opera-
tion from -65°C to +200°C
[-85°F to +392°F] and for
short periods at tempera-
tures as high as 400°C
[752°F].
Mechanical Performance
Radiation crosslinking of the
SPEC 55 insulation signifi-
cantly improves the follow-
ing mechanical character-
istics; scrape (sharp
edges), cross wire abrasion,
cut-through resistance and
creep resistance.
Solder Iron/Overload
Resistance
Radiation crosslinking
ensures that the insulation
resists melting at high
temperatures. As a result
SPEC 55 wireis resistant to
hot solder irons and current
overloads which would melt
most thermoplastic
insulations.
Chemical Resistance
SPEC 55 is unaffected by all
commonly used chemicals,
eg. fuels, hydraulic
fluids, defluxing agents,
cleaners, coolants and
de-icers. It also shows
excellent resistance to
weathering (UV, ozone,
pollutants, water).
Space Wire
SPEC 55 is available in
special versions suitable
for use in outer space
meeting both ESA and
NASA requirements for
outgassing.
Flammability
Special additives increase
the flame retardance of
SPEC 55 compared to unir-
radiated ETFE so that it
meets the latest high per-
formance tests, eg. BS
3G230 vertical test FAR 25.
Electrical Arc Tracking
Resistance
SPEC 55 insulation demon-
strates resistance to arc
tracking under both wet
and dry conditions at air-
craft system voltages.
Conductor Primary Wire Twisted Pair Shielded & Jacketed
Single Pair
55PC - Extra Light Weight Constructions
For applications where weight is critical, light weight tight tolerance conductors and insulations are available. These
are manufactured using statistical process control methods and achieve weights that are equal or lighter than the
equivalent polyimide/PTFE constructions.
SPEC 55 Wire & Cable:
Standard Constructions,
Nominal Sizes, Strandings,
Diameters and Weights
High Performance Wire and Cable
SPEC 55 (Continued)
9-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
55A - AWG Conductor:
Equipment/Interconnect Wires
&Cables
55A - AWG Conductor:
Airframe Wires & Cables Wire 55A081X 55A082X
Size Stranding Nom. Max. Weight Nom. Max. Weight
(AWG) (mm) OD
(g per m/lbs per kft)
OD
(g per m/lbs per kft)
26 19/102 1.01 [0.040] 2.5 [1.7] 2.10 [0.080] 5.06 [3.4]
24 19/127 1.14 [0.045] 3.4 [2.3] 2.33 [0.090] 6.84 [4.6]
22 19/0.16 1.27 [0.050] 4.8 [3.2] 2.64 [0.102] 9.98 [6.7]
20 19/0.203 1.47 [0.058] 7.0 [4.7] 3.07 [0.118] 14.73 [9.9]
18 19/0.25 1.78 [0.070] 10.7 [7.2] 3.63 [0.140] 21.88 [14.7]
16 19/287 1.96 [0.077] 13.4 [9.0] 4.06 [0.156] 27.53 [18.5]
14 19/0.36 2.40 [0.094] 20.5 [13.8] 4.90 [0.190] 42.26 [28.4]
12 37/0.32 2.82 [0.111] 30.5 [20.5] 5.80 [0.224] 63.00 [42.3]
10 37/0.403 3.40 [0.134] 48.3 [32.4] 7.10 [0.272] 98.96 [66.5]
Wire 55A011X 55A012X
Size Stranding Nom. Max. Weight Nom. Max. Weight
(AWG) (mm) OD
(gper m/lbs per kft)
OD
(gper m/lbs per kft)
307/0.102 0.61 [0.024] 0.98 [0.66] 1.27 [0.048] 1.94 [1.3]
287/127 0.68 [0.027] 1.35 [0.91] 1.42 [0.054] 2.68 [1.8]
2619/102 0.81 [0.032] 2.08 [1.4] 1.67 [0.064] 4.16 [2.8]
2419/127 0.94 [0.037] 2.98 [2.0] 1.93 [0.074] 5.96 [4.0]
2219/0.16 1.09 [0.043] 4.17 [2.8] 2.23 [0.086] 8.63 [5.8]
2019/0.203 1.27 [0.050] 6.40 [4.3] 2.66 [0.102] 13.24 [8.9]
18 19/0.25 1.52 [0.060] 9.67 [6.5] 3.20 [0.122] 20.09 [13.5]
16 19/287 1.73 [0.068] 12.35 [8.3] 3.58 [0.138] 25.75 [17.3]
14 19/0.36 2.20 [0.085] 19.34 [13.0] 4.47 [0.172] 39.58 [26.6]
12 37/0.32 2.62 [0.103] 29.32 [19.7] 5.38 [0.208] 59.97 [40.3]
10 37/0.403 3.25 [0.128] 47.32 [31.8] 6.65 [0.256] 96.58 [64.9]
8133/0.287 4.77 [0.188] 87.50 [58.8] 9.80 [0.376] 178.58 [120.0]
55A111X 55A112X
Wire Nom. Max. Weight Nom. Max. Weight
Size OD (g per m/lbs per kft) OD (g per m/lbs per kft)
(AWG)
30 1.51 [0.057] 5.06 [3.4] 2.12 [0.081] 7.74 [5.2]
281.59 [0.060] 5.80 [3.9] 2.27 [0.087] 8.90 [6.0]
26 1.71 [0.065] 6.85 [4.6] 2.53 [0.097] 11.32 [7.6]
24 1.84 [0.070] 8.19 [5.5] 2.80 [0.107] 13.84 [9.3]
22 1.99 [0.076] 10.27 [6.9] 3.07 [0.119] 17.86 [12.0]
20 2.20 [0.084] 13.40 [9.0] 3.50 [0.135] 23.81 [16.0]
18 2.45 [0.094] 17.86 [12.0] 4.10 [0.155] 32.60 [21.9]
16 2.67 [0.102] 21.73 [14.6] 4.43 [0.171] 39.73 [26.7]
14 3.10 [0.119] 30.36 [20.4] 5.30 [0.205] 57.00 [38.3]
12 3.55 [0.137] 42.41 [28.5] 6.30 [0.243] 81.10 [54.5]
10 4.20 [0.161] 62.65 [42.1] — —
8 5.80 [0.223] 110.42 [74.2] — —
55A181X 55A182X
Wire Nom. Max. Weight Nom. Max. Weight
Size OD (g per m/lbs per kft) OD (g per m/lbs per kft)
(AWG)
26 1.71 [0.073] 7.89 [5.3] 2.63 [0.113] 14.29 [9.6]
24 1.84 [0.078] 9.37 [6.3] 2.80 [0.123] 16.37 [11.0]
22 1.99 [0.084] 11.76 [7.9] 3.07 [0.135] 20.68 [13.9]
20 2.20 [0.092] 14.88 [10.0] 3.50 [0.151] 27.08[18.2]
18 2.45 [0.103] 19.79[13.3] 4.10 [0.173] 36.46 [24.5]
16 2.67 [0.111] 23.81[16.0] 4.43 [0.189] 42.86 [28.8]
14 3.10 [0.128] 33.03 [22.2] 6.30 [0.225] 61.61 [41.4]
12 3.55 [0.145] 45.09 [30.3] 6.30 [0.259] 85.42 [57.4]
10 4.20 [0.168] 66.97[45.0] — [0.308] 127.54 [85.7]
High Performance Wire and Cable
SPEC 55 (Continued)
9-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
55PC121X 55PC122X
Wire Nom. Max. Weight Nom. Max. Weight
Size OD (g per m/lbs per kft) OD (g per m/lbs per kft)
(AWG)
261.52 [0.064] 6.54 [4.4] 2.33 [0.100] 11.34 [7.62]
24 1.65 [0.069] 7.86 [5.28] 2.89 [0.109] 13.90 [9.34]
22 1.80 [0.075] 9.81 [6.59] 2.89 [0.122] 17.89 [12.02]
20 2.00 [0.083] 12.83 [8.62] 3.30 [0.139] 23.84 [16.02]
18 2.23 [0.093] 17.01 [11.43] 3.78 [0.158] 32.10 [21.57]
16 2.44 [0.100] 20.36 [13.68] 4.16 [0.174] 39.00 [26.21]
14 2.79 [0.116] 28.69 [19.28] 4.92 [0.204] 55.21 [37.10]
12 3.30 [0.135] 40.73 [27.37] 5.92 [0.244] 80.23 [53.91]
10 3.98 [0.159] 59.90 [40.25] 7.39 [0.297] 123.65 [83.09]
X = 1-Tin plated copper conductor.
4-Silver plated high strength copper alloy conductor. (Recommended for size 24 & 26 in airframe applications and
mandatory for CAA release.)
55PC - AWG Conductor:
Statistical Process Controlled
Airframe Wires & Cables
Wire 55PC021X 55PC022X
Size Stranding Nom. Max. Weight Nom. Max. Weight
(AWG) (mm) OD
(gper m/lbs per kft)
OD
(gper m/lbs per kft)
2619/102 0.087 [0.045] 2.05 [1.38] — —
2419/127 1.00 [0.0395] 2.95 [1.98] 2.00 [0.079] 5.95 [4.00]
2219/0.16 1.15 [0.0455] 4.31 [2.90] 2.31 [0.091] 8.74 [5.87]
2019/0.203 1.37 [0.0540] 6.51 [4.38] 2.74 [0.108] 13.2 [8.87]
1819/0.25 1.61 [0.0635] 9.81 [6.59] 3.22 [0.127] 19.84 [13.33]
1619/287 1.80 [0.0710] 12.46 [8.37] 3.60 [0.142] 25.21 [16.94]
14 19/.036 2.18 [0.0860] 19.17 [12.88] 4.36 [0.172] 38.80 [26.07]
12 37/0.32 2.66 [0.1047] 29.36 [19.73] 5.30 [0.209] 59.42 [39.93]
10 37/0.403 3.27 [0.1290] 46.31 [31.12] 6.55 [0.258] 93.92 [63.11]
High Performance Wire and Cable
SPEC 55 (Continued)
9-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Jacket Color (in accordance with MIL-STD-681,white preferred)
Primary Wire Insulation Color
(in accordance with MIL-STD-681)
0-Black 3 -Orange 7 -Violet
1 - Brown 4 -Yellow 8 - Gray
2-Red 5 -Green 9 -White
2L - Pink 6 - Blue
Additional number after base color indicates stripe
Conductor Size
Conductor Type
1 - Tin-plated copper
2-Silver-plated copper
3-Nickel-plated copper
4-Silver-plated high strength copper alloy
6 - Nickel-plated high strength copper alloy
Number of Conductors
0-10 conductors
Class of Wire
1 - 600 V equipment wire, light weight
2-600 V airframe wire, light weight
4-450 V equipment wire (55M Only sizes 20-30)
7-1000 V heavy duty, airframe wire
8 - 600 V airframe wire, normal weight
Constructions
0-Primary wire and shielded, unjacketed cables
1 - Round braid screened & jacketed cable †
2-Flat braid screened & jacketed cable †
3-Round braid, screened cable, no jacket †
4-Jacketed cable, no screen
5-Spiral screened and jacketed cable †
8 - Special constructions (part numbers not coded)
9-Special constructions including light weight
† Screen material same as conductor material except all flat screens and screen for conductor types 4 and 6
shall be tin-plated copper. Other combinations are special. (Refer to Wire and Cable Division).
Type
A-General purpose
M - Metric conductor
/-Space wire
PC -Process control
D - Defense Standard 61-12 Part 33 Issue 4
Basic Specification Number
55 X X X X X- Size- X/X- X
Part Numbering System
9
Wire and Cable
High Performance Wire and Cable
SPEC 55 (Continued)
9-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Typical Ordering Example 3conductors, red, yellow, blue, 600 volt equipment wire with overall round braid, 20 AWG tinned conductor
and white jacket: total part number is 55A1131-20-2/4/6-9.
Ordering Information Alist of stock policy items can be identified by contacting Tyco Electronics.
Stock policy items are recognized by the use of a suffix, such as (300) defining the pack size, typically
55A0111-22-9(300). UK only.
Temperature Rating Conductor Material AWG Range Available Raychem Part No. MIL-SPEC No.
600-V Lightweight Single-wall Hookup Wire, .152 [.006] Nominal Wall
150°C [302°F] Tin-coated copper 12–30 55A0111 M22759/32
200°C [392°F] Silver-coated copper 12–28 55A0112 M22759/44
200°C [302°F] Nickel-coated copper 12–28 55A0113 M22759/45
200°C [392°F] Silver-coated high-strength alloy 20–30 55A0114 M22759/33
200°C[392°F] Nickel-coated high-strength alloy 20–28 55A0116 M22759/46
600-V Lightweight Dual-wall Airframe Wire, .203 [.008] Nominal Wall
150°C[302°F] Tin-coated copper 6–26 55A0211 —
200°C [392°F] Silver-coated copper 10–26 55A0212 —
200°C[392°F] Nickel-coated copper 10–26 55A0213 —
200°C [392°F] Silver-coated high-strength alloy 18–30 55A0214 —
200°C [392°F] Nickel-coated high-strength alloy 16–26 55A0216 —
600-V Dual-wall Airframe Wire, .254 [.010] Nominal Wall
150°C [302°F] Tin-coated copper 00–24 55A0811 M22759/34
200°C [392°F] Silver-coated copper 00–26 55A0812 M22759/43
200°C [392°F] Nickel-coated copper 00–26 55A0813 M22759/41
200°C [392°F] Silver-coated high-strength alloy 20–26 55A0814 M22759/35
200°C [392°F] Nickel-coated high-strength alloy 20–26 55A0816 M22759/42
600-V Medium-Weight Dual-wall Airframe Wire, .381 [.015] Nominal Wall
150°C[302°F] Tin-coated copper 10–24 55A0711 —
200°C [392°F] Silver-coated copper 16–24 55A0712 —
200°C [392°F] Nickel-coated copper 16–24 55A0713 —
200°C[392°F] Silver-coated high-strength alloy 16–24 55A0714 —
200°C [392°F] Nickel-coated high-strength alloy 16–26 55A0716 —
SPEC 55 Part Numbering
System
High Performance Wire and Cable
SPEC 55 (Continued)
9-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
SPEC 55 Cable
Constructions
Number of Component Shield Part Number
Construction Components Conductor1Material1Light Wt.2Medium Wt.
2–10 1 — 55*01X1-AWG-Y 55*08X1-AWG-Y
Unshielded, 2— 55*01X2-AWG-Y 55*08X2-AWG-Y
unjacketed 3— 55*01X3-AWG-Y 55*08X3-AWG-Y
4— 55*01X4-AWG-Y 55*08X4-AWG-Y
6— 55*01X6-AWG-Y 55*48X6-AWG-Y
2–10 1 — 55*41X1-AWG-Y 55*48X1-AWG-Y
Unshielded, 2 — 55*41X2-AWG-Y 55*48X2-AWG-Y
jacketed 3 — 55*41X3-AWG-Y 55*48X3-AWG-Y
4 — 55*41X4-AWG-Y 55*48X4-AWG-Y
6— 55*41X6-AWG-Y 55*18X6-AWG-Y
1–10 1 1 55*11X1-AWG-Y 55*18X1-AWG-Y
Shielded 2 2 55*11X2-AWG-Y 55*18X2-AWG-Y
(round braid), 3 3 55*11X3-AWG-Y 55*18X3-AWG-Y
jacketed 4 1 55*11X4-AWG-Y 55*18X4-AWG-Y
6 3 55*11X6-AWG-Y 55*18X6-AWG-Y
1–10 1 1 55*21X1-AWG-Y 55*28X1-AWG-Y
Shielded 2 1 55*21X2-AWG-Y 55*28X2-AWG-Y
(flat braid), 3 1 55*21X3-AWG-Y 55*28X3-AWG-Y
jacketed 4 1 55*21X4-AWG-Y 55*28X4-AWG-Y
6 1 55*21X6-AWG-Y 55*28X6-AWG-Y
1Type of conductor or shield material: 2X=no. of wire components
1=tin-coated copper Y = color code
2=silver-coated copper For complete part number, see Part Numbering System on page 9-15.
3=nickel-coated copper
4=silver-coated high-strength copper alloy
6=nickel-coated high-strength copper alloy
* = A or PC
High Performance Wire and Cable
SPEC 55 (Continued)
9-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Basic Specification Number
Component Wire ID/Shield Coverage Code
Shield Coverage
85% 90% Component Wire Identification
- C Colored Stripes on White Wire
(9/96/93/95/92/90/94/97/98/91... etc.)
A D Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.)
B E Band Marks on Solid Colors (by AWG)
F H Alternate Colored Stripes
(92/96/94/95/9/90/91/93/97/98...etc)
G J Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.)
K M Number Marking on Solid Colors (by AWG)
L N Number Marking on White Wires
P R Band Marks on Colored Stripes (by AWG)
S T Band Marks on White Wires
Conductor Size (AWG)
Basic Wire Spec Code (MIL-W-22759) and Slash Sheet
SB - 32 = 55A0111
SC - 33 = 55A0114
SD - 34 = 55A0811
for 2 AWG and larger, use 55A8039
SE - 35 = 55A0814
SM - 41 = 55A0813
for 2 AWG and larger, use 55A8595
SN - 42 = 55A0816
SP - 43 = 55A0812
for 2 AWG and larger, use 55A6089
SR - 44 = 55A0112
SS - 45 = 55A0113
ST - 46 = 55A0116
Number of Component Wires
1 through 9; 10 Components = 0
Shield Material and Style Code
U - No shield
T - Tin-coated copper, round
J - Tin-coated copper, flat
S - Silver-coated copper, round
G - Silver-coated copper, flat
N - Nickel-coated copper, round
V - Tin-coated copper, round, double shield
W - Silver-coated copper, round, double shield
Jacket Material and Style Code
00 - No jacket
23 - Single jacket crosslinked, modified ETFE, white
73 - Double jacket crosslinked, modified ETFE, white
M27500 X AWG XX X X XX
Raychem Part No.
Military Part No.
M27500-22SB3T23 = 55AM1131-22-9/96/93-9
NEMA WC-27500 Cable
Part Numbering System
Example:
High Performance Wire and Cable
RCW
9-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
Raychem Composite Wire
(RCW) is insulated with a
combination of PTFE and
Polyimide materials. It has a
temperature rating of -65˚C
to +260˚C [-85˚F to +500˚F]
continuous using a nickel-
plated conductor,and com-
bines the easy handling of a
flexible wire with excellent
cut-through characteristics.
Chosen for its balance of
properties, RCW has
outstanding resistance to
chemicals and solvents,
excellent arctrack resist-
ance, and is not susceptible
to UV and moisture degra-
dation.
RCW can be supplied in
athin wall, lightweight
construction which provides
considerable weight and
size savings over compara-
ble wires.
RCW is available in twisted
pairs, triples, etc. and
shielded and jacketed
constructions.
Physical Characteristics
Size and Weight
RCW provides one of the
most comprehensive wiring
product ranges for aero-
space users with a wide
choice of conductor sizes
and insulation wall thick-
nesses.
RCW airframe wirehas an
insulation wall thickness of
either .006” or 0.008” for
robustness in unprotected
harnesses and has excel-
lent wire-to-wire abrasion
properties.
Handling
Excellent flexibility and
handleability makes RCW
ideal for installation in new
aircraft and equipment,
and is easily replaced
during maintenance
procedures.
RCW is easily stripped with
conventional tooling, and
readily marked by laser or
ink jet.
Product Facts
n-65°C to +260°C [-85°F to
+500°F]
nSmall size, ultra light weight
nResistant to electrical arc
tracking in wet or dry
conditions
nExcellent cut-through
resistance
nExceptional chemical
resistance
Available in:
Americas n
Europe n
Asia Pacific n
High Performance Wire and Cable
RCW (Continued)
9-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Specifications
Conductor -
Silver-Coated
Copper /
Nickel-Coated
Copper
Insulation - Tape Wraps
RCW insulation system
MIL-DTL-22759/81-92
Lockheed Martin Selected C-Specs
Typical Properties Lightweight / Normal Weight
Conductor Silver Copper / Nickel Copper
Temperature -65°C to +200°C [-85°F to +392°F] / -65°C to +260°C [85°F to +500°F]
Voltage Rating 600V
Dielectric Strength 4,000 volts/mil (avg. min.)
Wet Arc Propagation Resistance MIL-STD-2223 Method 3006 *
Dry Arc Propagation Resistance MIL-DTD-2223 Method 3007 *
Dynamic Cut-Through ASTM D 3032 Section 22 *
Flammability MIL-STD-2223, Method 1006,
Procedure A *
Insulation Resistance 5000 megohms for 1000 ft. (min.)
Life Cycle 500 hours @ 230°C [446°F] / 500 hrs @ 290°C [554°F]
Low Temperature (Cold Bend) -65°C [-85°F] (4 hrs)
Smoke 200°C[392°F] / 260°C [500°F]
No visible smoke
Thermal Index 200°C [392°F] min. / 260°C min. [500°F] 10,000 hrs.
*as defined by the applicable MIL-Spec slash sheets
Environmental Performance Temperature Rating
RCW wire and cable is
rated for continuous opera-
tion from -65°C to +260°C
[-85°F to +500°F] and for
short periods at tempera-
tures as high as 320°C
[608°F].
Mechanical Performance
RCW incorporates superior
abrasion protection and
cut-through performance.
Like all Raychem products,
this latest addition is
designed for electrical and
electronic applications in
tough environments.
Chemical Resistance
RCW is unaffected by all
commonly used chemicals,
eg. fuels, hydraulic
fluids, defluxing agents,
cleaners, coolants and
de-icers. It also shows
excellent resistance to
weathering (UV, ozone,
pollutants, water). RCW
is highly resistant to
hydrolysis.
Flammability/Smoke
Advanced combination of
materials allow superior
performance in areas such
as flammability and smoke
generation properties.
Exceeds FAR 25 test
requirements for flame
resistance and smoke
density.
Electrical Arc Tracking
Resistance
RCW insulation demon-
strates resistance to arc
tracking under both wet
and dry conditions at air-
craft system voltages.
Conductor Primary Wire Twisted Pair Shielded & Jacketed
Single Pair
RCW Wire & Cable: Standard
Constructions, Nominal Sizes,
Strandings, Diameters and
Weights
High Performance Wire and Cable
RCW (Continued)
9-21
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
RCW - AWG Conductor:
Equipment/Interconnect Wires
&Cables
(Lightweight)
RCW - AWG Conductor:
Airframe Wires & Cables
(Normal Weight)
Wire RCW59xx RCWxWx2U00-AWG
Size Stranding Nom. Max. Weight Nom. Max. Weight@90%
(AWG) (mm) OD max.
(g per m/lbs per kft)
OD max.
(g per m/lbs per kft)
26 19 x 38 0.52 [0.0204] 2.31 [1.55] 1.88 [0.074] 4.70 [3.16]
24 19 x 36 0.62 [0.0244] 3.19 [2.15] 2.13 [0.084] 6.53 [4.39]
22 19 x 34 0.87 [0.0314] 4.46 [3.00] 2.39 [0.094] 9.11 [6.12]
20 19 x 32 1.00 [0.0394] 6.77 [4.55] 2.79 [0.110] 13.81 [9.28]
18 19 x 30 1.25 [0.0494] 9.97 [6.70] 3.30 [0.130] 20.39 [13.70]
16 19 x 29 1.41 [0.0554] 12.80 [8.60] 3.71 [0.146] 26.04 [17.50]
14 19 x 27 1.76 [0.0694] 19.27 [12.95] 4.37 [0.172] 39.29 [26.40]
12 37 x 28 2.27 [0.0894] 29.91 [20.10] 5.33 [0.210] 61.01 [41.00]
10 37 x 26 2.84 [0.112] 46.73 [31.40] 6.45 [0.254] 95.39 [64.10]
8 133 x 29 4.29 [0.169] 85.72 [57.60] 9.55 [0.376] 174.86[117.50]
6 133 x 27 5.38 [0.212] 131.40 [88.30] — —
4 133 x 25 6.81 [0.268] 212.81 [143.0] — —
Wire RCW59XX RCWxWx2U00-AWG
Size Stranding Nom. Max. Weight Nom. Max. Weight
(AWG) (mm) OD(max.)
(gper m/lbs per kft)
OD(max.)
(gper m/lbs per kft)
26 19 x 38 0.48 [0.019] 2.13 [1.43] 1.73 [0.068] 4.35 [2.92]
24 19 x 36 0.61 [0.024] 2.87 [1.93] 1.93 [0.076] 5.86 [3.94]
22 19 x 34 0.76 [0.030] 4.24 [2.85] 2.18 [0.086] 8.65 [5.81]
20 19 x32 0.97 [0.038] 6.52 [4.38] 2.59 [0.102] 13.30 [8.94]
18 19 x 30 1.22 [0.048] 9.82 [6.60] 3.05 [0.120] 20.09 [13.5]
16 19 x29 1.37 [0.054] 12.35 [8.30] 3.40 [0.134] 25.15 [16.9]
14 19x 27 1.73 [0.068] 18.75 [12.6] 4.06 [0.160] 38.25 [25.7]
12 37 x 28 2.21 [0.087] 29.17 [19.6] 5.08 [0.200] 59.53 [40.0]
10 37 x 26 2.79 [0.110] 45.54 [30.6] 6.25 [0.246] 92.86 [62.4]
Wire RCWxWx1xxx-AWG-x RCWxWx2xxx-AWG-x
Size Shield Nom. Max. Weight@90% Nom. Max. Weight@90%
(AWG) Size (A WG) ODmax.
(gper m/lbs per kft)
ODmax.
(gper m/lbs per kft)
2638 1.83 [0.072] 8.27 [5.56] 2.69 [0.106] 13.84 [9.30]
2438 1.93 [0.076] 9.52 [6.40] 2.89 [0.114] 16.22 [10.9]
2238 2.06 [0.081] 1 1.55 [7.76] 3.15 [0.124] 20.24 [13.6]
20 382.26 [0.089] 14.88 [10.0] 3.56 [0.140] 26.64 [17.9]
1838 2.49 [0.098] 19.35 [13.0] 4.01 [0.158] 35.42 [23.8]
16 38 2.67 [0.105] 22.77 [15.3] 4.37 [0.172] 42.12 [28.3]
1438 2.99 [0.118] 30.95 [20.8] 5.03 [0.198] 58.19 [39.1]
1238 3.50 [0.138] 44.05 [29.6] 6.15 [0.242] 85.57 [57.5]
10 38 4.09 [0.161] 63.69 [42.8] 7.32[0.288] 124.41[83.6]
Wire RCWxWx1xxx-AWG-x RCWxWx2xxx-AWG-x
Size Shield Nom. Max. Weight@90% Nom. Max. W eight@90%
(AWG) Size (A WG) OD max.
(g per m/lbs per kft)
OD max.
(g per m/lbs per kft)
26 38 1.91 [0.075] 8.82 [5.93] 2.84 [0.112] 14.88 [10.0]
24 38 2.03 [0.080] 10.45 [7.02] 3.10 [0.122] 18.01 [12.1]
22 38 2.16 [0.085] 12.28 [8.25] 3.35 [0.132] 21.58 [14.5]
20 38 2.36 [0.093] 15.63 [10.50] 3.76 [0.148] 27.98 [18.8]
18 38 2.62 [0.103] 20.09 [13.50] 4.27 [0.168] 36.76 [24.7]
16 38 2.82 [0.111] 24.11 [16.20] 4.67 [0.184] 44.35 [29.8]
14 38 3.15 [0.124] 32.29 [21.70] 5.33 [0.210] 60.57 [40.7]
12 38 3.63 [0.143] 45.54 [30.60] 6.40 [0.252] 88.25 [59.3]
10 38 4.19 [0.165] 65.33 [43.90] 7.52 [0.296] 127.83 [85.9]
High Performance Wire and Cable
RCW (Continued)
9-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
RCW X XX # X XX - AWG - X
Basic Product Number
Component Wire ID/Shield Coverage Code (per WC 27500)
(Note: Some ID methods of WC 27500 may not be available -
standard codes offered are A, B, D and E, as defined below)
A - 85% min. shield cov. (if applic.); solid wire colors selected
in order from the following: White, Blue, Orange, Green,
Red, Black, Yellow, Violet, Gray, Brown
B - 85% min. shield coverage (if applic.); band-marked solid
wire colors based on AWG size as follows:
AWG Color AWG Color AWG Color
26 Black 18 White 10 Brown
24 Blue 16 Blue 8 Red
22 Green 14 Green 6 Blue
20 Red 12 Yellow 4 Yellow
D - Same as A, except 90% min. shield coverage
E - Same as B, except 90% min. shield coverage
Component Wire Code (per WC 27500) and
MIL-W-22759 Slash Sheet
WC = 81 = RCW5981
WE = 82 =RCW5982
WJ = 86 = RCW5986
WK = 87 =RCW5987
WM = 89 = RCW5989
WN = 90 = RCW5990
WP = 91 = RCW5991
WR = 92 = RCW5992
Number of Component Wires
Shield Code (per WC 27500)
U-No Shield
T-Tin-coated copper, round
S - Silver-coated copper, round
N - Nickel-coated copper, round
G - Silver-coated copper, flat
Jacket Code (per WC 27500)
00 - No jacket
06 -PTFE tape wrap
24 -FP/PI/FP and PTFE tape wraps
Conductor Size (AWG)
Jacket Color Code (per MIL-STD-681)
0 - Black 5-Green
1-Brown 6 -Blue
2 - Red 7-Violet
3-Orange 8 - Gray
4-Yellow 9 -White
Part Numbering System —
Cable
(Per NEMA WC 27500)
Example:
RCWAWJ2G24-22-9 = M27500A22WJ2G24 Military Part Number
Raychem Part Number
High Performance Wire and Cable
RCW (Continued)
9-23
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
RCW59 XX - AWG - X
Basic Product Number
MIL-W-22759 Slash Sheet as follows:
81 - Lightweight, silver-coated, high-strength or ultra high-strength copper
alloy, AWG 26-20
82 - Lightweight, nickel-aoted, high-strength or ultra high-strength copper
alloy, AWG 26-20
86 - Normal weight, silver-coated copper, AWG 26-4
87 - Normal weight, nickel-coated copper, AWG 26-4
89 - Normal weight, silver-coated, high-strength or ultra high-strength copper
alloy, AWG 26-20
90 - Normal weight, nickel-coated, high-strength or ultra high-strength copper
alloy, AWG 26-20
91 - Lightweight, silver-coated copper, AWG 26-10
92 - Lightweight, nickel-coated copper, AWG 26-10
Conductor Size (AWG)
Insulation Color Code (per MIL-STD-681)
(Note: Colors are in accordance with the UV laser markable color limits specified in the
applicable MIL-W-22759 slash sheet. Standard wire color is white).
0 - Black 5 -Green
1 - Brown 6- Blue
2 - Red 7-Violet
3-Orange 8 - Gray
4 - Yellow 9- White
Part Numbering System —
Primary Wire
(Per MIL-W-22759)
Example:
RCW5991-22-9 = M27559/91-22-9 Military Part Number
Raychem Part Number
High Performance Wire and Cable
RCW (Continued)
9-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
M27500 X AWG XX # X XX
Basic Product Number
Component Wire ID/Shield Coverage Code
(Note: Some ID methods may not be available for RCW cable -
standard codes offered are A, B, D and E, as defined below)
A - 85% min. shield cov. (if applic.); solid wire colors selected
in order from the following: White, Blue, Orange, Green,
Red, Black, Yellow, Violet, Gray, Brown
B - 85% min. shield coverage (if applic.); band-marked solid
wire colors based on AWG size as follows:
AWG Color AWG Color AWG Color
26 Black 18 White 10 Brown
24 Blue 16 Blue 8 Red
22 Green 14 Green 6 Blue
20 Red 12 Yellow 4 Yellow
D - Same as A, except 90% min. shield coverage
E - Same as B, except 90% min. shield coverage
Conductor Size (AWG)
Basic Wire Spec Code (MIL-W-22759 Slash sheet & RCW Wire)
WC = 81 = RCW5981
WE = 82 = RCW5982
WJ = 86 = RCW5986
WK = 87 = RCW5987
WM = 89 = RCW5989
WN = 90 = RCW5990
WP = 91 = RCW5991
WR = 92 = RCW5992
Number of Component Wires
Shield Material and Style Code
U-No Shield
T-Tin-coated copper, round
S - Silver-coated copper, round
N - Nickel-coated copper, round
G - Silver-coated copper, flat
Jacket Material and Style Code
00 -No jacket
06 -PTFE tape wrap, white
24 -FP/PI/FP and PTFE tape wraps, white
Part Numbering System —
Cable
(Per NEMA WC 27500)
Example:
M27500A22WJ2G24 = RCWAWJ2G24-22-9
Raychem Part Number
Military Part Number
FlexLine
SPEC 80
9-25
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
FlexLine wire (also known
as SPEC 80) is insulated
with a flexible modified
radiation cross-linked ETFE
polymer. It has a tempera-
turerating of -65°Cto
+150°C [-85°F to +302°F]
continuous using silver
copper conductor, and
combines the easy
handling of our SPEC 55
wire and cable with addi-
tional flexibility. FlexLine
wire is used in a broad
range of applications, from
Hook-up wireto Power
Cables.
Product Facts
nReduced weight
nFlexibility
nLow outgassing
nFunction over a broad
temperature range
nFlammability
nArc track resistance
nResistance to atomic oxygen
nRadiation resistance
nHigh quality and reliability
nEase of fabrication (into
Harnesses due to flexibility)
nAgency approvals
n-65°C up to +150°C
[-85°F up to +302°F]
nSmall size
n600V rating
nOptional high strand count
for increased flexibility
nVariety of insulation/jacket
options
nDual wall and single wall
options
nEasy to install
nMechanically tough
nCompliance with FAR 25
flammability requirements
nResistance to harsh fluids &
solvents per MIL-W-22759
FlexLine wireconstructions
provide maximum flexibility
similar to the MIL-W-22759
products in Mechanical,
Chemical and Thermal
properties.
Available in: Americas Europe Asia Pacific
nnn
FlexLine
SPEC 80 (Continued)
9-26 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Jacket Color Identification Code (in accordance with MIL-STD-681)
Primary Wire Insulation Color
(in accordance with MIL-STD-681)
0-Black 4 -Yellow 8 - Gray
1 - Brown 5 -Green 9 -White
2 - Red 6 - Blue
3-Orange 7 -Violet
Conductor Size (AWG)
Conductor Type
1 - Tin-coated copper 4 - Silver-coated high strength
2-Silver-coated copper copper alloy
3-Nickel-coated copper 6 - Nickel-coated high strength
copper alloy
Number of Conductors
1 through 9
Class of Wire
1 - 600 V general purpose wire, lightweight
8 - 600 V airframe wire, normal weight
Construction
0-Primary wire & unshielded, unjacketed
1 - Round-braid shielded & jacketed cable*
2-Flat-braid shielded & jacketed cable*
3 - Round-braid shielded cable, no jacket*
4-Jacketed cable, no shield
5-Spiral-shielded & jacketed cable*
6-9 Special constructions
Wire Type
A-General Purpose
/-Outer Space
AC- 90% Shield Coverage
Basic Specification Number
1 - Normal Stranding
2-High Stranding
*Shield coating same as conductor coating except for the following:
-shield for conductor type 4 shall be tin-coated copper
-round braid shield constructions for conductor type 6 shall be
nickel-coated copper
-flat braid shield constructions for conductor type 6 shall be
tin-coated copper
Other shield variations are designated as Special Constructions
8x X X X X X- Size- X/X- X
Part Numbering System
FlexLine Insulation System
Single Wall Dual Wall
Single Wall 82 Wire
High strand count conductors
Light weight
AWG sizes 28 to 00
(6-mil nominal insulation thickness)
Dual Wall 81 Wire
Standard M22759 conductor stranding
Increased toughness
AWG sizes 28 to 000
(10-mil nominal insulation thickness)
9
Wire and Cable
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Low-Fire-Hazard Wire and Cable
9-27
FR-1000
Halogen-Free, Fire
Resistant Cable Range
Applications
Tyco Electronics has devel-
oped a new halogen-free,
lightweight, small size, fire
resistant Raychem cable to
exceed the exacting fire
resistant requirements of
IEC 60331 (ie withstands
950°C [1742°F] for 3 hours
as opposed to the 750°C
[1382°F] requirement)
and meet the flame-retar-
dant requirements of IEC
60332-3 (Cat A), while
maintaining significant size
and weight savings over
conventional materials.
FR-1000 cable consists of
Raychem Type 95 primary
wirewith a Zerohal jacket
and can be used throughout
the installation, simplifying
the selection for designers
and electrical engineers. By
acombination of our proven
expertise in polymer and
radiation chemistry, low fire
hazard technology and pre-
cision extrusion capability,
Tyco Electronics has been
able to develop a range of
Raychem cables featuring
reduced size and weight
over existing thickwall
cables. This offers savings
of approximately 30% and
optimizes the space avail-
able. This results in lower
installed costs by downsiz-
ing connectors, glanding,
cable support structures,
and reduced time on
installation.
With increasing complexity
of electronic systems,
sensors, communications
and safety equipment,
more cables are required
to fit into smaller spaces.
FR-1000 small size cable
can offer distinct advantages
over conventional cables.
These include:
nTough and flexible con-
structions aiding installa-
tion through smaller bend
radii and extending serv-
ice life.
nControlled dimensions
simplifying connector and
transit selection.
nResistance to widely used
fluids such as diesel fuels,
oils, and greases.
Operating Temperature Range
-30°Cto +90°C
[-22°F to +194°F]
Product Facts
nHighly flame retardant
nHalogen-free
nLow smoke generation
nLow toxicity index
nLow acid gas emission
nLow water uptake
nCompatible with Raychem
System 100 heat-shrink
components, heat-shrink
tubing, molded parts and
adhesives
Available in: Americas Europe Asia Pacific
nnn
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-28 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Generic Cable Construction
Conductors Tin-plated copper to BS 6360.
Insulation Mica based tape, halogen-free, low smoke material complying with Raychem spec
WSD695.
Core Pairs – black and white and numbered.
Identification Triples – black, red and white and numbered.
Multicore – white and numbered.
Shielding Aluminized Mylar® tapewrap in contact with tinned copper drainwire.
Inner Sheath Halogen-free, low smoke material complying with Raychem specification WCD51/1663
and WSD696.
Armor Galvanized steel wire braid in accordance with Raychem specification
WSD696 and BS6883 (BS1442).
Outer Sheath Raychem Zerohal material complying with Raychem specification WSD696 and exceeding
the requirements of BS6899, Type D.
Flame retardant to IEC60332-3(Cat A) and fire resistant to IEC60331
(enhanced to 950 ± 50°C [122°F], 3 hours).
Sheath printed with Raychem number and size of conductors,
IEC60331 (950°C [1742°F).
Sheath color black. Oxygen index >30% (BS2782).
Temperature index >260°C [500°F] (BS2782). Smoke index <13 (BS6883).
Toxicity index <2 (NES713).
Temperature Rating 90°C [194°F] maximum operating temperature.
Voltage Rating 600/1000V.
Example:
FR-1000 4x1.5 93497A
RAYCHEM FR-1000 4x1.5 Batch No.
MYLAR is a trademark of
Dupont Teijin Films U.S.
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-29
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Diameter Cable
Part No. Conductor CSA Over Outer Nominal
EPD Construction Stranding Nominal Inner Diameter Weight Jacket
mm2Sheath (min.) (max.) kg/km Color
87486A 2x1.5 19/0.32 1.5 6.6 [.260] 10.2 [.402] 11.2 [.441] 178 Black
87488A 3x1.5 19/0.32 1.5 7.1 [.280] 10.8 [.425] 11.6 [.457] 203 Black
87490A 4x1.5 19/0.32 1.5 7.7 [.303] 11.2 [.441] 12.4 [.488] 236 Black
87492A 7x1.5 19/0.32 1.5 9.4 [.370] 13.0 [.512] 14.4 [.567] 328 Black
87494A 12x1.5 19/0.32 1.5 12.5 [.492] 16.0 [.630] 17.6 [.693] 486 Black
87496A 19x1.5 19/0.32 1.5 14.7 [.579] 18.2 [.717] 20.2 [.795] 677 Black
87498A 27x1.5 19/0.32 1.5 17.9 [.705] 21.3 [.839] 23.5 [.925] 906 Black
87487A 2x2.5 7/0.67 2.5 7.7 [.303] 11.2 [.441] 12.4 [.488] 224 Black
87489A 3x2.5 7/0.67 2.5 8.2 [.323] 11.7 [.461] 12.9 [.508] 257 Black
87491A 4x2.5 7/0.67 2.5 9.0 [.354] 12.6 [.496] 14.0 [.551] 312 Black
87493A 7x2.5 7/0.67 2.5 10.9 [.429] 14.7 [.579] 15.7 [.618] 429 Black
87495A 12x2.5 7/0.67 2.5 14.6 [.575] 18.1 [.713] 20.1 [.791] 661 Black
87497A 19x2.5 7/0.67 2.5 17.5 [.689] 20.9 [.823] 23.1 [.909] 936 Black
87499A 27x2.5 7/0.67 2.5 21.1 [.831] 25.3 [.996] 27.3 [1.075] 1321 Black
*Cables are armored with an overall galvanized steel wire braid armor.
Outer Sheath Inner Sheath
Insulation
ConductorMica
Based
Tape
Armor
Halogen-Free, Fire
Resistant Cable Range
FR-1000 Multicore Control Cables, Unshielded,
Armored, 600/1000V*
Selection Table
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-30 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Cable
Part No. Conductor CSA Outer Nominal
EPD Construction Stranding Nominal Diameter Weight Jacket
mm2(min.) (max.) kg/km Color
87472A 2x1.5 19/0.32 1.5 7.5 [.295] 7.9 [.311] 87 Black
87474A 3x1.5 19/0.32 1.5 7.8 [.307] 8.6 [.339] 108 Black
87476A 4x1.5 19/0.32 1.5 8.4 [.331] 9.2 [.362] 134 Black
87478A 7x1.5 19/0.32 1.5 10.1 [.398] 11.1 [.437] 204 Black
87480A 12x1.5 19/0.32 1.5 13.3 [.524] 14.3 [.563] 332 Black
87482A 19x1.5 19/0.32 1.5 15.2 [.598] 16.8 [.661] 490 Black
87484A 27x1.5 19/0.32 1.5 18.5 [.728] 19.9 [.783] 684 Black
87473A 2x2.5 7/0.67 2.5 8.4 [.331] 9.2 [.362] 122 Black
87475A 3x2.5 7/0.67 2.5 8.8 [.346] 9.8 [.386] 150 Black
87477A 4x2.5 7/0.67 2.5 9.7 [.382] 10.7 [.421] 192 Black
87479A 7x2.5 7/0.67 2.5 11.5 [.453] 12.7 [.500] 288 Black
87481A 12x2.5 7/0.67 2.5 15.1 [.594] 16.7 [.657] 475 Black
87483A 19x2.5 7/0.67 2.5 17.9 [.705] 19.7 [.776] 720 Black
87485A 27x2.5 7/0.67 2.5 21.3 [.839] 23.5 [.925] 995 Black
Conductors Tin plated copper to BS6360
Insulation Mica based tape, halogen-free, low smoke material complying with Raychem specification
WSD695
Core Identification White and numbered
Inner Sheath Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and
WSD696
Armor Galvanized steel wire braid in accordance with Raychem specification WSD696 and
BS6883 (BS1442)
Raychem Zerohal material complying with Raychem specification WSD696 and exceeding
the requirements of BS6899, Type D.
Flame retardant to IEC60332-3(Cat A) and fire resistant to IEC60331
(enhanced to 950 +/- 50°C [122°F], 3 hours)
Outer Sheath Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and
EPD number
Sheath color black
Oxygen index >30% (BS2782), Temperature index > 260°C (BS2782),
Smoke index <13 (BS6883)
Toxicity Index <2 (NES713)
Temperature Rating 90°C [194°F] maximum conductor operating temperature
Voltage Rating 600/1000V
Outer Sheath Mica
Based
Tape
ConductorInsulation
Selection Table
FR-1000 Multicore Control Cables, Unshielded,
Unarmored, 600/1000V
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-31
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Diameter
CSA (Nominal) Cable
Part No. Construction Conductor Nominal Over Over Outer Nominal Jacket
EPD Stranding mm2Shield Inner Diameter Weight Color
Sheath (min.) (max.) kg/km
93491A 3x2x0.75 19/0.23 0.75 9.7 [.382] 11.1 [.437] 14.6 [.575] 16.2 [.638] 319 Grey
93492A 7x2x0.75 19/0.23 0.75 13.1 [.516] 14.6 [.575] 18.1 [.713] 20.1 [.791] 484 Grey
93493A 12x2x0.75 19/0.23 0.75 16.4 [.646] 18.1 [.713] 21.5 [.846] 23.7 [.933] 685 Grey
93494A 20x2x0.75 19/0.23 0.75 21.2 [.835] 23.0 [.906] 26.8 [1.055] 29.6 [1.165] 1090 Grey
87500A 2x1.5 19/0.32 1.5 5.4 [.213] 6.7 [.264] 10.7 [.421] 11.3 [.445] 192 Black
87501A 2x2x1.5 19/0.32 1.5 7.2 [.283] 8.6 [.339] 12.3 [.484] 13.5 [.531] 267 Black
87502A 3x2x1.5 19/0.32 1.5 11.2 [.441] 12.7 [.500] 16.1 [.634] 17.9 [.705] 404 Black
87503A 5x2x1.5 19/0.32 1.5 13.8 [.543] 15.3 [.602] 18.8 [.740] 20.8 [.819] 541 Black
87504A 7x2x1.5 19/0.32 1.5 15.2 [.598] 16.9 [.665] 20.3 [.799] 22.5 [.886] 649 Black
87505A 10x2x1.5 19/0.32 1.5 17.5 [.705] 19.2 [.756] 22.5 [.886] 24.9 [.980] 817 Black
87506A 12x2x1.5 19/0.32 1.5 19.0 [.748] 20.7 [.815] 25.2 [.992] 26.6 [1.047] 999 Black
87507A 20x2x1.5 19/0.32 1.5 24.7 [.972] 26.5 [1.043] 30.5 [1.201] 33.7 [1.327] 1541 Black
87508A 24x2x1.5 19/0.32 1.5 26.6 [1.047] 28.6 [1.126] 33.6 [1.323] 35.6 [1.402] 1762 Black
*Cables have an overall aluminized Mylar® shield with drainwire and an overall galvanized steel wire braid armor.
Outer Sheath Inner Sheath Drainwire
Insulation ConductorAluminized
Mylar®
Screen
Armor
Mica
Based
Tape
Halogen-Free, Fire
Resistant Cable Range
FR-1000 Multipair Control Cables, Collectively
Shielded and Armored 600/1000V*
Selection Table
MYLAR is a trademark of
Dupont Teijin Films U.S.
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-32 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Diameter
CSA (Nominal) Cable
Part No. Construction Conductor Nominal Over Over Outer Nominal Jacket
EPD Stranding mm2Shield Inner Diameter Weight Color
Sheath (min.) (max.) kg/km
87509A 1x3x1.5 19/0.32 1.5 5.9 [.232] 7.2 [.283] 10.7 [.421] 11.9 [.469] 216 Black
87510A 3x3x1.5 19/0.32 1.5 12.0 [.472] 13.5 [.531] 16.9 [.665] 18.7 [.736] 480 Black
87511A 7x3x1.5 19/0.32 1.5 16.2 [.638] 17.9 [.705] 21.3 [.839] 23.5 [.925] 815 Black
87512A 12x3x1.5 19/0.32 1.5 22.2 [.874] 24.0 [.945] 28.1 [1.106] 31.1 [1.224] 1357 Black
*Cables have an overall aluminized Mylar® shield with drainwire and an overall galvanized steel wire braid armor.
Conductors Tin plated copper to BS6360
Insulation Mica based tape, halogen-free, low smoke material complying with Raychem specification WSD695
Core Identification Pairs – black and white and numbered. Triples – black, red and white and numbered
Shielding Aluminized Mylar® tapewrap in contact with tinned copper drainwire
Inner Sheath Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and WCD696
Armor Galvanized steel wire braid in accordance with Raychem specification WSD696 and BS6883 (BS1442)
Raychem Zerohal material complying with Raychem specification WSD696 and exceeding the requirements of BS6899, Type D.
Flame retardant to IEC60332-3(Cat A) and fire resistant to IEC60331 (enhanced to 950 +/- 50°C [122°F]z, 3 hours)
Outer Sheath Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and EPD number
Sheath color black
Oxygen index >30% (BS2782), Temperature index > 260°C [482°F] (BS2782), Smoke index <13 (BS6883)
Toxicity Index <2 (NES713)
Temperature Rating 90°C maximum conductor operating temperature
Voltage Rating 600/1000V
Outer Sheath Inner Sheath
Aluminized
Mylar®
Screen
Drainwire Insulation Mica
Based
Tape
ConductorArmor
Selection Table
FR-1000 Multitriple control cables,
Collectively Shielded and Armored, 600/1000V*
MYLAR is a trademark of
Dupont Teijin Films U.S.
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-33
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Halogen-Free, Fire
Resistant Cable Range
Diameter
CSA (Nominal) Cable
Part No. Construction Conductor Nominal Over Over Outer Nominal Jacket
EPD Stranding mm2Shield Inner Diameter Weight Color
Sheath (min.) (max.) kg/km
93491A 3x2x0.75 19/0.23 0.75 9.7 [.382] 11.1 [.437] 14.6 [.575] 16.2 [.638] 319 Grey
93492A 7x2x0.75 19/0.23 0.75 13.1 [.516] 14.6 [.575] 18.1 [.713] 20.1 [.791] 484 Grey
93493A 12x2x0.75 19/0.23 0.75 16.4 [.646] 18.1 [.713] 21.5 [.846] 23.7 [.933] 685 Grey
93494A 20x2x0.75 19/0.23 0.75 21.2 [.835] 23.0 [.906] 26.8 [1.055] 29.6 [1.165] 1090 Grey
87500A 2x1.5 19/0.32 1.5 5.4 [.213] 6.7 [.264] 10.7 [.421] 11.3 [.445] 192 Black
87501A 2x2x1.5 19/0.32 1.5 7.2 [.283] 8.6 [.339] 12.3 [.484] 13.5 [.531] 267 Black
87502A 3x2x1.5 19/0.32 1.5 11.2 [.441] 12.7 [.500] 16.1 [.634] 17.9 [.705] 404 Black
87503A 5x2x1.5 19/0.32 1.5 13.8 [.543] 15.3 [.602] 18.8 [.740] 20.8 [.819] 541 Black
87504A 7x2x1.5 19/0.32 1.5 15.2 [.598] 16.9 [.665] 20.3 [.799] 22.5 [.886] 649 Black
87505A 10x2x1.5 19/0.32 1.5 17.5 [.689] 19.2 [.756] 22.5 [.886] 24.9 [.980] 817 Black
87506A 12x2x1.5 19/0.32 1.5 19.0 [.748] 20.7 [.815] 25.2 [.992] 26.6 [1.047] 999 Black
87507A 20x2x1.5 19/0.32 1.5 24.7 [.972] 26.5 [1.043] 30.5 [1.201] 33.7 [1.327] 1541 Black
87508A 24x2x1.5 19/0.32 1.5 26.6 [1.047] 28.6 [1.126] 33.6 [1.323] 35.6 [1.402] 1762 Black
*Cables have an overall aluminized Mylar® shield with drainwire and an overall galvanized steel wire braid armor.
Outer Sheath Inner Sheath
Aluminized
Mylar®
Screen
Drainwire
Insulation
Mica
Based
Tape
ConductorArmor
FR-1000 Multipair Control Cables, Collectively
Shielded and Armored 600/1000V*
Selection Table
MYLAR is a trademark of
Dupont Teijin Films U.S.
Low-Fire-Hazard Wire and Cable
FR-1000 (Continued)
9-34 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Diameter
CSA (Nominal) Cable
Part No. Construction Conductor Nominal Over Outer Nominal Jacket
EPD Stranding mm2Inner Diameter Weight Color
Sheath (min.) (max.) kg/km
93500A 3x3x0.75 19/0.23 0.75 12.4 [.488] 15.9 [.626] 17.5 [.689] 407 Grey
93501A 7x3x0.75 19/0.23 0.75 16.8 [.661] 20.2 [.795] 22.4 [.881] 682 Grey
93502A 12x3x0.75 19/0.23 0.75 22.6 [.890] 26.4 [1.039] 29.2 [1.150] 1111 Grey
93503A 3x1.00 19/0.25 1.0 6.6 [.260] 10.6 [.417] 11.6 [.457] 198 Grey
*Cables have pairs individually shielded with aluminized Mylar® and drainwire and an overall galvanized steel wire braid armor.
Conductors Tin plated copper to BS6360
Insulation Mica based tape, halogen-free, low smoke material complying with Raychem specification WSD695
Core Identification Pairs – black and white and numbered. Triples – black, red and white and numbered
Shielding Aluminized Mylar® tapewrap in contact with tinned copper drainwire
Inner Sheath Halogen-free, low smoke material complying with Raychem specification WCD51/1663 and WSD696
Armor Galvanized steel wire braid in accordance with Raychem specification WSD696 and BS6883 (BS1442)
Raychem Zerohal material complying with Raychem specification WSD696 and exceeding the requirements of BS6899, Type D.
Flame retardant to IEC60332-3(Cat A) and fire resistant to IEC60331 (enhanced to 950 +/- 50°C [122°F], 3 hours)
Outer Sheath Sheath printed with number and size of conductors, IEC331, Raychem, voltage rating and EPD number
Sheath color black
Oxygen index >30% (BS2782), Temperature index > 260°C [500°F] (BS2782), Smoke index <13 (BS6883)
Toxicity Index <2 (NES713)
Temperature Rating 90°C [194°F] maximum conductor operating temperature
Voltage Rating 600/1000V
Outer Sheath Inner Sheath
Aluminized
Mylar®
Screen
Drainwire
Insulation
Mica
Based
Tape
ConductorArmor
Selection Table
FR-1000 Multitriple Control Cables,
Individually Shielded, Armored,
600/1000V*
MYLAR is a trademark of
Dupont Teijin Films U.S.
Low-Fire-Hazard Wire and Cable
9-35
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Type 99M
Applications
Type 99M wirehas a dual
wall construction of radia-
tion cross-linked modified
polyester.This combines
excellent mechanical per-
formance and chemical
resistance with a range of
enhanced firehazard
properties. Type 99M wire is
designed to meet the
stringent low firehazard
performance now being
specified by many authori-
ties, in particular for naval,
mass transit and industrial
control panel wiring.
During the 1980’sthere
were major changes in the
demands of many wire and
cable specifications to
reduce the risks associated
with all aspects of fire
hazards. Specifications
such as Def Stan 61-12
Part 18, have been devel-
oped over the last decade
demanding improved
performance of wires
and cables under fire
conditions.
This has led to a tightening
of the requirements for
flammability, smoke genera-
tion, corrosive gas genera-
tion and hazardous fume
emission. Type 99M wire
achieves these improve-
ments in performance
whilst retaining small size,
light weight, flexibility,
handleability, resistance to
carbon arc tracking and
resistance to chemicals
and fluids.
Physical Characteristics
Handleability
Type 99M wire has been
designed to be compatible
with modern wiring and
harnessing techniques.
It is a flexible wirewith virtu-
ally no springback once
set. It is easily stripped with
tools such as conventional
die-blade strippers.
Small Size
Type 99M equipment wire
has a nominal 0.2 mm insu-
lation wall thickness which
is comparable to other
established thin wall wires
such as SPEC 44 wire.
Light Weight
Type 99M wireis designed
to have the same weights
as SPEC 44 wire.
Product Facts
nLow flammability
nLow smoke generation
nLow toxicity index
nLow generation of corrosive
gases
nSmall size, lightweight
Available in: Americas Europe Asia Pacific
nnn
Low-Fire-Hazard Wire and Cable
Type 99M (Continued)
9-36 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Raychem WCD 281
Def Stan 61-12 Part 18 Issue 4 Type 1
Italian Navy STN-SR-01
Lloyds Register
99M011X (600 V) 99M021X (1000 V) 99M1111 99M1121
Size Stranding ODWeight ODWeight ODWeight ODWeight
(mm) (g/m) (g/m) (g/m) (g/m)
2619x0.10 0.88 [.035] 2.00 1.01 [.040] 2.2 1.80 [.071] 7.5 2.91 [.115] 13.3
24 19x0.12 0.98 [.039] 3.00 1.17 [.046] 3.4 1.90 [.075] 9.2 3.20 [.126] 16.6
22 19x0.15 1.13 [.044] 4.40 1.37 [.054] 4.9 2.05 [.081] 11.1 3.52 [.139] 20.5
20 19x0.20 1.40 [.055] 6.50 1.57 [.062] 7.3 2.30 [.091] 14.6 4.02 [.158] 27.7
18 19x0.25 1.65 [.065] 9.90 1.85 [.073] 10.9 2.55 [.100] 19.3 4.57 [.180] 37.1
16 19x0.30 1.90 [.075] 14.15 2.10 [.083] 14.5 2.95 [.116] 24.9 5.13 [.202] 48.5
14 37x0.25 2.25 [.089] 18.62 2.50 [.098] 21.8 3.13 [.123] 30.9 5.72 [.225] 60.5
12 37x0.32 2.60 [.102] 25.70 2.97 [.117] 31.3 3.48 [.137] 43.4 6.42 [.253] 86.0
Typical Properties
Test Method Typical value
Temperature rating BS G230 125°C [257°F]
Voltage rating Raychem 600 V thin wall
Tensile strength/elongation of insulation — 30 MPa/250%
Notch propagation (0.05 mm notch) BS G230 Pass
Shrinkage 200°C [392°F] BS G230 <1%
Low temperature bend BS G230 -55°C [-67°F]
Voltage withstand BS G230 2.5 kV
Insulation resistance (20°C [68°F]) BS G230 1000 M ohms km (min)
Pliability rating Def Stan 61-12 (18) 82 - Pliable
Fluid resistance Def Stan 61-12 (18)
Fuels - aircraft Pass
Oils - (ASTM No 3) Pass
Solvents Pass
Type 99M Wire and Cable -
Nominal Sizes, Strandings
and Weights
Primary Wires/Shielded and
Jacketed Cables - 99M
99M011X (600 V)
Primary Wire 99M021X (1000 V)
Primary Wire
99M1111
Shielded & Jacketed 99M1121
Shielded & Jacketed
Approvals
Low-Fire-Hazard Wire and Cable
Type 99M (Continued)
9-37
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Environmental Properties
Mechanical Performance
The scrape abrasion and
cut through resistance of
Type 99M wire out performs
the well-established per-
formance of SPEC 44 wire
throughout its operating
temperature range.
Fluid Resistance
Type 99M wire demon-
strates outstanding resist-
ance to most acids, alkalis,
hydrocarbon solvents, fuels,
lubricants and water.
Electrical Arc Tracking
Type 99M wire is resistant to
electrical arc tracking under
both wet and dry condi-
tions.
Voltage Ratings
Standard available voltage
ratings for Type 99M wire
are 600 V (0.2 mm wall
thickness) and 1000 V (0.3
mm wall thickness).
Fire Hazard Characteristics
Low Toxicity Index
Type 99M wire is designed
to meet the low hazardous
fume emission levels
required in modern specifi-
cations. For example, the
change in the Toxicity Index
requirement from 1.5 to 0.2
between Issue 2 and Issue
3of Def Stan 61-12 (Part
18), is met by Type 99M
wire.
Flammability
Type 99M wire has passed
some of the most stringent
flammability tests, such as
the test in IEC 332 Part 3
(ladder test) and
Underwriter’s Laboratory for
VW1 (individual wire)
Smoke Generation
Type 99M wire has been
designed to meet stringent
smoke tests such as those
specified in Def Stan 61-12
(Part 18) and in many mass
transit specifications.
Fire Hazard Properties
Test Method Typical value
Flammability IEC 332 Pt 3 Pass
Toxicity index Def Stan 61-12 (18) 0.1 per meter of wire
Smoke index Def Stan 61-12 (18) 8 per meter of wire
Acid gas equivalent TDE 76/P/76 <1.5%
Corrosivity
Type 99M wire has a low
corrosive gas emission,
demonstrated by its low
acid gas value and meets
the latest requirements of
low fire hazard specifica-
tions.
Low-Fire-Hazard Wire and Cable
Type 99M (Continued)
9-38 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Jacket Color
(in accordance with MIL-STD-681, black preferred)
Primary Wire Insulation Color
0=Black 1=Brown 2=Red 2L=Pink 3=Orange 4=Yellow
45=Yellow/Green 5=Green 6=Blue 7=Violet 8=Grey 9=White
Additional number after base color indicates stripe
Conductor Size
Conductor Type
1 - Tin-plated copper 9 - Bare copper
Number of Conductors
1, 2, 3, 4 etc.
Class of Wire
1 - 600V equipment wire
2 - 1000V equipment wire
Constructions
0 - Primary wire & unscreened, unjacketed cables
1 - Round braid screened & jacketed*
9 - Special construction
Wire Type
M - Military wire
Basic Specification Number
99 X X X X X- Size- X/X- X
Part Numbering System
*The cable jackets are Raychem Zerohal and the preferred color is black.
Low-Fire-Hazard Wire and Cable
Zerohal 100A
9-39
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
Raychem’s latest generation
LFH, thinwall wire has been
designed for use primarily
in signal, control and light
power circuits in subway,
regional and high speed
trains. It is ideal for applica-
tions wherespace and
weight are at a premium;
fire safety is important; relia-
bility is imperative; rugged
properties to withstand
service in an RMT environ-
ment are required.
The construction is a dual
wall combination of
Raychem formulated poly-
mer blends developed to
meet the specification
requirements while main-
taining the desirable fea-
tures of small size, light-
weight, flexibility,non-wrin-
kling, ease of stripping,
compatibility with standard
stripping equipment, lack of
recoil and mechanical
robustness.
Physical Characteristics
Handleability
Zerohal 100A has been
designed for minimum
recoil during harnessing
operations, to be readily
handleable by modern
wiring and harnessing tech-
niques and to be easily
stripped with standard
equipment and tools.
Conductor - tin
plated copper Insulation - dual wall
modified polymer blend
Product Facts
nHalogen free, low smoke
nHighly flame retardant
nFlexible, easy to install
nSmall size, lightweight (thin
wall construction)
Available in: Americas Europe Asia Pacific
nnn
Low-Fire-Hazard Wire and Cable
Zerohal 100A (Continued)
9-40 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Typical Properties
Test Method Typical Values
Physical Properties
Insulation Tensile Strength ASTM D3032 Tensile Strength 3500 psi minimum
and Ultimate Elongation Ultimate Elongation 250% minimum
Scrape Abrasion AAR S 501 1000 cycles minimum
Resistance (90°, 0.01 inch radial edge blade, 6N load, 20°C [68°F])
Dynamic Cut Through ASTM D3032 20 lbs. minimum
(90°, 0.01 inch radial edge blade, 0.2 inch per min, 20°C [68°F])
Static Cut-through AAR S 501 No contact with the conductor
Penetration (90°, 0.01 inch radial edge blade, 10 min, 9N load, 125°C [257°F])
Thermal Properties
Temperature Index ASTM D3032 10,000 hours minimum at 125°C [257°F]
Accelerated ageing ASTM D3032 No cracks, flow or dielectric breakdown. (168hr at 170°C [338°F])
Shrinkage IEC 811-1-3 0.5% maximum at each end. (6hr at 160°C [320°F)
Insulation Blocking MIL-W-22759E Cores must be easily separated without damage
(24hr at 125°C [257°F], 6X mandrel.)
Electrical Properties >10000 MΩkft at 20°C [68°F]
IRConstant ASTM D3032 >100 MΩkft at 60°C [140°F]
>10 MΩkft at 90°C [194°F]
Environmental Properties Fluid NATO code Temp (°C) Time (hr)
ASTM No.1 Oil — 100 70
IRM 902 Oil — 100 70
IRM 903 Oil — 100 70
70/30 iso-octane/toluene — 23 24
Engine lubricating oil O-236 70 24
Fluid Immersion ASTM D3032 Grease G-354 70 24
Hydraulic fluid, petroleum base H-515 50 24
Silicone damping fluid S-1724 70 24
Automotive brake fluid H-542 23 24
Fire resistant hydraulic fluid H-544 50 24
De-icing fluid S-745 23 24
Methyl Ethyl Ketone — 23 1
5% max swell. No dielectric breakdown. (30mm diameter mandrel)
Fire Hazard Properties
Flammability - small scale IEC 332-1 Charring confined between 50mm and 540mm from lower edge
of top support. (Single vertical wire, 60 s flame)
Flammability - large scale IEC 332-3 2.5m maximum burn length.
(Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame)
Ds1.5 of 100 max., Ds4 of 150 max.,
Smoke - small scale ISO 5659-2 Dmax of 150 max., VOF4 of 300 max.
(‘NBS’ smoke box with cone heater, 1.8m of wire
50 kW/m2 heat flux with and without a pilot flame)
90% minimum transmittance.
Smoke - large scale IEC 1034 (3m cube smoke box. Eight 1m long 7-wire bundles, horizontal.
Fire source: 1 litre burning alcohol.)
Toxicity IMO FTPC Toxicity index < 1 (Test conditions as in smoke - small scale)
Halogen Content IEC 684-2 Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis)
Copper Mirror Corrosion ASTM D2671 5% maximum etched area. (0.4g sample, 200°C [392°F], 16hr.)
Acid Gas Detection IEC 754-2 pH greater than 4.3 10 µS/mm maximum
(1g sample, tube furnace, T >935°C [1715°F], gases dissolved in water)
Ordering Information
Finished Wire
Conductor Maximum Diameter Maximum
Wire Stranding Diameter Resistance Weight Part No.
Size No x AWG Min. Max. at 20°C Min. Max. lbs/kft kg/km
AWG Dia (mm) /kft/km
24 19x36 0.550 [0.022] 0.63 [0.025] 25.7 [84.32] 1.09 [0.043] 1.19 [0.047] 2.41 [3.59] 100A0111-24-*
22 19x34 0.735 [0.029] 0.79 [0.031] 15.9 [52.2] 1.26 [0.050] 1.33 [0.052] 3.34 [4.98] 100A0111-22*
20 19x32 0.940 [0.037] 1.01 [0.040] 9.9 [32.4] 1.46 [0.057] 1.54 [0.061] 4.98 [7.42] 100A0111-20*
18 19x30 1.170 [0.046] 1.26 [0.050] 6.2 [20.4] 1.69 [0.067] 1.79 [0.071] 7.31 [10.89] 100A0111-18*
16 19x29 1.321 [0.052] 1.37 [0.054] 4.8 [15.8] 1.84 [0.072] 1.94 [0.076] 9.19 [13.70] 100A0111-16*
14 19x27 1.650 [0.065] 1.79 [0.070] 3.1 [10.0] 2.27 [0.089] 2.39 [0.094] 14.45 [21.53] 100A0111-14*
12 37x28 2.080 [0.082] 2.24 [0.088] 2.0 [6.63] 2.71 [0.107] 2.86 [0.113] 21.03 [31.33] 100A0111-12*
10 37x26 2.690 [0.106] 2.83 [0.111] 1.3 [4.13] 3.33 [0.131] 3.51 [0.138] 33.27 [49.58] 100A0111-10*
Low-Fire-Hazard Wire and Cable
Zerohal 100A (Continued)
9-41
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Fire Hazard Properties
Test Method Typical Value
Flammability - small scale IEC 332-1 Charring confined between 50mm and 540mm from lower edge
oftop support. (Single vertical wire, 60 s flame)
Flammability - large scale IEC 332-3 2.5m maximum burn length.
(Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame)
Flammability IEEE 383 Pass
Ds1.5 of 100 max., Ds4 of 150 max.,
Smoke - small scale ISO 5659-2 Dmax of 150 max., VOF4 of 300 max.
(‘NBS’ smoke box with cone heater, 1.8m of wire
50kW/m2 heat flux with and without a pilot flame)
Smoke density - Ds4 (Max.)
Smoke - small scale ASTM E662 Flaming - 200
Non-Flaming - 75
Toxicity IMO FTPC Toxicity index < 1 (Test conditions as in smoke - small scale)
Halogen Content IEC 684-2 Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis)
Copper Mirror Corrosion ASTM D2671 5% maximum etched area. (0.4g sample, 200°C [392°F], 16hr.)
Acid Gas Detection IEC 754-2 pH greater than 4.3 10 µS/mm maximum
(1g sample, tube furnace, T >935°C[715°F], gases dissolved in water)
Environmental Properties
Fluid Resistance
Zerohal 100A wire demon-
strates an outstanding
balance of resistance to a
wide range of commonly
used solvents, fluids and
lubricants.
Voltage Rating
Zerohal 100A wire is a 600
volt rated wire.
Fire Hazard Characteristics
Zerohal 100A is a halogen
free insulation system and
does not contain phospho-
rus or sulphur. It meets the
toxicity, smoke density,
halogen content, corrosivity
and flammability require-
ments of major recognized
agencies.
Flammability
Zerohal 100A meets the
flammability/burning behav-
ior requirements of major
recognized agencies.
Primary Wire Insulation Color
0 - Black 4 - Yellow 8 - Gray
1 - Brown 5 - Green 9 - White
2 - Red 6- Blue
3 - Orange 7- Violet
Conductor Size
Conductor Type
1 - Tin-plated copper
Number of Conductors
1 to 9
Class of Wire
1 - 600 V equipment wire
Construction
0 - Primary wire and unscreened, unjacketed cables
1 - Roundbraid, screened and jacketed
4 - Jacketed, no screen
Wire Type
A-AWG construction (US Specification)
Basic Specification Number
100 A X X X X- Size- X
Part Numbering System
Low-Fire-Hazard Wire and Cable
Zerohal 100G
9-42 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Zerohal 100G wire has been
developed to meet the
requirements of German
Specification VG 95218-20,
Type E primarywire.
The construction is a dual
wall combination of
Raychem formulated
polymer blends developed
to meet the specification
requirements while
maintaining the desirable
features of small size, light-
weight, flexibility, non-
wrinkling, ease of stripping,
compatibility with standard
stripping equipment, lack
of recoil and mechanical
robustness.
System
nSystem 100
Physical Characteristics
Handleability
Zerohal 100G wire has
been designed for minimum
recoil during harnessing
operations, to be readily
handleable by modern
wiring and harnessing
techniques and to be
easily stripped with
standard equipment and
tools.
Conductor - tin
plated copper Insulation - dual wall
modified polymer blend
Product Facts
nQualified to VG 95218-20,
Type E
nHalogen free, low smoke
nHighly flame retardant
nFlexible, easy to install
nSmall size, lightweight (thin
wall construction)
Available in: Americas Europe Asia Pacific
nnn
Low-Fire-Hazard Wire and Cable
Zerohal 100G (Continued)
9-43
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
VG 95218-20, Type E (Electrical cables and insulated wires for low frequency
-Part 20: Single core insulated wires.)
Test Method Typical Value
Max. operating temperature VG 95218-20, ASTM D 3032 125°C [257°F] (20,000 h)
Insulation shrinkage (160°C) DIN VDE 0472 Pt 628, <0.5%
IEC 811-1-3
Low temperature bend VG 95218 - Pt 2 -55°C [-67 °F]
Pressure test at high temperature DIN VDE 0472 Pt 609, 125°C [257°F] < 30% indentation
IEC 811-3-1
Heat aging (150°C, 6 h) DIN VDE 0472 Pt 303, No cracking, no dielectric
(140°C, 120 h) IEC 811-1-2 breakdown
Voltage rating VG 95218-20 750/1300 V AC
Abrasion resistance VG 95218 - Pt 2 Pass
Insulation blocking (125°C) VG 95218 - Pt 2 Pass
Voltage withstand DIN VDE 0472 pt 509 Pass
(23°C, 2.5 kV rms)
Insulation resistance DIN VDE 0472 pt 502, > 500 M ohms. km (20°C [68°F])
IEC 885-1 > 0.5 M ohms. km (90°C [194°F])
Chemical resistance
Grease VG 95218 - Pt 2, 70°C 24h <5% diameter change,
(G-354)* no dielectric breakdown
Hydraulic fluid VG95218 - Pt 2, 50°C 24h <5% diameter change,
(H-515, H-544)* no dielectric breakdown
Brake fluid VG95218 - Pt 2, 23°C 24h <5% diameter change,
(H-542)* no dielectric breakdown
De-icing fluid VG 95218 - Pt 2, 23°C24h <5% diameter change,
(S-745)* no dielectric breakdown
MEK VG 95218 - Pt 2, 23°C 1h <5% diameter change,
no dielectric breakdown
70/30 ISO-Octane/ VG 95218 - Pt 2, 23°C 24h <5% diameter change,
Toluene no dielectric breakdown
Insulation
Tensile strength DIN VDE 0472 pt 602, >20 MPa
IEC 811-1-1
Elongation at break DIN VDE 0472 pt 602, >200%
IEC 811-1-1
*NATO code. For further details please consult the German Standard VG 95218-20, Type E.
Approvals
Typical Properties
Primary Wire Insulation Color
0 - Black 3 - Orange 7 - Violet
1 - Brown 4 - Yellow 8 - Gray
2 - Red 5 - Green 9 - White
2L - Pink 6 - Blue
NB. VG 95218 T020-EXXX wire only available in colors 0, 1, 45, 6, 9
Conductor Size
Conductor Type
1 - Tin-plated copper
Number of Conductors
1
Class of Wire
1 - 750 V equipment wire
Construction
0 - Primary wire
Wire Type
G - Meeting the performance requirements of German
Specification VG 95218-20, Type E
Basic Specification Number
100 G X X X X- Size- X
Part Numbering System
Low-Fire-Hazard Wire and Cable
Zerohal 100G (Continued)
9-44 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Fire Hazard Properties
Test Method Typical value
Toxicity NES 713 3.5
Smoke density IEC 1034 Pt 1 and 2 95% light transmittance
Halogen content DIN VDE 0472 pt 815 Non-detected
Corrosivity of combustion gases DIN VDE 0472 pt 813, 5.0 pH, <4 µS/mm
IEC 754-2 conductivity
Flammability VG 95218 Pt 2 <15 sec afterburn
<150 mm burn length
Environmental Properties
Fluid Resistance
Zerohal 100G wire demon-
strates an outstanding bal-
ance of resistance to a wide
range of commonly used
solvents, fluids and lubri-
cants.
Voltage Rating
Zerohal 100G wire is a
750/1300 V AC rated wire.
Fire Hazard Characteristics
Zerohal 100G is a halogen
free insulation system and
does not contain phospho-
rus or sulphur. It meets the
toxicity, smoke density,
halogen content, corrosivity
and flammability require-
ments of VG 95218-20,
Type E.
Flammability
Zerohal 100G meets the
flammability/burning behav-
ior requirements of VG
95218-20, Type E.
Ordering Information
Conductor Insulated Wire
Nominal Stranding Diameter Maximum Diameter Maximum
Cross No x nom Resistance Weight VG 95218
Sectional Dia (mm) min. max. at 20°C min. max. g/m Part No. Part No.
Area ohms/km
mm2
0.40 19x0.16 0.74 [.029] 0.79 [.031] 50.50 1.28 [.050] 1.39 [.055] 5.17 VG 95218 T020-E02* 100G0111-0.40-*
0.50 19x0.18 0.82 [.032] 0.90 [.035] 40.10 1.37 [.054] 1.47 [.058] 6.60 VG 95218 T020-E03* 100G0111-0.50-*
0.60 19x0.20 0.95 [.037] 1.01 [.040] 31.10 1.47 [.058] 1.57 [.062] 7.54 VG 95218 T020-E04* 100G0111-0.60-*
0.75 19x0.23 1.04 [.041] 1.15 [.045] 26.70 1.59 [.063] 1.70 [.067] 8.90 VG 95218 T020-E05* 100G0111-0.75-*
1.00 19x0.25 1.17 [.046] 1.26 [.050] 20.00 1.69 [.067] 1.80 [.071] 10.73 VG 95218 T020-E06* 100G0111-1.00-*
1.20 19x0.29 1.32 [.052] 1.42 [.056] 15.30 1.88 [.074] 1.98 [.078] 13.59 VG 95218 T020-E07* 100G0111-1.20-*
1.50 37x0.23 1.46 [.057] 1.58 [.062] 13.70 2.03 [.080] 2.13 [.084] 15.96 VG 95218 T020-E08* 100G0111-1.50-*
2.00 37x0.25 1.68 [.066] 1.82 [.072] 10.50 2.31 [.091] 2.41 [.095] 20.29 VG 95218 T020-E09* 100G0111-2.00-*
2.50 37x0.29 1.85 [.073] 2.01 [.079] 8.21 2.48 [.098] 2.63 [.104] 25.65 VG 95218 T020-E10* 100G0111-2.50-*
3.00 37x0.32 2.12 [.083] 2.24 [.088] 6.58 2.70 [.106] 2.86 [.113] 31.00 VG 95218 T020-E11* 100G0111-3.00-*
4.00 56x0.30 2.41 [.095] 2.56 [.101] 4.86 3.01 [.119] 3.16 [.124] 43.48 — 100G0111-4.00-*
The VG 95218-20, Type E specification defines that the insulation color shall be black, brown, yellow/green, blue or white only.
To ensure full compliance with the specification, order the VG 95218 part number complete with color code.
Raychem Type 100G wire, meeting the performance requirements of VG 95218-20, Type E, is available in other colors (see part numbering system). To order
these colors, order the Raychem 100G part number.
*Color code in accordance with part number system.
Commercial Wire Family
FlexLite
9-45
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Selection Guide
Application Temperature Rating (°C/°F) Features and Benefits Product Name
nInsulation that does not melt and flow at
Intermittent-duty motors -45°Cto 125°C high temperatures FlexLite DW
and heating elements -49°F to 257°F nExcellent chemical resistance
nVW-1
Electronics, appliance, and -55°Cto 135°C nSmall size, light weight FlexLite TW
motor applications -67°F to 275°F nNo plasticizers or corrosive outgassing
General purpose -55°C to 150°C nGood mechanical and shop handling characteristics FlexLite MT
appliance wire -67°F to 302°F nVW-1
nExcellent chemical resistance
nInsulation does not melt and flow at high temperature
Lighting, motor applications -55°C to 200°C nVW-1 FlexLite HT
-67°F to 392°F nExcellent shop handling
nNo cold-flow problems
nVery high temperature
Lighting, appliances, motors -65°Cto 250°C nVW-1 FlexLite TX
-85°F to 482°F nSuperb chemical resistance
nExcellent shop handling
Primary Wire
Temperature Voltage AWG
Product UL Style Rating Rating Range Part Description
FlexLite DW 3584 125°C [257°F] 600 volts 4–28 FLDWX031X
FlexLite TW 10208 135°C [275°F] 600 volts 10–32 FLTWX031X
FlexLite MT 10916 150°C [302°F] 600 volts 6–26 FLMTX031X
FlexLite HT 3557 200°C [392°F] 600 volts 6–26 FLHTX031X
FlexLite TX 10297 250°C [482°F] 600 volts 4–28 FLTXX031X
Note: Additional UL-recognized cable constructions are available. Please contact Tyco Electronics for details.
UL Marking and Labeling
All FlexLite products are UL
labeled and reel marked.
UL surface marking is
additional. Please contact
Tyco Electronics for further
information.
FlexLite/UL Style
Cross-Reference
Available in:
Americas n
Europe n
Asia Pacific n
Commercial Wire Family
FlexLite (Continued)
9-46 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
FL XX X X X X X - Size - X/X - X
Basic Product Number
Product Type (UL Style - Temperature Rating)
DW - UL Style 3584 - 125˚C
TW - UL Style 10208 - 135˚C
MT - UL Style 10916 - 150˚C
HT - UL Style 3557 - 200˚C
TX - UL Style 10297 - 250˚C
Conductor Stranding
A - Solid
B-7strand
C-19 strand
D - 37 strand
E - Rope Lay
Number of Conductors
1 through 10 (designator for 10 conductor = 0)
Conductor Size (AWG) or (Metric)
Jacket Color (code per MIL-STD-681)
(codes same as for Primary Wire Insulation Color)
Construction
0 - Primary wire; or unshielded & unjacketed cable
1 - Round braid shielded & jacketed cable*
6 - Special constructions
Class of Wire
1 - 150 volt
2 - 300 volt
3 - 600 volt
Conductor Type
1 - Tin-coated copper
2 - Silver-coated copper
3 - Nickel coated copper
9 - Bare copper
Primary Wire Insulation Color (code per MIL-STD-681)
0 - Black 3-Orange 6 - Blue 9 - White
1 - Brown 4 - Yellow 7- Violet
2 - Red 5 - Green 8 - Gray
*Shield coating same as conductor coating
Part Numbering System
Typical ordering example 19 strand, 20 AWG tin-coated copper, two component, shielded and jacketed cable, 600 volt, blue and white
components, white jacket; part number FLDWC1321-20-6/9-9.
Ordering information For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part
numbering descriptions above DO NOT apply. Please contact Tyco Electronics for further information.
Commercial Wire Family
FlexLite DW
9-47
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Dual-Wall Primary Wire
Applications
FlexLite DW (FLDW) offers
ahigh-performance
non melting insulation
suitable for a variety of
applications, especially
those with occasional high-
temperature excursions,
such as high-power battery-
operated devices or
intermittent-duty motors or
heating elements.
Primary insulation
Radiation-crosslinked,
extruded polyalkene
Conductor
Tin-coated
copper
Jacket
Radiation-crosslinked,
modified PVDF
Specifications/Approvals
Series UL CUR CSA Raychem
Style 3584
DW Flammability VW-1 Recognized Certified AWMIA WCD-3106
Temperature rating 125°C [257°F]
Product Facts
nUL rated operating
temperature to 125°C
[257°F]
nNon melting insulation
material
nThin-wall product for size
and weight savings
nExcellent chemical
resistance
nDual-wall construction for
increased mechanical
performance
nCompatibility with
automated stripping
equipment
nVariety of colors and
constructions
Available in: Americas Europe Asia Pacific
nnn
Commercial Wire Family
FlexLite DW (Continued)
9-48 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Construction Details
Finished Wire
Wire Conductor Nominal Maximum Diameter Nominal
Part No. Size Stranding Diameter Resistance Minimum Nominal Maximum Weight in
(AWG) (No. x AWG) mm [inch] at 20°C (68°F) mm [inch] mm [inch] mm [inch] kg/km
Ω/km [Ω/1000 ft] [lb/1000 ft]
FLDWC0311-26-* 26 19 x 38 .470 [.0185] 132 [40.1] .965 [.038] 1.02 [.040] 1.07 [.042] 2.38 [1.6]
FLDWC0311-24-* 24 19 x 36 .597 [.0235] 83.3 [25.4] 1.12 [.044] 1.17 [.046] 1.22 [.048] 3.57 [2.4]
FLDWC0311-22-* 22 19 x 34 .749 [.0295] 52.2 [15.9] 1.32 [.052] 1.37 [.054] 1.42 [.056] 5.21 [3.5]
FLDWC0311-20-* 20 19 x 32 .953 [.0375] 32.0 [9.76] 1.52 [.060] 1.57 [.062] 1.63 [.064] 7.59 [5.1]
FLDWC0311-18-* 18 19 x 30 1.18 [.0465] 20.4 [6.22] 1.78 [.070] 1.85 [.073] 1.93 [.076] 11.46 [7.7]
FLDWC0311-16-* 16 19 x 29 1.33 [.0525] 15.8 [4.82] 1.98 [.078] 2.06 [.081] 2.13 [.084] 14.58 [9.8]
FLDWC0311-14-* 14 19 x 27 1.68 [.0660] 10.0 [3.05] 2.39 [.094] 2.49 [.098] 2.59 [.102] 21.88 [14.7]
FLDWD0311-12-* 12 37 x 28 2.16 [.0850] 6.59 [2.01] 2.87 [.113] 2.97 [.117] 3.07 [.121] 32.89 [22.1]
*Replace asterisk with color code designator:
0=Black 3 = Orange 7 = Violet
1 = Brown 4 = Yellow 8 = Gray
2=Red 5 = Green 9 = White
For example: FLDWC0311-20-9 = AWG 20, white.
Construction Details
Finished Wire
Nominal Wire Conductor Diameter Maximum Diameter Nominal
CSA Size Stranding (min.) (max.) Resistance Lower Target Upper Weight in
Part No. (mm2) (No. x Dia.) at 20°C (68°F) Spec. Limit Value Spec. Limit kg/km
mm [inch] mm [inch] Ω/km [Ω/1000 ft] mm [inch] mm [inch] mm [inch] [lb/1000 ft]
FLDWC0311-0.25* 0.25 19 x 0.127 0.55 [.022] 0.63 [.025] 83.6 [25.5] 1.12 [.044] 1.17 [.046] 1.22 [.048] 3.77 [2.53]
FLDWC0311-0.35* 0.35 19 x 0.15 0.72 [.028] 0.77 [.030] 56.1 [17.1] 1.31 [.052] 1.37 [.054] 1.42 [.056] 5.17 [3.46]
FLDWC0311-0.50* 0.50 19 x 0.19 0.86 [.034] 0.88 [.035] 40.1 [12.2] 1.46 [.057] 1.51 [.059] 1.56 [.061] 6.92 [4.64]
FLDWC0311-0.75* 0.75 19 x 0.23 1.05 [.041] 1.08 [.043] 24.7 [7.53] 1.65 [.065] 1.70 [.067] 1.75 [.069] 9.53 [6.39]
FLDWC0311-1.00* 1.00 19 x 0.25 1.17 [.046] 1.26 [.050] 20.0 [6.1] 1.78 [.070] 1.85 [.073] 1.93 [.076] 11.88 [7.96]
FLDWC0311-1.50* 1.50 19 x 0.32 1.46 [.057] 1.51 [.059] 13.7 [4.2] 2.21 [.095] 2.28 [.090] 2.36 [.093] 17.88 [11.98]
*Replace asterisk with color code designator:
0=Black 3 = Orange 6 = Blue 9 = White
1 = Brown 4 = Yellow 7 = Violet
2=Red 5 = Green 8 = Gray
For example: FLDWC0311-20-9 = AWG 20, white.
FLDWC0311-1.00-9 = Size 1.00 mm2,white.
For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part numbering
descriptions above DO NOT apply. Please contact Tyco Electronics for further information.
Commercial Wire Family
FlexLite TW
9-49
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
FlexLite TW (FLTW) wire
is commonly used in
applications that demand
smaller, more rugged
components, often in
elevated temperatures.
Designed to offer reduced
size while maintaining
superior mechanical
performance, FLTW in
many cases is a lower-cost
solution than expensive
fluoropolymer wire.
Conductor
Tin-coated copper
Insulation
Modified polyester
Thin-Wall Hookup
Wire and Cable
Product Facts
nUL rated operating
temperature to 135°C
[275°F]
nThin-wall product for size
and weight savings
nTough insulation material
nExcellent chemical
resistance
nGauge sizes from 10-32
AWG
nNo plasticizers or corrosive
outgassing, which can be
detrimental to sensitive
electrical and electronic
components
Available in: Americas Europe Asia Pacific
nnn
Commercial Wire Family
FlexLite TW (Continued)
9-50 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Series UL CUR CSA Raychem
TWStyle 10208 Recognized Certified WCD-3106
Temperature rating 135°C AWMIA
[275°F]
Construction Details
Finished Wire
Wire Conductor Nominal Maximum Diameter Nominal
Part No. Size Stranding Diameter Resistance Minimum Nominal Maximum Weight in
(AWG) (No. x AWG) at 20°C (68°F) mm [inch] mm [inch] mm [inch] kg/km
mm[inch] Ω/km [Ω/1000 ft] [lb/1000 ft]
FLTWC0311-26-* 26 19 x 38 .470 [.0185] 132 [40.1] .813 [.032] .864 [.034] .914 [.036] 1.93 [1.3]
FLTWC0311-24-* 24 19 x 36 .597 [.0235] 83.3 [25.4] .965 [.038] 1.02 [.040] 1.07 [.042] 2.83 [1.9]
FLTWC0311-22-* 22 19 x 34 .749 [.0295] 52.2 [15.9] 1.14 [.045] 1.19 [.047] 1.24 [.049] 4.17 [2.8]
FLTWC0311-20-* 20 19 x 32 .953 [.0375] 32.0 [9.76] 1.35 [.053] 1.40 [.055] 1.45 [.057] 6.25 [4.2]
FLTWC0311-18-* 1819 x 30 1.18 [.0465] 20.4 [6.22] 1.60 [.063] 1.65 [.065] 1.70 [.067] 9.52 [6.4]
FLTWC0311-16-* 16 19 x 29 1.33 [.0525] 15.8 [4.82] 1.75 [.069] 1.83 [.072] 1.91 [.075] 12.20 [8.2]
FLTWC0311-14-* 14 19 x 27 1.68 [.0660] 10.0 [3.05] 2.16 [.085] 2.26 [.089] 2.36 [.093] 18.90 [12.7]
FLTWD0311-12-* 12 37 x 28 2.16 [.0850] 6.59 [2.01] 2.64 [.104] 2.74 [.108] 2.84 [.112] 28.87 [19.4]
*Replace asterisk with color code designator:
0=Black 3 = Orange 6 = Blue 9 = White
1 = Brown 4 = Yellow 7 = Violet
2=Red 5=Green 8=Gray
For example: FLTWC0311-22-9 = AWG 22, white.
Specifications/Approvals
For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part numbering
descriptions above DO NOT apply. Please contact Tyco Electronics for further information.
Commercial Wire Family
FlexLite MT
9-51
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Medium Temperature
Hookup Wire
Applications
FlexLite MT is a general
purpose wirefor appliance,
electronics, and electrical
equipment that require
150°C [302°F] and 600 V
ratings.
Product Facts
nUL rated operating
temperature to 150°C
[302°F]
nThin-wall, for size and
weight savings
nTough fluoropolymer
insulation material
nExcellent stripping and
handling
nVariety of constructions and
colors
nVW-1 flammability rating
n600 V rating
Insulation
Modified ETFE
Conductor
Tin-coated
copper
Available in: Americas Europe Asia Pacific
nnn
Commercial Wire Family
FlexLite MT (Continued)
9-52 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Construction Details
Finished wire
Wire Conductor Maximum Diameter Nominal
Part No. Size Stranding Nominal Resistance Minimum Nominal Maximum Weight in
(AWG) (No. x AWG) Diameter at 20°C (68°F) mm [inch] mm [inch] mm [inch] kg/km
mm [inch] Ω/km [Ω/1000 ft] [lb/1000 ft]
FLMTC0311-26-* 26 19 x 38 .470 [.0185] 150 [45.8] .765 [.030] .800 [.032] .836 [.034] 1.89 [1.29]
FLMTC0311-24-* 24 19 x 36 .597 [.0235] 94.2 [28.7] .892 [.035] .927 [.037] .963 [.039] 2.75 [1.88]
FLMTC0311-22-* 22 19 x 34 .749 [.0295] 59.4 [18.1] 1.04 [.041] 1.08 [.043] 1.12 [.045] 4.08 [2.75]
FLMTC0311-20-* 20 19 x 32 .953 [.0375] 37.4 [11.4] 1.25 [.049] 1.28 [.051] 1.32 [.053] 6.21 [4.17]
FLMTC0311-18-* 18 19 x 30 1.18 [.0465] 23.5 [7.15] 1.52 [.060] 1.56 [.062] 1.61 [.064] 9.66 [6.49]
*Replace asterisk with color code designator:
0=Black 3 = Orange 6 = Blue 9 = White
1 = Brown 4 = Yellow 7 = Violet
2=Red 5 = Green 8 = Gray
For example: FLMTC0311-18-9 = AWG 18, white.
Series UL CUR Raychem
MTStyle 10916
Flammability VW-1 Recognized WCD-3106
Temperature rating 150°C
[302°F]
Specifications/Approvals
For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part numbering
descriptions above DO NOT apply. Please contact Tyco Electronics for further information.
Commercial Wire Family
FlexLite HT
9-53
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
High-Temperature
Hookup Wire
Applications
FlexLite HT (FLHT) wire
is the product of choice
for high-temperature
applications. It offers
shop-handling advantages
over silicone/ fiberglass
constructions (SF1/SF2)
and is cost-competitive with
other fluoropolymer wire.
Applications include
halogen lights and small
high-end appliances
wherespace and
temperature are issues.
Insulation
Radiation-crosslinked,
modified ETFE
Conductor
Tin-coated
copper
Product Facts
nUL rated operating
temperature to 200°C
[392°F]
nExceptional chemical
resistance
nThin-wall, for size and
weight savings
nTough fluoropolymer
insulation material
nExcellent stripping and
handling
nVariety of constructions and
colors
nCrosslinked to minimize cold
flow
nVW-1 flammability rating
n600 V rating
Available in: Americas Europe Asia Pacific
nnn
Commercial Wire Family
FlexLite HT (Continued)
9-54 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Construction Details Finished Wire
Wire Conductor Nominal Maximum Diameter Nominal
Part No. Size Stranding Diameter Resistance Minimum Nominal Maximum Weight in
(AWG) (No. x AWG) mm [inch] at 20°C (68°F) kg/km
Ω/km [Ω/1000 ft] mm [inch] mm [inch] mm [inch] [lb/1000 ft]
FLHTC0311-26-* 26 19 x 38 .470 [.0185] 132 [40.1] .765 [.0301] .800 [.0315] .836 [.0329] 1.89 [1.27]
FLHTC0311-24-* 24 19 x 36 .597 [.0235] 83.3 [25.4] .892 [.0351] .927 [.0365] .963 [.0379] 2.75 [1.85]
FLHTC0311-22-* 22 19 x 34 .749 [.0295] 52.2 [15.9] 1.04 [.0411] 1.08 [.0425] 1.12 [.0439] 4.08 [2.74]
FLHTC0311-20-* 20 19 x 32 .953 [.0375] 32.0 [9.76] 1.25 [.0491] 1.28 [.0505] 1.32 [.0519] 6.21 [4.17]
FLHTC0311-18-* 18 19 x 30 1.18 [.0465] 20.4 [6.22] 1.48 [.0583] 1.52 [.0600] 1.57 [.0617] 9.43 [6.34]
FLHTC0311-16-* 16 19 x 29 1.33 [.0525] 15.8 [4.82] 1.67 [.0656] 1.71 [.0675] 1.76 [.0694] 12.0 [8.09]
FLHTC0311-14-* 14 19 x 27 1.68 [.0660] 10.0 [3.05] 2.03 [.0799] 2.08 [.0820] 2.14 [.0841] 18.6 [12.5]
FLHTD0311-12-* 12 37 x 28 2.16 [.0850] 6.59 [2.01] 2.50 [.0984] 2.57 [.1010] 2.63 [.1036] 28.7 [19.3]
Construction Details
Finished Wire
Nominal Conductor Diameter Maximum Diameter Nominal
Part No. CSA Stranding Resistance Lower Target Upper Weight
(mm2) No/Dia. (min.) (max.) at 20°C(68°F) Spec. Limit Value Spec. Limit (kg/km)
(mm) mm [inch] mm [inch] (ohms/km) mm [inch] mm [inch] mm [inch]
FLHTC0311-0.25-* 0.25 19/0.127 0.55 [.022] 0.63 [.025] 84.3 0.96 [.038] 1.00 [.039] 1.03 [.041] 2.95
FLHTC0311-0.35-* 0.35 19/0.15 0.74 [.029] 0.76 [.030] 56.1 1.12 [.044] 1.16 [.046] 1.19 [.047] 4.22
FLHTC0311-0.50-* 0.50 19/0.19 0.86 [.034] 0.88 [.035] 40.1 1.24 [.049] 1.27 [.050] 1.31 [.052] 5.59
FLHTC0311-0.75-* 0.75 19/0.23 1.05 [.041] 1.08 [.043] 24.7 1.43 [.056] 1.47 [.058] 1.51 [.059] 7.95
FLHTC0311-1.00-* 1.00 19/0.25 1.17 [.046] 1.26 [.050] 20.0 1.58 [.062] 1.62 [.064] 1.66 [.065] 9.85
FLHTC0311-1.50-* 1.50 19/0.32 1.35 [.053] 1.58 [.062] 13.7 1.82 [.072] 1.87 [.074] 1.92 [.076] 15.69
FLHTC0311-2.00-* 2.00 19/0.36 1.66 [.065] 1.79 [.070] 9.7 2.05 [.081] 2.10 [.083] 2.16 [.085] 18.67
FLHTC0311-2.50- 2.50 19/0.41 1.85 [.073] 2.01 [.080] 8.2 2.24 [.088] 2.31 [.091] 2.38 [.094] 24.62
*Replace asterisk with color code designator:
0=Black 3 = Orange 6 = Blue 9 = White
1 = Brown 4 = Yellow 7 = Violet
2=Red 5 = Green 8 = Gray
For example: FLHTC0311-22-9 = AWG 22, white.
FLHTC0311-0.50-9 = Size 0.50mm2,white.
Series UL CUR CSA Raychem
Style 3557
HT Flammability VW-1 Recognized Certified AWMIA/B WCD-3106
Temperature rating 200°C
[392°F]
Specifications/Approvals
For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part numbering
descriptions above DO NOT apply. Please contact Tyco Electronics for further information.
Commercial Wire Family
FlexLite TX
9-55
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
FlexLite TX wire is a UL
recognized hookup wire for
lighting fixtures, appliance,
wiring and industrial appli-
cations requiring a 250°C
[482°F] rated wire.
Insulation
Modified
fluoropolymer
Conductor
Nickel-coated
copper
Product Facts
nUL rated operating
temperature -65°C to 250°C
[-85°F to 482°F]
nUL Style 10297
n600 V rating
nClear legible wire marking
nExcellent fluid resistance
nExcellent handling
characteristics
Ultrahigh-Temperature
Hookup Wire
Available in: Americas Europe Asia Pacific
nnn
Commercial Wire Family
FlexLite TX (Continued)
9-56 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Construction Details Finished Wire
Wire Conductor Nominal Maximum Diameter Nominal
Part No. Size Stranding Diameter Resistance Minimum Nominal Maximum Weight in
(AWG) (No. x AWG) at 20°C (68°F) mm[inch] mm [inch] mm [inch] kg/km
mm [inch] Ω/km [Ω/1000 ft] [lb/1000 ft]
FLTXB0313-28-* 28 7 x 36 .368 [.0145] 224 [68.2] .940 [.037) .991 [.039) 1.04 [.041) 2.20 [1.48]
FLTXC0313-26-* 26 19 x 38 .470 [.0185] 132 [40.1] 1.04 [.041] 1.09 [.043] 1.14 [.045] 2.96 [1.99]
FLTXC0313-24-* 24 19 x 36 .597 [.0235] 83.3 [25.4] 1.17 [.046] 1.22 [.048] 1.27 [.050] 3.97 [2.67]
FLTXC0313-22-* 22 19 x 34 .749 [.0295] 52.2 [15.9] 1.30 [.051] 1.37 [.054] 1.45 [.057] 5.46 [3.67]
FLTXC0313-20-* 20 19 x 32 .953 [.0375] 32.0 [9.76] 1.50 [.059] 1.57 [.062] 1.65 [.065] 7.84 [5.27]
FLTXC0313-18-* 18 19 x 30 1.18 [.0465] 20.4 [6.22] 1.73 [.068] 1.80 [.071] 1.88 [.074] 11.3 [7.60]
FLTXC0313-16-* 16 19 x 29 1.33 [.0525] 15.8 [4.82] 1.88 [.074] 1.96 [.077] 2.03 [.080] 13.9 [9.32]
FLTXC0313-14-* 14 19 x 27 1.68 [.0660] 10.0 [3.05] 2.18 [.086] 2.29 [.090] 2.39 [.094] 20.5 [13.8]
FLTXD0313-12-* 12 37 x 28 2.16 [.0850] 6.59 [2.01] 2.67 [.105] 2.77 [.109] 2.87 [.113] 30.8 [20.7]
FLTXD0313-10-* 10 37 x 26 2.72 [.1070] 4.13 [1.26] 3.23 [.127] 3.33 [.131] 3.43 [.135] 48.1 [32.3]
*Replace asterisk with color code designator:
0=Black 3=Orange 6=Blue 9=White
1 = Brown 4 = Yellow 7 = Violet
2=Red 5=Green 8=Gray
For example: FLTXC0313-18-9 = AWG 18, white.
Series UL CUR CSA Raychem
TX Style 10297 Recognized AWMIA/B WCD-3106
Flammability VW-1
Temperature Rating 250°C
[482°F]
Specifications/Approvals
For product requiring CUR (Canadian UL) or CSA marking in 14-10 AWG, 19 strand conductors only, the part numbering
descriptions above DO NOT apply. Please contact Tyco Electronics logistics for further information.
Commercial Wire Family
FLT
9-57
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
FLT dual-wall wire combines
flexibility with tough thin wall
insulation to enable bundles
to be routed through areas
in which conventional wires
cannot be used. Typical
applications include control
panels, instruments, lighting
equipment, electrical
appliances, electric motors,
electric pumps, robotics,
and the automotive
industries.
Flexible, Double Insulated,
High Performance Wire for
aWide Range of Industrial
Applications
Product Facts
nHighly flame retardant/non
melting
nLimited fire hazard
n600V rated
nExcellent fluid resistance
nFlexible
nDouble insulation (for Class
2equipment)
nTough, thin wall
nSmall size, light weight
Available in: Americas Europe Asia Pacific
n
Commercial Wire Family
FLT (Continued)
9-58 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Small Size
FLT equipment wire 600 volt
rated has a 0.20 mm nominal
wall thickness compared to
0.25mm and 0.38mm for
equivalent PTFE and PVC
wires in MIL-W-16878,
MIL-W-22759 or BS3G210.
Light Weight
Due to the thin wall and low
density of the insulation
materials, considerable
weight savings aremade
over similarly rated
PTFE wires.
For Example: FLT0111 -
0.35 equipment wire4.38
grams/meter max.
22 AWG PTFE equipment
wire MIL-W-22759 5.54
grams/meter max.
General Handling
The flexibility of FLT and
the ease with which it takes
a‘set’ makes it one of the
easiest of the ‘high perform-
ance’ wires to install.
Stripping is done with
conventional die blade
UL Styles 1385
CSA Class 5851
IEC 332-1
Standard Colors
Color Black Brown Red Orange Yellow
Code 0 1 2 3 4
Color Green Blue Violet Grey White
Code 5 6 7 8 9
Temperature rated (Tin-plated conductor) -65°C to +150°C [-85°F to +302°F]
Rated at 125°C [257°F] In UL style sheet 1385
Voltage rating 600V
No Voltage rating specified In UL style sheet 1385
Tensile strength + elongation of insulation 30 N/mm 2 , 230%
Notch propagation BS 3G230 0.05 mm notch Pass
Meets BS4066/IEC332-1 Flammability test Pass
Solder iron resistance (370°C [698°F], 1 minute) Pass
Shrinkage @ +150°C[+302°F] < 1%
Low temperature bend -65°C [-85°F]
strippers. For details of
appropriate tools see sepa-
rate wirehandling guide.
The tin-plated copper con-
ductor usually specified is
easily soldered or crimped.
Lengths
FLT is available in long
continuous lengths and
can be supplied for use on
automatic cut and strip
preparation machines.
Physical Characteristics
Approvals
Typical Properties
Commercial Wire Family
FLT (Continued)
9-59
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Environmental Performance
Temperature Rating
FLT wire is rated for continu-
ous operation from -65°C
to+125°C [-85°F to +257°F]
and for short periods at
much higher temperatures.
Mechanical Performance
Radiation crosslinking of the
FLT insulation significantly
improves the following
mechanical characteristics;
scrape (sharp edges),
cut-through resistance and
creep resistance.
Solder Iron/Overload
Resistance
Radiation crosslinking
ensures that the insulation
does not melt at high
temperature. As a result
FLT wire is resistant to hot
solder irons and current
overloads which would
melt most thermoplastic
insulations.
Flexible, Double Insulated,
High Performance Wire for
aWide Range of Industrial
Applications
Finished Wire
Nominal Conductor Conductor Maximum Diameter Nominal
CSA Stranding Diameter Resistance Weight Ordering
mm 2No/Dia @20°C(68°F) kg/km Description
mm min. max. ohms/km min. max.
0.25 19/0.127 0.55 [.022] 0.63 [.025] 83.6 0.91 [.036] 1.04 [.041] 2.96 FLT011X-0.25-Y
0.35 19/0.15 0.70 [.028] 0.80 [.031] 56.1 1.06 [.042] 1.21 [.048] 4.14 FLT011X-0.35-Y
0.50 19/0.19 0.82 [.032] 0.90 [.035] 40.1 1.18 [.046] 1.31 [.052] 6.63 FLT011X-0.50-Y
0.75 19/0.23 1.05 [.041] 1.15 [.045] 24.7 1.41 [.056] 1.56 [.061] 8.20 FLT011X-0.75-Y
1.00 19/0.25 1.17 [.046] 1.26 [.050] 20.0 1.55 [.061] 1.70 [.067] 10.86 FLT011X-1.00-Y
1.50 19/0.32 1.35 [.053] 1.60 [.063] 13.7 1.73 [.068] 2.06 [.081] 16.47 FLT011X-1.50-Y
2.00 19/0.36 1.66 [.065] 1.85 [.073] 9.9 2.12 [.083] 2.38 [.093] 20.32 FLT011X-2.00-Y
2.50 19/0.41 1.85 [.073] 2.05 [.081] 8.2 2.31 [.091] 2.61 [.103] 26.56 FLT011X-2.50-Y
Note: X = Conductor Type 1 = Tin Plated Copper 9 = Bare Copper
Y = Color (see color code on page 9-58)
Conductor -
Tin plated Copper
or Bare Copper
Primar y Insulation -
Radiation Crosslinked Modified Polyolefin
Jacket -
Radiation Crosslinked
Modified (PVDF)
Ordering Information
mm [inch] mm [inch] mm [inch] mm [inch]
Thermocouple Extension Cables
Thermocouple Extension Cable
9-60 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Tyco Electronics
manufactures a broad
range of Raychem
Thermocouple extension
cables in four thermoele-
ment combinations. Each
provides accurate
transmission of electro-
motive force (EMF) from a
Thermocouple element lead
wireof the same conductor
material to a thermometer,
also known as a pyrometer.
All four types of
Thermocouple extension
cables use 19-strand con-
ductors and are available in
twisted pair,jacketed
twisted pair,and shielded
Product Facts
n19-strand conductor for
flexibility
and jacketed twisted pair
configurations. A range of
cables is available from 16
AWG to 24 AWG.
Wires and cables are
insulated and jacketed
with radiation-crosslinked
ETFE, which has a
continuous operating
temperatureof -65°C to
+200°C [-85°F to +392°F].
This material, which is fully
specified in Raychem
SPEC 55, has excellent
physical properties and is
highly resistant to a wide
range of chemicals.
Operating Temperature Range
-65°C to 200°C
[-85°F to 392°F]
Available in: Americas Europe Asia Pacific
nnn
Thermocouple Extension Cables
Thermocouple Extension Cable (Continued)
9-61
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Properties
Initial Calibration Tolerances for Thermocouple Extension Wires
Extension Thermoelement EMF (mv)*
Cable Type Combination Temperature Range Limit of Range (min.–max.)
EX Chromel-Constantan 0°C to 200°C [0°F to 392°F] ±1.7°C [35.1°F] 6.18–6.45
JX Iron-Constantan 0°C to 200°C [0°F to 392°F] ±2.2°C [36.0°F] 5.15–5.39
KX Chromel-Alumel 0°C to 200°C [0°F to 392°F] ±2.2°C [36.0°F] 4.00–4.19
TX Copper-Constantan 0°C to 100°C [0°F to 212°F] ±1.0°C [32.0°F] 4.24–4.32
Note: The above is in accordance with ANSI-MC-96.1-1982.
*EMF is measured in millivolts (mv) at 100°C [212°F] with reference junction at 0°C [0°F].
Twisted Pair Twisted, Shielded, 38 AWG
AWG Twisted, Jacketed Pair Braid Strand, Jacketed Pair
Size Outside Weight Outside Weight Outside Weight
Diameter in kg/km Diameter inkg/km Diameter inkg/km
(lb/1000 ft) (lb/1000 ft) (lb/1000 ft)
24 2.29 [.090] 7.3 [4.9] 2.67 [.106] 9.9 [6.7] 3.12 [.123] 16.5 [11.1]
22 2.60 [.102] 9.9 [6.7] 2.99 [.118] 13.0 [8.8] 3.43 [.135] 21.4 [14.4]
20 2.99 [.118] 14.4 [9.7] 3.40 [.134] 18.0 [12.1] 3.83 [.151] 27.8 [18.7]
18 3.56 [.140] 20.9 [14.1] 3.96 [.156] 25.1 [16.9] 4.34 [.173] 37.5 [25.2]
16 3.96 [.156] 26.3 [17.7] 4.37 [.172] 30.9 [20.8] 4.80 [.189] 44.9 [30.2]
**Dimensions for 19-strand-conductor thermocouple. Extension Types EX, JX, KX, and TX.
Product Dimensions**
(Nominal)
Extension Cable
Jacket Color code
Type EX Chromel + Constantan - (if present) Wire Jacket
ANSI-MC-96.1 Violet Red Violet 7/2 7
British Std.-BS 1843 Brown Blue Brown 1/6 1
JIS-C-1602 Violet Red Violet 7/2 7
Type JX Iron + Constantan - Jacket Wire Jacket
MIL-STD-687 Black Yellow White 0/4 9
ANSI-MC-96.1 White Red Black 9/2 0
British Std.-BS 1843 Yellow Blue Black 4/6 0
JIS-C-1602 Red White Yellow 2/9 4
Type KX Chromel + Alumel - Jacket Wire Jacket
MIL-STD-687 White Green White 9/5 9
ANSI-MC-96.1 Yellow Red Yellow 4/2 4
British Std.-BS 1843 Brown Blue Red 1/6 2
JIS-C-1602 Red White Blue 2/9 6
Type TX Copper + Constantan - Jacket Wire Jacket
MIL-STD-687 Red Yellow White 2/4 9
ANSI-MC-96.1 Blue Red Blue 6/2 6
British Std.-BS 1843 White Blue Blue 9/6 6
JIS-C-1602 Red White Brown 2/9 1
Color-Coding
Thermocouple extension
cables areavailable with the
wires color-coded in accor-
dance with four standards:
MIL-STD-687, ANSI-MC-
96.1, British Standard Code
BS 1843, and Japanese
JIS-C-1602.
Special Cables
Thermocouple extension
cables arealso available in
solid-conductor and seven-
strand-conductor configura-
tions. They come in a
variety of thermoelement
combinations, gauges,
Extension Cable insulations, and multiple-
pair designs, and they are
available for outer space
applications. Contact
Tyco Electronics for details.
Thermocouple Extension Cables
Thermocouple Extension Cable (Continued)
9-62 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
The Thermocouple cable
options outlined in the table
onthe previous page can
be ordered from the table
below.
Tyco Electronics will assign
anew part number on
request for cables falling
outside the range shown in
the table.
Twisted, Twisted, Shielded,
Type Twisted Pair Jacketed Pair Shield Plating* Jacketed Pair
EX CTC-0077 CTC-0079 TCTC-0074
N 55A6169
JX 55A8131 CTC-0080 TCTC-0044
T CTC-0018
KX 55A8002 CTC-0012 N CTC-0015
S CTC-0057
TX CTC-0078 CTC-0081 T CTC-0073
*T =Tin-coated copper.
N=Nickel-coated copper.
S=Silver-coated copper.
Part Number
Selection Table
Controlled Electrical Cables
ElectroLoss Filterline
9-63
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Lightweight, Ruggedized
Filterline Wire and Cable
Applications
Today’s performance needs
for military and commercial
electronic systems require
increasingly sophisticated
equipment and greater use
of composite structures and
enclosures. As electronics
become moresensitive,
the EMI protection level for
electrical equipment is
increasing. The Raychem
ElectroLoss FilterLine wire
and cable provide a high
degree of EMI protection
while functioning as con-
ventional electrical wiring.
ElectroLoss FilterLine
products include high-
performance wire and
cable, which when used
as specified, suppress
conducted and radiated
EMI above 100 MHz.
A reliable alternative to
conventional discrete filters
and filter-pin connectors,
ElectroLoss FilterLine
cables areflexible, light-
weight, and compatible with
high-density connectors.
The Raychem ElectroLoss
FilterLine wire and cable
meets the performance
requirements of MIL-C-
85485, a military specifica-
tion developed to provide
EMI protection for military
electrical interconnects.
The absorptive layer in
ElectroLoss FilterLine cable
is constructed of a ferrite-
loaded high-temperature
polymer,which provides
high-frequency EMI
absorptive characteristics.
Achieving maximum attenu-
ation requires concentrating
the electromagnetic fields
Radiation-crosslinked,
modified ETFE
Radiation-crosslinked,
modified, conductive
ETFE
Radiation-crosslinked,
modified ETFE
Absorptive layerConductor
S
Radiation-crosslinked
PVDF
Radiation-crosslinked
PVDF
Radiation-crosslinked,
modified ETFE
Absorptive layerConductor
Radiation-crosslinked,
modified, conductive
ETFE
Radiation-crosslinked,
modified ETFE
Absorptive layerConductor
Shield
Radiation-crosslinked
PVDF
Radiation-crosslinked
PVDF
55FA0511 55FB1511
Product Facts
nSuppresses EMI above 100
MHz
nLight weight, small size
nSPEC 55 insulation
n600 volt
n-65°C to 150°C †
[-85°F to 302°F]
†-65°C to 200°C [-85°F to 392°F]
also available
†-65°C to 200°C [-85°F to 392°F] also available.
in the absorptive layer —
either with a metallic shield
on each wire or by an over-
all metallic shield protecting
abundle of individual
component wires.
Radiation-crosslinked,
modified conductive EFTE
jackets are used over
shielded filter line cables
to eliminate pathways
between adjacent cable
shields.
Application-driven alterna-
tive ElectroLoss FilterLine
constructions built to the
same rigorous standards
demanded of the MIL SPEC
products are also available.
These alternatives offer
significant weight savings
through the use of flat
braids, improved laser mark
contrast, and a broader
choice of conductors.
Available in:
Americas n
Europe n
Asia Pacific n
Controlled Electrical Cables
ElectroLoss Filterline (Continued)
9-64 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Performance
Effective against conducted
EMI ElectroLoss FilterLine
wire and cable systems
attenuate high-frequency
EMI and allow low frequency
signals to pass with mini-
mum loss. When properly
installed and used, filter line
wire and cables function
aslow-pass electrical
filters, attenuating both
conducted and radiated
EMI above 100MHz. The
performance of ElectroLoss
FilterLine product is best
demonstrated by measuring
the attenuation (insertion
loss) of a length of cable
over a broad range of
frequencies. Graph 1
depicts typical insertion
loss characteristics.
200
180
160
140
120
100
80
60
40
20
010 100 1000
1.2m
0.6m
0.3m
Attenuation
55FB1511-22 Frequency (MHz)
2 ft
1 ft
4 ft
Graph 1 - Typical insertion loss
Temperature rating -65°C to +150°C † [-85°F to302°F]
Voltage rating 600V r.m.s
†-65°C to 200°C [-85°F to 392°F] also available
Controlled Electrical Cables
ElectroLoss Filterline (Continued)
9-65
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Lightweight, Ruggedized
Filterline Wire and Cable
Conductor Maximum Maximum MIL-SPEC Raychem
AWG Stranding Outside Weight Part Part
Size (Number x AWG) Diameter mm (in) Kg/Km (Ib/1000 ft) Number Number
19 x 36 silver coated
24 high strength 1.19 [.047] 4.46 [3.0] M85485/10-24A 55FA0514-24-*
copper alloy
2219 x 34 tin coated 1.37 [.054] 5.95 [4.0] M85485/9-22A 55FA0511-22-*
copper
20 19 x 32 tin coated 1.57 [.062] 8.63 [5.8] M85485/9-20A 55FA0511-20-*
copper
18 19 x 30 tin coated 1.85 [.073] 12.95 [8.7] M85485/9-18A 55FA0511-18-*
copper
1619 x 29 tin coated 2.08 [.082] 16.67 [11.2] M85485/9-16A 55FA0511-16-*
copper
14 19 x 27 tin coated 2.51 [.099] 23.96 [16.1] M85485/9-14A 55FA0511-14-*
copper
1237 x 28 tin coated 2.95 [.116] 35.71 [24.0] M85485/9-12A 55FA0511-12-*
copper
10 37 x 26 tin coated 3.58 [.141] 55.06 [37.0] M85485/9-10A 55FA0511-10-*
copper
Single Conductor Wire
Specifications
*The color of component wire shall be light violet designated by 7L.
The designated colors for components in finished cable shall be light violet
for component 1 and light violet with stripe designators for remaining
component wires as follows:
Component wire 1 2 3 4 5
Color designator 7L 7L6 7L3 7L5 7L2
Controlled Electrical Cables
ElectroLoss Filterline (Continued)
9-66 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Maximum Maximum MIL-SPEC Raychem
AWG Number of Outside Weight Part Part
Size Conductor Diameter Kg/Km (Ib/1000 ft) Number Number.
24 22.39 [.094] 9.08 [6.1] M85485/11-24M2A 55FA0524-24-*
22 22.74 [.108] 12.20 [8.2] M85485/11-22T2A 55FA0521-22-*
2023.15 [.124] 17.56 [11.8] M85485/11-20T2A 55FA0521-20-*
1823.71 [.146] 26.34 [17.7] M85485/11-18T2A 55FA0521-18-*
1624.17 [.164] 33.93 [22.8] M85485/11-16T2A 55FA0521-16-*
1425.03 [.198] 48.81 [32.8] M85485/11-14T2A 55FA0521-14-*
2432.59 [.102] 13.69 [9.2] M85485/11-24M3A 55FA0534-24-*
2232.97 [.117] 18.15 [12.2] M85485/11-22T3A 55FA0531-22-*
2033.40 [.134] 26.34 [17.7] M85485/11-20T3A 55FA0531-20-*
1834.01 [.158] 39.58 [26.6] M85485/11-18T3A 55FA0531-18-*
16 34.50 [.177] 51.03 [34.3] M85485/11-16T3A 55FA0531-16-*
14 35.44 [.214] 73.36 [49.3] M85485/11-14T3A 55FA0531-14-*
2443.28 [.129] 18.15 [12.2] M85485/11-24M4A 55FA0544-24-*
2243.78 [.149] 24.25 [16.3] M85485/11-22T4A 55FA0541-22-*
20 44.34[.171] 35.27 [23.7] M85485/11-20T4A 55FA0541-20-*
18 45.11 [.201] 52.82 [35.5] M85485/11-18T4A 55FA0541-18-*
16 45.74 [.226] 68.00 [45.7] M85485/11-16T4A 55FA0541-16-*
14 46.91 [.272] 97.76 [65.7] M85485/11-14T4A 55FA0541-14-*
24 53.58 [.141] 22.77 [15.3] M85485/11-24M5A 55FA0554-24-*
22 54.11 [.162] 30.36 [20.4] M85485/11-22T5A 55FA0551-22-*
20 54.72 [.186] 44.04 [29.6] M85485/11-20T5A 55FA0551-20-*
18 55.56 [.219] 66.07 [44.4] M85485/11-18T5A 55FA0551-18-*
16 56.25 [.246] 84.96 [57.1] M85485/11-16T5A 55FA0551-16-*
14 57.54 [.297] 122.16 [82.1] M85485/11-14T5A 55FA0551-14-*
*The color of component wire shall be light violet designated by 7L.
The designated colors for components in finished cable shall be light violet
for component 1 and light violet with stripe designators for remaining
component wires as follows:
Component wire 1 2 3 4 5
Color designator 7L 7L6 7L3 7L5 7L2
Unshielded, Unjacketed 2-5
Conductor Cable
Specifications
Controlled Electrical Cables
ElectroLoss Filterline (Continued)
9-67
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Lightweight, Ruggedized
Filterline Wire and Cable
Shield Size
AWG Number of AWG Maximum Maximum MIL-SPEC Raychem
Size Conductors Tin Coated Outside Weight Part Part Number
Copper Diameter mm (in) Kg/Km (Ib/1000 ft) Number
24138 2.13 [.084] 10.86 [7.3] M85485/12-24U1A 55FB1514-24-*
22138 2.31 [.091] 13.09 [8.8] M85485/12-22T1A 55FB1511-22-*
20138 2.51 [.099] 16.67 [11.2] M85485/12-20T1A 55FB1511-20-*
18138 2.79 [.110] 22.17 [14.9] M85485/12-18T1A 55FB1511-18-*
16138 3.02 [.119] 26.78 [18.0] M85485/12-16T1A 55FB1511-16-*
14 138 3.45 [.136] 35.86 [24.1] M85485/12-14T1A 55FB1511-14-*
12 1 38 3.89 [.153] 49.40 [33.2] M85485/12-12T1A 55FB1511-12-*
10 138 4.55 [.179] 71.57 [48.1] M85485/12-10T1A 55FB1511-10-*
24 238 3.33 [.131] 19.34 [13.0] M85485/12-24U2A 55FB1524-24-*
22 238 3.68 [.145] 23.81 [16.0] M85485/12-22T2A 55FB1521-22-*
20 238 4.09 [.161] 30.50 [20.5] M85485/12-20T2A 55FB1521-20-*
18 238 4.65 [.183] 41.37 [27.8] M85485/12-18T2A 55FB1521-18-*
16 238 5.11 [.201] 50.59 [34.0] M85485/12-16T2A 55FB1521-16-*
14 238 6.02 [.237] 69.49 [46.7] M85485/12-14T2A 55FB1521-14-*
24 338 3.53 [.139] 25.30 [17.0] M85485/12-24U3A 55FB1534-24-*
22 338 3.91 [.154] 31.10 [20.9] M85485/12-22T3A 55FB1531-22-*
20 338 4.34 [.171] 41.07 [27.6] M85485/12-20T3A 55FB1531-20-*
18 338 4.95 [.195] 56.54 [38.0] M85485/12-18T3A 55FB1531-18-*
16 338 5.44 [.214] 69.94 [47.0] M85485/12-16T3A 55FB1531-16-*
14 338 6.43 [.253] 96.87 [65.1] M85485/12-14T3A 55FB1531-14-*
24 438 4.19 [.165] 31.69 [21.3] M85485/12-24U4A 55FB1544-24-*
22 438 4.67 [.184] 39.58 [26.6] M85485/12-22T4A 55FB1541-22-*
20 438 5.23 [.206] 52.68 [35.4] M85485/12-20T4A 55FB1541-20-*
18 438 5.99 [.236] 72.91 [49.0] M85485/12-18T4A 55FB1541-18-*
16 438 6.68 [.263] 91.36 [61.4] M85485/12-16T4A 55FB1541-16-*
14 438 7.85 [.309] 125.59 [84.4] M85485/12-14T4A 55FB1541-14-*
24 538 4.52 [.178] 37.80 [25.4] M85485/12-24U5A 55FB1554-24-*
22 5 38 5.05 [.199] 47.32 [31.8] M85485/12-22T5A 55FB1551-22-*
20 538 5.66 [.223] 63.39 [42.6] M85485/12-20T5A 55FB1551-20-*
18 538 6.55 [.258] 89.43 [60.1] M85485/12-18T5A 55FB1551-18-*
16 5 38 7.24 [.285] 111.00 [74.6] M85485/12-16T5A 55FB1551-16-*
14 538 8.53 [.336] 153.26 [103.0] M85485/12-14T5A 55FB1551-14-*
Fluid Resistance Hydrocarbons
Fuels and lubricants
Alcohols
Fluids Cleaning fluids
Glycols
Synthetic fuels and lubricants
Ketones
Shielded, Jacketed 1-5
Conductor Cable
Specifications
Electroloss Filterline Wire and
Cable Light Weight
Ruggedized Constructions
*The color of component wire shall be light violet designated by 7L.
The designated colors for components in finished cable shall be light violet
for component 1 and light violet with stripe designators for remaining
component wires as follows:
Component wire 1 2 3 4 5
Color designator 7L 7L6 7L3 7L5 7L2
Controlled Electrical Cables
Cheminax Coaxial Cables
9-68 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Small, Lightweight Coaxial
Cables
Applications
Cheminax controlled electri-
cal cables are used in the
aircraft and aerospace
industries. They have a
wide range of applications
in missiles, avionics, radio-
frequency and microwave
systems, computers, secu-
rity and surveillance sys-
tems, and communications.
Cheminax coaxial cables
were designed to solve
interconnect problems in
electronic systems, such as
computers, militaryequip-
ment, and other areas of
high-density packing,
wherecables are required
to performto moreexacting
specifications than standard
radio-grade (RG) or UL rec-
ognized (UR) constructions.
Tyco Electronics’ advanced
materials technology has
allowed the design and
development of Raychem
DCBA
A Conductor
B Dielectric
CShield
D Jacket
Product Facts
nLight weight, small size
nTemperature range of
-65°C to 200°C
[-85°F to 392°F]
nLow capacitance and
attenuation
nHigh velocity of propagation
nHigh flexibility
Cheminax miniature coaxial
cables that offer substantial
savings in size and weight
while improving mechanical
performance and reducing
attenuation.
Cables can be designed
that are either smaller and
lighter than standardRG
and UR cables or provide
significantly lower attenua-
tion and capacitance with no
significant increase in size.
Available in: Americas Europe Asia Pacific
nnn
Controlled Electrical Cables
Cheminax Coaxial Cables (Continued)
9-69
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Jacket Color Identification Code
0 - Black 4 - Yellow 8 - Gray
1 - Brown 5 - Green 9 - White
2 - Red 6 - Blue 9X - Translucent White
3 - Orange 7 - Violet X - Clear
Conductor Type
1 - Tin-coated copper
2 - Silver-coated copper
3 - Nickel-coated copper
4 - Silver-coated high strength copper alloy
5 - Aluminum
6 - Nickel-coated high strength copper alloy
7 - Tin-coated copper-clad steel
8 - Silver-coated copper-clad steel
9 - Bare copper
0 - Other
A - Silver-coated CS95
Dielectric Material
1 - Rayfoam L (Polyethylene) 6 - Modified XL-ETFE (SPEC 55)
2 - Rayfoam H (Foamed FEP) 7- Flex XL-ETFE
3-Rayolin F (Solid) 8 - Rayfoam M (Foamed MFA)
4 - Modified FEP (Solid) 0 - Other
Outer Jacket Material
1 - General purpose PVF² 6 - Modified XL-ETFE (SPEC 55)
2 - Outerspace PVF² 7 - Flex XL-ETFE (SPEC 80)
3 - Thermorad F & S 8 - Zerohal & Thermorad Low Smoke
4 - Modified FEP 9 - None
5 - ETFE (Uncrosslinked) 0- Other
Construction
1-Round braid 6 - Triax - other
2 - Flat braid 7 - Other
3 - 2 round braids 8 - Composite shield
4 - 2 shields (other) 9 - Core only
5-Triax-round braids 0 - Other
Variation
A - Standard U - Low Loss
B - Low Noise W - Waterblocked
C-Z - Sequential within any PNs S - Outer Space Requirements
Conductor Size (AWG)
Always 2 digits - 0X if under 10 AWG
Impedance
Always 2 digits - last 2 digits if over 100 ohms
0X(1 digit) if under 10 ohms
XX XX X X X X X - X
95 27 A 1 3 1 7 - 0 Example: 9527A1317-0
Part Numbering System
Controlled Electrical Cables
Cheminax Coaxial Cables (Continued)
9-70 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Dimensions (Nominal)
Attenuation A B C D
Typical Impedance Capacitance at 400 MHz Conductor Dielectric Shield Jacket Weight in
Product (ohms) pF/m dB/100m Diameter Diameter Diameter Diameter kg/km
Part No. (pF/ft) (dB/100 ft) (lb/1000ft)
5012E1339 50 98.4 [30.0] 14.8 [4.5] 2.26 [.089] 7.24 [.285] 7.98 [.314] 10.24 [.403] 162.2 [109.0]
5012M1612 50 82.0 [25.0] 16.1 [4.9] 2.26 [.089] 6.07 [.239] 6.60 [.260] 7.06 [.278] 74.5 [50.1]
5024A1311 50 83.7 [25.5] 50.3 [15.3] 0.62 [.025] 1.70 [.067] 2.18 [.085] 2.67 [.104] 11.8 [7.9]
5026D1027 50 88.9 [27.1] 63.7 [19.4] 0.48 [.019] 1.27 [.050] 1.70 [.067] 2.21 [.087] 11.8 [7.9]
5030A1317 50 90.2 [27.5] 97.5 [29.7] 0.30 [.012] 0.79 [.031] 1.12 [.044] 1.57 [.062] 4.5 [3.0]
5030A1424 50 100.4 [30.6] 94.5 [28.8] 0.30 [.012] 0.86 [.034] 1.19 [.047] 1.60 [.063] 5.7 [3.8]
7520A1311 75 56.1 [17.1] 20.0 [6.1] 1.02 [.040] 4.57 [.180] 5.11 [.201] 6.12 [.241] 43.2 [29.0]
7524A1311 75 56.4 [17.2] 31.8 [9.7] 0.62 [.025] 2.82 [.111] 3.25 [.128] 3.86 [.152] 19.2 [12.9]
7528H1424 75 54.5 [16.6] 44.0 [13.4] 0.32 [.013] 1.37 [.054] 1.73 [.068] 2.13 [.084] 8.9 [6.0]
7530A1317 75 60.4 [18.3] 58.8 [17.9] 0.30 [.012] 1.35 [.053] 1.78 [.07] 2.29 [.09] 8.3 [5.6]
7530H1424 75 57.4 [17.5] 58.1 [17.7] 0.30 [.012] 1.30 [.051] 1.73 [.068] 2.03 [.08] 8.5 [5.7]
9522A1311 95 44.3 [13.5] 19.7 [6.0] 0.79 [.031] 5.51 [.217] 6.05 [.238] 7.32 [.288] 55.1 [37.0]
9527J1528 9544.3 [13.5] 31.8 [9.7] 0.43 [.017] 2.84 [.112] 3.18 [.125] 3.58 [.141] 19.2 [12.9]
9530H1014 95 44.3 [13.5] 44.3 [13.5] 0.30 [.012] 1.83 [.072] 2.26 [.089] 2.62 [.103] 13.1 [8.8]
Note: All values are nominal.
General Conductor Range 12 AWG to 30 AWG
Operating Temperature Range* -65°C to 200°C [-85°Fto 392°F]
Impedance range 50 ohms to 125 ohms
Electrical Dielectric constant 1.65–2.3
Velocity of propagation 67%–80%
*Temperature rating varies depending on materials used in specific construction.
Series Raychem
Cheminax cables 1200
Specifications/Approvals
Product Characteristics
Small, Lightweight Coaxial
Cables
Properties (per SCD)
Typical Value of Dielectric Material
Physical Rayfoam L Rayfoam H Rayolin F
Tensile (min.) 6.8 MPa 4.1 MPa 12.2 MPa
(1000 psi) (600 psi) (1800 psi)
Elongation (min.) 50% 50% 200%
Electrical
Dielectric withstand (min.) 1000 V 1000 V 1000 V
Velocity of propagation (nom.) 78% 78% 67%
Dielectric constant 1.65 1.65 2.2
Type Value of Jacket Material
Physical Thermorad SPEC 55 FlexLine FEP Zerohal SPEC 44
Tensile (min.) 13.6 MPa 34 MPa 20.4 MPa 13.6 MPa 8.2 MPa 27.2 MPa
(2000 psi) (5000 psi) (3000 psi) (2000 psi) (1200 psi) (2500 psi)
Elongation (min.) 250% 50% 100% 200% 150% 150%
Temperature (max.) 125°C 200°C 200°C 200°C 125°C 150°C
[257°F] [392°F] [392°F] [392°F] [257°F] [302°F]
Flammability* Method C Method B Method B Method B Method B Method B
Fluid category* CAAAC
*See Raychem specification WCD-1200 for details.
Controlled Electrical Cables
Cheminax — High Performance Alternatives to Standard Cables
9-71
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Raychem Alternatives to RG Cables
Raychem
RG/U Alternative Comments
45020A3311-0 Small/light
5018D3311-0 Improved electricals
5 5018D3311-0 Small/light
8 5012E1339-0 Dimensionally similar
11 7518A1311-0 Small/light
29 5020A1311-0 Small/light
31 5012E1339-0 Dimensionally similar
55 5020A3311-0 Small/light
5018D3311-0 Improved electricals
5021D1331-0 Dimensionally similar
58 5020A1311-0 Small/light
5018A1311-0 Improved electricals
7523D1331-0 Dimensionally similar
59 7524A1311-0 Small/light
7520A1311-0 Improved electricals
62 9524A1311-0 Small/light
63 2524A1311-0 Small/light
87 5012A3311-0 Small/light
89 5012A3311-0 Small/light
115 5012A3311-0 Small/light
122 5020A1311-0 Improved electricals
124 7524A1311-0 Small/light
133 9524A1311-0 Small/light
140 7524A1311-0 Small/light
141 5020A1311-0 Small/light
142 5019D3318-0 Small/light
5018D3311-0 Improved electricals
144 7518A1311-0 Small/light
149 7518A1311-0 Small/light
Raychem
RG/U Alternative Comments
159 5020A1311-0 Small/light
174 5026A1311-0 Small/light
5024A1311-0 Improved electricals
178 5030A1317-0 Small/light
5028A1317-0 Improved electricals
179 7530A1317-0 Small/light
7528A1317-0 Improved electricals
180 9530E1014-0 Small/light
9527A1318-9 Improved electricals
188 5026A1311-0 Small/light
5024A1311-0 Improved electricals
210 9524A1311-0 Small/light
213 5012E1339-0 Dimensionally similar
214 5012A3311-0 Small/light
223 5019D3318-0 Small/light
5018D3311-0 Improved electricals
225 5012A3311-0 Small/light
235 5012A3311-0 Small/light
279 7524A1311-0 Dimensionally similar
282 5024A1311-0 Small/light
302 7524A1311-0 Small/light
303 5020A1311-0 Small/light
304 5018A1311-0 Small/light
316 5026A1311-0 Small/light
5024A1311-0 Improved electricals
393 5012A3311-0 Small/light
400 5020A3311-0 Small/light
5018D3311-0 Improved electricals
403 5030A5314-0 Small/light
Note: To complement the mechanical and electrical features of Cheminax miniature coax cable, Tyco Electronics offers Raychem SolderSleeve, SolderTacts,
and PinPak termination devices and RF connector devices. Controlled electrical cables and components are available for data bus systems.
Controlled Electrical Cables
Cheminax — High Performance Alternatives to Standard Cables (Continued)
9-72 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Raychem Alternatives to UR Cables
Raychem
UR Alternative Comments
43 5020A1311-0 Small/light
57 7518A1311-0 Small/light
65 7518A1311-0 Small/light
67 5012E1339-0 Dimensionally similar
70 7524A1311-0 Small/light
72 5020A1311-0 Small/light
76 5020A1311-0 Small/light
84 7524A1311-0 Small/light
90 7522A1311-0 Small/light
95 5026A1311-0 Small/light
96 9524A1311-0 Dimensionally similar
102 5012E1339-0 Dimensionally similar
104 7522A1311-0 Small/light
105 7518A1311-0 Small/light
106 7222A1311-0 Small/light
107 5012E1339-0 Small/light
108 5020A1311-0 Small/light
109 5026A1311-0 Small/light
110 5030A1317-0 Small/light
111 7530A1317-0 Small/light
112 5012A3311-0 Small/light
113 7518A1311-0 Small/light
116 5026A1311-0 Small/light
117 7524A1311-0 Small/light
200 7524A1311-0 Dimensionally similar
201 7522A1311-0 Dimensionally similar
202 7522A1311-0 Dimensionally similar
203 7520A1311-0 Small/light
204 7518A1311-0 Dimensionally similar
205 7518A1311-0 Dimensionally similar
207 7524A1311-0 Small/light
208 7524A1311-0 Small/light
210 7524A1311-0 Small/light
301 5020A1311-0 Small/light
306 7524A1311-0 Small/light
Note: To complement the mechanical and electrical features of Cheminax
miniature coax cable, Tyco Electronics offers Raychem SolderSleeve,
SolderTacts, and PinPak termination devices and RF connector devices.
Controlled electrical cables and components are available for data bus
systems. For further information see the Electrical Interconnect Products
section of this catalog.
Controlled Electrical Cables
Cheminax Twin Axial Cable
9-73
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Small, Lightweight Twin
Axial Cables
Applications
These small, lightweight
cables arespecially
designed for use in
MIL-STD-1553 data bus
applications. Raychem
materials technology allows
the design and construction
of cables that meet rigorous
electrical and environmental
performance requirements
while minimizing size and
weight.
DCBA
A Conductor
B Dielectric
C Shield
DJacket
Product Facts
nLight weight, small size
nTemperature range of
-65°C to 200°C
[-85°F to 392°F]
nLow capacitance
nHigh data rates
nExcellent shop handling
Available in: Americas Europe Asia Pacific
nnn
Cheminax twin axial cables
provide elegant solutions to
an increasing range of data
bus and multiplex signal
transmission applications.
Cheminax Twin Axial Cable (Continued)
Product Dimensions*
Typical ABCDWeight in
Product Impedance Capacitance Conductor Dielectric Shield Jacket kg/km
Part No. (ohms) pF/m(pF/ft) Diameter Diameter Diameter Diameter (lb/1000ft)
5024A1661 50 104.7 [31.9] .64 [.025] 0.89 [.035] 2.21 [.087] 2.62 [.103] 14.4 [9.7]
5026A1664 50 136.2 [41.5] .48 [.019] 0.66 [.026] 1.75 [.069] 2.16 [.085] 10.0 [6.7]
7520A1662 75 74.2 [22.6] 1.02 [.040] 2.03 [.080] 4.60 [.181] 5.05 [.199] 42.9 [28.8]
7526J1660 75 88.6 [27.0] .48 [.019] 0.99 [.039] 2.41 [.095] 2.82 [.111] 14.9 [10.0]
7820D0331 78 67.3 [20.5] 1.02 [.040] 2.11 [.083] 4.75 [.187] 5.72 [.225] 46.9 [31.5]
7824E0422 78 55.1 [16.8] .64 [.025] 1.19 [.047] 2.82 [.111] 3.33 [.131] 19.6 [13.2]
0022E0311 100 49.2 [15.0] .79 [.031] 1.98 [.078] 4.39 [.173] 5.16 [.203] 30.5 [20.5]
0024A0024 100 44.3 [13.5] .64 [.025] 1.30 [.051] 3.02 [.119] 3.63 [.143] 25.1 [16.9]
0026A0024 100 44.0 [13.4] .48 [.019] 1.14 [.045] 2.72 [.107] 3.23 [.127] 18.7 [12.6]
2524H0524 125 39.4 [12.0] .64 [.025] 1.83 [.072] 4.09 [.161] 4.50 [.177] 25.3 [17.7]
2526E1114 125 36.1 [11.0] .48 [.019] 1.40 [.055] 3.33 [.131] 3.73 [.147] 21.7 [14.6]
2530A0314 125 39.4 [12.0] .30 [.012] 0.86 [.034] 2.16 [.085] 2.67 [.105] 10.6 [7.1]
10595-24 7091.9 [28.0] .64 [.025] 1.19 [.047] 2.82 [.111] 3.23 [.127] 17.9 [12.0]
10606-26 75 91.9 [28.0] .53 [.021] 0.99 [.039] 2.41 [.095] 2.82 [.111] 13.4 [9.0]
10612-24 77 91.9 [28.0] .64 [.025] 1.22 [.048] 2.90 [.114] 3.30 [.130] 23.7 [15.9]
10613-24 77 91.9 [28.0] .64 [.025] 1.22 [.048] 3.33 [.131] 3.73 [.147] 39.0 [26.2]
10614-24 77 91.9 [28.0] .64 [.025] 1.22 [.048] 3.73 [.147] 4.09 [.161] 40.3 [27.1]
*All dimensions are nominal.
Specifications/Approvals
Small, Lightweight Twin
Axial Cables Product Characteristics
General Conductor range 20 AWG to 30 AWG
Operating temperature range* -65°C to 200°C [-85°F to 392°F]
Electrical Impedance range 50 ohms to 125 ohms
Capacitance range 30 pF/ft to 10 pF/ft
*Temperature rating varies depending on materials used in specific construction.
Properties (per SCD)
Typical Value of Dielectric Material
Physical Radiation-Crosslinked
Rayfoam L Rayfoam H Rayolin F FEP (solid) XL ETFE
Tensile (min.) 6.8 MPa 9.1 MPa 12.2 MPa 6.8 MPa 34 MPa
(1000 psi) (600 psi) (1800 psi) (1000 psi) (5000 psi)
Elongation (min.) 50% 50% 200% 150% 50%
Electrical
Dielectric withstand (min.) 1000 V 1000 V 1000 V 1000 V 1000 V
Velocity of propagation (nom.) 78% 78% 67% 69% 61%
Permittivity (nom.) 1.65 1.65 2.2 2.1 2.7
Typical Value of Jacket Material
Physical Thermorad SPEC 55 FlexLine FEP Zerohal SPEC 44
Tensile (min.) 13.6 MPa 34 MPa 20.4 MPa 13.6 MPa 8.2 MPa 27.2 MPa
(2000 psi) (5000 psi) (3000 psi) (2000 psi) (1200 psi) (2500 psi)
Elongation (min.) 250% 50% 100% 200% 150% 150%
Temperature (max.) 125°C 200°C 200°C 200°C 125°C 150°C
[257°F] [392°F] [392°F] [392°F] [257°F] [302°F]
Flammability** Method C Method B Method B Method B Method B Method B
Fluid category** C A A A C B
*See Raychem specification WCD-1200 for details.
Series Raychem
Cheminax cables 1200
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9-74
Controlled Electrical Cables
Multiconductor (Multicore) Cables
Custom-designed and standard Multiconductor (Multicore) Cables
9-75
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Tyco Electronics is the
leading manufacturer of
Raychem custom-designed,
small-size, lightweight,
high-performance multi-
conductor (multicore)
cables. Applications are
found in the aerospace,
commercial marine, naval,
mass transportation,
automotive, offshore,
military ground vehicle,
ground support, high-per-
formance instrumentation,
industrial, and commercial
markets. Raychem multi-
conductor (multicore)
cables have been approved
to many standards demand-
ing high performance
criteria in service use.
Multiconductor (Multicore)
Cables Purpose Built and
Designed Using Raychem
Components and Technology
Multiconductor cables are
used in widely varying
applications and environ-
ments. Careful considera-
tion must be given to the
selection of components
with the right combination
of physical, chemical, and
electrical properties for
specific applications.
Tyco Electronics’ leadership
in the technologies of poly-
mer blending and subse-
quent radiation crosslinking
has led to the development
of a particularly broad range
of Raychem cables. High-
performance component
wires and miniature coaxial
cables are combined with
unique cable jacket materi-
Product Facts
nTemperature capability:
-55°C to +260°C [-67°F to
+500°F]
nSmall size, lightweight
nSystem compatibility with
other Raychem products
nComplete range of
components
nSpecially formulated jacket
materials
nSpecial shielding to address
EMI/EMC problems
nCustom designed and
purpose built
nFast response—design,
pricing, and delivery
nPrototype length facility
nRaychem Dynalink extended
flex-life and
increased flexibility
nFire-resistant: circuit
integrity (IEC331,
enhanced 950°C [1742°F],
3hours)
nSmall-size, lightweight,
low-fire-hazard for modern
high-speed vessels
als to meet the requirements
of demanding environments.
Established as one of the
leading manufacturers of
special purpose Raychem
cables, Tyco Electronics
has continued to develop
both its design and manu-
facturing expertise.
Development of a sophisti-
cated CAD system has
allowed increasingly rapid
response to any design
request, followed by manu-
facturing to the highest
quality standards.
Planar Film-Bonded Cables
Tyco Electronics can custom-
design and build a variety
of Raychem component
wires and cables onto high-
performance carrier films.
Components and carriers
are matched to ensure
temperature and environ-
mental stability.
Agency Industry Military Raychem
Underwriters’ Laboratories Lloyd’s Register of Shipping Def. Stan. 61-12 Pt 25 WCD series
BSENISO9001 Det Norske Veritas VG 95218 Pts 27 and 28 —
MSV 34410-34413, 34435,34436 — — —
Specifications/Approvals
Available in:
Americas n
Europe n
Asia Pacific n
Multiconductor (Multicore) Cables
Multicore Cables
9-76 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Components
nSPEC 44 wireand cable
nSPEC 55 wire and cable
nType 99 wire and cable
n100 wire
nCoaxial cables
Wraps and Braids
nFabric and film tapes
nKevlar®or steel strength members
nFull range of electrical screens
(including SuperScreens)
Jacket Materials
nFDR 25 - Fluid resistant, flexible, high
temperature
nThermorad - General purpose
nThermorad HTF/ - Very high temperature,
Fluoroelastomer fluid
resistant
nRaythane C - Tough and flexible
nRaythane FR - Tough, flexible, flame-
retardant
nRayolin - Low moisture transmission
nNeoprene -Low-temperatureflexibility
nZerohal - LFH
nElectroLoss FilterLine cables
nFlexible power cables
nOptical fibers
nSpecial components
Design Flexibility
KEVLAR is a trademark of E. I. du Pont
de Nemours and Company
Cable Jacket Materials
Properties and Specifications
9-77
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Properties and
Specifications
Specifications and Approvals (Components and Jacket Materials)
Specifications
UKDesignation
FDR Zerohal Fluoro
-
Thermorad Rayolin Raythane C AFR Neoprene
44 55 100 99 Hytrel
25
elastomer
Wire Wire Wire Wire
US Designation
Zerohal Thermorad Thermorad F Raythane FR Thermorad
44 55 100
HTF
NTFR
Wire Wire Wire
Def Stan 61-12 Part 31 (NES 518) X
Def Stan 61-12 Part 25 X X
Def Stan 61-12 Part 18 type 1 (issue 4) X
(Maintenance range)
Def Stan 61-12 Part 18 type 1 (issue 4) X X
Def Stan 61-12 Part 25 X X
Def Stan 61-12 Part 26 X
34435, 34436 XX
VG95218 Part 20, 21, 22 and 23 XX
VG95218 Part 24, 25 and 26 X
VG95218 Part 27 and 28 X X X X
VG95218 Part 1000 X
VG 95218 Part 1001 and 1002 X
MIL-C-24640 (PMS 400) X X
MIL-W-81044/MIL-C-27500 X
MIL-W-22759/MIL-C-27500 X
A014000 X X
O2-517 X X X
Approvals
Lloyds Register of Shipping/DNV X X X XX
Bureau Veritas X X X X X X X X X
UL X X (FR) XXX
CAA XX
BWB X X X X
VDE X X X X
Det Norskeveritas
Germanischer Lloyds X X
American Bureau of Shipping X X
Lloyds X X
Bureau Veritas X X
Cable Jacket Materials
Properties and Specifications (Continued)
9-78 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Major Cable Specifications
Country Cable Specification Specification Description Approved Jacket
Royal Navy specification covering limited fire hazard
UK Def Stan 61-12 Part 25 thin-wall insulated electric cables using Zerohal
Def-Stan 61-12 Part 18 approved wire.
Signal, control and light power circuits.
Military ground systems specification for signal, control
Germany VG 95218 (parts 27 and 28) and power cables. Wire to VG 95218 FDR-25
Parts 20-23 and 1000.
Navy specification covering limited fire hazard thin-wall
USA MIL-C-24640 (PMS 400) insulated electric cables for signal, control and light Zerohal
power circuits. Wire to MIL-W-81044.
Summary of Typical Cable Jacket Properties
Property Chemical Resistance
UK Designation US Designation Temperature Abrasion Flexibility Flame Acid Alkaline Hydrocarbon
Range °C* Resistance Resistance
FDR25 — -40 to 150 Fair Very good Self-ext;ing Good Good Very Good
Zerohal Zerohal UK & US -30 to 105 Good Good Self-ext;ing Good Good Good
Fluoroelastomer Thermorad HTF -20 to 200 Good Good Nonburning Excellent Excellent Excellent
Thermorad Thermorad F -55 to 125 Good Good Self-ext;ing Good Good Good
Raythane C — -25 to 80 Excellent Excellent Self-ext;ing Fair Fair Excellent
— Raythane FR -65 to 90 Excellent Excellent Self-ext;ing Fair Fair Excellent
Neoprene Thermorad NTFR -55 to 110 Very Good Excellent Self-ext;ing Good Good Good
Rayolin — -55 to 95 Very Good Fair — Good Good Good
AFR — -40 to 105 Excellent Good Self-ext;ing Good Good Good
—Thermorad LS -30 to 105 Good Good Self-ext;ing Good Good Good
— Thermorad O -55 to 125 Good Good Self-ext;ing Good Good Good
— Thermorad 300 -65 to 200 Very Good Fair Self-ext;ing Excellent Excellent Excellent
Polyvinylidene Fluoride Thermorad K -65 to 150 Very Good Fair Self-ext;ing Excellent Good Excellent
Modified ETFE Thermorad HT -65 to 200 Very Good Fair Self-ext;ing Excellent Excellent Excellent
Modified Flexible ETFE Thermorad FL -55 to 200 Very Good Good Self-ext;ing Excellent Excellent Excellent
*Operating temperatures for cables are application dependent. Figures shown are for guidance only. In many cases the limits shown may be extended at both
ends of the temperature range. Consult Tyco Electronics for guidance.
Cable Jacket Materials
FDR25
9-79
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
FDR 25 cable jacket was
originally developed for the
LeopardII main battle tank
to provide an exceptional
range of properties. Used in
compartments exposed to
hot diesel fuels and vibra-
tion, FDR 25 resists a wide
range of aggressive fluids
and offers excellent low
temperature flexibility.
These properties have also
led to a widespread use of
FDR 25 on other military
vehicles and in many appli-
cations such as test and
communications equip-
ment. FDR 25 is fully com-
patible with Raychem's high
performance harnessing
system — System 25.
FDR 25
Flexible, Diesel Resistant
Wire and Cable Jacket
Material
Product Facts
nHighly flame retardant
nCompatible with Raychem
System 25 tubing, molded
parts and adhesives
nQualified to VG standards
Operating Temperature Range
-40°Cto 150°C
[-40°F to 302°F]
Available in:
Americas n
Europe n
Asia Pacific n
Cable Jacket Materials
FDR25 (Continued)
9-80 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Typical Characteristics when Tested in Accordance with Raychem Specification WCD 2002 (UK) and WCD 3304 (US)
Tensile strength (MPa) 20
Elongation (%) 500
Mechanical Tear strength (N/mm) 5
Abrasion resistance (1.6 kg load) 40 scrapes min.
Cold bend -40°C [-40°F]
Endurance IEC 216 2500 h 150°C [302°F]
Thermal aging Heat aging 120h, 175°C [347°F] TS 8 MPa (min). Eb 150% (min)
Heat shock 4 h at 225°C [437°F] No cracks, drips or flowing,
6mm total shrinkage in 300 mm
24himmersion %Retention of properties
Tensile strength Elongation
Diesel fuels 70°C [158°F] 70 70
Fluid resistance Hydraulic fluids 50°C [122°F] 70 70
Lubricating oils 100°C [212°F] 70 80
Cleaning fluids 23°C [73°F] 90 95
Deicing fluids 23°C [73°F] 90 95
Electrical Insulation resistance 20°C [68°F] M ohm.km min. 2
45° flammability 30 s (max) afterburn
Other 100 mm (max) burn length
Vertical flammability Self extinguishing
Acid gas 4% HCl equivalent (max.)
Cable Jacket Materials
Zerohal
9-81
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Cables rarely initiate fires,
but they could be involved
in them and can signifi-
cantly increase the damage
caused should they propa-
gate the fire. Until recently
the flame retarding of
cables was achieved by
the use of halogenated
flame retardants which are
effective fire suppressants,
but which unfortunately
produce dense smoke and
corrosive acid gases when
burned. These effects are
highly undesirable in a fire,
hindering evacuation and
fire fighting, endangering
life and causing corrosion
damage to expensive
and vital equipment.
Raychem Zerohal is a
halogen-free cable jacket
material developed by
Tyco Electronics and
approved to the most
exacting requirements for
low firehazardcables in
many countries and, as
such, is the most widely
accepted material for these
applications in the marine,
process and mass transport
industries. Combined with
SPEC 44 wireor Type 99
and 100 wire, this jacket
material provides small
size, light weight cables
(approximately 40% weight
saving over conventional
materials).
Zerohal
Low Fire Hazard
Performance Wire and
Cable Jacket Material
Product Facts
nHalogen free
nLow smoke generation
nHighly flame retarded
nLow toxicity index
nLow corrosive gas emission
nTemperature rating -30°C to
+105°C [-22°F to +221°F]
Zerohal combines the good
mechanical and electrical
features of some conven-
tional cables with good
flame retardancy,low
smoke generation, low
evolution of hazardous and
corrosive gases, and good
resistance to diesel fuel,
lubricating oils and water.
Zerohal jacket material is
fully compatible with the
low fire hazard harnessing
system - System 100.
System
nSystem 100
Available in:
Americas n
Europe n
Asia Pacific n
Cable Jacket Materials
Zerohal (Continued)
9-82 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Characteristics when Tested in Accordance with Raychem Specification WCD 2015 and WC 2001 (Zerohal with Fungicide)
Tensile strength (MPa) 8
Elongation (%) 200
Mechanical Tear strength (N/mm) 5
Abrasion resistance (1.6 kg load ) 30 scrapes min.
Cold bend -30°C [-22°F]
Heat aging 120 h 130°C [266°F] 60% min retention of TS and Eb
Thermal aging Heat shock 4 h at 225°C [437°F] No cracks, drips or flowing,
6mm total shrinkage in 300 mm
Retention of properties
Tensile strength Elongation
Fluid resistance Diesel fuels 100°C [212°F] /24 h 85 75
IRM 902 24h, 100°C [212°F] 90 75
Lubricating oils 50°C [122°F]/24 h 80 75
Water uptake (ASTM D570) 70°C [158°F]/28 days 2% weight uptake (max)
Electrical Insulation resistance 20°C [68°F] 40
Mohms km (min)
45° flammability Self extinguishing
Vertical flammability Self extinguishing
(Swedish Chimney)
Acid gas 1.2% HCl equivalent (max)
Other Limiting oxygen index 32%
Temperature index 275°C[527°F]
Toxicity index 2.5 per 100 g
Smoke index 18
Halogen content None detected
Low Fire Hazard Performance
Flammability
Current thinking on fire
hazard defines the term
‘FireRisk’. This description
recognizes that the risk in a
fire situation is influenced
strongly from several factors
including, ignitability, heat
release, smoke evolution
and toxic gas emission
together with flammability.
There are several test
procedures available used
to assess flammability of
wires and cables. Still in
widespread use is Limiting
Oxygen Index (LOI), but it is
now generally recognized
that because the test is
conducted on a single
specimen (of cable jacket
or wire) in laboratory condi-
tions, the results are, at
best, only weakly correlated
to actual fire situations.
Critical TemperatureIndex
(CTI), is a related test and
assesses performance at
elevated temperature but
nevertheless it is still con-
ducted on a single speci-
men. Morerecent evidence
and thinking places signifi-
cantly greater importance
on large scale flammability
tests, such as IEC 60332-3,
in which the sample con-
sists of several bundles of
wires. These tests predict
more accurately the likely
behavior of cables in actual
firescenarios. Raychem
Zerohal cable jackets give
very good results in small
scale laboratory based
tests (e.g. LOI, CTI) and
Zerohal cables perform
very well in large scale
tests (e.g. IEC 60332-3).
Overall Zerohal jacketed
cables have been shown
to exhibit excellent
flammability characteristics.
Corrosivity
Under fire conditions, poly-
mers containing halogens,
sulphur and phosphorous
all form corrosive acid
gases or liquids. These
acids can then attack items
such as printed circuit
boards, connectors, control
relays and metal structures,
including steel reinforce-
ment bars embedded in
concrete.
Test methods to evaluate
corrosivity involve direct
measurement of the amount
of acid gas produced dur-
ing pyrolysis, eg to British
Rail Specification TDE
76/P/16 or measurement of
pH and electrical conduc-
tivities of solutions.
Toxicity Index
The various gases given off
by combustion of polymeric
materials are toxic to differ-
ing degrees.
The Def Stan 02-713,
assesses the concentration
of each of the possible by-
products and, by measuring
the amounts of these mate-
rials, a Toxicity Index is
assigned.
Zerohal jacket material has
atypical Toxicity Index of
1.7, compared to a typical
value of 6 for CSP and 20
for PVC jacketed cable.
The Def Stan 61-12 part 31
specification requirement
for a cable jacket is <5.
Smoke
The problems of classifying
flammability and corrosive
gas generation equally
apply to measuring smoke
generation. The method
accepted by most authori-
ties involves the use of
the NBS smoke chamber
whereoptical density of
the chamber's atmosphere
is constantly measured
during pyrolysis.
The 10% visibility line indi-
cates the density of smoke
which would cause human
disorientation and confu-
sion. The rate of change
of smoke density can be
summarized to a single
numerical value, as in NES
711, to give a smoke index
for a material and thus
offers simple comparison of
materials performance.
Cable Jacket Materials
Zerohal (Continued)
9-83
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
keep the “top weight” to a
minimum and since most of
the equipment is located on
the upper decks, system
weight must be kept as low
as possible.
The diagram shows a light-
weight cable compared
with a traditional Navy cable
having the same cross-
sectional area of copper.
Both cables have the same
number of conductors. A
saving in size has been
made on the insulation
material, but without
sacrificing the mechanical
or electrical characteristics
of the cable. A typical
saving in cable tray volume
could be as high as 40%.
Lightweight cables can
also save in excess of
twenty tons on a typical
frigate and three to five
tons on a fast patrol boat.
Raychem lightweight,
small size cables are giving
reliable service in frigates,
corvettes, fast patrol boats,
hydrofoils and submarines
in many major Navies.
Raychem Cable
Cable to
toDef Stan DGS
61-12 Pt25 212
Diameter 12.5 mm (nom.) 21.3 mm
Weight 328 g/m (nom.) 526 g/m
Conductor 0.60 mm2(nom.) 0.5 mm2
Ships arebecoming smaller
and moresophisticated,
with an ever increasing
complexity of electronic
systems, sensors and
weapons. As technology
advances shipbuilders are
called upon to update and
modify existing systems or
fit completely new ones.
The proliferation of elec-
tronic hardware requires
more and more communica-
tion systems to transfer data
from one place to another.
To provide all the necessary
interconnections, hundreds
of multicore cables have to
run throughout the ship.
These, along with cables for
power, lighting and other
basic services, create a
severespace problem
within ducts and hangers.
For the vessel to achieve
maximum speed, maneuver-
ability and range, it is vital to
Due to recent improvements
in manufacturing, Raychem
can now offer an even
tighter tolerance of ±2.5%
on cable diameter. This is
well within the limits
imposed by specifications
such as Def Stan 61-12 part
25, and offers significant
benefits to system design-
ers, particularly wherecable
glanding is involved.
Weight savings within
“maxima allowed” by exist-
ing specifications arealso
achievable.
Other applications
The increasing awareness
of many areas of industry
of the need to minimize fire
hazard risk is leading to a
rapid growth in the use of
Zerohal jacketed cables.
Applications include rail
and mass transit, offshore
platforms and other
enclosed areas where a
firewould present a
significant threat to
people or equipment.
Navy Applications
37 Component Cable
Comparison
Cable Jacket Materials
Thermorad HTF/ Fluoroelastomer
9-84 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
High Temperature
Performance Wire and
Cable Jacket Material
Applications
Thermorad HTF/
Fluoroelastomer is a mate-
rial specially formulated for
use in applications where
exceptional performance is
required.
It displays excellent stability
during continuous high
temperature exposure to
adverse chemical
environments.
Thermorad HTF/
Fluoroelastomer has a con-
tinuous operating tempera-
Thermorad HTF/
Fluoroelastomer
Product Facts
nHigh temperature capability
-20°C to +200°C [-4°F to
392°F]
nExcellent chemical
resistance
nFlame retardant
nContinuous aircraft fuel
immersion
ture of up to 200°C [392°F],
and finds applications in
aircraft fuel tanks and on
high performance engine
cables. Thermorad HTF/
Fluoroelastomer cable
jackets are compatible
with the Raychem high
temperatureharnessing
systems — System 200.
System
nSystem 200
Typical Characteristics when Tested in Accordance with Raychem Specification WCD 51/367
Tensile strength 12 MPa
Mechanical Elongation 400%
Abrasion resistance (1.6 kg load) 40 scrapes min.
Cold bend -0°C±3°C [37°F] No cracking
Heat age 168 h 250°C [482°F]
Thermal aging Heat shock 4 h at 300°C ± 3°C [572°F ± 37°F] No cracks, drips or flowing,
6mm total shrinkage in 300 mm
72 h immersion %Retention
Fluid resistance Tensile strength Elongation
Diesel oil 100°C[212°F] 60 60
ASTM No 2 oil 100°C[212°F] 60 60
Electrical Insulation resistance 20°C [68°F] M ohms. km (min) 10
45°flammability 30 s (max) afterburn
Other 100 mm (max) burn length
Vertical flammability Self extinguishing
Available in:
Americas n
Europe n
Asia Pacific n
Cable Jacket Materials
Thermorad/Thermorad F
9-85
Wire and Cable
9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
General Purpose Wire and
Cable Jacket Material
Applications
Thermorad is a general
purpose jacket material
which is unaffected by most
common chemicals and sol-
vents and is suitable for use
during N.B.C. decontamina-
tion. Thermorad is highly
flame retardant and has an
overall balance of physical
and chemical properties.
Thermorad
Product Facts
nTemperature rating -55°C to
+125°C [-67°F to 257°F]
nHighly flame retardant
nResistant to fuels, oils and
greases
nResistant to NBC
decontaminant
nUL approved
Thermorad cables find
widespread use in industrial,
commercial and military
applications. This includes
railways, commercial vehi-
cles, medical equipment,
communication equipment
and commercial electronics.
Thermorad cable jackets are
compatible with Raychem
polyolefin tubings, molded
parts and adhesives.
Tensile strength 22 MPa
Mechanical Elongation 550%
Abrasion resistance (1.6 kg load) 300 scrapes min.
Cold bend -55°C [-67°F]
Heat aging 120 h, 170°C[338°F] 60% min. retention of TS and Eb
Thermal aging Heat shock 4 hours at 225°C [437°F] No cracks, drips or flowing,
6mm total shrinkage in 300 mm
72 hour immersion, 50°C [122°F] %Retention of properties
Fluid resistance Tensile strength Elongation
IRM 902 60 60
Skydrol® 60 60
Electrical Insulation resistance 20°C [68°F] 100
Mohms km (min)
45° flammability 30 s (max.) afterburn
Other 75 mm (max.) burn length
Acid gas 4% HCl equivalent (max.)
Typical Characteristics when
Tested in Accordance with
Raychem Specification WCD
51/1602 (UK) and WCD 3310
(US)
Available in:
Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Raythane, Neoprene, Rayolin and AFR
Applications
In addition to the preferred
cable jacket materials,
Tyco Electronics offers a
variety of Raychem cable
jackets for specialized
applications. For example,
specialized materials are
available for extreme low
temperatureflexibility or for
enhanced abrasion resist-
ance, or non-cross-linked
materials for cable splicing
or overmolding.
Jacket material
Product Facts
Raythane C
n-25°C to +80°C
[-13°F to +176°F]
and Raythane FR
n-65°C to +90°C
[-85°F to +194°F]
nMechanically tough
nCan be overmolded
Rayolin
n-55°C to +95°C
[-67°F to +203°F]
nExcellent long term water
immersion
nCan be overmolded
nCompatible with Raychem’s
underwater cable splices
Neoprene (US designation
Thermorad NTFR)
n-55°C to +90°C
[-67°F to +194°F]
nExtreme flexibility
nHighly flexible at low
temperatures
AFR
n-40°C to +105°C
[-40°F to +221°F]
nAbrasion resistant
nFuel resistant
nFlame retardant
Specialized Wire and Cable
Jacket Material
WCD51/1625 WCD3310 WCD51/147 WCD51/1601 WCD51/1619
Raythane C Raythane FR Neoprene* Rayolin AFR
Tensile strength (MPa) 45 45 12 14 12
Elongation (%) 400 400 400 250 150
Mechanical Abrasion resistance 500 scrapes 500 scrapes 30 scrapes 300 scrapes 200 scrapes
(1.6 kg load)
Cold bend -25°C -15°C -55°C -55°C -40°C
[-13°F] [5°F] [-67°F] [-67°F] [-40°F]
Thermal aging Endurance (10000 h) 80°C90°C 90°C 95°C 105°C
[176°F] [194°F] [194°F] 203°F] [221°F]
24 h immersion
Fluid resistance Diesel fuels 50°C [122°F] Excellent Excellent Good — Good
Skydrol® 50°C [122°F] — — Excellent Excellent Excellent
IRM 902 100°C[212°F] Excellent Excellent Good Good Good
Electrical Insulation resistance 20°C 11 5 100 100
[68°F] M ohms. km (min)
Other 45° flammability Pass Pass Pass — Pass
*In the US use Thermorad NTFR to WCD 3314.
Typical Characteristics when Tested in Accordance with Raychem Specification WCD
Available in:
Americas n
Europe n
Asia Pacific n
9-86
Cable Jacket Materials
Miscellaneous
Electrical Shielding
9-87
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Interference — Designing
for the Threat
Available Shields
Shield type Construction Typical Application
Aluminized Mylar® Electrostatic shielding
Single Braid Low level EMI
Low sensitivity
Single Optimized Braid Sensitive lines
High EMI
Double Optimized Braid Highly sensitive lines
Severe EMI
Supershielded EMP/Tempest
Double Supershielded Severest of applications
Applications
In many applications,
shielding of cables is
important, whether it be
to minimize cross-talk
within the cable, to prevent
interference from external
sources, or to eliminate
radiation from the cable
itself.
The design of cables to
provide effective shielding
over a broad frequency
spectrum is complex, and
cables must be tailored to
specific electromagnetic
environments. From simple
aluminized Mylar®film that
provides electrostatic
shielding, progressively
more complex shielding can
be designed incorporating
plated copper braids and
Mu metal wraps.
Optimization
Performance of conven-
tional braiding can be
significantly improved by
computer optimization.
This tightly controlled
process can give many
times the shielding per-
formance of a basic
braided shield with minimal
weight penalty or increase
in optical coverage.
Supershielded cables
combine Mu metal wraps
with optimized braids to
provide even further
enhanced performance,
especially at low
frequencies.
Available in:
Americas n
Europe n
Asia Pacific n
MYLAR is a trademark of
Dupont Teijin Films U.S.
Miscellaneous
Electrical Shielding (Continued)
9-88 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Measuring Shielding
Efficiency
Surface Transfer Impedance (Zt)
Toassess the effectiveness
ofashield, Tyco Electronics
has adopted the line injec-
tion method as described in
IEC 1196-1 to measure the
surface transfer impedance
(Zt) of a cable shield. This
relates the open circuit volt-
age generated on a compo-
nent wire inside the cable to
the current injected on the
overall shield. The unit of Zt
is Ohms per meter, thus the
voltage coupling is length
dependent and long cables
exhibit more leakage than
similar but shorter length
ones. To determine the sur-
face transfer impedance
across a range of frequen-
cies, a drive signal is gener-
ated by the internal tracking
generator of a spectrum
analyzer, and amplified. The
voltage is induced on the
center conductor of the
sample which is amplified
and returned to the signal
generator for measurement.
The understanding of leak-
age mechanisms has
enabled Tyco Electronics to
design Raychem cables
with guaranteed minimum
Zt values for the desired
operating environment.
Supershielding
EMP Hardened Cables
The requirements for
nuclear hardened cables
present the engineer with
arange of problems. The
waveform of the EMP is such
that the majority of power is
dissipated in a frequency
band between 1 KHz
and 5 MHz, where little
protection is given by con-
ventionally shielded cables.
Tyco Electronics has solved
this problem with a range of
Design and Manufacturing
Expertise
The problems of shielding
cables are complex.
However, with the introduc-
tion of optimized braids and
supershielded cables, Tyco
Electronics has the capabil-
ity to solve the most difficult
shielding problems.
Shielding of cables without
degrading cable flexibility
can be provided for coaxial
and multiconductor cables
for all EMC and EMP
conditions. To complement
this range of cables,
Tyco Electronics manufac-
tures Raychem cable
terminations and connector
back fittings to give total
interconnection system
shielding performance.
supershielded cables which
give shielding performance
at these frequencies by
incorporating materials
which change the induc-
tance of the shield and
lower the transfer imped-
ance. Raychem super-
shielded cables have a
sandwich construction of
Mu metal tapes between
optimized braids. Mu metal
is a ferro-magnetic material
which has a high perme-
ability over a wide range of
field strengths. It is applied
to the cable in a way which
maintains cable flexibility
and minimizes work harden-
ing and any consequent
reduction in permeability.
Supershielded cables not
only give protection against
EMP but also other major
interference modes.
Shielded Cables
Controlling the Threat
Testing
Tyco Electronics EMC test
facilities have the capability
for bulk current injection
and radiation field testing in
addition to surface transfer
impedance measurements.
The installation is a proven
facility in characterizing
new design parameters.
100
10
1
0.1
0.01
0.001
0.000110
3
10
4
10
5
10
6
10
7
10
8
Screening performance
of various types of screen constructions
55
65
75
85
95
105
115
125
135
145
155
165
175
EM Shielding effectiveness (dB/meter)
Frequency (Hz)
Surface transfer impedance
(m.ohms/meter)
Aluminized
Mylar Single
Stranded Braid
Single
Optimized
Double
Optimized
Single
Superscreen
Solid
Copper screen
Double
Superscreen
Miscellaneous
Computer Aided Design
9-89
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Applications
Everyyear,Tyco Electronics
designs and builds several
thousand custom, high-
performance, multiconduc-
tor cables that meet unique
product needs.
Design staff can draw on
an extensive range of high-
performance cable compo-
nents and jacket materials,
while incorporating both
color-coding and alphanu-
meric marking techniques
for component identifica-
tion. These options, com-
bined with a full range of
EMI shields, lead to a huge
variety of construction
possibilities.
Tyco Electronics developed
computer-aided design
tools to provide a fast
response to design
requests. The software,
used by factoryengineers
or product specialists in the
field, can generate cable
design proposals with
drawings and quotations in
minutes. A design drawing
details all the cable data
and can be used as the
input to harness or cable
splice (joint) design. The
resulting cable is tailored to
customers’ exact needs in
an efficient design that is
superior to the compromise
cable selected from a
product catalog.
Quality Assurance
Raychem WCD and WSD
cable specifications ensure
that performance and
quality standards aremain-
tained to the highest level.
Tyco Electronics manufac-
turing sites have obtained
the highest available quality
system approvals, including
ISO 9000 and QS9000.
Raychem cables are
manufactured to meet the
requirements of several
major specifications.
Custom Design Capability
Available in:
Americas n
Europe n
Asia Pacific n
Miscellaneous
Power Cables
9-90 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
Tyco Electronics offers a
range of flexible Raychem
power cables that are
insulated and jacketed
using materials that provide
improved performance over
other materials, such as
CSP/EPR, silicone, or
PCP/Butyl. Four different
types of cable are available:
Type TR is a general
purpose, single-wall,
125°C[257°F] construction
normally specified for use
inside cabinets in protected
areas.
Type ZHI is a halogen-free
105°C [221°F] cable with
good oil resistance. It is
particularly suitable for use
in offshore, ship, and mass
transit applications where
low-fire-hazard performance
is required. Refer to
Raychem specification
WCD 2015.
Type FTR is a dual-wall,
125°C [257°F], diesel-oil-
resistant cable originally
developed for tank engine
compartment applications.
It meets the German BWB
VG 95218 specification.
Refer to Raychem specifi-
cation WCD 2002.
Type AFR is a 105°C [221°F],
single-extrusion, abrasion-
resistant, flame- and fuel-
resistant,radiation-crosslink
ed polyolefin.
Type ZHPCG is a halogen-
free, 115°C [239°F] cable
with good oil resistance
and resistance to water.
It is particularly suitable to
the Mass Transit, Marine
and Off-Shore industries
where its low fire hazard
performance and flexibility
are key to a successful
installation. Refer to
Raychem Specification
WSD 1265.
Product Facts
nChoice of jacket materials
n-55°C to +125°C
[-67°F to +257°F]
nSize and weight savings
nExcellent flexibility
nResistance to solvents and
chemicals
Each offers particular
advantages for specific
applications and each is
also available in multicon-
ductor constructions and
shielded and jacketed
versions. Cables offer size
and weight savings, good
resistance to abrasion and
cut-through, and the ability
to operate in difficult
environments.
Available in:
Americas n
Europe n
Asia Pacific n
Miscellaneous
Power Cables (Continued)
9-91
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Specifications/Approvals*
Series Agency Military Raychem
TR — Def. Stan. 61-12 Part 31 (jacket material) WCD 2003, WCD 51/160
ZHI — — WCD 2015
FTR — BWB VG 95218 Types G, H, and K WCD 2002
AFR UL style 3496 — WCD 2011, WCD 51/160
ZHPCG — — WSD 1265
*See specifications listed for details of performance.
Conductors (Tinned Soft Copper)
Stranding
Conductor Size IEC Class 5 IEC Class 6 Max. Resistance at 20°C in Ω/km (Ω/1000 ft)
mm2No. x mm Nom. Dia. No. x mm Nom. Dia. Class 5/6
1.5 30 x 0.25 1.49 [.05] 85 x 0.15 1.53 [.06] 13.20 [4.02]
2.5 50 x 0.25 1.90 [.07] 140 x 0.15 2.40 [.09] 7.82 [2.38]
4.0 56 x 0.30 2.49 [.10] 228 x 0.15 2.90 [.11] 4.85 [1.48]
6.0 84 x 0.30 3.00 [.12] 189 x 0.20 3.60 [.14] 3.23 [0.98]
10.0 80 x 0.40 4.60 [.18] 324 x 0.20 4.55 [.18] 1.88 [0.57]
16.0 126 x 0.40 5.70 [.22] 513 x 0.20 5.50 [.22] 1.19 [0.36]
25.0 196 x 0.40 7.10 [.28] 783 x 0.20 7.30 [.29] 0.78 [0.24]
35.0 276 x 0.40 8.50 [.33] 1107 x 0.20 8.55 [.34] 0.55 [0.17]
50.0 396 x 0.40 10.30 [.41] 702 x 0.30 10.15 [.40] 0.39 [0.12]
70.0 360 x 0.50 12.40 [.49] 999 x 0.30 12.00 [.47] 0.27 [0.08]
95.0 475 x 0.50 14.50 [.57] 1332 x 0.30 14.05 [.55] 0.20 [0.06]
120.0 608 x 0.50 16.00 [.63] 1702 x 0.30 16.30 [.64] 0.15 [0.05]
150.0 777 x 0.50 18.00 [.71] 2109 x 0.30 17.40 [.68] 0.13 [0.04]
185.0 925 x 0.50 20.00 [.79] 2590 x 0.30 20.00 [.79] 0.10 [0.030]
240.0 1221 x 0.50 23.00 [.91] — — 0.08 [0.024]
300.0 1554 x 0.50 26.00 [1.0] — — 0.06 [0.018]
400.0 2035 x 0.50 30.00 [1.2] — — 0.05 [0.015]
Note: Types TR and FTR use IEC Class 6 conductors.
Types ZHI and AFR use IEC Class 5 conductors.
Materials Performance Summary
Tensile Temperature
Material Strength Abrasion Cut Through Rating °C Preferred
N/mm2typical Resistance 10000 h Color
TR 20 Excellent Good 125 Black
ZHI 9Good Very Good 105 Black
FTR 18 Good Good 125 Black
AFR 18 Excellent Very Good 105 Grey
ZHPCG 8Good Good 115 Black
Note: Where a higher operating temperature is required, Raychem SPEC 55 provides outstanding performance up to 200°C continuous operating temperature.
For these or other special applications, please contact Tyco Electronics.
Miscellaneous
Power Cables (Continued)
9-92 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Notes: Users should independently evaluate the suitability of the product for their application.
Before ordering, contact Tyco Electronics check for most current data.
Table 1. Nominal Diameters and Maximum Weights
TR 16 FTR 16
Conductor Nom. OD Max. weight in Nom. OD Max. weight in
Size (mm2)Part No. in mm (in) kg/km (lb/1000 ft) Part No. in mm (in) kg/km (lb/1000 ft)
1.5 — — — — — —
2.5 TR 16-2.5 3.9 [.15] 34.0 [22.8] — — —
4.0 -4 4.5 [.17] 51.0 [34.2] FTR 16-4 5.6 [.22] 69.0 [46.2]
6.0 -6 5.2 [.20] 73.0 [48.9] -6 6.3 [.25] 94.0 [63.0]
10.0 -10 6.2 [.24] 117.0 [78.4] -10 7.5 [.29] 147.0 [98.5]
16.0 -16 7.4 [.29] 182.0 [121.9] -16 8.8 [.35] 220.0 [147.4]
25.0 -25 9.3 [.37] 274.0 [183.6] -25 10.7 [.42] 323.0 [216.4]
35.0 -35 10.6 [.42] 383.0 [256.6] -35 12.1 [.48] 444.0 [297.5]
50.0 -50 12.5 [.49] 542.0 [363.1] -50 14.0 [.55] 619.0 [414.7]
70.0 -70 14.6 [.57] 765.0 [512.6] -70 16.2 [.64] 861.0 [576.9]
95.0 -95 17.0 [.67] 1020.0 [683.4] -95 18.8 [.74] 1148.0 [769.2]
120.0 — — — -120 21.3 [.84] 1484.0 [994.3]
Table 2. Nominal Diameters and Maximum Weights
ZHI 15 AFR 35
Conductor Nom. OD Max. Weight in Nom. OD Max. Weight in
Size (mm2) Part No. in mm (in) kg/km (lb/1000 ft) Part No. in mm (in) kg/km (lb/1000 ft)
1.5 ZHI 15 -1.5 4.09 [.16] 33.5 [22.4] AFR 35-1.5 2.8 [.11] 31.0 [20.8]
2.5 -2.5 4.69 [.18] 48.8 [32.7] -2.5 3.9 [.15] 42.0 [28.1]
4.0 -45.49 [.22] 72.1 [48.3] -4 4.8 [.19] 61.0 [40.9]
6.0 -6 6.16 [.24] 99.8 [66.9] -6 6.2 [.24] 92.0 [61.6]
10.0 -10 8.20 [.32] 159.0 [106.5] -10 7.0 [.28] 143.0 [95.8]
16.0 -16 9.30 [.37] 223.0 [149.4] -16 8.1 [.32] 211.0 [141.1]
25.0 -25 10.90 [.43] 331.0 [221.8] -25 10.3 [.41] 333.0 [223.1]
35.0 -35 12.30 [.48] 448.0 [300.2] -35 11.7 [.46] 452.0 [302.8]
50.0 -50 14.70 [.58] 631.0 [422.8] -50 13.7 [.54] 634.0 [424.8]
70.0 -70 16.80 [.66] 852.0 [570.8] -70 16.0 [.63] 885.0 [593.0]
95.0 -95 19.10 [.75] 1108.0 [742.4] -95 18.5 [.73] 1165.0 [780.6]
120.0 -120 21.00 [.83] 1438.0 [963.5] -120 20.4 [.80] 1480.0 [991.6]
150.0 -150 23.00 [.91] 1748.0 [1171.2] -150 22.6 [.89] 1825.0 [1222.8]
185.0 -185 25.60 [1.01] 2088.0 [1399.0] -185 24.8 [.98] 2215.0 [1484.1]
240.0 -240 28.60 [1.13] 2705.0 [1812.4] -240 27.8 [1.1] 2875.0 [1926.3]
300.0 -300 32.00 [1.26] 3363.0 [2253.2] -300 32.0 [1.2] 3645.0 [2442.2]
400.0 -400 36.40 [1.43] 4396.0 [2945.3] -400 36.0 [1.4] 4730.0 [3169.1]
Table 3. Nominal Diameters and Maximum Weights
ZHPCG-15 ZHPCG-35
Conductor Nom. OD Max. Weight in Nom. OD Max. Weight in
Size (mm2)Part No. in mm [in] kg/km [lb/1000 ft] Part No. in mm [in] kg/km [lb/1000 ft]
1ZHPCG-15-1 3.77 [.14] 28.0 [18.1] ZHPCG-35 -1 — —
1.5 -1.5 3.79 [.15] 36.0 [24.2] -1.5 4.55 [.18] 60.0 [40.3]
2.5 -2.5 4.27 [.17] 45.0 [30.2] -2.5 5.07 [.20] 82.0 [55.1]
4.0 -4 4.64 [.18] 60.0 [40.3] -4 5.66 [.22] 100.0 [67.2]
6.0 -6 5.31 [.21] 85.0 [57.1] -6 6.15 [.24] 130.0 [87.4]
10.0 -10 6.53 [.26] 135.0 [90.7] -10 7.33 [.29] 185.0 [124.3]
16.0 -16 8.03 [.32] 195.0 [131.0] -16 8.83 [.35] 250.0 [167.9]
25.0 -25 9.70 [.38] 300.0 [201.6] -25 10.50 [.41] 350.0 [235.2]
35.0 -35 11.30 [.44] 443.0 [297.7] -35 11.70 [.46] 430.0 [288.9]
50.0 -50 13.50 [.53] 623.0 [418.6] -50 13.48 [.53] 590.0 [396.5]
70.0 -70 15.60 [.61] 847.0 [569.1] -70 15.33 [.60] 790.0 [530.8]
95.0 -95 18.10 [.71] 1119.0 [751.9] -95 17.93 [.71] 1020.0 [685.4]
120.0 -120 19.80 [.78] 1445.0 [970.9] -120 19.80 [.78] 1320.0 [887.0]
150.0 -150 22.00 [.87] 1775.0 [1192.7] -150 21.44 [.84] 1550.0 [1041.5]
185.0 -185 24.40 [.96] 2115.0 [1421.2] -184 23.28 [.92] 1900.0 [1276.7]
240.0 -240 27.80 [1.09] 2762.0 [1856.0] -240 27.33 [1.08] 2500.0 [1679.9]
300.0 -300 31.20 [1.23] 3452.0 [2320.0] -300 32.50 [1.28] 3562.0 [2393.5]
400.0 -400 35.20 [1.39] 4474.0 [3006.4] -400 37.00 [1.46] 5645.0 [3793.3]
Miscellaneous
Power Cables (Continued)
9-93
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Standard Colors
0 = Black 8 = Gray
Conductor Cross Section
(1.5 to 400 mm2)
Conductor Type
5 = IEC Class 5 - Flexible 6 = IEC Class 6 - Very flexible
Voltage Rating
1=600/1000 V
3 = 1900/3300 V
Insulating Type
TR
FTR
ZHI
AF
XXX XX - XX - X
Part Numbering System
Miscellaneous
Conductor Sizes, Strandings, and Resistance Values
9-94 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
The conductors used with
Raychem wires are concen-
tric in construction and are
specifically designed for
use with thin-wall insula-
tions. The table on the next
page gives nominal values
for tin-plated copper,silver-
plated copper,and silver-
plated high-strength copper
alloy (SPHSCA) construc-
tions. Typically, tin-plated
copper is suitable for use in
applications up to 150°C
[302°F] and silver-plated
copper in applications up to
200°C[392°F] (SPEC 55
wire only).
The current-carrying
capacities assume a
maximum 60°C [140°F]
increase in temperature of
asingle wirein free air at
40°C[104°F]. For details of
performance in conditions
other than 40°C [104°F],
contact Tyco Electronics.
Available in:
Americas n
Europe n
Asia Pacific n
Miscellaneous
Conductor Sizes, Strandings, and Resistance Values (Continued)
9-95
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Nominal Values of American Wire Gauge (AWG) and Metric Conductors
Outside Max Resistance Current-
Size Stranding Stranding Diameter inΩ/km (Ω/1000 ft) Carrying
AWG mm2No./mm No./AWG (min.–max.) Capacity
Tin-copper Silver-copper SPHSCA (amps)
30 0.06 7/0.10 7/38 0.28-0.31 [0.011-0.012] 347 [106] 324 [99] 377 [115] 3.0
28 0.09 7/0.13 7/36 0.36-0.39 [0.014-0.015] 220 [67] 205 [62] 239 [73] 4.0
26 0.15 19/0.10 19/38 0.46-0.49 [0.018-0.019] 133 [40] 123 [37] 144 [44] 5.5
24 0.25 19/0.13 19/36 0.55-0.62 [0.022-0.024] 84 [26] 78 [24] 91 [28] 7.5
22 0.40 19/0.15 19/34 0.70-0.76 [0.028-0.030] 51 [16] 49 [15] 56 [17] 10.0
20 0.60 19/0.20 19/32 0.92-0.97 [0.036-0.038] 31 [9] 30 [9] 34 [10] 13.0
18 1.00 19/0.25 19/30 1.18-1.26 [0.046-0.050] 20 [6] 20 [6] — 17.5
16 1.20 19/0.30 19/29 1.34-1.48 [0.053-0.058] 15 [4] 15 [4] — 20.0
14 2.00 37/0.25 37/30 1.65-1.72 [0.065-0.068] 10 [3] 10 [3] — 28.0
12 3.00 37/0.32 37/28 2.12-2.18 [0.083-0.086] 7 [2] 7 [2] — 3705.0
10 4.50 37/0.40 37/26 2.69-2.74 [0.106-0.108] 4 [1] 4 [1] — 53.0
89.00 133/0.29 133/29 4.01-4.20 [0.158-0.165] 2 [0.6] 2 [0.6] — 78.0
613.5 133/0.36 133/27 5.03-5.48 [0.198-0.216] 1.4 [0.4] 1.4 [0.4] — 105.0
[5.30]
4 21.0 133/0.45 133/25 6.35-6.96 [0.250-0.274] 0.9 [0.3] 0.9 [0.3] — 142.0
[6.62]
2 33.0 665/0.25 665/30 8.13-8.64 [0.320-0.340] 0.6 [0.2] 0.6 [0.2] — 196.0
[8.54]
051.0 1045/0.25 1045/30 10.00-10.80 [0.394-0.425] 0.4 [0.1] 0.4 [0.1] — 266.0
[10.87]
Note: Abbreviations:
Cond. = Conductor
SPHSCA = Silver-plated high-strength copper
Tin-copper = Tin-plated copper
Silver-copper = Silver-plated copper
N/A = Not available
For product details, please refer to relevant specification control drawing.
Current Derating Factors for Wire Bundles in Free Air
No. of wires 2 3 4 7 9 12 15 18 21 24 27 30 37
Derating factor .825 .73 .66 .54 .49 .43 .39 .36 .33 .31 .29 .28 .26
Miscellaneous
Fiber Optic Cables
9-96 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
High Performance
Interconnection Fiber Optic
Link
Standard Fiber Optic Cable
Constructions
The use of increasingly sen-
sitive and more sophisti-
cated equipment in marine
and militaryapplications
means a corresponding
requirement for high per-
formance interconnection
links. Fiber optic links offer
high performance and have
many advantages over cop-
per systems such as:
nInterference immunity
(EMI & RFI).
nHigh bandwidth (for
improved message
capacity).
nSmall size, lightweight.
nLow loss, durability.
nSecurity and safety.
However,to ensurethe reli-
ability of a fiber system the
cable design, materials and
interconnection accessories
employed are all extremely
important.
Tyco Electronics provides a
range of single and multi-
coreFiber Optic Cables
offering innovative solutions
to interconnect problems.
Tyco Electronics leadership
in the field of advanced
material technology,cou-
pled with more than 15
years experience of supply-
ing ruggedized cables for
marine and militaryapplica-
tions, ensures superior per-
formance levels in the
harshest of environments.
Product Facts
nLow smoke
nLow corrosive gas emission
nLimited fire hazard
nHalogen free
nSmall size and lightweight
nCustom design
nRange of jacket materials
nInherent security of trans-
mitted signals
nLow loss, high performance
cables
nWater-blocking options
nMeets the requirements of
Def Stan 60-1 part 2
Typical applications
nMilitary communications
nMilitary control systems
nNaval applications
nUnderwater and ROV’s
nHazardous Environments
Available in:
Americas n
Europe n
Asia Pacific n
Miscellaneous
Fiber Optic Cables(Continued)
9-97
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Simplex Fiber Optic Cable Component Fiber Size Qty/Diameter
1.Secondary Buffered Fiber (62.5/125) 1
2.Strength Member — 1.5 mm
3.Zerohal Sheath — 2.7 ± 0.2 mm
Ruggedized Simplex Fiber Optic Cable Component Fiber size Qty/Diameter
1.Secondary Buffered Fiber (62.5/125) 1
2.Strength Member — 1.5 mm
3.Zerohal Sheath — 2.7 mm
4.Strength Member — 3.3 mm
5.Zerohal Sheath — 5.3 ± 0.2 mm
2Channel Ruggedized Fiber Optic Cable Component Fiber size Qty/Diameter
1. Strength Member 2
2. Simplex Cable (62.5/125) 2
3. Strength Member 6.0 mm
4. Zerohal Sheath 8.2 ± 0.3 mm
4Channel Ruggedized Fiber Optic Cable Component Fiber size Qty/Diameter
1. Strength Member — 1
2. Simplex Cable (62.5/125) 4 / 6.7 mm
3. Strength Member — 7.3 mm
4. Zerohal Sheath — 9.5 ± 0.5 mm
8Channel Ruggedized Fiber Optic Cable Component Fiber size Qty/Diameter
1. Strength Member — 1
2. Simplex Cable (62.5/125) 8 / 9.8 mm
3. Strength Member — 10.4 mm
4. Zerohal Sheath — 12.5 ± 0.5 mm
1
2
3
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
1
2
3
4
5
1
2
3
4
1
2
3
4
1
2
3
4
Miscellaneous
Fiber Optic Cables(Continued)
9-98 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Fiber Optic Equipment
Cable
The diagram on the right
shows a typical equipment
cable, which can also be
used as a sub-unit or sim-
plex component for the
larger multi-core cables, as
shown in the diagrams on
the previous page.
The fiber used is a high per-
formance tight buffer type
comprising an all silica fiber,
with multiple coatings
designed to provide
mechanical and environ-
mental protection, micr o-
bend resistance, and ease
of handling in the field. Most
common fiber types are
readily available (see table
below) and more specialized
fibers areavailable on
request.
The equipment cable has a
layer of served aramid yarn
providing high flexibility and
tensile strength, while the
outer sheath provides envi-
ronmental and mechanical
protection, along with low
smoke emission and
chemical resistance.
Outer Zerohal sheath
Aramid yarn
Primary fiber unit
Secondary (tight)
buffer coating
Primary buffer
Core and cladding
Fiber Types and Common Features
Type Attenuation Bandwidth Dispersion Slope Numerical Aperture
— dB/km@850/1300/1550nm MHz-km@850/1300nm ps/(nm2-km) —
8/125 —/0.4/0.25 n/a 0.093 0.1
50/125 3.5/1.2/— 400/600 n/a 0.20
62.5/125 3.5/1.2/— 160/500 n/a 0.275
100/140 4.5/2.0/— 200/200 n/a 0.29
All fibers supplied with a high performance three layer tight buffer. Cables can be supplied with water-blocking and marking to suit customer requirement, and
any combination of the fiber types listed above.
Simplex Fiber Optic
Equipment Cable
Typical 2-Channel Cable
The materials and types of
designs employed have
been thoroughly tested to
Def Stan 60-1 (see test data
on the next page) and Def
Stan 61-12 Part 31 which
demonstrate the suitability of
the cables and fibers for use
in high performance and
critical marine applications.
While offering a standar d
range of tight buffered multi
and single mode fiber optic
cables, Tyco Electronics
also offers the option of cus-
tom design for specific
applications. These cables
capitalize on the small size
of the fiber thereby enabling
efficient, ergonomic and
reliable interconnection.
High Performance
Interconnection Fiber Optic
Link
Miscellaneous
Fiber Optic Cables(Continued)
9-99
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
9
Wire and Cable
Definition Requirements Part 2
Cable tensile <0.5% cable elongation no increase in attenuation at 1000N applied at 100N/minute Pass
strength full load and after test compared to pre-test value.
Cable bend Nocracking or deformation of cable sheath. 20N load, 10 cycles of wind and unwind. 6 wraps. Pass
<0.5dB change after test.
Cold bend Nocracking or deformation of cable sheath. 20N load, 10 cycles of wind and unwind. 6 wraps, -30°C. Pass
<0.5dB change after test.
Cyclic bend No cracking or deformation of cable sheath. 40N, 1000 cycles. Pass
<0.5dB change after test.
Cable impact Nocracking or deformation of cable sheath. 12.5 mm radius, 1kg hammer, 100 mm height Pass
<0.5dB change after test. 100 impacts.
Cable crush No cracking or deformation of cable sheath. Pass<0.5dB change after test <20% reduction 2000N/5 min
from original diameter.
Cable snatch Nocracking or deformation of cable sheath. Pass<0.5dB change after test <20% reduction 1kg, 10 cycles
from original diameter.
Dynamic cut through ≥25N 85°C, 60N/minute, 0.45mm diameter needle blade Pass
Tear resistance 5 N/mm — Pass
Shrinkage <3mm total 16 hrs at -30°C and 16 hrs at 85°C Pass
Scrape abrasion 500 cycles minimum 5N, 85°C, 0.45 mm diameter needle blade Pass
Volume 25 TSret 60 Ebret 60 Diesel F76 28 days @ 20°C Pass
swell 15 min % 60 min % 60 OX-30 28 days @ 50°C Pass
max % 15 60 60 OX-40 HS200X 28 days @ 50°C Pass
Fluids 10 60 60 OMD-113 28 days @ 50°C Pass
50 50 50 OX-28 28 days @ 50°C Pass
10 80 80 Deionized water 28 days @ 50°C Pass
10 80 80 Deionized water + 3.5% NaCI 28 days @ 50°C Pass
Accelerated ageing <20% change in TS/Eb/tear between 14 and 28 days. 110°C for 14 and 28 days. Pass
Eb ≥150%
Arrhenius plot 40,000 hours at 85°C End point measurement: 50% absolute elongation Pass
Stability 175% max. elongation, 25% max. permanent elongation. 105°C, 0.2N/mm2 stress. Pass
Pressure Indentation not to exceed 50%. 85°C for 4 hrs. Pass
Ozone No cracks with normal vision. 80 – 100ppm for 120 hrs Pass
UV light resistance ≤80% Eb change, ≤20% TS change. 8hrs UV 55°C, 4 hrs humidity 40°C, (UV-B) 1000 hrs. Pass
Smoke Index 20 maximum NES 71 1 Pass
Toxicity index 5 maximum NES 713 Pass
Halogen index No detectable halogens. Sodium fusion test (Lassaigne) Pass
Oxygen index 29 minimum BS 2782 Part 1 Method 141D Pass
Temperature index 250°C minimum Nes 715 Pass
Flammability Not to reach within 50 mm of the lower clamp. BS 4066 Part 1 Pass
Table of Requirements and
Results from Def Stan 60 – 1
Part 2
9-100
Wire and Cable
Engineering Notes
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Table of Contents
Raychem application
equipment is designed
and engineered specifically
for installation of Raychem
heat-shrinkable products.
These tools provide the
optimal heating tempera-
tures, performance, and
control features for maxi-
mum production efficiency.
AA-400 Super Heater
Compressed-air heating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
AD-1319-9
Holding fixture tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
AD-1377, AD-1522
Hand-operated crimp tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
AD-3050-SEAL-TEST-EQUIP
Seal test equipment Splice sealing and connector sealing evaluation
-various products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
AD-5000 and RH-396X
Tinel-Lock installation tool Tinel-Lock screened termination products . . . . . . . . . .10-7
AD-5010-Tinel-Bench-230V
Tinel-Lock installation tool Tinel-Lock screened termination products . . . . . . . . . .10-9
CV-1981, CV-1983
Heavy-duty hot-air heating tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
HL1802E/HL2005E
Steinel®general purpose hot-air heating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
IR-1891
Shuttle machine - twin workstation heater for multiple installation of
short length tubing products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
IR-550 Mark II
Infrared heating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-17
IR-1759 MiniRay
Infrared heating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-18
Model 16B
Belt heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-19
Model 19
Conveyor heater for processing Raychem heat-shrinkable tubing
and terminating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-21
Model 81CE
Discrete heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-23
Model 105
Tunnel oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-25
RBK-ILS-Processor MkII
Installation of splice sealing products adjacent to ultrasonic welder . . . . . . . . . .10-27
ThermoGun HG
Hot-air heating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-29
Note: Users should independently
evaluate the suitability of the
product for their application.
Before ordering, check with
Tyco Electronics for most
current data. 10-1
10-2
Application Equipment
AA-400 Super Heater Compressed-Air Heating Tool
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model Voltage Description Part No.
AA-400 Super Heater with stand, needlepoint tip, 120 Vac AA-400-32-Mk3 (110V) 582602-000
Mini SolderSleeve reflector, and input air filter 240 Vac (CE version) AA-400-200-CE-SUPERHTR 281917-000
Accessories and Replacement Parts* Part No. Description NSN Stock No.
SolderSleeve reflector 979646-000 AA-400-94-SLD-SLV-TIP-KIT 4940-00-609-4993
Needlepoint tip 979647-000 AA-400-96 4940-00-148-9847
Boot and tubing tip 979691-000 AA-400-101 4940-00-148-9848
Mini SolderSleeve reflector 979663-000 AA-400-102 4940-01-043-7634
Low-flow tip 979672-000 AA-400-103 3439-01-173-8810
Heating Element replacement kit, 120 V 013750-000 AA-400-128 —
Heating Element replacement kit, 240 V (CE) 444179-000 AA-400-228-EL-KT-240V-CE —
Stand 979649-000 AA-400-09 —
Input air filter 979673-000 AA-400-P-Y-92-Filter —
Air hose replacement kit 156553-000 AA-400-136 —
Gun and air hose replacement kit 238231-000 AA-400-229-Gun-Hse-Kit —
*Controller is not sold separately.
Ordering Information
Product Facts
nAutomatic power cut-off
switch to protect heating
element if air flow is
interrupted
nPressure regulator and
gauge for adjusting air flow
and temperature
nIndicator light that goes on
when power is applied to
heating element
nVery focused heat
nWide variety of reflectors
available
nExcellent tool for small
items and confined areas
Applications
Used for installing heat-
shrinkable tubing in multiple
applications. Excellent for
installing SolderSleeve
devices (wire-to-pin appli-
cations) and SolderTacts
contacts.
Specifications
Utility Requirements
Electrical 120-V model: 120 Vac, 4 A, 50–60 Hz
240-V model: 240 Vac, 2 A, 50–60 Hz
Air (oil free) 60 psig minimum, 5 cfm
Available in: Americas Europe Asia Pacific
nnn
Model Description Part No.
Holding fixture AD-1319-9 993850-000
38999 size 8 SolderTacts adapter AT-1319-22 395241-000
38999 size 16 SolderTacts adapter AT-1319-78 413186-000
Submin SolderTacts adapter AT-1319-12 993872-000
748 SolderTacts adapter AT-1319-14 993877-000
723 SolderTacts adapter AT-1319-19 993938-000
482 size 16 SolderTacts adapter AT-1319-17 993917-000
Note: Additional tooling for SolderTacts can be found under SolderTacts contacts, see section 8.
Ordering Information
Product Facts
nAD-1319-9 comes with two
lateral wire clamps as
standard
nSecures wire or cable,
enabling easy installation
of products
Applications
Simplifies and speeds
installation of Raychem
SolderSleeve terminators or
splices and SolderTacts
shielded contacts.
Dimensions 18 cm [7.07 in] W x 15 cm [5.91 in] L
Weight 300 g [.67 lb]
Product Range Covered
SolderSleeve splices MiniSeal, CWT-9XXX, D-1744, D-110
Shield terminators D-100-XX
SolderTacts contacts D-602-XX
Specifications and Dimensions
10-3
Application Equipment
Holding Fixture Tool AD-1319-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Available in: Americas Europe Asia Pacific
nnn
10-4
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model Description Part No.
AD-1377 MiniSeal crimp tool AD-1377-CRIMP-TOOL 992008-000
AD-1386 Calibration gauge AD-1386-CALIBRATION-GAUGE 992013-000
AD-1522 DuraSeal crimp tool AD-1522-1-CRIMPING TOOL 047011-000
Ordering Information
Hand-Operated Crimp Tools AD-1377, AD-1522
AD-1377, AD-1522
AD-1377 Crimp Tool
The Raychem AD-1377
crimp tool fits all MiniSeal
crimp barrels. It also
meets MIL specification
M22520/37-01. A calibra-
tion verification gauge,
AD-1386, is also available
for the AD-1377. The gauge
meets MIL specification
M22520/39-01
AD-1522 Crimp Tool
The Raychem AD-1522
crimp tool crimps all
DuraSeal crimp and
PolyCrimp products.
It has a preset crimp depth
that provides the optimum
combination of tensile
strength and insulation
integrity in the finished
splice.
Available in: Americas Europe Asia Pacific
nnn
10-5
Application Equipment
AD-3050-SEAL-TEST-EQUIP
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Seal Test Equipment Splice
Sealing and Connector
Sealing Evaluation –
Various Products
Product Facts
nSimple fixture design
allows fast sealing
test result assisting
determination of installation
conditions for splice sealing
products
nConnector fixture adapter
allows connector sealing
verification
nStrong portable container
allows use in various
locations
Applications
The AD-3050-SEAL-TEST-
EQ-NC is a manually oper-
ated pneumatic device,
intended for use as a
convenient ‘in-process’
sampling technique for
checking sealed splices.
Different combinations of
in-line or stub splices can
be pressure tested in any of
the combination of fixtures
(8 in total). There is also a
facility to allow leak testing
of various connectors.
Tyco Electronics UK has
seen good correlation
between results obtained
with the AD-3050 and those
obtained through water
immersion testing. However
testing in accordance with
the OEM specification is the
only guaranteed way of
confirming that the OEM
spec is being met. The
splice products are located
in clamps which deliver the
test pressure. The product
is immersed in water and
pressure is delivered down
the wire(s) to the sealed
area.The test result is deter-
mined visually by looking
for bubbles in the area of
the sealing product.
Use of this equipment
is described in
Tyco Electronics UK
procedure, reference No.
PIP/017/95. This equipment
can also check for poke
through i.e. where individ-
ual wire strands poke
through the installed heat-
shrinkable sleeve by using
the AD-3050-SEAL-POKE-
IND. Poke through is elimi-
nated by ensuring correct
welding and subsequent
handling conditions.
Available in: Americas Europe Asia Pacific
nnn
10-6
Application Equipment
AD-3050-SEAL-TEST-EQUIP (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Seal Test Equipment Splice
Sealing and Connector
Sealing Evaluation –
Various Products
(Continued)
6bar maximum, filtered supply.
Pneumatic Supply 2 bar test pressure maximum.
(Test pressure typically 0.5 bar)
Machine Cycle Times for seal testing: Typically 1 minute
Total System Noise: Negligible noise from air test
Dimensions: 550 x 350 x 215 [22 x 14 x 8 in]
(Excludes packing case)
Weight:
4Kg (8.80 lb)
(Excludes packing case)
9.6 Kg (21.20 lb)
(Includes packing case)
Technical Specification
Description Part No.
Seal Test Equipment AD-3050-SEAL-TEST-EQ-NC C82893-000
Ordering Information
Description Part No.
Tool Case AD-3050-SEAL-TEST-CASE-ONLY F66989-000
Splice Poke-through Indicator AD-3050-SEAL-POKE-IND E63259-000
Accessories
Description Part No.
Set of 8 Seals** AD-3050-SEAL-8-KIT 299155-000
Clamp assembly including seals AD-3050-SEAL-CLAMP-ASSY 168927-000
Sealing tape EPDM foam, 6 mm x 9 mm, —
with acrylic adhesive backing.
** Full set of seals
Recommended Spares
Application Equipment
10
10-7
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
The AD-5000-TINEL-ASSY
is a manually operated
resistance heating tool
designed specifically to
install Raychem Tinel-Lock
ring screened terminations
in small batches.
Recommended maximum
continuous batch is 15, 6
second installations. The
standard tool accommo-
dates Tinel Rings from size
TR04 to TR24 inclusive.
Various electrode (jaws)
types can be used to install
other Tinel-Lock ring sizes
and types. The operator
uses the hand-held tool to
install the Tinel-Lock ring
in its correct position on
screened terminations.
The Tinel-Lock ring has two
patches of thermochromic
paint on the Tinel-Lock ring.
AD-5000 and RH-396X Tinel-Lock Installation Tool
Tinel-Lock Screened Termination Products
The operator positions
the Tinel-Lock ring on the
terminations, with at least
one of the patches of
thermochromic paint visible.
The Tinel-Lock ring is then
clamped in the jaws to start
the installation. Installation
is complete when the
thermochromic paint turns
black.
RH-396X available in: Americas Europe Asia Pacific
nn
AD-5000 available in: Americas Europe Asia Pacific
nnn
10-8
AD-5000 and RH-396X Tinel-Lock Installation Tool
Tinel-Lock Screened Termination Products (Continued)
Technical Specification Electrical Supply 220V-240V-50Hz
Machine Cycle Times for Tinel-Lock rings used 5 to 15 Seconds depending on ring size and braid
on typical range of harnesses: type on the termination.
Mains Fuse 240 V 2 Amp (Type T anti - surge)
Total System Noise Silent Operation
Dimensions 340 x 320 x 170 mm [13.4 x 13 x 6.7 in]
Weight 4.2 Kg
Tinel-Lock Rings
STANDARD ELECTRODES FITTED : Sizes TRO4 to TR24
Conduit Electrodes Fitted Conduit systems / TR rings on double braid
Square Profile Electrodes Fitted TC02-TC03 RINGS
Product Range
Description Part No.
Tinel installation tool (220V-240V) AD-5000-TINEL-ASSY 411993-000
Also available in the US and Asia Pacific:
Resistance heating tool: 915088-01.
Use with American Beauty Transformer - #105-A12 (110V) or #105-A12-220V (220V) and foot switch #10519
Tinel installation tool (120 VAC) RH-3960-1-TINEL-KIT-120V 173643-000
Tinel installation tool (220 VAC) RH-3965-1-TINEL-KIT-220V 859855-000
Ordering Information
Hand Tool Assembly AD-5000-TINEL-HAND-TOOL 795257-000
Standard Electrodes (TR04 to TR24 RINGS) AD-5000-TINEL-STD-ELECT 180245-000
Conduit Electrodes AD-5000-TINEL-COND-ELECT 747235-000
(Conduit systems or TR rings on double braid)
Square Profile Electrodes (TC02-TC03 RINGS) AD-5000-TINEL-SQ-EXT-ELEC 065583-000
Recommended Spares —
AD-5000
Recommended Spares —
RH-396X Hand Tool Assembly 915088-01-TINI-RING-HEATR 170224-000
Foot Switch IR-500-P-FOOT-SWITCH 993702-000
120 VAC Transformer TRNSFMR-120V-105-A12-250W 570939-000
220 VAC Transformer TRNSFMR-220V-105-A12-250W 574557-000
N.B. Electrodes are two per P.C.N.
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
10-9
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
The AD-5010-TINEL-
BENCH-230V is a manually
operated resistance heating
tool designed specifically to
install Raychem Tinel-Lock
ring screened terminations
in large batches, in continu-
ous operation. The tool
accommodates Tinel Rings
from size TR04 to TR24
inclusive. Various electrode
(jaws) types can be used to
install other Tinel-Lock ring
sizes and types.
The operator uses the tool
to install the Tinel-Lock ring
in its correct position on
screened terminations. The
Tinel-Lock ring has two
patches of thermochromic
paint to ensure consistent
installation.
The operator positions the
Tinel-Lock ring on the
termination, with at least
one of the patches of
thermochromic paint
visible, and operates the
push-button (or footswitch
if fitted).
The Tinel-Lock ring is then
located in spring-loaded
jaws (it is not necessary to
clamp the ring manually).
The push button or
footswitch (if fitted) is then
operated to start the cycle,
the cable is held in position
for the duration of the instal-
lation. This is complete
when the thermochromic
paint turns black. This
normally takes between 3 to
12 seconds, depending on
ring size, braid type etc. An
AD-5010-Tinel Bench-230V Tinel-Lock Installation Tool
Tinel-Lock Screened Termination Products
ammeter on the front panel
shows installation current
used. A needle file is pro-
vided for periodic cleaning
of the electrodes.
Available in: Americas Europe Asia Pacific
nnn
10-10
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
AD-5010-Tinel Bench-230V Tinel-Lock Installation Tool
Tinel-Lock Screened Termination Products(Continued)
Electrical Supply 230 V 50 Hz
Machine Cycle Times for Tinel-Lock rings used 3 to 12 Seconds depending on ring size and braid
ontypical range of harnesses: type on the termination.
Mains Fuses (2) 240 V 2 Amp
(Type T anti - surge)
Total System Noise Silent Operation
Dimensions 245 x 305 x 290 mm [10 x 12 x 11 in]
Weight 24 Kg
Tinel-Lock rings
STANDARD ELECTRODES FITTED : Sizes TRO4 to TR24, conduit systems and TR rings on double braid
Square Profile Electrodes Fitted TC02-TC03 RINGS
Description Part No.
Footswitch Kit AD-5010-BENCH-FOOTSW-KIT 072845-000
Description Part No.
Standard Electrodes (TR04-TR24 RINGS) AD-5010-BENCH-STD-ELECT 222899-000
Square Profile Electrodes (TC02-TC03 RINGS) AD-5010-BENCH-SQ-ELECT 727799-000
Mechanism Assembly (Including electrode set) AD-5010-BENCH-MECH 924079-000
N.B Electrodes are two per P.C.N.
Description Part No.
Tinel installation tool AD-5000-TINEL-ASSY 411993-000
Technical Specification
Product Range
Accessories
Recommended Spares
Ordering Information
10-11
Application Equipment
CV-1981 and CV-1983 Heavy-Duty Hot-Air Heating Tools
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Product Facts
nRobust, double-insulated,
heavy-duty unit
nHighest-wattage unit
(1600–2260 watts)
nIntegral stand that allows
use as bench tool
nSafe, quiet operation
nPrecisely variable
temperature
nVariety of reflectors
available
nEasy fixturing for dual
opposing heating
Electrical Supply
CV-1981-MK2 120 V and 230 V
CV-1983 120 V and 230 V
CV-1981 PID 120 V and 230 V
Power Consumption
CV-1981-MK2 1600 W
CV-1983 2260 W/3060 W
CV-1981 PID 1600 W
Total System Noise
CV-1981-MK2 65dB
CV-1983 65dB
CV-1981 PID >70dB
Length
CV-1981-MK2 340 [13]
CV-1983 320 [13]
CV-1981 PID 350 [13]
Weight
CV-1981-MK2 1.3 Kg [2.90 lb]
CV-1983 1.5 Kg [3.30 lb]
CV-1981 PID 1.4 Kg [3.10 lb]
Air Flow
CV-1981-MK2 Max 230 l/min
CV-1983 Max 500 l/min
CV-1981 PID 230 l/min
Product Range
All dual wall, single wall and molded part products.
Various devices products.
For other Raychem products , contact Tyco Electronics.
Technical Specification
Applications
Used for installing dual wall
or single wall tubing up to
three inches in diameter
and for installing
SolderSleeve devices.
Closed loop version (PID)
also available.
Available in: Americas Europe Asia Pacific
nnn
10-12
Application Equipment
CV-1981 and CV-1983 Heavy-Duty Hot-Air Heating Tools (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Equipment Description Part No. Voltage Hz
CV-1981-120V1600W-CANMK2 A42716-000 120V 50/60 Hz
CV-1981-120V1600W-UKMK2 E95798-000 120V 50/60 Hz
CV-1981-230V1600WMK2 813914-000 230V 50/60 Hz
CV-1981-230V1600W-SEVMK2 F25836-000 230V 50/60 Hz
CV-1981-230V1600-UKMK2 340970-000 230V 50/60 Hz
CV-1983-110V-2260W-UK 441753-000 120V 50/60 Hz
CV-1983-220V-2260W 773898-000 230V 50/60 Hz
CV-1983-220V-2260W-UK 985426-000 230V 50/60 Hz
CV-1983-220V-3060W 538361-000 230V 50/60 Hz
CV-1983-220V-3060W-UK 231866-000 230V 50/60 Hz
CV-1981-120V-1600W-CANPIDF 839218-000 120V 50/60 Hz
CV-1981-120V-1600W-UKPID 928826-000 120V 50/60 Hz
CV-1981-230V-1600WPID 958770-000 230V 50/60 Hz
CV-1981-230V-1600W-SEVPIDF 434366-000 230V 50/60 Hz
CV-1981-230V-1600W-UKPIDF 385828-000 230V 50/60 Hz
AD-1962 989172-000 — —
Application Part No.
PR-12 reflector Tubing: 6.3–25.4 mm [0.25–1 in] 991973-000
PR-13 reflector Tubing: Up to 6 mm [0.25 in] 991963-000
PR-13C reflector Large SolderSleeve products 991974-000
PR-21 reflector Tubing: Up to 25.4 mm [1 in] 991984-000
PR-24 reflector Tubing/molded parts: 25.4–34.93 mm [1–1.38 in] 991964-000
PR-24A reflector Tubing/molded parts: 34.93–60.33 mm [1.38–2.38 in] 991989-000
PR-25 reflector SolderSleeve products: Up to 7 mm [0.28 in] 991965-000
PR-25D reflector SolderSleeve products: 6.3–12.7 mm [0.25–0.50 in] 989523-000
PR-26 reflector Small SolderSleeve products 991967-000
PR-33 reflector SolderSleeve products: 19.05–25.4 mm [0.75–1 in] 997768-000
AD-1962 adapter for larger-barrel CV-1983 — 989172-000
PR-34 reflector SolderSleeve products: 12.0–20.0 mm [0.47–0.79 in] 989111-000
PR-51 Special narrow reflector for molded part transitions 113069-000
(21.5 x 3.5 mm nozzle) [.85 x .14 in]
Ordering Information
Accessories
CV-1981-MK2
CV-1983
CV-1981-PID
CV-1983 Barrel Adapter
*Note: A42716 supersedes and replaces 538005
340970 supersedes and replaces 923002
10-13
Application Equipment
HL1802E and HL2005E Steinel®General Purpose Hot-Air Heating Tool
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Products Facts
nLight weight
nEasy, quiet operation
nPrecise variable
temperature
n1500 watts
nReflectors and stand
(optional)
nWide variety of applications
nCEapproved (230 V only)
Applications
Used for installing heat-
shrinkable tubings and
molded parts, SolderSleeve
devices, and SolderTacts
contacts.
Steinel®(120 V) power requirement 120 V, 60 Hz, 12.5 A
Steinel®(230 V) power requirement 230 V, 50 Hz, 8.7 A
Rated heater element power 110V - 1500 W/230V-2000W
Weight 850 g [1.9 lb]
Cord length Approx. 3 m [approx. 8 ft]
Typical temperature output* 49°Cto 593°C[120°Fto 1100°F]
*The Steinel®heating tool is equipped with a variable temperature control.
The correct temperature setting of the tool will vary, depending on application
characteristics. The recommended procedure is to experiment with scrap
materials and start with the lowest temperature range.
Specifications
Available in: Americas Europe Asia Pacific
nnn
10-14
Application Equipment
HL1802E and HL2005E Steinel®General Purpose Hot-Air Heating Tool (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model /Description Part No.
HL1802E-Kit-120 V** 289759-000
HL2005E-230V-Euro 910424-000
HL2005E-230V-UK 629014-000
HL2005E-Kit-230-Euro** 849224-000
Accessories and Replacement Parts Description Part No.
SolderSleeve reflector HL1802E-074616 832011-000
HL1802E-ADAPT for use with PR reflectors*** HL1802E-ADAPT-PR 444817-000
Tubing reflector HL1802E-070519 022611-000
Bench stand HL1802E-BENCH-STD 717083-000
9-mm-diameter reduction nozzle HL1802E-070618 930321-000
**Complete with SolderSleeve reflector.
***Selection of PR reflectors can be found in CV-1981/CV-1983 section.
Accessories
Ordering Information
Clip-on bench stand
(P/N 717083-000) for heating tool.
Must be ordered separately.
SolderSleeve reflector (P/N
832011-000) for SolderSleeve
terminators, SolderTacts contacts,
and small-diameter tubing. Comes
standard with Steinel®heating tool.
Optional tubing reflector (P/N
022611-000) for larger tubing and
molded parts. Must be ordered
separately.
Application Equipment
10
10-15
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Applications
The IR-1891 is suitable for
the installation of a range
of Raychem heat-shrinkable
tubing products onto a
variety of small compo-
nents, e.g. ring terminals,
FASTON terminals and
small connectors etc. The
machine is provided with
two work stations and a
moveable heating head.
Each workstation is provid-
ed with supports for tooling
fixtures (which must be
specified and ordered sep-
arately). These support the
workpieces and locate the
tubing products. The opera-
tor loads the workpieces
into the fixtures at one of the
workstations, ensures that
the tubing product is cor-
rectly positioned and then
slides the heat head into
position before initiating the
heating cycle. The operator
then continues with loading/
unloading the other work
station whilst the heating
cycle is taking place.
The IR-1891-220V-Shuttle-
Retn is provided with
closed loop temperature
control and in addition the
heat head is ‘locked’ into
position by use of an elec-
tromagnet during the heat-
ing cycle.
Once the other workstation
has been loaded and the
first installation is complete,
the heat head is moved into
position over the product
and the next heating cycle
initiated. Heating times vary
typically from 3 to 30
seconds depending on the
size and type of tubing
product. Process rates up
to 1200 pieces/hour can be
achieved depending on the
heating time and the time
taken by the operator to
load unload the workpieces.
The installation tempera-
ture/power can be varied
according to product
type/size and required
cycle times.
The heating elements,
which are continuously
energized, are of the infra-
red medium wave length
type and consist of a coiled
resistance wire contained
in quartz glass tubes. The
closed loop temperature
control uses similar ele-
ments but having integral
thermocouple sensors.
Product Facts
nAutomatic cycle start once
heater is manually
positioned over product,
which gives improved
process control
(recommended for adhesive
lined heat-shrinkable tubing
e.g. sealing applications)
nAutomatic heating head
retraction at end of cycle
prevents damage to
components
nMultiple product fixture
assemblies give increased
process rates
nCooling fan above each
fixture assembly maintains
holding fixture at an
acceptable temperature
IR-1891 Shuttle Machine — Twin Workstation Heater for Multiple Installation of Short
Length Tubing Products
Available in: Americas Europe Asia Pacific
n
10-16
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Electrical Supply 230 V Single Phase
Power Consumption 1600 W
Operating Temperature 650°C max
Process Rate 1200 / hour maximum depending on application and operator
Heating Times 3 to 20 seconds depending on application
System Noise < 70 dB
Dimensions – 508636-000 L1100 x H650 x D500 mm [L43 x H25 x D20 in]
Dimensions – 613148-000 / 167309-000 / 289588-000 L1100 x H900 x D500 mm [L43 x H35 x D20 in]
Base Plate Dimensions 289588-000 / 167309-000 L1040 x D450 mm [L41 x D18 in]
Base Plate Dimensions 613148-000 L1040 x D397 mm [L41 x D16 in]
Technical Specification
Wide range of Raychem tubing products in particular LSTT, RNF-3000, RNF-100, HTAT, ATUM.
Maximum diameter 20 mm [0.8 in] and maximum length 60 mm [2.0 in]
Product Range
Ordering Information
Accessories
IR-1891 Shuttle Machine — Twin Workstation Heater for Multiple Installation of Short
Length Tubing Products (Continued)
Description Part No.
*IR-1891-220VShttle-Retn 289588-000
*IR-1891-220V-Retn-Syl 613148-000
Description Part No.
Grippers:
IR-1891-SI-GRP-165-RD-1mm Red Gripper with 1mm hole 629602-000
IR-1891-SI-GRP-165-CL-2mm Clear Gripper with 2mm hole 112676-000
IR-1891-SI-GRP-165-BK-3mm Black Gripper with 3mm hole F83221-000
IR-1891-SI-GRP-165-WT-6mm White Gripper with 6mm hole 554196-000
Fixtures:
IR-1891-Quick-Rel-ESS-6/1 ESS Cap (6/1) Fixture 096735-000
IR-1891-Quick-Rel-ESS-8/2 ESS Cap (8/2) Fixture 148597-000
IR-1891-Tool-Fixt-Bas-ESS Base Unit for Fixtures 760221-000
Note: Awider range of tooling fixtures and grippers designed for previous applications are available. Please contact
Tyco Electronics for details.
*Note: The descriptions given here DO NOT include the supply of the necessary tooling fixtures.These are designed
for each individual application.
10-17
Application Equipment
Infrared Heating Tool IR-550 Mark II
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Product Facts
nLightweight, portable unit
with pedestal base for
benchtop operation
nFoot switch, so both hands
can be free to hold parts
nCommercially available
tungsten-halogen lamp
nFan-cooled housing
nInstant on/off heat
nViewing window that allows
parts to be inspected during
installation
nQuiet, focused IR operation
Input power 105–120 V, 50–60 Hz, 4.5 A
Normal lamp life More than 1000 hours of intermittent use
Weight Approximately 2.5 Kg [5.5 lb]
Duty cycle 80%, 90-second max. heating times
Specifications
Applications
Used for installing small and
large SolderSleeve devices
and SolderTacts contacts.
Model Description Part No.
IR-550 heating tool* (120 V) IR-550-50-MARKII-HT-TOOL 994350-000
with RG-2 reflector, viewing window, and foot switch
Note: For 230V CE-approved version, contact Tyco Electronics
IR-550 foot switch IR-550-216 994375-000
(included with tool assembly 994350)
RG-6 reflector for large-diameter SolderSleeve terminations; IR-550-19 994590-000
aperture is 25.4 mm [1.0 in] wide
RG-11 reflector; aperture is 12.7 mm [.5 in] wide IR-550-41 993695-000
RG-9 reflector; aperture is 9.525 mm [.375 in] wide IR-550-39 993693-000
RG-2 reflector, included with 994350; IR-550-24 993770-000
aperture is 19.05 mm [.75 in] wide
Lamp (120 V) IR-1000-P-N-13 993020-000
Optical filter IR-550-237 118902-000
Viewing window (frame not included) IR-550-238 007510-000
IR-550 upgrade kit: filter, viewing window, inner reflector, IR-550-240-Refurb 529600-000
outer reflector
Ordering Information
Accessories and
Replacement Parts
Available in: Americas Europe Asia Pacific
nn
10-18
Application Equipment
IR-1759 MiniRay Infrared Heating Tool
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Facts
nSmall, lightweight,
fan-cooled unit
nSmall profile for installation
where space is restricted
nHandheld operation
nFocused heat
nQuiet, efficient IR operation
nCE approved
Applications
Used for installing
SolderSleeve devices and
SolderTacts contacts.
Tungsten-halogen
Nominal power 250 W, 24 Vac, 50–60 Hz
Fan 12 Vac (supplied through control unit)
Weight .73 kg [1.6 lb]
Cable length 2 m [6.5 ft]
Electronic Control Unit
Main supply 110/230 Vac, 50/60 Hz, 11 A/5.5A universal
Weight 3.4 kg [7.6 lb]
Dimensions 16.3 x 12.2 x 12.2 cm [6.4 x 4.8 x 4.8 in]
Specifications and Dimensions Lamp
Description Part No.
Complete kit consisting of:
Handtool/Reflector/Control Box (Manual control,
Dual voltage) IR1759-MK3-AT3130-EDCont 898738-000
Handtool, standard aperture IR-1759-MK3/A 986899-000
Handtool, large aperture IR-3104-MK3/A 035343-000
Control box with time control-230 V ED-7-001-MK2-230V-50HZ 869233-000
Control box with time control-110 V ED-7-002-MK2-110V-60HZ 903553-000
Control box with manual control-110/230V ED-7-CONT-230/110V 684886-000
Battery powered control box ED-7-Batterybox-230/110V 448969-000
Conversion kit (AE-897) for adapting standard- AT-313/AE-897 934630-000
aperture MiniRay heating tool to wide-aperture
MiniRay tool (includes reflector)
Inner reflector (standard aperture) AE-424 547918-000
Inner reflector (wide aperture) AE-153 988285-000
Lamp (250 W, 24 V) NAE-143-3 988208-000
Filter (standard aperture) AES-IR1759-100-FILTER-DUL 431468-000
Filter (large aperture) AES-IR1759-300-FLTR-LRG F52511-000
Ordering Information
Accessories and
Replacement Parts
*IR tools are not recommended for use with black wire or cable insulations.
* Control box not shown
Available in: Americas Europe Asia Pacific
nnn
Applications
Designed for processing a
broad range of heat-shrink-
able tubing products up to
19 [75] in diameter and 101
[4.0] long. Suitable for
either single-wall or adhe-
sive-lined tubing. Heating-
element temperature is
adjustable up to 600°C
[1112°F] and the belt
speed is adjustable to2.28
[7.5] per minute. Operator
simply positions the heat-
shrink tubing over the
assembly and feeds it
into the process chamber.
Heating and cooling take
place automatically with the
cables or wires securely
fixed.
Product Facts
nControlled heating for
installation of Raychem
heat-shrinkable tubing at
rates required for mass
production
nControlled repeatable
heating: time and
temperature settings can be
fixed to maintain repeatable
installation parameters
nPart positioning that is
clearly defined and easy to
maintain
nOperation that requires only
minimal skill
nEfficient and economical
operation, which greatly
reduces labor costs. In most
cases the throughput rate is
limited only by the rate at
which an operator can load
parts into the heater
10-19
Application Equipment
Model 16B Belt Heater
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Available in: Americas Europe Asia Pacific
nn
10-20
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model 16B Belt Heater (Continued)
Specifications and Dimensions Electrical Part No. 827429-000 Part No. 047143-000 Part No. 584313-000
Power requirements 120 Vac, 1 Ø, 220 Vac, 1 Ø, 230 Vac, 1 Ø,
50/60 Hz, 20 A 50/60 Hz, 15 A, 3-wire 50/60 Hz, 15 A, 4-wire
Heating elements 875 W (upper and lower) 875 W (upper and lower) 875 W (upper and lower)
Mechanical
Conveyor belt system Two sets of pinch belts right and left, four belts total
Machine dimensions 48 cm [19 in] W x 110 cm [43 in] L x 33 cm [13 in] H
Shipping dimensions 61 cm [24 in] W x 111 cm [44 in] L x 56 cm [42 in] H
Machine weight without crate 55 Kg [120 lb]
Shipping weight with crate 91 Kg [200 lb]
Tubing Sizes
Inside diameter before recovery Up to 19 mm [0.75 in]
Length Up to 101mm [4.0 in]
Optional Attachment
Ring terminal kit Part No. 060053-000
Application Equipment
10
10-21
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product Facts
nClosed-loop speed and
temperature control
nCEapproved for worldwide
use
nAdaptable for different
applications
nContinuous controlled
process
Applications
The Model 19 conveyor
heater is the latest genera-
tion of reliable and versatile
process heaters for a wide
variety of heat-shrinkable
products.
Two sets of timing belts grip
the individual assemblies
and carry them through a
closed-loop infrared heating
zone, then through a cool-
ing zone, and deposit the
completed assemblies in a
collection bin.
The processor was
designed to meet the
requirements of the
European Safety Directives
and is CE approved, allow-
ing for worldwide use.
The processor is designed
to operate on the following
line voltages: 210 to 240
Vac, 20 A, 1 Ø, 50/60 Hz.
Options for this processor
include:
nPowered or unpowered
extension tables to
support long or heavy
harnesses.
nKit for processing ring
terminals and end termi-
nations.
nFloor stand with wheels.
nWider heating elements
for tubing up to
178 [7.0] long.
nNarrow heating elements
for SolderSleeve devices
up to 10 [0.4] diameter
and 45 [1.8] long or short
length tubing less than 50
mm [2.0].
Product Features
Controlled Heating Zone
The Model 19 has two
etched- foil heating ele-
ments mounted under a
quartz face. Consistent
heating chamber tempera-
tures are obtained with a
closed-loop temperature
controller. There is a lock-
out on the controller to pre-
vent unauthorized changes.
Speed Control
Consistent speed is
obtained with a closed-loop
speed controller. The
speed is adjusted using a
3-digit thumbwheel on the
front control panel. There is
alockout on the thumb-
wheel to prevent unautho-
rized changes.
Minimal Skill Requirements
There are clearly marked
guides for aligning the
assembly as well as the
tubing or device being
processed. The operator
only has to center the
assembly; the grippers carry
it through the heating and
cooling zone and deposit it
into the unloading bin.
Economical Production
The throughput rate is
determined by the rate at
which an operator can load
the processor.
Versatility
The tool description
CLTEQ-M19-Belt-htr part
number 714529-000 will
handle tubing up to 25 [1.0]
diameter and 102 [4.0]
long. Tubing up to 178 [7.0]
long can be handled with
the use of tool description
CLTEQ-M19-Belt-Htr-6in
part number 075131-000.
The tool description
CLTEQ-M19-Beltheater-SS
part number D43037-000
will handle SolderSleeve
devices up to 10 [0.4]
diameter and 45 [1.8] long,
or short length tubing (less
than 50 [2.0], where appli-
cations require a narrow
heat width.
Self-Diagnostic Circuitry
There are several “self-
diagnostic” circuits that
alert the operator if any
major component fails or
if an unsafe processing
condition occurs. A light will
turn on and a lockout gate
will lift in the entry zone,
preventing the operator
from loading assemblies
until the situation has been
corrected.
Other Features Include:
nEmergency stop.
nAutomatic cool-down
circuit to extend the life
of components.
nLockout on temperature
and speed controllers to
prevent unauthorized
changes.
Model 19 Conveyor Heater for Processing Raychem Heat-Shrinkable Tubing and
Termination Devices
Available in:
Americas n
Europe n
Asia Pacific n
10-22
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model 19 Conveyor Heater for Processing Raychem Heat-Shrinkable Tubing and
Termination Devices (Continued)
Electrical
Power requirements 210–240 Vac, 20 A, 1 Ø, 50/60 Hz
Heating elements Std = 3160 W/Wide = 3320 W/Narrow = 1760 W
Mechanical
Conveyor belt system Double-sided timing belts, pitch - 9.5 [0.375]
Belt speed Up to 152 cm/min [5.0/min]
Processor dimensions 53 cm [21 in] W, 135 cm [53 in] L, 45 cm [18 in] H
Shipping dimensions 66 cm [26 in] W, 147 cm [58 in] L, 58 cm [23 in] H
Shipping weight with crate 86 Kg [190 lb]
Tubing sizes
Tubing diameter (max) 25 mm [1.0 in]
102 mm [4.0 in]
Tubing length (max) 178 mm [7.0 in] wide heating element tool
50 mm [2.0 in] narrow heating element tool
Work-piece length (min) 240 mm [9.5 in]
Version Part No.
Model 19 Standard 714529-000
Model 19 Wide 075131-000
Model 19 Narrow D43037-000
Specifications and Dimensions
10-23
Application Equipment
Model 81CE Discrete Heater
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Applications
The Model 81CE is a
discrete heater that can
process large, complex
assemblies or other suitable
substrates using a wide
variety of heat-shrinkable
tubing products up to 25
mm [1.0] in diameter and
127 mm [5.0] in length. It is
suitable for use with both
single wall and adhesive-
lined tubing. Two jaws grip
the assembly or substrate,
carry it into an infrared
heating chamber for a user-
selectable predetermined
period of time, then return
the completed assembly
back to the start position
for removal.
Product Facts
nClosed-loop temperature
control for a precise and
repeatable thermal process
nOven dwell time precisely
set by a 3-digit thumb wheel
digital timer
nHeat output can be
controlled to accommodate
awide variety of
applications
nOperation requires only
minimal skill
nContains numerous safety
features
nMeets the requirements of
CE, OSHA and the NEC
Available in: Americas Europe Asia Pacific
nnn
10-24
Application Equipment
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Model 81CE Discrete Heater (Continued)
Electrical Part No. 071965-000 Part No. 704393-000
Power requirements 120 VAC, 1Ø, 50/60 Hz, 15 A 220 VAC, 1Ø, 50/60 Hz, 15 A
Heating elements Two 400 watt infrared stamped foil Two 400 watt infrared stamped foil
with infrared heating elements, one with infrared heating elements, one
top and bottom. top and bottom.
Timing system Eagle digital timer, 1 to 999 seconds Eagle digital timer, 1 to 999 seconds
Pneumatic
Requirements for jaw traverse 30-40 psi clean shop air 30-40 psi clean shop air
Dimensions
Control box dimensions:
Length 432 mm [17 in] 432 mm [17 in]
Width 216 mm [9 in] 216 mm [9 in]
Height 165 mm [7 in] 165 mm [7 in]
Control box weight 7.7 Kg [17 lb.] 7.7 kg [17 lb.]
Heating chamber dimensions:
Length 380 mm [15 in] 380 mm [15 in]
Width 240 mm [10 in] 240 mm [10 in]
Height 343 mm [14 in] 343 mm [14 in]
Heating chamber weight 18 Kg [40 lb.] 18 kg [40 lb.]
Shipping Dimensions
Length 610 mm [24 in] 610 mm [24 in]
Width 610 mm [24 in] 610 mm [24 in]
Height 530 mm [21 in] 530 mm [21 in]
Shipping weight 41 Kg [90 lb.] 41 kg [90 lb.]
Tubing Sizes
Inside diameter before heat Up to 25.4 mm [1 in] Up to 25.4 mm [1 in]
Length Up to 127 mm [5 in] Up to 127 mm [5 in]
Specifications and Dimensions
10-25
Application Equipment
Model 105 Tunnel Oven
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Applications
Table conveyor heater that
provides a controlled
process system suitable for
installing a wide variety of
heat-shrinkable tubing
products up to 76 mm [3.0]
diameter and unlimited in
length. Ideally suited for
efficient processing of fiber
and fabric HFT and both
single wall and dual wall
tubing. Designed as an
integrated modular unit.
Assemblies are placed on
the entry section of a mesh
belt, transported through a
heating chamber, across a
bank of cooling fans then
discharged from the rear of
the conveyor.
Product Facts
nClosed-loop temperature
control for a precise and
repeatable thermal process
nConveyor speed precisely
set by a 3-digit
potentiometer
nOperation requires only
minimal skill
nContains numerous safety
features
nCustom length conveyors for
longer entry and/or exit
sections available
nOptional accessories to
customize the tunnel oven
Available in: Americas Europe Asia Pacific
nnn
10-26
Application Equipment
Model 105 Tunnel Oven (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Optional Accessories
Specifications and Dimensions Electrical Part number 955018-000
Power requirements 208/240 VAC, 1Ø, 50/60 Hz, 15 A
Heating elements Two 1500 watt infrared stamped foil with
black quartz face, one top and bottom
Operating temperature Ambient to 650°C [1202°F]
Drive System DC motor with SCR drive controller and 3 digit
speed potentiometer
Conveyor Speed 0.06 M/min. to 1.5 M/min. [0.20 to 5.0 ft/min]
Conveyor Belt Wire mesh 70% open
Heater Oven Gap 2 Position; 53.6 mm [2.11 in] Lower Position,
98 mm [3.86 in] Upper Position
Effective heating width 356 mm [14 in]
Dimensions
Control box dimensions
Length 515 mm [20 in]
Width 210 mm [8 in]
Height 178 mm [7 in]
Control box weight 7.7 Kg [17 lb]
Heating conveyor dimensions
Length 990 mm [39 in]
Width 685 mm [27 in]
Height 417 mm [17 in]
Heating conveyor weight 68Kg [150 lb]
Shipping Dimensions
Length 1346 mm [53 in]
Width 1168 mm [46 in]
Height 635 mm [25 in]
Shipping weight 146 Kg [320 lb]
Tubing sizes
Inside diameter before heat Up to 76.2 mm [3 in]
Length
Perpendicular to belt travel 356 mm [14 in]
Parallel to belt travel Unlimited
nPowered outboard conveyor for processing large assemblies that require only a
portion of the assembly to be heated (1 side only).
nPowered entry and exit conveyors for processing long and rigid assemblies requiring
entry and exit support of the product.
nAbility to add additional heater chambers to extended custom length wire mesh
conveyors.
nCustom floor stands.
10-27
Application Equipment
RBK-ILS-Processor Mkll
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Applications
The RBK-ILS-Processor
MkII is a semi-automatic
unit designed specifically
to install splice sealing
products onto ultrasonically
welded or crimped splice
joints used in automotive
harnesses.
The tool can operate in
several modes:
nStand-alone — operator
sets time and temperature.
nSequenced — preset
times and temperatures
can be sequenced
automatically (and can
also be randomly
selected from sequence
stored.)
nAutomatic —
communication with
upstream ultrasonic
welder can allow time
and temperature to be
automatically set without
operator intervention.
The operator is able to
efficiently load both
machines and so minimize
‘dead time’. Installing
Raychem splice sealing
products immediately after
welding gives reduced
installation time and earliest
possible mechanical pro-
tection for the welded joint.
The operator positions the
splice sealing product cen-
trally over the splice joint
and then locates the
assembly into the gripper
mechanism.
Product Facts
nIncreased heating element
life
nInstallation times,
temperatures and product
size information (individual
selection)
nSequenced installations
nOperator key lock/password
protection levels
nAutomatic heater retraction
on mains failure
nAutomatic calibration
(single cycle)
nRS232 interface allows
time, temperature and
product sizes for the next
installation to be transferred
from a remote machine
(e.g. an ultrasonic welding
tool)
nMachine hours and
installation cycle counters
nSoftware upgradeable to
support special applications
nAir cooling can be provided
to an optional stub splice
fixture in the RBK-Proc-
MK2-Proc-Aircool version
Installation of Splice
Sealing Products Adjacent
toUltrasonic Welder
Available in: Americas Europe Asia Pacific
nnn
The wire assembly is
automatically ejected, with
the splice sealing product
installed and the joint area
sealed, insulated and strain
relieved. In-line or stub-type
splices can be installed.
10-28
Application Equipment
RBK-ILS-Processor Mkll (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Installation of Splice
Sealing Products Adjacent
toUltrasonic Welder
(Continued)
Electrical Supply 220V-240V-50Hz
Power Consumption 1.7 Amps (Max)
Operating Temperature 550°C [1022°F] (Max)
(500°C [932°F] recommended)
Machine Cycle Times for splice sealing products 6 to 20 seconds depending on wire size
used on typical range of automotive splices and the number or wires used
Total System Noise <80dB
Dimensions 390 x 365 x 225 mm [15 x 14 x 9 in.]
Weight 18 Kg [40 lb]
Technical Specification
RBK-ILS-125 Products Sizes 1 to 3A
RBK-ILS-85 Products Sizes 6/1 to 12/3
For Other Raychem Products (eg. RBK-VWS, RBK-ESS….) Contact Tyco Electronics
Product Range
Description Part No.
Equipment RBK-Proc-Mk2-Processor 740331-000
RBK-Proc-MK2-Proc-Aircool A96930-000
Stub splice fixture - RBK-ILS-Proc-Stub-Sp-Fix 981721-000
Accessories Air cooled stub splice fixture - RBK-ILS-Proc-Air-Cool-Kit 843800-000
8mm ring terminal fixture - RBK-ILS-Proc-Termfix-08mm 049857-000
Ordering Information
10-29
Application Equipment
ThermoGun HG Hot-Air Heating Tool
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Application Equipment
10
Product Facts
nStand-mounted or
handheld, rugged unit for
heavy-duty use
nBuilt-in stand and turbo-fan-
driven blower
nAdjustable side vents
nAdjustable temperature
n1680 to 2160 watts
nLarge reflector size
nHigh heat output for fast
installation
Model Power Requirements Input Watts Temperature Range CFM* RPM**
HG-501A 120 V, 60 Hz, 14 A 1680 260°C–399°C [500°F–750°F] 23 1700
HG-502A 230 V, 50/60 Hz, 7 A 1680 260°C–399°C [500°F–750°F] 23 1700
HG-751A-C 120 V, 60 Hz, 18 A 2160 399°C–538°C [750°F–1000°F] 23 1700
HG-752A 230 V, 50/60 Hz, 9 A 1740 399°C–538°C [750°F–1000°F] 23 1700
*CFM = Cubic feet per minute.
**RPM = Revolutions per minute.
Specifications
Applications
Used for installing molded
parts onto adapters or
harnesses and installing
abroad range of heat-
shrinkable products, includ-
ing boots and tubing up to
three inches in diameter..
Available in: Americas Europe Asia Pacific
nn
10-30
Application Equipment
ThermoGun HG Hot-Air Heating Tool (Continued)
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
A-160-HG reflector
(P/N 991017) for short
lengths of tubing up to
19.05 [75] in diameter.
Must be ordered separately.
A-170-HG reflector
(P/N 991018) for short lengths
of tubing 19.05–50.8
[.75–2] in diameter.
Must be ordered separately.
TG-23 reflector (P/N 991026)
for boots up to 44.45
[1.75] in diameter.
Must be ordered separately.
Accessories
Model* Housing Color Part No.
HG-501A Red 462047-000
HG-502A Red 389363-000
HG-751A-C Red 926935-000
HG-752A Red 026239-000
Accessories Tubing Application Part No.
A-160-HG standard reflector Diameters up to 19.05 mm [0.75 in] 991017-000
A-170-HG large tubing reflector Diameters of 19.05–50.8 mm [0.75–2 in] 991018-000
TG-23 small boot reflector Diameters up to 44.5 mm [1.75 in] 991026-000
TG-24 large boot reflector — 991027-000
*Complete with bench stand.
Ordering Information
Supporting Information
Table of Contents
11-1
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Equivalents and Conversions ......................................................................................11-2, 11-3
Temperature Conversion Formula................................................................................11-4, 11-5
Glossary ..............................................................................................................11-6 to 11-18
Part Index ..........................................................................................................11-19 to 11-21
Supporting Information
Equivalents and Conversions
11-2 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Fraction of Decimal Decimal Fraction of Decimal Decimal
Inch of Inch Millimeters Inch of Inch Millimeters
1/64 .0156 0.3969 .5118 13.0000
1/32 .0313 0.7938 33/64 .5156 13.0969
.0394 1.0000 17/32 .5313 13.4938
3/64 .0469 1.1906 35/64 .5469 13.8906
1/16 .0625 1.5875 .5512 14.0000
5/64 .0781 1.9844 9/16 .5625 14.2875
.0787 2.0000 37/64 .5781 14.6844
3/32 .0938 2.3813 .5906 15.0000
7/64 .1094 2.7781 19/32 .5938 15.0813
.1181 3.0000 39/64 .6094 15.4781
1/8 .1250 3.1750 5/8 .6250 15.8750
9/64 .1406 3.5719 .6299 16.0000
5/32 .1563 3.9688 41/64 .6406 16.2719
.1575 4.0000 21/32 .6563 16.6688
11/64 .1719 4.3656 .6693 17.0000
3/16 .1875 4.7625 43/64 .6719 17.0656
.1969 5.0000 11/16 .6875 17.4625
13/64 .2031 5.1594 45/64 .7031 17.8594
7/32 .2188 5.5563 .7087 18.0000
15/64 .2344 5.9531 23/32 .7188 18.2563
.2362 6.0000 47/64 .7344 18.6531
1/4 .2500 6.3500 .7480 19.0000
17/64 .2656 6.7469 3/4 .7500 19.0500
.2756 7.0000 49/64 .7656 19.4469
9/32 .2813 7.1438 25/32 .7813 19.8438
19/64 .2969 7.5406 .7874 20.0000
5/16 .3125 7.9375 51/64 .7969 20.2406
.3150 8.0000 13/16 .8125 20.6375
21/64 .3281 8.3344 .8268 21.0000
11/32 .3438 8.7313 53/64 .8281 21.0344
.3543 9.0000 27/32 .8438 21.4313
23/64 .3594 9.1281 55/64 .8594 21.8281
3/8 .3750 9.5250 .8661 22.0000
25/64 .3906 9.9219 7/8 .8750 22.2250
.3937 10.0000 57/64 .8906 22.6219
13/32 .4063 10.3188 .9055 23.0000
27/64 .4219 10.7156 29.32 .9063 23.0188
.4331 11.0000 59/64 .9219 23.4156
7/16 .4375 11.1125 15/16 .9375 23.8125
29/64 .4531 11.5094 .9449 24.0000
15/32 .4688 11.9063 61/64 .9531 24.2094
.4724 12.0000 31/32 .9688 24.6063
31/64 .4844 12.3031 .9843 25.0000
1/2 .5000 12.7000 63/64 .9844 25.0031
11.0000 25.4000
Decimal Equivalents
Supporting Information
Equivalents and Conversions (Continued)
11-3
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Length Area Volume Mass
Inches x 25.40 = Millimeters Sq. inches x 6.452 = Sq. centimeters Cu. inches x 16.39 = Ounces x 28.35 = Grams
Cu. centimeters
Millimeters x 0.03937 = Inches Sq. centimeters x 0.1550 = Sq. inches Cu. cm. x 0.06102 = Cu. inches Grams x 0.03527 = Ounces
Feet x 0.3048 = Meters Sq. feet x 0.0929 = Sq. meters Cu. feet x 0.02832 = Cu. meters Pounds x 0.4536 = Kilograms
Meters x 3.281 = Feet Sq. meters x 10.76 = Sq. feet Cu. meters x 35.31 = Cu. feet Kilograms x 2.205 = Pounds
Miles x 1.609 = Kilometers Sq. miles x 2.59 = Sq. kilometers Kilograms/km x 0.6214 =
Pounds/kft
Kilometers x 0.6214 = Miles Sq. kilometers x 0.3861 = Sq. miles Pounds/kft x 1.4881 =
Kilograms/km
Ohms/km x 0.3048 = Ohms/kft Circular mils x 0.7854 = Sq. mil
Prefix Value Symbol Prefix Value Symbol
Tera 1012 T Deci 10-1 d
Giga 109 G Centi 10-2 c
Mega 106 M Milli 10-3 m
Kilo 103 k Micro 10-6 µ
Hecto 102 h Nano 10-9 n
Deca 101 da Pico 10-12 p
Conversion Factors
Prefixes (SI), Values,
and Symbols
Supporting Information
Temperature Conversion Formula
11-4 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
°C = (°F -32) ÷ 1.8
°F = (°C x 1.8) + 32 -103 -75.00
-101.2 -74.00
-99.4 -73.00
-97.6 -72.00
-95.8 -71.00
-94.0 -70.00
-92.2 -69.00
-90.4 -68.00
-88.6 -67.00
-86.8 -66.00
-85.0 -65.00
-83.2 -64.00
-81.4 -63.00
-79.6 -62.00
-77.8 -61.00
-76.0 -60.00
-74.2 -59.00
-72.4 -58.00
-70.6 -57.00
-68.8 -56.00
-67.0 -55.00
-65.2 -54.00
-63.4 -53.00
-61.6 -52.00
-59.8 -51.00
-58.0 -50.00
-56.2 -49.00
-54.4 -48.00
-52.6 -47.00
-50.8 -46.00
-49.0 -45.00
-47.2 -44.00
-45.4 -43.00
-43.6 -42.00
-41.8 -41.00
-40 -40.00
-38 -38.89
-36 -37.78
-34 -36.67
-32 -35.56
°F°C
°F°C °F °C °F °C
-30 -34.44
-28 -33.33
-26 -32.22
-24 -31.11
-22 -30.00
-20 -28.89
-18 -27.78
-16 -26.67
-14 25.56
-12 -24.44
-10 -23.33
-8 -22.22
-6 -21.11
-4 -20.00
-2 -18.89
0-17.78
1 -17.22
2 -16.67
3-16.11
4 -15.56
5-15.00
6-14.44
7 -13.89
8 -13.33
9 -12.78
10 -12.22
11 -11.67
12 -11.11
13 -10.56
14 -10.00
15 -0.44
16 -8.89
17 -8.33
18 -7.78
19 -7.22
22 -6.11
21 -6.11
22 -5.56
23 -5.00
24 -4.44
25 -3.89
26 -3.33
27 -2.78
28 -2.22
29 -1.67
30 -1.11
31 -0.56
32 0.00
33 0.56
34 1.11
35 1.67
36 2.22
37 2.78
38 3.33
39 3.89
40 4.44
41 5.00
42 5.56
43 6.11
44 6.67
45 7.22
46 7.78
47 8.33
48 8.89
49 9.44
50 10.00
51 10.56
52 11.11
53 11.67
54 12.22
55 12.78
56 13.33
57 13.89
58 14.44
59 15.00
60 15.56
61 16.11
62 16.67
63 17.22
64 17.78
65 18.33
66 18.89
67 19.44
68 20.00
69 20.56
70 21.11
71 21.67
72 22.22
73 22.78
74 23.33
75 23.89
77 25.00
77 25.00
78 25.56
79 26.11
80 26.67
81 27.72
82 27.78
8328.33
84 28.89
85 29.44
8630.00
87 30.56
88 31.11
89 31.67
90 32.22
91 32.78
92 33.33
93 33.89
94 34.44
95 35.00
96 35.56
97 36.11
98 36.67
99 37.22
100 37.78
101 38.33
102 38.88
103 39.44
104 40.00
Supporting Information
Temperature Conversion Formula (Continued)
11-5
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
°C = (°F -32) ÷ 1.8
°F = (°C x 1.8) + 32
(Continued)
°F °C °F °C °F °C °F °C
105 40.55
106 41.11
107 41.66
108 42.22
109 42.77
110 43.33
111 43.88
112 44.44
113 45.00
114 45.55
115 46.11
116 46.66
117 47.22
118 47.77
119 48.33
120 48.89
121 49.44
122 50.00
123 50.55
124 51.11
125 51.67
126 52.22
127 52.77
128 53.33
129 53.88
130 54.44
131 55.00
133 56.11
133 56.11
134 56.66
135 57.22
136 57.77
137 58.33
138 58.88
139 59.44
140 60.00
141 60.55
142 61.11
143 61.66
144 62.22
145 62.78
146 63.33
147 63.88
148 64.44
149 65.00
150 65.56
151 66.11
152 66.66
153 67.22
154 67.77
155 68.33
156 68.88
157 69.44
158 70.00
159 70.55
160 71.11
161 71.66
162 72.22
163 72.77
164 73.33
165 73.89
166 74.44
167 75.00
168 75.55
169 76.11
170 76.67
171 77.22
172 77.77
173 78.33
174 78.88
175 79.44
176 80.00
177 80.55
178 81.11
179 88.66
180 82.22
181 82.77
182 83.33
183 83.88
184 84.44
185 85.00
186 85.55
187 86.11
189 87.22
189 87.22
190 87.78
191 88.33
192 88.88
193 89.44
194 90.00
195 90.55
196 91.11
197 91.66
198 92.22
199 92.77
200 93.33
205 96.11
210 98.89
215 101.67
220 104.44
225 107.22
230 110.00
235 112.78
240 115.56
245 118.33
250 121.11
255 123.89
260 126.67
265 129.44
270 132.22
275 135.00
280 137.78
285 140.55
290 143.33
295 146.11
300 148.89
305 151.67
310 154.44
315 157.22
320 160.00
325 162.78
330 165.56
335 168.33
340 171.11
345 173.89
350 176.67
355 179.44
360 182.22
365 185.00
370 187.78
375 190.55
380 193.33
385 196.11
390 198.89
395 201.67
400 204.44
405 207.22
410 210.00
415 212.78
425 215.56
425 218.33
430 221.11
435 223.89
440 226.67
445 229.44
450 232.22
455 235.00
460 237.78
465 240.55
470 243.33
475 246.11
480 248.89
485 251.67
490 254.44
495 257.22
Supporting Information
Glossary
11-6 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Abrasion-resistance
Ameasure of the ability of
awire or wire covering to
resist damage by mechani-
cal means.
Accelerated Aging
Atest in which voltage,
temperature, or other test
parameters are increased
above normal operating
values to obtain observable
deterioration in a relatively
short time. The plotted
results give service life with-
in the context of the test.
Adapter
Adevice usually attached
to the rear of connectors
that provides for the attach-
ment of harnessing compo-
nents, such as strain-relief
clamps, heat-shrinkable
boots, and braid.
Adhesive Liner
Lining that melts and flows
inside a sleeve or molded
part, filling any voids in
between the substrate and
the sleeve or molded part.
DuraSeal has an adhesive
liner.
Adhesive (Hot Melt)
Dual-wall tubing and pre-
coated molded parts whose
inner layer melts and flows
when heated, fills voids in
the areas being covered,
and forms a mechanical
bond to the substrate.
Unlike an encapsulant, an
adhesive forms a mechani-
cal bond to the substrate.
Aging
Change in the properties of
amaterial over time and
under specific conditions.
Generally refers to environ-
mental stimulus such as
heat and light.
Altitude Immersion Seal
Aseal able to withstand
substantial pressure
change (for example, from
sea level to 75,000 feet).
Amnesia
The tendency over time for
aheat-shrinkable elas-
tomeric tubing or molded
part to fail to recover com-
pletely to its specified
recovered size.
See Shelf Life.
Ampacity
See Current-carrying
Capacity.
ASTM
(American Society for Testing
and Materials)
Anonprofit industry wide
organization that formulates
test methods and material
specifications, and publish-
es standards, testing meth-
ods, recommended
practices, definitions, and
other materials.
Attenuation
Power loss resulting in
weaker signals in an electri-
cal system as the signals
travel along wires. In
cables, generally
expressed in dB per unit
length, usually 100 feet.
AWG
(American Wire Gauge)
The recognized method (in
the United States) of speci-
fying conductor size. The
higher the gauge number,
the smaller the conductor
size.
Back-mounted
Atermination assembly
mounted from the inside of
apanel or box with its
mounting flange inside the
equipment.
Band Marking
Acontinuous circumferen-
tial band applied to a wire
at regular intervals for iden-
tification.
Bare Conductor
Aconductor not covered
with insulating material.
Barrel
1.) Connector barrel: The
section of the terminal,
splice, or contact that
accommodates the
stripped conductor.
2.) Insulation barrel: The
section of the terminal,
splice, or contact that
accommodates the con-
ductor insulation.
3.) Open barrel: The section
of a cap that accommo-
dates the conductor.
Batch Number
See Lot Number.
Bayonet Coupling
Aquick-coupling device for
plug and receptacle con-
nectors. Mating is accom-
plished by rotation of the
two parts under pressure.
Beaming
Crosslinking by means of
high-energy electrons.
Binder
Aspiral wrapping of a
thread to hold together the
members of a cable.
Blocking
The sticking together of
insulated wires; usually
caused by heat.
Body
Aprotective covering of
resilient material over any
portion of a cable, wire
termination, or termination
assembly in addition to
normal jacketing of insula-
tion, to prevent entry of
moisture. Also, a form for
holding potting compound.
Bonding Temperature
Temperature above which
adhesive melts and flows
sufficiently to form an
adhesive bond between
substrates.
Braid
Awoven metallic or fiber
layer applied over wire or
cable to act as a protective
barrier or shielding.
Supporting Information
Glossary (Continued)
11-7
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Braid Angle
The angle between the
braid strands and the axis
ofthe cable.
Breakdown Voltage
The voltage at which an
insulator or dielectric fails
to maintain the applied
voltage.
Breakout
Aregion in a harness
assembly where a wire or a
group of wires is detached
to form a separate, termi-
nated branch. Also known
as a transition.
Brittle Temperature
The temperature below
which a material becomes
brittle, often measured by a
cold impact test.
Bunch Stranding
Amethod of twisting individ-
ual strands to form a fin-
ished stranded conductor.
Specifically, a number of
strands twisted together in
acommon direction and
with a uniform pitch (or
twist) per inch.
Bus
Acommunal circuit over
which data or power is
transmitted.
Cable
Two or more wires in a twist-
ed or parallel configuration.
Also, a shielded wire.
Cable Clamp
Amechanical clamp
attached to the cable side
of a termination assembly to
support the cable or wire
bundle. It provides strain
relief and absorbs vibration
and shock that would other-
wise be transmitted by the
cable terminations.
Cable Clamp Adapter
Amechanical adapter that
attaches to the rear of a ter-
mination assembly to allow
the attachment of a cable
clamp.
Cable Sealing Clamp
Adevice consisting of a
gland nut designed to seal
around the jacket of a
cable.
Cabler
Amachine that mechanical-
ly assembles a group of
insulated wires.
Cabling
The act of twisting together
two or more insulated com-
ponents to form a cable.
Capacitance
The ability of an insulation
to store electrical energy.
This is a function of the per-
mittivity (dielectric constant)
of the insulation. Usually
expressed in pico
farads/foot for a cable.
Carrier
Agroup of strands or ends
used to form a finished
braid.
Characteristic Impedance
The impedance of a trans-
mission line that is indepen-
dent of length. Also, the
ratio of voltage to current at
any point along a transmis-
sion line on which there are
no standing waves.
Chemical Resistance
The ability of an insulation
to withstand the presence
of materials—such as
acids, bases, water, salt
water, and fuels—that can
deteriorate the insulation, or
that, if penetrable to the
conductor, can cause
dielectric loss of insulating
qualities.
Cheminax Cables
Raychem’s registered trade
name for coaxial cables.
Circuit
The interconnection of a
number of electrical ele-
ments or parts to accom-
plish a desired function.
Clocking
The arrangement of con-
nector inserts, jackscrews,
polarizing pins, sockets,
keys/keyways, or housing
configurations to prevent
the mismating or cross-mat-
ing of connectors. See also
Polarization.
CMA (Circular Mil Area)
The unit for expressing the
cross-sectional area of a
conductor. Equal to the
diameter of a conductor
strand (expressed in mils)
squared, times the number
of strands.
Coax
See Coaxial Cable.
Coaxial Cable
Acable composed of two
insulated conductors—such
as a conductor and a
shield—whose center axis
is the same. Usually this
term applies only to cable
used in electronic signal
circuits.
Cold Bend
Atest conducted by wrap-
ping tubing or cable around
amandrel or by bending it
in an arc while at a low tem-
perature.
Cold Flow
Permanent deformation of
polymeric materials (insula-
tion) at ambient tempera-
ture due to mechanical
force or pressure (not due
to heat softening).
Cold Impact
Atest performed by sub-
jecting a component to a
specified impact during
exposure to low tempera-
ture. It measures the brittle-
ness of the material.
Cold Joint
Asoldered joint made with
insufficient heat. (Solder
hasn’t completely flowed
and wet the substrate.)
Supporting Information
Glossary (Continued)
11-8 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
difference causing the flow.
The reciprocal of resis-
tance.
Conductor
The metallic strand or
strands used to carry an
electric current.
Conductor Resistance
The resistance to flow of the
electrical current along a
conductor. Expressed in
ohms/1000 feet. (Usually
referenced to 20°C [68°F]).
Conduit
Atubular raceway for hold-
ing wires or cables.
Configuration
Arrangement of contacts
in a multiple-contact
connector.
Connector
Adevice used to physically
and electrically connect two
or more conductors.
Connector Classes
Categories based on
shape, function, and small-
est-size contact in a series.
Connector Insert
In connectors with metal
shells, the part that holds
contacts in proper arrange-
ment while electrically insu-
lating them from each other
and from the shell.
Contact
The element in a connector
that makes the actual elec-
trical connection. Also the
parts of a connector that
actually carry the electrical
current, and are touched
together or separated to
control the flow.
Contact Crimp
Acontact whose rear por-
tion is a hollow cylinder that
accepts the conductor. A
crimping tool is applied to
swage or form the contact
metal firmly against the con-
ductor. Sometimes referred
to as a solderless contact.
Contact Resistance
The direct-current resis-
tance of a pair of mated
contacts.
Contact Size
The diameter of the
engagement end of a pin
contact; also related to the
current-carrying capacity
of a contact.
Continuity
Acontinuous path for
the flow of current in an
electrical circuit.
Continuous Operating
Temperature
Maximum temperature at
which a component will
maintain an acceptable life-
time performance, based
on accelerated aging pre-
diction.
Continuous Service
Conditions (time, tempera-
ture, environment) that
describe the lifetime
requirements of a compo-
nent.
Core
1.) In cables, a component
or assembly of compo-
nents over which addi-
tional components, such
as a shield or a sheath,
are applied.
2.) Inner wall of dual-wall
heat-shrinkable tubing.
Coupling Ring
The portion of a plug that
aids in the mating and
demating of a plug and
receptacle and holds the
plug to the receptacle.
Cover, Electrical Connector
An item specifically
designed to cover the
mating end of a connector
for mechanical and/or
environmental protection.
Also known as a dust cover.
Coverage
Color Code
Ameans of identifying
cable components using
solid colors or stripes. Also,
the scheme that assigns a
number from 0 to 9 for each
of 10 colors.
Color Stability
The time and temperature
ranges within which the
color of a material will
remain within the specified
color limit.
Component
Awire or cable that is com-
bined with other wires or
cables to make a multicom-
ponent cable.
Compound
An insulating or jacketing
material made by formulat-
ing polymeric materials and
additives.
Compound Under Strands
(CUS)
Aproblem that occurs
when loose stranding, or
overheating during extru-
sion, allows compounds to
get under individual strands
of conductor.
Concentric Stranding
Amethod of stranding
conductor. Specifically, the
final conductor is built up in
layers so that the inner
diameter of a succeeding
layer is always equal to
the outer diameter of the
underlying layer.
Concentricity
Ratio (expressed as a per-
centage) of the thinnest to
the heaviest wall thickness.
Measured on expanded or
recovered tubing, or wire
insulation, or jacketing.
Conductivity
The capability of a material
to carry electrical current,
usually expressed as a per-
centage of copper conduc-
tivity (copper being 100%).
Specifically, the ratio of the
current flow to the potential
Supporting Information
Glossary (Continued)
11-9
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Acalculated percentage
that defines the complete-
ness with which a braid or
shield covers the surface of
the underlying insulated
conductor or conductors.
Crimp
Final configuration of a ter-
minal barrel formed by the
compression of the terminal
barrel and conductor.
Crimping Die
Portion of the crimping tool
that shapes the crimp.
Crimping Tool
Mechanism used for
crimping.
Crosslinking
The formation of bonds
between molecular chains
in a polymer by means of
chemical catalyzation or
electron bombardment. The
properties of the resulting
thermosetting material are
usually improved.
Crosslinking by Irradiation
Amethod of crosslinking
polymers that makes a non-
flowing material. This gener-
ally improves the properties
of the polymer.
Crosstalk
Signal interference between
adjacent conductors
caused by a transfer of
energy.
Crystallinity
The portion of polymer
chains that are ordered in a
regular (as opposed to
amorphous) structure or a
crystal lattice. Crystallinity
tends to improve mechani-
cal properties and fluid
resistance. Crystalline or
semicrystalline materials
have a well-defined melting
point (shrink temperature) at
which the structure
becomes disordered and
the polymer flows.
CSA (Canadian Standards
Association)
An agency that has devel-
oped standard specifica-
tions for products with
particular emphasis on
safety in the end use.
Curing
See Thermoset.
Current
Amovement or flow of elec-
trons. Also, the measure of
this flow, expressed in
amperes.
Current-carrying Capacity
The maximum current an
insulated conductor is
capable of carrying without
exceeding its insulation-
and /or jacket-temperature
limitations under specified
ambient conditions. Also
known as ampacity.
Current Rating
The maximum continuous
electrical flow of current for
which a device is designed
to conduct for a specified
time at a specified opera-
tion temperature. Usually
expressed in amperes.
Cutout
The hole, usually round or
rectangular, cut into a metal
panel in order to mount a
connector. The cutout may
also include holes for
mounting screws or bolts.
Cut-through Resistance
Resistance of solid material
to penetration by an object
(typically a closely con-
trolled knife edge) under
conditions of pressure,
temperature, and other
elements.
Dielectric
Any insulating material
between two conductors
that permits electrostatic
attraction and repulsion to
take place across it. A
material having electrical
insulating properties.
Dielectric Breakdown
The voltage required to
cause an electrical failure or
breakthrough of the insula-
tion. Determined by a
destructive test. See also
Breakdown Voltage.
Dielectric Constant
(also K)
The ratio of the capacitance
between two electrodes
with a solid, liquid, or
gaseous dielectric, to the
capacitance with air
between the electrodes.
Also called permittivity and
specific inductive capacity.
Generally low values are
desirable for insulation.
Dielectric Strength
The maximum voltage a
dielectric can withstand
without rupture. Usually
expressed as volts per mil.
Dielectric Withstand Voltage
(DWV)
Atest voltage for a wire,
cable, or insulation.
Direct Current Resistance
(DCR)
The resistance offered by
any circuit to the flow of
direct current.
Direction of Lay
The lateral direction in
which the strands or
elements of a cable run
over the top of the cable
as they recede from the
observer. Expressed as
right-hand or left-hand lay.
Discontinuity
Abroken connection, or the
loss of a specific connec-
tion characteristic. Also, the
temporary interruption or
variation in current or volt-
age.
Dissipation Factor
The ratio between the per-
mittivity and the conductivi-
ty of a dielectric.
Drain Wire
Supporting Information
Glossary (Continued)
11-10 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Description of a system to
keep out moisture, dirt, air,
or dust that might reduce
performance.
Epoxy
Afamily of thermosetting
resins usually used as
adhesives or encapsulants.
ETFE
(Ethylenetetrafluoroethylene)
Afluoropolymer used as
base resin for SPEC 55 wire
and HCTE.
Expanded ID (EID)
The specified minimum (as
supplied) internal diameter
of tubing.
Expansion Ratio
An expression of how much
larger the inside diameter of
atubing is before shrinking.
Specifically, the relationship
of the minimum (expanded)
inside diameter of tubing to
the maximum (recovered)
inside diameter, expressed
as a ratio. See also Shrink
Ratio.
Extraction Tool
Atool used for removing
contacts from a connector
body.
Extrusion
Aprocess that conveys
plastic insulation material,
generally via a screw,
through forming dies and
subsequently cools the
insulation material to form a
predetermined shape.
Feedthru (feedthrough)
Abushing in a wall or bulk-
head with terminations on
one or both sides.
Filler
Amaterial used in a cable
construction to fill large
interstices, thus providing a
round construction; can be
shaped, round, or in mastic
forms. A nonfunctional
member used in a cable to
provide a more circular
cross section.
Flame-resistant
Adescriptor applied to a
material that is inherently
resistant to burning.
Flame Retardant
Adescriptor applied to a
material that has been
made or treated so as to
resist burning.
Flat Braid
Abraided shield composed
of flat strands.
Flat Cable
Acable with each compo-
nent in a single, flat plane.
Flat Conductor
Aconductor having a
rectangular cross section,
as opposed to a round or
square cross section.
Flex Life
Ameasure of the suscepti-
bility of a conductor or other
device to failure due to
fatigue from repeated
bending.
Fluoropolymer
Apolymer that contains
atoms of fluorine.
Flux
Aliquid or solid that, when
heated, exercises a clean-
ing and protective action
upon surfaces.
Used to promote or facili-
tate fusion during soldering
or welding.
Front Release Contacts
Connector contacts that are
released from the front side
of the connector and then
removed from the back,
wire side of the connector.
Full Recovery Temperature,
Minimum
See Recovery Temperature.
Gauge
Aterm used to denote the
physical size of a wire.
See also AWG.
In a cable, an uninsulated
conductor laid over the
component, or compo-
nents, in a foil-shield cable.
Used as a ground connec-
tion.
Dust Cover
See Cover, Electrical
Connector.
EID
See See Expanded ID.
Elastic Memory
The ability of a crosslinked
polymer to be deformed to
some predetermined
shape, hold that shape for a
period, and then return to
its original shape upon the
application of heat.
Elastomer
Amaterial that exhibits very
low or zero crystallinity and
ahigh degree of flexibility
(rubber is a synonym).
Elongation
The ultimate elongation, or
elongation at rupture.
Expressed as a percentage
of original length.
EMI
Abbreviation for electro-
magnetic interference.
Encapsulant
Description related to the
way dual-wall tubing prod-
ucts and precoated molded
parts melt and flow when
heated, filling any void in
the area being covered.
Unlike an adhesive, an
encapsulant does not form
amechanical bond to the
substrate.
Encapsulation
Covering and sealing.
End
The number of fibers or
strands per carrier in braid-
ing operations.
Environmentally Sealed
Supporting Information
Glossary (Continued)
11-11
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Grounding Conductor
Aconductor that provides a
current return path from an
electrical device to ground.
Hardness
Ageneral term that corre-
lates with strength, rigidity,
and resistance to abrasion
or penetration. Measured
on Shore or Rockwell
scales. See also Shore.
Harness
Asystem providing electri-
cal connection between two
or more points.
Heat Aging
Atest that subjects compo-
nents or materials to tem-
peratures above normal
operating values to evaluate
changes in performance in
order to predict service life.
See also Accelerated
Aging.
Heat Shock
Atest to determine the
stability of a material by
continuously exposing it
to an extremely high tem-
perature for a short period
of time. The test was
developed both to
demonstrate that the
material is crosslinked
and to observe any
problems in dripping,
cracking, or flowing.
Heat-Shrinkable Material
Apolymeric material
capable of being reduced
in size when exposed to
heat.
Hertz (Hz)
Ameasure of frequency
equal to one cycle per
second.
Hookup Wire and Cable
Wiring used to connect
various points in electronic
assemblies.
Hot-Melt Adhesive
An adhesive that becomes
activated by heating. When
heated, it melts, flows over
the substrate surface, and
forms an adhesive bond.
Reheating causes the
adhesive to remelt.
ID (Internal Diameter)
The inside or internal
diameter of a tubing.
Impedance
The total opposition that a
circuit offers to the flow of
alternating current or any
other varying current at a
particular frequency. The
ohm is the unit of imped-
ance. Admittance is the
reciprocal of impedance.
Impulse Test
Ahigh-voltage test
designed to locate pinholes
in the insulation of a wire or
cable by applying a voltage
while the wire or cable is
being drawn through an
electrode.
Insert Cavity (Connector)
Adefined hole in the con-
nector insert into which the
contacts are inserted.
Insert
Meltable thermoplastic
ring placed within a
SolderSleeve device.
Aids in encapsulation
and sealing.
Insert (Connector)
Part that holds the contacts
in their proper arrangement
and electrically insulates
them from each other and
from the shell.
Insert Arrangement
(Connector)
The number, spacing, and
arrangement of contacts in
atermination assembly.
Insertion Tool (Connector)
Atool used to insert
removable contacts into a
connector.
Inspection Hole
Ahole placed at one end of
acontact barrel to permit
visual inspection, to ensure
that the conductor has been
inserted to the proper depth
in the barrel prior to crimp-
ing or soldering.
Insulated Terminal
Asolderless terminal with
aninsulated sleeve over the
barrel to prevent a short cir-
cuit in certain installations.
Insulation, Electrical
Anonconductive material
usually surrounding or
separating two conductive
materials. Often called
the dielectric in cables
designed for high-
frequency use.
Insulation, Thermal
Anonconductive material
that prevents the passage
of heat.
Insulation Resistance
Minimum electrical resis-
tance permitted between
any pair of contacts and
between conductors and
grounding devices of the
same connectors in various
combinations. An indication
of the insulating properties
of a material.
Interconnection
The joining of one individual
device with another.
Interstice
In a cable construction, the
space or void left between
or around the cabled com-
ponents.
Irradiation
In insulations, the exposure
of the material to high-
energy emissions for
the purpose of favorably
altering the molecular
structure via crosslinking.
Supporting Information
Glossary (Continued)
11-12 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Lanyard
Adevice, attached to
certain quick-disconnect
connectors, that permits
uncoupling and separation
of connector halves by a
pull on a wire or cable.
Lay
Refers to direction or some-
times the ratio of lay length
to core diameter.
Lay Length
Aterm used in cable manu-
facturing to denote the dis-
tance of advance of one
member, or a group of spi-
rally twisted members in
one turn, measured axially.
The lay of any helical ele-
ment of a cable or conduc-
tor is the axial length of a
turn of the helix of that ele-
ment.
Life Cycle
Atest to determine the
length of time before failure
in a controlled, usually
accelerated environment.
Liner
See Core.
Longitudinal Change (Shrink
Tubing)
The change in length of
tubing when recovered.
Expressed in the percent
of change from the original
length.
Loss
Electrical energy that is
dissipated as heat.
Loss Factor
The product of the power
factor and dielectric con-
stant of an insulating
material.
Lot Number
The number that identifies
one production run of mate-
rial. Also known as a batch
number.
Low-loss Dielectric
An insulating material that
has a relatively low dielec-
tric loss, such as polyethyl-
ene or Teflon®.
Lug
Atermination, usually
crimped or soldered to a
conductor, that allows
connection to be made
with a retaining screw.
Marking
Aprinted identification
number or symbol applied
to the surface of a wire or
cable.
Mate (Connections)
To join connector halves in
anormal engaging mode.
Megarad
Aunit for measuring radia-
tion dosage.
Melt/Flow Index
Measurement of the flow of
thermoplastic material
under given conditions of
temperature and pressure.
Expressed as grams per
unit of time.
Melting Point
The temperature at which
crystallinity disappears
when crystalline material is
heated.
Mil
Aunit equal to one one-
thousandth of an inch
(.001"); used in measuring
the diameter of a conductor
or thickness of insulation
over a conductor.
MIL-SPEC
Abbreviation for Military
Specification, which is a
document the U.S.
Government issues to
define a product that will be
used in military end-use
applications.
Jackscrew
Ascrew attached to one
half of a two-piece, multi-
ple-contact connector and
used to draw both halves
together and to separate
them.
Jacket
1.) A material covering
over a wire or cable
assembly.
2.)Outer covering of a
dual-wall heat-shrinkable
tubing.
Kapton
DuPont’s trade name for
polyimide film.
Key (Connector)
Ashort pin or other projec-
tion that slides into a mating
slot or groove to guide two
parts being assembled.
Keying (Connector)
Mechanical arrangement
of guide pins and sockets,
keying plugs, contacts,
bosses, slots, keyways,
inserts, or grooves in a
connector housing, shell or
insert that allows connec-
tors of the same size and
type to be lined up; used in
situations where there is
danger of making a wrong
connection.
Keyway
The slot or groove in which
akey slides.
kV (Kilovolt)
Aunit equal to 1000 volts.
Kynar
Trade name (of Atofina
Chemicals, Inc.) for
polyvinylidene fluoride and
its copolymers.
Lacing Cord or Twine
Used for lacing and tying
cable forms, hookup wires,
cable ends, cable bundles,
and wire harness assem-
blies. Available in various
materials and impregnants.
TEFLON is a trademark of E.I. du Pont
de Nemours and Company
Supporting Information
Glossary (Continued)
11-13
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Milking Off
Action that occurs when the
inner layer (the encapsulant
oradhesive) of the tubing or
molded part acts as a lubri-
cant, allowing the tubing to
slip off the substrate
(because the tubing wants
to recover to a smaller
diameter).
Minimum Full Recovery
Temperature
See Recovery Temperature.
MO (Manufacturing Order)
Aseries of operation-work-
order cards identifying
materials to be used and
the type and quantity of
products to be manufac-
tured. An MO is controlled
and issued by Production
Control to the manufactur-
ing operation.
MOD Code (Material
Modification Code)
Acode designating a par-
ticular stage in the produc-
tion process. Most MOD
codes describe the way the
product is packaged.
MS (Manufacturing
Specification)
Aset of process instruc-
tions used in the manufac-
turing of tubing products.
Customer Logistics,
Product Management, or
Manufacturing Engineering
initiate the MS;
Manufacturing Engineering
controls it. The product
design and quality parame-
ters are provided to
Manufacturing Engineering
by Product Development
and Quality Assurance.
Successful trial runs of a
new product or design
usually precede the initia-
tion of an MS (see SMO).
Aproprietary Raychem
document, an MS is not
available to customers.
Multiconductor
More than one component
within a single-cable
complex.
Multiple-Conductor Cable
Acombination of two or
more components cabled
together.
Nick
Asmall cut or notch in con-
ductor strands or insulation.
Nominal
Adescriptor applied to a
dimension representing the
center of the range of toler-
ance or a value if no toler-
ance is applied.
OFT (Optional Flame Test)
Canadian Standards
Association’s test for flame-
retardance. Tubing with an
OFT rating is highly flame-
retardant.
Ohm
The unit of electrical
resistance.
Operating Temperature
The maximum internal tem-
perature at which a system,
harness, or connector may
operate in continuous ser-
vice; generally expressed
as a time and temperature.
Operating Temperature Range
The range between the
maximum and the minimum
internal temperature of insu-
lation in a system, harness,
or connector in continuous
service. The lower limit is
determined by low-temper-
ature flex test.
Optional Flame Test
See OFT.
Packaging
The process of physically
locating, connecting, and
protecting devices or com-
ponents.
Panel
The side or front (usually
metal) of a piece of equip-
ment on which connectors
are mounted.
Panel-mount
Method of fixing one-half of
aconnector to a board,
panel, or frame. Usually, the
female half of the connector
is the mounted portion and
the male half is the remov-
able portion.
PC (Production Control)
Group responsible for
directing and regulating the
movement of goods through
the entire manufacturing
cycle, from the requisition-
ing of raw materials to the
delivery of the finished
products.
PCN
See RPN.
Peripheral Seal
Aseal provided around the
periphery of connector
inserts to prevent the
ingress of fluids or contami-
nants at the perimeter of
mated connectors.
Permittivity
See Dielectric Constant.
Pick
The number of crossovers
of braiding units per inch
of cable.
Pigtail
Ashort conductor or wire
extending from an electrical
or electronic device to
serve as a jumper or ground
connection.
Pin Contact
An electrical terminal,
usually in a connector.
Normally a smaller termina-
tion than a lug.
Plastic Deformation
Change in dimensions
under a load that does not
recover when the load is
removed.
Plasticizer
Asoftener or lubricant
added to a compound to
make it easier to process
or more flexible in use.
Plating
Supporting Information
Glossary (Continued)
11-14 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
The permanent sealing of
the cable end of a connec-
tor with a compound or
material that thermosets into
an elastomer, to exclude
moisture and/or to provide
strain relief.
Pre-etching
The act of surface prepara-
tion before encapsulating.
Pretinned
Description of an electrical
component to which solder
has been applied prior to
soldering.
Pretinned Solder Cup
Solder cup whose inner sur-
faces have been precoated
with a small amount of sol-
der.
Preform
Usually, the solder ring in a
SolderSleeve device.
Primary Insulation
The inner member of a
dual-wall wire insulation.
The insulation applied
directly on the conductor.
Also referred to as the core.
See also Core.
Push-back
That property of a braid or
shield that allows the braid
or shield to be pushed back
easily along the cable core.
PVC (Polyvinyl chloride)
Apolymer compound used
as wire insulation.
PVDF
Polyvinylidene fluoride.
Quality Assurance
Systematic, planned, and
documented activities
designed to provide confi-
dence that a product will
meet specifications.
Quality Control
Activities that monitor, mea-
sure, and control the char-
acteristics of a material,
component, or product to
documented specifications.
Quick Disconnect
Atype of connector shell
that permits rapid locking
and unlocking of two
connector halves.
RA Flux
Rosin-activated flux.
Radiation Crosslinking
The act of crosslinking a
material with ionizing radia-
tion. (Most Raychem prod-
ucts are radiation
crosslinked, with an elec-
tron beam as the form of
ionizing radiation.) See also
Crosslinking by Irradiation.
Rated Temperature
The maximum temperature
at which a component can
operate for extended peri-
ods with acceptable
changes in its basic
properties.
Rated Voltage
The maximum voltage at
which an electric compo-
nent can operate for
extended periods without
undue degradation.
Rear Release Contacts
Connector contacts
designed to be released
and removed from the rear
(wire side) of the connector.
The removal tool engages
the contact from the rear
and pulls the contact out of
the connector contact
retainer.
Receptacle
Usually the fixed or station-
ary half of a two-piece mul-
tiple contact connector.
Also the connector half usu-
ally mounted on a panel
and containing socket con-
tacts.
Recover (Heat-shrinkable
Components)
Activation of the elastic
memory principle (usually
with heat) to cause a tubing
or molded part to return to
its original size.
Recovered ID (RID)
The overlaying of a thin
coating of metal on metallic
components to improve
conductivity, facilitate
soldering, or prevent
corrosion.
Plug
The part of a connector that
is normally “removable”
from the other, permanently
mounted part; usually that
half of a two-piece connec-
tor that contains the pin
contacts.
Plug Connector
An electrical connector that
is intended to be attached
to the free end of a conduc-
tor, wire, cable, or bundle,
and that couples or mates
to a receptacle connector.
Poke Through
Aterm describing stray
wires in a solder joint that
poke through the insulation.
Polarization (Connectors)
Amechanical arrangement
of inserts or the shell con-
figuration (referred to as
clocking in some instances)
that prohibits the mating of
mismatched plugs and
receptacles. See also
Clocking.
Polyamide
Apolymer formed by the
reaction of a diamine and a
diacid. Nylons are commer-
cial polyamides character-
ized by toughness, solvent
resistance, and sharp melt-
ing point.
Polymer
Amaterial of high molecular
weight formed by the chem-
ical union of monomers.
Polyolefin
Afamily of polymers (such
as polyethylene and
polypropylene) made from
olefin monomers.
Potting
Supporting Information
Glossary (Continued)
11-15
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
In heat-shrink tubing, the
guaranteed maximum inter-
nal diameter of tubing after
being freely recovered.
Recovery Temperature
The minimum temperature
required to fully shrink a
product, that is, for the
product to recover com-
pletely.
Removable Contact
Acontact that can be
mechanically joined to or
removed from an insert.
Usually special tools are
required to lock the contact
in place or remove it for
repair or replacement.
Resistance
Ameasure of the difficulty
in moving electrical current
through a conductor or
insulation when a voltage is
applied. It is measured in
ohms.
Ribbon Cable
Flat cable with conductors
that have been individually
insulated together. Its struc-
ture is usually characterized
by individual colors of insu-
lation for each conductor,
although a single color may
be used for all conductors.
RID
See Recovered ID.
RMA Flux
Rosin-mildly-activated flux.
Rope Lay
Atype of conductor lay that
uses stranded conductors
as components to build a
larger conductor.
RPN (Raychem Product
Number)
A10-digit number (such as
123456-4-001) assigned to
every standard product and
every product manufac-
tured on a special manufac-
turing order (SMO). The first
6digits represent the PCN
(Product Control Number),
followed by a 1-digit MOD
Code, and finally a 3-digit
suffix. See also MOD Code
and SMO.
RT and RW specifications
Specification that describes
standard product proper-
ties. Qualification and
acceptance inspection cri-
teria are incorporated into
RT and RW specifications.
RT and RW specifications
are issued and controlled
by the Specifications
Group.
SCD (Specification Control
Drawing)
Drawing that defines con-
figuration and material
parameters. Issued and
controlled by the specifica-
tions group, SCDs are fre-
quently used in conjunction
with RT Specifications for
Thermofit products.
Scoop-proof
Afeature that prevents the
damage of contacts during
misaligned mating.
Sealant
Soft, tacky, pliable material
that seals where mechani-
cal strength is not required.
Sealed
Environmentally protected
by the thermoplastic inserts
or core of encapsulant/
adhesive that has melted
down around the substrate.
Sealing Plug
Aplug that is inserted to fill
an unoccupied contact
aperture in a termination
assembly.
Secant Modulus
Ameasure of material stiff-
ness; stiffer material has a
higher secant modulus.
More specifically, the
secant modulus is the ratio
of stress (nominal) to corre-
sponding strain at any
specified point on the
stress-strain curve.It is
expressed in force per unit
area (usually kilograms per
square centimeters or
pounds per square inch),
and reported together with
the specified stress or
strain.
Service Life
Period of time during which
the product is expected to
perform satisfactorily.
Service Loop
The extra cable required at
abreakout to facilitate
maintenance and servicing.
Service Rating
The maximum voltage or
current that a termination is
designed to carry continu-
ously.
Shelf Life
Generally, the length of time
aproduct or material may
be stored without deteriora-
tion. Specifically, the length
of time during which shrink
tubing will retain its expand-
ed ID and return to its
recovered ID. Usually not a
concern—except for some
“amnesic” materials.
See Amnesia.
Shell (Connector)
The outside case, usually
metallic, into which the
insert (body) and contacts
are assembled. Shells of
mating connector halves
usually provide for proper
alignment and polarization
as well as for protection of
projecting contacts.
Shield
Aconducting layer placed
around an insulated con-
ductor or cable to limit the
penetration, or escape, of
electric or electromagnetic
fields, thereby preventing
electromagnetic interfer-
ence. The shield may be
formed of metallic braid,
metal tape, metal-backed
foil, metal tube, or conduc-
tive polymer. Usually
grounded, the shielding is
Supporting Information
Glossary (Continued)
11-16 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
The ability of a material to
retain physical and electri-
cal properties after being
immersed in specific sol-
vents.
SPC
Silver-plated copper.
SPC (Statistical Process
Control)
The use of statistical tech-
niques such as control
charts to analyze a process
or its output so as to take
appropriate actions to
achieve and maintain a
state of control and to
improve the capability of
the process.
Specific Gravity
The ratio of the density
(mass per unit volume) of a
material to that of water.
Specific Inductive Capacity
See Dielectric Constant.
Splice
Ajoint connecting conduc-
tors with good mechanical
strength and conductivity; a
terminal that permanently
joins two or more wires.
Strain Relief
The technique for or act of
removing or lessening the
strain or stress on a joint,
splice, or termination.
SolderSleeve devices pro-
vide strain relief.
Strain Relief Clamp
See Cable Clamp.
Strand
Asingle unit of a conductor.
Stranded Conductor
Aconductor composed of
more than one single
strand. The strands in
stranded conductors are
usually twisted or braided
together.
Strip
To remove insulation from a
wire or cable.
Stripe
carried through the connec-
tor shell, or through a spe-
cial internal shell in the
case of individual coaxial
contacts.
Shielding
See Shield.
Shielding Effectiveness (SE)
The reduction in field
strength resulting from inter-
posing a metallic barrier
between a source and
receptor of electromagnetic
energy.
Shore
Ascale for comparing hard-
ness. Higher Shore values
represent harder materials.
The hardness of a polymer,
for example, is usually rep-
resented as Shore A or
Shore D, with D being
harder.
Shrink Ratio
An expression of how much
the inside diameter of
shrink tubing will reduce in
size when recovered. The
inverse of the expansion
ratio. See also Expansion
Ratio.
Shrink Temperature, Minimum
The minimum temperature
at which a product begins
to recover.
Signal Cable
Acable designed to carry
current of less than 12
amperes per conductor.
Skew
Any out-of-squareness of
the cut end of a piece of
tubing after shrinking.
SMO (Special Manufacturing
Order)
An order to evaluate manu-
facturing and production
capability for a new or
changed design for a cus-
tomer and to provide devel-
opment samples of
potential products for cus-
tomers. SMO products are
separate and distinct from
standard products. New,
potential products are usu-
ally run as SMO products
for a minimum of three times
before being considered for
manufacture as a standard
product.
Solder
An alloy that melts at rela-
tively low temperatures and
isused to join metals with
higher melt points.
Solder Contact
Acontact or terminal having
acup, hollow cylinder, eye-
let, or hook to accept a wire
for a conventional soldered
termination.
Solder Cup
Atubular end of a terminal
into which a wire conductor
is inserted prior to being
soldered.
Solderability
The property of a metal sur-
face that allows it to be
readily wetted by molten
solder. See also Wetting.
Soldering
Aprocess of joining metallic
surfaces with solder without
melting the base metal.
SolderSleeve Device
Adevice of flux-coated sol-
der preform encapsulated
in a heat-recoverable plas-
tic sleeve. Upon the appli-
cation of heat, the flux and
solder will melt and flow as
the sleeve recovers, forcing
the solder around and onto
the metallic parts being
joined, thus forming an
electrically insulated and
strain-relieved joint.
Solid Conductor
Aconductor composed of
one single strand.
Solvent Resistance
Supporting Information
Glossary (Continued)
11-17
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Acontinuous longitudinal or
spiral color strip applied on
the surface of a wire, cable,
or tubing for identification.
Substrate
The material—such as a
wire, post, or tab—over
which an interconnection
device is used.
Surface Resistance
The ratio of the direct cur-
rent applied to an insulation
system to the current that
passes across the surface
of the system.
Tape Wrap
Aterm denoting a spirally or
longitudinally applied tape
material wrapped around
insulated or uninsulated
wire and used as a
mechanical barrier.
TC
Tinned copper.
Tear Test
Atest to determine the tear
strength of an insulating
material. Usually includes
exposure to given thermal
conditions or a pro-
grammed series of condi-
tions for prescribed periods
of time.
Temperature Rating
The maximum temperature
at which the insulating
material may be used in
continuous operation with-
out loss of its basic proper-
ties. Usually time
dependent.
Tensile Strength
The pull stress (in force per
unit area) required to break
agiven specimen.
Thermal Rating
The effect of heat or cold
applied at such a rate that
nonuniform thermal expan-
sion or contraction occurs
within a given material or
combination of materials. In
electrical terminations, the
effect can cause inserts
and other insulation material
to pull away from the metal
parts.
Thermal Shock
The effect of high and low
temperatures applied at a
rapid rate such that nonuni-
form thermal expansion or
contraction occurs within a
given material or combina-
tion of materials. The result
could be stress-cracking or
-shattering of material.
Thermochromic Indicator
Special compound that
changes color when the
proper wetting temperature
has been reached in the
solder joint.
Thermoplastic
Amaterial that softens
(melts and flows) when
heated and becomes firm
when cooled. A type of
plastic that can be remelted
anumber of times without
any important change in
properties. Nylon, GE’s
Lexan, and PVC—examples
of this type of plastic—are
resilient after molding.
Thermoset
Amaterial that hardens or
sets when heated and,
once set, cannot be resoft-
ened by heating. This appli-
cation of heat is called
“curing.”
Thermosetting Plastic
Atype of plastic in which an
irreversible chemical reac-
tion takes place while the
plastic is being molded
under heat and pressure.
Thermosetting Adhesive
Acuring adhesive that
requires heat to promote
curing. This type of plastic
will not soften when reheat-
ed. See Epoxy.
Tolerance
The total amount by which a
quantity is allowed to vary
from nominal; thus, the tol-
erance is half the algebraic
difference between the
maximum and minimum
limits.
Traceability
The ability to trace the histo-
ry, application, or location of
an item and like items or
activities by means of
recorded identification. The
lot number/manufacturing
order (MO) number, or SMO
number used to identify
items or groups of items is
traceable back to inspection
and procurement records.
Transmission Cable
Two or more transmission
lines. If the structure is flat,
it is sometimes called flat
transmission cable to differ-
entiate it from a round struc-
ture such as a jacketed
group of coaxial cables.
See also Transmission Line.
Transmission Line
Asignal-carrying circuit with
controlled electrical charac-
teristics; used to transmit
high-frequency or narrow-
pulse signals.
Triaxial Cable
Aconcentrically construct-
ed cable, with a common
axis, composed of a center
connector, first shield, and
second shield, all insulated
from each other.
UL (Underwriters’
Laboratories)
Anonprofit independent
testing organization that
operates a listing service for
electrical and electronic
materials and equipment.
Ultraviolet Degradation
The degradation caused by
long-time exposure of a
material to sunlight or other
ultraviolet rays.
Velocity of Propagation
The ratio of the speed of a
radio frequency wave within
acable or dielectric as
compared with the same
wave in free space.
Voltage
Supporting Information
Glossary (Continued)
11-18 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
The term most often used in
place of electromotive
force, potential, potential
difference, or voltage drop
to designate the electric
pressure that exists
between two points and that
is capable of producing a
current when a closed cir-
cuit is connected between
the two points.
Voltage Breakdown
The voltage necessary to
cause insulation failure.
Voltage Drop
Loss of voltage through a
connection or conductor.
Voltage Rating
The voltage that may be
continuously applied to
wire.
Volume Resistivity
Reciprocal of conductivity;
the resistance of a material
to the flow of electrical cur-
rent, usually expressed in
ohm-cm.
VSWR (Voltage Standing Wave
Ratio)
Ameasure of the uniformity
of impedance along a trans-
mission line, or the quality
of the impedance match
between a line and the
source or load.
VW-1
Arating determined by the
Underwriters’ Laboratories’
(UL) optional Vertical Wire
Flame Test—the most diffi-
cult flame test for tubing.
Tubings with a VW-1 rating
are highly flame-retardant.
Wall Thickness
The thickness of the applied
insulation or jacket.
Water Absorption Test
Amethod to determine the
water uptake of a material.
It is time and temperature
dependent.
Water Blocking
The sticking together of
insulated wires; usually
caused by heat.
Wetting (Solder)
The formation of a relatively
uniform, smooth, unbroken,
and adherent film of solder
to a base metal. Also, the
free flow of solder alloy, with
proper application of heat
and flux, on a metallic sur-
face to produce an adher-
ent bond.
Wicking
The longitudinal flow of a
liquid in a wire or cable
construction due to capil-
lary action. (This may also
apply to solder.)
Wire
Asingle conductor covered
with insulation.
Wire Dress
The orderly arrangement of
wires and laced harnesses.
Withstanding Voltage
The test voltage an electri-
cal connector can withstand
for one minute without
showing evidence of
electrical breakdown when
the voltage is applied
between conductors and
grounding devices of the
connectors in various
combinations.
Supporting Information
Part Index
11-19
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Product or Part Number Page Number
-3 Material 4-25
-4 Material 4-27
-12 Material 4-29
-25 Material 4-31
-25S Material 4-33
-50 Material 4-35
-51 Material 4-37
-55 Material 4-39
-71 Material 4-41
-100 Material 4-43
-100S Material 4-45
-125 Material 4-47
101A011 to 094 4-49
10612 8-78
10613 8-78
10614 8-78
202A111 to 196 4-53
202C611 to 663 4-54
202D121 to 196 4-55
202D211 to 299 4-56
202D921 to 963 4-57
202F211 to 274 4-58
202G211 to 253 4-59
202G611 to 653 4-60
202K121 to 185 4-61
202W302 to 342 4-91
207W213 to 256 4-75
214A011 to 052 4-62
214A311 to 352 4-63
214P009 to 037 4-64
222A111 to 196 4-65
222D121 to 196 4-66
222D211 to 299 4-67
222D921 to 963 4-68
222F211 to 285 4-69
222K121 to 185 4-70
234A011 to 071 4-71
234A111 to 152 4-72
234A611 to 671 4-73
242W042 to 63 4-74
301A011 to 048 4-76
301A511 to 514 4-77
322A112 to 158 4-78
342A012 to 058 4-79
362A014 to 114 4-80
381A301 to 304 4-81
382A012 to 046 4-82
382C312, 322 & 332 4-83
400W242 4-93
462A011 to 060 4-84
462A421 to 424 4-85
562A011 to 067 4-86
7724 H 0664 8-78
AA-400 Super Heater 10-2
AD-1319-9 Holding Fixture Tool 10-3
Product or Part Number Page Number
AD-1377, AD-1522 Hand Operated Crimp Tools 10-4
AD-3050-SEAL-TEST-EQUIP 10-5
AD-5000 and RH-396X Tinel-Lock Tools 10-7
AD-5010-Tinel-Bench-230V 10-9
Adhesives 5-2 to 5-7
ATUM Tubing 3-33
B-02X/04X 8-51
B-046 8-53
B-106 8-27 to 8-31
B-202 8-64
BSTS/BSTS-FR 3-53
C-203 8-20, 8-21
CES 4-95
CGPE-105 3-7
CGPT 3-9
Cheminax Coaxial Cables 9-68 to 9-72
Cheminax Twin Axial Cable 9-73, 9-74
Code 18 MIL-C-5015 (MS3100) 6-28 to 6-36
Code 21 MIL-C-26482 Series 1 6-37 to 6-43
Code 32 MIL-C-22992 6-44 to 6-49
Code 40 MIL-C-38999 Series III and IV 6-50 to 6-57
Code 41 MIL-C-38999 Series I and II 6-58 to 6-65
Code 54 MIL-C-5015 (MS3400),
MIL-C-26482 Series 2,
MIL-C-83723 Series I and III,
MIL-C-81703 Series III 6-66 to 6-73
Code 76 BS 9522 F0017 (Pattern 105) 6-74 to 6-76
Computer aided design 9-89
Conductor sizes, strandings and resistance 9-94, 9-95
CRES-Lock Bands 6-27
CRN 3-11
CV-1981, CV-1983 10-11
CWT 8-6, 8-40, 8-44, 8-51
CWT-15XX 8-40
CWT-900X 8-7
D-71X 8-41
D-110 8-6, 8-8, 8-41
D-129 8-40 to 8-42
D-141 8-40 to 8-42
D-150 8-62, 8-63, 8-64 8-90
D-181 8-51, 8-52
D-184 8-51, 8-52
D-406 8-18, 8-19
D-436 8-23, 8-24
D-500 8-79 to 8-86, 8-90, 8-97
D-600 8-75, 8-90
D-602 8-67 to 8-74
D-607 8-53
D-609 8-24
D-621 8-90 to 8-93
D-1744 8-6, 8-9
Data Bus Accessories 8-89 to 8-93
Data Bus Box Couplers 8-85, 8-86
Data Bus Cables 8-77, 8-78
Data Bus Customer-Specified Harness
Assemblies and HarnWare Software 8-98
Supporting Information
Part Index (Continued)
11-20 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Product or Part Number Page Number
Data Bus Discrete Connectors 8-87, 8-88
Data Bus In-line Microcouplers 8-79 to 8-81
Data Bus Space-Grade Components 8-95 to 8-97
Data Bus Triaxial Size 8 Contacts 8-94
Data Bus Ultra Lightweight In-line Microcouplers 8-82
DCPT 3-13
DK-3716 8-93
DK-602 8-94
DK-621 8-87, 8-91, 8-92, 8-93, 8-97
DR-25 3-65
DuraSeal Crimp Terminals & Disconnects 8-27 to 8-32
DuraSeal Crimp Splices 8-18, 8-19
DWP-125 3-35
Electrical Shielding 9-87, 9-88
ElectroLoss FilterLine 9-63 to 9-67
ES1000 3-37
ES2000 3-39
ESCaps 3-67
FDR 25 9-79
Fiber Optic Cables 9-96 to 9-99
FL2500 3-41
FlexLine Wire & Cable 9-25
FlexLite Wire & Cable 9-45
FlexLite DW Wire 9-47
FlexLite HT Wire 9-53
FlexLite MT Wire 9-51
FlexLite TW Wire 9-49
FlexLite TX Wire 9-55
FLT Wire 9-57
FR-1000 Cable 9-27 to 9-34
HarnWare Harness Design Software 2-6 to 2-14
HCTE 3-69
HexaShield High Performance Adapters 8-99 to 8-104
HF 3-55
HFT5000 3-71
HL1802E/HL2005E 10-13
HRHF/HRNF/HRSR 3-57
HTAT 3-43
IR-1891 10-15
IR-550 Mark II 10-17
IR-1759 MiniRay 10-18
KTKK Product Family Overview 7-2
KTKK Assemblies 7-3 to 7-5
LSTT 3-15
MicroFit Tubing 3-73
MiniSeal Crimp Splices 8-22 to 8-25
Model 16B Belt Heater 10-19
Model 19 Conveyor Heater 10-21
Model 81CE Discrete Heater 10-23
Model 105 Tunnel Oven 10-25
MT1000 3-75
MT2000 3-77
MT3000 3-79
MT5000 3-81
MTC Crimp Connectors 8-105 to 8-111
MTCP-122 8-106 to 8-108
Product or Part Number Page Number
Multiconductor, Custom-Designed,
(multi) Cables 9-75
Multiconductor (Multicore) Cables 9-76
NT 3-83
NT-MIL 3-85
NTFR 3-87
PD Caps 3-89
Power Cables (Type TR, FTR, AFR, ZHI, ZHPCG) 9-90
PolyCrimp Wire Splices 8-20, 8-21
QFT 4-87
RayBlock 85 Tubing 3-91
RayBlock 105 Tubing 3-93
Rayflex Polyester Sleeving 3-95
Rayflex PETM 3-97
RayOLOn Kits 4-99
Rayrim Edging Material 3-99
Raythane, Neoprene, Rayolin, AFR 9-86
RBD 8-58
RBK-ILS-Processor MkII 10-27
RCW 9-19 to 9-24
RFOne-step BNC/TNC Connectors 8-55 to 8-60
RHW 3-59
RMW 3-61
RNF-100 3-17
RNF-150 3-101
RNF-3000 3-19
RP-4800 3-21
RPPM 3-45
RT-3 3-23
RT-375 3-103
RT-555 3-105
RTD 8-59, 8-60
RW-175 3-107
S-1006 5-2
S-1009 5-2
S-1017 5-2
S-1030, S-1048, S-1275 (Rayaten) 5-2, 7-9
S-1124 5-2
S-1125 5-2
S-1255 5-2
S-1278 5-2
S-1297 5-2
S-1305 5-2
S01 8-44 to 8-49
S02 8-44 to 8-49
S03 8-46, 8-47
SCL 3-47
SCT 3-49
SESK (Shipboard Electrical Splice Kits) 7-10 to 7-12
SFR 3-109
SGRP 8-12 to 8-17
SGRS 8-12 to 8-17
SGRT 8-33 to 8-36
Ship or Shore Breakout Kits 7-13
shrinkHOoP Grommet 4-101
SO63 8-44 to 8-49
Supporting Information
Part Index (Continued)
11-21
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
11
Product or Part Number Page Number
SO96 8-44 to 8-49
SO175 8-44 to 8-49
SolderGrip Self-fixturing Insulated
Terminals 8-33 to 8-37
SolderGrip Closed End Connector Splices 8-12 to 8-17
SolderShield Shielded and Coaxial
Cable Splices 8-62 to 8-65
SolderSleeve Discrete Wire Terminators 8-39 to 8-42
SolderSleeve Coaxial Cable Terminators 8-51, 8-52
SolderSleeve PCB/Coaxial Cable
Terminators 8-53, 8-54
SolderSleeve Shield Terminators 8-44 to 8-49
SolderSleeve Wire Splices 8-6 to 8-11
SolderTacts Shielded One-piece
Solder Contacts 8-67 to 8-75
SPEC 44 Wire 9-3 to 9-9
SPEC 55 Wire 9-10 to 9-18
SPEC 80 Wire 9-25, 9-26
SRFR 3-111
SSC 4-51
SSB, D, T, F to 8S 4-89
SST/SST-FR 3-63
TAT-125 3-51
Product or Part Number Page Number
TCFS/R Cable Feedthroughs 7-6 to 7-8
TFE and TFE-R 3-113
Thermocouple Extension Cable 9-60
ThermoGun HG Hot-Air Heating Tool 10-29
Thermorad HTF/Fluoroelastomer 9-84
Thermorad/Thermorad F 9-85
Tinel-Lock Ring 6-26
TUGA-GP 3-25
Type 99M Wire and Cable 9-35 to 9-38
Versafit Tubing 3-27
Versafit V2 Tubing 3-29
Versafit V4 Tubing 3-31
Viton® (E, HW, TW) 3-115
XFFR 3-117
XLProducts 4-104, 4-105
Zerohal Wire and Cable 9-81 to 9-83
Zerohal 100A Wire and Cable 9-39
Zerohal 100G Wire and Cable 9-42
ZH-100 3-119
ZHTM 3-121
VITON is a trademark of Dupont Dow
Elastomers LLC.
Supporting Information
Engineering Notes
11-22 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
Engineering Notes
11-23
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
Engineering Notes
11-24 Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
Supporting Information
Engineering Notes
11-25
Catalog 1654025 Dimensions are in millimeters Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 12-04 and inches unless otherwise reference purposes only. Canada: 1-905-470-4425 Japan: 81-44-900-5102
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Singapore: 65-4866-151
www.tycoelectronics.com are U.S. equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-1793-528171
